Ingersoll-Rand Variable Speed Voyager TZC036E3 User manual

SAFETY WARNING
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
Packaged Rooftop Air Conditioners
Variable Speed Voyager™ and Precedent™
3 to 5Tons and 12.5 to 17.5Tons, 60 Hz
Diagnostic
Manual
Models Numbers: T/YZC036E3/4 T/YZ*150F3/4
T/YZC048F3/4 T/YZ*180F3/4
T/YZC060E4 T/YZ*210F3/4
RT-SVD05C-EN
February 2018

© 2018 Ingersoll Rand RT-SVD05C-EN
Introduction
Read this manual thoroughly before operating or servicing
this unit.
Warnings, Cautions, and Notices
Safety advisories appear throughout this manual as
required.Your personal safety and the proper operation of
this machine depend upon the strict observance of these
precautions.
Important Environmental Concerns
Scientific research has shown that certain man-made
chemicals can affect the earth’s naturally occurring
stratospheric ozone layer when released to the
atmosphere. In particular, several of the identified
chemicals that may affect the ozone layer are refrigerants
that contain Chlorine, Fluorine and Carbon (CFCs) and
those containing Hydrogen, Chlorine, Fluorine and
Carbon (HCFCs). Not all refrigerants containing these
compounds have the same potential impact to the
environment.Trane advocates the responsible handling of
all refrigerants-including industry replacements for CFCs
such as HCFCs and HFCs.
Important Responsible Refrigerant
Practices
Trane believes that responsible refrigerant practices are
important to the environment, our customers, and the air
conditioning industry. All technicians who handle
refrigerants must be certified.The Federal Clean Air Act
(Section 608) sets forth the requirements for handling,
reclaiming, recovering and recycling of certain
refrigerants and the equipment that is used in these
service procedures. In addition, some states or
municipalities may have additional requirements that
must also be adhered to for responsible management of
refrigerants. Know the applicable laws and follow them.
The three types of advisories are defined as follows:
WARNING Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTIONsIndicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury. It
could also be used to alert against
unsafe practices.
NOTICE Indicates a situation that could result in
equipment or property-damage only
accidents.
WARNING
Proper Field Wiring and Grounding
Required!
Failure to follow code could result in death or serious
injury. All field wiring MUST be performed by qualified
personnel. Improperly installed and grounded field
wiring poses FIRE and ELECTROCUTION hazards.To
avoid these hazards, you MUST follow requirements for
field wiring installation and grounding as described in
NEC and your local/state electrical codes.
WARNING
Personal Protective Equipment (PPE)
Required!
Installing/servicing this unit could result in exposure to
electrical, mechanical and chemical hazards.
• Before installing/servicing this unit, technicians
MUST put on all PPE required for the work being
undertaken (Examples; cut resistant gloves/sleeves,
butyl gloves, safety glasses, hard hat/bump cap, fall
protection, electrical PPE and arc flash clothing).
ALWAYS refer to appropriate Material Safety Data
Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA
guidelines for proper PPE.
• When working with or around hazardous chemicals,
ALWAYS refer to the appropriate MSDS/SDS and
OSHA/GHS (Global Harmonized System of
Classification and Labelling of Chemicals) guidelines
for information on allowable personal exposure
levels, proper respiratory protection and handling
instructions.
• If there is a risk of energized electrical contact, arc, or
flash, technicians MUST put on all PPE in accordance
with OSHA, NFPA 70E, or other country-specific
requirements for arc flash protection, PRIOR to
servicing the unit. NEVER PERFORM ANY
SWITCHING, DISCONNECTING, OR VOLTAGE
TESTING WITHOUT PROPER ELECTRICAL PPE AND
ARC FLASH CLOTHING. ENSURE ELECTRICAL
METERS AND EQUIPMENT ARE PROPERLY RATED
FOR INTENDED VOLTAGE.
Failure to follow instructions could result in death or
serious injury.

