Trane TR1 6006, TR1 6011, TR1 6004, TR1 6003, TR1 6016 Installation And Operation Manual

...

TR1 Series VFD Variable Frequency Drive

Installation and Operation Manual

August, 2004 TR1-SVX10A-EN

175R5559

WARNING

Equipment Hazard!

Rotating shafts and electrical equipment can be hazardous. Therefore, it is strongly recommended that all electrical work conform to National Electrical Code (NEC) and all local regulations. Installation, start-up and maintenance should be performed only by qualified personnel. Failure to follow the NEC or local regulations could result in death or serious injury.

Factory recommended procedures, included in this manual, should be followed. Always disconnect electrical power before working on the unit.

Although shaft couplings or belt drives are generally not furnished by the manufacturer, rotating shafts, couplings and belts must be protected with securely mounted metal guards that are of sufficient thickness to provide protection against flying particles such as keys, bolts and coupling parts. Even when the motor is stopped, it should be considered alive as long as its controller is energized. Automatic circuits may start the motor at any time. Keep hands away from the output shaft until the motor has completely stopped and power is disconnected from the controller.

Motor control equipment and electronic controls are connected to hazardous line voltages. When servicing drives and electronic controls, there will be exposed components at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case of an emergency. Disconnect power whenever possible to check controls or to perform maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electric control or rotating equipment.

Safety Guidelines

1. The drive must be disconnected from the AC line before any service work is done.

2. The STOP/OFF key on the local control panel of the drive does not disconnect the equipment from the AC line and is not to be used as a safety switch.

3. Correct protective grounding of the equipment must be established. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations.

4. Ground currents are higher than 3 mA.

Warnings Against Unintended Start

1. While the drive is connected to the AC line, the motor can be brought to a stop by means of external switch closures, serial bus commands or references. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stops are not sufficient.

2. During programming of parameters, the motor may start. Be certain that no one is in the area of the motor or driven equipment when changing parameters.

3. A motor that has been stopped may start unexpectedly if faults occur in the electronics of the drive, or if an overload, a fault in the supply AC line or a fault in the motor connection or other fault clears.

4. If the LOCAL/HAND key is activated, the motor can only be brought to a stop by means of the STOP/OFF key or an external safety interlock.

Motor Overload Protection

NOTE Person installing drive is responsible to provide proper grounding and branch circuit protection for incoming power and motor overload according to National Electrical Code (NEC) and local codes.

WARNING

Hazardous Voltage!

Touching electrical parts may be fatal, even after equipment has been disconnected from the AC input line. To be sure that capacitors have fully discharged, wait 14 minutes for 208 V and 480 V units and 30 minutes for 600 V units over 25 hp after power has been removed before touching any internal component. Failure to wait for capacitors to fully discharge before touching internal components could result in death or serious injury.

The electronic thermal relay (ETR) in UL listed TR1s provides Class 20 motor overload protection in accordance with the NEC in single motor applications when parameter 117 is set for ETR TRIP and parameter 105 is set for the rated motor current.

Never ignore warnings, cautions and notes in this manual. They are provided to alert anyone installing, operating, or maintaining this equipment to potential hazards or ineffective practices. Notes are used to call special attention to information which, if ignored or not clearly understood, in most cases will result in degraded or less then optimum equipment operation.

Become familiar with all warnings, cautions, and notes in this manual. These are important guidelines intended for your safety and for full utilization of the operational features of the equipment.

WARNING

CAUTION

NOTE

Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in injury. It may

also be used to alert against unsafe practices.

In dic ates a situa tio n wh ich , if ignored, could result in substantial equipment or property

damage.

Contains important information that, if not clearly understood or ignored, could result in

degraded or less than optimum equipment operation.

Table of Contents

General ................................................................................................................................................................................................................... 7

Clearances ............................................................................................................................................................................................................. 7

Backplate Requirements .......................................................................................................................................................................................... 7

Plenum Mounting..................................................................................................................................................................................................... 8

Grounding Plate ...................................................................................................................................................................................................... 8

Shielded Wires ........................................................................................................................................................................................................ 8

Standard Service Conditions ................................................................................................................................................................................... 8

UL, C-UL, and CE Conformity ................................................................................................................................................................................. 8

Drive Output Ratings ............................................................................................................................................................................................... 9

Input Fuses ........................................................................................................................................................................................................... 10

Internal Drive Fuses .............................................................................................................................................................................................. 11

Terminal Identification ............................................................................................................................................................................................. 11

Input Power Delay ................................................................................................................................................................................................ 11

Power Connections ............................................................................................................................................................................................... 12

Input Power Connection ........................................................................................................................................................................................ 13

Motor Wiring Connection ........................................................................................................................................................................................ 13

Grounding ............................................................................................................................................................................................................. 13

Electronic Thermal Protection ................................................................................................................................................................................. 13

Terminal Tightening Torque ................................................................................................................................................................................... 14

Terminal Tightening Torque for Optional Auxiliary Control Panels ........................................................................................................................... 14

External DC Bus Connection ................................................................................................................................................................................. 17

High Voltage Form C Relay ................................................................................................................................................................................... 17

Control Connections .............................................................................................................................................................................................. 18

Electrical Installation, Control Terminals .................................................................................................................................................................. 18

Drive Inputs and Outputs ....................................................................................................................................................................................... 18

Input Signals ......................................................................................................................................................................................................... 18

Output Signals ....................................................................................................................................................................................................... 19

Programming Control Terminals............................................................................................................................................................................. 19

Control Terminal Functions .................................................................................................................................................................................... 19

Typical Control Connections .................................................................................................................................................................................. 21

Electrical Installation, Control Wiring ....................................................................................................................................................................... 22

DIP Switches 1 through 4 ...................................................................................................................................................................................... 22

Ground Leakage Current .........................................................................................................

Galvanic Isolation .................................................................................................................................................................................................. 23

Extra Safety Protection .......................................................................................................................................................................................... 23

Electrical Noise ...................................................................................................................................................................................................... 23

Application Control Connection Examples .............................................................................................................................................................. 24

Control Panel ........................................................................................................................................................................................................ 25

Keys for Parameter Changes ................................................................................................................................................................................ 25

Indicator Lamps ..................................................................................................................................................................................................... 26

Local Control......................................................................................................................................................................................................... 26

Display Modes ...................................................................................................................................................................................................... 26

Changing Data...................................................................................................................................................................................................... 28

Changing Numeric Values ..................................................................................................................................................................................... 28

Changing Functional Values .................................................................................................................................................................................. 28

Changing Numeric Values in a List......................................................................................................................................................................... 28

Quick Menu ........................................................................................................................................................................................................... 29

To Enter or Change Quick Menu Parameter Data .................................................................................................................................................. 29

Example of Changing Parameter Data ................................................................................................................................................................... 29

Extended Menu..................................................................................................................................................................................................... 30

Manual Initialization of Parameters.......................................................................................................................................................................... 30

Uploading Parameters........................................................................................................................................................................................... 30

TR1 Series VFD Start-Up...................................................................................................................................................................................... 31

Pre-installation Checks .......................................................................................................................................................................................... 31

Installation Checks ................................................................................................................................................................................................. 31

............................................................................. 22

Setting Up Drive for Motor Start ............................................................................................................................................................................. 31

HAND Operational Tests........................................................................................................................................................................................ 31

AUTO Operational Tests ........................................................................................................................................................................................ 31

Final Adjustments ................................................................................................................................................................................................... 31

Programming......................................................................................................................................................................................................... 32

Description of Parameters ...................................................................................................................................................................................... 32

Operation and Display

Parameters 000 through 017 ......................................................................................................................................................................... 32

Setup Configuration and Copying Parameters ........................................................................................................................................................ 32

Setup of User-defined Readout.............................................................................................................................................................................. 33

Load and Motor

Parameters 100 through 118.......................................................................................................................................................................... 38

Procedure for Automatic Motor Adaptation: ............................................................................................................................................................. 40

DC Braking ........................................................................................................................................................................................................... 42

Motor Thermal Protection....................................................................................................................................................................................... 43

References and Limits

Parameters 200 through 228 ......................................................................................................................................................................... 44

Reference Handling .............................................................................................................................................................................................. 45

Reference Type .................................................................................................................................................................................................... 48

Warning Functions................................................................................................................................................................................................. 50

Inputs and Outputs

Parameters 300 through 328 ......................................................................................................................................................................... 52

Analog Inputs ........................................................................................................................................................................................................ 55

Analog/Digital Outputs............................................................................................................................................................................................ 58

Relay Outputs........................................................................................................................................................................................................ 61

Application Functions

Parameters 400 through 427 ......................................................................................................................................................................... 63

Sleep Mode .......................................................................................................................................................................................................... 64

Feedback Signals in Open Loop ............................................................................................................................................................................ 68

PID for Process Regulation.................................................................................................................................................................................... 69

Feedback .............................................................................................................................................................................................................. 69

Reference (Setpoint) ............................................................................................................................................................................................. 69

