tr150 PDF

TR150 and TR170
Service Manual
Literature Order Number BAS-SVM04B-EN

Date February 2017
Supersedes November 2013
www.trane.com
For more information, contact your local Trane Trane has a policy of continous product and product data improvement and reserves the right to
office or e-mail us at [email protected] change design and specifications without notice.
BAS-SVM04B-EN
February 2017 BAS-SVM04B-EN
130R0538 MG18K202 02/2017
*MG18K202*
Contents TR150 and TR170 Service Manual
Contents
1 Introduction 6
1.1 Purpose 6
1.2 Product Overview 6
1.3 Safety 6
1.4 Electrostatic Discharge (ESD) 6
1.5 Tools Required 9
1.6 Electrical Installation in General 10
1.6.1 Electrical Installation in General 10
1.7 Exploded Views – H Frame Size 11
1.8 Exploded Views - I Frame Size 14
1.9 Ratings 17
1.9.1 Short Circuit and Overcurrent Trips 17
1.9.2 DC Voltage Levels 17
2 Frequency Converter Control 18

2.1 Introduction 18
2.2 Status Messages 18
2.3 Frequency Converter Inputs and Outputs 18
2.3.1 Input Signals 18
2.3.2 Output Signals 19
2.4 Service Functions 19
2.5 Control Terminals 19
2.6 Control Terminal Functions 20
2.7 Grounding Shielded Cables 22
3 Internal Frequency Converter Operation 23

3.1 General 23
3.2 Description of Operation 23
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 24
3.3.1 Rectifier Section 24
3.3.2 Intermediate Section 24
3.3.3 Inverter Section 25
3.3.4 Fan Speed Control 25
4 Troubleshooting 27
4.1 Troubleshooting Tips 27
4.2 Exterior Fault Troubleshooting 27
BAS-SVM04B-EN 02/2017 All rights reserved. 1

Contents
4.3 Fault Symptom Troubleshooting 27

4.4 Visual Inspection 28
4.5 Fault Symptoms 30
4.5.1 No Display 30
4.5.2 Intermittent Display 30
4.5.3 Display (Line 2) Flashing 30
4.5.4 WRONG or WRONG LCP Shown 30
4.5.5 Motor Will Not Run 30
4.5.6 Incorrect Motor Operation 31
4.6 Warnings and Alarms 32
4.6.1 Alarms 32
4.6.2 Warnings 32
4.6.3 Warning And Alarm Messages 32
4.7 After Repair Tests 38
5 Frequency Converter and Motor Applications 39

5.1 Torque Limit, Current Limit, and Unstable Motor Operation 39
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 41
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 Effects 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 45
6.1 Non-repairable Units 45
6.2 Introduction 47
6.3 Static Test Procedures 47
6.3.2 Rectifier 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 52
6.4.1 No Display Test (Display is Optional) 52
2 02/2017 All rights reserved. BAS-SVM04B-EN

6.4.2 Input Voltage Test 52

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 53
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 56
7 H-Frame Size Disassembly and Assembly Instructions 57

7.1 Electrostatic Discharge (ESD) 57
7.2 General Disassembly Procedure 57
7.3 H6 Frame Size Disassembly and Assembly Instructions 57
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
7.4.2 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 Rectifier 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
7.5.2 Power Card 66
7.5.4 Rectifier Modules 67
7.5.5 RFI Filter 68
7.5.7 IGBT 69
7.5.9 DC Coil 71

Contents

7.6.2 Power Card Cover 72
7.6.3 Power Card 73
7.6.4 Heat Sink and DC Coils 73
8 I-Frame Size Disassembly and Assembly Procedures 75

8.1 General Disassembly Procedure 75
8.2 I6 Frame Size Disassembly and Assembly Instructions 75
8.2.2 Cable Mounting Plate 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 79
8.3.2 Power Card 80
8.3.3 Power Card Mounting Plate 80
8.3.5 Bus Bar 81
8.3.6 RFI Filter 82
8.3.8 Fan 83
8.3.9 Terminal Plate 83
8.3.10 DC Bus Bar Assembly 84
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 86
8.4.2 Power Card 87
8.4.3 Power Card Mounting Plate 88
8.4.5 Bus Bar 89
8.4.6 RFI Filter 89

8.4.8 Terminal Plate 90

8.4.9 DC Bus Bar Assembly 91
8.4.12 DC Coil 92
8.4.13 IGBT 93
8.4.14 Thyristor 93
9 Block Diagrams 94
9.1 Block Diagrams, Frame Sizes H and 9 94
9.1.1 H6 Frame Size 94
9.1.2 I6 Frame Size 95
9.1.3 H7, H8, I7, I8 Frame Size 96
Index 99

Introduction
1 1 1 Introduction
1.1 Purpose nected (linkage of DC intermediate circuit). There

may be high voltage on the DC-link even when
This manual provides the technical information and the LEDs are turned off. Before touching any
instructions required, for a qualified technician approved potentially live parts of the frequency converter,
by Trane to identify faults and perform repairs and wait at least as stated in Table 1.1.
maintenance on the frequency converter:
2. Before conducting repair or inspection,
• Data for the different enclosure sizes disconnect mains.
• Description of user interfaces and internal
3. [Off] on the LCP does not disconnect mains.
processing
4. During operation and while programming
• Troubleshooting and test instructions
parameters, the motor may start without warning.
• Assembly and disassembly instructions Press [Stop] when changing data.
The manual applies to frequency converter models and 5. When operating on a PM motor, disconnect
voltage ranges described in Table 1.2 to Table 1.4. motor cable.
1.2 Product Overview Minimum waiting
Voltage [V] Power range [kW]
time (minutes)
TR150 and TR170 frequency converters are designed for
3x200 0.25–3.7 4
the Heating, Ventilation, and Air-Conditioning (HVAC)
3x200 5.5–11 15
markets. They operate in variable torque mode, and
include features suited for fan and pump applications 3x400 0.37–7.5 4
within the HVAC market. 3x400 11–90 15
3x600 2.2–7.5 4
1.3 Safety 3x600 11–90 15
CAUTION Table 1.1 Discharge Time
Frequency converters contain dangerous voltages when

connected to mains. Only qualified personnel should 1.4 Electrostatic Discharge (ESD)
carry out the service. See also chapter 2.1 Introduction.
CAUTION
CAUTION ELECTROSTATIC DISCHARGE
When performing service, use proper electrostatic
For dynamic test procedures, main input power is
discharge (ESD) procedures to prevent damage to
required and all devices and power supplies connected
sensitive components. Many electronic components
to mains are energized at rated voltage. Take extreme
within the frequency converter are sensitive to static
caution when conducting tests in a powered frequency
electricity. The voltage of static electricity can reduce
converter. Contact with powered components could
lifetime, affect performance, or completely destroy
result in electrical shock and personal injury.
sensitive electronic components.
1. DO NOT touch electrical parts of the frequency • Do not touch components on the circuit boards.
converter when connected to mains. Also make • Hold circuit boards by the edges or corners
sure that other voltage inputs have been discon- only.

Introduction TR150 and TR170 Service Manual
1.4.1 Frame Size Definitions 1 1

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 IP20 No
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

Introduction
1 1 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 IP20 No
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
Table 1.3 TR150 and TR170 Frequency Converters 380–480 V AC

Model HP @525–600 V AC kW @525–600 V AC Frame Size IP Rating Repairable Yes/No 1 1

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
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 1 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 IP class 3x200–240 V 3x380–480 V Mains Motor DC Control Ground Relay
size connection terminals
TR150
H1 IP20 0.25–1.5 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)
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) 24 (212)1) 24 (212)1) – 0.5 (4) 3 (27) 0.5 (4)
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)
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 IP class 3x525–600 V Mains Motor DC Control Ground Relay
size connection terminals
TR150
H9 IP20 2.2–7.5 (3–10) 1.8 (16) 1.8 (16) Not 0.5 (4) 3 (27) 0.6 (5)
recommended
H10 IP20 11–15 (15–20) 1.8 (16) 1.8 (16) Not 0.5 (4) 3 (27) 0.6 (5)
recommended
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 14 (124)/24 – 0.5 (4) 3 (27) 0.5 (4)
(212)2) (212)2)
Table 1.7 Tightening Torques for Enclosure Sizes H6–H10, 3x525–600 V

1) Cable dimensions >95 mm2
2) Cable dimensions ≤95 mm2

1.7 Exploded Views – H Frame Size 1 1

NOTICE
Non-repairable units are not shown with exploded views.
1 Blind cover 10 Filter protection cover

2 Front cover LCP 11 RFI filter
3 Cradle 12 EMC 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 1
1 Blind cover 13 Relay/transducer card mounting plate

2 LCP 14 DC coil cover plate
3 Front cover 15 Bus bar
4 EMC shield 16 Plastic cover
5 Cradle 17 Rectifier modules
6 Control card 18 Heat sink fan assembly
7 Control card mounting plate 19 DC coils
8 Power card 20 Capacitors
9 Power card mounting plate 21 Base plate
10 RFI filter 22 Relay/transducer card
11 EMC shield 23 IGBT
12 Inrush card 24 Cable mounting plate

1 1
1 LCP 12 SMPS 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 Rectifier modules
8 Plastic cover 19 Heat sink fan assembly
9 RFI filter 20 Capacitors
10 DC coil cover plate 21 Base cover
11 Bus bar unit 22 Connection terminals

Introduction
1 1 1.8 Exploded Views - I Frame Size
1 Local Control Panel (LCP) 9 DC coil

2 Front cover 10 Heat sink
3 Cradle 11 Fan assembly
4 Control card 12 Cable mounting plate
5 Control card mounting plate 13 RFI filter
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

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 filter 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

Introduction
1 1
1 LCP 11 DC coil
2 Front cover 12 Rectifier modules
3 Cradle 13 IGBTs
4 LCP gasket 14 Capacitors
5 Control card 15 Heat sink fan assembly
6 Control card mounting plate 16 Fan
7 Support bracket 17 Cable mounting plate
8 RFI filter 18 Relay/transducer card with mounting plate
9 Power Card 19 Cable entry
10 Power card mounting plate

1.9 Ratings 1 1
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 off 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 H6–H8 H6–H10
I2–I3–I4 I6–I8
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

Frequency Converter Control
2 Frequency Converter Control

2 2
2.1 Introduction - Supplies commands and references to
the frequency converter.
This section describes the optional display interfaces
- Programs the frequency converter.
available for the frequency converter, the inputs and
outputs, and the control terminal functions. - Reads status data from the frequency
converter.
The following optional interfaces are available: • Via signal wiring connected to the frequency
• Numerical Local Control Panel (LCP 21). converter control terminals. Improperly connected
control wiring can result in the frequency
• Graphical Local Control Panel (GLCP or LCP 102).
converter failing to start or to respond to a
Use the selected interface to adapt parameter settings or remote input.
read status.
Commands given to the frequency converter are indicated
on the selected interface display. Fault logs are maintained
2.3.1 Input Signals
within the frequency converter, for fault history. The
frequency converter issues warnings and alarms for fault The frequency converter can receive 2 types of remote
conditions arising within or external to the frequency input signals: digital or analog. Digital inputs are wired to
converter itself. Usually, the fault condition is found outside terminals 18, 19, 20 (common), 27, 29. Analog or digital
of the frequency converter. inputs are wired to terminals 53 or 54 and 55 (common). A
switch placed under the LCP sets the terminal functions.
2.2 Status Messages Some options include additional terminals.
Status messages appear in the bottom of the display. The

Analog signals can be either voltage (0 V to +10 V DC) or
left part of the status line indicates the active operation
current (0–20 mA or 4–20 mA). Analog signals can be
model of the frequency converter.
varied like dialing a rheostat up and down. The frequency
converter can be programmed to increase or decrease
The center part of the status line indicates the references output in relation to the amount of current or voltage. For
site. The last part of the status line gives the operation example, a sensor or external controller may supply a
status, for example: variable current or voltage. The frequency converter
• Running. output, in turn, regulates the speed of the motor
• Stop. connected to the frequency converter in response to the
analog signal.
• Standby.
Other status messages may appear and are related to the
Digital signals are a simple binary 0 or 1 acting as a switch.
software version and frequency converter type.
A 0-24 V DC signal controls the digital signals. A voltage
2.3 Frequency Converter Inputs and signal lower than 5 V DC is a logic 0. A voltage higher than
Outputs 10 V DC is a logic 1. 0 is open, 1 is close. Digital inputs to
the frequency converter are switched commands such as
The frequency converter operates by receiving control start, stop, reverse, coast, reset. (Do not confuse these
input signals. The frequency converter can also output digital inputs with serial communication formats where
status data or control auxiliary devices. digital bytes are grouped into communication words and
protocols).
Control input is sent to the frequency converter in 3 ways:
• Via the optional LCP connected by cable to the The RS485 serial communication connector is wired to
frequency converter, operating in [Hand On] terminals (+) 68 and (-) 69. Terminal 61 is a common
mode. These inputs include start, stop, reset, and terminal. It is used for terminating shields only when the
speed reference. control cable is run between frequency converters, and not
between frequency converters and other devices.
• Via serial communication from a fieldbus,
connected to the frequency converter through
the RS485 serial port, or through a communi- Parameters for configuring the input and output using
cation option card. The serial communication NPN and PNP.
protocol:
These parameters cannot be changed while the motor is
running.

Frequency Converter Control TR150 and TR170 Service Manual
2.3.2 Output Signals See the Quick Guide for detailed information on accessing
and showing parameters, and for descriptions and
The frequency converter also produces output signals that procedures for service information available in parameter
are carried either through the RS485 serial bus or terminal group 6-** Analog In/Out. 2 2
42. Output terminal 42 operates in the same manner as 2.5 Control Terminals
the inputs. The terminal can be programmed for either a
variable analog signal in mA or a digital signal (0 or 1) in For proper function of the frequency converter functioning,
24 V DC. In addition, a pulse reference can be provided on the input control terminals must be:
terminals 27 and 29. Output analog signals generally • Wired properly.
indicate the frequency, current, torque, and so on, to an
external controller or system. Digital outputs can be
• Powered.
control signals used to open or close a damper, or send a • Programmed correctly for the intended function.
start or stop command to auxiliary equipment. Ensure that the input terminal is wired correctly:
1. Confirm that the control and power sources are
Additional terminals are Form C relay outputs on terminals wired to the terminal.
01, 02, and 03, and terminals 04, 05, and 06.
2. Check the signal in either of 2 ways:
Terminals 12 and 13 provide 24 V DC low voltage power, • Press [Display Mode], then select Digital
Input. The LCP shows the digital inputs
often used to supply power to the digital input terminals
which are correctly wired.
(18–33). Those terminals must be supplied with power
from either terminal 12 or 13, or from a customer supplied • Use a voltmeter to check for voltage at
external 24 V DC power source. Improperly connected the control terminal.
control wiring is a common service issue for a motor not Confirm that each control terminal is programmed for the
operating or the frequency converter not responding to a correct function. Each terminal has specific functions and a
remote input. numbered parameter associated with it. The setting
selected in the parameter enables the function of the
Number of digital outputs 2 terminal.
Terminal number 42, 451)
Voltage level at digital output 17 V See the Quick Guide for details on changing parameters
Maximum output current at digital 20 mA and the functions available for each control terminal.
output
Maximum load at digital output 1 kΩ
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 different 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.

2.6 Control Terminal Functions

Table 2.2 describes the functions of the control terminals.
2 2 Many of these terminals have multiple functions
determined by parameter settings. See Illustration 2.1.
Terminal Function
number
01, 02, 03 Form C relay output on control card. Maximum 240
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.
04, 05 Form A relay output on control card. 30 V AC, 42.5
V DC. Can be used for indicating status and
warnings.
12, 13 Voltage supply to digital inputs and external
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.
16–33 Programmable digital inputs for controlling the
frequency converter. R=2 kΩ. Less than 5 V=logic 0
(open). Greater than 10 V=logic 1 (closed).
20 Common for digital inputs.
39 Common for analog and digital outputs.
42, 45 Analog and digital outputs for indicating values
such as frequency, reference, current, and torque.
The analog signal is 0–20 mA, or 4–20 mA at a
maximum of 500 Ω. The digital signal is 24 V DC at
a minimum of 600 Ω.
50 10 V DC, 17 mA maximum analog supply voltage
for potentiometer or thermistor.
53, 54 0–10 V DC voltage input, R = 10 kΩ Used for
reference or feedback signals. A thermistor can be
connected here.
55 Common for analog inputs. This common is
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.
60 Programmable 0–20 mA or 4–20 mA, analog
current input, Resistance=approx. 200 Ω. Used for
reference or feedback signals.
61 RS485 common.
68, 69 RS485 interface and serial communication.
Table 2.2 Terminal Functions

Frequency Converter Control TR150 and TR170 Service Manual
2 2
Illustration 2.1 Control Terminal Electrical Overview
Control terminals must be programmed. Each terminal has specific 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.

