Ingersoll-Rand Nirvana 5.5 User manual

1
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Nirvana 5.5 - 11kW (7.5 – 15 HP)
Variable Speed Drive
Technicians
Diagnostics and
troubleshooting
Guide
T2
T1
Revision 02, July 2008

2
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Copyright Notice
©2001 Ingersoll-Rand Company
Proprietary Notices and Disclaimer
PROPRIETARY NOTICES
Copyright 2001 Ingersoll-Rand company
Confidential and trade secret information. This manual contains confidential and trade secret information
owned by Ingersoll-Rand Company (hereinafter referred to as "Proprietary Matter"). In consideration of the
disclosure of the Proprietary Matter herein to the authorised recipient hereof, the recipient shall treat the
Proprietary Matter as secret and confidential; shall not disclose or give such Proprietary Matter to third parties
without the express written authorisation of INGERSOLL-RAND; shall not use the Proprietary Matter except to
the extent necessary to sue or service the equipment disclosed herein; and shall disclose such Proprietary
Matter only to those of its employees whose use or knowledge of the Proprietary Matter is necessary. This
manual shall be returned upon request by Ingersoll-Rand Company. The unauthorised use of this manual may
be punishable by law.
DISCLAIMERS
PROVIDED "AS IS". THIS GUIDE AND THE CONTENTS THEREOF ARE PROVIDED "AS IS" AND
WITHOUT ANY IMPLIED WARRANTIES.

3
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Table of Contents Page
• General Run and Monitor Information 04
• Secure disable 07
• User 1 08
• OI-AC Over current 10
•MotorI
2t11
• Blank CDC 12
• Other fault codes 13
• Appendix 1: sec disable information 14
• Appendix 2: User 1 information 16
• Appendix 3: CDC 17
• Appendix 4: Intellikey 18
• Appendix 5: Other faults 19
• Appendix 6: CDC parameters 20
• Appendix 7: Indicator 23
• Appendix 8: Electrical schematics 27
• Appendix 9: Site log form 30
• Appendix 10: Revision number 31

4
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Safety
Danger of Hazard
•The drive has various voltages present on the power terminal
blocks and in cables connected to them that may cause fatal
electrical shocks.
•The drive contains capacitors which remain charged at a fatal
voltage for a period of time even after the power supply has been
removed.
•Do not perform operations on the drive without first manually
opening the power supply circuit to the drive. Lock out and tag out
the fused isolator or circuit breaker to prevent accidents.
•Please utilise extreme caution when performing work within the
starter cabinet with power on or off. Always use approved electrically
insulated gloves.

5
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Run and Monitor.
This step means that each time it will be necessary to check:
•Power Input Voltage displayed and compare with your meter between
each phases.
•DC Bus Voltage displayed and compare with your meter.
(See below restrictions regarding the Input and DC Bus voltage)
•Current Motor Amps displayed and compare with your meter, the output
•Current imbalance must not exceed ± 5% for each phase.
•Motor speed displayed (unstable, lower than speed reference asked).
•Motor noise or other abnormal noises.
•Motor vibration if mechanical issue has been resolved previously?
if trouble persists record the Alarms History information from CDC, list all
actions performed and contact Technical Support.
IMPORTANT!!
Drive Data
POWER INPUT VOLTAGE :
380 to 480 VAC ± 10%, 50 or 60 Hz ± 2% (HV Drives)
200 to 230 VAC ± 10%, 50 or 60 Hz ± 2% (LV Drives)
The phase voltage imbalance must not exceed 2% on 50hz units and 3% on 60Hz units.
DC BUS VOLTAGE :
Approximately equal to AC voltage multiplier by 1.4
Use CDC to record the Bus voltage when unit is not running.

6
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
WINDING INSULATION TEST (MEGGER).
•Isolate compressor from incoming Power Supply.
•Disconnect motor leads from the VSD.
•Connect one cable of the Insulation Tester on the main ground
Connect the other cable of the megohmmeter (Insulator Tester) to each motor
leads (one at a time, make sure you disconnect the brass bars from the stator
connection bloc). and test using 500V D.C. . Each motor leads should give a
minimum value of 10 M Ohm.
•AFTER MOTOR WINDING INSULATION TEST.
•AFTER STATOR REPLACEMENT.
! !
You must be sure that the motor leads are connected as
specified below :