Inverse Regulation ................................................................................................................................................................................................ 69

Anti-windup ........................................................................................................................................................................................................... 69

Start-up Conditions ................................................................................................................................................................................................ 69

Differentiator Gain Limit .......................................................................................................................................................................................... 70

Lowpass Filter....................................................................................................................................................................................................... 70

Optimization of the Process Regulator ..................................................................................................................................................................... 70

PID Overview ....................................................................................................................................................................................................... 70

Feedback Handling ............................................................................................................................................................................................... 70

Serial Communication

Parameters 500 through 571 ......................................................................................................................................................................... 75

Programming Custom Display Text ........................................................................................................................................................................ 80

Warning Words, Extended Status Word and Alarm Word ........................................................................................................................................ 82

Serial Communication for FC Protocol .................................................................................................................................................................... 83

Protocols ............................................................................................................................................................................................................... 83

Packet Communication ........................................................................................................................................................................................... 83

Service Functions

Parameters 600 through 631 ......................................................................................................................................................................... 88

Relay Card Functions

Parameters 700 through 711.......................................................................................................................................................................... 93

Electrical Installation of the Relay Card ................................................................................................................................................................... 93

Status Messages ................................................................................................................................................................................................... 94

Warnings and Alarms............................................................................................................................................................................................. 96

Warnings............................................................................................................................................................................................................... 97

Alarms................................................................................................................................................................................................................... 97

Factory Settings................................................................................................................................................................................................... 102

SOFTWARE VERSION NOTICE: The software version number can be read in parameter

624, Software Version.

General

The specific installation instructions may vary depending upon the model of TR1 Series VFD being installed. When this occurs, the model can be identified by a TR1 Type 6XXX number. This number can be found on the red nameplate on the outside left side of the drive enclosure, or the outside right side of a drive with an auxiliary enclosure.

The drive must always be installed vertically. To ensure that no injury or damage occurs, the drive must always be firmly attached to the wall or the floor before further installation work is carried out.

Clearances

The drive is cooled by air circulation. For proper cooling, the minimum distances above and below the unit must be maintained as shown in the table below. For units in an auxiliary enclosure with the drive mounted on a backpanel, the required clearances are measured from the top and bottom of the drive, not the backpanel.

Backplate Requirements

Mount directly to the wall all drives without a backplate. This ensures that air flow is in contact with the heatsink all the way from the bottom of the drive. If this is not possible, a metal plate at least as large as the back of the drive may need to be firmly mounted to the back of the drive (see tables below). A backplate assembly is available from Trane.

Drive Size Top Cleara nce Bottom Clearance

1 to 3 hp, 200-240 V 1 to 10 hp, 380-460, 550-600 V 5 to 30 hp, 200-240 V 15 to 75 hp, 380-460, 550-600 V 40 to 60 hp, 200-240 V 100 to 125 hp, 380-460, 550-600 V

150 to 300 hp, 380-460, 550-600 V 12" (300mm) 12" (300mm)

350 to 600 hp, 380-460 V 16" (400mm) Floor mou nt

4" (100mm) 4" (100mm)

8" (200mm) 8" (200mm)

9" (225mm) 9" (225mm)

All drives can be mounted with no side clearance. Sufficient space must be provided in front of the drive for door swing on units with a hinged door. TR1 drives 350 hp and above require 25 inches (605 mm) front space for access. In addition, sufficient room must be available for installation and service access. On units with an auxiliary enclosure, the auxiliary enclosure door will have a greater door swing than the drive. See the dimensional drawings of the auxiliary enclosure which are included with the drive.

Drives without a backplate must be mounted directly to a solid wall with no spacers between the drive and the wall. Free-standing drives without a backplate require a backplate to be mounted.

NEMA 1

Backplate Required

Drive Size Power

5 to 30 hp 200-240 V

15 to 75 hp 380-460 V

150 to 300 hp 380-460 V

15 to 75 hp 550-600 V

200 to 300 hp 550-600 V

NEMA 12

Backplate Required

Drive Size Power

1 to 30 hp 200-240 V

1 to 75 hp 380-460 V

Plenum Mounting

The drive is UL rated for plenum mounting as well as auxiliary panels that may be supplied with the drive. If the equipment is to be mounted in the plenum, allow sufficient access for servicing. All normal clearance, temperature, humidity limitations and local codes apply.

Standard Service Conditions

The mechanical and electrical components of the TR1 Series VFDs can be adversely affected by the environment. High temperatures and harsh environments may reduce life of drive if proper precautions are not taken.

Grounding Plate

Drives up to 3 hp, 200 to 240 V, and up to 10 hp, 380 to 460 V and 550 to 600 V with a NEMA 1 enclosure have a plastic bottom cover with provision for conduit entry. To meet UL requirements, the metal grounding plate must be in place above the plastic bottom cover. The plate must be grounded to the chassis and the conduit grounded to the plate. If the grounding plate is not factory installed, it must be installed in the drives that have a plastic bottom panel to ensure proper grounding of the conduit to the enclosure. Connect the ground wire from the grounding plate to the ground tab marked with the ground symbol.

This tab is located near the AC line terminal strip. Mount the bottom cover on the control unit.

Shielded Wires

Wires to control signals should be shielded to reduce radiofrequency noise interference. When RFI is a concern, shielded cable should be used between the drive and the motor.

If unshielded control wires are used, control inputs are subject to signal disturbances. Such disturbances may affect drive operation. Extreme noise levels may disturb the microprocessor of the control card.

The shield of the control wires must be grounded at the cable clamp at the bottom of the drive, but the shield must continue with the cable all the way up to the control card. The shield is not to be connected to any of the terminals on the control card. For safety reasons, the insulation around the shield should only be removed where it is connected to the cable clamp. The insulation should be left on the shield between the clamp and the terminals.

Airborne Liquids

Rain, steam, oil, water vapor, high humidity, and such may cause corrosion of drive components. In such environments, use NEMA 12 enclosures. NEMA 12 enclosures limit the exchange of outside air into the drive enclosure. Extremely harsh environments may require a higher levels of protection.

Solids

Dust, dirt, metal drill shavings, foreign objects and the like may cause mechanical, electrical or thermal failure in the drive. A NEMA 1 enclosure provides a reasonable degree of protection against falling particles but will not prevent the drive fan from pulling dirty air into the drive. A typical indicator of excessive levels of airborne particles is dust around the fan. In dusty environments, use NEMA 12 enclosures.

Corrosive Chemicals

In environments with high temperatures and humidity, corrosive gases such as sulfur, nitrogen and chlorine compounds cause corrosion to occur in the drive. Such chemical reactions rapidly affect and damage electronic components. An indication of corrosion is blackened copper or oxygenation of steel or aluminum. In such environments, it is recommended that the equipment be mounted in a cabinet with fresh air ventilation and that corrosive compounds be kept away from the drive. A non-ventilated cabinet fitted with an air conditioner as a heat exchanger may be used. Conformal coated circuit boards may be specified to reduce the corrosive effects of a harsh environment.

Maximum Relative Humidity

Generally speaking, all conductors coming from a shieldedcontrol cable must be as short as possible. Long conductor ends attract noise. The shield must be connected to the chassis by means of the cable clamp. Long pigtails on the shield reduce the effectiveness of the shield.

95% non-condensing

Ambient Temperature

14°F to 104°F (-10°C to 40°C)

14°F to 122°F (-10°C to 50°C) for 200-240 V units of 40 hp or less and 380-600 V units of 125 hp or less when used with motor leads of 50 ft (15m) or less

UL, C-UL, and CE Conformity

All 200-240 V and 380-460 V TR1 Series VFDs are CE marked. All drives and option packages are UL and C-UL listed.

