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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 E o m mum U4TJEJ 8 A SIT bilo 6 e A De eren e E a epi e 1 MI ID jamal ID D d pI 4 b 4 pi AG OA PA AD PA K D SPACERS la
2. 9 DOOR PILLAR M5x16 CW SCREWS 9 ST prim B CLEAR LEXAN 5 gs uA wem INTERNAL SHIELD LA O O RSS ig tne 2 2 1 M4x16 CW SCREWS 4 CLEAR LEXAN _ f amp INTERNAL gij ian 2 j e I 7 POWER TRAY RETAINING SCREW U PHASE d gt 2 9 S 9 M5x16 CW SCREWS OUTPUT SHEET Wists it t OUTPUT SHEET BUS Fe e US POWER TRAY jee sa ASSEMBLY ES Roa xL Ol sl No olo plo O e ou ole o ES E Fe fat LONG mij pm 1 9 NPUT FUSES d 1 3PERPHASE alf dp alf agp dt e e e e e e Z ewes Frame 7 123 7 2 3 SERVICING THE OUTPUT SHEET BUS Frame 7 construction allows one phase to be disassembled without affecting the other two This section and the follo
3. SPACERS 16LG Elite Series Service Manual H A OUTPUT BUSBAR REMOVED ELECTRONICS Figure 7 14 SPACER 16 0 LG 2 OUTER POSITIONS SPACER 16 8 LG 2 MIDDLE POSITIONS
4. o oo oio ocloz ED Gres te 9750 0 SJ rex Sr oa d B s pi imer 4 8 9 9 e o o 8 JE 9 JE D F 6 CW SCREWS d e JG afe es ais a d 6 IGBT amp THERMSTRATE NOTE ORIENTATION 5 9 IGBTs TO BE MATCHED c EE c 05 d ES uw ES c si egea M5x12 CW SCREWS d d d 4 o o WH CAPACITORS 3 25 K NOTE POLARITY i q 3 CLAMPING PLATE THIS ROW 440 540 and 1 420 480 ONLY Tolol G S zz TA o fe o o o lt 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 5 16 CW SCREWS 4 OF PER RECTIFIER L THERMAL SENSE PCB Figure 6 15 Frame 6 IGBT Capacitors and SCR Level Elite Series Service Manual 4201 230 Rev B6
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6. 3 Remove the screws G and H and 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 e a e o o G EARTH TAB e GATEDRIVE BOARD A M6 x 12 CW SCREW B M4 x 10 CW SCREW M4 x 10 CW SCREW Ui bolo CHOKE RECTIFIER BUSBAR P D M3 x 10 CW SCREW 6 x 16 CW SCREW F M8 x 16 BOLT FLAT AND 96 SCHNORR WASHER q 4 Eg SCR BOARD J G 3 10 CW SCREW T3 HD og 10 CW SCREW EARTH TAB di peld D o 5 di jp e PEE EE E 4 8 ro o o i a mm B E a p le eg B 4508 285A Z d Figure 5 15 Frame 5 Snubber and SCR Board Elite Series Service Manual 4201 230 Rev B5 94 Frame 5 15 2 7 SERVICING THE IGBT Refer to the upper section of figure 5 16 Each IGBT is held by 4 off M6x16 CW screws A thermstrate is used between the IGBT and heatsink to ensure good thermal cont
7. e le E U OUTPUT SHEET BUS 1 V OUTPUT SHEET BUS U W OUTPUT SHEET BUS e z tj _ C B e t ie al S Be Bo Je a eH EP e Be B eh 2 5 Ne HEHE le TE e oll e C 3 oles s Ea Je Jele RS 3 rd of Psi mai m Woo ab 9 Deest 8 8 i s a 2 B Hj HE HE A Bl dk D Es a of o i i p e 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 brass 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 th
8. o C M4 x 10 CW SCREW AG E Be B e g CHOKE RECTIFIER BUSBAR 6 D M3 x 10 CW SCREW q E M6 x 16 CW SCREW F 8 16 BOLT FLAT AND o ios T5 SCHNORR WASHER q 4 E FOU scr BOARD 4 S es o fla o F F M3 x 10 CW SCREW T3 d 5 LE 1026 Ta G x 10 CW SCREW EARTH TAB 0 p 5 Y d I THERMAL SENSE SS no 5 P PCB LOOM EE LEE is 4i In 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 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 IGB
9. RFT RECTIFIER OOo m 06 FRAME 2 ONLY PE v POWER BOARD 2 POWER BOARD L L o Pur OUTPUT CHOKE OUTPUT CHOKE N ae 4508 253 TERMINALS 69 NVMOVIA 42078 3119 3AIHOOSOIIN A008 ANY A00 Z ANY 5 8L Z S 9ul J4 Frame 1 amp 2 1 7 SERVICE 1 7 1 REMOVING THE CONTROL BOARD Refer to figure 1 11 while following this instructions Read section 1 1 for isolation and testing prior to starting work 1 Static safe procedures must be observed i e a grounding strap must be worn and earthed while servicing a unit In addition to the grounding strap an earthed antistatic mat is required if the product is being serviced on a bench 2 Mark the location and remove the control wiring plugs use a felt pen and number each plug Remove fibre optic cables if used and the Display unit 3 Remove the Control board cover under the Display unit by unscrewing the Phillips 8G x 1 2 wafer Screw 4 Remove the Terminal plate by unscrewing 8 off Phillips 8G x 1 2 wafer screws and one Phillips head which is the OV control earth Note this screw may have been already removed during installation 5 Remove the earth connection for the Control board and terminal cover situated under the terminal plate 6 The Control board is secured at the top by 2 off P
10. A M5 x 30 CW SCREW 16 mm SPACER B M5 x 30 CW SCREW 16 mm SPACER C M5 x 30 CW SCREW O D M6 x 25 BOLT NUT SCHNORR AND 2 FLAT WASHERS 4508 284A Figure 5 13 Frame 5 Positive and Negative Sheet Bus Elite Series Service Manual 4201 230 Rev B5 92 Frame 5 Removing the Positive and Negative Sheet Bus Note This drawing has been labelled to assist more with reassembling than the disassembling 1 Refer to figure 5 13 and remove bolts D Refer to figure 5 14 2 Remove bolts E and J Slide the busbar into the termination area do not slide it completely through the grommet Use soapy water if the bus bar is sticking 3 Remove the Positive Sheet Bus starting from F to J 3 Remove the Negative Sheet Bus starting from B to E 4 If you are not going to change the capacitors do not remove the cap centre Sheet Bus screws A POSITIVE SHEET BUS F M3 x 10 CW SCREWS G M6 x 16 CW SCREWS H 5 12 CW SCREWS M6 x 16 CW SCREWS J M6 x 20 BOLT WASHERS AND POWER SUPPLY BOARD SHEET BUS SHIELD CLEAR LEXAN THIS ROW 210 AND 250 AMP ONLY NEGATIVE SHEET BUS B M8 x 16 BOLT AND WASHERS M5x 12 CW SCREW D M6 x 16 CW SCREW 8 16 BOLT AND WASHERS A THIS ROW 210
11. H Frame 7 Positive and Negative Sheet Bus A 5 30 CW SCREW 5 30 CW SCREW C M6 x 25 BOLT NUT SCHNORR AND 2 x FLAT WASHERS 4508 317A 4201 230 Rev B7 Frame 7 125 Removing the Positive and Negative Sheet Bus Note This drawing has been labelled to assist more with reassembling than disassembling 1 Remove the DC output busbar by removing See figure 7 15 and figure 7 14 Slide the busbar to the into the termination area do not slide it completely through the grommet Use soapy water if it is sticking Refer to figure 7 15 2 3 4 Remove the positive Sheet 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 POSITIVE SHEET BUS F M3 x 10 CW SCREWS M6 x 16 CW SCREWS H M5 x 12 CW SCREWS M6 x 16 CW SCREWS J M8 x 20 BOLT WASHERS amp NUT POSITIVE SHEETBUS JOINING BOLTS M8 x 20 WASHER amp NUT SHEETBUS SHIELDS CLEAR LEXAN NEGATIVE SHEET BUS M8 x 16BOLT amp WASHERS M5 x 12 CW SCREWS D M6 x 16 CW SCREWS E M8 x 20 BOLT WASHERS amp NUT B co CLEAR LEXAN lt gt co s
12. 4508 312A Figure 7 13 Frame 7 Output Sheet Bus Removal Elite Series Service Manual 4201 230 Rev B7 124 Frame 7 7 24 SERVICING THE POSITIVE AND NEGATIVE SHEET BUS Removing the Bus Sharing and Power Supply Board Removal Refer to figure 7 14 and 7 15 1 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 brass spacers It is best to remove them as a full assembly keeping the screws and spacers together This makes it easier to reassemble 2 Remove the Power Supply Board This is secured by 4 off M5 x 30 CW screws and has 4 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 it easier to reassemble 3 It is not necessary to unbolt the DC Bus fuses as the positive Sheet Bus can be removed as one piece of a 8i s ES 91 dui CN gt al ef e Je el e ne e
13. i REVISION HISTORY Em i IMPORTANT NOTES Ke ii DISC EA w P aai ii e M M iii FRAME 1 2 FAULT FINDING TESTING AND SERVICE SECTION 1 0 PAGE 7 6 FRAME 3 FAULT FINDING TESTING AND SERVICE SECTION 2 0 PAGE 25 FRAME 4 FAULTFINDING TESTING AND SERVICE SECTION 3 0 PAGE 45 a i iia 1 FRAME 5 6 AND 7 FAULT FINDING AND TESTING 8 T SECTION 4 0 PAGE 68 im 4 FRAME 5 SERVICE SECTION 5 0 PAGE 83 Ek Il m FRAME 6 SERVICE 8 SECTION 6 0 PAGE 99 i FRAME 7 SERVICE SECTION 7 0 115 APPENDIX 5 SECTION 8 0 133 Elite Series Service Manual 4201 230 Rev BF NOTES Elite Series Service Manual 4201 230 Rev BF 1 0 MICRODRIVE ELITE FRAMES 1 amp 2 This section covers 400V models ME 2 5 to ME 22 5 and 500V models ME 2D to ME 21D Frame 1 ME 2 5 to ME 12 ME 2D to ME 11D Frame 2 ME 18 to ME 22 5 ME 16D to ME21D These are referred to within this manual as Frame 1 and 2 The 400V and 500V models are essentially identical for assembly purposes When specific differences exist between the 400V and 500V models these are noted CO 4508 291A CONTENTS 1 4 BEFORE STARTING TESTING OR SERVICE WORK 8 1 2 PRINTED CIRCUIT BOARD DESCRIPTIONS 9 1 3 FAULT FINDING GUIDE 10 1 4 TESTING 14 1 5 SOFT POWERING AFT
14. NOTE ORIENTATION IGBTs TO BE MATCHED IGBT amp THERMSTRATE 4 MEx12 CW SCREWS 4 CAPACITORS 1 NOTE POLARITY q CLAMPING PLATE THIS ROW 440 540 and q 420 480 AMP ONLY olfjolffo ollel a 5 8 8 er i T o of fe ole o of Ur 4 RECTIFIER 8 THERMSTRATE FIT M3x 6 CW SCREWS TO PLUG THESE HOLES LOCTITE SCREW NEAR H S EDGE 4508 3104 M5x16 CW SCREWS 4 OF PER RECTIFIER LTHERMAL SENSE PCB Figure 5 16 Frame 5 IGBT Capacitors and SCR Level Elite Series Service Manual 4201 230 Rev B5 Frame 5 5 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 of the machine Sealing rings are used to prevent air leakage through to the inside of the machine To remove the capacitors undo 15 off M5x12 P
15. ZE F 9 sna 1000 2 Quvog I 1 1 ONIHVHS sna Se 9 35 SE SE m gw m E x ti auyoa E z lec zzz n1090 sna I Quvo8 Y a lauvoe I ONIBYHS zana ONHVHS sna n na N asna asnd i HVOR i z od 20 24 AAA xe ve he ONES SOHO LAdNI o sna 319905 903 uu 4 Quvoa AlddNS H3MOd LULL m 014 m eS no 20601 20031 T2 i s 00 2014 Hn ui uu af ua alm um T HI QuvogHOs OHVOBHOS QuvOS HOS w i un 504 1 20101 pwe 001031 Cl 0 01 TL Te ip 004 018 HA 208d HA 20101 001031 T ti gogo e080 208d 1 T amal ama yor t Zold M m 20101908 001031 2 gosol 902071 S d gr esl 004 Y SUE 8 1 904 HM HM aig Salao Mali 7 HREEOLONOOT S0801 908091 quvog ZAHOALVO SOHVOB HOSN3S TWNHJHLX 21 _ toed N H3GWNN AWS 9019 3 20 92 0019 TVNAJINI 3 Hold 206 maj TVNEJUNI 103195 JAKO me wd eosam AVHL H3MOd WVHOVIC X90718 099 3N OL S873 Z JAVHA LIOA 007 TORINO JN ANAS Frame 7 400V Block Diagram Figure 7 3 4201 230 Rev B7 Elite Series Service Manual 118 Frame 7 7 1 3
16. 4508 203A Figure 1 15 Terminal Board Removal 21 Removing theTerminal board for Frame 2 Refer figure 1 16 when removing the terminal board Note Before proceeding it is critical that all wiring be labelled to guarantee correct reassembly especially the output phases Remove the terminal board by removing 1 M4x400mm Phillips screw N which holds the common mode choke body to the heatsink 2 M5x12mm Phillips screws K L and M which holds the red yellow and blue wires to the Gatedrive board 3 7 off M4x100mm Phillips screws A to G which will disconnect all the choke wiring 4 A M4x10mm Phillips screw which is not shown attaches the earth wire from the Terminal board to the heatsink and under the same screw is the gland plate earth The Terminal board is now held by a 4 pin socket lift the board vertically to disconnect it from the power board 5 x 12mm eu 3 OFF K ja M4x40mm N 1 4508 209 Figure 1 16 Terminal Board Removal Frame 2 Elite Series Service Manual 4201 230 Rev B 22 Frame 1 amp 2 5 1 7 5 SERVICING GATE DRIVE BOARD Removing the Gatedrive Board Frame 2 Removing the Gatedrive Board Frame 1 Refer figure 1 18 when removing the Gatedrive board Remove the Control boar
17. UPPER FAN BARRIER zl CONNECTOR 2 WAY 2 OFF M3 FLAT WASHER 4 OFF M3 SCHNORR WASHER e e 4 OFF M3 HEX NUT 4 OFF CONNECT FAN PLUGS 4508 221A Figure 2 17 Internal Fan Removal Elite Series Service Manual Figure 2 16 CAPACITOR BOARD SERVICING THE CAPACITOR BOARD Refer figure 2 16 Capacitor Board removal The Capacitor board is directly connected to the DC Bus with 4 off M4x10 Phillips screws Remove these and lift the Capacitor board from the enclosure a 4508 217B OUTPUT PHASES Capacitor Board Removal 4201 230 Rev B3 Frame 3 41 2 7 6 REMOVING THE GATEDRIVE 2 7 7 500V MICROTHERMS AND THERMAL SENSE BOARD Remove Phillips screws A and B and lift the board off the gatedrive connections to the IGBT s evenly The 500V models have two Thermal sense boards and a microtherm for heatsink temperature monitoring The Loom to the Thermal sense board plugs in to the Gatedrive board Note the Drive Select board is shown as well this is unique to the 500V models e L DRIVE unc SELECT BOARD 4 10 Refer figure 2 17 Gatedrive removal 400V models note the heatsink temperature is monitored by a NTC resistor via the tab held down by screw B M3x6 CAPTIVE SCREW MICROTHERM GATEDRIVE PCB ASSY lt p PONER E e 4508 3
18. Figure 4 10 Individual SCR Conduction Test Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 amp 7 79 4 4 5 TESTING INDIVIDUAL IGBT You must wear a static grounding wrist strap and it must be earthed The IGBTs should be tested individually this can be done with or with out the Gatedrive board in place The preliminary tests are done with a multi meter The meter readings below are a guide and may vary with differing meter brands It is best to compare the suspect IGBT s with a known good IGBT Note the gate and emitter are shorted together for one test as shown below The IGBTs should be stored and handled in this state SHORT GATE TO EMITTERFOR STORAGE AND HANDLING SHORT GATE TO EMITTER FOR THIS TEST p i Emitter V 4 Te ei Diode E conduction H 0 3 0 45V Flyback gt 10K IGBT Diode Collector 4508 261A Figure 4 11 Individual IGBT Testing The final tests are done as shown in figure 4 12 This test is very important as it is possiblefor the multi meter tests to I u show the IGBTs are OK but the IGBT may not actually work the IGBT does not respond to a Gatedrive signal If this is not detected and the Elite is reassembled with a non functioning IGBT in parallel with good IGBTs the current will be shared between the good IGBT s When the Elite is supplying full load current the IGBT s in the half phase with t
19. 490 G A006 pue 00 DE MICROTHERM 500 VOLT MODELS ONLY THERMAL SENSE BOARD DRIVE SELECT BOARD 0 VOLT MODELS NLY 50 MICROTHERM 500 VOLT MODELS ONLY THERMAL SEN BOARD L1 o L2 o L3 o RFI BOARD L1 DC BUS BOARD L2 L3 DC JE c DC OUTPUT CHOKE _ EEA OC OUTPUT CHOKE ADD OUTPUT CHOKE 4508 237 INVHOVIO 320718 31173 3ATHOVHIE TO A008 ANY p Frame 4 3 7 SERVICE 3 7 1 REMOVING THE CONTROL BOARD See section 3 1 before commencing service work for isolation and testing prior to starting work 1 2 3 4 5 Mark the location of the control wiring plugs use a felt pen and number each plug then remove them Remove the fibre optic cables and serial communications interface if used Remove the top cover plate by undoing six Phillips head M4x10 screws as per figure 3 14 Lift the cover slightly at the end retained by the four screws then slide it towards the bottom of the drive to clear the fibre optic input outputs The following instructions refer to figure 3 15 Note the figure shows the Power tray removed from the Elite for clarity There are tw
20. Screw 8GX5 8 wafer philips 7 places 4508 247 Figure 3 31 Fan Connections Elite Series Service Manual 4201 230 Rev B4 66 Frame 4 NOTES Elite Series Service Manual 4201 230 Rev B4 67 ULTRADRIVE ELITE FRAMES 5 6 AND 7 FAULT FINDING AND TESTING This section covers 400V models UE 170 to UE 660 and 500V models UE 170D to UE 700D Frame 5 UE 170 to UE 250 UE 170D to UE 250D Frame 6 UE 305 to UE 480 UE 305D to UE 540D Frame 7 UE 575 to UE 660 UE 620D to UE 700D These will be referred to Frames 5 6 or 7 The voltage range will not be mentioned unless there are specific differences between the 400V and 500V models 9 a ULTRADAVE sa o TN Ne AG ig 4 CE 7 Contents 4 1 BEFORE STARTING TESTING OR SERVICE WORK 68 4 2 PRINTED CIRCUIT BOARD DESCRIPTION 69 4 3 FAULT FINDING GUIDE 71 44 TESTING 77 4 5 SOFT POWERING AFTER REPAIR 81 Elite Series Service Manual 4201 230 Rev B57 68 Frame 5 6 amp 7 4 1 BEFORE STARTING TESTING OR SERVICE WORK 4 1 1 SITE PREPARATION 1 The work area in front of the Elite be cleaned I 2 Some flat surfaces are arranged for placement of parts 3 Provide containers for small items like screws and bolts Tool Requirements 1 x No 2 Phillips Screw Drivers 1
21. 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 Series Service Manual Sealing Ring Before Inserting Capacitor Into Heatsink Figure 6 16 Clamping Plate r Capacitor Replacement
22. LJA LEE 20 oa 20 x xw xz gt sna 7064 owed ch j 04 m zoro ponia 7 1 20801 206031 0014 2014 Hn zotal 001031 10 01 108037 auvos anuozivo 1 504 JA OW zwo pw ooro G 2 oeo 08031 004 Da 04 HA HA 219 0091 t 0 01 808037 2084 04 09 1 208d id T 1084 n m 5 1019 M prre imi x m 2001001081 7 ti 90 01 906051 SOZd X Old 5 1 9019 HM HM 20101 001037 WSRSOOLONNOOT 1 9001 90091 908 504708 HOSN3S TVWHJHL XZL ABL HJMOd bedn H3GWNN SWS 59019 27 3 ogre 004 TVNEJUNI told 193138 je T LT 808d M AVHL d3MOd E i EE LINA AVIdSIO WVHOVIC Y90718 087 36 OL 80 91 9 3iINVH3 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 Rectifier Thermstrate IGBT Block 24 x 1757 136 IGBT Thermstrate 24 x 1781 104 Gate Drive Board 3 x E481 612 poo External Fans 5 x 2941 024 5 x 2941 022 Miorotherm Including Loom Loom To Power Board 1 x 2726 105 1 Thermal Sensor Looms Short Linking Loom 4 x 2721 114 3 Long Linki
23. 106 Frame 6 DOOR PILLAR M5x16 CW SCREWS z Smile INTERNALFAN 2 OF POWER TRAY SUPPORT RAIL POWER TRAY PH RETAINING SCREWS LEXAN CLEAR M5x16 CW SCREWS INTERNAL SHIELD LEXAN CLEAR M4x16 CW SCREWS INTERNAL SHIELD U PHASE M4x16 CW SCREWS OUTPUT SHEETBUS mE Hi H _ POWER TRAY elt T ASSEMBLY 05 k gee e 2 W PHASE 5 5 TEE ET
24. Figure 3 8 Individual IGBT Conduction Testing Elite Series Service Manual 4201 230 Rev B4 Frame 4 55 3 4 5 TESTING THE DCCT AND DCCT SUPPLY Fal The DCCTs measure motor current and are located on the output of the Elite DCCT failure may be indicated by Fault 21 Ground fault or Fault 58 Current imbalance even with the motor disconnected If fault 21 is apparent and the motor and motor cable have been checked check the DCCT terminations as shown in figure 3 9 and the Inverter as shown in figure 3 4 The 6 pin connector is located at the very top of the Control board Check plugs P301 P302 and P303 connecting the DCCTs to the Power tray Ensure they are correctly inserted How to test the DCCTs 1 Power up the Elite but do not start refer to figure 3 9 This drawing shows two options for testing the DCCTs Test between ground and terminal 1 then ground and terminal 4 to confirm the DCCT has a 14V supply or test at the plug If the 14 supply is not present unplug the DCCT s and recheck the 14 supply If the supply has returned one or more of the DCCTs are faulty If the supply has not returned the Control board or Power tray s switchmode power supply may be faulty see section 3 3 4 to determine which 2 Test the DCCTs by measuring between ground and T3 ground and T5 and ground and T6 This should measure OV If the 3 readings are not at OV then replace the faulty DCCT s DCCT PLUG GROUND RED WHITE BLACK BLUE
25. 4508 293A Elite Series Service Manual 4201 230 Rev B57 78 Frame 5 6 amp 7 4 4 3 TESTING FOR CORRECT SCR CONDUCTION Using a 24Vdc current limited power supply or battery arrangement as shown in figure 4 9 Connect the supply positive Jto the respective input fuse choke terminal and the supply negative to the positive DC Bus terminal F Unplug the other end of the corresponding gatedrive cable from the Power tray Turn on the power supply and set the output voltage to 24Vdc approx Apply a trigger pulse to the SCR under test with 24Vdc via a resistor of between 18 and 100 ohms via the plug on the unplugged end of the gate drive cable Trigger the SCR as per figure 4 9 below H Note the SCR will not be damaged if the red lead makes contact with the trigger lead from the power supply When the gate has been triggered the SCR should latch into conduction and the supply go to current limit or the lamp glow for the alternative testing arrangement Since the supply is DC the SCR will not turn off until the supply is removed If the SCR will not stay latched on check the current limit is not set too low or the lamp is too low a wattage to allow sufficient current for the SCR to maintain a latched state If the SCR fails to conduct suspect a failed input fuse SCR Gate Trigger PCB or interconnecting loom Rectifier VE DC
26. Filer CHOKE RECTIFIER BUSBAR soj 5 0 oe D M3 x 10 CW SCREW E M6 x 16 CW SCREW gt F M8x16 BOLT FLAT AND 9 de 5 SCHNORR WASHER Ollio iog FO O o 289 scRBOARD 8 i o Ho o Ho o G M3 x 10 CW SCREW 73 di TS al G 4 GIBGI ql GI PH H M3x 10 CW SCREW EARTH TAB Bo z m EE EE EE 4508 315A Figure 7 16 Frame 7 Gatedrive and SCR Board Elite Series Service Manual 4201 230 Rev B7 Frame 7 127 7 2 7 SERVICING AN IGBT Refer to the upper section of figure 7 16 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 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 M6 x 16 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 7 2 8 SERVICING THE SCR DIODE BLOCK Refer to the lower section of figure 7 15 Each SCR diode block is held by 4 off M5x16 CW screws and a thermstrate is use
27. ce e ci s ce s ce CENTER SHEETBUS X A M5x 12 CW SCREWS d SA AK A POWER TRAY DC SUPPLY BOARD NEGATIVE SHEETBUS JOINING BOLTS 7 8 x 20 WASHER amp NUT 4508 314 Rev A Figure 7 15 Frame 7 Positive and Negative Sheet Bus 3D View Elite Series Service Manual 4201 230 Rev B7 126 Frame 7 7 2 5 SERVICING THE IGBT GATE DRIVE 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 7 16 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 Short out the gate and emitter on the IGBTs 7 2 6 SCR BOARD SERVICE Refer to the lower section of figure 7 16 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 M4 x 12 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 busbar 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 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 vertica
28. r SCRPCBLOOM THERMAL SENSE BLOOM OA 30FCTLOOM CONTROLBOARD EARTH 3WAY PLUG oc CONTROL CABLE 1 CLAMPS 4808 257 Figure 7 6 Frame 5 to 7 Power Tray Elite Series Service Manual A Control 772 Board E Plugs FAN USED ON FRAMES 6 amp 7 ONLY CONTROL BOARD Figure 7 7 Frame 5 to 7 Power Tray and Control Board vezz 209r Figure 7 9 Frame 4 to 7 Control Board Biscuit 4201 230 Rev B7 Frame 7 7 2 2 SERVICING THE POWER TRAY The Power Electronics board is replaced as an entire assembly inclusive of the mounting tray This assembly is referred to as the Power tray 1 See section 7 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 7 11 For 400V models this can be done after the Control board is in place see figure 7 10 Refer to figure 7 12 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 Atthe 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 tra
29. 004 2064 A 0064 5064 ANAL H3MOd Frame 5 500V Block Diagram Figure 5 4 4201 230 Rev B5 Elite Series Service Manual 88 5 5 2 I 5 2 1 1 2 3 4 5 6 7 8 9 10 11 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 5 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 slightly to clear the fibre optic connections before lifting it clear Referring to figure 5 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 Figure 5 6 Frame 5 to 7 Power Tray and Control place Board Control 74 Board Plugs FAN USED ON FRAMES 6 amp 7 ONLY _ CONTROL BOARD The replacemen
30. 44 Frame 3 2 7 11 REMOVING THE RECTIFIER Refer figure 2 27 To remove the Rectifier assembly remove 1 1 off M4x6 screw which earths the rectifier board to the heatsink 2 6 off M6x16 screws 3 Lift the board off the heatsink the thermstrates are the only thing holding it down To replace rectifier blocks 1 Remove the remaining screws that hold the block to the PCB Be careful to support the weight of the block as it is only held by the Gatedrive connections 2 Unplug the block from the Power board 3 Plug in the new SCR and replace the screws 4 Place the new thermstrates on the heatsink Avoid touching the surface of the thermstrate and remove the paper packing strips 5 Reassemble the Elite RECTIFIER PCB ASSY THERMSTRATE NOTE LOWER SKIRTS OMITTED FOR CLARITY p 4508 220B Figure 2 27 Rectifier Assembly Elite Series Service Manual 4201 230 Rev B3 3 0 This section covers 400V models from UE 60 to UE 140 and 500V models UE 60D to UE 140D ULTRADRIVE ELITE FRAME 4 45 The 400V and 500V models are essentially identical for assembly purposes When specific differences exist between the 400V and 500V models these are noted a s EA 4508 324 CONTENTS 3 1 BEFORE STARTING TESTING OR SERVICE WORK 3 2 PRINTED CIRCUIT BOARD DESCRIPTIONS 3 3 FAULT FINDING GUIDE 3 4 TESTING 3 5 SOFT POWERING AF
31. Decrease acceleration rate Screen R1 Increase the torque limit Screen L4 amp L5 Increase Rs Screen X3b 30 SP LIM T O Detail At speed limit for longer than specified Sense level Set by Screen L6 Possible cause Load condition or inappropriate setting of Screen L6 Action Fault Action Check load condition or alter Screen L6 Fault 31 CAL FLT Detail Internal reference voltage levels are incorrect Possible cause Elite Series fault Seek service 32 S W T O Detail Internal timing requirements exceeded Possible cause PDL Vysta for Windows configuration too complex Fault Action Simplify configuration Fault 33 LVDC FLT Detail Failure of the low voltage dc power supplies Possible cause Heatsink cooling fan failure control PCB failure Action Seek service Fault 34 VYSTA TRIP Detail Custom configuration developed using PDL Vysta for Windows has deliberately tripped the Elite Series Possible cause Refer to custom configuration schematic Action Refer to custom configuration schematic 133 Fault Detail 35 NO DISPLAY The Elite Series has detected that the display unit is disconnected or faulty The Elite Series will trip on this fault only if the display unit is enabled via Screen 11 11 LOCAL 5 5 1 2 3 Possible cause Display removed by personnel display mounted more than 3m distance from the Elite Series unit faulty display unit Action Connect display unit and disable ke
