eseries service manual b section 6 frame 6
Contents
1. Remove the Power Supply board this is secured by 4 off M5x30 CW screws and has four brass spacers The outer two spacers are 16mm long and the inner pair are 16 8 mm long It is best to remove them as a one assembly keeping the screws and spacers together this makes for easier reassembly i EHD Z o m mum m TI 8 o A SIT bil2. lo oio jelo ocloz ED O 5 re Ste OO SJ rex d B s pi imer r 8 9 9 0 0 e e o o 8 JE 9 JE D F mexie CW SCREWS d 6 JG afe J ais a d 6 IGBT amp THERMSTRATE NOTE ORIENTATION A 9 IGBTs TO BE MATCHED c EE c 5 d ES uw ES c si egea M5x12 CW SCREWS d d d 4 o o o WH CAPACITORS Z K NOTE POLARITY i i q 3 CLAMPING PLATE THIS ROW 440 540 and q 420 480 AMP ONLY ooo e gs FSI FOSSILER E G S TE g TA o o fe o o o m pe qnl LRECTIFIER amp THERMSTRATE FIT MG x 6 CW SCREWS TO PLUG THESE H 4508 310A LOCTITE SCREW NEARY H S EDGE M5x16 CW SCREWS 4 OF PER
3. e le i U OUTPUT SHEET BUS V OUTPUT SHEET BUS U W OUTPUT SHEET BUS e z tj H C B e t ie S Be Bo Je a Bi EP e Bo B C eh seja 2 s Ne HEHE e le TE e EH oll e Kari C 83 Ga 2 Beg o el g Je Jele ioe 3 Tao rd Psi mai m i Woo ab 9 Deest f 8 i s a Ke I B hb Hj HE HE A Bl dk GB q D Es a B 4F cij of o i a i p ae N V 4508 304A Figure 6 12 Frame 6 Output Sheet Bus Removal Elite Series Service Manual 4201 230 Rev B6 108 6 2 4 Refer to figure 6 13 and 6 14 1 Bus Sharing and Power Supply Board Removal SERVICING THE POSITIVE AND NEGATIVE SHEET BUS Frame 6 Remove the Bus Sharing boards and Bus Sharing cable These two assemblies are secured with 6 off M5x30 CW screws and use 6 off 16mm long b
4. C M4 x 10 CW SCREW mun A AG E Be B e l 9 6 6 a CHOKE RECTIFIER BUSBAR e D M3 x 10 CW SCREW q E M6 x 16 CW SCREW F 8 x 16 BOLT FLAT AND Sallo SCHNORR WASHER q 4 EI E Log scr BOARD 4 El El S es o fla o F F M3 x 10 CW SCREW T3 d 5 LE 1026 FIUPG Ta G x 10 CW SCREW EARTH TAB 0 p 5 Y d iko I I THERMAL SENSE no 5 P PCB LOOM EE LEE Yy 4 m 4508309A Figure 6 14 Frame 6 Snubber and SCR Board Elite Series Service Manual 4201 230 Rev B6 Frame 6 111 6 2 7 SERVICING THE IGBT Refer to the upper section of figure 6 13 Each IGBT is held by 4 off M6x16 CW screws a thermstrate is used between the IGBT and heatsink to ensure good thermal contact Remove the old IGBTs and clean the heatsink surface 1 Do not remove the gate emitter shorting
5. POWER TRAY RETAINING SCREWS LEXAN CLEAR M5x16 CW SCREWS INTERNAL SHIELD LEXAN CLEAR M4x16 CW SCREWS INTERNAL SHIELD U PHASE M4x16 CW SCREWS OUTPUT SHEETBUS Hi H POWER TRAY ASSEMBLY r k gee e 2 W PHASE bb TEE ETE OUTPUT SHEETBUS ee og 9s lth ee Be ell e bl le Fs OPO OJ ell e oje Ki E ll lle O O oe E 3 lepe 1 T be L Z JETT q dia INPUT FUSES gt a _ E 7 ke 2 PER PHASE i 4r IE i f t E 6 ma mdk a m E 4508303A Figure 6 11 Frame 6 Power Tray Removal Elite Series Service Manual 4201 230 Rev B6 Frame 6 107 6 2 3 Frame 6 construction allows one phase to be disassembled without affecting the other two This section and the following describe how to disassemble U Phase The other two phases are similar in construction SERVICING THE OUTPUT SHEET BUS EM Ensure you have adequate small containers to place the Bus Sharing Board DC Supply Board positive Sheet Bus and negative Sheet Bus fixings in their own container This will help to speed up reassembly To remove the U Phase output Sheet Bus remove 1 2 3 4 The door pillar which is held by 8 off M5x16 CW screws See figure 6 12 The Lexan shield 2 off M5x 6 CW screws See figure 6 12 Screws A and B Bolts C and D Thread the fibre optic loom through the output Sheet Bus Slide the output busbar towards the bottom of the Elite d
