VSD Manual

Registration Code: 2946 1189 00

Date: 24/04/2009

Atlas Copco Airpower NV

www.atlascopco.com
VSD Repair Manual

INDEX

1. Preface ................................................................................................ 8
2. VSD basics ......................................................................................... 9
2.1 Components .................................................................................................................................. 9

3. Measurements on frequency converters Diodes ............................ 9

3.1 Diodes ........................................................................................................................................... 9
3.1.1 Testing rectifier diodes.......................................................................................................... 10
3.2 Thyristors..................................................................................................................................... 11
3.3 IGBTs .......................................................................................................................................... 11
3.4 Precharge resistor ....................................................................................................................... 12

4. Elektronikon module........................................................................ 13
4.1 Position of Components .............................................................................................................. 13
4.2 Faults and Alarms........................................................................................................................ 13
4.2.1 MK III faults and alarms ....................................................................................................... 13
4.2.2 MK III – Failures.................................................................................................................... 15
4.2.2.1 Recoverable Failures ..................................................................................................... 15
4.2.2.2 Unrecoverable failures generated by the module .......................................................... 16
4.2.2.3 Unrecoverable failures generated by the expansion modules....................................... 16
4.2.2.4 General failures generated by the expansion modules ................................................. 17
4.2.2.5 Recoverable failures during Autoconfiguration .............................................................. 18
4.2.2.6 Converter Related Failures ............................................................................................ 19
4.2.3 MK IV - Failures .................................................................................................................... 20
4.2.3.1 Converter Related Failures ............................................................................................ 20
4.4 Handling Software ACS 550........................................................................................................ 23
4.4.1 Communication Cable MK III and MK IV to VSD.................................................................. 23

5. ABB ACS 600.................................................................................... 24

5.1 Location of components....................................................................................................... 24
5.1.1 ACS 601 frame size R7................................................................................................... 24
5.1.2 ACS 604 frame size R8................................................................................................... 25
5.2 Faults and alarms ................................................................................................................ 26
5.2.1 ABB Converter failures.................................................................................................... 33
5.3 Repair Instructions............................................................................................................... 35
5.3.1 Capacitor reforming ......................................................................................................... 35
5.3.1.1 Method 2A .............................................................................................................. 35
5.3.1.2 Method 2B .............................................................................................................. 36
5.3.2 Replacing the circuit boards ................................................................................................. 37
5.3.2.1 Replacing the NAMC-51 (control) board ................................................................ 39
5.3.2.2 Replacing the NINT (main circuit interface) board ................................................. 40
5.3.2.3 Replacing the NPOW (power supply) board and their fuse.................................... 41
5.3.2.4 Replacing the NIOC (input output controller) card ................................................. 42
5.3.3 Changing current transducer........................................................................................... 42
5.3.4 Testing the diodes of the rectifier .................................................................................... 43
5.3.5 Testing the thyristors of the rectifier ................................................................................ 44
5.3.6 Testing the condition of the IGBT module....................................................................... 44
5.3.6.1 Measuring the collector-emitter resistance............................................................. 44
5.3.6.2 Measuring the emitter ............................................................................................. 44
5.3.6.3 Measuring the diode ............................................................................................... 44
5.3.6.4 Measuring the gate ................................................................................................. 45
5.3.6.5 Measuring the thermistor ........................................................................................ 45
5.3.6.6 Measurements against frame ................................................................................. 45
5.3.7 Measuring the precharge resistor.................................................................................... 45
5.3.8 Changing air intake filter mats......................................................................................... 45
5.4 Important Parameters.................................................................................................................. 46
5.5 Service switch.............................................................................................................................. 50

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5.5.1 Functionality .................................................................................................................... 50

5.5.2 Position of Service switch................................................................................................ 50
5.5.3 Normal operation of compressor ..................................................................................... 50
5.5.4 Communication Fault ...................................................................................................... 50
5.5.5 Operation in Service Mode .................................................................................................. 50
5.5.6 Practical ...............................................................................................................................51
5.6 Installation ................................................................................................................................... 51
5.6.1 Mechanical Installation ......................................................................................................... 51
5.6.1.1 Installing in a Cooling Air Duct ....................................................................................... 52
5.6.2 Electrical Installation ............................................................................................................. 52
5.6.2.1 Main Fuses..................................................................................................................... 53
5.6.2.2 Input Cable Protection.................................................................................................... 54
5.6.2.3 Mains, Motor and Control Cable Connection ................................................................. 54
5.6.2.4 Cable Connections......................................................................................................... 55
5.6.2.5 Replacing the Front Cover ............................................................................................. 56
5.6.2.6 Control Panel in Remote Use......................................................................................... 57
5.7 Warranty Acceptance and Rejection ................................................................................... 57
5.8 Handling Software and firmware ................................................................................................. 57
5.8.1 Panel Operation .................................................................................................................... 57
5.9 DriveWindow ...............................................................................................................................59
5.9.1 Placement ......................................................................................................................... 59
5.9.2 Power Supply for the Module .......................................................................................... 59
5.9.3 Fibre Optic Link ............................................................................................................... 59
5.9.4 Connection Examples ..................................................................................................... 60
5.10 Spare Parts................................................................................................................................ 62

6. Siemens Masterdrives ..................................................................... 64

6.1 Position of components ....................................................................................................... 64
6.1.1 GA30VSD ........................................................................................................................ 64
6.1.2 GA50VSD ........................................................................................................................ 66
6.1.3 GA90VSD ........................................................................................................................ 70
6.1.4 Layout of Electronic Boards and its functions ................................................................. 73
6.1.4.1 PCU: PreCharge Unit ............................................................................................. 73
6.1.4.2 PCC: PreCharge Control ....................................................................................... 74
6.1.4.3 PSU: Power Supply Unit......................................................................................... 74
6.1.4.4 CUVC: Control Unit Vector Control ........................................................................ 75
6.1.4.5 IGD: IGBT Gate Driver............................................................................................ 76
6.1.4.6 IVI: InVerter Interface.............................................................................................. 76
6.1.4.7 ABO: Adapter Board ............................................................................................... 77
6.1.4.8 SMU: Snubber Modul Upper .................................................................................. 78
6.1.4.9 SML: Snubber Modul Lower ................................................................................... 78
6.1.4.10 PMU ........................................................................................................................ 78
6.1.4.11 Converter Fan .............................................................................................................. 79
6.1.5 Serial number of Master Drive......................................................................................... 79
6.2 Faults ................................................................................................................................... 80
6.3 Repair Instructions............................................................................................................... 83
6.3.1 General trouble shooting and repair................................................................................ 83
6.3.1.1 Repairing Damaged Converters: Some general hints............................................ 85
6.4 Important Parameters .......................................................................................................... 86
6.5 Service Switch ..................................................................................................................... 91
6.5.1 Functionality .................................................................................................................... 91
6.5.2 Location and lay-out of Service Switch ........................................................................... 91
6.5.3 Normal operation of compressor ..................................................................................... 92
6.5.4 Communication fault........................................................................................................ 92
6.5.5 Operation in Service Mode.............................................................................................. 93
6.6 Error detection with Testbox ................................................................................................ 93
6.6.1 Before starting................................................................................................................... 94
6.6.2 Mounting the Testbox...................................................................................................... 94
6.6.3 Measurements................................................................................................................. 96
6.6.3.1 Testing IGBT’s ........................................................................................................ 98
6.6.4 Remarks on Testbox ....................................................................................................... 99
6.7 Replacing CU board ............................................................................................................ 99

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6.7.1 Warning ........................................................................................................................... 99

6.7.2 Power section Definition................................................................................................ 100
6.7.3 Parameter reset............................................................................................................. 101
6.8 Fault memory..................................................................................................................... 102
6.8.1 How Faults are recorded ................................................................................................... 102
6.8.2 Fault group......................................................................................................................... 103
6.8.3 Operating Hours ............................................................................................................ 105
6.8.4 Function of P952 ........................................................................................................... 105
6.8.5 Working of the fault memory ......................................................................................... 106
6.8.6 Other functions .............................................................................................................. 108
6.9 Installation ................................................................................................................................. 109
6.9.1 EMC: Poor Grounding ................................................................................................... 109
6.9.2 EMC: Good Grounding.................................................................................................. 110
6.9.3 Operation with incorrect Ground ................................................................................... 110
6.9.4 Correct Motor Grounding............................................................................................... 110
6.9.5 Operation with incorrect Ground ................................................................................... 111
6.9.6 Operation with unearthed Supplies (IT Supplies).......................................................... 111
6.9.7 Torque settings.............................................................................................................. 111
6.9.7.1 For GA50VSD....................................................................................................... 111
6.9.7.2 For GA90VSD....................................................................................................... 116
6.10 Short Guide to Basic Functions ......................................................................................... 124
6.11 Warranty Acceptance and Rejection ................................................................................. 126
6.11.1 Potential Supply Problems ............................................................................................ 127
6.11.1.1 Maintenance............................................................................................................... 127
6.11.1.2 Environment ............................................................................................................... 127
6.11.2 Dust Contamination ........................................................................................................ 127
6.11.3 Re-Forming Capacitors ................................................................................................. 130
6.12 Handling Software and firmware ....................................................................................... 130
6.12.1 Changing Firmware ....................................................................................................... 130
6.12.1.1 Using DOS application.......................................................................................... 132
6.12.1.2 Using Windows application................................................................................... 135
6.12.1.3 Remarks (common for DOS and windows application)........................................ 138
6.12.2 Drive Monitor ................................................................................................................. 139
6.13 Spare Parts ........................................................................................................................ 158

7. Micromaster 440............................................................................ 165

7.1 Position of components ............................................................................................................ 165
7.1.1 Micromaster 440 Connection Drawing – Frame Size Fx ................................................... 165
7.1.2 General Circuit Diagram .................................................................................................... 166
7.1.3 Technical Connection Diagram.......................................................................................... 167
7.2 Faults and Alarms.................................................................................................................... 168
7.2.1 Faults ................................................................................................................................. 168
7.2.2 Alarms................................................................................................................................ 175
7.3 Repair Instructions.................................................................................................................... 180
7.3.1 General trouble shooting and repair ................................................................................... 180
7.3.1.1 Repairing Damaged Converters: Some general hints ................................................. 184
7.3.2 Repair and Exchange procedures .................................................................................... 184
7.3.2.1 For frame sizes Fx and Gx.......................................................................................... 185
7.3.2.2 Changing the Control Board........................................................................................ 185
7.3.2.3 Setting up the new control board ................................................................................ 188
7.3.3 Exchanging a Converter (Frame sizes A to F) .................................................................. 188
7.3.4 Repairing a Converter (Sizes Fx and Gx).......................................................................... 189
7.4 Important Parameters............................................................................................................... 189
7.5 Service Switch .......................................................................................................................... 191
7.5.1 Functionality....................................................................................................................... 191
7.5.2 Location and lay-out of Service Switch.............................................................................. 191
7.5.3 Normal operation of compressor ....................................................................................... 192
7.5.4 Communication Fault ......................................................................................................... 192
7.5.5 Operation in Service Mode ................................................................................................ 192
7.5.6 Practical ............................................................................................................................. 192
7.6 Error detection with Test-Box ................................................................................................... 193
7.6.1 Using a multimeter ............................................................................................................. 193

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7.6.1.1 Testing input diodes .................................................................................................... 193

7.6.1.2 Testing lower diodes ................................................................................................... 194
7.6.1.3 Testing output diodes.................................................................................................. 194
7.6.2 Test Box - Requirements ................................................................................................... 195
7.6.2.1 Test Box for testing of Larger MICROMASTERs........................................................ 195
7.6.2.2 Power component tests with test box ......................................................................... 196
7.7 Fault Memory............................................................................................................................ 199
7.7.1 How Faults are recorded ................................................................................................... 199
7.7.1.1 Fault Codes ................................................................................................................. 199
7.7.1.2 Fault and Warnings ..................................................................................................... 200
7.8 Installation ................................................................................................................................ 200
7.9 Warranty Acceptance and rejection................................................................................... 201
7.10 Handling Software and Firmware - Firmware and Power stack data on MM4....................... 202
7.10.1 Firmware .......................................................................................................................... 202
7.10.2 Parameter Settings .......................................................................................................... 202
7.10.3 Power Stack Data ............................................................................................................ 202
7.10.3.1 Power Stack Data and Control board settings .......................................................... 202
7.10.3.2 Checking the Power Stack Data ............................................................................... 203
7.10.3.3 Loading the Power Stack software ........................................................................... 203
7.10.4 Block Diagrams................................................................................................................ 204
7.10.4.1 MM440 Frame size A-C ............................................................................................ 204
7.10.4.2 MM420 Frame size A-C ............................................................................................ 204
7.10.4.3 Frame size D, E ........................................................................................................ 205
7.10.4.4 Frame size F ............................................................................................................. 205
7.10.4.5 Frame size Fx, Gx..................................................................................................... 206
7.10.5 Drive Monitor.................................................................................................................... 206
7.11 Spare Parts............................................................................................................................. 207

8. AC Simovert P- 6SE13 .................................................................. 209

8.1 Position of Components ........................................................................................................... 210
8.1.1 GA90VSD ........................................................................................................................... 210
8.1.2 AC Simovert P- 6SE13 : General Diagram......................................................................... 211
8.1.2 AC Simovert P- 6SE13 : General Diagram......................................................................... 211
8.1.1.1 CCU : Control card and microprocessor ...................................................................... 213
8.1.1.2 GAX : Power supply and extra functions ..................................................................... 213
8.1.1.3 PCC : Precharging card ............................................................................................... 214
8.1.1.4 FDC : Fan Control ........................................................................................................ 214
8.1.1.5 Fuses on GAX Card ..................................................................................................... 215
8.1.1.6 Connectors on GAX-card ............................................................................................. 216
8.1.1.7 Connectors on CCU Card ............................................................................................ 219
8.1.3 Order Number of Simovert P SE12/13 ............................................................................... 220
8.2 Faults and Alarms...................................................................................................................... 221
8.2.1 Communication Failure ................................................................................................. 226
8.3 Repair Instructions..................................................................................................................... 227
8.3.1 Output Current Measurement ............................................................................................. 227
8.3.2 Current Normalization on GAX Card .................................................................................. 228
8.3.3 GAX Removement .............................................................................................................. 231
8.3.4 Replacing the Fans ............................................................................................................. 232
8.4 Important Parameters................................................................................................................ 235
8.4.1 Operator Panel.................................................................................................................... 235
8.4.2 Assigning parameters ......................................................................................................... 238
8.5 Replacing CCU Board ............................................................................................................... 242
8.6 Fault Diagnosis.......................................................................................................................... 243
8.7 Installation ................................................................................................................................. 244
8.7.1 Installation and Mounting.................................................................................................... 244
8.7.1.1 Notes on Installation and Mounting.............................................................................. 244
8.7.1.2 Operator panel in Chassis Units .................................................................................. 244
8.7.1.3 Special conditions of Installation .................................................................................. 245
8.7.2 Connections ........................................................................................................................ 245
8.7.2.1 EMC ( Electromagnetic Compatibility ) ........................................................................ 245
8.7.2.2 Power Terminals .......................................................................................................... 246
8.7.2.3 Typical Connections..................................................................................................... 247

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8.7.3 Warranty Acceptance and Rejection .................................................................................. 249

8.8 Handling Software and Firmware .............................................................................................. 249
8.8.1 Software options ................................................................................................................. 249
8.8.2 Speed control using DC tacho and torque control (A10) .................................................... 250
8.8.3 Flying restart (A11) and kinetic buffer................................................................................. 251
8.9 Spare Parts................................................................................................................................ 252

9. ABB ACS 800.................................................................................. 255

9.1 Position of Components ............................................................................................................ 255
9.1.1 Main Circuit and Control ..................................................................................................... 256
9.2 Faults......................................................................................................................................... 257
9.3 Repair Instructions..................................................................................................................... 260
9.3.1 Measuring key electrical components................................................................................. 260
9.3.1.2 Charging Diode (V17) .................................................................................................. 260
9.3.1.3 Current Transducers (U31, U32, U33) (CTs)............................................................... 260
9.3.1.4 Fan Fuses (F41, F42) .................................................................................................. 260
9.3.1.5 Fan Transformer (T41)................................................................................................. 261
9.3.1.6 Thyristor/diode modules (V11, V12, V13) .................................................................... 261
9.3.2.7 IGBT Modules (V21, V22, V23).................................................................................... 261
9.4 Important Parameters................................................................................................................ 261
9.5 Installation ................................................................................................................................. 262
9.5.1 Mechanical Installation ....................................................................................................... 263
9.5.1.1 Mechanical Installation Steps....................................................................................... 263
9.5.2 Electrical Installation ........................................................................................................... 267
9.5.2.1 Planning the Electrical Installation ............................................................................... 267
9.5.2.2 Electrical Installation Steps .......................................................................................... 271
9.6 Warranty Acceptance and Rejection ................................................................................. 281
9.7 Handling Software and Firmware .............................................................................................. 281
9.7.1 DriveSize............................................................................................................................. 281
9.7.3 DriveWindow 2.................................................................................................................... 282
9.7.4 DriveWindow Light 2 ........................................................................................................... 283
9.7.5 DriveOPC............................................................................................................................ 284

ADDENDUM ........................................................................................ 285

A. Repair Instructions ...................................................................................................................... 285
I. Check input line voltage............................................................................................................ 285
II. How to Measure DC link voltage ............................................................................................ 287
III. How to check 3ph rectifier .................................................................................................... 287
IV. Check input currents............................................................................................................. 287
V. How to check the precharge resistor..................................................................................... 287
VI. Diagnostics ........................................................................................................................... 288
VII. How to check motor winding resistance .............................................................................. 289
VIII. How to overcome “Motor Stall”?.......................................................................................... 290
IX. How to check the Compressor condition.............................................................................. 290
X. Check P381 ............................................................................................................................ 290
XI. Check the KTY84 .................................................................................................................. 291
XII. How to check temperature sensor........................................................................................ 291
XIII. General parameters to check in Inverter Temperature problem ......................................... 291
XIV. UCE shutdowns .................................................................................................................. 291
XV. Fault in measured value sensing ......................................................................................... 292
XVI. How to overcome External fault 1 and External fault 2....................................................... 293
B. Repair Instructions – ABB ACS600 / 800 ................................................................................... 294
I. Heatsink .................................................................................................................................... 294
II. Fan ........................................................................................................................................... 294
III. Additional fan in IP 55 units and certain IP 21 units ............................................................... 296
IV. Capacitors .............................................................................................................................. 297
V. Reforming Capacitors.............................................................................................................. 297
VI. LEDs ....................................................................................................................................... 297
C. Cabling Instructions – ABB ACS 600 / 800 ................................................................................ 298
I. General Rules ........................................................................................................................... 298
II. Power Factor Compensation Capacitors ................................................................................. 299
III. Equipment Connected to the Motor Cable ............................................................................. 299

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IV. Protecting relay output contacts and attenuating disturbances in case of inductive loads .... 300
V. Motor Cable Shield .................................................................................................................. 300
VI. Control Cables........................................................................................................................ 300
VII. Connection of a Motor Temperature Sensor to the Drive I/O................................................ 301
VIII. Routing the Cables ............................................................................................................... 301
IX. Cabling of I/O and Fieldbus Modules ..................................................................................... 303
X. Fibre optic link ......................................................................................................................... 304
XI. External +24 V power supply for the RMIO board ................................................................. 304
XII. Installation Checklist.............................................................................................................. 307
XIII. Technical Data...................................................................................................................... 308
D. INSTRUCTIONS for the electrical installation of the Oil-free Air VSD compressors:................ 317

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VSD Repair Manual

1. Preface

Warning! All maintenance and repair work described in this chapter should only be undertaken
by a qualified electrician.

In our intention to solve problems on VSD compressors in the first line, a troubleshooting procedure
has been worked out for the most common faults concerning frequency converters.

This manual is intended as a guide for Atlas Copco Field Service Technicians doing service and
repair on VSD units equipped with the following frequency converters:

ACS60401202000C0000903
ACS60101405S00C1200003
ABB ACS600 ACS60401706000C0000903
ACS60401705000C0000903
ACS60402106000C0000903
ACS 800-01-0040-5 + K458 + E202
ABB ACS800
ACS 800-01-0070-5 + K458 + E202
6SE 7031-5EF60-0BB0
6SE 7031-5EF20-Z
6SE 7031-1FF20-0BB0
Siemens Masterdrive
6SE 7031-5EF60-0BB0
6SE 7031-1FF60-0BB0
6SE 7032-1EG60
6SE 6440-2AD31-1CA1
6SE 6440-2UD31-1CA1
6SE 6440-2AD32-2DA1
6SE 6440-2AD32-2DA2
6SE 6440-2AD33-7EA1
Siemens Micromaster
6SE 6440-2UD34-5FA1
6SE 6440-2UD35-5FA1
6SE 6440-2UD37-5FA1
6SE 6440-2UD38-8FA1
6SE 6440-2UD41-1FA0

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2. VSD basics

Variable Frequency Drives (VFDs) are solid-state power electronics, which are designed to enable
induction motors to operate at variable speed as opposed to fixed speed. VFDs are alternatively
called adjustable speed drives (ASD) or variable speed drives (VSD) or inverters.

Normally, an induction motor is constrained by design to a few specific. VFDs offer greater flexibility
and large energy savings potential particularly in compressor, fan and low head pump applications.
Today’s VFDs are typically pulse width modulation (PWM) drives that vary speeds by rectifying
incoming AC waveform to DC and then sending out a series of short DC voltage pulses to the motor.
By changing the timing and polarity of these pulses, the motor can be operated at any speed.

2.1 Components
We can distinguish the following components:

Rectifier: Converts the incoming three-phase AC voltage to DC voltage through the use of a three-
phase diode or thyristor bridge. A diode can be compared with a non-return valve. It allows current to
flow in one direction.

DC-link: Filters and stabilizes the DC voltage supplied by the rectifier. It consists of an inductor and a
capacitor, which insures a stable supply of DC voltage to the inverter.

Inverter: A three-phase bridge of IGBTs (Insulated Gate Bipolar Transistors). This device can be seen
as a semiconductor switch, capable of switching high power levels at high frequencies. It supplies the
motor with a variable voltage and frequency.

3. Measurements on frequency converters Diodes

3.1 Diodes
It is possible to test the power components using a multimeter to locate faults. Although this is not
foolproof, it is a quick and easy way of locating the nature and extent of power component faults.

Semiconductor diodes have a forward voltage drop of between 0.3 and 0.8V. Since these
components are nonlinear devices, this drop does not depend on the current. In the reverse direction,
there should be no measurable conduction.

A standard digital multimeter has a diode drop function that can be used to test all sizes of diodes.
Although it cannot be used to test IGBTs or Thyristors, faults in these components can often be
detected as a short circuit.

0.35V

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3.1.1 Testing rectifier diodes

Figure shows one of the three combinations.

–V11 –V12 –V13

–V14

–R11
1
–R14
–C11.1
1U1
3

1V1 –C12.1
4

1W1
–C13.1
2 500v

0.35V O.K.

C13 ONLY IN
500V SERIES

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3.2 Thyristors

Measuring Thyristor for short circuit

Result : ± 10 to 30 Ω

3.3 IGBTs

Measure IGBT diodes (in Diode area)

DC+ to output busbars:

Conducting direction Æ ~ 0,4 V
Reverse direction Æ Open Loop

DC– to output busbars:

Conducting direction Æ ~ 0,4 V
Reverse direction Æ Open Loop

NOTE:
Measuring Thyristor/diode or IGBT modules with multimeter does not necessarily reveal if it is faulty!

The measured values of all same type semiconductor modules in the same unit should be close to
each other.

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3.4 Precharge resistor

When the drive is powered, the DC link charges through the rectifier. Because this results in quite a
big inrush current, it has to be tempered. The precharge resistor limits this current. When the DC link
is charged (after a few seconds), this resistor is by-passed. This is done either through a closing relay
contact or by means of a second rectifier.

The value of the precharge resistor can be de measured using a multimeter. When the resistor fails,
its value amounts infinite. Also check its corresponding diode.

Measuring Precharge Resistor:

±7

Measuring Diode of Precharge Resistor:

0.5V

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4. Elektronikon module

4.1 Position of Components

Keys and functions:

1. To start the compressor

2. To stop the compressor

3. To enter the menu / to go back to main screen

4. To go to individual help screen

5. To retrieve information on the expansion module / compressor runs manually unloaded

6. To select previous menu

7. To check the menu item status data

8. To retrieve more compressor information / to select next menu

4.2 Faults and Alarms

4.2.1 MK III faults and alarms

FAULTS – Control Type/Series

53 - Elektronikon Mk III HRR / VSD
Meaning (Auto configuration) No VSD COM module during configuration.

These failures are generated after the auto configuration start. They indicate that one or more
Cause
conditions, checked during the auto configuration phase, are not valid.
To proceed with the auto configuration, it is necessary to remove the condition(s) and to restart the auto
Counter measure configuration.
Please connect COM module to regulator before auto configuration.

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54 - Elektronikon Mk III HRR / VSD

Meaning (Auto configuration) More than 1 VSD COM module connected.
These failures are generated after the auto configuration start. They indicate that one or more
Cause
conditions, checked during the auto configuration phase, are not valid.
To proceed with the auto configuration, it is necessary to remove the condition(s) and to restart the auto
Counter measure configuration.
Make sure that there is only ONE COM module for the VSD. Then restart auto configuration.
70XX - Elektronikon Mk III HRR / VSD
Meaning (Online) Internal communication failed.
Cause Internal communication between master and a COM module.
- Check the cable for connection between the 2 modules.
- Check the power supply to the modules (24V).

Counter measure - 700X, where X = the com module no., for example, 7001 implies no. 1 module is not communicating
with Master module. 7002 implies no. 2 module is not communicating. This is more relevant when there
are more than one communication module is configured to the Master / Compressor.
- Try to power OFF the compressor, then ON again a short time later.
71XX - Elektronikon Mk III HRR / VSD
Meaning (Online) A module in INOPERATIVE UNLOCK was connected to an OPERATIVE regulator.
Module XX became inoperative and it was connected to another operative module.
e.g. ZR315VSD with COM2 modbus module.
Cause F71XX ==> 01 = fault @ module 01 (module 01 = SIOE module)
==> 02 = fault @ module 02 (module 02 = VSD's COM2)
==> 03 = fault @ module 03 (module 03 = modbus COM2)
Counter measure Try to reprogram the modules and check the start configuration.
72XX - Elektronikon Mk III HRR / VSD
(Online) A module in INOPERATIVE LOCK was connected to an INOPERATIVE or OPERATIVE
Meaning
regulator.
Cause Module XX (COM module) is inoperative by incorrect programming or by connecting an empty module.
Counter measure Try to reprogram.
73XX - Elektronikon Mk III HRR / VSD
Meaning (Online) Communication failure between regulator and converter
- Loose connection between HRR and converter.
- COM 1 (or COM 2) is faulty.
- CU /CUVC in doubt (Siemens).
- GAX card (power supply card for 90 VSD Simovert P) is in doubt.
- Main Control Card (ABB).
* 730X, where x = 1 means communication module no.1 or communication related to it has a problem.
* x = 2 means communication module no.2 or communication related to it has a problem.
* COM 2 was not properly earthed.
Cause
- Loose connection between HRR and converter.
- COM 1 (or COM 2) is faulty.
- CU /CUVC in doubt (Siemens).
- GAX card (power supply card for 90 VSD Simovert P) is in doubt.
- Main Control Card (ABB).
* 730X, where x = 1 means communication module no.1 or communication related to it has a problem.
* x = 2 means communication module no.2 or communication related to it has a problem.
* COM 2 was not properly earthed.
Counter measure - Check connections of converter / COM module
- Isolate converter from COM module, and use VSD simulation software to test whether COM module or
converter is at fault. A pc with RS232 cable or RS485 (such as that use for SDP4win) is required. The
cable is to be connected in place of converter cable connection.
- If converter at fault:
* If fault occurs all the times, it is more likely the GAX card need to be looked at. Please take care
when changing GAX card, and watch out for resistor bank jumpers. GAX card = power supply card (for
GA90VSD with Simovert P drive)

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 VSD Repair Manual

* If intermittently, then CU or CCU card fault is more likely. These cards normally arrive with no
memory. Please see programming procedures if required.
- ABB - Reprogram the Elektronikon Mk III and test again.
- Siemens - This fault could occur when the CUVC control card is freshly (re)programmed. This is due
to the fact one or more parameters have incorrect communication baud rate. The correct settings
should be:
P701.1 = 6 (baud rate = 9600 for communication between converter and PC (Simovis)). This
parameter setting may be changed so that both the Simovis and the Converter have the same values.
For some machines, it is default at 9600, while others, default at 19200
P701.2 = 7 (baud rate = 19200 for communication between converter and COM2 / Elektronikon).
If this parameter has the wrong setting, F7301 will be displayed. This setting should be identical to that
of the VSD simulation program.
P701.3 = 7 (baud rate = 19200).

PLEASE BE ENSURED THAT THE RESISTOR BANK FROM THE GAX CARD IS FUNCTION PROPERLY. AS
EXPERIENCED IN ACNZ HAS SHOWN THAT FAULTY RESISTOR BANK CAN (AND PROBABLY WILL) DISGUISE
ITSELF HAS F14, F12, ETC. AND ARE INTERMITTENT FAULTS.

BECAUSE THE RESISTOR BANK HAS TO BE TAKEN OUT EVERYTIME THE GAX CARD BEEN CHANGED,
HENCE THERE IS A CHANCE IT WILL DETERIORATE OVER TIMES.

74XX - Elektronikon Mk III HRR / VSD SIEMENS / ABB

Meaning (Online) Incorrect format in data send from converter to regulator.
Error 0 - incorrect data format (byte 6/7, read back status).
Error 100 - incorrect data format (byte 2/3/8/9, parameters).
Error 200 - Checksum failure.
Siemens VSD: A possible fault would that some data in EPROM is lost, or corrupted, or during
programming, incorrect parameters were used.
Therefore, Elektronikon is not able to communicate with converter.
Cause Error 49 - Service switch in the wrong position.
Error 97 - Relay K05 in MK III defective.

ABB VSD: Error 70 - Service switch in the wrong position.

Error 80 - Converter panel is in the LOCAL mode (L).
Error 90 - Relay K05 of MK III is open during operation.
Error xxx - Check the Status Word in the converter.
- Switch machine OFF then back ON again. Allow a few minutes for all power inside elektronikon to
dissipate.
Counter measure - Reprogram the converter.
- Check parameters, compare with list and adjust any discrepancies.

4.2.2 MK III – Failures

4.2.2.1 Recoverable Failures

These failures indicate some critical, but not disastrous, situations. The compressor can start after the
failure reset.
These failures can be cleared with the reset function key of the system failure display.

• The source failure is the High Range regulator

• The controller status remains stopped
• The display activated is the number 0 with the reset facility and the failure number indication

Failure number Cause Counter measure

Watch dog error - Check Time and Date.
- Check the Power Supply
200 Real Time Clock fails - Replace the module
Power Supply out of range Else:
Component failure - Push the " RESET " function key

201 Power failure interrupt, routine execution not ended. - Push the " RESET " function key

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VSD Repair Manual

202 Backup ram checksum incorrect. - Push the " RESET " function key

Power failure interrupt routine interrupted the eeprom

203 - Push the " RESET " function key
buffer writing (longer than 4 bytes).

Power failure interrupt routine execution not ended and

204 interrupted the eeprom buffer writing (longer than 4 - Push the " RESET " function key
bytes).

Power failure interrupt routine interrupted the eeprom

205 buffer writing (longer than 4 bytes) and, the backup ram - Push the " RESET " function key
checksum is incorrect.

4.2.2.2 Unrecoverable failures generated by the module

These failures indicate dangerous situations caused by h/w and/or s/w problems.
To clear these failures can be sufficient to switch off and on the regulator. When the failure persists, it
needs to repair or change the regulator.

• The source failure is the High Range regulator

• The controller status goes (or remains) in the stopped status
• The display activated is the number 0 with the failure number indication

Failure number Cause Counter measure

- Switch off / on the regulator or change
10 Read back output error
the module
- Switch off / on the regulator or change
11 12V short circuit or FET to enable 12V damaged
the module
- Switch off / on the regulator or change
20 Reserved area checksum incorrect
the module
- Switch off / on the regulator or change
21 Eprom checksum incorrect
the module
- Switch off / on the regulator or change
22 Flash checksum incorrect
the module
- Switch off / on the regulator or change
30 Division by 0
the module
- Switch off / on the regulator or change
31 Wrong activated display
the module
- Switch off / on the regulator or change
100 Register file error
the module
- Switch off / on the regulator or change
101 External volatile RAM error
the module
- Switch off / on the regulator or change
102 12V relays not disabled at power on
the module
Read back output error : relays wrong state with 12V - Switch off / on the regulator or change
103
disabled the module
- Switch off / on the regulator or change
104 12V short circuit or FET to enable 12V damaged
the module
Read back output error : relays wrong state with 12V - Switch off / on the regulator or change
106
enabled the module
- Switch off / on the regulator or change
107 Serial line error
the module
- Switch off / on the regulator or change
108 Keyboard error
the module

4.2.2.3 Unrecoverable failures generated by the expansion modules

Only a failure of this type exists.
It indicates that a module locked has been connected to the system.

• The source failure can be one of : SIOE / DIOE / COM 1

• The controller status goes (or remains) in the stopped status
• The display activated is the number 0 with the failure number indication and the failing module

Failure number Cause Counter measure

- Put the module in INOPERATIVE UNLOCK
72xx A module in INOPERATIVE LOCK connected to the
- Switch off and on the regulator
regulator when this is OPERATIVE or INOPERATIVE
- Make again the autoconfiguration

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 VSD Repair Manual

4.2.2.4 General failures generated by the expansion modules

These failures cause warning or shutdown, depending by the failure type, by the functions type set on
the module and by the controller operational modes.
In some cases, to clear the failure, it needs to switch off and on the module (when the failure cause a
shutdown, it is also necessary to reset it), otherwise it needs to repeat the autoconfiguration. When
the failure persists, can be necessary to change the module.

• The source failure can be one of : SIOE / DIOE / COM 1

• The controller status goes (or remains) in the stopped status when a shutdown is generated. It
doesn't change when a warning is generated
• When a shutdown is generated the display change to 4B otherwise an overwrite message is
shown.

In both the cases the failure number and the failing module are indicated.

Failure number Cause Counter measure

- Switch off and on the module or change the

module
10xx Read back output error.
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

module
11xx 12V short circuit or FET to enable 12V damaged.
- When a shutdown is generated, push the "
RESET " function key

- Correct the checksum of the module

generating the failure
20xx Reserved area checksum incorrect
- Switch off and on the module
- Make again the autoconfiguration

- Correct the checksum of the module

generating the failure
21xx Eprom checksum incorrect
- Switch off and on the module
- Make again the autoconfiguration

- Correct the checksum of the module

generating the failure
22xx Flash checksum incorrect
- Switch off and on the module
- Make again the autoconfiguration

- Switch off and on the module

30xx Division by 0 - When a shutdown is generated, push the "
RESET " function key

Case of warning :
- The failure disappears automatically when
the communication runs normally again or
- Switch off and on the module or
- Change the module
70xx Internal communication failed
Case of shutdown :
- Push the " RESET " function key or
- Switch off and on the module and push the "
RESET " function key or
- Repair change the module

A module in INOPERATIVE UNLOCK was connected

71xx - Make again the autoconfiguration
to the regulator when this was OPERATIVE

- Switch off and on the module or change the

module
100xx Register file error
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

module
101xx External volatile RAM error.
- When a shutdown is generated, push the "
RESET " function key

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- Switch off and on the module or change the

module
102xx 12V relays not disabled at power on.
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

Read back output error : relays wrong state at power module
103xx
on. - When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

module
104xx 12V short circuit or FET to enable 12V damaged.
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

module
106xx Read back output error : relays enabled at power on
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

module
107xx Serial line error.
- When a shutdown is generated, push the "
RESET " function key

- Switch off and on the module or change the

200xx Watch dog error
module

4.2.2.5 Recoverable failures during Autoconfiguration

These failures are generated after the autoconfiguration start; they indicate a not valid condition,
during the autoconfiguration phase.
To proceed with the autoconfiguration, it is necessary to remove the cause of the failure.

• The source failure is the High Range regulator

• The controller status remains INOPERATIVE - AUTOCONFIGURATION
• It remains activated the display " B "

Failure number Cause Counter measure

- Add, through the download port or the

service COM 1 module, a delivery pressure
40 There isn't delivery pressure input. input
- Push the " NOT OK " function key
- Restart the autoconfiguration

- Remove, through the download port or the

service COM 1 module, the delivery pressure
41 Delivery pressure inputs number > 1. inputs exceeding
- Push the NOT OK function key
- Restart the autoconfiguration

- Remove, through the download port or the

service COM 1 module, the backup pressure
42 Backup pressure inputs number > 1. inputs exceeding
- Push the NOT OK function key
- Restart the autoconfiguration

- Remove, through the download port or the

service COM 1 module, the intercooler
43 Intercooler pressure inputs number > 1. pressure inputs exceeding
- Push the NOT OK function key
- Restart the autoconfiguration

- Remove the modules exceeding

44 DIOE modules number > 4. - Push the " NOT OK " function key
- Restart the autoconfiguration

- Remove the modules exceeding

45 SIOE modules number > 4. - Push the " NOT OK " function key
- Restart the autoconfiguration

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 VSD Repair Manual

- Remove the module exceeding

COM 1 modules number > 3. (2 optional modules + 1
46 - Push the " NOT OK " function key
service module)
- Restart the autoconfiguration

- Remove the modules generating the failure

48 COM 3 modules in the configuration. - Push the NOT OK function key
- Restart the autoconfiguration

- Change CCM to 1 or 2a or 2b
50 CCM is different from 1 / 2a / 2b. - Push the NOT OK function key
- Restart the autoconfiguration

- Remove the module generating the failure

51 DIOE PCB modules in the configuration. - Push the NOT OK function key
- Restart the autoconfiguration

4.2.2.6 Converter Related Failures

These failures are due to the fact that the communication with the frequency converter is not in an
optimal condition.
These failures are always indicated by the top-line message:

“ System Failure “

Different failure levels can be described:

Communication Failures:
No communication between the Elektronikon Mk III and the Converter can be established.

Failure number Cause Counter measure

- Check the communication cable and connections

7301 No communication with converter - Check the MkIII communication module
- Check the converter Parameters

Converter Condition Failures:

The communication between the Elektronikon MkIII and the Converter is OK, but the transmitted
messages are not conform the expected messages.

These failures are displayed with the Failure number: 7401 and an extra ERROR number.

Failure number Cause Counter measure

- In Running condition the Elektronikon K05 relay

7401
External Run Enable = OFF should be active.
(Expected to be = ON) (Connection between X22:1 and X22:8 on the
ERROR: 90
frequency converter control board )

7401 - Converter was set to LOCAL Control by the push-

Remote Control = OFF
button “LOC/REM” on the control Panel. Set
(Expected to be = ON)
ERROR: 80 the Converter back to Remote.

7401 - The Service Switch is in the wrong position ( is

External Control Location = EXT2
set to Service mode ) . Set the SS back to
(Expected to be = EXT1)
ERROR: 70 normal position.

7401 The communicated messages cannot be

understood or are not conform the expected - Contact the CTE department
ERROR: 0 messages.

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4.2.3 MK IV - Failures

4.2.3.1 Converter Related Failures

Three different types of failures can appear:

Elektronikon II: Convert.Timeout

Conv.Format Fail
Convert.Fail
Elektronikon III: Converter Timeout
Converter Format Failure
Converter Failure

1. Communication Failures
No communication between the Elektronikon and the Converter can be established. This failure is
always indicated by the message:

Elektronikon II: Convert. Timeout

Elektronikon III: Converter Timeout

Converter Timeout - Mk IV, VSD: ABB ACS600 / 800, Siemens, Vacon

Meaning No communication between Elektronikon and converter
- Communication cable
- Elektronikon module
Cause
- Converter communication card
- Modbus adapter card
- Check communication cable
- Isolate converter from module, and use the VSD simulation software to test whether module or
converter is at fault.
Counter measure A PC and RS485 <-> RS232 converter box is required as well as the DFM4win cable. The cable is to be
connected in place of converter cable connection. If the RS485 port is faulty ==> new module is
required.
- Replace modbus adapter card

2. Converter Format Failures

The communication between the Elektronikon and the converter is established, but the status of the
converter is not what the elektronikon module is expecting it to be. The error code depends on the
type of converter. This failure is always indicated by the message:

Elektronikon II: Conv.Format Fail Number

Elektronikon III: Converter Format Failure Number

ABB converter

Converter Format Fail 0 - Mk IV-II and VSD: ABB

Communications cannot be understood or are not conform the expected messages.
Meaning
DC Link fluctuations.
- Check the converter for correct message.
Cause - If ABB converter says "Supply Phase" but supply phase is ok, then probably the rectifier circuit, i.e.
NINP board is faulty.

Counter measure - Replace NINP in ABB, if the DC link voltage fluctuated beyond 13%, also, when ID motor run failed.

Converter Format Fail 70 - Mk IV-III and VSD: ABB ACS600 / 800, Vacon
Converter Status failures.
Meaning ABB: External Control Location = EXT2 (expected to be EXT1).
Vacon: Remote Control = OFF (ON expected).
Cause The service switch is in the wrong position (is set in SERVICE MODE).

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 VSD Repair Manual

Counter measure Set the service switch back to normal position.

Converter Format Fail 80 - Mk IV-III and VSD: ABB, Vacon
Remote Control of Converter is OFF (expected to be ON).
Meaning ABB: External Control Location = EXT2 (expected to be EXT1).
Vacon: Remote Control = OFF (ON expected).
- Cause / trigger by the converter condition.
Cause * Converter was set to LOCAL when it was supposed to be on REMOTE.
This is possible when performing programming procedures on the converter.
Counter measure In the control panel, push the "LOC / REM" to set the converter to REMOTE.
Converter Format Fail 90 - Mk IV-III and VSD: ABB ACS600 / 800, Vacon
Converter Status failure.
Meaning
External Run Enable = OFF, (expected to be = ON).
- Cause / trigger by the converter condition.
* In running condition:
1. For Main motor converter, the elektronikon K05 relay should be closed.
Cause
2. For Dryer converter (if present) the elektronikon K02 relay should be closed.
3. For Fan converter (if present) the Elektronikon K03 relay should be closed.
- Check NIOC (input / output card).
- Check the connection between the relevant relay and the corresponding frequency converter.

Counter measure - NIOC card on the ABB converter could be faulty, please check this. This is done by: on X2 of NIOC
board, link DI1 and DI13. If this solves the problem, then the problem is in the cable to the Service
Switch or the K05 relay of the elektronikon. Check the elektronikon if not done so.

Converter Format Fail “other numbers” - Mk IV and VSD: ABB ACS600/800, Vacon, Siemens
Meaning Converter Status failure.
Cause The communicated messages cannot be decoded, nor conforms with the expected message.
- Contact technical support.
Counter measure - Check the converter display panel for further messages. If there are messages, please go to the
relevant fault search list for further details.

Siemens converter

Converter Format Fail 49 Mk IV and VSD : Siemens MM440

Meaning Communications cannot be understood or are not conform the expected messages.

Error 49 means 'converter is ready'. You only can have this code when the converter is in stopped
Cause
condition. Normally it's not possible to have this while the compressor is running at high speed.

You only can have this code when the converter is in stopped condition. Normally it's not possible to
Counter measure
have this while the compressor is running at high speed.
Converter Format Fail 65/97 MK IV-III and VSD : Siemens
Meaning Communications cannot be understood or are not conform the expected messages
Cause Converter is in "stopped mode" and cannot be started
- The service switch in the wrong position (is set in service mode)
- Set the service switch back to normal position
Counter measure
- Outside electrical interference, switch OFF and ON compressor
- Check the fault message on the Siemens PMU / BOP (operator panel)

Converter Format Fail 113 MK IV-III and VSD : Siemens

Meaning Communications cannot be understood or are not conform the expected messages
- Converter is in "stopped mode" and cannot be started
Cause
- Service switch in wrong position
- The service switch is in the wrong position (is set in service mode)
- Set the service switch back to normal position
Counter measure
- Outside electrical interference, switch OFF and ON compressor
- Check the fault message on the Siemens PMU (operator panel)
Converter Format Fail 180 MK IV and VSD : Siemens MM440
Meaning Communications cannot be understood or are not confirmed to the expected messages.
Cause The converter is running with a warning. The converter can't be stopped in the regular way.
Counter measure Stop the converter by means of emergency and download the original parameters.

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Converter Format Fail 209 MK IV and VSD : Siemens

Meaning Communications cannot be understood or are not conforming expected messages.
Cause Service switch is in the wrong position.
Counter measure Set the service switch back to normal position.
Converter Format Fail 225 MK IV and VSD : Siemens
Meaning Communications cannot be understood or are not conform the expected messages.
Cause Converter is in "stopped mode" and cannot be started.
- Run the converter manually with service switch on to see whether it is the drive or the elektronikon.
Counter measure - Outside electrical interference, switch OFF and ON compressor.
- check the fault message on the Siemens PMU (operator panel).
Converter Format Fail - "Other numbers" MK IV and VSD : ABB ACS600/800, Vacon, Siemens
Converter Status failures
Meaning
The communicated messages cannot be decoded, not conforms with the expected message
Cause Contact technical support
Check the converter display panel for further messages. If there are messages, please go to the
Counter measure
relevant fault search list for further details.

If another number occurs, you can convert the fault number to its binary value. This value
corresponds to the status word of the converter.