Drive Output Ratings

208 V Input

TR1 Type Max. Nominal

Output HP

6002 1 / 1½ 6.9 6003 2 7.8 6004 3 11 6006 5 17.5 6008 7½ 26 6011 10 33 6016 15 48.3 6022 20 62.1 6027 25 78.2 6032 30 92 6042 40 120 6052 50 143 6062 60 170

460 V Input

TR1 Type Max. Nominal

Output HP

6002 1 / 1½ 3.0 6003 2 3.4

6004 3 4.8 6006 5 8.2 6008 7½ 11.0 6011 10 14.2 6016 15 21 6022 20 27 6027 25 34 6032 30 40 6042 40 52 6052 50 65 6062 60 77 6072 75 106 6102 100 130 6122 125 160 6150 150 190 6152 150 190 6172 200 240 6175 200 240 6222 250 302 6225 250 302 6272 300 361 6275 300 361 6350 350 443 6352 450 443 6400 450 540 6500 500 590 6550 600 678

Max. Drive

Output Current

Max. Drive

Output Current

230 V Input

TR1 Type Max. Nominal

6002 1 / 1½ 6.9 6003 2 7.8 6004 6006 5 17.5 6008 7½ 26 6011 10 33 6016 15 48.3 6022 20 62.1 6027 25 78.2 6032 30 92 6042 40 104 6052 50 130 6062 60 154

380 V Input

TR1 Type Max. Nominal

6002 1 / 1½ 3.0 6003 2 4.1

6004 3 5.6 6006 5 10 6008 7½ 13 6011 10 16 6016 15 24 6022 20 32 6027 25 37.5 6032 30 44 6042 40 61 6052 50 73 6062 60 90 6072 75 106 6102 100 147 6122 125 177 6150 150 212 6152 150 212 6172 200 260 6175 200 260 6222 250 315 6225 250 315 6272 300 368 6275 300 368 6350 350 480 6352 350 480 6400 450 600 6500 500 658 6550

600 V Input

TR1 Type Max. Nominal

6002 1½ 2.4 6003 2 2.7 6004 3 3.9 6006 5 6.1 6008 7½ 9 6011 10 11.4 6016 15 17 6022 20 22 6027 25 27 6032 30 32 6042 40 41 6052 50 52 6062 60 62 6072 75 77 6100 100 99 6125 125 1 25 6150 150 1 44 6175 200 1 92 6225 250 2 42 6275 300 2 89

Output HP

311

Output HP

600 745

Output HP

Max. Drive

Output Current

Max. Drive

Output Current

Max. Drive

Output Current

Input Fuses

208/230 Volt Input

CAUTION

Branch Circuit Fuses Required!

All drives must be protected with branch circuit

fuses in accordance with the National Electrical

Code. Failure to provide branch circuit fuses in

accordance with the NEC may result in

equipment or property damage.

To comply with UL508C, input fuses shown in the tables below must be installed in the power supply to drives which are 208 V above 30 hp, and 380/460 V and 600 V drives above 75 hp. The fuse ratings in the tables below are the recommended maximum ratings.

NOTE Any UL listed Class T fuse with equivalent voltage and current rating may be used in place of JJS and JJN fuse types.

Trane recommends input fuses on all drives. If specified as a drive option, input fuses will be installed by The Trane Company in an enclosure external to the drive, which may include other optional features. If not supplied, they must be provided by the drive installer as part of installation.

380/460 Volt Input

Maximum Fuse

TR1 Type

6002 10 JJS 6003 15 JJS 6004 15 JJS 6006 25 JJS 6008 35 JJS 6011 45 JJS 6016 70 JJS 6022 90 JJS 6027 110 JJS 6032 125 JJS 6042 175 JJS 6052 200 JJS 6062 200 JJS 6072 250 JJS 6102 300 JJS 6122 350 JJS 6150 300 FWH 6152 300 FWH 6172 300 FWH 6175 350 FWH 6222 350 FWH 6225 400 FWH 6272 400 FWH 6275 500 FWH 6350 600 FWH 6352 600 FWH 6400 700 FWH 6500 800 FWH 6550 800 FWH

Rating (Amps)

Bussmann Type

Maximum Fuse

TR1 Type

6002 20 JJN or JJS 6003 20 JJN or JJS 6004 40 JJN or JJS 6006 50 JJN or JJS 6008 80 JJN or JJS 6011 100 JJN or JJS 6016 150 JJN or JJS 6022 200 JJN or JJS 6027 225 JJN or JJS 6032 300 JJN or JJS 6042 400 JJN or JJS 6052 200 FW X or FWH 6062 250 FW X or FWH

Rating (Am ps) Bussmann Type

600 Volt Input

Maximum Fuse

TR1 Type

6002 10 JJS 6003 10 JJS 6004 15 JJS 6006 20 JJS 6008 25 JJS 6011 35 JJS 6016 50 JJS 6022 60 JJS 6027 80 JJS 6032 90 JJS 6042 110 JJS 6052 150 JJS 6062 175 JJS 6072 100 JJS 6100 125 FW P 6125 175 FW P 6150 200 FW P 6175 250 FW P 6225 350 FW P 6275 400 FW P

200-240 V drives are suitable for use on a circuit capable of supplying a maximum of 100,000 A RMS (symmetrical), 250 V maximum.

380-460 V drives are suitable for use on a circuit capable of supplying a maximum of 100,000 A RMS (symmetrical), 500 V maximum.

550-600 V drives are suitable for use on a circuit capable of supplying a maximum of 100,000 A RMS (symmetrical), 600 V maximum.

Rating (Amps) Bussmann Type

Internal Drive Fuses

The table below specifies fuses used internally in the TR1 series drives. Use the specified fuse or an exact replacement only.

Terminal Identification

The connectors for input and output power, auxiliary relay connections, and external DC bus are identified in the tables below.

Internal Fuses Provided with TR1 Series VFDs

TR1 Type Soft Charge Fuse

6042 Littelfuse KLK-15 Littelfuse KL K-D-12 Bussmann KTK-5 6052 Littelfuse KLK-15 Littelfuse KL K-D-12 Bussmann KTK-5 6062 Littelfuse KLK-15 Littelfuse KL K-D-12 Bussmann KTK-5

TR1 Type Soft Charge

6072 Littelfuse KLK-15 Littelfuse KL K-D-12 (1X) Bussmann KT K-5 6102 Littelfuse KLK-15 Littelfuse KL K-D-12 (1X) Bussmann KT K-5 6122 Littelfuse KLK-15 Littelfuse KL K-D-12 (1X) Bussmann KT K-5 6150 Littelfuse KLK-30 Littelfuse KL K-D-12 (1X) Bussmann KT K-5 6175 Littelfuse KLK-30 Littelfuse KL K-D-12 (2X) Bussmann KT K-5 6225 Littelfuse KLK-30 Littelfuse KL K-D-12 (2X) Bussmann KT K-5 6275 Littelfuse KLK-30 Littelfuse KL K-D-12 (2X) Bussmann KT K-5

TR1 Type Soft Charge

6350 Littelfuse KLK-9 Littelfuse KLK-15 Bussmann KTK-5 6400 Littelfuse KLK-9 Littelfuse KLK-15 Bussmann KTK-5 6500 Littelfuse KLK-9 Littelfuse KLK-15 Bussmann KTK-5 6550 Littelfuse KLK-9 Littelfuse KLK-15 Bussmann KTK-5

TR1 Type

6152 Bussmann

6172 Bussmann

6222 Bussmann

6272 Bussmann

6352 Bussmann

(3X)

Fuse (3X)

Soft Charge

Fuse (3 phase)

FWH20A6F

200 – 240 VAC

Soft Charge Resistor

Fuse (1X)

380 – 460 VAC

Soft Charge Resistor

Fuse (1X or 2X)

Line Snubber

Fuse (3X)

Fan Fuse (1 phase)

Bussmann KTK-4 Bussmann KTK-4

Power Car d

Fuse (1X)

Power Car d

Fuse (1X)

Interface Board

Fuse (1X)

Power Card/SM PS Fuse (1 phase)

AC Line

Motor

L1 L2 L3 91 92 93

U V W PE (ground)

96 97 98 99

AUX RELAY 01 02 03

DC Bus

(-) DC (+) DC

88 89

CAUTION

Drive Failure!

Do not connect input power to drive output motor terminals. Connecting input power to motor terminals will result in drive failure when power is applied.

On drives with an auxiliary enclosure, some or all of the power connections at the drive will be factory made. Custom input and output terminals may be inside the auxiliary enclosure. See the drawings supplied with the drive for details on custom terminal blocks and conduit entry locations for the auxiliary enclosure.

Input Power Delay

To ensure that the input surge suppression circuitry performs correctly, a time delay between successive applications of input power must be observed.

The table below shows the minimum time that must be allowed between applications of input power.

Input voltage 380 V 415 V 460 V 600 V W aiting time 48 sec 65 s ec 89 sec 133 sec

Power Connections

1. Make all power connections with 75o C rated copper wiring.

2. Conduit entry must be from the bottom on all drives. Conduit entries are provided on smaller drives. For drives with auxiliary enclosures, refer to the dimensional drawings provided for conduit entry locations.

3. To meet UL requirements, install the metalgrounding plate in all drives that have a plastic bottom. Install the grounding plate just above the plastic bottom. Ground the metal plate to the chassis and ground the conduit to the metal plate.

4. The conduit entries provide strain relief for the wires in drives mounted in NEMA 1 or NEMA 12 enclosures. With chassis mounted drives, the power and control wires must have strain relief supplied by the installer. D provide strain relief.