2.7 Grounding Shielded Cables Serial communication control cables

Low-frequency noise currents between frequency
Connect the shielded control cables to the metal cabinet converters can be eliminated by connecting 1 end of the
2 2 of the frequency converter with cable camps at both ends. shielded cable to frequency converter terminal 61. This
Illustration 2.3 shows ground cabling for optimal results. terminal connects to ground through an internal RC link.
To reduce the differential mode interference between
Correct grounding conductors, use twisted-pair cables.
To ensure the best possible electrical connection, fit
control cables and cables for serial communication with
cable clamps at both ends.
Illustration 2.5 Serial Communication Control Cables
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 different,
electrical noise may occur that can disturb the entire
system. Resolve the electrical noise by fitting an equalizing
cable next to the control cable. Minimum cable cross-
section is 10 mm2 (8 AWG).
1 Minimum 10 mm2 (8 AWG)

2 Equalizing cable
Illustration 2.3 Ground Potential Protection
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 undesired program changes. With the addition of a remote

mounting kit, the LCP can be mounted in a remote
This chapter provides an operational overview of the main
assemblies and circuitry in the frequency converter.
location. 3 3
3.2 Description of Operation Control terminals, with programmable functions, are
provided for input commands such as run, stop, forward,
3.2.1 Control Logic Section reverse and speed reference. Additional output terminals
are provided to supply signals to run peripheral devices or
The control card includes most of the logic section (see for monitoring and reporting status.
Illustration 3.2). The primary logic element of the control
card is a microprocessor, which supervises and controls all The control card logic
functions of frequency converter operation. In addition, a • Communicates via serial link with outside devices
separate PROM contains the parameters to provide the such as personal computers or Programmable
user with programmable options. These parameters are Logic Controllers (PLC).
programmed to enable the frequency converter to meet
specific application requirements. This data is stored in an
• Provides 2 voltage supplies for use from the
control terminals.
EEPROM providing security during power-down and also
allows the flexibility to change the operational character- 24 V DC is used for switching functions such as start, stop,
istics of the frequency converter. 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.
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
Illustration 3.1 Logic Section • Serial communications
• Additional relays
Another part of the logic section is the removable LCP or • Cascade pump controller
display mounted on the front of the frequency converter. • Custom operating software
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 profile 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

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.
3 3
• Power Card
• Gate Driver
Illustration 3.2 Typical Power Section
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 3.3 Sequence of Operation
on the interface sections before processing by the control
card.
3.3.1 Rectifier Section
The rectifier provides a path for current flowing from the

The power card contains a Switch Mode Power Supply
line to the DC-link circuitry. As a result, the DC-link
(SMPS). The SMPS provides the unit with 24 V DC, 16 V DC,
capacitors charge.
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 The rectifier section consists of 6 diodes.
to the logic circuitry with main input disconnected. It can
keep units with communication options live on a network Inrush current, which appears when connected to grid, is
when the frequency converter is not powered from the limited with a PTC. A relay short-circuits the PTC when the
mains. DC-link capacitors are fully charged.
Circuitry for controlling speed of the cooling fans is also As long as power is applied to the frequency converter,
provided on the power card. voltage is present in the DC link and the inverter circuit.
Voltage is also fed to the switch mode power supply
3.2.3 Power Section (SMPS) on the power card and is used for generating all
other low voltage supplies.
The DC coil is a single unit 2 two coils wound on a
common core. One coil resides in the positive side of the 3.3.2 Intermediate Section
DC bus and the other in the negative. The coil aids in the
reduction of mains harmonics. From the rectifier section, voltage passes to the
intermediate section. The DC link is an LC filter circuit
The DC bus capacitors are arranged into a capacitor bank consisting of the DC-link inductor and the DC-link
along with bleeder and balancing circuitry. capacitor bank that smooths the rectified voltage.
The inverter section is made up of six IGBTs, commonly The intermediate section consists of the following
referred to as switches. One switch is necessary for each components:
half phase of the 3-phase power, for a total of 6. The 6 • The DC-link inductor located in the positive side
IGBTs are contained in 3 dual modules. of the DC link provides series impedance to
changing current. This impedance aids the
filtering process while reducing harmonic
A Hall effect type current sensor is located on each phase
distortion to the input AC current waveform
of the output to measure motor current.
normally inherent in rectifier circuits.
• The DC-link capacitors are arranged into a
capacitor bank along with bleeder and balancing
circuitry.
• High frequency (HF) filter film 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 the voltage delivered to the motor. A thermal sensor
voltage of the input AC line. Theoretically, this voltage can mounted inside the IGBT module provides heat sink temp
be calculated by multiplying the AC line value by 1.414 feedback for the inverter.
(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. 3 3
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
Illustration 3.3 Output Voltage and Current Waveforms
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. 3.3.4 Fan Speed Control
IP20
3.3.3 Inverter Section
Enclosure H6 H7 H8
Voltage T2 T2 T2 T2 T2 T2
The inverter section is made up of six IGBTs, commonly
Power rating
referred to as switches. One switch is necessary for each 15 18.5 22 30 37 45
[kW]
half phase of the 3-phase power, for a total of six. The six
IGBTs are contained in one power module shared with the FAN start
45 45 45 45 45 45
rectifier. The inverter section receives gate signals from the temperature °C
MOC. FAN maximum
speed 60 60 60 60 60 60
temperature °C
Once a run command and speed reference are present, the
FAN stop
IGBTs begin switching to create the output waveform, as 36 36 36 36 36 36
shown in Illustration 3.3. Looking at the phase to phase temperature °C
voltage waveform with an oscilloscope, a train of pulses of
Table 3.1 Fan Speed Control, IP20, H6–H8, T2
different widths is shown. The amplitude of the pulses
measures the DC-link voltage. To view the fundamental IP20
sinusoidal curve, set the oscilloscope to filter out high
Enclosure H6 H7 H8
harmonic content.
Voltage T4 T4 T4 T4 T4 T4
Power rating
When measuring current, the normal view will be a 30 37 45 55 75 90
[kW]
sinusoidal curve. The amplitude of the measured current
FAN start
depends on the loading form. 45 45 45 40 40 40
temperature °C
FAN maximum
This waveform, as generated by the frequency converter, speed 60 60 60 55 55 55
provides optimal performance and minimal losses in the temperature °C
motor. FAN stop
41 41 41 30 30 30
temperature °C
Hall effect current sensors monitor the output current and
feed it back to the control. The current signal is used for Table 3.2 Fan Speed Control, IP20, H6–H8, T4
two purposes:
• to compensate for dynamic motor operation. IP54
Enclosure I6 I7 I8
• to monitor overcurrent conditions, including
ground faults and phase-to-phase shorts. Voltage T4 T4 T4 T4 T4 T4 T4
Power rating
During normal operation, the power card and control 22 30 37 45 55 75 90
[kW]
monitor various functions within the frequency converter.
FAN start
The current sensors provide current feedback information. 45 45 45 40 40 40 40
temperature °C
The DC bus voltage and mains voltage are monitored and

Internal Frequency Converte...
IP54
Enclosure I6 I7 I8
FAN maximum
speed 60 60 60 55 55 55 55
temperature °C
FAN stop
3 3 temperature °C
35 35 35 30 30 30 30
Table 3.3 Fan Speed Control, IP54, I6–I8
IP20
Enclosure H9 H10 H6 H7 H8
Voltage T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6
Power
rating 2.2 3.0 5.5 7.5 11 15 22 30 45 55 75 90
[kW]
FAN start
tempera- 35 35 35 35 45 45 45 45 40 40 40 40
ture °C
FAN
maximum
speed 55 55 55 55 60 60 60 60 55 55 55 55
tempera-
ture °C
FAN stop
tempera- 31 31 31 31 36 41 41 41 30 30 30 30
ture °C
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 CAUTION

Before repairing a frequency converter, read and RISK OF INJURY OR PROPERTY DAMAGE
understand the following instructions. Never assume that a motor is wired properly after a
service of the frequency converter. Check for:
1. Note all warnings concerning voltages present in
the frequency converter. Always verify the
• Loose connections. 4 4
presence of AC input voltage and DC link voltage • Improper programming.
before working on the unit. Some points in the • Added equipment.
frequency converter are referenced to the Failure to perform these checks can result in personal
negative DC link. They are at DC link potential injury, property damage, or less than optimal
even though it sometimes appears on diagrams performance.
to be a neutral reference.
CAUTION Take a systematic approach, beginning with a visual

inspection of the system. See Table 4.1 for items to
Voltage can be present for as long as 20 minutes on
examine.
frequency converters after removing power from the
unit. See the label on the front of the frequency 4.3 Fault Symptom Troubleshooting
converter door for the specific discharge time.
2. Never apply power to a unit that is suspected of The troubleshooting procedures are divided into sections
being faulty. Many faulty components within the based on the different occurring symptom.
frequency converter can damage other 1. See the visual inspection check list in Table 4.1.
components when power is applied. Always Often, incorrect installation or wiring of the
perform the procedure for testing the unit after frequency converter causes the problem. The
repair as described in chapter 4.7 After Repair check list provides guidance through the items to
Tests. inspect during servicing of the frequency
3. Never attempt to defeat any fault protection converter.
circuitry within the frequency converter, as this 2. The most common fault symptoms are described
results in unnecessary component damage and in chapter 4.5 Fault Symptoms:
can cause personal injury.
• Problems with motor operation.
4. Always use factory approved replacement parts.
The frequency converter is designed to operate
• A warning or alarm shown by the
frequency converter.
within certain specifications. Incorrect parts can
affect tolerances and result in further damage to The frequency converter processor monitors
the unit. inputs and outputs as well as internal frequency
converter functions. An alarm or warning does
5. Read the instruction manual. A thorough
not necessarily indicate a problem within the
understanding of the unit is the best approach. If
frequency converter itself.
ever in doubt, consult the factory or authorised
repair centre for assistance.
For each incident, further description explains how to
4.2 Exterior Fault Troubleshooting troubleshoot that particular symptom. When necessary,
further referrals are made to other parts of the manual for
There may be slight differences in servicing a frequency more procedures.
converter that has been operational for extended time,
compared to a new installation. In either case, use proper
When troubleshooting is complete, perform the list of tests
troubleshooting procedures.
provided in chapter 6.5 Initial Start-up Or After Repair Drive
Tests.

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 • 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.
4 4 • Check function and installation of pressure sensors or encoders, and other equipment used for
feedback to the frequency converter.
Cable routing • 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.
Control wiring • 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.
Frequency converter cooling Check operational status of all cooling fans:

• When voltage is applied to the frequency converter, the fan activates for a few seconds.
• Check for blockage or constrained air passages.
Frequency converter display The display shows important items, such as:
• Warnings.
• Alarms.
• Frequency converter status.
• Fault history.
Frequency converter interior • 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.
EMC considerations • Check for proper installation regarding electromagnetic capability.
• Refer to the frequency converter operating instructions and this chapter for further details.
Environmental conditions • Under specific conditions, these units can be operated within a maximum ambient of 50 °C (122 °F).
• Humidity levels must be less than 95% non-condensing.
• Check for harmful airborne contaminates such as sulfur-based compounds.
GLCP • If supplied, check that the GLCP is correctly installed, and that the display is lit when powered on.
Grounding • 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.

Inspect for Description

Input power wiring Check for:
• Loose connections.
• Proper fusing.
• Blown fuses.
Memory module • Check that the memory module is plugged in correctly.
Motor • Check nameplate ratings of the motor.
• Ensure that motor ratings coincide with frequency converters. 4 4

• 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.
Output to motor wiring Check for:

• Loose connections.
• Switching components in output circuit.
• Faulty contacts in switch gear.
PROFIBUS option • Check that the option is mounted correctly on the control card.
Programming Ensure that frequency converter parameter settings are correct according to:
• Motor.
• Application.
• I/O configuration.
Proper clearance The frequency converter requires top and bottom clearance adequate to ensure proper air flow for
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 flat, solid surface.
Vibration • 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.
Table 4.1 Visual Inspection Check List

Troubleshooting
4.5 Fault Symptoms If the display continues to cut out, follow the procedure for
chapter 4.5.1 No Display as though the display was not lit
4.5.1 No Display at all.
The LCP display provides 2 display indications. One with 4.5.3 Display (Line 2) Flashing
the backlit alphanumeric display. The other is 3 LED
indicator lights near the bottom of the LCP. When line 2 flashes, it indicates that an LCP stop command
has been given by pressing [Off/Reset]. The frequency
converter cannot accept any further run command until
4 4 the LCP stop is cleared. To clear the LCP stop, press [Auto
On] or [Hand On].
CAUTION
IMMEDIATE START
If the frequency converter is operated in local control, or
remote control with a maintained run signal, the
frequency converter starts immediately. Failure to be
prepared for immediate start can cause personal injury.
Illustration 4.1 LED Indicator Lights
• Be prepared for immediate start.
If the green power-on LED is illuminated, but the backlit 4.5.4 WRONG or WRONG LCP Shown
display is dark, it indicates that the LCP is defective and
must be replaced. Be certain, however, that the display is
The message WRONG or WRONG LCP appears due to a
dark.
faulty LCP or the use of an incorrect LCP.
A single character or just a dot in the upper corner of the

Replace the LCP with a correct and functioning one.
LCP indicates that communications may have failed with
the control card. This situation typically appears when a
fieldbus communication option has been installed in the NOTICE
frequency converter and is either not connected properly Error 84 appears when the LCP cannot communicate
or is malfunctioning. with the frequency converter.
If neither indication is available, then the source of the 4.5.5 Motor Will Not Run
problem is elsewhere. Proceed to the next troubleshooting
steps. If this symptom is detected, verify that the unit is properly
powered up (display is lit) and that there are no warning
4.5.2 Intermittent Display or alarm messages displayed. The most common cause of
this problem is either incorrect control logic or an
Cutting out or flashing of the entire display and power LED incorrectly programmed frequency converter. Such
indicates that the supply (SMPS) is shutting down due to occurrences result in one or more of the following status
overload. Improper control wiring or a fault within the messages being displayed.
frequency converter itself can cause the overload.
LCP Stop
The first step is to rule out a problem in the control wiring. [Off] has been pressed. Line 2 of the display also flashes
To do so, disconnect all control wiring by unscrewing or when this situation occurs.
unplugging the control terminal blocks from the control Press [Auto On] or [Hand On]. Refer to the Input Terminal
card. Signal Test.
Standby
If the display stays lit, the problem is in the control wiring This message indicates that there is no start signal at
(external to the frequency converter). Check all control terminal 18.
wiring for short circuits or incorrect connections.
Ensure that a start command is present at terminal 18.
Refer to the Input Terminal Signal Test.