Introduction
RT-SVD05C-EN 3
Copyright
This document and the information in it are the property of
Trane, and may not be used or reproduced in whole or in
part without written permission.Trane reserves the right
to revise this publication at any time, and to make changes
to its content without obligation to notify any person of
such revision or change.
Trademarks
All trademarks referenced in this document are the
trademarks of their respective owners.
Revision History
• Updated electrical block diagram for control & power
circuitry of 230VAC 3-phase drive.
WARNING
Follow EHS Policies!
Failure to follow instructions below could result in
death or serious injury.
• All Ingersoll Rand personnel must follow Ingersoll
Rand Environmental, Health and Safety (EHS)
policies when performing work such as hot work,
electrical, fall protection, lockout/tagout, refrigerant
handling, etc. All policies can be found on the BOS
site.Where local regulations are more stringent than
these policies, those regulations supersede these
policies.
• Non-Ingersoll Rand personnel should always follow
local regulations.

4 RT-SVD05C-EN
Table of Contents
Introduction ............................. 2
Warnings, Cautions, and Notices ........ 2
Important Environmental Concerns ..... 2
Important Responsible Refrigerant Practices
2
Copyright ............................. 3
General Information ..................... 5
Variable speed compressor drive ........ 5
Control circuitry ..................... 5
Power circuitry ...................... 5
Electrical block diagrams ................. 7
Drive pictures ........................... 8
................................... 8
Main drive box .......................... 9
Drive mounting locations in applications . 9
Key drive components .................. 10
Sequence of operation .................. 11
Normal operation ................... 11
Abnormal operation ................. 11
Variable speed compressor drive troubleshoot-
ing .................................... 12
Error & protection codes list ........... 12

RT-SVD05C-EN 5
General Information
Variable speed compressor drive
Each variable speed system is equipped with an electric
drive primarily focused at controlling variable speed
compressors.The inverter modules in these electric drives
are cooled using refrigerant cooled heat sinks.The electric
drive platform can be divided into two separate functional
areas: control circuitry and electric power circuitry.The
control circuitry consists of a printed circuit board referred
to as “interface module” and it's utilized with both 230VAC
3-phase and 460VAC 3-phase voltage drives.The electric
power circuitry is different for 230VAC and 460VAC
3-phase drives and it consists of the Power Factor
Correction “PFC” box and main drive box.
Control circuitry
The core control circuitry is the same for both 230VAC &
460VAC 3-phase voltage drives.This core consists of a PCB
module referred to as the interface module and it is located
in the main control box of the unit. Control circuitry for the
electric drive consist of 24VAC “Compressor Command
Signal”, 0-10VDC “Compressor Speed Signal” and“5VDC”
alarm signals.These signals are applied to/received
directly from the interface module of the electric drive.
Interface module
Interface module PCB board is used to receive and
transmit commands from theTrane® unit controller to the
electric drive inverter module. It serves as the main
connection hub for nearly all of the control circuitry wiring
for the variable speed compressor drive. It includes an LED
display that shows the drive status both during standby
and operation mode.The dip switch settings on the
interface module are unique to each compressor model
and should be already preset from the factory. Please refer
to the table below for dip switch settings per each
compressor model:
Please refer to the following graphic for location of LED
display & dip switch settings on the interface module:
The interface module also features a query mode display
which allows the end user to look at key information about
electric drive status. Query mode can be accessed anytime
power is applied to the electric drive. In order to enter
query mode display, press SET button and press UP or
DOWN buttons to scroll through the IDs shown per table
below. Press SET button again to enter normal status
mode which displays the requested compressor
frequency command. If UP/DOWN buttons are not pressed
for 30 seconds, it will also return to the normal status.
During query mode, the LED screen will display active
feedback from the drive board.
Power circuitry
The power circuitry is the high voltage portion of the
electric drive that controls the current and voltage output
to the compressor motor. It is controlled via the
connections to the interface module in the control
circuitry.The power circuitry consists of a Power Factor
Correction (PFC) solution, EMI filter, DC bus board, and the
inverter module.The rectifier section is designed into the
Inverter Module PCB board.The power circuitry designs
are different between 3-phase 230VAC & 460VAC drives.
SW1 SW2 SW3 SW4 SW5 SW6
Compressor
model
LED display
at power up
OFF OFF ON OFF OFF OFF VRJ028 J028
OFF OFF ON OFF OFF ON VRJ035/044 J035
OFF OFF ON OFF ON OFF VRJ035/044 J044
Figure 1. Dip switch settings for VRJ035 compressor
model
LED Display Description
1.***
Compressor running mechanical frequency
(value: 15-100 means 15-100 Hz). For example:
1.080 means the compressor is running at 80 Hz
speed.
2.*** N/A
3.*** N/A
4.*** Drive output current Arms (value: 0-500 means
0-50 Arms
5.*** DC bus voltage (value: 0-800 means 0-800 VDC)
6.*** Heat sink temp (value: 0-200 means 0 to 200°C)
Note: * can be any value from 0 to 9
1–OFF
2–OFF
3–ON
4–OFF
5–OFF
6–ON
LED Display ON/OFF
UP
SET
DOWN