Model

6002 6.3 10 6003 7.3 10 6004 10.4 10 6006 16.8 10 6008 23.8 6 6011 32.2 6 6016 48.3 6 6022 61.9 2 6027 78.2 2 6032 92.0 0 6042 117.0 1/0 6052 139.2 3/0 6062 165.5 4/0

200 - 208 VAC Input Current/Wire Gage

Model

6002 2.8 10 6003 3.8 10 6004 5.3 10 6006 9.1 10 6008 12.2 10 6011 15 10 6016 24 6 6022 32.0 6 6027 37.5 6 6032 44 6 6042 60 2 6052 72 2 6062 89 2 6072 104 1/0 6102 145 2/0 6122 174 3/0 6150 206 2x1/0 6152 206 2x1/0 6172 256 2x1/0 6175 256 2x1/0 6222 317 2x3/0 6225 317 2x3/0 6272 366 2x4/0 6275 366 2x4/0 6350 467 3x1/0 6352 467 3x1/0 6400 584 3x3/0 6500 648 3x3/0 6550 734 3x4/0

380 VAC Input Current/Wire Gage

O NOT rely on the terminal blocks to

Drive Input

Current

Drive Input

Current

Maximum

AWG

Maximum

Current ratings are in Amps

WARNING

Induced Voltage!

Run output motor cables from multiple drives separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately could result in death or serious injury.

Drive Input

Model

6002 2.5 10 6003 3.4 10 6004 4.8 10 6006 8.3 10 6008 10.6 10 6011 14 10 6016 21 6 6022 27.6 6 6027 34 6 6032 41 6 6042 53 2 6052 64 2 6062 77 2 6072 104 1/0 6102 128 2/0 6122 157 3/0 6150 185 2x1/0 6152 185 2x1/0 6172 236 2x1/0 6175 236 2x1/0 6222 304 2x3/0 6225 304 2x3/0 6272 356 2x4/0 6275 356 2x4/0 6350 431 3x1/0 6352 431 3x1/0 6400 526 3x3/0 6500 581 3x3/0 6550 668 3x4/0

Current

460 VAC Input Current/Wire Gage

Model

Drive Input

Current

6002 2.3 10 6003 2.6 10 6004 3.8 10 6006 5.9 10 6008 8.8 10 6011 11.1 10 6016 16.6 6 6022 21.4 6 6027 26.3 6 6032 31.2 2 6042 39.9 2 6052 50.6 1/0 6062 60.4 1/0 6072 75 1/0 6100 92.4 3/0 6125 117 3/0 6150 134 4/0 6175 179 2 x 4/0 6225 226 2 x 4/0 6275 270 2 x 4/0

550 - 600 VAC Input Current/Wire Gage

Maximum

AWG

All current ratings are in amps.

NOTE

Run input power, motor wiring and control wiring in three separate metallic conduits or raceways for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum drive and associated equipment performance.

WARNING

Grounding Hazard! For operator safety, it is important to ground drive properly. Follow the grounding guidelines provided. Failure to follow grounding guidlines could result in death or serious injury.

Input Power Connection

For drives with no auxiliary enclosure, connect input power to drive terminals L1, L2, and L3, (terminal numbers 91, 92, and 93). If an auxiliary enclosure is provided, input power connections are made in the auxiliary enclosure. Refer to the connection diagrams shipped with the drive.

Size wiring to the input current of the drive as shown in the tables below. Maximum AWG wire size is also provided. Local codes must be complied with for cable sizes.

Motor Wiring Connection

For drives with no auxiliary enclosure, connect the motor to drive terminals U, V, and W (terminal numbers 96, 97, and 98). Terminal 99 is earth ground. If an auxiliary enclosure is provided, refer to the connection diagrams shipped with the drive. Ground the shield on the motor wire, if used, at both the drive and the motor.

Grounding

Ground the drive properly. Use a ground wire at least 7 AWG (10mm2). Connect the ground wire directly to a reliable earth ground. Do not use the conduit connecting to the drive as a replacement for a ground wire. Do not ground one drive to another in a daisy chain fashion.

Electronic Thermal Protection

The electronicthermal relay is UL approved for single motor thermal protection as long as the following is complied with:

1. Parameter 117, Thermal Protection, is set to ETR TRIP.

2. Parameter 105, Motor Current, is set for the full-load nameplate motor current.

Terminal Tightening Torque

Tighten terminals connecting the drive input power, output to the motor(s) and ground to the values shown in the tables below. Drives with 200 to 240 volts of 88 amps and less, and drives with 380 to 600 volts of 90 amps and less, have removable terminal blocks with screws. Larger drives have fixed bolts. (See the drive nameplate for maximum drive output current.)

Max. Drive

Output Current

6.9 5 (0.6)

7.8 5 (0.6) 11 5 (0.6)

17.5 5 (0.6) 26 17 (1.8) 33 17 (1.8)

48.3 28 (3.0)

62.1 28 (3.0)

78.2 28 (3.0) 92 35 (4.0)

115 100 (11.3) 143 100 (11.3) 170 100 (11.3)

Tor que

in-lbs (Nm)

200 to 240 VAC Terminal Tightening Torque

Max. Drive

Output Current

Torque

in-lbs (Nm)

Max. Drive

Output Current

Torque

in-lbs (Nm)

to 10 5 (0.6) 147 100 (11.3)

16 5 (0.6) 177 100 (11.3) 24 17 (1.8) 212 100 (11.3) 32 17 (1.8) 260 100 (11.3)

37.5 17 (1.8) 315 100 (11.3) 44 28 (3.0) 368 100 (11.3) 61 28 (3.0) 487 372 (42.0) 73 28 (3.0) 594 372 (42.0) 90 28 (3.0) 649 372 (42.0)

106 100 (11.3) 746 372 (42.0)

380 to 460 VAC Terminal Tightening Torque

Max. Drive

Output Current

to 11 5 (0.6)

27 17 (1.8) 41 28 (3.0)

77 35 (4.0) 144 100 (11.3) 289 100 (11.3)

Torque

in-lbs (Nm )

All current ratings are in amps.

Terminal Tightening Torque for Optional Auxiliary Control Panels

For drives with an optional auxiliary control panel enclosure, tighten terminal connections in accordance with the tables provided.

200-208 V Hp

Rat ing

1 1/2

7 1/2

Overload

Rel ay

17 (1.9) 15 (1.7) 2 2 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

17 (1.9) 15 (1.7) 2 2 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

17 (1.9) 35 (4.0) 2 2 (2.5) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

40 (4.5) 175 (19. 8) 44 (5) 18 (2) 18 (2) 45 (5.1) 45 (5.1) 50 (5.6)

40 (4.5) 175 (19. 8) 44 (5) 18 (2) 18 (2) 120 (13 .6) 120 (13.6) 50 (5.6)

40 (4.5) 175 (19.8) 44 (5) 55 (6 .2) 55 (6.2) 120 (13.6) 275 (30.1) 50 (5.6)

40 (4.5) 175 (19.8) 44 (5) 70 (7 .9) 70 (7.9) 120 (13.6) 275 (30.1) 50 (5.6)

200 (22.6) 275 (30. 1) 27 5 (30.1) 375 (42.4) 375 (42.4) 275 (31.1) N/A 50 (5.6)

200 (22.6) 275 (30. 1) 27 5 (30.1) 375 (42.4) 375 (42.4) 450 (50.8) N/A 275 (30. 1)

In/Out Power

Termina l

CTK Breaker

Ma in Disco

Switch

550 to 600 VAC Terminal Tightening Torque

Drive Di sco

Switch

MN/BYP Fuse

BLK

Drive Fuse

BLK

Ground

Terminal

200 to 208 VAC Auxiliary Control Panel Tightening Torques

Current ratings are in amps. Torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

Terminal Tightening Torque for Optional Auxiliary Control Panels (continued)

230-240 V Hp

Rati ng

1 1/2

7 1/2

380-460 V Hp

Rating

1 1/2

7 1/2

100

125

150

200

250

300

Overload

Rel ay

17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 35 (4.0) 45 (5.1)

17 (1.9) 15 (1.7) 22 (2.5) 7 (.8) 7 (.8) 25 (2.8) 45 (5.1) 45 (5.1)

17 (1.9) 35 (4.0) 22 (2.5) 7 (.8) 7 (.8) 45 (5.1) 45 (5.1) 45 (5.1)

40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 45 (5.1) 45 (5.1) 50 (5.6)

40 (4.5) 175 (19.8) 44 (5) 18 (2) 18 (2) 120 (13.6) 120 (13.6) 50 (5.6)

40 (4.5) 175 (19.8) 44 (5) 55 (6.2) 18 (2) 120 (13.6) 275 (30.1) 50 (5.6)

40 (4.5) 175 (19.8) 275 (30. 1) 70 (7.9 ) 55 (6.2) 275 (31.1 ) 275 (30.1) 50 (5.6)

40 (4.5) 175 (19.8) 275 (30. 1) 375 (42. 4) 70 (7.9) 275 (31.1 ) N/A 50 (5.6)

200 (22.6) 275 (30 .1) 275 ( 30.1) 375 (42. 4) 375 (42. 4) 275 (31.1 ) N/ A 50 (5. 6)

200 (22.6) 275 (30 .1) 275 ( 30.1) 375 (42. 4) 375 (42. 4) 450 (50.8 ) N/ A 275 (30.1)