Unit ready Motor speed unstable

Terminal 27 is low (no signal). Possible causes:
Ensure that terminal 27 is logic “1”. Refer to the Input • Incorrect parameter settings.
Terminal Signal Test.
• Faulty current feedback circuit.
Run OK, 0 Hz
This message indicates that a run command has been
• Loss of motor (output) phase.
given to the frequency converter but the reference (speed Actions:

command) is zero or missing. 1. Check settings of all motor parameters, including
Check control wiring to ensure that the proper reference

all motor compensation settings (slip compen-
sation, load compensation, and so on).
4 4
signal is present at the input terminals. Also check that the
unit is properly programmed to accept the signal provided. 2. For closed-loop operation, check PID settings.
Refer to the Input Terminal Signal Test. 3. Perform test as described in chapter 6.4.7 Input
Off 1 (2 or 3) Terminal Signal Tests to check for faulty reference
This message indicates that bit #1 (or #2, or #3) in the signals.
control word is logic “0”. This situation only occurs when 4. Perform test as described in chapter 6.4.6 Output
the frequency converter is being controlled via the Imbalance of Motor Supply Voltage Test to check
fieldbus. for loss of motor phase.
A correct control word must be transmitted to the Motor runs rough
frequency converter over the communication bus.
Possible cause:
STOP • Overmagnetisation (incorrect motor settings).
One of the digital input terminals 16, 17, 27, 29, 32, or 33
is programmed for “Stop Inverse” and the corresponding
• IGBT misfiring.
terminal is low (logic “0”). NOTICE
Ensure that the above parameters are programmed The motor may stall when loaded, or the frequency
correctly and that any digital input programmed for “Stop converter may trip occasionally on Alarm 13, Over
Inverse” is high (logic “1”). Current.
Display Indication that the unit is functioning, but there

Action:
is no output.
1. Check the setting of all motor parameters, see
If the unit is equipped with external 24 V DC option, check
chapter 6.4.6 Output Imbalance of Motor Supply
that the main power is applied to the frequency converter.
Voltage Test.
NOTICE 2. If output voltage is unbalanced, see
In this case, the display alternately flashes Warning 8. chapter 6.4.6 Output Imbalance of Motor Supply
Voltage Test.
4.5.6 Incorrect Motor Operation
Motor draws high current but cannot start
A fault can occur in the event of incorrect motor
Possible causes:
operation. The symptoms and causes may vary consid-
erably. The following sections list many of the possible
• Open winding in motor.
problems by symptom along with recommended • Open connection to motor.
procedures for determining their causes. Actions:
1. Perform the test in chapter 6.4.6 Output Imbalance
Wrong speed/unit does not respond to command of Motor Supply Voltage Test to ensure that the
Possible cause: Incorrect reference (speed command). frequency converter provides correct output (see
Actions: Motor Runs Rough above).
1. Ensure that the unit is programmed correctly 2. Check motor for open windings. Check all motor
according to the reference signal being used. wiring connections.
2. Ensure that all reference limits are set correctly. 3. Run an AMA to check the motor for open
3. Perform the test chapter 6.4.7 Input Terminal windings and unbalanced resistance. Inspect all
Signal Tests to check for faulty reference signals. motor wiring connections.

Troubleshooting
4.6 Warnings and Alarms 4.6.2 Warnings

When the frequency converter fault circuitry detects a fault During a warning, the frequency converter remains
condition, or a pending fault, a warning, or alarm is issued. operational, although the warning flashes for as long as
A flashing display on the LCP indicates an alarm or the condition exists. The frequency converter could,
warning condition and the associated number code on line however, reduce the warning condition. For example, if the
2. Sometimes a warning precedes an alarm. Table 4.2 warning shown was warning 12, Torque Limit, the frequency
defines whether a warning precedes an alarm and whether converter would reduce speed to compensate for the
the frequency converter suspends operations (trips). overcurrent condition. Sometimes, if the condition is not
4 4 corrected or worsens, an alarm condition is activated and
4.6.1 Alarms the frequency converter stops output to the motor
terminals. Line 1 identifies the warning in plain language,
An alarm causes the frequency converter to trip (suspend and line 2 identifies the warning number.
operation). The frequency converter has 3 trip conditions
which are displayed on line 1: 4.6.3 Warning And Alarm Messages
TRIP (AUTO RESTART) The LEDs on the front of the frequency converter and a
The frequency converter is programmed to restart code in the display signal a warning or an alarm.
automatically after the fault is removed. The number of
automatic reset attempts can be continuous or limited to a A warning indicates a condition that may require attention
programmed number of attempts. If the selected number or a trend that may eventually require attention. A warning
of automatic reset attempts is exceeded, the trip condition remains active until the cause is no longer present. Under
changes to TRIP (RESET). some circumstances, motor operation may continue.
TRIP (RESET)
Requires resetting of the frequency converter before A trip is the action when an alarm has appeared. The trip
operation after a fault is cleared. The frequency converter removes power to the motor. It can be reset after the
can be reset manually by pressing [Reset], a digital input, condition has been cleared by pressing [Reset], or through
or a serial bus command. For TR150 and TR170 frequency a digital input (parameter group 5-1* Digital Inputs). The
converters, stop and reset are the same key. If [Off/Reset] is event that caused an alarm cannot damage the frequency
used to reset the frequency converter, [Start] must be converter or cause a dangerous condition. Alarms must be
pressed to initiate a run command in either local or reset to restart operation once their cause has been
remote. rectified.
TRIPLOCK (DISC> MAINS)
Requires that the main AC input power to the frequency The reset can be done in 3 ways:
converter must be disconnected long enough for the
display to go blank. The fault condition must be removed • Press [Reset]
and power reapplied. Following power up, the fault
indication changes to TRIP (RESET) and allow for manual,
• A digital reset input
digital, or serial bus reset. • Serial communication/optional fieldbus reset

signal
Line 2 displays alarm and the associated number while line
3 identifies the alarm in plain language. NOTICE
After a manual reset pressing [Reset] on the LCP, press
NOTICE [Auto On] to restart the motor.
When exchanging the unit which requires fire mode
activation, carefully check that the Fire Mode parameters An (X) marked in Table 4.2 means that action occurs. A
warning precedes an alarm.
• Parameter 24-00 FM Function
• Parameter 24-05 FM Preset Reference If a situation occurs that can damage the frequency
• Parameter 24-09 FM Alarm Handling converter or connected equipment, an alarm triggers a trip
lock. Power is removed from the motor. A trip lock can
are correctly transferred into the exchange unit.
only be reset after a cycling power has cleared the
condition. Once the problem has been rectified, only the
alarm continues flashing until the frequency converter is
reset.

No. Description Warning Alarm Trip Lock Parameter Reference

2 Live zero error (X) (X) 6–01
3 No motor (X) 1–80
4 Mains phase loss (X) (X) (X) 14–12
7 DC over voltage (X) (X)
8 DC under voltage (X) (X)
9 Inverter overloaded (X) (X)
10 Motor ETR over temperature (X) (X) 1–90
11 Motor thermistor over (X) (X) 1–90

4 4
temperature
13 Over Current (X) (X) (X)
14 Ground fault (X) (X) (X)
16 Short Circuit (X) (X)
17 Control word timeout (X) 8–04
24 Fan Fault (Only on 400 V (X) 14–53
30-90 kW)
30 Motor phase U missing (X) (X) 4–58
31 Motor phase V missing (X) (X) 4–58
32 Motor phase W missing (X) (X) 4–58
38 Internal fault (X) (X)
44 Ground fault 2 (X) (X)
47 Control Voltage Fault (X) (X)
48 VDD1 Supply Low (X) (X)
50 AMA Calibration Failed (X)
51 AMA check Unom and Inom (X)
52 AMA low Inom (X)
53 AMA motor too big (X)
54 AMA motor too small (X)
55 AMA Parameter out of (X)
range
56 AMA interrupted by user (X)
57 AMA timeout (X)
58 AMA internal fault (X) (X)
59 Current limit (X)
60 External Interlock (X)
66 Heat sink Temperature Low (X)
69 Pwr Card Temperature (X) (X) (X)
79 Illegal PS config (X) (X)
80 Drive Initialised to Default (X)
Value
84 LCP Error X
87 Auto DC Braking (X)
95 Broken Belt (X) (X) 22–6*
201 Fire Mode (X)
202 Fire M Limits Exceeded (X)
250 New spare parts (X) (X)
251 New Type Code (X) (X)
Table 4.2 Alarm/Warning Code List
(X) Dependent on parameter. A trip is the action when an that caused an alarm cannot damage the frequency
alarm has appeared. The trip coasts the motor and can be converter or cause dangerous conditions. A trip lock is an
reset by pressing [Reset] or make a reset by a digital input action when an alarm occurs, which can damage the
(parameter group 5-1* Digital Inputs [1]). The original event

Troubleshooting
frequency converter or connected parts. A trip lock Troubleshooting

situation can only be reset by a power cycling. • Check that the supply voltage matches the
frequency converter voltage.
Warning Yellow • Perform an input voltage test.
Alarm Flashing red
• Perform a soft-charge circuit test.
Table 4.3 LED Indication WARNING/ALARM 9, Inverter overload
The frequency converter has run with more than 100%
The alarm words, warning words and extended status overload for too long and is about to cut out. The counter
4 4 words can be read out via serial bus or optional fieldbus for electronic thermal inverter protection issues a warning
for diagnosis. at 98% and trips at 100% with an alarm. The frequency
WARNING/ALARM 2, Live zero error converter cannot be reset until the counter is below 90%.
This warning or alarm only appears if programmed in Troubleshooting
parameter 6-01 Live Zero Timeout Function. The signal on 1 • Compare the output current shown on the
of the analog inputs is less than 50% of the minimum keypad with the frequency converter rated
value programmed for that input. Broken wiring or a faulty current.
device sending the signal can cause this condition.
• Compare the output current shown on the
Troubleshooting keypad with the measured motor current.
• Check connections on all analog mains terminals.
• Show the thermal frequency converter load on
- Control card terminals 53 and 54 for the keypad and monitor the value. When running
signals, terminal 55 common. above the frequency converter continuous
- General Purpose I/O terminals 11 and 12 current rating, the counter increases. When
for signals, terminal 10 common. running below the frequency converter
continuous current rating, the counter decreases.
- Analog I/O Option terminals 1, 3, and 5
for signals, terminals 2, 4, and 6 WARNING/ALARM 10, Motor overload temperature
common. According to the electronic thermal protection (ETR), the
motor is too hot.
• Check that the frequency converter programming
and switch settings match the analog signal type. Select 1 of these options:
• Perform an input terminal signal test.

• The frequency converter issues a warning or an
alarm when the counter is >90% if
WARNING/ALARM 4, Mains phase loss parameter 1-90 Motor Thermal Protection is set to
A phase is missing on the supply side, or the mains warning options.
voltage imbalance is too high. This message also appears • The frequency converter trips when the counter
for a fault in the input rectifier. Options are programmed in reaches 100% if parameter 1-90 Motor Thermal
parameter 14-12 Function at Mains Imbalance. Protection is set to trip options.
Troubleshooting The fault occurs when the motor runs with more than
• Check the supply voltage and supply currents to 100% overload for too long.
the frequency converter.
Troubleshooting
WARNING/ALARM 7, DC overvoltage • Check for motor overheating.
If the intermediate circuit voltage exceeds the limit, the
frequency converter trips after a time.
• Check if the motor is mechanically overloaded.
Troubleshooting
• Check that the motor current set in
parameter 1-24 Motor Current is correct.
Extend the ramp time
Change the ramp type
• Ensure that the motor data in parameters 1-20 to
1-25 is set correctly.
Increase parameter 14-26 Trip Delay at Inverter
Fault
• If an external fan is in use, check that it is
selected in parameter 1-91 Motor External Fan.
WARNING/ALARM 8, DC under voltage
If the DC-link voltage drops below the undervoltage limit,
• Running AMA in parameter 1-29 Automatic Motor
Adaptation (AMA) tunes the frequency converter
the frequency converter checks for 24 V DC back-up
to the motor more accurately and reduces
supply. If no 24 V DC back-up supply is connected, the
thermal loading.
frequency converter trips after a fixed time delay. The time
delay varies with unit size.

WARNING/ALARM 11, Motor thermistor over temp Troubleshooting

Check whether the thermistor is disconnected. Select • Remove power to the frequency converter and
whether the frequency converter issues a warning or an repair the ground fault.
alarm in parameter 1-90 Motor Thermal Protection.
• Check for ground faults in the motor by
measuring the resistance to ground of the motor
WARNING cables and the motor with a megohmmeter.
Live Electrical Components!
• Reset any potential individual offset in the 3
current transducers in the frequency converter.
Troubleshooting
• Check for motor overheating.
Perform the manual initialization or perform a
complete AMA. This method is most relevant
4 4
• Check if the motor is mechanically overloaded. after changing the power card.
• When using terminal 53 or 54, check that the
thermistor is connected correctly between either WARNING
terminal 53 or 54 (analog voltage input) and Disconnect power before proceeding.
terminal 50 (+10 V supply). Also check that the
terminal switch for 53 or 54 is set for voltage. ALARM 16, Short circuit
Check that parameter 1-93 Thermistor Resource There is short-circuiting in the motor or motor wiring.
selects terminal 53 or 54. Troubleshooting
• When using terminal 18, 19, 31, 32, or 33 (digital • Remove the power to the frequency converter
inputs), check that the thermistor is connected and repair the short circuit.
correctly between the digital input terminal used
(digital input PNP only) and terminal 50. Select WARNING
the terminal to use in parameter 1-93 Thermistor HIGH VOLTAGE
Resource. Frequency converters contain high voltage when
connected to AC mains input, DC supply, or load sharing.
WARNING Failure to use qualified personnel to install, start up, and
Disconnect power before proceeding. maintain the frequency converter can result in death or
serious injury.
WARNING/ALARM 13, Over current
The inverter peak current limit (approximately 200% of the
• Disconnect power before proceeding.
rated current) is exceeded. The warning lasts about 1.5 s,

then the frequency converter trips and issues an alarm.
Shock loading or fast acceleration with high inertia loads
WARNING
can cause this fault. Disconnect power before proceeding.
Troubleshooting:
WARNING/ALARM 17, Control word timeout
Remove power and check if the motor shaft can
There is no communication to the frequency converter.
be turned.
The warning is only active when parameter 8-04 Control
Check that the motor size matches the frequency Word Timeout Function is NOT set to [0] Off.
converter. If parameter 8-04 Control Word Timeout Function is set to [5]
Check parameters 1-20 to 1-25 for correct motor Stop and Trip, a warning appears. The frequency converter
data. then ramps down until it trips, while giving an alarm.
Parameter 8-03 Control Timeout Time could possibly be
ALARM 14, Earth (ground) fault increased.
There is current from the output phase to ground, either in
the cable between the frequency converter and the motor,
or in the motor itself. The current transducers detect the
WARNING
Live Electrical Components!
ground fault by measuring current going out from the
frequency converter and current going into the frequency
Troubleshooting
converter from the motor. Ground fault is issued if the
deviation of the 2 currents is too large. The current going • Check connections on the serial communication
cable.
out of the frequency converter must be the same as the
current going into the frequency converter. • Increase parameter 8-03 Control Word Timeout
Time.
• Check the operation of the communication
equipment.

Troubleshooting
• Verify a proper installation based on EMC

WARNING
requirements.
Disconnect power before proceeding.
WARNING 24, External fan fault
The fan warning function is a protective function that
Troubleshooting
checks if the fan is running/mounted. The fan warning can
be disabled in parameter 14-53 Fan Monitor ([0] Disabled). • Remove the power from the frequency converter
and check motor phase V.
For frequency converters with DC fans, a feedback sensor
ALARM 32, Motor phase W missing
is mounted in the fan. If the fan is commanded to run and
Motor phase W between the frequency converter and the
4 4 there is no feedback from the sensor, this alarm appears.
For frequency converters with AC fans, the voltage to the
motor is missing.
fan is monitored.
WARNING
Troubleshooting
HIGH VOLTAGE
Frequency converters contain high voltage when
• Check for proper fan operation. connected to AC mains input, DC supply, or load sharing.
• Cycle power to the frequency converter and Failure to use qualified personnel to install, start up, and
check that the fan operates briefly at start-up. maintain the frequency converter can result in death or
• Check the sensors on the heat sink. serious injury.
ALARM 30, Motor phase U missing • Disconnect power before proceeding.
Motor phase U between the frequency converter and the
motor is missing.
WARNING
WARNING Disconnect power before proceeding.
HIGH VOLTAGE
Frequency converters contain high voltage when Troubleshooting
connected to AC mains input, DC supply, or load sharing. • Remove the power from the frequency converter
Failure to use qualified personnel to install, start up, and and check motor phase W.
maintain the frequency converter can result in death or
ALARM 38, Internal fault
serious injury.
When an internal fault occurs, a code number defined in
• Disconnect power before proceeding. Table 4.4 is displayed.
Troubleshooting
Cycle power
WARNING Check that the option is properly installed
Disconnect power before proceeding.
Check for loose or missing wiring
Troubleshooting It may be necessary to contact your Trane supplier or
• Remove the power from the frequency converter service department. Note the code number for further
and check motor phase U. troubleshooting directions.
ALARM 31, Motor phase V missing
No. Text
Motor phase V between the frequency converter and the
0 Serial port cannot be initialised. Contact your Trane
motor is missing.
supplier or Trane Service Department.
WARNING 256-258 Power EEPROM data is defective or too old.