General Information
6 RT-SVD05C-EN
PFC solution
Power Factor Correction (PFC) solution mainly consists of
anAC line inductor and in the case of 230VAC drives, it also
includes 3 capacitors. Purpose of the AC line inductors is
to improve input power factor and reduce line harmonic
emissions.These solutions are packaged separately inside
a sheet metal box and are mounted in the indoor section
of the unit. Specific location of these solutions could vary
depending on the unit model type. Please refer to“Drive
mounting locations in applications,” p. 9, for more details
on the location of these boxes inside the units. Phase
power is applied directly to the PFC box which is
connected in series to the main drive box.
EMI filter
Each voltage drive comes with a unique EMI filter
specifically designed to provide AC line filtering to the
inverter module as well as reduce conducted and radiated
emissions from the electric drive.These components are
located inside the main drive box.
Rectifier section
The rectifier section converts the incoming AC power from
the utility to DC power.The rectifier is a three-phase
rectifier, typical of most power systems.The rectifier
section is located on the inverter module and is connected
to the line filter module.
DC bus board
The DC bus is the intermediary power stage of the electric
drive.The film capacitors on the DC bus PCB board form
a DC power portion of the electric drive.The DC bus board
is also located inside the main drive box.
Inverter section
The inverter section takes the DC power from the DC bus
and creates the AC output which drives the compressor
motor. It consists of an Integrated Power Module (IPM)
which contains the insolated gate bipolar transistors
(IGBTs), the gate drive modules, and current sensing
circuit.The IGBTs are semiconductor devices which pulse
at the switching frequency to synthesize a voltage
waveform. Current sensing circuit provides feedback to
the drive of the motor current.This is used both for control
and protection of the drive.

