G5 IDM Unit Troubleshooting Class

Omron IDM Controls
Unit Troubleshooting Class

G5/P5
(0.4 ~ 15kW)
TRMB30
Version 1.31
2/6/2019
1
Introduction
 This manual explains the troubleshooting
procedures for the following inverter models.
230V 460V
G5 G5
CIMR-G5U20P4 CIMR-G5U40P4
CIMR-G5U2011 CIMR-G5U47P5
CIMR-G5U2015 CIMR-G5U4011
CIMR-G5U4015 2
Introduction
 This manual explains the troubleshooting
procedures for the following inverter models.
230V 430V
P5 P5
CIMR-P5U23P7 CIMR-P5U43P7
CIMR-P5U2011 CIMR-P5U47P5
CIMR-P5U2015 CIMR-P5U4011
CIMR-P5U4015
3
Introduction
This manual is divided into Three sections:
 Section One is called “Checks Without Power”; it explains

the steps used to check out the inverter, with no power
applied, using an ohmmeter.
 Section Two is called “Power Checks”; this section
explains a systematic method of applying power to the
inverter and checking various points on the inverter to
verify proper operation.
 Section Three is called “Fault Codes”; this section
explains the fault indications, possible causes, and
corrective actions.
Mfg. part numbers and code numbers listed in this manual are subject to change.
4
Test Equipment
The basic tools used for troubleshooting a OIDM inverter are as follows:
Analog Multimeter Digital Multimeter

5
Test Equipment
• An ungrounded Oscilloscope with a 10X and 100X probe.

• A 30 watt, 1K ohm resistor.
6
Decoding The Model Number
CIMR-G5U23P7
Inverter
kW Rating*
Product
3P7 = 3.7kW
G5/P5
(kW 0.75 = Hp)
Specification Voltage Rating
U - Americas 2 - 230V 3 phase
A - Japan/Asia 4 - 460V 3 phase
E - Europe * - kW rating is based on 200 and 400 volt values
7
Inverter Markings
On every OIDM inverter is an inspection stamp and lot number. The
information contained in the inspection stamp is the date and year that the
inverter was tested. The lot number contains more detail about when the
inverter was produced. The date stamp information and lot number are
needed when submitting a warranty claim to OIDM.
Assembled in the U.S.A
Inspection Stamp Production
PRD
Manufacture Date
96 3. 31
INSP2
Inspector Number
Lot Number
U-9603250-3
Manufactured in U.S.A. Unit Number in Work Order
Year Computer Generated Number
Month
8
Inverter Markings
On every OIDM inverter is an inspection stamp and lot number. The
information contained in the inspection stamp is the date and year that the
inverter was tested. The lot number contains more detail about when the
inverter was produced. The date stamp information and lot number are
needed when submitting a warranty claim to OIDM.
Manufactured in Japan
Inspection Stamp YEC Production
INSP
Manufacture Date
96 4. 11
T.K
Inspector
Lot Number
NR5GA09-573A-15
Manufactured in Japan Month
Year
9
Power Component Replacement
Incorrect Method for Replacement of Circuit Board Mounted Components
Large board-mounted components (input diodes, output IGBT’s, and power

modules) are not being correctly installed into small size inverters during repair.
The components are being soldered to the power board, before being mounted to
the heat sink.
POWER BOARD
POWER MODULE
AIR GAP
7MBR30NF060
HEAT SINK
10
Correct Method for Replacement of Circuit Board Mounted Components
When mounted correctly, the power module with thermal compound applied, will be
in contact with the heatsink. The specifications for the thermal compound can be
found on the following page.
POWER BOARD
POWER MODULE
THERMAL
HEAT SINK COMPOUND
7MBR30NF060
11
Thermal Compound
In the chart below is a list of thermal compound specifications. The thermal
compound used on all power components in OIDM inverters is highlighted.
Vendor SHIN-ETSU SHIN-ETSU TOSHIBA CASTALL

Description Thermal Compound Thermal Compound Thermal Compound Thermal Compound
Material Silicon Grease Silicon Grease Silicon Grease Silicon Grease
Appearance White Paste - - -
Model Number G746 KS609 YG6260 CASTALL800
Thermal Conductivity 1.6 x 10 ³ cal/cm•sec•°C 1.5 x 10 ³ cal/cm•sec•°C 2 x 10 ³ cal/cm•sec•°C 1.8 x 10 ³ cal/cm•sec•°C
Temperature Range -50° C ~ 150° C -55° C ~ 200° C -50° C ~ 150° C -55° C ~ 205° C
12
The component must first be mounted to the heat sink. The power board should then
be installed into the inverter, over the top of the components. Then the components
should be soldered to the power board.
1. Mount components to heat sink

(include thermal compound)
1. Mount components to heat sink 2. Install power board

(include thermal compound) over components
1. Mount components to heat sink 2. Install power board 3. Solder components to

(include thermal compound) over components the power board
13
Section One:
Checks Without Power
14
Main Circuit Test Procedure
This test procedure must be performed before making a repair.
TEST PROCEDURE CHECKLIST
Completed
 1. Check DC bus voltage.
 2. Check input diodes.
 3. Check soft charge resistor.
 4. Check soft charge contactor.
 5. Check DC bus fuse.
 6. Check the braking circuit. (If internal)
 7. Check output transistors.
 8. Check the control power fuse.
 9. Check the cooling fan.
15
DANGER!
LETHAL VOLTAGES ARE PRESENT!
Before attempting any checks in this troubleshooting manual, make sure that the three
phase power is disconnected and locked out. With power removed from the unit, the DC
bus capacitors will stay charged for several minutes. The charge LED in the unit will glow
red until the DC bus voltage is below 10 VDC. To ensure that the DC bus is completely
discharged, measure between the positive and negative bus with a DC voltmeter set to
the highest scale.
Checking the inverter for power
Test Equipment - DC voltmeter set to the highest scale
This test is a mandatory safety check! Before touching any components inside the
inverter, perform the following test. Look at the charge LED on the inverter. If high voltage
is present on the DC bus, the charge LED will glow red. As the DC bus capacitors
discharge, the charge LED will fade out. There is a possibility that voltage will be present
on the DC bus even when the charge LED is off. To determine if the DC bus is completely
discharged, measure between the positive and negative portions of the DC bus with a DC
voltmeter. Set the meter to it’s highest scale and place the positive lead onto the positive
portion of the DC bus and place the negative lead onto the negative portion of the DC bus.
If the measured voltage is below 10 VDC, you can safely work inside the unit.
16
Input Diodes
The input diodes are located inside the power module PM1 or in a separate module
labeled DM1. The input diodes rectify or transform the three-phase input AC voltage
into a DC voltage. The DC voltage level is proportional to the input AC voltage and is
the main reference voltage in the inverter called the DC Bus. The DC bus voltage
should normally be about 325 VDC for a 230V model and 650 VDC for a 460V model.
- Schematic diagram
17
Input Diodes
The individual diodes that form the three-phase input rectifier bridge can easily be
checked by measuring the forward and reverse resistance of the diodes. Simply use
an analog or digital meter and measure the resistance across each diode. Refer to
the elementary diagram to determine the relationship between the main input
terminals (L1, L2, L3) and the DC bus terminals. By checking the resistance from
each input terminal to the positive bus and the negative bus (then swapping your
meter leads) you can check each of the diodes. Remember, you should see a
resistance reading typical of a diode, with low resistance in one direction and fairly
high resistance after you swap the meter leads.
Cathode (-)
0.5 OL
DVM DVM
+ _ + _
Anode (+)
Resistance Readings
18
Input Diode Check
Test Equipment - Analog Ohmmeter Set to R X 1 Scale
or Digital Multimeter set to the Diode Check.
Ohmmeter Ohmmeter Expected Expected
Step No. Positive Lead Negative Lead Reading Reading
(Analog Meter) (Digital Meter)
L1 Terminal
1 Terminal labeled (+) Approximately Approximately
L2 Terminal
10 Ohms 0.5 Volts
L3 Terminal
L1 Terminal
2 L2 Terminal Terminal labeled (-) Infinite Ohms 0L displayed
L3 Terminal
L1 Terminal Approximately Approximately