32. Elite Series Service Manual 4201 230 Rev BA 134 Fault 43 MAS U DES 44 MAS U DES 45 MAS V DES 46 MAS V DES 47 MAS W DES 48 MAS W DES 49 SLV U DES 50 SLV U DES 51 SLV V DES 52 SLV V DES 53 SLV W DES 54 SLV W DES Internal protection of a semiconductor switching device has occurred MAS Master Ultradrive Elite SLV Slave Ultradrive Elite DES DESAT Possible Cause Output short circuit extreme output over current wiring fault IGBT Desaturation IGBT failure Detail Action Check entire output circuit and motor for wiring or winding faults f fault persists when output leads are disconnected replace or service the Ultradrive Elite Fault 55 MAS I FLT Detail The MASTER Ultradrive Elite output current has reached a dangerous level Possible Cause Short circuit wiring fault circuit fault motor fault Action Check entire output circuit and motor for wiring or winding faults Check output circuit contactors and or isolators for correct operation Fault 56 SLV I FLT Detail The SLAVE Ultradrive Elite output current has reached a dangerous level Possible Cause Short circuit wiring fault circuit fault motor fault Action Check entire output circuit and motor for wiring or winding faults Check output circuit contactors and or isolators for correct operation Fault 57 DESAT OCT Detail The SLAVE drive indicates a common desat or over current fault Possible Cause Shor
33. SIRO MOREM VEM 1 2 off 8Gx1 2 Screws holding the body link to the To remove the shrouds remove lower end of the skirts 1 6 off 8Gx1 2 wafer screws 2 4 off rubber grommets 2 3 off 12x3 4 pan square screws 3 8 off M6x110 bolts 3 2 off M4x10 phillips screws 4 2 off M6x16 Phillips head screws SCREW sx T ERES The top half of the skirts can now be lifted clear TUE ta yes M6X110 BOLT 8 OFF M6 SCHNORR WASHERS 8 OFF 2 FLAT WASHERS M6 X 12 5 16 OFF SCREW 8GX1 2 M6X16 SET SCREW 2 OFF WAFER PHILIPS M6 SCHNORR WASHER 2 OFF 2 OFF 97 FLAT WASHER M6 X 12 5 2 OF GROMMET DIA16 4 HOLE TOP SHROUD SHROUD RIGHT ELITE SHROUD TABS FIT BETWEEN FAN PLATES amp BOTTOM MTG BRACKET 4508 2168 Figure 2 13 Shroud Removal 4508 215A Elite Series Service Manual 4201 230 Rev B3 Frame 3 eo Figure 2 16 Skirt Removal 2 7 4 REMOVING THE INTERNAL FAN Refer figure 2 17 The fan mounting lexan sheet is clipped in place between the gatedrive board and the Capacitor board The fans are powered from the DC bus Board 1 The upper fan barrier is a small lexan sheet that must be bowed sufficiently to remove the locating tab from the gatedrive or the Capacitor board 2 Unplugging the fans from the DC bus Board requires removing the Capacitor board BLUE M3X25 SCREW OFF BLUE gt RED
34. Service only by qualified personnel Always isolate and allow to discharge before servicing Never replace ceramic fuses with glass types Always wear safety glasses when operating with the cover removed The Elite Series contains static sensitive printed circuit boards Use static safe procedures when handling these boards Never work on live equipment alone Observe all recommended practices NOTES This manual and the screen list contained within this document relate to Elite Series software version 3 8 Refer to Screen Z2 for the software version of your Elite Series It is the responsibility of the end user purchaser to ensure that operators understand how to use this equipment safely Please read this manual thoroughly The latest revision of this manual is available from our web site www pdl co nz DISCLAIMER This service manual applies to Elite Series Variable Speed Drives and is current at August 2002 While there have been minor changes in preceding Elite models and there may be minor changes in future Elite models this manual should still convey the basic service information required If you have any concerns contact PDL Electonics or our agent Elite Series Service Manual 4201 230 Rev BF CONTENTS DEDICATION TO QUAL IT Y agr a cu gota Fa i COMPREHENSIVE SUPPORT PROGRAM 2 00 0 000
35. gently lift the Control board evenly off the 40 way socket connecting pins 9 Unplug the DC current transformer DCCT Interface board from under the 6 way socket on the top left of the Control board 10 Place the Control board in a static proof bag or on antistatic foam Replacing the Control Board 1 Continue to observe static safe work procedures 2 Avoid excessive handling of the new Control board 3 The replacement Control board will be in biscuit format and will have to be trimmed to size This is done with a fine pair of side cutters cutting as close to the Control board as possible If the stubs of the joining bridges are too large they will need to be filed down or inserting the Control board will be more difficult See figure 2 14 4 Plug the DCCT interface into the Control board and place the Control board on the 40 pin connector The lexan mounting sheet for the internal cooling fans is fixed through some slots in the Control board The lexan may have to be moved to allow 4808 286A the Control board to fix correctly on the pins Figure 2 12 Frame 3 Control Board Biscuit PU 10 Elite Series Service Manual 4201 230 Rev B3 Frame 3 39 2 7 2 REMOVING THE SHROUD 2 7 3 REMOVING THE SKIRT Further service of the Elite requires better access This Refer figure 2 16 will require the removal of the shrouds and top skirts To remove the top half of the skirts remove Reter figure
36. 6 Pin Connector 6 Pin e Connector V DCCT Output 6 5 ubccr Output n 14 Volts 4 3 W DCCT Oputputs k 1 14 volt Control Board Ground 4508 336A Figure 3 9 DCCT and Supply Testing 3 4 6 TESTING THE DC BUS CAPACITOR Test the rectifier and inverter by following the procedure in section 3 4 1 Test the capacitors by using a meter set to OHMS between HVDC terminals and The resistance should start low then increase as the capacitors charge to the meter battery voltage ensure the DC bus capacitors are fully discharged first This charging period could take some time and it is best carried out by testing the suspect machine against a known good Elite of the same amperage rating or check the spare parts list and pick an Elite of the same frame size with the same number of DC Bus capacitors Time the rate of charge i e the increase in ohms on the meter and compare this against the suspect Elite If this test indicates reasonable variation there may be a problem with the capacitors Further testing requires disassembly of the Elite To test for individual open or short circuited capacitors the Elite must be dismantled and each capacitor individually checked with a multimeter Ensure all capacitors are fully discharged Then connect the meter on OHMS range across each capacitor in turn Make sure the meter positive is to the capacitor positive On a good capacitor the resistance should
37. PDL ELECTRONICS LTD ELITE SERIES SERVICE MANUAL Part No 4201 230 Rev B Head Office 81 Austin Street P O Box 741 Napier Schneider New Zealand 4 Tel 64 6 843 5855 Electric Fax 64 6 843 5185 Elite Series Service Manual 4201 230 Rev BF Elite Series Service Manual 4201 230 Rev BF DEDICATION TO QUALITY AC Motor Control Products can dramatically improve your process control productivity and energy efficiency but only if they are working correctly Which is why we at PDL Electronics go to great lengths in our design and manufacturing to ensure that our products operate correctly first time every time An extensive research and development investment ensures that this product is one of the most technically advanced in the world with built in strength and robustness to suit your application and environment Our AS NZS ISO 9001 certification gives you the confidence of our international independently certified Quality Assurance program All staff are actively involved in continuous improvement programs with a customer focus The components that go into our products are selected from the best in the world and must pass our rigorous and demanding test program Finally every new drive design is run through a rigorous test program including full load operation at above rated temperature under the most demanding load conditions Our dedication to quality makes the PDL Electronics product regardless of pric
38. o UGATRADRIMZ Di 4508 296A Figure 5 1 Frame 5 Ultradrive Elite Contents 5 1 PARTS LISTS AND BLOCK DIAGRAMS 84 5 2 SERVICE 88 Elite Series Service Manual 4201 230 Rev B5 84 541 L 5 1 1 PARTS LISTS AND BLOCK DIAGRAMS FRAME 5 400V ULTRADRIVE ELITE PARTS LIST 400 VOLT ULTRADRIVE ELITE PARTS LIST Frame Size Model Display Unit Control Board Power Tray SCR Board SCR Loom AC Power to Power Tray Loom Rectifier Block Rectifier Thermstrate IGBT Block IGBT Thermstrate Gate Drive Board DC Bus Capacitors Capacitor Sealing Rings External Fans Main Internal Fan DC Bus Fuse Input Fuses SCR Board Fuse Power Supply Board Fuses DC Power Supply Board Thermal Sensor Boards Thermal Sensor Looms DC Power to Power tray Loom DCCT Bus Sharing PCB Fibre Optic Loom UH VH amp WH Fibre Optic Loom UL amp WL Fibre Optic Loom VL Figure 5 1 Elite Series Service Manual FRAME 5 E250 620S E000 610S E660 611S 3 x E660 615S 2721 091 2721 119 3 x 1421 040 x 1781 103 12 x 1757 135 12 x 1781 104 3 x E250 612S 12 x 1352 453 18 x 1352 453 12 x 3907 004 18 x 3907 004 2 x 2941 011 2941 006 3 x 3302 616 3 x 3302 615 3 x 2401 025 2 x 2404 063 E660 621S Includes Fuses 6 x E000 619S Loom To Power Board 1 x 2726 104 Short Linking Loom 4 x 2721 114 Long Linking Loom 1 x 2726 103 2721 119 3 x 2521 071 4 x 037
39. 101 Frame 6 FRAME 6 400V ULTRADRIVE ELITE BLOCK DIAGRAM 6 1 2 ATNO 087 SHOLIOVdVO 3S3HL 795 809 na 8 Li 8 Xx 8 Xi A L891 T3TIVa Vd X 189 IJTIVHVA X 189 IJTIVEVA X SHOLJOVAVO 91800 dui eh o l cI tra sna odo 3411934 31411938 T T T T sna s NEN NE gt gt EN t NEN NEN NE NEN wu HE H oa NEN 1 M Quvo8 1999 S E E i 19808 ERE FERT ita 1 BEN T T 1 T FT ITI TI 1 C iy qa lb n Lil ul A1000 l FT F EN A NE AN x 2 ie ERN BEN 1 FI Sed snl P 851 spl moo A BE 1 JO gt 0408 t ETI L LUI ONIYHS sna INANI zi jes esi 251 zal A1ddns HIMOd M 3snd asnd
40. The Elite Series operates from HIGH VOLTAGE HIGH ENERGY ELECTRICAL SUPPLIES Stored charge is present after switch off Due to the high leakage currents inherent to AC drives earth connection of both the motor and the Elite Series is essential before connection to the supply The Elite Series must be permanently connected to the supply For safety reasons normal operation of the Elite Series requires front covers doors to be place and secured closed Do not attempt to isolate the motor while the Elite Series is running Some parameter settings may cause the Elite Series to start automatically after power failure Motor overspeed operation be limited by mechanical constraints RELIABILITY WARNINGS Always screen control wiring Ensure that the Elite Series is not mounted in adverse environment ENVIRONMENTAL WARNINGS Corrosive vapours or gases may interfere with the correct operation of electronic equipment These compounds may include fumigants such as methyl bromide or gases such as sulphur dioxide hydrogen sulphide or chlorine derivatives Please consult the manufacturer if there are any doubts about the environmental conditions this equipment may be operating in or subjected to The rating refers to dust and water ingress and not corrosive gases PDL products are designed and manufactured to a pollution degree 1 or 2 Neither of which cover corrosive vapours or gases SERVICING WARNINGS
41. This weakened area may show signs of bulging or be split if the capacitor has overheated or suffered an internal fault Elite Series Service Manual 4201 230 Rev B3 Frame 3 35 2 5 SOFT POWERING AFTER REPAIR Once all the faulty components and assemblies have been replaced and the Elite has been carefully reassembled itis recommended that the machine be tested as per section 2 4 1 then Soft Power Soft Powering Refer to figure 2 9 Connect a 24Vdc current limited power supply to T36 positive and T37 0 volt Energise the supply and the Display unit should activate Set the Elite to local control as per the technical manual PDL part no 4201 180 Disconnect the supply Connect a PDL softpower supply to the DC bus as shown in figure 2 9 The softpower supply is available from PDL Electronics or the circuit diagram to build one is available in section 8 of this manual This power supply is a 600Vdc power source which can be used to power up the DC Bus The procedure enables any remaining DC Bus or inverter fault to be found without causing damage Connect the soft power supply to the mains The isolating transformer is not required for galvanic isolation between supplies as only one supply is used compared to Frames 4 to 7 It is recommended as a safety measure The lamps in series reduce the current that will flow if the Elite is faulty Set the variac to the lowest setting switch on the variac and increase the voltage setting to 2
42. 116 BE dev Boso BOBS OG PED de 69 Gal mm 69 69 Sa Gr Hm Bo gen F OW OPO E OPO OOO Ole s O lO A o je a Hela AS o je 8 H Jer gd lel 2 jel J g H 1 mr 19 Hr Up n 2 3 Ti 9 9 lt tH te peg 9 1 7 i SPACER 16 0 LG A M W SCREW 2 OUTER POSITIONS c c H 2 5 30 CW SCREW SPACER 16 8 LG C M6 x 25 BOLT NUT SCHNOR 2 MIDDLE POSITIONS H H 4508 306A 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 T 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 Sheet 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 t
43. 3 4 Rectifier and Inverter Testing Frame 4 3 4 2 TESTING FOR CORRECT SCR CONDUCTION Using a 24Vdc current limit power supply or battery arrangement as shown in figure 3 5 Connect the supply positive to the respective input fuse choke terminal and the supply negative to the positive DC BUS terminal Remove plug P11 from the Power Tray and apply a gate signal Apply a trigger pulse to pins 12 L1 13 L2 14 L3 with 24Vdc via a resistor of between 18 and 100 ohms via the plug on the unplugged end of the gate drive cable Trigger the SCR as per the figure 3 5 When the gate has been triggered the SCR should latch into conduction and the supply Go to current limit or the lamp glow for the alternative testing arrangement The supply is DC therefore the SCR will not turn off until the supply is removed If the SCR will not stay latched on check the current limit is not set too low or the lamp is too low a wattage to allow sufficient current for the SCR to maintain a latched state If the SCR fails to conduct suspect the SCR Gate Trigger PCB or interconnecting loom Rectifier VE DC Bus d CN EN i Cy 24V Current DC Bus limited Power P Board supply Apparatus A A A Power tray Lamp to Limit Current and Protect Battery L1 18 to 100 Ohm Resistor 18 to 100 e
44. 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 Atthe 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 correctly 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
45. 9 gt Iv s AlddnS H3MOd 8 ja 04 NIOQ AH 2 3 Cola m 493 HOS auvog UOS 0 pue 206041 vor VOLT 20ld 10 9I pue 106031 Hn Id L Id l fre pil jpg VA i13lv9 1064 NY4 ISYHd d AOOP XZ H Mu pue 0 031 HA 1 nt 9029 HAISILOSY X HJIHJANIX ro HOSNIS vum 906 amp 3H13901 Q3 001 900031 aei aa uri Zd d 14 SES HM E UU S0 9I 606031 HE ANN GNA YSN IWYS SIMd OML Old wed id quvog 103738 JAHO ved E eL OLOL 2064 A TWNINHJL oea TOHINOD LINN AVIdSIG 5054 M AVHL H3MOd Frame 5 400V Block Diagram Figure 5 2 4201 230 Rev B5 Elite Series Service Manual 86 Frame 5 5 1 3 FRAME 5 500V ULTRADRIVE ELITE PARTS LIST 500 VOLT ULTRADRIVE ELITE PARTS LIST Frame Size FRAME 5 Spares Guide Display Unit E250 620S Control Board 000 6105 1 Power Tray E661 611S 1 SCR Board 3 x 661 6155 2 SCR Loom 2721 091 AC Power to Power Tray Loom Rectifier Block Rectifier Thermstrate IGBT Block IGBT Thermstrate Gate Drive Board DC Bus Capacitors Capacitor Sealing Rings External Fans Main Internal Fan DC Bus Fuse Input Fuses SCR Board Fuse DC Power Supply Board Fuses Power Supply Board Thermal Sensor Boards Microtherm Including Loom Thermal Sensor Looms DC Power to Power tray Loom DCC
46. BUS FILTER The DC Bus filter is comprised of electrolytic capacitors and chokes The chokes are mounted in series with L1 L2 and L3 and are called line chokes The filter s function is to reduce the harmonic current drawn by the Elite and the ripple on the DC Bus Excess ripple gt 40Vac will be detected and displayed as a supply fault see section 4 3 1 for further details To achieve the required voltage rating two capacitors are connected in series The capacitors are rated at 400V and 450V for the 400V and 500V models respectively Possible Causes of Failure The definition of capacitor failure is for the capacitance of the capacitor to drop or exceed the manufacturers tolerance or to suffer a catastrophic failure which is an open or short circuit While this section is quite detailed the capacitors seldom cause any problems 400V capacitors rating 2200 MFD 20 at 20 C and 120Hz 500V capacitors rating 1800 MFD 20 at 20 C and 120Hz Factors Affecting The Life of The DC Bus Capacitors Stress related issues these are vibration excessive ripple above rated voltage and or temperature Over heating is the most likely cause of premature failure and can be brought about by reduction in cooling air flow to the drive Check the heatsink for blockage and fans excessive ambient temperature or excess ripple due to some of the capacitors going open circuit Shelf life the recommended storage period without use should not exceed 3 y
47. Bus br 4 a 24V Current limited Power SCR SOR SCR PCB supply Alternative Test Apparatus we FSR A A A Power fone ote DI 18 to 100 Ohm Tray Lamp to Limit Current Resistor and Protect Battery L1 ZW M f z 18 to 100 YYY Touch Ohm Resistor Briefly to i IYYY 13 Trigger 5 I O 7 pun c z 8 12 to 24 Volt A A m a Battery To L2 and L3 VE DC Bus SCR 4508 262 Figure 4 9 SCR Conduction Test 4 44 INDIVIDUAL SCR TESTING When the Elite is disassembled the SCR s can be tested individually as shown in figure 4 10 DIODE TESTS SCR TESTS SCR TESTS gt gt 100 bd gt 100K conduction 0 3 0 45V ALTERNATIVE TEST APPARATUS O O Lamp to Limit Current and Protect Battery 24V Current limited Power Pm SER supply 18 to 100 Ohm Resistor ON aioe anti VL NA Touch Gate Briefly 18 to 100 i Trigger SCR Ohm Resistor 12 to 24 Volt pet a c c 5 Battery O 4508 297A KM
48. Bus filter will not be capable of maintaining the ripple below 40Vac and the Elite will trip The Display unit will stay live the Elite can be reset and will run to about the same current before tripping again Excessive mains distortion harmonics can also cause excessive ripple on the DC Bus The cause of excessive supply distortion in an industrial situation may be SCR controlled heating equipment DC drives current source inverters and other high current non linear loads This can also occur where backup generators are used and they have not been sized correctly relative to the total variable speed drive load VSD The total loading of VSDs on a backup generator should be about 60 and the remaining 4096 made up of linear loads 3 3 2 FUSE FAILURE Fuse failure is not a normal event and it usually indicates a more serious fault Thus the reason for fuse failure should be investigated Supply Fuses Location At point of supply to the Elite Possible reason for failure Supply surge age or cyclic stress failure wrong fuses fault in supply cable to the Elite rectifier or inverter fault motor or motor cable fault Elite Series Service Manual Frame 4 Action 1 See section 3 1 before starting 2 Perform a visual inspection for mechanical damage water entry or any other possible damage to the system 3 For new or modified installations check the wiring is correct as per the technical manual 4201 180 4 Ch
49. 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 a linear AC to 24Vdc 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 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 516 op AO m OROAO 0 oe 4508 288A 119939 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 115 7 0 FRAME 7 ULTRADRIVE ELITE SERVICE This section covers 400V models from UE 575 to UE 660 and 500V models from UE620D to UE700D The 400V and 500V models are essentially identical for disassembly and r
50. E041 623 Rectifier Block 3 x 1421 037 IGBT Block 3 x 1757 127 1757 128 1757 128 IGBT Thermstrate 3 x 1781 006 Rectifier Thermstrate 3 x 1781 002 Capacitor Board E032 617S E039 617S E047 617S DC Bus Capacitors 10 x 1277 546 12 x 1277 546 14 x 1277 546 Thermal Sense Board 1 x E000 619S Microtherm 2721 102 Includes Wiring Loom and Plug External Fans 2 x 2941 012 Internal Fans 2 x 2941 010 IP54 only 4508 272A Figure 2 11 Frame 500V Microdrive Elite Parts list Elite Series Service Manual 4201 230 Rev B3 Jenueyy S seues F EJ 84 052 1067 IZL Z weubelq xoo g AOOG pue euer DISPLAY CONTROL BOARD EXTERNAL FAN DRIVE SELECT BOARD 500 VOLT MODELS ONLY DCCT INTERFACE BOARD 1 mm COMMON MODE CHOKE RECTIFIER BOARD Thermal Sense Tab GATEDRIVE BOARD O CAPACITOR BOARD 900 VALJ m POWER BOARD EXTERNAL FAN INTERNAL FAN 40mm p IP54 MODELS ONLY INTERNAL FAN 40mm IP54 MODELS ONLY 47 COMMON MODE TOROID 4508 254B 69 INVHOVIO 32078 31173 3AIHGOO IN A00S ANY owel4 26 38 Frame 3 9 2 7 SERVICE 5 Gently push the 40 pin connector onto the pins once step 4 is completed and check through t
51. Fibre Optic Loom UH VL 8 WL 3 x 2727 018 715mm Fibre Optic Loom WH Fibre Optic Loom VH 1 x 2727 016 370mm Figure 7 2 Frame 7 400V Parts List Elite Series Service Manual Spares Guide Level 1 Level 2 m IN jo A o Level 1 Minimum spare stock Level 2 Typical spare stock 4508 279A 4201 230 Rev B7 117 Frame 7 FRAME 7 400V ULTRADRIVE ELITE BLOCK DIAGRAM 7 1 2 yu 392809 3i 1891 TATWHVd 9 5 1891 3TIVHVd 9 5 1991 TAT Wed 9 SH0 LOYdvI SNE JA SHOLIOWdW9 SNE 20 SHOLJOVAVI SNE 20 sna 20 an 331411995 31411934 sna 1 20 IJN L L 5 zm JAA sne A 1 t T BO n a IT S M1990 7 4 M 4 t a y x 0408 alk 5 5
52. MATCHED NOTE ORIENTATION d 4 CAPACITORS NOTE POLARITY q CLAMPING PLATE gt q 4 ort 3 o mer i RECTIFIER amp THERMSTRATE m Mor GW SCREWS 4508 316A M5x16 CW SCREWS THERMAL SENSE PCB 4 OF PER RECTIFIER 2 OF M4x10 CW SCREWS Figure 7 16 Frame 7 IGBT Capacitors and SCR Level Elite Series Service Manual 4201 230 Rev B7 128 Frame 7 7 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 of the machine Sealing rings are used to prevent air leakage through to the inside of the machine To remove the capacitors undo 15 off M5x12 Phillips screws See figure 7 17 7 2 10 REPLACING THE CAPACITORS The capacitors should be installed using a jig PDL part number 5101 190 this ensures the height and rotational position are exact 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 7 17 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
53. Reduce to 3 metres Replace Display Unit 4508 249A Note 1 Terminal 10 red Terminal 11 white Terminal 12 black screen Note 2 See Elite Series Technical Manual 4201 180 Screens Z to Z1 Figure 4 2 Display Fault Finding 73 CONTROL BOARD 4 3 4 Control board fault finding Check field control wiring for faults or disconnect it Is 28VDC present on the fan terminals see note 1 Replace the Power Tray Yes high voltage applied Is 24VDC present on terminals 20 amp 21 Replace the Control Board Check the field wiring again and replace the 500mA fuse on the Control Board 24VDC present on terminals 37 amp 36 Replace the Control Board 4508 327A Note 1 The fan terminals are located between the fibre optic connections at the bottom of the Control Board These are not used in these frame sizes but still indicate that the Power Tray switch mode power supply is producing the 28Vdc required by the Control Board Figure 4 3 Control Board Fault Finding Elite Series Service Manual 4201 230 Rev B57 74 Frame 5 6 amp 7 4 3 5 INPUT RECTIFIER Rectifier is a half controlled bridge that combines DC conversion and the Soft Charge section of the Elite into stage The SCR s on Line 1 are phase controlled to limit the inrush current due to the DC Bus capacitors w
54. by removing the gold coloured panel above the electronics cabinet The panel is held by 6 off M5x10 CW screws An exploded assembly view is shown in figures 5 18 and 5 19 amp 5 FORGED NUT S SCHNORR WASHER M5 FLAT WASHER M5 X 10 9 places M5X12 CAPTIVE WASHER SCREW 4 places Black ve White ve 4508 287A d 9 4508 288A ZU LAM ae Figure 5 19 Frame 5 to 7 500V External Fan Supply Connections Elite Series Service Manual 4201 230 Rev B5 Frame 5 97 NOTES Fa Elite Series Service Manual 4201 230 Rev B5 98 Frame 5 Notes Elite Series Service Manual 4201 230 Rev B5 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 4508299 6 1 PARTS LISTS AND BLOCK DIAG
55. capacitors and the SCR Diode blocks by 22 off M5x12 Phillips screws Note This is for the UE 140 D The models below UE 140 D have less capacitors see the parts list for the exact numbers 3 6 off M16x12 Phillips screws which secure the board to the IGBT s 4 The board is now held by the SCR Diode block connections lift it carefully off these 63 Replacing the DC Bus board The most important part is to ensure the female spade terminals on the underside of the board are aligned on to the SCR Diode block terminals Mex12 captive washer screw 6 places 115 140 0 ONLY E140 busbar PCB bus UE60 140 PCB bus assembly x10 captive washer screw M5x12 captive washer screw 22 places E145 140 D ONLY Busbar UE140 rectifier 4508 229B Figure 3 25 DC Bus Board Elite Series Service Manual 4201 230 Rev B4 64 Frame 4 Fa 3 7 6 SERVICING THE CAPACITOR Sealing Ring Before Capacitor Replacement Inserting Capacitor Complete The capacitors are mounted through the heatsink with _ Into Heatsink e TERRE the bulk of the capacitor in the main cooling air flow at the EET Plate JE ee back of the Elite Sealing rings are used to prevent air leakage through to the inside of the Elite r Heatsink To remove the capacitors undo 15 off M5x12 Phillips screws see figure 3 26 Sealing