RT-SVD05C-EN 7
Electrical block diagrams
Figure 2. Electrical block diagram - 230VAC 3-phase drive
208-230VAC 60 Hz
INDUCTOR
CAPACITORS
PFC BOX
INVERTER MODULE
MAIN DRIVE BOX
DC BUS BOARD
GND
+5V
B
A
TRANE CONTROLLER
CN108 CN107
PIN 1
OUTPUT
PIN 3
CN102
PIN 4
SETF
COMMON
PIN 1
CN101
CN105
+5V
GND
A
B
PIN4
PIN1
24VAC
0~10VDC
OUTPUT ALARM
COMPRESSOR
M
3~
GND
EMI FILTER
INTERFACE MODULE
CN623
B
A
GND +5V
PIN4 PIN1
5
RS T DC-OUT DC+OUT
CN606 CN607 CN608 CN611 CN610
2R
2S
2T
1
2
3
4
10
9
8
GND
1R 1S 1T
L1-IN L2-IN L3-IN
CN1 CN2 CN3
PE
PE
CN9
CN8
CN4 CN5 CN6
L1-OUT
L2-OUT
L3-OUT PE
CN7
CN620 CN617 CN618 CN619 CN621
DC+IN Uvw DC-IN
P-1
P-2
P+1
P+2
RST
67
1
PFC2
PFC3
1
2
2
PFC1 1 2
ABC
ABC
3R 3S 3T
L1 L2
L1
L2
L3
L3
Figure 3. Electrical block diagram - 230VAC 3-phase drive
INDUCTOR
L1
L2
L3
L1 L2 L3
AC460V 60HZ
R
S
T
1T 1S 1R
NL3 L2 L1
L1L2L3N
PFC BOX
TRANE CONTROLLER
INTERFACE MODULE
GND
24VAC
0-10VDC
OUTPUT ALARM
CN102
CN101
PIN 3
OUTPUT
PIN 1
PIN 4
SETF
COMMON
PIN 1
GND
+5V
+5V
CN107
CN108
GND
PIN1
PIN2
PIN1
PIN4
GND
A B
+5V
CN105
PIN4 PIN1
7
6
145 2
3
2T 2S 2R
EMI FILTER
GND
CN606
CN609
CN602CN603
INVERTER MODULE
RSTDC-
L1 L2 DC+ P U V W N
GND +5V
PIN1 PIN5
+5V
GND
RX
TX
DC BUS BOARD
DC1+
DC+
DC1-
DC-
MAIN DRIVE BOX
GND
+5V
+5V
GND
RX
TX
M
3~
COMPRESSOR

8 RT-SVD05C-EN
Drive pictures
Figure 4. Interface module
Figure 5. PFC box
LINE SIDE
LOAD SIDE
Figure 6. 230VAC 3-phase main drive box with front
cover removed
Figure 7. 460VAC 3-phase main drive box with front
cover removed
INVERTER MODULE
EMI FILTER
CONTROL
WIRING
OUTPUT
POWER
WIRING
DC BUS BOARD
INPUT POWER WIRING
DC BUS BOARD
IN VERTER MODULE
CONTROL
WIRING
INPUT
POWER
WIRING
EMI FILTER
OUTPUT
POWER
WIRING

RT-SVD05C-EN 9
Main drive box
Drive mounting locations in applications
Figure 8. Voyager™, 12.5 to 17.5 tons, 60 Hz, horizontal
flow
Figure 9. Voyager™, 12.5 to 17.5 tons, 60 Hz, downflow
30.85
24.21
36.39
29.82
17.86
Figure 10. Precedent™ 3 tons, 60 Hz
Figure 11. Precedent™4&5tons, 60 Hz

10 RT-SVD05C-EN
Key drive components
Table 1. 230VAC 3-phase drive
Description Part Number
Interface Module X13651608010
Main Drive Box X13610006020
PFC Box X13610007020
Table 2. 460VAC 3-phase drive
Description Part Number
Interface Module X13651608010
Main Drive Box X13610009020
PFC Box X13610007030

RT-SVD05C-EN 11
Sequence of operation
In case of a cooling demand and presence of no alarm
signal, 24VAC compressor command signal is sent to the
interface module. A speed signal of 0-10VDC is also
applied to the interface module.This would enable the
electric drive to run the compressor at requested speed. In
case of a fault or an error, an error code is displayed on the
interface module LED display and a 5VDC alarm signal
should be present on the interface module.
Normal operation
During normal operation mode, the interface module LED
will display the requested frequency command at all
times. For example; if the LED displays “F060” then it
means that the requested compressor speed is 60Hz. In the
absence of compressor speed request, the LED display
should display “F000” which indicates that the
compressor should be at “0” Hz speed or Off.
Abnormal operation
During abnormal operation mode, the interface module
LED could be either off or display an error or protection
code. Error codes are identified with letter “E” followed by
a dash and two digits whereas protection codes are
identified with letter“P” followed by a dash and two digits.
For examples; E-04 or P-01. For complete list of Error and
protection modes, please refer to “Variable speed
compressor drive troubleshooting,” p. 12. When there are
more than one error or protection modes active, the LED
will display both error or protection codes with a delay of
0.5 seconds in between.