3 Terminal labeled (-) L2 Terminal 10 Ohms 0.5 Volts
L3 Terminal
L1 Terminal
4 Terminal labeled (+) L2 Terminal Infinite Ohms 0L displayed
L3 Terminal
19
Input Diodes
Part Numbers:
Inverter Model Inverter Model YEA Code Diode
Number Number Mfg. Part Number Number Specifications Designation
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4
G5U20P7 N/A
G5U21P5 INSIDE POWER MODULE PM1
G5U22P2 (SEE OUTPUT TRANSISTOR PARTS LIST)
G5U23P7 P5U23P7
G5U25P5 P5U25P5
G5U27P5 P5U27P5 DF75BA80 SID000594 800V 75A 6 IN 1
G5U2011 P5U2011 DF100BA80 SID000595 800V 100A 6 IN 1 DM1
G5U2015 P5U2015 DF150BA80 SID000596 800V 150A 6 IN 1
460V 460V
G5U40P4
G5U40P7 N/A
G5U43P7 P5U43P7
G5U44P0 P5U44P0
G5U45P5 P5U45P5 DF30AA160 SID000597 1600V 30A 6 IN 1
G5U47P5 P5U47P5 DM1
G5U4011 P5U4011 DF60AA160 SID000598 1600V 60A 6 IN 1
G5U4015 P5U4015
Caution: It is crucial that you remember to apply a thermal compound to the mounting surface
of the diode module, to ensure proper heat transfer from the module to the inverter’s heat sink.
Failure to do so may result in another component failure. 20
Soft Charge Resistor/Contactor
The soft charge resistor, or current-limiting resistor, works in conjunction with the soft
charge contactor to slowly charge the DC bus capacitors and minimize the inrush
current, when power is applied to the inverter. With no power applied to the inverter,
the DC bus is discharged and the contacts on the soft charge contactor are open.
The purpose of the soft charge contactor is to bypass the soft charge resistor after the
DC bus voltage has reached it’s normal operating level. When input power is applied to
the inverter, the DC bus voltage starts to increase. The contacts on the contactor are
open, so the current that is charging up the DC bus capacitors is passing through the
soft charge resistor. The soft charge resistor acts like a control valve, and allows the
DC bus capacitors to charge slowly. When the DC bus voltage has risen above the
under voltage detection point (190 VDC for 230V units and 380 VDC for 460V units),
the contacts on the contactor close bypassing the soft charge resistor. If a soft charge
resistor was not used, the large inrush current would damage the input diodes.
21
(+)
L1 0v
L2 DC
Volt
L3 + Meter -
(-)
16CN 15CN
1 2 1 5
Power Supply
Logic From
Control Board
2PCB Power Board 22
(+)
L1 100v
L2 0V DC
Volt
L3 + Meter -
(-)
16CN 15CN
1 2 1 5
Power Supply
Logic From
Control Board
2PCB Power Board 23
(+)
L1 190v
L2 24V DC
Volt
L3 + Meter -
(-)
16CN 15CN
1 2 1 5
Power Supply
Logic From
Control Board
2PCB Power Board 24
The soft charge resistor/contactor will change with the capacity of the inverter. The small
capacity inverters (7.5kW and smaller) use board mounted resistors mounted on the power
board. The larger capacity inverters (11kW and 15kW), use a single resistor mounted in the
main circuit. In 230V units 1.5kW and smaller and 460V units 4.0kW and below, the
contactor is soldered to the powerboard.
Soft Charge Resistor Check:
The first step is a visual inspection. Many times a damaged soft charge resistor has physical
damage, such as burn marks, discoloration, or has been broken into pieces. If there is no
physical evidence of damage, a check with an ohmmeter must be performed. Locate the soft
charge resistor(s) inside the inverter unit. With an ohmmeter set to the R x 1 scale, measure
across the resistor(s). If the resistor(s) is damaged, the measured value will be infinite ohms
(burned open).
Soft Charge Contactor Check:
With an ohmmeter set to the R x 1 scale or the ohm setting, measure across the contacts
and press in the plunger. On the smaller capacity inverters, the contactor will be totally
enclosed and this step can not be performed. When the plunger is pushed in, the resistance
across the contacts should read 0 ohms. When the plunger is released, the resistance will be
infinite ohms. On the units with the board mounted contactor, verify that the contacts read
infinite ohms across each contact. Measure across the coil of the contactor, it should read
about 300 ohms. 25
Soft Charge Resistor
Part Numbers:
Inverter Model Inverter Model Mfg. Part YEA Code Resistor
Number Number Number Number Specifications Designation
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4 KNYS7W400K R010064 7W 40 OHM +/- 10% R2
G5U20P7 N/A
G5U21P5 KNYS7W220K R010072 7W 22 OHM +/- 10% R2
G5U22P2 KNYS7W4R5K R010065 7W 4.5 OHM +/- 10% R14, R22
G5U23P7 P5U23P7
G5U25P5 P5U25P5 KNYS7W3R0K R010066 7W 3 OHM +/- 10% R79, R80
G5U27P5 P5U27P5 R80, R83
G5U2011 P5U2011 RGHS60LS2R2OHMJ R010062 2.2 OHM +/- 10% R1
G5U2015 P5U2015
460V 460V
G5U40P4
G5U40P7 N/A KNYS10W800K R010067 10W 80 OHM +/- 10% R4
G5U41P5
G5U42P2 R12
G5U43P7 P5U43P7 KNYS10W500K R010068 10W 50 OHM +/- 10% R8, R12
G5U44P0 P5U44P0 R8, R12
G5U45P5 P5U45P5 KNYS10W4R0K R010069 10W 4 OHM +/- 10% R79, R82
G5U47P5 P5U47P5
G5U4011 P5U4011 RGHS80LS6R2OHMJ R010063 80W 6.2 OHM +/-10% R1
G5U4015 P5U4015
26
Soft Charge Contactor
Part Numbers:
Inverter Model Inverter Model Mfg. Part YEA Code Contactor
Number Number Number Number Specifications Designation
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4
G5U20P7 N/A VSB-24MC POR003011
G5U21P5
G5U22P2 HE1AN-DC24V POR003013 MC1
G5U23P7 P5U23P7 DC 24V
G5U25P5 P5U25P5 HE2AN-DC24V POR003014
G5U27P5 P5U27P5
G5U2011 P5U2011 G7J-4A-B-DC24V POR003012
G5U2015 P5U2015
460V 460V
G5U40P4
G5U40P7 N/A JC2AF-B-DC24V POR003015
G5U41P5
G5U42P2 MC1
G5U43P7 P5U43P7 DC 24V
G5U44P0 P5U44P0 HE2AN-DC24V POR003014
G5U45P5 P5U45P5
G5U47P5 P5U47P5 HP-20GU MC003260
G5U4011 P5U4011 G7J-4A-B-DC24V POR003012
G5U4015 P5U4015
27
DC Bus Fuse
The DC Bus fuse is located in the positive portion of the DC bus in units 5.5kW and smaller,
and in the negative portion in all other sizes. The DC bus fuse is used to protect the main circuit
components if the output transistors short. If the DC bus fuse is open, at least one of the output
transistors has failed. When a transistor fails, there is a short between the positive and negative
portions of the DC bus. Again, the DC bus fuse does not protect the transistors, but protects the
rest of the main circuit from the high current present during a short. Never replace the DC bus
fuse without first checking all of the output transistors.
Caution: If the DC bus fuse is replaced without replacing the shorted output transistor, non-
warranty damage will occur.
(+)
L1 T1
L2 T2
L3 T3
1FU
(-)
Main Circuit Diagram