56. faults are listed below Fault 01 LOW Vdc The supply to the Elite is dropping below the switch mode power supply operating level and the Elite is shutting down This is usually caused by a weak supply or faults in the supply system Look for motors starting direct on line or other machines drawing high current For further details see the fault list in section 8 of this manual Fault 02 HIGH Vdc The supply to the Elite is surging too high Rapid load changes in the supply system may be faster than the automatic tap changing transformers can adjust to For further details see the fault list in section 8 of this manual Fault 04 SUPPLY FLT Is an indication that the ripple on the DC Bus has exceeded 40Vac This can be caused by diode s in the rectifier going open circuit see section 1 4 for more information This is more likely to be caused by The loss of an input phase which increases the ripple on the DC Bus The Elite will run on two phases up to half to two thirds of its current rating at which point the DC Bus filter will not be capable of maintaining the ripple below 40Vac and the Elite will trip The Elite can be reset using the display unit Excessive mains distortion harmonics can cause excessive ripple on the DC Bus The cause of excessive supply distortion in an industrial situation may be SCR controlled heating equipment DC drives current source inverters and other high current non linear loads This fault can also occur
57. it to the PCB Use a hacksaw blade between the Power board and the IGBT block then desolder the tabs remaining in the Power board Remove all traces of solder Clean the underside of the board and check for damage caused by the hacksaw 2 Clean the heatsink and place a new thermstrate on it note avoid touching the surface of it and be sure to remove the paper packer 3 Leave the foam on the gate terminals of the IGBT block Place the IGBT block on the heatsink and secure with screws G and H Note the IGBT block is extremely sensitive to static damage 4 Remove the foam from the IGBT gate terminals and carefully locate the Power board on to the IGBT block If it does not fit easily check for solder obstructing the holes in the Power board 5 Secure the Power board with screws A and E 6 The bottom of the Power board should be 15 5mm from the heatsink Ensure the Power board is parallel with the heatsink and solder in the IGBT block Elite Series Service Manual Removing Power Board Frame 2 Refer Figure 1 21 The Power board is secured to the heatsink the IGBT and rectifier blocks To remove the Power board remove 1 2 off Phillips screws C which secure the Power board to the heatsink 2 Phillips screws 3 off D and 5 off E which secure the Power board connections to the rectifier and IGBT blocks The Power board can now be removed Removing the IGBT or Rectifier Block Frame 2 To remove the rectifier
58. off the respective IGBT Monitoring the IGBTs for overload conditions and turns the relevant IGBTs off if this should occur and generates Desaturation Desat fault to the Control board The main switch mode power supply provides various isolated DC supplies required by the Elite These are 4 off 16 5V OV 13 5V for gatedrive circuitry s 28Vdc for the internal fans and the Control board s 24Vdc 500mA user power supply via the Control board Bus Live Indication One red light emitting diode LED to indicate the DC Bus is live Circulating Fans IP54 models only have two internal fans for circulating air within the Elite Thermal Sense 400V models An NTC thermal sensor circuit is connected to the heatsink via a small tab This circuit monitors the heatsink and will cause the Elite to trip on a thermal fault if the heatsink temperature exceeds 80 C 176 F Thermal Sense 500V models A separate Thermal Sense Board and 2 off 90 C 194 F microtherms are included in these models Capacitor Board This board has the DC Bus capacitors on it Power Board The Power Board has snubber capacitors and IGBT blocks power connections Rectifier Board The Rectifier Board has a switch mode power supply soft charge circuit snubber circuit RFI filtering voltage transient protection 500V only and SCR gatedrive There is no external control to this board the soft charge is initiated on power being applied to the board i e
59. replace or service the Elite Series 15 ELITE O L The temperature calculated by the Elite Series inverter thermal model has reached a dangerous level 150 of rated Elite Series rated current for 30 seconds at 50 C Maximum continuous operation possible without trip is 10596 of Elite Series rating Possible cause Continuous overload of Elite Series Action Fault Detail Action Fault Detail Sense level Action Check load requirements Fault 16 MOTOR OIL Detail The temperature calculated by the thermal model of the motor has reached a dangerous level Sense level 110 Possible cause Excessive load on motor current draw too high motor load exceeds cooling capacity at the operating speed motor phase loss motor winding fault motor thermal model parameters incorrectly set Refer also to the detailed descriptions of Screens N1 and N6 Check load and thermal model settings in Screens N1 and N6 Action Elite Series Service Manual 4201 230 Rev BA 132 Fault 17 BRAKE O L Detail The temperature calculated by the thermal model of the dynamic brake resistor has reached a dangerous level Sense level Set by dynamic brake thermal model in Screens D1 and D2 Possible cause Excessive regeneration for the resistor specified in Screens D1 and D2 Incorrect values entered Action Check values refer detailed descriptions of Screens D1 and D2 Reduce regeneration via Screen L8 Select a bigger brak
60. start low then increase as the capacitor charges to the meter battery voltage The capacitors are a sealed canister with a vent beside the terminal posts If the capacitor has overheated or suffered an internal fault and pressure has build up internally the bung in the vent hole should be displaced Elite Series Service Manual 4201 230 Rev B4 56 Frame 4 3 5 SOFT POWERING AFTER REPAIR Once all faulty components and assemblies have been replaced and the Elite has been carefully reassembled it is recommended that the machine be tested as per section 3 4 1 then Soft Power To Soft Power the Elite Refer to figure 3 10 Connect a 24Vdc current limited power supply to T36 positive and T37 0V Energise the supply and the Display unit should liven up Set the Elite to local control as per Technical manual part no 4201 180 Disconnect the supply Now connect a PDL Soft Power Supply to the DC bus as shown in figure 3 10 The Soft Power supply is available from PDL Electronics or the circuit diagram to build one can be found in the section 8 of this manual This power supply is a 600Vdc power source which can be used to power up the DC Bus The procedure enables any remaining DC Bus or inverter fault to be found without causing damage Connect the Soft Power Supply to the mains as shown in figure 3 10 The isolating transformer is not required for galvanic isolation between supplies as only one supply is used as compared to Fr
61. supply to the Elite and any low voltage supply that may be in parallel with the control power supply Allow approximately 5 minutes for the DC bus capacitors to discharge Open the cabinet door and check the red LED DC bus live indicator is not showing this is located on the lower righthand side of the Control board This indicates the DC bus is discharged Note this is only an indicator Remove the lexan terminal cover Test between input terminals L1 L2 L3 and L1 L2 L3 to earth to ensure the supply has been disconnected Finally test between the VE and VE DC bus terminals to ensure the DC bus has fully discharged Elite Series Service Manual 4201 230 Rev B4 Frame 4 47 3 2 PRINTED CIRCUIT BOARD DESCRIPTIONS Fal Display Unit The Display unit has three buttons and a 2 by 16 character liquid crystal display Itis the user interface for all parameter settings and is common to the Elite Series range The Display unit plugs into the Control board user terminals For a fault finding guide See section 3 3 3 Control Board The Control board is common to the Elite Series range and accepts all external control inputs and generates output signals These include digital analogue and fibre optic signals A Modbus RTU serial communications port is also included on the Control board A Shaft Encoder interface and 5V power supply is standard The Control board also has a bidirectional 24Vdc user power supply rated at 500mA Bus Assembly
62. the Elite Reduce to 3 metres Replace Display Unit 4508 249A Note 1 Terminal 10 red Terminal 11 white Terminal 12 black screen Note 2 See Elite Series technical manual 4201 180 screen Z to Z1 Figure 2 1 Display Fault Finding Elite Series Service Manual 29 2 3 4 CONTROL BOARD Control Board fault finding Check field control wiring for faults or disconnect it Is 28VDC present on the fan terminals see note 1 Check external fans see note 2 Control Board had Yes high voltage applied Is 24VDC present on terminals 20 amp 21 Replace the Control Board Check the field wiring again and replace the 500mA fuse on the Control Board 24VDC present on terminals 37 amp 36 Replace the Control Board 4508 250B Note 1 The fan terminals are located between the fibre optic connections at the bottom of the Control Board Note 2 Disconnect fan and recheck 28 volt supply If 28Vdc is not present the switch mode power supply on the Gatedrive Board is not functioning If the supply returns when the fans are disconnected the fans may be at fault Figure 2 2 Control Board Fault Finding 4201 230 Rev B3 30 Frame 3 NE 2 3 5 INPUT RECTIFIER The Rectifier is a half controlled bridge that combines DC conversion and the softcharge section of the Elite into one stage The SCR s on Line 1 are phase co
63. where backup generators are used and they have not been sized correctly relative to the total variable speed drive load VSD The total loading of VSDs on a backup generator should be about 60 and the remaining 40 made up of linear loads 1 3 2 FUSE FAILURE Fuse failure is not a normal event and it usually indicates a more serious fault Therefore the reason for the fuse failure should be investigated Supply Fuses Location At point of supply to the Elite Possible cause Supply surge age or cyclic stress failure wrong fuses fault in supply cable to the Elite rectifier or inverter fault motor or motor cable fault Action 1 See section 1 1 before starting 2 Perform a visual inspection for mechanical damage water entry or any other possible damage to the system 3 For new or modified installations check the wiring is correct as per the Elite Technical Manual PDL Part No 4201 180 4 Check fuses for correct rating 5 Disconnect supply cables and test for phase to phase or phase to earth fault 6 Mark and disconnect the output cables test the cables and motor for phase to phase and phase to earth fault 7 Test the Elite for rectifier inverter or DC Bus faults as per section 1 4 8 If no faults are found soft power the Elite as per section 1 5 9 If you consider the fuses have failed because of an external issue such as short term overload or cyclic stress reconnect the Elite replace the fuses and attempt to res
64. x No 3 Phillips Screw Drivers 1 x Flat blade 3 5 mm for terminals 2 x 10 mm Ring spanners 2 x 13mm Ring spanners 1 x 3 8 inch ratchet driver 1x 3 8 inch small extension 1 x 10mm socket 1 x 13mm socket 1 x Category 3 multimeter with ranges to 1000V AC and DC maximum 1 x PDL Soft Power Supply 1 x Isolating Transformer 1kVA These frame sizes are the most likely to be serviced in place due to their physical size and weight Many locations where they are mounted will not be ideal for servicing and therefore it is recommended that 1 x 24Vdc volt power supply a current limited supply is preferred but a simple plug pack or batteries can be used if it is not available with a lamp in series to limit the current flow to about 2 amps SAFETY 1 Static safe procedures must be observed grounding strap must be worn and earthed 2 Isolate and lock out the mains supply to the Elite and any low voltage supply that may be in parallel with the control power supply 3 Allow approximately 5 minutes for the DC bus capacitors to discharge 4 Open the cabinet door and check the red LED DC bus live indicator is not showing This is located on the lower right hand side of the control board This indicates the DC bus is discharged Note this is only an indicator TESTING BEFORE STARTING REPAIRS USING FRAME 5 AS AN EXAMPLE 1 Remove the 2 off M5x12 CW screws and remove the bottom front panel 2 Test between input terminals L1 L2 L3 a
65. 00W lamps Control LI 406 Display Unit v v 4508 325A Figure 3 10 Soft Power Supply Connections Elite Series Service Manual 4201 230 Rev B4 Frame 4 57 3 6 PARTS LIST AND BLOCK DIAGRAM 3 6 1 FRAME 4 400V ULTRADRIVE ELITE PARTS LIST 400 VOLT ULTRADRIVE ELITE PARTS LIST Frame Size FRAME 4 Spares Guide Model UE 60 UE 75 UE 90 UE 115 UE 140 Level1 Level2 Display Unit E141 620S Control Board E000 610S 1 Power Tray E060 611S E075 611S E090 611S E115 611S E140 611S 1 1 DC Bus Board Loom 2721 116 F 1 F 2 Power Tray 2401 025 2 2 Loom to Power Tray 2721 113 Thermal Sensor Loom Linking Loom 2721 114 Thermal Sensor 2 x 660 6195 DC Bus Board E140 621S DCCT 3 x 2521 086 3 x 2521 087 DCCT Loom 2726 102 3 looms supplied Rectifier Block 3 x 1421 030 3 x 1421 032 3 x 1421 038 2 Rectifier Thermstrate 3 x 1781 006 2 IGBT Block 3x 1757 131 3x 1757 124 3 x 1757 126 3 x 1757 134 2 IGBT Thermstrate 3x 1781 104 2 IGBT Gatedrive Loom 3 x 2721 117 3 DC Bus Capacitors 4 x 1352 453 6 x 1352 453 8 x 1352 453 Capaitor Sealing Ring 4 x 3907 004 6 x 3907 004 8 x 3907 004 Extemal Fans 150mm Fan 2941 015 1 1 120mm Fan 2941 012 1 1 Internal Fan 2941 013 1 1 Level 1 Min
66. 014 H pOEDI pue 408031 JA 04 C 029 pue 605041 HA STEVE sid 53789202140 IHH Z BHL3901 GaNOOT bs pue 905031 M 5318426 904 i LJ soea pue 606037 HM WYHOVIG Y90718 q0ose 3n 01 qozi 3n S JNVHA LIOA 00S S318Y9 OlLdO JKALA Z n 3NAuaalvo 0024 zoo pue 001037 quvog znorpuenniasi 31993499 Mr 002d C WM za peoo Qquvog HM pue 009031 3AIHG3LVI9 8313901 0311007 5 sna 90 33134938 V Quvog ONIHVHS sna EO 4 SJMOH 53504 LNdNI SNE PL l eu au QuvO8 HOS quvoa u9S GHVO HOS VOL vol T VOL dd Tu si m m D 131V9 coca Z1 31Y9 zd to 11 3LV9 10 S e m z 1 a a Hn wiorg 9084 HOSN3S TWESHL 3 15 S MA OML Qquvog 19313 JAHO alll 931314938 HJLHIMI X uvo HOSNJS TVNHJHL HOSNJS Zd d kd Zd Ed Id t HOH TT ANIT ANN r 06 SINHJHLOHOIN HJIHJANIX ZLOLOL Qquvog lOH1NOO LINN AVTdSIQ 104 loga
67. 1 609 3 x 2727 016 370mm 2 x 2727 017 620mm 1 x 2727 018 715mm 12 x 1757 136 3 x 3302 615 Level 1 Minimum spares stock Level 2 Typical spares stock 4508 275A Frame 5 400V Parts List Spares Guide Level 1 Level 2 Frame 5 DIA in IN m Jo 4201 230 Rev B5 85 Frame 5 FRAME 5 400V ULTRADRIVE ELITE BLOCK DIAGRAM 5 1 2 sna sna JO 3A 92 809 51991 ONIHVHS ONILVH LNJYYNI NO LNVIN3d3Q SHOLIOVAVO 30 HJANNN n zosorpue 001037 zuo pecora IMHOJLVO se T A 0 zororpue 001031 HA ve 000091 311393499 sp 31898 HM pue co 3180 01403982 MOOT 08 90 01 041 91 3INVH3 LIOA 007 SHOLIOVdV9 SNE 20 sng og HJIJILOJH Z Z O a 1 1 1 1 1 1 duvog ONIHVHS sna V S3wOHO s3snd 4 A INdNI 0 ap mur mus 18
68. 1277 547 6 x 1277 547 External Fan 2941 012 Internal Fan 2941 010 4508 269A Figure 1 8 Frames 1 amp 2 400V Microdrive Elite Parts List 1 6 2 FRAMES 1 AND 2 500V MICRODRIVE ELITE PARTS LIST rame Size FRAME 2 METGD MEZD Display Cover Label ront Cover Cover Gaskel Display Unit Control Board Power Board 0258715 Gatedrive Board 025 6125 Terminal Board E003 616S E007 616S E013 616S E023 616S Rectifier Block 1421 023 GBT Block 97108 1757 106 GBT Thermstrate 1781 205 1781 330 1781 108 DC Bus Capacitors 2 x 1277 546 2 x 1277 546 4 x 1277 546 4 x 1277 546 6 x 1277 546 6 x 1277 546 Microtherm Extemal Fan Fan 4508 271A Rectifier Thermstrate Figure 1 9 Frames 1 amp 2 500V Microdrive Elite Parts List Elite Series Service Manual 4201 230 Rev B1 Jenueyy S seues F ig nad 056 1057 07 eni 490 9 00 pue NOO Z 9 L Seuer L1 r MINA 24V from Gatedrive Board 40mm IP54 MODELS ONLY 22 Ue INTERNAL FAN CONTROL BOARD Thermal Sense Tab DRIVE SELEC 500 VOLT MODELS ONLY ill T BOARD o GATEDRIVE BOARD EXTERNAL FAN POWER BOARD TERMINAL BOARD NON ON TERMINAL BOARD COMMON MODE CHOKE
69. 19 Frame 5 to 7 500V External Fan Supply Connections Elite Series Service Manual 4201 230 Rev B7 130 Frame 7 Notes Elite Series Service Manual 4201 230 Rev B7 131 8 0 APPENDIX 8 1 FAULT SCREENS Fault conditions their interpretation and suggested remedies are listed below Fault NO FAULT Detail No fault detected Possible cause Normal operation Action None required Fault 01 LOW Vdc Detail Mains voltage has dropped too low zLOW V TRIP Screen 57 Sense level Model dependant Possible cause Mains interruption dip Action Check supply conditions Disable Low Volts Trip refer detailed description of Screen S7 Fault 02 HIGH Vdc Detail DC bus voltage has risen to a dangerous level Sense level 820Vdc 400V 900Vdc 500V Possible cause Very high mains surge Excessive regeneration from regenerative load or excessive deceleration rate refer detailed description of Screen R2 Earth fault on motor Dynamic Brake failure or undersized Action Reduce deceleration rate Check motor circuit for earth fault Apply Speed Filter via Screen R7 Fault 03 HI Vdc T O Detail DC bus voltage has risen to a dangerous level Sense level 750Vdc for greater than 5 seconds 400 850Vdc for greater than 5 seconds 500V Possible cause Mains too high for too long Earth fault on motor Action Check mains supply voltage Check motor circuit for earth fault Fault 04 SUPPLY FLT Detail Input supply phase vol
70. 28A Figure 2 20 500V Microtherm And Thermal Sense NOTE 7 LOWER SKIRTS Board Locations OMITTED FOR CLARITY M3x8 CAPTIVE SCREW M4x10 SCREW THERMAL SENSE Figure 2 17 Gatedrive Removal a 4508 3294 Figure 2 21 500V Microtherm And Thermal Sense Board Removal Elite Series Service Manual 4201 230 Rev B3 less Refer figure 2 22 42 Frame 3 POWER BOARD SERVICE The Power board assembly is supplied complete with the DC bus components Power board and IGBTs To remove it remove 1 3 off M5x12 Phillips screws and the positive DC bus bar 2 6 off M6x16 Phillips screws and washers The lexan shield under the lower end of the ve DC bus can be left in place It is important to replace it if it is removed as it ensures the correct internal air flow Replacing the Power board 1 Clean the Heatsink 2 Place the new thermstrates on the heatsink Avoid touching the surface of the thermstrate and remove the paper packing strips 3 Remove the shorting pins from the Power board assembly prior to replacing the gatedrive 4 When replacing the Power board ensure the terminals are located correctly M6x16 a FLAT WASHER M6x12 6 OFF POWER PCB ASSY em NOTE LOWER SKIRTS OMITTED FOR CLARITY Figure 2 22 Power Board Assembly Elite Series Service Manual 2 7 9 REPLACING THE IGBTS Refer fig
71. 30Vac over about 5 seconds Any longer risks burning out the soft charge resistor in the soft power unit The Display should activate when the supply reaches 280Vdc and the red DC Bus live LED should energise on the Gatedrive board visible at the bottom of the Control board Set the Elite to local start stop and speed reference control see technical manual part number 4201 180 for further details The Elite should respond to the Display unit Start Stop commands and speed reference changes Start the Elite from the Display unit and increase the output frequency or speed to 100 Use a multimeter set to AC VOLTS to measure the output voltage between terminals U V V W and W U These voltages should all be balanced at approximately 400Vac If there is any sign of imbalance measure between each output and earth to isolate which phase is faulty It is likely that there is an unrepaired fault on that particular phase or loose terminations If the test shows no faults and a good output voltage balance the test power supplies can be disconnected The mains and the motor can be reconnected and a full test done 1kV Isolating Variac Transformer Optional Filter DC Bus 230Vac Max 12 230Vac 100W lamps Control Board and Display Unit 4508 325A Figure 2 9 Soft Power Supply Connections Elite Series Service Manual 4201 230 Rev B3 36 Frame 3 2 6 PARTS LIST AND BLOCK DIAGRA
72. 40Vac will be detected and displayed as a supply fault To achieve the required voltage rating two capacitors are connected in series The capacitors are rated at 400V and 450V for the 400V and 500V models respectively The capacitors are connected in parallel Possible Causes of Failure The definition of capacitor failure is for the capacitance of the capacitor to fall outside manufacturers tolerance or suffer a catastrophic failure which is an open or short circuit While this section is quite detailed the capacitors seldom cause any problems 400V capacitors rating 680 MFD 20 at 20 C and 120Hz 500V capacitors rating 560 MFD 20 at 20 C and 120Hz Elite Series Service Manual 4201 230 Rev B3 Frame 3 31 Factors Affecting The Life of The DC Bus Capacitors Stress related issues these are vibration excessive ripple excessive voltage and or temperature bal Over heating is the most likely cause of premature failure and can be brought about by reduction in cooling air flow to the drive Check the heatsink for blockage and the fan operation Check for excessive ambient temperature or excess ripple due to some of the capacitors going open circuit Shelf life the recommended storage period without use should not exceed 3 years If there is concern regarding the time an Elite has been stored a DC supply can be connected to the DC Bus terminals Starting at about 50Vdc and over 8 hours the voltage is gradually increased to
73. AND lt si CAP CENTER SHIELD 250 AMP ONLY c CLEAR LEXAN s lt gt lt gt so s s lt gt lt gt gt s lt gt cs lt s lt gt lt gt lt gt CAP CENTER SHEET BUS a A M5 12 CW SCREW 4508 289 THIS ROW 210 250 ONLY Figure 5 14 Frame 5 Positive and Negative Sheet Bus 3D View Elite Series Service Manual 4201 230 Rev B5 Frame 5 93 5 2 5 SERVICING THE IGBT GATEDRIVE BOARD Fl 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 5 12 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 Short out the gate and emitter on the IGBTs 5 2 6 SERVICING THE SCR BOARD Refer to the lower section of figure 5 12 1 To get access to the SCR Board 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
74. Board Provides power to the Power tray voltage transient protection on the RFI board for the Elite and snubbering for the SCRs This board also has the connections to the IGBTs and SCRs Power Board The Power tray is made up of a metal support tray Control board mounting tray and Power board The Power Tray receives power from the DC bus The main switchmode power supply provides various isolated DC supplies required by the Elite These are x 6 off 16 5V OV 13 5V for Gatedrive circuitry 28V for the internal fans and Control board 24V 500 user power supply accessed via the Control board SCR switchmode power supply provides various isolated DC supplies required by the Elite These are 22V OV for SCR Gatedrive circuitry and DC Bus discharge control 15 OV for switchmode regulation circuitry The gatedrive control for the SCRs and DC Bus discharge circuit The drive select module plugs into the Power board Note the locations are different for the 400V and 500V models 6 off Gatedrive circuits to control the inverter IGBTs 6 off Desat circuits to monitor the voltage across the IGBTs and turn off the IGBTs in a controlled manner if they become overloaded On this condition the Desat circuitry also sends a trip signal to the Control board This signal will trip the Elite and the display will then indicate which half phase was overloaded LED RED DC Bus Indication Actual indication DC Bus Live Implicati
75. DC Bus capacitors or at a minimum all the opposing capacitors as well as the faulty one Normal Conditions One Capacitor Failed Short Y_4 44 Figure 4 6 Elite Series Service Manual vi2 vi2 4508 323A DC Bus Capacitor Short Circuit 4201 230 Rev B57 Frame 5 6 8 7 77 4 4 TESTING 4 4 1 TESTING FRAMES 5 TO 7 RECTIFIER AND INVERTER Refer figure 4 7 and using a Fluke 75 or similar check the rectifier as the drawing indicates Note each test is carried out 3 times once per phase which is a total of twelve tests Diode blocking gt 100k 4 4 2 ve DC Bus e SCR reverse blocking Diode 03 045v conduction 0 3 0 5V Figure 4 7 FURTHER TESTING DETAILS Diode conduction 4504 030B Rectifier and Inverter Testing Frames 5 to 7 conduction IGBT gt 10k IGBT Forward blocking gt 10k Forward blocking The components and the numbers per half phase are shown below to assist in understanding what you are testing 1 To test the rectifier components individually remove the input fuses and test on the load side of the fuses 2 To test the IGBTs individually requires disassembly of the Elite FRAME 5 POWER ELECTRONICS SUMMARY Figure 4 8 Rectifier and Inverter Power Electronics Summary