6. the same size as the existing board size as per figure 6 8 This is done with a fine pair of side cutters Place the Control board on the connecting pins 10 Gently push the 6 pin connector down slightly and repeat the process with the 40 pin connector When this is completed check through the slots to ensure no connecting pins are showing or damaged then push the Control board completely home Replace the 3 off M4x10 Phillips screws as per figure 6 6 11 Replace the remaining components of the Elite in the opposite order as detailed in removing the Control board INTERNAL FAN WIRES Sa FIBRE OPTIC COVER PANEL CW SCREW DC FUSE PCB LOOM POWER TO POWER PCBLOOM SCRPCBLOOM THERMAL SENSE BLOOM OA 30FCTLOOM EARTH 3WAYPLUG CONTROL CABLE oci CLAMPS 4506 267 Figure 6 5 Frame 5 to 7 Power Tray Elite Series Service Manual Control 772 Board Plugs FAN USED ON FRAMES 6 amp 7 ONLY CONTROL BOARD Figure 6 6 Frame 5 to 7 Power Tray and Control Board Vezz g0Sr yeg 0 0 Figure 6 8 Frame 4 to 7 Control Board Biscuit 4201 230 Rev B6 Frame 6 6 2 2 SERVICING THE POWER TRAY The Power Electronics board is replaced as an entire assembly that is inclusive
7. 6 0 FRAME 6 ULTRADRIVE ELITE SERVICE This section covers 400V models from UE 305 to UE 480 and 500V models from UE 305D to UE 540D The 400V and 500V models are essentially identical for disassembly and reassembly purposes When specific differences exist between the 400V and 500V models these are noted a oma s 4508299 6 1 PARTS LISTS AND BLOCK DIAGRAMS 100 6 2 SERVICE 104 Elite Series Service Manual 4201 230 Rev B6 100 Frame 6 6 1 PARTS LISTS AND BLOCK DIAGRAMS i 6 1 1 FRAME 6 400V ULTRADRIVE ELITE PARTS LIST 400 VOLT ULTRADRIVE ELITE PARTS LIST FRAME 6 UE 305 UE 340 UE 420 UE 480 E480 620S E000 610S E660 611S 6 x E660 615S 2721 091 2721 124 6 x 1421 027 6 x 1781 103 24 x 1757 136 24 x 1781 104 3 x E480 612S 24 x 1352 453 36 x 1352 453 24 x 3907 004 36 x 3907 004 4 x 2941 011 2 x2941 006 2941 014 6 x 3302 615 6 x 3302 615 6 x 2401 025 2 x 2404 063 E660 621S Includes Fuses 12 x E660 619S Loom To Power Board 1 x 2726 105 Thermal Sensor Looms Short Linking Loom 4 x 2721 114 Long Linking Loom 2 x 2726 103 2721 094 3 x 2521 073 6 x 0371 609 3 x 2727 018 715mm 2 x 2727 016 370mm Frame Size Spares Guide x r r D N Power Tray SCR Board SCR Loom IGBT Block DC Bus Fuse Input Fuses Fase Perna SOR Boxe r
8. N X 8O1 BTA Y suo iovavo sna oa suoLlovdvo SNE 90 SuO1I0vav9 SNE 20 4 d bi f amp b po i po r3 Sng 20 de U3IAILOJH 431411934 HJIALOJH c NEN sna lli SA EU HEN HEN K NEN l l AAA IO HEN n Ig 1 Quvog Ic IL I l M1990 E EF ONIHYHS ESI x 11808 kun 1 auvoa k Ji l r Tasta ONIHVHS NIBYHS ITI sna sna ILA L L i ms IO 1000 TUE 9 NEN NEN l HEN 2 F 91 FI 11990 H auvog Z So TT rt ONIHVHS t sna n sayoHo 83814 ANdNI I asm asn 1 7 7 00 00 i x W xz mm L w c x sna 4 I uet 903 074 HVOR HOS 0029 TJ 0ld m 0 20101 pue 001031 7 T 20801 20 031 008 C3 c 2014 Hn MNA MA Hn 20101 001091 CJ 10601 10037 i avoa BOS M A zaop 001091 Tm 0801 08021 ww Jal 001d bold HA T1 DUE HA 20101 00107 800 08031 208d QUOS JAHOJIVO 20640 m 1084 0084 1 4 2019 8028 m 20101908 004037 11 T 90801 906031 n 0018 NEST HM HM 20101 001031 sme ao au 7 REBOOT 7 90 01 808021 2 JAHOALVO SO d TTT FI 9 SOHVOB HOSN3S l nos z f uamoa 03 EA Ig 38AN ANS SOMA z Q Cx L 004 WNBIN N06 x SWHIHLOHOIW HJIHJANI X 9 o 4 TWN