DC Bus Fuse
The DC Bus fuse is located in the positive portion of the DC bus in units 5.5kW and smaller,
and in the negative portion in all other sizes. The DC bus fuse is used to protect the main circuit
components if the output transistors short. If the DC bus fuse is open, at least one of the output
transistors has failed. When a transistor fails, there is a short between the positive and negative
portions of the DC bus. Again, the DC bus fuse does not protect the transistors, but protects the
rest of the main circuit from the high current present during a short. Never replace the DC bus
fuse without first checking all of the output transistors.
Caution: If the DC bus fuse is replaced without replacing the shorted output transistor, non-
warranty damage will occur.
(+)
L1 T1
L2 T2
L3 T3
1FU
(-)

28
Part Numbers:
DC Bus Fuse
Inverter Model Inverter Model YEA Code Fuse
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4 A60Q10-2 FU002029 AC 600V 10A
G5U20P7 N/A
G5U21P5 A60Q15-2 FU002030 AC 600V 15A
G5U22P2 A60Q20-2 FU002031 AC 600V 20A
G5U23P7 P5U23P7 A60Q30-2 FU002032 AC 600V 30A FU1
G5U25P5 P5U25P5 A30QS50-4L FU002033 AC 300V 50A
G5U27P5 P5U27P5
G5U2011 P5U2011 A30QS75-4L FU002034 AC 300V 75A
G5U2015 P5U2015 A30QS100-4L FU002035 AC 300V 100A
460V 460V
G5U40P4
G5U40P7 N/A A60Q10-2 FU002029 AC 600V 10A
G5U41P5
G5U42P2
G5U43P7 P5U43P7 A60Q20-2 FU002031 AC 600V 20A FU1
G5U44P0 P5U44P0
G5U45P5 P5U45P5 A60Q30-2 FU002032 AC 600V 30A
G5U47P5 P5U47P5 A50QS50-4Y FU002037 AC 500V 50A
G5U4011 P5U4011 A50QS75-4Y FU002038 AC 500V 75A
G5U4015 P5U4015
29
Braking Circuit
The Braking Transistor is located in the main circuit and works in conjunction with
the braking Resistor option installed to terminals B1 and B2. The transistor turns on
when the DC bus voltage reaches 380VDC for 230V models, and 760VDC for
460V inverters. The transistor can be checked by following the steps below. The
most common failure is for the transistor to be shorted between the collector and
emitter. Readings will vary depending on inverter size.
Braking Transistor Check

Step No. Ohmmeter Positive Lead Ohmmeter Negative Lead
Collector
1 Connect to B2 terminal Connect to the Emitter
2 Connect to the Emitter Connect to B2 terminal

Gate
3 Connect to the Gate Connect to the Emitter
Emitter 4 Connect to the Emitter Connect to the Gate
5 Connect to B2 terminal Connect to the Gate

