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Altivar 38 - inverter - plc

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9. Jor 2 99 99019 801 YOLOANNOO 530 18 WOLO3NNOO 3dAL 900 7 Pri e MOTI3A 8504 3LIHM A349 389 038 9315 4315 711 Md 2411 MOOINA 111 MAIA LNOWS YOLOANNOD 2191439991 I3NI8VO Schneider TOSHIBA Electric 5 Replacement parts list MAINTENANCE MANUAL Description For ATV38 drives Qty per Reference number Content ATV38 ATV58 38 diagnostic kit ratings 1 VZ3N5820 2 floppy disks software version V2 1 IE12 1 board 1 ribbon cable Control board ratings 1 VX4A381 Control board option support light ducting 2 sub D pins connector shield for option card I F interface board Size 8 to 10 1 VX4A382 1 I F interface board Plug in control connectors ratings 1 VZ3N5812 Control board connectors connectors for I O Tacho PG AS i Interbus S power supply Option card connector shield ratings 1 VZ3N589 Sets of 10 connector shields for option card RS432 485 converter ratings 1 VZ3N586 1 RS432 485 converter Power sub assembly HU18N4 1 VX5A58HU18N4 Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HU29N4 1
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18. RS Section 8 14 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Analysis of Auto test N 2 results What do you do if a component is indicated as faulty fault noted ________ noted 4 244 noted SEE noted 244 noted noted Section 8 15 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 6 Auto test LIC Objective of the LIC auto test Check the current feedbacks and the LIC level The LIC is a current peak limit which avoids short circuit locking in the event of strong torque surges A succession of LICs can cause the drive to lock Wiring Connect phases L1 L2 and L3 to the AC supply Connect phases U V and W to the motor Do not connect anything to the control board terminals Operating mode Switch on the product Launch the diag58 38 program if you have not already done so Check the Auto test LIC button Press Enter or click on Run Analyse the results window Analysis of the LIC auto test result LIC U and LIC W should have the same order of magnitude and the same sign LIC U and LICW should have the same order of magnitude and the same sign LIC U and LIC U should have the same order of magnitude but opposite signs LIC W and LIC W should have the same order of magnitude but opposite signs These values should be compared with
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23. 8mm spanner screwdriver bit preferable ATV38 Size 6 and 7 screw driving machine 500 revs 1 5 to 3 9 Nm or torque wrench 0 5 to 10 Nm hexagon drive socket 8 across flat hexagon drive socket 10 across flat extension 150 mm and 80 mm hexagon drive socket 12 across flat hexagon drive socket 13 across flat 50 mm deep size 20 torx key ref FACOM 80TX 20 or size 20 torx shank bit 150 mm extension for screw driving machine hexagon shank bit 3 across flat hexagon shank bit 4 across flat hexagon shank bit 5 across flat 800 mm extension For ATV38 Sizes 6 and 7 use of an electric screwdriver makes it significantly quicker to assemble dismantle the drive ATV38 Size 8 and 10 crosshead screwdriver 3 types including one 250 mm long for size 9 flat screwdriver 13mm spanner 17 mm socket wrench 17 mm spanner flat pliers Section 4 1 25 efesotomasyon com Schneider TOSHIBA 4 2 4 2 1 4 2 2 4 3 Electric MAINTENANCE MANUAL Dialogue and diagnostics tool Dialogue tool First level diagnostics are obtained via the programming terminal or the setup software These tools are used primarily to Check the states Read the error log while displaying the operating phase during which the fault appeared Save and transfer drive configurations Diagnostic equipment for all ATV38 drives A diagnostic kit is available a
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25. Grasp the control board and turn it gently to the right making the same movement as if you were opening the driver cover Under the right hand section 4 cables are connected linked to the power board Remove these 4 connectors J5 J13 14 J15 c Change the power board The power board replacement kit also includes the heatsink on which the power board is mounted These cannot be separated After removing the plastic parts and the control board 19 see above Remove the side metal frames Right hand section 16 screws V23 V24 V25 V26 Left hand section 5 screws V7 V8 V9 V27 Remove the metal grille from the top of the drive by removing the 2 remaining screws V28 and V29 Disconnect internal cables J5 J13 J14 J15 and J18 Keep them for reassembling the product d Dismantling the cooling fan Disconnect the fan power supply cable via the heatsink Undo assembly screws V21 amp V22 while holding the protective grille 13 at the same time as the fan Section 9 4 297 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL REASSEMBLING ATV 38HU18N4 HU29N4 and HU41N4 Size 2 DRIVES a Reassembling the cooling fan Connect the fan power supply cable via the heatsink Position the fan with the label facing inwards put in place the fan prote
26. Note the last 8 faults in the error log in order to make an initial analysis Wiring ATV38 en panne Connecteur J18 il 230V AC arte contr le nappe du kit 2 Preliminary test of the input bridge Check that there is no short circuit on the input bridge thyristors and diodes This test is performed using a digital multimeter in diode test mode The values shown below are those which the multimeter should provide when used in this mode 22 _ Section 8 10 33 efesotomasyon com Schneider Electric MAINTENANCE MANUAL 3 Auto test 1 Objective of auto test n 1 Check the internal product wiring Check the control board Check the inverter bridge transistors diodes Calibrate the current offsets Wiring Connect phases L1 L2 and L3 to the AC supply Do connect phases U V W to the motor Connect the diagnostics card to the control board terminals Operating mode Switch on the product Launch the diag58 38 program if you have not already done so Check the Auto test n 1 button Press Enter or click on Run Analyse the results window Example of screen TOSHIBA EXDIAG 58 38 2 1 1202 ow Section 8 11 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Anal
27. d Reassembling the plastic parts Refit the front cover and place it at 90 Refitthe IP41 top protective cover clipped into place if it has been removed e Finalizing reassembly Reinstall the option card if it was present Reconnect the operator terminal Reconnect the plug in terminals control Section 9 21 297 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Interconnection diagram SIZE 3 Section 9 22 297 efesotomasyon com 11891 1 3 12 SH3INHOS
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30. If the difference between the measured speed and the stator frequency reference is higher than 10 Hz the drive locks in SPF fault mode Experience to date only with the option card No speed feedback gt check the connection electrical and mechanical of the speed sensor n open loop mode AI3 should not be assigned to Tacho Feedback Section 8 29 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL AnF Load Veer Fit Principle This fault is triggered e when an increase in speed is noticed that does not follow the ramp applied for at least 0 5 seconds e when the load drives the motor rotation in the opposite direction from the desired direction for at least 0 5 seconds Note The AnF fault can only be generated when an option card is connected to the drive and analog input AI3 is assigned to the Tacho feedback or PG feedback function Experience to date Check the speed feedback settings and wiring Speed feedback reversed change the feedback polarity Check the parameter settings of the speed feedback Tacho or PG Check the suitability of the settings for the load SOF overspeed Principle The output frequency is higher than 1 2 times the maximum frequency tFr that has been set Experience to date nstability gt check the adjustment parameters and the drive configuration Section 8 30 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENA
31. LSTA 2190 315500 NOI 18380 9 09955098 3 A 085 HON38 SHOLON 8 06 37 T3 NUH ep ap 812150 HINOQ H 5705 ssr e8J 00 172 4 SjTOJp no uolj2npoJday 3001489343731 2431 9049 21 2 2 Uasow Jed a juP IPB MOF 2242 juaunoo f Me 67015 01703 031 03 any nma 1821084 5 015 190331919 ALY NOLLO3NNOO 99A1V L3NI8VO LANIGVO HOOQ QN3931 9NILVH3dO QN3931 9NILVH3dO 5 1081409 39431035 1081409 JONANDAS 1084409 39491035 1081409 43MOd 39vd NOILVWINLIdVOSY AVATATA X3QNI NOILNTOAS NOILVN9IS3G EJ NOIL TOA3 NOILYNSISSG 06 97 OZBE T3 ONUH ouueb ep ap 2121601 70 1 027 5705 step jueunoog Jed arjuPJeb Jor 2 99
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34. 207500 9015 AON39u3IN3 T38V1ININ 09 607500 Pau We JHaIH LHVI ISN 20 200 1991409 9NIN3dO 62 00 1HOddhS 3S c0 00 401 AONSDHANA NOLING HSNd 507600 We 35 50 500 73991 GSSIDYANA 0 1909 15 35 0700 GN A 87 16 J9QI4 LUYO 35 20 200 HOLVOIGNI 20700 0 1HOddhS 3S 207600 H3IALL 0351983 217500 2082 We 3S 7 00 HOLOV LNOD AYVITIX 217500 018 LYOddNs 3S 20 200 I3SIOH3N3 807500 al 1 44 5 ISNA 1 c0 t00 80 500 72031409 HOIH3L 11 208 HAIL 0351093 50600 NH 01 15 1 15 191409 1 117600 30199109 AHVITIX 508 u Qr 3 HOLOW 117500 l1HVd WNOILIGGY YAN 707500 0557 3i1Vid TilHd 50 00 3011991409 500 X 027 ZH 09 0b2 109 50 200 00 YOLOVLNOOD AHVIIX 207500 f EG 1r 031 FINGOW NOILOSLOYd 6507 00 00 32018 LOVINOD 1VNOLLIGQV 217200 022 307021 LOVINOD 507600 00 0 4 E 0 0 0 0 0 0 0 0 0 w Go Go ca e e e gt
35. 8GSALV cOW TITOVT6E67TSM 6411 IILNHA 8SALV 1110920 6718 21 AdINOA 8EALY cOW 112089926718 6 T T d ATOULNOD SOTA SEALY VI 00 E9 6v18M ZIJT d 81 008 F E ZL TINJA 0 111082526718 ezeday wn zuesoduon 52 115 21432 501 gt 6 26111 6 G4 Pad Cale d CL IL 8SALY vov 611090 lt 667 78 94 EL ZL TL SP 8SALV COW 11105252 6718 141 CL IL 810 8SALY vov CLIOVCSE6UVISM VI d Od Ed 006 272 25 pear SIV 7 070848608 81 cL SSINd INYIOSI 8SALY LOW LIIOLII86SITVM STJIT d CL 8SALV S0V II1008St6YvIY CL 8SALY 60V cIIOOISCt6TIY LIT d CA CL H0dSSIGIOH4dd4H 8SALY cow TTTOSTC86STEM CL 4 5 GOW AHINI 8SALY COW TTCOL8SE67TEM CL 0641 ATIIYS 8SALV S0V TTTO99SE6TTIM 91 CL 8SALV vov 111059526711 6 6 SIA 90V 119098058201 OCAIT d ONZ CIXSNWN QAYA SLOELTCTA CCA d NO SEXFN SX IHO AAVA LLOELTEIA LEA 9 A GEA PEA DEAN 6ZA BCA LEN ICA GZA TEN 9TA VIA ETA 6A
