Nirvana Trouble Shooting Manual: IRN 15-30kW (20-40Hp)

NIRVANA
TROUBLE SHOOTING MANUAL

IRN 15-30kW (20-40Hp)
Rev. March 2007

Copyright Notice
© 2007 Ingersoll Rand Company
Proprietary Notices and Disclaimer

PROPRIETARY NOTICES
Copyright 2007 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 authorized 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 express written authorization of INGERSOLL RAND; shall not use the Proprietary matter except to the
extent necessary to use or service the equipment disclosed herein; shall disclose such Proprietary Matter only to
those of its employees whose knowledge of the Proprietary Matter is necessary. This manual shall be returned
upon request by Ingersoll Rand Company. The unauthorized use of this manual may be punishable by law.
DISCLAIMERS
PROVIDED “AS IS.” THIS MANUAL AND THE CONTENTS HEREOF ARE PROVIDED “AS “IS AND WITHOUT
ANY IMPLIED WARRANTIES.
Nirvana 15-30kW (20-40Hp)
Troubleshooting Manual
Introduction
This manual was created to provide support for the
15-30kW / 20-40 HP Nirvana.
Overview
Environmental concerns ..................................5
Pre-Installation Checks………………………....6
System Diagram…………………………………6
Technical Overview .........................................7
The LCD
Using the LCD…………………………………...8
Description of the LCD Screens ......................9
Status Display..................................................9
Setup Display.................................................10
Menu Display .................................................11
Service Information Display...........................12
Service Set Points Display ............................13
Alarm Log Display..........................................13
Alarm 1 Details ..............................................13
Factory Service Display .................................14
Fault Messages .............................................15
Warning Messages ........................................15
Alarm Messages ...........................................16
Trouble Shooting The LCD............................19
Fuses .............................................................21
Drive Terminal Pin Connections ....................21
Replacement of Drive Control Board.............22
Fault 13 Over Current ...................................24
Replacement of Drive Key .............................24
Power Fuse Replacement .............................24
Troubleshooting the Control Board................25
Using the Nirvana Service Tool .....................26
Diode Tests
Input Diode Test ............................................30
Output Diode Test..........................................31
Airend Replacement ......................................32

Main Blower Replacement.............................37
Turning the RFI Filter Off ...............................38
Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 3

Ingersoll Rand Global Service Education Team
Issue 01/Davidson, March 2007. ©Ingersoll Rand Proprietary Information
CAUTION!!!
• Dangerous Voltage Levels Present
• Output leads can have voltage to ground even

when motor is not running.
• Allow Sufficient time for DC Capacitors to

discharge after power is disconnected.
Environmental Concerns
Clean and Dry – 5% - 95% Humidity, non-
condensing
24-Hour temperature limit = 45°C (113°F)
Max temp limit = 50°C (122°F)
Altitude Limits – 1000m – reduced above 1000m
Storage Limits = -25° to +65°C (-13° to 149°F)
Keep the drive clean
Use dust covers to keep construction dust from
getting into it
Remove the dust covers before applying power
Do not use line reactors.

Pre-Installation Checks
4 Models
• 20/25 hp, 208V, I-R part# 22715916
VFD Rated Voltage = Line Voltage • 20/25 hp, 400V, I-R part# 22812697
• 208 – 240V • 30/40 hp, 200V, I-R part# 22715924
• 380 – 500V • 30/40 hp, 400V, I-R part# 22812721
• Correct Line Fuses
• Correct VFD Size 4 IntelliKey Modules
• 20/25 hp • 20 hp
• 30/40 hp • 25 hp
• IntelliKey Rated Hp = Motor Hp • 30 hp
• 40 hp
System Diagram
Nirvana 20-40
Application
Digital Inputs
Emergency
Stop
Remote
Load Enable
Remote Load
Dryer
HAT
VFD FIXED
VFD DRYER
Speed FAN
+
Fixed
- Speed
AC
MOTOR COMPRESSOR
Discharge Pressure P1
P2
Digital
Fan
Dryer
PORO
Common Alarm
Relay

Technical Overview
High Air Temp can be caused by Motor PTO, Hat
Switch or the Fan Starter Overload. The Fan starter
Overload requires a mechanical reset, the others
reset automatically.
The Danfoss 302 drive’s DC Buss is accessible at

the top of the drive. There are holes where a
voltmeter probes can be inserted.
The Danfoss drives used on the 20 to 40 HP Nirvana

use three different frame sizes,
• Drive frame B2 is used on the 20/25 High
Voltage units.
• Drive frame C1 is used on the 20/25 Low
Voltage units and the 30/40 High Voltage units.
• Drive frame C2 is used on the 30/40 Low
Voltage units.
• The B2 frames have all diodes on the input.
• The C1 and C2 frame sizes have 3 diode/SCR
packs on the input. The diodes feeds the –
Buss and the SCRs feed the + Buss.
On the frames with the SCRs in the input bridge,

when the drive first starts up a control circuit fires the
SCRs to get Buss voltage. The control board gets its
power directly from the incoming line after the input
filters. Under certain conditions the SCRs can be
turned off. If this happens there will be some Buss
voltage but it will be falling and there will be no
warning that the control board has shut the SCRs off.
After approximately 10 seconds if everything is

normal and the Buss voltage is built up, the drive
cooling fan will turn on and the 3 status LEDs will be
enabled. The fan will turn off if it is not needed.
The three status LEDs are at the left of the lower
programming key and on the Keypad. The green
LED is for power on, the yellow LED is a warning,
and the red LED is for a fault.