76. DC bus voltage is at 24Vdc energise the Soft Power Supply again Start the Elite from the keyboard and increase the output frequency or speed to100 Now use a multimeter set to AC VOLTS to measure the output voltage between terminals U V V W W U These voltages should all be balanced at approximately 17 5Vac If there is any sign of imbalance measure between each output and earth If any output voltage is significantly different suspect that there is still an unrepaired fault on that particular phase or a loose termination If the test shows no faults and a good output voltage balance the test power supplies can be disconnected mains and motor reconnected and a full test done UE FRAME 5 6 and 7 SOFT POWERING Bridge rectifier DC bus Inverter switches 4508 260A lt Isolated Power Supply 230Vac Output 24Vdc current limited 230Vac recommended Isolation Transformer 1 r Figure 4 14 Soft Power Supply Connections Elite Series Service Manual 4201 230 Rev B57 82 H d Elite Series Service Manual NOTES Frame 5 687 4201 230 Rev B57 83 5 0 FRAME 5 ULTRADRIVE ELITE SERVICE This section covers 400V models from UE 170 to UE 250 and 500V models from UE 170D to UE 250D 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
77. E OUTPUT SHEETBUS OS og os ye ell e OPO O eli e oje 5 E ll lle O O oe EJ lepe i T be L Z dL lt 4 dia INPUT FUSES a _ 2 PER PHASE i 4r IE i f ade adh 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 do 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
78. E T O Detail Time since last valid fibre optic input has exceeded timeout period on Screen 184 Sense level Set by Fibre T O value on Screen 184 Possible cause Speed or torque reference Screens I2 to 15 selected from fibre optic port with no fibre optic cable connected fibre optic cable connected to fibre optic output port instead of input port fibre optic cable fault Action Check fibre optic cable Check screen settings Seek service Fault 28 OVERSPEED Detail Maximum output speed has been exceeded Sense level 300 of motor rated frequency absolute maximum 450Hz Possible cause Loss of control of the motor while being driven by load excessive load Check actual operating conditions to determine cause Adjust load or set up to eliminate problem Action 4201 230 Rev BA Fault 29 TQ LIM T O Detail At torque limit for longer than specified Sense level Set by Screen 17 Possible cause Load condition or inappropriate setting of Screen L7 encoder failure Additional causes for this fault occurring during Open Loop mode starting are Insufficient start torque Screen X4c Too high an acceleration rate Screen R1 amp R3 and Insufficient start delay Screen S5 Another possible cause is the motor is overloaded while in Open Loop normal mode Check load condition or alter Screen L7 For Open Loop mode starting fault adjust any ofthe three screens mentioned above as follows Increase start torque Screen X4c
79. ER REPAIR 16 1 6 PARTS LIST AND BLOCK DIAGRAM 17 1 7 SERVICE 19 Elite Series Service Manual 4201 230 Rev B1 8 Frame 1 amp 2 E 1 1 BEFORE STARTING TESTING OR SERVICE WORK Site Preparation This size of Elite is best serviced on a bench We recommend a bench with an earthed antistatic mat to place the Elite on and an earthed wriststrap You will need flat surfaces for placing parts on and containers for small items like screws and bolts Tool Requirements 1 x No 2 Phillips screwdriver 1 x No 3 Phillips screwdriver 1 x Flat blade 3 5 mm screwdriver for terminals 1 x Flat blade 5 5 mm screwdriver 1 x No 3 Square drive screwdriver 1 x 5 5mm nut drivers 1 x 7mm nut drivers 1 x 10mm nut drivers 1 x Category 3 multimeter with ranges to 1000V AC and DC maximum 1 x PDL Soft Power Supply 1 x Single Phase Variac 1 x Isolating Transformer Optional 1 x 24Vdc power supply a current limited supply is preferred but a simple plug pack or batteries can be used with a lamp in series to limit the current flow 4 x 230VAC 100W lamps and lamp holders Safety amp Testing Before Starting Repairs 1 Isolate and lock out the mains supply to the Elite and any low voltage supply that may be in parallel with the control power supply 2 Allow approximately 5 minutes for the DC Bus capacitors to discharge 3 Remove the cover by undoing 6 off Phillps head screws Note these screws stay in the cover Check the DC Bus live indi
80. FRAME 7 500V ULTRADRIVE ELITE PARTS LIST 500 VOLT ULTRADRIVE ELITE PARTS LIST Display Unit AC Power to Power Tray Loom Rectifier Block Rectifier Thermstrate IGBT Thermstrate Gate Drive Board DC Bus Capacitors Capacitor Sealing Rings Main Internal Fans DC Power Supply Board Fuses Power Supply Board E660 621S Includes Fuses Microtherm Including Loom 6 x 2721 101 Thermal Sensor Boards 18 x E000 619S Loom To Power Board 1 x 2726 105 Thermal Sensor Looms Short Linking Loom 4 x 2721 114 Spares Guide Level 1 Level 2 Long Linking Loom 2 x 2726 103 DC Power to Power tray Loom 2721 094 DCCT 3 x 2521 072 Bus Sharing POB 12 x 0371 609 Fibre Optic Loom UL 2727 020 920mm Fibre Optic Loom UH VL 8 WL 3 x 2727 018 715mm Fibre Optic Loom WH 1 x 2727 019 440mm Fibre Optic Loom VH 1 x 2727 016 370mm External Fan P S Transformer 2571 068 External Fan P S Board E000 648 Level 2 Ty Figure 7 4 Frame 7 500V Parts List Elite Series Service Manual a Level 1 Minimum spares stock pical spares stock 4508 280A 4201 230 Rev B7 119 FRAME 7 500V ULTRADRIVE ELITE BLOCK DIAGRAM Frame 7 7 1 4
81. Figure 1 19 500V Microtherm and Drive Select 23 1 7 6 SERVICING THE POWER BOARD AND RECTIFIER IGBT Removing Frame 1 Power Board and IGBT Rectifier Remove the Control board Shrouds Skirts Terminal board and Gatedrive board before proceeding Refer figure 1 20 when removing the Power board Note the DC Bus capacitors on the Power Board compared to figure 1 21 The Rectifier IGBT block is soldered to the Power board and must be removed as one unit To do this remove a M4x12mm Phillips screws B C and D connecting the output chokes to the Power Board b M4x12mm Phillips screw F which connects the DC choke to the DC Bus on the Power board The wiring from the retaining holes in the Power board d M4x12mm Phillips screws G and H anchoring the IGBT Rectifier to the heatsink M4x6mm Phillips screws and E which anchor the Power board to the heatsink The Power board is now only held down by the thermstrate 4 E a cP Pent M4x12mm POWER BOARD A GE MN IGBT REC BLOCK SS 4508 2018 Figure 1 20 Rectifier IGBT Block Removal Frame 1 Elite Series Service Manual 4201 230 Rev B 24 Frame 1 amp 2 LEJ Replacing the Rectifier IGBT Block The rectifier IGBT block is soldered to the Power board in 10 places 1 If you do not have access to desoldering equipment the IGBT block can be removed by cutting all 10 tabs which secure
82. IN 1 SCHNORR WASHER OUTPUT SHEET BUS LOOM FIOPTIC 715mm LOOM FIGPTIC 620mm C M6 x 25 BOLT 2 X FLAT AND i ROUTE THROUGH GROMMET IN ROUTE THROUGH GROMMET IN 1 SCHNORR WASHER LOOM F OPTIC 715mm OUTPUT SHEET BUS OUTPUT SHEET BUS O HB gp o o gn 9 i D Ci k e Des nw
83. M 2 6 1 FRAME 3 400V MICRODRIVE ELITE PARTS LIST 400 VOLT MICRODRIVE ELITE PARTS LIST Frame Size FRAME 3 Model ME 31 ME 38 ME 46 Display Cover Label LHS 4101 582 RHS 4101 545 Front Cover 3903 116 Cover Gasket 3907 021 Display Unit E000 620S Control Board E000 610S DCCT Interface Board E046 618S DCCT 3 x 2521 085 3 x 2521 086 DCCT Loom 3 x 2721 113 Power Board E046 611S Rectifier Board E046 615S Gatedrive Board E031 612S E038 612S E046 612S Rectifier Block 3 x 1421 037 IGBT Block 3 x 1757 127 3x 1757 128 3x 1757 128 IGBT Thermstrate 3 x 1781 006 Rectifier Thermstrate 3 x 1781 002 Capacitor Board E031 617S E038 617S E046 617S DC Bus Capacitors 10 x 1277 547 12 x 1277 547 14 x 1277 547 External Fans 2 x 2941 012 Internal Fans 2 x 2941 010 IP54 only 4508 270A Figure 2 10 Frame 3 400V Microdrive Elite Parts list 2 6 2 FRAME 3 500V MICRODRIVE ELITE PARTS LIST 500 VOLT MICRODRIVE ELITE PARTS LIST Frame Size FRAME 3 Model ME 30D ME 35D ME 41D Display Cover Label LHS 4101 582 RHS 4101 545 Front Cover 3903 116 Cover Gasket 3907 021 Display Unit E000 620S Control Board E000 610S DCCT Interface E046 618S DCCT 3 x 2521 085 3 x 2521 086 DCCT Loom 3 x 2721 113 Power Board E047 611S Rectifier Board E047 615S Gatedrive Board E047 612S Drive Select E030 623 E035 623
84. M auvoa k Ji 1 TIL ONIHVHS NIBYHS ITI sna r sna ILA 7 L gi S ms IO M1990 TUE 9 NEN NEN HEN 2 11 a 91 el n1990 H Z So TT rt ONIHVHS 0 0 t sna n sayoHo 83814 asm asn 1 7 20 20 xz L w o x sna 44 I uet 903 QuVOGHOS HVOR HOS 0024 0ld m 20101 pue 001091 7 T 20801 20 031 008 a c 2014 Hn MNA Hun 20191 001031 27 10891 10691 RD avoa HOS M TW zaop 001091 Tm 0801 08021 ja e 00 bold HA TI DUE HA 20101 00107 5051 08031 208d QUOS JAHOJIVO 20640 m 1084 G 0084 1 4 2019 9024 m zope ooon T 90891 906031 n 0018 NEST HM HM 20101 001031 sme ao we ussorasmorU 90601 90809 JAHOALVO 9064 FI 9 SOHVOB HOSNJS l nos g f H3MOd 1 EA UJBANN ANS SOMA z Q L 004 4 N06 x ES SWHIHLOHOIW HJIHJANI X 9 o 4 20792 z TWNUAINI _ TVNUZIX3 q K E Quvog o E zo 10385 NHL H3MOd INOS LINN AVIASIO WVHOVIC 90718 qors 3n OL OSOL AN 9 SWVHS 110 009 ba Frame 6 500V Block Diagram Figure 6 4 4201 230 Rev B6 Elite Series Service Man
85. OS quvog HOS auvoa 806 V wi vor w vor vor vor 3 ux n Ja u mi ba x aata M da ad JA C E rosa T SY yop oT 014 HA HA 20101 7001037 e080 08031 ZAHOZIVO O s E N 1018 M T ce TM Zoo pue 001031 ti 90 01 906037 TU oid ch 8 98 HM 2200 00031 VERISEOLGSNCOT SOBO 508037 ET EET JAOJLVO Alddns vn 20772 SOHVOB HOSN3S TVWHJHL X 81 Zd Ed 14 Zd d 14 TN Ava m H Fm uix n JE Wed N H39WNN IWYS SONT Z 400 9 2 T 0018 j 1 1 id N N 00Nz 20Ed A 110 N06 i SWH3HLOHOIN H31EANI X 6 ved 8 08 FR 103135 5064 M AVHLH3MOd y quvos WVHOVIC 49078 d007 3n OL 0c9 3n Z JMVAA LIOA 006 li 4 E TOBINOD IND A dS 4201 230 Rev B7 Frame 7 500V Block Diagram Figure 7 5 SNv3 20 72 TWNH3 LX3 Elite Series Service Manual 120 Frame 7 7 2 LI L1 724 1 2 3 4 5 6 7 8 9 10 11 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 7 6 access to the wiring looms on the lower left hand side by removing screws A 3 off CW M4x10 retaini
86. Ohm Resistor 1 K Ohm Resistors Final IGBT Testing 4508 318A Elite Series Service Manual 4201 230 Rev B3 34 Frame 3 15 2 4 4 TESTING THE DCCT AND DCCT SUPPLY ss The DCCTs measure motor current and are located on the output of the Elite DCCT failure may be indicated by Fault 21 Ground fault or Fault 58 Current imbalance even with the motor disconnected If Fault 21 is apparent and the motor and motor cable have been checked and are OK Check the DCCT terminations as shown in figure 2 6 and the inverter as shown in figure 2 4 The 6 pin connector is located at the very top of the Control board How to test the DCCTs 1 Power up the Elite but do not start Test between ground T1 ground T4 and ground T6 to confirm the DCCT has a 14V supply If the 14 supply is not present the Control or Gatedrive boards switch mode power supply may be faulty See section 2 3 4 to determine which board is faulty 2 Test the DCCTs by measuring between ground T3 ground T5 and ground T6 This should be OV If the three readings are not at OV check the drive is not supplying current to the motor If no current is evident replace the terminal board Control Board 6 Pin Connector 6 Pin Connector V DCCT Output 6 5 U DCCT Output A 14 Volts 4 W DCCT Oputputs Ground 14 Volt 4508 339A Figure 2 8 DCCT Testing 2 4 85 DC BUS CAPACITOR TESTS Test the rectifier and inver
87. RAMS 100 6 2 SERVICE 104 Elite Series Service Manual 4201 230 Rev B6 100 Frame 6 6 1 PARTS LISTS AND BLOCK DIAGRAMS 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 r r D Power Tray SCR Board SCR Loom IGBT Block DC Bus Fuse Input Fuses FamSm ooo Perna Sad O 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 9 A 5 o 3 v O UJ ip r 5 8 zl 3 3 o al 3 AS 5 e ge jS o Bla DL 0 o o o 6 1 Frame 6 400V Parts List Elite Series Service Manual 4201 230 Rev B6
88. Ring Replacing the capacitors 1 The capacitors should be installed with a jig part number 5101 190 that ensures the height and rotational position are exact 2 The sealing rings must be fitted to the capacitors at Figure 3 27 Bus Capacitors Replacement 23 5mm below the top of the terminal post 3 Place the capacitors in the heatsink and loosely screw down the clamping plate 4 Fit the jig to the capacitors then tighten the clamping plate screws If a jig is not be available precise fitting of the individual capacitors is required see figure 3 27 5 Fit the capacitor sealing ring as above 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 threaded screws when the DC bus board is attached 6 Slight adjustments will need to be made as the clamping plate is clamped down Cap sealing ring 51 dia DC Bus Capacitor M ul M therm 90 NC CS 12S 12 MAx10 captive washer screw 2 places 2 places UE 8 hole cap Thermal clamping plate sense Boar M3x6 captive washer screw 2 places 4 places M5x12 captive washer screw 4508 2308 15 places Figure 3 26 Bus Capacitors Elite Series Service Manual 4201 230 Rev B4 Frame 4 65 3 7 7 REPLACING THE IGBT AND SCR DIODE BLOCK The IGBT s and SCR Diode blocks can b
89. Symptoms of DC Bus Capacitor failure Open Circuited Capacitor If a single DC Bus capacitor goes open circuit the symptoms may not be noticeable However the remaining capacitors will have an increased ripple current and will run hotter If more capacitors consequently go open circuit the DC bus ripple will increase and may cause a SUPPLY FLT trip especially when the Elite is running at or near full output current Short Circuited DC Bus Capacitor A shorted capacitor should cause two input fuses to fail during or soon after the soft charge interval because they are connected in series to share the DC bus voltage if one capacitor has shorted it will have exposed all the capacitors opposite it to above rated voltage This is shown in figure 1 3 In the drawing on the right the top set of capacitors have been exposed to full DC bus voltage which will be approximately twice their rating In this event it is recommended to replace all the DC Bus capacitors or at a minimum all the opposing capacitors as well as the faulty one Normal Conditions One Capacitor Failed Short 4508 323A Figure 1 3 DC Bus capacitor short circuit Elite Series Service Manual 4201 230 Rev B1 14 Frame 1 amp 2 fe 1 4 TESTING 1 4 1 TESTING THE RECTIFIER AND INVERTER Refer to figure 1 4 and using a multimeter check the rectifier as the drawing indicates NOTE each test is carried out 3 times i e once per ph
90. T Bus Sharing PCB Fibre Optic Loom UH VH amp WH Fibre Optic Loom UL amp WL Fibre Optic Loom VL External Fan P S Transformer External Fan P S Board Figure 5 3 Elite Series Service Manual 2721 125 3 x 1721 040 3 x 1781 103 12 x 1781 104 3 x E251 612S 2941 006 3 x 3302 615 3 x 2401 025 2 x 2404 063 E660 621S Includes Fuses 6 x E000 619S D RYH ID ID k k 2721 101 Loom To Power Board 1 x 2726 104 Short Linking Loom 4 x 2721 114 Long Linking Loom 1 x 2726 103 2721 119 3 x 2521 071 4 x 0371 609 3 x 2727 016 370mm 2 x 2727 017 620mm 1 x 2727 018 715mm 2571 066 E000 648 1 1 Level 1 Minimum spares stock m Level 2 Typical spares stock 4508 276A Frame 5 500V Parts List 4201 230 Rev B5 87 Frame 5 FRAME 5 500V ULTRADRIVE ELITE BLOCK DIAGRAM 5 1 4 sna IM x QO MO 1 M 1994 NO nO sna 99 8057 LII A1990 5 1991 SNLLVH NO INVONJAJU AHVA SHOLIOVdVI 30 H3aWNN quvog ONIHVHS sna 0024 l 018 m 20191 pue 001037 20 01 208031 004 20191 pue 001031 SYOLIOVdVO SNA 20 Bor aw an 7905 u340d 4 44 7054 NI 90 AH 2018 10601 06031 Hn 5
91. T 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
92. T with a known good IGBT Note the gate and emitter shorted together for one test as shown in figure 2 6 The IGBTs should be stored and handled in this state LEAVE KEEPER GATE EMITTER SHORTING LINK IN PLACE FOR STORAGE AND HANDLING il lig 114 KEEPER REMOVED FOR PHOTO Diode conduction 0 3 0 45V DIODE TESTS LINK LINK KEEPER Figure 2 6 IGBT TESTS Diode conduction 0 3 0 45V gt 10K Individual IGBT Testing IGBT TESTS Diode IGBT Blocking 10K Diode IGBT Blocking gt 10K gt 10K LINK LINK Diode IGBT Blocking gt 10K Diode IGBT Blocking gt 10K 4508 320A The final tests are done as shown in figure 2 7 This test is very important as it is possible that the multi meter tests show the IGBTs are OK but the IGBT may not actually work i e the IGBT does not respond to a Gatedrive signal Important note the 1K ohm resistor must be between the gate and emitter at all times during the tests 12V Current limited Power supply 1K Ohm Resistor CONDUCTION TEST 1K Ohm Resistor 1 Ohm Resistors Figure 2 7 ba C 12V Current 1K Ohm Resistor ALTERNATIVE TEST APPARATUS Hold Gate SIGNAL On 1 To Turn On The IGBT The IGBT Will Turn Off i i When the Gate Signal is Removed limited Power supply 12 Volt Battery O Lamp to Limit Current and Protect Battery T O 1 K
93. TER REPAIR 3 6 PARTS LIST AND BLOCK DIAGRAM 3 7 SERVICE Elite Series Service Manual 46 47 48 52 56 57 59 4201 230 Rev B4 46 Frame 4 3 1 BEFORE STARTING TESTING OR SERVICE WORK Site Preparation Many locations where the Elite is mounted will not be ideal for servicing and it is recommended that The work area in front of the Elite be cleaned Some flat surfaces are arranged for placing of parts Containers provided for small items like screws and bolts Tool Requirements 1 x No 2 Phillips screwdriver 1 x No 3 Phillips screwdriver 1 x Flat blade 3 5 mm screwdriver for terminals 2 x 10 mm Ring spanner 2 x 12mm Ring spanner 2 x 13mm Ring spanner 1 x 3 8 inch ratchet driver 1 x 3 8 inch small extension 1 x 10mm socket 1 x 13mm socket 1 x Category 3 multimeter with ranges to 1000V AC and DC maximum 1 off PDL Soft Power Supply 1 off Isolating Transformer 1kVA 1 off 24Vdc volt power supply a current limit supply is preferred but a simple plug pack or batteries can be used with a lamp in series to limit the current flow to about 2 amps Safety amp Testing Before Starting Repairs 1 2 3 4 5 6 7 Static safe procedures must be observed i e a grounding strap must be worn and earthed If the product is being serviced on a bench an earthed antistatic mat should be used to work on in addition to the grounding strap Isolate and lockout the mains
94. Y YA 2 Ohm Resistor Touch P11 53 Briefly to HEHREN KEJ Trigger 12 to 24 Volt SCR ra Battery A A A 17 16 15 14 13 12 1110987654321 o bd VE DC Bus To DC Bus 4508 231A Board Figure 3 5 SCR Conduction Test Elite Series Service Manual 4201 230 Rev B4 Frame 4 53 3 4 3 TESTING AN INDIVIDUAL SCR When the Elite is disassembled the SCR s can be tested individually as in figure 3 6 DIODE TESTS SCR TESTS SCR TESTS Blocking gt 100K gt 100K Diode conduction 0 3 045V 77 icu m CONDUCTION TEST ALTERNATIVE TEST APPARATUS NE ne Touch Gate Briefly To s Trigger SCR 18 to 100 Ohm Resistor 18 to 100 Ohm Resistor lu 24V Current 7 limited Power Lamp to Limit Current supply and Protect Battery 12 to 24 Volt Battery AN J 4508 319A Figure 3 6 Individual SCR Conduction Test Elite Series Service Manual 4201 230 Rev B4 54 Frame 4 4 3 44 INDIVIDUAL IGBT TESTS You must wear a static grounding wrist strap and it must be earthed when doing these tests The preliminary tests are done with a multimeter The meter readings in figure 3 7 are a guide and may vary with differing meter brands It is best to compare the suspect IGBTs with a known good IGBT Note When the gate and emitter are shorted together for one test as shown in figure 3 7 the IGBTs should be stored and handled in this sta
95. about 560 600Vdc for 400V models and 660 700Vdc for 500V models Failure to do this can cause failure of the DC Bus capacitors on initial application of full voltage Symptoms of DC Bus Capacitor Failure Open Circuited Capacitor If a single DC Bus capacitor goes open circuit the symptoms may not be noticeable However the remaining capacitors will have an increased ripple current and will run hotter If more capacitors consequently go open circuit the DC bus ripple will increase Which may cause a SUPPLY FLT trip especially when the Elite is running at or near full output current Short Circuited DC Bus Capacitor A shorted capacitor should cause two input fuses to fail during or soon after the soft charge interval Because they are connected in series to share the DC bus voltage if one capacitor has shorted it will expose all the capacitors opposite it to above rated voltage This is shown in figure 2 3 in the right hand drawing the top set of capacitors have been exposed to full DC bus voltage which will be approximately twice their rating In this event it is recommended to replace at a minimum all the opposing capacitors as well as the faulty one Normal Conditions One Capacitor Failed Short vi2 4508 323A Figure 2 3 DC Bus capacitor short circuit Elite Series Service Manual 4201 230 Rev B3 32 Frame 3 TE 2 4 TESTING 559 2 4 1 TESTING THE RECTIFIER AND INVERTER Refer figure 2 4 and
96. act Remove the old IGBTs and clean the heatsink surface 1 Leave the the gate emitter shorting 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 5 2 8 SERVICING THE SCR DIODE BLOCK Refer to the lower section of figure 5 15 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 M5 x 16 CW screws do not tighten yet and push the SCR Diode block towards the bottom of the Elite 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 M310 CW SCREW M6x16 CW SCREWS
97. ames 4 to 7 but it is recommended as a safety measure The lamps in series reduce the current that will flow if the Elite is faulty Set the variac to the lowest setting switch on the variac and increase the voltage setting to 230Vac over about 5 seconds any longer risks burning out the soft charge resistor in the Soft Power Unit The Display should power up when the supply reaches 280Vdc and the red DC Bus live LED should energise on Gatedrive board visible at the bottom of the Control board Set the Elite to local Start Stop and Local speed reference control see Technical manual part number 4201 180 for details The Elite should respond to the Display unit s Start Stop commands and speed reference changes Start the Elite from the Display unit and increase the output frequency or speed to 10096 Now use a multimeter set to AC VOLTS to measure the output voltage between terminals U V V W W U These voltages should all be balanced at approximately 400Vac If there is any sign of imbalance measure between each output and earth to isolate which phase is faulty It is likely that there is an unrepaired fault on that particular phase or loose terminations If the test shows no faults and a good output voltage balance the test power supplies can be disconnected the mains and motor reconnected and a full test done 1kV Isolating Variac Transformer Optional Filter DC Bus Inverter i i 230 230Vac 1
98. ard is replaced as an entire assembly inclusive of the mounting tray This assembly is referred to as the Power tray 1 See section 5 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 5 10 For 400V models this can be done after the Control Board is in place see figure 5 9 Refer to figure 5 11 Frame 6 Power tray Removal 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 Atthe 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 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 the 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 recommende
99. ase which is a total of twelve tests ve DC Bus Diode conduction 0 3 0 55V Diode conduction 0 5V 4 Diode k 4 IGBT blocking S Forward 100k blocking jo 10k Diode IGBT blocking Forward gt 100k blocking 4504 032B ve DC Bus Figure 1 4 Rectifier and Inverter Testing Frames 4 1 4 2 TESTING AN INDIVIDUAL DIODE Refer figure 1 5 when the Elite is disassembled so the diodes can be tested individually DIODE TESTS DIODE TESTS 3 x Diode Blocking tests 100K 3 x Diode conduction tests 0 3 0 45V 3 x Diode conduction tests 0 3 0 45V 4508 326A Figure 1 5 Individual Diode Test 1 4 3 TESTING AN INDIVIDUAL IGBT Individual tests are not practical as shown on Frames 3 to 7 in sections 2 to 4 within this manual Elite Series Service Manual 4201 230 Rev B1 Frame 1 amp 2 15 1 4 4 TESTING THE DCCT AND DCCT SUPPLY The DCCTs measure motor current and are located on the output of the Elite DCCT failure may be indicated by Fault 21 Ground fault or Fault 58 Current imbalance even with the motor disconnected If Fault 21 is apparent and the motor and motor cable have been checked check the DCCT terminations as shown in figure 1 6 and the Inverter as shown in figure 1 4 The 6 pin connector is located at the very top of the Control board How to test the DCCTs 1 Power up the Elite but
100. ault 62 CONNECT FLT Detail The MASTER and or SLAVE Ultradrive Elite looming connections are incorrect Possible Cause The fibre optic connections are plugged in incorrectly or not working Action Check all the wiring connections Fault 63 SLV WDT Detail An unknown fault has reset the SLAVE drive control board Possible Cause Power supply fault Software fault Action Reset fault seek service or replace the SLAVE drive control board Fault 64 SLV EEPROM Detail The SLAVE drive control board s nonvolatile memory EEPROM is faulty Possible Cause IC failure Action Seek service Fault 65 SLV PSU Detail The SLAVE Ultradrive Elite Control board power supply failure Possible Cause Fault IC Action Seek service Fault 66 SLV DATA Detail The SLAVE Ultradrive Elite control board s nonvolatile memory EEPROM reading error This fault can only be cleared using Screen Y2 to initialise settings Isolated motor before resetting fault Sense level Check sum in memory Possible Cause Spurious fault faulty memory Action If fault recurs replace SLAVE paralleling card 4201 230 Rev BA Fault 67 SLV CAL Detail The SLAVE Ultradrive Elite drive select modules are incorrect Possible Cause Incorrect combination of drive select modules are plugged into the SLAVE drive select card Action Check both drive select modules are identical on the SLAVE drive control board Fault 68 SLV SW VER Detail SLAVE Ultradrive Eli