12 RT-SVD05C-EN
Variable speed compressor drive troubleshooting
This section details the error and protection codes as
shown through the LED display of the interface module. It
includes detailed descriptions and troubleshooting
methods for each error or protection code. During all error
“E” codes, the compressor is shut down by the drive and
5Vdc alarm output is present on the interface module.
Error & protection codes list
Incorrect dip switch settings—Error code: E-01
Criteria. Dip switches on the interface module are not set
according to the table on p. 5 for appropriate compressor
model.
Troubleshooting. Verify the compressor model from
compressor nameplate and check if the dip switches are
set correctly on the interface module for that compressor
model.
Reset Criteria. Set the dip switches on the interface
module to correct settings and re-apply power to the drive.
Communication Failure—Error code: E-02
Criteria. Loss of communication between interface
module and the inverter module
Troubleshooting. Verify the wiring connections
between the interface module and the inverter module.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated when communication is re-established
between interface board and the inverter module.
Hardware Over-current limit—Error code: E-03
Criteria. Output current of the drive is higher than the
specified limit for hardware over-current protection.
During normal operation mode, the drive output current
should not reach this value.
Troubleshooting. Verify there are no loose connections
in input power wiring to the drive and output wiring from
the electric drive to the compressor. Check compressor
windings for any ground faults.
Check for abnormal conditions such as airflow blockage,
improper condenser fan operation, compressor locked
rotor situation, system charge or other conditions that
could cause the system to be overloaded.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated and drive will operate normally as long as the
overload condition is no longer present.
Drive Operation Failure —Error code: E-04
Criteria. Compressor doesn't start properly after five
tries with 15 second intervals between each try.This could
be caused by either loss of phase in drive output current to
the compressor, compressor motor locked rotor situation,
or damaged drive hardware.
Troubleshooting. Verify there are no loose connections
in input power wiring to the drive and output wiring from
the electric drive to the compressor. Check compressor
windings for any ground faults.
Check if LED 602 is flashing On or completely Off. If Off,
then inverter module is defective and needs to be
replaced.
Cut off power to the drive and disconnect the output power
(U, V, W) from the inverter module. By using the Diode
settings on the multimeter, check the following 6 pairs of
diodes: (DC+,U), (DC+,V), (DC+, W), (U,DC-), (V,DC-),
(W,DC-). Perform a continuity check between the following
pairs of terminals: (U, V), (V, W), (U, W). If any of the above
pairs are shorted, then Integrated Power Module “IPM” is
defective, and inverter module needs to be replaced.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated and drive will operate normally as long as the
overload condition is no longer present.
Software over-current limits —Protection
code: P-01 & Error code: E-05
Criteria. Output current of the drive is higher than the
specified limit for software over-current protection.
Over-current limits associated with P-01 code are lower
than the limits associated with E-05. During P-01, the
compressor speed is either reduced or held constant
whereas during E-05, the compressor is requested to shut
down to protect the drive.
During normal operation mode, the drive output current
should not reach the limits associated with E-05.
Troubleshooting. Verify there are no loose connections
in input power wiring to the drive and output wiring from
the electric drive to the compressor. Check compressor
windings for any ground faults.
Check for abnormal conditions such as airflow blockage,
improper condenser fan operation, compressor locked
rotor situation, system charge or other conditions that
could cause the system to be overloaded.
Reset Criteria. The protection or error code will remain
active for at least 2 minutes. After 2 minutes, protection or
error mode will be deactivated and drive will operate
normally as long as the overload conditions are no longer
present.
Output Current Sampling error —Error code:
E-06
Criteria. At power up when the compressor is in Off state,
if the inverter module doesn't properly detect the output
current then the compressor would not be allowed to start.