1
9
2 10
Using the LCD
3 11
Note that inactivity for 10 seconds the menu will re-
turn to Status 1.1 4 12
To change any of the values press OK to enable the 5 13
change. For a Yes or NO feature use the up or down
button to toggle between Yes and No. For a number 6 14
change use the right or left button to select the posi-
tion to enter a number and the up or down button to 7
change the value at that location. 15
8
The Factory Service screen has 4 sub menus, Ser- 16
vice Information, Service Setpoints, Alarm Log and
Factory Service.
Scroll up/down to submenu required and hit OK.
1. Selects Setup Main Screen
2. Selects Status Main Screen
3. Return to previous Screen
4. Left select
5. Green OK LED
6. Yellow warning LED
7. Red Alarm Led
8. Run Push Button
9. Selects Menu Main Screen
10. Selects Main Service Screen
11. Information about current screen is shown when

pushed.
12. UP arrow, moves up to next screen or increases

number when changing data
13. Right select
14. OK selects option offered on current screen and

then accepts data entered.

Description of the LCD Screens Status Display

Status
1.1 Displays pressure, Life Savings, etc Status Menu 1.1 Display:
1.2 Displays RPM, Savings, Pressure • Discharge pressure
1.3 Displays graph of pressure • Target pressure
1.4 Displays graph of Percent Load • Percent of Load
1.5 Displays Start time and Stop time, software • Lifetime Energy Saving
version, service contact number, running hours, date • Maintenance Indicator
• Warning Text Message
Setup
2.1 Target Pressure
2.2 Auto Stop Pressure
2.3 Enable Fixed speed
2.4 Enables Start/Stop time set
2.5 Scheduled Start Time
2.6 Scheduled Stop Time
2.7 Energy Savings Reset
Menu
3.1 Set Date and Time Status Menu 1.2 Display:
3.2 Turn Poro ON/Off • Discharge Pressure
3.3 PORO Start delay time • Target Pressure
3.4 Remote Control • Motor Speed
3.5 Modbus ON/OFF • Energy Saving (Trip meter)
3.6 Modbus Address
• Maintenance Indicator
3.7 Modbus Baud Rate
• Warning Text Message
3.8 Energy Rate
3.9 Units of Pressure PSI, Bar, kPA
3.10 Language Select
Service Information
Has an id number of 4.1.X, where X is from 1 to 6
4.1.1 Rated HP/KW
4.1.2 VFD Serial Number
4.1.3 After Cooler Discharge Pressure
4.1.4 Dryer Discharge Pressure
4.1.5 Dryer Pressure Drop Status Menu 1.3
Display:
4.1.6 Immediate Stop Pressure
• Discharge Pressure Numerical Value
Service Set Points • Logging Pressure Screen (XY Plot)
To activate select OK then push up or down button, • % Load Numerical Value
to escape push the Service button
Has an id of 4.2.X, where X is form 1 to 3
4.2.1 Calibrate P1
4.2.2 Calibrate P2
4.2.3 Maintenance Timer reset
Alarm Log
Has an id of 4.3.X, where X is from 1 to 15
The last alarm is display first.
Press OK on the selected alarm to obtain more
information. You can then scroll up/down to inspect
conditions

Setup Display
Status Menu 1.4 Display:
• % Load Numerical Value 2.1 Target
• Logging % Load Screen (XY Plot) vs Time Pressure
• Discharge Pressure Pressure at
which the unit will
start slowing
motor RPMs.
2.2 Auto Stop

Pressure is
Status Menu 1.5 Display: calculated 10 psi
• Hour meter above Target
• Current Date Pressure. It can
be adjusted 5—
• and Time
10 psi above
• Time to Scheduled Start
target.
• Time to Scheduled Stop
• Software Version
• Services Contact Information 2.3 Fixed Speed
• % Load Numerical Value Enable
• Discharge Pressure Activates /
deactivates fixed
speed. When
enabled the unit
will not6 run in
variable speed.
2.4 When
enabled, this can
start and stop the
compressor
anytime the start
or stop time is
reached and is
always active
anytime Scheduled Start / Stop parameter is
enabled.