7
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Compressor Trips on “Sec Disable” while
technician on site? – Toggle switch still on
“start” position and E-stop pulled ?
Check connections on E-stop (ESA1
and ESA2) – Connections OK?
No
Do not touch the toggle switch nor the E-stop.
8.09=“enable”? (8.02 must be=“active”)
Yes
Fix connection
No
Problem likely to be linked to: E-Stop / Wiring
or connection issues
No
Yes
Switch the toggle switch to the stop
position
Turn toggle switch to “stop” – Push & pull the
E-stop 10 times – Read 8.09 after each try
8.09 = “Enable” when E-stop pulled
& 8.09 = “Disable” when E-stop pushed ?
(Note : the “sec. disable” will be reset after
the first sequence of push/pull)
Problem may occur only when compressor is
running
Yes
Yes
Disconnect ESA1 & ESA2 so that the E-Stop is
no longer connected to the pins 13 & 14 –
Make contact between these two connectors
8.09 = “Enable” when ESA1 & ESA2 are in
contact
& 8.09 = “Disable” when no contact?
No
E-stop does not work properly – Change E-
Stop and restart the procedure
(with a multimeter, you can check the
resistance between ESA1& ESA2 Must read 0
ohm when the E-stop is pulled and OL ohm
when the E-stop is pushed)
Yes
Remove drive cover and check connections
(especially pins 13 & 14) – Connections loose
or misconnected cables?
No
Tighten the cables and re-conduct procedure -
Problem solved? (8.09 = “Enable” when E-stop
pulled out
& 8.09 = “Disable” when E-stop pulled in)
Yes
Contact IR customer’s service
No
Contact IR customer’s service No
Problem was due to misconnected cables Yes
“SECURE DISABLE” FAULT TREE
Unit trips while running
Power outage is unlikely
More than 3 consecutive “sec.disable” fault in the memory
See Appendix 1 for detailed explanation
on Sec Disable fault message

8
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Hats switch physically damaged / not connected ? No
Yes
“USER 1” FAULT : THERMAL ISSUE (OVERHEATING MOTOR and/or COMPRESSOR)
(“User 1” fault displayed and 8.03 shows “disabled”)
DRIVE CONTINUOUSLY ON USER1 FAULT
Prior to troubleshoot the unit, let it cool down for 15 minutes
Problem is likely to be due to :
Loose / damaged cable
Defective Hats switch / thermal sensor in the motor
Wrong harness
Replace Hats switch – Try to start the unit –
Does it keep tripping continuously Open drive –Loose connections ?
(inputs # 10 and 13)
Yes
Problem fixed
No Reconnect – “User 1” fault can
be reset and unit restarts ?
Yes Yes
Disconnect 10 and 13 and
check continuity –
Continuity OK ?
No
No
Phase I-II harness Nirvana harness Swap drive – Mount a
new drive – Problem
fixed or contact
Ingersoll Rand
No Yes
Molex connector ok
(male and female
parts well connected
and no loose cable) ?
Disconnect two parts –
Motor thermal sensor
continuity OK ?
Yes
Swap stator – Unit
restarts ?
No
Reconnect -
Continuity OK ?
No
No
Drive restarts?
Yes
No
Cable cut or
disconnected between
drive inputs and hats
switch
Repair or replace
broken cable – Drive
restarts ? User 1
fault can be reset ?
Yes
See Appendix 2 for detailed explanation on User 1 fault message
Replace hats switch –
Drive restarts ? User
1 fault can be reset ?
No
No
Problem fixed
Yes
Contact
Ingersoll Rand
Yes

9
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
“USER 1” FAULT : compressor tripson«User1»onregularbasisor and after
few minutes of running
Prior to troubleshoot the unit, let it cool down for 15 minutes
Problem likely to be due to :
-Cooling issue:
-Dusty pre-filter
-Blocked coolant cooler
-Blower not rotating (circuit breaker, fuses, fan
relays)
-Blower rotating in the wrong direction
-High ambient temperature (refer to User Manual)
-High current on stator ( thermal switch with Nirvana stators)
-Low coolant level
-Blocked thermostatic valve
- Mechanical issues within the drivetrain
See Appendix 2 for detailed explanation on User 1 fault message

10
Danger
Please utilise extreme caution when performing work within the compressor. Wear appropriate PPE
(Personal Protective Equipment), follow lock out-tag out procedures, and ensure all safety procedures.
Check power supply cables –
Everything OK ?
Yes
“OI-AC OVER CURRENT” : peak current that exceeds the hardware limit
of the drive
Repair or replace
cables
Check NDE bearing &
airend – OK?
No
Replace NDE bearing or /&
airend
No
Disconnect the output leads of the drive
Megger the stator (500V D.C.)
Insulation resistance < 10 MOhm ? No
Yes
Replace stator
Yes
Compressor keeps
tripping on “OI-AC” ?
Problem fixed
No
Contact Ingersoll
Rand
Yes