In/Out Powe r

Termina l

CTK Bre aker

Main Disco

Switch

Drive Disco

Switch

MN/BYP Fuse

BLK

Drive Fuse

BLK

Terminal

230 to 240 VAC Auxiliary Control Panel Tightening Torques

Overload

Rel ay

17 (1.9 ) 15 (1 .7) 22 (2.5) 7 (.8) 7 (.8) 25 (2. 8) 25 ( 2.8) 45 (5.1)

17 (1.9 ) 15 (1 .7) 22 (2.5) 7 (.8) 7 (.8) 25 (2. 8) 45 ( 5.1) 45 (5.1)

17 (1.9 ) 35 (4 .0) 22 (2.5) 7 (.8) 7 (.8) 45 (5. 1) 45 ( 5.1) 45 (5.1)

17 (1.9) 35 (4. 0) 22 (2. 5) 18 ( 2) 7 (.8) 45 (5.1) 45 (5. 1) 45 (5. 1)

40 (4.5) 35 (4. 0) 22 (2. 5) 18 ( 2) 1 8 (2) 45 (5.1) 45 (5. 1) 50 (5. 6)

40 (4.5) 17 5 (19.8) 44 (5) 18 (2) 18 (2) 45 (5. 1) 120 (13. 6) 50 (5.6)

40 (4.5) 17 5 (19.8) 44 (5) 55 (6. 2) 18 (2) 120 (13. 6) 120 (13. 6) 50 (5.6)

40 (4.5 ) 175 (1 9.8) 44 (5) 70 (7. 9) 55 (6.2) 120 (13 .6) 275 (30.1) 50 (5.6)

40 (4.5) 17 5 (19.8) 275 (30 .1) 375 (42. 4) 70 (7. 9) 275 (31.1 ) N/ A 50 (5. 6)

200 (22.6) 27 5 (3 0.1) 27 5 (30 .1) 37 5 (42.4) 375 (42 .4) 275 (31 .1) N/A 50 (5. 6)

200 (22.6) 27 5 (3 0.1) 27 5 (30 .1) 37 5 (42.4) 375 (42 .4) 275 (31 .1) N/A 275 (30.1)

200 (22. 6) 275 (3 0.1) 275 (30.1) 37 5 (42.4) 375 (42.4) 450 (50.8 ) 500 (56. 5) 275 (30. 1)

200 (22. 6) 375 (4 2.4) 275 (30.1) 50 0 (56.8) 500 (56.8) 450 (50.8 ) 500 (56. 5) 275 (30. 1)

375 (42. 4) 375 (4 2.4) 275 (30.1) 50 0 (56.8) 500 (56.8) 450 (50.8 ) 275 (30. 1) 275 (30. 1)

375 (42. 4) 375 (4 2.4) 275 (30.1) 50 0 (56.8) 500 (56.8) 375 (42.4 ) 375 (42. 4) 275 (30. 1)

In/Out Po wer

Termin al

CTK Breaker

Main Disco

Switch

Drive Disco

Switch

MN/BYP Fuse

BLK

Drive Fuse

BLK

Terminal

Ground

380 to 460 VAC Auxiliary Control Panel Tightening Torques

Current ratings are in amps. Torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

Terminal Tightening Torque for Optional Auxiliary Control Panels (continued)

550-600 V Hp

Rating

1 1/2

7 1/2

100

125

150

200

250

300

Overload

Relay

17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (. 8) 2 5 (2.8) 25 (2.8 ) 45 (5. 1)

17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (. 8) 2 5 (2.8) 45 (5.1 ) 45 (5. 1)

17 (1.9) 15 (1.7) 50 (5.6) 7 (.8) 7 (. 8) 4 5 (5.1) 45 (5.1 ) 45 (5. 1)

17 (1.9) 35 (4.0) 50 (5.6) 7 (.8) 7 (. 8) 4 5 (5.1) 45 (5.1 ) 45 (5. 1)

17 (1.9) 35 (4. 0) 50 (5. 6) 18 (2) 18 (2) 45 (5. 1) 120 (13. 6) 45 (5. 1)

40 (4.5) 35 (4. 0) 50 (5. 6) 18 (2) 18 (2) 45 (5. 1) 120 (13. 6) 50 (5. 6)

40 (4.5) 175 (19.8) 50 (5. 6) 70 (7. 9) 55 (6. 2) 120 (13. 6) 120 (13. 6) 50 (5.6)

40 (4.5) 175 (19.8) 275 (30. 1) 70 (7. 9) 55 (6. 2) 120 (13. 6) 120 (1 3.6) 50 (5. 6)

40 (4.5) 175 (19.8) 275 (30. 1) 375 (42 .4) 70 (7. 9) 275 (31. 1) 275 (3 0.1) 50 (5.6)

200 (22.6) 275 (30.1) 275 (30.1) 375 (42. 4) 375 (42. 4) 275 (31. 1) N /A 50 (5. 6)

200 (22.6) 275 (30.1) 275 (30.1) 375 (42. 4) 375 (42. 4) 275 (31. 1) N /A 275 (30. 1)

200 (22.6) 275 (30.1) 275 (30.1) 375 (42. 4) 375 (42. 4) 450 (50. 8) N /A 275 (30. 1)

375 (42.4) 375 (42.4) 275 (30.1) 500 (56. 8) 500 (56. 8) 450 (50. 8) 500 (56. 5) 275 (30. 1)

375 (42.4) 375 (42.4) 275 (30.1) 500 (56. 8) 500 (56. 8) 375 (42. 4) 275 (30. 1) 275 (30. 1)

In/Ou t P ower

Terminal

CTK Bre aker

Main Disco

Switch

Drive Disco

Switch

MN/BYP Fuse

BLK

Drive Fuse

BLK

Ground

Term inal

550 to 600 VAC Auxiliary Control Panel Tightening Torques

Current ratings are in amps. Torques are in in-lbs (Nm). All TB1 connections must be torqued to 8 in-lbs (0.9 Nm).

Multiple Motors

The TR1 can control several motors at once, all changing speed together. The sum of the nameplate currents of all the motors must not exceed the current rating of the drive.

External DC Bus Connection

Terminals 88 and 89 access the DC bus of the drive. They can provide DC backup power for the drive or to connect to a 12-pulse input rectifier.

CAUTION

Motor Damage!

When multiple motors are used, the drive electronic thermal relay cannot be used to provide individual motor protection. A separate motor overload must be supplied for each motor. Failure to provide individual motor protection when multiple motors are used could result in motor or equipment damage.

If the multiple motors are of significantly different sizes, starting problems may occur. This is because the higher electrical resistance of smaller motors will require more start voltage than larger motors.

NOTE Automatic†Motor Adaptation and Automatic Energy Optimization cannot be used for multiple motor installations.

WARNING

Hazardous Voltage!

Terminals 88 and 89 will be at approximately 150% of line voltage and remain at high voltage for up to 30 minutes after power has been removed from the drive. To be sure that capacitors have fully discharged, wait 14 minutes for 208 V and 480 V units and 30 minutes for 600 V units after power has been removed before touching terminals 88 and 89. Failure to wait for capacitors to fully discharge before touching DC bus terminals could result in death or serious injury.

CAUTION

Equipment Damage!

Do not connect anything to terminals 88 and 89 without first consulting with Trane. Failure consult with Trane could result in motor or equipment damage.

High Voltage Form C Relay

The connections for the high-voltage relay are terminals 01, 02, 03. The high-voltage relay is programmed in parameter 323, Relay

Output 1.

1+3 normally closed, 1+2 normally open

Max. 240 VAC, 2 Amp Min. 24 VDC, 10 mA or

24 VAC, 100 mA Max. wire gage: 10 AWG (4 mm Terminal Torque: 5 in-lbs ( 0.5 - 0.6 Nm)

)

Control Connections

All terminals for the low voltage control wires are located under the protective cover below the keypad. Remove the cover with a screwdriver or other pointed object as shown bellow.

Drive Inputs and Outputs

The drive operates by receiving control signals. Control input gets to the drive in three possible ways. One way is from input signals through the wiring connected to the drive control terminals. The drive control terminals are located below the LCP keypad.

Another control source is through serial communication from a serial bus. A serial communication protocol supplies commands and references to the drive and reads status and data from the drive. The serial bus connects to the drive through the RS-485 serial port. Use of serial communication may require installation of a corresponding option card.

A building management system, remote sensors, a speed command from associated equipment, or a PLC (programmable logic controller) are examples of possible remote drive controllers.

The third way for drive control input is through the keypad on the front of the drive when operating in local (hand) mode. These inputs include start, stop, reset, and speed reference.

Electrical Installation, Control Terminals

Torque control terminals to 5 in-lbs (0.5-0.6 N-m) Max. wire size: 16 AWG (1.5mm

The diagram below shows the location of the control terminals. The programming section of the manual covers the programmable terminals in greater depth.

)

Input Signals

The drive can receive two types of remote input signals: digital or analog. Digital inputs are wired to terminals 16, 17, 18, 19, 20 (common), 27, 29, 32, and 33. Analog inputs are wired to terminals 53, 54, and 55 (common), or terminal 60.