9. Po Fuse LT AN DC Power to Power tray Loom Fibre Optic Loom UH UL amp VL Fibre Optic Loom UL amp WL Fibre Optic Loom WL 1 x 2727 017 620mm mic 5 8 NjA o Q v O UJ ip r o 5 8 N Z S 3 o c al 3 2 5 e ge jS 2 o Bla gt 6 o o o 6 x gt Figure 6 1 Frame 6 400V Parts List Elite Series Service Manual 4201 230 Rev B6 101 Frame 6 FRAME 6 400V ULTRADRIVE ELITE BLOCK DIAGRAM 6 1 2 ATNO V08b SHOLIOVdVO 3S3HL Vr92 80Sr na S Xi S Xi S Xi A 1891 T3TIVa Vd X 189 IJTIVHVA X 189 T3TVHVd xp SHOLJOVAVO 91800 Si Mo eh sila o l r tra sna odo 3411934 31411938 T T T T sna lli UNI 1 lli iy ya 903 lli ify lli Z A EN ify L t lli NEN lli ify I lli NEN wu lli ify 1 lli ify M I lli ify Quvo8 M1090 S E zel Eli E i i FERT ita I T T 1 T FT ITI TI 1 C iy qa lli ify X j Ly n Li
10. RECTIFIER L THERMAL SENSE PCB Figure 6 15 Frame 6 IGBT Capacitors and SCR Level Elite Series Service Manual 4201 230 Rev B6 112 Frame 6 6 2 9 SERVICING THE CAPACITOR The capacitors are mounted through the heatsink with the bulk of the capacitor in the main cooling airflow at the back 1 To remove the capacitors undo 15 off M5 x 12 Phillips screws See figure 6 15 Replacing the Capacitors 1 The capacitors should be installed using a jig PDL part number 5101 190 this ensures the height and rotational position are exact of the machine Sealing rings are used to prevent air leakage through to the inside of the machine The sealing rings must be fitted to the capacitors at 23 5mm below the top of the terminal post Place the capacitors in the heatsink and loosely screw down the clamping plate Fit the jig to the capacitors then tighten the clamping plate screws If a jig is not available precise fitting of the individual capacitors is required Refer to figure 6 16 Fit the capacitor sealing rings exactly as shown this should help to align the capacitor terminal post at 29 5 mm above the heatsink when the clamping plate is secured The rotational alignment of the post is also critical to prevent cross threading of the screws into the capacitor terminal post when the Sheet Bus is attached Slight adjustments may need to be made as the clamping plate is clamped down 23 5mm Sealing Ring Elite Seri
11. UAINI wean r 10 _ WNUaLXa q K voed E Quvog o E zo 10385 A TURAE NHL d3MOd B GINOO LINN AVIASIO WVHOVIC 90718 qors 3n OL OSOL AN 9 3NVud LIOA 008 ba Frame 6 500V Block Diagram Figure 6 4 4201 230 Rev B6 Elite Series Service Manual 104 Frame 6 6 2 i 6 2 1 1 2 3 4 5 6 7 8 9 SERVICE SERVICING THE CONTROL BOARD Ensure the Elite is safe to work see section 4 2 before proceeding Number the three way controls to enable easy replacement then unplug them and remove the control cable clamps if used Referring to figure 6 5 access to the wiring looms on the lower left hand side by removing screws A 3 off CW M4x10 retaining this plate Unplug the 7 wiring looms under the plate Remove the remaining cover plates in one assembly by removing screws B 3 off M4x10 Slide the cover plate assembly down to clear the fibre optic connections before lifting it clear Referring to Figure 6 6 the Control board is held by the Phillips screws C 3 off M4x10 screws Remove these and lift the control board vertically off the connecting pins Note lift beside the plugs and keep the board level to avoid bending the connecting pins 500V models have a drive select board between the Control board and the Power tray leave this in place The replacement Control board will be in biscuit format i e it will have to be trimmed to