3. Converter Failure = Fault origin is in the converter itself

These failures are due to the fact that the Converter is in FAULT condition.
This failure is always indicated by the message:

Elektronikon II (4x16 display): Convert.Failure “ number “

Important note:

On the Elektronikon module there is a fault code linked to the “ Fault Word 1 “ of the converter itself.
These fault codes have to be interpreted as follows BUT it is always advised to check the fault
message on the converter panel itself!

Fault “number” Problem

0 Problem cannot be read, please check the frequency converter panel

1 Short circuit

2 Over current

4 DC Over Voltage

8 ACS 600/800 temperature

16 Earth fault

32 Thermistor problem

64 Motor temperature

128 System fault

A combination of faults will lead to sum of the fault numbers.

Example: fault number: 17

Active faults: 16 = Earth fault
1 = Short circuit

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4. Internal failures
The following text can appear:

Elektronikon II (4x16 display): Inten failure Number

Elektronikon III (4x40 display): Internal failure Number

Number stands for the number of the EXPANSION module giving a problem ( can be 1, 2, 3, 4, 5, 6,
or 7 )

Detailed information
The expansion module giving a problem can be found in the “EXTRA” display.
( EXTRA display can be seen: starting from the main display, pushing the ‘Arrow’ down, then ‘F3’ )

Display is showing the following info ( example ):

Display when everything = OK

Display when all expansion Display when first expansion

modules are OK module is NOT OK

Expansion Mods Expansion Mods

B 1 B 1 Å flashing
B 1 B
Back Back

Problem solving

Check the following items:

1. Connection cable between Master module ( 2X3 ) and expansion module ( ?X3 ) connected ?

2. Connect the cable and Power OFF and ON the compressor.

4.4 Handling Software ACS 550

4.4.1 Communication Cable MK III and MK IV to VSD

Converter to Elektronikon ( MK III or MKIV ) : Modbus Baudrate : 9600

Loose cable available: P.N. 1613 8420 50

Drive Windows Light Version 2.2 : 2908 0143 00

Shielded 6-pin Cable Connection Socket

modular plug
Pin 3 – Pin 8 9 Way ‘D’ Male
AMP 5-555174-2 Pin 4 – Pin 3 Connector Socket
Pin 5 – Pin 1

Plug

Screening soldered
inside connector

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5. ABB ACS 600

5.1 Location of components

The ABB ACS 600 comes with two frame sizes R7 and R8:

• GA 75VSD 380-500V uses the ACS 601, frame size R7

• GA 75VSD 200-230V and 575V uses the ACS 604, frame size R8
• GA 90VSD uses the ACS 604, frame size R8

The ACS 601 is a wall mounted unit (degree of protection IP22), whereas the ACS 604 is finished as
a module (IP00).

5.1.1 ACS 601 frame size R7

NRFC - 77
Precharge
Resistor R14

Screw X4
Balancing &
Discharge
Resistors R11

DC LINK

DC -
U21 & U22
DC + Current trafo’s

NRFC - 75

IN OUT

General layout

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5.1.2 ACS 604 frame size R8

Inputs
U1-V1-W1

Fan fuses

Output
U2
V2
W2
(See fig. Below)

UDC +
UDC –
Capacitor
bank
Transfo

Fan

General layout

Output
U2
V2
W2

UDC +
UDC –

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5.2 Faults and alarms

This section covers the errors and warnings that appear on the frequency converter drive control
panel:

WARNING: ACS 600 TEMP

Meaning High Temp warning
The ACS 600 internal temperature is excessive. A warning is given if inverter module temp. exceeds 115
Cause
deg. C
- Check ambient conditions.
- Check airflow and fan operation.
Counter measure
- Check heat sink fins for dust pick-up.
- Check motor power against unit power.
WARNING: Al < MIN FUNC
Meaning Analog control signal below min. allowed.
An analogue control signal is below minimum allowed value. This can be caused by incorrect signal level
Cause
or a failure in the control wiring.
- Check for proper analogue control signal levels.
Counter measure - Check the control wiring.
- Check Al < MIN FUNC Fault Function parameters.
WARNING: PANEL LOSS
Meaning Control Panel does not communicate with ACS 600.
Cause A Control panel selected as active control location for the ACS 600 has ceased communicating.
- Check the Panel is connected to the right connector (See manual).
- Check Control Panel connector.
Counter measure - Replace Control Panel in the mounting platform.
- Check PANEL LOSS fault function parameters.
Programmable Fault Function 30.02.
WARNING: MOTOR TEMP
Meaning Motor temperature too high.
Motor temperature is too high (or appears to be too high). This can be caused due to excessive load,
Cause
insufficient motor power, inadequate cooling or incorrect start-up data.
- Check motor ratings, load and cooling.
- Check start-up data.
Counter measure
- Check MOTOR TEMP Fault Function parameters.
Programmable Fault Function 30.04 … 30.10.
WARNING: THERMISTOR
Meaning Thermistor warning.
Cause Motor thermal protection mode selected as THERMISTOR and the temperature is excessive.
- Check motor ratings and load.
- Check start-up data.
Counter measure
- Check thermistor connections for digital input DI6 of NIOC board.
Programmable function 30.04 … 30.05.
WARNING: MOTOR STALL
Meaning Motor is operating in stall region.
Cause Motor is operating in the stall region. This can be caused by excessive load or insufficient motor power.
- Check motor load and the ACS 600 ratings.
Counter measure - Check MOTOR STALL Fault Function parameters.
Programmable Fault Function 30.10.
WARNING: COMM MODULE
Meaning Communication error between ACS 600 fieldbus and ACS 600 Master.
Cause Cyclical communication between ACS 600 and fieldbus/ACS 600 Master is lost.
- Check the status of fieldbus communication.
- Check the parameter settings:
* Group 51 (for CH0 fieldbus adapter), or
Counter measure
* Group 52 (for standard Modbus Link).
- Check cable connections.
- Check if the bus master is not communicating or configured.

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WARNING: UNDERLOAD
Meaning Motor load is too low.
Cause Motor load is too low. This can be caused by a release mechanism in the driven equipment.
- Check for a problem in the driven equipment.
Counter measure - Check UNDERLOAD Fault Function parameters.
Programmable Fault Function 30.13.
WARNING: ENCODER ERR
Meaning Communication fault.
Communication fault between the pulse encoder and the NTAC module or between the NTAC module
Cause
and the ACS 600.
Check the pulse encoder and its wiring, the NTAC module, Parameter Group 50 settings and the fiber
Counter measure
optic connections on NAMC channel CH1.
WARNING: ID N CHANGED
Meaning ID Number has been changed.
The ID number of the drive has been changed from 1 in Drive Selection Mode (the change is not shown
Cause
on the display).
To change the ID number back to 1, go to Drive Selection Mode by pressing DRIVE. Press “ENTER”.
Counter measure
Set the ID number to 1. Press “ENTER”.
WARNING: MACRO CHANGE
Meaning MACRO is being saved.
Cause -
Counter measure Please wait.
WARNING: ID MAGN REQ
Meaning Motor identification magnetization required.
Motor identification magnetization is required. This warning belongs to the normal start-up procedure.
The drive expects the user to select how the motor identification is to be performed: By ID magnetization
Cause or by ID Run.
This is usually happen when the motor has been changed / disconnected - re-connected.
To Start the ID magnetization:
- Press the Start Key.
Counter measure
- To Start the ID Run procedure:
* Select the Identification Run type (See Parameter 99.10 MOTOR ID Run).
WARNING: ID MAGN
Meaning Motor ID magnetization is on.
Cause Motor identification magnetization is on. This warning belongs to the normal start-up procedure.
Counter measure Wait until the drive indicates that motor identification is completed.
WARNING: ID DONE
Meaning Motor ID magnetization is done and ready for operation.
The ACS 600 has performed the motor id magnetization and is ready for operation. This warning
Cause
belongs to the normal start-up procedure.
Counter measure Continue drive operation.
WARNING: ID RUN SEL
Meaning Motor ID Run is selected.
Motor ID Run is selected, and the drive is ready to start the ID Run. This warning belongs to the ID Run
Cause
procedure.
Counter measure Press Start key to start the Identification Run.
WARNING: MOTOR STARTS
Meaning Motor ID Run Starts.
Cause Motor Identification Run starts. This warning belongs to the IR Run procedure.
Counter measure Wait until the drive indicates that motor identification is completed.
WARNING: ID RUN
Meaning ID Run is on.
Cause Motor Identification Run is on.
Counter measure Wait until the drive indicates that Identification Run is completed.
WARNING: ID DONE
Meaning ID Run done, and ready for operation.
The ACS 600 has performed the Identification Run and is ready for operation. This warning belongs to
Cause
the ID Run procedure.
Counter measure Continue drive operation.

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VSD Repair Manual

WARNING: WRITE ACCESS DENIED PAR. SETT. NOT POSSIBLE

Meaning Parameter Access Denied.
Certain parameters do not allow changes while motor is running. If tried, no change is accepted, and a
Cause warning is displayed.
Parameter Lock is on.
- Stop the motor and then change the parameter value.
Counter measure
- Open parameter Lock (See Parameter 16.02 PARAMETER LOCK).
WARNING: DOWNLOAD FAILED
Meaning Download failed.
Cause Download function of the panel has failed. No data has been copied from the Panel to the ACS 600.
Make sure the Panel is in local mode.
Counter measure - Retry (there might be interference on the link).
-Contact ABB.
WARNING: UPLOAD FAILED
Meaning Upload has failed.
Cause Upload function of the panel has failed. No data has been copied from the Panel to the ACS 600.
- Make sure the Panel is in local mode.
Counter measure - Retry (there might be interference on the link).
- Contact ABB.
WARNING: NOT UPLOADED DOWNLOADING NOT POSS.
Meaning Not uploaded.
Cause No upload function has been performed.
Counter measure Perform the Upload function before downloading.
WARNING: DRIVE INCOMPATIBLE DOWNLOADING NOT POSS.
Meaning Program and Panel do not match.
Program versions in the Panel and in the ACS 600 do not match. It is not possible to copy data from
Cause
Panel to the ACS 600.
- Check program version.
Counter measure
(See parameter group 33).
WARNING: DRIVE RUNNING DOWNLOAD NOT POSS.
Meaning Drive is running, download not possible.
Cause Downloading is not possible while the motor is running.
Counter measure Stop the motor. Perform the downloading.
WARNING: NO FREE ID NUMBERS ID NUMBER SETTING NOT POSS.
Meaning -
Cause The Panel Link already includes 31 stations.
Counter measure Disconnect another station from the link to free an ID number.
WARNING: NO COMMUNICATION (X)
Meaning Communication lost.
There is a cabling problem or hardware malfunction on the Panel Link.

Cause (4) = Panel type is not compatible with the version of the drive application program. CDP 312 Panel does
not communicate with Standard Application Program (ACS) version 3.x or earlier. The CDP 3.11 Panel
does not communicate with Standard Application Program (ACS) version 5.x or later.
- Check the Panel Link connections.
- Press the RESET key. The panel reset may take up to half a minute.
Counter measure
- Check the Panel type and the version of the drive application program. The Panel type is printed on the
cover of the Panel. The application program version is stored in Parameter 33.02 APPL SW VERSION.

FAULT: ACS 600 TEMP

Meaning Internal temperature is excessive.
The ACS 600 internal temperature is excessive. The trip level of inverter module temperature is 125
Cause
deg. C.
- Check ambient conditions.
- Check airflow and fan operation.
Counter measure
- Check heat sink fins for dust pick-up.
- Check motor power against unit power.
FAULT: OVERCURRENT
Meaning Output current is excessive.
Cause Output current is excessive. The software overcurrent trip limit is 3.5 * I 2hd.

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 VSD Repair Manual

- Check motor load.

- Check acceleration time.
Counter measure - Check motor and motor cable (including phasing).
- Check there are no power factor correction capacitors or surge absorbers in the motor cable.
- Check encoder cable (including phase).
FAULT: SHORT CIRC
Meaning Short-circuited.
Short circuit in the motor cable(s) or motor.
Cause
The output bridge of the converter unit is faulty.
- Check the motor and motor cable.
Counter measure - Check that there are no power factor correction capacitors or surge absorbers in the motor cable.
- Contact ABB.
FAULT: PPCC LINK
Meaning Fiber optic link is faulty.
Cause The fiber optic link to the NINT board is faulty.
Counter measure Check the fiber optic cables connected to the power plates.
FAULT: DC OVERVOLT
Meaning DC Voltage is excessive.
Intermediate circuit DC voltage is excessive. DC overvoltage trip limit is 1.3 U1max, where U1max is the
Cause maximum value of the mains voltage range. For 400 V units, U1max is 415V. The actual voltage in the
intermediate circuit corresponding to the mains voltage trip level is 738 Vdc for 400 V units.
- Check that the overvoltage controller is on (parameter 20.05).
- Check mains for static or transient overvoltage.
- Check Braking Chopper and Resistor (if used).
Counter measure
- Check deceleration time.
- Use Coasting to Stop function (if applicable).
- Retrofit the frequency converter with a Braking Chopper and a Braking Resistor.
FAULT: SUPPLY PHASE
Meaning DC Voltage is oscillating.
Intermediate circuit DC voltage is oscillating. This can be caused due to a missing mains phase, a blown
fuse or a rectifier bridge internal fault.
A trip occurs when the DC voltage ripple is 13 % of the DC voltage.
Cause
The problem is more probable when the motor power is bigger than the nominal power of the inverter.
Inverter is loaded into a torque limit.
Maybe the rectifier circuit is faulty.
- Check main fuses.
- Check for mains supply imbalance.
- Maybe motor overload. Check !! = = > Fuse blown.
Counter measure
- Mains supply contactor. Check all three contacts.
- When the machine is running at various frequencies, then all the sudden shutdown, but the supply
voltage seemed to be ok, DC fluctuated, and then the problem is the rectifier card, i.e. the NINP card.
FAULT: DC UNDERVOLT
Meaning DC Voltage is not sufficient.
Intermediate circuit DC voltage is not sufficient. This can be caused due to a missing mains phase, a
blown fuse or a bridge internal fault.
Cause DC undervoltage trip limit is 0.65 U1min, where U1min is the minimum value of the mains voltage range.
For 400 V and 500 V units, U1min is 380 V. The actual voltage in the intermediate circuit corresponding
to the mains voltage trip level is 334 Vdc.
Counter measure Check mains supply and fuses.
FAULT: OVERFREQ
Meaning Motor is turning faster then allowed.
Motor is turning faster than the highest allowed speed. This can be caused by an incorrectly set
minimum/maximum speed, insufficient braking torque or changes in the load when using torque
reference.
Cause
The trip level is 40Hz over the operating range absolute maximum speed limit (Direct Torque Control
active). The operating range limits are set by Parameters 20.01 and 20.02 (DTC mode active) or 20.07
and 20.08 (Scalar Control active).
Counter measure - Check minimum/maximum speed settings.
- Check adequacy of motor braking torque.
- Check applicability of torque control.

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VSD Repair Manual

- Check the need for a Braking Chopper and Resistor(s).

- Make sure all the parameters in the group 99 START-UP DATA are correct, and correspond to the
motor nameplate data.
FAULT: START INHIBIT
Meaning -
Cause Optional start inhibit hardware logic is activated.
Counter measure Check the start inhibit circuit (NGPS board).
FAULT: EARTH FAULT
Meaning Load imbalance.
The load on the incoming mains system is out of balance. This can be caused by a fault in the motor,
Cause
motor cable or an internal malfunction.
- Check motor.
- Check motor cable.
Counter measure
- Check there are no power factor correction capacitors or surge absorbers in the motor cable.
Programmable Fault Function 30.17.
FAULT: Al < MIN FUNC
Meaning Analog signal is below allowed value.
An analogue control signal is below minimum allowed value. This can be caused by incorrect signal level
Cause
or a failure in the control wiring.
- Check for proper analog control signal levels.
- Check the control wiring.
Counter measure
- Check Al < MIN FUNC Fault Function parameters.
Programmable Fault Function 30.01.
FAULT: PANEL LOSS
Meaning Loss of communication.
A Control Panel or Drives Window selected as active control location for the ACS 600 has ceased
Cause
communicating.
- Check the Panel is connected to the right connector (see manual).
- Check Control Panel connector.
- Re-insert Control Panel in the mounting platform.
Counter measure
- Check PANEL LOSS Fault Function parameters.
- Check Drive Window connection.
Programmable Fault Function 30.02.
FAULT: EXTERNAL FLT
Meaning External fault.
There is a fault in one of the external devices.
Cause
(This information is configured through one of the programmable digital inputs.)
- Check external devices for faults.
Counter measure
- Check Parameter 30.03 EXTERNAL FAULT.
FAULT: MOTOR TEMP
Meaning Motor temperature too high.
Motor temperature is too high (or appears to be too high). This can be caused due to excessive load,
Cause
insufficient motor power, inadequate cooling or incorrect start-up data.
- Check motor ratings and load.
- Check start - up data.
Counter measure
- Check MOTOR TEMP Fault Function parameters.
Programmable Fault Function 30.04 … 30.09.
FAULT: THERMISTOR
Meaning Motor thermal protection fault.
Cause Motor thermal protection mode selected as THERMISTOR and the temperature is excessive.
- Check motor ratings and load.
- Check start-up data.
Counter measure - Check thermistor connections for digital input DI6.
- Check thermistor cabling.
Programmable Fault Function 30.04 .. 30.05.
FAULT: I/O COMM
Meaning Communication error.
Cause A communication error has occurred on the NAMC board, channel CH1.
Electromagnetic interference.

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 VSD Repair Manual

There is an internal fault on the NIOC board.

- Check the connections of the fiber optic cables on NAMC channel CH1.
- Check all I/O modules (if present) connected to channel CH1.
Counter measure - Check for proper earthing of the equipment.
- Check for highly emissive components nearby.
- Replace the NIOC board.
FAULT: AMBIENT TEMP
Meaning -
Cause I/O Control board temperature is lower than -5 … 0 deg. C or exceeds +73 … 82 deg. C.
Counter measure Check airflow and fan operation.
FAULT: USER MACRO
Meaning -
Cause There is no User Macro saved or file is defective.
Counter measure Create the User Macro again.
FAULT: MOTOR STALL
Meaning Motor is operating in stall region.
Cause This can be caused by excessive load or insufficient motor power.
- Check motor load and the ACS 600 ratings.
- Check MOTOR STALL Fault Function parameters.
Counter measure
- Check power supply to motor. May be a phase is missing.
Programmable Fault Function 30.10 … 30.12.
FAULT: NO MOT DATA
Meaning Motor data not given / not avail.
Cause Motor data is not given or motor data does not match with inverter data.
Counter measure Check the motor data given by Parameters 99.04 … 99.09.
FAULT: UNDERLOAD
Meaning Motor load too low.
Cause Motor load is too low. This can be caused by a release mechanism in the driven equipment.
- Check for a problem in the driven equipment.
Counter measure - Check UNDERLOAD Fault Function parameters.
Programmable Fault Function 30.13 .. 30.15.
FAULT: ID RUN FAIL
Meaning ID Run not successful.
Cause The motor ID Run is not completed successfully.
Check the maximum speed (Parameter 20.02). It should be at least 80% of the nominal speed of the
Counter measure
motor (Parameter 99.08).
FAULT: MOTOR PHASE
Meaning One of the phases is lost.
Cause This can be caused by a fault in the motor, the motor cable, a thermal relay (if used) or an internal fault.
- Check motor and motor cable.
- Check thermal relay (if used).
Counter measure - Check MOTOR PHASE Fault Function parameters. Disable this protection.
- Check power supply to motor. May be a phase is missing.
Programmable Fault Function 30.16 (ACC: 30.10).
FAULT: COMM MODULE
Meaning Communication error.
Cause Cyclical communication with ACS 600 and fieldbus/ACS 600 Master is lost.
- Check the status communication.
- Check the parameter settings:
* Group 51 (for CH0 fieldbus adapter), or
Counter measure
* Group 52 (for Standard Modbus Link).
- Check cable connections.
- Check if the bus master is not communicating or configured.
FAULT: LINE CONV
Meaning -
Cause Fault on the line side converter.
- Shift the Panel from the motor side converter control board to line side converter control board.
Counter measure
- See the line side converter manual for the fault description.

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FAULT: SC (INU 1)
Meaning Short circuit in the inverter.
Short circuit in the inverter unit consisting of several parallel inverter modules. Number refers to the
faulty inverter module number.
Cause
NINT board fiber optic connection fault in inverter unit consisting of several parallel inverter modules.
Number refers to the inverter module number.
- Check the motor and motor cable.
- Check the power semiconductors (IGBT power plates) of the inverter module. (INU 1 stands for
Counter measure inverter module 1, etc).
- Check the connection from the inverter module Main Circuit Interface Board, NINT to the PPCC
Branching Unit, NPBU. (Inverter module 1 is connected to NPBU CH1 etc).
FAULT: SC (INU 2)
Meaning Short circuit in the inverter.
Short circuit in the inverter unit consisting of several parallel inverter modules. Number refers to the
faulty inverter module number.
Cause
NINT board fiber optic connection fault in inverter unit consisting of several parallel inverter modules.
Number refers to the inverter module number.
- Check the motor and motor cable.
- Check the power semiconductors (IGBT power plates) of the inverter module. (INU 1 stand for inverter
Counter measure module 1, etc).
- Check the connection from the inverter module Main Circuit Interface Board, NINT to the PPCC
Branching Unit, NPBU. (Inverter module 1 is connected to NPBU CH1 etc).
FAULT: SC (INU 3)
Meaning Short circuit in the inverter.
Short circuit in the inverter unit consisting of several parallel inverter modules. Number refers to the
faulty inverter module number.
Cause
NINT board fiber optic connection fault in inverter unit consisting of several parallel inverter modules.
Number refers to the inverter module number.
- Check the motor and motor cable.
- Check the power semiconductors (IGBT power plates) of the inverter module. (INU 1 stands for
Counter measure inverter module 1, etc).
- Check the connection from the inverter module Main Circuit Interface Board, NINT to the PPCC
Branching Unit, NPBU. (Inverter module 1 is connected to NPBU CH1 etc).
FAULT: SC (INU 4)
Meaning Short circuit in the inverter.
Short circuit in the inverter unit consisting of several parallel inverter modules. Number refers to the
faulty inverter module number.
Cause
NINT board fiber optic connection fault in inverter unit consisting of several parallel inverter modules.
Number refers to the inverter module number.
- Check the motor and motor cable.
- Check the power semiconductors (IGBT power plates) of the inverter module. (INU 1 stands for
Counter measure inverter module 1, etc).
- Check the connection from the inverter module Main Circuit Interface Board, NINT to the PPCC
Branching Unit, NPBU. (Inverter module 1 is connected to NPBU CH1 etc).
FAULT: CURR MEAS
Meaning Current transformer failed.

Cause Current transformer failure in output current measurement circuit.

Counter measure Check the current transformer connected to Main Circuit Interface Board, NINT.
FAULT: IN CHOKE TEMP
Meaning Excessive heat.
Cause Excessive input choke temperature.
- Stop drive and let it cool down. Check ambient temperature.
Counter measure
- Check airflow and fan rotation direction.
FAULT: MOTOR STALL
Meaning Motor is operating in the stall region.
- Excessive load or insufficient motor power.
- Motor overload.
Cause
- Seized element.
- Faulty bearings

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- Check power supply to motor. May be a phase is missing.

Counter measure
- Check fault function parameters for further details.

FAULT: MOTOR 1 TEMP

Meaning Measured motor temp has exceeded fault limit set by parameter 35.03 (150 deg. C).
Possible causes:
- Faulty thermistor.
Cause
- Loose / broken connection of thermistor (PT100) cable.
- Motor is hot.
- Check the wiring of the temperature measurement (+ connections PT100).
- Check the value of the fault limit. Ensure proper motor cooling: check cooling fan, clean cooling
surfaces, etc.
- Check if the PT100 resistance is off-circuit; e.g., unplugged from the NIOC-02 card.
Counter measure - Measure either at pin 3-4 or pin 9-10.
- As an indication, resistance should be: 20 Deg. C = 107 Ohms
100 Deg. C = 139.20 Ohms
150 Deg. C = 158.80 Ohms
- Check / replace NIOC-02 card & perform Motor ID Run.
FAULT: MOTOR 2 TEMP
Meaning Measured motor temp has exceeded fault limit set by parameter 35.06 (110deg C).
Possible causes:
- Faulty thermistor.
Cause
- Loose / broken connection of thermistor (PT100) cable.
- Motor is hot.
Counter measure Check the wiring of the temperature measurement (+ connections PT100).
FAULT: RUN DISABLE
Meaning No "Run enable" signal received.
Cause -
- Check setting of parameter 16.01.
Counter measure
- Check connection X22:8-11.
FAULT: START INTERLOCK
Meaning No "Start Interlock" signal received.
Cause -
Counter measure Check connections 8-11 (X22) and 7-1 (X22).

5.2.1 ABB Converter failures

These failures are caused due to a converter in faulty condition, and is always indicated as:
Elektronikon II: Convert.Fail Number

Elektronikon III: Converter Failure Number

ABB converters display their fault both through the Elektronikon and the frequency converter.
Consult the Masterdrive manual for detailed information about the error messages that appear on the
frequency converter. Fault numbers that appear on the Elektronikon should be interpreted according
the following table. Note that a combination of faults, result in the sum of their numbers.

Converter Failure 0
Meaning Problem cannot be read, please check the frequency converter panel.
Converter problem.
Cause
See Converter format fail 0.
- Check the frequency converter panel for fault messages and go to the relevant VSD drive fault search
Counter measure list for further information.
- Check DC link voltage, if this is fluctuated, then check NINP card.
Converter Failure 1
Meaning Short circuit.
Short circuit in the motor cable(s) or motor.
Cause
The output bridge of the converter unit is faulty.

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VSD Repair Manual

- Check the motor and motor cable.

Counter measure - Check there are no power factor correction capacitors or surge absorbers in the motor cable.
- Contact ABB.
Converter Failure 2
Meaning Overcurrent.
Cause Output current is excessive. The software overcurrent trip limit is 3.5 * I 2hd.
- Check motor load.
- Check acceleration time.
Counter measure - Check motor and motor cable (including phasing).
- Check there are no power factor correction capacitors or surge absorbers in the motor cable.
- Check encoder cable (including phase).
Converter Failure 4
Meaning DC Over Voltage.
Intermediate circuit DC voltage is excessive. DC overvoltage trip limit is 1.3 U1max, where U1max is the
Cause maximum value of the mains voltage range. For 400 V units, U1max is 415V. The actual voltage in the
intermediate circuit corresponding to the mains voltage trip level is 738 Vdc for 400 V units.
- Check that the overvoltage controller is on (parameter 20.05).
- Check mains for static or transient overvoltage.
- Check Braking Chopper and Resistor (if used).
Counter measure - Check deceleration time.
- Check parameter group 22.
- Use Coasting to Stop function (if applicable).
- Retrofit the frequency converter with a Braking Chopper and a Braking Resistor.
Converter Failure 8
Meaning ACS 600 / 800 temperature is excessive.
The ACS 600 / 800 internal temperature is excessive. The trip level of inverter module temperature is
Cause
125 deg. C.
- Check ambient conditions.
- Check air flow and fan operations.
Counter measure
- Check heatsink fins for dust pick-up.
- Check motor power against unit power.
Converter Failure 16
Meaning Earth Fault - Load imbalance.
Cause Typically due to earth fault in motor or motor cables.
Counter measure Check the motor and motor cables.
Converter Failure 32
Meaning Thermistor problem.
Cause Motor thermal protection mode selected as THERMISTOR and the temperature is excessive.
- Check motor ratings and load.
- Check start-up data.
- Check thermistor connections for digital input DI6.
Counter measure
- Check thermistor cabling.
- Check Thermistors (PT100).
Programmable Fault Function 30.04 .. 30.05.
Converter Failure 64
Meaning Motor temperature too high.
Motor temperature is too high (or appears to be too high). This can be caused due to excessive load,
Cause
insufficient motor power, inadequate cooling or incorrect start-up data.
- Check motor ratings and load.
- Check start-up data.
Counter measure
- Check MOTOR TEMP Fault Function parameters.
Programmable Fault Function 30.04 … 30.09.
Converter Failure 128
Meaning System Fault.

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 VSD Repair Manual

Cause No idea. Please contact ABB.

- No idea. Please contact ABB.
Counter measure
- Check the fault mess on the operator panel.

5.3 Repair Instructions

Warning! Do not attempt any work on a powered ACS600! After switching off the mains, wait
five minutes before attempting any work on the unit!

5.3.1 Capacitor reforming

The converter DC link capacitors need to be reformed (re-aged) if the converter has been non-
operational for more than one year. Without reforming, capacitors may be damaged when the
converter starts to operate. The reforming methods introduced in this guide require, that the converter
has been stocked clean and dry. It is recommended to reform the capacitors once a year.

In case the converter is stocked (non-operational) less than 2 years, switch the power on to the
converter for a time given in figure (Method 1). The converter “wakes up” its capacitors by itself.
Power the ACS 600 MultiDrive ACN 634 drive units and the ACx 604/607 units 0400-3, 0490-5 and
0490-6 and up once a year to keep the capacitors in operational condition.

In case the converter is stocked for 2 years and over, use method 2 A or method 2 B (below) for
capacitor reforming if the converters have been stocked (non-operational) for two or more years.

Warning: The inverter module of ACS 600 MultiDrive units and ACx 604/607 units 0400-3, 0490-
5 and 0490-6 and up must be reformed outside the cabinet.

Reforming Time

The intermediate circuit of the converter is kept in its nominal voltage for the reforming time to “wake
up” the capacitors. The reforming time required depends on how long the converter has been stocked
(non-operational).

Capacitor Reforming Time

5.3.1.1 Method 2A

Capacitor reforming is realized by switching-in a rectifier and a resistor circuit, which is connected to
the converter DC link. The reforming circuit is given below. Circuit component values for different
voltages are given in the table below. See the reforming time from figure above.

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VSD Repair Manual

Recommended Components
A R C
380 V < Ux < 415 V SKD 82/16 220 Ohm / 700 W 22 nF / 2000 V
380 V < Ux < 500 V SKD 82/16 470 Ohm / 1200 W 22 nF / 2000 V
525 V < Ux < 690 V SKD 82/16 680 Ohm / 1700 W 22 nF / 2000 V

Warning: The converter supply must be disconnected while reforming circuit is connected.

Reforming Circuit for method 2A

5.3.1.2 Method 2B

Capacitor reforming is based on DC power supply, which is connected to converter DC link. Power
supply current charges converter capacitors. If power supply cannot limit the current, voltage is
increased gradually (with e.g. 100 V steps). Maximum recommended reforming current is 500 mA. An
appropriate reforming voltage is (1.35... 2 ) x UX. See reforming time from figure.

Warning: The converter supply must be disconnected while reforming circuit is connected.

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Reforming Circuit for method 2B ( R = 100 Ohm / 500 W )

5.3.2 Replacing the circuit boards

Caution: Electrostatic discharge (ESD) can damage electronic circuits. Do not handle any
components without following the necessary ESD precautions.

The frequency converter contains several printed circuit boards. These boards can fail. The boards
available as spare part are:

• NAMC: control board

• NINT: main circuit interface board
• NIOC: input–output control
• NPOW: power supply board
• NINP
• NRFC: RFI board

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VSD Repair Manual

NINP-61

NPOW-42
NINT-52

NAMC-51

NPOW-43

NIOC-01

General Layout – Frame size R7

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Input
Fuses, Fan

NINP-61

NAMC-51

NIOC-01

NPOW-42

NINT-53

General Layout – Frame size R8

The table below shows the indications of the LEDs on the control boards.

Circuit Board LED When the LED is lit

NAMC Green The power supply of the board is OK
Red Fault
NINT Green V14 The board is powered
NIOC Green V4 The power supply of the board is OK
Red V6 Fault
NPOW Green V4 The board is powered (OK)
Green blinking Possible current transducer failure
NINP Green LED The board is OK

Some of these control boards depend on the type of converter. Other boards are compatible with all
converters. Please consult section 0 for a complete overview of all available spare parts for the
ACS600 product family as related to each converter type. In the following sections, replacement of the
different circuit boards is briefly discussed.

5.3.2.1 Replacing the NAMC-51 (control) board

This is the application and motor control board. The layout of the board is displayed in figure.

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VSD Repair Manual

Optical Link
24V From to NINT
NPOW-42

Optical Link
to NIOC
Green LED = OK

Red LED = Not OK

NMAC detail

The same control board NAMC-51 is compatible with all converter variants of both the GA 75VSD en
GA 90VSD. This board requires no hardware configuration before or after installation. However, after
the board has been replaced, the parameters concerning the technical specifications of the converter
units must be re-defined. (Parameter groups 97, 112 and 190)

The parameters groups 97 (needed for 690V units only), 112 and 190 have to be set only once.
Normally this is done at the manufacturing plant prior to delivery. The parameters are not intended to
be changed by the user, and they are not dealt with in the ACS 600 Firmware Manual. In order to gain
access to parameter groups 112 and 190, code 564 must be entered at parameter 16.3 (PASS
CODE). The pass code to parameter group 97 is 5600.

Follow the next procedure:

• Access parameter 99.03 and set the value YES (Factory settings become effective)
• Access parameter 112.06 as described above. Set value to “xgNONE”
• Switch power off and on
• Access parameter 112.06. Set the correct value (this depends on the unit size, see list
below). The correct value can be found by scrolling the units by a single arrow button on the
CDP panel.
• Switch power off and on again.

The following table contains the values of parameter 112.06, corresponding to a particular
compressor -drive combination.

5.3.2.2 Replacing the NINT (main circuit interface) board

The NINT-xx board must be configured for the particular type of converter prior to replacement. The
board has special configuration pad pairs on the solder side. They are located next to connector X41.
These pads must be connected by soldering according to the table below. Note that this instruction
applies to the 400V, 500V and 690V only.

Compressor Type Converter Type Par Value

GA 75VSD 200-230V ACS6xx-0120-2 sg0120_2
ACS6xx-0140-5 sg0140_5
GA 75VSD 575V ACS6xx-0170-6 sg0170_6
GA 90VSD 200-230V ACS6xx-0120-2 sg0120_2
ACS6xx-0170-5 sg0170_5
GA 90VSD 575V ACS6xx-0210-6 sg0210_6

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Controlling Power Supply from

IGBT’s NPOW-42

Converter
output
voltage
control

Converter Optical
output connection
Current
control

NINT detail

5.3.2.3 Replacing the NPOW (power supply) board and their fuse
The NPOW board supplies power to the other circuit boards. This board contains a fuse, which can be
replaced by an AC spare part. Also the NPOW board is available as a spare part for replacement.

Powered from DC link

Green LED = OK

Power supply for

converter control
electronics

NPOW-42 detail

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VSD Repair Manual

5.3.2.4 Replacing the NIOC (input output controller) card

The NIOC card connects the converter to the elektronikon, the service switch, the PT100 from the
motor, and the fan as indicated on figure.

24V
From
NPOW-42

Fan Control
on GA90 VSD

Pt 100
from Motor

To
Elektronikon

NIOC detail

5.3.3 Changing current transducer

Two outgoing phases are equipped with current transformers. Current transducer failure may result in
a converter fault message “Over Current”, “Short Circuit trip”, or “Earth Fault trip”. The most common
current transducer failure modes are short circuit between transducer power supply connections and
an excessive offset value, which can be dependent on the ambient temperature. This results in an
overload of the inverter power supply, which will fail to start (green LED on NPOW-board is blinking
and a clear ticking sound can be heard). The failed transducer can be found by disconnecting the
transducers one by one and monitoring when the normal operation of the NPOW-board returns.

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The current transducer offset failure can be detected by monitoring parameters 160.1 (current in
phase U) and 160.3 (current in phase W) while the inverter is stand-by. These parameter values
should be close to zero. The pass code to access parameter groups above 100 is 2303 for the ACS
600 SingleDrive.

The current transformers are connected to connector X45 and X41 of the converter’s NINT control
board. Consult section 5.1 to locate this control board for both frame sizes 7 and 8, and the two
current transformers.

You can check the current transducer with a multimeter:

• Disconnect the transducer from the inverter

Note: do not run the inverter with current transducers disconnected!

• Measure the resistance with a multimeter (ohms) between current transducer power supply
pins (pins 1 and 3). If the reading is lower than 1kOhm, the transducer’s internal transient
voltage projection components are damaged.
• Measure from pin 1 to 2, 2 to 3 and 1 to 3 using the diode measurement. They should identify
as forward biased diodes. Resistance measuring between those pins should be high.
• Check the current transducer output offset with the following test circuit, using a ±24V DC and
1kOhm resistor:

+24VDC pin#3

GND pin#2

1k

– 24VDC pin#1

Current transducer test circuit

The voltage over the 1kOhm resistor is measured with the multimeter and the value should be:

Compressor Type Converter Type Cur. Transducer type Voltage over resistor
ACS6xx-0120-2 ES500
GA 75/90VSD 200-230V < 1,0 V DC
Other ES300

• Reconnect the transducer in the drive. After changing a current transducer it is recommended
to make an ID run before running the drive to calibrate the current measurements for optimal
performance. If this is not possible the next choice is:
• Store the previous ID run parameters
• Make First Start
• Store parameter 192.13-16 values
• Restore the original ID run parameters
• Correct 192.13; 192.14; 192.15; 192.16; values according to the first start results,
these parameters are related to the gain of current in phase a and c, and the offset of
the current in phase a and c.

5.3.4 Testing the diodes of the rectifier

The ACS converters feature a half bridge rectifier. The diodes should be tested when it seems that the
rectifier power circuit is damaged. The principles of these measurements are described in section 0.
Consult section 5.1 to locate the input power connection leads and the negative side of the DC-link.

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5.3.5 Testing the thyristors of the rectifier

The thyristors of the half bridge rectifier should be tested when it seems that the rectifier power circuit
is damaged. The principles of these measurements are described in section 0.

5.3.6 Testing the condition of the IGBT module

The IGBT modules should be tested when it seems that the inverter power circuit is damaged. The
converters with frame size R7 and R8, both feature a different powerplate setup: frame size R7
consists of a single IGBT module, while the other consists of a setup with three IGBT modules.
Consult section 5.1 to locate the output power connection leads and the DC-link.

One should get the observations described underneath, when the IGBT module is not damaged. For
these tests a standard multimeter is applied.

5.3.6.1 Measuring the collector-emitter resistance

This measurement is done with the multimeter in the “diode” selection.

Plus-probe Minus-probe Display

+ P1 OL
+ P2 OL
+ P3 OL
P1 - OL
P2 - OL
P3 - OL

5.3.6.2 Measuring the emitter

This measurement is done with the multimeter in the “resistance” selection.

Plus-probe Minus-probe Display

P1 ≈ 0 Ohm
E11
P2 ≈ 0 Ohm
E13 P3 ≈ 0 Ohm
- ≈ 0 Ohm
E21
- ≈ 0 Ohm
E23 - ≈ 0 Ohm

5.3.6.3 Measuring the diode

The principles of these measurements are described in section 0. They are done with the multimeter
in the “diode” selection. Figure shows one of the six measurements. The forward voltage drop of the
diodes should be approximately 0.35V.

Plus-probe Minus-probe Display

+ ≈ 0.35V
P1
+ ≈ 0.35V
P3 + ≈ 0.35V
P1 ≈ 0.35V
-
P2 ≈ 0.35V
- P3 ≈ 0.35V

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5.3.6.4 Measuring the gate

This measurement is done with the multimeter in the “resistance” selection.

Plus-probe Minus-probe Display

E11 OL
G11
E21 OL
G12 E12 OL
G22 E22 OL
E13 OL
G13
E23 OL

5.3.6.5 Measuring the thermistor

This measurement is done with the multimeter in the “resistance” selection. Note that this resistance
depends on the temperature, so the measurement has to be done when the power plate is at room
temperature.

Plus-probe Minus-probe Display

T1 T2 10 kOhm

Note that the thermistor has a certain tolerance (10%).

5.3.6.6 Measurements against frame

This measurement is done with the multimeter in the “resistance” selection.

Plus-probe Minus-probe Display

T1 Frame OL
T2 Frame OL
Auxiliary + Frame OL
Auxiliary - Frame OL
P1 Frame OL
P2 Frame OL
P3 Frame OL

5.3.7 Measuring the precharge resistor

The principle of this measurement is described in section 0. The precharge resistor of the ACS600
should be measured according to figure. The value should be approximately 7 Ohms. The
corresponding diode is of type anode to stud. This measurement is described in section 0. The
forward voltage drop of this diode should be approximately 0.5 V.

5.3.8 Changing air intake filter mats

The GA75 VSD is equipped with a frame size “R7” converter featuring 2 intake grids. The GA90 VSD
has a frame size “R8” converter, which has 4 intake grids. Depending on the contamination the filter
mats in these intake grids may require service. The converters require a flow of respectively 660 m³/h
(70 Pa pressure difference over the module) and 1640 m³/h (180 Pa pressure difference).

The following spare part filter mat is available: 1089 9475 16.

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CONVERTER
GA75 VSD - GA90 VSD / 2000

Converter IP 54

Converter Air GA75 VSD : 2 Air Intake Grids

GA90 VSD : 4 Air Intake Grids
=> Filter mat : P.N. 1089 9475 16
=> Service interval : Depending on contamination
=> Not included in the Service Kit

Converter Air GA75 & 90 VSD : 2 Outlet Grids - No Filter mat

Fine Filter Mat

Paper Side at
the back

5.4 Important Parameters

The ACS 600 parameters are arranged into groups by their function. Some parameters that are not in
use in the current application are hidden to simplify programming.

CAUTION!
Exercise caution when configuring input/output connections, as it is possible (albeit not
recommended) to use one I/O connection to control several operations. If an I/O is programmed for
some purpose the setting remains, even if you select the I/O for another purpose with another
parameter.

1. Group 10: Start/Stop/Dir

These parameter values can only be altered with the ACS 600 stopped. The Range/Unit column in
table below shows the allowable parameter values.

Parameter Range/Unit Description

1 EXT1 NOT SEL; Digital Inputs; Selects source of Start/Stop/ Direction
STRT/STP/DIR KEYPAD; COMM. MODULE commands for External control location EXT1.
2 EXT2 NOT SEL; Digital Inputs; Selects source of Start/Stop/ Direction
STRT/STP/DIR KEYPAD; COMM. MODULE commands for External control location EXT2.
3 DIRECTION FORWARD; REVERSE; REQUEST Rotation direction lock.

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2. Group 11: Reference Select

These parameter values can be altered with the ACS 600 running, except those marked with (O). The
Range/Unit column in table below shows the allowable parameter values.

Parameter Range/Unit Description

1 KEYPAD REF SEL REF1 (rpm); REF2 (%) Selection of active keypad reference
DI1 ... DI6; EXT1; EXT2;
2 EXT1/EXT2 SELECT (O) External control location selection input.
COMM. MODULE
KEYPAD; Analogue and
Digital Inputs; COMM. REF;
3 EXT REF1 SELECT (O) External reference 1input.
COMMREF+AI1;
COMMREF*AI1
4 EXT REF1 MINIMUM (0 ... 18000) rpm External reference 1 minimum value.
5 EXT REF1 MAXIMUM (0 ... 18000) rpm External reference 1 maximum value.
KEYPAD; Analogue and
Digital Inputs; COMM. REF;
6 EXT REF2 SELECT (O) External reference 2 input.
COMMREF+AI1;
COMMREF*AI1
7 EXT REF2 MINIMUM 0 ... 100 % External reference 2 minimum value.
8 EXT REF2 MAXIMUM 0 ... 500 % External reference 2 maximum value.

3. Group 12: Constant Speeds

These parameter values can be altered with the ACS 600 running, except those marked with (O). The
Range/Unit column in table below shows the allowable parameter values.

Parameter Range/Unit Description

1 CONST SPEED SEL (O) NOT SEL; Digital Inputs Constant speed selection
2 CONST SPEED 1 0 ... 18000 rpm Constant speed 1
3 CONST SPEED 2 0 ... 18000 rpm Constant speed 2
4 CONST SPEED 3 0 ... 18000 rpm Constant speed 3
5 CONST SPEED 4 0 ... 18000 rpm Constant speed 4
6 CONST SPEED 5 0 ... 18000 rpm Constant speed 5
7 CONST SPEED 6 0 ... 18000 rpm Constant speed 6
8 CONST SPEED 7 0 ... 18000 rpm Constant speed 7
9 CONST SPEED 8 0 ... 18000 rpm Constant speed 8
10 CONST SPEED 9 0 ... 18000 rpm Constant speed 9
11 CONST SPEED 10 0 ... 18000 rpm Constant speed 10
12 CONST SPEED 11 0 ... 18000 rpm Constant speed 11
13 CONST SPEED 12 0 ... 18000 rpm Constant speed 12
14 CONST SPEED 13 0 ... 18000 rpm Constant speed 13
15 CONST SPEED 14 0 ... 18000 rpm Constant speed 14
16 CONST SPEED 15 -18000 ... 18000 rpm Constant speed 15/ Fault speed

4. Group 16: System Ctrl Inputs

These parameter values can only be altered with the ACS 600 stopped. The Range/Unit column in
table below shows the allowable parameter values.

Parameter Range/Unit Description

1 RUN ENABLE YES; DI1 ... DI6; COMM. MODULE Run enable input.
2 PARAMETER LOCK OPEN; LOCKED; Parameter lock input.
3 PASS CODE 0 ... 30000 Parameter lock pass code.
NOT SEL; DI1 ... DI6; ON STOP;
4 FAULT RESET SEL Fault reset input.
COMM. MODULE
Restores parameters to user macro setting
5 USER MACRO IO CHG NOT SEL; DI1 ... DI6
values.

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6 LOCAL LOCK OFF; ON Disables local control (Panel)

7 PARAM SAVE SAVE..; DONE Parameter saving to the permanent memory

5. Group 20: Limits

These parameter values can be altered with the ACS 600 running. The Range/Unit column in table
below shows the allowable parameter values.