36. Jed arjueJeG juauanbrun MOF e ua 99 9 jueunoo CH 190405 d 01703 031 03 m 1821088 1105502 INHNH 33843 YAS A 926 088 HON38 SHOLOW E SO ZI 4855048 4 15185 S OJ u0 5 50 21 9 Estes I 3931035 1OMINO2 25750721 M3INP3U 9 114811 NOIIBSI IBNSIS 418 ZO EDO lt q A 207 00 C93 20 00 EZ _ T CS 929 ce NNH El 45 g NO HOLIMS 104109 INNHS JH 7 2 X 22 378 69 TH X 15 dois FIOSNOI NO HOLIMS a 7 2212 dH 4045 105 N 4015 3 43MOd p0 E00 ES 05 N 4015 3 WYOHLYId 95 60 608 9 O00 AlddNS NHO3 V 1d HOS NO HOLIMS NOLLVGMVA NOILVQI IVA NOILWHAdO 39IOHO YAMOd HOLVIHVA 1 3SVHd319NIS Jed arjueJe6 MOF e 1 61 ua 2833 jueunao EB 06 94 13 auuee er anbrjeusuos 2121601 0
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38. T38V1 82 200 02 32018 191409 717700 807700 231107 HOLIMS HOLVInWWOO 90 1 0 13877 217500 BZ 32018 LOVLNOD 117700 YHOLVLAWWOD 21508 43 HOLIMS HO1VIQININOO 117 00 0 13877 307500 0 392018 LOVLNOO 607700 HOLVIDWNOO 38 528 E HOLIMS HOIVInINWOO 60700 0 ONIDDNEAG 138V1 207500 30018 LOVINOD 1VNOLLIQQV 207700 YOLYINNWOO 207500 431060 HOLIMS HOLVINWWOD 07 00 401 INHOJIVTd T38V1 71700 32018 LOVLNOD V0 00 1700 23106022 HOLIMS HO1VIQINWOO 70700 0 8S VS INNHS 138 1 117700 62 338 80700 YOLVLNWWOD 117700 2 338 vNINH3LHV 40 7700 HL 3IONIS T38V1 607700 20622 434 ONINVH TVNINH3I HV 617500 Qv3H HOLVLAWWOD 607700 uueT 3d EDO AQO8 HOLVLAWWOD 507700 89S2SH 086 3 469 HOLOANNOO Zid 200 4015 138V1 607700 89625 91 TANN NLLHVIN 00 NOLLNE HSNd 6808 0501221 YAWHOSSNYHL ALISN3LNI EBO 08 022 138V1 07 00 1997 HOLON 200 HOLVIQWINOO 07700 2221 V 07 0 Y3LINNY 200 AQO8 HOLVInWWOO 707700 01001 0001010 YAGIAIG 7200 401 TOHINOO 138V1 0 7 00 T38V1 9NDIVH8 00 NOLING HSNd 0700 96 952210018018 H313ALTOA 217500 ONISWO 4015 AON39H3W3 NOLLAG HSNd 707700 022 H3 HOJSNVHI3SVHd31ONIS
39. Yes bythesame byan other witch one Did you change a part in the drive Yes Witch one After changing did you solve the problem Yes No Thanks to return this document to GHD or attach it with your Vantive case T l 331 41 39 39 00 mailto Cl GHD Rueil Gare mail schneider fr efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 2 Required skills Training 2 1 2 2 2 2 1 2 2 2 2 2 3 2 2 4 Required skills An Altivar should be repaired by technicians with the following experience Knowledge of the operation of rotating machines driven by electronic variable speed drives Principle of power switching and electronic control n depth knowledge of the following tools PCs oscilloscopes multimeters etc For the protection of equipment and personnel the qualified maintenance technician should implement the procedure detailed in this manual Read interpret and follow the instructions and precautions described in this manual as well as in other reference material Use the necessary tools in a professional manner Training ATV38 training is included in the ATV58 training courses Customer training S F Schneider Training Institute organizes training courses on variable speed drives for people to become familiar with these products and learn how to install them For further information please contact the 1 5 Tel 33 0 1 41 3
40. gt size 2 to 7 change the power board Long motor cable or motor in parallel gt add a motor choke Section 8 25 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL CRF Charging relay fault Principle This fault is triggered when an operating anomaly has been detected in the charging relay ie when The charging relay is not triggered in the 2 seconds following power up or product reset Closing of the charging relay is detected while the motor is supplied with power Experience to date Control fault on the charging relay gt check the drive internal connections Charging resistor or charging relay damaged change the power board Charging resistor temperature too high size 8 to 10 DC bus ripple of 4 V on closing of the charging relay gt measured on J18 SLF 5485 serial link fault terminal port Principle This fault is detected when the connection on the serial link is detected as non operational while the drive is being controlled by it expiry of a 2 second time out Experience to date Link fault when the drive is controlled by a terminal a PC a PLC via the RS485 serial link gt check the RS485 link and its wiring ncorrect configuration of the device connected to the drive gt configure the device correctly Faulty control board component gt change the control board Disconnection of terminal parameter LCC has been configured as y
41. 4949 2 SI peo au JO JO 8218 128099 00 JUBUND pejqeue sosneo 91415304 0 ouenbeJ penuguoo 141 LON SJOA YOLOW JHL IVANVW 213529 3 V8iIHSO L Joprou a Ka 25 Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 Help with troubleshooting 8 1 Preamble On receipt of the product carefully note down the following information The option card reference and its software version To do this open the drive cover The reference number is recorded on a small label attached to the card and the software version is recorded on a label attached to the uP located on top of the card The product software version To do this remove the operator terminal The product software version is recorded on a label attached to the control board support The operator terminal software version The software version appears on a label attached to the back of the terminal The position of the 50 60 Hz switch located below the display LEDs Then reassemble the various elements option card and operator terminal If the faulty product is accompanied by a sheet describing the fault observed by the customer use this information to locate the faulty component If not follow the inst
42. Drive incorrectly supplied or fuses blown gt check the power connection and the fuses Size 6 and 7 ASIC SSC gt change the power board Size 6 and 7 resistor on single phase fault operation gt change the power board USF Line undervoltage Principle The fault is triggered when the voltage measured at the filter capacitor terminals is less than maiins lt 430 gt 430 V U41N4 260V DC 360V DC U18N4 U29N4 054 4 U72N4 330 V DC 360V DC U90N4 D12N4 D16N4 D23N4 D25N4 280V DC 360V DC D28N4 D33N4 D46N4 D54N4 D64N4 D79N4 C13N4X 15 360V DC 360V DC C19N4X C23N4X C25N4X C28N4X C3 1N4X C33N4X The USF fault is automatically reset once the fault has disappeared or when another fault appears It is reset once the voltage measured at the filter capacitor terminals is higher than 460 V DC for 380 460 V drives Experience to date Line voltage too low gt check the line voltage Transient voltage dip sizes 8 to 10 gt check the fuses the transformer and the power supply board Section 8 21 33 efesotomasyon com TOSHIBA Schneider TOSHIBA Electric MAINTENANCE MANUAL OSF Line supply overvoltage Principle This fault is triggered when the voltage measured at the filter capacitor terminals is higher than When the drive is switched on 800 V DC for 380 460V drives 760 V DC for sizes 8 to 10 Afte
43. This sheet is associated with case VANTIVE Customer name Was this drive already repaired for preventive maintenance Yes or a commercial gesture Yes No PRODUCT CHARACTERISTICS Reference Soft version Quantity Serial number Install date Other options CUSTOMER APPLICATION Fan Pump Hoisting Other machine Winder Convoyor Packing MOTOR CHARACTERISTICS Asynchronous motor Slip rings motor Other motor Parallel motors Nominal Power kW Motor voltage en V How many Nominal speed tr mn Motor current A Shielded cable Dephasing Cos Phi Frequency Hz Cable length Motor Coupling Encoder type SUPPLY Measured voltage Frequency min max e Neutral regime m N FAILURE DESCRIPTION When does the failure appear 2 At the first On anew machine After a machine retrofit During adjusment During working Permanent fault Intermitent fault Frequency Ambiant temperature C drive working time per day IMPORTANT Precise in what environment is the drive who did observe the failure the state and the eventual modifications of the installation when did the failure happen in the sequence Acc Dec speed load etc the nature of the eventual bad conformity Joint the setting file Powersuite PC software the list of the past fault in memory diagram and photos if necessary FIXING OF THE FAILURE Did you change the drive
44. lt 61 6 GGA gt GND 18 5 lt 2428 ICH 28428 61 ale YNALVIILNIA LIX lt eH WSSA 85 7 gt ong x fel tio 1 JONVSSINd 101 N 83r 91 I Tea M031031N02 st si lt 915 ei 915 el SE S831 6 6 58 1 OMOIN gen 88 Ls 8 8 10 tet 42 58 lt ouo 7 L lt 9 9 25 E 2 lge ano 1s S v T 1 is z19 19 18 35 lt m and pari HERE lt S19 612 _ 914053848 2 210538 7 ui Hc 4 4 amp on AM Iu on Eun QN 2 1 L 9r o SS eve T 5 As 5 E sersu mu 155254 _ 3 H EE Javaa aN zi 8 oy 7 E ON vado gs 4 swij 0 52 4 35 si sw 2 ITT sma 5701 u f jig IAZ 4 A A 5 39vanoo3a lt d 8 y wv das 4 p WSSA 8 5 OVW 318VO 8 4 aan 3 5 55 WSSAQ VSSA 5 von cuo ma 2 zji 8 B 1038 Ix sir Fir M E 8 39931 i g sna 8 ig 8 8 _ 99 vo 2 G Y _ xl gt 90 40 zo n
45. 11 9E8TOONVAT 96 67 6 112026926716 111081926716 TTTOLLSE67TEM 0 48606 II0SLCVC9Tl8M 111060286518 1110716 6718 III09E LC6VI8M L11c0899 6v 18M VI 00 E9 6v 18M 1080 lt 6671 18 91132913 Schneider TOSHIBA Electric MAINTENANCE MANUAL ATV38 SIZE 3 Section 9 19 297 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL DISMANTLING ATV38HU54NA4 HU72N4 and HU90N4 Size 3 VARIABLE SPEED DRIVES Open the protective front cover of the drive to 90 Remove the plug in connectors Remove the option card if there is one a Remove the plastic protective parts Remove the protective front cover 26 when it is open at 90 Use a screwdriver and take care not to break this plastic part Undo screws V38 V39 V40 V41 while keeping the plastic belt 22 around the drive b Change the control board Remove the plastic belt 22 by pulling to release it from the drive You can take out the control board without removing the plastic parts Undo the 4 screws V34 V35 V36 V37 fixing the control board on the metal support 20 Disconnect the cable at the top of the drive J18 passing between the control board and the metal support Grasp the assembly and turn it gently to the right making the same movemen
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47. BA d NO OTXPW SX IHO CAVA FLOELTZIA exedex wal 3uesoduoj 5 2 105 6 930N ep LOW eorpur L H 00S Z Z SSV uorgeu rseq V SI 1792671 TISTLPIESHIEM eouersgeH VNNVIN 32NVN3LNIVIN 21432913 V8iIHSO L Joprouq s SI el 07 6c 0 71 LE 8c vc 61 V8IHSO L Or Ar A Ay A WN 26 81 6 7 1 2 21 6 A008 MMZ Z 4 IIMS COW OSXOSTH 09X09 INHA ATTIS NOILD3 L ZL A09P 6 d8GALV 8SALV LIOT THAVTI 8SALY ILH 8EALY O XSpy HR AIA OILG XEC GEX09 ADA AIA OILa WHLITISVOVHL ILU dX4 SNOO Od 1410 WYL 5 NU CL IILNYA ddd 4 S1 0 06 1 dI OH 8SALV Od 8SALY VN 8SALV OO 8EALY ATOULNOO 2074 BEALY TINA LOW TOW 007 COW TOW 80V TOW COW vov COW 0 2 1 5 TWANVIN 39NVN3 LNIVIN CS86c00SVMI 0 00