Analog signals can be either voltage (0 to +10 VDC) connected to terminals 53 and 54, or current (0 to 20 mA or 4 to 20 mA) connected to terminal 60. Analog signals can be varied like dialing a rheostat up and down. The drive can be programmed to increase or decrease output in relation to the amount of current or voltage. For example, a sensor may supply a variable current. The drive output, in turn, regulates the speed of the motor connected to the drive in response to that analog signal.

Digital signals are a simple binary 0 or 1 which, in effect, act as a switch. Digital signals are controlled by a 0 to 24 VDC signal. A voltage signal lower than 5 VDC is a logic 0. A voltage higher than 10 VDC is a logic 1. Zero is open, one is close. Digital inputs to the drive are switched commands such as start, stop, reverse, coast, reset, and so on. (Do not confuse these digital inputs with serial communication formats where digital bytes are grouped into communication words and protocols.)

The RS-485 serial communication connector is wired to terminals (+) 68 and (-) 69. Terminal 61 is common and may be used for terminating shields only when the control cable is run between VLT drives, not between drives and other devices.

Output Signals

The drive also produces output signals that are carried through either the RS-485 serial bus or terminals 42 and 45. Output terminals 42 and 45 operate in the same manner as the inputs. These terminals can be programmed for either a variable analog signal in mA or a digital signal (0 or 1) in 24 VDC. In addition, the terminals can provide a pulse reference of 0 to 32,000 pulses. Output analog signals generally report the drive 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, for example, or send a start or stop command to auxiliary equipment.

Additional terminals are 01, 02, and 03, which are a Form C relay output. Terminals 04 and 05 are a 1 A low voltage relay output.

Terminals 12 and 13 provide 24 VDC low voltage power, often used to supply power to the digital input terminals (16-33). Those terminals must be supplied with power from either terminal 12 or 13, or from a customer supplied external 24 VDC power source. Improperly connected control wiring can be the cause of a motor not operating or the drive not responding to a remote input.

Programming Control Terminals

Control terminals must be programmed. Each terminal has specific functions it is capable of performing and a numbered parameter associated with it. See the table below for associated parameter numbers. The setting selected in the parameter enables the function of the terminal.

It is important to confirm that the control terminal is programmed for the correct function. See Control Panel for details on operator interface and changing parameters.

In addition, the input terminal must be receiving a signal. Confirm that the control and power sources are wired to the terminal. Then check the signal.

Control Terminal Functions

The following is a description of the functions of the control terminals. Many of these terminals have multiple functions determined by parameter settings.

Terminal No. Function

01, 02, 03 FormC relay output. Maximum 240 VAC, 2 A.

Minimum 24 VDC, 10 mA or 24 VAC, 100 mA.

(Location of Form C relay output varies with unit

type. See connection diagram with unit for

location.)

04, 05 30 VAC, 42.5 VDC, 1 A relay output can be used

for indicating status and warnings.

12, 13 Voltage supply to digital inputs and external

transducers. For the 24VDC to be used for digital

inputs, switch 4 on the control card must be closed,

position on. The maximum output current is 200 mA.

16 - 33 Digital inputs. R

>10V = logical 1. See parameters 300 through

307, Digital Inputs.

20 Common for digital inputs.

39 Common for analog and digital outputs.

42, 45 Analog and digital outputs for indicating frequency,

reference, current and torque. The analog signal

is 0 to 20 mA, or 4 to 20 mA at a maximum of

500Ω. The digital signal is 24VDC at a minimum

of 600Ω. See parameters 319-322, Analog/digital

Outputs.

50 10 VDC, 17mA maximum analog supply voltage to

potentiometer and thermistor.

=2kohm. <5V = logical 0,



Signals can be checked in two ways. Relay status can be selected in the display using the [DISPLAY MODE] key (see Display Modes), or a voltmeter may be used to check for voltage at the control terminal.

In summary, for proper drive functioning, the drive control terminals must be:

1. wired properly

2. programmed correctly for the intended function

3. powered

4. receiving a signal

Term 16 17 18 19 27 29 32 33 53 54 60 42 45 1-3 4-5 Para 300 301 302 303 304 305 306 307 308 311 314 319 321 323 326

Control terminals must be programmed. Each terminal has specific functions it is capable of performing and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal.

53, 54 0 to 10 VDC voltage input, R = 10 kΩ.

55 Common for analog inputs. This common is

isolated from the common of all other power

supplies. If, for example, the drives 24 VDC

power supply is used to power an external

transducer which provides an analog input signal,

terminal 55 must be wired to terminal 39.

Control Terminals and Associated Parameter

Control Terminal Functions (continued)

Terminal No. Function

60 0 to 20 mA or 4 to 20 mA, analog current input,

R=188 Ω. See parameters 314 through 316.

61 Shield for serial communication.

68, 69 RS-485 interface and serial communication. When

the drive is connected to an RS-485 serial communication bus, DIP switch settings on the control card may have to be reset. See Dip Switches 1 through 4 in this manual.

Electronic Control Terminals

Typical Control Connections

Shown below are typical interfaces between the TR1 and other components in an HVAC system. The terminal numbers and the functions of the terminals are identical on all TR1s. An optional relay card, not shown, can provide four additional Form C output relays. The RS-485 connections allow direct communication through the drives built-in serial communication protocols.

Typical TR1 Wiring

3 Phase

Power

Input

External

DC Bus

Connection

+10 V DC

0 - 10 V DC

Ref. Input*

0 - 10 V DC

Ref. Input*

4 - 20 mA

Ref. Input*

Reset*

Lockout*

Run/Stop*

Reverse*

Interlock*

Preset Speed*

91 (L1)

92 (L2)

93 (L3)

99 (PE)

88 (-)

89 (+)

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

60 (A IN)

12 (+24 V OUT)

13 (+24 V OUT)

16 (D IN)

17 (D IN)

18 (D IN)

19 (D IN)

20 (COM D IN)

27 (D IN)

29 (D IN)

SW4

Switch Mode

Power Supply

10 V DC

17 mA

+ -

EIA-485

Interface

24 V DC

200 mA

+ -

5 V

SW2 SW3

(COM EIA-485) 61

(U) 96

(V) 97

(W) 98

(PE) 95

(AUX RELAY) 01

( AUX RELAY) 02

(AUX RELAY) 03

(RELAY) 04

(RELAY) 05

(COM A OUT) 39

(A OUT) 42

0 V

(A OUT) 45

(P EIA-485) 68

(N EIA-485) 69

Motor

Fault Indication* 240 V AC, 2 A

Run Indication* 30 V AC, 1 A

Output Current Indication* 4 - 20 mA

Output Speed Indication* 4 - 20 mA

+

EIA-485

-

Setup Select*

32 (D IN)

33 (D IN)

* The operation of all control inputs and outputs is programmable.

* Typical terminal functions are shown.

NOTE

Electrical Installation, Control Wiring

Torque: 5 - 6 in-lbs Screw size: M3

Shielded control wires are recommended. To reduce interference from electrical noise, ground the cable shield at a cable clamp, as shown below, at both ends. Connect the shield to the grounded clamp. Very long control wires may create 60 Hz interference. To resolve this, connect one end of the shield to earth with a 0.1µF capacitor, keeping the leads as short as possible. If interference persists, disconnect the grounded shield connection at the end opposite to the drive.

DIP Switches 1 through 4

DIP switches are located on the control card.

They are used for serial communication and the common of digital inputs 16 through 33. The switch positions shown are the factory settings.

Sw itc h 1 i s no t used .

Switches 2 and 3 are used for terminating serial communication. On the first and last drive in a multiple device network, or on the only drive of a single drive network, switches 2 and 3 must be ON (the default setting). On all other drives in a multiple device network, set switches 2 and 3 to OFF.

Switch 4 separates the common for the internal 24 VDC supply from the common of the external 24 VDC supply. Normally this switch is ON and the power supply is present at terminals 12 and 13. Set Switch 4 to the OFF position when an external 24 VDC supply is used.

Ground Leakage Current

It is normal for there to be some leakage current from the drive to earth ground. Paths of current leakage are shown on the drawing below. The leakage current will exceed 3.5 mA.

Paths of Normal Current Leakage to Ground

Galvanic Isolation

Galvanic isolation offers protection from electric shock. All control terminals of all TR1 drives, and terminals 1 through 3 of the relay output, offer galvanic isolation. The galvanic isolation in the TR1 conforms to the European standard EN 50178. (See figure below.)

The components that make up the galvanic isolation are:

1. Power supply, including signal isolation.

2. Gate drive for the IGBTs, the trigger transformers and optocouplers.

3. The output current Hall effect transducers.

Galvanic Isolation

Extra Safety Protection

Residual Current Device (RCD) relays for ground fault protection, or multiple protective grounding, can be used as extra safety protection, provided that local safety regulations are complied with. In case of a grounding fault, the fault current may contain a DC component. If RCD relays, also known as Earth Leakage Circuit Breakers (ELCB), are used, they may be suitable for protection of 3-phase equipment with a bridge rectifier and for a brief current surge at power-up.