Parameter Range/Unit Description

-18000/(number of pole pairs)... 20.02 Operating range minimum speed. Cannot be
1 MINIMUM SPEED
MAXIMUM SPEED used in the SCALAR mode.
18000/(number of pole pairs)… Operating range maximum speed. Cannot be
2 MAXIMUM SPEED
20.01 MINIMUM SPEED used in the SCALAR mode.
3 MAXIMUM CURRENT 0 % Ihd ... 200 % Ihd Maximum output current.
Maximum torque. Cannot be used in the
4 MAXIMUM TORQUE 0.0 % ... 300.0 %
SCALAR mode.
5 OVERVOLTAGE CTRL YES; NO DC overvoltage controller
6 UNDERVOLTAGE CTRL YES; NO DC undervoltage controller
Operating range minimum frequency. Visible in
7 MINIMUM FREQ -300 Hz ... 50 Hz
the SCALAR mode only.
Operating range maximum frequency. Visible in
8 MAXIMUM FREQ -50 ... 300 Hz
the SCALAR mode only.
Minimum torque limit selector. Cannot be used
9 MIN TORQ SELECTOR -MAX TORQ; SET MIN TORQ
in the SCALAR mode.
Minimum torque value, when Parameter 20.09
10 SET MIN TORQUE -300.0 % ... 0.0 % MIN TORQ SELECTOR is SET MIN TORQ.
Cannot be used in the SCALAR mode.

6. Group 30: Fault Functions

These parameter values can be altered with the ACS 600 running. The Range/Unit column in table
below shows the allowable parameter values.

Parameter Range/Unit Description

FAULT; NO; CONST SP 15; LAST
1 AI<MIN FUNCTION Operation in case of AI <Minimum fault.
SPEED
Operation in case the Control Panel selected
2 PANEL LOSS FAULT; CONST SP 15; LAST SPEED as active control location for the ACS 600 stops
communicating.
3 EXTERNAL FAULT NOT SEL; DI1-DI6 External fault input.
4 MOTOR THERM PROT FAULT; WARNING; NO Operation in case of overtemperature.
5 MOT THERM P MODE DTC; USER MODE; THERMISTOR Motor thermal protection mode selection.
6 MOTOR THERM TIME 256.0 ... 9999.8 s Time for 63 % temperature rise.
7 MOTOR LOAD CURVE 50.0 ... 150.0 % Motor current maximum limit.
8 ZERO SPEED LOAD 25.0 ... 150.0 % Motor load curve point at zero speed.
9 BREAK POINT 1.0 ... 300.0 Hz Break point of motor load curve.
10 STALL FUNCTION FAULT; WARNING; NO Operation in case of motor stall.
11 STALL FREQ HI 0.5 ... 50 Hz Frequency limit for stall protection logic.
12 STALL TIME 10.00 ... 400.00 s Time for stall protection logic.
13 UNDERLOAD FUNC NO; WARNING; FAULT Operation in case of underload fault.
14 UNDERLOAD TIME 0.0 ... 600.0 s Time limit for underload logic.
15 UNDERLOAD CURVE 1 ... 5 Torque limit for underload logic.
16 MOTOR PHASE LOSS NO; FAULT Operation in case motor phase is lost.
17 EARTH FAULT WARNING; FAULT Operation in case of earth fault.
FAULT; NO; CONST SP 15; LAST Operation of the drive in case of the Main
18 COMM FAULT FUNC
SPEED Reference Data Set loss.
Main Reference Data Set loss time delay for
19 MAIN REF DS T-OUT 0.1 s ... 60 s function specified in Parameter 30.18 COMM
FAULT FUNC.

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Operation of the relay output/analogue output

20 COMM FAULT RO/AO ZERO; LAST VALUE
in case of Auxiliary Reference Data Set loss.
Auxiliary Reference Data Set loss time delay
21 AUX REF DS T-OUT 0.1 ... 60.0 s for function specified in Parameter 30.18
COMM FAULT FUNC.

7. Group 52: Standard Modbus

These parameters define the basic settings for the Standard Modbus Link.

Parameter Range/Unit Description

Device address. Two units with the same
52.01 STATION
1 to 247 addresses are not allowed on-line. Default
NUMBER
value is 1.
600; 1200; 2400; Transfer rate of the link in bit/s. Default value is
52.02 BAUDRATE
4800; 9600; 19200 9600.
NONE1STOPBIT; NONE2STOPBIT;
52.03 PARITY Usage of parity bit(s). Default value is ODD.
ODD; EVEN

8. Group 92: D SET TR ADDR

These parameters are visible, and can be adjusted, only when a fieldbus communication is activated
with Parameter 98.02 COMM. MODULE LINK. These parameter settings will remain the same even
though the application macro is changed.

Parameter Range/Unit Description

92.01 Main DS Status

302 (fixed, not visible)
Word
92.02 MAIN DS ACT1 0 ... 9999 These parameters define the Main and
92.03 MAIN DS ACT2 0 ... 9999 Auxiliary Actual signal data sets, sent by
the ACS 600 to the fieldbus master
92.04 AUX DS ACT3 0 ... 9999 station.
92.05 AUX DS ACT4 0 ... 9999
92.06 AUX DS ACT5 0 ... 9999

9. Group 98: Option Modules

The parameters of this group are set if an option module is installed or external serial communication
is in use. For more information on option modules refer to the option module manuals. These
parameter values cannot be altered with the ACS 600 running. These parameter settings will remain
the same even though the application macro is changed.

Parameter Range/Unit Description

Pulse encoder option module selection. See
98.01 ENCODER MODULE NO; YES also Parameter Group 50 Encoder
Module.
98.02 COMM. MODULE NO; FIELDBUS; ADVANT: STD Option module selection. See also Group 51
LINK MODBUS; CUSTOMISED Communication Module.
98.03 DI/O EXT MODULE 1 NO; YES Option module selection.
98.04 DI/O EXT MODULE 2 NO; YES Option module selection.
98.05 DI/O EXT MODULE 3 NO; YES Option module selection.
NO; UNIPOLAR; BIPOLAR;
98.06 AI/O EXT MODULE Option module selection.
UNIPOLAR PRG; BIPOLAR PRG
98.07 COMM PROFILE ABB DRIVES; CSA2.8/3.0 Communication profile selection.

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5.5 Service switch

For certain tests (for example a vibration measurement), it may be useful to control the speed of the
compressor locally; i.e. using the converter control directly, not using the Elektronikon.

The Service Switch permits easy, local control of the converter and motor.

5.5.1 Functionality

When placing the Service Switch into ‘service mode‘, Elektronikon has no influence anymore.

The compressor can be started using the green button on the PMU.

The compressor can be stopped again using the red button.

The compressor will run at fixed minimum speed.

5.5.2 Position of Service switch

Service switch
Left position = Manual control
Right control = Elektronikon control

5.5.3 Normal operation of compressor

Refer to Normal operation of compressor in this manual.

5.5.4 Communication Fault

Refer to 6.5.4 Communication fault in this manual.

5.5.5 Operation in Service Mode

Refer to 6.5.5 Operation in Service Mode in this manual.

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5.5.6 Practical

The position of the service switch can be checked in parameter r050/51.

1 = Data set 1 (operation via Elektronikon)

2 = Data set 2 (operation in service mode)

To be checked
If the compressor is started from the Elektronikon with the service switch in service-position, it will
generate a fault.

5.6 Installation
5.6.1 Mechanical Installation

The ACx 601 should be installed in an upright position with the cooling section facing a wall. The wall
should be as close to vertical as possible, of non-flammable material and strong enough to carry the
weight of the unit. The floor/material below the installation should be non-flammable.

Sufficient room around the ACx 601 is required to enable cooling air flow, service and maintenance.

Steps for the installation:

1. Check the intended installation site for sufficient room and that there is nothing on the wall to
inhibit installation.

2. Mark the locations for the four holes.

3. Fix the screws to the marked locations.

4. Position the ACx 601 onto the screws on the wall.

Note: lift ACx 601 by its chassis and not by its cover. (Frame R7 is fitted with lifting lugs to allow
the use of a proper lifting device.)

5. Tighten the screws in the wall securely.

Installing ACS 601 on a wall

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5.6.1.1 Installing in a Cooling Air Duct

The ACx 601 design allows the unit to be recessed into a wall with the cooling section protruding into
a special cooling air duct (frames R2 to R6). The cooling air grates in the bottom and the top of the
unit must not be blocked by the wall or any other structure. Steps should be taken to enable service
and maintenance for the unit.
The air in the cooling duct must meet the requirements stated for ambient air. If the air in the cooling
duct is not clean the enclosure class of the ACx 601 must be IP 54. Note the power ratings of the IP
54 units.

To install the ACx 601 in a cooling air duct, carry out the following steps:

1. See dimensional drawings for dimensions of the opening in the duct.

2. Make the opening.

3. Mark the locations for the four holes. Drill the holes.

4. Frame R2 and R3: Undo the two screws at the lower front edge of the unit. Lift the front cover
somewhat and disconnect the Control Panel cable from the board fitted on the inside of the cover.
Remove the front and top covers.

5. Frames R4 to R6: Remove the Control Panel. Remove the telephone connector. Undo the two
screws at the lower front edge of the unit. Remove the front and top covers.

6. Follow the installation procedure in Figure below.

Step 1 Step 2 Step 3

Max 10 mm Upper screws

Air
flow
out

Air
flow Mounting flange Lower screws first
in

Installation procedure of the ACx 601 in a cooling air duct

5.6.2 Electrical Installation

Warning:
Insulation checks must be performed before connecting the ACx 600 to the mains. Before proceeding
with the insulation resistance measurements make sure that the ACx 600 is disconnected from the
mains.

1. Check that the motor cable is disconnected from the ACx 600 output terminals U2, V2 and W2.

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2. Measure the insulation resistances of motor cable and the motor between each phase and
Protective Earth with measuring voltage 1 kV d.c. The insulation resistance must be greater than
1 MW.

5.6.2.1 Main Fuses

The ACx 601 is not equipped with input fuses. When installing the ACx 601, it is recommended to
connect the supply via ultrarapid fuses introduced in following table. For types ACx 601-0030-3 and -
0040-5 and larger, ultrarapid fuses must always be used.
If a fuse is blown, it must not be replaced with a normal slow fuse rated according to the following
table. An ultrarapid fuse must be used.

Fuses
Type Type
ACx 601 Type DIN 43620 DIN 43653
2
A A S V Manufacturer
Size Size

ACx 601-0005-3 16 48 660 Bussmann 170M1559 000 170M1359 000/80

ACx 601-0006-5
ACx 601-0006-3 16 48 660 Bussmann 170M1559 000 170M1359 000/80
ACx 601-0009-5
ACx 601-0009-3 25 130 660 Bussmann 170M1561 000 170M1361 000/80
ACx 601-0011-5
ACx 601-0011-3 32 270 660 Bussmann 170M1562 000 170M1362 000/80
ACx 601-0016-5
ACx 601-0016-3 40 460 660 Bussmann 170M1563 000 170M1363 000/80
ACx 601-0020-5
ACx 601-0020-3 63 1450 660 Bussmann 170M1565 000 170M1365 000/80
ACx 601-0025-5
ACx 601-0025-3
ACx 601-0030-5
ACx 601-0030-3 80 1250 660 Bussmann 170M3811 1* 170M3011 1*/80
ACx 601-0040-5
ACx 601-0040-3
ACx 601-0050-5
ACx 601-0050-3 125 3700 660 Bussmann 170M3813 1* 170M3013 1*/80
ACx 601-0060-5
ACx 601-0060-3 160 7500 660 Bussmann 170M3814 1* 170M3014 1*/80
ACx 601-0070-5
1)
ACx 601-0070-3 200/ 28000/ 660 Bussmann 170M1570/ 000/ 170M1370/ 000/80/
1) 250 28500 170M3816 1* 170M3016 1*
ACx 601-0100-5
ACx 601-0100-3 400 105000 660 Bussmann 170M3819 1* 170M3019 1*/80
ACx 601-0120-5
ACx 601-0120-3
ACx 601-0140-5
ACx 601-0009-6 32 270 660 Bussmann 170M1562 000 170M1362 000/80
ACx 601-0011-6 32 270 660 Bussmann 170M1562 000 170M1362 000/80
ACx 601-0016-6 32 270 660 Bussmann 170M1562 000 170M1362 000/80
ACx 601-0020-6 32 270 660 Bussmann 170M1562 000 170M1362 000/80
ACx 601-0025-6 40 460 660 Bussmann 170M1563 000 170M1363 000/80
ACx 601-0030-6 50 770 660 Bussmann 170M1564 000 170M1364 000/80
ACx 601-0040-6 50 770 660 Bussmann 170M1564 000 170M1364 000/80
ACx 601-0050-6 63 1450 660 Bussmann 170M1565 000 170M1365 000/80
ACx 601-0060-6 100 4650 660 Bussmann 170M1567 000 170M1367 000/80
ACx 601-0070-6 100 4650 660 Bussmann 170M1567 000 170M1367 000/80
ACx 601-0100-6 125 8500 660 Bussmann 170M1568 000 170M1368 000/80
ACx 601-0120-6 200 28000 660 Bussmann 170M1570 000 170M1370 000/80

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200 A and 250 A Bussmann fuses can be used with ACx 601-0070-3 and ACx 601-0100-5 units.

Example:

For ACS 601-0120-3, the recommended fuses for the input bridge protection are 400 A ultrarapid
fuses.

The values I2N, I2hd and I2Nsq for ACS 601-0120-3 are 178 A, 147 A and 200 A respectively.
1.1 · 178 A = 195.8 A and 1.5 · 147 A = 220.5 A and 1.0 · 200 A = 200 A. Normal fuses with nominal
currents higher than 195.8 A or 220.5 A or 200 A can be used to protect the input cable; thus, 200 A
or 250 A fuses are selected depending on the use (normal, heavy-duty or pump and fan,
respectively).

5.6.2.2 Input Cable Protection

Normal slow fuses can be used to protect the input cable in case of a short circuit. (They do not
protect the input bridge of ACx 600 in case of a short circuit.) Slow fuses must be dimensioned
according to local safety regulations, appropriate mains voltage and the rated current of the ACx 600.

5.6.2.3 Mains, Motor and Control Cable Connection

The mains and motor cables connect to the terminal block of the ACx 601 in the lower part of the
frame, the control cables over them to the NIOC/NIOCP board (A2).

To connect the mains, motor and control cables carry out the following procedure.

Make sure that the ACx 601 is disconnected from the mains network during installation. If the
ACx 601 is already connected to the mains, wait for 5 minutes after disconnecting mains
power.

Frames R4 to R6: removal of the cover

1. Remove the Control Panel.

2. Remove the telephone connector.
3. Undo the two screws at the lower front edge of
the unit and remove the front cover by lifting it
carefully from the bottom.

Frames R2 and R3: Removal of the cover

1. Undo the two screws at the lower front edge of

the unit.
2. Lift the lower edge of the cover to gain access to
board A6. Disconnect the cable from connector
X2.
3. Remove the cover.

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Frame R7: Removal of the cover

1. Loosen the screws of the cover.

2. Lift the cover somewhat upwards to release it
from the screws.
3. Leave the cover hanging by its upper edge.
4. Lift the lower edge of the cover to gain access to
board A6. Disconnect the cable from connector
X2.
5. Remove the cover.

5.6.2.4 Cable Connections

Recommended earthing, mains and motor cable connections are presented below.

ACP 600: Control and

encoder cables
NIOC
/NIOCP

INPUT OUTPUT

PE

Control
cables

Earth the other end of the mains cable at the distribution board.

For minimum radio frequency interference (RFI) at the motor end, earth the cable screen 360 degrees
at the lead-through of the motor terminal box or earth the cable by twisting the screen (flattened width
> 1/5 · length).

1. Alternative to earthing of the ACx 601 and the motor through the cable screen.
Note: Connecting the fourth conductor of the motor cable at the motor end increases bearing
currents, thus causing extra wear.

2. Used if the conductivity of the cable screen is < 50% of the conductivity of the phase conductor.

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Frame R7:

Clamp cable lugs on the phase conductors.

Isolate the ends of the cable lugs by self-fusing (self-amalgamating) tape.

Earthing, Mains and Motor Cable Connections:

1. Lead the mains cable through the INPUT cable entry, and the motor cable through the OUTPUT
entry into the unit.

2. Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals and the phase
conductors of the motor cable to the U2, V2 and W2 terminals.

3. Connect the twisted screen of the mains cable to the earthing terminal. Perform the same with the
motor cable screen.

Connect the additional PE conductors (if present) of the mains and motor cables to the earthing
terminal. Connect the separate PE conductor (if used) to the earthing terminal.

Control Cable Connections:

1. Lead the cable inside the unit through the SIGN entry.

2. Connect the conductor in appropriate terminal at the NIOC/NIOCP board (A2, Firmware Manual)
and tighten screw to secure connection. Connect the twisted screen (earthing wires) as short as
possible to the earthing rail next to the NIOC board. For ACP 600 see control and encoder cable
clamping and earthing.

5.6.2.5 Replacing the Front Cover

• Frames R2 to R3, Frame R7:

Frames R2 to R3 Frame R7

Connect the Control Panel cable to the connector X2, and replace the front cover.

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• Frames R4 to R6:

1. Replace the front cover.

2. Replace the telephone connector.

3. Attach the Control Panel by pushing it

softly down onto the connector in the
front cover hollow.

5.6.2.6 Control Panel in Remote Use

Connect the Control Panel cable to terminal X19 of the NAMC-11, or with NAMC-03 board to terminal
X28 of the NIOC board (X300 of the NIOCP board).

ACx 601/604 with NAMC-3 ACx 601/604 with

board and ACx 607 NAMC-11 board

Earth the cable

screen at the near
earthing screw.

See Installation Checklist in ADDENDUM.

5.7 Warranty Acceptance and Rejection

Warranty has been expired. Refer ECB number : AII 0269
[ACS 600 has been converted to ACS 800. ACS 800 has 1 year warranty]

5.8 Handling Software and firmware

Programming the ABB ACS 600

The ABB converter parameters can be manipulated manually or through parameter files. These files
with .dwp extension are to be used with the ABB software Drive Window. Since this software is not
available through Atlas Copco, the most common way to reprogram the parameters is by setting the
relevant parameters manually.

5.8.1 Panel Operation

Keypad modes
The Control Panel has four different keypad modes: Actual Signal Display Mode, Parameter Mode,
Function Mode, and Drive Selection Mode. In addition to these, there is a special Identification
Display, which is displayed after connecting the panel to the link.

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• Identification Display:

When the panel is connected for the first time, or the power is applied to the drive, the Identification
Display appears.
Note: The panel can be connected to the drive while power is applied to the drive.

After two seconds, the display will clear, and the Actual Signals of the drive will appear.

• Keypad Modes

1. Actual Signal Display Mode

Act. Signal/Fault History selection

Act. Signal/Fault Message scrolling

ENTER Enter selection mode, Accept new signal

2. Parameter Mode
Group selection, Parameter selection

Enter change mode, Accept new value

Fast value change, Slow value change

ENTER

3. Function Mode

Row selection

Function start
ENTER

4. Drive Selection Mode

Drive selection, ID number change

ENTER Enter change mode, Accept new value

Operational commands of the Control Panel keys:

Keypad / External Control Forward Start

Fault Reset Reverse Stop

Reference Setting Function

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To change parameters, parameter access must be granted. Follow this procedure to unlock
parameters:

• Stop the compressor on the Elektronikon

• Open the converter cabinet
• Push the “PAR” button on the converter
panel
• Push the arrow keys till parameter P16.3
appears
• Push the “ENTER” button
• Change P16.3 from 0 to 358
• Push the “ENTER” button (P16.2 is
automatically set to “open”)
• All parameters can now be changed

After all parameters are set, the parameters must

be locked again:

• Set P16.2 to “locked” (P16.3 is

automatically changed)

5.9 DriveWindow

5.9.1 Placement

The module should be installed inside the unit on the location shown in the dimensional drawings.
Option modules for the frame sizes R2 and R3 are installed outside the frequency converter. Follow
the instructions given in the Mechanical Installation chapter of the module manual.

5.9.2 Power Supply for the Module

The 24 V d.c. supply for one optional module is provided by the NIOC/NIOCP board of the converter
(NIOC: terminal X23, NIOCP: terminal X4). The location of the NIOC/NIOCP board is shown in the
dimensional drawings.

5.9.3 Fibre Optic Link

Optional modules are connected via a DDCS fiber optic link to the NAMC board or NDCO board (both
mounted on top of the NIOC board). The terminals on the NAMC/NDCO board to which the cables are
connected are given in the table below. Channel CH1 is on NAMC-11 board. Channels CH0, CH2 and
CH3 are on NDCO board. NAMC-3 board includes channels CH0 to CH3.

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Module Type Channel Terminals

Fieldbus Adapter Modules CH0* V13*, V14*
I/O Extension Modules CH1 V15, V16
CH2* with ACS 600 Standard
V17*, V18*
Application Program 5.0
Pulse Encoder Interface Module CH1 with ACS 600 System, Crane,
Master/Follower and Template V15, V16
Application Programs
DriveWindow 1) CH3* V19*, V20*

* On NDCO board when NAMC-11 board is used.

1)
DriveWindow Light is connected via NPCU RS-232/485 converter to the panel connector on the
cover (or to telephone connector X19 on NAMC-11 board).

Observe colouring codes when installing fibre optic cables. Blue connectors should go to blue
terminals, and grey connectors to grey terminals.

In case multiple modules are installed on the same channel, they must be connected in a ring.

5.9.4 Connection Examples

Fieldbus Adapter Module

ACx 600
NMAC NIOC/
NIOCP
NDCO

NIOC Terminal X23

NIOCP Terminal X4

The terminals for

the power supply
connection vary.
Consult adapter
module manual.

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I/O Extension Module

ACx 600
Pulse Encoder Module with ACS 600 NMAC NIOC
Crane (version 5.x), System,
Master/Follower and Template
Application Programs NDCO

NIOC Terminal X23

The terminals for Not supported by ACP 600

the power supply
connection vary.
Consult module
manual.

Pulse Encoder Module (NTAC) with

ACS 600 Standard Application Program ACx 600*
NMAC NIOC

NDCO

NIOC Terminal X23

The terminals for The ACP 600 supports the

the power supply NTACP Double Pulse Encoder
connection vary. instead. See NTACP Installation
Consult module and Start-up Guide.
manual.

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DriveWindow
ACx 600
NMAC NIOC/
NIOCP
NDCO

Laptop PC

NDPC NISA

NDPA Desktop PC

5.10 Spare Parts

The following spare parts are available for the ABB ACS600:
ASC604-0120-2

ACS60x-0140-5

ACS60x-0170-5

ACS60x-0170-6

ACS60x-0210-6
A.C. Part
Description Type
Number

Frame Size: R8 R7 R8 R8 R8
Quantity
POWER SUPPLY BOARD, COATED NPOW-43C 2903 0067 01 1
POWER SUPPLY BOARD, COATED NPOW-42C 2903 0067 02 1 1 1
POWER SUPPLY BOARD, COATED NPOW-62C 2903 0067 03 1 1
THYRISTOR/DIODE MODULE KIT THYR./DIODE 130A SP KIT 2903 0067 04 3
IGBT MODULE KIT IGBT 300A SP KIT 2903 0067 05 1
IGBT MODULE KIT IGBT (1PH) 150A SP KIT 2903 0067 06 3
IGBT MODULE KIT IGBT (1PH) 200A SP KIT 2903 0067 07 3
IGBT MODULE KIT IGBT MODULE 90A/SP 2903 0067 08 3
IGBT MODULE KIT IGBT MODULE 120A/SP 2903 0067 09 3
INPUT PROTECTION CARD KIT,
NINP-21C - 2903 0067 10 1 1 1
COATED
INPUT PROTECTION CARD KIT,
NINP-61C 2903 0067 11 1 1 1 1
COATED
THICK-FILM HYBRID NRED-61, 16328 2903 0067 12 1 1
CURRENT TRANSDUCER ES300-9643 700A +/-24V 2903 0067 13 2 2 2 2
CURRENT TRANSDUCER ES500-9647 1000A+/-24V 2903 0067 14 2
DIODE SKR20/12 2903 0067 15 1 1 1
DIODE DIODE 1600V SM320A 2903 0067 16 1 1
QFBR-3895 170MM FIBRE OPTIC CABLE 2903 0067 17 2 2 2 2 2

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HFBR-RNS5D2 FIBRE OPTIC CABLE 2903 0067 18 2 2 2 2 2

MATCHING BOARD NXPP-01 2903 0067 19 2 2 2 2
THYRISTOR/DIODE MODULE KIT THYR./DIODE 160A SP KIT 2903 0067 20 3
THYRISTOR/DIODE MODULE KIT THYR./DIODE 250A SP KIT 2903 0067 21 3
THYRISTOR/DIODE MODULE KIT THYRI./DIODE MODULE 160A/SP 2903 0067 22 3 3
GATE CIRCUIT CARD KIT, COATED NGDR-02C SP KIT 2903 0067 23 3 3 3 3
DDCS COMMUN. OPTION, COATED NDCO-03C SP KIT 2903 0067 25 1 1 1 1 1
RESISTOR 6R8 1700WS GBF30/156A 6R8 2903 0067 26 1 1
RESISTOR 3R3 3920WS GBF30/156A 3R3 2903 0067 27 1 1 1
STANDARD I/O BOARD, COATED NIOC-01C 2903 0067 28 1 1 1 1 1
MAIN CIRC. INTERFACE, COATED NINT-52C 2903 0067 29 1
MAIN CIRC. INTERFACE, COATED NINT-53C 2903 0067 30 1 1
MAIN CIRC. INTERFACE, COATED NINT-63C (COATED) 2903 0067 31 1 1
CONTROL BOARD, COATED NAMC-51C 2903 0067 32 1 1 1 1 1
CONNECTION CABLE 3M NPLC-03C OPTION/SP KIT 2903 0067 33 1 1 1 1 1
GATE CIRCUIT CARD KIT, COATED NGDR-03C (2 PIECES / KIT) 2903 0067 34 1
RFI BOARD NRFC 75 2903 0067 35 1
RFI-FILTER NRFC 77 2903 0067 36 1
RFI BOARD NRFC 92 2903 0067 37 1
Earth fault transfo U11 NEFT3 REV.B 2903 0067 38 1 1
Capacitors C11.1- C12.2 - C13.3 B43586-S0688-Q3 2903 0067 39 6
Capacitors C1-3 or C1-6 CAPACITOR 1,2UF 1200V 5 % 2903 0067 40 3 6
Fan capacitor MOD.345.4151 1,5UF 400V 10% 2903 0067 42 1
Fuses for the fan 2903 0067 43 2
D4E180-CA02-36 +10UF/400
Fan assembly, frame size R8 2903 0067 44 1 1 1
KOND.
Transformer T41 500-380V/230V 2,2A 2903 0067 45 1
DICHARGING RESISTOR HSCC88 3X4K7 2903 0067 46 1 1
6224N-VAR183 ABB FAN 24VDC 336M3/H 145PA 2903 0067 47 2
Fuses NPOW 42 & 43 2903 0067 48 2 1
CONTROL PANEL CDP 312 1089 9486 50 1 1 1 1 1

Field Tools:

Device Description / Product Description AC P/Nr

Communication cable between ACS600 and MK IV 1613 8420 50

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6. Siemens Masterdrives

6.1 Position of components

6.1.1 GA30VSD

Fan fuses
Mains supply

Converter rating
PMU
Plate & serial
number
CUVC board
RFI-filter

KT - motor
temp. Sensor

Fan transformer Input choke

Primary winding Motor

of transformer connections

GA30VSD – Front view

Figure 1: GA30VSD Front - View

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DC-link
capacitors

E-box

Fan capacitor

Fan transformer

Figure 2: GA30VSD Side - View

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6.1.2 GA50VSD

PCU

DC link Inverter
C W2
W1
Rectifier

V1 V2

U1
D
U2

Fan
24V
External

IGD
PSU
PCC

Binary output
function

Temp
sens. IVI

ABO
E-box

CUVC PMU

W1, U1, V1 - Incoming power supply

PCU - PreCharge Unit
PCC - PreCharge Control
PSU - Power Supply Unit
IVI - Inverter Interface
ABO - Adapter Board
IGD - IGBT gate driver
CUVC - Control Unit Vector control
W2, U2, V2 - Motor connections

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Precharge Mains supply

resistor
Input choke

PCU-board RFI-filter
PSU1-board

PMU
DC-link
capacitors
CUVC-board

KTY - motor
temp. Sensor

Fan

Fan
transformer Motor
connections

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PCC

IVI

ABO

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Temperature
sensor

IGD

E - Box

Current Sensor

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6.1.3 GA90VSD

PCU

DC link Inverter
C SMU W2
W1 Rectifier

V1 V2

U1
D SML
U2

Fan
24V
External

IGD
PSU
PCC

Binary output
function

Temp
sens. IVI

ABO
E-box

CUVC PMU

W1, U1, V1 - Incoming power supply

PCU - PreCharge Unit
PCC - PreCharge Control
PSU - Power Supply Unit
IVI - Inverter Interface
ABO - Adapter Board
IGD - IGBT gate driver
CUVC - Control Unit Vector control
W2, U2, V2 - Motor connections

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PCU
E-Box PCC

CUVC PSU
ABO

Fan
Fan transformer

Current Sensor

Precharge resistor
SMU
SML

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IVI

IGD

Temperature sensor

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PMU

6.1.4 Layout of Electronic Boards and its functions

6.1.4.1 PCU: PreCharge Unit

For GA50VSD

For GA90VSD

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6.1.4.2 PCC: PreCharge Control

For GA50VSD

For GA90VSD
6.1.4.3 PSU: Power Supply Unit

For GA50VSD

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For GA90VSD

6.1.4.4 CUVC: Control Unit Vector Control

For GA50VSD

For GA90VSD

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6.1.4.5 IGD: IGBT Gate Driver

For GA50VSD

For GA90VSD

6.1.4.6 IVI: InVerter Interface

For GA50VSD

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For GA90VSD

6.1.4.7 ABO: Adapter Board

For GA50VSD

For GA90VSD

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6.1.4.8 SMU: Snubber Modul Upper

6.1.4.9 SML: Snubber Modul Lower

6.1.4.10 PMU

For GA50VSD

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6.1.4.11 Converter Fan

For GA50VSD

6.1.5 Serial number of Master Drive

s T - M 7 1 74 7 5 0 0 0 2 3

Year of construction
J = 1997
K = 1998
L = 1999
M = 2000
N = 2001
O = 2002
P = 2003
Q = 2004

Month of construction
1 = January
2 = February
3 = March
4 = April
5 = Mai
6 = Juin
7 = July
8 = August
9 = Septembre
O = Octobre
N = November
D = December

Day of construction
01 …. 31

'475' = specific for Master Drive

Serial number

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Example of data plate

Order Number (Master Drive, with

CUVC, book size D, on 400V, from
72A.)
Edition

Serial Number (Produced on March 1st,

in 1999, as drive nr. 4.)

6.2 Faults

Number / Fault Cause Counter-measure

1. Check the supply voltage & Compare

When pre-charging, the minimum DC link voltage with P071 Line Volts on the PMU.
of 80 % has not been reached.
F002
The maximum pre-charging time of 3 seconds 2. Check the DC link voltage (P071 Line
Pre-charging has been exceeded. Volts x 1.34), should be equal to r006.

3. Check the 3 ph. Rectifier.

Shutdown has occurred due to excessive DC link 1. Check the supply voltage & Compare
voltage. with P071 Line Volts on the PMU
F006 (See F002).
Line voltage DC voltage range I Shutdown value
DC link overvoltage -------------------------------------------------------------- 2. Check the DC link voltage (P071 Line
208 V - 230 V I 280 V - 310 V I appr. 410 V Volts x 1.34), which should be equal
380 V - 460 V I 510 V - 620 V I appr. 820 V to r006 (See F002).
500 V - 575 V I 675 V - 780 V I appr. 1020 V
660 V - 690 V I 890 V - 930 V I appr. 1220 V 3. Check the motor for earth fault.

The lower limit value of 76% of the DC link 1. Check the supply voltage & Compare
voltage (P071 Line Volts) has been fallen short with P071 Line Volts on the PMU
F008 of. (See F002).

DC link undervoltage Under voltage in the DC link in ’normal’ operation 2. Check the DC link voltage (P071 Line
(i.e. no SIMULATION). Volts x 1.34), should be equal to r006
(See F002).
It was a ’brief power failure’, which was not
detected until system recovery (auto restart flag). 3. Check input currents.

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1. Check the load for an overload

condition (element/motor free, oil stop
valve, dp oil sep…).

2. Check whether the dynamic

requirements are too high.
(Fluctuating air demand).
F011 Overcurrent shutdown has occurred.
3. Disconnect the motor and check the
The shutdown threshold has been exceeded. converter output for short-circuit or
Overcurrent earth fault.

4. Try to start the compressor without

backpressure.

5. Check the motor for earth fault.

6. Check the motor windings (ohmic).

1. Check the motor.

F012
During excitation of the induction motor, the
current did not rise above 12.5 % of the setpoint 2. Check current detection; check power
I too low magnetizing current for no-load operation. section.

Motor has stalled or is locked:

- If the static load is too high,
F015 - If the acceleration, or 1. Check for motor stall.
- If deceleration time is too fast, or
- If load change is too fast and too great, 2. Check mechanical side of
Motor stall compressor.
The fault is only generated after the time set in
P805.

The motor temperature limit value has been

exceeded.

r949 = 1 limit value of motor temperature 1. Check the motor (load, ventilation,
exceeded. etc.). The actual motor temperature
can be read in r009: Motor
F020 r949 = 2 short-circuit in the cable to the motor Temperature.
temperature sensor or sensor defective.
Motor temperature 2. Check P381 Motor Temp. Fault.
r949 = 4 wire break in the cable to the motor
temperature sensor or sensor defective. 3. Check the KTY84 for short circuit at
connector on CUVC.
r949 = 5 wire break and limit value monitoring.

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The limit value of the inverter temperature has

been exceeded.
Alarm: (r949): Measure the air intake and ambient
Bit0 Inverter overtemperature temperature. Please observe the
Bit1 Wire break of cable to temperature sensor reduction curves at >40°C.
Bit4 Number of the temperature sensor
Bit5
Bit6
Bit8 Multiparallel circuit: Slave number Check:
Bit9
Bit10 - See that the air entry and discharge
openings are not restricted.
F023 Examples:

r949 = 1: Limit value of inverter temperature - Whether the fan -E1 is connected and
Inverter temperature has been exceeded. is rotating in the correct direction.

r949 = 2: Sensor 1: wire break of sensor cable or - The temperature sensor at -X30.
sensor defective.

r949 = 18: Sensor 2: wire break of sensor - Socket on thermocouple to heat sink.
cable or sensor defective.
- Temperature value on heat sink
r949 = 34: Sensor 3: wire break of sensor P833.
cable or sensor defective.

r949 = 50: Sensor 4: wire break of sensor

cable or sensor defective.

Check:

1. The power-leads connections at input

side for 3 phases (tightening of bolts)
2. The voltage before and after the main
F025 switch/filter
There has been an UCE shutdown in phase
3. Phase L1 for short-circuit or ground
UCE Ph. L1 L1
fault (-X2:U2- including motor)
4. CU (VC) is correctly inserted
5. The switch for "SAFE OFF" (X9/5-6)
is open (only for units with order No.
...-11,...-21,...-31, ...-61).

Check:

1. The power-leads connections at input

side for 3 phases (tightening of bolts)
2. The voltage before and after the main
F026 switch/filter
There has been an UCE shutdown in phase
L2 3. Phase L2 for short-circuit or ground
UCE Ph. L2 fault (-X2:V2- including motor)
4. CU (VC) is correctly inserted
5. The switch for "SAFE OFF" (X9/5-6)
is open (only for units with order No.
...-11,...-21,...-31, ...-61).

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Check:

1. The powerleads connections at input

side for 3 phases (tightening of bolts).
2. The voltage before and after the
F027 mainswitch / filter.
There has been an UCE shutdown in phase
L3 3. Phase L3 for short-circuit or ground
UCE Ph. L3 fault (-X2:W2- including motor).
4. CU (VC) is correctly inserted.
5. The switch for "SAFE OFF" (X9/5-6)
is open (only for units with order No.
...-11,...-21, ...-31, ...-61).

1. Fault in power section. (Valve cannot block.)

2. Fault on CU (VC).

3. A fault has occurred in the measured value

sensing system:
1. Check for fault in measured value
(r949 = 1) Offset adjustment in phase L1 not sensing.
F029 possible. 2. Replace CU (VC)-board.
(r949 = 2) Offset adjustment in phase L3 not 3. Check for bad contacts or broken
Meas. Value sensing possible. wires in the current measurement
(green – brown – white).
(r949 = 3) Offset adjustment in phases L1 and L3
not possible.

(r949=65) Autom. Adjustment of the analogue

inputs is not possible.

Check:

F035 Parameterizable external fault input 1 has been 1. Whether there is an external fault
activated. 2. Whether the cable to the appropriate
Ext. Fault 1 digital input has been interrupted
3. P575 Src No Ext Fault1

Check:
F036 1. Whether there is an external fault
Parameterizable external fault input 2 has been
activated. 2. Whether the cable to the appropriate
Ext. Fault 2 digital input has been interrupted
3. P585 Src No ExtFault2

6.3 Repair Instructions

6.3.1 General trouble shooting and repair

• Check the fault history and look for signs of damage or misuse.

• Check the fan is operating and there are no obvious signs of faults (broken connections etc.)

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• Always check supply is present at the converter and within limits on all three phases.

• Always check if the converter will run in ‘local’ control. This will eliminate communication
problems with Elektronikon.

• Disconnect the motor and run the converter with another motor, or with no motor connected. If
the converter runs, but with a warning, it is probably OK.

• If possible, measure the output currents on the drive using a clamp meter and oscilloscope; if
the currents look similar, the drive is probably OK.

The following Flow Charts give general guidance on initial troubleshooting.

This Simple flow chart will help determine if the fault is in the converter, or external.
If the fault is in the converter and cannot be reset, further trouble shooting information can be found in
the relevant fault compendium.

Start: Power
Up

Yes Lights on Converter ? No

See note 1

Check Power to
Check Display Converter:
LI/L2;L2/L3;L3/L1

No Check Power Supply , No

Fault or Warning
fuses, contactor wiring Power OK ?
present ?
etc.

Yes Yes

Check fault list

Power Cycle
See note 3

Carry out corrective

action according to fault Yes
Converter Lights ?
types. Clear Fault
See note 4

No
Next Page

Converter Faulty;
Replace

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Note 3:
Most common faults are listed in the fault compendium; all faults and warning are listed in the
parameter list.

Note 4:
The fault may be cleared by pressing the reset key or cycling the power.

Note 5:
If the converter attempts to start, but trips, the motor may be at fault; disconnect the motor and run
again.

Note 6:
Parameters may be reloaded using Drive monitor to download a new parameter set.

Start machine from

Elektronikon

Yes No Service Switch to

Converter attempts
Local;start drive from
Start? Note 5
Operator Panel

Fault or Warning No
Occurs ?

No Converter attempts
Suspect Converter
Start ?
Yes

Yes
Check fault list
See Fault Compendiun

Suspect Elektronikon or
Converter settings

Carry out corrective

action according to fault Check system and test
types . Clear Fault thoroughly Reload Parameter
See note 4 settings of Converter
Note 6

6.3.1.1 Repairing Damaged Converters: Some general hints

• If an IGBT is replaced, the drive board should be replaced as well.

• If an IGBT is replaced, consider replacing all IGBTs as they may be stressed or damaged.

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• In some cases, power components are packaged in pairs or even ‘six packs’ and the
complete pack must be replaced.

• If the IGBTs are fixed to the Drive printed circuit board, they must be replaced as a complete
assembly.

• Replace any parts that show signs of burning; it is not possible to clean PCBs or other
components.

For more Repair Instructions, see Addendum.

6.4 Important Parameters

Some parameters may be read to give more information about the state of the converter and some of
them are read only parameters, which cannot be changed.

The converters have been set up with a set of parameters to suit the motor and its application; do not
adjust parameters from these preset values.

i) r001: Drive Status

Shows the current status of the converter or inverter. The converter status is, for example, determined
by the control commands for the internal sequence control (see control word 1 and 2, r550, r551) and
by menu selection P060.

0 = Power section definition 11 = Ready for operation

1 = Initialization of converter or inverter 12 = Ground fault test
2 = Hardware initialization 13 = "Flying restart" is active
3 = Drive system initialization 14 = Operation
4 = Board configuration 15 = OFF1 is active
5 = Drive setting 16 = OFF3 is active
6 = Selection of several drive test functions 17 = "DC braking" is active
7 = Fault 18 = Motor data identification at standstill is active
8 = Start inhibit 19 = Optimization of speed controller
9 = Ready for ON 20 = "Synchronization" active
10 = Pre-charging of DC link bus 21 = Download
11 = Ready for operation

ii) r002: Rotor frequency

Shows the actual value of output frequency in Hz. This should correspond to the motor speed
This value is also displayed in r000 (i.e. Display), when the VSD is in operation. (See P049).

iii) r003: Output voltage

Shows the output voltage of the converter (fundamental rms).

The output voltage varies with the output frequency; the exact value depends on the motor type and
the set up. At low frequencies there will be proportionally more output voltage.

iv) r004: Output Current

Shows the output current of the converter (fundamental rms).

Output current is dependent on load, but there will always be some loading in a compressor
application.

v) r006: DC-link voltage

Shows the DC-link voltage of the converter (V).

The DC link voltage will approximately be equal to the peak of the input voltage.

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vi) r007: Motor torque

Shows the motor torque, referred to the reference-value, programmed in P354. (%)
This will give some idea of the level of loading.

vii) r009: Motor temperature

Shows the current motor temperature. A correct display is only possible if the motor temperature is
measured with a KTY84 temperature sensor.

viii) r012: Active BicoDataSet

Shows the currently active BICO data set

1 = Data set 1 = Normal operation (via Elektronikon)
2 = Data set 2 = Service Switch operation

When the Converter is in Service Switch Operation it uses one set of parameters, when in
Elektronikon, it uses a second set.

ix) r014: Setpoint Speed

Shows the speed setpoint at the speed controller input or at the frequency input of the v/f control.
(rot/min)

The Setpoint is the desired speed of the Converter and motor. It will differ from the actual speed when
the converter is changing speed (accelerating or decelerating) or when the converter is switched off or
in a fault or limit condition.

x) r015: Actual Speed

Shows the actual speed. (rot/min)

This should represent the calculated actual speed of the motor.

xi) P053: Parameter access

Function parameter for enabling interfaces for parameterization.

0 Hex = None
1 Hex = Cbx communication board
2 Hex = PMU operator control panel
4 Hex = Serial interface (SCom/SCom1), also OP1S and PC
8 Hex = SCB serial input/output modules
10 Hex = Txxx technology board
20 Hex = Serial interface 2 (SCom2)
40 Hex = Second CB board
Each interface has a code number. When the number or the sum of different numbers assigned to the
interfaces is/are entered, the interface(s) is/are released for use as a parameterizing interface.

Example:
The factory-setting value 6 is the sum of 2 and 4. This means that parameterization is allowed via the
PMU and serial interface 1 and thus for the OP1S as well.

xii) P060: Menu select

Function parameter for selecting the current menu

0 = User parameter (selection of the visible parameters in P360)

1 = Parameter menu
2 = Fixed settings (for factory settings)
3 = Quick parameterization (changes to "Drive Setting" state
4 = Board configuration (changes to "Board Configuration“ state)

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5 = Drive setting (changes to "Drive Setting" state)

6 = Download (changes to "Download" state)
7 = Upread/Free access
8 = Power section definition (changes to "Power section definition" state)

xiii) r069: Software version

Visualization parameter for displaying the software versions of the basic board as well as the optional
boards in slots A to G

Index 1: Software version of basic board

Index 2: Software version of optional board Slot A
Index 3: Software version of optional board Slot B
Index 4: Software version of optional board Slot C
Index 5: Software version of optional board Slot D
Index 6: Software version of optional board Slot E
Index 7: Software version of optional board Slot F
Index 8: Software version of optional board Slot G

In Atlas Copco Compressors, NO optional boards are used

xiv) P070: Order number 6SE70…

Function parameter for entering the order numbers of converter or inverter modules
These numbers tell the CUMC control board which power section it works with. They are entered in
the "Power section definition" status and are only necessary after the CU has been replaced.

For GA30VSD / 400V: P070 = 66

For GA50VSD / 400V: P070 = 90
For GA50VSD / 500-575V: P070 = 78
For GA90VSD / 400V: P070 = 102
For GA90VSD / 500-575V: P070 = 100

xv) P071: Line volts

Function parameter for entering the line voltage of the converter

Converter (AC/AC): rms value of the line AC voltage
The value is for calculating the rated DC link voltage as a basis for the voltage limits of the Vd(max)
and Vd(min)-controller (e.g. undervoltage failure limit).

xvi) P100: Control mode

Function parameters for selecting the open/closed loop control mode:

Parameter values:
0: v/f control with superposed speed control
1: v/f control
2: v/f control for textile applications;
3: Frequency control (without tachometer)
4: Speed control
5: Torque control
This parameter can only be changed with P060=5.

xvii) P115 : Calculate motor model

Function parameter for selecting various start-up sections and special functions

Parameter values:

1 = Automatic parameterization
Calculation of parameters for the v/f open-loop control and closed-loop control from the rating plate
data of the motor and the gating unit configuration (e.g. P340 Pulse frequency)

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2 = Motor data identification at standstill

Parameterization of closed-loop control from the measured motor data (without setting the n/f
controller); contains the ground fault test and function 1. (Only for P095 = 10, 11 induction motor).
3 = Complete motor data identification (contains the functions 1, 2, 4, 5, 7) (only for P100 = 3, 4, 5
vector control types) (only for P095 = 10, 11 induction motor)

4 = No-load measurement
(Only for P100 = 3, 4, 5 vector control types
Only for P095 = 10, 11 induction motor)

5 = n/f controller optimization

(Only for P100 = 3, 4, 5 vector control types)

6 = Self-test
(Corresponds to the functions of 2, but no parameters are changed) (Only for P095 = 10, 11 induction
motor)

7 = Tachometer test
(Only for P100 = 4, 5 n/m control)

Note: After alarm A078, the unit must be switched on and the measurement at standstill commences.
After the measurement at standstill has been completed, the alarm message A080 appears and the
unit has to be powered up again. Then the no-load measurement and the speed controller
optimization begin.

xviii) P700: Serial communication bus address

Bus address of the serial interfaces (see section "Serial interfaces" in operating instructions, Part 2)

Index 1 = SCom1: bus address of the ser. Interface 1(CU)

Index 2 = SCom2: bus address of the ser. interface 2 (CU),
Index 3 = SCB: bus address of the SCB
Index 1 is used for communication with Drive monitor. Index 2 is the communication speed for
Elektronikon.