48. Block diagram of the power circuits 8 3 Connecting the DC bus 8 4 Diagnostics 8 5 Faults that may be displayed 8 6 Troubleshooting based on the fault displayed 9 Changing the faulty component drawings parts lists 9 0 Safety instructions and precautions 9 ATV38 Size2 9 2 ATV38 Size3 9 3 ATV38 Size4 9 4 ATV38 Size 5 9 5 ATV38 Size 6 9 6 ATV38 Size 7 9 7 ATV38 Size 8 9 8 ATV38 Size 9 9 9 ATV38 Size 10 10 Procedure for validation after repair 10 1 ATV38 sizes 2 to 10 10 2 Quality reporting to the VSD division Section 2 2 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 1 General 1 1 Objective This document defines the policy and methods to be put in place in each country based organization for repairing the Altivar 38 locally Repairs are carried out using replacement parts supplied by SCHNEIDER This comes solely within the framework of the service agreement Once this agreement has been signed a country will have a local representative responsible for this offer 1 2 Products concerned Product coding Eg ATV38HD28NA X Type ATV38 H heatsink N4 380 460 V X without EMC Reference ATV38HU18N4 ATV38HU29N4 ATV38HU41N4 ATV38HU54N4 ATV38HU72N4 ATV38HU90N4 ATV38HD12N4 ATV38HD16N4 ATV38HD25NA X ATV38HD28N4 X ATV38HD33N4 X ATV38HD46N4 X ATV38HD54N4 X ATV38HD64N4 X ATV38HD79N4 X ATV38HC10N4X Section 1 1 3 efesotom
49. Complete IPM bridge 150A 1200 V HD54N4 HD54NAX HD64N4 HD64N4X 3 VZ31M2200M1258 IPM bridge arm 200A 1200 V HD79N4 HD79NAX IGBT braking transistor HD28N4 HD28N4X 1 VZ3IM1050M1258 IGBT 50A 1200 V HD33N4 HD33N4X HD46N4 HD46N4X HD54N4 HD54NAX 1 VZ3IM1100M1258 IGBT 100A 1200 V HD64N4 HD64NAX 1 VZ3IM1150M1258 IGBT 150A 1200 V HD79N4 HD79NAX Mixed thyristor diode module HD25N4 HD25N4X 3 VZ3TD1055M1658 Bridge arm 55A 1600 V HD28N4 HD28N4X HD33N4 HD33N4X HD46N4 HD46N4X 3 VZ3TD1090M1658 Bridge arm 90A 1600 V HD54N4 HD54NAX HD64N4 HD64N4X 3 VZ3TD1130M1658 Bridge arm 130A 1600 V HD79N4 HD79NAX Section 5 1 4 efesotomasyon com Schneider Electric MAINTENANCE MANUAL TOSHIBA Description For ATV38 drives Qty per Reference number Content ATV38 Transistor Size 8 3 VZ31381 1 transistor MG400Q2YS60A Size 9 3 VZ31382 2 transistors MG400Q2YS60A board VFA7D 4596A 2 metal supports 16 screws HC23N4X HC25NAX 3 VZ31383 4 transistors MG400Q2YS60A 2 boards VFA7D 4596A 4 metal supports 2 cables 32 screws 28 HC31N4X 3 VZ31384 5 transistors MG400Q2YS60A 1 board VFA7D HC33N4X 4596 1 board VFA7D 4597A 4 metal supports 2 cables 39 screws Diode bridge Size 8 and 9 3 VZ3D381 1 diode bridge DD240KB160 Size 10 6 VZ3D381 1 diode bridge DD240KB160 Gate drive
50. HC23N4X HC25N4X 3 VY1A38114 1 current transformer HC MSN590V4B15G 590AT 4V HC28N4X HC31N4X 3 VY1A38115 1 current transformer HC MSN760V4B15G 760AT HC33N4X 4V filter board HD25N4 HD28N4 1 VX4A58101 1 board HD33N4 HD46N4 1 VX4A58102 1 board HD33N4 HD46N4 1 VX4A58112 1 board HD54N4 1 VX4A58103 1 board HD54N4 1 VX4A58113 1 board HD64N4 HD79N4 1 VX4A58104 1 board HD64N4 HD79N4 1 VX4A58114 1 board Filter Size 8 to 10 1 VZ3D382 1 filter VCR1005 Non EMC filter board HD25N4X HD28N4X 1 VX4A58156 1 board HD33N4X HD46N4X HD54NAX HD64N4X 1 VX4A58157 1 board HD79N4X IPM connection interface board HD25N4 HD25N4X 1 VX4A58901 1 board pin HD28N4 HD28N4X HD33N4 HD33N4X HD54N4 HD54NAX HD46N4 HD46N4X 1 VX4A58902 1 board pin HD64N4 HD64N4X 1 VX4A58903 1 board pin Section 5 2 4 efesotomasyon com Schneider Electric MAINTENANCE MANUAL TOSHIBA HD79N4 HD79NAX Description For ATV38 drives Qty per Reference number Content ATV38 Thermal sensor board Size 6 and 7 1 VZ3G586 1 board Thermal sensor Size 8 to 10 1 VZ3G381 1 thermal sensor EF6F203A2 02014 Power supply board Size 8 to 10 1 VY1A38120 1 power supply board VFA7D 1877C Power supply board Size 4 and 5 1 VX5A58V01 1 board Internal fan Capacitor kit HD12N4 1 VY1ADC5801 2 capacitors 1500F 450V HD23N4 2 top and bottom liners HD1
51. HD64NAX HD79N4 HD79NAX Internal Size 6 1 VZ3V584 1 fan 40 connection screw kit fan kit Size 7 1 VZ3V585 1 fan 60 connection screw kit Size 8 and 9 1 VZ3V3818 1 fan Size 10 1 VZ3V3820 Kit of 2 fans Additional internal fan HC19N4X 1 VZ3V3819 1 fan Heatsink fan Size 8 1 VZ3V3808 Kit of 2 fans Size 9 1 VZ3V3809 Kit of 3 fans Size 10 1 VZ3V3810 Kit of 6 fans Internal connection kit Size 2 1 VZ3N582 Cable kit for Size 2 Size 3 1 VZ3N583 Cable kit for Size 3 Size 4 and 5 1 VZ3N584 Cable kit for Size 4 and 5 Size 6 1 VZ3N587 Cable kit for Size 6 Internal connection kit Size 7 1 VZ3N588 Cable kit for Size 7 Size 8 1 VZ3N3808 Cable kit for Size 8 Size 9 1 VZ3N3809 Cable kit for Size 9 Size 10 1 VZ3N3810 Cable kit for Size 10 Section 5 3 4 efesotomasyon com Schneider Electric MAINTENANCE MANUAL TOSHIBA Description For ATV38 drives Qty per Reference number Content ATV38 Screw kit Size 2 to 5 1 581 Set of screws and pins for the product Size 6 1 VYIADVS582 Set of screws and pins for the product Size 7 1 VYIADV583 Set of screws and pins for the product Size 8 1 384 Screw kit for 90 KW HC13N4X 1 VY 1ADV385 Screw kit for 110 KW 15 4 1 VY1ADV386 Screw kit for 132 KW HCI9NAX 1 VYIADV387 Screw kit for 160 KW HC23N4X HC25N4X 1 VYIADV388 Screw kit
52. L 28 ou i2efoud 55 5 28 39v18V2 30 3n0lLdONAS ON lt C M 55 5g 5 0 I Jim H ge suoisueuuip U0ND409 4 199330 H a uon2ejod eopjns lt vSS e Ice WSSAO 55 WSSA 8 Bu en vosne adsit MEREEN A T 34 upang queunpen jeu _ lt isya o oc 1558 Litt 54 43350 6 62 43350 3061 4 2 28 30049515995 Jo puopubis 299 sb Lair DEEE BE as z 31940412945 euuou Jupning gt Ha 2 Hone is lt 6 gt zk 52 oweur ddo epp nas 6 1 ue 19106 lt aber 3109 ud uonoonyipow 1440 eoN eig 4 gt mn 3 2 2 2 1 Ze S gz gt 633412 333 Tg ou v v RE 116 gt 89H8 12 done E sapwood Jequinu quod gt 02 oo WOSd33 dc o 61 2 1 1 ejna ejoquis MHdl 81 1 3 L gt 98388 Z1 i oxda a vSS
53. Non repairable drive 4 After sales category 4 repairable drive These are identified in the product file by a code with the suffix TA The stated price corresponds to the repair cost if the product is returned to the factory net price 1 5 Assistance 1 5 1 Work carried out on site The customer will be provided with on site assistance by technicians and engineers from the SCHNEIDER service teams in the customer s country 1 5 2 Technical support The first level of technical support is provided by the level 1 and 2 forums that the customer can access The third level of technical support is provided by the Schneider Vantive intranet vantive self service HTTP 139 160 73 11 Services IServices4 nsf or in emergencies call the Global Help Desk direct line Tel 33 0 1 41 39 39 00 Fax 33 0 2 32 78 11 64 1 5 3 Customer returns Faulty equipment complete products or sub assemblies may be returned according to the terms of the SCHNEIDER warranty policy When returning products complete and attach the form below This form will shortly be available on the Intranet 1 5 4 Updating the installed base If there is a major fault or new functions have been added it may be necessary to update the products In this case advice will be sent to all the SCHNEIDER networks Section 1 3 3 efesotomasyon com neider d Electric Product Failure Description Made the Agency Official distributor
54. T FLOELTZIA exedex wal 3uesoduoj 105 6 930N ep LOW eorpur L H 009 9 9 SSY 8 uorgeu rseq 6GS9 6YvI IIGI6S9 6 18M OTOTIAY eouersegeH 21432913 5 1 gt 6 LT 6 SI VI TE cE Ge 05 6c ca 9c ET I 94 54 24 ON c Y Qu Or Qu C Qu A A A ezedey WA VWalHsSoL L6Z VE 6 vP IXL CIX6 vVW 0SX0 A00S MMG G d IIMS COW 09X09 IN A NOILIOHIOHd 8SALV ZL dd OILS 8 ALV EL 6 DEXSP HR AIA OILG XEC GEX09 ADA AIA OILa WHLITISVOVHL ILU 1486 17 86 LIOTdXH SNOO Od TALO WYL 5 NU IILNHA ddd EL a dIn0d S1 0 06 v t CIL dI OH 8SALV Od 8SALY VN 8SALW OO 8EALY J IOHLNOO 2074 BEALY TINA L ddd VN 8SALV LOW TOW COW COW TOW 80V TOW COW GOW COW
55. The card is recognized as another Communication card In the Communication menu several parameters appear but only the AdrC parameter should be modified DO NOT MODIFY ANY OTHERS If this were to happen the drive locks in fault mode and remains disabled To unlock it switch off take out the Profibus DP card switch on follow the instructions given by the terminal for returning to factory settings switch off reconnect the Profibus card switch on the drive 6 11 Can Open card software VW3A58308 IV 1 0 1st version of the Can Open card List of anomalies None to date Section 6 3 4 efesotomasyon com Schneider TOSHIBA p Electric MAINTENANCE MANUAL 6 12 Devicenet card software VW3A58309 V1 0 IE05 1st version of the Devicenet card List of anomalies None to date 6 13 Ethernet card software VW3A58310 V1 0 12 1st version of the Ethernet card List of anomalies None to date Section 6 4 4 efesotomasyon com 6 1 2 401295 uoneJedo Bulun o ne 994915451 9 X JOWN Auges YLS pue pue ejejd eoejdei Jo eu JO ezis ay 0 dSU 195 974 U poujeui Buum eu 12909 suonniog eui jo yey uey 1ueun
56. VX5A58HU29NA Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HU41N4 1 VX5A58HUAINA Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HUS54N4 1 VX5A58HUS54N4 Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HU72N4 1 VXSA58HU72N4 Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HU90N4 1 VX5A58HU90NA Power board insulating liner SKIIP heatsink fan SKIIP thermal liner screws HD12N4 1 VXSA58D12N4 Power board insulating liner SKIIP IPM IS HD16N4 1 VX5A58D16N4 Power board insulating liner SKIIP IPM IS HD23N4 1 VX5A58D23NA4 Power board insulating liner SKIIP IPM IS HD25N4 HD25N4X 1 VX5A38D25NA 1 board interface board insulating sheet HD28N4 HD28N4X 1 5 58 28 4 1 board interface board insulating sheet HD33N4 HD33N4X 1 VX5A58D33N4 1 board interface board insulating sheet HD46N4 HD46NAX 1 VX5A58D46N4 1 board interface board insulating sheet HD54N4 HD54N4X 1 VX5A58D54NA4 1 board interface board insulating sheet HD64N4 HD64N4X 1 VX5A58D64NA 1 board interface board insulating sheet HD79N4 HD79N4X 1 VXSAS8D79N4 1 board interface board insulating sheet IPM modules HD25N4 HD25N4X 1 VZ3IM6075M 1258 Complete IPM bridge 75A 1200 V HD28N4 HD28N4X HD33N4 HD33N4X 1 VZ31M6100M1258 Complete IPM bridge 100A 1200 V HD46N4 HD46N4X 1 VZ31M6150M1258