Electrical Noise

In general, electrical noise can be divided into two forms: wire-borne electromagnetic interference (EMI), and radiating radio frequency interference (RFI).

Using shielded motor cables reduces RFI but increases EMI. This is because shielded wires have a greater capacitance than unshielded wires. Unshielded input power connections to the drive generate more noise in the radio frequency range on the AC line. The shield reduces the radiated noise, but increases the low-frequency electromagnetic noise on the AC line. But, since the noise current is taken back to the unit through the shield, only a small electromagnetic field is generated from shielded motor wires.

With an EMI filter, the noise level on the AC line will be reduced to about the same level for shielded and unshielded wires alike.

Connect the motor wiring shield, if used, in the enclosure of the drive as well as at the motor. Use shield brackets to avoid pigtail shield ends. Even short pigtails increase the shields impedance at higher frequencies, which reduces the shields effect and increases the noise produced.

It is generally easier and less complicated to use unshielded motor wires than shielded cables. If unshielded wires are used, the RFI will be greater. But, since the strength of the radiated signal decreases with distance from the signal source, radiated noise is generally not a problem.

To reduce the noise level from the total system (drive + installation) make the motor wiring as short as possible.

Provide separate conduits, or raceways, for power, motor and control wiring to provide the greatest immunity from distortion.

Since leakage current is greater than 3.5 mA, reinforced grounding must be provided if compliance with EN 50178 is required. The relays must be suitable to meet the following requirements:

1) protecting equipment with a DC content (Din VDE 0664) in the fault current (3-phase rectifier)

2) power-up with short pulse-shaped charging current to ground

3) high leakage currents

RCD fault relays type B comply with these requirements according to the norm IEC 755-2.

Application Control Connection Examples Two-wire Start/Stop

In Auto mode, closing the contact to terminal 18 will make the drive run. In any mode, opening the safety interlock contact to terminal 27 will stop the drive.

Set Parameter 302 to Start. Set Parameter 304 to Safety Interlock.

Digital Speed Up/down

Closing the switch to terminal 32 will make the drive accelerate. Closing the switch to terminal 33 will make the drive decelerate.

Run Permissive

After receiving a run command, the drive will apply power to the damper motor and wait until it receives permission via the switch that is connected to terminal 16.

Set Parameter 300 to Run Permissive. Set Parameter 302 to Start. Set Parameter 304 to External Fault. Set Parameter 323 to Start Signal Applied.

Two Feedback Signals

The drive processes two independent feedback signals during closed loop operation. It can respond to the sum, difference, average, minimum or maximum of these signals.

Set Parameter 306 to Speed up. Set Parameter 307 to Speed down. Set Parameter 305 to Freeze reference.

Potentiometer Reference

A manual potentiometer is used as a input reference for the drive.

Set Parameter 308, Terminal 53, Analog Input Voltage, to Reference. Set Parameter 309, Terminal 53, Min. Scaling, to 0 V. Set Parameter 310, Terminal 53, Max. Scaling, to 10 V.

Set Parameter 308 to Feedback. Set Parameter 311 to Feedback Set Parameter 417 for the desired operation.

Transmitter Connection

The drives internal 24 VDC power supply is used to power an external 4 to 20 mA transducer.

Set Parameter 314, Terminal 60, Analog Input Current, to correspond to the purpose of the 4 to 20mA signal. Set Parameter 315, Terminal 60, Min. Scaling, to 4 mA Set Parameter 316, Terminal 60, Max. Scaling, to 20mA.

Because the commons of the +24 VDC power supply and the input reference follower have separate circuit commons, it is necessary to connect a jumper between terminals 39 and 55.

Control Panel

The Local Control Panel (LCP), normally mounted on the front of the drive, is a complete interface for programming and operating the drive. The control panel can be removed from the drive and installed up to 10 feet (3 meters) from the drive by using a remote mounting kit.

The control panel has five functions:

1. Display

2. Keys for changing the display

3. Keys for changing programming parameters

4. Indicator lamps

5. Keys for controlling drive operation

The LCP uses a four-line, alpha-numeric, back-lit, LCD display. The display can show four operating data values and three operating condition values continuously. During programming, all the information required for quick, effective parameter setup of the drive will be displayed. As a supplement to the display, there are three indicator lamps for power on (ON), warning (WARNING) and alarm (ALARM).

All drive parameters can be changed from the control panel, unless this ability has been locked out by setting parameter 016, Lock for Data Change, to Locked, or by a digital input to terminals 16 through 33. See the related parameters for more information.

Keys for Parameter Changes

The keys are divided into groups by function. The keys between the display and indicator lamps are used for parameter setup, selecting the display indication during normal operation and controlling the drive speed during local speed control operation. The keys below the indicator lamps are used for Start/Stop control and selection of the operating site.

The DISPLAY MODE key is used to change the mode of the display or to return to the Display Mode from either the Quick Menu or the Extend Menu mode.

The QUICK MENU key gives access to the parameters available for the Quick Menu setup. Parameters in this menu are the 12 most important setup parameters for the drive.

The EXTEND MENU key gives access to all parameters.

The CHANGE DATA key is used for changing the value of a parameter selected either in the Extend Menu or the Quick Menu mode. The desired parameter is first selected. Then the CHANGE DATA key is pressed to enable the editing of the parameter. The underline in the display will move under the parameters value to show that it is being edited.

The CANCEL key is used if a change of the selected parameter is not to be carried out.

The OK key is used for confirming a change of the parameter selected.

The + and - keys are used to scroll through parameters and to change the value of a chosen parameter. These keys are also used to change the local reference. In Display Mode, these keys are used to switch between readouts.

The v and w keys are used to select a parameter group and also to move the cursor to the desired digit when changing numerical values.

Indicator Lamps

At the bottom of the control panel is a red alarm LED, a yellow warning LED, and a green poweron LED.

AUTO START is used if the drive is to be started via the control terminals and/or serial communication. When a remote start signal is active, the drive will start if the AUTO START key has been pressed.

WARNING

Unintended Start!

In Auto Mode, a start signal via digital inputs may cause drive to start at any time. The drive, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness in Auto Mode could result in death, serious injury, or equipment or property damage.

red yellow green

If certain threshold values are exceeded, the alarm and/or warning lamps will flash and text describing the alarm or warning condition will be displayed.

Local Control

Below the indicator lamps are keys which are used to determine the point of control. Each of these keys can be individually enabled or disabled using parameter 012 through 015. The Hand Start and Auto Start keys will also be disabled if any of the control terminals are programmed for either Remote Hand or Remote Auto.

The HAND START key is used if the drive is to be started from the control panel. Pressing HAND START will give a start command to the drive.

NOTE If a minimum speed is set in parameter 201, Output Frequency, Low Limit, the motor will start and ramp up to this frequency when HAND START is pressed. If drive is running in Auto Mode when the HAND START key is pressed, drive control will switch to Hand Mode.

The OFF/STOP key is used for stopping the connected motor in either the Hand or Auto mode. Enable or disable via parameter 013. If this stop function is activated, the second line in the LCD display will flash.

The RESET key is used for manually resetting the drive after a fault trip (alarm). In this case, the top line of the display will show TRIP (RESET). If the top line of the display shows TRIP (AUTO START), the drive will automatically restart. If the top line of the display shows TRIPLOCK (DISC. MAINS), input power to the drive must be removed before the trip can be reset.

Display Modes

In Auto operational mode, information is displayed in any of three programmable displays. Pressing the DISPLAY MODE key enters display mode and toggles between modes I and II. While in Display mode, the [+] and [-] keys scroll through all data display options. When in Mode II, holding down the DISPLAY MODE key enters Mode III which identifies the units on the top line that the display is showing. Mode IV is available only in local Hand operation and displays the local speed reference.

In normal operation, three data readouts can be shown on the first (top) line of the display. Parameters 008, 009 and 010 select the data displayed on the top line. One readout is available for the large display (line 2). Parameter 007, Large Display Readout, selects the data displayed on line 2. The list on the next page defines the operating data that can be selected for the display readouts.

During an alarm (fault trip), ALARM and the alarm number are shown on the large display. An explanation is given in line 3 or in lines 3 and

4. For a warning, WARN. and the warning number are shown with an explanation in line 3 and/or 4. Both alarms and warnings cause the display to flash.

Line 4 (bottom line), in normal operation, automatically displays the operating status of the drive.

The active setup number and an arrow indicating the direction of motor rotation is shown on the right side of the large display. Clockwise indicates forward and counterclockwise indicates reverse. The arrow body is removed if a stop command is given or if the output frequency falls below 0.01 Hz.

The table below gives the operating data options for the first and second lines of the display.

