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Service Manual - Power Electronics

1. 60 6 5 gt lt 61 6 67 Gheckimng external iot 62 7 SUBASSEMBLY AND REPLACEMENT 64 7 1 64 7 2 FING PME 72 d Frame o OO e D 84 TAn et cies eee ie Ee n aie 99 7 5 ET AUS 115 7 6 mici cc Sateen 132 pes AEEA EE ERE 149 7 8 mc MEER 164 7 9 Dt 180 SERVICE MANUAL 3 50700 POWER ELECTRONICS 8 PARTS LIST 8 1 196 8 2 EIS aidan PDC EU 199 8 3 Frame 201 8 4 ere LA cu ea uS 203 8 5 ProM O cem 205 9 IBLOCK DIAGBHAM eee 207 9 1 Franio KHEN 208 9 2 209 9 3 210 9 4 211 9 5 212 4 SERVICE MANUAL POWER ELECTRONICS 5
2. Figure 7 1 6 Remove the control board POWER ELECTRONICS Assembly of the control board 1 2 Continue with the safety conditions which are described in the previous section While replacing the control board avoid an excessive handling of the board Pick the new control board from the static proof bag Put the new control board in the same place than the replaced one matching the board holes with the hexagonal plastic spacers M3x20 see figure 7 1 6 Match the male connector of 40 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins Once the board is properly placed screw the 6 plastic screws M3x8 DIN 933 in the corresponding hexagonal plastic spacers M3x20 50700 7 1 5 POWER BOARD Disassembly of the Power Board Before proceeding the control board must have been disassembled see section 7 7 4 See the figure 7 1 7 while reading the following instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the wires which connected to this board Before AC choke voltage measurement DC Bus Voltage measurement Quickly discharge SCR Trigger 2 resistor Nee 7 Fan supply After Ac choke voltage measurement Output voltage measurement Fig
3. O E aei i iB cali am id pm un f D mice s Bn e 0 90 7 J102 100 J200 J202 J907 Connection of the Encoder Expansion PCB J101 and J102 Connection of the Devicenet PCB J100 Connector for programming the microprocesor BOOTSTRAP J202 Connector for programming the DSP BOOTSTRAP J200 Programming of the DSP through the JTAG J1201 Connection of the Dynamic Braking expansion PCB J906 Connection of the Analogue and Digital inputs Expansion PCB J1102 Connection of the Fiber Optics Expansion PCB JP1103 Jumper for 232 and 485 JP1104 Jumper for USB SERVICE MANUAL 57 50700 POWER ELECTRONICS 6 TESTING 6 1 Testing the rectifier and inverter Refer to figure 1 4 by using a multimeter check the rectifier as the drawing indicates NOTE each test is carried out 3 times i e once per phase which makes a total of 12 test Wwe BUS nl di Le L3 3 ZI Figure 2 1 Rectifier and inverter testing The components and the numbers per phase are shown below to assist in understanding what you are testing 1 In order to test the rectifier components individually remove t
4. 7746 Ux 7 40 VOCAB i ME L160 DV6224TDU 845 IP54 24VDC 89W L192 4114NXU IP54 24VDC 4 5W T 202 SERVICE MANUAL PONER ae 50700 8 4 50700 7 5 SD700 FRAME 7 380 IP54 IP20 models 50705805 50706505 50707205 Control PCB E024HA E024HA E024HA Power PCB E028GJ E028GJ E107BD 60700 7 690V IP54 IP20 models SD703856X SD704606X E024HA E107BD E113BB 1158 Upper Gate Drive G005A IGBTs connector PCB E087AB E024HA E107BD E113BB E115BC G005A E087AB IGBT selection module E040BA E040BA SCRs 380V NUMBER P067 SD705805X 9 067 SD706505X 9 690V NUMBER 114 50703856 9 P114 5070460 9 P114 50707205 9 IGBT IGBT 3807 NUMBER FF300R12ME3 SD7058005X 9 FF450R12ME3 D706505X 9 IGBT 690 NUMBER FF300R17ME3 SD703856X 9 FF450R17ME3 SD704606X 9 FF450R12ME3 5 707205 9 BUS CAPACITORS 380V 1 SD705805X 3 12 36 SD706505X 3 16 48 0707205 3 16 48 203 SERVICE MANUAL 690V 517703856 50704606 3 12 36 3 15 45 50700 POWER ELECTRONICS DCCT ____ 380V NUMBER DCCT 690V NUMBER OUTPUT CHOKE Output Turns Wire Output Turns Wire choke section choke section 50706505 9
5. 8 debo AOOUD 8 1 23 shobld Inertake EON 9 1532 9 9 2 BEFORE STARTING TESTING OR SERVICE 4 10 3 PRINTED BOARD DESCRIPTIONS 11 CINE RE ERI Emm 11 3 2 Output Inverter 11 oro MEE POWER CB EP 11 od COMO soc Net et TS eT O 11 4 FAULT MESSAGES DESCRIPTIONS AND 5 1 1 3 12 RN 12 iatis AE A PETE E E iratos TTE 12 4 32 MOIS DIA TAU c 22 LE EU EU 23 AS Jndicalor Leds dbepdawsek 35 5 GONNEGIIONS 55 Bu 5 OR OR CRN 55 5 2 8191 0 Gi 57 lt TESTING 58 61 Testing the rectifier and 58 6 2 Individual 60 6 3 Testing the DC Bus 60 64 Individual I Ies
6. 5 Q O 5 o D 5 Ss 5 5 296 E c OSY 2 2 8 225 o S s 2 270 s o o a LL In IP20 models Disassemble the upper cover slowly in order to disconnect the fans supply wire 2 2 y 9 X3 ff f Figure 7 4 Disassemble the upper cover Figure 7 3 Assembly of the plastic protector r of the Upper cove Assembl 1 2 connect the fan supply wire J In IP20 models Join the upper cover and the SD700 chassis 7895H by screwing the 14 Phillips screw M4x8 DIN 181 SERVICE MANUAL 50700 7 9 3 CONTROL BOARD Disassembly of the Control Board The use of a static grounding wrist strap and being earthed is highly required Follow figure 7 5 while reading these instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control PCB and the plastic hexagonal spacers M3x20 2 Disassemble the Control Board disconnnecting the 40 32 y 28 pin connectors which join the Control Board and the Power Board 3 When the control Board is out place it in a static proof bag for safekeeping M3x8 s Figure 7 5 Disassembly of the Control Board Assembly of the Control Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control Board 2 Place the new Control Bo
7. Remove the Bus and Bus insulator Unscrew the special hexagonal screws M5x20 which join the capacitors and the Bus Remove the Bus Remove the Bus and the middle Bus insulator Unscrew the special hexagonal screws M5x20 which join the middle Bus and the capacitors Dissassemble the middle Bus Take out the capacitors of their rings Assembly of the Bus capacitors Place the new capacitors in their rings Insert the middle Bus figure 3 16 Screw the special hexagonal screws 5 20 Insert the Bus and the middle Bus insulator Insert the Bus figure 3 16 Screw special hexagonal screws M5x20 which join with Bus to the capacitors Place the Bus and Bus insulator Insert the Bus figure 3 16 Screw special hexagonal screws M5x20 which join with Bus to the capacitors 124 SERVICE MANUAL POWER ELECTRONICS Bus and middle Bus insulator 5 Middle Bus 72 y Ring capactitor Capacitor Figure 3 16 Disassembly of the Bus capacitors POWER ELECTRONICS 7 5 15 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 17 while reading these instructions 1 Disconnect the IGBT trigger cable which connects this board to the Power board 2 Disconnect the 3 NTC wires which connect this board to the Upper Gate
8. 2 1 3 gt 2 gt Il imm gt 83 B 2l 9 gt A 2 e EE roy Pa 8 PUN LJ gt 2 r a F 4 i Ped LJ cro a lt 14 gt E o Q Q w uo 210 SERVICE MANUAL POWER ELECTRONICS 50700 L VIL OS OO 1 ______ 1111 i 1j gt 111 tl 8 L4 if 8 4 8 gt 30 vi3nWvi 3HOLO3NOO V13rWHvL sng ad LO SERVICE MANUAL 211 50700 POWER ELECTRONICS WEE CE ES 8 VIIVL REE Eh Poe ise ont gt NN E a 1215 18 gt 2 af E gt nC Ld ls 1 111 1 if BEL 1j 8 cs ZS gt ON p gt 212 SERVICE MANUAL POWER ELECTRONICS 50700 SERVICE MANUAL 213
9. 1 Put the new discharging resistor in the correct position on the electronic tray 2 Fix the discharging resistor to the electronic tray by using the 2 screws M3x6 DIN 7895H SERVICE MANUAL 97 50700 7 3 19 BUS CAPACITORS Disassembly of the bus capacitors It is necessary to remove the DC Bus of the drive before performing this action see section 7 3 9 See figure 7 3 33 while following the next instructions 1 Unscrew the 8 special hexagonal screws M5X10 which fix the capacitors to the electronic board of the bus see figure 7 3 33 Remove the electronic board Remove the capacitors which are going to be repaired Figure 7 3 33 Assembly of the bus capacitors 1 2 98 Put the new capacitor on the ring which is inserted in the capacitor support Put the electronic board of the bus and the capacitors in the correct position Insert the screws of the capacitors with a tightening pressure of 3N m SERVICE MANUAL POWER ELECTRONICS POWER ELECTRONICS 7 4 50700 FRAME 3 90 1154 ACCESS TO THE INSIDE OF THE DRIVE 7 4 1 Disassembly of the embellishers In order to repair or replace any component of the drive you should access to the inside of it See figure 7 4 1 and figure 7 4 2 while reading the following instructions 1 Open the door of the drive 2 Disconnect the Display For this disconnect ethernet cable which joins the display and the drive Push
10. 3 Push the 40 32 y 28 pins connectors down Do not apply force 4 Screw the 6 plastic screws M3x8 DIN 933 in the plastic hexagonal spacers M3x20 POWER ELECTRONICS 7 5 5 POWER BOARD Disassembly of the Power board Before proceeding the Control Board must have been disassembled section 7 5 4 The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 5 while reading these instructions 1 Disconnect the wires which connected to this Board Before AC choke voltage measurement DC Bus Voltage measurement Quickly discharge gt SCR Trigger ed 13 resistor Fan supply After Ac choke voltage measurement Output voltage measurement Figure 3 6 Removal of the Power Board wires 2 Remove the 6 plastic hexagonal spacers M3x20 which are inserted in the Power Board and held the control board 3 Unscrew the 5 Phillips screws M3x8 DIN 7895H 4 Remove the power PCB Assembly of the Power Board Continue to observe static safe work procedures 1 Avoid excessive handling of the new Control Board 2 Place the new power board on the electric tray and fit the board holes in the electric tray bolts see figure 7 6 3 Screw the 5 Phillips screws M3x8 DIN 7895H in the electric tray bolts 4 Connect the power board wiring see figure 7 6 5 Place the plastic hexagonal spacers M3x20 on the Power Board in order to in
11. 3 Screw 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 4 Connect the phone wires Figure 7 15 Disassembly of the IGBT s Connector Board SERVICE MANUAL 191 50700 POWER ELECTRONICS Cable telefonico 7 9 14 IGBT Disassembly of the IGBT Before proceeding the upper Gate Drive board must have been disassembled section 7 9 14 Follow figure 7 17 a and figure 7 17 b while reading these instructions 1 Unscrew the 4 hexagonal spacers M3x18 where the upper Gate Drive is inserted 2 Unscrew the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs 3 Remove the DC Bus section 7 9 10 4 Remove the Snubber capacitors 5 Unscrew the 3 Phillips screws M6x20 DIN 7895H which join the IGBT and the bar where the DCCTs are screwed 6 Remove the bar where the DCCTs are screwed 7 Unscrew the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 8 Disassemble the IGBT v M6x12 DC Bus M6x20 ess Condensador IGBT Figure 7 16 Disassembly of the Upper Gate drive Figure 7 17 a Disassembly of the IGBT 192 SERVICE MANUAL POWER ELECTRONICS M3x18 BER Figure 7 17 b Disassembly of the IGBT Assembly of the IGBT Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Take out
12. Approach the door and fix it with the 4 Phillips M4x8 DIN 7895H screws SERVICE MANUAL 65 50700 7 1 3 UPPER AND LOWER COVERS Disassembly of the upper and lower covers 1 2 4 Unscrew the 8 Phillips M4x8 DIN 7895H screws that join the upper covers and the drive chassis see figure 7 1 4 Unscrew the 8 Phillips M4x8 DIN 7895H screws which join the lower covers and the drive chassis see figure 7 1 5 Remove the upper and lower covers Figura 7 1 4 Figura 7 1 5 Assembly of the upper and lower covers 1 66 Screw the lower covers to the drive chassis with the 8 Phillips M4x8 DIN 7895H Screws Screw the upper covers to the drive chassis with the 8 Phillips M4x8 DIN 7895H screws SERVICE MANUAL POWER ELECTRONICS 7 1 4 CONTROL BOARD Disassembly of the control board The use of a static grounding wrist strap and being earthed is highly required to repair the unit See the figure 7 1 6 while reading the following instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control board and the plastic hexagonal spacers M3x20 2 Remove the control board by pulling it up until disconnecting the female connectors of 40 32 and 28 pins of the control board from the male connectors of the power board where control board is connected 3 Once the control board is removed put this board into a static proof bag for a safekeeping M3x8 y 1
13. D216 RED colour In normal operation it is always ON It indicates that the power supply 24V_DISP_COM is correct If it is not lit there is a communication fault between the Display and the Control Board D212 RED colour In normal operation it is always ON It indicates that the power supply 15V_SCR is correct If it is not lit it indicates there are problems in the triggering thyristor pulse generator circuit D214 RED coloutr In normal operation it is always ON It indicates that the power supply 28V_USR is correct If it is not lit all the voltages referred to the user ground dissapear D215 RED colour In normal operation it is always ON It indicates that the power supply 15V_IGBT is correct If it is not lit there are not pulses in the IGBT s There is some faulty component in the inverter circuit IGBTs GateDrive D213 RED colour In normal operation it is always ON It indicates that the power supply 24 CONTROL is correct If it is not lit all the voltages referred to the analogue and digital ground dissapear D230 RED colour In normal opertion it is always ON It indicates that the power supply 15V_TEMP is correct If it not lit the temperature measurement faults LED 1 LED2 AND LED 3 GREEN colour It is only lit one of them and corresponds to the output phase IGBT s with higher temperature SERVICE MANUAL POWER ELECTRONICS 50700 Indicator Leds of Control Board D1101 D10 D1201
14. Function protection for input voltage measurement circuit before chokes and detection of input voltage to avoid the discharge of the bus The value is 2 A SERVICE MANUAL POWER ELECTRONICS 50700 Possible reason for failure Circuit fault or faulty fuse Action Replace the fuse or the board b Fuses of the Power Connection Board In the power connection board there are 3 fuses located where the figure 1 5 shows FUSE 1 FUSE 2 FUSE 3 Figure 1 5 Fuses of the power connection board Fuse 1 Fuse 2 and Fuse 3 Function Protection for soft load circuits The value is 4 A Possible reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board SERVICE MANUAL 29 50700 POWER ELECTRONICS 4 4 4 Fuses Frame 3 90 115A a Fuses of the Power Board In the power board there are 6 fuses located where the figure 1 4 shows 9 TEE Ea FUSE4 EUSE5 HJSE 6 Ln p ac CIENT IB a eae FUSE1 FUSE 2 FUSE 3 Figure 1 4 Fuses of the power board Fuse 1 and Fuse 2 Characteristics They are very fast acting ceramic fuses Their value is 4 A Function Power supply for the power board from its bus Possible reason for failure Internal short circuit in the power board Action Replace the power board Fuse 3 Characteristics glass tube fuse The value is 100 mA Function It discharg
15. Figure 3 1 Display connection and control terminals SD70ITMOO01AE 4 Remove the 4 Phillips MAx8 DIN 7895H screws with their corresponding whasers and grover whasers which join the lateral internal cover and the chassis See figure 7 2 1 a SD700 Figure 7 2 1a In case of IP54 model of SD700 drives disconnect the power supply of the fans that are in the embellishers Remove the support of the cover of the control board with the 2 screws M4x8 DIN 7895H see figure 7 2 1 b PS pen 1 Wy ci Hw 1 Mur ANE did Bef 4 wm 1 1 4 1 as d Figure 7 2 1 b Hemove the embellishers Remove the plastic protector for the power connections Figure 7 2 2 Access to the inside of the drive SERVICE MANUAL 73 50700 Assembly of the embellishers 1 74 Place the embellishers on the supports of the drive s sides as the figures 7 2 1a and 7 2 1b show Screw the embellishers to the supports of the sides with 6 Phillips M4x8 DIN 7895H SCrews Put the plastic protector for the power connections on the sides of the drive Connect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input Connect the Display by means of the ethernet cable which goes from the display to the drive SERVICE MANUAL
16. Possible cause Input power is wrong damaged fuses Actions Check conditions of input power supply Check input Fuse section 4 4 1 If the fault happens when the device is loaded check that the DC Bus voltage doesn t fall down If the voltage falls down might be due to a fault in the rectifiers section 6 1 Fault F18 IMB V OUT Description Voltage imbalance higher than 5 of the average drive output voltage for a time longer than 100ms Possible cause Motor is driving an unstable load Motor wiring fault Motor is wrong Actions Check motor circuit completely in case of possible wiring faults or motor fault If the fault persists after disconnecting output wires change Power PCB SERVICE MANUAL POWER ELECTRONICS 50700 Fault F19 IMB OUT Description Current imbalance of more than 25 of the average output motor current for a time longer than 1s Possible cause Motor is supporting unstable loads Motor wiring fault Motor is wrong Actions Check motor circuit completely in case of possible wiring faults or motor fault Compare the current at the output with the current shown in the display If the current is different change the Power PCB Fault F20 GROUND FLT Description Current level to the ground has exceeded the level set G11 3 GND I LIMT Possible cause Motor or wiring has short circuited to ground Ground is incorrectly connected or wrong Actions Disconnect the motor and wiring of the SD700 an
17. SERVICE MANUAL POWER ELECTRONICS Figure 7 3 25 10 Remove dV dt chokes Assembly of dV dt chokes 1 Put the new dV dt chokes matching their holes and fix them at the bottom by using 4 screws M4x8 DIN 7895H See figure 7 3 25 Fix the upper bar of dV dt chokes with their 4 screws M4x8 DIN 7895H to the drive s chassis see figure 7 3 24 Hold the fixing bar of the fan cables with their 2 screws M4x8 DIN 7895H see figure 7 3 23 Fix the medium bar by using 5 screws M4x8 DIN 7895H See figure 7 3 20 Fix the connections bar with the 2 screws M4x8 DIN 7895H Connect the cables of dV dt choke the upper cables are connected to the lower gate drive board and the lower cables are connected to the output in the connections bar Connect the remaining cables of the DC Bus and the power cables coming from the choke POWER ELECTRONICS 7 3 15 THYRISTORS Disassembly of the thyristors Before removing the thyristors you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 and the power connections board see section 7 3 8 See the figure 7 3 26 while following the next instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the control cable of the thyristors 3 Remove the Phillips screws M5x16 DIN 7895H which join the thyristors and their heatsink 4 Remove the th
18. 6 Remove the bar where DCCTs are screwed 7 Unscrew the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 8 Remove the IGBT Figure3 19 Disassembly of the IGBT b Assembly of the IGBT Continue to observe static safe work procedures 1 Avoid excessive handling of the new board 2 Take out the new IGBT from the static box SERVICE MANUAL 127 50700 3 Spread the thermal paste over the back of the IGBT 4 Place the IGBT on the heat exchanger 5 Screw the 4 Phillips screws 5 16 DIN 7895H which join the IGBT and the heat exchanger 6 Place the DCCT Bar as it is shown in figure 3 19 7 Screw the 3 Phillips screws M6x20 DIN 7895H which joint the DCCT bar and the IGBT 8 Insert the DC Bus section 7 5 12 9 Putthe Snubber capacitor on the DC Bus 10 Screw the 2 Phillips screws M6x12 DIN 7895H which join the snubber capacitors and the IGBTs 11 Screw the 4 hexagonal spacers M3x18 where the Upper Gate Drive is inserted 12 Connect the phone cables 128 SERVICE MANUAL POWER ELECTRONICS 7 5 18 SOFT CHARGE AND QUICK DISCHARGE RESISTORS Disassembly of the soft charge and quick discharge resistors Before proceeding the upper cover section 7 5 3 the snubber trigger and the soft charge board section 7 5 7 and the DC Bus section 7 5 13 must have been disassembled Follow figure 3 20 while reading these instructions 1 Unscre
19. Before proceeding the bars which join the AC choke with SCRs must have been disassembled section 7 7 15 Follow figure 5 18 while reading these instructions 1 Unscrew the 2 Phillips screws M5x12 DIN 7895H which join the SCR with the heat exchanger 2 Disassemble the SCR Figure 5 18 Disassembly of the SCH Disassembly of the SCRs 1 Spread the thermal paste over the back of the new SCR 2 Insert the SCR in the heat exchanger figure 5 18 3 Screw the 2 Phillips screws M5x12 DIN 7895H which join the SCR and the heat exchanger POWER ELECTRONICS 7 7 17 POWER FAN Disassembly of the Fan support Follow figure 5 19 while reading these instructions 1 Unscrew the Phillips screw 4 8 DIN 7895H which join the fan support and the fan box 2 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Disconenct the fan power wire 4 Disassemble the fan support 7 1 lt Se NI Sy NI RE lt lt Figure 5 19 Disassembly of the power fan 50700 24VDC 2A 48W 172X172 FAN Follow figure 5 20 a while reading these instructions Unscrew the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan and its support Figure 5 20 Disassembly of the fan support 24VDC 89W 172X172 FAN Follow figure 5 20 a while reading these instructions Unscrew the 2 Phillips sc
20. POWER ELECTRONICS 7 2 2 DOOR Disassembly the door See the figure 7 2 3 while following the next instructions 1 2 Remove the door by unscrewing 4 Phillips M4x8 DIN 7895H screws Disconnect the ethernet cable from the display Remove the display from the support of the door Remove the door Figure 7 2 3 Remove the door Assembly of the door Put the display on the support of the door Connect the ethernet cable of the display Approach the door and fix it with the 4 Phillips M4x8 DIN 7895H screws POWER ELECTRONICS 7 2 3 UPPER AND LOWER COVERS Disassembly of the upper covers and the lower covers See the figure 7 2 4 while following the next instructions 1 Unscrew the 10 Phillips M4x8 DIN 7895H screws that join the upper covers and the drive chassis 2 In IP20 models remove the upper cover slowly until disconnecting the power supply cable of the fans Once disconnected the cable remove the cover completely 3 Unscrew the 8 Phillips M4x8 DIN 7895H screws which join the lower covers and the drive chassis 4 Remove the upper and lower covers Figure 7 2 4 Remove the covers Assembly of the upper covers and the and lower covers 1 Put the lower covers as the figure 3 4 shows 2 Fix the covers to the chassis of the drive by using the 8 Phillips screws 4 8 DIN 7895H that join the lower covers and the chassis 3 Move the upper covers closer to the chassis of
21. R35 R34 7 AAE E AA A 02 LED1 LED2 LED3 Figure 1 9 Leds of pluggable PCB of trigger thyristors D2 RED colour It reports us that the power supply for the triggering of the thyristors is correct 5v_SCR LED 1 LED 2 AND LED 3 GREEN colour They report us that the triggerings of the thyristors are being correctly performed SERVICE MANUAL 45 50700 POWER ELECTRONICS e Indicator Leds of the Upper Gate Drive Board Wing anne cane Lr dee E 1 gt U Figure 2 0 Upper gate drive board LED 1 RED colour In normal operation it is always ON It indicates 15V IGBT FUSE L1 GREEN colour In normal operation it is always ON It indicates desaturation W L2 GREEN colour In normal operation it is always ON It indicates desaturation W L3 GREEN colour In normal operation it is always ON It indicates desaturation V L4 GREEN colour In normal operation it is always ON It indicates desaturation V L5 GREEN colour In normal operation it is always ON It indicates desaturation U L6 GREEN colour In normal operation it is always ON It indicates desaturation U 46 SERVICE MANUAL POWER ELECTRONICS 50700 4 5 4 Indicator Leds Frame 3 90 115A a Indicator Leds of Power Board The PCB s of the SD700 drives have several leds which report us about t
22. mwzwoer 59 WMNDARWCAN ___ _ 8 ws wema o um _ H6 Um CO 690V ue um Um 8 us wempmoosW w emon ea avoa i 092 DCCT DCCT 3807 NUMBER DCCT 6907 NUMBER L154 0708405 152 50705506 L154 50709255 152 SD706606X OUTPUT CHOKE Output Turns Wire Output Turns Wire choke section choke section Ce 6 8 74 2 5 SERVICE MANUAL 206 POWER ELECTRONICS 50700 BLOCK DIAGRAM SERVICE MANUAL 207 50700 POWER ELECTRONICS 1 ow 012890 01990 Zur ec EF er VVIIVI Ir 1 20 Resistencla Resistencia Eaulllbrlo Equillbrle 1 gt 1 1 e seu qoq os sna eGueoseg ol epsendsep oiedsiq sna epeque 004 004 901r u jsua 5 1 epipaw gt gt 8 A C 8 N gt gt a 2 9 Er gt v gt zog 4 m gt gt 2 F Activaci n Lo Ventiladores
23. Damaged power supply Actions Reset the device and if the fault persists ask for technical assistance Fault F51 SCR TEMP Descrtiption Rectifier heat sink temperature has reached a dangerous level Posible cause Temperature limits for SD700 rectifier has been exceeded Actions Verify that the ambient conditions are the proper ones for the device Be sure that there is nothing obstructing the cooling fans dust papers dirt etc and that these rotate correctly In frame 6 7 and 8 check that the current is the same in each rectifier SERVICE MANUAL POWER ELECTRONICS 50700 Fault 52 SOFT TEMP Descrtiption A fault in the Fan power supply unit occurred Posible cause The fans of the device are operating wrongly The Fan power supply unit is overheated Actions Verify that fans are not obstructed Check that fans are not dirty and rotate correctly Wait for the temperature of the power supply to go down to a normal value and restart it You can disconnect the device connect it again and restart the power supply again If the fault persists check the fan power supply fuses Fault F53 INTRNAL TEMP Descrtiption Internal temperature of the SD700 control electronics chamber has reached a dangerous level Posible cause The limit of internal temperature of the electronics chamber has been exceeded Actions Verify that the ambient conditions are proper for the equipment Be sure that there 15 nothing obstructin
24. SD700 7 7 4 POWER BOARD Disassembly of the Power Board Before proceeding the Control Board must have been disassembled section 7 7 5 Follow figure 5 6 a and figure 5 6 b while reading these instructions 1 Disconnect all the wires which are connected to this Board Before AC choke oltage measurement v DC Bus Voltage measurement Quickly discharge j gt resistor SCR Trigger Fan supply After Ac choke voltage measurement Output voltage measurement Figure 5 6 a Disconnection of the Power Board wires 2 Remove the 6 plastic hexagonal spacers M3x20 inserted in the Power Board 3 Unscrew the 5 Phillips screws M3x8 DIN 7895H 4 Remove the Power Board Assembly of the Power Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control Board 2 Place the new board on the electric tray and fit the holes of the board in the electric tray bolts figure 5 6 a 3 Screw the 5 Phillips screws M3x8 DIN 7895H on the electric tray bolts 4 Connect the Power Board wiring figure 5 6 a SERVICE MANUAL 151 50700 POWER ELECTRONICS 7 7 5 DRIVE SELECT AND IGBT SELECTION MODULE 3 20 The use of a static grounding wrist strap being earthed is highly required Follow figure 5 7 while reading these Disassembly of the Drive Select Instructions Unscrew the 2 plastic screws M3
25. Unscrew the 2 Phillips screws 4 12 DIN 7895H which join the DCCT and the DCCT support 2 Disconnect the current measure cable 3 Disassemble the DCCT _ Figure 5 11 Disassembly of the DCCT Assembly of the DCCT 1 Place the new DCCT in the place of the old one 2 Join the DCCT and the DCCT support by screwing the 2 Phillips screws 4 12 DIN 7895H 3 Connect the current measure cable SERVICE MANUAL 155 50700 POWER ELECTRONICS 7 7 10 DC BUS Disassembly of the DC Bus Before proceeding the Snubber Trigger and Soft charge board must been disassembled section 7 7 6 Follow figure 5 12 a figure 5 12 b figure 5 12 c and figure 5 12 d while reading these instructions 1 Disassemble the electronic tray by unscrewing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the chassis sides 2 Disassemble the snubbers capacitors by unscrewing the Phillips screws M6x12 DIN 7895H which join the snubbers capacitors and the DC Bus 3 Disassemble the hexagonal spacers M3x10 which are inserted in the DC Bus and where the back of the Snubber Trigger and Soft charge Board leans 4 Disassemble the hexagonal spacers M3x15 which are inserted in the DC Bus and where the front of the Snnuber Trigger and soft charge Board leans 5 Unscrew the 8 Phillips M4x8 DIN 7895H screws which join the DC Bus and the Bridge bus 6 Unscrew the 2 Phillips M4x8 DIN
26. d 15 f 004 05 E 8 ga lt i eg 98 M 29 55 38 58 ME p poo gt o U c 00 gt lt UJ C E ce o o 208 SERVICE MANUAL POWER ELECTRONICS 50700 S vilvi Reslstencla Resistencia Equlllbrio o 5 gt z 5 f gt n 5211909 95 sna efueosag 111 epsendsep ojeds q oozr oor 90Lf uo Su9 uo suey d 4 gt gt E zorr 2 2 m 5 24 p mes Z o T 5 202 m t E r 4 gt Act vacl n Ventlladores Kj 002 QS 1891 ep JODPUJJOJSURJ as F 5 T sna 25 LI M Q A n SERVICE MANUAL 209 50700 POWER ELECTRONICS Qon x 3d 1 smg zer Sir tf C1 acr 2 M38gniNS 1 1 lt 4 j gt 2 E 20 Recslenncd me Equll rb Equibrb amp gt 1 3 i 1 E 5 gt o
27. imu dj 9 Oca Eh A E Jo ia B Mm ia aif H i 0368 Us Figure 1 7 Leds the Control Board LED 10 GREEN colour In normal operation it is blinking It indicates that the microprocessor is operating correctly LED 901 GREEN colour In normal operation it is always ON It indicates that the power supply for the DSP 3 3V is correct LED 1101 GREEN colour In normal operation it is always OFF It is lit if there is overheating in the integrated circuit for RS485 communications LED 1201 RED colour In normal operation it is always OFF It is lit when the Hardware current limitation is performing d Indicator Leds of Dc Bus Board LED 1 LED 2 Figure 1 8 Leds of DC BUS LED 1 RED colour In normal operation it is always ON It indicates that DC Bus is powered LED 2 RED colour In normal operation it is ON during the soft charge and once the DC Bus is charge the led becomes OFF SERVICE MANUAL 49 50700 POWER ELECTRONICS e Indicator Leds of Pluggable Pcb of Thyristors 98 115 oi SOB 2 3 50 DISPARO TIRISTORES TALLA 3 C 15 5 3c FR LZ D2 LED1 LED2 LEDS Figure 1 9 Leds of pluggable PCB of trigger thyristors D2 RED colour It reports us that the power supply for the triggering of the thyristors is correct 45v SCR LED 1 LED 2 AND L