57. for 200 220 KW HC28N4X HC31N4X 1 VY1ADV389 Screw kit for 250 280 315 KW HC33N4X Plastic part kit for Size 2 1 VY1A38202 Front cover IP41 cover belt label ATV38 Fascia LED and Danger 5 languages Size 3 1 VY1A38203 Front cover IP41 cover belt label Fascia LED and Danger 5 languages Size 4 1 VY1A38204 Front cover IP41 cover belt label Fascia LED and Danger 5 languages Plastic part kit for ATV38 Size 5 1 VY1A38205 Front cover IP41 cover belt Fascia LED and Danger label 5 languages Size 6 1 VY1A38206 Top and Bottom cover IP41 cover Size 7 1 VY1A38207 Top and Bottom cover IP41 cover Plastic belt for control board Size 8 to 10 1 VY1A38201 plastic part kit Protection kit Size 8 1 VY1A38210 Size 8 insulating sheets Size 9 1 VY1A38211 Size 9 insulating sheets Size 10 1 VY1A38212 Size 10 insulating sheets Output ferrite Size 6 and 7 1 VY1A58406 Ferrite mounted on support Choke seal Size 6 1 VY1A58806 Choke seal capacitor seal plate seal Size 7 1 VY1A58807 Choke seal capacitor seal plate seal Control power transformer Size 8 1 VZ3TR381 Size 8 control power transformer Size 9 1 VZ3TR382 1 Size 9 control power transformer Size 10 1 VZ3TR383 1 Size 10 control power transformer Contactor kit HCIONAX 1 VY1A38101 1 contactor S N65 1 filter RFM2E224KD HC13N4X 1 VY1A38102 1 contactor S N65 1 filter RFM2E224KD 15 4 HCI9NAX 1 VY1A38103 1 contactor C 80A 1 filter RFM2E224KD Size 10 1 VY1A38104 1 contactor
58. if a motor run command is present and a downstream contactor or an open vario is being used One phase open circuit at the drive output gt check the motor connections Significant difference between the drive power and the motor power example 0 75 kW motor for a 2 2 kW drive Significant difference between the drive power and the motor power with reduced flux no load motor or inertia Failure of the transistor control circuit gt change the power board size 2 to 10 change the power supply board size 8 to 10 change the current gain board faulty current sensors LFF loss of 4 20mA Principle This fault is triggered when signal AI2 is less than 3 mA This fault can be enabled disabled by parameter LFL in the Fault menu Experience to date Incompatibility between the drive configuration and the signal sent to Al2 Section 8 24 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL OCF Overcurrent Principle This fault is triggered when the motor current reaches the LIC for more than 50 milliseconds peak current limit peak equals 2 8 times the value of the drive nominal current Size2to 5 LIC reached 100 times in 3 seconds Size 6to 10 LIC reached 50 times in 250 milliseconds Experience to date Ramp too short nertia or load too high Mechanical locking or load surge Failure of the transistor control circuit gt change the power boa
59. the theoretical values these are approximately equal to 2 8 times the drive nominal current in high torque mode DIAG_58 38 2 1 IE02 BEE Communication 34 Test Result COMT TEST ok LIC auto test x No Test Auto test N 1 Auta test 23 Auto test N 2 6 Auto test LIC Current calibration AS LIC U 67 Industrialization LIC U 58 TAS LIC W 67 Industrialization values LIC w 65 Figure 5 Auto test LIC Example of screen Section 8 16 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 7 Calibration Objectives of calibration Calibrate the current feedbacks Wiring Connect phases L1 L2 L3 to the AC supply Connect phases U V and W to the motor Do not connect anything to the control board terminals Operating mode Switch on the product Launch the diag58 38 program if you have not already done so Check the Current calibration button Press Enter or click on Run A Analyse the results window Analysis of the test result BS DIAG_58 38 2 1 IE02 Mi E p Communication p Test Result Pot com TEST Fa Calibration Xx No Test Auto test N 1 Auto test thyristors Auto test N 2 Auto test LIC Curent calibration Industri
60. to the initial position Switch off on Section 8 33 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 9 Changing the faulty component drawings parts lists 9 0 Safety instructions and precautions Safety instructions Before carrying out any work on an ATV38 Disconnect the drive power supply Wait for 3 to 10 minutes before opening the front cover and check that the Power and Fault LEDs are off ATV38 sizes 1 6 and 7 measure the DC bus voltage between the and terminals before starting work Never touch the connector on the control board option card when the drive is switched on When the product is switched on the control board option card connector must always be protected Precautions If you are not wearing anti static wristbands handle the electronic boards by taking hold of them by the edge and using the palm of your hand do not touch components with your fingers as this risks damaging the components due to an electrostatic discharge Tightening torque N m Size 2 to 7 indicated on the assembly drawings Size8to 10 Copper aluminium brass Steel of the screw Standard Tightening range Tightening range M3 0 54 0 39 0 59 0 54 10 49 0 69 M4 1 28 1 08 1 7 1 28 1 28 1 67 M5 2 55 2 06 2 84 2 55 2 55 3 43 M6 4 4 3 34 4 5 44 1422 5 69 8 crosshead 7 3 6 4 8 3 8
61. 0 09 NO 15 NOLLO3NNOO 96 ans WYS NO I uaalAld E 52 cH ex IX Ve JL Yax 1082 500 2 100 suyozz 144 3008 3105 00 NO FONVISISAY Svea HOLIMS 015 E8 06 94 0 286 T3 QNUH e anbryeuayss ap 312150 TOYLNOI H SMOS esr 9 3141200 voreJon q p j sjpo p ajrpJajur WOT PINAY 4101 82343 141 2191909 BT T 1 T T TA I I T1 1 Jed arjuPJeb juauanbpun Jor 2 99 Ep 18904 gaa co BPRIS anbrue3aus a E 01104 031 21 0 7921088 57915 necc 808 90 91874 nig See rl Ser ER 15185 56750771 qe13 8l 01cA8c8Z 208c8X CA8c8Z c08c8X cA8c8Z 08 8 87 012 8287 441574594 2 8282 CA8c8Z 208282 60178287 012 8287 cV 98c8X 01cA8c8Z 08282 80178687 012 8287 8 ve X 6 48 287 c0138c8Z cb 18c8X 01cA8c8Z 87039 110 690848 210218 ENUCU 102 ENUCU c1 cU LITENOEU NOLLNG HSNd SNONINNT 0 0 0 HOLIMS HOLYINNWOO 217700 FO
62. 01cAdc8 T38V1 A 909 200 geemaza NOLLAG HSNd SNONINNT POO 87037 9709 A 97 POD 012 828 T38V1 A 082 POO 9 8 NOLLAG HSNd SNONINNT 91 8839110 gingAer 607700 0164887 TH8v1 d3SI9H3N3 H3MOd 507200 11618287 dVO3llHM 607 00 8c8X NOLLAG HSNd SNONINNT 60 2110 gingAer 70 8282 T38V1 03SI983N3 TOHINOO 07 00 8282 07 00 J gt lt M gt lt lt 109 39vd 30N343434 IN3WdIND3 gan NOILdIHOS3Q 9NILVH34O N3931 SNILVd3dO 3930 E8 06 94 0 286 T3 QNUH e anbryeuayss ap 312150 TOYLNOI H SMOS esr 9 3141200 worsen q p j Sjpolp Uorjonpo dew lt ANDINGDAWT sp amp 9 TT T va I1 I1 1 Jed arjueJeG juauanbrun Jmof e asr anb jPu i0JuT ua 99 9 juaunoo Ep 18904 19903 018 10 GB 01104 03 4 1821084 A 926 088 HON38 SHOLON 46780741 04555098 4 9TS S S OJ u0 5 50 21 YAINNAW 9 Estes LANIEVO 3004 26750741 YSINASW 9 119813 X 10 119
63. 1 9 15125 LI LI 12 31835 704109 2660721 NAINNSW 9 114813 011951 IBNSIS J NNO 108 60 00 yaa TW 61 00 9 090 108 3SvHdlu L 3SVHd319NIS 4565 0086 SAlMddNS 91819973 E8 06 94 0 286 T3 QNUH e anbryeuayss ap 312150 TOYLNOI H SMOS esr 9 3141200 worsen q p j Sjpodp npINdO3ui sp eiar4eeJd ap 9 T TT sa I1 1 1 T1 J Jed arjueJeG juauanbrun Jmof e asr anb jPu i0JuT ua 99 9 juaunoo 14803 sharo 01105 031 02 7821 088 Srars rosd A 926 086 HON38 SHOLON 26 SO C1 04555098 4 15185 46790741 YSINNAW 9 15125 79490035 704105 2650701 YANN 9 20195 14033 310 09 NO YALAWLIOA 3019 1NOUJ 310 09 NO 15 NOLLO3NNOO Nid 95 ans 2015 AV3S re 08 52 cH ex IX Ve JL Yax Mase 5090 0 109 500 7 a FIOSNOO 16 3ONV ISIS3H 3 IVH8 HOLIMS 015
64. 1 027 SMOS esr 8 juaunoog 2 vorsuan 4 S TOJP no 3701449343731 2321 9009 21 je8 juaunoop SEITE 01103 031 03 m 821089 57016 3105307 405 926 08 HON38 SHOLOW 45750 1 03955048 3 aT OI UO 4550 1 JINNAH 9 FSTES I 3990095 104109 9 119813 011851 13915 NNO 108 117500 200 717500 e cu cu 95 807500 A udi 80 Cz i 38588 _ Ayr 8S en el EL 95 45 61600 9 06 18 AVT3u AY134 GUVMYOJ AUVIO3INH3 INI S9NI99n83 68 06 94 0 286 T3 QNUH e ap J0N NO2 H SMOS esr a 31241200 totean 4 STOP 90 4 amp 9 TT T va I1 1 1 T1 J Jed arjueJeG juauanbrun MOF e ua 99 9 jueunoo 01104 031 02 m 1821088 570 5 3 105309 983 5 N 929 096 SHOLOW 55721 5750 2
65. 1 T1 J Jed arjueJeG juauanbrun Jmof e asr anb jPu i0JuT ua 99 9 juaunoo Ep 294804 185804 aia 10 E anbrue3aus a es 01704 031 03 GPITS 022 086 WNOAFLWId Nib 1 anozo aters 9192893 VI 50040 15185 13 9 9 650 71 0 114813 81 cI dois YO LOW A 0cc EU FO39nQONI SNDIVH8 ONDIVUg O O eu 7 suyopg suyo 2 39NVLSIS3H 39I0H9 155 QOO 800 DOO STWNIWYAL Z 151538 9 vorsuan 4 SYTOJP no ajrpJejur 3001449343731 2121 90 09 21
66. 6N4 1 VY1ADC5802 2 capacitors 2200uF 450V top and bottom liners HD25N4 HD25N4X 1 VY1ADC5803 2 capacitors 2400uF 450V HD28N4 HD28N4X 4 pins damper HD54N4 HD54NAX 2 Capacitor kit HD33N4 HD33N4X 1 VY1ADC5804 2 capacitors 3300uF 450V HD64N4 HD64N4X 2 4 pins damper HD46N4 HD46N4X 1 VY1ADC5805 2 capacitors 4300uF 450V HD79N4 HD79N4X 2 4 pins damper HC10N4X 1 VZ3C3810 1 metal support 4 resistors 40W 21Kohms 4 capacitors 400V 8200uF 2 insulating sheets 1 copper bar kit cables 752 91 12 screws HC13N4X 15 1 VZ3C3811 1 metal support 6 resistors 40W 21Kohms 19 4 6 capacitors 400V 8200uF 1 insulating sheet 1 copper bar kit cables J752 CN91 18 screws HC23N4X HC25N4X 1 VZ3C3812 2 main metal supports 2 capacitor metal supports 16 resistors 40W 21Kohms 8 capacitors 400V 8200uF 1 copper bar kit cables J752 CN91 24 screws HC28N4X HC31NAX 1 VZ3C3813 2 main metal supports 2 capacitor metal supports HC33N4X 20 resistors 40W 21Kohms 8 capacitors 400V 8200uF 1 copper bar kit cables J752 CN91 24 screws Fan kit Size 2 to 5 2 VZ3V581 Kit of 2 fans IP20 heatsink HD25N4 HD25N4X 1 VZ3V58202 1 fan 120 connection screw kit HD28N4 HD28N4X HD33N4 HD33N4X HD46N4 HD46N4X HD54N4 HD54NAX HD64N4 HD64NAX HD79N4 HD79NAX Fan kit HD25N4 HD25N4X 1 VZ3V58203 1 fan 90 connection screw kit IP20 heatsink HD28N4 HD28N4X HD33N4 HD33N4X HD46N4 HD46N4X HD54N4 HD54NAX HD64N4
67. 716 111081926716 TTTOLLSE67TEM 0 48606 04 20070918 0606864 lt 18 1110716 6718 IIIOLELC6TI8M I120699E6 7 18M VI 00 E9 6vV 18M 11108252 6718 14090 lt 66718 91432913 L6Z LE 6 Fall d EL ZL TL SP 8SALV COW 11105252 6718 141 L 8107 8SALV S0V LIZOPZSEETTEM MMy PN8SALV SIV 272080858208 8 SSI d LNVIOSI 8SALY 1110811869517 L JHOVO 8SALV vov 11101852 6717 L 8SALV S0V LII0O8SSt6UvVIVM L dIIMS COW AHINI 8SALV COW 0 86 667 6 LIT d HO0d4SSIGIOHdJWH 8SALY cow TTTOPTSE6PTE 041 L 8SALV 100 lt 66 6 L 8SALV cow TTTO69SE6FTIT 81 d 8SALY 0 TTTO89SE67TIM GTA d S SW AYdINOA SIA 90V 119098058201 049 OV 007069 ETAT d ONZ CIXSN AAYA 8LOELICIA GVA SCA d SEXFN SX IHO AAVA LLOELTEIA CVA TPA OPA 6EA LEA GEA PEA CEA TEN TEA DEN OCA 82 LZA 9CA 6TA 81A LIA 9IA OTA 6A 8A SC d NO OTXPN SX IHO CAVA T FLOELTZIA exedex wal 3uesoduoj
68. 8 34119358 9NISVO ANTE 1394409 ASEBTAN 188 531 055322 IVNIAH3L 0 lt neeatan 188 53 055322 IVNIAH3L DBEX 51 0 815 87608 08cnzcaau 3ONVISIS3H M 086 SINHO 2 31700 C33 004122040011 3ONVISIS3H 004 SNHO Ze 917200 138 202104175 YALAWOILNALOd 917700 d 05139110 gina 061 31700 6 012 828 T38V1 9NDIVH8 917700 50828 HOLVOIGNI 917200 1 2 l 9 9 87835 9709 97 01cAdc8 19871 022 200 geemaza HSNd SNONINNT POO 8783317 gina A 8 POO 012 828 138 1 086 yaa 9 8 NOLLAG HSNd SNONINAT 917700 8839110 ging A8 607700 016A8c8Z Ta9V1 GASIDUANA H3MOd 607200 11618687 dVO3llHM 60700 828 NOLLAG HSNd SNONINNT 607200 2110 gingAer 07 00 8282 738V1 0381983N3 1031405 707700 8282 dVO3llHM x M gt lt gt lt INAWdINOA 049132 34 340 m 39N3U3433H 0 3931 SONILVd3dO 3339 E8 06 94 0 286 T3 QNUH e anbryeuayss ap 312150 TOYLNOI H SMOS esr 9 3141200 worsen q p j UDrionpo dew ANDINGDAWS ap 9 TT T ca I1 I1