Data Item: Unit:

Resulting reference, % % Resulting reference unit chosen in par. 415 Frequency Hz % of maximum output frequency % Motor current A Power kW Power HP Output energy kWh Hours run hours User defined readout unit chosen in par. 006 Setpoint 1 unit chosen in par. 415 Setpoint 2 unit chosen in par. 415 Feedback 1 unit chosen in par. 415 Feedback 2 unit chosen in par. 415 Feedback unit chosen in par. 415 Motor voltage V DC link voltage V Thermal load on motor % Thermal load on TR1 % Input status, digital input binary code Input status, analog terminal 53 V Input status, analog terminal 54 V Input status, analog terminal 60 mA Pulse reference Hz External reference % Heat sink temperature

Display Mode I:

In Display mode I, the drive is in Auto mode with reference and control determined via the control terminals. Following is an example in which the drive is running in setup 1, in Auto mode, with a remote reference, and at an output frequency of 40 Hz.

Status line (Line 4): Additional automatic displays for the drive status line are shown below. See Status Messages section in this manual for additional information.

80.0% 5.08A 2.15HP

SETUP

40.0Hz

AUTO REM. RUNNING

HAND

OFF

LOCAL

STOP

RAMPING JOGGING

. . . .

STAND BY

The left indicator on the status line displays the active control mode of the TR1 drive. AUTO is displayed when control is via the control terminals. HAND indicates that control is local via the keys on the LCP. OFF indicates that the drive ignores all control commands and will not run.

The center part of the status line indicates the reference element that is active. REM. (Remote) means that reference from the control terminals is active, while LOCAL indicates that the reference is determined via the [+] and [-] keys on the control panel.

The last part of line 4 indicates the drive's operational status, for example: RUNNING, STOP, or RUN REQUEST, and so on.

Display Mode II:

This display mode shows three operating data values in the top line programmed via parameters 008, 009, and 010. Pressing the DISPLAY MODE key toggles between Display modes I and II.

The text in line 1, FREQUENCY, describes the meter shown in the large display. Line 2 (large display) shows the current output frequency (40.0 Hz), direction of rotation (reverse arrow), and active setup (1). Line 3 is blank. Line 4 is the status line and the information is automatically generated for display by the drive in response to its operation. It shows that the drive is in auto mode, with a remote reference, and that the motor is running.

FREQUENCY

40.0 Hz

AUTO REMOTE RUN

SETUP

100% 7.8A 5.9HP

SETUP

50.0 Hz

AUTO REMOTE RUN

Display Mode III:

Press and hold the [DISPLAY MODE] key while in ModeII. Mode III is visible as long as the key is depressed. The top line changes to identify the data names and units displayed. Lines 2 and 4 are unchanged. When the key is released, the display returns to Mode II.

Changing Numeric Values

If the chosen parameter represents a number value, the flashing digit can be changed by means of the [+]and [-] keys. Position the cursor by using the [<]and [>] keys, then change the data value using the [+] and [-] keys.

REF% CURR.A POW.HP

SETUP

50.0 Hz

AUTO REMOTE RUN

Display Mode IV:

This display mode is available when local reference is selected. In this display mode, the speed reference is increased or decreased via +/- keys.

The first line shows the present speed reference. The second line shows the present drive output frequency. The third line show a bar graph of the relative value of the present drive output frequency in relation to the maximum frequency.

USE +/- 56Hz

SETUP

40.0Hz

0 ••-----60

FREQUENCY

SETUP

24.2 Hz

205 MAX. REFERENCE

000060.000 Hz

The selected digit is indicated by a flashing cursor. The bottom display line gives the data value that will be entered (saved) by pressing the OK button. Use CANCEL to ignore the change.

Changing Functional Values

If the selected parameter is a functional value, the selected text value can be changed by means of the [+] and [-] keys.

MOTOR CURRENT

SETUP

3.90 A

210 REFERENCE TYPE SUM

HAND LOCAL RAMPING

Changing Data

Regardless of whether a parameter has been selected under the Quick Menu or the Extend Menu, the procedure for changing data is the same. Pressing the CHANGE DATA key gives access to changing the selected parameter. Line 3 displays the parameter number and title. The underlined function or number flashing in line 4 on the display is subject to change.

The procedure for changing data depends on whether the selected parameter represents a numerical data value or a function.

The functional value flashes until signing off by pressing the OK button. The functional value has then been selected. Use CANCEL to ignore the change.

Changing Numeric Values in a List

A few parameters offer numeric lists of values that can be selected from or changed. This means that if the numeric value is not listed, a value may be entered using the procedure for changing numeric values. This applies to parameter 102, Motor power, parameter 103, Motor voltage, and parameter 104, Motor frequency.

Quick Menu

The Quick Menu gives access to the 12 most important setup parameters of the drive. After programming the Quick Menu items, the drive will, in many cases, be ready for operation. The Quick Menu

parameters are described in the table below. A detailed description of the functions are given in the Programming section of this manual. The Quick Menu is activated by pressing the QUICK MENU key on the control panel.

Quick Menu Parameter Item Number Name

1 001 Language Selects language used for all displays. 2 102 Motor Power Sets output characteristics of drive based on kW (HP) of motor. See

chart in parameter 102, Motor Power, to convert HP to kW. 3 103 Motor Voltage Sets output characteristics of drive based on voltage of motor. 4 104 Motor Frequency Sets output characteristics of drive based on nominal frequency of

motor. This is typically equal to line frequency. 5 105 Motor Current Sets output characteristics of drive based on full load current in amps

(FLA) of motor. This sets overload protection for motor. 6 106 Motor Nominal Speed Sets output characteristics of drive based on nominal full load speed of

motor. 7 201 Minimum Frequency Sets minimum controlled frequency at which motor will run. 8 202 Maximum Frequency Sets maximum controlled frequency at which motor will run. 9 206 Ramp Up Time Sets time to accelerate motor from 0 Hz to nominal motor frequency

set in Quick Menu Item 4.

10 207 Ramp Down Time Sets time to decelerate motor from nominal motor frequency set in

Quick Menu Item 4 to 0 Hz.

11 323 Relay 1 Function Sets function of high voltage Form C relay.

12 326 Relay 2 Function Sets function of low voltage Form A relay.

Description

To Enter or Change Quick Menu Parameter Data

Enter or change parameter data or settings in accordance with the following procedure.

1. Press Quick Menu key.

2. Use t and u keys to find parameter group to edit.

3. Use + and - keys to find parameter you chose to edit.

4. Press Change Data key.

5. Use + and - keys to select correct parameter setting. Or, to move to digits within a number, use t and u arrows. Flashing cursor

indicates digit selected to change.

6. Press Cancel key to disregard change, or press OK key to accept change and enter new setting.

Example of Changing Parameter Data

Assume Parameter 206, Ramp Up Time, is set at 60 seconds. Change the ramp up time to 100 seconds in accordance with the following procedure.

1. Press Quick Menu key.

2. Press + key until you reach Parameter 206, Ramp Up Time.

3. Press Change Data key.

4. Press t key twice  hundreds digit will flash.

5. Press + key once to change hundreds digit from 0 to 1.

6. Press u ke y to move cur sor to t ens digit.

7. Press - key until 6 counts down to 0 and setting for Ramp Up Time reads 100 s.

8. Press OK key to enter new value into drive controller.

NOTE Programming additional parameter functions available through Extended Menu key is done in accordance with same procedure as described for Quick Menu functions.

Extended Menu

In some applications, the Quick Menu will not access all additional parameters necessary to set up the drive. To access all parameters, including Quick Menu items, use the Extended Menu. The Extended Menu is enabled by pressing the EXTEND. MENU key. The Programming section of this manual describes in detail all the parameters available through the Extended Menu.

Manual Initialization of Parameters

NOTE Manual initialization using either procedure described below, or in parameter 620, will reset the drive to standard default parameters. Any special application programming performed at the factory, during start-up or thereafter, will be lost. As a backup, upload drive settings into the driveís local control panel (LCP) keypad as described in parameter 004, LCP Copy.

It is possible to reset parameters back to their original default values at once. To reset the drive parameters to their read only default values, first remove power from the drive. Then press and hold the DISPLAY MODE, the CHANGE DATA and the OK keys down simultaneously while reapplying power. Continue to hold down the three keys. Shortly after power is reapplied, the bottom line of the display will read Initialized. After the display stops changing, release the keys. If Initialized did not appear, repeat the procedure.

Uploading Parameters

At any time the present parameters may be copied to the local control panel (LCP). This may be useful when setting up multiple drives. It is also useful when it is desired to return to a previous set of parameters. See parameter 004, LCP Copy, for more information.

Manually initializing the drive using either the procedure described above or parameter 620, Operating Mode, does not change the values uploaded to the local control panel.

These parameters are not reset by manual initialization:

Parameter 600 Operating hours Parameter 601 Hours run Parameter 602 kWh counter Parameter 603 Number of power-ups Parameter 604 Number of overtemperatures Parameter 605 Number of overvoltages

Initialization can also be done using Parameter 620.

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Trane TR1 6006, TR1 6011, TR1 6004, TR1 6003, TR1 6016 Installation And Operation Manual

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