2.5 Only works when Menu Display

Scheduled Start / Stop
is Enabled, Press OK to
change. This is a 7 day/ 3.1 Allows time and
week timer. date adjustments by
using the Left, Right,
UP, Down and OK
button
2.6 Only when
Scheduled Start / Stop
is Enabled. Press OK to
Change. This is a 7 day/
week setting.
3.2 If a PORO option is

installed, you will be
able to enable/disable
PORO operation
2.7 This menu will allow
you to reset the Energy
Savings by pressing the
OK key and then using
the Navigation Keys to
select yes or no. Once
the selection has been 3.3 PORO restart delay
made, press the OK key time adjustable
again. between 10 to 120 Sec
3.4 Enable / Disables

Remote Control
operation
3.5 Allows the Modbus

Protocol to be enabled
or disabled

3.6 Allows the setting of Service Information Display

the Modbus Address
from 1 to 255. The 4.1.1 Read only display
default address value is of Horse power and
1 Kilowatts Per hour
3.7 The following Baud 4.1.2 Read only display

rates will be available: of the drive serial
• 9600 (default) number, you must have
• 19200 this information when
• 38400 calling technical
• 115200 support.
4.1.3 Aftercooler
Discharge Pressure
used as control
3.8 This menu will allow feedback in VFD or
a currency amount to be Fixed mode
entered to calculate the
energy cost.
4.1.4 Dryer Discharge

Pressure is displayed
3.9 Units of Measure: when dryer option is
PSI, Bar/kPa installed.
4.1.5 When the dryer is

3.10 English, Chinese, installed the Aftercooler
Spanish, Portuguese, Discharge Pressure and
French, Italian, German, Dryer Discharge
Dutch, Danish, Pressure is used to
Norwegian, Swedish, determine the pressure
Finnish, Turkish, drop across the dryer
Lithuanian, Latvian, module.
Estonian, Maltese,
Slovenian, Slovakian,
Czech, Hungarian, 4.1.6 Immediate Stop
Polish. Pressure is not
adjustable.

Service Set points Display
4.2.1 Selecting YES

starts the calibration
procedure for
transducer P1. After the
procedure ends, this
value will automatically
Alarm 1 Details
return to NO.
4.2.2 Selecting YES

starts the calibration
procedure for
transducer P2. After the
procedure ends, this
value will automatically
return to NO.
4.2.3 Selecting YES

and then pressing OK,
allows the Maint Timer
to be RESET
Alarm Log Display

Alarm Log 4.3.0 The alarm log contains a list of
alarms with date, time and alarm type information.
Pressing the Up and Down Arrows on the Alarm Log
display will scroll through the Alarms log list,
pressing OK enters the selected alarm details
display.
Alarm 1 Details: Pressing the Up and Down Arrows

on the Alarm Details display will scroll through the
available data, pressing OK provides a graph if
available for that parameter data at the time of the
alarm. See the screen shots to the right.

Factory Service Display 4.4.3

If a PORO option is
4.4.0 installed the available
A 5 digit numerical Factory service password must be selections are: OFF –
entered correctly each time the Factory Service Menu ON
is entered to gain access to the following parameters: The Default is: OFF
• Service Contact Information Phone Number
Only
• Dryer Enable
• PORO Option Installed
• Hourmeter Adjust 4.4.4 This menu
• VFD Special Parameter contains the number of
• RFI Filter hours the compressor
• Hourmeter Adjust motor has run throughout
• VFD Special Pa- its entire lifetime. The
rameter Hour Meter is inactive
• RFI Filter when the drive is in
Stopped in Auto Restart.
4.4.5
4.4.1
Any drive parameter can
Service Contact Information Phone Number Only— be viewed using this
can be letters, numbers, or a combination of both. parameter.
4.4.2 With this you can

indicate whether or not 4.4.6 Turns RFI filter
a dryer is installed. On or Off. Use only on Y
supplies.

Fault Messages Warning Messages

Warnings Immediate Stop Pressure Exceeded
• Close to Critical Level Warning condition that will stop compressor and
will automatically reset when monitored pressure
• Compressor Still Running (In Most Cases) falls below the Target Pressure
• Not Stored in Alarm Log Dryer Delta Pressure Exceeded

Appears when the pressure between the Dryer
and the package discharge pressure readings ex-
Alarms ceed 20 PSI
• Critical Level Reached
Dryer Stopped High Pressure
• Motor Coasts to Stop Warning will appear when Dryer is Enabled and the
Dryer Status switch input is open
• Reset Only After Alarm Condition is Corrected
Scheduled Start Countdown / PORO Count-
Reset down Active
Appears when either the above selection are made
Automatic: Indicates items that will automatically
reset when the fault condition is corrected Compressor will start in xxx amount of seconds
Manual: Indicates items that require a manual Services Soon

reset using the “Reset” button on the LCP Appears when the bar graph has 20% or less time
remaining of services time remaining
Locked: Indicates that the drive will be in a locked
alarm state until power is cycled Maintenance Due
Appears when the maintenance timer reaches
zero.

Warning Messages Alarm Messages

Alarm 4 – Main Phase Loss
Warn- Alar Check Input Voltage & Current for Balance
Description ing
Lock
No. m
Must be Balanced Within 3% @ Full Load
Alarm 7 - Over voltage

Immediate Stop Pres- Check Input Voltage
X
215 sure Exceeded
Check for High Inertia or Short Ramp Down
If all checks are good (Please call Customer

Dryer Delta Pressure Services)
X
217 Exceeded
Alarm 8 – Under voltage
Check Input Voltage
Check all Input Voltage Wiring for Good

Dryer Stopped High Connections
X
218 Pressure
Check Fusible Disconnect
Alarm 9 – Inverter Overload

PORO Countdown Check Bearings/Mechanical Load (Compressor)
X
219 Active
Check for Correct IntelliKey
Check that Motor and Compressor turns freely
Scheduled Start Check Motor Windings