12. ctifier Thermstrate IGBT Block 24 x 1757 136 IGBT Thermstrate 24 x 1781 104 Gate Drive Board 3 x E481 612 LL E External Fans 5 x 2941 024 5 x 2941 022 Miorotherm Including Loom 1 6X2201 Loom Power Board 1 2726 105 1 Thermal Sensor Looms Short Linking Loom 4 x 2721 114 3 Long Linking Loom 2 x 2726 103 1 Fibre Optic Loom UH UL amp VL 327274018 715 Fibre Optic Loom ULa WL N Fibre Optic Loom WL 0 565 External Fan P S Transformer o 8707 External Fan P S Board ree Ed Level 1 Minimum spares stock NEN ka NN NM km NN X evel 2 Typical spares stock 4508 278A Figure 6 3 Frame 6 500V Parts List Elite Series Service Manual 4201 230 Rev B6 103 Frame 6 FRAME 6 500V ULTRADRIVE ELITE BLOCK DIAGRAM 6 1 4 NINO 0098 007 SHOLIOVdVO SSSHL 292 809 gt S Xi 8 x 8 x i 189 BTW Y 189 HT VA
13. ctly without risk of damage should something else be faulty or an error made during reassembly See section 4 6 Figure 6 9 400V Power tray Figure 6 10 105 500V Power tray Elite Series Service Manual 4201 230 Rev B6 106 Frame 6 DOOR PILLAR M5x16 CW SCREWS Smile INTERNAL 2 OF POWER TRAY SUPPORT RAIL
14. eet Bus starting from screws F to J and the positive Sheet Bus joining bolts Remove the negative Sheet Bus Starting from screws B to E and the negative Sheet Bus joining bolts If you are not going to change the capacitors do not remove the cap centre Sheet Bus screws A I POSITIVE SHEET BUS gt s F M3 x 10 CW SCREWS G M6 x 16 CW SCREWS H M5 x 12 CW SCREWS M6 x 16 CW SCREWS J M8 x 20 BOLT WASHERS amp NUT I POSITIVE SHEETBUS V JOINING BOLTS 8 20 WASHER amp SHEETBUS SHIELDS CLEAR LEXAN POWER SUPPLY BOARD THIS ROW 420A TO 540A ONLY NEGATIVE SHEET BUS B M8 x 16 BOLT 8 WASHERS C M5 x 12 CW SCREWS D M6 x 16 CW SCREWS E M8 x 20 BOLT WASHERS amp NUT NEGATIVE SHEETBUS JOINING BOLTS M8 x 20 WASHER amp NUT CAP CENTER SHIELDS CLEAR LEXAN THIS ROW 420A 2 CAP CENTER SHEETBUS TO 540A ONLY ep AX A M5 x 12 CW SCREWS 4508 308 Rev THIS ROW 420 TO 540A ONLY Figure 6 14 Frame 5 Positive and Negative Sheet Bus 3D View Elite Series Service Manual 4201 230 Rev B6 110 Frame 6 6 2 5 SERVICING THE IGBT GATEDRIVE BOARD Ensure you have a means of shorting out the gate and emitter of the IGBTs before you remove the Gatedrive board Refer to the upper section of figure 6 14 1 Remove screws A 2 off B 8 off and C 1 off on the phase you require access to and lift off the Gatedrive board 2 Sh
15. es Service Manual Sealing Ring Before Inserting Capacitor Into Heatsink Figure 6 16 Clamping Plate Capacitor Replacement Capacitor Replacement Complete 4508 302A 4201 230 Rev B6 Frame 6 113 6 2 10 500V MODELS EXTERNAL FAN POWER SUPPLY The 500V models have linear AC to 24 power supply for the external fans This is located directly above the internal cooling fan and is accessed by removing the gold coloured panel above the electronics cabinet The panel is held by 6 off M5 x 10 CW screws An exploded assembly view is shown in figures 6 17 and 6 18 S o M5HEX FORGED NUT S SCHNORR WASHER M5 FLAT WASHER M5 X 10 9 places M5X12 CAPTIVE WASHER SCREW 4 places Black ve White tve 4508 287A Figure 6 17 Frame 5 to 7 500V External Fan Supply O ffe op AO m OROAO O T oe 4508 288A 1999 D D 19 Figure 6 18 Frame 5 to 7 500V External Fan Supply Connections Elite Series Service Manual 4201 230 Rev B6 114 Notes Elite Series Service Manual 4201 230 Rev B6