Replace power card.
HIGH VOLTAGE 512-519 Internal fault. Contact your Trane supplier or Trane
Frequency converters contain high voltage when Service Department.
connected to AC mains input, DC supply, or load sharing.
783 Parameter value outside of min/max limits
Failure to use qualified personnel to install, start up, and
1024-1284 Internal fault. Contact your Trane supplier or the
maintain the frequency converter can result in death or
Trane Service Department.
serious injury.
1379-2819 Internal fault. Contact your Trane supplier or Trane
• Disconnect power before proceeding. Service Department.
1792 HW reset of DSP
1793 Motor derived parameters not transferred correctly
to DSP

No. Text ALARM 56, AMA interrupted by user

1794 Power data not transferred correctly at power up The AMA is manually interrupted.
to DSP ALARM 57, AMA internal fault
1795 The DSP has received too many unknown SPI Try to restart the AMA. Repeated restarts can overheat the
telegrams motor.
1796 RAM copy error
ALARM 58, AMA Internal fault
2561 Replace control card
Contact a Trane supplier.
2820 LCP stack overflow
WARNING 59, Current limit
2821
2822
Serial port overflow
USB port overflow The current is higher than the value in 4 4
3072-5122 Parameter value is outside its limits
parameter 4-18 Current Limit. Ensure that motor data in
parameters 1-20 to 1-25 is set correctly. Increase the current
5376-6231 Internal fault. Contact your Trane supplier or Trane
limit if necessary. Ensure that the system can operate safely
Service Department.
at a higher limit.
Table 4.4 Internal Fault Codes WARNING 60, External interlock
A digital input signal indicates a fault condition external to
ALARM 44, Earth fault II the frequency converter. An external interlock has
There is a discharge from the output phases to earth, commanded the frequency converter to trip.
either in the cable between the frequency converter and
Troubleshooting
the motor or in the motor itself.
• Clear the external fault condition.
Troubleshooting
Turn off the frequency converter and remove the • To resume normal operation, apply 24 Vdc to the
terminal programmed for external interlock.
earth fault.
Measure the resistance to ground of the motor • Reset the frequency converter.
leads and the motor with a megohmmeter to WARNING 66, Heatsink temperature low
check for earth fault in the motor. This warning is based on the temperature sensor in the
IGBT module.
WARNING 47, 24 V supply low
The 24 Vdc is measured on the control card. Troubleshooting
WARNING 48, 1.8 V supply low The heatsink temperature measured as 0 °C could indicate
The 1.8Vdc supply used on the control card is outside of that the temperature sensor is defective, thus causing the
the allowable limits. The supply is measured on the control fan speed to increase to the maximum. If the sensor wire
card. between the IGBT and the gate drive card is disconnected,
this warning is produced. Also, check the IGBT thermal
Troubleshooting
sensor.
• Check for a defective control card.
ALARM 79, Illegal power section configuration
• If an option card is present, check for
The scaling card has an incorrect part number or is not
overvoltage.
installed. The MK102 connector on the power card could
ALARM 51, AMA check Unom and Inom not be installed.
The settings for motor voltage, motor current, and motor
ALARM 80, Drive initialised to default value
power are wrong.
Parameter settings are initialized to default settings after a
Troubleshooting manual reset. To clear the alarm, reset the unit.
• Check the settings in parameters 1-20 to 1-25. ALARM 84, LCP error
ALARM 52, AMA low Inom ALARM 84 is generated by the LCP and indicates an error
The motor current is too low. with the LCP.
Troubleshooting ALARM 95, Broken belt
• Check the setting in parameter 1-24 Motor Current. Torque is below the torque level set for no load, indicating
ALARM 53, AMA motor too big a broken belt. Parameter 22-60 Broken Belt Function is set
The motor is too large for the AMA to operate. for alarm.
ALARM 54, AMA motor too small Troubleshooting

The motor is too small for the AMA to operate. • Troubleshoot the system and reset the frequency
converter after clearing the fault.
ALARM 55, AMA parameter out of range
The parameter values of the motor are outside of the
acceptable range. AMA does not run.

Troubleshooting
WARNING 200, Fire mode 4.7 After Repair Tests

The frequency converter is operating in fire mode. The
warning clears when fire mode is removed. Refer to the Following any repair to a frequency converter or testing of
fire mode data in the alarm log. a frequency converter suspected of being faulty, the
following procedure must be followed. Following the
WARNING 202, Fire mode limits exceeded
procedure ensures that all circuitry in the frequency
While operating in fire mode, 1 or more alarm conditions
converter is functioning properly before putting the unit
that would normally trip the unit have been ignored.
into operation.
Operating in this condition voids unit warranty. Cycle
power to the unit to remove the warning. Refer to the fire
4 4 mode data in the alarm log. 1. Perform visual inspection procedures as described
in Table 4.1.
WARNING 250, New spare part
The power card or switch mode power supply has been 2. Perform static test procedures to ensure that
exchanged. The frequency converter type code must be frequency converter is safe to start.
restored in the EEPROM. Select the correct type code in 3. Disconnect motor cables from output terminals
parameter 14-23 Typecode Setting according to the label on (U, V, W) of frequency converter.
the unit. Remember to select ‘Save to EEPROM’ to
4. Apply AC power to frequency converter.
complete.
5. Give the frequency converter a run command and
WARNING 251, New typecode
slowly increase reference (speed command) to
The frequency converter has a new type code.
approximately 40 Hz.
6. Use an analog voltmeter or a DVM capable of
measuring true RMS, measure phase-to-phase
output voltage on all three phases: U to V, U to
W, V to W. All voltages must be balanced within 8
V. If unbalanced voltage is measured, refer to
chapter 6.4.2 Input Voltage Test.
7. Stop the frequency converter and remove input
power. Allow 20 minutes for DC capacitors to fully
discharge.
8. Reconnect motor cables to frequency converter
output terminals (U, V, W).
9. Reapply power and restart frequency converter.
Adjust motor speed to a nominal level.
10. Use a clamp-on style ammeter, measure output
current on each output phase. All currents must
be balanced.

Frequency Converter and Mot... TR150 and TR170 Service Manual
5 Frequency Converter and Motor Applications
5.1 Torque Limit, Current Limit, and NOTICE

Unstable Motor Operation Never adjust these parameters to random values even
though it seems to improve operation. Such adjustments
Excessive loading of the frequency converter can result in can result in unpredictable operation under changing
warning or tripping on torque limit, overcurrent, or inverter conditions.
overload. Avoid this situation by sizing the frequency
converter properly for the application. Ensure that
5.1.1 Overvoltage Trips
intermittent load conditions cause anticipated operation in
torque limit or an occasional trip. Pay attention to the
following parameters when matching the frequency
Overvoltage trip occurs when the DC-link voltage reaches 5 5
its DC link alarm voltage high (see chapter 1.9.1 Short
converter to the motor for optimum operation.
Circuit and Overcurrent Trips). Before tripping, the frequency
converter shows a high-voltage warning. Mostly, fast
Parameters 1-20 to 1-25 configure the frequency converter
deceleration ramps concerning load inertia causes an
for the connected motor.
overvoltage condition. During deceleration of the load,
inertia of the system acts to sustain the running speed.
These parameters set: Once the motor frequency drops below the running speed,
• Motor power. the load begins overhauling the motor. The motor then
• Voltage. becomes a generator and starts returning energy to the
frequency converter. This is called regenerative energy.
• Frequency.
Regeneration occurs when the speed of the load is greater
• Current. than the commanded speed. The diodes in the IGBT
modules rectify this return and raises the DC link. If the
• Nominal motor speed.
amount of returned energy is too high, the DC voltage
It is important to set these parameters accurately. Enter the increases, causing the frequency converter to trip.
motor data required as listed on the motor nameplate. The
frequency converter relies on this information for accurate
There are a few ways to overcome this situation. One
motor control in dynamic loading applications.
method is to reduce the deceleration rate so it takes
longer for the frequency converter to decelerate. A rule of
Parameter 1-29 Automatic Motor Adaption (AMA) activates thumb is that the frequency converter can only decelerate
the automatic motor adaptation (AMA) function. When the load slightly faster than it would take for the load to
AMA is performed, the frequency converter measures the naturally coast to a stop. A second method is to allow the
electrical characteristics of the motor and sets various overvoltage control function (parameter 2-17 Over-voltage
frequency converter parameters based on the findings. This Control) to take care of the deceleration ramp. When
function sets the following parameter values: enabled, the overvoltage control function regulates
• Parameter 1-30 Stator Resistance (Rs) deceleration at a rate that maintains the DC-link voltage at
• Parameter 1-35 Main Reactance (Xh) an acceptable level. One caution with overvoltage control
is that it does not make corrections to unrealistic ramp
• Parameter 1-37 d-axis Inductance (Ld)
rates.
If motor operation is unstable, perform AMA if this
operation has not already been performed. AMA can only
For example, the deceleration ramp has to be 100 s due to
be performed on single-motor applications within the
the inertia, and the ramp rate is set at 3 s. Overvoltage
programming range of the frequency converter. Refer to
control initially engages, then disengages and allows the
the operating guide/quick guide for more information on
frequency converter to trip. This is purposely done so the
this function.
unit's operation is not misinterpreted.
Set parameter 1-30 Stator Resistance (Rs) and

The frequency converter has an AC brake function, which
parameter 1-35 Main Reactance (Xh) parameters for the
increases magnetization current to increase loss in motor
AMA function. Use factory default values, or values that are
and reduce DC-link voltage. If the DC-link voltage exceeds
supplied by the motor manufacturer.
a certain voltage, the overvoltage control changes the
frequency.

Frequency Converter and Mot...
5.1.2 Mains Phase Loss Trips The frequency converters are designed to accept various
signals. First, determine which of these signals the
The frequency converter monitors phase loss by frequency converter is receiving:
monitoring the amount of ripple voltage on the DC bus. • Digital inputs (18, 19, 27, and 29).
Ripple voltage on the DC bus is a product of a phase loss • Analog outputs (42 and 45).
and can cause overheating in the DC-bus capacitors and
the DC coil. If the ripple voltage on the DC bus is • 10 V output.
unchecked, the lifetime of the capacitors is drastically • Analog inputs (53 and 54).
reduced.
• Serial communication bus (68 and 69).
The presence of a correct reading indicates that the
When the input voltage becomes unbalanced or a phase
microprocessor of the frequency converter has detected
disappears completely, the ripple voltage increases. This
5 5 increase causes the frequency converter to trip and issue
the wanted signal. See chapter 2.3 Frequency Converter
Inputs and Outputs.
alarm 4, Mains Phase Loss. In addition to missing phase
voltage, a line disturbance or imbalance can cause an
increased bus ripple. This data can also be read in parameter group 16-6* Inputs
and Outputs.
Possible sources of disturbance
If there is no correct indication, check if the signal is
• Line notching.
present at the input terminals of the frequency converter.
• Defective transformers. Use a voltmeter or oscilloscope in accordance with
• Other loads that can affect the form factor of the chapter 6.4.7 Input Terminal Signal Tests.
AC waveform.
Mains imbalances which exceed 3% cause sufficient DC- • If the signal is present at the terminal, the control
bus ripple to initiate a trip. card is defective and must be replaced.
• If the signal is not present, the problem is
Other causes of increased ripple voltage on the DC bus external to the frequency converter. Therefore,
are: check the circuitry providing the signal along
• Output disturbance. with its associated wiring.
• Missing or lower than normal output voltage on

1 phase. 5.1.4 Programming Problems
Checks
Difficulty with operation of the frequency converter can be
When a mains imbalance trip occurs, check both the input
a result of improper programming of the frequency
and output voltage of the frequency converter.
converter parameters.
Severe imbalance of supply voltage or phase loss is
detectable with a voltmeter. View line disturbances
through an oscilloscope. Conduct tests for: Three areas where programming errors can affect
• Input imbalance of supply voltage. frequency converter and motor operation are:
• Motor settings.
• Input waveform.
• References and limits.
• Output imbalance of supply voltage.
See details in chapter 4 Troubleshooting.
• I/O configuration.
See chapter 2.3 Frequency Converter Inputs and Outputs.
5.1.3 Control Logic Problems

Set up the frequency converter correctly for the motor or
motors connected to it. Parameters must have data from
Problems with control logic can often be difficult to
the motor nameplate entered into the frequency converter.
diagnose, since there is usually no associated fault
These data enable the frequency converter processor to
indication. The typical complaint is that the frequency
match the frequency converter to power characteristics of
converter does not respond to a given command. To
the motor. Inaccurate motor data can cause the motor to
obtain an output, give the following 2 basic commands to
draw higher than normal amounts of current when
the frequency converter:
performing a task. In such cases, setting the correct values
• Start command: To execute. to these parameters and performing the AMA function
• Reference or speed command: To identify the usually solves the problem.
speed of execution.

Any references or limits set incorrectly result in less than 5.2 Internal Frequency Converter Problems
acceptable frequency converter performance. For instance,
if maximum reference is set too low, the motor is unable 5.2.1 Overtemperature Faults
to reach full speed. Set these parameters according to the
requirements of the particular installation. References are If an overtemperature indication is shown, determine
set in parameter group 3-0* Reference Limits. whether this condition actually exists within the frequency
converter, or whether the thermal sensor is defective.
Incorrectly set I/O configuration usually results in the
frequency converter not responding to the function as 5.2.2 Current Sensor Faults
commanded. Remember that for every control terminal
input or output there are corresponding parameter Sometimes an over-current alarm that cannot be reset,
settings. These settings determine how the frequency even with the motor cables disconnected, indicates when a
converter responds to an input signal or the type of signal current sensor fails. However, the frequency converter 5 5
present at that output. Utilizing an I/O function involves a experiences frequent false ground fault trips. This is due to
2-step process. Wire the wanted I/O terminal properly, and the DC offset failure mode of the sensors.
set the corresponding parameter accordingly. Control
terminals are programmed in parameter group 5-0* Digital
The simplest method of determining whether a current
I/O Mode and parameter group 6-0* Analog I/O Mode.
sensor is defective is to disconnect the motor from the
frequency converter. Then observe the current in the
5.1.5 Motor/Load Problems frequency converter display. With the motor disconnected,
the current should be zero. A frequency converter with a
Problems with the motor, motor wiring, or mechanical load defective current sensor indicates some current flow. An
on the motor can develop in several ways. The motor or indication of a fraction of 1 A is tolerable. However, that
motor wiring can develop a phase-to-phase or phase-to- value should be considerably less than 1 A. If the display
ground short circuit resulting in an alarm indication. Check shows more than 1 A of current, there is a defective
whether the problem is in the motor wiring or the motor current sensor. All 3 current sensors in TR150 and TR170
itself. units are mounted on one circuit board (either power card,
SMPS card, or current transducer card). The repair
A motor with unbalanced, or asymmetrical, impedances on procedure is to replace all 3 current sensors at the same
all 3-phases can result in uneven or rough operation, or time.
unbalanced output currents. For measurements, use a
clamp-on style ammeter to determine whether the current 5.2.3 Signal and Power Wiring
is balanced on the 3 output phases. See Considerations for Electromagnetic
chapter 6.4.6 Output Imbalance of Motor Supply Voltage Test. Compatibility
Usually, a current limit warning indicates an incorrect This section provides an overview of general signal and
mechanical load. If possible, disconnect the motor from the power wiring considerations when addressing the electro-
load to determine if the load is incorrect. magnetic compatibility (EMC) concerns for typical
commercial and industrial equipment. Only certain high
Often, the indications of motor problems are similar to the frequency phenomena (such as RF emissions, RF immunity)
problems of a defect in the frequency converter itself. To are discussed. Low-frequency phenomena (such as
determine whether the problem is internal or external to harmonics, mains voltage imbalance, notching) are not
the frequency converter, disconnect the motor from the covered.
frequency converter motor terminals. Perform the initial
procedure with no motor connection on all 3-phases with NOTICE
an analog voltmeter, see chapter 6.4.6 Output Imbalance of
Special installations or compliance to the European CE
Motor Supply Voltage Test. If the 3 voltage measurements
EMC directives require strict adherence to relevant
are balanced, the frequency converter is functioning
standards and are not discussed here.
correctly. Hence, the problem is external to the frequency
converter.
If the voltage measurements are not balanced, the

frequency converter is malfunctioning. Typically, 1 or more
output IGBTs are not functioning correctly. This problem
can be a result of a defective IGBT or gate signal.