28. see figure 7 4 23 Figure 7 4 19 Figure 7 4 23 8 Remove the screws which fix dV dt chokes to the top of the chassis see figure 7 4 24 Figure 7 4 20 1 Remove the protection bars for the control cables Figure 7 4 21 Figure 7 4 24 9 Remove the 4 screws M4x8 DIN 7895H which fix dV dt chokes to the bottom of the Figures 7 4 21 chassis see figure 7 4 25 2 Disconnect all cables which are joined to the connections bar and the three cables of dV dt choke which go to the IGBT see figure 7 4 22 Figure 7 4 22 SERVICE MANUAL 109 50700 7 4 25 10 Remove dV at chokes Assembly of dV dt chokes 1 Put the new dV dt chokes matching their holes and fix them at the bottom by using 4 screws M4x8 DIN 7895H figure 7 4 25 Fix the upper bar of dV dt chokes with their 4 screws M4x8 DIN 7895H to the drive s chassis see figure 7 4 24 Hold the fixing bar of the fan cables with their 2 screws M4x8 DIN 7895H see figure 7 4 23 Fix the medium bar by using 5 screws M4x8 DIN 7895H See figure 3 20 Fix the connections bar with the 2 screws M4x8 DIN 7895H Connect the cables of dV dt choke the upper cables are connected to the IGBT and the lower cables are connected to the output in the connections bar Connect the remaining cables of the DC Bus and the power cables coming from the choke 110 SERVICE MANUAL POWER ELECTRONICS 7 4 15
29. 4 70 SD760x 9 6 5 s 4 FANS 380V OS OO 3 1 o we LL Ww amp us um am ug LLL Ue WAND 8 Ue um aero noc sow n 4 690V 22 ue emaumwonw f __ Toa um 5 L119 DV6224TD 24VDC 89W L120 4314 180 24VDC 9 5W L202 8314HU IP54 6W 80X80 L162 6224NTDAU IP54 24VDC 48W fC a L160 DV6224TDU 845 IP54 24VDC 89W L192 4114NXU 54 24VDC 4 5W SERVICE MANUAL 204 PONER ae 50700 8 5 50700 Frame 8 SD700FRAME 8 380V IP54 IP20 models SD708405X SD709255X Control PCB E024HA E024HA Power PCB E028GJ E0286J SD700FRAME 8690V E107BD SCRs P067 SD708405X P114 0705506 067 0709255 P114 SD706606X IGBT IGBT 380V NUMBER _ IGBT 690V FF450R12ME3 50708405 FF450R17ME3 SD705506X FF450R12ME3 SD709255X FF450R17ME3 50706606 BUS CAPACITORS 380V 690V 0708405 4 16 64 SD705506x 4 15 60 50709255 4216 64 50706606 60 41560 205 SERVICE MANUAL 50700 POWER ELECTRONICS 380 V L163 BEHMNH2AVDC 24W Lo ww
30. 6 Insert the plastic hexagonal spacers Mix on 7 Unscrew the 2 Phillips screws M4x8 DIN the DC Bus where the snubber trigger and 7895H which join the DC Bus and the soft charge PCB leans chassis 7 Insert the plastic hexagonal spacers M3x15 8 Unscrew the 4 Phillips screws M4x8 DIN on the DC Bus where the snubber trigger 7895H which join the DC Bus and the and soft charge PCB leans SCRs heat exchanger 8 Place the snubbers capacitors on the back 9 Unscrew the 6 Phillips screws M6x12 DIN part of DC Bus figure 3 15 by screwing 7895H which join the Bus and the Bus the Phillips screws M6x12 DIN 7895H and the 3 SCRs 2 9 Insert the chassis side section 7 5 10 10 Insert the electronic tray where the Power Assembly of the DC Bus and Control Board are inserted by means of 4 Phillips screws M4x8 DIN 7895H 1 Place the DC Bus on the chassis 2 Screw 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 3 Screw 2 Phillips screws M4x8 DIN 7895H 4 Screw 6 Phillips screws M6x12 DIN 7895H which join the DC Bus and the SCRs SERVICE MANUAL 123 50700 7 5 14 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding the DC Bus must have been disassembled section 7 5 13 Follow figure 3 16 while reading these instructions 1 Unscrew the special hexagonal screws M5x20 which join the capacitor and the Bus Remove the
31. 6 6 and the Bus output terminals see section 7 6 11 must have been disassembled Follow figure 4 15 a 4 15 b and 4 15 c while reading these instructions 1 Disassemble the electronic tray where the Control and Power Board are inserted by unscrewing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the chassis sides 2 Disassemble the Snubbers capacitors by unscrewing the Phillips screws M6x12 DIN 7895H which join the Snubbers capacitors and the DC Bus 3 Remove the hexagonal spacers M3x10 inserted in the DC Bus which are inserted in the DC bus where the Snubber Trigger and Soft Charge Board leans 4 Remove the hexagonal spacers M3x15 which are inserted in the DC bus inserted in the DC Bus where the front of the Snubber Trigger and Soft Charge Board leans 5 Disassemble one chassis side see section 7 6 10 6 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 7 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the chassis 8 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger 9 Unscrew the 6 Phillips screws M6x12 DIN 7895H which join the Bus and the Bus with the 3 SCRs Assembly of the DC Bus 1 Place the DC Bus on the chassis 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 3 Screw th
32. 8 b and figure 6 8 c while reading these instructions 1 Disconnect the voltage measure cable before and after the AC Choke by unscrewing the Phillips screw M4x8 DIN 7895H which join the wire terminals and the board figure 6 8 a Disconnect all output wiring figure 6 8 b Figure 6 8 a Disassembly of the Snubber Trigger and Soft charge protection Before AC choke voltage measure SCR tigger SD700 SCR tigger Soft charge resitance After AC choke Figure 6 8 b Disassembly of the Snubber Trigger 5 Figure 6 8 Disassembly of Snubber Trigger Soft charge protection and Soft charge protection Unscrew the 3 Phillips screws on M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Unscrew the 3 Phillips screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Disassemble the Board SERVICE MANUAL sk voltage measure 169 50700 Assembly of _Snubber trigger and soft charge protection board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the Board in the position shown in figure 6 8 c 3 Screw the 3 screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 4 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x15 5 Connect all input
33. Connect the terminals of the output choke wire to the DCCT bar and output bar by screwing the 2 hexagonal screws M8x25 DIN 933 186 SERVICE MANUAL 7 9 9 DCCT Disassembly of the DCCT Before proceeding output choke must have been disassembled section 7 9 8 Follow figure 7 11 while reading these instructions 1 Unscrew the 2 Phillips screws M4x12 DIN 7895H which join DCCT and the DCCT support 2 Disconnect the current measure wire 3 Disassemble the DCCT 4 12 Figure 7 11 Disassembly of the DCCT Assembly of the DCCT 1 Put the new DCCT in the place of the old DCCT 2 Join the DCCT and the DCCT support by screwing the 2 Phillips screws M4x12 DIN 7895H 3 Connect the current measure wire POWER ELECTRONICS 7 9 10 DC BUS Disassembly of the DC Bus Before proceeding snubber trigger and soft charge board must have been disassembled section 7 9 6 Follow figure 7 12 a figure 7 12 b figure 7 12 c figure 7 12 d and figure 7 12 e while reading these instructions 1 10 Remove the electronic tray by unscrewing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the sides of the chassis Remove the Snubber capacitors by unscrewing the Phillips screws M6x12 DIN 7895H which join the snubber capacitors and the DC Bus Remove the hexagonal spacers M3x10 inserted in the DC Bus where the back of the Snubber Trigger and s
34. Disconnect the power cable of chokes the temperature cable of the IGBT s and the falt cable 3 Remove the 4 screws M5X16 DIN 7895H that fix the IGBT to the heatsink 4 Remove the medium and lower Gate Drive boards together see figure 7 3 14 Em E ERES Figure 7 3 14 Disassembly of the medium and lower Gate Drive boards Assembly of the medium and lower Gate Drive board 1 Continue with the safety conditions which are described in the previous section 2 Spread the heatsink area where the IGBT is going to be placed with new thermal paste 3 Putthe IGBT matching the fixing holes see figure 7 3 14 4 Insert the fixing screws of the IGBT M5X16 DIN 7895H and thighten at 5 N m 5 Connect the flat cable the temperature cable of the IGBT and the power cables which are connected to the dV dt choke SERVICE MANUAL 91 50700 7 3 12 CURRENT TRANSFORMERS Disassembly of the current transformers Before removing the transformers you should remove the embellishers see section 7 3 1 and the tray boards figure 7 3 7 See the figure 7 3 15 while following the next instructions 1 Disconnect the 3 current measurement cables of the transformers and the 3 screws M6x16 DIN 7895H which connect dV dt choke to the output 2 Remove the 3 Phillips screws M4x8 DIN 7895H that join the current transformers with the chassis 3 Remove the current transformers Figur
35. Remove the 6 hexagonal plastic spacers M3x20 which are joined to the electronic tray and support the control board 4 Unscrew the 6 Phillips screws M3x8 DIN 7895H 5 Remove the power board of the drive Assembly of the power board 1 Continue with the safety conditions which Figure 7 4 7 Disassembly of the power board are described in the previous section 2 While replacing the power board avoid an excessive handling of the board 3 Pick the new power board from the static proof bag 4 Put the new power board in the same place than the replaced one 5 Put the board on the electronic tray matching the bolts of the tray with the holes of the board see figure 7 4 7 102 SERVICE MANUAL POWER ELECTRONICS 7 4 6 DRIVE SELECT BOARD Disassembly of Drive Select Board Unscrew the 2 plastic screws M3x8 DIN 933 which join this board and the plastic hexagonal Spacers M3x12 Drive Select SD700 7 4 7 PLUGGABLE PCB OF TRIGGER THIRISTOR Disassembly of the pluggable PCB of trigger thyristors Before removing the pluggable PCB of trigger thyristos it is necessary to remove the tray where the control and power boards are inserted For this remove the 4 Phillips screws M4x8 DIN 7895H which join this tray with the sides of the drive s chassis See the figure 7 4 9 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconne
36. THYRISTORS Disassembly of the thyristors Before removing the thyristors you should remove the embellishers See section 7 4 1 the tray for the boards see figure 7 4 7 the connection bars for the thyristors see figure 7 4 10 a and the bus bars see figure 7 4 17 a See the figure 7 4 26 while following the next instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the control cable of the thyristors 3 Remove the Phillips screws M6x20 DIN 7895H which join the thyristors and their heatsink 4 Remove the thyristor Figure 7 4 26 Restaurar los tiristores 1 Take the new thyristors and spread with thermal conductor paste the bottom of the thyristors 2 Put them over the heatsink matching the holes of the thyristor with the holes of the heatsink as the figure 7 4 26 shows 3 Insert the Phillips screws M6x20 DIN 7895H which join the thyristors with their heatsink 4 Connect the control cables of the thyristors POWER ELECTRONICS 50700 7 4 16 FANS Assembly of the fan for the toroids Disassembly of the power heatsink fan 1 dna new fan and fix it by using the See the figure 7 4 27 while following the next 2 Connect the power fan cable to the fan instructions 1 Disconnect the power supply fan of the fan 2 Remove the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan with the chassis 3 Remove th
37. Upper Gate Drive Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the new board on the hexagonal spacers M3x18 figure 5 75 3 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 4 Connect the phone wires 176 SERVICE MANUAL POWER ELECTRONICS 7 8 14 IGBT Disassembly of the_the IGBT Before proceeding the upper Gate Drive board must have been disassembled section 7 8 14 Follow figure 6 16 a and figure 6 16 b while reading these instructions 1 Unscrew the 4 hexagonal spacers M3x18 where the Upper Gate Drive is inserted 2 Unscrew the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs 3 Remove the DC Bus section 7 8 10 4 Remove the snubber capacitors 5 Unscrew the 3 Phillips screws M6x20 DIN 7895H which join the IGBT and the bar where the DCCTs are screwed 6 Remove the bar where the DCCTs are screwed 7 Unscrew the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 8 Disassemble the IGBT M6x12 ib DC Bus M6x20 Snubber capacitor Figure 6 16 a Disassembly of the IGBT POWER ELECTRONICS Assembly of the Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Take out the new IGBT of the static box 3 Spread the therm
38. cases and are joined to the hexagonal spacers M3x18 located under the upper Gate Drive 4 Screw the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 5 Connect the IGBT trigger wire 6 Connect the NTC wires 50700 Figure 5 14 Disassembly of the IGBT Connector Board SERVICE MANUAL 159 50700 7 7 13 UPPER GATE DRIVE Disassembly of the Upper Gate Drive Before proceeding the IGBTs connector board must have been disassembled section 7 7 12 Follow figure 5 15 while reading these instructions 1 Disconnect the phone wires which connect this board and the lower Gate Drive 2 Unscrew the Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 3 Disassemble the Upper Gate Drive Phone wire Figure 5 15 Disassembly of upper Gate Drive Assembly of the Upper Gate Drive Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the new board on the hexagonal spacers M3x18 figure 5 15 3 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 4 Connect the phone wires 160 SERVICE MANUAL POWER ELECTRONICS 7 7 14 IGBT Disassembly of the IGBT Before proceeding the upper Gate Drive board must have been disassembled section 7 7 14 Follow figure 5 16 a and figure 5 16 b while reading th
39. chassis of the drive by using the 6 Phillips screws M4x8 DIN 7895H that join the lower covers and the chassis 3 Move the upper cover closer to the chassis of the drive and connect the power supply cable of the fans 4 Screw the upper cover to the drive chassis by using the 7 Phillips screws M4x8 DIN 7895H POWER ELECTRONICS 7 4 4 CONTROL BOARD Disassembly of the control board The use of a static grounding wrist strap and being earthed is highly required to repair the unit See the figure 7 4 5 while reading the following instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control board and the plastic hexagonal spacers M3x20 Remove the control board by pulling it up until disconnecting the female connectors of 40 32 and 28 pins of the control board from the male connectors of the power board where control board is connected Once the control board is removed put this board into a static proof bag for safekeeping Figure 7 4 5 Remove the control board 50700 Assembly of the control board 1 2 Continue with the safety conditions which are described in the previous section While replacing the control board avoid an excessive handling of the board Pick the new control board from the static proof bag Put the new control board in the same place than the replaced one matching the board holes with the hexagonal plastic spacers M3x20 see figur
40. holes Insert the 4 Phillips screws M4x8 DIN 7895H that join the bus and the chassis Insert the power connections board see figure 7 3 11 Insert the 2 screws M5X12 DIN 7895H which join the power connections board and the DC bus Connect the two power cables to the DC bus with screws M5X12 DIN 7895H POWER ELECTRONICS 7 3 10 UPPER GATE DRIVE BOARD Disassembly of the upper Gate Drive board Before removing the upper Gate Drive board you should remove the embellishers see section 7 3 1 and the tray for the boards see figure 7 3 7 1 Disconnect the flat cable and the phone cables 2 Remove the 6 plastic screws M3x8 DIN 933 See figure 7 3 13 3 Remove the board board Assembly of the upper Gate Drive board 1 Put the board in the correct position see figure 7 3 13 2 Insert the 6 plastic screws M3x8 DIN 933 3 Connect the flat cable and the phone cables 50700 7 3 11 MEDIUM AND LOWER GATE DRIVE BOARD Disassembly of the medium and lower Gate Drive board Before removing the medium and lower Gate Drive board you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 the power connections board see section 7 3 8 and the upper Gate Drive board see section 7 3 10 See figure 7 3 13 while following the next instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2
41. in the DC Bus where the back of the Snubber Trigger and Soft charge Board leans Insert the hexagonal spacers M3x15 in the DC Bus where the back of the Snubber Trigger and Soft charge Board leans Place the Snubber capacitors on the back of the DC Bus see figure 3 15 by screwing the Phillips screws M6x12 DIN 7895H Screw the 8 Phillips screws which join the DC Bus and the Bus bridge Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN 7895H SERVICE MANUAL 157 50700 7 7 11 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding the DC Bus must have been disassembled section 7 7 10 Follow figure 5 13 while reading these instructions 1 Unscrew the specials hexagonal screws M5x20 which join the capacitor and the Bus Remove the Bus Remove the Bus and Bus insulator Unscrew the special hexagonal screws M5x20 which join the capacitor and the Bus Remove the Bus Remove the Bus and the middle Bus insulator Unscrew the special hexagonal screws M5x20 which join the middle Bus and the capacitors Remove the middle Bus Take out the capacitors of their rings Assembly of the Bus capacitors Place the new capacitors in their rings Insert the middle Bus figure 5 12 Screw the special hexagonal screws 5 20 Insert the Bus and the middle Bus insulator Insert the Bus figure 5 12 Screw the special hexagonal scr
42. no pulses in the IGBT s Any component of the inverter circuit is failing IGBT s GateDrive D216 RED colour In normal operation always ON It shows that 28V_DISP_PWR supply is OK If it does not turn on the Display is not being supplied D230 RED colour In normal operation always ON It shows that 15V_TEMP supply is OK If it does not turn on the temperature measure circuit 15 failing D103 RED colour In normal operation always ON It shows that Power PCB Bus is charged If it does not turn on the main power supply is not operating LED 1 LED2 GREEN colour In normal operation only one out of three is on It shows the highest temperature of the three output phase IGBTs LED3 SERVICE MANUAL POWER ELECTRONICS 50700 D311 D307 LED 3 LED 2 LED 1 Lm Me rag X nmn DW pui D m i prion d C qc S j x 000 0000 4 800 00 nan e C Bm D114 D507 D1000 D103 D216 D244 D212 D214D215D230D213 Figure 1 8 Power PCB Leds b Control PCB LED 10 GREEN colour It FLICKERS during normal conditions It shows that the processor is in normal operation LED 901 GREEN colour During normal operation always OFF It shows that DSP 3 3V supply is OK LED 1101 GREEN colour During no
43. normal operation it is always OFF It is lit when the Hardware current limitation is performing 36 SERVICE MANUAL POWER ELECTRONICS Dc Bus Board Frame 1 LED2 LED1 STU 50700 LED 1 RED colour In normal operation it is always ON indicates that DC Bus is powered LED 2 RED colour In normal operation it is ON during the soft charge and once the DC Bus is charge the led becomes OFF SERVICE MANUAL 37 50700 POWER ELECTRONICS d Gate Drive Board Frame 1 LED1 L5 L6 L4 L1 L2 LEDDB LED8 LED9 LED 1 RED colour In normal operation it is always ON It indicates 15V IGBT FUSE L1 GREEN colour In normal operation it is always ON It indicates desaturation W L2 GREEN colour In normal operation it is always ON It indicates desaturation W L3 GREEN colour In normal operation it is always ON It indicates desaturation V L4 GREEN colour In normal operation it is always ON It indicates desaturation V L5 GREEN colour In normal operation it is always ON It indicates desaturation U 4 L6 GREEN colour In normal operation it is always ON It indicates desaturation U LED DB GREEN colour In normal operation it is always ON It indicates braking desaturation fault in this case it becomes OFF LED 8 YELLOW colour In normal operation it is always ON It indicates 15V dynamic brake LED 9 YELLOW colour In
44. normal operation it is always ON It indicates 15V dynamic brake NOTE Leds L1 L2 L3 L4 L5 L6 and LED DB become OFF during 1s when saturation 38 SERVICE MANUAL POWER ELECTRONICS 50700 4 5 2 Indicator Leds Frame 2 a Indicator Leds of Power Board The PCB s of the SD700 drives have several leds which report us about the operation of the drive and can give us the information about the component that operates wrongly D114 RED colour In normal operation OBS NM Oa ___ it is always ON It indicates that DC Bus SE is charged When it is OFF the Bus is completely discharged D507 RED colour In normal operation it is always OFF It is blinking if there is a fault in the main power supply This fault can be D212 D216 High Bus voltage D214 D213 Low Bus voltage D215 High internal temperature of the E drive D307 A c C Short circuit in the main power Z E He supply of the power board 1 Ld D103 RED colour In normal operation it is always ON It indicates that the bus of the power board is powered D212 RED colour In normal operation it 0207 is always ON It indicates 24V Fans OK D204 D216 RED colour In normal operation it is always ON It indicates 28V Display Power D214 RED colour In normal operation it LED1 is always ON It indicates 24V User D213 RED colour In normal operation it D215 RED colour In n
45. of the Snubber Trigger and Soft charge Board leans Put the Snubber capacitors on the back of the DC Bus see figure 3 15 by screwing the Phillips screws M6x12 DIN 7895H Screw the 8 Phillips screws M6x20 DIN 7895H which join the DC Bus and the Bus bridge Screw the 2 Phillips screws M6x20 DIN 7895H which join the DC Bus and the Bus bridge Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN 7895H SERVICE MANUAL 187 POWER ELECTRONICS 50700 Lf RS ur mc N 2 N y oy HEN 8 ay 2 SY Q9 e AS eS Snubber capacitors Figure 7 12 c Bus bridge Figure 7 12 b Disassembly of the DC Bus iR N N 75 QN 7 Figure 7 12 a Disassembly of the DC Bus LT py NV Ne NN 9 WAS Figure 7 12 b Disassembly of the DC Bus 188 SERVICE MANUAL POWER ELECTRONICS La TX 4 4 ie E NM Figure 7 12 d Disassembly of the DC Bus SD700 7 9 11 BUS CAPACITORS Before proceeding the DC Bus must have been disassembled section 7 9 10 Folow the figure 7 13 while reading these instructions 1 Unscrew the special hexagonal screws M5x20 which join the capacitor and the Bus 2 Remove the Bus 3 Remove the Bus and the Bus insulator 4 Unscre
46. of the power board SERVICE MANUAL 87 50700 7 3 6 DRIVE SELECT BOARD Disassembly of Drive Select board Unscrew the 2 plastic screws M3x8 DIN 933 which join this board and the plastic hexagonal Spacers M3x12 Drive Select Figure 7 3 8 Disassembly of the Drive Select board Assembly of Drive Select board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN 933 68 SERVICE MANUAL POWER ELECTRONICS 7 3 7 PLUGGABLE PCB OF TRIGGER THYRISTORS Disassembly of the pluggable PCB of trigger thyristors Before removing the pluggable PCB of trigger thyristos it is necessary to remove the tray where the control and power boards are inserted For this remove the 4 Phillips screws M4x8 DIN 7895H which join this tray with the sides of the drive s chassis See the figure 7 3 9 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the 3 cables from he thyristors and the communication cable from the pluggable PCB Figure 7 3 9 Disassembly of the pluggable PCB of trigger thyristors 3 Remove the 4 plastic screws M3x8 DIN 933 which join the back of the board to the 4 hexagonal plastic spacers M3x10 which are inserted in the power connections board 4 Remove the board Disassembly of the pluggable PCB of trigger thyristors 1 Continue with the safety conditions
47. semiconductors Possible cause Short circuit Extreme overcurrent overload Wiring fault circuit fault Desaturation of IGBT IGBT fault Actions Check if there are possible wiring faults or a motor fault If the fault persists after disconnecting output wires Check IGBTs section 6 4 Fault F10 NEG DESAT Description An automatic internal protection of several of the IGBT semiconductors tripped Possible cause Short circuit Extreme overcurrent device overload Desaturation of IGBT IGBT fault Actions Check conditions of input power supply and wiring conditions Check the Fuse 4 in the Power PCB section 4 4 2 Fault F11 VIN LOSS Description Power supply loss of any input phase for a time higher than 20ms occurred Possible cause Input power is incorrect damaged fuses Input wiring is incorrect Actions Check conditions of input power supply Check wiring Check input Fuse section 4 4 1 Fault F12 IMB V IN Description Power supply loss of any input phase for a time higher than 20ms has occurred Possible cause Input power is incorrect damaged fuses Actions Check conditions of input power supply Check wiring Check input Fuse section 5 4 1 Check Fuses of Snubber PCB section 4 4 3 Fault F13 HI V IN Description Input voltage imbalance higher than 10 of average input power supply of SD700 for a time higher than 100ms Possible cause Input power is incorrect Incorrect setting of parameter G11 6 HIGH VO
48. the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis SD700 7 5 22 HEAT EXCHANGERS Disassembly of the heat exchangers Before proceeding SCRs section 7 5 19 and IGBTs section 7 5 77 must have been disassembled Follow figure 3 25 while eading these instructions 1 Disconnect the thermal wire of SCRs heat exchanger 2 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join SCRs heat exchanger and the chassis 3 Remove the SCRs heat exchanger 4 Unscrew the 2 Phillips screws M5x16 DIN 7895H which join the output IGBTs bakelite and the IGBTs heat exchanger 5 Remove the output IGBTs bakelite 6 Unscrew the 6 Phillips screws M6x16 DIN 7895H which join IGBTs heat exchanger and the chassis 7 Remove the IGBTs heat exchanger f Thermal wire SCRs heat d exchanger D Output IGBTS bakelite IGBTs heat exchanger Figure 3 25 Disassembly of the heat exchangers SERVICE MANUAL 131 50700 1 6 50700 FRAME 5 7 6 1 ACCESS INSIDE Disassembly of the covers Follow figure 4 7 and figure 4 2 while reading these instructions 1 Open the SDrive door 2 Disconnect the Display from the Control PCB 3 Disconnect all control terminals analogue inputs digital inputs PTC Control p terminals Figure 4 1 Disconnect the Display and the control terminals 4 Unscrew the 2 Phillips screws 4 12 DIN 7895H whi
49. the capacitor and the Bus Remove the Bus Remove the Bus and Bus insulator Unscrew the special hexagonal screws M5x20 which join with capacitor to the Bus Remove the Bus Remove the Bus and the middle Bus insulator Unscrew the special hexagonal screws M5x20 which join the middle Bus and the capacitors Remove the middle Bus Take out the capacitors of their rings Assembly of the Bus capacitors Place the new capacitors on their rings Insert the middle Bus figure 3 16 Screw the special hexagonal screws M5x20 Insert the Bus and middle Bus insulator Insert the Bus figure 3 16 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors Place the Bus and the Bus insulator Insert the Bus figure 3 16 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors SD700 Figure 4 15 Disassembly of the Bus capacitors SERVICE MANUAL 141 50700 POWER ELECTRONICS 7 6 14 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 16 while eading these instructions 1 Disconnect the IGBT trigger cable which connects this board to the Power board 2 Disconnect the 3 NTC wires which connect 27 this board to the upper Gate Drive m y 3 Unscrew the 2 plastic screws M3x6 DIN
50. the drive and connect the power supply cable of the fans 4 Screw the upper covers to the drive chassis by using the 10 Phillips screws M4x8 DIN 7895H 50700 7 2 4 CONTROL BOARD Disassembly of the control board The use of a static grounding wrist strap and being earthed is highly required to repair the unit See the figure 7 2 5 while reading the following instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control board and the plastic hexagonal spacers M3x20 2 Remove the control board by pulling it up until disconnecting the female connectors of 40 32 and 28 pins of the control board from the male connectors of the power board where control board is connected 3 Once the control board is removed put this board into a static proof bag for a safekeeping M3x8 1 Figure 7 2 5 Remove the control board SERVICE MANUAL 75 50700 Assembly of the control board 1 2 76 Continue with the safety conditions which are described in the previous section While replacing the control board avoid an excessive handling of the board Pick the new control board from the static proof bag Put the new control board in the same place than the replaced one matching the board holes with the hexagonal plastic spacers M3x20 see figure 7 2 6 Match the male connector of 40 32 and 28 pins of the control board with the corresponding female connector of the power boar
51. the input voltage measure circuit before the AC choke Possible reason for failure Short circuit in the Power PCB Action Change the Power PCB c Fans Power Supply There are 3 fuses with the same function Function Fan s power supply protection Possible reason for failure Short circuit in the fans power supply Action Change the fans power supply FUSE 1 FUSE 2 FUSE 3 Figure 1 7 Fans power supply fuses 34 SERVICE MANUAL POWER ELECTRONICS 50700 4 5 Indicator Leds 4 5 1 Indicator Leds Frame 1 a Indicator Leds of Power Board The PCB s of the SD700 drives have several leds which report us about the operation of the drive and can give us the information about the component that operates wrongly D114 RED colour In normal operation it is always ON It indicates that DC Bus is charged When it is OFF the Bus is completely discharged D507 RED colour In normal operation it is always OFF It is blinking if there is a fault in the main power supply This fault can be D212 D216 High Bus voltage D214 D213 Low Bus voltage D215 High internal temperature of the drive D307 infi Short circuit in the main power Z E Hg supply of the power board 1 Ld D103 RED colour In normal operation it is always ON It indicates that the bus of the power board is powered D212 RED colour In normal operation it 0207 is always ON It indicates 24V Fans OK D204 D216 RE