69. 9 60 00 E mail schneiderformation com Fax 33 0 1 41 39 60 72 Internal training Several courses concerning selection and setup of variable speed drives are available Descriptions of their content are attached to this document For further information please refer to the IC SBS training guide After sales training This course is reserved for Schneider personnel working on site It requires a good knowledge of the product as well as associated applications cooling pumping etc For further information please contact the IC SBS training representative Training support Training support is available on Intranet Connect via the IC SBS server HTTP 139 160 73 11 PortailDAS ci nsf Technical support and training menu CDROM labelled CIFOR To be ordered from Schneider Comm Services Meylan France Tel 33 0 4 76 60 59 17 or 33 0 4 76 60 59 02 Fax 33 0 4 76 60 67 32 Section 2 1 3 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL FORMATION VARIATION DE VITESSE ELECTRONIQUE Fili re de formation Formations assur es par les ISF Section 2 2 3 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL ATV 58 EXPERT Training COURSE CONTENT 58 objectives Range Technology 1 Performance Protection Customer terminals sequences To become an expert in Functionality Options setting up Alt
70. Al I O extension board List of anomalies None to date Section 6 1 4 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 6 4 extension board software VW3A38202 extension boards only send data to the ATV38 control board from its own terminals except for functions which are only accessible if an option card is present V1 1 IE04 Earlier versions must not be used on the ATV38 List of anomalies None to date 6 5 Fipio card software VW3A58301 IV 1 3 05 Earlier versions must not be used on the ATV38 List of anomalies None to date 6 6 Modbus Plus card software VWA58302 IV 1 0 IE04 1st version of the Modbus Plus card List of anomalies None to date 6 7 Interbus S card software VW3A58304E V1 1 1 1st version of the Interbus S card List of anomalies None to date Section 6 2 4 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 6 8 AS i card software VW3A58305 V1 1 01 1st version of the AS i card List of anomalies None to date 6 9 Unitelway Modbus Jbus card software VW3A58303 V1 1 1 Earlier versions must not used the ATV38 List of anomalies None to date 6 10 Profibus DP card software VW3A58307 V1 1 01 1st version of the Profibus DP card List of anomalies None to date Warning
71. C 180A 1 filter REM2E224KD Power fuse Size 8 1 VZ3F3801 1 fuse 6 6URD30TTF0350 Size 9 1 VZ3F3802 1 fuse 6 6URD30TTF0550 HC23N4X HC25NAX 1 VZ3F3804 1 fuse 6 6URD32TTF0900 HC28N4X HC31N4X 1 VZ3F3803 1 fuse 6 6URD32TTF1000 HC33N4X Control fuse Size 8 and 9 1 VZ3F3820 1 fuse 314 003 Size 10 1 VZ3F3821 fuse 314 005 Section 5 4 4 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 6 Software 6 1 ATV38 drive software Anomalies corrected on a version of IE x have also been corrected on a version of IE x 1 V5 1 05 First software version integrating the ATV38 List of anomalies None to date 6 2 Operator terminal software The operator terminal is used to display the various parameters The drive authorizes access to a parameter The operator terminal limits the values if necessary The operator terminal contains the messages in all 5 languages The operator terminal is the master in exchanges with the drive Anomalies corrected on a version of IE x have also been corrected on a version of IE x 1 V5 1 IEI9 First version of the operator terminal integrating the ATV38 List of anomalies None to date 6 3 Al I O extension board software VW3A58201 extension boards only send data to the ATV38 control board from its own terminals except for functions which are only accessible if an option card is present IV 1 0 03 1st version of the
72. EN POINTILLES SUIVANT VU 149365100453 02 1 ua i gt gt gt ww gt re Te D gt gt gt e 5 5 Sm 5 o o 5 2 gt 5 5 gt 9 2 5 a 2 8 5 e 1 16 Sas 5 lt 3 S wl 5 Be 21 18 8 2313 ee ce o 5 5 x 25 28 Efel gt L 2 2 a Sl ss IED rev efesotomasyon com Original format efesotomasyon com Pro Engineer S E FINAL ATV58 T3 RADICAL No note application application memo no Date note application appl memo date 12 09 97 Etabli par issued by GROUPE SCHNEIDER Telemecanique Porametres VU VU porometers J10500 Modificotion du process de fabrication ajout flanc 3 vis 130913 Modificotion des couples de serrage 310311 Loncement Note oppl Modificotion modificotion Jappl memo 10 04 98 12 09 91 Dote dale Symbole Article 29104199 03 02 01 1199 PJ099D LOS suos juaios nb sjenb sje sel 55005 JoUd 50 JOU pesn sq puo WS 2IHI23 13 93919 25 10 19904
73. I Configuration fault Principle This fault is triggered on an invalid configuration command incompatible functions and received by a fieldbus a communication card or the RS485 serial link This fault is auto reset once a valid configuration is sent to the drive Experience to date Send a valid configuration to the drive Inl Initialization Principle The Ini message appears when the drive is in its initialization phase This phase can be interrupted for several reasons If the green LED is illuminated the drive is working Communication or compatibility problem between the control board and the terminal After 1 min a fault ILF errX may appear The switch mode power supply is not charged enough Experience to date Check that the terminal is compatible with the drive Change the terminal Change the control board T6 and 7 Check that the fans are working If the red LED is illuminated a fault message should appear 10 sec after Ini Take the necessary action to remedy the fault indicated Change the power board Section 8 32 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL nOF No fault This message is not a fault code but simply indicates that there is no past fault saved in the memory ErrX Error Principle These types of fault are generated by the terminal and the latter communicates with the control board microcontroller When there is an incon
74. IMS YAMOd HO VIBVA NOLLVQITVA NOILWHAdO 1 NOLLVAITYA NOIL VH3dO 3SVHd31ONIS 27600 1087 68 06 94 0 286 T3 QNUH e enbrjeuguos ap J0N NO2 H SMOS esr a 31241200 vorsuan q p j STOP Uorjonpo dew amp 9 TT T va I1 i 1 T1 Jed arjueJeG juauanbrun Jmof e ua 99 9 500 EI 15 anbrue3aus a 01703 031 03 m 1921084 3 105309 INH 284 405 0022 08 80331814 nig Eteri 1 30070 18185 39 31035 1051309 11911 011951 193915 J NNO 108 717500 c0 G00 74082 95 807500 sp YUBA 80 5802 tz 30500 __ __ 5 61 haa 9 09 108 AVI3H AVT3d 1 EB 06 92 1370 enbrjeusos TYINOI H snos esr es jueun
75. LY cOW 111052526718 141 CL IL 810 8SALV vov 10725 6718 OLIT d Od 004 SL cS PEAL VELOVOSS8 E08M SJT d cL SSINd INYIOSI 8SALY TOW TTTOLTT86ST IM STIT d CL AHOWO 8SALV S0V 111008526717 041 CL 8SALY 60V 1007466717 LIT CL H HSSIGIOHJHH 8SALV cow TTTOSTC86STE lt d dIIMS GOW AHINI 8SALV COW TTCOL8SE67TTEM LET d CL 0641 WTIIIHO 8SALV SOW 111099526711 91 8SALY vov 110595667 G GW SIA 90V TT90980S8E0T OCA T d ONZ ZIXSW QAYA SLOELTCTA LEA IEA SEA TEA TEA OCA 6CA BCA LEN 9CA GCA PCA CTA GTA VIA ETA CIA 6A 8A LATS OTXPW SX IHO CAVA VLOELICLIA 52 FNS 6 eorpur 1 3 005 51 0354 Sealy V Lv9 6vI 79 67 8 eanje oueuow VNNVIN 32NVN3LNIVIN J1329 3 65 1 gt 6 16 91 6 WalHsSoL SI Lt 07 6c 05 vt c LC 8c vc A A A A NOTAN vV IXL CIX6 vVW GNO 1005 MMSL O dIIMS GOW tu Ay 6 A A NOIIOHIONd THAVI 8SALY EL ZL
76. NCE MANUAL CnF communication network fault Principle This fault is triggered when a problem has been detected in the network communication part of a communication card This fault is detected by the communication card which feeds it back to the base product via the internal communication bus Experience to date Check the network connection to the drive A Check the time out ILF internal communication fault Principle This fault is triggered when the internal communication bus is inoperative for more than a second value of the internal time out Experience to date Check the connection of the option card to the control board Capacitor problem on the option card see VSD note no 17 Option card incorrectly screwed onto the control board or incorrectly clipped on connector J6 nterference gt check the connections to ground No 24 V power supply on the card only with Interbus S option card Section 8 31 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL CFF rating option error option removed CKS EEprom incorrect Principle This fault is triggered on power up when the drive hardware configuration does not correspond to the drive configuration contained in the EEprom Experience to date Change of power board rating Change of option card type Option card removed Installation of an option card although the configuration was customized CF
77. NUAL 8 3 3 Connecting the DC bus on the ATV38 size 4 Deconnection of the earth DC J 16 DC SIZE 4 Section 8 5 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 3 4 Connecting the DC bus on the ATV38 size 5 7 Y SIZE 5 DC J 16 Section 8 6 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 3 5 Connecting the DC bus on the ATV38 sizes 6 and 7 The DC bus can be accessed directly on the product s external terminals marked and CAUTION An external charging circuit must be provided as ATV38 sizes 6 and 7 do not have a pre charge resistor Section 8 7 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 4 Diagnostics 8 4 1 Diagnostics an ATV38 size 2 to 10 Power up the control board using the ribbon cable from the kit as shown in the diagram below and Save the customer configuration using the programming terminal or the setup software Note the last 8 faults in the error log in order to make an initial analysis If the product is locked by an access code enter code 6969 to delete the code Wiring Using an ATV58 control box check the I O on the control board and any option card fitted by comparing the state of the selector switches with the values recorded on the Map see the programming software ATV38 en panne Connecteur J18 il 230V AC arte