5.2.4 Effects of EMI equipment has a high level of EMI immunity. However,
non-industrial, commercial, and consumer equipment is
While electromagnetic interference-related (EMI) distur- often susceptible to lower levels of EMI.
bances to the operation of the frequency converter are
uncommon, the following detrimental EMI effects Detrimental effects to these systems include the following:
sometimes occur: • Pressure/flow/temperature signal transmitter
• Motor speed fluctuations. signal distortion or aberrant behavior.
• Serial communication transmission errors. • Radio and TV interference.
• Frequency converter CPU exception faults. • Telephone interference.
• Unexplained frequency converter trips. • Computer network data loss.
5 5 A disturbance resulting from other nearby equipment is

more common. Generally, other industrial control
• Digital control system faults.
5.2.5 Sources of EMI
Modern frequency converters (see Illustration 5.1) utilize fast-switching electronic devices to generate the modulated output
voltage waveform necessary for accurate motor control. These devices rapidly switch the fixed DC-link voltage creating a
variable frequency, and variable voltage PWM waveform. This high rate of voltage change [dU/dt] is the primary source of
the frequency converter generated EMI.
The high rate of voltage change caused by the IGBT switching creates high frequency EMI.
1 RFI filter 6 PWM waveform

2 Rectifier 7 IGBT
3 DC link 8 Filter reactor
4 Inverter 9 Sine-wave
5 Motor 10 AC line
Illustration 5.1 Frequency Converter Principle Diagram

5.2.6 EMI Propagation
Frequency converter generated EMI is both conducted to

the mains and radiated to nearby conductors. See
Illustration 5.2.
5 5
1 AC line
2 Frequency converter
3 Motor cable
4 Motor
1 AC line 5 Stray capacitance
2 Frequency converter 6 AC line, to BMS
3 Motor cable 7 Signal wiring
4 Motor
Illustration 5.3 Signal Conductor Currents
5 Stray capacitance
6 Signal wiring
7 Signal wiring
8 Signal wiring NOTICE
9 Ground Unprotected or poorly routed signal conductors located
close to or in parallel to motor and mains conductors are
Illustration 5.2 Ground Currents susceptible to EMI.
Signal conductors are especially vulnerable when they run

NOTICE in parallel to the power conductors for any distance. EMI
coupled into these conductors can affect either the
Stray capacitance between the motor conductors,
frequency converter or the interconnected control device.
equipment ground, and other nearby conductors results
See Illustration 5.3.
in induced high frequency currents.
While these currents tend to travel back to the frequency

High ground circuit impedance at high frequencies results
converter, imperfections in the system cause some current
in an instant voltage at points reputed to be at ground
to flow in undesirable paths. This flow exposes other
potential. This voltage can appear throughout a system as
locations to the EMI.
a common mode signal that can interfere with control
signals.
NOTICE
Theoretically, these currents return to the DC-bus via the High frequency currents can be coupled into the mains
ground circuit and a high frequency (HF) bypass network supplying the frequency converter, when the mains
within the frequency converter itself. However, conductors are located close to the motor cables.
imperfections in the frequency converter grounding or the
equipment ground system can cause some of the currents
to travel out to the power network.

5.2.7 Preventive Measures separately from the signal and mains wiring, no further
consideration is needed. If the conductors are routed close
EMI-related problems are more effectively alleviated during to other susceptible conductors, or if the system is
the design and installation phases rather than after the suspected to cause EMI problems, consider alternate motor
system is in service. Many of the listed steps can be wiring methods.
implemented at a relatively low cost compared to the cost Installing shielded power cable is the most effective way to
of identifying and fixing the problem later. alleviate EMI problems. The cable shield forces the noise
current to flow directly back to the frequency converter.
Grounding Thus, the noise current cannot get back into the power
Ground the frequency converter and motor solidly to the network or take other undesirable high frequency paths.
equipment frame. A good high-frequency connection is Unlike most signal wiring, the shielding on the motor cable
necessary to allow the high frequency currents to return to must be terminated at both ends.
5 5 the frequency converter instead of traveling through the
If a shielded motor cable is not available, then 3-phase
power network. The ground connection is ineffective if it
conductors along with ground in a conduit provides some
has high impedance to high frequency currents. Therefore,
degree of protection. This technique is not as effective as
it must be as short and direct as possible. Flat-braided
shielded cable due to the unavoidable contact of the
cable has lower high frequency impedance than round
conduit with various points within the equipment.
cable. Mounting the frequency converter or motor onto a
painted surface creates an effective ground connection. In Serial communications cable selection
addition, running a separate ground conductor directly There are various serial communication interfaces and
between the frequency converter and the running motor is protocols in the market. Each of these interfaces
recommended. recommends 1 or more specific types of twisted pair,
shielded twisted pair, or proprietary cables. Refer to the
Cable routing
manufacturer’s documentation when selecting these
Avoid parallel routing of:
cables. Similar recommendations apply to serial communi-
• Motor wiring. cation cables as to other signal cables. Using twisted-pair
• Mains wiring. cables and routing them away from power conductors is
encouraged. While shielded cable provides extra EMI
• Signal wiring.
protection, the shield capacitance may reduce the
If parallel routing is unavoidable, preferably maintain a maximum allowable cable length at high data rates.
separation of 200 mm (6–8 in) between the cables or
separate them with a grounded conductive partition. Avoid
routing cables through free air.
Signal cable selection

Single conductor 600 V rated wires provide the least
protection from EMI. Twisted pair and shielded twisted-pair
cables are available which are designed to minimize the
effects of EMI. While unshielded twisted-pair cables are
often adequate, shielded twisted-pair cables provide
another degree of protection. Terminate the signal cable
shield in a manner that is appropriate for the connected
equipment. Avoid terminating the shield through a pigtail
connection as it increases the high frequency impedance
and spoils the effectiveness of the shield.
A simple alternative is to twist the existing single
conductors to provide a balanced capacitive and inductive
coupling. This operation cancels differential mode
interference. While not as effective as true twisted-pair
cable, it can be implemented in the field using the
materials at hand.
Motor cable selection
Motor conductors have the greatest influence on the EMI
characteristics of the system. These conductors must
receive the highest attention whenever EMI is a problem.
Single conductor wires provide the least protection from
EMI emissions. Often, if these conductors are routed

Test Procedures TR150 and TR170 Service Manual
6 Test Procedures
6.1 Non-repairable Units

H1–H5 and I2–I4 are non-repairable units and should not
be repaired. The information about Line/Motor/UDC+-
terminals is useful to verify what went wrong with these
frequency converters, for statistics and WIIS purposes, but
also to avoid replacing a frequency converter that is not
defective.
6 6
1 RS485
2 Line in
3 Ground
4 Wire clamps
5 Motor
6 UDC
7 Relays
1 Line 8 I/O
2 Ground
3 Motor Illustration 6.2 I2 Frame
4 Relays IP54 380–480 V, 0.75–4.0 kW
Illustration 6.1 H1–H5 Frame

IP20 200–240 V, 0.25–11 kW and IP20 380–480 V, 0.37–22 kW

Test Procedures
6 6
1 RS485
2 Line in
1 RS485
3 Ground
2 Line in
4 Wire clamps
3 Ground
5 Motor
4 Wire clamps
6 UDC
5 Motor
7 Relays
6 UDC
8 I/O
7 Relays
8 I/O
Illustration 6.4 I4 Frame
IP54 380–480 V, 0.75–4.0 kW
Illustration 6.3 I3 Frame
IP54 380–480 V, 5.5–7.5 kW

6.2 Introduction • Oscilloscope

• Current meter
WARNING 6.3 Static Test Procedures
DISCHARGE TIME!
Frequency converters contain DC-link capacitors that can The purpose of performing static testing is to check for
remain charged even when the frequency converter is any short circuit of the power components.
not powered. To avoid electrical hazards, disconnect AC
mains, any permanent magnet type motors, and any For all tests, use a meter capable of testing diodes. Use a
remote DC-link power supplies, including battery back- digital Volt-Ohm Meter (VOM) set on the diode scale or an
ups, UPS, and DC-link connections to other frequency analog ohmmeter set on Rx100 scale.
converters. Wait for the capacitors to fully discharge
before performing any service or repair work. The Before making any checks, disconnect all connections for:
amount of wait time is listed in the Table 1.1. Failure to • Input.
wait the specified time after power has been removed
• Motor.
before doing service or repair could result in death or
serious injury. • Brake resistor.
6 6
Ensure that the frequency converter is disconnected from
This section contains detailed procedures for testing power, before performing static tests.
frequency converters. Previous sections of this manual
provide symptoms, alarms, and other conditions which
require additional test procedures to diagnose the WARNING
frequency converter further. The results of these tests SHOCK HAZARD
indicate the appropriate repair actions. Again, because the Disconnection of the input cable while the frequency
frequency converter monitors input and output signals, converter is powered could result in electrical shock
motor conditions, AC, and DC power and other functions, causing death or personal injury.
the source of fault conditions may exist outside of the
frequency converter. Testing described here isolates many • Do not disconnect the input cable while the
frequency converter is powered.
of these conditions as well. Disassembly and Assembly
Instructions describes detailed procedures for removing
and replacing frequency converter components. 6.3.1 Pre-test Precautions
Frequency converter testing is divided into Static Tests, and Consider the following safety precautions before
Dynamic Tests. Static tests are conducted without power performing static tests.
applied to the frequency converter. Most frequency • Prepare the work area according to the ESD
converter problems can be diagnosed simply with these regulations.
tests. Static tests are performed with little or no
disassembly. The purpose of static testing is to check for • Ground the ESD mat and wrist strap.
shorted power components. Perform these tests on any • Ensure that the ground connection between
unit suspected of containing faulty power components body, the ESD mat, and the frequency converter
before applying power. is always present while performing service.
• Handle disassembled electronic parts with care.
CAUTION • Perform the static test before powering up the

For dynamic test procedures, main input power is fault unit.
required. All devices and power supplies connected to • Perform static test after completing the repair
mains are energized at rated voltage. Use extreme and assembly of the frequency converter.
caution when conducting tests on a powered frequency
converter. Contact with powered components could
• Connect the frequency converter to the mains
only after completion of static tests.
result in electrical shock and personal injury.
• Complete all necessary precautions for system
Dynamic tests are performed with power applied to the start-up, before applying power to frequency
frequency converter. Dynamic testing traces signal circuitry converter.
to isolate faulty components.
• Digital voltmeter/ohmmeter capable of reading
real RMS
• Analog voltmeter

Test Procedures
6.3.2 Rectifier Circuit Test 6.3.3 Inverter Section Tests
Pay close attention to the polarity of the meter leads to The inverter section is primarily made up of the IGBTs used
ensure the identification of any faulty component, in case for switching the DC bus voltage to create the output to
an incorrect reading appears. the motor. The frequency converter also has clamping
capacitors between +UDC and -UDC on the IGBT.
Described next is the procedure to conduct the static test
on the rectifier.
CAUTION
Disconnect motor cables when testing inverter section.
NOTICE With leads connected, a short circuit in one phase reads
In H6 units the +/-UDC terminals are not readily in all phases, making isolation difficult.
accessible. Find terminals K601 (+) and K611 (-) between
the DC capacitors.
Before starting tests, ensure that meter is set to diode
In H7-H8 units the +/-UDC terminals are directly
scale.
6 6 accessible on MK900 on the power card.
In I7-I8 units the +/-UDC terminals are accessible on
Inverter test part I
MK900 on the power card or on MK3 on the current
1. Connect the positive (+) meter lead to the
sensor board.
positive (+) DC bus terminal.
For further details, see chapter 6.3.5 Location of UDC
Terminals before measuring). 2. Connect the negative (-) meter lead to terminals
U, V, and W in sequence.
Before starting tests, ensure that meter is set to diode Each reading must show infinity.
scale.
Inverter test part II
Rectifier test part I 1. Reverse the meter leads by connecting the
1. Connect the positive (+) terminal of the negative (-) meter lead to the positive (+) DC bus
multimeter lead to the positive (+) DC Bus. terminal.
2. Connect the negative (-) terminal of the 2. Connect the positive (+) meter lead to U, V, and
multimeter lead to the input terminal L1, L2, L3 W in sequence. Each reading should show a
in turn. The multimeter indicates Infinity. diode drop.
Rectifier test part II Inverter test part III
3. Reverse the meter leads by connecting the 1. Connect the positive (+) meter lead to the
negative (-) terminal of the multimeter lead to negative (-) DC bus terminal.
the positive (+) DC Bus.
2. Connect the negative (-) meter lead to terminals
4. Connect the positive (+) terminal of the U, V, and W in sequence. Each reading should
multimeter lead to the input terminal L1, L2, L3 show a diode drop.
in turn. The multimeter indicates Diode drop.
Inverter test part IV
Rectifier test part III 1. Reverse the meter leads by connecting the
5. Connect the positive (+) terminal of the negative (-) meter lead to the negative (-) DC bus
multimeter lead to the negative (-) DC Bus. terminal.
6. Connect the negative (-) terminal of the 2. Connect the positive (+) meter lead to U, V, and
multimeter lead to the input terminal L1, L2, L3 W in sequence.
in turn. The multimeter indicates a diode drop.
Each reading should show infinity.
Rectifier test part IV
7. Reverse the meter leads by connecting the
negative (-) terminal of the multimeter lead to
the negative (-) DC Bus.
8. Connect the positive (+) terminal of the
multimeter lead to the input terminal L1, L2, L3
in turn. The multimeter indicates Infinity.

6.3.4 Intermediate Section Tests 6.3.5 Location of UDC Terminals
NOTICE H6
This test is applicable for H7, H8, I7, and I8 units only. Remove the IP20 front cover, then remove the capacitor
vibration support. The terminals K601 (+UDC) and K611 (-
UDC) are located between the 4 capacitors on the circuit
The intermediate section of the frequency converter is
board. Remove the metal cover to access these terminals.
made up of the DC bus capacitors, the DC coils, and the
balance circuit for the capacitors.
1. Test for short circuits with the ohmmeter set on

Rx100 scale or, for a digital meter, select diode.
2. Measure across the positive (+) DC terminal and
the negative (–) DC terminal. Observe the meter
polarity.
3. The meter starts out with low ohms and then
6 6
move towards infinity as the meter charges the
capacitors.
4. Reverse meter leads.
5. The meter pegs at zero while the meter
discharges the capacitors. The meter then begins
moving slowly toward 2 diode drops as the meter
charges the capacitors in the reverse direction.
Illustration 6.5 UDC Terminals Location on H6 Frequency
Although the test does not ensure that the
Converter
capacitors are fully functional, it ensures that no
short circuits exist in the DC link.
Incorrect reading
A short circuit could be caused by a short in the inrush
circuit, rectifier, or inverter section. Be sure that the tests
for these circuits have already been performed successfully.
A failure in one of these sections could be read in the
intermediate section since they are all routed via the DC
bus.
The only other likely cause would be a defective capacitor
within the capacitor bank.
There is not an effective test of the capacitor bank when it
is fully assembled. If suspecting a failure within the
capacitor bank, replace the entire bank. Replace the
capacitor bank in accordance with the disassembly
procedures.
Illustration 6.6 Metal Cover over Terminals

Test Procedures
Illustration 6.9 +/- UDC Terminals

6 6
H9
The UDC terminals are available on connectors at the
bottom of the frequency converter. Static measurements
can be done directly from here.
Illustration 6.7 The UDC Terminals on the Circuit Board
H7 and H8
Remove the IP20 front cover to access the terminals
directly on the power card MK900.