52. the new IGBT of the static box 3 Spread the thermal paste over the back of the IGBT 4 Putthe IGBT on the heat exchanger 5 Screw the 4 Phillips screws 5 16 DIN 7895H which join the IGBT and the heat exchanger 6 Place the DCCT Bar as it is shown in figure 7 16 7 Insert the DC Bus section 7 9 10 8 Place the Snubber capacitor on the DC Bus 50700 7 9 15 SCRs Disassembly of the SCRs Before proceeding the Upper cover section 7 9 2 Snubber Trigger and Soft charge board section 7 9 6 and DC Bus section 7 9 10 must have been disassembled Follow figure 7 18 and figure 7 19 while reading these instructions 1 Unscrew the hexagonal screws M8x25 DIN 933 which join the bars and the SCRs 2 Remove the voltage measure wires after the AC choke by unscrewing the Phillips screws M4x8 DIN 7895H which join these wires and the bars 3 Remove the bars 4 8 After AC choke current measurement Figure 7 18 Disassembly of the bars SERVICE MANUAL 193 50700 Unscrew the 2 Phillips screws M5x12 DIN 7895H which join the SCR and the heat exchanger Remove the SCR Figure 7 19 Disassembly of the SCR Assembly of the SCRs Spread the thermal paste over the back of the new SCR 1 194 SERVICE MANUAL Insert the SCR in the heat exchanger figure 7 16 Screw 2 Phillips screws M5x12 DIN 7895H which join the SCR and the heat exchanger Insert the
53. the power connections board Before proceeding you should remove the embellishers see section 7 4 1 the tray for the boards see figure 7 4 7 the pluggable PCB of the trigger thyristors see section 7 4 7 and the bars for the connections to the thyristors see figure 7 4 10 a 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Remove the 3 screws that are fixed to the AC choke M6x16 DIN 7895H 3 Remove the 5 Phillips screws M3x6 DIN 7895H See figure 7 4 10 4 Figure 7 4 10 Disassembly of the power connections board Assembly of the power connections board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the power connections board avoid an excessive handling of the board 3 Pick the new power connections board from the static proof bag 4 Put the board in the correct position as the figure 7 4 10 shows matching the holes with the choke 5 Insert the 5 Phillips screws M3x6 DIN 7895H 6 Insert the screws which are fixed to the AC choke M6x16 DIN 7895H tightening pressure of 3N m 7 Plug the PCB of trigger thyristors See figure 7 4 9 POWER ELECTRONICS Figure 7 4 10 a 50700 7 4 9 DC BUS Disassembly of DC Bus Before proceeding you should remove the embellishers see section 7 4 1 the tray for the boards see figure 7 4 7 the plugg
54. trim and the Formica piece 1 Unscrew the 4 Phillips M4x8 DIN 7895H which join the plastic protector and the 6 In IP54 models disconnect the fan power Sdrive chassis wires which are in the trims before removing them 2 Remove the plastic protecotr 7 Remove the trims Assembly of the plastic protector 1 Replace the plastic protector of the power terminals in the SDrive chassis by screwing the 4 Phillips M4x8 DIN 7895H 114 SERVICE MANUAL POWER ELECTRONICS 7 5 2 DOOR Disassembly of the door Follow figure 3 3 while instructions reading these 1 Open the door 2 Disconnect the ethernet Display wire 3 Remove the Display of the door 4 Disconnect the earth cable of the door 5 Unscrew the 2 specials screws M6x12 which join the door and the chassis 6 Remove the door 6 12 N SU a 4 gt i 2 Figure 3 3 Disassembly of the door Assembly of the door 1 Place the door follow the figure 3 3 2 Join the door and the SD700 chassis by screwing 2 specials screw M6x12 3 Place the Display on the door 4 Connect the cable 50700 7 5 3 UPPER AND LOWER COVERS Disassembly of the upper and lower covers Follow figure 3 4 while instructions reading these 1 Unscrew the 6 Phillips M4x8 DIN 7895H which join the upper cover and 0700 chassis 2 In IP20 models remove the upper cover slowly in o
55. ul 933 which join this board and the plastic hexagonal spacers M3x18 NIS 4 Unscrew the 2 slotted cheese head screws M3x30 DIN 84 which join this Board and the Upper Gate Drives 5 Remove the IGBTs connector board The plastic hexagonal spacers and the Nylon cases are not fixed anywhere They are simply helding this board so that take care not to lose them when the board is disassembled Assembly of the IGBTs connector board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the new board on the plastic hexagonal spacers M3x18 Nylon cases 3 Screw the 2 slotted cheese head screws 16 Di ly of the IGBT M3x30 DIN 84 which go through the Nylon Rom e IGBT Connector cases and are joined to the hexagonal spacers M3x18 located under the Upper Gate Drive 4 Screw the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 5 Connect the IGBT trigger cable 6 Connect the NTC cables 142 SERVICE MANUAL POWER ELECTRONICS 50700 7 6 15 UPPER GATE DRIVE M3x8 Assembly of the Upper Gate Drive Before proceeding the IGBTs connector board must have been removed removed section 7 6 14 Phone wire The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 17 while reading these instructions 1 Disconnect the phone cables which con
56. which join the wire terminals and the board figure 7 8 a Disconnect all output wiring figure 7 8 b Figure 7 8 a Disassembly of the Snubber Trigger and soft charge protection 184 SERVICE MANUAL Before AC choke p voltage measure 4 SCR tigger POWER ELECTRONICS SCR tigger Soft charge resitance After AC choke sk voltage measure Figure 7 8 b Disassembly of the Ssnubber Trigger 3 and Soft charge protection Unscrew the 3 Phillips screws on M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 which are placed in the Bus Unscrew the 3 Phillips screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 which are placed in the Bus Disassemble the Board Figure 7 8 c Disassembly of the Ssnubber Trigger and Soft charge protection POWER ELECTRONICS Assembly of the Snubber trigger and soft charge protection board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Putthe Board in the position as it is shown in figure 7 8 c 3 Screw the 3 screws M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 4 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and hexagonal spacers M3x15 5 Connect all input wiring voltage measure wire before and after the AC Choke by screwing the Phillips screw M4x8 DIN 7895H which join the wire
57. wiring voltage measure wire before and after the AC Choke voltage measurement by screwing the Phillips screw M4x8 DIN 7895H which join the wire terminals and the board figure 6 8 a 6 Connect all output wiring figure 6 8 b 170 SERVICE MANUAL POWER ELECTRONICS 7 8 7 FANS POWER SUPPLY Disassembly of the fan power supply The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 9 while reading these instructions 1 Disconnect the 2 fan power wires and power wire of the fans power supply 2 Unscrew the 3 Phillips screws M3x6 DIN 7895H which join the fan power supply and the fans tray 3 Remove the fan power supply Power Fans power supply Fans power supply try M3X6 Fans power 41 7 Figure 6 9 Disassemb ly of the fan power supply Assembly of the fans power supply Continue to observe static safe work procedures 1 Place the new fans power supply in the fan tray 2 Screw the 3 Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Connect the 2 fan power wires and the fan power supply power wire POWER ELECTRONICS 50700 7 8 8 OUTPUT CHOKE 7 8 9 DCCT Disassembly of the Output choke Disassembly of the DCCT Follow figure 6 10 while reading these Before proceeding output choke must have instructions been disassembled section 7 8 8 1 Unscrew the 2 hexagonal screws M8x25 Follow figure 6 11 whil
58. you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 the power connections board see section 7 3 8 the DC bus see section 7 3 9 the upper gate drive board see section 7 3 10 the medium and lower gate drive board see section 7 3 11 the thyristors See section 7 3 15 and the fans only the fan for the power heatsink see section 7 3 16 1 Remove the 2 Phillips screws M5x12 DIN 7895H which fix the heatsink to the side of the chassis see figure 7 3 29 Figure 7 3 29 2 Remove the 2 Phillips screws M5x12 DIN 7895H which fix the heatsink by the top see figure 7 3 30 Figure 7 3 30 3 Remove the heatsink POWER ELECTRONICS 50700 Assembly of the heatsink 7 3 18 DISCHARGING RESISTOR 1 Put the new heatsink in the correct position and fix it with their 4 Phillips screws M5x12 DIN Disassembly of the discharging resistor 7895H In order to remove the discharging resistor first 1 Take the thyristors and the lower gate drive you should remove the embellishers see board and spread the thermal conductor section 7 3 1 paste on the bottom see figure 7 3 31 1 Remove the 2 screws M3x6 DIN 7895H 2 Follow all the steps described previously in which fix the discharging resistor to the order to insert all the components again electronic tray see figure 7 3 32 2 Remove the discharging resistor Figure 7 3 32 Assembly of the discharging resistor
59. 0700 SAFETY INSTRUCTIONS IMPORTANT Read this manual carefully to maximize the performance of this product and to ensure its safe use n this manual safety messages are classified as follows N WARNING Do not remove the cover while power is applied or the unit is in operation Otherwise electric shock could occur Do not run the drive without the front cover Otherwise you may get an electric shock due to the high voltage terminals or to the exposure of charged capacitors Do not remove the cover except for periodical inspections or wiring even if the input power is not applied Otherwise you may access the charged circuits and suffer an electric shock Wiring and periodic inspections should be performed at least 10 minutes after disconnecting the input power and after checking the DC Link voltage is discharged with a meter below 30VDC Otherwise you may suffer an electric shock Operate the switches with dry hands Otherwise you may suffer an electric shock Do not use cables with damaged insulation Otherwise you may suffer an electric shock Do not subject the cables to abrasions excessive stress heavy loads or pinching Otherwise you may suffer an electric shock SERVICE MANUAL 5 50700 POWER ELECTRONICS N CAUTION Install the drive on a non flammable surface Do not place flammable material nearby Otherwise fire could occur Disconnect the input power if the drive gets damaged Otherwise it could r
60. 18 Fault F46 EEPROM FLT Descrtiption Trip generated due to excessive stopping time The elapsed time from stop signal activation has exceeded the value set in parameter G11 2 STOP TO Posible cause Integrated circuit fault Actions Change the Control PCB Fault 47 COMMS T O Descrtiption Trip generated due to excessive delay of serial communication The elapsed time from the last valid data transmission has exceeded the time set in parameter G20 2 COMMS T O Posible cause Communications cable has come loose or cut Master device has not sent valid data in the required frame or it has sent incorrect data Actions Verify the wiring of communications system verify the data and settings of the master device If the fault persists change the Control PCB Fault F48 5 COM Descrtiption Trip due to a wrong data bus transfer Posible cause Input power fault Actions Reset the device and if the fault persists change the Control PCB Eault F49 SPD LIMIT Descrtiption Motor speed has exceeded the speed limit parameters G10 1 to G10 4 for the time set in G11 1 SP LIM TO Posible cause Speed reference is higher than the speed limit Motor speed is out of control or motor is accelerating because of the load Actions Verify speed limits Fault F50 PSU FAULT Descrtiption Internal power supply is not supplying the correct voltage The voltage level has dropped to zero value for 100ms approx Posible cause
61. 2 Disconnect the power supply cable 3 Remove 2 screws M4x35 DIN 84 which join the fan and the chassis See figure 7 2 26 4 Remove the fan 4 Figure 7 2 26 POWER ELECTRONICS 50700 Assembly of the fan of the lateral internal Cover 1 Putthe new fan and fix it with the screws 2 Connect the power supply cable SERVICE MANUAL 83 50700 7 3 50700 FRAME 3 60 75A ACCESS TO THE INSIDE OF THE DRIVE 7 3 1 Disassembly of the embellishers In order to repair or replace any component of the drive you should access to the inside of it See figure 7 3 1 and figure 7 3 2 while reading the following instructions 1 Open the door of the drive 2 Disconnect the Display For this disconnect ethernet cable which joins the display and the drive Push the tab of the RJ45 connector and pull it up 3 Disconnect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input POWER ELECTRONICS Remove the plastic protector for the power connections Figure 7 3 2 Access to the inside of the drive Assembly of the embellishers Display 1 Q 2 3 Cable Ethernet 4 Conector RJ45 5 Terminales de control wm Figure 7 3 1 Display connection and control terminals SD70ITMOO01AE 4 Remove the 4 Phillips M4x8 DIN 7895H screws with their corresponding whasers and grover whasers which join the embellishers t
62. 2 Refr the value of the analogue input 2 has to be the highest one allowed SERVICE MANUAL 6 6 2 Check digital inputs The screen SV 3 Input DG shows whether the Digital Inputs are activated or not from 011 to DI6 as it is shown in figure 2 11 y 2 12 A X is Active is not active Jumper terminal 1 with terminal 2 and verify that the digital input 1 is connected Input DG X00000 Digital Input 1 Figure 2 11 Digital Input 1 active Jumper terminal 1 with terminal 3 and verify that the digital input 1 is connected Input DG 0X0000 Digital Input 2 Figure2 12 Digital Input 2 active Verify that all inputs are right 50700 POWER ELECTRONICS T SUBASSEMBLY REPLACEMENT Make sure the SD700 is safe to work see section 3 before proceeding 1 1 SD700 FRAME 1 4 Remove the 3 Phillips M4x8 DIN 7895H AE screws with their corresponding whasers and grover whasers which join the 74 1 ACCESS TO THE INSIDE embellisher and the chassis See figure OF THE DRIVE 7 1 1 a Disassembly of the embellishers In order to repair or replace any component of the drive you should access to the inside of it See figure 7 1 1 and figure 7 1 2 while reading the following instructions 1 Remove the drive s door by unscrewing the 4 M4x8 DIN 7895H screws which fix it the the chassis 2 Disconnect the Display For this disconnect ethernet cable which joins the display and the drive Push the t
63. 2 UPPER COVER Disassembly of the Upper Cover Follow figure 6 4 while reading these instructions 1 Unscrew the 12 Phillips M4x8 DIN 7895H which join the upper cover and the chassis of the SD700 2 IP20 models disassemble the upper cover slowly and then disconnect the fans supply wire Afterwards remove the Upper Cover _ 4 12 Figure 6 3 Disassembly of the plastic protector Figure 6 4 Disassemble upper cover Assembly of the plastic protector Assembly the upper cover Place the plastic protector of the power terminals Assembly of the upper cover in the SDrive chassis by screwing the 6 Phillips M4x8 DIN 7895H 1 In IP20 models connect the fans supply wire 2 Join the upper cover with SD700 chassis screwing on 12 Phillips screw 4 8 DIN 7895H 166 SERVICE MANUAL POWER ELECTRONICS 7 8 3 CONTROL BOARD Disassembly of the Control Board The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 5 while reading these instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control PCB and the plastic hexagonal spacers M3x20 2 Disassemble the Control Board by removing the 40 32 y 28 pin connectors which join the Control Board and the Power Board 3 When the control Board has been disassembled place it in a static proof bag for safekeeping M3x8 s Figure 6 5 Disassembly of the Contro
64. 7 4 1 and the tray boards figure 7 4 7 See the figure 7 4 15 while following the next instructions 1 Disconnect the 3 current measurement cables of the transformers and the 3 screws M6x16 DIN 7895H which connect dV dt choke to the output 2 Remove the 6 Phillips screws M4x8 DIN 7895H that join the current transformers with the chassis 3 Remove the current transformers Figure 7 4 15 Disassembly of the current transformers Assembly of the current transformers 1 Insert the Phillips screws M4x8 DIN 7895H and fix the transformers to the chassis 2 Connect the cables of the current transformers 3 Put the cables of dV dt chokes on the inside of the transformers and connect them to the output by using 3 screws M6x16 DIN 7895H and thighten at 5 N m SERVICE MANUAL 107 50700 POWER ELECTRONICS 7 4 13 AC CHOKE 3 Remove the AC choke see figure 7 4 18 Disassembly of the AC choke In order to remove the AC choke first you should remove the embellishers see section 7 4 1 the tray for the boards see figure 7 4 7 the power connections board see section 7 4 8 the connection bars for the thyristors see figure 7 4 10 a the bus bars see figure 7 4 17 a the Ac choke DC bus see section 7 4 9 and the tray where the connections board is supported see figure 7 4 16 See the figure 7 4 17 while following the next instructions Figure 7 4 18 Disassembly of the AC choke Asse
65. 7895H screws which join the DC Bus and the Bus bar 7 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the chassis 8 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger 9 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 10 Unscrew the 6 Phillips screws M6x12 DIN 7895H which join the Bus and the Bus with the 3 SCRs Figure 5 12 b Disassembly of the DC Bus 156 SERVICE MANUAL POWER ELECTRONICS SM Figure 5 12 d Disassembly of the DC Bus 5 e 0 4 8 Qo RE I 1 1 A 9 3 q Orr Figure 5 12 c Bus bridge M4x8 M6x12 M6x12 jt LP P SRO 50700 Assembly of DC Bus 1 2 10 11 Place the DC Bus on the chassis Screw the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC BUS and the chassis Screw the 6 Phillips screws M6x12 DIN 7895H which join DC Bus and the SCRs Screw the 6 Phillips screws M6x12 DIN 7895H which join DC Bus and the SCRs Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger Insert the plastic hexagonal spacers M3x10
66. 895H 3 Connect the power cables to the choke as the figure 7 3 17 shows 4 Insulate the power cables see figure 7 3 18 Figure 7 3 18 50700 7 3 14 DV DT CHOKES Disassembly of the dV dt chokes It is necessary to remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 the power connections board see section 7 3 8 the DC Bus see section 7 3 9 the control cable bars see figure 7 3 21 the bar for connectios see figure 7 3 19 and the medium bar see figure 7 3 20 Figure 7 3 19 Figure 7 3 20 1 Remove the protection bars for the control cables Figure 7 3 21 Figures 7 3 21 2 Disconnect all cables which are joined to the connections bar and the three cables of dV dt choke which go to the lower gate drive board see figure 7 3 22 SERVICE MANUAL 93 Figuea 7 3 22 3 Remove the 2 screws M4x8 DIN 7895H which fix the connections bar to the chassis 4 Remove the connections bar 5 Remove the 5 screws M4x8 DIN 7895H which fix the medium bar 6 Remove the medium bar 7 Remove the 2 screws M4x8 DIN 7895H which hold the fixing bar for the fan cables to the chassis see figure 7 3 23 Figure 7 3 23 8 Remove the screws which fix dV dt chokes to the top of the chassis see figure 7 3 24 Figure 7 3 24 9 94 Remove the 4 screws M4x8 DIN 7895H which fix dV dt chokes to the bottom of the chassis see figure 7 3 25
67. CS L119 DV6224TD 24VDC 89W um um femra Hep GXNIDAU O o _ WMNAGPRINDASN 380V we 7 46 Ws overeat 1 Um Ue td 7 40 um __ 402 7000 60 REFERENCE DESCRIPTION SD7006265 Ue ___ _ 20 8314H 24VDC 6W 6 _ _ UN Ux SMHUPRWEXE _ 2 PRDNDCARW _ L6 _ Up UU 507010565 ue RUN DAVDC La aL Ws um Ux H8 _ 198 SERVICE MANUAL PONER ae 50700 6 2 50700 Frame 5 SD700FRAME5380V Snubbers PCB E068BB E068BB 80700 FRAME 5 690V IP54 IP20 models SD701306X SD701506X SD701706X Control PCB E024HA E024HA E024HA Power PCB E107BD E107BD E107BD Snubbers PCB E113BB E113BB E113BB Lower Gate Drive E117BC E115BC E115BC Upper Gate Drive G005A G005A G005A IGBTs connector PCB E083AA E083AA E083AA IGBT selection module E038BA E038BA E038BA SCR
68. D colour In normal operation it is always ON It indicates 28V Display Power D214 RED colour In normal operation it LED1 is always ON It indicates 24V User D213 RED colour In normal operation it is sieve ON It indicates 24V Control D215 RED colour In normal operation it is always ON It indicates 15V IGBT D307 RED colour In normal operation it is always ON It indicates 8V User D207 RED colour In normal operation it is always ON It indicates 15V Dynamic Brake D204 RED colour In normal operation it is always ON It indicates 15V Dynamic Brake LED1 GREEN colour In normal operation it is always ON It indicates detection from the IGBT thermal protection SERVICE MANUAL 35 50700 POWER ELECTRONICS b Indicator Leds of Control Board D1101 D10 D1201 me 4 mea DOO o n Tue Lr di B u ATO mE 0368 pm ojo Bin Oi Figure 1 7 Leds of Control Board LED 10 GREEN colour In normal operation it is blinking It indicates that the microprocessor is operating correctly LED 901 GREEN colour In normal operation it is always ON It indicates that the power supply for the DSP 3 3V is correct LED 1101 GREEN colour In normal operation it is always OFF It is lit if there is overheating in the integrated circuit for 485 communications LED 1201 RED colour In
69. DC Bus terminals to ensure the DC Bus has been fully discharged 10 INSTALLATION AND CONNECTION POWER ELECTRONICS 50700 3 PRINTED CIRCUIT BOARD DESCRIPTIONS 3 1 Input Rectifier The three phases mains supply the rectifier circuit through terminals L1 L2 L3 Each input supplies through a high speed fuse and one winding on a three phase AC choke The input rectifier is a three phase half controlled bridge circuit with three diode SCR modules Each SCR module has a Snubber PCB This PCB restricts the current to avoid a damage in the circuits and smooths the commutations of each diode SCH This PCB has also incorporated a circuit to control the current which charges the DC Bus The output of the rectifier supplies to the DC Bus The DC Bus has a bank of capacitors This capacitors are joined in series in parallel For 400 Vac input the DC Bus output on no loads is approximately 565 Vac Wire wound resistors are fixed across the capacitors in order to share voltage of the series capacitors 3 2 Output Inverter Bridge The DC Bus supplies to the three phases of the inverter bridge which is composed of 3 IGBTs Insolated gate bipolar transistors The IGBTs modulate the required three phases output waveform to supply to the motor through terminals U V W The Current Transformers DCCT and the Output Chokes are placed In the middle of the IGBTs and the output terminals U V W The IGBTs are protected by two PCBs the gate driv
70. DIN 84 which join this Board and the Upper Gate Drives 5 Remove the IGBTs connector board The plastic hexagonal spacers and the Nylon cases are not fixed anywhere they are simply holding this board Take care of not loosing them when the board is disassembled Assembly of the IGBTs conector board Continue to observe static safe work procedures Figure 6 14 Disassembly of the IGBT Connector Board 1 Avoid an excessive handling of the new board 2 Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases 3 Screw the 2 slotted cheese head screws M3x30 DIN 84 which are inserted into the Nylon cases and are joined to the hexagonal spacers M3x18 located under the upper Gate Drive 4 Screw the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 5 Connect the IGBT trigger wire 6 Connect the NTC wires SERVICE MANUAL 175 50700 7 8 13 UPPER GATE DRIVE Disassembly of upper Gate Drive Before proceeding the IGBTs connector board must have been disassembled section 7 8 12 Follow figure 6 15 while reading these instructions 1 Disconnect the phone wires which connect this board to the lower Gate Drive 2 Unscrew the Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 3 Disassemble the Upper Gate Drive Phone wire Figure 6 15 Disassembly of the Upper Gate Drive Assembly of the
71. Display from the Control Board 3 Disconnect all control terminals analogue inputs digital inputs PTC Figure 7 1 Disconnect the Display and the control terminals 4 Unscrew the 9 Phillips screws 4 12 DIN 7895H which join the cover and the chassis upper part 5 Unscrew the 9 Phillips screws M4x8 DIN 7895H which join the cover and the lower part of the chassis 6 In IP54 models disconnect the fan power wires which are in the covers before disassembling them 7 Remove the covers Assembly of the 50700 Covers 1 Place the covers in the chassis as is shown in the figure 7 2 2 Screw the 6 Phillips screws 4 12 DIN 7895H which join the covers and the Upper part of the chassis 180 SERVICE MANUAL POWER ELECTRONICS 3 Screw the 6 Phillips screws 4 8 DIN 7895H which join the covers and the lower part of the chassis 4 Connect the Display 4 12 Ventiladores en IP54 Figure 7 2 Disassembly of the covers Disassembly of the plastic protector 1 Unscrew the 7 Phillips M4x8 DIN 7895 H which join the plastic protector and the SDrive chassis 2 Remove the plastic protector Assembly of the plastic protector Place the plastic protector of the power terminals in the SDrive chassis by screwing the 7 Phillips M4x8 DIN 7895H 50700 POWER ELECTRONICS 7 9 2 UPPER COVER Lo LON n Z 2 2 5
72. Drive 3 Unscrew the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 4 Unscrew the 2 slotted cheese head screws M3x30 DIN 84 which join this Board and the Upper Gate Drives 5 Remove the IGBTs connector board The plastic hexagonal spacers and the Nylon cases are not fixed anywhere They are simply helding this board so that take care not to lose them when the board is disassembled Assembly of the IGBTs conector board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases 3 Screw 2 slotted cheese head screws M3x30 DIN 84 which fit into the Nylon cases and are joined to the hexagonal spacers M3x18 located under the upper Gate Drive 4 Screw 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 5 Connect GBT trigger cable 6 Connect the NTC cables SD700 Figure 3 17 Disassembly of the IGBT Connector Board SERVICE MANUAL 125 50700 POWER ELECTRONICS 7 5 16 UPPER GATE DRIVE M3x8 9 Disassembly of the upper Gate Drive must have been disassembled section 7 5 15 The use of a static grounding wrist strap and being earthed is highly required Before proceeding the IGBTs connector board Upper GateDrive Follow figure 3 18 while re
73. E 7 SD705500X _____ FRAME 8 SD708405X SD705506X 50709255 0706606 80710305 07505 5046059 90714405 FRAME 10 0715805 50718005 11 50722005 Note 1 All drives of frame 9 obtained assembling models of frame 6 Note 2 All drives of frame 10 are obtained by assembling 3 models of frame 7 Note 3 All drives of frame 11 are obtained by assembling 3 models of frame 8 0714405 3 x 0704605 SD718005x 3 x SD706505X SD712706x 3x SD704606X Lr ee 0 3x SD704606X SD722005x 3 x SD708405X SD715006x 3x SD705506X SD715805x 3 x SD705805X SD711406x 3x SD703856X __ 50715006 3x SD706606X This manual outlines all the procedures for a field testing repair and re powering of a faulty SDrive It is not intended as a commissioning guide Refer to the SD700 Getting Started Manual for commissioning information SERVICE MANUAL POWER ELECTRONICS 50700 1 2 Who should undertake service Servicing of an SD700 should be only undertaken by suitably qualified or experienced technicians The service personnel should be qulified in the principles of power electronics 1 3 Level of servicing All the SD700 covered in this manual are built on a modular basis These modules are designed to be disassembled and replaced as necessary to perform repair A list of available spare parts and modules is in Section 8 of this manual Printed circuit board assemblies are not
74. ED 3 GREEN colour They report us that the triggerings of the thyristors are being correctly performed f Indicator Leds of the Upper Gate Drive Board 15 2140 42 IN AN B JI TAN Ha 09 0210 Fr E CE ois m Figure 2 0 Upper gate drive board 50 SERVICE MANUAL POWER ELECTRONICS 50700 LED 1 RED colour In normal operation it is always ON It indicates 15V IGBT FUSE L1 GREEN colour In normal operation it is always ON It indicates desaturation W L2 GREEN colour In normal operation it is always ON It indicates desaturation W L3 GREEN colour In normal operation it is always ON It indicates desaturation V L4 GREEN colour In normal operation it is always ON It indicates desaturation V L5 GREEN colour In normal operation it is always ON It indicates desaturation U L6 GREEN colour In normal operation it is always ON It indicates desaturation U SERVICE MANUAL 51 50700 POWER ELECTRONICS 52 4 5 5 CB LED Indicators The PCBs contains a certain number of LEDs to indicate the status of the SD700 and they can notify if one element is wrong a Power PCB D114 RED colour In normal operation always ON It shows that the DC Bus is charged When it is off that means that the bus is completerly discharged D507 RED colour In normal operation always
75. ER COVER AND LOWER COVERS 7 3 3 covers See the figure 7 3 4 while following the next instructions 1 Assembly of the upper cover and the lower Unscrew the 7 Phillips M4x8 DIN 7895H screws that join the upper cover and the drive chassis In IP20 models remove the upper cover slowly until disconnecting the power supply cable of the fans Once disconnected the cable remove the cover completely Unscrew the 6 Phillips M4x8 DIN 7895H screws which join the lower covers and the drive chassis Remove the lower covers Upper M4X8 cover Lower MM gt 42 Covers M5X10 Figure 7 3 4 Remove the covers covers 1 2 Put the lower covers as the figure 7 3 4 shows Fix the covers to the chassis of the drive by using the 6 Philips screws M4x8 DIN 7895H that join the lower covers and the chassis Move the upper cover closer to the chassis of the drive and connect the power supply cable of the fans Screw the upper cover to the drive chassis by using the 7 Phillips screws M4x8 DIN 7895H SERVICE MANUAL 85 50700 POWER ELECTRONICS 7 3 4 CONTROL BOARD Disassembly of the control board The use of a static grounding wrist strap and being earthed is highly required to repair the unit See the figure 7 3 5 while reading the following instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control board and the plastic hexagonal spac