The bus-address is dependent from the type of Elektronikon.

xix) P701 : Serial communication baud rate

Function parameter for entering the baud rates for the serial interfaces with USS protocol
Index 1: serial interface 1 (Scom/SCom1)
Index 2: serial interface 2 (SCom2)
Index 3: SCB
Index 1 is used for communication with Drive monitor. Index 2 is the communication speed for
Elektronikon.

1 = 300 Baud
2 = 600 Baud
3 = 1200 Baud
4 = 2400 Baud
5 = 4800 Baud
6 = 9600 Baud
7 = 19200 Baud
8 = 38400 Baud

xx) r782 : Trip time

Visualization parameter for displaying the times at which the last 8 faults occurred
The current status of the operating hours counter (r825) is displayed.

Index 1: Day of the 1st (last) fault trip

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Index 2: Hour of the 1st fault trip

Index 3: Second of the 1st fault trip
Indexes 4 to 6: 2nd fault trip
Indexes 7 to 9: 3rd fault trip
Indexes 10 to 12: 4th fault trip
Indexes 13 to 15: 5th fault trip
Indexes 16 to 18: 6th fault trip
Indexes 19 to 21: 7th fault trip
Indexes 22 to 24: 8th (oldest) fault trip

xxi) r783 : Fault n/f actual

Frequency/speed actual value (r218) at the time of tripping

xxii) r784 : Fault dn/dt

Frequency/speed change per second at the time of tripping

If the value is positive, the motor was accelerating. If the value was negative, the motor was
decelerating.

xxiii) r785 : Fault Isq (actual)

Actual value of the torque-generating current component (K0184) at the time of tripping

xxiv) r786 : Fault Output volts

Actual value of the converter output voltage (r003) at the time of tripping.

xxv) r825 : Operating Hours

Visualization parameter for displaying the operating hours counter

Only that time is counted during which the unit is operated with released firing pulses (inverter
release; motor running).
Index 1: Days
Index 2: Hours
Index 3: Seconds

xxvi) r828 : Software Version ID

Visualization parameter for displaying the software codes

With the help of these codes, the compatibility of the individual software versions can be checked.
Index 1: Basic board
Index 2: Optional board in slot A
Index 3: Optional board in slot B
Index 4: Optional board in slot C
Index 5: Optional board in slot D
Index 6: Optional board in slot E
Index 7: Optional board in slot F
Index 8: Optional board in slot G

xxv) r833 : Drive Temperature

Maximum temperature of all measuring points in the converter (heat sink and maybe air flow); in °C

xxvi) r947; r949 & r952 : Fault memory

Fault number, Fault value and number of faults in the memory

See 6.8 - Fault memory in this manual.

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6.5 Service Switch

For certain jobs or tests, (for example a vibration measurement), the speed of the compressor
element may not be regulated by Elektronikon.
The Service Switch permits easy and local control of the converter and motor.

6.5.1 Functionality

When placing the Service Switch into ‘service mode‘, Elektronikon has no influence anymore.
The compressor can be started using the green button on the PMU.
The compressor can be stopped again using the red button.
The compressor will run at fixed minimum speed.
A warning A016 is displayed onto the PMU when the service switch is activated.

6.5.2 Location and lay-out of Service Switch

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Normal operation of compressor

Service switch is OFF

0V: Parameterset 1 active
Serial communication OK
Commands & speed setpoint from
Elektronikon

Elektronikon Masterdrive
1 24V

K05 SS

Communication

Communication OK : K05 closed 24V : no ‘emergency stop’

6.5.4 Communication fault

Service switch is OFF

Serial communication fault 0V: Parameterset 1 active
Commands & speed setpoint from
Elektronikon

Elektronikon Masterdrive
1 24V

K05 SS

Communication

Communication failed : K05 open 0V : ‘emergency stop’

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6.5.5 Operation in Service Mode

Service Switch is ON.

24V : Parameterset 2 active
Commands & speed setpoint from
Master Drive

Elektronikon Masterdrive
1 24V

K05 SS

Communication

Communication disabled : K05 open 24V : no ‘emergency stop’

The position of the service switch can be checked in parameter r012.

r012 = 1 = Data set 1 (operation via Elektronikon)

r012 = 2 = Data set 2 (operation in service mode)

Depending of the version of parameterset, a warning A016 is displayed onto the PMU with an active
service-switch.

If the compressor is started from the Elektronikon with the service switch in service-position, it will
generate a fault.

6.6 Error detection with Testbox

When doing error detection on a Master Drive, it‘s sometimes difficult to know when something is
defective or not.

With some help of the TestBox, it is possible to make a better diagnosis of several components in the
drive.

To do error-detection with the Test Box; the following equipment is needed:

• Siemens TestBox (6SE7090-0XX84-1FK0)

• 24Vdc Power Supply (Minimum : 2A)

• Screwdriver to remove CU-board

• Digital multimeter

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Flat Cable

Interface board

Textbox

6.6.1 Before starting

• Switch off the main power Supply.

• Wait 5 minutes.

• Disconnect the motor at the converter terminals.

• Remove PMU and CU-card out of Electronic box.

6.6.2 Mounting the Testbox

1. The Test Box is inserted in the same ‘slot‘ as the CU-card.

2. The interface card slides into the guide rails in the electronic box, just as the CU-board.

3. The multipole connector and flat cable have to be at the bottom side.

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Make sure the interface card is fully pushed home into the connector. It cannot be fixed with screws.

Make sure the interface card is fully pushed home into the connector. It cannot be fixed with screws.

Connect 24V at X9

Connect external 24V at X9 onto the PSU-board.

X9: 1 = +24V
X9: 2 = 0V

+24V 0V

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6.6.3 Measurements

Switch on the power supply. 8 LED’s should light; all IGBT’s switches in middle position.

1. LDSAVE
2. P150K
3. +24V
4. +15V
5. -15V
6. +5V
7. VREFU
8. VREFI

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1. Status signal inverter (Feedback signals).
2. Switch for activation of IGBT’s
3. Checking IGBT’s and feedback signals
4. Checking current measurements
5. Checking temperature sensors
6. Earth points (measuring references)
VSD Repair Manual

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7. Checking DC-link voltage normalisation
8. Checking main contactor relay and precharging
9. Checking internal power supplies
VSD Repair Manual

Check Tolerance
+5V : Measure between Earth point (6) & 5V(9) 4,9 ... 5,3V
-15V : Measure between Earth point (6) & -15V(9) -15,75 ... –14,25V
+15V : Measure between Earth point (6) & +15V(9) 14,25 ... 15.75V
+24V : Measure between Earth point (6) & +24V(9) 22 ... 30 V
Temperature sensor (TWRN): Measure between 6 & 5 See table below
DC-link normalization: Measure between 6 & 7 From –50mV... +50mV with Ud = 0V
Output current phase 1: Measure between 6 & 4(IRN) -50mV ... + 50mV
Output current phase 2: Measure between 6 & 4(ISN) -50mV ... + 50mV
Output current phase 3: Measure between 6 & 4(ITN) -50mV ... + 50mV

Temperature Voltage socket ‘TWRN’ against ‘earth’

10°C 4,75...5,55V
20°C 4,53...5,29V
30°C 4,23...4,94V
40°C 3,86...4,51V

The sensor measures the temperature of the cooling plate, which can deviate from the ambient
temperature!
Activating switch ‘main contactor’ will close the relay-contact X9: 4 and 5.
This must be clearly audible.
Activating switch ‘uberbrucken’ will close a relay-contact for internal use only.
This must be clearly audible.

6.6.3.1 Testing IGBT’s

For this test, we will also need 24V on the DC-link. This 24V can come from the same power supply
that we use to feed the electronics.
At this step, it is absolutely necessary that the motor be disconnected!

C D-
+

X9

Volts
dc

Connect X9 and DC-link to 24V like shown here.

Check the DC-link voltage if it is 24Vdc.
24V

By switching the IGBT’s via the TestBox, we can determine if there is a bad IGBT, or bad control
(electronic boards) of an IGBT.

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6.6.4 Remarks on Testbox

1) The led’s UCER, UCES and UCET are feedback signals from the inverter. There is one led for
each output phase. If one or more led’s is shining, there is a problem with one ore more feedback
signals. This can be due to faulty IGBT’s or to faulty electronic boards.

2) The switch for MASTER/SLAVE is only used for bigger master drives with two or more converters
in parallel. When testing a ‘single’ drive, the position of this switch does not matter.

3) The temperature switch buttons are used for bigger drives, that have more than one temperature
sensor inside the drive. By pushing the buttons, there can be made a selection of which
temperature sensor is measured in the ‘TWRN’ socket.

4) The led’s ‘VREFU’ and ‘VREFI’ must always shine, these are indications for the standardisation
for the actual values for voltages and currents.

The led’s ‘LDSAVE’ and ‘P150K’ must also always shine.

6.7 Replacing CU board

The control board (CUVC) contains the firmware, the Power Section definition and the parameter
settings.

Replacement control boards may be supplied with the latest version of the firmware, which may need
to be changed.

During the power section definition, the control electronics is informed which power section it is
working with. This step is necessary for all Master Drives.
This is carried out by setting a few parameters using the Drivemonitor programme or the Operator
Panel, and is described below.
If CUVC boards are changed over between different units without the power section being re-defined,
the unit can be destroyed when it is connected up to the voltage supply and energized.

If a control board is exchanged then the correct parameters must be reloaded to suit that application.
This is most easily done using Drivemonitor, but individual parameters may be adjusted using an
Operator panel on the converter.

If a new control board is to be installed:

Upload the parameter settings from the old one using Drivemonitor (or make sure you already have
the settings available)

1. Exchange Control board

2. Check Firmware issue and reload if necessary
3. Carry out Power Section definition
4. Download Parameter settings

6.7.1 Warning

The board contains components which can be destroyed be electrostatic discharge.

These components can be easily destroyed if not carefully handled. If you have to handle electronic
boards, please observe following:

1. Electronic boards should only by touched when absolutely necessary

2. The human body must be electrically discharged before touching an electronic board.
3. CAUTION!
Boards must not come into contact with highly insulating materials.
4. Boards must only be placed on conductive surfaces.
5. Boards and components should only be stored and transported in conductive packaging.
6. If the packing material is not conductive, the boards must be wrapped with a conductive
packaging material (conductive foam rubber or household aluminium foil.
7. Practical: always carry CU with the 2 clips.

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6.7.2 Power section Definition

The parameterisation can be done on the PMU, or using Drivemonitor.

Select “Power Section Definition” menu.
Input the code number for the unit concerned. The code number is allocated to the order numbers
(MLFB). The order number can be read off the unit’s rating plate. The list of the Atlas Copco units is
on the following slide.
Return to parameter menu.

P060 = 8

P070 =?

P060 = 1

Compressor P070 Order number

(Type/voltage) (MLFB)
GA30VSD / 400V P070 = 66 6SE7027-2ED61

GA50VSD / 400V P070 = 90 6SE7031-5EF60

GA50VSD / 500-575V P070 = 78 6SE7031-1FF60

GA90VSD / 400V P070 = 102 6SE7032-1EG60

GA90VSD / 500-575V P070 = 100 6SE7032-0FG60

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When setting P060 to ‘8’, the drives goes to °000 (condition ‘power definition’).
This is the only possibility to change P070.
If downloading a parameter set, with another P070 then in the CU-board, P070 will not be changed
(safety reason) !!
When receiving a new CU-card, it’s already into °000 when powering up the first time.
It is necessary to program a value for P070 (different from 0), to leave condition °000.

Power definition has to be carried out before downloading a parameterset from Atlas Copco.
If downloading a ‘short list’, it’s necessary to reset the drive before downloading the short list.
When downloading a ‘complete list’, it’s not necessary to reset the drive first.
When changing the firmware from 3.xy to 3.x’y’ and x to x’ are different, the power definition have to
be carried out.
After changing the firmware, the drive goes automatically to °000.

To check the programmed P070, the values for the converter supply voltage in P071 and the
converter current in P072 should be checked after returning to the parameter menu. They must be
identical with the data given on the unit rating plate.

6.7.3 Parameter reset

1. After changing P070, we need to carry out a parameter reset before downloading a short list.

P053 = 6 Parameter access

(for PMU and Drivemonitor)

P060 = 2 Select fixed settings menu

Standard parameter reset (start-stop and setpoint via PMU after reset).
P366 = 0

Start parameter reset

0 = Parameter reset
P970 = 1
1 = No parameter change

2. Parameters related to a parameter reset, can be selected in Drivemonitor using Parameters

menu/ Fixed Settings

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3. Parameters related to parameter-reset and software-version are displayed in the fixed-

settings selection.

6.8 Fault memory

6.8.1 How Faults are recorded

The Master Drive VC has a fault memory. This feature makes it possible to see which faults have
occurred in the past

The fault memory can contain 8 fault-groups. A fault group can contain a maximum of 8 faults.

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High byte = Current fault number r947.01 <1>

K0250
Low byte = Current alarm number
Fault Masking Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s 0 ... 255
Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
P830 (0)
"ON" status from Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09

1 2 3
Sequence control FNo. r947.01 FValue r949.01 FNo. r947.0 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 9 .10 .10 .18 .18
Fault trigger signal .03 .03 .11 .11 .19 .19
from sequence control .04 .04 .12 .12 .20 .20
.05 .05 .13 .13 .21 .21
Day Hours Seconds .06 .06 .14 .14 .22 .22
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating .08 .08 .16 .16 .24 .24
hours
Current fault 1st acknowledged fault 2nd acknowledged fault
counter
Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17

4 6
Fault time in seconds .12 .15 Fault time in seconds .18

5
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0 .27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
.29 .29 .37 .37 .45 .45
memory to be deleted .30 .38 .46
.30 .38 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault
Status at time of the
last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23

8
Fault time in seconds .21 Fault time in seconds .24
r 784 Fault dn/dt

7
FNo. r947.49 r949.49 FNo. r947.57 FValue r949.57
r 785 Fault Isq(act)
.50 .50 .58 .58
r 786 Fault Out Volts .51 .51 .59 .59
r 787 Fault CtrlStatus .52 .52 .60 .60
.53 .53 .61 .61
<1> K0250 = 0000 if there is no fault
Auto Acknowledge .54 .54 .62 .62 and no alarm
P514 .55 .55 .63 .63
.56 .56 .64 .64
6th acknowledged fault 7th acknowledged fault

Fault group 1 contains the faults at THIS moment.

If the drive has no fault, fault group 1 is empty.
If the drive is NOW in fault, the fault information will be located in fault group 1.

The oldest faults are located in group 8.

Older faults, then those in fault group 8, are erased.

6.8.2 Fault group

Fault group 1 contains the faults at THIS moment.

If the drive has no fault, fault group 1 is empty.
If the drive is NOW in fault, the fault information will be located in fault group 1.

The oldest faults are located in group 8.

Older faults, then those in fault group 8, are erased.

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Fault time in days r782.04

Fault time in hours .05
Fault time in seconds .06
FNo. r947.09 FValue r949.09
.10 .10
.11 .11
.12 .12
.13 .13
.14 .14
.15 .15
.16 .16
1st acknowledged fault

One fault group can contain several informations:

Example: fault group 2

A maximum of 8 fault numbers.

Each fault number can contain a fault value. On some faults, there can be more information in the
fault value.
The fault time when the fault(s) appeared:

Fault time in days r782.04

Fault time in hours .05
Fault time in seconds .06
FNo. r947.09 FValue r949.09
.10 .10
.11 .11
.12 .12
.13 .13
.14 .14
.15 .15
.16 .16
1st acknowledged fault

The fault time, when the fault(s) appeared, is displayed in operating hours.

When, for example, the fault between two fault-groups 24 hours is, it can be that there are a few days
between the faults.

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6.8.3 Operating Hours

High byte = Current fault number r947.01
K0250
Low byte = Current alarm number

Fault time in days r782.01

1s Fault Masking Fault time in hours .02
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03
sequence control FNo. r947.01 FValue r949.01
.02 .02
.03 .03
Fault trigger signal
& from sequence control .04
.05
.04
.05
.06 .06
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07
Operating
hours .08 .08
counter Current fault

r825.01 : Operating hours [days]

r825.02 : Operating hours [Hours]
r825.03 : Operating hours [seconds]

6.8.4 Function of P952

Fault time in days r782.10

Fault time in hours .11
Fault time in seconds .12
FNo. r947.25 FValue r949.25
.26 .26
P952=0
.27 .27
Causes the diagnosis .28 .28
memory to be deleted .29 .29
.30 .30
.31 .31
.32 .32
3rd acknowledged fault

P952 has two functions:

• It tells how many fault groups are used.

• If it is programmed to ‘0‘, it will erase the fault memory complete.

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6.8.5 Working of the fault memory

High byte = Current fault number r947.01 <1>
K0250
Low byte = Current alarm number

Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s Fault Masking Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09
sequence control FNo. r947.01 FValue r949.01 FNo. r947.09 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger signal
& from sequence control .04
.05
.04
.05
.12
.13
.12
.13
.20
.21
.20
.21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating
hours .08 .08 .16 .16 .24 .24
counter Current fault 1st acknowledged fault 2nd acknowledged fault

Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17
Fault time in seconds .12 Fault time in seconds .15 Fault time in seconds .18
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
memory to be deleted .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault

Status at time of the

last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23
r 784 Fault dn/dt Fault time in seconds .21 Fault time in seconds .24
r 785 Fault Isq(act)
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out Volts
r 787 Fault CtrlStatus .50 .50 .58 .58
.51 .51 .59 .59
Auto Acknowl .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no fault
and no alarm
6th acknowledged fault 7th acknowledged fault

Example:

High byte = Current fault number r947.01 <1>

K0250
Low byte = Current alarm number

Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s Fault Masking Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09
sequence control FNo.35 r947.01 FValue r949.01 FNo. r947.09 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger signal
& from sequence control .04
.05
.04
.05
.12
.13
.12
.13
.20
.21
.20
.21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating
hours .08 .08 .16 .16 .24 .24
counter Current fault 1st acknowledged fault 2nd acknowledged fault

Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17
Fault time in seconds .12 Fault time in seconds .15 Fault time in seconds .18
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
memory to be deleted .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault

Status at time of the

last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23
r 784 Fault dn/dt Fault time in seconds .21 Fault time in seconds .24
r 785 Fault Isq(act)
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out Volts
r 787 Fault CtrlStatus .50 .50 .58 .58
.51 .51 .59 .59
Auto Acknowl .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no fault
and no alarm
6th acknowledged fault 7th acknowledged fault

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Drive is now in fault: For example F035

High byte = Current fault number r947.01 <1>

K0250
Low byte = Current alarm number

Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s Fault Masking Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09
sequence control FNo. 0 r947.01 FValue r949.01 FNo. 35 r947.09 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger signal
& from sequence control .04
.05
.04
.05
.12
.13
.12
.13
.20
.21
.20
.21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating
hours .08 .08 .16 .16 .24 .24
counter Current fault 1st acknowledged fault 2nd acknowledged fault

Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17
Fault time in seconds .12 Fault time in seconds .15 Fault time in seconds .18
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
memory to be deleted .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault

Status at time of the

last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23
r 784 Fault dn/dt Fault time in seconds .21 Fault time in seconds .24
r 785 Fault Isq(act)
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out Volts
r 787 Fault CtrlStatus .50 .50 .58 .58
.51 .51 .59 .59
Auto Acknowl .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no fault
and no alarm
6th acknowledged fault 7th acknowledged fault

Fault is acknowledged, drive ready to start or running (no fault).

High byte = Current fault number <1>

K0250
Low byte = Current alarm

Fault time in r782.01 Fault time in r782.04 Fault time in r782.07

1s Fault Fault time in .02 Fault time in .05 Fault time in .08
0 ... 255
"ON" status P830 (0) Fault time in .03 Fault time in .06 Fault time in .09
sequence FNo. 23 r947.01 2
FValue r949.01 FNo. 35 r947.09 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger

& from sequence .04 .04 .12 .12 .20 .20

.05 .05 .13 .13 .21 .21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operatin
hours .08 .08 .16 .16 .24 .24
counter Current 1st acknowledged 2nd acknowledged

Fault time in r782.10 Fault time in r782.13 Fault time in r782.16

Fault time in .11 Fault time in .14 Fault time in .17
Fault time in .12 Fault time in .15 Fault time in .18
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the .28 .28 .36 .36 .44 .44
memory to be .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged 4ht acknowledged 5th acknowledged
Status at time of
last fault: Fault time in r782.19 Fault time in r782.22
r 783 Fault Fault time in .20 Fault time in .23
r 784 Fault Fault time in .21 Fault time in .24
r 785 Fault
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out
r 787 Fault .50 .50 .58 .58
.51 .51 .59 .59
Auto .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no
and no
6th acknowledged 7th acknowledged

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Drive is now in fault; F023 with r949=2.

High byte = Current fault number r947.01 <1>
K0250
Low byte = Current alarm number

Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s Fault Masking Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09
sequence control FNo. 0 r947.01 FValue r949.01 FNo. 35 r947.09 FValue r949.09 FNo.23 r947.17 FValue2 r949.17
.02 .02 36 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger signal
& from sequence control .04
.05
.04
.05
.12
.13
.12
.13
.20
.21
.20
.21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating
hours .08 .08 .16 .16 .24 .24
counter Current fault 1st acknowledged fault 2nd acknowledged fault

Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17
Fault time in seconds .12 Fault time in seconds .15 Fault time in seconds .18
FNo. 35 r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
memory to be deleted .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault

Status at time of the

last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23
r 784 Fault dn/dt Fault time in seconds .21 Fault time in seconds .24
r 785 Fault Isq(act)
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out Volts
r 787 Fault CtrlStatus .50 .50 .58 .58
.51 .51 .59 .59
Auto Acknowl .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no fault
and no alarm
6th acknowledged fault 7th acknowledged fault

Fault is acknowledged; drive ready to start or running (no fault).

6.8.6 Other functions

High byte = Current fault number r947.01 <1>
K0250
Low byte = Current alarm number

Fault time in days r782.01 Fault time in days r782.04 Fault time in days r782.07
1s Fault Masking Fault time in hours .02 Fault time in hours .05 Fault time in hours .08
0 ... 255
"ON" status from P830 (0) Fault time in seconds .03 Fault time in seconds .06 Fault time in seconds .09
sequence control FNo. r947.01 FValue r949.01 FNo. r947.09 FValue r949.09 FNo. r947.17 FValue r949.17
.02 .02 .10 .10 .18 .18
.03 .03 .11 .11 .19 .19
Fault trigger signal
& from sequence control .04
.05
.04
.05
.12
.13
.12
.13
.20
.21
.20
.21
.06 .06 .14 .14 .22 .22
Day Hours Seconds
r825.01 r825.02 r825.03 .07 .07 .15 .15 .23 .23
Operating
hours .08 .08 .16 .16 .24 .24
counter Current fault 1st acknowledged fault 2nd acknowledged fault

Fault time in days r782.10 Fault time in days r782.13 Fault time in days r782.16
Fault time in hours .11 Fault time in hours .14 Fault time in hours .17
Fault time in seconds .12 Fault time in seconds .15 Fault time in seconds .18
FNo. r947.25 FValue r949.25 FNo. r947.33 FValue r949.33 FNo. r947.41 FValue r949.41
.26 .26 .34 .34 .42 .42
P952=0
.27 .27 .35 .35 .43 .43
Causes the diagnosis .28 .28 .36 .36 .44 .44
memory to be deleted .29 .29 .37 .37 .45 .45
.30 .30 .38 .38 .46 .46
.31 .31 .39 .39 .47 .47
.32 .32 .40 .40 .48 .48
3rd acknowledged fault 4ht acknowledged fault 5th acknowledged fault

Status at time of the

last fault: Fault time in days r782.19 Fault time in days r782.22
r 783 Fault n/f(act) Fault time in hours .20 Fault time in hours .23
r 784 Fault dn/dt Fault time in seconds .21 Fault time in seconds .24
r 785 Fault Isq(act)
FNo. r947.49 FValue r949.49 FNo. r947.57 FValue r949.57
r 786 Fault Out Volts
r 787 Fault CtrlStatus .50 .50 .58 .58
.51 .51 .59 .59
Auto Acknowl .52 .52 .60 .60
P514
.53 .53 .61 .61
.54 .54 .62 .62
.55 .55 .63 .63
.56 .56 .64 .64 <1> K0250 = 0000 if there is no fault
and no alarm
6th acknowledged fault 7th acknowledged fault

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Fault masking: NEVER USE THIS !!!!

Status at time of last fault:

When the drive is in fault, the value stay fixed onto the values at the moment when the fault occurred.
This can be used, for example, to see if a fault always occurs at the same motor speed or, for
example during ramping up or ramping down.

Status at time of the last fault:

r783 Fault n/f(act)

r784 Fault dn/dt
r785 fault Isq(act)
r786 Fault Out Volts
r787 Fault ctrl status

6.9 Installation

As part of the repair process, it is important to try to find the cause of failure.

Converters in compressors are generally well installed, but it is useful to understand and check the
following installation points:

1. Grounding

2. Poor grounding

3. IT supplies

4. Supply Problems

5. Protection Levels and Contamination

6. Cooling

7. Reforming capacitors after storage

6.9.1 EMC: Poor Grounding

Interfering Voltage will build up in the long thin ground connections and cause interfering current to
flow.

PLC Inverter Motor

Current

Voltage Voltage

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6.9.2 EMC: Good Grounding

PLC Inverter Motor

Motor

There is much less interfering voltage because the ground is thick, short and Star connected.

6.9.3 Operation with incorrect Ground

The Earth must be an independent ground connection carrying no current.

Neutral grounding systems are not acceptable.

Converter Converter

Single Phase loads generate neutral currents – OK Single Phase loads generate Earth currents - NO!
All Standard Drives MUST BE EARTHED.

6.9.4 Correct Motor Grounding

Converter

Four Core cable with armour or screen correctly terminated at both ends.

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6.9.5 Operation with incorrect Ground

The Converter must be The Motor must be

The ground must be
grounded grounded to the Converter
connected to the neutral
at the supply

Additional grounding is useful to reduce EMI:

Ground the metal work to the cubicle.
Ground the motor
Ground the motor screen or armour at both ends

6.9.6 Operation with unearthed Supplies (IT Supplies)

Converter

Fit an output
choke

Drive and motor are still grounded

6.9.7 Torque settings

6.9.7.1 For GA50VSD

When changing parts or components in the drive, it is important that electrical and mechanical
connections are done well.
A screw or bolt can be tightened too hard or too loose.
Some components or cards can also be damaged, when the screw or bolt is tightened too hard.
Which torques to use where, is explained here.

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Torque

IGBT Screws to mount IGBT’s have to be mounted in a specific order. First 5Nm
hand-tighten them in order 1 – 2 – 3 - 4 (~0, 5Nm). After hand
tightening, tighten them in order 1 – 2 – 3 – 4.

IGD 2Nm

Thyristors 4Nm

Thyristors 6Nm

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Incoming line 25 Nm
supply

Capacitor 6Nm
bank
mechanical

Capacitor 6Nm
bank
electrical

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PCC 6Nm

PCU 6Nm

PCU- 6Nm
connection

PSU 1.8 Nm

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IVI 1.3Nm

Current 6Nm
sensor
connections

Connection 5Nm
plate to
IGBT’s

Connection 6Nm
plate to
cables

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Fan 10Nm

Motor 25Nm
connections

6.9.7.2 For GA90VSD

Torque

IGBT Screws to mount IGBT’s have to be mounted in a specific order. 5Nm

First hand-tighten them in order 1 – 2 – 3 - 4 (~0, 5Nm). After hand
tightening, tighten them in order 1 – 2 – 3 – 4.

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IGD 2Nm

Thyristors Screws to mount thyristors have to be mounted in a specific order. 6Nm

Mechanical First hand-tighten them in order 1 – 2 – 3 - 4 (~0,5Nm) After hand
tightening, tighten them in order 1 – 2 – 3 – 4.

Thyristors 9Nm
electrical

Thyristors 9Nm

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Thyristors 13Nm

Wirings 6Nm

Capacitor 10Nm
bank
mechanical

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Capacitor 6Nm
bank fixation

10Nm

PCC 1) 5Nm

And

2) 6Nm

PCU 5Nm

PSU 1.8Nm

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IVI 1.3Nm

Current 1) 13Nm
sensor
connections And

2) 5Nm

Current 1.8 Nm
sensor
mechanical
mounting

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DC- 25Nm
connection
plate (to
output)

DC- 25Nm
connection
plate (to DC)

DC- 1, 8Nm
connection
plate (to
resistors)

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SMU/SML 1)Siemens:
5Nm
Eupec:
8Nm

2)1,8Nm

Supporting 6Nm
piece

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Symmetric 2Nm
resistor

2Nm

2.5Nm

Fan 10Nm

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6.10 Short Guide to Basic Functions

Contd..

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6.11 Warranty Acceptance and Rejection

As part of the repair process, Atlas Copco Engineers are required to:
• Report the failure and repair
• Return exchanged equipment
• Decide on Warranty payment.
The exact procedures are still being prepared, but some general guidelines on warranty are given
below:

Basic Principles:

Warranty is the same for all customers. However, for certain customers support (Kulanz) is offered
and agreed by other parties. This will not affect the internal handling and reporting if warranty is
rejected.

Warranty is only honoured if the customer has followed the correct maintenance procedure and has
protected the equipment according to its specification. This applies to environmental issues
(temperature, contamination etc.) as well as electrical (supply voltage, correct connection etc.).

Supply Overvoltage

Clear evidence of high

supply voltage.
Varistor is badly damaged.

The Overvoltage protection devices have blown, causing arcing and board damage. This is caused
due to a high voltage transient on the supply.

Warranty must be rejected.

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6.11.1 Potential Supply Problems

Event waveform/detail
Volts Amps
1000 1000

750 750

500 500

250 250
Surge
0 0

-250 -250

-500 -500

-750 -750

-1000 -1000
06:51:33.955 06:51:33.960 06:51:33.965 06:51:33.970 06:51:33.975
CHD Volts CHA Amps CHB Amps CHC Amps
Phase V L1-L2 Phase V L2-L3 Phase V L3-L1

DV RMS Norm to Hi at 01/08/2002 06:51:33.966

Threshold Crossed: 750.0 V

This transient on the supply is causing a surge on the DC link, resulting in F0002, Overvoltage trip.

Higher surges may break the drive. Result captured by Dranetz recorder. These events are quite
difficult to catch

6.11.1.1 Maintenance
Check that the customer has followed the correct maintenance procedure. Written evidence must be
provided of this. Failure to carry out maintenance may lead to warranty rejection.

6.11.1.2 Environment
Warranty may be rejected on the converter if:

• There is evidence of insufficient cooling

• There is evidence of contamination (dust, liquid, corrosive gases)
• There is evidence of unauthorised interference with the converter
• There is evidence of incorrect or excessive supply voltage

Cooling the Converter:

o o
The maximum operating temperature for most Converters is 50 C (40 C for some units).

The minimum operating temperature is -10oC, 0oC for some units.

This temperature is the worst-case temperature inside the cubicle.

Additional derating is required for altitude, some switching frequencies and voltages.

6.11.2 Dust Contamination

This amount of dust will stop the fan, and eventually damage the drive by causing voltage breakdown
where it deposits.

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Many dusts are explosive (flour, paper) or conductive. Make sure the installation is suitable for the
drive.

Dust in inverter will reduce cooling or cause short circuit.

Wool has damaged the fans as well as reducing cooling.

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Water or similar liquid has entered the unit causing electrical short circuits.

Corrosive gas has damaged these plated parts.

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Customer has opened converter and damaged electrical links.

6.11.3 Re-Forming Capacitors

If a unit has been non-operational for more than one year, the DC link capacitors have to be newly
formed. If this is not carried out, the unit can be damaged when the line voltage is powered up.

If the unit was started-up within one year after having been manufactured, the DC link capacitors do
not have to be re-formed. The date of manufacture of the unit can be read from the serial number.

During forming, the DC link of the unit is connected up via a rectifier, a smoothing capacitor and a
resistor.

As a result, the DC link capacitors receive a defined voltage and a limited current, and the internal
conditions necessary for the function of the DC link capacitors are restored.

Warranty must be rejected.

6.12 Handling Software and firmware

6.12.1 Changing Firmware

Firmware can change due to time or evolution.

With Master Drive we have the possibility to change the firmware by software (so no exchange of
Eproms...).
It‘s also specified, that Atlas Copco VSD-compressors have to run with the same firmware version,
where all tests are done with.

When ordering a new CUVC-card, it will be loaded with the latest software-version. So, it will be
necessarily to change the firmware to an older version.

There are 2 possibilities for changing firmware: using a DOS-application or either a Windows-
application. The result is the same.

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1. Determining the firmware version

The actual firmware version in the drive can be found in parameters r069.1 and r828.1

Softwareversion 3.31
• r069.1
• r828.1
2. Requirements to change firmware

• PC with COM-port
• Firmware
• Cable to load the firmware (Siemens part nr. 9AK1012-1AA00)
Drive side
PC side

3. Preparing the Master Drive for firmware-upgrade

For safety-reasons, the Master Drive can only be upgraded in a special mode. Follow this procedure
to get into the special mode.

• Close Simovis or Drivemonitor.

• Connect Master Drive and PC with the cable (switch closed).
• Turn off main power of the drive (PMU have to be dark)
• Switch on the main power.

The drive have to display an ‘E‘ on the PMU.

The drive is now ready for a firmware-upgrade.

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6.12.1.1 Using DOS application

1. Unpacking received firmware

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2. Double click on BAT-file

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3. Routine starts

4. Routine busy

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6.12.1.2 Using Windows application

1. Open WIN – BSL- Program

2. Check COM – port

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3. Select software version

4. Start Software-transfer; (first erasing)

3. Routine busy

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5. Routing busy

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6. Firmware download ready

6.12.1.3 Remarks (common for DOS and windows application)

All parameters will be lost if the second number changes before and after the firmware download.
When changing only the last number, the parameters will be memorised in the drive.

V3.32 => V3.22 Parameters lost

V3.32 => V3.14 Parameters lost

When the drive is finished with the software-upgrade, it will come into condition °000 (Power def.; see
‘changing CU‘)

V3.14 => V3.12 Parameters not lost

V3.20 => V3.23 Parameters not lost

When the drive is finished with the software-upgrade, it will come directly to its normal condition (°008
or °009).

Communication settings on the CU-board do not influence this procedure.

Only the COM-port needs to be changed, in case of use of COM1, COM2 or COM3-port on the PC.
The baud rate is (independent of earlier parameters onto CUVC, always 38400bps).

Firmware can be downloaded onto this internet-site:

http://www4.ad.siemens.de/-snm-0135030360-1080832526-0000003300-0000000006-1081264401-
enm-WW/llisapi.dll?func=cslib.csinfo&foldersopen0=-2-73-74-111-113-
&lang=en&siteid=cseus&aktprim=0&startNode=4000024&nodeID0=10804947&basisview=4000003&v
iewLevel

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The different software versions, used on Atlas Copco compressors are contained on the
documentation CD-Rom.

6.12.2 Drive Monitor

Master Drive uses parameters to define its motor parameters, regulation data and other functions.

All parameters can be viewed or changed by the PMU.

For working more comfortable and faster, the software program ‘DriveMonitor‘ is available.

DriveMonitor is the replacement program for the older ‘Simovis‘.

The latest version at this moment is V5.2 SP1.

1. Starting screen

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2. Checking communication settings

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3. Menu file

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4. Choose between two choices

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5. Choose type of drive

6. Choose software version

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7. No technology, address 0 and PZD = 2 is OK

8. Type filename

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Example: ‘empty set’

9. Choose ‘direct to parameter list’

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10. DriveMonitor will open

11. Condition OFFLINE

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12. Condition NO CONNECTION

13. Condition ‘connection OK’

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14. Condition ‘connection and warning active’

15. Condition ‘connection and fault active’

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16. Condition ‘connection offline’

17. Displaying ‘all parameters’

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18. Displaying ‘custom parameter list’

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19. Upreading parameters

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20. Downloading parameters

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6.13 Spare Parts

Note :

A– B– C–
Converter: Converter: Converter:
Siemens P/Nr: 6SE7027- Siemens P/Nr: 6SE7031- Siemens P/Nr: 6SE7032-
2ED61 5EF60 1EG60
AC P/Nr: 1089 9338 30 AC P/Nr: 1089 9338 20 AC P/Nr: 1089 9338 12

Converter cubicles: Converter cubicles: Converter cubicles:

1900 2019 51 1900 2031 52 1900 2012 51
1900 2031 51 1900 2017 51 1900 2012 52
1900 2017 52
Compressor: 1900 2017 54 Compressor:
GA30VSD 380-460V GA90VSD 380-460V
>AII342000 Compressor: >491000
>AII355000 GA37/50VSD 380-460V
>AII350000

Device Designation Siemens Order

AC P/Nr A B C Pcs
Product Description Nr.
-A10
6SE7090-0XX84-
CONTROL UNIT VECTOR 1621 0398 00 x x x 1
0AB0
CONTROL
-A100,-A200,-A300
IGBT TRANSISTOR MODULE 6SY7000-0AC86 2903 0050 02 x 3
BSM150GB120DN2, 150A, 1200V
-A100,(-A101),-A110,(-A111),-
A200,(-A201),-A210,(-A211),-
A300,-A310
6SY7000-0AC82 2903 0050 03 x(6Pcs) x(12Pcs) 6/12
IGBT TRANSISTOR MODULE
BSM300GA120DN2S, 300A,
1200V

-A24
PRECHARGE UNIT PCU 6SE7024-7FD84-
2903 0050 04 x 1
F. UN. 47 U. 72A 3A C 380-460V 1HH0
34A U. 46.5A 3 AC 500-575V

-A27
PRECHARGE UNIT PCU1
6SE7031-7HF84-
FOR ENCLOSURE SIZES E AND 2903 0050 05 x 1
1HH0
F
3 AC 380-575V, 50/60HZ
-A27
PRECHARGE UNIT PCU2
6SE7033-5HH84-
FOR ENCLOSURE SIZES G AND 2903 0050 06 x 1
1HH0
H
3 AC 380-575V, 50/60HZ
A24
PRE-CHARGING CONTROL UNIT 6SE7031-7HH84-
2903 0050 07 x x 1
PCC 1HJ0
FOR ENCLOSURE SIZES E TO H

-A30
6SE7090-0XX84-
PARAMETERIZING UNIT PMU 2903 0050 08 x 1
2FB0
FOR ENCLOSUE SIZES C AND D

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-A30
PARAMETERIZING UNIT PMU 6SE7090-0XX84-
2903 0050 09 x x 1
FOR ENCLOSUE SIZES A, B AND 2FA0
E TO M

-C…
DC LINK CAPACITORS
6SY7000-0AD65 2903 0050 10 x 1
COMPLETE WITH HOLDER
3300UF, 800V

-C…
DC LINK CAPACITORS
6SY7000-0AD76 2903 0050 11 x 1
COMPLETE WITH HOLDER
7500UF, 800V

-C…
DC LINK CAPACITORS
6SY7000-0AD66 2903 0050 12 x 1
COMPLETE WITH HOLDER
12500UF, 800V

-C110
MKP CAPACITOR FOR COOLING
6SY7000-0AA36 2903 0050 13 x 1
FAN
2UF, 400V
-C110
MKP CAPACITOR FOR COOLING
6SY7000-0AA52 2903 0050 14 x 1
FAN
2,5UF, 400V
-C110
MKP CAPACITOR FOR COOLING
6SY7000-0AB10 2903 0050 15 x 1
FAN
4UF, 400V
-E1
RADIAL COOLING FAN
6SY7000-0AA80 2903 0050 16 x 1
R2E190-AE77-B3, AC 230V
FOR ENCLOSURE SIZE D

-E1
RADIAL COOLING FAN UNIT 220 6SY7000-0AB30 2903 0050 17 x 1
FOR ENCLOSURE SIZE F
-E1
RADIAL COOLING FAN UNIT
6SY7000-0AB66 2903 0050 18 x 1
225/B7
FOR ENCLOSURE SIZE G
-F101#,-F102#
FUSE SWITCH DISCONECTOR 6SY7000-0AA26 2903 0050 19 x 2
ST10 CSA B081145

-F101,-F102
FUSE LINK 6SY7000-0AC45 2903 0050 20 x 2
FNQ-R-6/10, 0,6A, 600V
-T10
TRANSFORMER FOR COOLING
6SY7000-0AA46 2903 0050 21 x 1
FAN
3 AC 380-500V - AC 230V
-T10
TRANSFORMER FOR COOLING
6SY7000-0AA56 2903 0050 22 x 1
FAN
3 AC 380-500V - AC 230V
-T10
TRANSFORMER FOR COOLING
6SY7000-0AB32 2903 0050 23 x 1
FAN
3 AC 380-500V - AC 230V

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-T4, -T5
CURRENT TRANSFORMER 6SY7000-0AA31 2903 0050 24 x 2
ES 100-9594, 100A

-T4, -T5
CURRENT TRANSFORMER 6SY7000-0AB20 2903 0050 68 x 2
ES 500-9661, 315A

-V1
BRIDGE RECTIFIER 6SY7000-0AA27 2903 0050 25 x 1
SKD 110/16, 110A, 1600V

EXTRAS
TERMINAL BLOCK PLUG SET
6SY7000-0AD27 2903 0050 26 x 1
FOR SIMOVERT VC
FOR ENCLOSURE A TO D

EXTRAS
TERMINAL BLOCK PLUG SET
6SY7000-0AD28 2903 0050 27 x x 1
FOR SIMOVERT VC
FOR ENCLOSURE E TO M
MECHANICAL SPARE PARTS
FRONT COVER FOR
ENCLOSURE
6SY7000-0AB25 2903 0050 28 x 1
SIZE D
WITH ORIGINAL UNIT RATING
PLATE
x
-A20 6SE7031-2HF84-
2903 0050 29 x (design 1
INVERTER INTERFACE UNIT IVI 1BG0
version B)
x
-A20 6SE7038-6GL84-
2903 0050 30 (design 1
INVERTER INTERFACE UNIT IVI 1BG0
version A)
-A26
STANDARDIZING MODULE ABO 6SE7031-5EF84-
2903 0050 31 x 1
FOR UNITS 3 AC 380-460V 1BH0
AND DC 510-620V, 146A

-A26
STANDARDIZING MODULE ABO 6SE7032-6EG84-
2903 0050 32 x 1
FOR UNITS 3 AC 380-460V 1BH0
AND DC 510-620V, 260A

-A29
INVERTER GATING MODULE
IGD1 6SE7031-5EF84-
2903 0050 33 x 1
FOR UNITS 3 AC 380-460V, 1JC1
50/60Hz
AND DC 510-620V, 92A & 146A
-G25
POWER SUPPLY UNIT PSU1
FOR ENCLOSURE SIZES E AND 6SE7031-7HG84-
2903 0050 34 x x 1
H 1JA1
3 AC 380-460, 660-690V, 50/60HZ
AND DC 510-620V, DC 890-930V

-G25-F1, -G25-F2
FUSE LINK 6SY7000-0AA24 2903 0050 35 x 2
FNQ-R-2, 2A, 600V

-G25-F1, -G25-F2
FUSE LINK 6SY7000-0AC46 2903 0050 36 x 2
ATDR2-1/2, 2,5A, 600V

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-V1, -V2,-V3
LINE SIDE THYRISTOR MODULE 6SY7000-0AA86 2903 0050 37 x 3
TT142N16KOF, 2 X 142A, 1600V

-V1, -V2, -V3

LINE SIDE THYRISTOR MODULE 6SY7000-0AA88 2903 0050 38 x 3
TT250N16KOF, 2 X 250A, 1600V

CURRENT CLAMP 6SY7000-0AA78 2903 0050 39 x ?