Converter
Illustration 6.8 Power Card

H10
Remove the front terminal cover to access the connectors.
The UDC terminals are located inside the frequency
converter.
Illustration 6.13 +/- UDC Terminals on Current Sensor Board

6 6
Converter
I7 and I8
Remove the IP54 front cover to access the +/- UDC
terminals, either on the power card MK900 or on MK3 on
the current sensor board.
Illustration 6.14 +/- UDC Terminals on Current Sensor Board -

Close-up View
Illustration 6.12 +/- UDC Terminals on Power Card

Test Procedures
6.4 Dynamic Test Procedures 6.4.1 No Display Test (Display is Optional)
NOTICE A frequency converter with no display in the LCP can be

Test procedures in this section are numbered for the result of several causes. First, verify that there is no
reference only. Tests do not need to be performed in this display. A single character in the display or a dot in the
order. Perform tests only as necessary. upper corner of the display indicates a communication
error. Check that all option cards are properly installed.
When this condition occurs, the green power-on LED is
WARNING illuminated.
Never disconnect the input cabling to the frequency
converter with power applied due to danger of severe If the LCD display is dark and the green power-on LED is
injury or death. not lit, proceed with the following tests.
CAUTION First test for proper input voltage.
6 6 Take all the necessary safety precautions for system

6.4.2 Input Voltage Test
start-up before applying power to the frequency
converter.
1. Apply power to frequency converter.
Dynamic tests are conducted to check the IGBT. The tests 2. Use the DVM to measure the input mains voltage
can indicate if an IGBT is faulty. The fault is indicated by a between the frequency converter input terminals
voltage drop on the terminals UVW. in sequence:
L1 to L2
Preparation: L1 to L3
• Disconnect the motor from the frequency L2 to L3
converter. For 380 V frequency converters, all measurements must be
• Ensure that the frequency converter is powered within the range of 342–550 V AC. Readings of less than
up. 342 V AC indicate problems with the input mains voltage.
For 525–600 V frequency converters, all measurements
• Program the frequency converter to approxi-
must be within the range of 446–600 V AC. Readings of
mately 50 Hz on start.
less than 446 V AC indicate problems with the input mains
• Set the multimeter to AC 1000 V. voltage.
Procedure for dynamic test on the IGBT.
In addition to the actual voltage reading, the balance of
1. Connect the positive terminal of the multimeter the voltage between the phases is also important. The
lead to the U connector, and connect the frequency converter can operate within specifications as
negative terminal to the V terminal. long as the imbalance of supply voltage is not more than
3%.
2. Connect the positive terminal of the multimeter
lead to the U connector, and connect the
calculates mains imbalance per an IEC specification.
negative terminal to the W terminal.
3. Connect the positive terminal of the multimeter Imbalance=0.67 X (Vmax–Vmin)/Vavg
lead to the V connector, and connect the
negative terminal to the W terminal. For example, if 3-phase readings were taken and the
results were 500 V AC, 478.5 V AC, and 478.5 V AC; then
The meter reading is 450 V ±25 V when performing the 500 V AC is Vmax, 478.5 V AC is Vmin, and 485.7 V AC is Vavg,
dynamic test at 400 V mains. With PM motors the reading resulting in an imbalance of 3%.
may differ. Contact hotline for help.
Although the frequency converter can operate at higher

The reading must be within ±1.5%. mains imbalances, the lifetime of components, such as DC
bus capacitors, is shortened.

Incorrect reading Voltage imbalances automatically result in a

corresponding current imbalance.
CAUTION
Open (blown) input fuses or tripped circuit breakers 2. Apply power to the frequency converter and
usually indicate a more serious problem. Before replacing place it in run.
fuses or resetting breakers, perform static tests. 3. Using a clamp-on ammeter (analog preferred),
read the current on each of 3 input lines at
An incorrect reading here requires further investigation of L1 (R), L2 (S), and L3 (T).
the main supply. Typical items to check would be: Typically, the current should not vary from phase-
• Open (blown) input fuses or tripped circuit to-phase by more than 5%. If a greater current
breakers variation exists, it indicates a possible problem
with the mains supply to the frequency converter,
• Open disconnects or line side contactors
or a problem within the frequency converter. One
• Problems with the power distribution system way to determine if the mains supply is at fault is
If this test was successful, check for voltage to the control to swap 2 of the incoming phases. This assumes
card. that 2 phases read 1 current while the 3rd
deviates by more than 5%. If all 3-phases are
6 6
different from one another, swap the phase with
6.4.3 Basic Control Card Voltage Test
the highest current with the phase with the
lowest current:
1. Measure the control voltage at terminal 12 with
reference to terminal 20. 3a Remove power to the frequency
The meter must read 21–27 V DC. converter.
An incorrect reading here could indicate that a fault in the 3b Swap the phase that appears to be
customer connections loads down the supply. Disconnect incorrect with 1 of the other 2 phases.
control wiring and repeat the test. If this test is successful, 3c Reapply power to the frequency
then continue. Remember to check the customer converter and place it in run.
connections. If still unsuccessful, replace the unit.
3d Repeat the current measurements.
2. Measure the 10 V DC control voltage at terminal If the imbalance of supply voltage moves with swapping
50 with reference to terminal 55. The meter must the leads, the mains supply is suspect. Otherwise, it may
read between 9.2 and 11.2 V DC. indicate a problem with the gating of the rectifiers.
An incorrect reading here could indicate that a fault in the

customer connections loads down the supply. Disconnect
6.4.5 Input Waveform Test
control wiring and repeat the test. If this test is successful,
then continue. Remember to check the customer Testing the current waveform on the input of the
connections. If still unsuccessful, replace the unit. frequency converter can help troubleshooting mains phase
loss conditions or suspected problems with the diode
modules. Phase loss caused by the mains supply can be
6.4.4 Input Imbalance of Supply Voltage
easily detected. In addition, the diode modules control the
Test
rectifier section. If 1 of the diode modules become
defective, the frequency converter provides a response
Theoretically, the current drawn on all 3 input phases must
which is the same as loss of 1 of the phases.
be equal. Some imbalance may be seen, however, due to
variations in the phase-to-phase input voltage, and single-
The following measurements require an oscilloscope with
phase loads within the frequency converter.
voltage and current probes.
A current measurement of each phase reveals the balanced

Under normal operating conditions, the waveform of a
condition of the line. To obtain an accurate reading, the
single-phase of input AC voltage to the frequency
frequency converter must run at its rated load, or at a load
converter appears as in Illustration 6.15.
of not less than 40%.
1. Perform the input voltage test before checking

the current, in accordance with procedure.

Test Procedures
6.4.6 Output Imbalance of Motor Supply

Voltage Test
Check the balance of the output voltage and current to

measure the electrical functioning between the frequency
converter and the motor. In testing the phase-to-phase
output, both voltage and current are monitored. Conduct
static tests on the inverter section of the frequency
converter before this procedure.
Illustration 6.15 Normal AC Input Voltage Waveform
If the voltage is balanced, but the current is not, it

indicates that the motor is drawing an uneven load. This
The waveform shown in Illustration 6.16 shows the input
could be the result of a defective motor, a poor connection
current waveform for the same phase as shown in
in the wiring between the frequency converter and the
Illustration 6.15 while the frequency converter is running at
motor, or a defective motor overload.
6 6 40% load. The 2 positive and 2 negative jumps are typical
of any 6-diode bridge. It is the same for frequency
converters with diode modules. If the output current and the voltage are unbalanced, it
indicates that the frequency converter is not working
properly. It could be the result of a defective power card or
an improper connection of the output circuitry.
NOTICE
Use an analog voltmeter for monitoring output voltage.
Digital voltmeters are sensitive to waveform and
switching frequencies and commonly return erroneous
readings.
Illustration 6.16 AC Input Current Waveform with Diode Bridge

Perform the initial test with the motor connected and
running its load.
With a phase loss, the current waveform of the remaining

If suspect readings are recorded, then:
phases would take on the appearance shown in
Illustration 6.17.
• Stop the motor and wait until the motor has
stopped rotating.
• Set the frequency converter to coast.
• Disconnect the motor cables to isolate the
problem further.
Then:
1. Using a voltmeter, measure AC output voltage at
frequency converter motor terminals U, V, and W.
Measure phase-to-phase checking U to V, then U
to W, and then V to W.
Illustration 6.17 Input Current Waveform with Phase Loss
All 3 readings must be within 8 V AC of each
other. The actual value of the voltage depends on
the speed at which the frequency converter is
running. The V/Hz ratio is relatively linear (except
Always verify the condition of the input voltage waveform
in VT mode). For example, if the rated motor
before drawing a conclusion. The current waveform follows
frequency is 60 Hz, the voltage should be approx-
the voltage waveform. If the voltage waveform is incorrect,
imately equal to the applied mains voltage. At
proceed to investigate the reason for the AC supply
30 Hz, it is about half of the applied mains
problem. If the voltage waveform on all 3-phases is correct,
voltage for any other speed selected. The exact
but the current waveform is not, the input rectifier circuit
voltage reading is less important than balance
in the frequency converter is suspect. Perform the static
between phases.
soft-charge and rectifier tests, and also the dynamic diode
module test. 2. Stop the frequency converter and disconnect
mains.

3. Reconnect the motor to the frequency converter. If 24 V is present, proceed with checking the individual
4. Connect mains to the frequency converter, and inputs as follows:
start the frequency converter. 2. Connect the (-) negative meter lead to reference
terminal 20.
5. Monitor current on the 3 output phases at the
motor terminals U, V, and W, using the clamp-on 3. Connect the (+) positive meter lead to the
ammeter. An analog device is preferred. To terminals in sequence.
achieve an accurate reading, run the frequency The presence of a signal at the desired terminal must
converter above 40 Hz as this is normally the correspond to the digital input display readout. A reading
frequency limitation of such meters. of 24 V DC indicates the presence of a signal. A reading of
The output current must be balanced from phase-to-phase, 0 V DC indicates that no signal is present.
and no phase must be more than 2–3% different from
another. If these tests are successful, the frequency Analog inputs
converter is operating normally. The value of signals on analog input terminals 53 and 54
can also be shown. The voltage or current in mA,
6. If the imbalance is greater than described depending on the switch setting, is shown in line 2 of the
display.
6 6
previously, disconnect the motor cables and
repeat the voltage balance test. If the desired signal is not present in the display, the
7. Stop the motor and disconnect mains from the problem is either in the external control wiring to the
frequency converter. frequency converter, or a faulty control card. To determine
the fault location, use a voltmeter to test for a signal at the
Since the current follows the voltage, it is necessary to control terminals.
differentiate between a load problem and a frequency
converter problem. When a voltage imbalance in the Verify that the reference voltage power supply is correct
output is detected with the motor disconnected, the as follows.
inverter is faulty. Exchange the frequency converter. 1. Use a voltmeter for measuring the voltage at
control card terminal 50 with respect to terminal
55. The meter must read between 9.2 and 11.2 V
6.4.7 Input Terminal Signal Tests DC.
The presence of signals on either the digital or analog If the 10 V supply voltage is not present, conduct basic
input terminals of the frequency converter can be verified control card voltage test, see chapter 6.4.3 Basic Control
on the frequency converter display. Digital or analog input Card Voltage Test.
status can be selected or read in parameters 16-60 to
16-64. If 10 V is present, proceed with checking the individual
inputs as follows.
Digital inputs 2. Connect the (-) negative meter lead to reference
With digital inputs shown, control terminals 18, 19, 27, and terminal 55.
29 are shown left to right, with a 1 indicating the presence 3. Connect the (+) positive meter lead to desired
of a signal. terminal 53 or 54.
If the desired signal is not present in the display, the For analog input terminals 53 and 54, a DC voltage
problem is either in the external control wiring to the between 0 and +10 V DC must be read to match the
frequency converter or a faulty control card. To determine analog signal sent to the frequency converter. Or a reading
the fault location, use a voltmeter to test for voltage at the of 0.9 V DC to 4.8 V DC corresponds to a 4–20 mA signal.
control terminals.
NOTICE
Verify that the control voltage power supply is correct A (-) minus sign preceding any reading above indicates a
as follows: reversed polarity. In this case, reverse the wiring to the
1. Use a voltmeter for measuring voltage at control analog terminals.
card terminal 12 and 13 with respect to terminal
20. The meter should read 21-27 V DC.
If the 24 V supply voltage is not present, test the control
card in chapter 6.2.1 Introduction.

Test Procedures
6.5 Initial Start-up Or After Repair Drive

Tests
Perform these tests under the following conditions:
• Starting a frequency converter for the first time.
• Approaching a frequency converter that is
suspected of being faulty.
• After repair of the frequency converter.
Following this procedure ensures that all circuitry in the
frequency converter is functioning properly before putting
it into operation.
1. Perform visual inspection procedures as described
in Table 4.1.
6 6 2. Perform static test procedures to ensure that the

frequency converter is safe to start.
3. Disconnect motor cables from output terminals
(U, V, W) of the frequency converter.
4. Apply AC power to frequency converter.
5. Give the frequency converter a run command and
slowly increase reference (speed command) to
approximately 40 Hz.
6. Use an analog voltmeter or a DVM capable of
measuring true RMS to measure phase-to-phase
output voltage on all 3-phases: U to V, U to W, V
to W. All voltages must be balanced within 8 V. If
measuring unbalanced voltage, refer to
chapter 6.4.6 Output Imbalance of Motor Supply
Voltage Test.
7. Stop the frequency converter and remove input
power. Wait for the discharge time listed in
Table 1.1 to allow DC capacitors to discharge fully.
8. Reconnect motor cables to frequency converter
output terminals (U, V, W).
9. Reapply power and restart the frequency
converter. Adjust motor speed to a nominal level.
10. Set load to 50%.
11. Using a clamp-on ammeter, measure output
current on each output phase. All currents must
be balanced.
12. The correct measurement is 50% rated current.

H-Frame Size Disassembly a... TR150 and TR170 Service Manual
7 H-Frame Size Disassembly and Assembly Instructions
7.1 Electrostatic Discharge (ESD) 7.3 H6 Frame Size Disassembly and

Assembly Instructions
CAUTION 7.3.1 Control Card and Control Card
Frequency converters contain dangerous voltages when
connected to the main voltage. Never perform any
Mounting Plate
disassembly when power is applied. Remove power to
the frequency converter, and wait until the frequency 1. Remove the LCP and the protection foil
converter capacitors fully discharge. Only a competent underneath it.
technician must carry out the service. 2. Remove the 3 screws (T10) from the control card.
Many electronic components within the frequency
3. Remove the control card.
converter are sensitive to static electricity. Voltages so
low that they cannot be felt, seen, or heard can reduce 4. Remove the 4 bolts on the bottom of the frame
the life, affect performance, or completely destroy underneath the cable connector.
sensitive electronic components. 5. Remove the screws (T10) in the control card
mounting plate. 7 7
CAUTION 6. Press barbs on ribbon cable and remove it.
Use correct ESD procedures to prevent damage to 7. Remove screws (T20) in cover plate.
sensitive components when servicing the frequency 8. Remove the control card mounting plate.
converter.
Reinstall in the reverse order.
NOTICE
Frame size is used throughout this manual where ever
procedures or components differ between frequency
converters based upon the unit's physical size. Refer to
chapter 1.4.1 Frame Size Definitions to determine frame
size.
7.2 General Disassembly Procedure

This procedure explains how to remove the outer parts of
the frequency converter that are common for H frame
sizes. When this procedure is completed, the inside
components are accessible.
1. Remove the plastic cover beneath the LCP with a

flat-edged screwdriver.
2. Loosen and remove 4 screws (T20) on the front
cover.
3. Remove the front cover.