76. LT Actions Check input power conditions Check parameters settings SERVICE MANUAL 13 50700 POWER ELECTRONICS 14 Fault F14 LW V IN Description Average supply voltage is lower than the value set in G11 4 LOW VOLT for a longer time than the one set in G11 5 LOW V TO Possible cause Input power is incorrect damaged fuses Incorrect setting of parameter G11 4 LOW VOLT Actions Check input Fuse section 4 4 1 Check Fuses of Snubber PCB section 5 4 3 Check input power conditions Check parameters settings Fault F15 CURL Vdc Description Unstable bus voltage There is a DC Bus voltage ripple higher than 100Vdc for more than 1 1 seconds Possible cause Input power is incorrect Motor is driving an unstable load Actions Check input power conditions load type of the application and all the motor mechanical parts If the fault persists after disconnecting output wires check rectifiers section 6 1 and check IGBTs section 6 4 Fault F16 HI Vdc Description DC Bus voltage has exceeded critical operating level gt 850Vdc Software Protection Possible cause High voltage peak at the input High load regeneration Deceleration ramp too high Actions Check conditions of input power supply Check stop conditions of the drive Decrease deceleration ramps parameters G5 2 DECEL1 and G5 4 DECEL2 Fault F17 LW Vdc Description DC Bus voltage is lower than the critical operating level lt 350Vdc
77. MANUAL POWER ELECTRONICS M3x20 7 Figure 4 6 Disassembly of the Power Board POWER ELECTRONICS 7 6 5 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly the Drive Select The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 M3x8 Drive Select Figure 4 7 Remove Drive select and IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal Spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal Spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 50700 7 6 6 SNUBBER TRIGGER SOFT CHARGE PROTECTION BOARD Disassembly of the Snubber trigger and soft charge protection board Follow figure 4 8 a figure 4 8 b and figure 4 8 c while reading these instructions 1 Disconnect the voltage measure cable before
78. OFF It flickers when detects some hardware fault These faults are DC Bus High voltage DC Bus Low voltage Hight temperature in SD700 Short circuit in Power PCB supply O O O 20 D1000 Green colour In normal operation always OFF It switches ON when the DC Bus discharge circuit is in operation D311 RED colour In normal operation always ON It shows that 5V_SCR supply is OK If it does not turn on this is an indicative of problems in the pulse generation circuit for firing the thyristors D307 RED colour In normal operation always ON It shows that 8V_USR supply is OK If ti does not turn on this is an indicative of problems in the user supply 5V_USR y 5V_COM D244 RED colour In normal operation always ON It shows that 24V_DISP_COM supply is OK If it does not turn on there might be a failure in the communication between the Display and the Control Board D212 RED colour In normal operation always ON It shows that 15V_SCR supply is OK 0213 RED colour In normal operation always ON It shows that 24V_CONTROL supply is OK If it does not turn on all the voltages referred to an analogical and digital mass disappear D214 RED colour In normal operation always ON It shows that 28V_USR supply is OK If it does not turn on all the voltages referred to the user mass disappear D215 RED colour In normal operation always ON It shows that 15V_IGBT supply is OK If it does not turn on there are
79. R ELECTRONICS 7 2 9 POWER CONNECTIONS BOARD Disassembly of the power connections board Before removing the power connections board you should remove the embellishers see section 7 2 1 the tray where the control and power boards are inserted see figure 7 2 7 the DC Bus see section 7 2 9 and the gate drive board see section 7 2 7 1 Disconnect the NTC cable 2 Remove the 4 screws of IGBT M5X16 DIN 7895H see figure 7 2 13 3 Remove the 6 nuts 5 that join the fan strucutre and the connections board see figure 7 2 14 4 Remove the Phillips screw M3x8 DIN 7895H of the chassis 5 Remove the 2 plastic screws M3x8 DIN 933 6 Remove the board Figure 7 2 13 Disassembly of the power connections board Figure 7 2 14 Assembly of the power connections board 1 Spread the heatsink area where the IGBT is going to be placed with new thermal paste 2 Put the board in the proper position see figure 7 2 13 50700 Screw the 4 IGBT screws 5 16 DIN 7895H with a tightening pressure of 5N m Fix the 6 nuts 5 that join the fan structure and the connections board Insert the 2 plastic screws M3x8 DIN 933 Insert the Phillips screw M3x8 DIN 7895H of the chassis Connect the NTC cable SERVICE MANUAL 79 50700 POWER ELECTRONICS 7 2 10 SINGLE PHASE Assembly of the single phase chokes CHOKES 1 Fix the new single phase chokes to the Disassembly of the single phase chokes ch
80. SD Series VARIABLE SPEED DRIVE Variable Speed Drive Service Manual Edition February 2011 SD70MS01CI Rev C 50700 POWER ELECTRONICS 2 SAFETY SYMBOLS Always follow safety instructions to prevent accidents and potential hazards from occurring WARNING This symbol means inadequate operation and may result in serious personal injuries or death This symbol Identifies shock hazards under certain conditions Particular CAUTION attention should be given as dangerous voltage might be present Maintenance operation should be done by qualified personnel Identifies potential hazards under certain conditions Read the message and follow the instructions carefully Identifies shock hazards under certain conditions Particular attention should be given as dangerous voltage might be present Edition of February 2011 This edition could present technical imprecisions or misprints The information here included will be periodically modified and updated and all those modifications will be incorporated in later editions In order to consult the most updated information of this product you might access our website www power electronics com where the latest version of this manual can be downloaded SERVICE MANUAL POWER ELECTRONICS 50700 INDEX SAFETY INSTRUCTIONS tudes feccdeacedatosaacacceusesetedsdeckenscedeadeeeacnt 5 1 INTRODUCTION a e
81. T Disassembly of IGBT Before removing the IGBT s you should remove the embellishers see section 7 4 1 the tray for the boards see figure 7 4 7 and the upper gate drive board see section 7 4 10 See the figure 7 4 13 while following the next instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the output bars ghich are connected to the power cable of the dV dt choke the cable for the IGBT s temperature and the flat cable see figure 7 4 13 a 3 Remove the screws M6x12 DIN 7895H which fix the capacitors and the bus bar to the IGBT see figure 7 4 14 a 4 Remove the 4 screws M5X16 DIN 7895H which fix the IGBT to the heatsink 5 Remove the IGBT Figure 7 4 14 Disassembly the IGBT DUM Figure 7 4 14 Assembly of the IGBT 1 Continue with the safety conditions which are described in the previous section 2 Spread the area of the heatsink where the IGBT is going to be placed with new thermal paste 3 Put the IGBT matching the fixing holes see figure 7 4 14 4 Insert the fixing screws for the IGBT M5X16 DIN 7895H and tighten them at 5 N m 5 Connect the output bars and the capacitors with the bus bar POWER ELECTRONICS 50700 7 4 12 CURRENT TRANSFORMERS Disassembly of the current transformers Before removing the transformers you should remove the embellishers see section
82. ab of the RJ45 connector and pull it up 3 Disconnect all cables from the control Figure 7 1 1a terminals of the drive analogue inputs and outputs digital inputs and outputs PTC 5 Disconnect the power supply cables of the input fans in the embellishers 6 Remove the embellishers Display 2 E Figure 7 1 2 Access to the inside of the drive 5070 C de control Figure 3 1 Display connection and control terminals Assembly of the embellishers 1 Place the embellishers on the supports of the drive s sides as the figure 7 1 1a shows 64 SERVICE MANUAL POWER ELECTRONICS 2 Screw the embellishers to the supports of the sides with 3 Phillips M4x8 DIN 7895H screws Connect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input Connect the Display by means of the ethernet cable which goes from the display to the drive SD700 7 1 2 DOOR Disassembly of the door See the figure 7 1 3 while following the next instructions 1 2 Remove the door by unscrewing 4 Phillips M4x8 DIN 7895H screws Disconnect the ethernet cable from the display Remove the display from the support of the door Remove the door Figure 7 1 3 Remove the door Assembly of the door Put the display on the support of the door Connect the ethernet cable of the display
83. able PCB of trigger thyristors see section 7 4 7 and the power connections board see figure 7 4 10 1 Disconnect the 2 power cables from the DC bus with the 2 screws 5 12 DIN 7895H 2 Remove the 4 Phillips screws M4x8 DIN 7895H which join the bus and the chassis 3 Remove the DC Bus Figure 7 4 12 Disassembly of DC Bus Assembly of DC Bus 1 Put the bus correctly in the chassis matching the holes 2 Insert the 4 Phillips screws 4 8 DIN 7895H that join the bus and the chassis 3 Insert the power connections board see figure 7 4 11 4 Insert the 2 screws M5X12 DIN 7895H which join the power connections board and the DC bus 5 Connect the two power cables to the DC bus with screws M5X12 DIN 7895H SERVICE MANUAL 105 50700 POWER ELECTRONICS 7 4 10 UPPER GATE DRIVE BOARD Disassembly of the upper Gate Drive board Before removing the upper Gate Drive board you should remove the embellishers see section 7 4 1 and the tray for the boards see figure 7 4 7 1 Disconnect the flat cable and the phone cables 2 Remove the 8 screws M3x8 DIN 933 See figure 7 4 13 3 Remove the board Figure 7 4 13 Disassembly of the upper Gate Drive board Assembly of the upper Gate Drive board 1 Put the board in the correct position see figure 7 4 13 2 Insert the 8 screws M3x8 DIN 933 3 Connect the flat cable and the phone cables 106 SERVICE MANUAL 7 4 11 IGB
84. ading these instructions Phone wire 1 Disconnect the phone wires which connect this board to the lower Gate Drive 2 Unscrew the Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 3 Remove the upper Gate Drive Assembly of the upper Gate Drive Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board Figure 3 18 Assembly of the upper GateDrive 2 Place the new board on the hexagonal spacers M3x18 figure 3 18 3 Screw 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 4 Connect the phone cables 126 SERVICE MANUAL POWER ELECTRONICS 7 5 17 IGBT Disassembly of the IGBT Before p roceeding the upper Gate Drive board must have been disassembled section 7 5 17 The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 19 a and figure 3 19 b while reading these instructions 1 Condensador Snubber DC Bus Unscrew the 4 hexagonal spacers M3x18 where the upper Gate Drive is inserted Unscrew the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs Remove the DC Bus section 7 5 12 Remove the snubber capacitors Figure 3 19 Disassembly of the IGBT a 50700 5 Unscrew the 3 Phillips screws M6x20 DIN 7895H which join the IGBT and the bar where DCCTs are inserted
85. agonal screws M5x20 which join the capacitor and the Bus Remove the Bus Remove the Bus and the middle Bus insulator Unscrew the special hexagonal screws M5x20 which join the middle Bus and the capacitors Remove the middle Bus Take out the capacitors of their rings Assembly of the Bus capacitors Place the new capacitors in their rings Insert the middle Bus figure 6 13 Screw the special hexagonal screws M5x20 Insert the Bus and the middle Bus insulator Insert the Bus figure 6 13 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors Place the Bus and the Bus insulator Insert the Bus figure 6 13 Screw special hexagonal screws M5x20 which join the Bus and the capacitors 1 4 SERVICE MANUAL POWER ELECTRONICS Figure 6 13 Disassembly of the Bus capacitors POWER ELECTRONICS 50700 7 8 12 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 14 while reading these instructions Disconnect the IGBT trigger wire which connects this board to the Power board 2 Disconnect the 3 NTC wires which connect this board to the upper Gate Drive 3 Unscrew the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 4 Unscrew the 2 slotted cheese head screws M3x30
86. al paste over the back of the IGBT 4 Place the IGBT on the heat exchanger 5 Screw the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 6 Place the DCCT Bar as it is shown in figure 6 16 7 Insert the DC Bus section 7 8 10 8 Place the Snubber capacitor on the DC Bus f 5 16 EE Figure 6 16 6 Disassembly of the IGBT 50700 7 8 15 SCRs Disassembly of the SCRs Before proceeding the Upper cover section 7 8 2 the Snubber Trigger and Soft charge board section 7 8 6 and the DC Bus section 7 8 10 must have been disassembled Follow figure 6 17 a and figure 6 17 b while reading these instructions 1 Unscrew the hexagonal screws M8x25 DIN 933 which join the bars and the SCRs 2 Remove voltage measure wires after the AC choke by unscrewing the Phillips screws M4x8 DIN 7895H which join these wires and the bars 3 Remove the bars 4 8 After AC choke current measurement Z GEO Figure 6 17 Disassembly of the SCR SERVICE MANUAL 177 50700 Unscrew the 2 Phillips screws M5x12 DIN 7895H which join the SCR and the heat exchanger 5 Disassemble the SCR Figure 6 17 b Disassembly of the SCR Assembly of the SCRs 1 Spread the thermal paste over the back of the new SCR 2 Insert the SCR in the heat exchanger figure 6 17 3 Screw the 2 Phillips screw
87. al screws 8 25 DIN 933 which join the output choke and DCCT bar and output bar 3 Remove the output choke Figure 4 11 Disassembly of the output choke Assembly of the output choke 1 Insert the output choke as it is shown in figure 4 11 2 Connect the terminals of the output choke wire to the DCCT bar and output bar by screwing the 2 hexagonal screws 8 25 DIN 933 3 Insert the fan tray by screwing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the chassis SERVICE MANUAL 137 50700 7 6 9 DCCT Disassembly of the DCCT Before proceeding the output choke must have been disassembled section 7 6 8 Follow figure 4 12 while reading these instructions 1 Unscrew the 2 Phillips screws 4 12 DIN 7895H which join the DCCT and the DCCT bakelite 2 Disconnect the current measure cable 3 Disassemble the DCCT 4 12 Figure 4 12 Disassembly of the DCCT Assembly of the DCCT 1 Insert the new DCCT in the DCCT bakelite 2 Join the DCCT and the DCCT bakelite by screwing the 2 Phillips screws 4 12 DIN 7895H 3 Connect the current measure cable 138 SERVICE MANUAL POWER ELECTRONICS 7 6 10 CHASSIS SIDES Disassembly of the chassis sides Before proceeding covers section 7 6 1 the electric tray section 7 6 12 the fan tray section 7 6 8 the output bakelite section 7 6 12 and the upper and lower covers section 7 6 2 must have been dis
88. and after the chokes by the Phillips screws M4x8 DIN 7895H which join the cable terminals and the Board 74 4 1 Figure 4 8 Disassembly of the Snubber Trigger and Soft Charge protection 2 Disconnect all output wiring figure 4 8 b SCR tigger Before AC choke voltage measure Soft charge resitance SCR tigger After AC choke sb voltage measure Figure 4 8 b Disassembly of the Snubber Trigger and Soft Charge protection SERVICE MANUAL 135 50700 5 Unscrew the 3 Phillips screws on M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Unscrew the 3 Phillips screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Remove the Board Assembly of the Snubber Trigger and Soft Charge protection board 1 2 Avoid an excessive handling of the new board Place the Board in the position shown in the figure 4 8 c Screw the 3 screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x15 Connect all input wiring voltage measure cable before and after the AC Chokes by screwing the Phillips screw M4x8 DIN 7895H which joins the wire terminals and the board figure 4 8 a Connect all output wiring figure 4 8 b 136 SERVICE MANUAL POWER ELECTRONICS Figur
89. and the chassis sides M 3 Remove the ourput bakelite Electronic tray 4 8 Figure 3 15 Disassembly of the DC Bus a 2 Disassembled the Snubber capacitors by unscrewing the Phillips screws M6x12 DIN Figure 3 14 Disassembly of the output bakelite 7895H which join the snubbers capacitors and the DC Bus 3 Remove the plastic hexagonal spacers Mix3x10 which are inserted in the DC bus Assembly of the output bakelite Assembly of the output bakelite and where the Snubber PCB leans 1 Place the output bakelite in the SD700 following figure 3 14 4 Remove the plastic hexagonal spacers Mix3x15 which are inserted in the DC bus 2 Screw 4 Phillips screws M4x18 DIN and where the Snubber PCB leans 7895H which join the output bakelite to the chassis sides 3 Screw 2 Phillips screws M6x20 DIN 7895H which join Bus output terminals and the DC Bus 122 SERVICE MANUAL POWER ELECTRONICS 50700 3 104 5 Screw 4 Phillips screws 4 8 DIN 7895H which join the DC Bus and the SCRs heat 6 12 l exchanger Snubber Capacitors M4x8 Figure 3 15 Disassembly of the DC Bus b 5 Disassemble one chassis side section 7 5 10 Figure 3 15 Disassembly of the DC Bus c 6 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger j
90. ard on the hexagonal spacers M3x20 making the holes fit 3 Push the 40 32 y 28 pins connectors down Do not apply excessive force 4 Screw the 6 plastic screws M3x8 DIN 933 in the plastic hexagonal spacers M3x20 182 SERVICE MANUAL POWER ELECTRONICS 7 9 4 POWER BOARD Disassembly of the Power Board Before proceeding the Control Board must have been disassembled section 7 8 3 Follow figure 7 6 a and figure 7 6 b while reading these instructions 1 Disconnect all the wires which are connected to this Board Before AC choke voltage measurement DC Bus Voltage measurement Quickly discharge Or SCR Trigger 2 gt resistor Fan supply i After Ac choke im voltage measurement measurement Figure 7 6 a Disassembly of the Power Board wires 2 Remove the 6 plastic hexagonal spacers M3x20 which are inserted in the Power Board 3 Unscrew the 5 Phillips screws M3x8 DIN 7895H 4 Disassemble the Power Board Assembly of the Power Board Continue to observe static safe work procedures Avoid an excessive handling of the new Control Board 1 Putthe new board on the electric tray and fit the holes with the electric tray bolts figure 7 6 a 2 Screw the 5 Phillips screws M3x8 DIN 7895H on the electric tray bolts 3 Connect all the wiring of the Power board figure 7 6 a POWER ELECTRONICS M3x20 Figure 7 6 b Disassembly of the Po
91. assembled Follow figure 4 13 while reading these instructions 1 Disassemble the chassis reiforcements 2 Unscrew the 4 hexagonal screws M8x18 DIN 933 which join the sides to the chassis 3 Remove the sides Chassis refoircement 5 Figure 4 13 Disassembly of the chassis sides Assembly of the chassis sides 1 Join the sides and the chassis by screwing the 7 hexagonal screws M8x18 DIN 933 2 Join the chassis reiforcements POWER ELECTRONICS 7 6 11 OUTPUT BAKELITE Disassembly of the output bakelite Before proceeding the covers see section 7 6 1 and the electric tray see section 7 6 12 must have been disassembled Follow figure 4 14 while reading these instructions 1 Unscrew the 2 Phillips screws M6x20 DIN 7895H which join the Bus output terminals and the DC Bus 2 Unscrew the 4 Phillips screws M4x18 DIN 7895H which join the output bakelite and the chassis sides 3 Remove the output bakelite Figure 4 14 Disassembly of the output bakelite Assembly of the output bakelite 1 Insert the output bakelite in the 0700 following figure 4 14 2 Screw the 4 Phillips screws M5x16 DIN 7895H which join the output bakelite and the chassis sides 3 Screw the 2 Phillips screws M6x20 DIN 7895H which join the Bus output terminals and the DC Bus 50700 7 6 12 DC BUS Disassembly of the DC Bus Before proceeding the Snubber Trigger and Soft Charge board see section 7
92. assis by using the nuts M5 In order to remove the single phase choke you 2 Take the cables of the chokes toward the should remove the embellishers see section top of the chassis see figure 7 2 18 7 2 1 and the tray for the boards see figure 7 2 7 before 1 It is necessary to disconnect the power cables in order to remove the single phase chokes from the chassis of the drive For this disconnect the power cables which are connected to the power connections board see figure 7 2 17 2 Remove the 6 nuts 5 which join the fan structure and the power connections board see figure 7 2 14 Figure 7 2 18 3 Connect the cables of the chokes to the power connections board see figure 7 2 17 4 Approach and fix the fan structure to the power connetions board by using the 6 nuts M5 5 Assembly again the top of the chassis qith the bottom of the chassis by using the 4 screws M6X16 DIN 7895H Figure 7 2 17 _ 3 Remove the 4 screws M6X16 DIN 7895H which join the upper chassis and the lower chassis 4 Remove the top of the chassis and put it face down see figure 7 2 18 Figure 7 2 18 5 Remove the 8 nuts 5 which fix the chokes to the chassis 6 Remove the chokes 80 SERVICE MANUAL POWER ELECTRONICS 7 2 11 DV DT CHOKES Disassembly of dV dt chokes It is necessary to remove the embellishers see section 7 2 1 the tray for the boards see figure 7 2 7 and separate the top of the chas
93. bars figure 7 16 a Insert the voltage measure wires after the AC Choke by imscreing the Phillips screws M4x8 DIN 7895H which join their wires and the bars Screw the Phillips screws M6x20 DIN 7895H which join the bars and the AC Choke Screw the Phillips screws M6x16 DIN 7895H which join the bars and the SCRs POWER ELECTRONICS 7 9 16 POWER FAN Disassembly of the Fan support Folow figure 7 20 while reading these instructions 1 Unscrew the Phillips screw M4x8 DIN 7895 which joins the fan support and the fan box 2 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Disconenct the fan power wire 4 Remove the fan support Figura 7 20 Disassembly of the fan support POWER ELECTRONICS 24VDC 2A 48W 172X172 FAN Follow figure 7 21 while instructions reading these Unscrew the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan and its support M4x60 Figure 7 21 Disassembly of the fan 24VDC 89W 172X172 FAN Follow figure 7 22 while instructions reading these Unscrew the 2 Phillips screws M4x12 DIN 7895H which join the power fan and 15 support Figure 7 22 Disassembly of the fan Assembly of the Fan power support 1 Before introducing the fan support in the fan box connect the fan power wire 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output
94. board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN 933 Figure 7 1 8 Disassembly of the power board 68 SERVICE MANUAL POWER ELECTRONICS 7 1 7 GATE DRIVE BOARD Disassembly of Gate Drive board Before removing the gate drive board it is necessary to remove the embellishers and the tray where control and power boards are inserted see sections 7 1 1 7 1 4 7 1 15 See figure 7 1 9 2 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 3 Disconnect the braking cable the bus cable and the cable for connections of the gate drive board Figure 7 1 9 Disassembly of the gate drive board 4 Unscrew the 3 Phillips screws M3x6 DIN 7895H 5 Remove the board Assembly of Gate Drive board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the gate drive board avoid an excessive handling of the board 3 Pick the new gate drive board from the Static proof bag 4 Put the board in the correct position as the figure 7 1 9 shows matching the holes 5 Insert the 3 Phillips screws M3x6 DIN 7895H 6 Connect the braking cable the bus cable and the cable for connections of the gate drive board 50700 7 1 8 DC BUS Disassembly of the DC Bus Before proceeding it is necessary to remove the embellishers see section 7 1 1 the tray where control a
95. ch join the cover and the upper part of the chassis 5 Unscrew the 2 Phillips screws M4x8 DIN 7895H which joint the cover and the lower part of the chassis 8 In IP54 models disconnect the fan power wires which are in the covers before disassembling them 9 Remove the covers 132 SERVICE MANUAL POWER ELECTRONICS M4x12 M4x12 Fan IP54 terminals outputs plastic protectors Covers 4 8 4 8 Assembly of the SD700 Covers 1 Place the covers on the chassis as it is shown in figure 4 2 2 In IP54 models connect the fan power wires which are in the covers before placing them 3 Screw the 2 Phillips screws M4x12 DIN 7895H which join the covers and the upper part of the chassis 4 Screw the 2 Phillips screws M4x8 DIN 7895H which join the covers and lower part of the chassis 5 Connect control terminals analogue inputs digital inputs PTC 6 Connect the Display to the Control PCB Removal of the plastic protector 1 Unscrew the 4 Phillips M4x8 DIN 7895 H which join the plastic protector and the SDrive chassis 2 Remove the plastic protector Assembly of the plastic protector 1 Place the power terminals plastic protector on the SDrive chassis by screwing 4 Phillips M4x8 DIN 7895H POWER ELECTRONICS 7 6 2 UPPER COVER Disassembly of the upper cover Follow Figure 4 4 while instructions reading these 1 Unscrew the 6 Phillips M4x8 DIN 7895H wh
96. choke support 3 Screw the Phillips screw M4x8 DIN 7895H which join the fan support and the fan box 50700 7 9 17 Disassembly of the AC Choke Before proceeding the bars which join the AC choke and the SCRs section 7 9 15 and the Upper cover section 7 9 2 must have been disassembled Follow figure 7 23 while instructions reading these 1 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 2 Remove the AC choke out of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN 961 which join the power wires and the AC choke 3 Disassemble the AC choke Figure 7 23 Disassembly of the AC choke Assembly of the AC choke 1 Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN 961 2 Place the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis SERVICE MANUAL 195 POWER ELECTRONICS 8 Parts list All SD700 components have a code which give us all the information about the component These codes have between 4 and 6 digits 1 digit kind of component C Printed circuits L Electrics E Electronics M Mecanics P Power V Others O O OOOO 2 29 4 digit number of the component 5 digit Revision of component 6 digit Only in electronic components It sh
97. ct the 3 cables from the thyristors and the communication cable from the pluggable PCB Figure 7 4 8 Disassembly of the Drive Select board Assembly of Drive Select Board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN 933 Figure 7 4 9 Disassembly of the pluggable PCB of trigger thyristors 3 Remove the 4 plastic screws M3x8 DIN 933 which join the back of the board to the 4 hexagonal plastic spacers M3x10 which are inserted in the bus bars and the power connections board 4 Remove the board Disassembly of the pluggable PCB of trigger thyristors 1 Continue with the safety conditions which are described in the previous section 2 While replacing the pluggable PCB of trigger thyristors avoid an excessive handling of the board 3 Pick the pluggable PCB of trigger thyristors from the static proof bag 4 Put the board in the proper position as the figure 7 4 9 shows matching the holes in the hexagonal plastic spacers M3x10 and plug the board in the connector of the power connections board SERVICE MANUAL 103 50700 5 Insert the 4 plastic screws M3x8 DIN 933 which join the back of the board to the hexagonal plastic spacers M3x10 6 Connect the cables to the thyristors and the communication cables to the power board trigger thyristors 104 SERVICE MANUAL POWER ELECTRONICS 7 4 8 POWER COINNECTIONS BOARD Disassembly of
98. curred by closing a contact in the digital input configured in this option Active in Pump Control mode only Actions Check if the pressure of the installation exceeds the set limits Verify the wiring of digital input Fault 67 LOW WATER Descrtiption An external trip occurred when the Pump Program G25 is activated and one of the digital inputs has been set as 59 LO WATER FLT Under these conditions if a contact is opened in such digital input the drive trips indicating that the pump is working with no load Posible cause An external trip occurred by opening a contact in the digital input Active in Pump Control mode only Actions A contact has been activated to indicate that there is a fault due to lack of water Verify the conditions of the installation Verify the wiring of digital input Fault 68 CAVIT UNDERL Descrtiption When the motor current is lower than the cavitation current and the motor speed 15 higher equal than the cavitation speed during the time set for that purpose the drive will trip This avoids that the pump operates with no water detection is done due to underload Posible cause Settings of the drive in protections group G25 6 are incorrect Actions Check if the pump of the installation is operating withoug water Verify the settings of the parameters referred to the cavitation protection depending on the installation Fault 69 FLOW SWITCH Description The digital input configured a
99. d and slightly push the control board down to connect the pins Once the board is properly placed screw the 6 plastic screws M3x8 DIN 933 in the corresponding hexagonal plastic spacers M3x20 SERVICE MANUAL POWER ELECTRONICS 7 2 5 POWER BOARD Disassembly of the power board Before proceeding the control board must have been disassembled see section 7 2 4 See the figure 7 2 6 while reading the following instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the wires which connected to this board Before AC choke voltage measurement DC Bus Voltage measurement Quickly discharge SCR Trigger 2 resistor PAN Fan supply After Ac choke voltage measurement Output voltage measurement Figure 7 2 6 Disconnect all connected wires from power board 3 Remove the 6 hexagonal plastic spacers M3x20 which are joined to the electronic tray and support the control board 4 Unscrew the 5 Phillips screws M3x8 DIN 7895H 5 Remove the power board of the drive Assembly of the power board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the power board avoid an excessive handling of the board 3 Pick the new power board from the static proof bag 4 Put the new power board in the same place than the replaced on