16. l ul A1000 I I ST A I lli ify I lli ify 1 lli ify lli AN x lli Wy 1 c I ERN BEN Al FPF moo A A yi 1 I MEE iff JO gt avos t ETI LUI BNIHVHS TT sasnd sna I SIMOHI INANI jes esi 251 zi ATddNS HIMOd M 3snd 3803 3803 20 00 20 w x xw xz ne sna W vOcd owed ch j 04 m 1 20401 pwe 001031 7 7 20801 208037 004 2014 Hn Hn zotal 001031 CF 1080 108037 auvos anuozivo j 8019 JA zwo pw ooro G 2 oeo 08031 00d Da 04 HA HA 219 0091 t 80891 808037 2084 1 208d id T 1084 n m L 1019 M prre imi x m 2001001081 7 ti 90 01 906051 SOZd X Old 5 9019 HM HM 20101 001031 WSRSOOLONNOOT 7 9001 90091 duvoa anuozivo 908 SOHVOB HOSN3S TVWHJHL X2 ABL HJMOd bedn H3GWNN SWS 59019 27 NV DONE 004 TWNUAINI told ayyoa 193138 3AHO zar T awie LT 808d M AVd1 d3MOd E i EE LINA AVIdSIO WVHOVIC Y90718 087 3N OL 80 91 9 JMVHA LIOA 007 Frame 6 400V Block Diagram Figure 6 2 4201 230 Rev B6 Elite Series Service Manual 102 Frame 6 6 1 3 FRAME 6 500V ULTRADRIVE ELITE PARTS LIST 500 VOLT ULTRADRIVE ELITE PARTS LIST Display Unit AC Power to Power Tray Loom Rectifier Block 6 x 1421 040 Re
17. link on the new IGBTs 2 Use a new thermstrate avoid touching the surface of it do not use the paper packer 3 Replace the 4 off M6x16 CW screws do not tighten yet and push the IGBT block towards the base of the Elite then tighten the screws This will align the replacement blocks in the same manner as the remaining half phases 4 Remove the gate emitter shorting ribbon from the IGBTs and replace the Gatedrive board 6 2 8 SCR DIODE BLOCK SERVICE Refer to the lower section of figure 6 12 Each SCR diode block is held by 4 off M5x16 CW screws and a thermstrate is used between the SCR diode block and heatsink to ensure a good thermal contact Remove the old SCR diode block and clean the heatsink surface 1 Use a new thermstrate avoid touching the surface of it do not use the paper packer 2 Replace the 4 off M5x16 CW screws do not tighten yet and push the SCR diode block towards the bottom of the Elite then tighten the screws This will align the replacement blocks in the same manner as the remaining half phases 500V MICROTHERMS The 500V models have three microtherms connected to and located above the top set of Thermal Sense boards M3x10 CW SCREW
18. o 6 e A De eren e E a epi E o rn r ID r mn rn o ID ILU ID D d 7 Bi 4 D 4 D AG A A OA PA AD PA K F SPACERS la i 116 BE dev Boso BOBS OG 59 de 69 Gal mm 69 69 e Gr Hm S gen F F OOO Oj ORES OOO ae V Ole OOO s O lO FREES o ler a ler AS o je 8 H Jer gd Jer 7 Jer J r H Db ct mr 19 Hr Up n 2 3 Ti 0 B 2 9 2 Y tH FI peg 7 FI bp 1 7 i SPACER 16 0 LG A M W SCREW 2 OUTER POSITIONS c F c H W0 M5 x 30 CW SCREW SPACER 16 8 LG C M6 x 25 BOLT NUT SCHNOR 2 MIDDLE POSITIONS H B H 4508 306A Nam BUSBAR REMOVED FROM rcc ELECTRONICS CABINET Figure 6 13 Frame 5 Positive and Negative Sheet Bus Elite Series Service Manual 4201 230 Rev B6 Frame 6 109 Positive and Negative Sheet Bus Removal iz Note This drawing has been labelled to assist more with reassembly than disassembly 1 Remove the DC output busbar by removing See figure 6 14 and remove bolts J these bolts connect the positive output busbar to the positive Sheet Bus See figure 6 13 and remove bolts C where the busbar exits the electronics cabinet Slide the busbar into the termination area do not slide it completely through the grommet use soapy water if it is sticking Refer to figure 6 14 2 3 4 Remove the positive Sh