X
220 Countdown Active
Check that all Motor connections are terminated
correctly at the Drive out put
Alarm 12 – Torque Limit

Service Soon X Check Mechanical Load (Compressor)
221
Check that Motor and Compressor Rotates Freely
Check Motor Windings (Megger and Ohm

windings)
Maintenance Due X Alarm 13 – Over current

222 Check Motor Windings and Ensure that Motor
Rotates freely
Check Mechanical Load / (Compressor), Ensure

that it Rotates freely
Check Drive Size by viewing Data Plate

Information

Alarm 48 – 1.8V Supply Low

Check Motor Wiring at Drive out put Phases Faulty Drive Power Supply
Check Fixed/Variable Speed Selector Wiring for

Alarm 14 – Earth Fault Short
Check Motor, Motor Wiring for Short to Ground
Check Motor Wiring at Drive out put Phases
Alarm 16 – Short Circuit

Check Motor, Motor Wiring for Phase to Phase
Short
Check Motor Phases with Megger or Volt Meter for

resistance values
Check Motor Wiring at Drive out put Phases
Alarm 29 – Over Temperature

Check Operation of Cooling Fans
Drive Fans should rotate momentarily when Power

is applied to the Compressor
Check for Blockage of Airflow
Check Main Blower for correct Rotation
Alarm 30, 31, 32 – Missing Motor Phase

Check Connections to Motor at the Out Put of the
Drive’s U V W Phases
Check for Open Winding in Motor
Megger and Ohm Motor
Check IGBT Connections
Alarm 33 – Inrush Fault

Possible Faulty Drive
Alarm 38 – Internal Fault

Defective Drive
Do Not Attempt to Reset & Restart Drive
Place Test Key into Drive to Check Control Board
Alarm 47 – 24V Supply Low

Check Control Wiring for Shorts
Possible Faulty Drive Power Supply

Alarm Messages
No. Description Warning Alarm Lock No. Description Reset
200 No IntelliKey X
4 Mains Phase Loss A
Incorrect
201 X
IntelliKey
7 DC Over voltage A
HATS
202 X
Opened
8 DC Under voltage A
P1 Sensor
203 X
Cal. Error
9 Inverter Overload A
P2 Sensor
204 X
Cal. Error
12 Torque Limit M
P1 Sensor
205 X
Failed
P2 Sensor 13 Over current L

206 X
Failed
Failed to Set
207 X 14 Earth Fault L
RTC Time
Reset column key:

A - automatic, M—manual, L—locked.

Alarm Messages Trouble Shooting The LCD
No. Description Reset
16 Short Circuit L
29 Drive Over Temperature L
30 Motor Phase U Missing L
31 Motor Phase V Missing L
32 Motor Phase W Missing L
33 Inrush Fault L
Check Input Fuses
Check Input Power

Possible Faulty Drive
34 Fieldbus Communication Fault A Check Power LED
Check LCP
Check LCP Cable
Check LCP Contrast
by holding the Status Button and Pressing the Up

and Down navigation keys

Trouble Shooting The LCD

Is LCP cable NO Properly seat
properly cable.
seated?
Check LCP YES

Is the Contrast
Power YES (Hold Status and
LED both the up and
down navigation Exchange YES
green? Replace LCP.
keys) LCP
Does it
work?
NO
NO
Is input NO
power Correct power
present? delivery.
Is 24VDC Call customer
present on YES
service.
power 800-820-0308
supply
YES
NO
NO
Are fuses
OK? Replace Plug controller
Note 1 fuse. YES directly into drive. If it
Check
control wires works replace the
for shorts, cable. If not, call
customer service.
YES
NO
NO Call customer
Continuity service.
check. Note 2 800-820-0308 Call customer
service.
800-820-0308
YES

Compressor has blown incoming fuse Drive Terminal Pin Connections

Do Not Attempt to Replace Fuses & Restart the
compressor! Further Damage May Result
Static Tests Must be Performed First
Terminal Function
18 VFD/Fixed
19 HAT (24 volts DC)
27 Dryer Status
29 Dryer Control (24 volts DC)
32 Remote Load Enable
33 Remote Load/Unload
37 Emergency Stop (24 volts DC)
42 PORO Alarm (24 volts DC)
01, 02, 03 Fan Control (24 volts DC)
04, 05, 06 Common Alarm Relay
53 Discharge Pressure (24 volts DC)
54 Dryer Output Pressure (24 volts DC)

Replacement of Drive Control Board

1. Turn power off and wait 15 minutes and then
remove drive access panel.
4. Remove plastic cover by squeezing in at the

sides of the cover.
2. Remove drive cover by removing 6 thorax

screws. (Some covers may have 8 screws.)
5. Remove Drive Intellikey key by pulling straight

out at arrows
3. Remove LCD cable and plastic adaptor by

loosing the two screws holding the cable plug to
the plastic cover. (Some plugs may be
connected directly to the board plug as shown at
step 5. If so then skip to step 6)

6. Go ahead and remove top screw for board

plate then remove screws to remove bottom 8. After removing the bottom cover remove the last
cover. screw holding the board to the drive at the
arrow. Board can now be removed by pulling
straight up.
9. Remove the metal frame from the control board

by holding the metal frame and pushing down on the
control board at the arrows.
10. To attach the metal frame

to the replacement control
board insert the metal tabs, of
the metal frame, into the metal
7. Push in at sides with straight blade holder of the control board.
screwdriver, then pull straight out. Reverse the removal
procedure to complete the
installation.