IGBT Transistor 6 Connect to the Gate Connect to B2 terminal
30
Braking Circuit
Braking Diode Check
Ohmmeter Ohmmeter Expected Reading Expected Reading
Step No.
Positive Lead Negative Lead (Analog Meter) (Digital Meter)
1 Connect to B2 Connect to B1 10 Ohms 0.5 Volts
2 Connect to B1 Connect to B2 Infinite Ohms OL Displayed
B1 B2
T1
T2
T3
G E
* The B1 Terminal is connected to the Positive portion of the DC bus. 31
Braking
Part Numbers:
Transistor
Inverter Model Inverter Model YEA Code IGBT
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4
G5U20P7 N/A
G5U23P7 P5U23P7
G5U25P5 P5U25P5
G5U27P5 P5U27P5 TM1
G5U2011 P5U2011 N/A
G5U2015 P5U2015
460V 460V
G5U40P4
G5U40P7 N/A
G5U41P5 PM1
G5U42P2 INSIDE POWER MODULE
G5U43P7 P5U43P7 (SEE OUTPUT TRANSISTOR PARTS LIST)
G5U44P0 P5U44P0
G5U45P5 P5U45P5 TM1
G5U47P5 P5U47P5
G5U4011 P5U4011 MG50Q1BS11 STR001058 1200V 50A 1 IN 1 TRM 4
G5U4015 P5U4015
of the power module, to ensure proper heat transfer from the module to the inverter’s heat sink.
Failure to do so may result in another component failure. 32
Output Transistors
The output transistors are used to switch the DC bus voltage to produce current
to the motor. Think of them as switches that turn on and off very quickly to supply
power to the motor. Large capacity inverters use the single pair style transistors
while the smaller capacity inverters use the 6-in-1 style transistor module. In the
single pair transistor, one transistor switches positive DC voltage to the motor,
while the other transistor switches negative DC voltage to the motor. The
terminals labeled T1, T2, and T3 are the leads that go out to the motor.
33
Output Transistors
The transistors can be checked by simply measuring the resistance from the
collector to the emitter. The power transistors used in the G5/P5 all have free-
wheeling diodes connected in parallel with the collector-emitter junction. When
measuring the resistance across the output transistors, you should use an
ohmmeter or a digital multimeter and expect to see resistance readings
characteristics of the free-wheeling diode. Resistance should be fairly low in the
forward direction and very high in the reverse direction.
+
T1
T2
T3
2PCB Power Board
*NOTE: If the DC bus fuse is open, choose a test point for the
negative bus on the output transistor side of the fuse.
34
Output Transistor Check
Ohmmeter Ohmmeter Expected Expected
Step No. Positive Lead Negative Lead Reading Reading
(Analog Meter) (Digital Meter)
T1 Terminal
1 Terminal labeled (+) Approximately Approximately
T2 Terminal
10 Ohms 0.5 Volts
T3 Terminal
T1 Terminal
2 T2 Terminal Terminal labeled (-) Infinite Ohms 0L displayed
T3 Terminal
T1 Terminal Approximately Approximately
3 Terminal labeled (-) T2 Terminal 10 Ohms 0.5 Volts
T3 Terminal
T1 Terminal
4 Terminal labeled (+) T2 Terminal Infinite Ohms 0L displayed
T3 Terminal
Note: When a transistor fails, all the transistors in the failed phase must be
replaced. They must be replaced with the identical transistor manufacturer and
part number.
35
Part Numbers:
Output Transistors
Inverter Model Inverter Model YEA Code Transistor
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4 CM10LD-12H STR001017 600V 10A 6 IN 1
G5U20P7 N/A CM20LD-12H STR001018 600V 20A 6 IN 1
G5U21P5 PM1
G5U22P2 7MBR30NF060 STR001049 600V 30A 7 IN 1
G5U23P7 P5U23P7 7MBR50NF060 STR001050 600V 50A 7 IN 1
G5U25P5 P5U25P5
G5U27P5 P5U27P5 7MBI75N-060 STR001059 600V 75A 7 IN 1 TM1
G5U2011 P5U2011 2MBI100N-060 STR001060 600V 100A 2 IN 1 TRM 1,2,3
G5U2015 P5U2015 2MBI150NC-060 STR001061 600V 150A 2 IN 1
460V 460V
G5U40P4
G5U40P7 N/A 7MBR10NF120 STR001051 1200V 10A 7 IN 1
G5U41P5 PM1
G5U42P2 7MBR15NF120 STR001052 1200V 15A 7 IN 1
G5U43P7 P5U43P7 7MBR25NF120 STR001053 1200V 25A 7 IN 1
G5U44P0 P5U44P0
G5U45P5 P5U45P5 7MBRI40N-120 STR001063 1200V 40A 7 IN 1 TRM1
G5U47P5 P5U47P5 7MBI50N-120 STR001064 1200V 50A 7 IN 1
G5U4011 P5U4011 2MBI75N-120 STR001065 1200V 75A 2 IN 1 TRM 1,2,3
G5U4015 P5U4015
of the transistor module, to ensure proper heat transfer from the module to the inverter’s heat
sink. Failure to do so may result in another component failure. 36
Control Power Fuse
All 230V and 460V series inverters have a control power fuse. If the
control power fuse is open, then the power board is defective. The
fuse is soldered to the power board .The fuse can easily be checked
using an ohmmeter set to the R X 1 scale. Place one lead of the
ohmmeter on one side of the fuse, and place the other lead of the
ohmmeter on the other side of the fuse. If the fuse is bad, the
measured value will be infinite ohms.
Control Fuse
Power Board
37
Control
Part Numbers:
Power Fuses
Inverter Model Inverter Model YEA Code Fuse
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4
G5U20P7 N/A
G5U21P5
G5U22P2 500V-FA6X32-1A FU000900 500V 1A (WITH PIG TAIL) FU2
G5U23P7 P5U23P7
G5U25P5 P5U25P5
G5U27P5 P5U27P5
G5U2011 P5U2011 FU1
G5U2015 P5U2015
460V 460V
G5U40P4
G5U40P7 N/A
G5U41P5
G5U42P2 500V-FA6X32-1A FU000900 500V 1A (WITH PIG TAIL) FU2
G5U43P7 P5U43P7
G5U44P0 P5U44P0
G5U45P5 P5U45P5
G5U47P5 P5U47P5
G5U4011 P5U4011 FU1
G5U4015 P5U4015
38
Cooling Fan
All P5 and most G5 units have a cooling fan that blows air across
the heat sink on the back of the unit. If the cooling fan is not
working properly, the inverter will trip on an overheat fault.
Visually check the cooling fan to make sure it turns freely. If there
is no physical evidence that the fan is bad, the motor can be
checked with an ohmmeter or a 24 VDC power supply. Using an
ohmmeter, measure across the fan motor terminals. If the fan
motor is good, the measured value should be close to 500 ohms.
If the measured value is 0 ohms, we can conclude that the motor
is shorted, or if the measured value is infinite ohms, we can
conclude that the motor is burned open. If the fan is not working,
then disconnect the fan and apply 24 VDC to the fan to test the
motor.
24 v The fan connector plugs in to

the powerboard at 9CN or
10CN.
+ -
DC Power Supply 39
Part Numbers:
Cooling Fan
Inverter Model Inverter Model YEA Code Fan
(G5) (PC5)
230V 230V
CIMR- CIMR-
G5U20P4
G5U20P7 N/A N/A
G5U21P5
G5U22P2
G5U23P7 P5U23P7 TSF613A2401 FAN001010 24V 3.24W 135MA 4500RPM FAN1
G5U25P5 P5U25P5
G5U27P5 P5U27P5 FAN1, FAN2
G5U2011 P5U2011 ASF865A2401 FAN001011 24V DC FAN1, FAN2
G5U2015 P5U2015
460V 460V
G5U40P4
G5U40P7 N/A N/A
G5U41P5
G5U42P2
G5U43P7 P5U43P7
G5U44P0 P5U44P0 TSF613A2401 FAN001010 24V 3.24W 135MA 4500RPM FAN 1
G5U45P5 P5U45P5
G5U47P5 P5U47P5 FAN 1, FAN 2
G5U4011 P5U4011 ASF865A2401 FAN001011 24V DC FAN 1,2
G5U4015 P5U4015
40
Time To Do An Exercise
Exercise One
• Answer the following questions using your knowledge and / or the documents
from this class.
1) True or False : The fuse is located in the negative portion of the DC bus for
all G5 and P5 Inverters?
2) True or False : A CIMR-G5U2015 inverter uses (2) 230V AC fans?
3) Using the repair manual, what is the code number for the input diode
module for a CIMR-P5U23P7?
4) True or False : All P5 inverters have an internal braking transistor?
5) What is the DC bus voltage for a 460V inverter?
41
Exercise One
• Answer the following questions using your knowledge and / or the documents
from this class.
1) True or False : The fuse is located in the negative portion of the DC bus for
all G5 and P5 Inverters?
2) True or False : A CIMR-G5U2015 inverter uses (2) 230V AC fans?
3) Using the repair manual, what is the code number for the input diode
module for a CIMR-P5U23P7? STR001050
4) True or False : All P5 inverters have an internal braking transistor?
5) What is the DC bus voltage for a 460V inverter? 650V DC