100. d check motor insulation Check and improve the ground connection system Fault F21 I LIM T O Description Motor current has exceeded the current limit set in G10 5 I LIMIT for the time set in G10 6 I LIM Possible cause Motor stalled Heavy load Motor mechanical brake is coupled Actions Check the motor load Increase maximum current limit Fault F22 TQ LIM T O Description Motor torque has exceeded the torque limit set in parameter G10 7 MAX TOR for the time set in G10 8 T LIMT TO Possible cause Motor stalled Heavy load Motor mechanical brake is coupled Actions Check the motor load Increase maximum current limit Fault F25 MTR O L Description Motor overload calculated by SD700 thermal model has exceeded 110 Possible cause High current injected to the motor due to heavy load The load exceeds the capacity of motor cooling under normal operating conditions Incorrect setting of the thermal model parameters Phase loss of the motor or a fault in motor windings Actions Check the motor load Check the setting of parameters G2 1 MTR CUR and G2 7 MTR COOL related to the motor thermal model Increasing the parameter G2 7 MTR COOL can be undertaken when there is a motor PTC fitted and it is connected to the SD700 Fault F27 DL SMTH Descrtiption DC Bus has not been charged in the expected time SERVICE MANUAL 15 50700 POWER ELECTRONICS 16 Posible cause Potential damage to the so
101. d the bars 3 Remove the bars After AC choke voltage measurement Figure 4 17 Assembly of the IGBT b Figure 4 18 Disassembly of the Soft charge and quick discharge resistors a 4 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the resistors support and the chassis 5 Remove the resistors SERVICE MANUAL 145 50700 POWER ELECTRONICS Soft charge resistors 7 6 18 SCRs Quickly discharge resistor Disassembly of the SCRs Before proceeding the bars which join the AC choke and the SCRs must been disassembled section 7 6 17 Follow figure 4 19 while reading these instructions 1 Unscrew the 2 Phillips screws M5x20 DIN 7895H which join the SCR and the heat exchanger 2 Remove the SCR Figure 4 18 Assembly of the Soft charge and quick 4 E e discharge resistors b Assembly of the Soft charge and quick 9 E discharge resistors 2 1 Insert the resistors support on the chassis 2 Screw the 4 Phillips screws M4x8 DIN 7895H which join the resistors support with the chassis m 3 Insert the bars figure 4 19 4 Insert the voltage measure cable after the X DDK A Choke by unscrewing the Phillips DM screws M4x8 DIN 7895H which join the Figure 4 19 Disassembly of the SCR wires and the bars 5 Screw the hexagonal screws M8x25 IN 933 895H which join the bars and the AC Choke Assembly of the SCRs 6 Screw the
102. designed to be serviced as components They are usually complex and require special test equipment for servicing 1 4 Notes It is the integrators responsibility to ensure the configuration and installation of the 50700 meets the requirements of any specific site local and national electrical regulations is the responsibility of the end user purchaser to ensure that operators understand how to use this equipment safely Please read this manual carefully SERVICE MANUAL 9 50700 POWER ELECTRONICS 2 BEFORE STARTING TESTING OR SERVICE WORK Site Preparation The SD700 is best serviced on a bench if it is possible The working area in front of the SD700 must be clean and tidy especially while servicing the biggest and heaviest SD700 sizes Flat surfaces for placing parts on and containers for small items like screws and bolts will be necessary Tools requirements No 2 Phillips screwdriver No 3 Phillips screwdriver 17 mm nut drivers 13 mm nut drivers 10 mm nut drivers Multimeter upto 1000V AC and DC maximum Variac Safety and Testing Before Starting Repairs 1 Isolate and lock out the mains supply to the 50700 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 be discharged 3 Test between input terminals L1 L2 13 and L1 L2 L3 to earth to ensure the supply has been disconnected 4 Test between the HVDC and HV
103. difference between both measurments the replacement of the DC Bus will be necessary In order to test the capacitors individually the DC Bus capacitors must have been disassembled from the SD700 and afterwards must be disassembled Every capacitor must be measured with a multimeter and all of them must be discharged The tester must be set in mode OHMS Then the positive of the tester must be conneted to the positive of the capacitor and repeat the operation with the negative If the capacitor works properly the resistance should start low and then increase as the capacitor is charged due to the voltage in the battery of the tester 6 4 Individual IGBT test In order to test an IGBT the use of a static grounding wrist strap and being earthed is necessary When the SD700 is disassembled the IGBTs can be tested individually as it is shown in figure 2 8 60 SERVICE MANUAL POWER ELECTRONICS 50700 EIE 10 to P C 22 53 14 08kf Figure 2 8 IGBT testing 6 5 Soft Powering After Repair Once all faulty components have been replaced and the SD700 has been dully reassembled a SD700 softpowering test is highly recommended through the plug in of an extgernal soft power supply unit called Variac This power supply generates 600 Vac Connect the Variac to HVDC Bus terminals Then when the Variac is on it is necessary to increase voltage little by little and check that LEDS of the Power Supply and the leds of the upper gater drive
104. e 5 Put the board on the electronic tray matching the bolts of the tray with the holes of the board see figure 7 2 7 POWER ELECTRONICS 6 Once the board is properly placed screw the 5 Phillips screws M3x8 DIN 7895H in the bolts of the electronic tray 7 Connect the cables to the corresponding connectors see figure 7 2 6 8 Put the hexagonal plastic spacers M3x20 screwing them in their corresponding bolts of the electronic tray in order to place the control board later M3x20 M3x8 27 Figure 7 2 7 Disassembly of the power board 50700 7 2 6 DRIVE SELECT BOARD Disassembly of the Drive Select board Unscrew the 2 plastic screws M3x8 DIN 933 which join this board and the plastic hexagonal spacers M3x12 Mix t Drive Select Figure 7 2 8 Disassembly of the Drive Select board Assembly of the Drive Select board Put the drive select board on the 2 plastic hexagonal spacers M3x13 and join them with 2 plastic screws M3x8 DIN 933 SERVICE MANUAL 77 50700 7 2 7 GATE DRIVE BOARD Disassembly of the Gate Drive board Before removing the gate drive board it is necessary to remove the embellishers and the tray where control and power boards are inserted see sections 7 2 1 7 2 4 7 2 15 See figure 7 2 9 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit 2 Disconnect the braking cable the bus cab
105. e reasons for failure and suggested corrective actions follows 4 4 1 Supply fuses Function Protect mains Place In the 3 SD700 input phases Possible reason for failure Supply surge Age or cyclic stress failure wrong fuses fault in supply cable rectifier or inverter fault Action Take out the covers and make a visual inspection Check that there is no fire or a blast sign Check the 50700 and follow figure 1 3 instructions to verify that any short circuit occurredt Each test 15 carried out 3 times i e once per phase which makes a total of 12 test IC BUS Ok IET _ SS 5 Figure 1 3 Display Fault L3 SERVICE MANUAL 23 50700 POWER ELECTRONICS 4 4 2 Fuses Frame 1 a Fuses of the Power Board In the power board there are 2 fuses located where the figure 1 4 shows FUSE FUSE 2 _ s He m 3 _ EH a __ TE mad ii ET Adm DRRECEEE E T 1 ad ideals H B k b LL al UNE X ad Figure 1 4 Fuses of the power board Fuse 1 and Fuse 2 Function protection for the fast charge circuits of the b
106. e 3 5 Match the male connector of 40 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins Once the board is properly placed screw the 6 plastic screws M3x8 DIN 933 in the corresponding hexagonal plastic spacers M3x20 SERVICE MANUAL 101 50700 POWER ELECTRONICS 7 4 5 POWER BOARD 6 Once the board is properly placed screw Disassembly of the power board the 6 Phillips screws M3x8 DIN 7895H in the bolts of the electronic tray Before proceeding the control board must have been disassembled see section 7 4 4 7 Connect the cables to the corresponding connectors see figure 7 4 6 See the figure 7 4 6 while reading the following instructions 8 Put the hexagonal plastic spacers M3x20 screwing them in their corresponding bolts 1 The use of a static grounding wrist strap of the electronic tray in order to place the and being earthed is highly required to control board later repair the unit 2 Disconnect all the wires which connected to this board Before AC choke voltage measurement DC Bus Voltage measurement M3x20 Quickly discharge j on SCR Trigger 2 2 j resistor Fan supply After Ac choke voltage measurement 4 TT pos i measurement M3x8 Figure 7 4 6 Disconnect all connected wires from power board Output voltage measurement 3
107. e 4 8 c Disassembly of the Snubber Trigger and Soft Charge protection POWER ELECTRONICS 7 6 7 FANS POWER SUPPLY Disassembly of the fans power supply The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 10 while instructions reading these 1 Disconnect the 2 fans power wires and the power wire of the fan power supply 2 Unscrew the 3 Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Remove the fan power supply M3X6 M3X6 T Fans power supply powel L Fans power 4 5 W 120x120 Fan Only in IP54 models Figure 4 10 Disassembly of the fans power supply Assembly of the fans power supply Continue to observe static safe work procedures 1 Place the new fans power supply in the fan tray 2 Screw the 3 Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Connect the 2 fans power wires and the power wire 50700 7 6 8 OUTPUT CHOKE Disassembly of the output choke Follow figure 3 10 while instructions reading these 1 Remove the fan tray by screwing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the chassis sides In IP54 models before disassembling the fan tray the fan power wire must have been disconnected IPOO and IP20 models have not any fan in this tray 2 Unscrew the 2 hexagon
108. e 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the chassis SERVICE MANUAL 50700 POWER ELECTRONICS SCRs heat exchanger 6 Insert the plastic hexagonal spacers M3x10 on the DC Bus where the back of the Snubber Trigger and Soft Charge Board leans 4 Screw the 6 Phillips screws M6x12 DIN M3x10 7895H which join the DC Bus and the M3x15 1 SCRs 5 Screw the 2 Phillips screws M4x8 DIN er Snubber 7895H which join the DC Bus and the ie capacitor lt lt 7 Insert the hexagonal spacers M3x15 on the DC Bus where the front of the Snubber Trigger and Soft charge Board leans 8 Place the Snubbers capacitors on the back of the DC Bus see figure 4 15 by screwing the Phillips screws M6x12 DIN 7895H 9 Insert the chassis side see section 7 6 10 10 Insert the electronic tray where the Power and the Control Board are joined by screwing the 4 Phillips screws M4x8 DIN Figure 4 15 Disassembly of the DC Bus b 7895H 4 8 Electronic tray 24 a Figure 4 15 Disassembly of the DC Bus c Figure 4 15 Disassembly of the DC Bus a 140 SERVICE MANUAL POWER ELECTRONICS 7 6 13 BUS CAPACITORS Disassembly of the Bus capacitors Before proceeding the DC Bus must have been disassembled section 7 6 12 Follow figure 3 16 while reading these instructions 1 Unscrew the specials hexagonal screws M5x20 which join
109. e 7 3 15 Disassembly of the current transformers Assembly of the current transformers 1 Insert the Phillips screws 4 8 DIN 7895H and fix the transformers to the chassis 2 Connect the cables of the current transformers 3 Putthe cables of dV dt chokes on the inside of the transformers and connect them to the output by using 3 screws M6x16 DIN 7895H and thighten at 5 N m 92 SERVICE MANUAL POWER ELECTRONICS 7 3 13 AC CHOKE Disassembly of the AC choke In order to remove the AC choke first you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 the power connections board see section 7 3 8 the DC bus see section 7 3 9 and the tray where the connections board is supported see figure 7 3 16 See the figure 7 3 17 while following the next instructions Figure 7 3 16 1 It is necessary to remove the power cables in order to remove the AC choke from the drive s chassis For this remove the power cables like this see figure 7 3 17 2 Remove the 4 Phillips screws M6x20 DIN 7895H that join the AC choke to the supports of the chassis see figure 7 3 17 gt Figure 7 3 17 POWER ELECTRONICS 3 Remove the AC choke see figure 7 3 18 Ac choke Figure 3 18 Disassembly of the AC choke Assembly of the AC choke 1 Insert the AC choke inside the chassis 2 Fix the AC choke to the chassis by using the 4 screws M6x20 DIN 7
110. e PCBs The upper gate drive controls the IGBTs logic pulses and detects an IGBT desaturation The lower Gate Drive contains the shot resistors and the protection varistors 3 3 Power PCB This PCB contains the following circuits Switch mode Power supply generates all required DC voltages SCR pulses generation generates the SCR firing pulses for soft charge ramp Protections Protections for a high and low Bus voltage shortcircuits and high temperature Drive Select module It is plugged to the power PCB shows the rating identification and scales the DCCT outputs for relaying to the control PCB 3 4 Control PCB This PCB generates the waveform control input and output processing mode selection and parameters setting It also controls an alohanumeric display and keypad for user interface SERVICE MANUAL 11 50700 POWER ELECTRONICS 4 FAULT MESSAGES DESCRIPTIONS AND ACTIONS 4 1 Introduction When a fault occurs the SD700 will stop the motor and show a fault in the display You can display this fault in the programming line lower line while motor current and the speed values are displayed in the upper line at the moment of the fault It is possible to navigate through the additional display lines to access other status parameters without resetting the fault These additional status parameters offer further information about the moment when the fault occurred Additionally the FAULT led will blink and the fa
111. e fan Figure 7 4 27 Assembly of the power heatsink fan 1 Putthe new fan and fix it with the screws 2 Connect the power supply cable to the fan Disassembly of the fan for the toroids See figure 7 4 28 while following ther next instructions 1 Disconnect the power supply cable 2 Remove the 4 slotted cheese head screws M4x40 DIN 84 which join the fan with the chassis 3 Remove the fan Figure 7 4 28 SERVICE MANUAL 111 50700 POWER ELECTRONICS 7 4 17 HEATSINK Assembly of the heatsink Disassembly of the heatsink 1 Put the new heatsink in the correct position and fix it with their 4 Phillips screws M5x12 In order to remove the heatsink first you should DIN 7895H remove the embellishers see section 7 4 1 the tray for the boards see figure 7 4 7 the power 2 Take the thyristors and the lower gate drive connections board see section 7 4 8 the board and spread the thermal conductor connection bars for the thyristors see figure paste on the bottom see figure 7 4 31 7 4 10 a the bus bars see figure 7 4 17 a the DC bus see section 7 4 9 the upper gate drive 3 Follow all the steps described previously in board see section 7 4 10 the IGBT s see order to insert all the components again section 7 4 11 the thyristors see section 7 4 15 and the fans only the fan for the power heatsink See section 7 4 16 1 Remove the 2 Phillips screws 5 12 DIN 7895H which fix th
112. e figure 7 2 7 the gate drive board see section 7 2 7 the DC bus see section 7 2 8 and the power connections board see section 7 2 9 1 Once removed the components mentioned before remove the screws that join the upper chassis and the lower chassis see figure 7 2 18 2 Remove the 4 screws M5X10 that fix the heasink to the chassis of the drive see figure 7 2 24 See figure 7 2 24 3 Remove the heatsink Assembly of the heatsink 1 Fix the new heatsink to the chassis by using 4 screws M5x10 with a tightening pressure of 3N m 2 Join the top and the bottom of the chassis 3 Spread the heatsink area where the IGBT of the power connections board 15 going to be placed with thermal conductor paste 4 Fix the power connections board see section 7 2 19 5 Fix the DC bus see section 7 2 8 6 Fix the gate drive board see section 7 2 7 82 SERVICE MANUAL POWER ELECTRONICS 1 1 13 FANS Disassembly of the fan of the heatsink 1 Remove the lower cover see section 7 2 3 2 Disconnect the power supply cable 3 Remove the 2 screws M4x45 DIN 84 that fix the fan to the structure see figure 7 2 25 4 Remove the fan Figure 7 2 25 Assembly of the fan of the heatsink 1 Put the new fan and fix it with the screws 2 Connect the power supply cable 3 Fix the cover Disassembly of the fan of the lateral internal cover 1 Remove the lateral internal cover see section 7 2 1
113. e heatsink to the side of the chassis see figure 7 4 29 Figure 7 4 31 Figure 7 4 29 2 Remove the 2 Phillips screws M5x12 DIN 7895H which fix the heatsink by the top see figure 7 4 30 Figure 7 4 30 3 Remove the heatsink 112 SERVICE MANUAL POWER ELECTRONICS 7 4 18 DISCHARGING RESISTOR Disassembly of discharging resistor In order to remove the discharging resistor first you should remove the embellishers see section 7 4 1 1 Remove the 2 screws M3x6 DIN 7895H which fix the discharging resistor to the electronic tray see figure 7 4 32 2 Remove the discharging resistor Figure 7 4 32 Assembly of the discharging resistor 1 Put the new discharging resistor in the correct position on the electronic tray 2 Fix the discharging resistor to the electronic tray by using the 2 screws M3x6 DIN 7895H 50700 7 4 19 BUS CAPACITORS Disassembly of the bus capacitors It is necessary to remove the DC Bus of the drive before performing this action see section 7 4 9 See figure 7 4 33 while following the next instructions 1 Unscrew the 12 special hexagonal screws M5X10 which fix the capacitors to the electronic board of the bus see figure 7 4 33 2 Remove the electronic board 3 Remove the capacitors which are going to be repaired Figure 7 4 33 Assembly of the bus capacitors 1 Put the new capacitor on the ring which is inserted in the capacitor suppo
114. e reading these DIN 933 which join the Output choke and instructions the DCCT bar and output bar 1 Unscrew the 2 Phillips screws M4x12 DIN 2 Disassemble the output choke 7895H which join DCCT and the DCCT support 8 25 2 Disconnect current measure wire 3 Disassemble the DCCT 1 i A Figure 6 10 Disassembly of the output choke Assembly of the Output choke 1 Insert the output choke as it is shown in figure 6 10 x Figure 6 11 Disassembly of the DCCT 2 Connect the terminals of the wire of the output choke to the DCCT bar and the output bar by screwing the 2 hexagonal screws M8x25 DIN 933 Assembly of the DCCT 1 Place the new DCCT 2 Join the DCCT and the DCCT support by screwing the 2 Phillips screws 4 12 DIN 7895H 3 Connect the current measure wire SERVICE MANUAL 171 50700 7 8 10 DC BUS Disassembly of the DC Bus Before proceeding the Snubber Trigger and Soft charge board must been disassembled section 7 8 6 Follow figure 6 13 a figure 6 13 b figure 6 13 c and figure 6 13 d while reading these instructions 1 Disassemble the electronic tray unscrewing the 4 Phillips screws M4x8 DIN 7895H which join this tray and the side of the chassis 2 Disassemble the snubber capacitors by unscrewing he Phillips screws M6x12 DIN 7895H which join the snubber capacitors and the DC Bus 3 Disassemble the
115. e unit 2 Disconnect all the wires which connected to this board Before AC choke voltage measurement DC Bus Voltage measurement Quickly discharge j on SCR Trigger eA 13 resistor Fan supply 1 After Ac choke voltage measurement Output voltage measurement Figure 7 3 6 Disconnect all connected wires from power board 3 Remove the 6 hexagonal plastic spacers M3x20 which are joined to the electronic tray and support the control board 4 Unscrew the 6 Phillips screws M3x8 DIN 7895H 5 Remove the power board of the drive Assembly of the power board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the power board avoid an excessive handling of the board 3 Pick the new power board from the static proof bag 4 Put the new power board in the same place than the replaced one 5 Put the board on the electronic tray matching the bolts of the tray with the holes of the board see figure 7 3 7 M3x8 7 50700 Once the board is properly placed screw the 6 Phillips screws M3x8 DIN 7895H in the bolts of the electronic tray Connect the cables to the corresponding connectors see figure 7 3 6 Put the hexagonal plastic spacers M3x20 screwing them in their corresponding bolts of the electronic tray in order to place the control board later M3x20 Figure 7 3 7 Disassembly
116. er supply and the chassis side 3 Remove the fans power supply unit Fans power power Figure 3 13 Disassembly of the fan power supply unit Assembly of the fan power supply unit Continue to observe static safe work procedures 1 Place the new fans supply power unit in the side of the chassis figure 3 13 2 Screw 3 Phillips screws M3x6 DIN 7895H which join the fan power supply unit and the side of the chassis 3 Connect the 2 fans power supply cables for the fans and the voltage measure cable SERVICE MANUAL fans supply 121 50700 POWER ELECTRONICS 7 5 12 OUTPUT BAKELITE 7 5 13 DC BUS Disassembly of the output bakelite Disassembly of the DC Bus Before proceeding covers see section 7 5 1 Before proceeding snubber trigger and soft and electric tray section 7 5 5 must have been charge board section 7 5 7 and Bus output disassembled terminals section 7 5 12 must have been disassembled Follow figure 3 14 while reading these instructions Follow figure 3 15 a figure 3 15 b and figure 3 15 while reading these instructions 1 Unscrew the 2 Phillips screws M6x20 DIN 7895H which join the Bus output 1 Remove the electronic tray where the terminals and the DC Bus Control Board and Power Board are inserted by unscrewing the 4 Phillips 2 Unscrew the 4 Phillips screws M4x18 screws M4x8 DIN 7895H which join this DIN 7895H which join the output tray and the chassis sides bakelite
117. ers M3x10 on the DC Bus where the back of Snubber Trigger and Soft charge Board leans Insert the hexagonal spacers M3x15 on the DC Bus where the back of the Snubber Trigger and Soft charge Board leans Place the Snubber capacitors on the back of the DC Bus see figure 3 15 by screwing the Phillips screws M6x12 DIN 7895H Screw the 8 Phillips screws M6x16 DIN 7895H which join the DC Bus and the Bus bridge Screw the 2 Phillips screws M6x16 DIN 7895H which join the DC Bus and the Bus bridge Insert the electronic tray by screwing the 4 Phillips screws M4x8 DIN 7895H 50700 POWER ELECTRONICS Figure 6 12 Bus bridge Figure 6 12 a Disassembly of the DC Bus mA eS E E 9 A 4 Q 4 A e 72 5 5 Ne EE a EAN N NC e 7 Ax e e N 9 9 NM Figure 6 12 b Disassembly of the DC Bus SERVICE MANUAL 173 50700 7 8 11 BUS CAPACITORS Before proceeding the DC Bus must have been disassembled section 7 8 10 Follow figure 6 13 while reading these instructions Disassembly of the Bus capacitors 1 Unscrew the special hexagonal screws M5x20 which join the capacitor and the Bus Remove the Bus Remove the Bus and the Bus insulator Unscrew the special hex
118. ers M3x20 Remove the control board by pulling it up until disconnecting the female connectors of 40 32 and 28 pins of the control board from the male connectors of the power board where control board is connected Once the control board is removed put this board into a static proof bag for a safekeeping M3x8 1 Figure 7 3 5 Remove the control board 86 SERVICE MANUAL Disassembly of the control board 1 2 Continue with the safety conditions which are described in the previous section While replacing the control board avoid an excessive handling of the board Pick the new control board from the static proof bag Put the new control board in the same place than the replaced one matching the board holes with the hexagonal plastic spacers M3x20 see figure 7 3 5 Match the male connector of 40 32 and 28 pins of the control board with the corresponding female connector of the power board and slightly push the control board down to connect the pins Once the board is properly placed screw the 6 plastic screws M3x8 DIN 933 in the corresponding hexagonal plastic spacers M3x20 POWER ELECTRONICS 7 3 5 POWER BOARD Disassembly of the power board Before proceeding the control board must have been disassembled see section 7 3 4 See the figure 7 3 6 while reading the following instructions 1 The use of a static grounding wrist strap and being earthed is highly required to repair th
119. es the bus of the drive Possible reason for failure Faulty circuit and bus always discharging Action Replace the power board 30 SERVICE MANUAL POWER ELECTRONICS 50700 Fuse 4 Fuse 5 and Fuse 6 Function protection for input voltage measurement circuit before chokes and detection of input voltage to avoid the discharge of the bus The value is 2 A Possible reason for failure Circuit fault or faulty fuse Action Replace the fuse or the board b Fuses of the Power Connection Board In the power connection board there are 3 fuses located where the figure 1 5 shows FUSE 1 FUSE2 FUSE 3 AL i 51 p Figure 1 5 Fuses of the power connection board Fuse 1 Fuse 2 and Fuse 3 Function Protection for soft load circuits The value is 4 A Possible reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board SERVICE MANUAL 31 50700 32 4 4 5 Fuses Frame 4 Frame 11 400VAC a Fuses of the Power Board There are 4 fuses in the Power PCB as it is showed in figure 1 4 gt EU Li LIII FUSE 2 Figure 1 4 Power PCB fuses Fuse 1 and Fuse 2 Characteristics These are ultrarrapid ceramic fuses These fuses are 4A Function Power supply PCB from the Power PCB s Bus Possible reason for failure Short circuit in the Power PCB Action Change the Power PCB Fuse 3 Characteristics These are ultrarrapid ceramic fuses I
120. ese instructions 1 Unscrew the 4 hexagonal spacers M3x18 where the Upper Gate Drive is inserted 2 Unscrew the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs 3 Remove the DC Bus section 7 7 10 4 Remove the Snubber capacitors 5 Unscrew the 3 Phillips screws M6x20 DIN 7895H which join the IGBT and the bar where DCCTs are screwed 6 Disassemble the bar where DCCTs are screwed 7 Unscrew the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 8 Disassemble the IGBT Assembly of the IGBT Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board POWER ELECTRONICS Put the new IGBT of the static box Spread the thermal paste over the back of the IGBT Place the IGBT on the heat exchanger Screw the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger Place the DCCT Bar as it is shown in figure 5 16 Insert the DC Bus section 7 7 10 Place the Snubber capacitor on the DC Bus Figure 5 16 b Disassembly of the IGBT 7 7 15 50700 SOFT CHARGE QUICK DISCHARGE RESISTORS Soft charge and quick discharge resistors Before proceeding the Upper cover section 7 7 2 Snubber Trigger and soft charge board section 7 7 6 and the DC Bus section 7 7 10 must have been disassembled Follow figure 5 17 a and figure 5 17 b w
121. esult in a secondary accident or fire After the input power is applied or removed the drive will remain hot for a couple of minutes Touching hot parts may result in skin burns Do not apply power to a damaged drive or to a drive with parts missing even if the installation is complete Otherwise you may suffer an electric shock Do not allow lint paper wood chips dust metallic chips or other foreign matter into the drive Otherwise fire or accident could occur N WARNINGS SAFETY Wear safety glasses when operating the drive with power applied and the front cover is removed Handle the drive with care according to its weight Install the drive according to the instructions incuded in this manual Do not place heavy objects on the drive Ensure that the mounting orientation is correct Do not drop the drive or subject it to impact The SD700 drives contain static sensitive printed circuits boards Use static safety procedures when handling these boards CONNECTION PRECAUTIONS For EMERGENCY STOP make sure supply circuitry is open Do not disconnect motor cables if input power supply remains connected The internal circuits of the SD700 series will be damaged if the incoming power is connected and applied to output terminals U V W Always check whether the DC Link LED is OFF before wiring terminals The capacitors may hold high voltage even after the input power is disconnected Use caution to prevent
122. ews M5x20 which join the Bus and the capacitors Place the Bus and the Bus insulator Insert the Bus figure 5 12 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors 158 SERVICE MANUAL POWER ELECTRONICS Figure 5 13 Disassembly of the Bus capacitors POWER ELECTRONICS 7 7 12 IGBTS CONNECTOR BOARD Disassembly of the IGBTs connector board The use of a static grounding wrist strap and being earthed is highly required Follow figure 5 14 while reading these instructions Disconnect the IGBT trigger wire which connects this board to the Power board 1 Disconnect the 3 NTC wires which connect this board and the upper Gate Drive 2 Unscrew the 2 plastic screws M3x6 DIN 933 which join this board and the plastic hexagonal spacers M3x18 3 Unscrew the 2 slotted cheese head screws M3x30 DIN 84 which join this Board and the upper Gate Drives 4 Remove the IGBTs connector board The plastic hexagonal spacers and Nylon cases are not fixed anywhere they are simply holding this board Take care of not loosing them when the board is disassembled Assembly of the IGBTs conector board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the new board on the plastic hexagonal spacers M3x18 and the Nylon cases 3 Screw the 2 slotted cheese head screws M3x30 DIN 84 which are inserted into the Nylon