Fault 13 Over Current Power Fuse Replacement

A failed or dirty check valve can cause a Fault 13 A failure of the control board or a fan failure could
(over current) fault. The failed check valve allows oil over current the power supply and blow fuse F1. This
to flood the airend after the unit sets for a period of fuse is connected to the DC Buss and the Control
time, as shown in the picture below. This results in a Board. When the Buss is charged there can be over
“locked rotor” condition and results in very high 500 VDC at the Fuse. Always allow time for the DC
current. Buss to discharge before checking the fuse.
1. Follow steps 1 and 2 of the Power card replace-

ment procedure. Make sure to allow 15 minutes
for the DC Buss to discharge.
2. Remove screws to remove cover.
The first time the drive faults the oil is usually cleared
out and the unit usually starts up the second time. To
check for this problem it is necessary to allow the
unit to set for a period of time and then check for
flooding as shown above.
If one of the six motor leads is loose or disconnected

a Fault 13 occur when it is first started up. Iit will run
after being reset just like the above fault.
.3. Remove fuse and check.
Replacement of Drive key
The Key covers a high and low voltage drive of the
same HP range. The ranges go from 20 –25 or 30-40
HP.
If the key is marked special, then contact the IR
customer service for replacement.
1. Follow steps 1 to 5 of the Power card replacement

procedure. Make sure to allow 15 minutes for the DC
Buss to discharge.

Troubleshooting the Control Board

If the drive program version is 1.01 or higher then
the Control Board Key test is available. If not then 5. Insert test plugs.
see “Using Scope Feature to observe inputs” or
Using the LCD to troubleshoot. 6. Remove the drive
plug with connections
The control board key test enables a test of the 39 to 55 and insert
digital and analog inputs. The 2 test plugs are used test plug with 39 to 55
to supply a voltage to these inputs. connections.
The Small Nirvana trouble shooting software can

show pressure inputs and digital inputs by using the
scope feature.
The LCD can show pressure transducer inputs only.
The control board has analog and digital inputs and

relay outputs. The Control board Key Test will check
all the inputs by looking at the input signals that are
supplied by the Control Board Test Plugs.
The test involves replacing the drive Intellikey with a

test Intellikey. There are 2 types of keys. One for 20-
25 HP and another for 30-40 HP.
If wrong key is used the LCD will display an error

message stating that an incorrect key is being used.
1. Follow steps 1 to 5 of the Power card 7. Turn power on the drive and wait until drive
replacement procedure. Make sure to allow 15 completely powers up
minutes for the DC Buss to Discharge.
8. Turn power off and wait until LCD goes blank.
2. Replace the Drive
Intellikey with the 9. Turn power back on. At this time the control
correct control board Boards test should be performed. ( The test is
test key . There are repeated every other time the drive is powered
two different sizes 20 up.)
to 25 and 30 to 40
HP. 10. If the control board test passes then the
message “Control Card OK Cut off mains supply
3. Reinsert cable for and remove test plug” appears on the LCD
LCD into DB-9
connector on drive. 11. If the control board fails the test then the
message “Control Card I/O failure. Replace unit
4. Remove the drive or Control Card” appears on the LCD.
plug with connections
12 to 37 and the drive 12. If the control board passes then check input
plug with 39 to 55 using voltmeter or Scope
connections.

Using the IR Nirvana Service Tool Cables

The Nirvana service tool can be used to download A regular USB cable is used to communicate with
and upload programs to the drive and observe some the 302 Danfoss drives used on the Nirvana 15-
drive parameters. The scope feature shows some 30kW.
additional parameters that are not visible on the
normal parameter list. Plug the USB cable into the remote cable
programming port of the Danfoss drive by removing
Updates the cabinet cover and then unscrewing the cover
The software will require updates in order to work from the programming port.
with different versions of drive software. The Warning: Pulling the USB cable from the drive while
procedure requires that the updates be done one at MCT 10 is communicating to the drive (Read from
a time. The updates have an upd file extension. In Drive /Write to Drive, Copy from Network to
order to install the updates, open the drive software project ...) may cause MCT 10 to operate
and select tools from the top menu, then click on abnormally.
update drive support. Pulling the USB
cable from the
drive while
downloading the
drive information
may require power
cycling the drive
for further
operation.
Starting the
Program
You will then be taken to a default location in your To load the Nirvana Field Service Tool, double click
“My Documents” directory. If the updates are not on the IR Danfoss field service tool Icon.
there, then go to the directory where they are located
and select one of the updates. Shown below is a If the cable is connected to the drive then a window
screen display where the default directory has been will appear stating “Detecting Drive on USB”.
changed.
If no cable is connected this screen is not shown.
You can insert the USB cable after the software is
loaded and it will display this screen.
A message will then popup telling you that you must

exit and then restart the Service tool. Select yes. The
next time you start the Service Tool the update will
be installed. Repeat this for all the updates