101. block remove 1 2 off Phillips screws A 2 To remove the IGBT block remove 4 off Phillips screws B Note the IGBT block is extremely sensitive to static damage Replacing the IGBT or Rectifier Frame 2 When replacing the IGBT Blocks use new thermstrates Do not use the paper packers and avoid touching the surface of the new thermstrate M5x12mm 3OFF AS 4 10 gt A 7 20FF M6x12mm 2 OFF RECTIFIER 4508 207 Rectifier IGBT Removal Frame 2 Figure 1 21 4201 230 Rev B 2 0 MICRODRIVE ELITE SERIES FRAME 3 This section covers 400V models ME 31 to ME 46 and 500V models ME 30D to ME 41D 25 The 400V and 500V models are essentially identical for assembly purposes When specific differences exist between the 400V and 500V models these are noted o o o o o o o o o o o eMe 8C O eMe w7 Xu v v 7 4508 290A CONTENTS 2 1 BEFORE STARTING TESTING OR SERVICE WORK 2 2 PRINTED CIRCUIT BOARD DESCRIPTIONS 2 3 FAULT FINDING GUIDE 2 4 TESTING 2 5 SOFT POWERING AFTER REPAIR 2 6 PARTS LIST AND BLOCK DIAGRAM 2 7 SERVICE Elite Series Service Manual 26 27 28 32 35 36 38 4201 230 Rev B3 26 Frame 3 9 2 1 BEFORE STARTING TESTING OR SERVICE WORK 121 Site Preparation This size of Elite is best serviced on a bench We recommend a bench with an earthed antistatic mat for wo
102. capacitors are connected in series the capacitors are rated for the 400V and 500V models Possible causes of failure The definition of capacitor failure is for the capacitance of the capacitor to fall outside the manufacturers tolerance or suffer a catastrophic failure which is an open or short circuit While this section is quite detailed the capacitors seldom cause any problems 400V capacitors rating 680 MFD 20 at 20 C and 120Hz 500V capacitors rating 560 MFD 20 at 20 C and 120Hz Factors affecting the life of the DC Bus Capacitors Stress related issues these are vibration excessive ripple above rated voltage and or temperature Over heating is the most likely cause of premature failure and can be brought about by reduction in cooling air flow to the drive check the heatsink for blockage and the fan operation excessive ambient temperature or excess ripple due to some of the capacitors going open circuit Shelf life the recommended storage period without use should not exceed 3 years If there is concern regarding the time an Elite has been stored a DC supply can be connected to the DC Bus terminals and starting at about 50Vdc and over 8 hours the voltage is gradually increased to about 560 to 600Vdc for 400V models and 660 to 700Vdc for 500V models Failure to do this can cause failure of the DC Bus capacitors on initial application of full voltage Elite Series Service Manual 4201 230 Rev B1 Frame 1 amp 2 13
103. cator on the bottom right hand side of the Control board The red LED should not be glowing 4 Test between input terminals L1 L2 L3 and L1 L2 L3 to earth to ensure the supply has been disconnected 5 Test between the HVDC terminals VE and VE to ensure the DC Bus has fully discharged Elite Series Service Manual 4201 230 Rev B1 Frame 1 amp 2 9 1 2 PRINTED CIRCUIT BOARD DESCRIPTIONS 8 Display Unit The Display Unit has three buttons and a 2 by 16 character liquid crystal display It is the user interface for all the parameter settings and is common to the Elite Series range The Display Unit plugs into the Control Board Control Board The Control Board is common to the Elite Series range The Control Board accepts all external control inputs and generates output signals The inputs and outputs include digital analogue and fibre optic A Modbus RTU serial communications port is also included A Shaft Encoder interface and 5V power supply is standard The Display Unit plugs into the Control Board The Control Board has a bi directional 24Vdc user power supply rated at 500mA Gatedrive Board The Gatedrive Board is a general purpose board and as such performs many functions Gatedrive and Desaturation Circuits Seven gatedrive circuits accept signals from the Control Board and turn either on or off the relevant IGBT Six of the gatedrive circuits are for the inverter and one for the Dynamic Brake The desaturation ci
104. ces Figure 3 19 Side Panel Disassembly T gt M5x12 captive screw 8 9 8609 512 61 8 places Ultradrive heatsink assembly E140 603 M6x25 set screw 6 flat washer M6 flat washer M6 schnorr washer M6 nut Figure 3 20 4508 2444 Heat Exchanger Removal Elite Series Service Manual 4201 230 Rev B4 62 Frame 4 3 7 4 REMOVING THE DCCT BRACKET The DCCT bracket can be removed in one piece Refer to figure 3 21 The DCCT removal requires the removal of 1 The output busbars are secured by a 3 off M6x16 Phillips screws b 3 off M6x20 Phillips screws 6 16 captive screw a 3 places Output busbars M6x20 a captive screw 4508 240 Figure 3 21 Output Busbars Refer to figure 3 22 2 The heatsink earth link is removed because it obscures one of the screws which secures the DCCT mounting bracket This earth link is held by a 1 off M6x12 Phillips screw b 1 off M6x25 bolt screw M6x20 set screw M6 flat washer M x12 M6 flat washer captive M6 schnorr washer screw M6x25 set screw UE60 140 earth link 4508 245A Figure 3 22 Earth Link Elite Series Service Manual Refer to figure 3 23 3 The DCCT assembly is held by a 2 off M5x16 Phillips screws which secure the input output DC busbars to the DC bus PCB b 1 off M6x20 Phillips screw which connects the output terminal U to the output out the RFI choke c 4 off M5
105. d Shrouds Skirts and Terminal The Gatedrive board removal for Frame 2 is similar to board before proceeding Frame 1 except the Gatedrive board plugs directly on to Refer figure 1 17 when removing the Gatedrive board thedate connections otthe IGBT as per figure 1 18 Do not attempt to remove the Gatedrive board without GATEDRIVE BOARD removing the Terminal board first This can damage the Terminal board when it is pulled to one side to allow access to the M4x10mm Phillips screws labelled A Remove M4 x 100mm Phillips screws A and B and lift the board vertically off the Power board and IGBT connecting pins Note When replacing the Gatedrive board the heatsink temperature monitoring is done through the tab secured by screw B M4x10mm M xi 0mm GATEDRIVE BOARD AA PLUGS INTO POWER BOARD 244 miom IN THIS POSITION GATEDRIVE BOARD GATEDRIVE BOARD PLUGS INTO POWER BOARD IN THIS POSITION 4508 208B Figure 1 18 Gatedrive Removal Frame 2 4508 202B Figure 1 17 Gatedrive Removal Frame 1 Elite Series Service Manual 4201 230 Rev B Frame 1 amp 2 Removing Gatedrive Board 500V Models Refer figure 1 19 when removing the Gatedrive board The Gatedrive board removal for 500V models is similar to the 400V Frame 1 except 1 The Microtherm is held in place by 2 off M3x6mm CW screws 2 Drive Select board located on the Gatedrive board DRIVE SELECT MICROTHERM 4508 228 A
106. d 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 XX FIBRE OPTIC COVER PANEL CW SCREW DC FUSE PCB LOOM POWER TO POWER POBLOOM SCRPCBLOOM THERMAL SENSE BLOOM OA 30FCTLOOM EARTH 3WAY PLUG CONTROL CABLE oci CLAMPS 4506 267 Figure 6 5 Frame 5 to 7 Power Tray Elite Series Service Manual A Control 772 Board E Plugs FAN USED ON FRAMES 6 amp 7 ONLY CONTROL BOARD Figure 6 6 Frame 5 to 7 Power Tray and Control Board VEZZ 809v yeg 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 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
107. d 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 500 VOLT MICROTHERI p CW SCREW Ld ge M6x16 CW SCREWS d IGBT amp THERMSTRATE d IGBTs TO BE
108. d one is in section 8 of this manual This power supply generates a 600Vdc power source which can be used to power up the power electronics PCB without powering up the DC bus Then the DC bus is energised with a separate DC power supply around 24Vdc with current limiting The procedure enables any remaining inverter fault to be found without causing further damage Energising of Power Electronics Sub Assembly Connect the Soft Power supply to the mains preferably via an isolating transformer Do not switch on Remove the Power tray DC supply plug P204 and connect the output plug from the soft power supply to plug P204 P204 is on the lower left hand side of the Power tray Energise the Soft Power supply The Display should come up as per normal and the red BUS LIVE LED should energise on the Power tray Set the Elite to local start stop and speed reference control see Technical manual part number 4201 180 for details The Elite should respond to Display key pad start stop commands and speed reference changes Bring the output to zero speed and stop Power down the Soft Power supply Energising the DC Bus Now connect a 24Vdc Power Supply current limited to the DC Bus and DC Bus terminals observing correct polarity Turn on this power supply and slowly bring up the output voltage to 24Vdc The supply should not draw noticeable current except the bus capacitor charging current when increasing the output voltage Once the
109. d to Soft Power the Elite to test the new parts are functioning correctly without risk of damage should something else be faulty or an error made during reassembly See section 4 6 Figure 5 9 400V Power tray Figure 5 10 500V Power tray WHEN INSTALLING F OPTIC LOOMS USE 35mm MINIMUM RADIUS POWER TRAY 16 CW SCREWS LEXAN SHIELD M4x10 CW SCREWS INTERNAL FAN CONNECTION INTERNAL SHIELD FIT AT FINAL ASSEMBLY POWER TRAY VE DC VE DC U OUTPUT V OUTPUT W OUTPUT Li INPUT L2 INPUT L3 INPUT 4508 282A Figure 5 11 Frame 6 Power Tray Removal Elite Series Service Manual 4201 230 Rev B5 90 Frame 5 5 2 3 SERVICING THE OUTPUT SHEET BUS Negative sheet bus fixings in there own container This will help speed up reassembly 1 2 Note All three output phases will have to be removed the details below indicates how to remove one 3 4 5 6 Remove the Power tray as in the previous section Referring to figure 5 12 remove the Lexan shield held at the top by 2 off M x16 CW Screws Ensure you have adequate small containers to place the Bus Sharing board DC Supply board Positive Sheet Bus and Remove the top Power tray support rail if you are replacing IGBTs If you are replacing DC Bus capacitors or the SCR diode blocks it can be left in place Unclip the fibre optic loom at each
110. damage the input rectifier Supply voltage excess The Elite has VDR s to protect against voltage transients These will not cope with a supply that is constantly above the maximum level the Elite was designed for The VDRs will fail and the Elite may be damaged 2 3 6 INVERTER The inverter consists of insulated gate bipolar transistors IGBTs Each IGBT block has two transistors one for the upper and one for the lower half phase Symptoms of Inverter failure Input fuses blowing on power application DESAT fault 08 to 13 constantly on the same phase and polarity Current limit fault 07 this is a hardware trip to indicate that 220 of rated current has been reached For all of the above faults test the IGBTs as per section 2 4 1 Check the motor and motor cables If no faults are found attempt to reset the Elite If the fault is repetitive on the same phase and polarity check the IGBTs again If the fault is a DESAT fault and not always on the same phase the problem is most likely in the Gatedrive board output cables or motor IGBT Replacement Batch matching of IGBTs is not required for Frame 3 but it is required with Frames 5 to 7 2 3 7 DC BUS FILTER The DC Bus filter is comprised of electrolytic capacitors and chokes The chokes are mounted in the DC Bus and are in series with the rectifier output The filter s function is to reduce the harmonic current drawn by the Elite and the ripple on the DC Bus excess ripple gt
111. do not start Test between ground T1 then ground T4 to confirm the DCCT has a 14 supply If the 14 supply is not present the switch mode power supply on the Control or Gatedrive board may be faulty refer to section 2 3 4 for fault finding on the Control board 2 Test the DCCTs by measuring between ground T3 ground T5 and ground T6 these should read OV If the three readings are not OV check the drive is not running then replace the terminal board 6 Pin Connector 6 Pin Connector V DCCT Output 16 5 U DCCT Output A 14 Volts 4 W DCCT Oputputs 14 Volt 4508 339A Figure 1 6 DCCT Testing 1 4 5 TESTING THE DC BUS CAPACITOR A general test without disassembling the Elite is recommended Follow section 1 4 1 to test the rectifier and then the inverter Use a meter set to OHMS to test the capacitors between HVDC terminals and The resistance should start low then increase as the capacitors charge to the meter battery voltage ensure the DC bus capacitors are fully discharged first This charging period could take some time It is best carried out by testing the faulty machine against a known good Elite of the same size or check the spare parts list and pick a model within the same frame size with the same number of DC Bus capacitors Time the rate of charge i e the increase in ohms on the meter and compare this against the faulty Elite If this test indicate
112. e less expensive than other controllers in the long run COMPREHENSIVE SUPPORT PROGRAM The PDL Electronics customer support program demonstrates our confidence in our Quality Assurance system We have total faith in our products and their reliability and so provide a comprehensive warranty Fully trained engineers and technicians with a wealth of experience and easy access to information can assist in solving any of your drive application projects Our service staff are available for commissioning after sales service and repairs 24 hours a day seven days a week We select capable and highly qualified representatives to act as our distributors and service agents Only after passing PDL Electronics intensive training program are they accredited for repair or on selling of our products To further support our products and customers we run a series of comprehensive training programs focusing on self maintenance and application advice These are available on site and at our Head Office REVISION HISTORY Date Revision Description Jan 2000 A Created and issued 400V models 2 5 to 140A Jan 2003 B Revised 400V range extended to 660A 500V range added Elite Series Service Manual 4201 230 Rev BF IMPORTANT NOTES SAFETY WARNINGS It is the installer s responsibility to ensure the configuration and installation of the Elite Series meets the requirements of any site specific local and national electrical regulations
113. e DC Bus fuses as the positive Sheet Bus can be removed as one piece
114. e signal from the Power tray and a 10 Amp fuse for the external fans or fan power supply on the 500V models 500V External Fan Power Supply A 400Vac to 500Vac to 24Vdc linear power supply for the 500V model external fans Note there are connection points for voltage ranges from 400V to and including 500V Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 amp 7 71 4 3 FAULT FINDING GUIDE 4 3 1 SUPPLY ISSUES Power supply problems can be misinterpreted as faults in the Elite some are listed below Fault 01 LOW Vdc The supply to the Elite is dropping below the switch mode power supply operating level and it is shutting down This is usually caused by a weak supply or faults in the supply system Look for motors starting direct on line or other p machines drawing high current For further details see the fault list in section 8 of this manual Fault 02 HIGH The supply to the Elite is surging too high Rapid load changes in the supply system may be at fault For further details see the fault list in section 8 of this manual Fault 04 SUPPLY FLT Supply fault Fault 04 is an indication that the ripple on the DC Bus has exceeded 40Vac The Elite will trip if this condition is reached and display fault 04 SUPPLY FLT This can be caused by diode s in the rectifier going open circuit see section 1 4 But is more likely to be caused by 1 The loss of an input phase will inc
115. e soft charge is finished the SCR s on L2 and L3 will be turned on fully applying a higher DC level to the DC bus than is currently there This can generate sufficient inrush current to damage the input rectifier 5 Supply voltage exceeding the Elite s rating The Elite has VDR s to protect against voltage transients These will not cope with a supply that is constantly above the maximum level the Elite was designed for The VDR s will fail and the Elite also may be damaged Soft Charge Failure 1 Failure of the Soft Charge function Some or all of the SCR s may not respond to a gate signal or the Power tray may not be producing a gatedrive signal Look for a dislodged cable and test the SCR s as per section 3 4 2 2 Diode or SCR failure If part of the rectifier stage has failed open circuit the Elite may not soft charge and no voltage will appear on the DC bus Note it is uncommon for semiconductors to fail open circuit Replacement SCR S Replacement SCRs do not require batch matching 3 3 6 INVERTER DESCRIPTION The inverter consists of insulated gate bipolar transistors IGBTs Each IGBT block has two IGBTs in it one for the upper and one for the lower half phase i e U and U Symptoms of Inverter failure 1 Input fuses blowing on power application 2 DC bus fuses blowing on power application frames 3 DESAT fault 08 to 13 constantly on the same phase and polarity 4 Current limit fault 07 this is a hardware trip to indica
116. e tested individually as per section 3 4 2 Replacing the blocks will require new thermstrates do not use the paper packing and avoid touching the surface of the new thermstrate Thermstrate 8 places IGBT block 3 places 8 Cable 4 way molex bridge 183 Thermstrate 3 places Microthert Thermal sense board Q M6x16 captive Rectifer washer screw Cable 2 way molex T sense 3 places 18 places 2 places 4508 229B Figure 3 28 Cable 4 way molex 170lg Rectifier IGBT blocks 3 7 8 The fans have DC brushless motors and hence are not phase sensitive Polarity is still important wen reassembling the Elite The air flow is from the top of the Ultradrive Elite and out the bottom REMOVING THE EXTERNAL FAN 1 To remove the fans cut the cable ties and unplug the inline connector and the spade terminals off the larger fan see figure 3 29 Inline 2 way with 2x Inline terminal BLACK attached to fan wires Cable 4 way molex 4000 ie NU N GA ec Figure 3 29 4508 246A Fan Connections 2 Remove the fan grill which is secured by 6 off M4x10 Phillips screws see figure 3 30 M4x10 captive screw 6 places UE60 140 fan grill 4508 248A e Figure 3 30 Fan Connections 3 Remove the Wafer screws from the fan to be replaced Fan papst 4214HR Fan DC axial papst CO 4 Me 3 NI 4
117. ears If there is concern regarding the time an Elite has been stored a DC supply can be connected to the DC Bus terminals and starting at about 50Vdc and over 8 hours the voltage is gradually increased to about 560 to 600Vdc for 400V models and 660 to 700Vdc for 500V models Failure to do this can cause failure of the DC Bus capacitors on initial application of full voltage Elite Series Service Manual 4201 230 Rev B57 76 Symptoms of DC Bus Capacitor Failure Open Circuited Capacitor H d current Short Circuited DC Bus Capacitor Frame 5 687 7 If a single DC Bus capacitor goes open circuit the symptoms may not be noticeable However the remaining capacitors will have an increased ripple current and will run hotter If more capacitors consequently go open circuit the DC bus ripple will increase and may cause a SUPPLY FLT trip especially when the Elite is running at or near full output A shorted capacitor should cause two input fuses to fail during or soon after the soft charge interval Because they are connected in series to share the DC bus voltage if one capacitor has shorted it will have exposed all the capacitors opposite it to above rated voltage This is shown in figure 4 6 In the right hand drawing the top set of capacitors have been exposed to full DC bus voltage which will be approximately twice their rating In this event it is recommended to replace all the
118. easiest it is worth replacing it first U HALF PHASE FRAME 5 INVERTOR LAYOUT a 4 k T ie 4 K V U HALF 4508 292A PHASE Figure 4 5 IGBT Half Phase Layout Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 amp 7 75 Replacing the IGBT The IGBTs are manufactured in batches and each batch has a unique batch number The IGBTs from a specific batch are made from the same silicon therefore their operating characteristics will be the same Therefore we require that IGBTs in each half phase be from the same batch When an Elite is repaired under warranty the complete half phase Eg must be replaced with the same batch or the warranty will be void Note the batch in a half phase does not have to match the batch in another half phase For example in a Frame 7 it may have transpired that 2 IGBTs are damaged and the other 4 in the half phase test OK with a multimeter In this ME situation PDL or its agent would replace all six IGBTs Apart from the batch issue we have found that while the remaining IGBTs in the half phase may test OK they will have been stressed The effect on their life span due to the stress cannot be gauged For these reasons a repair without full half phase IGBT replacement can not be guaranteed BATCH NUMBER 4508 235A Figure 4 5 Batch Number 4 3 7 DC
119. eassembly purposes When specific differences exist between the 400V and 500V models these are noted gl je URADE ETER amp ee 9 k 4508 300A E Figure 7 1 Frame 7 Ultradrive Elite CONTENTS 7 1 PARTS LISTS AND BLOCK DIAGRAMS 116 7 2 SERVICE 120 Elite Series Service Manual 4201 230 Rev B7 116 Frame 7 17 1 17 1 1 PARTS LISTS AND BLOCK DIAGRAMS FRAME 7 400V ULTRADRIVE ELITE PARTS LIST 400 VOLT ULTRADRIVE ELITE PARTS LIST Frame Size FRAME 7 Model UE 575 UE 660 Display Unit E660 620S Control Board E000 610S Power Tray E660 611S SCR Board 9 x E660 615S SCR Loom 2721 088 AC Power to Power Tray Loom 2721 124 Rectifier Block 9 x 1421 027 Rectifier Thermstrate 9 x 1781 103 IGBT Block 36 x 1757 136 IGBT Thermstrate 36 x 1781 104 Gate Drive Board 3 x E660 612S DC Bus Capacitors 54 x 1352 453 Capacitor Sealing Rings 54 x 3907 004 External Fans 5 x 2941 011 Main Internal Fans 2 x 2941 012 Power Tray Fan 2941 014 DC Bus Fuse 9 x 3302 500 Input Fuses 9 x 3302 615 SCR Board Fuse 9 x 2401 025 Power Supply Board Fuses 2 x 2404 063 Power Supply Board E660 621S Includes Fuses Thermal Sensor Boards 18 x E660 619S Loom To Power Board 1 x 2726 105 Short Linking Loom 4 x 2721 114 Long Linking Loom 2 x 2726 103 Thermal Sensor Looms DC Power to Power tray Loom 2721 094 DCCT 3 x 2521 072 Bus Sharing PCB 12 x 0371 609 Fibre Optic Loom UL 2727 020 920mm
120. eck fuses for correct rating 5 Disconnect supply cables and test for phase to phase or phase to earth fault 6 Mark and disconnect the output cables Test the cables and motor for phase to phase and phase to earth fault 7 Test the Elite for rectifier inverter or DC Bus faults as per section 3 4 8 If no faults are found the best option is to Soft power the Elite as per section 3 5 If you consider the fuses failed because of an external issue such as short term overload or cyclic stress reconnect the Elite replace the fuses and attempt to run the Elite Power Tray Fuses Fuse two is in the positive DC Bus feed to the Main switchmode power supply It must be replaced with a ceramic fuse of the same rating If the fuse has failed look for burnt components around the main switchmode transformer If none are found replace the fuse and repower the Elite If it fails again replace the Power tray Fuse three is in the Line 1 feed to the SCR switchmode power supply It must be replaced with a ceramic fuse of the same rating If the fuse has failed look for burnt components around the SCR switchmode transformer If nothing is found test the SCR gate drives and SCRs as per section 3 4 2 If these test OK replace the fuse and repower the Elite If it fails again replace the Power tray Control Board Fuse Located on the Control board this fuse is in series with the user 24Vdc 500mA power supply accessed via T36 and T37 The u
121. eck the spare parts list and pick an Elite of the same frame size with the same number of DC Bus capacitors Time the rate of charge i e the increase in ohms on the meter and comparing this against the suspect Elite If this test indicates reasonable variation there may be a problem with the capacitors Further testing requires disassembly of the Elite To test for individual open or short circuited capacitors Elite must also be dismantled and each capacitor individually checked with a multimeter Ensure all capacitors are fully discharged then connect the meter on OHMS range across each capacitor in turn with the meter positive to the capacitor positive On a good capacitor the resistance should start low then increase as the capacitor charges to the meter battery voltage Visual Inspection These capacitors are a sealed canister with a vent beside the terminal posts If the capacitor has overheated or suffered an internal fault and pressure build up internally the bung in the vent hole should be displaced Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 amp 7 81 4 5 SOFT POWERING AFTER REPAIR Once all faulty components and assemblies have been replaced and the Elite has been carefully reassembled it is recommended that the machine be tested as per section 4 4 1 then Soft Power 4 5 1 SOFT POWERING le This procedure uses a special Soft Power supply available from PDL Electronics or the circuit diagram to buil