78. Schneider TOSHIBA Electric MAINTENANCE MANUAL MAINTENANCE MANUAL CONTENTS Altivar 38 1 General 1 1 Objective 1 2 Products concerned 1 3 Product design and manufacture 1 4 Exchange and repair 1 5 Assistance 2 Required skills training 2 Required skills 2 2 Training 3 Documentation 3 1 Catalogue 3 2 User s manual 3 3 MIT Intranet 3 4 Vantive RGSA Return Good Service Agreement 4 Repair service equipment 4 Equipment 4 2 Dialogue and diagnostics tool 4 3 Test bench 5 Replacement parts list 6 Software 6 1 ATV38 drive software 6 2 Operator terminal software 6 3 AI I O extension board software VW3A58201 6 4 PG VO extension board software VW3A38202 6 5 Fipio card software VW3A58301 6 6 Modbus Plus card software VW3A58302 6 7 Interbus S card software VW3A58304E 6 8 AS i card software VW3A58305 6 9 Unitelway Modbus Jbus card software VW3A58303 6 10 Profibus DP card software VW3A58307 6 11 Can Open card software VW3A58308 6 12 Devicenet card software VW3A58309 6 13 Ethernet card software VW3A58310 Section 1 2 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 7 Installation diagnostics 7 1 The speed is unstable 7 2 Motor turning the wrong way 7 3 Motor overheating 7 4 Motor accelerating too slowly 7 5 Poor control of motor stopping or deceleration 7 6 The motor does not start 8 Help with troubleshooting 8 1 Preamble 8 2
79. VNALNIVIN TTTO6ECSCOTEM 111001286516 11106552 671 7 TTTOOTTSLEOPM 3uesoduoj TO V 20 69926771 91432913 162 62 6 Fall d EL ZL TL SP 8SALV COW 11105252 6718 TAJT d L 810 8SALV S0V LIZOPZSEETTEM MAE PN8SALV STW 271080858208 8 SSI d LNVIOSI 8SALV LIIOSII86SITVM L JHOVO 8SALV vov IIIOI8St6YvIY L 8SALV S0V LII0O8SSt6UvVIVM L dIIMS COW AHINI 8SALV COW 0 86 667 6 LIT d HO0d4SSIGIOHdJWH 8SALY cow TTTOPTSE6PTE 041 L 8SALV 100 lt 66 6 L 8SALV cow TTTO69SE6FTIT 81 d 8SALY 0 TTTO89SE67TIM GTA d S SW AYdINOA SIA 90V 119098058201 LV c d 049 OV 007069 EZAJT d ONZ CIXSN G4VA 8LOELICIA GCA d NO SEXFN SX IHO AAVA LLOELTEIA CPA TPA OPA BEA LEA IEA GEA VEA EEA CEA TEA OEA 6CA BCA LZA 9CA 6TA 81A LIA 9IA OTA 6A 8A SC d NO OTXPN SX IHO CAVA T FLOELTZIA exedex 3uesoduoj 105 6 930N ep
80. alization 3 Industrialization values Figure 6 Calibration of the current feedbacks Example of screen Section 8 17 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 4 3 Printing out the results files The diag58 38 software generates two files automatically the first one RESULT TXT contains the test results from one session of using Diag58 38 between opening and closing the program Backups are made incrementally After each test the result is saved in RESULT TXT The second RESULT OLD contains the test results from an earlier session of using Diag58 38 kkk kkk The test type appears between The test result appears between Section 8 18 33 efesotomasyon com Schneider Electric MAINTENANCE MANUAL 8 5 Faults that may be displayed List of faults that can be read using an Altivar 58 dialogue tool the operator terminal does not switch on abnormal motor noise PHF input phase break USF undervoltage OSF overvoltage OHF drive overheating OLF motor overload overbraking motor phase break LFF loss of 4 20mA overcurrent SCF motor short circuit CrF precharge fault RS485 fault OtF motor overheating sensor fault EEF EEPROM fault InF internal fault EPF external fault SPF speed f
81. asyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Motor power in KW 110 ATV38HC13N4X 132 ATV38HCIS5NA4X 160 ATV38HCI9NAX ATV38HC23N4X ATV38HC25N4X ATV38HC28N4X ATV38HC31N4X ATV38HC33N4X 1 3 Product design and manufacture All the modules accessories and software are designed and developed by Schneider Electric or in collaboration with their associates At all stages of design and manufacture the products are handled with great care The products are subject to continuous monitoring in order to achieve a high level of quality 1 4 Exchange and repair The Altivar 38 is a Category 4 repairable product for the SBS local repair for country based organizations that have signed the service agreement repair at the factory for other country based organizations The purpose of this document is to help you repair these products C dient duits produits ee repar s d f ecteux produits N d fecteuX produits change standard repar s local ya SR SRES 7 chan ge standard de sous ensembl es usine For repair at factory for expert advice consult the Intranet site HTTP 139 160 73 11 portailDAS ci nsf Technical support and Training About support What to do menu Section 1 2 3 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Reminder of after sales categories APV2 After sales category 2
82. board Size 8 to 10 1 VX5A38C10 1 gate drive board VFA7D 0585Z Gate drive Size 8 1 5 8 11 1 gate drive VFA7D 4595A Pre charge resistor Size 8 1 VZ3R3810 1 metal support 2 resistors 80W 1 filter VCR1005 460 V AC 1 OHD3 90M 1 insulating sheet 9 screws Size 9 1 VZ3R3811 1 metal support 2 resistors 80W 1 OHD3 90M 1 insulating sheet 4 screws Size 10 1 VZ3R3812 1 metal support 3 resistors 120W 1 OHD3 90M 1 insulating sheet 5 screws Thermal liners Size 2 1 VY1A58852 5 SKIIP IPM thermal liners Size 3 1 VY1A58853 5 SKIIP IPM thermal liners Size 4 1 VY1A58854 5 SKIIP IPM thermal liners Size 5 1 VY1A58855 5 SKIIP IPM thermal liners Thermal grease Size 6 to 10 1 VY1A58856 35ml thermal grease Current sensor board HD25N4 HD25N4X 1 VX4A58201 1 board HD28N4 HD28N4X HD33N4 HD33N4X 1 VX4A58202 1 board HD46N4 HD46N4X Current gain board Size 8 1 5 8 12 1 current gain board VF7X 2680A HCI5NAX 1 VX5A38C13 1 current gain board VF7X 2680B HC25N4X 19 4 1 VX5A38C14 1 current gain board VF7X 2680C HC23N4X HC28N4X 1 VX5A38C15 1 current gain board VF7X 2680D HC31N4X 1 5 38 16 1 current gain board VF7X 2680E HC33N4X 1 VXSA38C17 1 current gain board VF7X 2680F Current transformer Size 8 3 VY1A38111 1 current transformer HC SL212V4B15CA 212AT 4V HC13N4X 3 VY1A38112 1 current transformer HC SL300V4B15CA 300AT 4 15 4 HCI9NAX 3 VY1A38113 1 current transformer HC SL360VA4B15CA 360AT 4V
83. contr le nappe du kit Inspection of the input bridge This test is performed using a digital multimeter in diode test mode to check that there is no short circuit on the thyristors and diodes The values shown below are those which the multimeter should provide when used in this mode Section 8 8 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL Inspection of the inverter bridge This test is performed using a multimeter to check that there is no short circuit on the transistors and diodes The values shown below are those the multimeter should provide when used in this mode METH ou R 0 300 0 45V R 0 95V OL ry ale ZEN R 0 300 0 45V 300 9 45V Inspection of the braking transistor size 2 to 7 Inspection of the freewheel diode size 2 to 7 To perform this operation it is necessary to disconnect the braking resistor R 0 200 0 45V Section 8 9 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 4 2 Diagnostics on an ATV38 size 6 and 7 if you have the Diag58 38 test software The Diag58 38 software can initiate diagnostic routines in order to identify a defective part without dismantling the product The result of the diagnostics can be printed out 1 Before you begin Power up the control board using the cable from the kit and Save the customer configuration using the programming terminal or the setup software
84. ctive grille 13 b Reassembling the power board complete kit with associated heatsink Tighten assembly screws 4 21 amp 4 22 while holding the protective grille 13 Reinstall internal cables J5 J13 J14 J15 and J18 that were removed earlier Refit the upper metal grille 17 on the heatsink screws V28 and V29 Refit the side panels on the left screws V7 V8 V9 V27 and right screws V23 V24 V25 26 c Reassembling the control board Connect cables 5 J13 J14 and 15 of the power board on the control board Make sure that cable J5 is properly connected Connect cable 18 from the top of the power board to the top of the control board Place the control board on the metal frame created by the side panels and the upper grille Screw the control board onto the metal panels using screws V30 V31 V32 V33 d Reassembling the plastic parts Place the plastic belt 19 and fit screws V34 V35 V36 V37 Refit the front cover and place it at 90 Refit the IP41 top protective cover clipped into place if it has been removed e Finalizing reassembly Reinstall the option card if it was present Reconnect the operator terminal Reconnect the plug in terminals control Section 9 5 297 efesotomasyon com Schneider TOSHIBA Electr
85. der TOSHIBA Electric MAINTENANCE MANUAL REASSEMBLING ATV38HU54N4 HU72N4 and HU90N4 Size 3 VARIABLE SPEED DRIVES a Reassembling the cooling fans Connect the cables supplying power to the fans via the heatsink Position the fans with the label facing inwards place the fan protective grilles 14 and 15 Tighten assembly screws V24 V25 amp V45 V46 while holding protective grilles 14 and 15 b Reassembling the power board complete kit with associated heatsink Reinstall internal cables J5 J13 J14 J15 and J18 that were removed earlier Refit the upper metal grille 19 on the heatsink screws V30 and V31 Refit the side panels on the left screws V8 V9 V10 V33 and right screws V27 V28 V29 V32 c Reassembling the control board Connect cables J5 J13 J14 and J15 from the power board to the control board Make sure that cable J5 is properly connected Connect cable 18 from the top of the power board to the top of the control board Screw the control board 21 onto the metal support 20 screws V34 V35 V36 4 37 Place the control board support assembly on the metal frame created by the side panels and the upper grille the plastic belt 22 over the assembly and tighten the 4 screws V38 V39 V40 V41
86. eedback loss AnF load veering fault SOF overspeed communication network fault internal communication fault rating error option error option removed EEPROM checksum CFI configuration fault nl initialization nOF no fault error Section 8 19 33 TOSHIBA efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 6 Troubleshooting based on the fault displayed The operator terminal does not switch on Experience to date Change the operator terminal Charging resistor damaged gt change the power board Check fuses size 8 to 10 Abnormal motor noise Experience to date The motor plate data has not been entered in the drive menu and auto tuning has not been performed Fault due to broken SOVCOR resistors on the power sections with a date code lower than 9845 change the power board Section 8 20 33 efesotomasyon com Schneider Electric MAINTENANCE MANUAL PHF Input phase break Principle This fault is triggered when a line supply phase is detected as missing This fault is only recognised after a delay of 1 second This fault ceases to be displayed once the fault has disappeared or when another fault is present This fault can be inhibited IPL parameter in the Fault menu if power is being supplied directly via a DC bus This fault is not saved in the error log Experience to date