To display an active drive after the communication You must then choose “Save As” under the File
cable is plugged in. dropdown in order to close program. Be sure to
name the file something that you can remember.
Click on + beside Network Icon, click on + beside The Save As can also save Scope setups. If you
USB Icon and then click on + beside Drive ID Icon. do not save the file now you will be forced to save
To observe parameters click on ALL Parameters. it when you exit the program.
You can now scroll up and down to inspect

parameters. These parameters are for display
only; to save the drive data you must use the
“Save Drive Parameter Procedure”.
You can not reload Scope Setups to use on other
Saving Drive Parameter Procedure drives unless you modify them. The Setup is
To save the drive parameters choose “File “then looking for a specific drive ID. You can open a
“New Project” then “From Drive Network”. scope file for another drive and observe the
channel settings. Or you can load another Scope
Setup and add a new parameter to watch. When
you do you change the common scope setup to
the new drive.
Fault codes are saved with the saved drive’s

parameter list and can be observed later by
reloading the saved drive parameter list.
A pop up will show the progress of the download.

Screen showing active drive parameter list. Put curser on New, click on Scope Folder, A default
Setup 1 is the currently used parameter list. Setup scope name is now highlighted in blue.
2 is the factory default parameter list. These values
will be the same unless they have been change by
the drive hardware key.
To observe the Active drive’s Alarm Lists click on the

Alarms.
When viewing alarm folders in the network folder,

they are not polled as parameter folders are. The
alarm folder information is only updated when the
user changes to the alarm folder or tells MCT10 to
read from the drive
You can now rename folder now or right click to

accept default name.
Now you must select the parameter list that you

want to use the Scope Feature on by clicking on
the + beside Network Icon, clicking on + beside
USB, clicking on icon for the Drive.
When you
do this, the
To setup a new Scope function, right click on Parameter
Projects. list is
shown in
the lower
part of the
pop up.
Click on the
parameter
that you
want to
monitor.
Now you must set up the parameter to be displayed.

Use examples supplied with the program to help you
set it up.

After you have added the first channel you can add Here is a Scope Screen of a 25 HP Nirvana with
another by clicking below the first channel. This will one of the 6 motor leads loose. The compressor
bring up another pop up that gives you the option will fault the first time but will run the second time it
of adding additional channels. is started.
A choice of PC Polling Channel or Drive Real Time

Channel is available when you click on the drive
ID. The Drive Real Time Channel is limited to 4
choices.
If MCT10 cannot read a channel on the scope

folder consistently, it may disable polling of that
channel. The only way to re-enable polling is to
restart the logging.
At the top of the Unigy Field Service Tool there are
tools to start (wavelike colored lines), stop (straight
colored lines). Continue (green arrow point to the
right), Pause (two vertical lines), zoom in, and
zoom out, a curser that can be moved to view
values at a certain spot. Also there is an Icon to
store the Scope data as Excel spreadsheet data.
When you exit the program you must save any
files you have generated.
Below is a scope display of a 25 HP Nirvana with

1/3 of the motor leads disconnected. This would be
equal to an open output module. The blue vertical
line is a cursor that you can move across the
screen to display the values at its location on the
screen.

Input Diode Test For 20/25 HP/HV

Red Meter Lead +DC Bus and Black Meter Lead
on Input of Drive
• L1 Charging
• L2 Charging
• L3 Charging
Red Meter Lead - DC Bus and Black Meter Lead

on Input of Drive
• L1 Threshold
CAUTION!!! • L2 Threshold
• L3 Threshold
Dangerous Voltage Levels Present
Reverse Meter Leads, Repeat Test
Output leads can have voltage to ground even
when motor is not running. Black Meter Lead + DC Bus and Red Meter Lead
on Input of Drive
Allow Sufficient time for DC Capacitors to dis- • L1 Threshold
charge after power is disconnected or performing
• L2 Threshold
any testing on drive.
• L3 Threshold
Black Meter Lead - DC Bus and Red Meter Lead

on Input of Drive
• L1 OL
• L2 OL
• L3 OL

Output Diode Test For 20/25 HP/HV

Red Meter Lead - DC Bus and Black Meter Lead
on Output of Drive
• U Threshold
• V Threshold
• W Threshold
Red Meter Lead + DC Bus and Black Meter Lead

on Output of Drive
• U Charging
• V Charging
• W Charging
Reverse Meter Leads, Repeat Test
Black Meter Lead + DC Bus and Red Meter Lead

on Output of Drive .
• W Threshold
• V Threshold Note 1: Check fuses
• U Threshold Fuses must be removed and checked visually.
Black Meter Lead - DC Bus and Red Meter Lead NOTE: High voltage TAS units can give a false
on Output of Drive good reading because of the voltage transformer
• W Charging for the TAS unit.
• V Charging
• U Charging Note 2: Continuity check
A static test, performed with no power present.
Check continuity of the following with

The diode function of the voltmeter:
• +DC bus to L1, L2, L3
• +DC bus to U, V, W
• -DC bus to L1, L2, L3
• -DC bus to U,V,W
Reverse meter leads, repeat test.
If reading displays “diode drop” in one direction

and open in the other, the diode is good.
NOTE: Only 20-25HP – High voltage units can be

tested on the +DC bus. SCRs are present on other
units, prohibiting +DC bus testing validity.