19. o not slide it completely through the grommet If it is sticking use some soapy water A M6x16 CW SCREW LOOM FIOPTIC 715mm LOOM F OPTIC 370mm LOOM F OPTIC 370mm B M6 x 16 CW SCREWS C M8 x 40 BOLT FLAT AND ROUTE THROUGH GROMMET IN SCHNORR WASHER OUTPUT SHEET BUS LOOM FIOPTIC 715mm LOOM FIGPTIC 620mm C M x 25 BOLT 2 X FLAT AND i ROUTE THROUGH GROMMET IN ROUTE THROUGH GROMMET IN 1 X SCHNORR WASHER LOOM F OPTIC 715mm OUTPUT SHEET BUS OUTPUT SHEET BUS O O HB gp O o gn fro i D Ci l k 1 I Es Des nw
20. of the mounting tray This assembly is referred to as the Power tray 1 See section 6 2 1 on removing Control board 2 When the Control board has been removed put it onto the new Power tray For 500V models move the Drive Select board to the new Power Tray see figure 6 10 For 400V models this can be done after the Control board is in place see figure 6 9 Referring to figure 6 11 3 Remove any customising items that may have been fitted in the space provided on the mounting tray 4 Remove the lexan shield over the fibre optic looms 5 At the top of the Power tray remove the wired connectors UL to WH do not pull on the cables then remove the fibre optic plugs UL to WH 6 Unplug the internal fan plug from the top left of the Power tray 7 Loosen the two off Power Tray retaining screws and lift the Power tray clear 8 Place the new Power tray in the Elite and replace the wiring looms etc in the opposite order that they were removed Take care that the connectors are replaced without crossing phases and without inadvertently off setting pins The fibre optic looms and circuit board are marked to ensure the connections are made correctly Particular care must be taken with the fibre optic looms to avoid a bending radius of less than 35mm 9 Replace the lexan shield over the fibre optic looms Before mains powering the Elite it is recommended to Soft Power the Elite to test the new parts are functioning corre
21. ort out the gate and emitter on the IGBTs 6 2 6 SERVICING THE SCR BOARD Refer to the lower section of figure 6 14 1 To get access to the SCR Board first remove the DCCT and DCCT mounting bracket as one assembly The bracket is held by 2 off M4x12 CW screws Lay the DCCT and bracket carefully to one side 2 Remove the choke rectifier busbar fixings D E and F then slide the Bar through the grommet just enough to allow access to the SCR Board It is best to avoid pulling out the Bus Bars if possible as they can be difficult to put back in use soapy water if necessary 3 Remove the screws G and H unplug P1 Note P1 and P2 are common connections to the SCR gate 4 The SCR Board is now only held to the SCR by male spade terminals The SCR Board can now be lifted vertically off the SCR diode block o o EARTH TAB 4 ina qii Oo 0 Oo IE GATEDRIVE BOARD A M6 x 12 CW SCREW M4 x 10 CW SCREW
22. rass spacers It is best to remove them as a full assembly keeping the screws and spacers together this makes for easier reassembly 2 3 It is not necessary to unbolt the DC Bus fuses as the positive Sheet Bus can be removed as one piece
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