Leistungsteilbaugruppe peu f. 6SE7027-2ED84-

2903 0050 90 x
Geräte 72A 3AC 380-460V 1HF3

2x12 ohm pre charging resistor 6SY7000-0AA62 2903 0050 91 x 1

-A29
INVERTER GATING MODULE
x
IGD3 6SE7033-2EG84-
2903 0050 40 (design 1
FOR UNITS 3 AC 380-460V, 1JF0
version B)
50/60Hz
AND DC 510-620V, 210/260/315A
PTC sensor -40°C to 300°C
EWN:
KTY84L - Nickel plated leads 1089 0679 02 x 1
1.383.40555.01
450mm
-A29
INVERTER GATING MODULE
IGD5 x
6SE7031-6FG84-
FOR UNITS 3 AC 380-460V, 2903 0050 41 (design 1
1JC2
50/60Hz, 260A version A)
AND 3AC 500-575V, 50/60Hz,
156A

Note :

A - Converter: B - Converter:
Siemens P/Nr: 6SE7031- Siemens P/Nr: 6SE7032-
1FF60 0FG60
AC P/Nr: 1089 9338 21 AC P/Nr: 1089 9338 14

Converter cubicles: Converter cubicles:

1900 2017 61 1900 2012 61
1900 2017 62 1900 2012 62

Compressor: Compressor:
GA37/50VSD 500-575V GA90VSD 500-575V

Device Designation
Siemens Order Nr. AC P/Nr A B Pcs
Product Description

-A10
6SE7090-0XX84-0AB0 1621 0398 00 x x 1
CONTROL UNIT VECTOR CONTROL

x
-A20 (design
6SE7031-2HF84-1BG0 2903 0050 29 x 1
INVERTER INTERFACE UNIT IVI version
B)

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x
-A20 (design
6SE7038-6GL84-1BG0 2903 0050 30 1
INVERTER INTERFACE UNIT IVI version
A)

-A24
PRE-CHARGING CONTROL UNIT
6SE7031-7HH84-1HJ0 2903 0050 07 x x 1
PCC
FOR ENCLOSURE SIZES E TO H
-A26
STANDARDIZING MODULE ABO
6SE7031-3FG84-1BH0 2903 0050 46 x 1
FOR UNITS 3 AC 500-575V
AND DC 675-780V, 128A
-A26
STANDARDIZING MODULE ABO
6SE7032-3FH84-1BH0 2903 0050 47 x 1
FOR UNITS 3 AC 500-575V
AND DC 675-780V, 225A
-A27
PRECHARGE UNIT PCU1
6SE7031-7HF84-1HH0 2903 0050 05 x 1
FOR ENCLOSURE SIZES E AND F
3 AC 380-575V, 50/60HZ
-A27
PRECHARGE UNIT PCU2
6SE7033-5HH84-1HH0 2903 0050 06 x 1
FOR ENCLOSURE SIZES G AND H
3 AC 380-575V, 50/60HZ

-A29 x
INVERTER GATING MODULE IGD3 (design
6SE7031-7FG84-1JF0 2903 0050 50 1
FOR UNITS 3 AC 500-575V version
AND DC 675-780V, 192/225A B)

-A29
INVERTER GATING MODULE IGD5
6SE7032-6EG84-1JC1 2903 0050 51 x 1
FOR UNITS 3 AC 500-575V, 50/60Hz
AND DC 675-780V, 156A
-A29
INVERTER GATING MODULE IGD1
6SE7028-0FF84-1JC0 2903 0050 52 x 1
FOR UNITS 3 AC 500-575V, 50/60Hz
AND DC 675-780V, 61A & 79A

-A30
PARAMETERIZING UNIT PMU 6SE7090-0XX84-2FA0 2903 0050 09 x x 1
FOR ENCLOSUE SIZES A, B AND E TO M

-A100,(-A101),-A110,(-A111),-A200,(-A201),-
A210,(-A211),-A300,(-A301),-A310,(-A311)
6SY7000-0AC62 2903 0050 54 x x 6/12
IGBT TRANSISTOR MODULE
BSM300GA170DN2S, 300A, 1700V

-C…
DC LINK CAPACITORS
6SY7000-0AD81 2903 0050 55 x 1
COMPLETE WITH HOLDER
5000UF, 1000V
-C…
DC LINK CAPACITORS
6SY7000-0AD24 2903 0050 56 x 1
COMPLETE WITH HOLDER
10000UF, 1000V

-C110
MKP CAPACITOR FOR COOLING FAN 6SY7000-0AA52 2903 0050 14 x 1
2,5UF, 400V

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-C110
MKP CAPACITOR FOR COOLING FAN 6SY7000-0AB15 2903 0050 58 x 1
5UF, 400V

-E1
RADIAL COOLING FAN UNIT 220 6SY7000-0AB30 2903 0050 17 x 1
FOR ENCLOSURE SIZE F
EXTRAS
TERMINAL BLOCK PLUG SET
6SY7000-0AD28 2903 0050 27 x x 1
FOR SIMOVERT VC
FOR ENCLOSURE E TO M

-G25
POWER SUPPLY UNIT PSU1
FOR ENCLOSURE SIZES E AND H 6SE7032-8FH84-1JA1 2903 0050 61 x x 1
3 AC 500-575V, 50/60HZ
AND DC 675-780V
-G25-F1,-G25-F2
FUSE LINK 6SY7000-0AC44 2903 0050 62 x 2
FNQ-R-1, 1/2, 1,5A 600V
-G25-F1,-G25-F2
FUSE LINK 6SY7000-0AC46 2903 0050 36 x 2
ATDR2-1/2, 2,5A, 600V
-R1
PRE-CHARGING RESISTOR 6SY7000-0AA60 2903 0050 64 x 1
2 X 15 OHM
-R10
TEMPERATURE SENSOR NTC 6SY7000-0AD10 2903 0050 65 x 1
10K
-R100
SYMMETRY RESISTOR 6SY7000-0AB08 2903 0050 66 x 1
3 X 3K6 OHM 143W 5%

-R109,-R209,-R309,-R119,-R219,-R319
SHADING RESISTOR 6SY7000-0AB18 2903 0050 67 x 6
2R0 OHM 20W 5%

-T4,-T5
CURRENT TRANSFORMER 6SY7000-0AB20 2903 0050 68 x 2
ES 500-9661, 315A
-T4,-T5
CURRENT TRANSFORMER 6SY7000-0AA42 2903 0050 93 x 2
ES 500-9661, 315A
-E1
RADIAL COOLING FAN UNIT 250/B7 6SY7000-0AB67 2903 0050 69 x 1
FOR ENCLOSURE SIZE G
-T10
TRANSFORMER FOR COOLING FAN 6SY7000-0AA57 2903 0050 70 x 1
3 AC 500-575V - AC 230V
-T10
TRANSFORMER FOR COOLING FAN
6SY7000-0AD06 2903 0050 71 x 1
3 AC 500,525,575V - AC 230V
50/60Hz; 1,85A
-V1,-V2,-V3
LINE SIDE THYRISTOR MODULE 6SY7000-0AB01 2903 0050 72 x 3
TT85N18KOF, 2 X 85A, 1800V
-V1,-V2,-V3
LINE SIDE THYRISTOR MODULE 6SY7000-0AB04 2903 0050 73 x 3
TT210N18KOF, 2 X 210A, 1800V

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General Tools:

Device Description / Product Description

DriveMonitor Download Cable AC P/Nr : 2908 0126 00
Masterdrive Testbox AC P/Nr : 2903 0002 01
Screwdriver Torx T10 till T30
Fluke 179 Multimeter Refer http://www.fluke.com/

Fluke 321 clamp meters Refer http://www.fluke.com/

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7. Micromaster 440
7.1 Position of components

7.1.1 Micromaster 440 Connection Drawing – Frame Size Fx

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7.1.2 General Circuit Diagram

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7.1.3 Technical Connection Diagram

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7.2 Faults and Alarms

7.2.1 Faults

Number / Fault Cause Counter-measure

1. Check the cable lengths.

2. Check supply voltage, which should be in

the range 380 V to 480 V ( + 10%).

3. Check if the motor parameters correspond

to those of the motor being used.

4. Check if the motor is overloaded or stalled

Short-circuit at the output (locked rotor).

Ground fault 5. Increase the accelerating time.

Excessively large motor (the motor power 6. Reduce the gain.

F0001 rating P0307 is greater than the inverter
power r0206) 7. Use a motor with a lower power rating.
Overcurrent 8. Check the stator resistance value (P0350).
Defective final stage (end stage)

Converter internal Short Circuit 9. For converter internal short circuit:

Disconnect converter at output, clear fault
Motor or wiring Short Circuit and run converter. If converter runs with
warning A0922, fault is probably in motor or
motor wiring. If converter gives fault again,
converter is faulty and must be changed.

10. For Motor or wiring short circuit:

Re-connect motor, run converter. If
converter trips again immediately, motor or
wiring is faulty. If converter and motor run
OK, look for other signs of overload.

1. Check supply voltage, which should be

between 380 and 480 V (+/- 10%).

2. Check if the DC current DC link monitoring

DC link voltage (r0026) higher than the has been enabled (P1240) and correctly
overvoltage threshold (refer to parameter parameterized.
r0026)
3. Extend the deceleration ramp (ramp-down
Ground fault time P1121, P1135)
F0002 High Supply Voltage
4. Remove the ground fault.

Overvoltage Regenerative load:

If a motor and load are decelerated too 5. Check the braking power.
rapidly, the energy may return to the
inverter and cause overvoltage. This is 6. Find out if there is evidence of a high
very unlikely in compressor applications, voltage, which may have caused the trip
and unlikely in fan applications unless (e.g. rising supply at weekends, transients
converter settings have be adjusted caused by lightning strikes, other equipment
etc.). Try to prevent further trips by tracing
and eliminating source of high voltage. An
input inductor (choke) may help in some
cases.

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Line voltage failed / Supply interruption

Shock stressing outside the permissible 1. Check supply voltage, which should be
limits between 380 and 480 V (+/- 10%).

F0003 Low DC Link (intermediate Voltage) in

2. Check if the line supply voltage is stable with
Converter
respect to sporadic failures and voltage dips
Undervoltage Low supply voltage: (brown-outs).
If the supply falls below the lower limit
(approx 342V) the converter will indicate 3. If fault persists, check supply; if supply is in
a warning or fault. If the supply falls limits, converter is faulty and must be
further the fault will be recorded as the changed.
converter shuts down. The converter will
restart as normal.

Inadequate cooling
1. Check the pulse frequency P1800. If
Ambient temperature too high required reset P1800.

F0004 Faulty or blocked fan. (Note fan turns 2. Check the ambient temperature.
only when converter is enabled)
3. Reduce the load and / or ensure adequate
Inverter Over- Blocked filters cooling.
temperature
Excessive dust or contamination in 4. Check whether the fan rotates while the
converter inverter is operational.

Continuous, high load in combination 5. Remove blockage in filter.

with high temperature

Inverter overloaded.

F0005 Load duty cycle too high. 1. Check the load duty cycle.

The motor power rating (P0307) is 2. Use a motor with a lower rating (motor
Inverter I2T greater than that of the inverter (r0206). power P0307 is greater than inverter power
r0206).
100 % overload reached (refer to
utilization r0036)

1. Check the load cycle.

2. Check if the rated/nominal motor

F0011 overtemperatures are correct (P0626-
P0628).
Motor overloaded
Motor Over-
3. Check if the alarm threshold is correct for
temperature the motor temperature (P0604).

4. Check the motor for overload / fault.

F0012
Wire breakage of the inverter-
Replace the inverter.
temperature sensor (heatsink)
No inverter
temperature signal

Motor temperature sensor either short-

F0015 circuited or open-circuit
Check the wiring to the sensor, and measure the
Motor temperature If it is identified that a signal has been
sensor impedance.
signal lost lost, then the temperature monitoring
changes-over to monitoring based on
the thermal-motor model

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F0020
A fault is output if one of the three input
Line supply phase phases is missing, the pulses are Check the power connections.
missing enabled and a load is present

The fault occurs if the sum of the phase

F0021 currents is greater than 5 % of the 1. Check the connections at the motor terminal
inverter rated current. boxes.
Ground fault NOTE 2. Check the motor cable connections at the
This fault only occurs for inverters with 3 inverter.
current sensors (sizes D to F, GX, FX).

You must first identify as to whether the fault is

permanent (i.e. the inverter cannot be started
without the fault occurring) or it sporadically
occurs (occasionally occurs or under certain
operating conditions).

1. Permanent fault F0022:

Check whether the I/O module is correctly

inserted (refer to the Operating Instructions).

Check if there is a ground fault or short-circuit at

the inverter output or at an IGBT.

You can identify this by disconnecting the motor

cable.

In the case that the fault occurs, if all of the

external cables (with the exception from the line
DC link overcurrent condition = IGBT supply voltage) are disconnected, then with a
F0022 short-circuit high degree of probability, the drive unit is
defective and must be repaired.
Braking chopper short-circuit
Hardware
monitoring active Ground fault 2. Sporadic fault F0022:

I/O module not correctly inserted This fault should be treated as "overcurrent". If
fault F0022 sporadically occurs, the causes can
be as follows:

Sudden load changes or mechanical obstructions

Extremely short ramp-up times (accelerating

times)

Poor optimization of the sensor-less closed-loop

vector control

Incorrect braking resistor is installed with an

excessively low resistance

3. All of these faults are assigned to a signal in

the power module. This means that it is not
possible to determine which fault actually
occurred.

F0023 1. Check the connections at the motor terminal

boxes.
One output phase has not been correctly
Output fault connected.
2. Check the motor cable connections at the
inverter.

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F0024 Check if the fan rotates when the inverter

Inadequate cooling is powered-up (A0520, A0521).
Rectifier Fan is not operational 1. Reset the pulse frequency if required.
temperature too
high Ambient temperature is too high 2. Check the ambient temperature
(A0520, A0521).

F0030 1. Fault cannot be suppressed if an

AOP or BOP is connected.
Fan no longer functions
Fan failed 2. A new fan is required.

F0035
Auto-restart due to attempts exceeding the
Refer to parameter P1211.
value of parameter P1211
Restart after n

A calibration error has occurred for the

automatic calibration of the analog inputs /
outputs or the current actual value sensing.
F0040
The calibration is only carried-out once in the
Change the drive.
Fault, for automatic factory.
calibration A fault F0040 is therefore only to be expected
while the inverter is being manufactured and
not in operation.

Motor data identification run unsuccessful (refer

to fault value r0949):

- r0949 = 0: Load missing.

- r0949 = 1: Current limit was reached during
the identification run.
- r0949 = 2: Identified stator resistance less
than 0.1% or greater than 100%.
- r0949 = 3: Identified rotor resistance less than
0.1% or greater than 100%.
- r0949 = 4: Identified stator reactance less than Check the following:
50% or greater than 500%
- r0949 = 5: Identified magnetizing reactance 1. r0949 = 0:
less than 50% or greater than 500% Check whether the motor is connected to
F0041 - r0949 = 6: Identified rotor time constant less the inverter.
than 10ms or greater than 5s
Failure, motor data - r0949 = 7: Identified total leakage reactance 2. r0949 = 1-40:
less than 5% or greater than 50% Check whether the motor data in P0304-
identification - r0949 = 8: Identified stator leakage reactance P0311 is correct.
less than 25% or greater than 250%
- r0949 = 9: Identified rotor leakage reactance Check whether motor circuit configuration
less than 25% or greater than 250% (star, delta configuration) is correct.
- r0949 = 20: Identified IGBT response voltage
less than 0.5 or greater than 10 V
- r0949 = 30: Current controller at voltage limit
value
- r0949 = 40: Identified data set inconsistent; at
least one identification run unsuccessful

NOTE
Percentage values based on the impedence Zb
= Vmot,rated / sqrt(3) / Imot,rated

Automatic data identification run unsuccessful

F0042 (refer to fault value r0949):

Fault/error when - r0949 = 0: Time slice overflow while waiting Stop II.
optimizing the for a stable speed
- r0949 = 1: No matching/appropriate value
speed controller when reading

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F0051 1. Reset to factory setting and then re-

Read or write operation while saving
parameterize.
parameters in the EEPROM was unsuccessful.
Parameter EEPROM
2. If required, change the drive.
fault

F0052
Read error, power data or invalid power module
Change the drive.
data.
Power Stack fault

1. Check I/O data and if required repeat

F0053 the operation.
Fault with I/O EEPROM read operation or
invalid data. 2. Check the installation of the I/O module
I/O EEPROM fault in the inverter. If required, replace the I/O
module.

1. Check I/O data and if required repeat

F0054 the operation.
Incorrect I/O module inserted.
2. Check the installation of the I/O module
Incorrect I/O module No ID of the I/O module found, no data.
in the inverter. If required, replace the I/O
module.

F0060 1. If the error still occurs, replace the

inverter.
Internal communications failure/error
Asic time slice
2. Contact customer service!
overflow

F0070
No setpoints received via the communications Check the communications module (CB)
bus during the telegram failure time. and communications partner.
CB setpoint fault

F0071
No setpoint was received via the USS during
Check USS master.
USS (BOP link) the telegram off time
setpoint fault

F0072
No setpoints received via the USS during the
Check USS master.
USS (COMM link) telegram off time
setpoint fault

F0080
Wire breakage 1. Check the wires.
ADC input signal Signal outside the limit values 2. Check signal values.
lost

F0085
External fault as a result of command input via
Inhibit terminal input to initiate fault.
terminals.
External fault

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1. Check if there is an integrated encoder.

If there is no integrated encoder, then set
P0400 = 0 and select the operating mode
sensorless closed-loop vector control
(P1300 = 20 or 22).
Encoder signal between the encoder and
F0090 inverter is interrupted
2. Check the connection between the
encoder and the inverter.
Signal loss, encoder Excessively large difference between the
setpoint (reference) and actual frequency
3. Check if the encoder is faulty. (Select
P1300 = 0, operation with fixed speed,
check the encoder signal in r0061)
Increase the encoder signal threshold in
P0492, P0494.

F0101
Software error or processor failure Carry out self-test routines.
Stack overflow

F0221
1. Change value of P2268.
PID feedback below the minimum value P2268.
PID feedback below 2. Set feedback gain.
the minimum value

F0222
1. Change value of P2267.
PID feedback above maximum value P2267.
PID feedback above 2. Set the feedback gain.
minimum value

F0422
No Load is applied to the inverter. As a result,
some functions may not work as under normal N. A.
No load applied to load conditions.
inverter

Self-test routine unsuccessful (refer to fault

value r0949):

- r0949 = 1: Self-test routine for power module

components unsuccessful
F0450 - r0949 = 2: Self-test routine for closed-loop 1. The drive is functional, but several
control module components unsuccessful functions are not correctly executed.
- r0949 = 4: Several function tests were
Failure BIST tests unsuccessful 2. Replace the drive.
- r0949 = 8: Several tests carried-out at the I/O
module were unsuccessful (only
MICROMASTER 420)
- r0949 = 16: Failure of the internal RAM at the
switch-on test

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Please check the following:

1. No braking, failure or destruction of the
mechanical drive transmission line.

2. If required, lubricate the mechanical

drive transmission line.

3. If you are using an external encoder,

please check the following parameter
settings:
P2192 (delay time, load torque
F0452 monitoring).
Load conditions at the motor signify a load
torque fault (e.g. belt failure) or a mechanical
Load torque fault 4. If you are operating within a specific
fault.
speed range, please check the following:
detected
- P2182 (load torque monitoring F1)
- P2183 (load torque monitoring F1f2)
- P2184 (load torque monitoring F1f3)
- P2185 (upper torque threshold 1)
- P2186 (lower torque threshold 1)
- P2187 (upper torque threshold 2)
- P2188 (lower torque threshold 2)
- P2189 (upper torque threshold 3)
- P2190 (lower torque threshold 3)
- P2192 (delay time, load torque
monitoring)

1. Check the motor connections.

2. Increase the ramp-up time P1120 or the

ramp-down time P1121.
Up/ or down ramp too steep
(excessive gradient) 3. Activate the flying restart function
P1200.
Inverter connected to an already spinning motor
F0453 without using the flying restart function 4. Use a larger motor.

Motor incorrectly connected 5. Increase the voltage boost P1611 for

Motor stalled sensorless closed-loop vector control.
Motor too small
6. Use closed-loop vector control with
Voltage boost P1611 for sensorless vector encoder instead of sensorless closed-loop
control too low vector control.

7. Activate the V/f closed-loop control

mode (P1300 less than 20) instead of
closed-loop vector control.

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7.2.2 Alarms

Number / Alarm Cause Counter-measure

1. Check if the motor power rating

(P0307) matches the inverter power
rating (r0206).

2. Check the cable lengths.

The motor power rating does not correspond to
3. Check the motor cable or motor for
the inverter power rating
short-circuit or ground fault.
A0501
Motor cables are too long
4. Check the motor parameters.
Current limit value Ground fault
5. Check the stator resistance value
(P0350).
Converter current is excessive.
6. Check if the motor is overloaded or
the rotor is locked (cannot rotate).

7. Check if the ramp-up time P1120 is

too low.

1. If this alarm is permanently displayed,

check the inverter input voltage.
A0502
The overvoltage limit value has been reached 2. Check if the DC link voltage controller
(actual value of the DC link voltage r0026 (Vdc_max controller) de-activated (refer to
Overvoltage limit greater than r1242). parameter P1240).
value
3. Check for Short ramp times and/or large
flywheel masses (moment of inertia)

A0503 Line supply has failed

Line voltage and therefore also the DC link Check the line voltage.
Undervoltage limit voltage (r0026) below the defined limit value
value (refer to parameter r0026)

A0504 Alarm threshold of the inverter heatsink

temperature (P0614) was exceeded; this 1. Check the ambient temperature.
results in a reduction of the pulse frequency
Inverter over- and/or the output frequency (dependent on the 2. Check the load and load duty cycle.
temperature parameterization in (P0610).

Overload alarm limit P0294 is exceeded (refer

A0505 to utilization r0036)
Check whether the load duty cycle lies
The pulse frequency and/or the output within the permissible limits.
Inverter I2T frequency is reduced as a function of the
setting of parameter P0290.

A0506
Difference between the temperature at the
Please ensure that the load duty cycle and
heatsink and IGBT exceeds the alarm limit
Inverter load duty load surge lie within the permissible limits.
values.
cycle

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1. Check, independent of the type of

temperature monitoring:
- P0604 alarm threshold, motor
overtemperature
- P0625 motor ambient temperature

2. If P0601 = 0 or 1:
- Check the motor data (rating plate). If
data is incorrect, carry out a fast
commissioning routine.
A0510 or A0511 - Check for the precise temperature values
Motor is overloaded from the motor identification routine
(P1910=1).
Motor Load duty cycle is exceeded - Check the motor weight (P0344).
overtemperature - The permissible overtemperature can be
changed using P0626, P0627, P0628, if
the motor is not a standard Siemens
motor.

3. If P0601 = 2:
- Check whether the temperature
displayed in r0035 is plausible.

4. Check if a KTY84 temperature sensor is

being used (others are not supported).

1. Check the ambient temperature.

A0520
Alarm threshold of the rectifier heatsink 2. Check the load and load duty cycle.
Rectifier exceeded.
3. Check whether the fan operates if the
overtemperature inverter is operational.

1. Check the ambient temperature.

A0521
2. Check whether the fan operates if the
Alarm threshold of the permissible ambient
Ambient temperature exceeded.
inverter is operational.
temperature too
3. Check if the air feed to the fan is
high obstructed.

A0522
Cyclic access to UCE values and power
Contact Airpower or Siemens Technical
module data via i2c bus (only for sizes FX and
Read I2C, time Support.
GX) is faulted.
exceeded

A0523
An output cable is not connected. Alarm can be suppressed.
Output fault

The load duty cycle of the braking resistor has

A0535 been exceeded.
Use a braking resistor with higher power
rating / higher load duty cycle.
Brake resistor hot When the load duty cycle is exceeded, then it
is automatically limited to the value P1237.

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A0541
Motor data identification routine (P1910)
Motor data selected and is active
N. A.
identification routine
active

A0542
Speed controller optimization (P1960) is
N. A.
Speed controller selected and is presently active.
optimization running

Stop the inverter, and

1. Check the speed encoder. If an encoder

is not being used, set P0400 to 0 and
select the sensorless closed-loop vector
A0590 control mode (P1300 = 20 or 22).
No speed encoder signals
2. Check the encoder connections.
Alarm, no signals Inverter has changed-over to encoderless
from the speed vector control. 3. Check whether the encoder is operating
encoder correctly (set P1300 = 0 and operate the
drive at a fixed speed and check the
encoder signal in r0061).

4. Increase the permissible speed

deviation in P0492.

A0600
1. Use lower baud rate for USS.
Time slice overflow was identified.
RTOS data loss 2. De-activate inverter functions.
alarm

A0700
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 1

A0701
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 2

A0702
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 3

A0703
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 4

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A0704
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 5

A0705
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 6

A0706
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 7

A0707
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 8

A0708
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 9

A0709
CB-(communications module)-specific Refer to the CB User Manual.
CB alarm 10

A0710
Loss of communications with the CB
Check the CB hardware
CB communications (communications module).
error

A0711
CB (communications module) signals a
Check the CB parameters
CB communications communications error.
error

Vdc max controller was de-activated, as it was

not able to keep the DC link voltage (r0026)
within the limit values (refer to r0026 and
P1240).
A0910
1. Check the input voltage (P0756).
This occurs,
Vdc-max controller - If the line supply voltage is permanently too
2. Check the load duty cycle and load
disabled/switched- high.
limits.
- If the motor is driven by an active load, it
out means that the motor goes into regenerative
operation.
- While decelerating (short down-ramps P1121)
for extremely high load torques

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Vdc max controller is active

A0911
The ramp-down times are automatically
N. A.
Vdc-max controller increased in order to keep the DC link voltage
(r0026) within the limit values (refer to r0026
active and P1240).

Vdc min controller is activated, if the DC link

voltage (r0026) falls below the minimum value
A0912 (refer to r0026 or P1240).

The kinetic energy of the motor is used to buffer N. A.

Vdc-min controller the DC link voltage and therefore to slow down
active the drive.
Therefore brief line failures no longer
automatically result in an undervoltage trip.
ADC parameters should not be set to identical
values, as this would lead to illogical results.
A0920
- Index 0: Parameter settings for output ADC parameters should not be set to
ADC parameters not identical. identical values.
- Index 1: Parameter settings for input identical.
correctly set - Index 2: Parameter settings for input do not
correspond to ADC type.
DAC parameters (P0777 and P0779) have
A0921 1. Check output parameter settings.
identical values.
Ensure P0777 and P0779 are not identical.
OR
DAC parameters not DAC parameters (P0778 and P0780) have
2. Check input parameter settings. Ensure
identical values.
set properly Identical values would produce illogical results.
P0778 and P0780 are not identical.

A0922 No load is connected to the inverter

Check whether the motor is properly
No load at the Therefore several functions can run differently connected to the inverter.
than under normal load conditions
inverter
A0923
Both JOG clockwise and JOG counter-
JOG counter- clockwise (P1055/P1056) have been requested.
N. A.
clockwise as well as This is the reason that the RFG output
frequency has been frozen to the actual value.
JOG clockwise are
requested
1. Please check the following:
- No braking, failure or destruction of the
mechanical transmission line
- If required, lubricate the mechanical
transmission line.

2. If you are using an external encoder,

please check the following parameter
settings:
- P2192 (delay time, load torque
monitoring)
A0952
Load conditions at the motor indicate a load
3. If you are using a specific speed range,
fault or mechanical fault.
Load fault detected then please check the following:
- P2182 (load torque monitoring F1)
- P2183 (load torque monitoring F1f2)
- P2184 (load torque monitoring F1f3)
- P2185 (upper torque threshold 1)
- P2186 (lower torque threshold 1)
- P2187 (upper torque threshold 2)
- P2188 (lower torque threshold 2)
- P2189 (upper torque threshold 3)
- P2190 (lower torque threshold 3)
- P2192 (delay time, load torque
monitoring)

A0936
PID auto tuning (P2350) is selected or is After automatic PID optimization has been
PID auto tuning presently running. completed, the alarm is reset.
active

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7.3 Repair Instructions

7.3.1 General trouble shooting and repair

• Check the fault history and look for signs of damage or misuse.

• Check the fan is operating and there are no obvious signs of faults (broken connections etc.).

• Always check supply is present at the converter and within limits on all three phases.

• Always check if the converter will run in ‘local’ control; this will eliminate communication
problems with Elektronikon.

• Disconnect the motor and run the converter with another motor, or with no motor connected. If
the converter runs, but with a warning, it is probably OK.

• If possible, measure the output currents on the drive using a clamp meter and oscilloscope; if
the currents look similar, the drive is probably OK.

The Flow Charts on next pages give general guidance on initial troubleshooting.

This simple flow chart will help determine if the fault is in the converter, or external.
If the fault is in the converter and cannot be reset, further trouble shooting information can be found in
the relevant fault compendium.

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Note 1: Converter indicator lights

There are two indicator lights on the converter

Yellow + Green means ready to run
Green means running
Yellow means Fault
Flashing Yellow and Green has different meanings, including Fault and programming.

Note 2: Fitting a BOP or AOP

Additional information may be obtained by fitting a BOP (Basic Operating Panel) or AOP (Advanced
Operating Panel).

Use these panels to read fault and warning information, run the converter, or change parameter
settings (see next page).
A panel may be fitted to a drive at any time.

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To read and change parameters:

Press P button.
Use the up and down arrows to scroll though parameters
Press P to access the parameter value (some parameters have indexes IN000, IN001 etc – scroll
through if necessary and press P again)
Scroll to parameter value.
Press P to accept value and return
It shouldn’t be necessary to change parameters as these are set for best performance.
Set P0003 to 3 will allow all parameters to be read.
However, read only parameters may be used to give more information about the converter, and fault
and warning history is recorded in parameters P0947, r2110.

The Red and Green buttons may be used for starting and stopping the converter only under certain
circumstances as control is normally via digital inputs.

Note 3: Common Faults and Warnings

Further information concerning faults and warnings is given in section 7.2 Faults and Alarms in this
manual. The most common faults and warnings are listed there, with special reference to compressor
applications.

Note 4: Clearing the Fault

A fault indication may be cleared by:

Cycling the power
Pressing the Fn button on the BOP (not AOP)
Using an external fault reset signal if a digital input is programmed to accept this.

See flowchart on next page.

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Note 5: Converter Attempts Start

An attempted start may or may not run the motor, but shows that the converter is receiving a valid run
command, either from the Elektronikon, or from local control.

Checking the Converter Inputs and outputs:

If there is a fault on the converter input, fuses or circuit breakers may fail again if power is re-applied.
To check for a fault, disconnect the power from the converter, and use a standard multimeter on the
Diode setting to test as follows:

DC+ to L1 should read open circuit in one direction, a diode drop of between 0.3 and 0.7V in the other
– i.e. reverse leads.

The same readings should be obtained at:

DC+ to L2
DC+ to L3
And the same, but reversed
DC- to L1
DC- to L2
DC- to L3

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A short circuit or open circuit at any connection indicates a faulty converter, which must be changed.

A similar measurement between the DC and output terminals can usually show if the output section of
converter is healthy – the diode drop is generally a little lower.

Note 6: Reloading Parameters

The parameter settings for Compressor applications have be carefully selected and set up at the
factory. Parameter corruption and changes are very unusual. Therefore it should only be necessary to
reload parameters if:

• A replacement converter is fitted, which is not pre-programmed.

• The original parameters have been lost, over written, or deleted.

7.3.1.1 Repairing Damaged Converters: Some general hints

Refer to 6.3.1.1 - Repairing Damaged Converters in this manual.

7.3.2 Repair and Exchange procedures

The table below shows the different converters fitted to different compressors. This is subject to
change, so check the converter type before going to site.

Converter

200V 380-460V 500-575V

Earthed supply Unearthed supply

GA11VSD - 6SE6440-2AD31- - -
1CA1

GA18VSD 6SE6440-2UC32- 6SE6440-2AD32- 6SE6440-2UD32- 6SE6440-2UE32-

2EA1 2DA1 2DA1 2DA1

GA30VSD 6SE6440-2UC34- 6SE6440-2AD33- 6SE6440-2UD33- 6SE6440-2UE33-

5FA1 7EA1 7EA1 7EA1

GA75VSD - 6SE6440-2UD38- 6SE6440-2UD38- -

8FA1* 8FA1*

GA90VSD - 6SE6440-2UD41- 6SE6440-2UD41- -

1FA1 1FA1

(*May change from frame size Fx to F.)

Note: −
This digit defines the frame size; D in this case
MLFB Part Number:

6SE6440-2AD31-8DA0

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7.3.2.1 For frame sizes Fx and Gx

For frame sizes Fx and Gx, repair is to be carried out on site by exchange of modules.
When power parts are replaced, it may be necessary to load Power stack Data.

Note that it will also be necessary to load the parameters into the new converter if this is not already
done.

To load Power Stack data or Parameters the following parts are needed:

PC with Drivemonitor installed.

PC to Converter interface kit (part number 6SE6400-1PC00-0AA0)
Parameter data
Power Stack data.

7.3.2.2 Changing the Control Board

Introduction:

Firmware, Power Stack setting and Parameter settings.

The control board contains the firmware, the Power Stack setting and the parameter settings.
Detailed information concerning this software is given in elsewhere. In summary:

The firmware is fixed in the control board.

The correct power stack setting must be checked, and new power stack data loaded if necessary.
The parameter settings for the machine must be downloaded.

Procedure:

The control board is easy to exchange. The control board is mounted below the I/O board. On frame
sizes A, B, C this is directly under the display panel; on D,E,F it is in the options well, and a short
extension is used to connect to the display.

1. If the existing control board is functional, upload the existing parameter set using Drivemonitor.
Note the software issue (r0018).
2. Switch off the power and disconnect the supply. Wait 5 minutes.
3. Remove the display panel (different panels may be fitted) by pressing the button on top the drive.

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4. On D, E, F drives, remove the metal cover by undoing the Torx 20 fixing. On frame size A units
remove the plastic cover by sliding it down and lifting. On frame sizes B and C remove the plastic
cover first. On Px frame sizes the mounting is similar to FSA.

FSD, E, F FSA,B,C

FSB,C

5. On D, E, F drives, remove the interconnecting cable from the adaptor plate, then press the blue
button upwards, and lift the adaptor from the i/o board.

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6. Remove the I/O board by levering the board upwards using a terminal driver.

7. Remove the spring catch and button by lifting the spring out. Wear eye protection and be careful
not to lose the parts. The two pips on the button show the top for re-assembly.

8. The plastic cover over the control board may now be removed. There are seven retaining clips;
remove the bottom one first and work around the rest. Lift the plastic part clear.

Hook clips are part of

the cover; push to lift
the cover.

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9. Undo the Torx 20 screw at the top of the control board, and lift the fastener and spring clear. The
control board may now be removed. Ease the control board carefully away from the connector on
the left of the board and lift clear.

Spring sits in slot to stop rotation.

10. Fit the new control board carefully onto the connector and push into position. Reassembly using
the reverse procedure.

Take care in particular:

• To fit the control board onto the connector properly.
• To fit the fixing screw and clip so the spring doesn‘t rotate.
• To push the control board cover into position.
• To refit any Operator Panel correctly.

7.3.2.3 Setting up the new control board

• After complete reassembly, apply power to the drive.
• Read parameter r0200 and note the value. Check that P0201 is the same value. If not, set it to
this value, and cycle the power.
• It may be necessary to reload Power Stack Data – see separate foils
• Check parameter r0018 is the correct Software issue as required by Atlas Copco equipment.
• Download the parameter settings to the Drive using Drivemonitor as described elsewhere.
• Check out and commission the Drive and compressor.

7.3.3 Exchanging a Converter (Frame sizes A to F)

• If possible, upload the parameters from the converter.

• Disconnect the power, isolate elsewhere, wait 5 minutes.
• Disconnect all connections to the converter, noting the terminals used.
• Remove the converter by undoing the mounting fixings. Take care, larger units are heavy.
• Refit the new converter, reconnect and apply power.
• Download the parameters for the converter.
• Set the additional parameters to enable the converter to communicate with the
Elektronikon.
• P2010.i000=7 -> baud rate
• P2011.i000=1 -> address (different for auxiliary converters)
• P2013.i000=3 -> PKW length.

Carry out a final test on the complete compressor.

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7.3.4 Repairing a Converter (Sizes Fx and Gx)

• Repair of converters is best carried out with the drive in the compressor or cubicle.
• If possible, upload the parameters from the converter.

• Disconnect the power, isolate elsewhere, wait 5 minutes.

• Repair the converter: following the detailed instructions included on the CD.

• As the repair is by module replacement only, ensure that the appropriate parts are available
before dismantling the converter.

• For Frame size Fx and Gx the power stack data is stored in the control assembly (CIB). If this
is changed, check that the correct power stack data is present.

• Following repair, download the correct parameter set.

• Set the additional parameters to enable the converter to communicate with the Elektronikon.
• P2010.i000=7 -> baud rate
• P2011.i000=1 -> address (different for auxiliary converters)
• P2013.i000=3 -> PKW lengthCarry out a final test on the complete compressor.

Carry out a final test on the complete compressor.

7.4 Important Parameters

Key Parameters:

This parameter information is included to assist with fault finding and diagnostics.

Parameters for the Converter and compressor combination have been carefully selected, and should
not be changed.

The correct parameter settings must be loaded into the Converter if a new Converter is installed or a
new control board fitted.

Parameters can be reset to the Factory default settings by setting P0010 to 30 and P0970 to 1. The
correct parameters must then be loaded as before.

Read only parameters are indicated by rXXXX.

Setting parameters

Parameters, which can be written into and read – "P" parameters

These parameters directly influence the behavior of a function. The value of this parameter is saved in
a non-volatile memory (EEPROM) as long as the appropriate option was selected (non-volatile data
save). Otherwise, these values are saved in the non-volatile memory (RAM) of the processor, which
are lost after power failure or power-off/power-on operations.

Notation:

P0927 setting parameter 927

P0748.1 setting parameter 748, bit 01
P0719[1] setting parameter 719, index 1
P0013[0...19] setting parameter 13 with 20 indices (indices 0 to 19)
Abbreviated notation
P0013[20] setting parameter 13 with 20 indices (indices 0 to 19)

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i) P0003: Access Levels

P0003 limits the number of parameters the user can see. Set this to 3 to see all parameters.

ii) r0021: Output frequency

Shows the actual value of output frequency in Hz. This should correspond to the motor speed, with
allowance for slip.

This value is also displayed in r0000 (i.e. Display), when the Converter is in operation.
Other useful read only parameters are:
r0025 Output Voltage
r0026 DC Link Voltage
r0027 Output Current

iii) r0035: Motor Temperature

Shows the motor temperature, which may be calculated or measured, depending on type of
compressor and if a sensor (KTY84 - not a PTC) is fitted to the motor.

r0037 indicates the inverter temperature, with several indexes showing different sensors within the
Converter.
The above parameters are useful if overheating (real or calculated) is suspected in the motor or
inverter.

iv) r0027: Output current

Shows the output current of the converter (fundamental rms).
Output current is dependent on load, but there will always be some loading in a compressor
application.

v) r0050/1: Active parameter sets

Shows the Active parameter set for the converter.

Operating the service switch will change the active parameter set.

There are two types of parameter set, CDS and DDS, r0050 indicates which CDS set is active, and
r0051, which DDS set.

There are three sets of each.

vi) r0200; P0201: Power stack number

The Power stack data contains information about the power part of the Converter (current rating,
voltage etc.)

The Power stack is stored on the power part of the Converter and is copied, usually automatically, into
the control board at power up.

The Power stack number indicates the particular type of power stack; the control board value is in
P0201, and the value on the power part is in r0200.

These two values must match. See control board exchange for detailed description.

vii) P0300 – 400 Motor Parameters

These parameters, especially P0300 – 310 are set to match the Converter to the motor.
P0640 Sets the overload factor of the Converter; this usually allows short-term overload of the
Converter or motor for acceleration for example.

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7.5 Service Switch

For certain tests (for example a vibration measurement), it may be useful to control the speed of the
compressor locally; i.e. using the converter control directly, not using the Elektronikon.

The Service Switch permits easy, local control of the converter and motor.

7.5.1 Functionality

When placing the Service Switch into ‘service mode‘, Elektronikon has no influence anymore.

The compressor can be started using the green button on the PMU.

The compressor can be stopped again using the red button.

The compressor will run at fixed minimum speed.

7.5.2 Location and lay-out of Service Switch

Overview

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Detail 2 Pole Service Switch Service Switch

7.5.3 Normal operation of compressor

Refer to Normal operation of compressor in this manual.

7.5.4 Communication Fault

Refer to 6.5.4 Communication fault in this manual.

7.5.5 Operation in Service Mode

Refer to 6.5.5 Operation in Service Mode in this manual.

7.5.6 Practical

The position of the service switch can be checked in parameter r050/51.

r050/51 = 1 = Data set 1 (operation via Elektronikon)

r050/51 = 2 = Data set 2 (operation in service mode)

To be checked
If the compressor is started from the Elektronikon with the service switch in service-position, it will
generate a fault.

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7.6 Error detection with Test-Box

Introduction
It is possible to test the power components using a multimeter to locate faults. Although this is not
foolproof, it is a quick and easy way of locating the nature and extent of power component faults.
A test box can be used on PX drives.

Warning:
All these tests must be carried out with the VSD disconnected from the supply; wait at least five
minutes before working on the VSD.

7.6.1 Using a multimeter

All semiconductor diodes have a forward voltage drop of between 0.3 and 0.8V, independent of
current. In the reverse direction there is no measurable conduction.
A standard digital multimeter has a diode drop function that can be used to test all sizes of diodes.
Although it cannot be used to test IGBTs or Thyristors, fault in these components can often be
detected as a short circuit.
The output IGBTs have ‘commutation’ diodes in parallel, allowing the diodes to be tested.

7.6.1.1 Testing input diodes

1. The input diodes may be tested individually:
2. Set the meter to Diode Test (typical marking).
3. Connect the negative lead to DC+ (may be marked C/L+).
4. Connect the positive lead to L1. A forward voltage drop should be measured of between 0.3
and 0.8 V.
5. Reverse leads; meter should read OL to indicate no conduction.
6. Repeat for L2 and L3 to test the remaining ‘top’ diodes.

DC+ C/L+
0.655

C
L1
L2
L3

DC- D/L-

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7.6.1.2 Testing lower diodes

1. Connect the positive lead to DC- (may be marked D/L-).
2. Connect the negative lead to L1. A forward voltage drop should be measured of between 0.3
and 0.8V.
3. Reverse leads; meter should read OL to indicate no conduction.
4. Repeat for L2 and L3 to test the remaining ‘top’ diodes.

DC+ C/L+
0.655

C
L1
L2
L3

DC- D/L-

This test does not test the pre-charge circuit.

On Px drives, this test checks the diodes in the pre charge circuit, but not the main Thyristor
rectifier.

7.6.1.3 Testing output diodes

To test the output diodes, follow the procedure for testing the input diodes, but instead of connecting
to the inputs L1, L2, L3, connect to the outputs U, V and W.

Note that this test does not test the IGBTs, but will often show a short-circuited device.

DC+ C/L+

0.655
C
U
V
W

DC- D/L-

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7.6.2 Test Box - Requirements

To do error-detection with the TestBox; the following equipment is needed:

• Siemens TestBox (6AG1064-1AA04-0AA0)

• 24Vdc Power Supply (Minimum : 2A)
• Digital multimeter

7.6.2.1 Test Box for testing of Larger MICROMASTERs

Part No - 6AG1064-1AA04-0AA0

This Test box simplifies testing of the Px

units.
The output and input power components
may be tested at a safe (24V) voltage
before full power is applied.
Faults can be isolated to individual power
components.
The test box is significantly different from
the test box used for Masterdrive testing.

Important Note:

The PSU for test box must be 24V dc

with a 3 Amp current limit.
The supply voltage to the Test Box
should not fall below 24Vdc. This is
important, as the test box will not function
correctly with less.

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7.6.2.2 Power component tests with test box

The following parts of the power section can be tested at low voltage.

Precharge diodes Main Thyristor Output Drive

and resistors rectifiers Output IGBTs Circuits

Circuit Diagram

Overview

The test-box is intended to check three functional areas of the MM4 PX Power Block, spanning all FX
& GX units.

Test 1 – Test Rectifier

This test verifies correct operation of the pre-charging circuit, rectifier diodes and thyristors.

Test box connection details

• 24VDC connection from external source should be made to test box (OV, P24V)
• Electrical connection between test box (X244) and TDB (Thyristor Driver Board)
• Flying test leads should be made at the test box to both the STV+ & STV- terminals

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Test Sequence

• Rotary switch 9 should be in the off position.

• It is possible to check individual Thyristor operation. In order to this it is necessary to
configure the roving test leads in the following six combinations. For each combination the
reset button (4) should be pressed to reset the circuit, followed by the start button (5).

Connection Test combinations

at test box
STV+ L1 L2 L3 L- L- L-
STV- L+ L+ L+ L1 L2 L3

Understanding the test results

• With all the electrical connections made and the external 24V supplied to the test box the
TDB status LED (3) should turn green showing correct operation of the TDB board.
• With each of the above combinations, after the reset button (4) is pressed, the preload (1)
LED should turn green to indicate correct operation of the pre-charge resistors. This is also a
good indication as to the health of the pre-charging bridge rectifier block. It is however
recommended that a standard rectifier check be made with a DVM.
• When the start button (5) is pressed for each of the above combinations the green status LED
(2) should illuminate. If the green LED fails to illuminate then this indicates a problem.

Test 2 – Test IGBT, UCE

This test switches individual IGBT’s on. Selection switch 9 is used to set the phase or IGBT pair while
switch 6 is used to select the individual IGBT in that phase.

Switch 6

US = upper switch or IGBT.

LS = lower switch or IGBT.
Switch 6 has a third position called UCE. UCE = VCE (Voltage, Emitter, Collector). This measurement
checks that the voltage drop across the IGBT, when in the on state is not too large. This is a proven
method for checking the health of functioning IGBT’s.

IGBT, Inverter

Test box connection details

• 24VDC connection from external source should be made to test box (OV, P24V).
• Supply connection should be made to gate driver board. Use IGD+ & IGD- terminal on test
box with cable provided, and connect to the X1 connector on the board.
• T1, T2 & T3 fiber optic gate driver connection should be made to gate driver board.
• DC link connection should be made from test box (L-, L+) to the power block DC link. Connect
to DC link with crocodile clips to copper bus bars.
• A roving test lead should be connected to the test box (T1 – T3).