Air End Replacement Remove the front top center blower guard and
lower center guard
Lock out / Tag out electrical power and use all
safety precautions to ensure unit is disconnected
from all power supplies.
Relieve ALL air pressure from receiver and isolate

the receiver or base plate unit from being back fed
with air from another source.
Center blower
Remove center front and center back panels, and

the 3 panels around the air end
Lower center
Air end front

Disconnect wires from transformer and pull back
thru the air baffle panel and remove the air baffle
panel.
Center Front
Air end panel
Air baffle
Center back
Air end back

Transformer

Disconnect all tubing from manifold block to air end Remove the small panel assembly from around the
(Caution—coolant will drain from tubing once the air end
connections are broken.)
Panel
Remove inlet valve and filter assembly by first Remove the larger panel between air end and
loosening the separator tank mounting bracket blower compartment by pushing the panel toward
bolts and then removing the 4 inlet valve assembly the separator tank to allow for the foam clearance
mounting bolts. (Caution—once the inlet and filter to the back vertical column and then slide panel
assembly is removed, protect the air end opening out. The top should not have to be removed for this
from debris being dropped into air end) step except for the 30-40Hp unit
Note: The 30-40Hp top will have to be loosened

and raised to allow clearance for the panel to be
removed.
Tank mounting
bolts
Inlet valve assembly
Remove
this panel

Remove the front Place a support under

vertical column the “air end flange” by
next to the motor raising the motor end
and air end. just enough to clear
the stator to base
bracket.
Disconnect the
This vertical column
hose that runs to
to be removed. the bottom of air
end, at the
manifold.
Caution—hose will
have coolant in it Remove the 4 mounting screws that hold the motor
so lower the hose stator to the air end
and drain coolant Note: during re-assembly these 4 mounting screws
into a container. must be torqued in criss-cross pattern to the proper
torque value of 13 LBS FT.
On the 30-40Hp unit will have to remove the cooling

fan assembly first for access to the motor stator
Disconnect
hose
mounting screws.
Support the motor

stator on each
side of the stator
base plate
mounting bracket
Disconnect the Remove the end cover from stator

mounting bracket
from motor stator

Separate the motor stator from the air end adaptor Lower the separator tank to allow clearance of tube
ring. (Note: 30-40 hp does not have an adaptor fitting to the tube.
ring. The Stator mounts directly to the air end.)
CAUTION: Removal of stator from rotor / shaft Note: The large
assembly must be done with extreme care so as to discharge elbows
not damage stator windings. The Stator is heavy. have an O-ring on
The air end must be supported under the air end the flare and care
flange to prevent tipping toward the motor while should be taken to O-ring
removing the stator protect them from
damage. Inspect
O-ring for damage.
Disconnect the high air temperature switch (HATS)

wiring from the starter
Remove the air end cap screws that attach the air
end to the air end support (3 each)
Slide the stator off of the rotor carefully and

manipulate stator out of the way
Disconnect the large discharge tube nut at the

separator tank end only.
Loosen separator tank mounting cap screws
Note: Leave the tube

at the air end
connection tight until
the air end can be
located to an area to
catch the coolant that
will drain from the air
end when this
connection is
loosened.
Remove air end using caution not to damage the Remove the rotor
stator windings during removal. assembly, spacer
and wave spring
Once the air end is located where the coolant can be from the air end
drained from it, remove the discharge tube and air shaft.
end adaptor plate from air end.
Tool 22860563 is
recommended to
remove the CF75X
motor rotor
Adaptor plate
On 20-25 hp units,
remove the stator
adaptor plate / ring Spring washer and
from the air end to spacer
Discharge tube nut be use on the new
air end replacement
Remove any other

fittings that will be
used on the new air
end replacement.
Remove the High Air Temp Switch (HATS)
Remove the hose that is attached to the bottom of

the air end connector and the hose connector. Note:
observe condition of O-ring and replace connector if
required. Note: When installing fittings into new air end, be
sure the washers that are inside these holes are
remove once the plug is removed or the fitting will
leak.
Hose connector
See note
Hose
Remove the rotor retaining bolt from air end shaft.

See note
Note: During
reassembly,
Loctite 242 is to
be applied to
Rotor retaining
rotor retaining bolt
bolt and torqued Install plugs that were removed from the new air
to maximum of end back into the replaced air end for shipping
158 FT LBS. purposes.