Variable speed compressor drive troubleshooting
RT-SVD05C-EN 13
Troubleshooting. Verify input power wiring to the drive
and output power wiring from the drive to the compressor.
Reset Criteria. Error code can be de-activated by
removing power to the drive and re-applying power.
Heat sink over heat —Protection code P-02 &
Error code: E-07
Criteria. Temp sensor on the inverter module detects the
temperature to be exceeding the limits defined in the
inverter module software. Temp limits associated with P-
02 are lower than the temp limits for E-07. During P-02, the
compressor speed is either reduced or held constant
whereas during E-07, the compressor is requested to shut
down to protect the drive.
Troubleshooting. Verify refrigerant is flowing through
the copper tubes used to cool the heat sink. Check for
abnormal conditions such as airflow blockage, improper
condenser fan operation, system over or under charge or
other conditions that could result in higher Amp draw on
the drive and cause overheating.
Reset Criteria. The protection or error code will remain
active for at least 2 minutes regardless of changes in
temperature. After 2 minutes, if the temp is below the
specified limits in the drive software, the protection or
error mode will be deactivated.
DC bus over voltage & under voltage—Error
code: E-08
Criteria. DC bus voltage of the drive is above or below the
specified limits for the drive.
230VAC Drive limits: Above 370Vdc or below 170Vdc.
460VAC Drive limits: Above 800Vdc or below 300Vdc
Troubleshooting. Verify input voltage to the R, S,T
terminals on the inverter module is within +/-10% of the
rated unit voltage. Inspect DC bus board for any damaged
capacitors.
Reset Criteria. The protection will remain active for at
least 2 minutes regardless of DC bus voltage. After 2
minutes, Protection mode will be deactivated when DC
bus voltage is below or above the specified limits for the
drive.
Incorrect Compressor Code—Error code:
E-09
Criteria. Interface module sends the compressor code
that is not supported by the inverter module.
Troubleshooting. Verify dip switch settings on the
interface module are set correctly for appropriate
compressor model and re-apply power to the drive.
Reset Criteria. Error mode can be de-activated by
removing power to the drive board and re-applying power.
Heat sink temperature sensor error—Error
code: E-12
Criteria. Heat sink temp sensor on the inverter module is
reporting temperature readings outside the spec limit.
Troubleshooting. Verify heat sink temp sensor
connector is plugged into the drive board and the sensor
itself is not shorted/open.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated when sensor reading is within the allowed
spec.
Drive board internal communication error—
Error code: E-13
Criteria. Internal communication loss between the
inverter module chips for at least 15 sec.
Troubleshooting. Verify connections between the
interface module and the inverter module.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated when communication is re-established
between the inverter chips.
3-phase AC input power phase-loss —Error
code: E-15
Criteria. Loss of any of three phases ofAC input power for
longer than 30 msec when the drive has been powered for
at least 8 sec.
Troubleshooting. Verify all three phases of AC input
power to the R, S,T terminals on the inverter module.
Reset Criteria. The protection will remain active for at
least 2 minutes. After 2 minutes, protection mode will be
deactivated and drive will operate normally.
Magnetic Field Weakening Control—
Protection code: P-05
Criteria. When the magnetic field angle between the
compressor rotor and stator is below the specified value in
the software, protection mode will be activated and
compressor speed will be reduced gradually.
Troubleshooting. Check for abnormal conditions such
as airflow blockage, improper condenser fan operation,
system over or under charge or other conditions that could
result in overload conditions on the compressor and cause
this situation.
Reset Criteria. The protection mode will remain active
until the angle value is smaller than specified value in the
software.

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RT-SVD05C-EN 06 Feb 2018
Supersedes RT-SVD05B-EN (Aug 2015)