Section Two:
Power Checks
42
Power Checks
TEST PROCEDURE CHECKLIST
Completed
 1. Remove the DC bus fuse and replace it with a 30W,
1k ohm resistor.
 2. Apply power to terminals L1, L2, & L3.
 3. Check the DC bus voltage.
 4. Check the 15V power supply.
 5. Check the (-15V) power supply. (G5 Only)
 6. Check the isolated 24V power supply.
 7. Check the output voltage waveform.
 8. Check the gate firing pulses(if necessary).
 9. Remove the 1k ohm resistor, re-install the DC bus fuse.
 10. Run the motor.
 11. Check the output current waveform. 43
Caution!
Extreme caution must be used when working on the inverter. Make sure the
charge LED is not lit and the DC bus voltage is below 10VDC before touching
any components. The motor must be disconnected to perform the following
tests!
(+)
L1 T1
L2 T2 M
L3 T3
1FU
(-)
44
Remove DC Bus Fuse
Step 1
Remove the DC bus fuse and replace it with a 30 watt 1 k ohm
resistor.
(+)
L1 T1
L2 T2 M
L3 T3
(-)
Resistor assembly.....
30 watt 1k ohm
No. 12 AWG wire (stranded)
Alligator Clips (large size)
Small enclosure*
* In case of a short, the
enclosure will contain the
resistor if it fragments.
45
Apply Power
Step 2
Apply the appropriate AC voltage (230V or 460V) to the input terminals marked
L1, L2, and L3 and watch for the following signs of trouble.
1. The 30W 1k Ohm resistor gets hot.
2. The DC bus voltage is low.
• For a 230V inverter with 230V AC applied to the input, the DC bus
voltage should be approximately 325VDC.
• For a 460V inverter with 460V AC applied to the input, the DC bus
voltage should be approximately 650VDC.
3. The digital operator displays an undervoltage fault.
4. No display on the digital operator.
If any of these conditions occur, Turn off the power immediately!

It is possible that there is still a short between the positive and
negative portions of the DC bus. Refer to page 15 and perform the checks
without power again.
46
Check The DC Bus Voltage
Step 3
With a DC voltmeter set to the highest scale, measure the DC bus
voltage at the (+) and (-) terminals.
(+)
L1 T1
230V L2 T2 M
L3 T3
(-)
DC Bus Check
VDC  x VAC
325v
DC
230V AC  325V DC
Volt
- Meter + 460V AC  650V DC
47
Power Supply Check (15V)
Step 4 (For G5 models)
Measure the 15V power supply on the control board at terminals 15
and 17 (Gnd).
G5
ETC61501X-SXXXX
15V
DC
- Volt
Meter
+
11 15 17 33
1 2 3 4 5 6 7 8
48
Step 4 (For P5 models)
Measure the 15V power supply on the control board at terminals FS
and FC (Gnd).
P5
ETC61502X-SXXXX
15V
DC
- Volt
Meter
+
S1 S2 S3 SC SCS4 S5 S6 FS FC
49
Power Supply Check (-15V)
Measure the (-15V) power supply on the control board at terminals
33 and 17 (Gnd).
G5
ETC61501X-SXXXX
-15V
DC
- Volt
Meter
+
11 15 17 33
1 2 3 4 5 6 7 8
50
Measure the isolated 24V power supply on the control board at
terminals 1 ~ 8 using terminal 11 (Gnd) as a common point.
G5
ETC61501X-SXXXX
24V
DC
- Volt
Meter
+
11 15 17
1 2 3 4 5 6 7 8
51
Step 6 (For P5 models)
Measure the isolated 24V power supply on the control board at
terminals S1 ~ S6 using terminal SC (Gnd) as a common point.
P5
ETC61502X-SXXXX
24V
DC
- Volt
Meter
+
S1 S2 S3 SC SCS4 S5 S6 FS FC
52
Output Voltage Waveform
Step 7
Test Equipment - Ungrounded oscilloscope with X 100 probe
Set scope to 200V/div. and 5mSec., in order to observe the output voltage waveform.
Before attempting to run the inverter, make a list of all the parameters that have been
changed from the factory settings. Initialize the drive and set it up to accept a run
command and frequency reference from the digital operator.
1. Using the oscilloscope, measure between T1 and T2.
2. Run the inverter up to 60 Hz, watching the waveform as it accelerates.
3. Compare the waveform with the waveform shown below.
4. Stop the inverter.
5. Repeat steps 1 through 4 measuring T1 to T3 and T2 to T3.
53
Gate Circuit Check
Step 8
Test Equipment - Ungrounded oscilloscope with X 10 probe
Set scope to 2V/div. and 2mSec., in order to observe the gate firing pulses.
1. Using the oscilloscope, measure between the gate and emitter pins which lead
to the output IGBT.
2. Run the inverter at 60HZ, and compare the waveform you see with the one
shown below.
4. Repeat steps 1 through 3 measuring all six gate pulses.
• Never power up the inverter with the Gate wires removed or the IGBT will be
damaged!
54
Install DC Bus Fuse
Step 9
Shut the power off to the inverter drive and lock it out if possible. Allow the DC
bus to discharge. When the charge LED has gone out, use a DC voltmeter to
check the DC bus voltage. When the DC bus voltage reaches 10 VDC, it is
safe to work inside the unit. Remove the resistor and re-install the DC bus
fuse.
(+)
L1 T1
L2 T2 M
L3 T3
1FU
(-)
55
Step 10
Run The Motor
1. Making sure that the power is not applied to the inverter, and the DC Bus
voltage is below 10V, hook up the motor to the output terminals labeled
T1, T2, and T3.
2. Apply power to the inverter.
3. Set the acceleration time and the deceleration time to 10 seconds.
G5 P5
Acceleration time (C1-01) Acceleration time 1 (n019)
Deceleration time (C1-02) Deceleration time 1 (n020)
4. Set the frequency reference for 6 Hz.
5. Give the inverter a forward run command. Observe the motor for abnormal
operation. Repeat this step giving the inverter a reverse run command.
6. Set the frequency reference to 30 Hz and run the motor in both directions
once again observing the operation.
7. Set the frequency reference to 60 Hz and run the motor once again.
8. Give the inverter a stop command.
56
Output Current Waveform
Step 11
Test Equipment - Ungrounded oscilloscope with clamp on current probe.
Set scope to 0.2V/div. and 5mSec., in order to observe the output current waveform.
1. Using the clamp on current probe, clamp the probe to one of the output leads T1, T2, or T3.
3. Compare the waveform with the waveform shown below. (Output will vary with load)
5. Repeat steps 1 through 4 with the two remaining output leads.
• If a clamp on meter is not available, an oscilloscope with a X 10 probe can be used for 11kW
and 15kW units by following the test procedure on the following page.
57
Output Current Waveform
Step 11 (For 11kW and 15kW units)
Test Equipment - Ungrounded oscilloscope with x10 probe.
Set scope to 0.2V/div. and 5mSec., in order to observe the output current waveform.
1. Using the oscilloscope, measure between 22CN pin 6 (Gnd) and pin 1 (IU).
3. Compare the waveform with the waveform shown below.
5. Repeat steps 1 through 4 monitoring 22CN pin 2 (IV) and pin 3 (IW) with reference to
pin 6 (Gnd).
58
Exercise Two
• Answer the following questions using your knowledge and / or the documents from this
class.
1) What would be the DC Bus voltage for a 460V inverter with an input voltage of
480V AC? What is the formula used?
2) True or False: The motor can be run with the resistor installed in place of the fuse and
no damage will occur.
3) True or False: When checking the gate firing circuit, it is always a good idea to
remove the connector from the gate drive board to isolate the gate being checked.
4) True or False: The P5 inverter has a (-15VDC) power supply available at it’s
terminal strip.
5) True or False: The output current waveform check should be performed with a load
applied?
59
Exercise Two
class.
1) What would be the DC Bus voltage for a 460V inverter with an input voltage of
480V AC? What is the formula used?
679VDC VDC  VAC x 1.414
2) True or False: The motor can be run with the resistor installed in place of the fuse and
no damage will occur.
3) True or False: When checking the gate firing circuit, it is always a good idea to
remove the connector from the gate drive board to isolate the gate being checked.
4) True or False: The P5 inverter has a (-15VDC) power supply available at it’s
terminal strip.
5) True or False: The output current waveform check should be performed with a load
applied?
Section Three:
Fault Codes
REMOTE
SEQ REF