122. ed Is 24VDC present on terminals 20 amp 21 Replace the Control Board Check the field wiring again and replace the 500mA fuse on the Control Board 24VDC present on terminals 37 amp 36 Replace the Control Board 4508 250B Note 1 The fan terminals are located between the fibre optic connections at the bottom of the Control Board Note 2 Disconnect fan and recheck 28 volt supply If 28Vdc is not present the switch mode power supply on the Gatedrive Board is not functioning If the supply returns when the fans are disconnected the fans may be at fault Figure 1 2 Control Board Fault Finding Elite Series Service Manual 4201 230 Rev B1 12 Frame 1 amp 2 1 3 5 RECTIFIER The rectifier is a full bridge rectifier with 6 diodes built into a single block failure is typically indicated by two supply fuses blowing See section 1 4 for testing of the rectifier Possible causes of Rectifier failure Internal fault in Elite i e DC Bus capacitors or inverter failure Fault in supply cable motor cable or motor Soft Charge relay shorted The Soft Charge circuit is a resistor in series with the positive DC Bus the resistor limits the current drawn when the Elite is powered up When the soft charge period is complete the resistor is shorted out by a relay The Soft Charge circuit is mounted on the Terminal Board Supply voltage exceeding the Elite s rating The 500V Eli
123. end of the rail then remove the 4 off M4x10 CW screws at each end Remove screws 2 off screws A and 2 off bolts B and C The output Sheet Bus can be lifted clear and the output busbar can be pulled through the grommet If the bus bar is sticking to the grommet some soapy water will help it slide out Unplug the lower fibre optic looms from the Gatedrive board Leave the looms in the nylon cable clamps A M6x16 CW SCREW OUTPUT SHEET BUS 5 pe B NO uen o R M6x16 SET SCREW ee M6 FLAT WASHER je Z M6 SCHNORR WASHER ilga E s 3 o C Figure 5 1 Elite Series Service Manual 1 6 16 SET SCREW M6 FLAT WASHER M6 SCHNORR WASHER OUTPUT BUS BAR 4508283A Frame 5 Output Sheet Bus Removal 4201 230 Rev B5 Frame 5 91 5 2 44 SERVICING THE POSITIVE AND NEGATIVE SHEET BUS Fe Removing the Bus Sharing and Power Supply Board Refer to figure 5 13 and figure 5 14 1 Remove the Bus Sharing boards and Bus Sharing cable These two assemblies are secured by screws A B and use 6 off 16mm long brass spacers It is best to remove them as a full assembly keeping t
124. fier or inverter fault motor or motor cable fault Action 1 See section 4 1 before starting 2 Perform a visual inspection for mechanical damage water entry or any other possible damage to the system 3 For new or modified installations check the wiring is correct as per the Technical Manual 4201 180 4 Check fuses for correct rating 5 Disconnect supply cables and test for phase to phase or phase to earth fault 6 Mark and disconnect the output cables test the cables and motor for phase to phase and phase to earth fault 7 Test the Elite for rectifier inverter or DC Bus faults as per section 4 5 1 8 If no faults are found the best option is to Soft Power the Elite as per section 4 5 If you consider the fuses failed because of an external issue such as short term overload or cyclic stress reconnect the Elite replace the fuses and attempt to run the Elite Control Board Fuse Located on the Control board This fuse is in series with the user 24Vdc 500mA power supply accessed via T36 and T37 The user power supply is short circuit protected and will shut down if a short is present in the field control wiring or other device connected to T36 and T37 Elite Series Service Manual 4201 230 Rev B57 72 Frame 5 6 8 amp 7 12A 440V Power Tray DC Supply Fuses Fitted on Elite Power Supply Board _ Possible reason for failure Fault in main switch mode power supply on Power tray Inspect the Power tra
125. he Ee 2 7 1 REMOVING THE CONTROL BOARD slots to ensure no pins are showing Refer to figure 2 13 See section 2 1 before commencing service work DISPLAY UNIT DN 1 Mark the location of the control wiring plugs and PLUG 3 WAY eam remove them use a felt pen and number each nad izi MAS DE plug Remove the fibre optic cables if used OV EARTH s M3x6mm 5 2 Remove the Display unit M3x10mm 3 Remove the Phillips head screw the Display unit SCREW 8GX1 2 5 WAFER PHILIPS 4 OFF mounting plate and ease the mounting plate off the locating tabs on the control terminal plate CONTROL TERM PLATE PLATE SCREW 8GX1 2 4 To remove the Terminal plate remove iion LES a 4 off Phillips 8Gx1 2 head screws b 1 off M3x10mm Phillips head screws which is the Control board earth c 1 off M5X16mm which is the Gland Plate earth connection d 1 off M3X6mm which is the OV control earth if it FIT bv AND W has not been removed on installation INTERFACE v 2 5 Remove the earth connection e 6 Remove the external fan wires from the bottom of lt the Control board 7 Remove the 2 off 8Gx1 2 Phillips head screws securing the Control board Remove the 40 pin connector top right that is holding it in place CONTROL TERM PLATE EARTH X GLAND PLATE EARTH 8 Using the tool provided with the Control board Figure 2 13 Frame 3 Control Board Removal
126. he faulty one will be overloaded and will fail prematurely Important note the 1K resistor must be between the gate and emitter at all times during the tests CONDUCTION TEST ALTERNATIVE TEST APPARATUS 1K Ohm Resistor 1K Ohm Resistor 1 K Ohm Resistor 1 K Ohm Resistor 12V Current limited Power supply Lamp to Limit Current and Protect Battery Gate Emitter i Hold Gate SIGNAL On To Turn On The IGBT The IGBT Will Turn Off i p When the Gate Signalisi 2 Removed i Flyback US Diode Collector 12 Volt Battery 4508 298A Figure 4 12 Individual IGBT Testing Elite Series Service Manual 4201 230 Rev B57 80 Frame 5 6 amp 7 4 4 6 TESTING THE DCCT AND DCCT SUPPLY The DCCTs measure motor current and are located on the output of the Elite DCCT failure may be indicated by Fault 21 Ground fault or Fault 58 Current imbalance even with the motor disconnected If fault 21 is apparent and the motor and motor cable have been checked and are OK check the DCCT terminations as shown in figure 3 9 and the Inverter as shown in figure 4 7 The 6 pin connector is located at the very top of the Control Board Check plugs P1 P2 and P3 connecting the DCCTs to the Power tray Ensure they are correctly inserted How to test the DCCTs 1 Power up the Elite but do not start refer to f
127. he capacitors do not remove the cap centre Sheet Bus screws A POSITIVE SHEET BUS 3 F M3 x 10 CW SCREWS G M6 x 16 CW SCREWS M5 x 12 CW SCREWS M6 x 16 CW SCREWS J 8 x 20 BOLT WASHERS amp NUT POSITIVE SHEETBUS V JOINING BOLTS 8 20 WASHER amp NUT SHEETBUS SHIELDS CLEAR LEXAN POWER SUPPLY BOARD THIS ROW 420A TO 540A ONLY NEGATIVE SHEET BUS B M8 x 16BOLT amp WASHERS 5 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 27 CAP CENTER SHEETBUS TO 540A ONLY ua AX A MS x 12 CW SCREWS 4508 308 THIS ROW 420A 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 Short 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 o
128. he screws and spacers together This makes it easier to reassemble 2 Remove the Power Supply board This is secured by screws C and have 4 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 it easier to reassemble 3 It is not necessary to unbolt the DC Bus fuses as the positive Sheet Bus can be removed as one piece DC FUSE NO NEED TO REMOVE NEGATIVE SHEET BU SHEET BUS SHIELD POSITIVE SHEET BU BUS SHARING CABLE DC FUSE ASSEMBLY BUS SHARING PCB M5x 30 CW SCREW SPACER A SPACER 16 0 LON SPACER 9 50D 16 8 LON 2 MIDDLE POSITIONS o M5x30 CW SCREW q 3 SPACER 16 0 LON 2 OUTER POSITIONS I 1 CENTRE SHIELD CAP CENTRE SHEET BUS
129. hen the Elite is powered up this is termed Soft Charge The phase control is continued until the capacitors are fully charged then all SCRs are turned on Rectifier Soft Charge failure can be indicated R Input fuses blowing on power application or display of SUPPLY FAULT especially on application of load See section 4 4 1 for supply problems Causes of Rectifier Failure Bus Capacitor Failure Excess current drawn by a shorted capacitors may damage the rectifier See section 4 3 3 Internal fault in Elite Failure to a short circuit will cause two input phase fuses to blow See section 4 3 Fault in supply cable motor cable or motor Input supply imbalance If Line 1 L1 is low with respect to yellow and blue the Elite will soft charge the capacitors to 1 414 x the L1 RMS voltage level When the soft charge is finished the SCRs on L2 and L3 will be turned on fully applying a higher DC level to the DC bus than is currently there This can generate sufficient inrush current to damage the input rectifier Supply voltage exceeding the Elite s rating The Elite has VDR s to protect against voltage transients these will not cope with a supply that is constantly above the maximum level the Elite was designed for The VDR s will fail and the Elite may be damaged also Soft Charge Failure Failure of the Soft Charge function Some or all of the SCR s may not re
130. hillips 8G x 1 2 wafer screws Once these are removed the 40 pin top right and 6 pin top left connectors are all that is holding it down 7 Disconnect the external fan wire from the bottom of the Control board 8 Using the tool supplied gently lift the Control board evenly off the connecting pins by inserting it in the slots at the end of the connectors and pulling up 9 To slide the Control board out of the Elite lift it slightly at the fibre optic input output end and gently slide it out of the Elite cabinet When the Control board is removed place it in a static proof bag or on static safe foam for safekeeping Replacing the Control Board 1 Continue to observe static safe work procedures 2 Avoid excessive handling of the new Control board 3 The replacement Control board will be in biscuit format i e it will have to be trimmed to the same size as the existing Control board see figure 1 12 for the biscuit shape This is done with a fine pair of side cutters cutting as close to the Control board as possible 4 Unsolder the Control board earth from the old Control board and solder it onto the replacement board 5 6 7 8 9 19 Ensure the Terminal board and Gatedrive boards are located in the vertical slots at the top of the Elite cabinet bi Place the Control board on the connecting pins Move the Control board until the pins appear to be in place through the slots at each end of the co
131. hillips screws See figure 5 16 5 2 10 REPLACING THE CAPACITORS 95 The capacitors should be installed using a jig PDL part number 5101 190 this ensures the height and rotational position are exact 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 5 17 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 Sealing Ring Before Inserting Capacitor Into Heatsink Figure 5 17 r Frame Capacitor Replacement Clamping Plate Capacitor Replacement Complete 4508 302A Elite Series Service Manual 4201 230 Rev B5 96 Frame 5 15 2 11 500V MODELS EXTERNAL FAN POWER SUPPLY The 500V models have a linear AC to 24Vdc power supply for the external fans This is located directly above the internal cooling fan and is accessible
132. igure 4 13 This drawing shows two options for testing the DCCTs either test between ground and terminal 1 then between ground and terminal 4 and 6 to confirm the DCCT has a 14V supply or test at the plug If the 14 supply is not present unplug the DCCT s and recheck the 14 supply If the supply has returned one or more of the DCCTs are faulty If the supply has not returned the Control board or Power tray s switch mode power supply may be faulty see section 3 3 4 to determine which is faulty 2 Test the DCCTs by measuring between ground and terminals 3 5 and 6 this should be OV if the three readings are not at O volts replace the faulty DCCT s DCCT PLUG GROUND GREY DCCT Output ovd YELLOW ve PURPLE BROWN 14Vde 6 Pin Connector 6 Pin Connector Control Board V DCCT Output U DCCT Output 14 Volts W DCCT Oputputs Ground 2 14 Volt 4508 259A Figure 4 13 DCCT and Supply Testing 447 DC BUS CAPACITOR TESTS First test the rectifier and inverter by following the procedure in section 4 4 1 Test the capacitors by using a meter set to OHMS between HVDC terminals and The resistance should start low then increase as the capacitors charge to the meter battery voltage ensure the DC bus capacitors are fully discharged first This charging period could take some time and it is best carried out by testing the suspect machine against a known good Elite of the same amperage rating or ch
133. imum spares stock Level 2 Typical spares stock 4508 273A Figure 3 11 400V Frame 4 Parts list 3 6 2 FRAME 4 500V ULTRADRIVE ELITE PARTS LIST 500 VOLT ULTRADRIVE ELITE PARTS LIST Frame Size FRAME 4 Spares Guide Model UE 60D UE 75D UE 90D UE 115D UE 40D Level1 Level2 Display Unit E141 620S Control Board E000 610S 1 j Power Tray E141 627S 1 1 DC Bus Board Loom 2721 116 1 F1 F 2 Power Tray 2401 025 2 2 E Lom Loom to Power Tray 2721 113 1 Linking Loom 2721 114 1 Thermal Sensor 2 x E000 619S 1 Microtherm 2 x 2721 101 Includes Wiring Loom and Plug 1 DC Bus Board E140 621 1 DCCT 3 x 2521 086 3 x 2521 087 DCCT Loom 2726 102 3 looms supplied Rectifier Block 3 x 1421 030 3 x 1421 032 3 x 1421 038 2 Rectifier Thermstrate 3 x 1781 006 2 IGBT Block 1757 131 1757 124 1757 126 3 x 1757 134 2 IGBT Thermstrate 3 x 1781 104 2 IGBT Gatedrive Loom 3 x 2721 117 3 DC Bus Capacitors 4 x 1352 552 6 x 1352 552 8 x 1352 552 Capaitor Sealing Ring 4 x 3907 004 6 x 3907 004 8 x 3907 004 External Fans 150mm Fan 2941 015 1 1 120mm Fan 2941 012 1 1 Internal Fans 2941 013 1 1 Level 1 Minimum spares stock Level 2 Typical spares stock 4508 274A Figure 3 12 500V Frame 4 Parts list Elite Series Service Manual 4201 230 Rev B4 29 84 CONTROL BOARD EXTERNAL FAN INTERNAL FAN 80mm EXTERNAL FAN DISPLAY UNIT n3 120mm Jenueyy S seues 91113 bg 84 0 c LOCF 51
134. ing resistor Reduce deceleration rate Screen R2 Note Active whether a dynamic brake is connected or not Fault 18 DATA FLT Detail Nonvolatile memory EEPROM reading error This fault can only be cleared using Screen Y2 to initialise user and motor settings Be sure motor is isolated before resetting fault and entering correct data Sense level Check sum in memory Possible cause Spurious fault faulty memory Action If fault recurs replace Elite Series Fault 19 ZERO PARAM Detail Zero parameters N screens have been detected Possible cause Elite Series has been reinitialised ex factory state error in set up Action Enter all N values correctly Fault 20 PARAM FLT Detail Inconsistent set of parameters N screens L9 screen selected Possible cause Action Enter consistent set of N values Fault 21 GROUND FLT Detail Excessive current flow to ground Sense level Internally set Possible cause Motor or cable insulation fault Action Check motor and cables isolate from Elite Series first Refer to Screen L 13 Fault 22 EXT PTC Detail External trip device has operated External motor winding temperature sensor PTC thermostat etc circuit Terminal T19 has operated Sense level Circuit resistance exceeds 4kOhms Possible cause Operation of external trip device Motor has become too hot motor load exceeds cooling capacity at the operating speed Fault in sensor wiring Action Check external trip sw
135. ing at or near full output current Short Circuited DC Bus Capacitor A shorted capacitor should cause two input fuses to fail during or soon after the soft charge interval Because they are connected in series to share the DC bus voltage if one capacitor has shorted it will expose all the capacitors opposite it to above rated voltage This is shown in figure 3 3 In the righthand drawing the top set of capacitors have been exposed to full DC bus voltage which will be approximately twice their rating In this event it is recommended to replace all the DC Bus capacitors or at a minimum all the opposing capacitors as well as the faulty one Normal Conditions One Capacitor Failed Short b d 2 v V 2 gee 4508 323A Figure 3 3 DC Bus Capacitor Short Circuit Elite Series Service Manual 4201 230 Rev B4 52 Frame 4 3 4 TESTING 3 4 1 TESTING THE RECTIFIER AND THE INVERTER Refer Figure 3 4 and using a multimeter check the rectifier as the drawing indicates Note each test is carried out 3 times i e once per phase a total of twelve tests SCR ve DC Bus forward A T 1 T T blocking E ay ae Diode locking conduction gt 100k 0 3 0 45V JIGBT amp Dode blocking se gt 10k 4 Diode blocking gt 100k IGBT 8 Dode blocking gt 10k conduction 0 3 0 5V T7 Ne DC Bus 4508 210B v Figure
136. itch if fitted Elite Series Service Manual Error in set up wrong values chosen Check motor temperature and sensor wiring Fault 23 H S TEMP Detail Elite Series heatsink too hot Sense level 90 C Possible cause Poor ventilation obstructed ventilation path Elite Series cooling fan failure local ambient temperature exceeds 50 C Action Check fan is operating Check ventilation and thermal conditions Improve cooling Clean fins with compressed air Seek service Fault 24 INT TEMP Detail Elite Series internal temperature too hot Sense level 80 C Possible cause Poor ventilation obstructed ventilation path Elite Series heatsink and internal cooling fan failure local ambient temperature exceeds 50 C Action Check heatsink and internal cooling fans are operating Check ventilation and thermal conditions Improve cooling Seek service Fault 25 COMMS TRIP Detail Host computer generated trip Sense level Possible cause Trip generated by the host computer via serial communications Action No action required Fault 26 COMMS T O Detail Time since last valid serial communication has exceeded timeout period on Screen H2 Sense level Set by communications timeout value on Screen H2 Possible cause Serial communications wiring faults host computer fault incorrect settings on Screens H1 to H4 Action Check complete serial communications system Check screen settings Seek Service Fault 27 FIBR
137. ite Series Service Manual Replacing the Power Board The Power tray is sold as a complete assembly and excludes the Control board Replacing the Power tray is done in the opposite order to removing it eae NE M4x10 captive screw 4 places Ultradrive powertray assembly 4508 236A Figure 3 18 Power Tray 4201 230 Rev B4 Frame 4 3 7 3 REMOVING THE HEAT EXCHANGER If further disassembly is required it is expedient to remove the heat exchanger from the Elite 1 2 3 4 5 6 4508 243A Remove the Door by removing the M6 Bolt that holds the RFI Earth strap to the door and the two pins which retain the door hinge pivots Cut the cable ties securing the fan wiring and unplug the fans Refer to figure 3 19 remove the side panels by removing a 4 off M5x12 Phillips head screw from the top of the Elite b 4 off M8x20 Bolt from the lifting lugs C 2 off M8x16 bolts from the lower end of the side panel Loosen the 8 off M8 nuts the side panel is slotted The side panels can now be lifted clear Remove the 8 off M5x12 Phillips head screws from the top and bottom of the heat exchanger frame as shown in figure 3 20 M5x12 captive screw _ 4 places Label UE60 140 E Rating Plate e M8 flat washer M8 schnorr washer M8x20 set screw 4 places e T M8 flat washer M8 schnorr washer e M8 flat washer M8 nut 8 schnorr washer 8 places M8x16 set screw 2 pla
138. later 5 Remove all internal wiring from the terminal board 6 The DCCT s are mounted under the terminal assembly and are connected to the Control board by three 4 pin plugs Ensure the plugs at the DCCT s are labelled then unplug them 7 The terminal DCCT assembly is attached to the upper terminal mounting bracket by 1 off M5x10 screw and it is a push fit on to the lower mounting bracket 8 The terminal assembly is held by the output wires labelled U V amp W These come from the IGBT s through their respective DCCT s then a torroid which all three wires pass through The wiring must be pulled through these when the terminal assembly is lifted clear 6 0mm RED DC 6 0mm RED DC 6 0mm RED N 7 6 0mm RED lt TOROID THREAD iiie e LEADS THROUGH 4 6 0mm RED DC Figure 2 22 Power Termination Removal 43 Common Mode Input Choke Wiring Refer figure 2 25 Remove 3 off M6x12 screws A to remove the assembly When the wiring has been removed replace the screws This is to support the SCR s when the assembly is removed s Rectifier Board 4508 231A Figure 2 23 Common Mode Choke DC Choke Wiring Refer figure 2 26 Remove the DC bus and Choke wiring by removing the 2 off M6x12 screws B When the wiring has been removed replace the screws 4508 232A Figure 2 26 DC Bus Choke Wiring Elite Series Service Manual 4201 230 Rev B3
139. le this section is quite detailed the capacitors seldom cause any problems 400V capacitors rating 2200 MFD 20 at 20 C and 120Hz 500V capacitors rating 1800 MFD 20 at 20 C and 120Hz Factors affecting the life of the DC Bus Capacitors 1 Stress related issues include vibration excessive ripple above rated voltage and or temperature Over heating is the most likely cause of premature failure and can be brought about by reduction in cooling air flow to the drive excessive ambient temperature or excess ripple due to some of the capacitors going open circuit Check the heatsink for blockage and fans for operation 2 The recommended storage period without use should not to exceed 3 years If there is concern regarding the time an Elite has been stored a DC supply can be connected to the DC Bus terminals Starting at about 50Vdc and over 8 hours the voltage is gradually increased to about 560V to 600Vdc for 400V models and 660V to 700Vdc for 500V models Failure to do this can cause failure of the DC Bus capacitors on initial application of full voltage Symptoms of DC bus capacitor failure Open Circuited Capacitor If a single DC Bus capacitor goes open circuit the symptoms may not be noticeable However the remaining capacitors will have an increased ripple current and will run hotter If more capacitors consequently go open circuit the DC bus ripple will increase and may cause a SUPPLY FLT trip especially when the Elite is runn
140. lly off the SCR diode block 7 O ru o ey o O O LJ e ee M a oe TE e Asp raj B gt gt CLUS ea E di B Con B Be o o o o o o o GATEDRIVE BOARD E E E B B B A M6 x 12 CW SCREW M4 x 10 CW SCREW rd o C M4 x 10 CW SCREW AG AG AG AG AG AG 9 Be B __ BET Be Be Li Be B B zu Be Be
141. n two phases up to about half to two thirds of its current rating at which point the DC Bus filter will not be capable of maintaining the ripple below 40Vac and the Elite will trip The Display unit will stay live The Elite can be reset and will run to about the same current before tripping again s Excessive mains distortion harmonics can also cause excessive ripple on the DC Bus The cause of excessive supply distortion in an industrial situation may be SCR controlled heating equipment DC drives current source inverters and other high current non linear loads This can also occur where backup generators are used and they have not been sized correctly relative to the total variable speed drive load VSD The total loading of VSDs on a backup generator should be about 60 and the remaining 40 made up of linear loads 2 3 2 FUSE FAILURE Fuse failure is not a normal event and it usually indicates a more serious fault Therefore the reason for fuse failure should be investigated Supply Fuses Location At point of supply to the Elite Possible reason for failure Supply surge age or cyclic stress failure wrong fuses fault in supply cable to the Elite rectifier or inverter fault motor or motor cable fault Action 1 See section 2 1 before starting 2 Perform a visual inspection for mechanical damage water entry or any other possible damage to the system 3 For new or modified installations check the wiring is correct as per
142. nd L1 L2 L3 to earth to ensure the supply has been disconnected 3 Finally test between the VE and VE DC bus terminals to ensure the DC bus has fully discharged Figure 4 1 Frame 5 Cabinet View Elite Series Service Manual S ULTRAJEME ROMOTOR EARTH LINK BRAID Hinge Plate FF M6 x 16 CW SCREWS 2 OFF M6 x 12 CW SCREWS DISPLAY LOOM AND SERIAL 4201 230 57 Frame 5 6 amp 7 69 4 2 PRINTED CIRCUIT BOARD DESCRIPTION L Display The Display has three buttons and a 2 by16 character display It is the user interface for all parameter settings and is _ common to the Elite Series for a fault finding guide see section 4 3 3 The Control board is common to the Elite Series For a description and a fault finding guide see section 4 3 4 The Control board accepts all external control inputs and generates output signals The inputs and outputs include digital analogue fibre optic and Modbus serial communications A shaft encoder interface and 5V power supply is standard The Display plugs into the control board The Control board also has a bidirectional 24Vdc user power supply rated at 500mA Power Tray The Power tray Power Electronics Assembly is made up of a metal support tray Con
143. ne 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 a EARTH TAB 4 ina qii Oo 0 Oo o IM GATEDRIVE BOARD A M6 x 12 CW SCREW M4 x 10 CW SCREW
144. ng Loom 2 x 2726 103 1 FbreOplioLoomUH UL amp a VL Fibre Optic Loom ULa WL 22 Fibre Optic Loom WL External Fan P S Transformer 28740 External Fan P S Board 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 0075 007 SHOLIOVdVO SSSHL 292 809 o 5 Xi 8 x 8 x m 189 1ZTIVEVA Y 189 HT VAN X TST Y suo iovavo sna od suoLlovdvo SNE oa SHOLJOVAVO SNE 20 4 2 d bi f bi po i po r3 Sng 20 de 43141193H 431411934 HJIALOJH c NEN sna EU HEN R Im NEN IO HEN n n s l 1 Quvog Ic IL M1990 E EF ONIHYHS ESI x 11908 kun REN E