123. ft charge resistors of the SD700 Actions Try to reset the fault Disconnect and re connect again the input power If the fault persists check rectifiers Section 6 1 Fault 228 MICRO FLT Descrtiption Microprocessor has detected wrong data Posible cause Input power fault Parameters setting is not recognised Actions Disconnect and re connect the SD700 input power of the drive If the same fault appears initialize all of the parameters parameter G1 5 INITIALISE and connect the input power again If the fault persists change Control PCB Fault F29 DSP FLT Descrtiption DSP has detected wrong data Posible cause Input power fault Parameters setting is not recognised Actions Disconnect and connect again SD700 input power If the same fault appears initialize all the parameters parameter G1 5 INITIALISE and connect the input power again If the fault persists change Control PCB Fault F30 WATCHDOG Descrtiption An unknown fault has reseted the microprocessor of the control board Posible cause Input power fault Actions Reset the fault If the fault persists change Control PCB Fault F31 SCR L1 F32 SCR 12 F33 SCR L3 Descrtiption Trip on conduction status of thyristor 1 2 or 3 The thyristor has not turned on correctly Posible cause A conduction fault occurred in the corresponding thyristor The thyristor is OFF when it should be on Actions Try to reset the fault Disconnect and re connect the input
124. g any signal in the analogue input 1 and G4 2 14 AIN1 LOSS is set Yes The signal connected to this input has been lost Posible cause Analogue input cable has come loose or disconnected terminals 10 and 11 Actions Verify the wiring and the device which provides the analogue signal If the fault persists change Control PCB Fault F43 AIN2 LOSS Descrtiption The 50700 is not receiving any signal in the analogue input 2 and G4 2 14 AIN1 LOSS is set Yes The signal connected to this input has been lost Posible cause Analogue input cable has come loose or disconnected 112 and T13 Actions Verify the wiring and the device which provides the analogue signal If the fault persists change Control PCB Fault F44 CAL FLT Descrtiption Internal reference voltage levels are wrong Posible cause SD700 fault Actions Verify drive select Replace the drive select Fault F45 STOP T O Descrtiption Trip generated due to excessive stopping time The elapsed time from stop signal activation has exceeded the value set in parameter G11 2 STOP TO Posible cause Deceleration ramps parameters G5 2 DECEL1 and G5 4 DECEL2 too slow 50700 is limiting voltage due to the regeneration of the motor Actions Verify that the time set in parameter G11 2 STOP TO to stop the system after setting deceleration ramps and checking the system performance SERVICE MANUAL 17 50700 POWER ELECTRONICS
125. g the cooling fans dust papers dirt in general and that these rotate correctly If the fault persists change fans Fault 54 WATCHDOG Descrtiption Internal fault of the microcontroller Posible cause A fault in the microcontroller occurred Actions Disconnect and re connect the input power of the drive If the fault persists change Control PCB Fault 56 EMERGEN STOP Descrtiption Digital input configured as EXTERN EMERGE has been activated NC contact Posible cause An external trip occurred by closing a contact in the digital input configured in this option Actions Verify the wiring of digital input Check the installation Fault Feb LOW PRESSURE Descrtiption Active only when operating in Pump Control mode Trip generated when the pressure level is lower than the minimum pressure level set in G25 6 7 LoPre Posible cause Pressure reference is lower than the minimum pressure level Active in Pump Control mode only Actions Verify the setting of minimum pressure level Check the operation of the low pressure switch detector Check the status of the analogue inputs 1 and 2 in parameters SV3 1 and SV3 4 in displaying group GO Fault F66 HI PRESSURE Descrtiption Active only when operating in Pump Control mode External trip occurred when a digital input is configured in this option Hi Pressure Switch is closed SERVICE MANUAL 19 50700 POWER ELECTRONICS 20 Posible cause An external oc
126. he input fuses and test on the load side the fuses 2 In order to test the IGBTs individually requires the disassembly of the 50700 1 d n it gt d gii ICI Figure 2 2 Frame 4 1 it i gt ier ixi 1 1x 21 IECIT Figure 2 3 Frame 5 58 SERVICE MANUAL POWER ELECTRONICS 50700 Figure 2 4 Frame 6 lt Figure 2 5 Frame 7 Figure 2 8 Frame 8 SERVICE MANUAL 59 50700 POWER ELECTRONICS 6 2 Individual SCR testing When the SD700 is dissembled the SCR can be tested individually as it is shown in figure 2 7 TESTEO PUERTAICATODO DELTIRISTOR TESTEO DEL DIODO TESTEO DELTIRISTOR Figure 2 7 Individual SCR conduction test 6 3 Testing the DC Bus Capacitor A general test without disassembling the SD700 is recommended Use a multimeter set in mode OHMS to test the capacitors between HVDC terminals and At first the resistance should offer a low value but afterwards as the resistance will increase as the it is supplied voltage from the battery of the multitester ensure the DC bus capacitors are fully discharged first This charging period could take some time and it is better to ensure this procedure by testing a similar DC Bus capacitors in good conditions It is necessary to apply the same load time to both DC Buses and then compare results If there is a reasonable
127. he operation of the drive and can give us the information about the component that operates wrongly D307 D230 LED 1 LED2 LED 3 i FILS mj IE p ERI gs c XO D114 0507 01000 D103 D216 D262 D212 D214 D215 D213 Figure 1 6 Leds of the power board D114 RED colour In normal operation it is always ON It indicates that DC Bus is charged When it is OFF the Bus is completely discharged D507 RED colour In normal operation it is always OFF It is blinking if there is a fault in the main power supply This fault can be High Bus voltage Bus voltage High internal temperature of the drive Short circuit the main power supply of the power board D1000 GREEN colour In normal operation it is always OFF It is lit when the discharging circuit for the DC BUS is active D307 RED colour In normal operation it is always ON It indicates that the power supply 8V_USR is correct If it is not lit it indicates there are problems in the user power supply 5V_USR and 45V D103 RED colour In normal operation it is always ON It indicates that the internal Bus of the power board is charged If it is not lit the main power supply is not operating SERVICE MANUAL 47 50700 POWER ELECTRONICS 48 D262 RED colour In normal operation it is always ON It indicates that the power supply 28V_DISP_PWR is correct If it is not lit the Display is not powered
128. he wood bakelite by screwing 2 Phillips screws M4x12 DIN 7895H POWER ELECTRONICS 7 5 10 CHASSIS SIDES Disassembly of the chassis sides Before proceeding to disassemble the sides covers section 7 5 1 the electric tray section 7 5 5 and the upper and lower covers section 7 5 2 must have been disassembled Follow figure 3 12 while reading these instructions 1 Disassemble the chassis reinforcements 2 Unscrew the 7 hexagonal screws M8x18 DIN 933 which join the sides and the chassis 3 Disassemble the sides Reiforcement 4 Figure 3 12 Disassembly of the chassis sides Assembly of the chassis sides 1 Place the sides as it is shown in the figure 1 7 so that the holes fit the ones in the chassis 2 Join the sides and the chassis by means of 7 hexagonal screws M8x18 DIN 933 3 Join the chassis reinforcements to the sides by means of 7 hexagonal screws M8x18 DIN 933 SD700 7 5 11 FANS POWER SUPPLY Disassembly of the fans power supply units Before proceeding the chassis side where the fans power supply is inserted must have been disassembled section 7 5 10 The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 12 while instructions reading these 1 Disconnect the 2 fans power supply cables for the fans and the voltage measure cable 2 Unscrew the 3 Phillips screws M3x6 DIN 7895H which join the fans pow
129. hexagonal screws M8x25 IN 933 1 Spread the thermal paste on the back of 895H which join the bars and the SCRs new SCR 2 Insert the SCR in the heat exchanger see figure 4 19 3 Screw the 2 Phillips screws M5x20 DIN 7895H which join the SCR and the heat exchanger 146 SERVICE MANUAL POWER ELECTRONICS 7 6 19 POWER FANS Disassembly of the Fan support Follow figure 4 20 a while reading these instructions 1 Unscrew the Phillips screw 4 8 DIN 7895H which joint the fan support and the fan box 2 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Disconnect the fan power wire 4 Remove the fan support M4x8 Fan power wire Figure 4 20 Disassembly of the fan support Disassembly of the power fan support 24VDC 2A 48W 172X172 FAN Follow figure 4 21 a while reading these instructions Unscrew the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan and its support M4x60 Figure 4 21 Disassembly of the power fan 50700 24VDC 89W 172X172 FAN Follow figure 4 21 b while reading these instructions Unscrew the 2 Phillips screws M4x12 DIN 7895H which join the power fan and its support Figure 4 21 b Disassembly of the power fan Assembly of the Fan support 1 Before inserting the fan support on the fan box connect the fan power wire and then insert the fan support i
130. hexagonal spacers M3x10 inserted in the DC Bus and where the back of the snubber trigger and soft charge Board leans 4 Disassemble the hexagonal spacers M3x15 inserted in the DC Bus where the front of the snubber trigger and soft charge Board leans 5 Unscrew the 8 Phillips M6x16 DIN 7895H screws which join the DC Bus and the bus bridge 6 Unscrew the 2 Phillips M6x16 DIN 7895H screws which join the DC Bus and the Bus bar 7 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the chassis 8 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger 9 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 10 Unscrew the 6 Phillips screws M6x12 DIN 7895H which join the Bus and the Bus with the 3 SCRs Assembly of the DC Bus 1 Place the DC Bus in the chassis 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 172 SERVICE MANUAL 10 11 12 POWER ELECTRONICS Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC BUS and the chassis Screw the 6 Phillips screws M6x12 DIN 7895H which join DC Bus and the SCRs Screw the 6 Phillips screws M6x12 DIN 7895H which join DC Bus and the SCRs Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger Insert the plastic hexagonal spac
131. hile reading these instructions 1 Unscrew the hexagonal screws M8x25 DIN 933 which join the bars and the SCRs 2 Disassemble the measure voltage wire after the AC Choke by unscrewing the Phillips screws M4x8 DIN 7895H which join these wires and the bars 3 Remove the bars 4 8 After AC choke current measurement T e 3 M BX Figure 5 17 a Disassembly of the Soft charge and quick discharge resistors SERVICE MANUAL 161 50700 4 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the support of the resistors and the chassis 5 Remove the resistors Soft charge resistors Quickly discharge resistors 27 Figure 5 17 b Disassembly of soft charge and quick discharge resistors Disassembly of the soft charge and quick discharge resistors 1 Insert the support of the resistors in the chassis 2 Screw the 4 Phillips screws M4x8 DIN 7895H which join the support of the resistors and the chassis 3 Insert the bars figure 5 17 a 4 Insert the voltage measure wire after the AC Choke by unscrewing the Phillips screws M4x8 DIN 7895H which join the wires and the bars 5 Screw the Phillips screws M6x20 DIN 7895H which join the bars and the AC Choke 7 Screw the Phillips screws M6x16 DIN 7895H which join the bars and the SCRs 162 SERVICE MANUAL POWER ELECTRONICS 7 7 16 SCRs Removing the SCRs
132. hile reading these instructions 1 Disconnect the voltage measure cable before and after the AC Choke and the earth cable Afterwards unscrew the Philips screws 4 8 DIN 7895H which join the wire terminals and the board n 1 Figure 3 9 a Disassembly of the Ssnubber Trigger and Soft charge protection 2 Disconnect all output wiring figure 3 9 b 3 Unscrew the 3 plastic screws M3x8 DIN 933 which join the board and the plastic hexagonal spacers Mix placed in the Bus 4 Unscrew the 3 Phillips screws on M3x8 DIN 7895H which join the board and the hexagonal spacers Mix placed in the Bus POWER ELECTRONICS 50700 5 Remove the Board M3x8 7 M3x6 7 SCR tigger Before AC choke 4 voltage measure h Soft charge resitance After AC choke 55 voltage measure Figure 3 9 b Disassembly of the Snubber Trigger and Soft charge protection Assembly of the Snubber trigger and soft charge protection board Continue to observe static safe work procedures 1 Avoid excessive handling of the new board 2 Place the Board in the position as it is Figure 3 9 c Disassembly of the Ssnubber Trigger shown in the figure 3 9 c and Soft charge protection 3 Screw the 3 plastic screws M3x8 DIN 933 which join the board and the plastic hexagonal spacers Mix 4 Screw the 3 Phillips screws M3x8 DIN 7895H which join this boa
133. ich join the upper cover and the SD700 chassis 2 In IP20 models before removing the upper covers The fans supply wire must have been disconnected Therefore separate some the upper cover from the chassis disconnect the wire and then remove the upper cover M4x8 M 2544 gt t Figure 4 3 Removal of the upper covers Assembly of the upper cover 1 In IP20 models connect the fans supply wire 2 Join the upper cover and the 50700 chassis by screwing the 6 Phillips screw M4x8 DIN 7895H 50700 7 6 3 CONTROL BOARD Disassembly of the Control Board The use of a static grounding wrist strap and being earthed is highly required Follow Figure 4 4 while instructions eading these 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control PCB and the plastic hexagonal spacers M3x20 2 Remove the Control Board by disconnecting the 40 32 y 28 pin connectors which join the Control Board and the Power Board 3 When the control Board has been already disassembled place it in a static proof bag for safekeeping 7 M3x8 a Figure 4 4 Disassembly of the Control Board Assembly of the Control Board Continue to observe static safe work procedures 1 Avoid excessive handling of the new Control Board 2 Place the new Control Board on the hexagonal spacers M3x20 figure 4 5 3 Push down the 40 32 y 28 pin connector
134. ich join this board and the plastic hexagonal spacers M4x40 which are inserted in the IGBT heat exchanger 4 Disassemble the IGBTs connector board Cay Cy CS Assembly of the IGBTs conector board CS CS C CM aD Continue to observe static safe work procedures 1 Avoid an excessive handling of the new LY board Figure 7 13 Disassembly of the Bus capacitors 2 Put the new board on the plastic hexagonal spacers M4x40 3 Screw the 4 Phillips screws M4x8 DIN 7895H which join this board and the plastic hexagonal spacers M4x40 which are inserted in IGBT s heat exchanger 4 Connect the IGBT trigger wire 5 Connect the NTC wires 190 SERVICE MANUAL POWER ELECTRONICS 50700 2 4 40 7 9 13 UPPER GATE DRIVE lt gt Disassembly of the Upper Gate Drive 3 8 Before proceeding the IGBTs connector board must have been disassembled section 7 9 12 Follow figure 7 15 while reading these instructions 1 Disconnect the phone wires which connect this board to the lower Gate Drive 2 Unscrew the Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 3 Disassemble the Upper Gate Drive Assembly of the upper Gate Drive Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Put the new board on the hexagonal spacers M3x18 figure 7 15
135. ion it is ON during the soft charge and once the DC Bus is charge the led becomes OFF SERVICE MANUAL POWER ELECTRONICS d Dc Bus Board Frame 2 Bus is powered e Gate Drive Board Frame 2 LED1 L5 L6 L4 L1 L2 LEDDB 1 08 LED9 SD700 LED 1 RED colour In normal operation it is always ON It indicates that DC LED 1 RED colour In normal operation it is always ON It indicates 15V IGBT FUSE L1 GREEN colour In normal operation it is always ON It indicates desaturation W L2 GREEN colour In normal operation it is always ON It indicates desaturation W L3 GREEN colour In normal operation it is always ON It indicates desaturation V L4 GREEN colour In normal operation it is always ON It indicates desaturation V L5 GREEN colour In normal operation it is always ON t indicates desaturation U L6 GREEN colour In normal operation it is always ON It indicates desaturation U LED DB GREEN colour In normal operation it is always ON It indicates braking desaturation fault in this case it becomes OFF LED 8 YELLOW colour In normal operation it is always ON It indicates 15V dynamic brake LED 9 YELLOW colour In normal operation it is always ON It indicates 15V dynamic brake NOTE Leds L1 L2 L3 L4 L5 L6 and LED DB become OFF during 1s when saturation SERVICE MANUAL 41 50700 POWER ELECTRONICS 4 5 3 Indicato
136. ion 7 1 1 the tray for the boards see figure 7 1 7 and separate the top of the chassis from the bottom follow the steps described in section 7 1 9 and 7 1 10 1 Remove the 4 nuts M4 which fix dV dt chokes to the chassis see figure 7 1 20 Figure 7 1 20 2 Disconnect all cables of the dV dt choke from the connections board 3 Remove dV dt chokes Assembly of the dV dt chokes 1 Fix the new dV dt chokes to the chassis by means of their nuts M4 2 Put the cables of the new dV dt choke through the holes of the chassis see figure 7 1 21 Figure 7 1 21 3 Assembly again the top of the chassis with the bottom by means of the 4 screws M5X10 DIN 7895H SERVICE MANUAL 71 50700 POWER ELECTRONICS 7 1 12 HEATSINK 1 1 13 FANS Disassembly of the heatsink Disassembly of the heatsink fan In order to remove de heatsink first you should remove the embellishers see section 7 1 1 the 1 Remove the lower cover see section 7 1 3 tray for the boards see figure 7 1 7 the gate drive board see section 7 1 7 the DC bus see 2 Disconnect the power supply cable section 7 1 8 and the power connections board see section 7 1 9 and separate the top of the 3 Remove the 2 screws M4x45 DIN 84 that fix chassis from the bottom follow the steps of the fan to the structure see figure 7 1 23 sections 7 1 9 and 7 1 10 4 Remove the fan 1 Remove the 4 screws M5X10 which fix the heatsink to the chassi
137. l Board Assembly of the Control Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control Board 2 Place the new Control Board on the hexagonal spacers M3x20 3 Push the 40 32 y 28 pins connectors down Do not apply excessive force 4 Screw the 6 plastic screws M3x8 DIN 933 in the plastic hexagonal spacers M3x20 SD700 7 8 4 POWER BOARD Disassembly of the Power Board Before proceeding the Control Board must have been disassembled section 7 8 3 Follow figure 6 6 a and figure 6 6 b while reading these instructions 1 Disconnect all the wires which are connect to this Board Before AC choke oltage measurement v DC Bus Voltage measurement Quickly discharge tls P i resistor SCR Trigger Fan supply After Ac choke voltage measurement Output voltage measurement Figure 6 6 a Disassembly of the Power Board wires 2 Remove the 6 plastic hexagonal spacers M3x20 which are inserted in the Power Board 3 Unscrew the 5 Phillips screws M3x8 DIN 7895H 4 Disassemble the Power Board SERVICE MANUAL 167 50700 POWER ELECTRONICS Assembly of the Power Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control Board 2 Place the new board on the electric tray and fit the holes of the board with the electric tray bolts figure 6 6 a 3 Screw the 5 Phillip
138. le and the cable for connections of the gate drive board Figure 7 2 9 Disassembly of the gate drive board 3 Unscrew the 4 Phillips screws M3x8 DIN 7895H 4 Remove the board Assembly of the Gate Drive board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the gate drive board avoid an excessive handling of the board 3 Pick the new gate drive board from the static proof bag 4 Put the board in the correct position as the figure 7 2 9 shows matching the holes 5 Insert the 4 Phillips screws M3x8 DIN 7895H 6 Connect the braking cable the bus cable and the cable for connections of the gate drive board 78 SERVICE MANUAL POWER ELECTRONICS 7 2 8 DC BUS Disassembly of DC Bus Before proceeding it is necessary to remove the embellishers see section 7 2 1 and the tray where the control and power board are inserted see figure 7 2 7 1 Unscrew the 2 screws M5X10 DIN 7895H which fix the bus board with the power connections board 2 Unscrew the 3 Phillips screws M3x8 DIN 7895H which join the bus and the chassis See figure 7 2 12 3 Remove the DC bus Figure 7 2 12 Disassembly of DC Bus Assembly of DC Bus 1 Putthe bus matching the holes 2 Screw the 3 Phillips screws M3x8 DIN 7895H which join the bus and the chassis 3 Screw the 2 screws 5 10 DIN 7895H which join the connections board with the DC Bus POWE
139. low figure 4 44 while instructions reading these 1 Unscrew the 9 Phillips M4x8 DIN 7895H which join the upper cover and the SD700 chassis 2 In IP20 models pull out the upper cover slowly in order to disconnect the fans supply wire Figure 5 4 Disassembly of the upper cover Assembly of the Upper cover 1 In IP20 models connect the fans supply wire 2 Join the Upper cover and the SD700 chassis by screwing the 9 Phillips screws M4x8 DIN 7895H POWER ELECTRONICS 7 7 3 CONTROL BOARD Disassembly of the Control Board The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 4 while reading these instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control PCB and the plastic hexagonal spacers M3x20 2 Disconnect the 40 32 y 28 pin connectors which join the Control Board and the Power Board and then remove the Control Board 3 Put the Control Board in a static proof bag for safekeeping M3x8 1 Figure 5 5 Disasembly of the Control Board Assembly of the Control Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control Board 2 Place the new Control Board on the hexagonal spacers 3 20 fit the holes 3 Push the 40 32 y 28 pins connectors down Do not apply force 4 Screw the 6 plastic screws M3x8 DIN 933 in the plastic hexagonal spacers M3x20
140. mbly of the AC choke 1 Insert the AC choke inside the chassis 2 Fix the AC choke to the chassis by using the 4 screws M6x20 DIN 7895H 3 Connect the power cables to the choke as the figure 7 4 17 shows 4 Insulate the power cables see figure 7 4 18 Figure 7 4 16 1 It is necessary to remove the power cables in order to remove the AC choke from the drive s chassis For this remove the power cables like this see figure 7 4 17 2 Remove the 4 Phillips screws M6x20 DIN b 7895H that join the AC choke to the Figure 7 4 18 supports of the chassis see figure 7 4 17 Figure 7 4 17 a Figure 7 4 17 108 SERVICE MANUAL POWER ELECTRONICS 50700 7 4 14 DV DT CHOKES 3 Remove the 2 screws M4x8 DIN 7895H which fix the connections bar to the chassis Disassembly of dV dt chokes 4 Remove the connections bar It is necessary to remove the embellishers see section 7 4 1 the tray for the boards see figure 5 Remove the 5 screws M4x8 DIN 7895H 7 4 7 the power connections board see section which fix the medium bar 7 4 8 the connection bars for the thyristors see figure 7 4 10 a the bus bars see figure 7 4 17 6 Remove the medium bar a the DC Bus see section 7 4 9 the control cable bars see figure 7 4 21 the bar for 7 Remove the 2 screws M4x8 DIN 7895H connectios see figure 7 4 19 and the medium which hold the fixing bar for the fan cables bar see figure 7 4 20 to the chassis
141. n Before AC choke voltage measure SCR tigger 50700 SCR tigger Soft charge resitance After AC choke Figure 5 8 b Disassembly of the Snubber Trigger and Soft charge protection Unscrew the 3 Phillips screws on M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Unscrew the 3 Phillips screw M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 placed in the Bus Disassemble the Board Figure 5 8 c Disassembly of the Ssnubber Trigger and Soft Charge protection SERVICE MANUAL sk voltage measure 153 50700 Assembly of the Snubber Trigger Soft charge protection board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the Board in the position as it is shown in Figure 4 8 c 3 Screw the screws M3x8 DIN 7895H which join the board and the hexagonal spacers M3x10 4 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x15 5 Connect all the input wiring before and after the AC Choke voltage measure cable by screwing the Phillips screw M4x8 DIN 7895H which join the wire terminals and the board figure 5 8 a 6 Connect all the output wiring figure 5 8 b 154 SERVICE MANUAL POWER ELECTRONICS 7 7 7 FANS POWER SUPPLY Assembly of the fans power supply The use of a static grounding
142. n the door 2 Disconnect the ethernet cable from the display 3 Remove the display from the support of the door 4 Disconnect the earth cable 5 Remove the 2 special screws of the 5 hinges M6x12 which join the door to the side of the drive 6 Remove the door Figure 7 4 3 Remove the door Assembly the door 1 Put the door matching the hinges with the holes of the side 2 Insert the special screws of the hinges M6x12 which join the door to the side of the drive 3 Put the display on the support of the door 4 Connect the ethernet cable of the display 100 SERVICE MANUAL POWER ELECTRONICS 7 4 3 UPPER COVER AND LOWER COVERS Disassembly of the upper cover and lower covers See the figure 7 4 4 while following the next instructions 1 Unscrew the 7 Phillips M4x8 DIN 7895H screws that join the upper cover and the drive chassis 2 In IP20 models remove the upper cover slowly until disconnecting the power supply cable of the fans Once disconnected the cable remove the cover completely 3 Unscrew the 6 Phillips M4x8 DIN 7895H screws which join the lower covers and the drive chassis 4 Remove the lower covers M4X8 Upper cover FP Lower l covers gt M5X10 Figure 7 4 4 Remove the covers Assembly of the upper cover and the lower covers 1 Put the lower covers as the figure 7 4 4 shows 2 Fix the covers to the
143. n the fan box 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Screw the Phillips screw M4x8 DIN 7895H which join the fan support and the fan box SERVICE MANUAL 147 50700 POWER ELECTRONICS 7 6 20 AC CHOKE Disassembly of the AC Choke Before proceeding the bars which join the AC choke and the SCRs section 7 6 17 the AC choke SCR bars section 7 6 17 and the Upper cover section 7 62 must been disassembled Follow figure 4 22 while reading these instructions 1 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 2 Remove the AC choke out of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN 961 which join the power wires and the AC choke 3 Remove the AC choke Figure 4 22 Disassembly of the AC choke Asembly of the AC choke 1 Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN 961 2 Insert the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 148 SERVICE MANUAL POWER ELECTRONICS 7 7 50700 FRAME 6 7 7 1 ACCESS INSIDE Disassembly of the covers Follow figure 5 7 y la figure 5 2 while reading these instructions 1 Open the SDrive door 2 Disconnect the Display from the Control Board 3 Disconnect all con
144. nd power boards are inserted see figure 7 1 7 the gate drive board see section 7 1 7 the connections board see section 7 1 9 1 Unscrew the 7 screws M3X6 DIN 7895H which fix the bus board to the chassis see figure 7 1 10 2 Remove the 4 nuts M5 which fix the connections of the choke to the bus see figure 7 1 1 3 Remove the DC bus Figure 7 1 11 Assembly of the DC Bus 1 Putthe bus matching the holes 2 Screw the 7 Phillips screws M3x6 DIN 7895H that join the bus and the chassis 3 Insert the 4 nuts M5 that join the choke and the bus board SERVICE MANUAL 69 50700 7 1 9 POWER CONNECTIONS BOARD Disassembly of the power connections board Before removing the power connections board you should remove the embellishers see section 7 1 1 the tray wher the control and power boards are inserted see figure 7 1 7 and the gate drive board see section 7 1 17 1 Disconnect the cables of the dV dt coils motor voltage measurement cable for soft load relay cable for coil relay and NTC cable Remove the 2 screws of IGBT M5X16 DIN 7895H see figure 7 1 12 3 Remove the 6 screws M3X6 see figure 7 1 13 4 Figure 7 1 13 Remove the board Assembly of the power connections board 1 70 Spread the heatsink area where the IGBT is going to be placed with new thermal paste Put the board in the proper position see figure 7 1 13 Screw the 2 IGBT
145. nect this board to the lower Gate Drive 2 Unscrew the Phillips screws M3x8 DIN 7895H which join this board and the hexagonal spacers M3x18 3 Remove the Upper Gate Drive Assembly of the Upper Gate Drive Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Place the next board on the hexagonal spacers M3x18 figure 4 17 3 Screw the 3 Phillips screws M3x8 DIN 7895H which join this board and the Figure 4 17 Assembly of the Upper Gate Drive hexagonal spacers M3x18 4 Connect the phone cables SERVICE MANUAL 143 50700 7 6 16 IGBT Disassembly of the IGBT Before proceeding the Upper Gate Drive board must have been disassembled section 7 6 15 The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 17 a and figure 4 17 b while reading these instructions 1 Unscrew the 4 hexagonal spacers M3x18 where the Upper Gate Drive is inserted 2 Unscrew the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs 3 Remove the DC Bus section 7 6 12 4 Remove the Snubber capacitors 5 Unscrew the 3 Phillips screws M6x20 DIN 7895H which join the IGBT and the bar where DCCTs are inserted 6 Remove the bar where the DCCTs are inserted 7 Unscrew the 4 Phillips screws 5 16 DIN 7895H which join the IGBT and the heat exchanger 8 Remove the IGBT Assembl