H-Frame Size Disassembly a...
7.3.2 Heat sink Fan Assembly
1. Unplug the fan cable

2. Remove 4 screws on fan cover plate.
3. Remove the fan.
7 7
1 LCP
2 Cradle 1 Fan cover plate
3 Control card 2 Screws
4 Control card mounting plate 3 Fan assembly
Illustration 7.1 Control Card and Control Card Mounting Plate Illustration 7.2 Heat Sink Fan Assembly

7.3.3 DC Coil 7.3.4 DC Link Card
1. Remove the 4 screws on the DC coil cover to 1. Remove the 6 screws on coil mounting plate.
access the DC coils. 2. Remove the coil mounting plate.
2. Remove the 4 screws to loosen the cables from 3. Loosen the 4 screws from the DC Link card.
the DC Link card.
4. Press one of the barbs to loosen the link card.
3. Remove the 6 screws on the DC coils (3 screws
on each coil). 5. Unplug the 10-pin ribbon cable and the filter
cable.
4. Remove the coils.
6. Remove the DC Link card.
Reinstall in the reverse order. Join the mounting snaps.
7 7
1 DC coil cover
2 DC coils 1 Coil mounting plate
2 Capacitor bank metal cover
Illustration 7.3 DC Coil 3 DC link card
Illustration 7.4 DC Link Card

7.3.5 RFI Filter 7.3.6 Power Card
1. Remove the protection cover. 1. Remove the 3 screws on the U V W cable

2. Remove the 6 distance bushes. connector.
3. Remove the 2 screws on the frame side. 2. Remove the connector.
4. Remove the 3 screws from U V W cables. 3. Remove the 3 small screws (T10) from the power
card.
5. Press the barbs on the side of the filter.
6. Remove the RFI filter.
NOTICE
If it is difficult to get out the screws, use a magnet.
4. Remove the 6 remaining screws (T20).
5. Lift the power card and slide it out of the frame.
NOTICE
7 7 If it is difficult to remove the power card, it is helpful to
press the frame sides outwards while pressing the barbs
on the side of the power card.
1 RFI filter
1 Power card
2 EMC shield
Illustration 7.5 RFI Filter


7.4 H7 Frame Size Disassembly and 7.4.2 Power Card

1. Remove the LCP ribbon cable from the power
7.4.1 Control Card and Control Card card.
Mounting Plate 2. Unplug all other cables from the power card,
including the 3 gate cables at the bottom of the
1. Remove the LCP by pressing the barbs on the card.
side.
3. Remove the 3 screws (T20) from the mounting
2. Remove the foil. plate.
3. Remove the 3 screws (T10). 4. Remove the power card by pushing in the 6
4. Gently, lift off the control card. retaining clips.
5. Press the barb on the LCP ribbon cable and pull NOTICE
it out of the control card mounting plate. Use a screwdriver if the retaining clips are hard to reach.
6. Remove the mounting plate. 5. Slide the power card out and remove it.
Reinstall in the reverse order. Reinstall in the reverse order.
7 7
1 Power card

1 LCP
2 Cradle
3 Control card
4 Control card mounting plate
Illustration 7.7 Control Card and Control Card Mounting Plate

7.4.3 Inrush Card 7.4.4 RFI Filter
1. Remove the 2 screws (T20) from the filter shield. 1. Remove the red/black cables from the filter cable.
2. Remove the shield. 2. Remove the protective foil.
3. Remove the 4 screws (T20) from the power card 3. Remove the 3 filter cables screws using a hex 8
mounting plate. key.
4. Remove the power card mounting plate. 4. Remove the 2 screws (T20) from the EMC shield.
5. Unplug all cables from the inrush card. 5. Remove the EMC shield.
6. Remove the 6 screws (T20) from the inrush card. 6. Remove the 8 screws (T20) on the filter cable
7. Remove the inrush card. cover.
Reinstall in the reverse order. 7. Loosen the left cable connector using a hex 5 key
8. Remove the entire filter assembly.
7 7
1 RFI filter
2 Screws
3 EMC shield
1 EMC shield
3 Inrush card
Illustration 7.9 Inrush Card

7.4.5 Relay Transducer Card 7.4.6 Rectifier Modules
1. Unplug cables on the relay transducer card. 1. Loosen and remove the 2 cables (T20).
2. Loosen the right cable connector using a hex 5 2. Remove the 6 screws (T20) from the shield.
key. 3. Remove metal shield and plastic cover.
3. Open the plastic clamp to remove the cables 4. Remove the 2 screws (T20) from each of the
from the connector.
rectifier modules.
4. Remove the 2 screws (T20) from the holding 5. Remove the 3 rectifier modules.
bracket.
5. Remove the holding bracket. 7.4.7 IGBT
6. Remove the 3 cable screws (T20).
1. Remove the 4 screws (T20) from the cable
7. Remove the 3 screws on relay card (T20).
connector plate.
8. Remove the relay card by pushing in the
2. Remove the cable connector plate.
retaining clips on the standoffs. Use a screwdriver
if necessary. 3. Loosen the coil cables (T20).
9. Remove the mounting plate. 4. Unplug the cables. 7 7
Reinstall in the reverse order. 5. Remove the 2 screws from each of the 2
capacitors
6. Remove the capacitors.
7. Remove the 4 screws (T20) from the bus bar.
8. Remove the cables from the IGBTs.
9. Remove the 2 screws (T20) from each IGBT.
10. Remove the IGBTs.
CAUTION
The IGBTs and the heat sink have thermal paste on them.
Be careful not to touch the paste directly as it is
poisonous.
11. Remove the thermal paste from the IGBT.
12. Clean the heat sink.
1 Relay transducer card
2 Relay card mounting plate
Illustration 7.11 Relay or Transducer Card

7.4.8 Heat Sink Fan Assembly
1. Remove the 4 screws (T20) from the fan cover

plate.
2. Press the fan cover plate outwards using a
screwdriver.
3. Remove the fans and the fan cover plate.
7 7
1 Cable mounting plate

2 IGBT 1 Fan cover
3 Bus bar 2 Fan assembly
4 Capacitor
Illustration 7.13 Heat Sink Fan Assembly
Illustration 7.12 IGBT

7.4.9 DC Coil 7.4.10 Capacitor Bank
1. Remove the 4 screws (T20) from the DC coil cover 1. Remove the foil.
plate. 2. Remove the 6 screws on the base plate.
2. Remove the 4 screws (T20) from the heat sink. 3. Remove the base plate.
3. Remove the heat sink. 4. Remove the 4 screws (T20) from the capacitor
4. Remove 4 screws (T20) from each of the 2 DC mounting plate.
Coils. 5. Remove the mounting plate.
5. Remove the coils. 6. Turn the capacitor bank upside-down.
Reinstall in the reverse order. 7. Remove the hex nut with a hex 19 key.
8. Remove the capacitor.
7 7
1 DC coil cover plate

2 Heat sink
3 DC coil
Illustration 7.14 DC Coil

1 Foil
2 Base plate
3 Capacitor bank
Illustration 7.15 Capacitor Bank

7.5 H8 Frame Size Disassembly and 7.5.2 Power Card

1. Remove 2 screws (T20) from the EMC shield.
7.5.1 Control Card and Control Card 2. Remove cables from EMC shield.
Mounting Plate
3. Remove the EMC shield.
1. Remove the LCP by pressing the barbs on the 4. Remove the LCP ribbon cable from the power
side. card.
2. Remove the foil. 5. Unplug all other cables from the power card.
3. Remove the 3 screws (T10). 6. Remove the 3 screws (T20) from the mounting
4. Gently, lift off the control card. plate.
5. Press the barb on the LCP ribbon cable and pull 7. Remove the power card by pushing in the 6
it out of the control card mounting plate. retaining clips.
6. Remove the mounting plate. NOTICE

Use a screwdriver if the retaining clips are hard to reach.
8. Slide the power card out and remove it.
7 7 Reinstall in the reverse order.
1 Power card
1 LCP
2 Cradle
3 Control card

7.5.3 Inrush Card 7.5.4 Rectifier Modules
1. Remove the 4 screws (T20) from the power card

mounting plate. CAUTION
Wear protective gloves when cleaning up the thermal
2. Remove the power card mounting plate. paste as it is poisonous.
3. Unplug all cables from the inrush card.
4. Remove the 6 screws (T20) from the inrush card. 1. Remove cables and foil.
5. Remove the inrush card. 2. Remove coil cords (T20).
Reinstall in the reverse order. 3. Remove 6 screws (T25).

4. Remove screws in coil cables (T20).
5. Remove the 6 screws (T25) from the bar.
6. Remove the bar.
7. Loosen and remove the 3 cables using a hex 10
key.
8.
9.
Remove the plastic cover.
Remove the 2 screws (T20) on each of the
7 7
rectifier modules
10. Remove the thermal paste paper.
11. Clean up any excessive thermal paste.
1 EMC shield
3 Inrush card

7.5.5 RFI Filter
1. Remove the 3 screws (T20) from the small EMC

shield.
2. Remove the EMC shield.
3. Loosen left cable connector using a hex 8 key.
4. Remove the 4 screws (T20) from the filter.
5. Remove the entire filter assembly.
7 7
1 Foil
2 Bus bar
3 Plastic cover
4 Rectifier modules 1 RFI filter
2 Screws
Illustration 7.19 Rectifier Modules 3 EMC shield

7.5.6 Relay Transducer Card 7.5.7 IGBT
1. Remove the 4 screws (T20) on the plate.

CAUTION
2. Carefully remove cables before removing the Wear protective gloves when cleaning up the thermal
plate. paste as it is poisonous.
3. Loosen the cables in the right cable connector
using a hex 8 key. 1. Remove the 2 screws from the cable retaining
4. Pull out the cables. guide.
5. Remove the 3 screws (T30) on the relay card. 2. Remove the cable retaining guide.
6. Remove the 2 10-pin ribbon cables. 3. Remove the 4 screws (T20) from the cable
connector plate.
7. Remove the 3 screws (T20) from the relay card.
4. Remove the cable connector plate.
8. Press the 3 retaining clips.
5. Remove the 2 cable screws (T20)
9. Remove the relay card.
6. Remove the 2 screws (T30) in each of the 2
10. Remove the relay card mounting plate.
capacitors.
7. Remove the capacitors. 7 7
8. Remove the 2 screws (T30) from the bus bar.
9. Remove the 4 screws (T20) holding the
capacitors.
10. Remove the bus bar.
11. Remove the gate cables from the IGBTs.
12. Remove the 4 screws from each IGBT.
13. Remove the thermal paper.
14. Remove the thermal paste from the IGBTs and
the heat sink.

2 Relay card mounting plate
Illustration 7.21 Relay Transducer Card

1. Remove the 4 screws (T20) from the fan cover

plate.
2. Press the fan cover plate outwards using a
screwdriver.
3. Remove the fans and the fan cover plate.
7 7

2 IGBT 1 Fan cover
3 Bus bar 2 Fan assembly
4 Capacitor

7.5.9 DC Coil 7.5.10 Capacitor Bank
1. Remove the 4 screws (T20) from the DC coil cover 1. Remove the foil.
plate. 2. Remove the 4 screws from the base plate.
2. Remove the 4 screws (T20) from the heat sink. 3. Remove the base plate.
3. Remove the heat sink. 4. Remove the 4 screws from the capacitor bank
4. Remove 4 screws (T20) from each of the 2 DC assembly.
Coils. 5. Remove the assembly.
5. Remove the coils. 6. Turn the assembly upside-down.
Reinstall in the reverse order. 7. Remove the 2 hex nuts with a hex 19 key.
8. Remove the 2 capacitors.
7 7
1 DC coil cover plate

2 Heat sink
3 DC coil

1 Foil
2 Base plate
3 Capacitor bank
Illustration 7.25 Capacitor Bank

7.6 H10 Frame Size Disassembly and 7.6.2 Power Card Cover
1. Press and loosen the 3 barbs at the bottom, and
7.6.1 Control Card and Control Card the 3 barbs at the top.
Mounting Plate 2. Remove the power card cover.
1. Remove the LCP cradle. LCP cradle can be Reinstall in the reverse order. Join the mounting snaps.
removed by hand.
2. Remove 3 screws (T10) securing the control card
mounting plate to the control assembly support
bracket.
3. Carefully lift out the control card.
7 7
1 Power card cover
Illustration 7.27 Power Card Cover
1 LCP
3 Control card

7.6.3 Power Card 7.6.4 Heat Sink and DC Coils
1. Remove the 4 screws (T10) for the DC coil cables. 1. Remove the 7 mounting screws from top surface.
2. Remove the 5 screws (T10) for the heat sink. 2. Press and loosen the 3 barbs at the bottom.
3. Remove the 4 IGBT screws (T25). 3. Unplug the DC coil cables.
4. Unplug fan cable connector. 4. Remove the heat sink.
5. Lift out the DC coils.
CAUTION
The power card and the heat sink have thermal paste on Reinstall in the reverse order.
them. Wear protective gloves as the paste is poisonous.
5. Lift out the power card.
6. Remove the capacitor bank gasket.
7 7
1 Heat sink
Illustration 7.29 Heat Sink

1 Power card
1 DC coil

1. Remove 2 screws (T10) on the DC coil mounting

plate
2. Remove the plate.
3. Press and loosen the 2 barbs on the fan.
4. Remove the fan.
7 7
1 Heat sink fan

2 Fan mounting plate

I-Frame Size Disassembly an... TR150 and TR170 Service Manual
8 I-Frame Size Disassembly and Assembly Procedures
8.1 General Disassembly Procedure

This procedure explains how to remove the outer parts of
the frequency converter that are common for all I-frame
sizes. When this procedure is completed, the inside
components are accessible.
1. Loosen and remove the 4 screws (T20) from the

front cover.
2. Remove the front cover.
3. Remove the screw and sheet metal next to the
EMC shield.
4. Loosen and remove the 4 screws (T20) from the
cable entry.
5. Remove the cable entry.
8.2 I6 Frame Size Disassembly and 8 8

8.2.1 Control Card and Control Card
Mounting Plate
1. Remove LCP cradle.

2. Remove 3 screws (T12) on the control board.
3. Remove the control board.
1 LCP and cradle
4. Remove 1 screw (T20) on the fan bracket. 2 Control card and mounting plate
5. Unplug the fan cable and remove the fan. 3 Support bracket
4 Terminal plates
6. Remove 4 screws (T20) on the control card
5 EMC shield
mounting plate.
7. Unplug ribbon cable. Illustration 8.1 Control Card and Control Card Mounting Plate
8. Remove control card mounting plate.

I-Frame Size Disassembly an...
8.2.2 Cable Mounting Plate 8.2.3 Heat Sink Fan Assembly
1. Remove the ribbon cable. 1. Unplug cable from power card.

2. Remove 1 screw (T20) from shield metal. 2. Remove 2 screws (T20) from the fan mounting
3. Use a flat screwdriver to release the retainers and plate.
connection terminals. 3. Push the cable downwards. Use a screwdriver to
4. Use a hex 4 key to loosen the screws in the cable press the gasket down through the entry.
connector. 4. Pull out fan assembly.
5. Pull out the cables. Reinstall in the reverse order.
6. Slide the connector to the side and remove it.
7. Remove 2 screws (T20) from the mounting plate.
8 8
1 Fan cover
2 Fan assembly

1 EMC shield
Illustration 8.2 Cable Mounting Plate

8.2.4 SMPS Card 8.2.5 Bus Bar Unit
1. Remove the 3 black plastic covers. 1. Remove the 2 screws from the snubber capacitor
2. Unplug and remove the fan. on the bus bar unit.
3. Unplug all other cables. 2. Remove the snubber capacitor.
4. Remove the 2 screws (T20) at MK101. 3. Use a Hex 8 key to remove 2 screws from the bus
bar unit.
5. Remove the 3 screws (T20) at K103A, K104A, and
K105A. 4. Remove the 6 small screws (T10).
6. Remove the 4 screws (T20) and from the SMPS 5. Remove the remaining 9 screws (T20).
card. 6. Unplug cables.
7. Lift off the SMPS card. 7. Lift out the bus bar unit.
8 8
1 SMPS card
Illustration 8.4 SMPS Card
1 Fan
2 Bus bar unit
Illustration 8.5 Bus Bar Unit

8.2.6 Power Card 8.2.7 DC Coil
1. Remove 7 screws (T20) 1. Remove 4 screws (T20) from the coil.

2. Remove 5 screws (T10) on the Power Card. 2. Lift the coil.
3. Lift out the power card. Reinstall in the reverse order.
8 8 1 DC coil
1 Power card

8.2.8 RFI Filter 8.3 I7 Frame Size Disassembly and

1. Remove 2 screws (T20) from the filter.
2. Lift out the filter.
Mounting Plate
1. Remove 2 screws (T20) from the 2 cover plates.
2. Remove the LCP cradle.
3. Remove 3 screws (T10) from the control card.
5. Remove 2 screws (T20) from the bracket next to
the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8. Remove the control card mounting plate.
1 RFI filter
8 8
1 LCP and cradle

2 Control card and mounting plate
3 EMC shield
4 Terminal plates
5 EMC shield
Illustration 8.9 Control Card Mounting Plate

8.3.2 Power Card 8.3.3 Power Card Mounting Plate
1. Unplug and remove the LCP ribbon cable. 1. Remove 4 screws (T20) from the power card
2. Unplug all other cables from the power card. mounting plate.
3. Remove 3 screws (T20) on the power card. 2. Remove the power card mounting plate with the
fan attached.
4. Remove the power card.
8 8
1 Power card Illustration 8.11 Power Card Mounting Plate

8.3.4 Inrush Card 8.3.5 Bus Bar
1. Unplug all cables. 1. Unplug and remove the red/black cable.

2. Remove 6 screws (T20) from the inrush card. 2. Remove the black plastic cover.
3. Remove the inrush card. 3. Remove 8 screws (T20) from the support bracket.
Reinstall in the reverse order. 4. Remove the bus bar assembly.
8 8
1 Inrush card
1 Bus bar
Illustration 8.13 Bus Bar

8.3.6 RFI Filter 8.3.7 Relay Transducer Card
1. Unplug the 3 filter cables from the thyristors 1. Remove the 3 clamps on each side of the 2 cable
using a hex 8 key. connectors.
2. Loosen the 3 cables from the cable connector 2. Remove the cable connector with no cables
using a hex 5 key. attached.
3. Remove 3 screws (T20) from the support bracket. 3. Remove 3 screws (T20) from the support bracket.
4. Remove support bracket. 4. Loosen the 3 cables from the relay transducer
5. Remove 4 screws (T20) from the RFI filter. card.
6. Remove the entire assembly. 5. Remove the cable connector with cables and
retaining guide attached.
6. Unplug all other cables from the relay transducer
card.
7. Remove the 3 screws (T20)
8. Remove the relay transducer card.
8 8
1 RFI filter

8.3.8 Fan 8.3.9 Terminal Plate
1. Remove 2 screws (T20) on the fan bracket. 1. Remove the black plastic cover.
2. Remove 2 screws (T20) from the fan. 2. Remove 4 screws (T20) on the cover plate.
3. Remove the fan. 3. Remove the terminal plate.
8 8
1 Fan 1 Terminal plate
Illustration 8.16 Fan Illustration 8.17 Terminal Plate

8.3.10 DC Bus Bar Assembly 8.3.11 Heat Sink Fan Assembly
1. Remove 2 screws (T20) from the 2 snubbers. 1. Remove gate cables from IGBTs.
2. Remove the snubbers. 2. Remove 2 screws (T20) from the heat sink fan
3. Loosen and remove cables from bus bar assembly assembly.
and DC coil. 3. Push the fan cable down through the gasket.
4. Remove 6 screws (T20) from the bus bar 4. Carefully press the gasket down with a
assembly. screwdriver.
5. Remove the bus bar assembly. 5. Remove the fan assembly.
8 8
1 DC bus bar assembly 1 Fan cover plate

2 Fan assembly
Illustration 8.18 DC Bus Bar Assembly

8.3.12 Capacitor Bank 8.3.13 DC Coil
1. Remove 4 screws (T20) from each of the 1. Remove 5 screws (T20) on the potted coil.
capacitors. 2. Remove the DC coil.
2. Remove the capacitors. Reinstall in the reverse order.
1 Bus bar
8 8
1 Capacitors 2 DC coil
Illustration 8.20 Capacitors Illustration 8.21 DC Coil

8.3.14 IGBT 8.3.15 Thyristor
1. Remove 2 screws (T20) from each of the 3 IGBTs. 1. Remove 2 screws (T20) from each of the 3
thyristors.
CAUTION
The IGBTs and the heat sink have thermal paste on them. CAUTION
Wear protective gloves as the paste is poisonous. The thyristors and the heat sink have thermal paste on
2. Remove all IGBTs. them. Wear protective gloves as the paste is poisonous.
Reinstall in the reverse order. 2. Remove the thyristors.
8 8
1 IGBT
1 Thyristor
Illustration 8.23 Thyristor
8.4 I8 Frame Size Disassembly and

Assembly Procedure
Mounting Plate
1. Remove 2 screws (T20) from the 2 cover plates.