Note Reassemble unit in reverse order with required

When reassembling the new air end, recommend replacement O-ring, seals, gaskets, fittings, etc.
both the fitting and hose be connected to the
bottom of the air end before installing the air end For torque value requirements: see Torque Chart
into position due to ease of access. (Reference Campbellsville work instruction
MEI-2027)
SECO INSERTS- Torque Wrench

Wrench Flat Wrench Flat Torque Method Method-
Method-Tube Method-Hose ft lb ft lb
(hand tight, mark, turn (hand tight, mark, turn (Torque to setting, mark (Torque to setting, mark setting
Tube/Hose Size Number Size additional flats) additional flats) setting on nut, Indicate "I") on nut)
1/4 -4 2 flats 2 flats 13 11

5/16 -5 2 flats 2 flats 17 15
3/8 -6 1.5 flats 1.25 flats 26 22
1/2 -8 1.5 flats 1 flat 44 44
5/8 -10 1.5 flats 1 flat 61 55
3/4 -12 1.25 flats 1 flat 85 81
7/8 -14 1 flat 1 flat 100
1 -16 1 flat 1 flat 114 114
1-1/4 -20 1 flat 1 flat 150 159
1-1/2 -24 1 flat 1 flat 184 184
1-1/2
Flare-O torque only-100 ft lb torque only-100 ft lb torque only-100 ft lb torque only-100 ft lb
Main Blower Replacement

Remove motor / blower assembly from front side of
Primary Fan Motor / Blower change out package unit.
Perform Lockout / Tagout procedure and ensure all Loosen setscrew located on side of fan shaft hub
power to unit is disconnected. Remove retaining hex head bolt and washer from
Relieve all pressure in receiver. end of motor shaft that retains blower onto shaft
Remove front and back center panels
Remove front top and bottom guards Remove blower from motor.
Remove front right vertical column
Disconnect wiring from blower motor at motor Reassemble in reverse order
junction box
Note position of motor base to mounting slots

location in support to assist in reassembly of motor
to mounting support.
CAUTION----- removal of motor mounting bolts will
allow motor / blower assembly to fall. It is
recommended that a support be placed under the
blower to assist in assembly removal.
Vertical column
Remove motor mounting bolts, washers and nuts.
The motor and fan assembly is heavy. Caution must
be used during removal of assemble to prevent
injury.

NOTE: Turning RFI Filter OFF

Loctite 242 is used on the blower to motor shaft The RFI filter is set to on by default.
retaining screw. Once motor and fan assembly are
installed back in unit, fan must be positioned over If you have a balanced incoming line voltage, such
cone. as a Y supply, the filter can be left on, otherwise
the drive may trip out on DC Over volts or it may
trip on Over Current, this depends on the software
Fan must be positioned over revision. It is necessary to turn the filter off if this
cone. A gap between fan and occurs.
cone is not acceptable
Note that if the LCD detects inactivity for over 10
seconds the LCD will return to the default screen,
which is the Status screen, if this occurs.
Fan To turn the AC Filter off, push the Service button

rotation on the LCD and the push the down arrow until you
reach the Factory Service screen, then press OK
button to enter this screen.
Fan over
Press OK to allow the entering of the password.
cone Cone
To enter the password of 01945, use the left button
to position the curser at 00000 and the up arrow to
change the numbers. Use the right button to enter
The cone must be adjusted for clearance to the next number. Continue until you have entered
prevent contact between blower and cone during the last number on the right, then push the OK but-
operation. ton to accept.
Vertical column must be installed prior to adjusting Push the down arrow until you reach the RFI
cone. After assembly of motor / blower and all screen, press the OK button enable the changing
safety guards are in place, verify fan rotation is of the filter. Use the up or down button to turn the
correct per figure above. filter on or off. Use the OK button to accept the
change. You can either hit the Status button to re-
turn to the home position or wait for 10 seconds for
the automatic return to home position.


Nirvana Trouble Shooting Manual: IRN 15-30kW (20-40Hp)

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Nirvana Trouble Shooting Manual: IRN 15-30kW (20-40Hp)

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NIRVANA

TROUBLE SHOOTING MANUAL

Rev. March 2007

Proprietary Notices and Disclaimer

Replacement of Drive Control Board.............22

Fault 13 Over Current ...................................24

Replacement of Drive Key .............................24

Power Fuse Replacement .............................24

Troubleshooting the Control Board................25

Using the Nirvana Service Tool .....................26

Airend Replacement ......................................32

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 3

• Output leads can have voltage to ground even

• Allow Sufficient time for DC Capacitors to

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 5

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 6

The Danfoss 302 drive’s DC Buss is accessible at

The Danfoss drives used on the 20 to 40 HP Nirvana

On the frames with the SCRs in the input bridge,

After approximately 10 seconds if everything is

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 7

2. Selects Status Main Screen

3. Return to previous Screen

6. Yellow warning LED

7. Red Alarm Led

8. Run Push Button

9. Selects Menu Main Screen

10. Selects Main Service Screen

11. Information about current screen is shown when

12. UP arrow, moves up to next screen or increases

13. Right select

14. OK selects option offered on current screen and

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 8

Description of the LCD Screens Status Display

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 9

2.2 Auto Stop

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 10

2.5 Only works when Menu Display

3.2 If a PORO option is

3.4 Enable / Disables

3.5 Allows the Modbus

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 11

3.6 Allows the setting of Service Information Display

3.7 The following Baud 4.1.2 Read only display

4.1.4 Dryer Discharge

4.1.5 When the dryer is

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 12

Service Set points Display

4.2.1 Selecting YES

4.2.2 Selecting YES

4.2.3 Selecting YES

Alarm Log Display

Alarm 1 Details: Pressing the Up and Down Arrows

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 13

Factory Service Display 4.4.3

4.4.2 With this you can

Nirvana 15—30kW (20-40Hp) Troubleshooting Manual Page 14

Fault Messages Warning Messages