87. es Section 8 26 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL OtF Motor overheating Principle This fault is triggered when the value of the motor temperature measured via the PTC sensors exceeds the following thresholds The sensor circuit resistor is such that Rsensor gt 2000 Ohm gt sensor 1 66 V Automatic reclosing is possible if The sensor circuit resistor is such that Rsensor lt 1500 Ohm gt sensor lt 1 3 V Experience to date No feedback only with the I O option card Caution It is necessary to use the recommended wiring as well as the resistance values R 10 kOhm in series with the sensor tSF temperature sensor fault Principle This fault is triggered when The sensor fault detection threshold is reached sensor gt 6 6 V Rsensor 20 kOhm The sensor short circuit detection threshold is reached U sensor lt 0 2 V Rsensor 20 Ohm Experience to date only with the I O option card ncorrect sensor connection gt check the sensor connection and the value of the divider bridge resistor Check the sensors Section 8 27 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL EEF EEprom fault Principle This fault is triggered when write access to the EEprom does not occur correctly ie Following a write operation the EEprom status does not indicate within a 10 ms period that the write o
88. hexagonal 9 8 8 3 11 2 11 8 10 13 5 M10 19 6 157 22 5 245 1209 28 12 37 317 42 8 44 137 5 50 M16 93 79 107 108 92 124 Section 9 1 297 efesotomasyon com Schneider Electric MAINTENANCE MANUAL TOSHIBA Mounting the power module of the screw Pre tightening Tightening Standard Tightening range Standard Tightening range 4 0 6 049 0 69 1 3 108 1 47 M5 0 6 0 49 0 69 2 55 2 35 2 75 M6 0 6 049 0 69 4 4 4 22 4 61 Section 9 2 297 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL ATV38 SIZE 2 Section 9 3 297 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL DISMANTLING THE ATV38HU18N4 HU29N4 and HU41N4 Size 2 Open the protective front cover of the drive to 90 Remove the plug in connectors Remove the option card if there is one a Remove the plastic protective parts Remove the protective front cover 24 when it is open at 90 Use a screwdriver and take care not to break this plastic part Undo screws 4 34 V35 4 36 V37 while keeping the plastic belt 20 around the drive b Change the control board Remove the plastic belt 20 by pulling to release it from the drive Disconnect the cable at the top of the drive J18 Undo screws V30 V31 V32 V33 fixing the control board 19
89. ic MAINTENANCE MANUAL Interconnection diagram SIZE 2 Section 9 6 297 efesotomasyon com e ia vaan 210298 Sans L L qpenssi 119073 26 er LP 33 ol 83 3 n 20 6 61 V8lIHSO L e 101 ge lop emp 52 ddp 3 E uonpaiddo eyou eyoq 3ONVSSInd ig o vN6C VNSLNHBEALV Lizzie 966 ES WOd33 1 1 15500 SERES
90. ivar 58 drives Accessories 0 37 to 55 kW DOCUMENTATION SUPPLIED Requir ed level of Altivar ATV58 training manual expertise Programming manual gt Knowledge of mechanical COMMENTS principles involved gt In depth knowledge of power More complete variable speed drive than the Altivar 28 integrating numerous additional electronics functions for more complex applications Familiarity with asynchronous motors Familiarity with VSD products Good hands on experience Lectures 7096 Practical 3096 gL LOCATION RUEIL GARE PRICE Free EQUIPMENT USED Altivar ATV58 Section 2 3 3 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 3 Documentation 3 1 Catalogue 3 2 User s manual Different user s manuals are available French English German Spanish DESCRIPTION ATV38 user s guide VVDED 302071 extension board VW3A58201 VVDED 397046 extension board VW3A58202 VVDED 397051 Pump option card VW3A58210 VVDED 398009 French English DESCRIPTION FIPIO communication card VW3A58301 VVDED 397045 Modbus communication card VW3A58302 VVDED 397044 Unitelway Modbus Jbus com card VW3A58303 VVDED397054 Interbus S com card VW3A58304 VVDED 397053 Interbus S com card VW3A58304E VVDED397053 with separate 24V power supply Internal communication variables 3 3 M LT Intranet These are technical information sheets regarding VSD products software version
91. nd can be ordered from Evreux quoting reference VZ3N5820 It includes ribbon cable which can be used to supply the control board from an ATV58HU18M2 without supplying the power circuit which can be connected to the control terminals in order to test the I O Diagnostic software to help you identify the faulty component s and test your repair It performs the following functions Testing the control board power supply and I O Testing all power circuits Calibrating the power Test bench In order to test the Altivar 38 after repair a document is attached showing how to build a test bench It corresponds to that used to test Altivar 66 and Altistart 48 drives Only the cable linking the Altivar 38 connectors to the 15 pin Sub D connector is different Schematic diagram of this cable Connecteur 15 broches Connecteur carte femelle contr le ATV38 Vue de devant b A Section 4 2 25 efesotomasyon com CONSTRUCTION OF THE TEST PLATFORM efesotomasyon com 06 92 TI ONYH euueb enbrjeusuos 2791607 70 4027 108 8er ee iueunoog 172 worsuay 4 sipoJp no uoTj2npo dey 91014934373 2491 5049 2 2 TE Jed o jueJe5 juauanbjun MOF 51 1 18 99 juounoo EN 194903 Me s 6r 018 enb ueseus a IND INUIIUI7AL 01104 121 4 m 7821093
92. o aiqissod XIMOTS OOL SNILV 31322V HOLOIN uogounjy eur TWANVIN 39NVN3 LNIVIN 31132944 Joprou a Ka 25 V8iIHSO L 6 9 114835 YLS pue JO 2215 574 eui ued 9u yead anbuo Jo pue pue epi oJd yes eui Je y ey jueuno OU si eseeJoui peeds eu eed enbuo pue v1 s pue xeed uang 974 Jo s6umes eu Y29249 2949 sosneo 91415304 y JO Bumes JO ezis ouenbayJj OOL SNILV3I31329V UOLON 5 91492913 gt 6 39NVN3 LNIVIN 6 4 2 uonejejeoep y Jo dois jo ed pue uonoefui OG 1snfpy euin 0 Jewod e esf 119 juano y eseeJou uoneJejeoep eui jsn py uni eu jeg 0 oo
93. oog L Z sjpo p ajpp ajur uopj2npo day 3101 4934373 291 5049 T T 71 T Jed arjueJeb MOF e asr anb jeu juT ua 88 juaunao 900 015 anbrue2aua a fes 01704 031 03 67915 3105 02 INH 284 NS 0022 08 i0JiiU ld nig 5 1 30070 18185 32N3np3s 03109 seen 011851 16 915 14 NNOLAQE 62 P00 TW 51608 9 100 108 3SVHd3TONIS f cc nase 53119915 21919913 06 9 0086 1470 anbrjeusu3s 8797607 Snos esr es4 jusunsog vorssan 4 131 BP aa I1 I1 1 T1 17 Jed arjuPJeb nor 1 161 40 ua 99 5 20 14803 sharo 01105 ox 02 m 7821 088 BOTS 0022 08 WHOA Id niu 5 A VI 1 30070 18185 39351035 1041 02 56 0 vI 719813 2015 310 09 NO W313IAL 10A C 3015 1 31
94. own the Test Result window c This value can be used for future auto tests n 2 performed at a later date Operating mode Switch on the product Launch the diag58 38 program if you have not already done so Check the Auto test n 2 button Enter values Rs min 0 5 x Rs and Rs max 1 5 x Rs Analyse the results window Analysis of the test result Auto test LIC Current calibration DIAG_58 38 2 1 202 Communication p Test Result Port ow Test NoTest Auto test N 1 RS 6 Auto test N 2 L Figure 1 Start of Auto test n 2 without knowing RS Ae i Cancel 25 Mini 0 Industralization RS Maxi 0 RS 7388 Industrialization values Figure 2 End of Auto test n 2 without knowing RS BS DIAG_58 38 V2 1 1E02 _ 01 Communication p Test Result Port COMI T1 x P T2 K T3 x No Test T4 x RS MINI fon CIA IE 1 T5 x 07000 Auto test N x x RS MAXI _ 08000 6 Autotest N 2 C Auto test LIC 1 Cancel Current calibration e Figure 3 Start of Auto test n 2 With Min Max RS as 25 Mini 7000 Industrialization RS Maxi 8000 767 Industrialzation values i Figure 4 End of Auto test n 2 With Min
95. peration has been taken into account The read write validation cycle has revealed an error the read value is different from the written value Experience to date Cut the power supply to the drive and reset If the fault persists transfer a configuration to the drive then disconnect and reconnect the drive power supply Re check the drive configuration If the configuration is correct change the power board if not change the control board Permanent backup in the EEprom lifetime gt change the control board InF Internal drive fault Principle This fault is triggered on power up when one of the following anomalies has been detected ncorrect calibration constants Drive rating not recognized by the control board option not recognized terminal not recognized Experience to date nternal fault or connection fault J5 gt check the connections in the drive ATV58 control board on ATV368 size 8 to 10 EEprom on faulty power board gt change the power board Section 8 28 33 efesotomasyon com M e TOSHIBA Electric MAINTENANCE MANUAL EPF External fault Principle This fault is triggered by a peripheral device communicating with the drive via a fieldbus connected on the RS485 serial link or an ATV38 communication board bit 3 of word CMI at 1 Experience to date Fault tripping requested by the PLC program SPF loss of speed feedback Principle
96. r switching on the drive 840 V DC for 380 460 V drives 800 V DC for sizes 8 to 10 This fault appears when the motor is stopped or during DC injection braking Experience to date Line supply too high gt check the line voltage Line supply disturbed by the DC drive gt check on J18 U mains x v2 Scaling resistor gt change the power board OHF Drive overheating Principle This fault appears when the temperature measured on the heatsink exceeds the 11896 threshold Thermal state Thd This measurement is provided by a temperature sensor located in the drive 118 100 on the heatsink size 2 to 7 Experience to date Heatsink temperature too high Monitor the motor load Monitor the drive ventilation Check the value of the Thd parameter in the Display menu Wait for the drive to cool down before resetting Switching frequency too high SFt Section 8 22 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL OLF Motor overload Principle This fault is triggered when the estimated value of the motor temperature exceeds a certain threshold Triggered when the Thr parameter reaches 118 The thermal state is calculated according to the ItH parameter and the measured rms motor current The motor thermal state is memorized and decreases according to the drive rating time constants even if the drive is switched off For correct thermal protec