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Test Sequence

• Press the reset button (7) to test the health of the board.
• In order to check a specific IGBT the roving lead should be connected to the appropriate
motor output phase, usually starting with T1. This will now enable the upper and lower IGBT
to switch in that phase.
• Select the position T1 on rotary switch 9.
• Select the transistor to be tested be using switch 6, US – Upper IGBT test, LS – Lower IGBT
test and UCE to check the voltage drop. When performing UCE test press the reset button (8)
before hand to clear previous test results.
• Press the execute button (12) to perform the test. Please note the execute button should not
be held down for longer than 2 seconds.

The same procedure should be adopted with the roving test lead connected to “T2” motor output
phase and finally “T3”.

Understanding the test results

• When button 7 is pressed the IGBok LED (6) should change to green to indicate that the
board is OK.
• When the execute button (12) is pressed for the upper test (switch 6 set to US) LED 13
should light while the button is held.
• When the execute button is pressed for lower test (switch 6 set to LS) LED 14 should light
while the button is held.
• When the execute button is pressed for a UCE test (switch 6 set to UCE) the LED UCEok (8)
should become green.

Test 3 – CT Test

This test passes a current through two CT’s at any one time and checks the measured current is
balanced. When the three combinations “T1 to T2”, “T1 to T3” and “T1 to T3” have been checked
against each then the CT’s can be considered as good.

The test can be performed with the power block located in the unit and a motor connected or with the
power block removed located on a bench without a motor. Switch 10 should be used to select
between these two options.

Note – When a bench test is being performed and no motor is present then an electrical connection
should be made between the appropriate pair of motor terminals. In the case of figure 3 the electrical
connection should be made between T1 & T2.

Test box connection details

• 24VDC connection from external source should be made to test box (OV, P24V)
• Supply connection should be made to gate driver board. Use IGD+ & IGD- terminal on test
box with cable provided, and connect to the X1 connector on the board.
• T1, T2 & T3 fiber optic gate driver connection should be made to gate driver board.
• DC link connection should be made from test box (L-, L+) to the power block DC link. Connect
to DC link with crocodile clips to copper bus bars.

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• Electrical connection between test box (X43) and CTs should be made.
• Roaming cable to short output terminals (T1-T2, T1-T3 or T2-T3).

Test sequence

• Switch 9 is used to select the IGBT combinations that will be switched. It should be noted that
switch 9 has many positions however not all are needed for this test. The only 3 positions of
importance are “T1+ to T2-”, “T2+ to T3-” and “T3+ to T1-”. The test should be performed in
each of these positions in turn, with the corresponding terminals shorted together with the
roaming cable if no motor is connected.
• Press the reset button (11) to clear previous results.
• Press the execute button (12) to perform the test. When button 12 is pressed and the motor
terminals T1 and T2 are shorted together (no motor option) then IGBT’s T1 upper and T2
lower will discharge the DC link through the two CT’s T1 and T2. This will generate a large
instantaneous current as the DC link capacitors discharge. It’s this current that is checked for
symmetry (balance). When the test button is pressed sometimes a small audible noise can be
heard, this no reason for concern.

Understanding the test results

• When the CT’s are balanced then the status LED located above the reset switch (11) will
illuminate green while the execute button is held. At the same time the current status LEDs
(13 & 14) will illuminate. It should be pointed out that execute button (12) should not be held
down for longer than 2 seconds.
• If the status LED illuminates green but the current status LEDs (13 & 14) do not light then no
current is flowing (no current is still balanced, hence the green light).
• If the status LED does not turn green but turns red and stays illuminated then the test has
failed. Before a second test can be made the fault will need to be cleared by pressing reset
button 11. By using different test combinations it should be easy to determine which CT has
the fault.

7.7 Fault Memory

7.7.1 How Faults are recorded

The fault memory system is much simpler compared with Masterdrive.

• Fault codes are stored in r0947.

• Additional information is stored in r0949.
• Warning information is stored in r2110.

7.7.1.1 Fault Codes

• Fault codes are stored in r0947.
• Fault history information is stored in the indexes in pairs
• The fault in index 0 is the most recent unacknowledged fault.
• The fault in index 1 is the most recent acknowledged fault
• As more faults occur, these faults move to higher odd or even fault values.
• This is detailed in the parameter list.

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Extract from Parameter List

7.7.1.2 Fault and Warnings

Additional information for some faults is given in r0949.

The fault descriptions are included at the end of the parameter list; these indicate the meanings of any
value stored in r0949.

Warning information is stored in r2110.

Warnings occur under certain conditions (e.g. overload). The Drive does not stop, but may, for
example, reduce frequency to reduce load.

Warning information moves from index 0 to index 1 etc. to store warning history.

7.8 Installation
Refer to 6.9 Installation in this manual.

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Warranty Acceptance and rejection

Example of damaged power board

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For further information, refer to 6.11 - Warranty Acceptance and Rejection in this manual.

7.10 Handling Software and Firmware - Firmware and Power stack data on MM4
7.10.1 Firmware

Is the control software that sets the functionality of the converter, and is stored in the control board,
usually in ROM on MM4 converters.

This means that the only way to change the software is to change the complete control board. This
process is described in section 7.3.2.2 Changing the Control Board in this manual.

The firmware version is can be read from the rating label or can be read from r0018 (example 2.08).

7.10.2 Parameter Settings

Do not confuse Firmware with the parameter settings that customize the operation of the converter for
a particular motor and application. These settings are stored in parameters in the control board and
can be easily changed. If a control board is exchanged then the correct parameters must be reloaded
to suit that application. This is most easily done using DriveMonitor, but individual parameters may be
adjusted using an Operator panel on the converter.

Details of how to use DriveMonitor to upload and download parameter sets are given elsewhere.

7.10.3 Power Stack Data

When an MM4 Converter is manufactured, a small rewritable memory is included in the power part of
the converter on a PCB (i.e. not the control board).

This memory is programmed with the data relating to that power rating of converter (e.g. 30 or 37kW).
Therefore, if the power part containing the memory is changed, the Power Stack Data must be
reprogrammed to suit that size of converter, as boards may be used on several different converters.

7.10.3.1 Power Stack Data and Control board settings

Note that when the control board is changed, the board must be told the power rating of the power
assembly (stack) it is connected to. This is automatic with later software, but can be done or checked
manually:

Set P0003 = 3
Read r0200
Set P0201 to this value
Cycle power

Power Stack Re-programming

The memory containing the power stack data is on a PCB located on the converter. If this PCB is
changed, the power stack data must be re-loaded into the repaired converter.

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Note that on 90 and 110kW drives the power stack data is located on the control assembly and is not
normally changed when the Power module is changed.

7.10.3.2 Checking the Power Stack Data

A converter with incorrect power stack data will possibly run, but will give a variety of faults, such as
F0052, F0011 etc.
Check parameter r0200 and if reads 0, new power stack data must be programmed in.
If the value of P0201 is different to r0200 try setting P0201 as described previously, otherwise re-
programme as described below.

Power Stack Re-programming

Power stack reprogramming requires a PC to be connected to a powered drive using a standard

interface, and the appropriate software used to download the data.
These instructions are available separately and shown below.
Connect PC interface, com1, by means of PC converter assembly kit (6SE6400-1PC00-0AA0) with
converter. Parameterize converter interface to 9600 Baud (Parameter P2010 to 6).
Select the correct programme for MM420 (Basic), MM440 (Vector) or MM440 Px 90 or 110kW (Px)
Do this by running the batch file that will select the correct programme Start with PC program
“MM4Prog.exe“.

Enter the actual power section-Code

number into the input mask (see
also Operating instructions,
Parameter r200) and confirm with
value by pressing the button “load“.
After the successful download of the
Power-Stack-data program close
with “EXIT“, and check that r0200 is
equal to P0201.

7.10.3.3 Loading the Power Stack software

1. Delete any existing directory named "MM4 Power Stack"

2. Unzip attachment in to root of the C: drive.
3. You should see C:\MM4 Power Stack.
4. Click the setup icon and click yes to replace all files!
5. In the directory "Batch File Swapping" you will find two files, change the file extension from
txt. to bat. on both files. When the files have been renamed make a short cut of the "swap
basic bat." and "swap vector bat." Drag the new shortcuts out on to your desktop. The names
are changed to make it easier to mail the zip file as some firewalls strip out .exe files.
6. In the directory "MM4 Power Stack" make a short cut of the "MM4_prog.exe". Drag the new
shortcut out on to your desktop.
7. With these three Icons’ you will be able to program both MM420 & MM440 units. Use the
appropriate batch file to switch between Vector & Basic.

Special Notes:
Do not change any directory names or location including file names. This will stop the batch files
being able to swap the appropriate format used within the CSV files (this being the problem in the first
place). The following foils show the location of the memory (EEPROM) that contains the Power Stack
Data.

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7.10.4 Block Diagrams

7.10.4.1 MM440 Frame size A-C

Power
Assembly Link board FSB,C Control board I/o board BOP etc

Power Stack
EEPROM

All power components are mounted on the three-board assembly, linked by flexible solder links.

(P.T.O.)

7.10.4.2 MM420 Frame size A-C

Power
Assembly Link board FSB,C Control board A/o board BOP etc

Power Stack
EEPROM

All power components are mounted on the three-board assembly, linked by flexible solder links.

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7.10.4.3 Frame size D, E

Filter board Power Gate Control

(input) Board Driver Board I/o Board TOPI BOP etc

GAP
Power
DC link
Input Supply,
capacitors
links Monitoring
Inrush relay
and
filter Power
components Power Stack
EEPROM

7.10.4.4 Frame size F

Filter board Power Gate Control

(input) Board Driver Board I/o Board TOPI BOP etc

GPC
Power
CBV RCC Supply,
Inrush Rectifier Monitoring,
relays, And Gate Drive
dc link Brake
caps Chopper Power Stack
EEPROM

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7.10.4.5 Frame size Fx, Gx

Fan Power Control Assembly I/o BOP

Control Stack Assembly (CIB) Board etc

Trans Rectifier, inrush

control MIVI
Main Thyristor
Rectifier

Heatsink Power
Supply
ABO Calibration

Fan Power Stack

EEPROM

7.10.5 Drive Monitor

Refer to 6.12.2 - Drive Monitor in this manual.

Please note the change in step 5> Choose type of drive

Select
MICROMASTER 440
as the type of drive.

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7.11 Spare Parts

Device Designation
AC P/Nr Siemens Order Nr.
Product Description
GA75VSD
1089 9338 42 6SE6440-2UD38-8FA1 Frequency Converter 380-460V / 50-6Hz
2908 0094 00 6SE6400-0BP00-0AA0 MICROMASTER BASIC OPERATOR PANEL (BOP)
2903 0060 01 6SE6400-7AA00-0BA0 MICROMASTER 440 VECTOR I/O MODULE
SINAMICS/MICROMASTER PX REPLACEMENT POWER
2903 0060 08 6SL3351-1AE32-1AA1 BLOCK FOR 3AC380-480V, 50/60HZ, 210A AC
DRIVE/POWER MODULES RECTIFIER AND 3 PHASES
MICROMASTER 440 PX REPLACEMENT CONTROL
2903 0060 09 6SL3351-6GE32-1AA1 INTERFACE BOARD FOR 3AC 380-480V, 50/60HZ, 210A AC
DRIVE
SINAMICS/MICROMASTER PX REPLACEMENT POWER
2903 0060 10 6SL3352-6BE00-0AA0 SUPPLY FOR 3AC 380-480 V, 50/60 HZ AC
DRIVE/POWER/MOTOR MODULE
SINAMICS/MICROMASTER PX REPLACEMENT FAN
TRANSFORMER FOR 3AC 380-480 V, 50/60 HZ, 210 A AC
2903 0060 11 6SL3352-7AE32-1AA1 DRIVE/POWER/MOTOR MODULE CHASSIS UNIT
FRAMESIZE F
SINAMICS/MICROMASTER PX REPLACEMENT FAN FUSE
FOR 3AC 380-480 V, 50/60 HZ, 210 A AC
2903 0060 12 6SL3352-7BE32-1AA1 DRIVE/POWER/MOTOR MODULES
CHASSIS UNIT FRAMESIZE F
SINAMICS/MICROMASTER PX REPLACEMENT FAN FOR
2903 0060 19 6SL3362-0AF00-0AA1 3AC 380-480 V, 50/60 HZ, 205 A AC DRIVE/POWER/MOTOR
MODULES CHASSIS UNIT FRAMESIZE F
MICROMASTER PX REPLACEMENT DOOR FOR AC DRIVE
2903 0060 13 6SL3361-3AF00-0AA1 CHASSIS UNIT FRAMESIZE F
SINAMICS/MICROMASTER PX REPLACEMENT TERMINAL
2903 0060 14 6SL3362-2CA00-0AA0 STRIP X9
GA90VSD
1089 9338 37 6SE6440-2UD41-1FA1 Frequency converter 380-460V / 50-6Hz
2908 0094 00 6SE6400-0BP00-0AA0 MICROMASTER BASIC OPERATOR PANEL (BOP)
2903 0060 01 6SE6400-7AA00-0BA0 MICROMASTER 440 VECTOR I/O MODULE
SINAMICS/MICROMASTER PX REPLACEMENT POWER
2903 0060 15 6SL3351-1AE32-6AA1 BLOCK FOR 3AC380-480V, 50/60HZ, 260A A DRIVE/POWER
MODULES RECTIFIER AND 3 PHASES
MICROMASTER 440 PX REPLACEMENT CONTROL
2903 0060 16 6SL3351-6GE32-6AA1 INTERFACE BOARD FOR 3AC 380-480V, 50/60HZ, 260A AC
DRIVE
SINAMICS/MICROMASTER PX REPLACEMENT POWER
2903 0060 10 6SL3352-6BE00-0AA0 SUPPLY FOR 3AC 380-480 V, 50/60 HZ AC
DRIVE/POWER/MOTOR MODULE
SINAMICS/MICROMASTER PX REPLACEMENT FAN
TRANSFORMER FOR 3AC 380-480 V, 50/60 HZ, 260 A AC
2903 0060 17 6SL3352-7AE32-6AA1 DRIVE/POWER/MOTOR MODULE CHASSIS UNIT
FRAMESIZE F
SIMOVERT MASTERDRIVES FUSE LINK ATDR2-1/2, 2.5A,
2903 0060 18 6SY7000-0AC46 600V
SINAMICS/MICROMASTER PX REPLACEMENT FAN FOR
2903 0060 22 6SL3362-0AF01-0AA1 3AC 380-480 V, 50/60 HZ, 250 A AC DRIVE/POWER/MOTOR
MODULES CHASSIS UNIT FRAMESIZE F
MICROMASTER PX REPLACEMENT DOOR FOR AC DRIVE
2903 0060 13 6SL3361-3AF00-0AA1 CHASSIS UNIT FRAMESIZE F
SINAMICS/MICROMASTER PX REPLACEMENT TERMINAL
2903 0060 14 6SL3362-2CA00-0AA0 STRIP X9
GA18-30VSD
1089 9338 48 6SE6440-2AD32-2DA1 7.5-13 bar - 380-460V
1089 9338 49 6SE6440-2AD33-7EA1 7.5-13 bar - 380-460V
2908 0094 00 6SE6400-0BP00-0AA0 MICROMASTER BASIC OPERATOR PANEL (BOP)
2903 0060 01 6SE6400-7AA00-0BA0 MICROMASTER 440 VECTOR I/O MODULE
2903 0060 23 6SE6400-7AA00-0AG0 MicroMaster Fan assembly FSD-FSE

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2903 0060 24 6SE6400-7AA00-0AF0 MicroMaster DIM Assembly FDS-FSF

GA37-55VSD
1089 9338 25 6SE6440-2UD34-5FA1 380-480V 60hp CT/75hp VT
1089 9338 41 6SE6440-2UD35-5FA1 380-480V 75hp CT/100hp VT
2908 0094 00 6SE6400-0BP00-0AA0 MICROMASTER BASIC OPERATOR PANEL (BOP)
2903 0060 01 6SE6400-7AA00-0BA0 MICROMASTER 440 VECTOR I/O MODULE
2903 0060 25 6SE6400-7AA00-0AB0 MicroMaster Fan assembly FSF
2903 0060 24 6SE6400-7AA00-0AF0 MicroMaster DIM Assembly FDS-FSF
Red Typical part for GA75VSD
Black Common part for GA75 & GA90VSD
Blue Typical part for GA90VSD

General Tools
Siemens Testbox for Micro Master (24V DC power
2903 0060 20 6AG1064-1AA04-0AA0 supply needed = Same as power supply for Master
Drive Testbox)
2903 0060 21 6AG1064-1AA05-0AA0 Cable set for Testbox Micro Master
2908 0095 00 MM440 PC Connection Kit
16mm ( M 16 ) Spanner with Extension
10 till T30 Screwdriver Torx
Refer http://www.fluke.com Fluke 179 Multimeter
Refer http://www.fluke.com Fluke 321 clamp meters

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8. AC Simovert P- 6SE13

Principle

Drive converter

Rectifier Inverter

Motor

M
3~

Û2

Û1

Û2

Line supply connection: DC link (DC busbar):

e.g. 3-ph. 400V AC Capacitors with the rectified
line supply voltage approx.
1.35 · 400V = 540V

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8.1 Position of Components

8.1.1 GA90VSD

Fans

CCU

Control terminals
and connections

DC-link fuses

DC-link
capacitors

Current sensors

Motor connections
PCC

Mains supply

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8.1.2 AC Simovert P- 6SE13 : General Diagram

Parts in the Converter:

CCU : Control card and microprocessor
GAX : Power supply and extra functions
PCC : Precharging card
IGD : Igbt driver card
FDC : Fan control

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Atlas Copco Diagram

2
22
2

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8.1.1.1 CCU : Control card and microprocessor

8.1.1.2 GAX : Power supply and extra functions

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8.1.1.3 PCC : Precharging card

8.1.1.4 FDC : Fan Control

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8.1.1.5 Fuses on GAX Card

F104

F103

F102

F101

F101, F102 and F103 are protecting :

• Current to the GAX (internal power supplies)

• Current to the fans.
• Value of F101 – F103 : 6,3A/500V

F104 is in the DC-side of the internal power supply on the GAX-card.

• Value of F104 : 4A/500V

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8.1.1.6 Connectors on GAX-card

X250 X240

X230

X222

X285

X211

X231

X214

X201
X215
X200
X221
X220

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• X201:
- Incoming power supply; 3 x 400V(500V); before fuses F101, F102 and F103
- Connected to incoming voltage by wire-bridges onto X23.

• X200:
- Connection to DC-link.
- Measurement of DC-link voltage

• X220:
- Control voltage for main contactor.
- Voltage goes to X23. (Not used in Atlas Copco compressors).

• X221:
3 x 400V(500V) to FDC (voltage for fans); after fuses F101-F103.

• X215:
- Potential free contacts from 4 relays above connector.
- Max. 60V/1A

• X214:
- Control for 4 output relays.
- Signals are coming from CCU (X14).

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• X231:
Temperature sensor for internal temperature measurement of the VSD.

• X211:
- Outgoing +15V, -15V and incoming output currents.
- Goes to current sensors.

• X285:
24Vdc – output for extra fan.

• X222:
Control of fan contactor on FDC.

• X230:
Control (flat-)cable to IGD-card to control inverter.

• X250:
Not used (Brake chopper).

• X240:
To PCC; control precharging and rectifier.

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8.1.1.7 Connectors on CCU Card

X110
X100

X14

X13

X12
X130
X11

X131

• X11 & X12:

Digital inputs.

• X13:
- Analog inputs
- Analog outputs
- Connection of motor PTC

• X14:
Digital outputs; goes to relays on GAX-card

• X131:
RS232-serial interface; is used for communication with Elektronikon module.

• X130:
Connection for Operator Panel. If not used, mount flat cable connector.
Atlas part 1088 0022 00

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• X100:
Not used.
For communication with technology boards (PT10) or communication board (CS51).

• X110:
Connection with GAX-board.

8.1.3 Order Number of Simovert P SE12/13

6SE1 x x x - x x x xx - Z

Simovert P 6SE12/13
Nominal power
204 = 3,5 kVA 245 = 45 kVA
206 = 6 kVA 252 = 52 kVA
207 = 6,5 kVA 260 = 60 kVA
210 = 10 kVA 275 = 75 kVA
211 = 11 kVA 290 = 90 kVA
216 = 16 kVA 311 = 112 kVA
218 = 18 kVA 312 = 115 kVA
222 = 22 kVA 314 = 144 kVA
227 = 27 kVA 316 = 160 kVA
233 = 33 kVA 320 = 200 kVA
236 = 36 kVA

Nominal voltage
2 = 380V - 415 V / 50 - 60 Hz
3 = 460 - 500V / 50 - 60Hz

Converter version
A = standard
Y = UL508 listed and CSA

Converter version and protection

A = chassis drive IP00 without brake chopper
B = chassis drive IP00 with brake chopper
C = complete drive IP54 without brake chopper
D = complete drive IP54 with brake chopper
E = cabinet drive IP20 without brake chopper
F = cabinet drive IP20 with brake chopper

Function release
Options

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8.2 Faults and Alarms

Fault / Alarm Cause Counter-measure

F001
Line power connection has the wrong
Reverse 2 incoming lines.
phase sequence or phase missing
Phase Sequence

May occur after a long period of standstill. In this

case, restart the machine for up to 10 times.
If fault persists, check:
F002
Precharging malfunction:
- Supply voltage is within tolerance 400V +/- 10%
Line voltage, inverter defective
Precharge Error
- PCC (PreCharging Circuit)

- One of the capacitors may be defective

- Reprogram Mark III and put in ARAVF.

F003
DC-link voltage (ULC) too low:
- Check DC link voltage during operation, which
Line power failure, phase failure, fuses
Undervoltage defective, inverter defective
should be around 1.34 x Supply voltage.

- Check fuses.

W004
ULC lower than 405 V:
Generator buffering, e.g. as a result of
Low Line Voltage temporary power outage

W/F005 - Check supply voltage, which should be between

Line voltage too high, extreme generator 380 and 480 V (+/- 10%).
Overvoltage operation, ramp-down rate too fast
- Remove the ground fault, Check braking power.

- Check operation of cooling fan, as well as power

W/F006 Heat sink over temperature:
supply (380V) over K5 towards these fans
Ambient temperature too high, site
altitude, inadequate cooling (e.g. polluted
Heat Sink Temp - Check for polluted heat sink
heat sink)

Check resistance value of both sets of thermistors

which should be < 500 ohm at 20 Deg.C

Check proper engagement of connector at X13 of

CCU.

Check cooling flow over the drive motor

2 sets of thermistors of which the one with the

lowest setting (155 deg C) is generating a speed
reduction of 10% during 12 minutes. The speed
W/F007 Motor overtemp. (PTC thermistor term. limitation is performed over K35 and digital input
X13:24/25), motor overload 2x6 nr 8. During these 12 minutes running at
reduced speed, a warning (red steady LED) is on.
Motor Overtemp In an emergency, if this thermistor is faulty, it may
be bridged out or replaced by a 50-400 Ohms
resistor.

The other thermistor is wired up to the converter at

X13: 24/25 terminal. This thermistor is design to
shutdown converter hence compressor when the
limit of the thermistor has been reached. In an
emergency, when this thermistor is faulty, it may
be disabled via the converter with the hand held
controller panel and parameter P54.

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- CHECK: Voltage unbalance leads to higher

currents in the motor. Typical 1% unbalance in
supply voltage can lead to 10% extra current in
one of the motor phases. 3.5% unbalance in
supply voltage will give 25 deg. C higher in motor
temperature.

CU :- Voltage dips might be the reason,

Reprogram the MKIII with latest service software
and put ARAVF active.

W/F008 Housing top cover overheated:

- Check DC link voltage during operation through
r006 on the Siemens PMU.
Pulsed resistor or electronics overheating,
Pulsed Res Temp ambient temperature too high, internal
- IGBT or IGD1 defective is possibility. Maybe
cooling fan (if fitted) defective
loose or bad connection.

CCU: - Pulsed Resistor or electronics overheating,

ambient temp too high. Cooling fan may be
defective

F009 Converter overloaded:

Converter output current too high for long
INV Overload period (i x t) Planning error, converter too
small

F010 Fault in pulsed resistor:

Pulsed resistor transistor defective, fuse
Pulsed Res Fail F5 on pulsed resistor electronics module
defective. P0062 not activated

F011
Pulsed resistor "on" for too long:
Pulsed Res Time Planning error (unit dimensions)

- Check supply voltage, which should be in the

range 380 V to 480 V ( + 10%).

- Check if the motor parameters correspond to

those of the motor being used.
F012
- Check if the motor is overloaded or stalled
Short circuit low-resistance ground fault
Overcurrent (locked rotor).

- For Motor or wiring short circuit:

Re-connect motor, run converter. If converter trips
again immediately, motor or wiring is faulty. If
converter and motor run OK, look for other signs
of overload.

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W/F013 Motor overload (calculated):

Motor current too high for too long for a
Motor Overload period

- Check for mechanical resistance in compressor /

motor

- Check the small hole of 4mm in the center of the

boss in the check valve housing which ensures the
full opening of the check valve.

- PLEASE NOTE: on former model GA90 VSD

(SN < AII 492 000) Please observe ECB AII0070
F014 (Priority IV) with regards to OIL RESTRICTION AT
Load too high or excessive dynamic LOW SPEED for GA90VSD with Simovert P
stressing converter.
Motor Pullout
- Please be ensured that the resistor bank from the
GAX card is functioning properly. As experienced
in ACNZ has shown that faulty resistor bank can
(and probably will) disguise itself has F14, F12 etc
and are intermittent faults.
Because the resistor bank has to be taken out
every time the GAX card was changed, hence
there is a chance it will deteriorate over time.

W015
Load too high - Reduce Load
Pullout Warning

F017
"External fault" signal at terminal 9
External Fault

Pulse frequency too high:

Planning error (motor too large), motor
F018 leakage inductance too low, synchronous
motor application without prescribed
Pulse Frequency output reactor, power factor of connected
motor too high, motor stalled for long
period or ground fault

F019
Initial loading of parameters is incomplete
or incorrect.
Parameter Error

F020 Motor data are not plausible:

The efficiency calculated on the basis of The error can be overcome by slightly altering the
the motor data is not within "plausible" motor rated power specified in P0006.
Wrong Motor Data limits.

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F021
Fault in μP system
Processor Fault

F022
RAM error detected during memory test
RAM Failure

F024
EEPROM initialization error
Cont Bd Failure

F025
EEPROM defective
EEPROM Failure

F026 Interface board incorrectly parameterized:

Baud rate, message length, address not
CS5 Parameter permissible

F027 Optional board defective or not installed:

Optional board is parameterized, but does
Option Bd Fail not respond during initialization

W/F028 Loss of process data from the

automaton system:
Process Data Broken wire, optional board defective

F029
Program error:
Defective software
Software Failure

- Check the dummy connector at the CCU card for

proper engagement.
Basic unit operator panel failure (with
F030 - In case the operator panel is disconnected while
control command source setting Local
the convertor is under tension , it is absolutely
operator panel):
normal that the fault comes up at the next start
Oper Panel Fault Open circuit between operator panel and
attempt even when the convertor was powered off
control board
and on afterwards. This is due to the fault is
memorized. A simple reset will cure the problem.

F031
Incorrect application:
E.g. output of connected motor too high
Design Error

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F032 Software option is parameterized but not

enabled:
E.g. speed control, torque control, flying
Option Disabled restart, etc

Impermissible setpoint/actual value wiring:

F033 Two or more setpoints are connected to
the same parameter or first setpoint is
Param. P915/916 not connected to control word.

Optional PT1 board has been

parameterized, but is not ready for
F034 operation:
- PT1 not inserted
- Ribbon cable to PT1 is not inserted
Tech Bd HW Failed - No appropriately parameterized
EPROM card in PT1
- No checkback signal from CS5 to PT1

F035
Motor has not been restarted:
Search time set in P0065 too short
Flying Restart

Technology board (option) has detected

fault. Cause of fault is indicated by
number xxx. The fault numbers of
technology board are determined by
F036 configuration.

PT Fault Note:
The fault number xxx is not stored
permanently, i.e. 000 appears as a
fault number after the converter has been
switched off and on again.

W/F037 Line failure, phase failure, defective

fuses(This Fault code is due to fuses
The GAX card needs to be replaced.
F101/F102/F103 which had blown on the
AC-Line Fault GAX card)

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8.2.1 Communication Failure

Fault / Alarm Cause Counter-measure

- Check the cable connection between the
7001 2modules (1613 7305 00)
Internal communication between master
and com.Module
- Check the power supply to the modules (24V)

Module 01 became inoperative and it was Try to re-programme the modules and check the
7101 connected to another operative module. start configurations

7201 Module01 is inoperative by incorrect

programming or by connecting an empty Try to re-programme
module.

- Check for proper connection cable (p/n 1613

7307 00)
7301 Communication failed between - Check communication by means of data logger
communication module and convertor. when available.
- Might also occur during commissioning when
the phases are incorrectly connected

7401 Disturbance in communication ( Incorrect

- check communication by means of data logger
Format) between regulator and convertor

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8.3 Repair Instructions

8.3.1 Output Current Measurement

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Output Current Measurement

8.3.2 Current Normalization on GAX Card

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IMPORTANT :

When ordering a new GAX-card; the current normalisation resistors are not included !!
The GAX-card is identical for more types of 6SE13-convertors; adaptation is done by this set
of resistors !

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Values of the resistors / Mounting of Resistor-module :

Resistance number Ohmic value

R410
180 Ohm
R413
R416

R411
270 Ohm
R414
R417

R412
R415 No resistance
R418

Only valid for 160kVA !!

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8.3.3 GAX Removement

1. To remove the holder with GAX out of the converter, unscrew 2 screws, and take out the holder.

- Left side - - Right side -

2. To remove the GAX from the holder, unscrew first 3 screws on the GAX.

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3. Then unscrew 2 screws on the holder and pull holder open.

- Left side - - Right side -

8.3.4 Replacing the Fans

1. Remove the electrical connections.

2. Remove 2 screws for metal plate in front of fan.

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3. Remove cable protection from metal front cover.

4. Remove 2 screws for fan attachment.

5. The fan can then by slided out of the converter.

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6. The fan can be removed from the slide, by unscrewing 4 screws.

7. The slide with attached fan has to be supported by the 2 pins on the back of the converter.

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8.4.3 Parameter list

a) GA 90 VSD – 7-10 bar

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b) GA 90 - VSD 13 bar

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8.5 Replacing CCU Board

56B

1. List the parameters from the original CCU-board; if no list is available.

2. Turn off power and replace original CCU-board with new one. Check the position of the
dipswitches; connect all connectors and the operator panel.

3. Switch on the power again.

4. Follow these steps to change the parameters:

• P0003 = Initialize (3)

• P0004 = 1375 (access level 3; ~service mode)
• Program/check all available parameters in this mode:
• Settings for the converter
P0076 = Model number; choose the correct order number 6SE.

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P0075 = Inverter voltage

P0074 = Inverter power
• P0003 = Commission (2)
• P0004 = 4 (access level 2; ~expert mode)
• Program/check all available parameters in this mode:
• Motor data can be changed also
P0005, P0006, P0007, P0008, P0009, P0010….

To operate: P0003 = Operate (1)

If P0004 = 1 (access level 1; ~normal mode); some parameters can be changed (Like ramp-up time,
ramp-down time)

On the operator panel: parameters with ‘ * ’ cannot be changed in that mode.

5. Test compressor.

8.6 Fault Diagnosis

57B

Fault messages

A self-test is executed when the unit is switched on. If faults occur after start-up or in operation,
they are displayed in plain text on the operator panel and the red "fault" LED lights up at the
same time. A fault can also be signalled through one of the binary output terminals X14:27 to
XI4:30 or X215:1 to X215:12(GAX).

Fault acknowledgement

A fault is acknowledged with the "R" (Reset) key on the operator panel, via terminal 10, via the serial
interface or via an optional automation module. After a fault has been acknowledged the unit is in the
"restart inhibition" mode. An "OFF" command must then be issued before the unit can be switched on
again.

Diagnostic memory

When faults are acknowledged, the last five faults are entered in the diagnostic memory P0914 and
can be read out through parameter selection from the "Operate" mode. After the (§) key has been
pressed, the plaintext, messages are displayed in the sequence shown below:

0 Newest entry
1 Oldest entry
2 Second entry
3 Third entry
4 Fourth entry

Alarm messages

The red LED on the operator panel blinks to signal an alarm. The converter continues to operate while
an alarm is pending and does not trip until the alarm becomes a fault message, e.g. because it has
been pending for too long.
The type of alarm can be called from the operational status display by pressing the "R" key (the
display always shows the most recent alarm).
The display can be switched back to operational status mode by pressing the "R" key again. Alarms
cannot be reset.

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8.7 Installation
58B

8.7.1 Installation and Mounting

170B

The units are packed in suitable materials for shipment. When unpacking the equipment, check
whether any damage has occurred during shipment. If so, contact the responsible Siemens Sales
Office.

Warning

Safe operation is dependent upon proper installation and start-up by qualified personnel under
observance of all warnings contained in this Instruction Manual.
In particular, the general erection and safety regulations governing work on high-power installations
(e.g. DIN VDE, VBG 4) as well as regulations regarding the correct use of hoisting gear, tools and
personal protective gear must be observed.
Failure to observe the above warning can result in death, grievous injury or substantial damage to
property.

8.7.1.1 Notes on Installation and Mounting

291B

The units are designed for steady-state operation.

Note:
The cabinet-mounted unit affords protection against direct contact in the operational state in a form to
render it suitable for installation in general electrical operating areas.
The chassis unit does not afford any protection against direct contact. It is the responsibility of the
user to ensure the required protection against direct contact in compliance with accident prevention
regulation VBG 4 by taking the necessary precautions in the vicinity of the unit.

CAUTION

1. A clearance of 400 mm must be left above and of 200 mm at the front of and underneath all chassis
and cabinet-mounted units in order to ensure an unobstructed supply and removal of cooling air.

2. The units must not be exposed to dangerous gases or dust as these may eventually impair
operation of the unit.
It must be noted that the surface of the brake resistor in units fitted with the pulsed resistor option may
reach very high temperatures. The coolant must not therefore contain any inflammable substances. In
addition, a unit of this type must not be mounted on a wall made of an inflammable material.

8.7.1.2 Operator panel in Chassis Units

29B

The operator panel is mounted in the unit door in chassis units in degree of protection IP 20 and in
cabinet-mounted units.

The operator panel for chassis units in degree of protection IPOO is supplied separately packed and
can be mounted, for example, in a cabinet door of 1.5 mm to 2 mm thickness.
Cutout section required: 95.2 + 0.1 mm x 130.5 ± 0.1 mm.
The operator panel must be connected to the control board using the 2 m long cable. Other cables,
especially longer cables, must not be used.

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8.7.1.3 Special conditions of Installation

293B

Load reduction as a function of ambient temperature

Load reduction as a function of site altitude

8.7.2 Connections
17B

8.7.2.1 EMC ( Electromagnetic Compatibility )

294B

The term "electromagnetic compatibility" refers to two complex areas, i.e. the emitted Interference and
interference immunity.

To minimize interference emission:

1. Use shielded motor cables, making sure that the shield is properly grounded at both the converter
and motor ends.
If a shielded cable is not available, an unshielded motor cable can be laid in a metal conduit,
which acts as a shield. The conduit must be continuous with a direct electrical contact to the
converter and motor housings.

2. Shielded cables must be used to connect the external brake resistor. The shield must be
connected at the converter and at the brake resistor housing.

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3. When connecting cables to the converter power terminals, leave the largest possible distance
between the incoming AC supply cables and the motor cables. The motor cable shield must also
be connected to PE2.

To maximize interference immunity

1. The PE terminals of the converter and of higher-level control units must be connected to one
another and to the PE of the supply system via the shortest possible route (low impedance using
ground strip if necessary). Peak voltages, which may cause malfunctions, with otherwise occur
between the converter ground and the ground connection of the control unit.

2. Shielded signal cables must be used: connect the shield at both ends. It is best to connect the
shields to frame potential over a large area by attaching them by means of a hose clip to the
aluminium duct on the immediate left directly above or below the control board. Connecting the
shield at one end is of advantage only in exceptional cases (e.g. to prevent hum loops with
sensitive analog signals). In such cases, check to make sure that it is not in fact necessary to
contact the open shield end via a suppression capacitor (i.e. for RF suppression).

3. Never route the motor and signal leads in parallel (and/or in close proximity to one another) even
if they are shielded.

4. Do not put unit into operation unless the door is closed.

5. Connect converter and higher-level control units to separate supply systems if possible. If this is
not possible, the control unit and converter must each have a separate supply cable from the
common supply system.

6. Contactors and relays located close to one another or in the same cubicle must be equipped with
RC elements.

7. Placement of isolating amplifiers at control board inputs/outputs.

8.7.2.2 Power Terminals

295B

Converter Terminals
Connection
X1 Remarks
Incoming Supply L1 U1
Input: 3AC 400 V ± 15 % 49 Hz to 61 Hz
L2 V1
L3 W1
Caution: Ensure correct phase relation; CW phase sequence!
PE PE1
Motor U U2
Output: 3AC 0 V up to input voltage 0 Hz to 300 Hz
V V2
W W2
PE2 also acts as the shield terminal for the motor cable
PE PE2
DC-link P C Caution: The DC-link terminal "D" must not be connected to
N D terminal “H” (external brake resistor) (risk of damage to unit).
External Brake Trm.1 G
Caution: When the maximum possible continuous output is fully
Resistor Trm.2 utilized, the surface of the brake resistors will reach very high
H
temperatures if no separate ventilation is provided.

6SE12 converter 6SE13 converter

Incoming Supply ►
60 kVA/90 kVA 115kVA/160 kVA

Max. permissible cross- Motor, DC link 2 x 70 mm2 2 x 150 mm2

sectional area External brake resistor 1 x 25 mm2 1 x 50 mm2

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Warning!
The converter might be irreparably damaged if it is switched onto a ground fault!
Connecting the incoming AC power cables to the converter output terminals will irreparably damage
the unit!
The electronics continue to operate for several seconds after disconnection of the unit via the main
switch.
The coils of contactors and relays which are connected to the same supply system as the converter or
located near the converter must be equipped with surge limiters, e.g. RC elements or diodes.

8.7.2.3 Typical Connections

296B

1. Chassis units must be connected via switching elements and fuses according to the technological
requirements of the drive.

Example of a common power supply connection for power and control sections (chassis unit)

L1
L2
L3
PE

The unit is connected to the

power supply by the
ON Q1 contactor. The inverter is
enabled via the control
Manual (terminals) or operator panel.
Switch
OFF

Q1 Q1

U1 V1 W1 PE1

6SE12/13

U2 V2 W2 PE2

Option

3 ~
M

2. To ensure the correct rotational direction of the fan, the auxiliary supply must be connected to the
main power supply in the correct phase sequence.

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Example of separate power supply for power and control sections (chassis unit)

L1
L2
L3
PE

Manual
Switch Control Section

X23
X23 U1 V1 W1 PE1 2
9
X23 4
6SE12/13
10 6
U2 V2 W2 PE2

Option

3 ~
M

3. Cabinet-mounted units are equipped with an internal main switch, fuses (fuse-disconnectors) and
contactors. A separate power supply can also be provided for these units (power section and data
electronics).

Example of connection for cabinet-mounted unit

L1
L2
L3
PE

Control Section

U1 V1 W1 PE1 X23
2
6SE12/13 4
6
U2 V2 W2 PE2

3 ~
M

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8.7.3 Warranty Acceptance and Rejection

172B

Warranty has been expired. In case of complete failure Refer ECB number: AII 0160.

8.8 Handling Software and Firmware

59B

8.8.1 Software options

173B

SIMOVERT P series 6SE12/13 converters are shipped from the factory either with or without
software options depending on the customer's order. The integrated circuits required to enable the
optional functions can also be installed in the converter by the user after delivery. The procedure
is described below.

CAUTION

When installing the integrated circuit, which enables the optional functions, electrostatically
sensitive devices must be touched. The person carrying out the work must therefore make sure
that he himself is electrostatically discharged beforehand (e.g. by touching a bare metal, earthed
component or the protective earth contact of a socket outlet).

1. The control board directly behind the unit door in the center slot of the subrack is
equipped with a socket (D51) for the integrated circuit, which enables the optional software
functions (See figure below)

Connector

Socket D51 Notch

Section of CCU Board (Assembly side)

2. The integrated circuit must be inserted in the socket provided (location D51) with the notch
to the right. It must be ensured that the board is not bent when the circuit is inserted.

3. To insert the IC, remove the ribbon cable plugged in at the top of the control board by
pressing the two ejector levers apart.

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4. Remove the ribbon cable to the operator panel together with any connected terminals in the
terminal block.

5. Loosen the two screws on the bottom of the board by about one turn and then undo the screw
located in the center of the subrack rear panel above the control board.

6. Tilt the entire subrack forward. The control board can now be taken out.

7. It must be placed on a conductive, flat and clean surface so that the software option
component can be inserted.

8. The control board must then be reinserted in the subrack by following the instructions for
removal in the reverse order.

Any damage caused by incorrect insertion of the option IC is not covered by the warranty.

The software functions are available in the following packages:

• Package 1 (A10):
Speed control, torque control and frequency control with DC tacho
Option is automatically enabled when a PT1 board is incorporated (Order No.: 6SW1200-1XX80-
1AAO)

• Package 2 (A11):
Restart on the fly, generator buffering (Order No.: 6SW1200-1XX81-1AA0)

• Package 3 (A12):
Combination of packages 1 and 2 (Order No.: 6SW1200-1XX82-1AA0)

8.8.2 Speed control using DC tacho and torque control (A10)

174B

Speed control using DC tacho

In the speed control mode with DC tacho or in torque control mode (parameter P0050), the
actual speed value from the tacho is supplied via terminal X13:20. This signal can be scaled to
match tacho voltages of max. 10V, 20V or 30V via DIP switches S4 and S5 on the CCU board. The
matched tacho voltage of 10V is assigned to the frequency parameterized in P0014 (maximum
frequency). The signal can be finely calibrated in the 50% to 120% range in parameter P0025.

Analog setpoint input (terminal X13:20), setting of DIP switches for:

1. Actual voltage value:

-10V to +10V -20V to +20V -30V to +30V

S4 0 0 1 x 1 0 1 x 1 0 1 x
S5 0 0 1

1 = Closed; 0 = Open; = Not assigned

x = 1 - BS1 directly connected to PE potential (factory setting)

x = 0 - BS1 connected across high-ohmic resistance to PE potential
The control evaluates the tacho signal via a differential amplifier. In this case, a series resistor
(Rser = …(see following page)) must be connected in each case upstream of terminal X13:20 and
X13:21.

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CAUTION

The control board may be damaged by tacho voltages in excess of >30 V.

If the tacho voltage exceeds 30 V at maximum speed, a series resistor must be connected in front of
X13:20.

Calculation:
Rser = 20 kΩ x [(Tacho Voltage at Max Speed / 10V) –1]

In this case, the DIP switches S4 and S5 must be set to "from 10 V to 10 V".

The input of the differential amplifier must switch when S4 is opened. In addition, the calculated series
resistance must be connected both in front of terminal X13:20 and in front of terminal X13:21.

The actual value can be switched over to the 0-20 mA range (input impedance 300 Q) via DIP
switches S4 and S5 on control board A1. The actual speed value signal at maximum frequency must
correspond to 20 mA.

2. Actual current value:

20 mA
S4 0 1 0 x
S5 0

1 = Closed; 0 = Open; = Not assigned

x = 1 - BS2 directly connected to PE potential (factory setting)

x = 0 - BS2 connected across high-ohmic resistance to PE potential Input amplifier operates as
differential amplifier

Note:
As the value in P0014 increases, the frequency/speed resolution decreases as a result of the analog-
to-digital conversion. Problems may be encountered if the maximum frequency values are high
and large motors are used in which case it may be necessary to revert to frequency control with
DC tacho.

Torque control:

The actual speed value from the connected motor must be supplied via terminal X13.20 for the torque
control mode (switch settings and series resistors (if required) as for speed control via DC tacho).

8.8.3 Flying restart (A11) and kinetic buffer

175B

Flying restart:

If the flying restart option is used, it is advisable to operate the converter with a pulsed resistor.
The "Flying restart" option allows a motor, which is turning when the converter is switched on to be
"restarted on the fly".
The option is activated in P0064. The method by which the option operates depends on the control
mode parameterized in P0050:

a) Speed/torque control mode:

In these two control modes, the actual motor speed is supplied by a tacho. When the converter is
switched on, its output frequency is set to this value. After expiry of an excitation delay, the motor is
accelerated to the setpoint along the selected ramp.

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b) Frequency control:
In this control mode, the actual motor speed is not available • it must first be "found". The search is
made at rated motor current (P0008) between +fmax and -fmax (P0014) as shown in figure below. The
output frequency variation during the search is set in P0065.

f f

fmax fmax
t t
fmin fmin

Start in positive direction with last Start in negative direction with last
selected setpoint a positive value selected setpoint a negative value

Note:
When motor cannot be restarted, fault message F035 is output (extend search time if required).

Kinetic buffering:

When the generator buffering option is activated (via parameter P0056). The converter will continue to
operate during short interruptions in line power. The energy to operate the converter is temporarily
drawn from the driven machine by reducing the motor speed. The possible back-up period depends
on the type of driven machine (moment of inertia). It can be optimized by reducing the l-action
components (parameters P0069 and P0071 simultaneously (f control)).

The "kinetic buffering" function is inoperative when a PT1 board with speed/torque control is
employed.

8.9 Spare Parts

60B

Equipment Identifier Order No.