OC
FREF FOUT IOUT kWout
F/R MONTR ACCEL DECEL
VMTR V/F FGAIN FBIAS
FLA PID kWsav PRGM
DIGITAL OPERATOR JVOP-131U
DSPL ENTER
LOCAL
REMOTE
STOP
RUN RESET
G5 P5/P5
60
G5/P5/P5 Fault Codes
The P5/P5 and G5 inverter can store up to (4) faults.
The G5 inverter has a fault trace that saves the drive status at the time
of the fault, and a fault history indicating elapsed time of the stored
faults.
The fault codes can be grouped into (3) categories:
 Major Fault - Motor coasts to a stop, the fault is displayed on the

digital operator, and the fault relay is activated.
 Minor Fault - Operation continues and the fault flashes on the

digital operator. The fault relay does not activate.
 Parameter Setting Error - Inverter can’t run. The fault is

displayed on the digital operator, and the fault relay is not activated.
61
Major Fault - Motor coasts to a stop, the fault is displayed on the digital
operator, and the fault relay is activated.
G5 P5/P5
 Undervoltage of the main circuit when running.


Uu1 230V Units - trip point 190V DC or less.
460V Units - trip point 380V DC or less.
Possible Cause(s): Single phase condition on the input, low input voltage at L1, L2, and L3.
Corrective Action: Check the input three phase voltage, verify setting of L2-05 for G5 units.
 Undervoltage of the control circuit when running.

 Uu2 230V Units - 30kW ~ 75kW, monitors the (-15V)

power supply.
460V Units - 55kW ~ 160kW, monitors the (-15V)
power supply.
• This fault does not apply to smaller capacity inverters.
Possible Cause(s): External load connected pulling down the inverter power supplies.
Corrective Action: Repair or replace the power/gate drive board. 62
G5 P5/P5
 The pre-charge contactor opened when inverter
 Uu3
 running.
• This fault applies only to 230V units 18kW ~ 75kW and 460V units 22kW ~ 160kW.
Possible Cause(s): Contacts on contactor are dirty, contactor does not function
mechanically.
Corrective Action: Check the contactor, check the ribbon cable from the control board to
the power/gate drive board.
Overvoltage of the main circuit when running.

 ou 230V Units - trip point 400V DC or more.

460V Units - trip point 800V DC or more.
Possible Cause(s): High input voltage at L1, L2, and L3. The deceleration time is set to
low. Power factor correction capacitors are being used on the input to the inverter.
Corrective Action: Check the input circuit, verify the programming parameters, add a
braking resistor, remove power factor correction capacitors. 63
G5 P5/P5
 Designed to protect the inverter.
 oc
 Output current has exceeded 200% of the inverter
rated value instantaneously.
Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.
Corrective Action: Remove the motor and run the inverter without the motor. Check the
motor for a phase to phase short. Check the inverter for a phase to phase short at the output.
 Designed to protect the inverter.

 gf
 Inverter output grounding current has exceeded 50%
of the inverter rated current.
Possible Cause(s): Motor lead shorted to ground, DCCT defective.

motor for a phase to ground short. Check the output current with a clamp on meter to verify
DCCT reading.
64
G5 P5/P5
 sc The inverter output is short-circuited.


Possible Cause(s): Shorted inverter output phase to phase, shorted motor, locked rotor.
motor for a phase to phase short. Check the inverter for a phase to phase short at the output.

 PUf Detects if the DC bus fuse has opened.

Possible Cause(s): Shorted output transistor, shorted main circuit component.

Corrective Action: Remove power from the inverter and disconnect the motor. Perform the
checks without/with power starting on page 15. Replace the shorted component(s), then
replace the defective fuse.
65
G5 P5/P5
 Motor overload, designed to protect the motor.
 ol1
 Fully adjustable.
A pre-alarm can be selected as a minor fault by using
the multi-function outputs.
Possible Cause(s): Motor is overloaded.
Corrective Action: Verify the program settings, reduce the load on the motor.
 Inverter overload, designed to protect the inverter.
 ol2
 G5 - 150% of inverter rated current for 1 minute.
P5/P5 - 150% or 120% dependent upon inverter
capacity.
A pre-alarm can be selected as a minor fault by using
the multi-function outputs.
Corrective Action: Verify the program settings, reduce the load on the motor. 66
G5 P5/P5
 The transistor cooling fin temperature exceeded the
 oh2 allowable value. P5/P5 (100 ° C), G5 (110 ° C)

Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.
Corrective Action: Check for dirt build-up on the fans, reduce the ambient temperature
around the inverter.
 Transmission error. Control data was not received

 ce normally when the power supply is turned on.

Response is selectable.
Possible Cause(s): Connection not properly made, user software not configured to the
proper baud rate or configuration.
Corrective Action: Check all connections, verify all user side software configurations.
67
G5 P5/P5
 Inverter input power supply has an open phase.


sp1 Large imbalance in input voltage.
Possible Cause(s): Open phase on the input of the inverter. Loose terminal screws at
terminals L1, L2, or L3. Program parameters set incorrectly.
Corrective Action: Tighten the terminal screws, check the input voltage, verify the program
settings.

 spo Inverter output has an open-phase.

Possible Cause(s): Open phase on the output of the inverter. Loose terminal screws at
terminals T1, T2, or T3. Program parameters set incorrectly.
Corrective Action: Tighten the terminal screws, check the input voltage, verify the program
settings.
68
G5 P5/P5
 The braking transistor has failed.


rr 230V Units - 0.4kW ~ 7.5kW
460V Units - 0.4kW ~ 15kW
Possible Cause(s): Shorted braking transistor, high DC bus voltage, defective braking
resistor.
Corrective Action: Replace defective transistor or resistor, monitor DC bus level.

 The braking resistor temperature has exceeded the
 rh allowable value.

(Protects YEA 3% duty cycle resistors only)
Can be selected as a minor fault by using the multi-
function outputs for the G5 only.
Possible Cause(s): Overhauling load, extended braking duty cycle, defective braking
resistor.
Corrective Action: Verify braking duty cycle, monitor DC bus voltage, replace resistor. 69
G5 P5/P5

 ef3 External fault at terminal number 3.