145. ng 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 slight to clear the fibre optic connections before lifting it clear Referring to Figure 7 7 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 It will have to be trimmed to the same size as the existing board size as per figure 7 9 This is done with a fine pair of side cutters Place the Control board on the connecting pins 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 7 7 Replace the remaining components of the Elite in the opposite order as detailed in removing the Control board INTERNAL FAN WIRES SC FIBRE OPTIC COVER PANEL Maxd0 CW SCREW DC FUSE PCB LOOM POWER TO POWER POBLOOM
146. nnection sockets Be very careful at this point to avoid bending the pins on the Gatedrive and Terminal boards Gently push the 6 pin connector down repeat the process with the 40 pin connector If locating the 6 pin connector first does not work try locating the 40 pin connector then the 6 pin If problems are still encountered check step 5 again and ensure the bridges which held the removed part of the Control board biscuit are as short as possible Do not apply force Replace the remaining components back into the Elite reversing the order used when removing the Control board DISPLAY UNIT SCREW 8G x 1 2 TERMINAL PLATE 5222 fe WAFER PHILIPS TERMINAL SHIELD m ren 7 xm BOARD COVER SCREW 8G x 1 2 ax WAFER PHILIPS 77 8 OFF SCREW 8G x 1 2 9 WAFER PHILIPS 20FF CONTROL BOARD 000 610 4508 205 Figure 1 11 Control Board Removal 1 1 0 sei Y i Lr 2 r e VISC 80Sv Figure 1 12 Control Board Biscuit Elite Series Service Manual 4201 230 Rev B1 20 Frame 1 amp 2 1 7 2 REMOVING THE SHROUD 1 7 3 REMOVING THE SKIRT To access any other boards the shrouds and skirts in the Refer figure 1 14 when removing the skirt EIS mist DES FORD first 1 Remove the fan and pull the wire through the Complete previous section first rubber gasket Refer figure 1 13 when removing the shrouds 2 Remove tw
147. ntrolled to limit the inrush current to the DC bus capacitors when the Elite is powered up This is termed Soft Charge The phase control is continued until the capacitors are fully charged then all SCRs are turned on Rectifier softcharge failure can be indicated by input fuses blowing on power application or display of SUPPLY FAULT especially on application of load Soft Charge failure Failure of soft charge function Some or all of the SCR s may not respond to a gate signal or the rectifier board may not be producing a gatedrive signal This indicates a failure in the Rectifier board or SCR Diode block Diode or SCR Failure If part of the rectifier stage has failed open circuit the Elite may not soft charge and no voltage will appear on the DC bus Note it is uncommon for semiconductors to fail open circuit Some causes of rectifier failure Bus Capacitor Failure Excess current drawn by a shorted capacitors may damage the rectifier See section 2 3 7 Internal fault in Elite Failure to a short circuit will cause the two input phase fuses to blow Fault in supply cable motor cable or motor Input supply imbalance If Line 1 L1 is low with respect to yellow and blue the Elite will soft charge the capacitors to 1 414 x the L1 RMS voltage level When the soft charge is finished the SCRs on L2 and L3 will be turned on fully applying a higher DC level to the DC bus than is currently there This can generate sufficient inrush current to
148. o rubber grommets from the top skirt 1 To remove the shrouds remove a 4 off wafer Phillips 8G x 1 2 inch b 2 off 3 4 pan square screws C 2 off M4x10mm Phillips screws which also secure the fan 2 Tilt the top of the shrouds out from the Elite body slightly and lift clear of the locating lugs on the bottom of the shrouds 5 SCREW 8G x 1 2 WAFER PHILIPS 40FF SHROUD LEFT SHROUD RIGHT gi SCREW 12 x 3 4 PAN SQ 20FF ENSURE SHROUD TAB ii FITS BETWEEN FAN PLATE amp BOTTOM MTG PLATE Figure 1 13 Shroud Removal Frames 1 and 2 Elite Series Service Manual just above the gland plate 3 The gland plate earth link may need to be removed unless the gland plate has already been removed 4 Remove the 4 off M6x110mm bolts that hold the skirts to the heat sink The two skirts can now be lifted clear Replacing the Skirt For IP54 models it is important to ensure correct alignment of the top and bottom skirt to the Elite to maintain the IP54 rating of the Elite GROMMET 164 DIA HOLE 20FF BOLT M6x110mm 4 OFF SCHNORR WASHER B 40FF FLAT WASHER D M6x12 5mm 8 OFF EARTH LINK O 4508 204A Figure 1 14 Skirt Removal Frames 1 and 2 4201 230 Rev B Frame 1 amp 2 1 7 4 SERVICING THE TERMINAL BOARD Removing the Terminal Board for Frame 1 Refer figure 1 15 when removing the terminal board 1 Note before proceeding it i
149. o variations in Control board earthing which affects the location of one screw The Control board is now only held by the 6 pin and 40pin connecting sockets see figure 3 15 Lift the board gently and evenly at the connecting socket areas When the board is removed place it in a static proof bag or on static safe foam 9 4 10 captive screw 6 places 5 4508 224 Figure 3 14 Cover Plate 59 M4x10 z Elite control board 000 610 4508 226A Figure 3 15 Control Board Removal REPLACING THE CONTROL BOARD 1 2 3 4 5 Continue to observe static safe work procedures and avoid excessive handling of the new Control board The replacement Control board will be in biscuit format i e it will have to be trimmed to the same size as the existing board size as per figure 3 16 This is done with a fine pair of side cutters cutting as close to the Control board as possible Place the Control board on the connecting pins 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 Push the Control board completely home and replace the 3 off M4x10 Phillips screws as per figure 3 15 Replace the remaining components of the Ult
150. on The Elite has power connected A replacement Power tray will come complete with the metal support tray and Control board mounting plate Elite Series Service Manual 4201 230 Rev B4 te 3 3 48 FAULT FINDING GUIDE 3 3 1 SUPPLY ISSUES Power supply problems can be misinterpreted as faults in the Elite some are listed below Fault 01 LOW Vdc The supply to the Elite is dropping below the switchmode power supply operating level and it is shutting down This is usually caused by a weak supply or faults in the supply system Look for motors starting direct on line or other machines drawing high current For further details see the fault list in the section 8 of this manual Fault 02 HIGH Vdc The supply to the Elite is surging too high Rapid load changes in the supply system may be faster than the automatic tap changing transformers can adjust to For further details see the fault list in the section 8 of this manual Fault 04 SUPPLY FLT Supply fault Fault 04 is an indication that the ripple on the DC Bus has exceeded 40Vac The Elite will trip if this condition is reached and display fault 04 SUPPLY FLT This fault can be caused by diode s in the rectifier going open circuit see section 3 4 but is more likely to be caused by either The loss of an input phase which increases the ripple on the DC Bus The Elite will run on two phases up to about half to two thirds of its current rating at which point the DC
151. ontrol as per the Elite technical manual part no 4201 180 Disconnect the supply Connect a PDL Soft Power Supply to the DC bus as in figure 1 7 The Soft Power supply is available from PDL Electronics Ltd or refer to the circuit diagram is shown in section 8 of this manual to build one The power supply is a 600Vdc power source which is used to power up the DC Bus The procedure enables any remaining DC Bus or inverter fault to be found without causing damage Connect the Soft Power Supply to the mains as shown in figure 1 7 The isolating transformer is not required for galvanic isolation between supplies as only one supply is used but it is recommended to do so as a safety measure The lamps in series reduce the current that will flow if the Elite is faulty Set the variac to the lowest setting switch on and increase the voltage setting to 230Vac over 5 seconds any longer risks burning out the soft charge resistor in the Soft Power Unit The Display should come up when the supply reaches 280Vdc and the red DC Bus live LED should energise on Gatedrive board visible at the bottom of the Control board Now set the Elite to local start stop and speed reference control see Technical manual part number 4201 180 for details The Elite should respond to Display unit Start Stop commands and Speed reference changes Start the Elite from the Display unit and increase the output frequency or speed to 100 Now use a multimeter set to AC VOLTS to meas
152. 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 Sealing Ring Before Capacitor Replacement Inserting Capacitor Complete _ Into Heatsink Clamping ___________ 23 5mm Plate 29 5mm Sealing Ring 4508 302A Figure 7 17 Frame Capacitor Replacement Elite Series Service Manual 4201 230 Rev B7 Frame 7 129 7 2 11 500V MODELS EXTERNAL FAN POWER SUPPLY The 500V models have a linear AC to 24Vdc 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 M5x10 CW screws An exploded assembly view is shown in figure 7 18 and figure 7 19 M5HEX FORGED NUT amp SCHNORR WASHER M5 FLAT WASHER M5 X 10 8 places M5X12 WASHER SCREW 4 places Black ve White ve 4508 287A Figure 7 18 Frame 5 to 7 500V External Fan Supply 1 4 3 F 5 L Bd X n o 2929298562 i q A i O O O 4508 288A Figure 7
153. radrive in the opposite order as detailed in removing the Control board Note if you encounter problems locating the cover plate check the Control board bridges These were cut to remove the lower part of the control biscuit if they are too long they obstruct the top cover plate VEZZ 80SP 0 Figure 3 16 Control Board Biscuit Elite Series Service Manual 4201 230 Rev B4 60 Frame 4 lys SERVICING THE POWER TRAY Removing the Power Tray The Power tray is sold as an assembly and includes the steel work See section 3 7 1 and remove the Control board from the old Power tray and install on the new Power tray A tool is required for this procedure to protect the IGBT s when the gate connection plug is removed from the Power tray A typical shorting link is shown in figure 3 17 1 2 3 4 Figure 3 17 Shorting Link Continue to observe static safe procedures and remove the plugs as detailed a U V W Gate drive plugs and fit the shorting links b The fan supply plugs c The DCCT Plugs it is best to label them if they are the white series d The Thermal Sensor loom plug e The DC Bus Board loom plug 500V models have a Drive Select Board on the 40 pin connector transfer this to the new Power tray Remove the 2 off M4x16 and 3 off M4x10 Phillips head screws The Control board can now be lifted off the Power tray Place it in a static proof bag El
154. rcuit monitors the IGBTs for overload conditions If overload occurs the relevant IGBT is turned off and a desat fault is signalled to the control board Thermal Sense An NTC thermal sensor circuit is connected to the heatsink via a small tab This circuit monitors the heatsink and will cause the Elite to trip if the heatsink temperature exceeds 80 C 176 F Switch Mode Power Supply The switch mode power supply provides various isolated DC supplies required by the Elite these are 4 off 16 5V OV 13 5V for the gatedrive circuitry e 28Vdc for the internal fans and Control Board 24Vdc 500mA user power supply Via the Control Board Bus Live Indication One red light emitting diode LED to indicate the DC Bus is live One internal fan for circulating air within the Elite IP54 only Power Board The Power Board has RFI and snubber circuitry The rectifier and IGBT blocks attach to this board The IGBT block is soldered to the Power Board Frame 1only Hastwo DC Bus capacitors Frame 2 only Has VDRs for input voltage surge suppression 500V models Terminal Board The Terminal Board contains Power terminations e DC Current Transformers DCCTs DC Bus capacitors e Soft Charge relay and resistor Elite Series Service Manual 4201 230 Rev B1 10 Frame 1 amp 2 E 1 3 FAULT FINDING GUIDE 1 3 1 SUPPLY ISSUES Power supply problems can be misinterpreted as faults in the Elite Some of the
155. rcuits responds to a fibre optic signal from the control board via the Power tray and controls the inverter JIGBTs Desat Circuits monitors the voltage across the IGBTs and turn off the IGBTs in a controlled manner if they become overloaded On this condition the Desat circuitry also sends a trip signal to the Control board via the fibre optic link to the Power tray This signal will trip the Elite and the display will indicate which half phase was overloaded H po a Snubber Circuits 2 off protects the IGBTs from damage due to voltage spikes caused by inductance in the Elite the motor circuit and IGBTS rapid switching Power tray LED indicators are located by the fibre optic connections LED red One for each half phase Actual indication Transmit fibre OK Implication The Desat fibre optic driver has power this is not an indication of a fault it is a normal condition LED Green One for each half phase Actual indication IGBT Gatedrive circuit active Implication The Elite is running Power Supply Board Provides power to the power tray and has two LED s to indicate DC bus voltage is present Bus Sharing Boards This boards ensures that the DC bus voltage is divided evenly across the DC Bus capacitors SCR Boards These boards have voltage transient protection for the Elite and snubbering for the SCR s They also have a connection to the SCR gate for the Gatedriv
156. rease the ripple on the DC Bus The Elite can run on two phases up to about half to two thirds of its current rating At which point the DC Bus filter will not be capable of maintaining the ripple below 40Vac and the Elite will trip The Display will stay live and the Elite can be reset and will run to about the same current before tripping again 2 Excessive mains distortion harmonics can also cause excessive ripple on the DC Bus The cause of excessive supply distortion in an industrial situation may be SCR controlled heating equipment DC drives current source inverters and other high current non linear loads This can occur where backup generators are used which have not been sized correctly relative to the total variable speed drive load VSD The total loading of VSDs on a backup generator should be about 6096 and the remaining 4096 made up of linear loads 4 3 2 FUSE FAILURE Frames 5 to 7 Elite have a number of fuses for SAFETY backup Fuse failure is not a normal event and it usually indicates a more serious fault Thus the reason for fuse failure should be investigated A list of fuses with their locations possible reasons for failure and suggested corrective actions follows Input and DC Bus Fuses The input fuses are located in the lower cabinet and the DC bus fuses are located in the electronics cabinet Possible reason for failure Supply surge age or cyclic stress failure wrong fuses fault in supply cable to the Elite recti
157. rking on and an earthed wrist strap You will need flat surfaces for placing parts on and containers for small items like screws and bolts Tool Requirements 1 x No 2 Phillips screwdriver 1 x No 3 Phillips screwdriver 1 x Flat blade 3 5 mm screwdriver for terminals 1 x Flat blade 5 5 mm screwdriver 1 x No 3 Square drive screwdriver 1 x 5 5mm nutdriver 1 x 7mm nutdriver 1 x 10mm nutdriver 1 x Category 3 multimeter with ranges to 1000V AC and DC maximum 1 x PDL Soft Power Supply 1 x Single Phase variac 1 x Isolating transformer Optional 1 x 24Vdc volt power supply a current limit supply is preferred but a simple plug pack or batteries can be used with a lamp in series to limit the current flow 4 off 230Vac 100W lamps and lamp holders Safety amp Testing Before Starting Repairs 1 Isolate and lock out the mains supply to the Elite and any low voltage supply that may be in parallel with the control power supply 2 Allow approximately 5 minutes for the DC Bus capacitors to discharge 3 Remove the right hand cover by undoing 6 off Phillps head screws Note these screws stay in the cover Check the DC Bus live indicator on the bottom right of the Control board the red LED should not be glowing 4 Remove 6 off Phillps head screws to remove the left cover Then remove the lexan terminal cover 5 Test between input terminals L1 L2 L3 and L1 L2 L3 to earth to ensure the supply has been disconnected 6 Finally te
158. s critical that all wiring be labelled to guarantee correct reassembly especially the output phases To remove the Terminal board remove 2 M4x40mm Phillips screw H which holds the common mode choke body to the heatsink 3 M4x12mm Phillips screws I J and K which hold the red yellow and blue wires to the Power board Note there are extra 4mm washers 4 7 off M4x10mm Phillips screws A to G which will disconnect all the choke wiring 5 A M4x10mm Phillips screw not shown attaches the earth from the Terminal board and gland plate to the heatsink 6 The Terminal board is now held by a 4 pin socket lift the board vertically to disconnect it from the Power board Replacing Terminal boards for Frames 1 amp 2 The replacement Terminal board for Frame 1 will not have terminal blocks common mode choke or the main earth These need to be removed from the old board and placed onto the replacement board using the instructions set out below 1 Lift the terminal insulator block from the old Terminal board and place the terminal clamps on the new board Finger tighten the terminal clamp Screws 2 Place the terminal insulator block onto the terminal clamps and push it down until it locates against the Terminal board 3 Unsolder the common mode choke and main earth and re solder them to the new board Reassemble the Elite LAH Maxdomm
159. s reasonable variation there may be a problem with the capacitors Further testing requires disassembly of the Elite To test for individual open or short circuited capacitors the Elite must be dismantled and each capacitor individually checked with a multimeter Ensure all capacitors are fully discharged before proceeding then connect the meter on OHMS range across each capacitor in turn with the meter positive to the capacitor positive On a good capacitor the resistance should start low then increase as the capacitor charges to the meter battery voltage Visual Inspection of a capacitor Each capacitor is a sealed canister without a vent and as such are required to have a purposely weakened area to allow the case to split if the capacitor should fail and pressure build up internally This weakest area is found in the base or top of the capacitor and will show signs of bulging and splitting if the capacitor has overheated or suffered an internal fault Elite Series Service Manual 4201 230 Rev B1 16 Frame 1 amp 2 fe 1 5 SOFT POWERING AFTER REPAIR Once all faulty components and assemblies are replaced and the Elite has been carefully reassembled it is recommended the Elite be tested as per section 1 4 1 then Soft Powered To Soft Power an Elite Refer to figure 1 7 and connect a 24Vdc current limited power supply to T36 positive and T37 OV Start the Elite the Display unit should liven up then set the Elite to local c
160. ser power supply is short circuit protected and will close down if a short is present in the field control wiring or other device connected to T36 and T37 4201 230 Rev B4 Frame 4 3 3 3 DISPLAY Display Unit Fault Finding Is the screen Put the Elite in appearance normal commission mode see note 2 No Are there lines of pixels missing Yes Replace the Display Unit Re connect correctly No Note The Display Unit may be permanently damaged No Are the screen terminations correct see note 1 Yes Is 24VDC present between T10 amp T12 No See Control Board fault finding Yes Is the Display Unit Yes mounted 3 metres from the Elite Reduce to 3 metres Replace Display Unit 4508 249A Note 1 Terminal 10 red Terminal 11 white Terminal 12 black screen Note 2 See Elite Series Technical Manual 4201 180 Screens Z to Z1 Figure 3 1 Display Fault Finding Elite Series Service Manual 49 3 3 4 CONTROL BOARD Control board fault finding Check field control wiring for faults or disconnect it Is 28VDC present on the fan terminals see Replace the Power Tray Replace the Control Board 24VDC present on terminals 20 amp 21 Check the field wiring again and replace the 500mA fuse on the Control Board 24VDC present on terminals 37 amp 36 Replace
161. spond to a gate signal or the Power tray may not be producing an SCR gatedrive signal Look for a dislodged cable and test the SCR s as per section 4 4 2 Diode or SCR Failure If part of the rectifier stage has failed open circuit the Elite may not soft charge and no voltage will appear on the DC bus Note it is uncommon for semiconductors to fail open circuit REPLACEMENT SCR S Replacement SCRs do not require batch matching 4 3 6 INVERTER DESCRIPTION The inverter consists of insulated gate bipolar transistors IGBTs in parallel to achieve the required current rating Frame size 5 has two IGBTs per half phase Frame 6 has four and Frame 7 has six These are in parallel and share evenly the current supplied to the motor SYMPTOMS OF INVERTER FAILURE 1 Input fuses blowing on power application 2 DC bus fuses blowing on power application 3 DESAT fault 08 to 13 constantly on the same phase and polarity 4 Current limit fault 07 this is a hardware trip to indicate that 220 of rated output current has been reached For all of the above faults test the IGBTs as per section 4 4 1 Check the motor and motor cables If no faults are found attempt to reset the Elite If the fault is repetitive on the same phase and polarity check the IGBTs again If the fault is a DESAT fault and not always on the same phase the problem is most likely in the Gatedrive board There is a small possibility that the Power tray may be at fault and since it is the
162. st between the HVDC terminals VE and VE to ensure the DC Bus has fully discharged Elite Series Service Manual 4201 230 Rev B3 Frame 3 27 2 2 PRINTED CIRCUIT BOARD DESCRIPTIONS IP54 models are built in two enclosures with 4 bushes connecting the enclosures The right enclosure contains Display unit IGBT s DC Bus capacitors Gatedrive board Control board internal cooling fans DC current transformer interface amp control terminations The left enclosure contains Power terminations common mode choke rectifier and DC current transformers DCCTs Display Unit The Display unit has three buttons and a 2 by 16 character liquid crystal display It is the user interface for all parameter settings and is common to the Elite Series range The Display unit plugs into the Control board user terminals Control Board The Control board is common to the Elite Series range and accepts all external control inputs and generates output signals These include digital analogue and fibre optic signals A Modbus RTU serial communications port is also included on the Control board A Shaft Encoder interface and 5V power supply is standard The Control board also has a bidirectional 24Vdc user power supply rated at 500mA Gatedrive Board The Gatedrive board is a general purpose board and as such performs many functions Gatedrive and Desaturation Circuits e Six gatedrive circuits accept gatedrive signals from the Control board and turn on
163. standard screen list or remove Driveweb interface 135 Elite Series Service Manual 4201 230 Rev BA 8 2 SOFT POWER SUPPLY This Soft Power Supply is designed to be used with older products as well as the Elite Series It uses a 230 Volt single phase input and converts it to 600Vdc Output terminals 5 and 7 are not used to Soft Powering an Elite and the components associated with these can left out It is wise to retain a power on indication as LED 1 is used for A modification that can be made to this circuit is to add a switch to short out R1 the soft charge resistor when a variac is used for Soft Powering Frames 1 to 3 This allows the voltage to be increased slowly on the Elite without burning out the resistor 4600 Volts 1 kVA Isolating Transformer 0 Volts 4508 337A Figure 8 1 Soft Power Supply Circuit Diagram Component list for the Soft Power Supply Component Number PDL Part number STR SOW 1059117 0 25W 1001145 R2 R3 R4 R5 6K8 25W 1057 165 D RH 2905511 1277 447 1411 128 1421012 1401 016 1911 001 1 F1 10A Fuse 2401 025 1 LED1 Grout Bord SS 1401 016 8 2 Soft Power Supply Circuit Components Elite Series Service Manual 4201 230 Rev BA
164. t Control board will be in biscuit format It will have to be trimmed to the same size as the existing board size as per figure 5 8 This is done with a fine pair of side cutters Place the Control board on the connecting pins 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 5 6 Replace the remaining components of the Elite in the opposite order as detailed in removing the Control board INTERNAL FAN WIRES FIBRE OPTIC COVER PANEL le Maxto CW SCREW EJ e Figure 5 7 Frame 5 to 7 Power Tray Exploded View DC FUSE P BLOOM 5 a a EN A N 5 POWER TO POWER PCBLOOM SCRPCBLOOM THERMAL SENSE L n9 PoBLoom OA 3OFCTLOOM CONTROL BOARD zej EARTH o SWAY PLUG l EN CONTROL CABLE E oF 4 CLAMPS 7 8 mm 5 j 38 Figure 5 5 Frame 5 to 7 Power Tray Figure 5 8 Frame 4 to 7 Control Board Biscuit Elite Series Service Manual 4201 230 Rev B5 Frame 5 89 5 2 2 SERVICING THE POWER TRAY The Power Electronics bo