60 kVA 90 kVA 115 kVA 160 kVA
Product Description (SWE Item Number)
A1 6SE1200-1GA36-0
1x 1x 1x 1x
CCU control (470 102.9003.60)
A2 6SE1200-1EA50-0
1x
GAX 60 kVA (470 102.9205.00)
A2 6SE1200-1EA40-0
1x
GAX 90 kVA (470 102.9204.00)
A2 6SE1200-1EA30-0
1x
GAX 115 kVA (470 102.9203.00)
A2 6SE1200-1EA20-1
1x
GAX 160 kVA (470 102.9202.01)
A3 6SE1200-1AC50-0
1x 1x
Trigger circuit IGD2 60/90 kVA (470 102.9125.00)
A3 6SE1200-1AC00-1
1x 1x
Trigger circuit IGD2 115/160 kVA (470 102.9120.01)
A4 6SE1200-1CA20-0
1x 1x 1x 1x
DC-link precharging circuit PCU (470 102.9402.00)
A5 6SE1200-1DA50-0
1x 1x 1x 1x
Pulsed resistor electronics IGD3 (470 102.9505.00)
A7
6SE1300-2FA10-0
Pulsed resistor module 60/90 kVA 1x 1x
(470 209.9501.00)
IP00

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A7
6SE1300-2FA20-0
Pulsed resistor module 60/90 kVA 1x 1x
(470 209.9502.00)
IP20
A7
6SE1300-2FA30-0
Pulsed resistor module 115/160 kVA 1x 1x
(470 209.9503.00)
IP00
A7
6SE1300-2FA40-0
Pulsed resistor module 115/160 kVA 1x 1x
(470 209.9504.00)
IP20
A11 6SE1200-7AA10-1
1x 1x 1x 1x
Operator panel, complete, OPP (470 103.9001.01)
A41, A43, A45
6SY9637 3x
Thyristor module SKKH 105/12 E
A41, A43, A45
6SY9638 3x
Thyristor module SKKH 132/12 E
A41, A43, A45
6SY9640 3x
Thyristor module SKKH 131/12 E
A41, A43, A45
6SY9641 3x
Thyristor module SKKH 250/12 E
A52
Transistor module IGBT 6SY9642 1x 1x
BSM200GA100D
A52
Transistor module IGBT 6SY9643 1x 1x
BSM300GA100D
A110, A120, A210, A220, A310,
6SE1300-2EB10-0
A320 6x 6x
(470 209.9411.00)
RC2 circuit
A110, A210, A310 6SE1300-2ECOO-0
3x 3x
Pos. surge suppressor (470 209.9420.00)
A111, A121, A211, A221, A311,
A321
6SY9642 6x
Transistor module IGBT
BSM200GA100D
A111, A121, A211, A221, A311,
A321
6SY9643 6x
Transistor module IGBT
BSM300GA100D
A111, A112, A211, A212, A311,
A312, A121, A122, A221, A222,
A321, A322 6SY9642 12x
Transistor module IGBT
BSM200GA100D
A111, A112, A211, A212, A311,
A312, A121, A122, A221, A222,
A321, A322 6SY9643 12x
Transistor module IGBT
BSM300GA100D
A120, A220, A320 6SE1300-2EC10-0
3x 3x
Neg. surge suppressor (470 209.9421.00)
A300 6SE130O-2EB00-0
1x 1x
RCD circuit (470 209.9410.00)
C1, C2, C5, C6
6SY9463 4x
DC-link capacitors 6000 μF/350 V
C1-C10
6SY9463 6x 8x 10x
DC-link capacitors 6000 μF/350 V
6SE1300-2DA10-0
Capacitor bank 60 kVA 1x
(470 209.9301.00)
6SE1300-2DA20-0
Capacitor bank 90 kVA 1x
(470 209.9302.00)
Capacitor bank 115 kVA 6SE1300-2DA30-0 1x

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(470 209.9303.00)
6SE1300-2DA40-0
Capacitor bank 160 kVA 1x
(470 209.9304.00)
E1, E2
6SY9473 1x 1x 2x 2x
Fans
F1-F3
3NA3136 3x
Fuses for main switch 160A / 500V
F1-F3
3NA3244 3x
Fuses for main switch 250A / 500V
F1-F3
3NA3250 3x
Fuses for main switch 300A / 500V
F1-F3
3NA3260 3x
Fuses for main switch 400A / 550V
F101-F104
6SY9477 4x 4x 4x 4x
Fuse for GAX 8A / 500V
F31, F32
3NE8727 1x 2x
DC-link fuse 250A / 660V
F31, F32
6SY9644 1x 2x
DC-link fuse 350A / 660V
F50
3NE8725 1x 1x
Pulsed resistor fuse 200A / 660V
F50
6ZY1003-1AA00 1x 1x
Pulsed resistor fuse 315A / 660V
K1-3
6SY9542 2x 3x
Contactor (for cabinet-mounted units)
K1-3
6SY9543 2x 3x
Contactor (for cabinet-mounted units)
A21
FDC fan control 6SE1200-1HFOO-0 1x 1x 1x 1x
(for cabinet-mounted units)
L1
Reactor 220μH/3 x 90A 6SY9650 1x

L1
6SY9651 1x
Reactor 160μH/3 x 140A
L1
6SY9652 1x
Reactor 120μH/3 x 180A
L1
6SY9653 1x
Reactor 85μH/3 x 250A

General Tools:
Device Description / Product Description
Screwdriver Torx T10 till T30
Fluke 179 Multimeter Refer http://www.fluke.com/
H H

Fluke 321 Clamp meter Refer http://www.fluke.com/

H H

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9. ABB ACS 800

8B

9.1 Position of Components

61B

Control panel CDP312R

Heat Sink

Front Cover

Connection Box

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9.1.1 Main Circuit and Control

176B

Motor Control Optional module 1: RMBA, RAIO, RDIO,

and I/O Board RDNA, RLON, RIBA, RPBA, RCAN, RCNA,
(RMIO) RMBP, RETA or RTAC

Optional module 2: RTAC, RAIO or RDIO

External control via
analogue/digital
inputs and outputs DDCS communication option module 3:
RDCO-01, RDCO-02 or RDCO-03

Input power Output power

Brake chopper in frame sizes R2 and R3

(optional in other frame sizes)

R- UDC+ UDC-
R+

The table below describes the operation of the main circuit in short.

Component Description

Six-pulse rectifier Converts the three-phase AC voltage to DC voltage

Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage

Six-pulse IGBT Converts the DC voltage to AC voltage and vice versa. The motor operation is
inverter controlled by switching the IGBTs.

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9.2 Faults
62B

Fault Cause Counter-Measure

1. Power up the drive but do not start the
H

compressor, check actual signal 01.10 (=calculated

IGBT temperature)

- If temp is close to 100% even without

H

load, the measurement is not working.

- Components related to measurement are:
H

Current transducers (CTs), IGBTs, AINT-

Calculated IGBT junction temperature is too
01 & RDCU-02C
high
2. Start the drive and monitor the value of 01.10
- IGBT Junction temperature calculation is
H

ACS800 Temp based on measured IGBT case temperature

- If the value is low without load and starts
and measured output current.
H

to rise when the compressor is working,

the measurement is probably OK
- IGBT is too hot or the current or
temperature measurement is incorrect.
- Check the following:
H

-Is the drive installed to really hot ambient?

H

-Make sure that the compressor cabinet door filters

H

are not blocked.

-Check that the heat sinks are not blocked (is there
H

dust inside the drive?)

-Check that the fan (F41) is running and fan
H

transformer (T41) is tapped correctly H

Communication between the drive and the

PLC is lost

- Problem in cabling between drive

and PLC
Comm Module - Hardware problem in drive
- Problem in PLC

In case the problem is in the drive, either

RDCU-02C or RMBA-01 is broken

1. Compare actual DC voltage level (measured with

multimeter) with the value that the drive measures
(actual signal 01.07)

2. Check that there is correct software in the RDCU-

02C
- Atlas Copco uses standard software
- Permanent or temporary over
called ASXR (e.g. version ASXR7240)
voltage from network
- Unit type of the control board must
- Incorrect parameter setting for the
DC application
correspond the rating on the drive rate
Overvoltage plate (e.g. SR0550_5 in RMIO is correct
- Drive measures the DC voltage
software for ACS800-04M-0550-5)
incorrectly
- The software version and the unit type can
- Wrong software on drive
be checked by pressing the ‘Drive’ button
of the drive control panel

3. In case of incorrect measurement,

- Inspect wiring of APOW-01 – AINT-01 –
AINP-01
- Change AINT-01 and RDCU-02C

- Permanent or temporary under

Refer to DC Overvoltage.
voltage from network
- Incorrect parameter setting for the
DC application
In case the network and measurement are OK
Undervoltage - Inspect input bridge wiring, measure
- The drive measures the DC
H

thyristor/diode modules and main fuses

voltage incorrectly
- Change AINP-01
- Wrong software on drive

1. Check first that there is no earth fault in the motor

H

cable connection box (e.g. a conducting wire of one

Either a real earth fault caused by motor cable is touching or close to the motor frame)
Earth Fault cabling or motor or a problem in VSD earth
fault detection 2. Open motor cables from the VSD terminals and
H

make insulation resistance test for the motor and the

motor cable

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3. If the problem is in the frequency converter

- Make sure that there are no external
objects in the output busbars of the VSD
- HChange current transducers, AINT-01 and
RDCU-02C H

1. Check the motor, motor cable and motor cable

H

connections
Motor Phase
Loss 2. If the motor and the cabling are OK, then turn
parameter 30.16 to OFF

1. Check the compressor

H

The drive can’t produce enough torque to

Motor Stall get the motor running 2. Make sure that there are default Atlas Copco
parameter values stored into the RDCU-02C

1. If the problem is caused by VSD hardware or

Output current exceeds trip limit parameter setup problem, make sure that there are
default Atlas Copco parameter values stored into the
- Problems in motor or motor cable RDCU-02C
Overcurrent - Process problem or parameter
setup problem 2. If hardware problem is suspected, change
H

- Hardware or parameter setup - Current Transducers

H

problem - AINT-01
H

- RDCU-02C
H H

Local control has been selected to control

panel or to PC and the communication
between local control location and drive is Release local control from CDP312R by pressing
lost (Loc/Rem) button of the panel. Letter ‘L’ (which
Panel Loss indicates local control) will disappear from the panel.
This happens if local control is selected to Now the panel can be disconnected.
CDP312R and then the panel is
disconnected from the drive

1. Change RDCU-02C, AINT-01 and optical fibre

H

between the boards

2. In case the faults are sporadic and changing the

Communication between RMIO and AINT is above mentioned components does not help Æ
PPCC Link lost or there are too many communication contact your local ABB
errors
3. If the fault is active all the time and changing
RDCU and AINT did not help,
- HChange current transducers
- Change APOW-01
1. Find out if the short circuit is in the drive or in the
H

motor
- Disconnect motor from the drive output
H

- Set parameter 99.04 to SCALAR

The fault is activated if the short circuit
H

- Select local control from CDP312R

protection of the drive detects that the IGBT
H

- No short circuit fault Æ the problem is in

switching has not been successful. The
H

the motor or in the motor cable

reasons are:
Short Circuit - Short circuit fault Æ the problem is in the
H

drive
-Hardware problem in the drive
-Short circuit in the motor or in the motor
2. If hardware fault in VSD, change IGBTs of the
cable
H

drive

3. Remember to set parameter 99.04 back to DTC if

you have changed it to SCALAR
1. Check that there is a jumper on RDCU connector
X22 between pins 8 – 11
Start Interlock
2. If the jumper is OK, change RDCU-02C

Make sure that there is a jumper on AINT-01

Start Inhibit connector X5

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1. Check that all input fuses are OK

2. Measure supply network voltage between phases

H

3. In case of hardware fault in the drive

- Check wiring of AINP-01 – thyristor/diodes
H

– input phase busbars

- Change input bridge thyristor/diode
H

modules
- Change AINP-01
Supply Phase DC voltage ripple too high
- If the drive is old or it has been in stock for
H

long time, the problem can be caused by

low capacitance value of the DC-
capacitors
- If drive is in storage for more than one
year, let it be powered up for several
hours without starting the motor
- If the drive is in operation for 10 years or
H

more, change the DC capacitors to new

ones H

1. Check wiring between RDCU-02C – CDP312R

2. Measure if +24V is coming to the RDCU-02C

H

terminal X34

3. If +24V is OK, change the RDCU-02C

4. If no +24V on terminal X34, measure DC-bus

voltage with multimeter
No text on the - Be careful when measuring the DC-bus
CDP voltage! Remember that there can be almost
1000V DC in the DC-bus
- If the DC-bus voltage is up, but 24V DC
auxiliary voltage is missing, Check APOW-01
wiring and change APOW-01 if wiring is OK
- If the DC-bus voltage is 0V,
a) Measure condition of charging diode and
H

change it if broken
b) Measure condition of charging resistor and
change it if broken

1. Check condition of the main fuses

2. Check that the fan is not jammed

H

- Rotate the fan by hand to see that it can rotate

H

freely

3. Measure fan fuses (F41 & F42) (should be close

H

to 0 Ohms)

4. Measure fan transformer (T41) resistance from

H

Main Fan is the primary and secondary side (should be low

not running resistance)

5. Measure the fan transformer output voltage when

H

the drive is powered up

- Be careful when doing this! Remember that
H

there is almost 1000V in the DC-bus

- The output should be about 230V
H

6. If 230V is coming to the fan terminal X41, then the

H

fan or fan capacitor is broken

-Change fan and fan capacitor C41
H H

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9.3 Repair Instructions

63B

9.3.1 Measuring key electrical components

17B

9.3.1.1 Charging Resistor (R11)

The resistance of the charging resistor must be roughly 3-4 Ohms (Resistance measurement of a
multimeter).

9.3.1.2 Charging Diode (V17)

297B

The voltage must be ~ 0.5V when measured in conducting direction and Open Loop in reverse
direction. (Diode measurement of a multimeter.)

9.3.1.3 Current Transducers (U31, U32, U33) (CTs)

298B

1. Measure resistance between all three terminals of the CT.

2. There are total three CTs in one drive; the values found from the three CTs should be almost equal.
Note: Measuring CT with multimeter does not necessarily reveal if it is faulty!

Different CT types are used in different size units; the measurement results of different CT types vary
significantly. (CTs within one unit are always same type.)

9.3.1.4 Fan Fuses (F41, F42)

29B

Resistance should be close to 0 Ohms.

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9.3.1.5 Fan Transformer (T41)

30B

1. Primary side resistance (between N – 500 terminals) Æ ~ 30 Ohms

2. Secondary side resistance (between 0 – 230 terminals) Æ ~ 7 Ohms

9.3.1.6 Thyristor/diode modules (V11, V12, V13)

301B

1. Thyristor gate resistance about 15-20 Ohms (value depends on the module type).

2. Thyristor, in both directions Æ Open Loop (in Diode area)

3. Diode in conducting direction Æ 0,3 – 0,4 V (in Diode area)

4. Diode in reverse direction Æ Open Loop (in Diode area)

9.3.2.7 IGBT Modules (V21, V22, V23)

302B

Measure IGBT diodes (in Diode area)

DC+ to output busbars:

Conducting direction Æ ~ 0,4 V
Reverse direction Æ Open Loop

DC– to output busbars:

Conducting direction Æ ~ 0,4 V
Reverse direction Æ Open Loop

NOTE:
Measuring Thyristor/diode or IGBT modules with multimeter does not necessarily reveal if it is faulty!

The measured values of all same type semiconductor modules in the same unit should be close to
each other.

9.4 Important Parameters

64B

In Standard Application Program, set parameter 16.9 CTRL BOARD SUPPLY to EXTERNAL 24V if
the RMIO board is powered from an external supply.

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VSD Repair Manual

9.5 Installation
65B

See 218BXIII. Technical Data

Plan the installation.
See 304B9.5.2.1 Planning the Electrical Installation
Check the ambient conditions, ratings, required
cooling airflow, input power connection, compatibility For compliance with the European Union EMC
of the motor, motor connection, and other technical Directive, see 218BXIII. Technical Data: CE
data. Marking
Select the cables. Option manual (if optional equipment is included)

See 178B9.5.1 Mechanical Installation

Unpack and check the units.
If the converter has been non-operational for more
Check that all necessary optional modules and than one year, the converter DC link capacitors
equipment are present and correct. need to be reformed. Ask ABB for instructions.
Only intact units may be started up.

The ACS800-01/U1: Type code.

If the drive is about to be connected to an IT
(ungrounded) system, check that the drive is not For instructions on how to disconnect the EMC
equipped with EMC filtering. filtering, contact ABB.

See 178B9.5.1 Mechanical Installation

Check the installation site.
See 218BXIII. Technical Data

See 178B9.5.1 Mechanical Installation

Install the drive on a wall or in a cabinet.

See 218BXIII. Technical Data

Route the cables.
See 305B9.5.2.2 Electrical Installation Steps: CE

305B9.5.2.2 Electrical Installation Steps

Check the insulation of the motor and the motor cable.

305B9.5.2.2 Electrical Installation Steps

Connect the power cables.

305B9.5.2.2 Electrical Installation Steps, Motor

Connect the control and auxiliary control cables. control and I/O board (RMIO), and the optional
module manual delivered with the module.

See
Check the installation. 217BXII. Installation Checklist

Appropriate firmware manual

Commission the drive.

See 218BXIII. Technical Data

Commission the optional brake chopper (if present).

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9.5.1 Mechanical Installation

178B

NOTE

• ACS800-01: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place
the unit only on its back.

• ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt
the unit. The unit will overturn from a tilt of about 6 degrees.

• Make sure that dust from drilling does not enter the drive when installing. Electrically
conductive dust inside the unit may cause damage or lead to malfunction.

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding.

• Before adjusting the drive and putting it into service, make sure that the motor and all driven
equipment are suitable for operation throughout the speed range provided by the drive. The
drive can be adjusted to operate the motor at speeds above and below the speed provided by
connecting the motor directly to the power line.

• Do not activate automatic fault reset functions of the Standard Application Program if
dangerous situations can occur. When activated, these functions will reset the drive and
resume operation after a fault.

• Do not control the motor with the disconnecting device (means); instead, use the control
panel keys, or commands via the I/O board of the drive. The maximum allowed number of
charging cycles of the DC capacitors (i.e. power-ups by applying power) is five in ten minutes.

• If an external source for start command is selected and it is ON, the drive (with Standard
Application Program) will start immediately after fault reset unless the drive is configured for
3-wire (a pulse) start/stop.

• When the control location is not set to Local (L not shown in the status row of the display), the
stop key on the control panel will not stop the drive. To stop the drive using the control panel,
press the LOC/REM key and then the stop key.

Permanent magnet motor

These are additional warnings concerning permanent magnet motor drives.

Do not work on the drive when the permanent magnet motor is rotating.

Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet
motor feeds power to the intermediate circuit of the drive and the supply connections become live.

9.5.1.1 Mechanical Installation Steps

30B

1. The drive is delivered in a box that also contains:

• Plastic bag containing: screws (M3), clamps and cable lugs (2 mm2, M3) for grounding the
control cable screens
• Connection box (screws and clamps included)
• Residual voltage warning stickers
• Hardware manual
• Appropriate firmware manuals and guides
• Optional module manuals
• Delivery documents.
Unpack the unit.

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VSD Repair Manual

2. Delivery check:

Check that there are no signs of damage. Before attempting installation and operation, check the
information on the type designation label of the drive to verify that the unit is of the correct type. The
label includes an IEC and NEMA rating, UL, C-UL, CSA and CE markings, a type code and a serial
number, which allow individual recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively.
The remaining digits complete the serial number so that there are no two units with the same serial
number.

The type designation label is attached to the heat sink and the serial number label to the upper part of
the back plate of the unit. Example labels are shown below.

Before installation

The drive must be installed in an upright position with the cooling section facing a wall. Check the
installation site according to the requirements below. Refer to Dimensional drawings for frame details.

Requirements for the installation site

See XIII. Technical Data for the allowed operation conditions of the drive.
X X

Wall
The wall should be as close to vertical as possible, of non-flammable material and strong enough to
carry the weight of the unit. Check that there is nothing on the wall to inhibit the installation.

Floor
The floor/material below the installation should be non-flammable.

Free space around the unit

Required free space around the drive to enable cooling airflow, service and maintenance is shown
below in millimeters and [inches]. When mounting IP 55 units above one another, leave 200 mm (7.9
in.) free space above and below the unit.

See fig on next page.

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IP 21 (UL 1) IP 55 (UL 12)

Air flow (side view)

Mounting the drive on the wall

• Using the mounting template cut from the package; mark the locations for the four holes. The
mounting points are shown in Dimensional drawings.
• Fix the screws or bolts to the marked locations.
• IP 55 (UL 12) units: Remove the front cover by undoing the fixing screws.
• Position the drive onto the screws on the wall.
Note: Lift the drive by its chassis (R6: by its lifting holes), not by its cover.
• Tighten the screws in the wall securely.

See fig on next page.

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IP 55 (UL 12)

UL 12 units
Install the hood delivered with the drive 50 mm (2.0 in.) above the top of unit.

Cabinet installation
The required distance between parallel units is five millimeters (0.2 in.) in installations without the front
cover. The cooling air entering the unit must not exceed +40 °C (+104 °F).

Preventing cooling air recirculation

Prevent air recirculation inside and outside the cabinet.

HOT
Main air flow out AREA

Air baffle plates

COOL AREA

Main air flow in

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Unit above another

Lead the out-coming cooling air away from the unit above.

Max. +40 0C (+104 0F)

9.5.2 Electrical Installation

179B

9.5.2.1 Planning the Electrical Installation

304B

Checking the compatibility of the motor

See XIII. Technical Data for the drive ratings and the motor connection data.
X X

WARNING!
Operation is not allowed if the motor nominal voltage is less than 1/2 of the drive nominal input
voltage. The allowed range of the motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control
and 0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.

Protecting the motor winding and bearings

The voltage of the pulses can be almost double at the motor terminals, depending on the motor cable
properties. This in turn can cause additional stress on the motor insulation. The stress on motor
insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing
currents.

To avoid damage to motor bearings, insulated N-end (non-driven end) bearings and output filters from
ABB must be used according to the following table. In addition, the cables must be selected and
installed according to the instructions given in this manual. Three types of filters are used individually
or in combinations:
• Optional du/dt filter (protects motor insulation system and reduces bearing currents)
• Common mode filter (mainly reduces bearing currents)
• Light common mode filter (mainly reduces bearing currents)

The common mode filter is composed of toroidal cores installed onto the output busbars inside the
drive at the factory.

Requirements table
The following table shows how to select the motor insulation system and when optional ABB du/dt
filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required.
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following
requirements or improper installation may shorten motor life or damage the motor bearings.

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Motor Nominal Requirement for

type mains
Motor ABB du/dt filter, insulated N-end bearing and ABB
voltage (AC
insulation common mode filter
line
Manufacturer

system 100 kW < PN<

voltage) PN> 350 kW
PN < 100 kW and 350 kW
or
frame size < IEC or
frame size > IEC
315 frame size > IEC
400
315
134 HP < PN<
PN< 134 HP
469 HP
and frame size < PN> 469 HP
or frame size >
NEMA 500
NEMA 500
A Random- UN< 500 V Standard - +N + N + CMF
B wound
B 500 V < UN< + du/dt + N +
M2_ and Standard + du/dt + du/dt + N
600 V LCMF
M3_
or
Reinforced - +N + N + CMF
600 V < UN< + du/dt + N +
Reinforced + du/dt + du/dt + N
690 V LCMF
Form- 380 V < UN< Standard n.a. + N + CMF + N + CMF
wound 690 V
HXR and
AM_
Old* form- 380 V < UN< Check with the + du/dt with voltages over 500 V + N + CMF
wound 690 V motor
HX_ and manufacturer.
modular
Random- 380 V < UN< Check with the + du/dt with voltages over 500 V + N + CMF
wound 690 V motor
HXR and manufacturer.
AM_

Motor Nominal Requirement for

type mains
Motor ABB du/dt filter, insulated N-end bearing and ABB
voltage (AC
insulation common mode filter
line
Manufacturer

system 100 kW < PN<

voltage) PN < 100 kW PN> 350 kW
350 kW
and or
or
frame size < IEC frame size > IEC
frame size > IEC
315 400
315
134 HP < PN<
PN< 134 HP and
469 HP or frame
frame size < PN> 469 HP
size >
NEMA 500
NEMA 500
N Random- UN< 420 V Standard: ÛLL - + N or CMF + N + CMF
O wound = 1300 V
N and form-
- wound 420 V < UN< Standard: = + du/dt + du/dt + N + du/dt + N +
A 500 V ÛLL 1300 V CMF
or
B
B + du/dt + CMF
or
Reinforced: - + N or CMF + N + CMF
ÛLL = 1600 V,
0.2
microsecond
rise time
500 V < UN< Reinforced: = + du/dt + du/dt + N + du/dt + N +
600 V ÛLL1600 V LCMF
or
+ du/dt + CMF

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or
Reinforced: = - + N or CMF + N + CMF
ÛLL 1800 V

600 V < UN< Reinforced: = + du/dt + du/dt + N + du/dt + N +

690 V ÛLL 1800 V LCMF
Form- 600 V < UN< Reinforced: = n.a. N + CMF N + CMF
wound 690 V ÛLL 2000 V,
0.3
microsecond
rise time

Note 1: The abbreviations used in the table are defined below.

Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filter at the output of the drive
CMF common mode filter +E208 (3 toroidal cores)
LCMF light common mode filter +E209 (1 toroidal core)
N-end bearing:
N
insulated motor non-driven end bearing
Motors of this power range are not available as standard units. Consult the motor
n.a.
manufacturer.

Note 2: Explosion-safe (EX) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.

Note 3: High-output motors and IP 23 motors

For motors with higher rated output than what is stated for the particular frame size in EN 50347
(2001) and for IP 23 motors, the requirements of range “100 kW < PN < 350 kW” apply to motors with
40 kW < PN < 100 kW. The requirements of range “PN > 350 kW” apply to motors with PN within the
range of “100 kW < PN < 350 kW”.

Note 4: HXR and AMA motors

All AMA machines (manufactured in Helsinki) to be supplied by a drive have form-wound windings. All
HXR machines manufactured in Helsinki since 1997 have form-wound windings.

Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Select according to non-ABB motors.

Note 6: Resistor braking of the drive

When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20%.
The voltage increase should be taken into consideration when determining the motor insulation
requirement.

Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.

Permanent magnet synchronous motor

Only one permanent magnet motor can be connected to the inverter output.

Install a safety switch between a permanent magnet synchronous motor and the motor cable. The
switch is needed to isolate the motor during any maintenance work in the drive.

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Supply connection
Disconnecting device (means)
ACS800-01, ACS800-U1, ACS800-02 and ACS800-U2 without the enclosure extension, ACS800-04,
ACS800-U4:
Install a hand-operated input-disconnecting device (means) between the AC power source and the
drive. The disconnecting device must be of a type that can be locked to the open position for
installation and maintenance work.

ACS800-U2 with the enclosure extension, ACS800-07 and ACS800-U7:

These units are equipped with a hand-operated input-disconnecting device (means), which isolates
the drive and the motor from the AC power as standard. The disconnecting device does not, however,
isolate the input busbars from the AC power. Therefore during installation and maintenance work on
the drive, the input cables and busbars must be isolated from the input power with a disconnector at
the distribution board or at the supplying transformer.

EU:
To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the
disconnecting device must be one of the following types:
• A switch-disconnector of utilization category AC-23B (EN 60947-3)
• A disconnector that has an auxiliary contact that in all cases causes switching devices to break
the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)
• A circuit breaker suitable for isolation in accordance with EN 60947-2

US:
The disconnecting means must conform to the applicable safety regulations.

Thermal overload and short-circuit protection

WARNING!
If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker
must be used for protecting each cable and motor. These devices may require a separate fuse to cut
off the short-circuit current.

Mains cable (AC line cable) short-circuit protection

Always protect the input cable with fuses. Size the fuses according to local safety regulations;
appropriate input voltage and the rated current of the drive (see Technical Data).

ACS800-01/U1, ACS800-02/U2 without enclosure extension and ACS800-04/U4:

When placed at the distribution board, standard gG (US: CC or T for the ACS800-U1; T or L for the
ACS800-U2 and the ACS800-U4) fuses will protect the input cable in short-circuit situations, restrict
drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.

Drive AC fuses (ACS800-07/U7 and ACS800-02/U2 with enclosure extension):

ACS800-07/U7 units and ACS800-02/U2 units with enclosure extension are equipped with standard
gG or optional aR fuses listed in Technical Data. The fuses restrict drive damage and prevent damage
to adjoining equipment in case of a short-circuit inside the drive.

Operating time of the fuses:

Check that the operating time of the fuse is below 0.5 seconds. The operating time depends on
the fuse type (gG or aR), supply network impedance and the cross-sectional area, material and length
of the supply cable. In case the 0.5 seconds operating time is exceeded with gG fuses, ultrarapid (aR)
fuses will in most cases reduce the operating time to an acceptable level. The US fuses must be of
the “noontime delay” type.

WARNING!
Circuit breakers are not capable of providing sufficient protection because they are inherently slower
than fuses. Always use fuses with circuit breakers.

Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the unit against
ground faults in the motor and the motor cable. This is not a personal safety or a fire protection

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feature. The ground fault protective function can be disabled with a parameter, refer to the appropriate
ACS 800 Firmware Manual.

Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control station and at other
operating stations where emergency stop may be needed.
Pressing the stop key on the control panel of the drive, or turning the operating switch of the drive
in cabinet installed units from position “ON” to “OFF” does not generate an emergency stop of the
motor or separate the drive from dangerous potential.

ACS800-07/U7
An emergency stop function is optionally available for stopping and switching off the whole drive. Two
stop categories according to IEC/EN 60204-1 (1997) are available: immediate removal of power
(Category 0) and controlled emergency stop (Category 1).

Restarting after an emergency stop

After an emergency stop, the emergency stop button must be released and the drive started by
turning the operating switch of the drive in cabinet installed units from position “ON” to “START”.

Prevention of Unexpected Start (ACS800-07/U7 only)

The drive can be equipped with an optional Prevention of Unexpected Start function according to
standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037:1996.

By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical
parts of the machinery can be performed without switching off the AC power supply to the drive. The
drive and machinery must be stopped using the appropriate stopping mode before using this function.
The function must not be used for stopping the drive when the drive is running.
The operator activates the Prevention of Unexpected Start function by opening a switch on a control
desk. An indicating lamp on the control desk will light, signaling that the prevention is active. The
switch can be locked out.

The user must install on a control desk near the machinery:

• Switching/disconnecting device for the circuitry. “Means shall be provided to prevent inadvertent,
and/or mistaken closure of the disconnecting device.”
EN 60204-1: 1997.
• Indicating lamp; on = starting the drive is prevented, off = drive is operative.

WARNING!
The Prevention of Unexpected Start function does not disconnect the voltage of the main and auxiliary
circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can
only be carried out after isolating the drive system from the main supply.

9.5.2.2 Electrical Installation Steps

305B

CAUTION!
Make sure that the drive is disconnected from the mains (input power) during installation. If the drive
is already connected to the mains, wait for 5 min after disconnecting mains power.

Checking the insulation of the assembly

Every drive has been tested for insulation between the main circuit and the chassis (2500 V rms 50
Hz for 1 second) at the factory. Therefore, do not make any voltage tolerance or insulation resistance
tests (e.g. hi-pot or megger) on any part of the drive. Check the insulation of the assembly as follows.

WARNING!
Check the insulation before connecting the drive to the mains. Make sure that the drive is
disconnected from the mains (input power).

1. Check that the motor cable is disconnected from the drive output terminals U2, V2 and W2.

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2. Measure the insulation resistances of the motor cable and the motor between each phase and the
Protective Earth by using a measuring voltage of 1 kV DC. The insulation resistance must be
higher than 1 Mohm.

IT (ungrounded) systems
Disconnect the EMC filter capacitors of selections +E202 and +E200 before connecting the drive to an
ungrounded system. For detailed instructions on how to do this, please contact your local ABB
distributor.

WARNING!
If a drive with EMC filter selection +E202 or +E200 is installed on an IT system [an ungrounded power
system or a high resistance-grounded (over 30 ohms) power system], the system will be connected to
earth potential through the EMC filter capacitors of the drive. This may cause danger or damage the
unit.

Connecting the power cables

For alternatives, see

Planning the electrical
installation:
Disconnecting device
(means)

1), 2)
If shielded cable is used (not required but recommended), use a separate PE cable (1) or a cable with
a grounding conductor (2) if the conductivity of the input cable shield is < 50 % of the conductivity of
the phase conductor.
Ground the other end of the input cable shield or PE conductor at the distribution board.

3) 360 degrees grounding recommended if shielded cable

4) 360 degrees grounding required

5) Use a separate grounding cable if the conductivity of the cable shield is < 50 % of the conductivity
of the phase conductor and there is no symmetrically constructed grounding conductor in the cable
(see 9.5.2.1 Planning the Electrical Installation/ Selecting the power cables).
X X

Note:
If there is a symmetrically constructed grounding conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor
ends.

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Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra wear.

Grounding of the motor cable shield at the motor end

For minimum radio frequency interference:
• Ground the cable shield 360 degrees at the lead-through of the motor terminal box.

• Or ground the cable by twisting the shield as follows:

Flattened width > 1/5 · length.

Conductor stripping lengths

Strip the conductor ends as follows to fit them inside the power cable connection terminals.

Frame Stripping length

size mm in.
R2, R3 10 0.39
R4, R5 16 0.63
R6 28 1.10

Wall installed units (European version)

Power cable installation procedure
1. Remove the front cover (in frame size R6 the lower front cover) by releasing the retaining clip with
a screwdriver and lifting the cover from the bottom outwards.
For IP 55 units, see 9.5.1 Mechanical Installation/Mounting the drive on the wall.
X X

2. Slide the back plate of the connection box to the holes below the drive.
3. Fasten the back plate to the drive frame with two screws / three screws in frame size R6.

4. Cut adequate holes into the rubber grommets and slide the grommets onto the cables. Slide the
cables through the holes of the bottom plate.

5. Strip off the plastic sheath of the cable under the 360 degrees grounding clamp. Fasten the clamp
onto the stripped part of the cable.

6. Connect the twisted shield of the cable to the grounding terminal. Note: cable lugs are needed in
frame sizes R2 and R3.

7. Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals and the phase
conductors of the motor cable to the U2, V2 and W2 terminals.

8. Fasten the bottom plate of the connection box with two screws to the already fastened back plate
and slide the grommets into their place.

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9. Secure the cables outside the unit mechanically. Connect the control cables as described in
section connecting the control cables. Fasten the covers (see Fastening the control cables and
covers).

Connection box (IP 21)

Back plate Fastening hooks

Fastening screws

360 degrees grounding

clamp Grommet

Input cable entry Motor cable entry

Brake resistor cable entry
Control cable entry
Bottom plate
Fasten the
control
cables
between
these plates
with cable
ties Cover

Frame sizes R2 to R4 Frame size R5

Input power cable Motor cable

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Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 4/0 AWG) cables]

Isolate the ends of Connection plate

the cable lugs with fastening screws
PE insulating tape or
shrink tubing

Frame size R6: Cable terminal installation (95 to 185 mm2 cables)

PE

a. Connect the cable to the terminal.

b. Connect the terminal to the drive.

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Wall installed units (US version)

Frame sizes R2 to R4

Input power cable Motor cable

1. Remove the front cover (in frame size R6 the lower front cover) by releasing the retaining clip with
a screwdriver and lifting the cover from the bottom outwards.

2. Make the cable entry holes in the gland box by breaking off the suitable knockout plates with a
screwdriver.

3. Fasten the cable glands to the opened holes of the gland box.

4. Fasten the gland box to the frame with two screws / three screws in frame size R6.

5. Lead the cables through the glands to the inside of the gland box.

6. Connect the PE conductors of the input and motor cables to the grounding terminal.
Note: cable lugs are needed in frame sizes R2 and R3. Connect the separate PE conductor (if
used) to the grounding terminal.

7. Connect the phase conductors of the input cable to the U1, V1 and W1 terminals and the phase
conductors of the motor cable to the U2, V2 and W2 terminals.

For frame size R6, see Wall installed units (European version) / figure Frame size R6: Cable lug
installation [16 to 70 mm2 (6 to 4/0 AWG) cables]. To meet UL requirements, use UL listed cable lugs
and tools given below or corresponding.

Compression lug Crimping tool

Wire size
kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps
Burndy YAV6C-L2 Burndy MY29-3 1
6
Ilsco CCL-6-38 Ilsco ILC-10 2
Burndy YA4C-L4BOX Burndy MY29-3 1
4
Ilsco CCL-4-38 Ilsco MT-25 1

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Burndy YA2C-L4BOX Burndy MY29-3 2

2 Ilsco CRC-2 Ilsco IDT-12 1
Ilsco CCL-2-38 Ilsco MT-25 1
Burndy YA1C-L4BOX Burndy MY29-3 2
Ilsco CRA-1-38 Ilsco IDT-12 1
1 Ilsco CCL-1-38 Ilsco MT-25 1
Thomas & Thomas &
54148 TBM-8 3
Betts Betts
Burndy YA25-L4BOX Burndy MY29-3 2
Ilsco CRB-0 Ilsco IDT-12 1
1/0 Ilsco CCL-1/0-38 Ilsco MT-25 1
Thomas & Thomas &
54109 TBM-8 3
Betts Betts
Burndy YAL26T38 Burndy MY29-3 2
Ilsco CRA-2/0 Ilsco IDT-12 1
2/0 Ilsco CCL-2/0-38 Ilsco MT-25 1
Thomas & Thomas &
54110 TBM-8 3
Betts Betts
Burndy YAL27T38 Burndy MY29-3 2
Ilsco CRA-3/0 Ilsco IDT-12 1
3/0 Ilsco CCL-3/0-38 Ilsco MT-25 1
Thomas & Thomas &
54111 TBM-8 3
Betts Betts
Burndy YA28-R4 Burndy MY29-3 2
Ilsco CRA-4/0 Ilsco IDT-12 1
4/0 Ilsco CCL-4/0-38 Ilsco MT-25 2
Thomas & Thomas &
54112 TBM-8 4
Betts Betts

8. Tighten the clamping nuts of the cable glands.

After connecting the control cables, fasten the front covers.

Warning sticker
There are warning stickers in different languages inside the packing box of the drive. Attach a warning
sticker in the language of your choice onto the plastic skeleton above the power cable terminals.

Cabinet installation (IP 21, UL type 1)

The drive can be installed in a cabinet without the connection box and front cover.
It is recommended:

• To ground the cable shield 360 degrees at the cabinet entry

• To lead the cable unstripped as close to the terminals as possible.

Secure the cables mechanically.

Protect the RMIO board terminals X25 to X27 against contact when input voltage exceeds 50 VAC.

Frame size R5
Cover the power cable terminals as follows:

1. Cut holes for the installed cables into the clear plastic shroud.
2. Press the shroud onto the terminals.

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Removal of the shroud with a screwdriver:

Frame size R6
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud in cable lug installations.
2. Press the shroud onto the terminals.

View of cable terminal installation

Removal of the shroud by lifting up with a screwdriver from the corner:

Connecting the control cables

Lead the cable through the control cable entry (1).

Connect the control cables as described below. Connect the conductors to the appropriate detachable
terminals of the RMIO board [refer to chapter Motor control and I/O board (RMIO)]. Tighten the
screws to secure the connection.

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Terminals

Frame sizes R2 to R4
U

The control cable connection terminals are

exposed when the control panel mounting
platform is turned aside by pulling this knob. Detachable connection terminals (pull up)
Be careful; do not use excess force when
X39 for control panel cable
pulling.

Optional module 1

Optional module 2
I/O cables: Ground the DDCS communication
control cable shields in the option module 3:
holes with screws. See RDCO
section 360 degrees
grounding. Place the warning
sticker here

(P.T.O.)

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Frame sizes R5 and R6

View of frame size R6

Control panel

Optional module 2

Optional module 1 DDCS communication option module 3: RDCO

Place the warning sticker here

Control cable
grounding: see Detachable connection terminals (pull up)
section 360
degrees
grounding

360 Degrees Grounding:

Insulation

Double shielded cable Single shielded cable

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When the outer surface of the shield is covered with non-conductive material
• Strip the cable carefully (do not cut the grounding wire and the shield)
• Turn the shield inside out to expose the conductive surface.
• Wrap the grounding wire around the conductive surface.
• Slide a conductive clamp onto the conductive part.
• Fasten the clamp to the grounding plate with a screw as close as possible to the terminals where
the wires are about to be connected.

Connecting the shield wires

Single shielded cables: Twist the grounding wires of the outer shield and connect them through the
shortest possible route to the nearest grounding hole with a cable lug and a screw. Double shielded
cables: Connect each pair cable shield (twisted grounding wires) with other pair cable shields of the
same cable to the nearest grounding hole with a cable lug and a screw.

Do not connect shields of different cables to the same cable lug and grounding screw.

Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high-
frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be grounded directly at both ends if they
are in the same ground line with no significant voltage drop between the end points.

Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its
return wire reduces disturbances caused by inductive coupling.

See Installation Checklist in ADDENDUM.

H

Warranty Acceptance and Rejection

6B

The manufacturer warrants the equipment supplied against defects in design, materials and
workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date
of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty
period different to the above and refer to local terms of liability as defined in the supply contract.

The manufacturer is not responsible for:

• Any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient
conditions of the drive do not fulfil the requirements specified in the documentation delivered with
the unit and other relevant documentation.
• Units subjected to misuse, negligence or accident
• Units comprised of materials provided or designs stipulated by the purchaser.

In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,
incidental or consequential damages, losses or penalties.

If you have any questions concerning your ABB drive, please contact the local distributor or ABB
office.

The technical data, information and specifications are valid at the time of printing. The manufacturer
reserves the right to modifications without prior notice.

9.7 Handling Software and Firmware

67B

9.7.1 DriveSize
180B

DriveSize is a PC program for helping the user to select the optimal motor, frequency converter and
transformer, especially in those cases where a straightforward selection from a catalogue is not
possible. Additionally it can be used to compute currents, network harmonics and to create
documents about the dimensioning based on actual load.

DriveSize contains the current versions of the ABB motor and frequency converter catalogues. The
default values make DriveSize simple to use, but the user is provided with ample options for drive

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selection. The shortcut keys make drive selection easy while giving the optimal dimensioning result. A
manual selection mode is also supported.
DriveSize is for drive system components:
• 3-phase standard, customized, Ex and user defined motors
• ABB low voltage AC drives
• Transformers

DriveSize features
• Selects the optimal motor, drive unit, supply unit and transformer
• Calculates network harmonics for a single supply unit or for the whole system
• Allows importation of own motor database
• Supplies dimensioning results in graphical and numerical format
• Prints and saves the results

The DriveSize PC program can be downloaded from:

http://www.abb.com/motors&drives
H

Æ Drives
Æ Drive PC Tools
Æ DriveSize

9.7.3 DriveWindow 2
18B

With DriveWindow the user is able to follow the operation of several drives simultaneously by
collecting the actual values from the drives onto a single screen or printout.

Additionally, the client part of DriveWindow may reside on one intranet PC, and the server on another
PC closer to the drives. This enables easy plant-wide monitoring with two PCs.

DriveWindow uses a high-speed fibre optic cable network with DDCS communication protocol. A fibre
optic communication card inside the computer is needed.

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Monitoring Drives
With DriveWindow you can monitor several drives simultaneously. The history buffer makes it
possible to record a large amount of data in the PC’s memory. The drive’s data logger can be
accessed with DriveWindow and viewed in graphical form. The fault logger inside the drive
automatically documents every fault, warning and event, which occurs. The fault history stored in the
drive can be uploaded to your computer.

Back-up Functions
Drive parameters can be saved to the PC with DriveWindow, and can easily be downloaded back to
the drive whenever needed. The same goes for the software. DriveWindow allows the entire control
board software to be saved and restored later, if needed. This makes it possible to use one control
board as a spare part for many different sizes of drives.

DriveWindow 2 features
• Easy-to-use tool for commissioning and maintenance
• Several drives connected and monitored at the same time
• Monitor, edit or save signals and parameters, clear graphical presentation
• High-speed communication between PC and drive
• Versatile back-up functions
• View data collected and stored in the drive
• Fault diagnostics; DriveWindow indicates the status of drives, and also reads fault history data
from the drive

9.7.4 DriveWindow Light 2

182B

It supports the following software: standard application, pump control, and spinning and traverse
control. DriveWindow Light uses the drive’s panel connector for communication.

DriveWindow Light 2 features

• Viewing and setting parameters in offline mode
• Editing, saving and downloading parameters
• Comparing parameters
• Graphical and numerical signal monitoring
• Drive control

DriveWindow Light requirements

• Windows 98/NT/2000/XP
• Free serial port from a PC
• Free control panel connector
• NPCU-01 PC connection unit

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9.7.5 DriveOPC
183B

DriveOPC is a software package, which allows OLE for Process Control (OPC) communication
between Windows applications and ABB industrial drives. It allows Object Linking and Embedding
(OLE) for Process Control (OPC) communication. This OPC server is an ideal tool for integrating ABB
industrial drives and commercial PC software, and creating PC based control and monitoring systems.

Remote Monitoring
DriveOPC enables remote connection over LAN (local area networks). The remote PC can be
connected through its IP address (e.g. “164.12.43.33”) or by the DNS name (e.g. “Gitas213”).

OPC Based Software

OPC is an industry standard created in cooperation with Microsoft. It is an open architecture interface
design, managed by the international OPC foundation. OPC is meant for different kinds of factory
automation. DriveOPC is based on the OPC foundation data access standard 1.0A and Microsoft
COM/DCOM technology. DriveOPC has full access to all drives, even when remote connection over
LAN is used.