146. nger 2 Remove the SCR M5X12 Figure 3 21 Removing SCR Disassembly of the SCRs 1 Spread the thermal paste over the lower side of the new SCR 2 Insert the SCR in the heat exchanger see figure 3 21 3 Screw the 2 Phillips screws M5x12 DIN 7895H which join the SCR and the heat exchanger SERVICE MANUAL 129 50700 POWER ELECTRONICS 7 5 20 POWER FAN Disassembly of the Fan support Follow figure 3 22 while eading these instructions 1 Fan Box Unscrew the Phillips screw 4 8 DIN 7895H which join the fan support and the fan box Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support Disconenct fthe fan power cable Remove the fan support M4X8 Output ckoke support A gt Fan support Fan power wire MCS gt Figure 3 22 Disassambly of fan support Disassembly of the fan support 24VDC 2A 48W 172X172 FAN Follow figure 3 23 a while reading these instructions Unscrew the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan and its support 130 SERVICE MANUAL M4x60 Figure 7 23 a Disassambly of the fan support 24VDC 89W 172X172 FAN Follow figure 3 23 a instructions while reading these Unscrew the 2 Phillips scre
147. o the chassis of the drive 5 Incase of IP54 model of SD700 drives disconnect the power supply of the fans that are in the embellishers 6 Remove the embellishers 84 SERVICE MANUAL Place the embellishers on the supports of the drive s sides as the figures 7 3 2 shows Screw the embellishers to the supports of the sides with 4 Phillips 4 8 DIN 7895H Screws Put the plastic protector for the power connections on the sides of the drive Connect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input Connect the Display by means of the ethernet cable which goes from the display to the drive POWER ELECTRONICS 7 3 2 DOOR Disassembly the door See the figure 7 3 3 while following the next instructions Open the door Disconnect the ethernet cable from the display Remove the display from the support of the door Disconnect the earth cable Remove the 2 special screws of the door s hinges M6x12 which join the door to the side of the drive Remove the door Figure 7 3 3 Remove the door Assembly the door 1 2 Put the door matching the hinges with the holes of the side Insert the special screws of the doors hinges M6x12 which join the door to the side of the drive Put the display on the support of the door Connect the ethernet cable of the display Disassembly of the upper cover and lower 50700 UPP
148. oft charge Board leans Remove the hexagonal spacers M3x15 inserted in the DC Bus where the front of the Snubber Trigger and Soft charge Board Unscrew the 8 Phillips M6x20 DIN 7895H screws which join the DC Bus and the bus bridge Unscrew the 2 Phillips M6x20 DIN 7895H screws which join the DC Bus and the Bus bar Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the chassis Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger Unscrew the 6 Phillips screws M6x12 DIN 7895H which join the Bus and the Bus to the 3 SCRs Assembly of the DC Bus 1 2 Place the DC Bus in the chassis Screw the 2 Phillips screws M4x8 DIN 7895H which join the DC Bus and the IGBTs heat exchanger 10 11 12 50700 Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC BUS and the chassis Screw the 6 Phillips screws M6x12 DIN 7895H which join DC Bus and the SCRs Screw the 6 Phillips screws M6x12 DIN 7895H which join the DC Bus and the SCRs Screw the 4 Phillips screws M4x8 DIN 7895H which join the DC Bus and the SCRs heat exchanger Insert the plastic hexagonal spacers M3x10 on the DC Bus where the back of the Snubber Trigger and Soft charge Board leans Insert the hexagonal spacers M3x15 on the DC Bus where the back
149. on it is always ON It indicates that the power supply 28V_DISP_PWR is correct If it is not lit the Display is not powered D216 RED colour In normal operation it is always ON It indicates that the power supply 24V_DISP_COM is correct If it is not lit there is a communication fault between the Display and the Control Board D212 RED colour In normal operation it is always ON It indicates that the power supply 15V_SCR is correct If it is not lit it indicates there are problems in the triggering thyristor pulse generator circuit D214 RED coloutr In normal operation it is always ON It indicates that the power supply 28V_USR is correct If it is not lit all the voltages referred to the user ground dissapear D215 RED colour In normal operation it is always ON It indicates that the power supply 15V_IGBT is correct If it is not lit there are not pulses in the IGBT s There is some faulty component in the inverter circuit IGBTs GateDrive D213 RED colour In normal operation it is always ON It indicates that the power supply 24 CONTROL is correct If it is not lit all the voltages referred to the analogue and digital ground dissapear D230 RED colour In normal opertion it is always ON It indicates that the power supply 15V_TEMP is correct If it not lit the temperature measurement faults LED 1 LED2 AND LED 3 GREEN colour It is only lit one of them and corresponds to the output phase IGBT s
150. ontrol PCB E024HA E024HA E024HA Power PCB E107BD E107BD E107BD SCRs SCR 380 NUMBER SCR 690 NUMBER P067 SD703300 6 P114 1 SD7020X P067 SD7OSTODX 6 P114 1 SD70200X Po67 070465 6 P114 509 6 IGBT 690 NUMBER FF450R17ME3 D702106X 6 FF300R17ME3 50702606 6 IGBT 380V NUMBER FF300R12ME3 SD703305X 6 FF300R12ME3 50703705 8 FF450R12ME3 0704605 FF450R17ME3 50703206 _ 6 BUS CAPACITORS 380V 690 0 SD703305X 212 24 SD702106X 2 9 18 SD703705X 2 12 24 SD702606X EN WE 2 12 24 50704605 2 16 32 SD703200X 30 24500 SERVICE MANUAL 201 50700 POWER ELECTRONICS __6 0 NUMBER L091 SD703705X SD702106X L092 SD704605X SD702606X L092 SD705805X SD703206X OUTPUT CHOKE Output Turns Wire Output Turns Wire choke section choke section 6 4 7 50702106 6 9 3 SDONOx 6 4 70 SD70606 6 7 3 5070460 6 4 70 50703206 6 9 3 FANS 222 1 __ 844NH2NDG 24W o 4 ws Um Gwum2wwsW a 8 uy LL Ue TT um 3 1 3 1 690 V we
151. ormal operation it is always ON It indicates 15V IGBT D307 RED colour In normal operation it is always ON It indicates 8V User D207 RED colour In normal operation it is always ON It indicates 15V Dynamic Brake D204 RED colour In normal operation it is always ON It indicates 15V Dynamic Brake LED1 GREEN colour In normal operation it is always ON It indicates detection from the IGBT thermal protection SERVICE MANUAL 39 50700 POWER ELECTRONICS 40 b Indicator Leds of Control Board D1101 D10 D1201 pei WEEE m O O 00 ee C4 5 6 Enton am Aa i 1 amm ur 11 03 Mum H 2 Ern Cay PU guu N Figure 147 Leds of Control Board 10 he In normal operation it is blinking It indicates that the microprocessor is operating correctly LED 901 GREEN colour In normal operation it is always ON It indicates that the power supply for the DSP 3 3V is correct LED 1101 GREEN colour In normal operation it is always OFF It is lit if there is overheating in the integrated circuit for RS485 communications LED 1201 RED colour In normal operation it is always OFF It is lit when the Hardware current limitation is performing c Power Connection Board RED colour normal operat
152. ower Module 2 CHASSIS SD700 ealactinn Rapid discharged resistor It connects this PCB with the Snubber Trigger and Soft charge protection board Measure of the input voltage before the AC chokes It connects this PCB with the Snubber Trigger and Soft charge protection board Measure of the input voltage after the AC chokes It connects this PCB with the Snubber Trigger and Soft charge protection board Trigger of the SCR It connects this PCB wiith the Va Snubber Trigger and Soft charge protection board Temperature of the SCR It connects this PCB with the heatsink of the thyristor an with the Fan power supply unit NTC 1 NTC 2 NTC 3 In frame frame 4 and 5 they connect this PCB with the IGBT s while in other frames they connect this PCB with the NTC PCB IGBT module selection Current measure It connects this PCB with the Current Transformers Output voltage measure connects this PCB with the Output bars SERVICE MANUAL 55 50700 POWER ELECTRONICS 56 Connector IGBT modules selection It connects this PCB with the NTC PCB s IGBT selection modules If there is only one PCB in the device the cable will come out from module 1 If there are two NTC PCB s the cables will come out from modules 2 and 3 If there are three PCB a cable will come out from any single module External supply This contactor allows an external supply of all devices which are sup
153. ower connections board 1 2 Continue with the safety conditions which are described in the previous section While replacing the power connections board avoid an excessive handling of the board Pick the new power connections board from the static proof bag SERVICE MANUAL 89 50700 4 90 Put the board in the correct position as the figure 7 3 10 shows matching the holes with the thyristors the choke and with the bus Insert the 5 Phillips screws M3x6 DIN 7895H Insert the 9 screws which are fixed to the bus and also the 4 screws which are fixed to the IGBT M5X12 DIN 7895H with a thightening pressure of 3N m Insert the screws that are fixed to the AC choke M6x16 DIN 7895H with a thightening pressure of 3N m Plug the PCB of trigger thyristors See figure 7 3 9 SERVICE MANUAL POWER ELECTRONICS 7 3 9 DC BUS Disassembly of DC Bus Before proceeding you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 the pluggable PCB of trigger thyristors see section 7 3 7 and the power connections board see figure 7 3 10 1 Disconnect the 2 power cables from the DC bus with the 2 screws M5X12 DIN 7895H Remove the 4 Phillips screws M4x8 DIN 7895H which join the bus and the chassis Remove the DC bus Figure 7 3 12 Disassembly of DC Bus Assembly of DC Bus 1 2 Put the bus correctly in the chassis matching the
154. ows the schematic revision E029GD Electronic Component Schema tic Revision revision 8 1 50700 Frame 4 PCBs SD700 FRAME 380V IP54 IP20 models Control PCB Power PCB Po 80700 4 69V Lower Gate Drive 1 IGBTs connector PCB IGBT selection module 196 SERVICE MANUAL POWER ELECTRONICS 50700 SCRs 5 380V 690 101 50700905 me P112 SD700526X NUMBER P101 50701155 P115 SD700626X 3 101 50701505 P111 50700806 P101 50701705 P111 0701056 IGBT IGBT 380V NUMBER IGBT 690 NUMBER BUS CAPACITORS _ _ DCCT DCCT 3807 NUMBER DCCT 690V NUMBER L116 SD700905X L201 SD700526X 50701155 1090 50701505 L116 50700806 1090 50701705 L116 50701056 OUTPUT CHOKE Output Turns Wire Output Turns Wire choke section choke section 3 5 5 3 5 8 SW 3 7 6 3 4 3 5 5 sores s 8 FANS 380V REFERENCE DESCRIPTION D7009052 SD7009055 SD7011552 SD7011555 a um 19 SERVICE MANUAL 197 50700 POWER ELECTRONI
155. plied from the Power PCB as well when the drive is not operating For instance it will allow to visualize in the Display when the drive does not work J804 this must be bridged so that IGBT s can receive trigger pulses JUMPERS By default only the even numbers are connected In this case the mass of the chassis are connecte in paralel with a capacitor a resistor and a baristor MAN ls ui EH dy entr Homo B qe CBE AUD A Ssp107 JP104 JP100 AP 102 JP106 JP101 JP103 JP106 It refers to the DGND which corresponds to the analogical and digital masses JP200 It refers to the GND USR which corresponds to the user mass JP104 It refers to the GND COM which corresponds to the Display mass supply If all the pairs of even and odd jumpers are connected the masses are driven to the chassis and are not connected This is used to solve field noises SERVICE MANUAL POWER ELECTRONICS 50700 9 2 Control Board J906 JP1104 P1103 J101 1201 J1102 Lu i NT 0 00 gm AD Dn ARTI Ol eet E mm dt fg mE i MER n 0 j 1 a EBD T m m 3m deo 4 mi a B
156. power If the fault persists check Fuses of Snubber PCB section 4 4 3 Fault F35 PHSE L1 LOSS F36 PHSE L2 LOSS F37 PHSE L3 LOSS Descrtiption Input phase L1 L2 or L3 is not present Phase fault Posible cause Input phase L1 L2 or L3 is not connected correctly or there is no voltage on it Actions Verify the wiring of the input power supply of the drive Check input voltage and input fuses If the fault persists Fault FA0 EXT PTC SERVICE MANUAL POWER ELECTRONICS 50700 Descrtiption External trip or motor PTC device has operated terminals 8 and 9 Values out of the range might 85Q to 2KQ generate this fault cause External device has operated Motor is overheated motor load exceeds the cooling capacity at operating speed Fault in sensor connection Actions Check the external trip switch if exists Check motor temperature To reset the fault the motor must be return to normal temperature Check sensor wiring Check input Fuse section 4 4 1 Fault 41 COMMS TRIP Descrtiption Trip generated through RS232 or RS485 communication Master PLC or PC is generating a fault in the SD700 through serial communication Posible cause Trip generated by a computer through serial communication Actions Disconnect the SD700 from the communication network and verify if the fault is generated again If the fault persists change Control PCB Fault 42 1 LOSS Descrtiption The 50700 is not receivin
157. r Leds Frame 3 60 75A a Indicator Leds of Power Board The PCB s of the SD700 drives have several leds which report us about the operation of the drive and can give us the information about the component that operates wrongly D307 LED 3 TF i jt mij E p TII iM NSH Esso 0114 0507 01000 0103 0216 D262 0212 0214 0215 0213 Figure 1 6 Leds of the power board D114 RED colour In normal operation it is always ON It indicates that DC Bus is charged When it is OFF the Bus is completely discharged D507 RED colour In normal operation it is always OFF It is blinking if there is a fault in the main power supply This fault can be High Bus voltage Low Bus voltage High internal temperature of the drive Short circuit the main power supply of the power board D1000 GREEN colour In normal operation it is always OFF It is lit when the discharging circuit for the DC BUS is active D307 RED colour In normal operation it is always ON It indicates that the power supply 8V_USR is correct If it is not lit it indicates there are problems in the user power supply 5V_USR and 45V D103 RED colour In normal operation it is always ON It indicates that the internal Bus of the power board is charged If it is not lit the main power supply is not operating 42 SERVICE MANUAL POWER ELECTRONICS 50700 D262 RED colour In normal operati
158. rd and the hexagonal spacers M3x15 5 Connect all voltage measure cables before and after the AC chokes and the earth cable 6 Connect all output wiring figure 3 9 b SERVICE MANUAL 119 50700 7 5 8 OUTPUT CHOKE Disassembly of the output choke Follow figure 3 10 while reading these instructions 1 Unscrew the 2 Phillips screws M6x20 DIN 7895H which join the output choke wire 2 Remove the output choke E Output Choke My 77 ee K SY Wz NN DCCT Bar Insolator Outp ut bar PD gt N NN ANS SX NN Figure 3 10 Disassembly of the output choke Assembly of the output choke 1 Place the output choke inside the plastic insulator 2 Join the terminals of the cables of the output choke to their own busbars by means of 2 Phillips screws M6x20 DIN 7895H 120 SERVICE MANUAL POWER ELECTRONICS 7 5 9 DCCT Disassembly of the DCCT Before proceeding output choke must have been disassembled section 7 5 8 Follow figure 3 11 while reading these instructions 1 Unscrew the 2 Phillips screws 4 12 DIN 7895H which join the DCCT and the bakelite 2 Remove the DCCT 4 12 DCCT Figure 3 11 Disassembly of the DCCT Assembly of the DCCT 1 Insert the DCCT in the aluminium busbar where it will be placed 2 Join the DCCT to t
159. rder to disconnect the fan supply wire 3 Unscrew the 12 Phillips M5x10 DIN 7895H which join the 3 lower covers and the SD700 chassis 4 Remove the 3 lower covers Upper cover M4X8 2 Lower covers M5X10 Figure 3 4 Disassembly of the upper and lower covers Assembly of the upper cover and lower covers 1 Screw the 3 lowers covers to the SD700 chassis with 12 Phillips screws M5x10 DIN 7895H 2 Connect the fan supply wire 3 Join the upper cover and the SD700 chassis with 6 Phillips screws M4x8 DIN 7895H SERVICE MANUAL 115 50700 7 5 4 CONTROL BOARD Disassembly of the Control Board The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 5 while reading these instructions 1 Unscrew the 6 plastic screws M3x8 DIN 933 which join the control PCB and the plastic hexagonal spacers M3x20 2 Remove the Control Board remove the 40 32 y 28 pin connectors which join the Control Board and the Power Board 3 When the control Board is out place it in a static proof bag for safekeeping M3x8 Figure 3 5 Disassembly of the Control Board 116 SERVICE MANUAL POWER ELECTRONICS Assembly of the Control Board Continue to observe static safe work procedures 1 Avoid an excessive handling of the new Control PCB 2 Place the new Control Board on the hexagonal spacers M3x20 and fit the holes figure 4 5
160. reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board 26 SERVICE MANUAL POWER ELECTRONICS 50700 b Fuses of the Power Connection Board In the power connection board there are 3 fuses located where the figure 1 5 shows 2 1 38 76 GR 48 1 77 0163 FUSE 1 FUSE 2 FUSE 3 Figure 1 5 Fuses of the power connection board Fuse 1 Fuse 2 and Fuse 3 Function Protection for input voltage measurement circuit before the chokes Value of 2 A Possible reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board SERVICE MANUAL 27 50700 POWER ELECTRONICS 28 4 4 3 Fuses Frame 3 60 75 a Fuses of the Power Board In the power board there are 6 fuses located where the figure 1 4 shows FUSE4 EUSE5 HJSE 6 Ti bbe E EE dr CT dicm M CINE A CAJ FUSE 1 FUSE 2 FUSE 3 Figure 1 4 Fuses of the power board Fuse 1 and Fuse 2 Characteristics They are very fast acting ceramic fuses Their value is 4 A Function Power supply for the power board from its bus Possible reason for failure Internal short circuit in the power board Action Replace the power board Fuse 3 Characteristics glass tube fuse The value is 100 mA Function It discharges the bus of the drive Possible reason for failure Faulty circuit and bus always discharging Action Replace the power board Fuse 4 Fuse 5 and Fuse 6
161. rews M4x12 DIN 7895H which join the power fan its support Figure 5 20 b Disassembly of the fan support Assembly of the Fan power support 1 Before inserting the fan support into the fan box connect the fan power wire 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Screw the Phillips screw M4x8 DIN 7895H which join the fan support and the fan box SERVICE MANUAL 163 50700 POWER ELECTRONICS 7 7 18 AC CHOKE Disassembly of the AC Choke Before proceeding the bars which join the AC choke and the SCRs section 7 7 15 and upper cover section 7 7 2 must been disassembled Follow figure 5 22 while reading these instructions 1 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 2 Disassemble the AC choke of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws 8 25 DIN 961 which join the power wires and the AC choke 3 Disassemble the AC choke Figure 5 22 Disassembly of the AC choke Assembly of the AC choke 1 Bring the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN 961 2 Insert the AC choke into the chassis and screw the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 164 SERVICE MANUAL POWER ELECTRONICS 7 8 50700 FRAME 7 7 8 1 ACCESS INSIDE Disa
162. rmal operation always OFF It switches ON when it detects am excessive temperature in 485 communications integrated circuit LED 1201 RED colour During normal operation always OFF It switches ON when the hardware current limit is on D1101 D10 D1201 rs Tm rpum mp ome TERE ott jm Sm le lt AOMA pee 2 dE am n ca p m cal p un D 0 BFN sis oH D901 Figure 1 9 Control PCB LEDs SERVICE MANUAL 53 50700 POWER ELECTRONICS c Upper Gate Drive Upper Econodual Driver GREEN colour In normal operation always ON They switch OFF when they detect an IGBT failure Du Du Figure1 10 Upper Gate Drive LEDs If the LEDs of all the IGBTs switch OFF that means that the Power PCB 4 fuses have blown 54 SERVICE MANUAL POWER ELECTRONICS 5 CONNECTIONS 5 1 Power PCB SCR trigger TEMP SCR E After AC choke voltage measurement Before AC choke voltage measurement Quickly discharge resistor DC BUS measurement current measurement Output voltage NTC2 measurement NTC3 1 J804 Outside power CHASSIS EOST due el DC BUS measure it connects this pcb with one of the thyristors where the voltage in the bus is measured Module 3 Module 1 Fan s p
163. rt 2 Put the electronic board of the bus and the Capacitors in the correct position 3 Insert the screws of the capacitors with a tightening pressure of 3N m SERVICE MANUAL 113 50700 POWER ELECTRONICS 7 9 50700 FRAME 4 7 5 1 ACCESS TO THE INTERIOR OF THE DRIVE Disassembly of the covers Follow figure 3 7 and figure 3 2 while reading these instructions 1 Open the SDrive door 2 Disconnect the Display from the Control PCB 3 Disconnect all control terminals analogue inputs digital inputs PTC Figure 3 2 Access inside Assembly of the SD700 trims 1 Place the trims over the supports sides of the chassis as it is shown in the figure 3 2 2 Screw the trims to the supports of the side pannels of the chassis with 6 Phillips M4x8 DIN 7895H 3 Screw Phillips 4 12 DIN 7895H which joins the side of the trim and the Formica Terminales de control E piece 4 Place the plastic protector of the power terminals on the sides of the drive Figure 3 1 Disconnect the Display and the control 5 Connect all the wiring of the control terminals terminals analogue inputs digital inputs PTC 4 Unscrew the 6 Phillips 4 8 7895 6 Connect the Display to the Control PCB screws which joins the trims and the SDrive through the Ethernet wire chassis Disassembly of the plastic protector 5 Unscrew the Phillips 4 12 DIN 7895H screw which joins the side of the
164. s 690V NUMBER SV NUMBER 50701300X 2067 50702105 30701506 P067 SD702505X P114 50701706 IGBT IGBT 380V NUMBER 690V NUMBER BUS CAPACITORS 380V 0702105 690V I 50702505 0701306 50701506 SDT01706x SERVICE MANUAL 199 50700 POWER ELECTRONICS DCCT DCCT 6907 NUMBER DCCT 380V NUMBER 1 SD701306X 1090 50702105 L116 SD701506X 1090 50702505 1090 0701706 Output Turns Wire Output Turns Wire choke section choke section 5 0 s wme s 9 FANS T 30V 507025058 TT BR 2 Ux a Ws Um _____ uy Ue WANDA US Um 4 L163 8414NH 24VDC 2 4W 050 8314H 24VDC 6W Uis ovea L120 4314 180 24VDC 9 5W 4 Ny Pa aw EM L192 4114NXU IP54 24VDC 4 5W 200 SERVICE MANUAL PONER ae 50700 8 3 50700 Frame 6 50700 FRAME 6 380 IP54 IP20 models SD703305X SD703705X 50704605 Control PCB E024HA E024HA E024HA Power PCB E028GJ E028GJ E0286J SD700FRAME 6 690V IP54 IP20 models SD702106X 0702606 50703206 C
165. s till they fit in the connectors of the Power Board Do not apply force 4 Screw the 6 plastic screws M3x8 DIN 933 in the plastic hexagonal spacers M3x20 SERVICE MANUAL 133 50700 7 6 4 POWER BOARD Disassembly of the Power board Before proceeding the Control Board must have been removed section 7 6 3 The use of a static grounding wrist strap and being earthed is highly required Follow figure 4 5 while eading these instructions 1 Disconnect the wires which connected in this Board Before AC choke oltage measurement v DC Bus Voltage measurement Quickly discharge ts resistor SCR Trigger Fan supply After choke voltage measurement measurement Figure 4 5 Disconnection of all Power Board wires 2 Remove the 6 plastic hexagonal spacers M3x20 inserted in the Power Board 3 Unscrew the 5 Phillips screws M3x8 DIN 7895H 4 Disassemble the Power Board Assembly of the Power Board Continue to observe static safe work procedures 1 Avoid excessive handling of the new Power PCB 2 Place the new Power Board on the electric tray and fit the holes in the electric tray bolts figure 7 6 3 Screw the 5 Phillips screws M3x8 DIN 7895H on the electric tray bolts 4 Connect the Power Board wiring figure 7 6 5 Place the plastic hexagonal spacers M3x20 on the Power Board so that the Control Board can be inserted later 134 SERVICE
166. s M5x12 DIN 7895H which join the SCR and the heat exchanger 4 Insert the bars figure 6 17 a 5 Insert the voltage measure wires after the AC Choke by unscrewing the Phillips screws M4x8 DIN 7895H which join their wires and the bars 6 Screw the Phillips screws M6x20 DIN 7895H which join the bars and the AC Choke 7 Screw Phillips screws M6x16 DIN 7895H which join the bars and the SCRs 178 SERVICE MANUAL POWER ELECTRONICS 7 8 16 POWER FAN Disassembly of the Fan support Folow figure 6 18 while reading these instructions 1 Unscrew the Phillips screw M4x8 DIN 7895H which join the fan support and the fan box 2 Unscrew the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Disconenct the fan power wire 4 Remove the fan support S AY WT M N eu d M AU IA bw CEN m 1 1 Figura 6 18 Disassembly of the Power Fan POWER ELECTRONICS 24VDC 2A 48W 172X172 FAN Follow figure 6 19 a while reading these instructions Unscrew the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan and its support M4x60 Figure 6 19 Disassembly of the fan support 24VDC 89W 172X172 FAN Follow figure 6 19 b while reading these instructions Unscrew the 2 Phillips screws M4x12 DIN 7895H which join the power fan with its support Fig
167. s flow detection indicates flow absence according to the parameters set See the protections set in G25 6 to obtain more detailed information Possible cause The pump is operating with no load Setting protections in group G25 6 are wrong Actions Check if the pump of the installation is operating without water verify the settings of the parameters referred to the cavitation protection depending on the installation Fault F70 IRRIGATOR F Description The digital input configured as 62 IRRIGAT TRIP detects that an external fault in the drive occurred Possible cause An external trip occurred due to the closure of a ontact in the digital input configured as IRRIGAT TRIP Actions Verify your irrigating equipment and check if the connections between the drive and the irrigating equipment are correct SERVICE MANUAL POWER ELECTRONICS 50700 Fault F71 CYCLING Description Conditions set in group G25 6 are not met compared to the cycle time of the drive and the cycle counter The SD700 has started a higher number of times than the allowed number without softening the time set Possible cause The drive shows several start stop cycles wake up sleep in a short time Actions Verify possible leakages in the installation verify the settings of this protection in group G25 6 Fault F72 INPRES SW Description This fault ocurrs mainly due to two causes 1 After starting the system the time set in G25 9 11 has been exceeded witho
168. s of the drive see figure 7 1 22 Figura 7 1 23 a B Assembly of the heatsink fan 1 Put the new fan and fix it with the screws 2 Remove the heatsink 2 Connect the power supply cable Assembly of the heatsink 3 Fix the cover 1 Fix the new heatsink to the chassis by using 4 screws M5x10 with a tightening pressure of 3N m 2 Join the top and the bottom of the chassis 3 Spread the heatsink area where the IGBT of the power connections board is going to be placed with thermal conductor paste 4 Fix the DC bus see section 7 1 8 5 Fix the power connections board see section 7 1 19 6 Fix the gate drive board see section 7 1 7 72 SERVICE MANUAL POWER ELECTRONICS 7 2 50700 FRAME 2 ACCESS TO THE INSIDE OF THE DRIVE 1 2 1 Disassembly of the embellishers In order to repair or replace any component of the drive you should access to the inside of it See figure 7 2 1 and figure 7 2 2 while reading the following instructions 1 Remove the drive s door by unscrewing the 4 M4x8 DIN 7895H screws which fix it the the chassis 2 Disconnect the Display For this disconnect 5 ethernet cable which joins the display and the drive Push the tab of the RJ45 connector and pull it up 6 3 Disconnect all cables from the control terminals of the drive analogue inputs and outputs digital inouts and outputs PTC input Display Q 7 8 Terminales de control wm
169. s screws M3x8 DIN 7895H to the electric tray bolts 4 Connect the power board wiring figure 6 6 a M3x20 Figure 6 6 b Disassembly of the Power Board 168 SERVICE MANUAL 7 8 5 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly of the Drive Select The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 Assembly of the_IGBT selection module The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 M3x8 Figure 6 7 Disassembly o Drive select IGBT selection module Assembly of Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 Assembly of IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 POWER ELECTRONICS 7 8 6 SNUBBER TRIGGER AND SOFT CHARGE PROTECTION BOARD Disassembly of the Snubber trigger and soft charge protection board The use of a static grounding wrist strap and being earthed is highly required Follow figure 6 8 a figure 6
170. screws M5X16 DIN 7895H with a tightening pressure of 5N m Screw the 6 screws M3x6 that join the board and the chassis Connect all cables before described SERVICE MANUAL POWER ELECTRONICS 7 1 10 SINGLE PHASE CHOKE Disassembly of the single phase choke In order to remove the single phase choke you should remove the embellishers see section 7 1 1 and the tray for the boards see figure 7 1 7 before 1 Unscrew the 4 screws M5X10 which join the bottom of the chassis and the top See figure 7 1 14 Figure 7 1 14 Before separating the two chassis completely disconnect the fan cable see figure 7 1 15 Figure 7 1 15 Remove the top of the chassis and put it face down see figure 7 1 18 Figure 7 1 18 Disconnect the cables of the single phase choke by removing the screws 5 10 which joins them and the spacers see figure 7 1 19 POWER ELECTRONICS Figure 7 1 19 5 Remove the 4 nuts M5 which fix the choke to the chassis 6 Remove the choke Assembly of the single phase choke 1 Fix the new single phase choke to the chassis by using the nuts 5 2 Connect the cables of the choke to the Spacers see figure 7 1 19 3 Connect the cable for the fans 4 Assembly again the top of the chassis with the bottom by means of the 4 screws M5X10 DIN 7895H 50700 7 1 11 DV DT CHOKES Disassembly of the dV dt chokes It is necessary to remove the embellishers see sect