Possible Cause(s): An external fault condition exists connected to terminal number 3.

Corrective Action: Check for an external condition, verify the programming parameters.
 External fault at the multi-function inputs terminal

 ef4 ~6 number 4 ~ 8.

Possible Cause(s): An external fault condition exists connected to one of the terminals 4,
5, 6, 7, or 8.
70
G5 P5/P5
N/A ef0 External fault from serial communication.
Possible Cause(s): An external fault condition exists.

External fault at the multi-function input terminal

N/A ef2 number S2.
Possible Cause(s): An external fault condition exists at terminal S2.

Corrective Action: Check for an external condition at terminal S2, verify the programming
parameters.
71
G5 P5/P5
 Transmission between the inverter and the operator


cpf0 cannot be established 5 seconds after supplying
power.
Possible Cause(s): Digital operator cable not securely connected, digital operator
defective, control board defective.
Corrective Action: Check the operator cable, replace the digital operator, replace the
control board.
 Communication fault between the inverter and the


cpf1 operator has occurred for more than 2 seconds.
Possible Cause(s): Digital operator cable not securely connected, digital operator
defective, control board defective.
Corrective Action: Check the digital operator cable, replace the digital operator, replace
the control board. 72
G5 P5/P5
 N/A Base block circuit fault at power up.


Possible Cause(s): Gate Array hardware failure during power up.

Corrective Action: Try a factory reset, cycle power, replace the control board.



cpf4 EEPROM fault, check sum not valid.
Possible Cause(s): Noise or spike on the control input terminals.

73
G5 P5/P5

 cpf5 CPU internal A/D converter fault.


 N/A CPU external A/D converter fault.




74
G5 P5/P5
 N/A
Option connection fault.


Possible Cause(s): An option card is not correctly connected to the control board, an
option board that is not made for the G5 inverter is attached to the control board
Corrective Action: Remove power to the inverter and connect the option card once more.
Try a factory reset, cycle power, replace the option board, replace the control board.
 N/A A/D converter fault on the (AI-14B) option card.



Possible Cause(s): Defective AI-14B option card, external input loading down option board.
Corrective Action: Remove all inputs to the option board. Try a factory reset, cycle power,
replace the option board, replace the control board.
75
G5 P5/P5
 N/A The motor speed has exceeded the overspeed level

 when operating in the Closed Loop V/f or Closed
Loop Flux Vector modes.
Possible Cause(s): The load has changed considerably, the program settings are not set
correctly.
Corrective Action: Check the load on the motor, verify the program settings (F1-08 PG
Overspeed Level, and F1-09 PG Overspeed Time).
 N/A The Pulse Generator feedback cable is broken.


Possible Cause(s): The Pulse Generator feedback wires may be broken or not properly
connected to the PG feedback option card.
Corrective Action: Check for a broken wire or a loose connection from the Pulse
Generator, verify the program settings.
76
G5/P5/P5 Fault Codes Minor
Fault - Operation continues and the digital operator indication blinks.
The fault relay does not activate.
G5 P5/P5
 The main circuit or control circuit voltage has fallen
 Uu
 below the under voltage trip point momentarily.
A minor fault contact output can be programmed by
using the multi-function outputs. (G5 only)
Possible Cause(s): Single phase condition on the input, low input voltage at L1, L2, and L3.
Corrective Action: Check the input three phase voltage, verify setting of L2-05 for G5 units.
 ou The DC bus voltage has exceeded the overvoltage


 trip point while the inverter output is off.
Possible Cause(s): High input voltage at L1, L2, and L3. Power factor correction
capacitors are being used on the input to the inverter.
Corrective Action: Check the input circuit, verify the programming parameters, add a
braking resistor, remove power factor correction capacitors.
77
G5 P5/P5
 The transistor cooling fin temperature exceeded the
N/A ?
 oh1 allowable value. P5/P5 (90 ° C), G5 (100 ° C)

Response is selectable.
Possible Cause(s): Cooling fan(s) are not working, high ambient temperature.
Corrective Action: Check for dirt build-up on the fans, reduce the ambient temperature
around the inverter.
 Inverter overheat pre-alarm signal is input from the

 oh3 multi-function input terminals.

Possible Cause(s): An external overheat condition exists connected to one of the multi-
function input terminals 3, 4, 5, 6, 7, or 8.
78
G5 P5/P5
 Over torque detection function.
 ol3
 A customer programmable current detection.
Response is selectable. A minor fault contact output
can be programmed by using the multi-function
outputs.
Corrective Action: Verify the program settings, reduce the load on the motor.
 Over torque detection function (2).

N/A

 A customer programmable current detection.
Response is selectable. A minor fault contact output
can be programmed by using the multi-function
outputs.
Corrective Action: Verify the program settings, reduce the load on the motor. 79
G5 P5/P5
 External baseblock command is input from the multi-
 bb function input terminals.

using the multi-function outputs.
Possible Cause(s): A base block command was accepted at the multi-function inputs
terminals 3, 4, 5, 6, 7, or 8.
 Both the forward and the reverse run commands are

 ef input simultaneously for 500 ms or more.

Possible Cause(s): An external forward and reverse commands are input simultaneously.
Corrective Action: Check for an external sequence logic.
80
G5 P5/P5
 N/A The deviation of the speed reference and speed

 feedback has exceeded the regulation level.
using the multi-function outputs.
Possible Cause(s): The load has changed considerably.

Corrective Action: Check the load on the motor, verify the program settings (F1-10 PG
Deviate Level, F1-11 PG Deviate Time. F1-04 PG Deviation Select.
81
Parameter Setting Error - Inverter can’t run. The fault is displayed
on the digital operator, and the fault relay is not activated.
G5 P5/P5

 ope 1 Inverter kVA setting error.

Possible Cause(s): The control board was replaced and the kVA parameter is set
incorrectly.
Corrective Action: Enter the correct kVA setting by referring to the inverter model number.

 ope 6 Constant data is out of range.
Possible Cause(s): Parameter set above the allowable range.

Corrective Action: Verify the program settings.
82
G5 P5/P5

 ope 3 Multi-function input selection fault.
Possible Cause(s): Duplicate functions are selected, up and down commands are not set
simultaneously.
Corrective Action: Verify program settings G5 (H1-01 ~ H1-06), P5 (n035 ~ n039).
 N/A Run command is selected through serial


 communication at 2CN but option card is not installed.
Possible Cause(s): Serial communication option card is not installed, option card is
installed incorrectly.
Corrective Action: Verify that an option card is installed. Remove power to the inverter and
connect the option card once more.
83
G5 P5/P5
 N/A Closed Loop Flux Vector mode has been selected

 without a PG card installed.
Possible Cause(s): PG option card not correctly installed or missing.

Corrective Action: Verify that an option card is installed. Remove power to the inverter and
connect the option card once more.
 V/F data setting fault.

 ope 5
Possible Cause(s): The V/f parameter settings are not set correctly.
Corrective Action: Check parameters (E1-04 ~ E1-10) for the G5 and parameters (n012 ~
n018) for the P5/P5. A minimum frequency/voltage value may be set higher than the maximum
frequency/voltage.
84
G5 P5/P5
 N/A
Carrier frequency data setting fault.