97. rd Power transistor broken gt change the power board and the modules Power transistor broken gt change the interface board and the modules size 8 to 10 Failure of a current sensor Motor drive not suitable for one another SCF Motor short circuit Principle This fault is triggered when the power section has signalled a phase phase or phase earth motor short circuit As this fault has to be dealt with very quickly it is managed by the hardware it is detected and dealt with directly in the power section and it is directed to the control board for saving and display This fault can never be reset even if a general reset has been programmed Experience to date Inappropriate setting gt enter the motor rating plate in the Drive menu and perform an auto tuning operation Short circuit or earthing at the drive output gt check the connection cables by disconnecting them from the drive and check the motor insulation Check the drive inverter bridge power transistor Ramp time too short gt increase the ramp time Power transistor faulty gt change the power sub assembly Connection cable J5 incorrectly connected to the control board or power board gt make sure that J5 is properly connected Interface board size 8 to 10 Current gain board size 8 to 10 Power supply board size 8 to 10 Failure of a current sensor Failure of the current feedbacks
98. ructions Switch off the product Oncerelay R1 changes state switch the product back on immediately Analyse the results window Diag58 38 screen Eg a thyristor auto test screen DIAG_58 38 V2 1 1E02 Communication Test Result Pot com TEST OK FAULT Thyristors auto test X Test No Test Autotest N 1 Auto test Thyristors Auto test N 2 Auto test LIC C Current calibration Industrialization Industrialization values Analysis of the Thyristors auto test result If the thyristors are shown to be faulty Check the gate connections Ifthe connections are correct dismantle the product to test each thyristor with a small torch If the thyristors are not faulty change the power board Section 8 13 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 5 Auto test n 2 Objective of auto test N 2 Check the transistors using the current and voltage feedbacks via the DC Bus Wiring Connect phases L1 L2 and L3 to the AC supply connect phases U V and W to the motor Do not connect anything to the control board terminals For this auto test you need to know the value of the motor stator resistance but if you do not know this Perform auto test n 2 without entering the and max values of Rs c An error will be displayed Note the resistance value Rs sh
99. ructions below Examine the product visually while switched off Check the external physical state of the drive traces of burning or overheating parts that have been subjected to knocks Check the connectors Check the state of the internal screws to determine whether the product has been dismantled Don t forget that the product displays the most recent fault Section 8 1 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 2 Block diagram of the power circuits 8 2 1 Block diagram of the power circuit on Altivar 38 Sizes 2 to 5 and 8 to 10 Pas pour les tailles N 8 10 Filtre Filter U V w 8 2 2 Block diagram of the power circuit on Altivar 38 Sizes 6 and 7 4 s Tha Th3 filter CA L2 2214224 cb cp U V w Section 8 2 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 3 Connecting the DC bus 8 3 1 Connecting the DC bus on the ATV38 size 2 Disconnection of the earth DC J 16 SIZE 2 Section 8 3 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 8 3 2 Connecting the DC bus on the ATV38 size 3 Deconnection of the earth DC J16 Der SIZE 3 Section 8 4 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MA
100. s application sheets etc These documents can be consulted on the IC SBS Intranet site Address HTTP 139 160 75 12 intramit2000 fr_vv index htm Select MIT Technical Information VSD Section 3 1 2 efesotomasyon com Schneider TOSHIBA 3 4 Electric MAINTENANCE MANUAL Vantive RGSA Return Good Service Agreement formerly known as BEST This database is accessed via the SCHNEIDER intranet Industrial control site technical support help desk HTTP 139 160 73 11 PortailDAS ci nsf This database allows users Toask a specific question and receive a personalized response from the SBS n country based organizations to consult their portfolio of current or answered questions whether or not the SBS is available Tosearch the database for all the questions that the SBS has already been asked in order to find a possible suitable response or search avenue Section 3 2 2 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 4 Repair service equipment 4 1 Equipment List of tools required to repair ATV38 drives General equipment contact grease Ref SCHNEIDER VY1A58856 multimeter ATV38 Size 2 to 3 torx key 150 mm deep Ref FACOM 80 TX 20 or 6 mm flat screwdriver 150 mm long ATV38 Size 4 and 5 torx key 150 mm deep Ref FACOM 80 TX 20 or 6 mm flat screwdriver 150 mm long size 3 Allen key IPM and capacitors size 4 Allen key SKIIP
101. s 38831 m a m 3ugnvo ane ANVAInS v 8 X 3 EHAO e 2 n LHA 4 38174 3119934 fo 1 8 8 9 Y i a 59 9 H N 2 P so A io 8 o NOSPIIW3S 3175 8 5 9 5 enr T or T el 6 8 L 9 S v 4 l Schneider TOSHIBA p Electric MAINTENANCE MANUAL Assembly SIZE 2 Chapitre 9 8 297 efesotomasyon com 8 ATV58 TESTE T 6JB24 10376 o Lu e gt 2 e c 49364500 53 02 6 TURPIN Porameires VU VU parameters Symbole Article part number Note appl Modification modification oppl memo 10 04 98 Jio499 MISE JOUR DU PLAN 12 09 97 10376 LANCEMENT IED Date rev 02 efesotomasyon com 0 6vo0rv9t6r 21 86A1V 3 5 INVAIQS 111113104 51834313 EZA NldanL 9 16 60 21 NOILINI LNAWNDOd 91 01f 2856 70879 y ejqu s ddo aop UOIjD2 JipouJ U0 D2 JIpOW 1000 SON 2100 031 9220 86 60 10 u131V111N3A NOILVXIJ 10423 2 30 100 Error 26 0 22 20 SIA NOIIVOLUBY3 30 5522044 10 NOILYJIJIQON 86 vO O 5 NA NA Jequmu pod GZA UN
102. sistency in the message the terminal after several repeat attempts indicates an ErrX fault This failure is generally very difficult to reproduce as it depends on the environment extension cable between product and terminal motor running site subject to interference and the combination between the terminal and the control board Without exception neither the control board nor the terminal are at the origin of the failure it is always the combination of the two which generates the fault code ErrX This failure can under no circumstances disturb the motor operation it can only hinder product programming Different types of Err Err1 Incorrect operation Err2 Incorrect address Err3 Incorrect value sent by the terminal write operation refused by the drive Err4 Incorrect execution Err5 Incorrect CRC Err6 Driver problem Err7 Time out fault the terminal has sent a request but has not had a response Err8 Interrupt overflow Err9 Structure error run or stop bits not recognized Err10 Incorrect size Experience to date Failure to comply with the wiring instructions Replace the terminal Replace the control board Change in the RS485 link data rate from 19200 to 9600 bauds with the terminal in this case display of err7 after switching off on To unlock the terminal the only solution is to proceed as follows Change the position of the 50 60 Hz switch Switch off on Reposition the 50 60Hz switch return
103. t as if you were opening the drive cover Under the right hand section 4 cables are connected linked to the power board Remove these 4 connectors J5 J13 14 J15 c Change the power board The power board replacement kit also includes the heatsink on which the power board is mounted These cannot be separated First take out the plastic parts see above Remove the steel plate 20 acting as a support for the control board 21 screws 4 34 4 35 V36 V37 Grasp the control board and its metal support and turn them gently to the right making the same movement as if you were opening the drive cover Under the right hand section 4 cables are connected linked to the power board Remove these 4 connectors J5 J13 14 J15 Remove the side metal frames Right hand section 18 screws V27 V28 V29 V32 Left hand section 5 screws V8 V9 V10 V33 Remove the metal grille from the top of the drive by removing the 2 remaining screws V30 and Disconnect internal cables J5 13 14 J15 and J18 Keep them for reassembling the product d Dismantle the cooling fans Remove the 4 fan screws V24 V25 amp V45 V46 Disconnect cables supplying power to the fan via the heatsink Remove the fans Section 9 20 297 efesotomasyon com Schnei
104. tion the ambient temperature around the motor should not exceed 40 C This thermal protection can be disabled Parameter tHt in the fault menu The fault can only be reset if the motor thermal state is less than 100 Experience to date Check the setting of parameter ItH Monitor the motor load Wait for approximately 7 minutes before resetting Monitor the level of DC injection automatic or via logic input Motor drive suitable for one another OBF Overbraking Principle This fault is triggered when the voltage measured at the filter capacitor terminals exceeds with the drive running 840 V DC for 380 460 V drives Experience to date Position the deceleration ramp auto adaptation parameter BRA to yes if the application allows it increase the deceleration time Forsize 2 to 7 add a braking resistor Section 8 23 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL OPF Motor phase break Principle This fault is triggered when 1 2 or 3 motor phases are detected as missing This fault is only recognised after a period of 2 s For rotation frequencies less than or equal to 5 Hz this period is longer This fault can be disabled by parameter OPL in the event of an uncontrolled break downstream insertion of a downstream contactor or a vario between the drive and the motor Experience to date Disable the motor phase loss protection parameter OPL
105. ysis of Auto test N 1 results If the component is gt Actions faulty 1 thecontrolboard TL Change 1 2 j ChngeT2 3 j ChngT3 Change TA TS Change TS 7 Change the control board ID jChangetheconrolboad 1 jChangetheconroboad L14 control board the controlboard R2 Change thecontrolboard Change the controlboard 1 Check the sensor wiring change the thermal Calibration 1 Read MAC Cal and Power Cal Comprv Change the powerboard SSCF 17 Nothing transistor has short circuited _______ MAC Cal 1 Change the controlboard Power Cal Change the power board Section 8 12 33 efesotomasyon com Schneider TOSHIBA Electric MAINTENANCE MANUAL 4 Auto test Thyristors Objective of the Thyristors auto test Check that the thyristors are working correctly Wiring Connect phases L1 L2 L3 to the AC supply Do not connect phases U V W to the motor Do not connect anything to the control board inputs Install a device to read the state of relay R1 Operating mode Switch on the product Launch the diag58 38 program if you have not already done so Check the Auto test Thyristors button Press Enter or click on Run Follow the on screen inst

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