2. Remove the LCP cradle.
3. Remove 3 screws (T10) from the control card.
5. Remove 2 screws (T20) from the bracket next to
the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8. Remove the control card mounting plate.

8.4.2 Power Card
1. Unplug and remove the LCP ribbon cable.

2. Unplug all other cables from the power card.
3. Remove 3 screws (T20) on the power card.
4. Remove the power card.
8 8
1 Power card
1 LCP and cradle
2 Control card and mounting plate
3 EMC shield
4 Terminal plates
5 EMC shield
Illustration 8.24 Control Card Mounting Plate

8.4.3 Power Card Mounting Plate 8.4.4 Inrush Card
1. Remove 4 screws (T20) from the power card 1. Unplug all cables.
mounting plate. 2. Remove 6 screws (T20) from the inrush card.
2. Remove the power card mounting plate with the 3. Remove the inrush card.
fan attached.
8 8
1 Inrush card

Illustration 8.26 Power Card Mounting Plate

8.4.5 Bus Bar 8.4.6 RFI Filter
1. Unplug and remove the red/black cable. 1. Unplug the 3 filter cables from the thyristors
2. Remove the black plastic cover. using a hex 8 key.
3. Remove 6 screws (T20) and 2 screws (T30) from 2. Loosen the 3 cables from the cable connector
the support bracket. using a hex 5 key.
4. Remove the bus bar assembly. 3. Remove 3 screws (T20) from the support bracket.
Reinstall in the reverse order. 4. Remove support bracket.

5. Remove 4 screws (T20) from the RFI filter.
6. Remove the entire assembly.
8 8
1 Bus bar
Illustration 8.28 Bus Bar
1 RFI filter
Table 8.1

8.4.7 Relay Transducer Card 8.4.8 Terminal Plate
1. Remove 2 screws (T20) from each of the 2 cable 1. Remove 4 screws (T20) on the cover plate.
connectors. 2. Remove the complete terminal plate including
2. Remove the cable connector. cable connector.
3. Remove 3 screws (T20) from the support bracket. Reinstall in the reverse order.
4. Loosen the 3 cables (T30) from the relay
transducer card.
5. Unplug all other cables from the relay transducer
card.
6. Remove the 3 screws (T20).
7. Remove the relay transducer card.
8 8
1 Terminal plate
Illustration 8.31 Terminal Plate

8.4.9 DC Bus Bar Assembly 8.4.10 Heat Sink Fan Assembly
1. Remove 2 screws (T30) from each of the 2 1. Remove 4 screws (T20) from the heat sink fan
snubbers. assembly.
2. Remove the snubbers. 2. Push the cables down through the gaskets.
3. Loosen and remove the 2 cables from bus bar 3. Carefully press the gaskets down with a
assembly and DC coil. screwdriver.
4. Remove 2 screws (T30). 4. Remove the fan assembly.
5. Remove 8 screws (T20) on top of the bus bar Reinstall in the reverse order.
assembly.
6. Remove the bus bar assembly.
8 8
1 Fan cover plate
2 Heat sink fan
1 Bus bar assembly
Illustration 8.32 DC Bus Bar Assembly

8.4.11 Capacitor Bank 8.4.12 DC Coil
1. Remove 4 screws (T20) from each of the 1. Remove 5 screws (T20) on the potted coil.
capacitors. 2. Remove the DC coil.
2. Remove the capacitors. Reinstall in the reverse order.
8 8 1 Bus bar
Illustration 8.34 Capacitors
2 DC coil
1 Capacitors Illustration 8.35 DC Coil

8.4.13 IGBT 8.4.14 Thyristor
1. Remove 4 screws (T20) from each of the 3 IGBTs. 1. Remove 2 screws (T20) from each of the 3
thyristors.
CAUTION
The UGBTs and the heat sink have thermal paste on CAUTION
them. Wear protective gloves as the paste is poisonous. The thyristors and the heat sink have thermal paste on
2. Remove all IGBTs. them. Wear protective gloves as the paste is poisonous.
Reinstall in the reverse order. 2. Remove the thyristors.
8 8
1 IGBT
1 Thyristor
Illustration 8.37 Thyristor

Block Diagrams
9 Block Diagrams
9.1 Block Diagrams, Frame Sizes H and 9

9.1.1 H6 Frame Size
9 9
Illustration 9.1 H6 Frame Size

Block Diagrams TR150 and TR170 Service Manual
9.1.2 I6 Frame Size
9 9
Illustration 9.2 I6 Frame Size

Block Diagrams
9.1.3 H7, H8, I7, I8 Frame Size
9 9
Illustration 9.3 H7, H8, I7, I8 Frame Size

Block Diagrams TR150 and TR170 Service Manual
9.1.4 H9 Frame Size
9 9

Block Diagrams
9.1.5 H10 Frame Size
9 9

Index TR150 and TR170 Service Manual
Index Diode............................................................... 24, 39, 47, 48, 49, 53, 54

Display
A Flashing (line 2)................................................................................. 30
Intermittent........................................................................................ 30
AMA...................................................................................... 31, 33, 39, 40 No display........................................................................................... 30
AMA Wrong................................................................................................... 30
Warning............................................................................................... 37 Display line.............................................................................................. 19
Analog
Signal.................................................................................................... 34 E
Analog output....................................................................................... 19 Electrical installation........................................................................... 10
Analog signal........................................................................... 19, 20, 55 EMC......................................................................... 28, 36, 41, 62, 66, 68
Analog signals........................................................................................ 18 EMI
Propagation....................................................................................... 43
C Source.................................................................................................. 42
Cable cross-section.............................................................................. 22
Capacitor..................... 12, 13, 15, 16, 24, 25, 38, 40, 48, 49, 57, 63
F
Fault
Capacitor bank............................................................................... 24, 49
symptom...................................................................................... 27, 30
Check list.................................................................................................. 28
Fieldbus............................................................................................. 18, 30
Circuitry............................................ 23, 24, 27, 32, 38, 40, 47, 54, 56
Fire mode................................................................................................. 38
Configuration......................................................................................... 40
Form A...................................................................................................... 20
Control
Form C relay..................................................................................... 19, 20
card................................................................................................ 25, 40
logic...................................................................................................... 40
terminal........................................................................................ 30, 41 G
wiring................................................................................................... 30
Gate signal................................................................................ 25, 41, 53
Control cable
Long control cable........................................................................... 22 Gating circuit.......................................................................................... 25
Serial communication control cable......................................... 22 Ground cabling..................................................................................... 22
Control card....................................................................... 20, 23, 53, 55
Control card H
Control card....................................................................................... 30 Heat sink........................................................ 11, 12, 13, 76, 84, 91, 93
Control card voltage....................................................................... 53
Live zero error.................................................................................... 34 Heatsink.................................................. 25, 58, 63, 65, 69, 71, 73, 74
Control terminal.......................................... 18, 19, 20, 21, 23, 34, 55

I
Control wiring................................................................... 18, 19, 31, 55
IGBT...................................... 12, 13, 16, 24, 25, 31, 39, 41, 42, 48, 52
Current
rating.................................................................................................... 34 Impedance......................................................................... 24, 41, 43, 44
waveform..................................................................................... 24, 53 Input
Output current.................................................................................. 34 Analog.................................................................................................. 34
Current waveform................................................................................ 25 Digital................................................................................................... 35
Input cabling.......................................................................................... 52
D Input signal........................................................................ 18, 20, 37, 41
DC bus capacitor................................................................................... 52 Input signals........................................................................................... 18
DC capacitor........................................................................................... 56 Intermediate section........................................................................... 24
DC coil.................................................................... 14, 15, 16, 24, 40, 49
DC-link capacitor.................................................................................. 24 L
DC-link inductor.................................................................................... 24 LCP....................................... 15, 16, 18, 19, 23, 30, 32, 57, 61, 66, 75
Deceleration rate.................................................................................. 39 LED................................................................................... 6, 30, 32, 34, 52
Diagnostic............................................................................................... 27
Digital input..................................................................................... 18, 20 M
Digital output........................................................................... 19, 20, 23 Main assemblies...................................................................................... 6

Index
Main assembly....................................................................................... 23 Serial communication......................................................................... 18

MOC........................................................................................................... 25 Short circuit................................................................ 17, 35, 47, 48, 49
Motor Signal conductor................................................................................... 43
Imbalance........................................................................................... 31 Status line................................................................................................ 18
Incorrect operation......................................................................... 31
current.................................................................................................. 37 Status message...................................................................................... 18
data................................................................................................ 34, 37 Status messages.................................................................................... 30
power................................................................................................... 37
Stall........................................................................................................ 31 Switch................................................................................................ 24, 28
Trip......................................................................................................... 31 Switching function............................................................................... 23
Unstable speed................................................................................. 31
T
O
Terminals
Output... 17, 18, 20, 23, 24, 25, 27, 28, 31, 37, 38, 39, 40, 41, 42, Control terminal........................................................................ 30, 41
47, 48, 52, 55, 56
Test
Output short circuit............................................................................. 24 Control card voltage....................................................................... 53
Output signal........................................................................... 19, 23, 47 ESD precaution................................................................................. 47
Input imbalance of supply voltage............................................ 53
Output voltage............................................ 18, 31, 38, 40, 52, 54, 56 Input waveform................................................................................ 53
Outputs Static..................................................................................................... 47
Analog output................................................................................... 40 Thermal sensor............................................................................... 25, 41
Over current........................................................................................... 17 Torque
Over temperature................................................................................. 33 limit................................................................................................ 39, 41
Overcurrent............................................................................................. 39 Trip condition......................................................................................... 32
Overheating............................................................................................ 35 Trip lock............................................................................................. 32, 34
Overtemperature........................................................................... 35, 41 Troubleshooting................................................................................... 27
Overvoltage trips.................................................................................. 39
V
P Vibration.................................................................................................. 29
Peak voltage........................................................................................... 25 Visual inspection................................................................................... 28
Phase loss........................................................................... 33, 34, 40, 53 Voltage imbalance................................................................. 34, 41, 55
Power card... 12, 13, 14, 15, 16, 20, 23, 24, 25, 49, 54, 60, 61, 62, Voltage waveform......................................................................... 25, 54
66, 67, 78, 80, 87, 88
Power component......................................................................... 28, 47 W
PTC............................................................................................................. 24 Waveform...................................................... 24, 25, 39, 40, 42, 53, 54
Pulse reference...................................................................................... 19
PWM................................................................................................... 25, 42
R
Rectifier.................................................................................................... 24
Reference signal.................................................................................... 31
Relay................................................................ 12, 13, 15, 16, 23, 63, 69
Remote input.................................................................................. 18, 19
Reset.......................................................................................................... 34
RS485................................................................................................. 18, 20
RS-485....................................................................................................... 18
S
SCR...................................................................................................... 25, 53
Serial bus................................................................................... 19, 32, 34

Index TR150 and TR170 Service Manual

TR150 and TR170
Service Manual
Literature Order Number BAS-SVM04B-EN

Date February 2017
Supersedes November 2013
www.trane.com
For more information, contact your local Trane Trane has a policy of continous product and product data improvement and reserves the right to
office or e-mail us at [email protected] change design and specifications without notice.
BAS-SVM04B-EN
February 2017 BAS-SVM04B-EN
130R0538 MG18K202 02/2017
*MG18K202*

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TR150 and TR170

Literature Order Number BAS-SVM04B-EN

February 2017 BAS-SVM04B-EN

130R0538 MG18K202 02/2017

2 Frequency Converter Control 18

3 Internal Frequency Converter Operation 23

BAS-SVM04B-EN 02/2017 All rights reserved. 1

4.3 Fault Symptom Troubleshooting 27

5 Frequency Converter and Motor Applications 39

2 02/2017 All rights reserved. BAS-SVM04B-EN

6.4.2 Input Voltage Test 52

7 H-Frame Size Disassembly and Assembly Instructions 57

BAS-SVM04B-EN 02/2017 All rights reserved. 3

7.6.1 Control Card and Control Card Mounting Plate 72

8 I-Frame Size Disassembly and Assembly Procedures 75

4 02/2017 All rights reserved. BAS-SVM04B-EN

8.4.8 Terminal Plate 90

BAS-SVM04B-EN 02/2017 All rights reserved. 5

1.1 Purpose nected (linkage of DC intermediate circuit). There

CAUTION Table 1.1 Discharge Time

Frequency converters contain dangerous voltages when

6 02/2017 All rights reserved. BAS-SVM04B-EN

1.4.1 Frame Size Definitions 1 1

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

BAS-SVM04B-EN 02/2017 All rights reserved. 7

1 1 Model HP @380–480 V AC kW @380–480 V AC Frame Size IP Rating Repairable Yes/No

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

8 02/2017 All rights reserved. BAS-SVM04B-EN

Model HP @525–600 V AC kW @525–600 V AC Frame Size IP Rating Repairable Yes/No 1 1

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

1.5 Tools Required

ESD Protection Kit Wrist strap and Mat

Table 1.5 Required Tools

Additional Tools Recommended for Testing

BAS-SVM04B-EN 02/2017 All rights reserved. 9

1 1 1.6 Electrical Installation in General

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

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

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

10 02/2017 All rights reserved. BAS-SVM04B-EN

1.7 Exploded Views – H Frame Size 1 1

1 Blind cover 10 Filter protection cover

Illustration 1.1 Exploded View - H6 Frame Size

BAS-SVM04B-EN 02/2017 All rights reserved. 11

1 Blind cover 13 Relay/transducer card mounting plate

Illustration 1.2 Exploded View - H7 Frame Size

12 02/2017 All rights reserved. BAS-SVM04B-EN

1 LCP 12 SMPS card

Illustration 1.3 Exploded View - H8 Frame Size

BAS-SVM04B-EN 02/2017 All rights reserved. 13

1 1 1.8 Exploded Views - I Frame Size

1 Local Control Panel (LCP) 9 DC coil

Illustration 1.4 Exploded View - I6 Frame Size

14 02/2017 All rights reserved. BAS-SVM04B-EN

1 Local Control Panel (LCP) 14 DC coil

Illustration 1.5 Exploded View - I7 Frame Size

BAS-SVM04B-EN 02/2017 All rights reserved. 15

Illustration 1.6 Exploded View - I8 Frame Size

16 02/2017 All rights reserved. BAS-SVM04B-EN