 Upper limit (C6-01) >5KHz, and the lower limit
(C6-02) <= 5KHz.
Carrier frequency proportional gain (C6-03) > 6 and
(C6-01) < (C6-02).
Possible Cause(s): Parameter setting incorrect.
Corrective Action: Check the program settings and correct the errors.
 SI-B transmission error. Control data was not

 call
 received normally when the power supply is turned
on.
Possible Cause(s): Connection not properly made, user software not configured to the
proper baud rate or configuration.
Corrective Action: Check all connections, verify all user side software configurations.
85
Exercise Three
class.
1) What are the specifications for an Over Current fault and what would cause this fault
to occur?
2) What are the specifications for an Over Voltage fault and what would cause this fault
to occur?
3) What are the specifications for an OL1 Fault, what does it protect, and what would
cause this fault to occur?
cause this fault to occur?
5) Which part of the inverter would you suspect was damaged if the unit experienced a
CPF fault?
6) What part of a P5 inverter would you expect to be damaged if the inverter displays a
27° fault?
Exercise Three
class.
1) What are the specifications for an Over Current fault and what would cause this fault
to occur? 200% of the Inverter rated current. Shorted motor, short
accel time........
2) What are the specifications for an Over Voltage fault and what would cause this fault
to occur? The DC bus voltage exceeded 400V DC for 200V models and
800V DC for 400V models. High input, short deceleration time.........
cause this fault to occur? Protects the motor.
cause this fault to occur? For the G5, 150% of the inverter rated current
for
1 minute. For the P5/P5, 120% or 150% for 1 minute. (dependent upon
capacity) Protects the inverter.
5) Which part of the inverter would you suspect was damaged if the unit experienced a
CPF fault? The control board.
6) What part of a P5 inverter would you expect to be damaged if the inverter displays a
27° fault? Nothing ! The drive is mounted upside down ! ol2
(OL2 Fault has Occurred)
Terminal Functions
B1 B2
L1 T1
Power G5
Supply L2 T2 IM
L3 T3
1 Forward Run Multi-function
0±10V 21 Analog Output
2 Reverse Run
Common 22 2mA maximum
3
0±10V 23 Multi-function
4 Analog Output
5 Multi-function 9
10 Multi-function Contact
6 Inputs Outputs
7 18 250Vac/30Vdc, 1A
19 Fault Contact
8
20 250Vac/30Vdc, 1A
11 Digital Common
25 * The braking circuit is
2K 15 (+15V, 20mA) factory installed in the
13 Main Ref.(0±10V) Multi-function following inverters;
26 Open Collector • 230V 1/2 - 10HP
2K
14 Main Ref.(4-20mA) Outputs • 460V 1/2 - 20HP

16 Aux. Ref.(0±10V) 27 48v, 50mA ** Input terminals 1-8 are
17 Analog Common level sensing type.
33 (-15V, 20mA) 87
Terminal functions of the P5
B1 B2
Braking resistor T1
L1
Power
Supply
L2
L3
P5
T2
T3
IM
S1 Forward Run 0-10V AM Multi-function
Output
S2 Common AC
S3
MA 2mA maximum
S4 Multi-function Multi-function output
Inputs MB
S5 250Vac/30Vdc 1A
S6 MC
SC Digital Common M1
Multi-function output
2K FS Analog Supply (15v) M2 250Vac/30Vdc 1A
2K FV Main Ref. (0-10V)
FI Aux Ref. (4-20mA)*
* Terminal FI is factory set as shown, but
FC Analog Common can be changed to a voltage input, with a
program change and by cutting jumper J1
on the control board.
88
 Omron IDM Controls Application
Engineering Department
 04/96
2/6/2019
89

G5 IDM Unit Troubleshooting Class

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G5 IDM Unit Troubleshooting Class

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Omron IDM Controls

Unit Troubleshooting Class

 Section One is called “Checks Without Power”; it explains

Analog Multimeter Digital Multimeter

• An ungrounded Oscilloscope with a 10X and 100X probe.

Inspection Stamp Production

Year Computer Generated Number

Large board-mounted components (input diodes, output IGBT’s, and power

Vendor SHIN-ETSU SHIN-ETSU TOSHIBA CASTALL

1. Mount components to heat sink

1. Mount components to heat sink 2. Install power board

1. Mount components to heat sink 2. Install power board 3. Solder components to

L1 Terminal Approximately Approximately

Main Circuit Diagram

Main Circuit Diagram

Braking Transistor Check

2 Connect to the Emitter Connect to B2 terminal

Emitter 4 Connect to the Emitter Connect to the Gate

5 Connect to B2 terminal Connect to the Gate

2PCB Power Board

24 v The fan connector plugs in to

2) True or False : A CIMR-G5U2015 inverter uses (2) 230V AC fans?

4) True or False : All P5 inverters have an internal braking transistor?

5) What is the DC bus voltage for a 460V inverter?

2) True or False : A CIMR-G5U2015 inverter uses (2) 230V AC fans?

4) True or False : All P5 inverters have an internal braking transistor?

5) What is the DC bus voltage for a 460V inverter? 650V DC

Main Circuit Diagram

If any of these conditions occur, Turn off the power immediately!

Main Circuit Diagram

F/R MONTR ACCEL DECEL

VMTR V/F FGAIN FBIAS

FLA PID kWsav PRGM

DIGITAL OPERATOR JVOP-131U

 Major Fault - Motor coasts to a stop, the fault is displayed on the

 Minor Fault - Operation continues and the fault flashes on the

 Parameter Setting Error - Inverter can’t run. The fault is

 Undervoltage of the control circuit when running.

 Designed to protect the inverter.

Possible Cause(s): Motor lead shorted to ground, DCCT defective.

Possible Cause(s): Shorted output transistor, shorted main circuit component.

 Transmission error. Control data was not received

Corrective Action: Replace defective transistor or resistor, monitor DC bus level.

Possible Cause(s): An external fault condition exists connected to terminal number 3.

 External fault at the multi-function inputs terminal

Possible Cause(s): An external fault condition exists.

External fault at the multi-function input terminal

Possible Cause(s): An external fault condition exists at terminal S2.

Possible Cause(s): Gate Array hardware failure during power up.

Possible Cause(s): Noise or spike on the control input terminals.

Possible Cause(s): Noise or spike on the control input terminals.

 N/A CPU external A/D converter fault.

Possible Cause(s): Noise or spike on the control input terminals.

 N/A A/D converter fault on the (AI-14B) option card.

 N/A The Pulse Generator feedback cable is broken.

 ou The DC bus voltage has exceeded the overvoltage

 Inverter overheat pre-alarm signal is input from the

 Over torque detection function (2).

 Both the forward and the reverse run commands are

Possible Cause(s): The load has changed considerably.

Possible Cause(s): Parameter set above the allowable range.

Corrective Action: Verify program settings G5 (H1-01 ~ H1-06), P5 (n035 ~ n039).

 N/A Run command is selected through serial

Possible Cause(s): PG option card not correctly installed or missing.