DriveOPC uses a high-speed fibre optic cable network with DDCS communication protocol. A fibre
optic communication card inside the computer is needed.

DriveOPC features
DriveOPC supports OPC’s data access 1.0A.

• Read access to:

• Drive status: local, running, direction, fault, warning, reference
• Signals and parameters
• Fault logger contents
• Event logger contents
• General drive information
• Data logger settings, status and contents

• Write access to:

• Drive control: local, start, stop, forward, reverse, coast stop, reset fault, home, teach-in,
contactor on/off, reference
• Parameters
• Fault logger clear
• Data logger init, start, trig, clear

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ADDENDUM
9B

A. Repair Instructions
68B

I. Check input line voltage

184B

Note: – Ensure correct input terminal of multimeter is selected.

Ensure correct AC/DC voltage range of multimeter is selected.

Measure input voltage L1 - L2, L1 - L3, and L2 - L3

L1
L2
L3
C+
D-

GA 30VSD

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L1
L2
L3
C+
D-

GA50VSD

L1
L2
L3

C+
D-

GA90VSD

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II. How to Measure DC link voltage

185B

Measure DC-link voltage between terminals ‘C‘ and ‘D‘:

Compare this value with r006 onto the PMU. It must be equal. (A few volts difference can be
possible). If there is a big difference; replace PSU board or complete converter.

III. How to check 3ph rectifier

186B

Note: – Ensure correct input terminal of multimeter is selected.

Ensure multimeter is in diode test mode.

a) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘+‘ and ‘L1‘. This measurement must give for about 0.3 – 0.4V for a good diode. 0V
or maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

b) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘+‘ and ‘L2‘. This measurement must give for about 0.3 – 0.4V for a good diode. 0V
or maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

c) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘+‘ and ‘L3‘. This measurement must give for about 0.3 – 0.4V for a good diode. 0V
or maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

d) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘-‘ and ‘L1‘. This measurement must give for about 0.3 – 0.4V for a good diode. 0V or
maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

e) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘-‘ and ‘L2. This measurement must give for about 0,3 – 0,4V for a good diode. 0V
or maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

f) Check the diode-bridge for the precharging, using the multimeter in ‘diode‘ test. Test diode
between ‘-‘ and ‘L3‘. This measurement must give for about 0, 3 – 0,4V for a good diode. 0V
or maximum voltage (dependent from multimeter) will be a result of a short-circuited or bad
diode.

IV. Check input currents

187B

Using a current clamp, we can measure the currents in the input rectifier.
It could be possible that one or more thyristors aren‘t working anymore, or not controlled anymore by
the electronics.

The 3 input currents must be equal.

Otherwise replace converter and repeat this measurement.

V. How to check the precharge resistor

18B

Note: Ensure correct input terminal of multimeter is selected.

Ensure resistance measurement range of multimeter is selected.

Measure the resistance of the precharge resistor. The resistor contains 2 separate resistors of 12
ohm.

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If there is visual damage, or a bad measurement, replace the precharge resistor.

VI. Diagnostics
189B

With F011, there are 2 possibilities:

• The fault can be reset.
• The fault cannot be reset.

a) If the fault cannot be reset, the problem is situated in the converter.

b) If it can be reset, the problem can be the converter, the motor, the incoming voltage, or the
compressor mechanics.
To examine the problem, there are few things we can test.

If F011 cannot be reset:

a) For GA30VSD
• Change CU-board
• Change complete converter

b) For GA50VSD/GA90VSD
• Check current sensors using test-box
• Check IVI and ABO for bad contacts
• Change CU-board
• Change IVI-board
• Change ABO
If F011 can be reset, we have the possibility to run the converter, without motor. Follow these steps to
carry out this test.

• Turn off the power, and wait 5 minutes.

• Disconnect motor leads at converter side.
• Put the compressor into service-mode (service-switch).

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• Change parameters, as showed on the next slide.

• Change CU-board.

P053 = 6 Uses access (possibility to program)

P060 = 5 Drive settings
P100 = 1 Regulation into U/f (running without motor possible).
P060 = 0/1 Back to normal state

The drive will come in condition °008 or °009.

It is now possible to start the converter on the PMU.

The drive will go to its set point for service-mode.

If F011 appears, the problem is situated in the converter.

If F011 don‘t show up, check the motor or compressor.

After this test, change the adapted parameters again to their original value!

P060 = 5 Drive settings

P100 = 3 Regulation into f-regulation (running into vector mode without an encoder).
P060 = 0/1 Back to normal state
P053 = 0 Block the possibility to change parameters.

The drive will come in condition °008 or °009.

If the drive is started now (without connected motor), it will trip on F012.

VII. How to check motor winding resistance

190B

Note : Ensure correct input terminal of multimeter is selected.

Ensure resistance measurement range of multimeter is selected.

a) F012 can occur if there is a winding open, or has a too high ohmic resistance. Check winding U2-
V2 with resistance measurement.
This measurement must give a very low ohmic value (<1Ω).

W2
V2
U2

GA30VSD

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W2
V2
U2

GA50VSD/GA90VSD

b) F012 can occur if there is a winding open, or has a too high ohmic resistance. Check winding U2-
W2 with resistance measurement.
This measurement must give a very low ohmic value (<1Ω).

c) F012 can occur if there is a winding open, or has a too high ohmic resistance. Check winding V2-
W2 with resistance measurement.
This measurement must give a very low ohmic value (<1Ω).

VIII. How to overcome “Motor Stall”?

19B

F015 can be caused by mechanical problems:

• Check for free running of element and motor

• Check if oil stop valve isn’t blocked
• Check dp oil separator
• Check for a combination of above points together with cold start conditions. (0°C or lower)
• Start the VSD in service mode. (Service switch).

IX. How to check the Compressor condition

192B

Following parameters to be checked to make sure that compressor is working in normal condition.

• Ambient temperature?
• Cooling fan on the motor?
• Dust on air inlets?
• Continuous start-stops?

X. Check P381
193B

In P381, the temperature can be programmed, at which temperature; the drive must trip to protect the
motor. It is programmed in °C.

Check this value with the original parameter set of this compressor.

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XI. Check the KTY84

194B

Check the measured temperature in r009. In this parameter, the temperature from the motor
(measured by the KTY84) is displayed in °C.

XII. How to check temperature sensor

195B

The motor temperature sensor is connected to X103:29 and X103:30.

Measure the ohmic value of the temperature sensor.
Check for bad contacts.
The ohmic value of the sensor, according to the temperature can be found in this curve.

MCD398
3

R
(kΩ)

0
–100 0 100 200 300
0
T amb ( C)

XIII. General parameters to check in Inverter Temperature problem

196B

• Check ambient temperature of compressor.

• Check air inlets for dust or obstructions.
• Check primary setting of fan transformer.

The primary setting of the fan transformer must be adapted to the customers line voltage.

• Check airflow / rotation of fan

• Check fan connection
• Check Temperature: Check the temperature measurement using the testbox.

The temperature can also be read out on the PMU or Drive monitor, with r833. This parameters
displays the inverter temperature in °C.
The sensor measures the temperature of the cooling plate, which can deviate from the ambient
temperature.

XIV. UCE shutdowns

197B

A problem has occurred in the power section of the drive. F025, F026 and F027 are identical faults;
they only point to a specific output phase.

F025, F026 and F027 detect a problem in the feedback signals from the inverter power section.

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They can be checked with the Testbox.

If the Led‘s UCER, UCES or UCET are lighting, this means a F025, F026 or F027.

F025
F026
F027

• Check the inverter with diode-test.

If an IGBT is faulty, there is a big chance that the internal freewheeling-diode is opened or short-
circuited.

The measurement must give for about 0,3V.

• If the measurement is 0V, the IGBT is in short-circuit.

If the measurement is the full voltage (depending of multimeter), the diode is open or defective.

• Check IGBT:

b) Between C(+) and U2.

c) Check IGBT between C(+) and V2.
d) Check IGBT between C(+) and W2.
e) Check IGBT between D(-) and U2.
f) Check IGBT between D(-) and V2.
g) Check IGBT between D(-) and W2.

• Check the inverter with testbox.

Put 24V on the DC-link and switch the IGBT‘s.

If problems occur, replace converter.

F025, F026 or F027 can also come from a defective motor.

XV. Fault in measured value sensing

198B

F029 is the result of a bad measurement. It can happen sporadically or it can be continuous.
a) Check ABO onto IVI for bad contacts or dust.
b) Change CUVC-card.
c) Check current sensors, using testbox.
d) Check current sensor connections for bad contacts.

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e) Change IVI-card.
f) Check complete converter with testbox.
g) Also check motor.

XVI. How to overcome External fault 1 and External fault 2

19B

F035 is a free programmable fault. It is programmed on P575.001 (normal operation) and on

P575.002 for service-switch operation.

It can be programmed for example onto a digital input.

a) On GA30VSD, this fault is not used.

F035 is controlled always. F035 can appear during standstill or during operation.

b) On GA50VSD (AII350000 to AII350650), there was a temperature switch inside the converter
cabinet. If the temperature was too high in the cabinet, F035 was generated. The switch was
connected to X100:1 and X100:7.

Later versions of the GA50VSD are using a PT1000, which was mounted onto the bottom of the
Electronic box, near to the CUVC-board. It is measured and controlled by the Atlas Copco
Elektronikon module.

c) On GA90VSD depending on the version of compressor or options on the compressor, this fault
can be triggered by different kind of sources (external drive, temperature switch...).

F036 is a free programmable fault. It is programmed on P585.001 (normal operation) and on

P585.002 for service-switch operation.

It can be programmed for example onto a digital input.

b) On GA30VSD, this fault is not used. F036 is only controlled when the drive is in operation. F036
can only occur when the drive is in operation.

c) On GA50VSD/ GA90VSD, if it is used, it is mostly used as fault detection for a second VSD inside
the compressor (fan or dryer). If there is a problem with this second VSD, the main VSD will trip
and there will be a fault message on Elektronikon. F036 is referring to a problem with this 2nd
VSD.

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B. Repair Instructions – ABB ACS600 / 800

69B

If installed in an appropriate environment, the drive requires very little maintenance. This table lists the
routine maintenance intervals recommended by ABB.

Maintenance Interval Instruction

Depends on the dustiness of
Heatsink temperature check
the environment (every 6 to 12 See I. Heatsink
and cleaning
X X

months)
Cooling fan change Every five years See II. Fan
X X

Change of additional cooling

See III. Additional fan in IP 55
fan in IP 55 units and in IP 21 Every three years
X

units and certain IP 21 units

units when included
X

Frame size R4 and up:

Every ten years See IV. Capacitors
Capacitor change
X X

Capacitor reforming Every year when stored See V. Reforming

X X

I. Heatsink
20B

The heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and
faults if the heatsink is not clean. In a “normal” environment (not dusty, not clean) the heatsink should
be checked annually, in a dusty environment more often.

Clean the heatsink as follows (when necessary):

1. Remove the cooling fan (see section Fan).

2. Blow clean compressed air (not humid) from bottom to top and simultaneously use a vacuum
cleaner at the air outlet to trap the dust.
Note: If there is a risk of the dust entering adjoining equipment, perform the cleaning in another room.

3. Replace the cooling fan.

II. Fan
201B

The cooling fan lifespan of the drive is about 60 000 operating hours. The actual lifespan depends on
the drive usage and ambient temperature. See the appropriate ACS800 firmware manual for an actual
signal, which indicates the hours of usage of the fan.

Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the
heatsink temperature in spite of heatsink cleaning. If the drive is operated in a critical part of a
process, fan replacement is recommended once these symptoms start appearing. Replacement fans
are available from ABB. Do not use other than ABB specified spare parts.

Fan replacement (R2, R3)

To remove the fan, release the retaining clips. Disconnect the cable. Install the fan in reverse order.

Bottom View

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Fan replacement (R4)

1. Loosen the screws that fasten the fan mounting plate to the frame.

2. Push the fan mounting plate to the left and pull it out.

3. Disconnect the fan power cable.

4. Undo the screws that fasten the fan to the fan mounting plate.

5. Install the new fan in reverse order.

Bottom View

View from above fan

plate pulled out

Fan replacement (R5, R6)

To remove the fan, undo the fixing screws. Disconnect the cable. Install the fan in reverse order.

Bottom View (R5)

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Bottom View (R6)

III. Additional fan in IP 55 units and certain IP 21 units

20B

In IP 21 units, there is an additional fan in types -0004-2 to 0020-2, -0006-3 to -0030-3, -0009-5 to -
0040-5, -0011-7 to 0060-7.

Replacement (R2, R3)

Remove the front cover. To remove the fan, release the retaining clip (1). Disconnect the cable (2,
detachable terminal). Install the fan in reverse order.

View from above when front

cover is removed

Replacement (R4, R5)

Remove the front cover. The fan is located on the lower right-hand side of the unit (R4) or on the right-
hand side of the control panel (R5). Lift the fan out and disconnect the cable. Install the fan in reverse
order.

Replacement (R6)
Remove the top cover by lifting it by the rear edge. To remove the fan, release the retaining clips by
pulling the back edge (1) of the fan upwards. Disconnect the cable (2, detachable terminal). Install the
fan in reverse order.

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View from above when top

cover is removed

IV. Capacitors
203B

The drive intermediate circuit employs several electrolytic capacitors. Their lifespan is from 45 000 to
90 000 hours depending on drive loading and ambient temperature. Capacitor life can be prolonged
by lowering the ambient temperature.

It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains fuse
failure or a fault trip. Contact ABB if capacitor failure is suspected. Replacements for frame size R4
and up are available from ABB. Do not use other than ABB specified spare parts.

V. Reforming Capacitors
204B

Reform (re-age) spare part capacitors once a year according to ACS 600/800 Capacitor Reforming
Guide (code: 64059629).

VI. LEDs
205B

This table describes the LEDs of the drive.

Where LED When the LED is lit

Red Drive in fault state

RMIO board *
Green The power supply on the board is OK.

Control panel mounting Red Drive in fault state

platform (with type code The main +24 V power supply for the control
selection +0J400 only) Green
panel and the RMIO board is OK.

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C. Cabling Instructions – ABB ACS 600 / 800

70B

I. General Rules
206B

Dimension the mains (input power) and motor cables according to local regulations:
• The cable must be able to carry the drive load current. See Technical data for the rated currents.
• For ABB ACS800, the cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For ABB ACS600, the maximum permissible temperature should be
60°C (140°F). For US, see Additional US requirements
X

• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated
according to permissible touch voltage appearing under fault conditions (so that the fault point
voltage will not rise excessively when an ground fault occurs).
• 600 VAC cable is accepted for up to 500 VAC. For the North American market, 600 VAC rated
cable is accepted for 600 VAC rated equipment. For 690 VAC rated equipment, the rated voltage
between the conductors of the cable should be minimum 1 kV.

For drive frame size R5 and larger, or motors larger than 30 kW (40 HP), symmetrical shielded motor
cable must be used (figure below). A four-conductor system can be used up to frame size R4 with up
to 30 kW (40 HP) motors, but shielded symmetrical motor cable is recommended.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended.
To operate as a protective conductor, the shield conductivity must be as follows when the protective
conductor is made of the same metal as the phase conductors:

Cross-sectional area of the phase conductors Minimum cross-sectional area of the corresponding
protective conductor
2 2
S (mm ) Sp (mm )
S < 16 S
16 < S < 36 16
35 < S S/2

Compared to a four-conductor system, the use of symmetrical shielded cable reduces

electromagnetic emission of the whole drive system as well as motor bearing currents and wear.

The motor cable and its PE pigtail (twisted shield) should be kept as short as possible in order to
reduce electromagnetic emission as well as capacitive current.

Alternative power cable types

Power cable types that can be used with the drive are represented below.

Recommended
Symmetrical shielded cable: three phase conductors
A separate PE conductor is required if the
and a concentric or otherwise symmetrically
conductivity of the cable shield is <50% of the
constructed PE conductor, and a shield
conductivity of the phase conductor.
PE conductor Shield Shield
and shield

PE
PE

PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor
Not allowed for motor cables Not allowed for motor cables with phase
2
conductor cross section larger than 10mm
[motors > 30 kW (40 HP)]

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Additional US requirements
309B

Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power
cable must be used for the motor cables if metallic conduit is not used. For the North American
market, 600 VAC cable is accepted for up to 500 VAC. 1000 VAC cable is required above 500 VAC
(below 600 VAC). For drives rated over 100 amperes, the power cables must be rated for 75 °C (167
°F).

Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor bonded to the
conduit on each side of the joint. Bond the conduits also to the drive enclosure. Use separate conduits
for input power, motor, brake resistors, and control wiring. Do not run motor wiring from more than
one drive in the same conduit.

Armored cable / shielded power cable

The motor cables can be run in the same cable tray as other 460 V or 600 V power wiring. Control
and signal cables must not be run in the same tray as power cables. Six-conductor (3 phases and 3
ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available
from the following suppliers (trade names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX)

Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and Pirelli.

II. Power Factor Compensation Capacitors

207B

Do not connect power factor compensation capacitors or surge absorbers to the motor cables
(between the drive and the motor). They are not designed to be used with drives, and will degrade
motor control accuracy. They can cause permanent damage to the drive or themselves due to the
rapid changes in the drive output voltage.

If there are power factor compensation capacitors in parallel with the three-phase input of the drive,
ensure that the capacitors and the drive are not charged simultaneously to avoid voltage surges,
which might damage the unit.

III. Equipment Connected to the Motor Cable

208B

Installation of safety switches, contactors, connection boxes, etc.:

To minimize the emission level when safety switches, contactors, connection boxes or similar
equipment are installed in the motor cable (i.e. between the drive and the motor):

EU: Install the equipment in a metal enclosure with 360 degrees grounding for the screens of both the
incoming and outgoing cable, or connect the screens of the cables otherwise together.

US: Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs
consistently without breaks from the drive to the motor.

Bypass connection
WARNING!
Never connect the supply power to the drive output terminals U2, V2 and W2. If frequent bypassing is
required, employ mechanically connected switches or contactors. Mains (line) voltage applied to the
output can result in permanent damage to the unit.

Before opening a contactor (DTC control mode selected)

Stop the drive and wait for the motor to stop before opening a contactor between the output of the
drive and the motor when the DTC control mode is selected. See the appropriate ACS 800 application
program firmware manual for the required parameter settings. Otherwise, the contactor will be
damaged. In scalar control, the contactor can be opened with the drive running.

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IV. Protecting relay output contacts and attenuating disturbances in case of inductive loads
209B

Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay
contacts on the RMIO board are protected with varistors (250 V) against overvoltage peaks. In spite of
this, it is highly recommended to equip inductive loads with noise attenuating circuits [varistors, RC
filters (AC) or diodes (DC)] in order to minimize the EMC emission at switch-off. If not suppressed, the
disturbances may connect capacitively or inductively to other conductors in the control cable and form
a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not install protective
components at the RMIO board terminal block.
See fig on next page.

V. Motor Cable Shield

210B

To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity
must be at least 1/10 of the phase conductor conductivity. One way of evaluating the effectiveness of
the shield is the shield inductance, which must be low and only slightly dependent on the frequency.
These requirements are easily met with a copper or aluminium shield/armour. The minimum
requirement of the motor cable shield of the ACx 600 is shown below. It consists of a concentric layer
of copper wires with an open helix of copper tape. The better and tighter the shield is, the lower is the
emission level and the bearing currents.

Insulation Copper Wire Helix of Inner

Jacket Screen Copper Tape Insulation

Cable Core

VI. Control Cables

21B

All control cables must be shielded. As a general rule, the control signal cable shield should be
earthed directly in the ACx 600. The other end of the shield should be left unconnected or earthed
indirectly via some nanofarads high frequency and high voltage capacitor (e.g. 3.3 nF / 3000 V). The
screen can also be earthed directly at both ends if they are in the same earth line with no significant
voltage drop between the end points.

Twisting the signal wire with its return wire reduces disturbances caused by inductive coupling. Pairs
should be twisted as close to terminals as possible.

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Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables, Finland) for analogue
signals. This type of cable is recommended for the pulse encoder signals also. Employ one
individually shielded pair for each signal. Do not use common return for different analogue signals.

A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded
twisted multipair cable (Figure b) is also usable.

A double shielded twisted A single shielded twisted

pair cable multipair cable

Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables
as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs.

Never mix 24 VDC and 115 / 230 VAC signals in the same cable.

Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX by LAPPKABEL, Germany) has been
tested and approved by ABB.

Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft).
The cable type tested and approved by ABB is used in control panel option kits.

VII. Connection of a Motor Temperature Sensor to the Drive I/O

21B

WARNING!
IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible
parts of electrical equipment which are either nonconductive or conductive but not connected to the
protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital
inputs of the drive can be implemented in three alternate ways:

1. There is double or reinforced insulation between the thermistor and live parts of the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected against contact and
insulated with basic insulation (the same voltage level as the drive main circuit) from other low
voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for the same
voltage level as the main circuit of the drive. For connection, see ACS 800 Firmware Manual.

VIII. Routing the Cables

213B

Route the motor cable away from other cable routes. Motor cables of several drives can be run in
parallel installed next to each other. It is recommended that the motor cable, input power cable and
control cables be installed on separate trays. Avoid long parallel runs of motor cables with other
cables in order to decrease electromagnetic interference caused by the rapid changes in the drive
output voltage.

Where control cables must cross power cables make sure they are arranged at an angle as near to 90
degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the grounding electrodes.
Aluminium tray systems can be used to improve local equalizing of potential.

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A diagram of the cable routing is below.

Control Cable Ducts

24 V 230 V 24 V 230 V

Not allowed unless the 24 V Lead 24 V and 230 V control

cable is insulated for 230 V or cables in separate ducts
insulated with an insulation inside the cabinet.
sleeving for 230 V.

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IX. Cabling of I/O and Fieldbus Modules

214B

Module
As short as possible

Shield

Note:

The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable
shields here.

Pulse encoder module cabling

As short as
possible

RTAC

Wrap copper tape around the stripped part of

the cable under the clamp. Be careful. Do not
cut the grounding wire. Clamp as close to the
terminals as possible.

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Note1:
If the encoder is of unisolated type, ground the encoder cable at the drive end only. If the encoder is
galvanically isolated from the motor shaft and the stator frame, ground the encoder cable shield at the
drive and the encoder end.

Note 2:
Twist the pair cable wires.

Fastening the control cables and covers

When all control cables are connected, fasten them together with cable ties. Units with a connection
box: fasten the cables to the entry plate with cable ties. Units with a gland box: tighten the clamping
nuts of the cable glands.

Fasten the connection box cover.

Replace the front cover.

Installation of Optional Modules and PC

The optional module (such as fieldbus adapter, I/O extension module and the pulse encoder interface)
is inserted in the optional module slot of the RMIO board (see Connecting the control cables) and
fixed with two screws. See the appropriate optional module manual for cable connections.

X. Fibre optic link

215B

A DDCS fibre optic link is provided via the RDCO optional module for PC tools, master/follower link,
NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for the connections. Observe colouring codes when installing fibre optic
cables. Blue connectors go to blue terminals, and grey connectors to grey terminals.
When installing multiple modules on the same channel connect them in a ring.

XI. External +24 V power supply for the RMIO board

216B

External +24 V power supply for the RMIO board is recommended if

• The application requires fast start after connecting the input power supply
• Fieldbus communication is required when the input power supply is disconnected.

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Connecting +24 V external power supply

1. Break off the tab covering the +24 VDC power input connector with pliers.

2. Lift the connector upwards.

3. Disconnect the wires from the connector (keep the connector for later use).

4. Isolate the ends of the wires individually with insulating tape.

5. Cover the isolated ends of the wires with insulating tape.

6. Push the wires inside the skeleton.

7. Connect the wires of the +24 V external power supply to the disconnected connector: + wire to
terminal 1 and - wire to terminal 2.

8. Plug the connector in.

Frame sizes R2 to R4 Frame sizes R5 and R6

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XII. Installation Checklist

217B

MECHANICAL INSTALLATION

‰ The ambient operating conditions are allowed. (See 9.5.1 Mechanical Installation, XIII.
U U U

Technical Data) U

‰ The unit is fixed properly on a vertical non-flammable wall. (See 9.5.1 Mechanical Installation.)
U U

‰ The cooling air will flow freely.

‰ The motor and the driven equipment are ready for start. (See 9.5.2.1 Planning the Electrical
U

Installation, XIII. Technical Data)

U U U

ELECTRICAL INSTALLATION
(See 9.5.2.1 Planning the Electrical Installation.)
U U

‰ The +E202 and +E200 EMC filter capacitors are disconnected if the drive is connected to an
IT (ungrounded) system.

‰ The capacitors are reformed if stored over one year (refer to ACS 600/800 Capacitor
Reforming Guide [64059629 (English)].

‰ The drive is grounded properly.

‰ The mains (input power) voltage matches the drive nominal input voltage.

‰ The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.

‰ Appropriate mains (input power) fuses and disconnector are installed.

‰ The motor connections at U2, V2 and W2 and their tightening torques are OK.

‰ The motor cable is routed away from other cables.

‰ There are no power factor compensation capacitors in the motor cable.

‰ The external control connections inside the drive are OK.

‰ There are no tools, foreign objects or dust from drilling inside the drive.

‰ Mains (input power) voltage cannot be applied to the output of the drive (with bypass
connection).

‰ Drive, motor connection box and other covers are in place.

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XIII. Technical Data

218B

• Ambient Conditions

Environmental limits for the drive are given below. The drive is to be used in a heated, indoor,
controlled environment.

Operation Storage Transportation

Installed for stationary use In the protective package In the protective package

0 to 4000 m (13123 ft)

Installation
site altitude
above sea level [above - -
1000 m (3281 ft)
Air -15 to +50 °C (5 to 122 °F). -40 to +70 °C (-40 to +158 -40 to +70 °C (-40 to
temperature No frost allowed. °F) +158 °F)
5 to 95% Max. 95% Max. 95%
Relative
humidity No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
No conductive dust allowed.
Contamination
levels Boards without coating: Boards without coating: Boards without coating:
(IEC 60721-3- Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
3, IEC 60721- Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
3-2, IEC Boards with coating: Boards with coating: Boards with coating:
60721-3-1) Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
pressure 0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
Vibration (IEC (5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
60068-2) max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
Not allowed
60068-2-29) 11 ms 11 ms
250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
Free fall Not allowed
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)

• IEC Ratings

The IEC ratings for the ACS800-01 with 50 Hz and 60 Hz supplies are given below.
The symbols are described below the table.

No- Light-
Nominal Heavy-duty Frame Air Heat
overload overload
ACS800- ratings use size flow dissipation
use use
01 size I2N PN I2hd Phd
Imax Pcont.max
Icont.max
A kW A kW m3/h W
A A kW
Three-phase supply voltage 208 V, 220 V, 230 Vor 240 V
-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 35 100
-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 35 100
-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 35 100
-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 35 120
-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 35 140
-0006-2 19 24 4 18 4 14 3 R3 69 160
-0009-2 25 32 5.5 24 5,5 19 4 R3 69 200
-0011-2 34 46 7.5 31 7.5 23 5.5 R3 69 250
-0016-2 44 62 11 42 11 32 7.5 R4 103 340
-0020-2 55 72 15 50 11 37 7.5 R4 103 440

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-0025-2 72 86 18.5 69 18.5 49 11 R5 168 530

-0030-2 86 112 22 80 22 60 15 R5 168 610
-0040-2 103 138 30 94 22 69 18.5 R5 168 810
-0050-2 141 164 37 132 37 97 30 R6 405 1190
-0060-2 166 202 45 155 45 115 30 R6 405 1190
-0070-2 202 282 55 184 55 141 37 R6 405 1440
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 35 100
-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 35 120
-0005-3 8.5 10.8 3 7.7 3 5.7 2.2 R2 35 140
-0006-3 10.9 13.8 4 10.2 4 7.5 3 R2 35 160
-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4 R2 35 200
-0011-3 19 24 7.5 18 7.5 14 5.5 R3 69 250
-0016-3 25 32 11 24 11 19 7.5 R3 69 340
-0020-3 34 46 15 31 15 23 11 R3 69 440
-0025-3 44 62 22 41 18.5 32 15 R4 103 530
-0030-3 55 72 30 50 22 37 18.5 R4 103 610
-0040-3 72 86 37 69 30 49 22 R5 168 810
-0050-3 86 112 45 80 37 60 30 R5 168 990
-0060-3 103 138 55 94 45 69 37 R5 168 1190
-0070-3 141 164 75 132 55 97 45 R6 405 1440
-0100-3 166 202 90 155 75 115 55 R6 405 1940
-0120-3 202 282 110 184 90 141 75 R6 405 2310
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 35 120
-0005-5 6.2 8.2 3 5.6 3 4.2 2.2 R2 35 140
-0006-5 8.1 10.8 4 7.7 4 5.6 3 R2 35 160
-0009-5 10.5 13.8 5.5 10 5.5 7.5 4 R2 35 200
-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 35 250
-0016-5 19 24 11 18 11 13 7.5 R3 69 340
-0020-5 25 32 15 23 15 18 11 R3 69 440
-0025-5 34 46 18.5 31 18.5 23 15 R3 69 530
-0030-5 42 62 22 39 22 32 18.5 R4 103 610
-0040-5 48 72 30 44 30 36 22 R4 103 810
-0050-5 65 86 37 61 37 50 30 R5 168 990
-0060-5 79 112 45 75 45 60 37 R5 168 1190
-0070-5 96 138 55 88 55 69 45 R5 168 1440
-0100-5 124 164 75 115 75 88 55 R6 405 1940
-0120-5 157 202 90 145 90 113 75 R6 405 2310
-0140-5 180 282 110 163 110 141 90 R6 405 2810
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 103 300
-0016-7 17 19 15 15 11 11 7.5 R4 103 340
-0020-7 22 28 18.5 20 15 15 11 R4 103 440
-0025-7 25 38 22 23 18.5 19 15 R4 103 530
-0030-7 33 44 30 30 22 22 18.5 R4 103 610
-0040-7 36 54 30 34 30 27 22 R4 103 690
-0050-7 51 68 45 46 37 34 30 R5 168 840
-0060-7 57 84 55 52 45 42 37 R5 168 1010
-0070-7 79 104 75 73 55 54 45 R6 405 1220
-0100-7 93 124 90 86 75 62 55 R6 405 1650
-0120-7 113 172 110 108 90 86 75 R6 405 1960

Symbols
Nominal ratings
Icont.max: Continuous rms output current. No overload capability at 40 °C.
Imax: Maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.

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Typical ratings:
No-overload use
Pcont.max: Typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.

Light-overload use (10 % overload capability)

I2N: Continuous rms current. 10 % overload is allowed for one minute every 5 minutes.

PN: Typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage, 230
V, 400 V, 500 V or 690 V.

Heavy-duty use (50 % overload capability)

I2hd: Continuous rms current. 50 % overload is allowed for one minute every 5 minutes.

Phd: Typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage, 230
V, 400 V, 500 V or 690 V.

• Cooling

Method: Internal fan, flow direction from bottom to top.

Free space around the unit: See 9.5.1 Mechanical Installation.
X X

• Input Power Connection

Voltage (U1)
208/220/230/240 VAC 3-phase ± 10 % for 230 VAC units
380/400/415 VAC 3-phase ± 10 % for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10 % for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10 % for 690 VAC units

Prospective short-circuit current (IEC 60439-1)

Maximum allowed prospective short-circuit current in the supply is 65 kA in a second providing that
the mains cable of the drive is protected with appropriate fuses. US: 65,000 AIC.

Frequency
48 to 63 Hz, maximum rate of change 17 %/s

Imbalance
Max. ± 3 % of nominal phase to phase input voltage

Fundamental power factor (cos phi1)

0.98 (at nominal load)

• Motor Connection

Voltage (U2)
0 to U1, 3-phase symmetrical, Umax at the field weakening point

Frequency
DTC mode: 0 to 3.2 · fFWP. Maximum frequency 300 Hz.

fFWP = UNmains/UNmotor
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency

Frequency resolution 0.01 Hz

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Current
See section XIII. Technical Data)/IEC Ratings.
X X

Power limit 1.5 · Phd

Field weakening point 8 to 300 Hz

Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).

• CE Marking

A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low
Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/
EEC, as amended by 93/68/EEC).

Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.

The EMC Directive defines the requirements for immunity and emissions of electrical equipment
used within the European Union. The EMC product standard [EN 61800-3 + Amendment A11 (2000)]
covers requirements stated for drives.

First environment includes establishments connected to a low-voltage network, which supplies

buildings used for domestic purposes.

Second environment includes establishments connected to a network not supplying domestic

premises.

Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in
the EMC requirements of the application of drives.

Unrestricted distribution: mode of sales distribution in which the supply of equipment is not
dependent on the EMC competence of the customer or user for the application of drives.

Compliance with the EMC Directive

The drive complies with the EMC Directive on low-voltage networks with the following provisions. First
environment (restricted distribution)

1. The drive is equipped with EMC filter +E202.

2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 meters.

WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.

Note: It is not allowed to install a drive equipped with the EMC filter +E202 on IT (unearthed)
systems.
The supply network becomes connected to earth potential through the EMC filter capacitors, which
may cause danger or damage the unit.

Second environment

The requirements of the EMC Directive can be met as follows:

1. The drive is equipped with EMC filter E200. The filter is suitable for TN (earthed) networks only.

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2. The motor and control cables are selected as specified in the Hardware Manual.

3. The drive is installed according to the instructions given in the Hardware Manual.

4. Maximum cable length is 100 meters.

If the above listed provisions cannot be met, e.g., the drive cannot be equipped with EMC filter E200
when installed to an IT (unearthed) network, the requirements of the EMC Directive can be met as
follows for restricted distribution:

1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In

some cases, the natural suppression in transformers and cables is sufficient. If in doubt, a supply
transformer with static screening between the primary and secondary windings can be used.

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.

3. The motor and control cables are selected as specified in the Hardware Manual.

4. The drive is installed according to the instructions given in the Hardware Manual.

Machinery Directive

The drive complies with the European Union Machinery Directive (98/37/EC) requirements for
equipment intended to be incorporated into machinery.

• Resistor Braking

A) Optional brake chopper and resistor(s) for the ACS800-01/U1

Braking power of
the chopper and the Brake resistor(s)
ACS 800-01
drive
type
PRcont
Pbrcont (kW) Type R (ohm) ER (kJ)
(kW)
230 V units
-3 0.55 SACE08RE44 44 248 1
-4 0.8 SACE08RE44 44 248 1
-5 1.1 SACE08RE44 44 248 1
-6 1.5 SACE08RE44 44 248 1
-7 2.2 SACE15RE22 22 497 2
-8 3 SACE15RE22 22 497 2
-11 4 SACE15RE22 22 497 2
-13 5.5 SACE15RE13 13 497 2
-18 11 SAFUR90F575 8 1800 4.5
-22 17 SAFUR90F575 8 1800 4.5
-27 23 SAFUR80F500 6 2400 6
-32 28 SAFUR125F500 4 3600 9
-42 33 SAFUR125F500 4 3600 9
-52 45 2xSAFUR125F500 2 7200 18
-62 56 2xSAFUR125F500 2 7200 18
-72 68 2xSAFUR125F500 2 7200 18
400 V units
-6 1.1 SACE08RE44 44 210 1
-7 1.5 SACE08RE44 44 210 1
-8 2.2 SACE08RE44 44 210 1

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-9 3 SACE08RE44 44 210 1
-12 4 SACE08RE44 44 210 1
-14 5.5 SACE15RE22 22 420 2
-19 7.5 SACE15RE22 22 420 2
-23 11 SACE15RE22 22 420 2
-28 23 SACE15RE13 13 435 2
-33 28 SACE15RE13 13 435 2
-43 33 SAFUR90F575 8 1800 4.5
-53 45 SAFUR90F575 8 1800 4.5
-63 56 SAFUR90F575 8 1800 4.5
-73 68 SAFUR80F500 6 2400 6
-103 83 SAFUR125F500 4 3600 9
-123 113 SAFUR125F500 4 3600 9
500 V units
-9 1.5 SACE08RE44 44 210 1
-10 2.2 SACE08RE44 44 210 1
-11 3 SACE08RE44 44 210 1
-14 4 SACE08RE44 44 210 1
-16 5.5 SACE08RE44 44 210 1
-21 7.5 SACE15RE22 22 420 2
-25 11 SACE15RE22 22 420 2
-30 15 SACE15RE22 22 420 2
-35 28 SACE15RE13 13 435 2
-45 33 SACE15RE13 13 435 2
-55 45 SAFUR90F575 8 1800 4.5
-65 56 SAFUR90F575 8 1800 4.5
-75 68 SAFUR90F575 8 1800 4.5
-105 83 SAFUR125F500 4 3600 9
-125 113 SAFUR125F500 4 3600 9
-145 135 SAFUR125F500 4 3600 9
690 V units
-18 5.5 SACE08RE44 44 248 1
-23 7.5 SACE08RE44 44 248 1
-27 11 SACE08RE44 44 248 1
-32 15 SACE08RE44 44 248 1
-37 18.5 SACE15RE22 22 497 2
-47 22 SACE15RE22 22 497 2
-57 30 SAFUR90F575 8 1800 4.5
-67 37 SAFUR90F575 8 1800 4.5
-77 45 SAFUR90F575 8 1800 4.5
-107 55 SAFUR80F500 6 2400 6
-127 75 SAFUR80F500 6 2400 6

Pbrcont : The drive and the chopper will withstand this continuous braking power. The braking is
considered continuous if the braking time exceeds 30 s.
Note: The braking energy transmitted to the specified resistor(s) in 400 seconds may not exceed ER.

R : Resistance value for the listed resistor assembly.

Note: This is also the minimum allowed resistance for the braking resistor.

ER : Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will
heat the resistor element from 40 °C (104 °F) to the maximum allowable temperature.

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PRcont : Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER
dissipates in 400 seconds.

All braking resistors must be installed outside the converter module. The SACE braking resistors are
built in an IP 21 metal housing. The SAFUR braking resistors are built in an IP 00 metal frame.

B) Optional brake chopper and resistor(s) for the ACS800-02/U2, the ACS800-04/U4 and the
ACS800-07/U7

Braking power of the chopper and

Brake resistor(s)
the drive
ACS 800 Frame
5/60 s 10/60 s 30/60 s
type size Pbrcont R ER PRcont
Pbr5 Pbr10 Pbr30 Type
(kW) (ohm) (kJ) (kW)
(kW) (kW) (kW)
400 V units
-0070-3 R6 - - - 68 SAFUR80F500 6 2400 6
-0100-3 R6 - - - 83 SAFUR125F500 4 3600 9
-0120-3 R6 - - - 113 SAFUR125F500 4 3600 9
-0140-3 R7 135 135 100 80 SAFUR200F500 2.70 5400 13.5
-0170-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
-0210-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
-0260-3 R8 240 240 240 173 2XSAFUR210F575 1.70 8400 21
-0320-3 R8 300 300 300 143 2xSAFUR200F500 1.35 10800 27
-0400-3 R8 375 375 273 130 4xSAFUR125F500 1.00 14400 36
-0440-3 R8 473 355 237 120 4xSAFUR210F575 0.85 16800 42
-0490-3 R8 500 355 237 120 4xSAFUR210F575 0.85 16800 42
500 V units
-0100-5 R6 - - - 83 SAFUR125F500 4 3600 9
-0120-5 R6 - - - 113 SAFUR125F500 4 3600 9
-0140-5 R6 - - - 135 SAFUR125F500 4 3600 9
-0170-5 R7 165 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0210-5 R7 198 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0260-5 R7 198 1) 1322) 120 80 SAFUR200F500 2.70 5400 13.5
-0270-5* R8 240 240 240 240 2xSAFUR125F500 2.00 7200 18
-0300-5* R8 280 280 280 280 2xSAFUR125F500 2.00 7200 18
-0320-5 R8 300 300 300 300 2xSAFUR125F500 2.00 7200 18
-0400-5 R8 375 375 375 234 2XSAFUR210F575 1.70 8400 21
-0440-5 R8 473 473 450 195 2xSAFUR200F500 1.35 10800 27
-0490-5 R8 480 480 470 210 2xSAFUR200F500 1.35 10800 27
-0550-5 R8 600 400 4) 300 170 4xSAFUR125F500 1.00 14400 36
-0610-5 R8 600 3) 4004) 300 170 4xSAFUR125F500 1.00 14400 36
690 V units
-0070-7 R6 - - - 45 SAFUR90F575 8.00 1800 4.5
-0100-7 R6 - - - 55 SAFUR80F500 6.00 2400 6
-0120-7 R6 - - - 75 SAFUR80F500 6.00 2400 6
-0140-7 R7 125 5) 110 90 75 SAFUR80F500 6.00 2400 6
-0170-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
-0210-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
-0260-7 R7 135 7) 120 100 80 SAFUR80F500 6.00 2400 6
-0320-7 R8 300 300 300 260 SAFUR200F500 2.70 5400 13.5
-0400-7 R8 375 375 375 375 SAFUR200F500 2.70 5400 13.5
-0440-7 R8 430 430 430 385 SAFUR200F500 2.70 5400 13.5
-0490-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0550-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0610-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18

Pbr5 : Maximum braking power of the drive with the specified resistor(s). The drive and the chopper
will withstand this braking power for 5 seconds per minute.

Pbr10 : The drive and the chopper will withstand this braking power for 10 seconds per minute.

Pbr30 : The drive and the chopper will withstand this braking power for 30 seconds per minute.

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Pbrcont : The drive and the chopper will withstand this continuous braking power. The braking is
considered continuous if the braking time exceeds 30 s.
Note: Check that the braking energy transmitted to the specified resistor(s) in 400 seconds
does not exceed ER.

R : Resistance value for the resistor assembly.

Note: This is also the minimum allowed resistance for the braking resistor.

ER : Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will
heat the resistor element from 40 °C (104 °F) to the maximum allowable temperature.

Prcont : Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER
dissipates in 400 seconds.

* ACS800-U7 types only

1. 240 kW possible if ambient temperature is below 33 °C (91 °F)

2. 160 kW possible if ambient temperature is below 33 °C (91 °F)
3. 630 kW possible if ambient temperature is below 33 °C (91 °F)
4. 450 kW possible if ambient temperature is below 33 °C (91 °F)
5. 135 kW possible if ambient temperature is below 33 °C (91 °F)
6. 148 kW possible if ambient temperature is below 33 °C (91 °F)
7. 160 kW possible if ambient temperature is below 33 °C (91 °F)

Combined braking cycles for R7:

Examples

Pbr max 5 s or 10 s

Pbr5 or Pbr10
Pbr30
Pbrcont

No braking t
min 30 s max 30 s min 30 s max 30 s min 30 s

• After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont
continuously.

• Pbr5, Pbr10 or Pbr30 braking is allowed once every minute.

• After Pbrcont braking, there has to be at least 30 seconds without any braking if the subsequent
braking power is greater than Pbrcont.

• After Pbr5 or Pbr10 braking, the drive and the chopper will withstand Pbr30 within a total braking
time of 30 seconds.

• Pbr10 braking is not acceptable after Pbr5 braking.

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Combined braking cycles for R8:

Examples

Pbr max 5 s, 10 s or 30 s

Pbr5, Pbr10 or Pbr30

Pbrcont
No braking t
min 60 s min 60 s

• After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont continuously.
(Pbrcont is the only allowed braking power after Pbr5, Pbr10 or Pbr30.)

• Pbr5, Pbr10 or Pbr30 braking is allowed once every minute.

After Pbrcont braking, there has to be at least 60 seconds without any braking if the subsequent
braking power is greater than Pbrcont.

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D. INSTRUCTIONS for the electrical installation of the Oil-free Air VSD compressors:
71B

1. General :

The electrical equipment of Atlas Copco Compressor is designed according to the safety regulations
described in IEC60204-1 or CENELEC EN60204.
It is the responsibility of the customers to install the compressor unit according to the safety regulation
in order to protect persons against electric shock from direct or indirect contact.

In drives with frequency converter leakage currents occur along the RFI filter and the cable capacities,
especially during the motor start. Class A leakage detection protections would switch-off the machine.
Therefore it is not recommended to use class A detection systems on frequency converters.

2. Installation instruction for TN, TT, IT :

In each network system (TN, TT or IT), the customer has to protect the installation using:

• Overcurrent protection by fuses

Or
• Automatic circuit breaker protection

With respect to the power distribution system an additional installation instruction is given:

2.1 Network type TN (TN-S, TN-C and TN-C-S) :

No additional protections have to be installed. If customers want to or have to install a leakage

detection device, it should be of type B and comply with IEC755 Amendment 2 “General requirements
for residual current operated protective devices”.

Atlas Copco advices to install the following earth-leakage detection device: BENDER RCMA 470LY
with external current transformer: http://www.bender.org/prod.html
H

2.2 Network type TT :

In case of TT-systems, safety regulations mostly impose the use of an earth-leakage circuit breaker
(e.l.c.b). In combination with frequency converters, the use of type B residual current operated
protective devices shall be used.

Atlas Copco advices to install the following earth-leakage detection device: BENDER RCMA 470LY
with external current transformer: http://www.bender.org/prod.html
H

2.3 Network type IT :

In IT-network systems, it is permissible that the power supply is continued in case of a first earth
leakage fault of a motor phase. However, the customer has to detect the first earth leakage fault. The
fault has to be indicated as an alarm (acoustic and visual). Otherwise, the first earth fault has to
initiate an automatic disconnection of the power supply (EN 60204-1 par.: 6.3).
However, the high frequency capacitive leakage currents, which are caused by frequency converters,
cannot be detected by standard earth-leakage detection systems. Atlas Copco recommends to install:
BENDER IRDH 275/435 http://www.bender.org/prod.html

Atlas Copco recommends not to connect the neutral conductor from the power supply to the
compressor unit. The exposed conductive parts of the installation have to be earthed locally. (EN
60204-1 par.: 7.2.3)

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