171. sert the Control Board later SD700 M3x20 M3x8 7 Figure 3 7 Disassembly of the Power Board SERVICE MANUAL 117 50700 7 5 6 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly of the Drive Select Continue to observe static safe work procedures Follow figure 3 8 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 5 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 M3x8 Figure 3 8 Disassembly of the Drive select IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 118 SERVICE MANUAL POWER ELECTRONICS 757 SNUBBER TRIGGER SOFT CHARGE PROTECTION BOARD Disassembly of the Snubber trigger and soft charge protection board The use of a static grounding wrist strap and being earthed is highly required Follow figure 3 9 a figure 3 9 b and figure 3 9 c w
172. sis from the bottom follow the steps described in section 7 2 9 and 7 2 10 Follow the steps while seeing the figure 7 2 19 Figure 7 2 19 1 Remove the 4 screws M4x8 DIN 7895H which fix dV dt chokes to the chassis see figure 7 2 22 2 Remove the 4 screws M4x8 DIN 7895H which join the fan structure to the chassis see figure 7 2 22 Figure 7 2 22 3 Disconnect all the cables of dV dt choke which are joined to the fan structure see figure 7 2 20 50700 Figure 7 2 20 4 Once disconnected the cables cut the terminals in order to get the cables out the structure see figure 7 2 21 Figure 72 21 5 Remove dV dt chokes Assembly dV dt chokes 1 Put the cables of the new dV dt choke through the holes of the fan structure see figure 7 2 21 2 Putthe terminals of the ne dV dt choke and connect them to the fan structure see figures 7 2 23 and 7 2 20 Figure 7 2 23 3 Fixthe fan structure to the chassis by using the 4 screws 4 8 DIN 7895H See figure 7 2 22 4 Fix dV dt chokes to the chassis by using the 4 screws M4x8 DIN 7895H See figure 7 2 22 5 Assembly again the top and the bottom of the chassis Follow the steps described in section 7 2 10 see figure 7 2 18 SERVICE MANUAL 81 50700 7 2 12 HEATSINK Disassembly of the heatsink In order to remove de heatsink first you should remove the embellishers see section 7 2 1 the tray for the boards se
173. ssembly of the covers Follow figure 6 7 and figure 6 2 while reading these instructions 1 Open the SDrive door 2 Disconnect the Display from the Control Board 3 Disconnect all control terminals analogue inputs digital inputs PTC Se terminals 22 Fan only IP54 lt p models WSS Figure 6 1 Disconnect the Display and the control terminals 4 Unscrew the 6 Phillips screws 4 12 DIN 7895H which join the cover and the upper part of the chassis 5 Unscrew the 6 Phillips screws M4x8 DIN 7895H which join the cover and the lower part of the chassis 6 In IP54 models disconnect the fan power wires which are placed in the covers before disassembling them 7 Remove the covers 50700 M4x121 Figure 6 2 Disassembly of the covers Assembly of the SD700 Covers Place the covers on the chassis as it is shown in figure 6 2 Screw the 6 Phillips screws M4x12 DIN 7895H which join the covers and the upper part of the chassis Screw the 6 Phillips screws M4x8 DIN 7895H which join the covers and the lower part of the chassis Connect the control terminals analogue inputs digital inputs PTC Connect the Display Disassembly of the plastic protector 1 Unscrew the 6 Phillips M4x8 DIN 7895 H which join the plastic protector and the SDrive chassis Disassemble the plastic protector SERVICE MANUAL 165 50700 POWER ELECTRONICS 7 8
174. terminals and the board figure 7 8 a 6 Connect all output wiring figure 7 8 b SD700 7 9 7 FANS POWER SUPPLY Disassembly of the fans power supply The use of a static grounding wrist strap and being earthed is highly required 7 9 while Follow figure these instructions reading 1 Disconnect the 2 fans power wires and the power wire of the fans power supply 2 Unscrew the 3 Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Remove the fan power supply Power Fans power supply S Fans power supply try M3X6 Fans power AHT Figure 7 9 Disassembly of the fans power supply Assembly of the fans power suppl Continue to observe static safe work procedures 1 Put the new fans power supply in the fan tray 2 Screw the 3 Phillips screws M3x6 DIN 7895H which join the fans supply power and the fan tray 3 Connect the 2 fans power wires and the fan power supply power wire SERVICE MANUAL 185 50700 POWER ELECTRONICS 7 9 8 OUTPUT CHOKE Disassembly of the output choke Follow figure 7 10 while reading these instructions 1 Unscrew the 2 hexagonal screws M8x25 DIN 933 which join the output choke and the DCCT bar and output bar 2 Disassemble the output choke 8 25 1 Figure 7 10 Disassembly of the output choke Assembly of the output choke 1 Insert the output choke as it is shown in figure 7 10 2
175. the possibility of personal injury TRIAL RUN Verify all parameters before operating the drive Alteration of parameters may be required depending on application and load Always apply voltage and current signals to each terminal that are within levels indicated within this manual Otherwise damage to the drive may result SERVICE MANUAL POWER ELECTRONICS 50700 EARTH CONNECTION The drive is a high frequency switching device and leakage current may flow Ground the drive to avoid electrical shock Use caution to prevent the possibility of personal injury Connect only to the dedicated ground terminal of the drive Do not use the case or the chassis screw for grounding When installing grounding wire should be connected the first and removed the last Motor ground must be connected to the drive ground terminal and not to the installation s ground We recommend that the section of the ground connection cable should be equal or higher than the active conductor Installation ground must be connected to the drive ground terminal SERVICE MANUAL 7 50700 POWER ELECTRONICS 1 INTRODUCTION 1 8 1 About this manual This manual refers to the SD700 Variable Speed Drive Specific models are shown in Table 1 380V 690V 0700905 SD700526X 0701155 SD700626X 50701505 50700806 0701705 0701056 0702105 0701306 570 SD705805X SD703856X FRAME 7 SD706505X SD704606X SD707205X re SIN
176. the tab of the RJ45 connector and pull it up 3 Disconnect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input SD700 Remove the plastic protector for the power connections Figure 7 4 2 Access to the inside of the drive Assembly of the embellishers Display 1 Q 2 3 Cable Ethernet 4 Conector RJ45 5 Terminales C de control Figure 7 4 1 Display connection and control terminals SD70ITMOO01AE 4 Remove the 4 Phillips M4x8 DIN 7895H screws with their corresponding whasers and grover whasers which join the embellishers to the chassis of the drive 5 In case of IP54 model of SD700 drives disconnect the power supply of the fans that are in the embellishers 6 Remove the embellishers Place the embellishers on the supports of the drive s sides as the figures 7 4 2 shows Screw the embellishers to the supports of the sides with 4 Phillips M4x8 DIN 7895H Screws Put the plastic protector for the power connections on the sides of the drive Connect all cables from the control terminals of the drive analogue inputs and outputs digital inputs and outputs PTC input Connect the Display by means of the ethernet cable which goes from the display to the drive SERVICE MANUAL 99 50700 7 4 2 DOOR Disassembly the door See the figure 7 4 3 while following the next instructions 1 Ope
177. trol terminals analogue inputs digital inputs PTC Cover fan model IP54 Display TN Figure 5 1 Disconnect the Display and the control terminals 4 Unscrew the 4 Phillips screws 4 12 DIN 7895H which join the cover and the chassis upper part 5 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the cover and the lower part of the chassis 6 In IP54 models disconnect the fan power wires which are in the covers before removing them 7 Disassemble the covers SD700 4 121 Figure 5 2 Disassembly of the covers Assembly of the SD700 Covers 1 2 Place the covers on the chassis as it is shown in figure 5 2 Screw the 4 Phillips screws M4x12 DIN 7895H which join the covers and the upper part of thechassis Screw the 4 Phillips screws M4x8 DIN 7895H which join the covers and the lower part of the chassis Connect the control terminals analogue inputs digital inputs PTC Connect the Display SERVICE MANUAL 149 Disassembly of the plastic protector 1 Unscrew the 5 Phillips M4x8 DIN 7895 H which join the plastic protector and the SDrive chassis 2 Remove the plastic protector Figure 5 3 Disassembly of the plastic protector Assembly of the plastic protector 1 Place the power terminals plastic protector on the SDrive chassis by screwing the 5 Phillips M4x8 DIN 7895H 7 7 2 UPPER COVER Disassembly of the upper cover Fol
178. ts value is 4A Function DC Bus Discharge Possible reason for failure Circuit damaged and DC Bus always discharged Action Change the Power PCB Fuse 4 Caracter sticas Glass fuse This is a 2A fuse Function 15V IGBT supply SERVICE MANUAL BI oo Loo POWER ELECTRONICS FUSE 4 POWER ELECTRONICS 50700 Possible reason for failure IGBT damaged Action Check IGBTs Section 6 4 b Snubber PCB FRAME 4 FUSE 1A FUSE 1B FUSE 2 FUSE 2 FUSE 3A FUSE 3B APS EAE E 5 461 ul Figure 1 5 Frame 4 Snubber PCB fuses FRAME 5 6 7 8 FUSE 1A FUSE 1B FUSE 2A FUSE 2B FUSE 3A FUSE 3B 1 1B IN 2 1 1 VOLTAGE VOLTAGE TENSION z COOB5RB corga wey c qe 1 2 WERE Figure 1 6 Frame 5 6 7 8 Snubber fuses Fuse 1A 2A 3A Characteristics These are ultrarrapid ceramic fuses These fuses are 4A Function 1 Soft circuit charge protection 2 Protection of the input voltage measure circuit after the AC choke Possible reason for failure Short circuit in the Power PCB Action Change the Power PCB Fuse 1B 2B 3B SERVICE MANUAL 33 50700 POWER ELECTRONICS Characteristics These are ultrarrapid ceramic fuses Their value depends on the device Function Protection of
179. turn on Connect the Display and verify that there are not faults and compare the voltage of variac Control Gate drive PCB Figure 2 9 Soft Power Supply Connections SERVICE MANUAL 61 50700 POWER ELECTRONICS 6 6 Checking external inputs 62 If the 50700 powers up correctly but fails to respond to external inputs the following procedures will enable these inputs to be checked Before checking the external inputs we must configure the SD700 in local mode Screen G4 1 CNTROL MODE 1 X1 CONNECTOR 24V Usr DI Common Terminal 24 gt 50 PMP START STP 012 3 63 SETPONT 1 013 3 64 SETPONT PIN2 014 gt 65 SETPONT PINS 015 gt 00 Not used Free programming Multifunction Digital Inputs 016 3 00 Not used Free programming Motor PTC Input Feedback Signal 4 20mA Programmable as V or mA Analogue Signal Common Common Terminal OVdc Common Terminal 24Vdc Figure 2 10 External inputs 6 6 1 Check the analogue inputs Analoque input 1 Jumper input 19 with input 11 and input 18 with input 10 In the screen SV 3 ANLG IN1 or SV 3 AIN1 Refr the value of the analogue input 1 has to be the highest one allowed Analoque input 2 Jumper input 19 with input 13 and input 18 with input 12 In the screen SV 3 ANLG IN2 or SV 3 AIN
180. ult message will be displayed until the fault is over and the drive is reset Fault Messages Pinse 391 3900 Udc S4AU 1 LAST FAULT 59 It shows the faults of the drive In the upper line are displayed the conditions at trip moment SD70ITCO0021AlI Figure 1 1 Fault displaying Programming Line 4 2 Faults List Fault I LIM FLT Description Output current has reached a dangerous level The value is above 220 of the drive rated current Protection is activated instantaneously Possible cause Motor output short circuit Wiring fault Circuit fault Motor fault Actions Check output cables and motor for possible wiring faults or short circuits Fault F2 V LIM FLT Description DC Bus voltage has reached a dangerous level gt 850Vdc Hardware Protection Drive will cut off the output to the motor Possible cause High voltage peak on the input High load regeneration Deceleration ramp too high 12 SERVICE MANUAL POWER ELECTRONICS 50700 Actions Check conditions of input power supply Decrease deceleration ramps parameters G5 2 DECEL1 and 5 4 DECEL2 Fault F3 PDINT FLT Description Bus voltage and the output current of the device have reached dangerous levels Possible cause See faults F1 and F2 Actions See faults F1 and F2 Fault FA U DESAT F5 DESAT F6 V F7 V DESAT F8 W DESAT F9 W DESAT Description An Internal protection tripped within the IGBT
181. ure 6 19 b Removing fan support Assembly of the Fan power support 1 Before inserting the fan support in the fan box connect the fan power wire 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Screw the Phillips M4x8 DIN 7895H which join the fan support and the fan box SD700 7 8 17 AC CHOKE Disassembly of the AC Choke Before proceeding the bars which join the AC choke and the SCRs section 7 8 15 and the Upper cover section 7 8 2 must have been disassembled Follow figure 6 20 while instructions reading these 1 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 2 Remove the AC choke out of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws 8 25 DIN 961 which join the power wires and the AC choke 3 Disassemble the AC choke Figure 6 20 Disasembly of the AC choke Assembly of the AC choke 1 Place the AC choke near to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN 961 2 Place the AC choke in the chassis and screw the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis SERVICE MANUAL 179 50700 1 9 50700 FRAME 8 7 9 1 ACCESS INSIDE Disassembly of the covers Follow figure 7 7 y la figure 7 2 while reading these instructions 1 Open the SDrive door 2 Disconnect the
182. ure 7 1 7 Disconnect all connected wires from power board 3 Remove the 6 hexagonal plastic spacers M3x20 which are joined to the electronic tray and support the control board 4 Unscrew the 5 Phillips screws M3x8 DIN 7895H 5 Remove the power board of the drive Assembly of the power board 1 Continue with the safety conditions which are described in the previous section 2 While replacing the power board avoid an excessive handling of the board 3 Pick the new power board from the static proof bag 4 Put the new power board in the same place than the replaced one 5 Put the board on the electronic tray matching the bolts of the tray with the holes of the board see figure 7 1 8 SERVICE MANUAL 67 50700 POWER ELECTRONICS 7 1 6 DRIVE SELECT BOARD 6 Once the board is properly placed screw the 5 Phillips screws M3x8 DIN 7895H in Disassembly of the Drive Select board the bolts of the electronic tray Unscrew the 2 plastic screws M3x8 DIN 933 7 Connect the cables to the corresponding which join this board and the plastic hexagonal connectors see figure 7 1 7 spacers M3x12 8 Put the hexagonal plastic spacers M3x20 screwing them in their corresponding bolts of the electronic tray in order to place the MAXxB T control board later Drive Select M3x20 7 Figure 3 8a Disassembly of the Drive Select board Assembly of the Drive Select board Put the drive select
183. us on power board Value of 4 A Possible reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board 24 SERVICE MANUAL POWER ELECTRONICS 50700 b Fuses of the Power Connection Board In the power connection board there are 3 fuses located where the figure 1 5 shows FUSE 1 FUSE 2 FUSE3 p uu wd 1 5 gt E Figure 1 5 Fuses of power connection board Fuse 1 Fuse 2 and Fuse 3 Function Protection for input voltage measurement circuit before the chokes Value of 2 A Possible reason for failure Fuse fault or faulty circuit Action Replace the fuse or the board SERVICE MANUAL 25 50700 POWER ELECTRONICS 4 4 3 Fuses Frame 2 a Fuses of the Power Board In the power board there are 2 fuses located where the figure 1 4 shows FUSE FUSE 2 _ s He m 3 _ EH a __ TE mad ii ET Adm DRRECEEE E T 1 ad ideals H B k b LL al UNE X ad Figure 1 4 Fuses of the power board Fuse 1 and Fuse 2 Function protection for the fast charge circuits of the bus on power board Value of 4 A Possible
184. ut the digital input configured as PRESSUR SWITC being activated 2 2 After the priming pump has stopped and the drive pump has started the digital input configured as PRESSUR SWITC 15 opened during the time set in G25 9 10 Possible cause Breakage or low water in aspiration circuit Actions Verify the water level in the aspiration circuit well tank etc Verify the status of the pressure switch SERVICE MANUAL 21 50700 POWER ELECTRONICS 4 3 Display fault YES Look for the solution failure Change The Displa did Control PCB ON Section 4 2 YES Failure Power PCB supply power YES There is input Led DC BUS ON Change Power PCB Change Power PCB voltage Input fuses Leds Power OK PCB OK Section 4 4 1 Section 4 51 Verify instalation Change Display There is voltage inBus Section 4 3 Power PCB Change Power fuses OK Section 4 4 2 Change Power PCB Fuses Figure 1 2 Display Fault 22 SERVICE MANUAL POWER ELECTRONICS 50700 4 4 Fuses fault The SDrive700 contains a certain number of fuses for safety reasons The failure of a fuse is not a normal event and is usually an indicative of further and more serious faults For this reason fuses failure should be investigated Most of the auxiliary fuses are located in the SDrive PCB A list of fuses with their locations possibl
185. w the Phillips screws M6x16 DIN 7895H which join the bars and the SCRs 2 Unscrew the Phillips screws M6x20 DIN 7895H which join the bars and the AC Choke 3 Remove all voltage measure cables after the the AC chokes by unscrewing the Phillips screws M4x8 DIN 7895H which join these wires and the bars 4 Unscrew the 4 Phillips screws M4x8 DIN 7895H which join the resistors support and the chassis 5 Remove the resistors Assembly of the soft charge and quick discharge resistors 1 Insert the resistors support in the chassis 2 Screw the 4 Phillips screws M4x8 DIN 7895H which join the resistors support and the chassis 3 Insert the bars figure 20 4 Insert all voltage measure cables after the AC chokes by screwing the Phillips screws M4x8 DIN 7895H which join these wires and the bars 5 Screw the Phillips screws M6x20 DIN 7895H which join the bars and the AC Choke 6 Screw the Phillips screws M6x16 DIN 7895H which join the bars and the SCRs POWER ELECTRONICS After AC Choke voltage measurement Figure 3 20 Assembly of the soft charge and quick discharge resistors 50700 7 5 19 SCRs Disassembly of the SCRs Before proceeding the bars which join the AC choke and the SCRs must been disassembled section 7 5 18 Follow figure 3 21 while reading these instructions 1 Unscrew the 2 Phillips screws M5x12 DIN 7895H which join the SCR with the heat excha
186. w the special hexagonal screws M5x20 which join the capacitor and the Bus 5 Remove the Bus 6 Remove the Bus and the middle Bus insulator 7 Unscrew the special hexagonal screws M5x20 which join the middle Bus and the capacitors 8 Remove the middle Bus 9 Remove the capacitors of their rings Assembly of the Bus capacitors 1 Putthe new capacitors on their rings 2 Insert the middle Bus figure 7 13 3 Screw the special hexagonal screws M5x20 4 Insert the Bus and the middle Bus insulator 5 Insert the Bus figure 7 13 6 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors 7 Put the Bus and the Bus insulator 8 Insert the Bus figure 7 13 9 Screw the special hexagonal screws M5x20 which join the Bus and the capacitors SERVICE MANUAL 189 50700 POWER ELECTRONICS 7 9 12 IGBTS CONNECTOR BOARD 1 Pe Disassembly of the IGBTs connector board In the SD700 frame 8 there are 3 IGBTs connector boards but in each board there are 4 upper Gate Drive connected The use of a static grounding wrist strap and being earthed is highly required Follow figure 7 14 while reading these instructions 1 Disconnect the IGBT trigger wire which connects this board and the Power board 2 Disconnect the 3 NTC wires which connect this board and the Upper Gate Drive 3 Unscrew the 2 Phillips screws M4x8 DIN 7895H wh
187. wer Board SD700 7 9 5 DRIVE SELECT AND IGBT SELECTION MODULE Disassembly of the Drive Select The use of a static grounding wrist strap and being earthed is highly required Follow figure 7 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 Assembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required Follow figure 7 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 M3x8 Figure 7 7 Disassembly of the Drive select and the IGBT selection module Disassembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 SERVICE MANUAL 183 50700 7 9 6 SNUBBER TRIGGER SOFT CHARGE PROTECTION BOARD Disassembly of the Snubber Trigger and Soft charge protection board The use of a static grounding wrist strap and being earthed is highly required Follow figure 7 8 a figure 7 8 b and figure 7 8 c while reading these instructions 1 Disconnect the voltage measure wire before and after the AC Choke by unscrewing the Phillips screws M4x8 DIN 7895H
188. which are described in the previous section 2 While replacing the pluggable PCB trigger thyristors avoid an excessive handling of the board 3 Pick the pluggable PCB of trigger thyristors from the static proof bag POWER ELECTRONICS 4 Put the board in the proper position as the figure 7 3 9 c shows matching the holes in the hexagonal plastic spacers M3x10 and plug the board in the connector of the power connections board Insert the 4 plastic screws M3x8 DIN 933 which join the back of the board to the hexagonal plastic spacers M3x10 Connect the cables to the thyristors and the communication cables to the power board trigger thyristors 50700 POWER CONNECTIONS BOARD 7 3 8 Disassembly of the power connections board Before proceeding you should remove the embellishers see section 7 3 1 the tray for the boards see figure 7 3 7 and the pluggable PCB of the trigger thyristors see section 7 3 7 1 The use of a static grounding wrist strap and being earthed is highly required to repair the unit Hemove the 9 screws that are fixed to the thyristors the 2 screws that are fixed to the bus and the 4 screws that are fixed to the IGBT M5X12 DIN 7895H Hemove the 3 screws that are fixed to the AC choke M6x16 DIN 7895H Remove the 5 Phillips screws M3x6 DIN 7895H See figure 7 3 10 up up Figure 7 3 10 Disassembly of the power connections board Assembly of the p
189. with higher temperature b Indicator Leds of Control Board D1101 D10 d 3 Imi Firme fh H1 dmi qm 00008 00 II jet P E 3 HD D CX D fop p pn 5 i t 1 0179 JU Jo 00 E Figure 1 7 Leds of the Control Board LED 10 GREEN colour In normal operation it is blinking It indicates that the microprocessor is operating correctly LED 901 GREEN colour In normal operation it is always ON It indicates that the power supply for the DSP 3 3V is correct LED 1101 GREEN colour In normal operation it is always OFF It is lit if there is overheating in the integrated circuit for RS485 communications LED 1201 RED colour In normal operation it is always OFF It is lit when the Hardware current limitation is performing SERVICE MANUAL 43 50700 POWER ELECTRONICS 44 c Indicator Leds of Dc Bus Board Figure 1 8 Leds of DC BUS LED 1 RED colour In normal operation it is always ON It indicates that DC Bus is powered LED 2 RED colour In normal operation it is ON during the soft charge and once the DC Bus is charge the led becomes OFF SERVICE MANUAL POWER ELECTRONICS 50700 d Indicator Leds of Pluggable Pcb of Trigger Thyristors 1 e9 T7T5A 2 ETE 21558 15 BURCH DISPARO TIRISTORES TALLA 3 C
190. wrist strap and being earthed is highly required Follow figure 5 9 while reading these instructions 1 Disconnect the 2 fans power wires and the power wire of the fans power supply 2 Unscrew the 3 Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Disassemble the fan power supply Power Fans power supply Fans power supply try M3X6 Fans power AT Figure 5 9 Disassembly of the fans supply power Assembly of the fans supply power Continue to observe static safe work procedures 1 Place the new fans supply power in the fan tray 2 Screw the Phillips screws M3x6 DIN 7895H which join the fans power supply and the fan tray 3 Connect the 2 fans power wires and the fan power supply power wire POWER ELECTRONICS 7 7 8 OUTPUT CHOKE Disassembly of the output choke Follow figure 5 10 while these instructions reading 1 Unscrew the 2 hexagonal screws M8x25 DIN 933 which join the output choke and the DCCT bar 2 Disassemble the output choke Assembly of the output choke 1 Place the output choke as it is shown in figure 5 11 2 Connect the terminals of the output choke wire to the DCCT bar by screwing the 2 hexagonal screws M8x25 DIN 933 50700 7 7 9 Disassembly of the DCCT Before proceeding the output choke must have been disassembled section 7 7 8 these Follow figure 5 11 while instructions reading 1
191. ws M4x12 DIN 7895H which join the power fan with its support Figure 3 23 b Removing fan support Assembly of the Fan power support 1 Before inserting the fan support in the fan box connect the fan power wire and then insert the fan support in the fan box 2 Screw the 2 Phillips screws M4x8 DIN 7895H which join the fan support and the output choke support 3 Screw Phillips screw M4x8 DIN 7895H which join the fan support with fan box POWER ELECTRONICS 7 5 21 AC CHOKE Disassembly of the AC Choke Before proceeding the bars which join the AC choke and the SCRs section 7 5 18 and the upper cover section 7 5 3 must have been disassembled Follow figure 3 24 while Instructions reading these 1 Disconnect the power wires to the input terminals because the wires are not long enough to remove the AC choke 2 Unscrew the 4 Phillips screws M6x16 DIN 7895H which join the AC choke and the chassis 3 Take the AC choke out of the chassis and disconnect the 3 power wires by unscrewing the hexagonal screws M8x25 DIN 961 which join the power wires and the AC choke 4 Remove the AC choke Cables de potencia 257 e Inductancia trif sica Figure 3 24 Disassembly of the AC choke Assembly of the AC choke 1 Bring near the AC choke to the chassis and connect the power wires by screwing the hexagonal screws M8x25 DIN 961 2 Insert the AC choke in the chassis and screw
192. x8 DIN 933 which join this Board and the plastic hexagonal spacers M3x13 Disassembly of the IGBT selection module The use of a static grounding wrist strap and being earthed is highly required Follow figure 5 7 while reading these instructions Unscrew the 2 plastic screws M3x8 DIN 933 which join this Board and the plastic hexagonal Spacers M3x13 M3x8 TR Figure 5 6 b Disassembly of the Power Board Figure 5 7 Disassembly of the Drive select and the IGBT selection module Assembly of the Drive Select Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 Assembly of the IGBT selection module Place the Board on the 2 plastic hexagonal spacers M3x13 and screw the 2 plastic screws M3x8 DIN 933 152 SERVICE MANUAL POWER ELECTRONICS 7 7 6 SNUBBER TRIGGER SOFT CHARGE PROTECTION BOARD Disassembly of the Snubber trigger and soft charge protection board The use of a static ground wrist strap and being earthed is highly required Follow figure 5 8 a figure 5 8 b and figure 5 8 c while reading these instructions 1 Disconnect the voltage measure cable before and after the AC by unscrewing the Phillips screws M4x8 DIN 7895H which join the wire terminals and the board figure 5 8 Disconnect all the output wiring figure 5 8 b Figure 5 8 a Disassembly of the snubber trigger and soft charge protectio
193. y of the IGBT Continue to observe static safe work procedures 1 Avoid an excessive handling of the new board 2 Remove the new IGBT of the static box 3 Spread the thermal paste over the IGBT lower side 4 Place the IGBT on the heat exchanger 5 Screw the 4 Phillips screws M5x16 DIN 7895H which join the IGBT and the heat exchanger 6 Put the DCCT Bar as it is shown in figure 4 17 7 Insert the DC Bus section 7 6 12 8 Place the Snubber capacitor on the DC Bus 9 Screw the 2 Phillips screws M6x12 DIN 7895H which join the Snubber capacitors and the IGBTs 144 SERVICE MANUAL SS gt gt POWER ELECTRONICS 10 Screw the 4 hexagonal spacers M3x18 where the Upper Gate Drive is inserted DCCT bar M3x18 M6x12 Snubber xD Figure 4 17 Assembly of the IGBT POWER ELECTRONICS 50700 7 6 17 SOFT CHARGE QUICK DISCHARGE RESISTORS Disassembly of the soft charge and quick discharge Before proceeding the Upper cover section 7 6 2 Snubber Trigger and soft charge board section 7 6 6 and the DC Bus section 7 6 12 must have been disassembled Follow figure 4 18 a and figure 4 18 b while reading these instructions 1 Unscrew the hexagonal screws M8x25 DIN 933 which join the bars and the SCRs 2 Remove the voltage measure cable the after AC choke by unscrewing the Phillips screws M4x8 DIN 7895H which join these wires an
194. yristor E Fig re 7 3 26 Assembly of the thyristors 1 Take the new thyristors and spread with thermal conductor paste the bottom of the thyristors 2 Put them over the heatsink matching the holes of the thyristor with the holes of the heatsink as the figure 7 3 26 shows 3 Insert the Phillips screws M5x16 DIN 7895H which join the thyristors with their heatsink 4 Connect the control cables of the thyristors SD700 7 3 16 FANS Disassembly of the power hetasink fan See the figure 7 3 27 while following the next instructions 1 Disconnect the power supply fan of the fan 2 Remove the 2 slotted cheese head screws M4x60 DIN 84 which join the power fan with the chassis 3 Remove the fan Figura 7 3 27 Assembly of the power heatsink fan 1 Putthe new fan and fix it with the screws 2 Connect the power supply cable to the fan Disassembly of the fan for the toroids See figure 7 3 28 while following ther next instructions 1 Disconnect the power supply cable 2 Remove the 4 slotted cheese head screws M4x40 DIN 84 which join the fan with the chassis 3 Remove the fan Figure 7 3 28 SERVICE MANUAL 95 50700 Assembly of the fan for the toroids 1 Put the new fan and fix it by using the screws 2 Connect the power fan cable to the fan 96 SERVICE MANUAL POWER ELECTRONICS 7 3 17 HEATSINK Disassembly of the heatsink In order to remove the heatsink first

Service Manual - Power Electronics

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