165. t circuit wiring fault circuit fault motor fault Action Check entire output circuit and motor for wiring or winding faults Check output circuit contactors and or isolators for correct operation Fault 58 CURR IMB Detail The MASTER and SLAVE Ultradrive Elite output current is out of balance Sense Level 10 of actual individual Drive output current Possible Cause Mismatch of IGBTs output impedances or input rectifier Check entire output circuit including IGBTs output bus work DC bus fuses and input rectifier Action Elite Series Service Manual Fault Detail 59 SLV HS FLT The SLAVE Drive has detected either MASTER or SLAVE drive heatsink is TOO HOT Sense Level 80 C Possible Cause Poor ventilation obstructed ventilation path Elite Series cooling fan failure local ambient temperature exceeds 50 C Action Check fan is operating check ventilation and thermal conditions Improve cooling Clean fins with compressed air Seek service Fault 60 SLV DC HI Detail The SLAVE Ultradrive Elite dc bus voltage has risen to a dangerous level Sense Level 820Vdc Possible Cause DC bus inter link cable fault Action Check dc bus inter link Fault 61 SLV EPLD Detail The SLAVE Ultradrive Elite internal processing units have faulted Possible Cause Faulty or unprogramed SLAVE drive control board Action Reset all Drive parameters using the INILTILISE ALL VAR at screen Y2 replace SLAVE drive control board F
166. tage imbalance Sense level 40Vac ripple voltage in Elite Series DC bus Phase imbalance is most sensitive under heavy load conditions Under light load conditions the Elite Series will run satisfactorily with only two phases connected Possible cause Loss of phase fuse motor phase loss motor winding fault Action Check supply conditions check wiring to motor check motor Fault 05 S W DL FLT Detail Incorrect software down loaded Possible cause Data transmission error incompatible software and hardware revisions Action Down load correct software Fault 06 EEPROM FLT Detail Nonvolatile memory EEPROM is faulty Possible cause IC failure Action Seek service Fault 07 LIM FLT Detail Output current has reached a dangerous level Sense level 220 of Elite Series rated current Possible cause Short circuit wiring fault circuit fault motor fault Check entire output circuit and motor for wiring or winding faults Check output circuit contactors or isolators for correct operation 08 U DESAT 09 V DESAT 10 W DESAT 11 U DESAT 12 V DESAT 13 W DESAT 14 NEG DESAT Automatic protection of the internal power switching semiconductor device has operated Possible cause Short circuit extreme overcurrent wiring fault circuit fault motor fault IGBT desaturation IGBT failure Check entire output circuit and motor for wiring or winding faults If fault persists when output leads are disconnected
167. tart the Elite Control Board Fuse Location On the Control Board This fuse is in series with the user 24Vdc 500mA power supply accessed via T36 and T37 The user power supply is short circuit protected and will shut down if a short is present in the field control wiring or any device connected to T36 and T37 Elite Series Service Manual 4201 230 Rev B1 Frame 1 amp 2 1 3 3 DISPLAY Display Unit Fault Finding Is the screen Put the Elite in appearance normal commission mode see note 2 No Are there lines of pixels missing Yes Replace the Display Unit Re connect correctly No Note The Display Unit may be permanently damaged No Are the screen terminations correct see note 1 Yes Is 24VDC present between T10 amp T12 No See Control Board fault finding Yes Is the Display Unit Yes mounted 3 metres from the Elite Reduce to 3 metres Replace Display Unit 4508 249A Note 1 Terminal 10 red Terminal 11 white Terminal 12 black screen Note 2 See Elite Series Technical Manual 4201 180 Screens Z to Z1 Figure 1 1 Display Fault Finding 1 3 4 11 CONTROL BOARD fe Control Board fault finding Check field control wiring for faults or disconnect it Is 28VDC present on the fan terminals see note 1 Check external fans see note 2 Control Board had Yes high voltage appli
168. te LEAVE KEEPER GATE EMITTER SHORTING LINK DIODE TESTS IGBT TESTS IGBT TESTS IN PLACE FOR STORAGE AND HANDLING 1 0 Diode Diode IGBT conduction h Blocking Diode IGBT 0 3 0 45V Diode 10K Blocking 2 7 H conduction gt 10K 4 1 0 3 0 45V nv NE Diode IGBT Diode IGBT ES Blocking Blocking 3 gt 10K gt 10K va LINK LINK LINK LINK KEEPER REMOVED KEEPER FOR PHOTO gt 10K 4508 320A Figure 3 7 Individual IGBT Testing The final tests are done as shown in figure 3 8 This test is very important as it is possible that the multi meter tests show the IGBTs are OK but the IGBT may not actually work i e the IGBT may not respond to a gatedrive signal Important Note the 1 K ohm resistor must be between the gate and emitter at all times during the tests CONDUCTION TEST ALTERNATIVE TEST APPARATUS 1K Ohm Resistor Lamp to Limit Current and Protect Battery To Turn On The IGBT i The IGBT Will Turn Off When the Gate Signal is Removed i 12V Current limited Power les supply dd 1K Ohm Resistor 12V Current limited Power supply 12 Volt Battery 1K Ohm Resistor 1 K Ohm Resistor 1 K Ohm Resistors 1 K Ohm Resistors 4508 318A
169. te has VDRs to protect against voltage transients these will not cope with a supply that is constantly above the maximum level the Elite was designed for The VDRs will fail and the Elite may be damaged 1 3 6 INVERTER The inverter consists of insulated gate bipolar transistors IGBTs The IGBT block has seven transistors six are for the inverter stage and one for the Dynamic Brake These are built into one block Symptoms of Inverter failure s Input fuses blowing on power application s DESAT fault 08 to 13 constantly on the same phase and polarity Current limit fault 07 this is a hardware trip to indicate that 220 of rated current has been reached For all of the above faults test the IGBTs as per section 1 4 1 and also check the motor and motor cables If no faults are found attempt to reset the Elite if the fault is repetitive on the same phase and polarity check the IGBTs again if the fault is a DESAT fault and not always on the same phase the problem may be is most likely in the Gatedrive Board 1 3 7 DC BUS FILTER The DC Bus filter is comprised of electrolytic capacitors and chokes The chokes are mounted in the heatsink and are in series with the rectifier output The filter s function is to reduce the harmonic current drawn by the Elite and the ripple on the DC Bus excess ripple gt 40VAC will be detected and displayed as a supply fault see section 1 3 1 for further details To achieve the required voltage rating two
170. te has incorrect software loaded Possible Cause The SLAVE drive control board data transmission error incompatible software and hardware revisions Action Download correct software to SLAVE drive control board Fault 69 SLV PCBTEM Detail The SLAVE Ultradrive Elite internal temperature is too hot Sense level 70 C Possible Cause Poor ventilation obstructed ventilation path fan failure local ambient temperature exceeds 50 C Action Check fan is operating Check ventilation and thermal conditions Seek service Fault 70 DC FUSE FLT Detail Fuse monitoring device has operated External fuse monitoring circuit on SLAVE Ultradrive Elite Parallel Board T30 has operated Sense level Possible Cause One of the monitored fuses has failed and the monitoring switch has opened Action Check for continuity on fuse monitoring circuit look for open circuit in wiring Fault 71 DWM1 TRIP Detail Drive web interface watchdog timer trip Sense level Time out set by Driveweb server during configuration Possible Cause Ethernet interface link to drive has been lost Driveweb interface has not been polled within the watchdog time specified Action Check Ethernet interface wiring Fault 72 DWMI BLOCKS Detail Driveweb interface is fitted and drive has detected Vysta program blocks are loaded Possible Cause No Vysta blocks are allowed in a drive fitted with a Driveweb interface Action Remove Vysta program from drive download
171. te that 22096 of rated output current has been reached For all of the above faults test the IGBTs as per section 3 4 1 check the motor and motor cables If no faults are found attempt to reset the Elite If the fault is repetitive on the same half phase check the IGBTs again If the fault is a DESAT fault and not always on the same phase the problem may most likely be in the Power tray output cables or motor IGBT replacement The IGBTs have two IGBTs per block one block does a positive and negative half phase for ONE output phase i e one block does U and U Batch matching of IGBT s is not required for Frame 4 3 3 7 DC BUS FILTER The DC Bus filter is comprised of electrolytic capacitors and chokes The chokes are mounted in series with L1 L2 and L3 and are called line chokes The filter s function is to reduce the harmonic current drawn by the Elite and the ripple on the DC Bus Excess ripple gt 40Vac will be detected and displayed as a supply fault see section 3 3 1 for further details To achieve the required voltage rating two capacitors are connected in series The capacitors are rated at 400V and 450V for the 400V and 500V models respectively Elite Series Service Manual 4201 230 Rev B4 Frame 4 51 Possible causes of failure Fal The definition of capacitor failure is the capacitance of the capacitor to drop and exceed the manufacturers tolerance or suffer a catastrophic failure which is an open or short circuit Whi
172. ter by following the procedure in section 2 4 1 Test the capacitors by using a meter set to OHMS between HVDC terminals and The resistance should start low then increase as the capacitors charge to the meter battery voltage ensure the DC bus capacitors are fully discharged first This charging period could take some time and it is best carried out by testing the suspect machine against a known good Elite of the same amperage rating or check the spare parts list and pick an Elite of the same frame size with the same number of DC Bus capacitors Time the rate of charge i e the increase in ohms on the meter and compare this against the faulty Elite If this test indicates reasonable variation there may be a problem with the capacitors Further testing requires the Elite to be disassembled To test for individual open or short circuited capacitors the Elite must be dismantled and each capacitor individually checked with a multimeter Ensure all capacitors are fully discharged Connect the meter on OHMS range across each capacitor in turn with the meter positive to the capacitor positive On a good capacitor the resistance should start low then increase as the capacitor charges to the meter battery voltage Disassemble the Elite for a visual inspection of the capacitors These capacitors are a sealed canister without a vent and have a purposely weakened area to allow the case to split if the capacitor should fail and pressure build up internally
173. the Control Board 4508 327A Note 1 The fan terminals are located between the fibre optic connections at the bottom of the Control Board These are not used in these frame sizes but still indicate that the Power Tray switch mode power supply is producing the 28Vdc required by the Control Board Figure 3 2 Control Board Fault Finding 4201 230 Rev B4 50 Frame 4 3 3 5 INPUT RECTIFIER The Rectifier is a half controlled bridge that combines DC conversion and the Soft Charge section of the Elite into one stage The SCR s on Line 1 are phase controlled to limit the inrush current due to the DC Bus capacitors when the Elite is powered up this is termed Soft Charge The phase control is continued until the capacitors are fully charged then all SCRs are turned on Rectifier Soft Charge failure can be indicated by Input fuses blowing on power application or Display of SUPPLY FAULT especially on application of load See section 3 3 1 for supply problems Some Causes of Rectifier Failure 1 Bus Capacitor Failure Excess current drawn by a shorted capacitors may damage the rectifier See section 3 3 6 2 Internal fault in Elite Failure to a short circuit will cause two input phase fuses to blow See section 3 4 3 Fault in supply cable motor cable or motor 4 Input supply imbalance If Line 1 L1 is low with respect to yellow and blue the Elite will soft charge the capacitors to 1 414 x the L1 RMS voltage level When th
174. the Technical Manual 4201 180 4 Check fuses for correct rating 5 Disconnect supply cables and test for phase to phase or phase to earth fault 6 Mark and disconnect the output cables test the cables and motor for phase to phase and phase to earth fault 7 Test the Elite for rectifier inverter or DC Bus faults as per section 2 4 8 If no faults are found the best option is to softpower the Elite as per section 2 5 If the fuses failed because of an external issue such as short term overload or cyclic stress reconnect the Elite replace the fuses and attempt to run the Elite Control Board Fuse Location on the Control board This fuse is in series with the user 24Vdc 500mA power supply accessed via T36 and T37 The user power supply is short circuit protected and will close down if a short is present in the field control wiring or other device connected to T36 and T37 Elite Series Service Manual 4201 230 Rev B3 Frame 3 2 3 8 DISPLAY UNIT Display Unit Fault Finding Put the Elite in commission mode see note 2 Is the screen appearance normal Are there lines of pixles missing Replace the Display Unit Re connect correctly No Note The Display Unit may be permantly damaged Are the screen terminations correct see note 1 Is 24VDC present between T10 amp T12 See Control Board fault finding Is the Display Unit mounted 3 metres from
175. trol board mounting tray and Power board The Power tray receives power from the DC bus via the DC Supply board Circuitry included on the Power Tray The main switch mode power supply provides various isolated DC supplies required by the Elite these are 1 6 off 17V OV 14V to the Gatedrive board 2 28V for the internal fans and Control board 3 24V 500mA user power supply via the Control board SCR switch mode power supply provides various isolated DC supplies required by the Elite these are 1 8V OV for SCR Gatedrive circuitry and DC Bus discharge control 2 15 OV for switch mode regulation circuitry The Gatedrive control for the SCR s and DC Bus discharge circuit are also located here The drive select module plugs into this board Note the locations are different for the 400V and 500V models The Power tray is also used as an interface board for the DCCT s and Gatedrive Board to the Control Board Light emitting diodes LEDS located on the Power tray LED Green One for each half phase 6 Actual indication IGBT Gatedrive circuit active Implication The Elite is running LED RED One for DC Bus indication Actual indication DC BUS is LIVE Implication The Elite has power connected When ordering a replacement Power Tray it will come with the metal support tray and Control Board mounting plate Elite Series Service Manual 4201 230 Rev B57 70 Frame 5 6 amp 7 Gatedrive Board Gatedrive Ci
176. ual 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 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 complete
177. ure 2 21 GBT removal There are 3 blocks and each contain 2 IGBT s Note the IGBT Gatedrive inputs are extremely sensitive to static damage The Power board DC Bus consists of three parts 1 The ve DC bus link 2 The ve DC bus link 3 The Power Board To replace the IGBT s the above assembly must be removed by removing 1 9 off M5x12 screws visible in figure 2 21 in the right cabinet 2 Lift the ve and ve DC bus clear 3 The Power board is held to the IGBT s by the gatedrive connections which are two plugs per IGBT Lift the Power board off the IGBT s The IGBT s can now be removed one at a time as required Replacing the Power board Ensure the Power board terminals are plugged in to the gate drive connections when locating the board on the IGBTs THREAD U V amp W WIRES THROUGH DCCTS M5x12 9 OFF DC 5 2 vi je e O e IME 4508 214A Figure 2 21 IGBT Removal 4201 230 Rev B3 Frame 3 2 7 10 SERVICING THE RECTIFIER Power Termination Removal Refer figure 2 22 Power Termination removal 1 Remove the left side cover 2 Figure 2 22 indicates the position of all wiring If you do not consider this adequate label all wiring 3 Remove the top half of the left side skirt see section 2 7 2 4 Ensure the internal wiring from the terminal connections are labelled adequately for correct reassembly
178. ure the output voltage between terminals U V V W W U These voltages should all be balanced at approximately 400Vac If there is any sign of imbalance measure between each output and earth to isolate which phase is faulty It is likely that there is an unrepaired fault on that particular phase or loose terminations If the test shows no faults and a good output voltage balance the test power supplies can be disconnected the mains and motor reconnected and a full test done 1kV Isolating Transformer Optional ih ih Control Board and Board Display Unit Gatedrive 4508 325A Figure 1 7 Soft Power Supply Connections Elite Series Service Manual 4201 230 Rev B1 Frame 1 amp 2 17 1 6 PARTS LIST AND BLOCK DIAGRAM Ej 1 6 1 FRAMES 1 AND 2 400V MICRODRIVE ELITE PARTS LIST 400 VOLT MICRODRIVE ELITE PARTS LIST Frame Size FRAME 1 FRAME 2 Model ME 2 5 ME 6 5 ME 10 5 ME 12 5 ME 18 ME 22 5 Display Cover Label 4101 545 Front Cover 3903 116 Cover Gasket 3907 021 Display Unit 000 6205 Control Board E000 610S Power Board E012 611S E022 611S Gatedrive Board E002 612S E006 612S E010 612S E012 612S E018 612S E022 612S Terminal Board E002 616S E006 616S E012 616S E022 616S Rectifier Block 1421 023 IGBT Block Vera ae 1757 106 IGBT Thermstrate 1781 205 Rectifier Thermstrate 17617999 1781 108 DC Bus Capacitors 2 x 1277 547 2 x 1277 547 4 x 1277 547 4 x 1277 547 6 x
179. using a multimeter check the rectifier as the drawing indicates Note each test is carried out 3 times i e once per phase which is a total of twelve tests ve DC Bus SCR reverse blocking conduction IGBT forward Forward blocking blocking gt 100k gt 10k Diode IGBT blocking Forward gt 100k blocking Diode conduction gt 10k ve DC Bus 4504 031B Figure 2 4 Rectifier and Inverter Testing Frame 4 2 4 2 TESTING AN INDIVIDUAL SCR When the Elite is disassembled the SCR s can be tested individually as shown in figure 2 5 DIODE TESTS SCR TESTS SCR TESTS OM ie gt 100 Diode Let dd conduction 0 3 0 45V 77 N 0 CONDUCTION TEST ALTERNATIVE TEST APPARATUS 18 to 100 Ohm Resistor 18 to 100 Ohm Resistor EC Y 24V Current tss limited Power supply Lamp to Limit Current and Protect Battery 12 to 24 Volt Battery 4508 319A Figure 2 5 Individual SCR Conduction Test Elite Series Service Manual 4201 230 Rev B3 Frame 3 2 4 3 TESTING AN INDIVIDUAL IGBT 33 You MUST wear a static grounding wrist strap which must be earthed The preliminary tests are done with a multi meter The meter readings in figure 2 6 are a guide and may vary with differing meter brands It is best to compare the suspect IGB
180. when the Elite is powered up SCR switch mode power supply provides various isolated DC supplies required by the Elite These are 15V OV for SCR Gatedrive circuitry and DC Bus discharge control 5V OV for switch mode regulation Elite Series Service Manual 4201 230 Rev B3 28 Frame 3 Ja 2 3 FAULT FINDING GUIDE 2 3 1 SUPPLY ISSUES Power supply problems can be misinterpreted as faults in the Elite some are listed below Fault 01 LOW Vdc The supply to the Elite is dropping below the switch mode power supply operating level and the Elite is shutting down This is usually caused by a weak supply or faults in the supply system Look for motors starting direct on line or other machines drawing high current For further details see the fault list in section 8 of this manual Fault 02 HIGH Vdc The supply to the Elite is surging too high Rapid load changes in the supply system may be faster than automatic tap changing transformers can adjust to For further details see the fault list in section 8 of this manual Fault 04 SUPPLY FLT Supply fault Fault 04 is an indication that the ripple on the DC Bus has exceeded 40Vac The Elite will trip if this condition is reached and will display Fault 04 SUPPLY FLT This can be caused by diode s in the rectifier going open circuit see section 2 4 but is more likely to be caused by The loss of an input phase which increases the ripple on the DC Bus The Elite will run o
181. wing describe how to disassemble U Phase The other two phases are similar in construction 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 speed up reassembly To remove the U Phase output Sheet Bus remove 1 The door pillar which is held by 8 off M5x16 CW screws See figure 7 12 2 The Lexan shield 2 off M5x16 CW screws See figure 7 12 3 Screws A and B 4 Bolts C and D Thread the fibre optic loom through the output Sheet Bus Slide the output busbar towards the bottom of the Elite do not slide it completely through the grommet If it is sticking use some soapy water LOOM F OPTIC 920mm LOOM F OPTIC 715mm LOOM F OPTIC 715mm ROUTE THROUGH GROMMET ROUTE THROUGH GROMMET IN ROUTE THROUGH GROMMET IN OUTPUT SHEET BUS OUTPUT SHEET BUS OUTPUT SHEET BUS A 6 x 16 CW SCREW 6 16 CW SCREWS 8 x 40 BOLT FLAT AND LOOM OTIC LOOM 370mm LOOM F OPTIC 440mm SCHNORR WASHER M6 x 25 BOLT 2 X FLAT AND 1X SCHNORR WASHER E Elle gm i ame ta e SIH Tio d V OUTPUT SHEET BUS W OUTPUT SHEET BUS C I C C Ha L4 amp 4 i UH E O
182. x10 Phillips screws which secure the steel bracket to the formica board When these are removed the DCCT assembly can be lifted clear 4 Remove 2 off M6x20 bolts these have no immediate effect M5x10 captive screw e _ M5x16 captive screw 7 4 places CT bracket Figure 3 23 DCCT assembly 3 7 5 SERVICING THE DC BUS BOARD The DC Bus Board is the same for all models but there are some variations regarding extra components for the larger sizes 1 400V and 500V models UE 115 D and UE 140 D have two busbars to increase the current carrying capacity or the PCB 2 400V and 500V models UE 140 D have an extra bus bar for the same reason 4201 230 Rev B4 Frame 4 Removing the Input busbar The input busbars supply the rectifier via the DC bus board see figure 3 24 1 The bars are held by a 3 off M6x20 Phillips screws b 3 off M6x16 Phillips screws Note When reinstalling the W Input busbar push it towards the U Busbar when tightening the M6x20 screw This allows clearance for the current transformer M5x16 captive screw 3 places SCR input busbar shield Input busbars M6x20 captive screw 3 places tighten to 4 5Nm 91 5 Mn Figure 3 24 Input Busbars 4508 242A Removing the DC Bus Board Remove the DC bus board by removing 1 1 off M4x10 Phillips head screw this earths the PCB 2 The board is secured to the
183. y 7 Loosen the two 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 the 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 correctly without risk of damage should something else be faulty or an error made during reassembly See section 4 6 Figure 7 10 400V Power tray Figure 7 11 121 500V Power tray Elite Series Service Manual 4201 230 Rev B7 Jenueyy S seues 91113 IZL Jenaoway J8MOg Z 29 na 055 1057
184. y for visibly damaged or blackened components If damaged components exist replace the Power tray If there is no visible damage replace the fuse and repower the Elite If the fuse blows again replace the Power tray WARNING These fuses must not be replaced with glass fuses glass fuses will rupture and cause catastrophic ERE damage Use only the specified ceramic fuse Action Replace fuses If failure persists replace Power tray 440V heatsink fan supply fuses Fitted on SCR boards Possible reason for failure Supply surge 400V models external cooling fan fault or for 500V models a fault in the external cooling fan power supply Action Check cooling fans or cooling fan power supply Check varistor on SCR boards for signs of damage a small dentist s style mirror is suitable for this Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 amp 7 4 3 3 DISPLAY Display Unit Fault Finding Is the screen Put the Elite in appearance normal Yes commission mode see note 2 No Are there lines of pixels missing Yes Replace the Display Unit Re connect correctly Note The Display Unit may be permanently damaged No Are the screen terminations correct see note 1 Yes Is 24VDC present between T10 amp T12 No See Control Board fault finding Yes Is the Display Unit mounted 3 metres from the Elite
185. yboard mode using Screen 11 11 LOCAL S STP 0 reduce distance replace display unit Fault 36 EPLD TRIP Detail An unrecognised fault has been detected by the control board EPLD Possible cause Power supply fault Action Reset fault if fault persists seek service or replace the Elite Series Fault 37 WATCHDOG Detail An unknown fault has reset the Control Board microcontroller Possible cause Power supply fault PDL Vysta for Windows configuration too complex Action Reset fault if fault persists seek service or replace the Elite Series simplify PDL Vysta for Windows configuration Fault 38 NO VYSTA PRG Detail User Program not set Action Reload Program via Drivelink software Fault 39 FIBRE TRIP Detail The Elite Series has tripped due to a fault being reported via the Fibre Optic Network Cause See other Elite Series connected to the network Action Reset fault on the other Elites Fault 40 ILIMIT T O Detail The hardware current limit has been active for longer than 30 seconds Possible Cause A partial short circuit in the cabling or motor Action Check cables and motor for possible short circuit Fault 41 STOP T O Detail The system has not stopped within the time out set by Screen S11 Possible Cause Parameters set incorrectly Stop Timeout Screen S11 Decel rates Screen R2 R4 R6 Speed filter R7 Mal tuned Speed pid in vector systems Check all parameters Check Dynamic brake Action

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