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Documente Profesional
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1. General
1.1. Objective
1.2. Products concerned- References- Sizes
1.3. Product design and manufacture
1.4. Exchange and repair
1.5. Assistance
3. Documentation
3.1. Catalogue
3.2. User's manual
3.3. M.I.T. Intranet
3.4. Vantive RGSA-Return Good Service Agreement- (formerly known as BEST)
6. Software
6.1. Starter software
6.2. Remote terminal software
6.3. Power Suite software workshop for motor starters
7. Installation diagnostics
7.1. The motor is turning but does not reach its nominal speed
7.2. The motor is not turning, even though there is current
7.3. The motor does not turn in the required direction
7.4. The ATS 7-segment displays are off
7.5. The display does not change when the keys are pressed
7.6. The motor speed is unstable
Contents - 1/2
REPAIR MANUAL
Contents - 2/2
REPAIR MANUAL
1. General
1.1. Objective
This document defines the policy and methods to be put in place in each country-based
organization for repairing the Altistart 48 locally.
Repairs are carried out using replacement parts supplied by SCHNEIDER. This comes solely
within the framework of the service agreement. Once this agreement has been signed, a
country will have a local representative responsible for this offer.
Section 1 - 1/4
REPAIR MANUAL
customer
faulty products
repaired products
APV4
national sales
office
faulty products
Standard replacement
repaired products
local technical
service centre SRES factory
For repair at the factory or for expert advice, consult the Intranet site:
http://139.160.73.11/portailDAS/ci.nsf/pages/accueilEN (Technical support and
Training/About support/What to do menu)
1.5. Assistance
Section 1 - 2/4
REPAIR MANUAL
When returning products, complete and attach the 'ATS48 additional information' form
(enclosed). This form will shortly be available on the Intranet.
Section 1 - 3/4
s ATS48 Additional information form
Date Submitted by Customer name:
Country:
PRODUCT CHARACTERISTICS
Reference: ATS48 Software version: V
Serial number: Install. date:
Other options:
CUSTOMER APPLICATION
Fan Pump Compressor Other machine:
MOTOR CHARACTERISTICS
Asynchronous motor Wound rotor motor Other motor:
SUPPLY
Measured voltage min/max Frequency 50/60 Hz = Neutral point connection TT IT TN
IMPORTANT: Please specify the conditions (pollution, humidity, etc) under which the starter is operating, who observed the fault, the state
of the installation and any modifications made to it, the stage in the sequence that the fault occurred (Acc, Dec, Speed, Load, etc), the
nature of the non-conformity. If possible, please attach the configuration file (Powersuite), the fault history log, diagrams and photos if
necessary.
ON-SITE SOLUTIONS
Have you changed the starter? Yes No By the same By another, which?
For the protection of equipment and personnel, the qualified maintenance technician should
implement the procedure detailed in this manual.
Read, interpret and follow the instructions and precautions described in this manual as
well as in other reference material
Use the necessary tools in a professional manner
2.2. Training
Section 2 - 1/2
REPAIR MANUAL
02/12/02
Section 2 - 2/2
REPAIR MANUAL
3. Documentation
3.1. Catalogue
http://www.schneider-electric.com
3.4. Vantive RGSA -Return Good Service Agreement- (formerly known as BEST)
This database is accessed via the SCHNEIDER Intranet.
Section 3 - 1/2
REPAIR MANUAL
Section 3 - 2/2
REPAIR MANUAL
-Thermal junction for semi-packs and temperature probe. Schneider reference for thermal joint:
1LUB004010
-Wire clamp
-Adhesive tape for repairing interconnecting ribbon cables (the ribbon cables are not identified in
the products)
-Wire cutter (for removing the wire clamps)
-PIF (small electrical torch) for testing electrical continuity, thyristors
Section 4 - 1/3
REPAIR MANUAL
Section 4 - 2/3
REPAIR MANUAL
Wiring for the cable connecting the test bench to the control terminal of the ATS48:
1
9
COM (0 V)
2
10
STOP
3
11
RUN
4
12
LI3
5
13
LI4
6
14
7 LO+
15
8
PL (+24V)
Section 4 - 3/3
CONSTRUCTION OF THE TEST PLATFORM
PAGE DESIGNATION EVOLUTION INDEX PAGE DESIGNATION EVOLUTION INDEX
FLYLEAF
RECAPITULATION PAGE
POWER
CONTROL SEQUENCE
CONTROL SEQUENCE
CONTROL SEQUENCE
CONTROL SEQUENCE
OPERATING LEGEND
OPERATING LEGEND
DOOR AND CABINET
CABINET-ATV66 CONNECTION
SUPPLY 380V TRIPHASE + NEUTRAL SUPPLY 220 V TRIPHASE
PC1: ON CABINET
ON CONSOLE DOOR ATV NETWORK SUPPLY
DOOR
CONTROL SEQUENCE SUPPLY
POWER
SINGLEPHASE TRIPHASE OPERATION VARIATOR POWER VOLTAGE CHOICE
OPERATION VALIDATION VALIDATION SWITCH ON FOR PLATFORM SUPPLY
PLATFORM
STOP
POWER
STOP
POWER
CONSOLE SWITCH ON
SWITCH ON STOP
VARIATOR
SECURITY
CONTROL SHUNT
SWITCH ON
SINGLEPHASE
RUN TRIPHASE
RUN RUN
380 V RUN
220 V
DEBUGGING INTERMEDIARY FORWARD BACKWARD BRAKE
RELAY RELAY RELAY RELAY RELAY
BRAKE RESISTANCE
ON CONSOLE ROOF
VOLTAGE
DIVIDER
VOLTMETER
ON CONSOLE FRONT SIDE
DEVICES OPERATING LEGEND
PAGE PAGE
REFERENCE COL
OPERATING DESCRIPTION SUPPLIER EQUIPMENT REFERENCE COL
OPERATING DESCRIPTION SUPPLIER EQUIPMENT
OPERATING LEGEND
DEVICES OPERATING LEGEND
PAGE
REFERENCE COL
OPERATING DESCRIPTION SUPPLIER EQUIPMENT
WHITE CAP
CONTROL ENERGISED LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
WHITE CAP
POWER ENERGISED LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
380 V LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
220 V LABEL
48 V BULB
INDICATOR LIGHT
BRAKING LABEL
130 V BULB
2.2 K POTENTIOMETER
27 OHMS 700 W RESISTANCE
27 OHMS 280 W RESISTANCE
PIN PLUG
TERMINAL + ACCESSORIES
TERMINAL + ACCESSORIES
BLUE CASING + BASEPLATE
OPERATING LEGEND
BRAKING RESISTANCE
2 TERMINALS
BRAKING-R
BRAKING INDUCED-I
BLUE
15-RECEPTACLE
CONNECTOR RED
GREEN
FRONT VIEW
GREY
UNLOCK
WHITE
YELLOW
BROWN
CABINET-ATV66 CONNECTION
MOTORS BENCH (380 525 V)
PAGE DESIGNATION EVOLUTION INDEX PAGE DESIGNATION EVOLUTION INDEX
FLYLEAF
RECAPITULATION PAGE
POWER
CONTROL SEQUENCE
CONTROL SEQUENCE
CONTROL SEQUENCE
CONTROL SEQUENCE
OPERATING LEGEND
OPERATING LEGEND
DOOR AND CABINET
CABINET-ATV66 CONNECTION
SUPPLY 380V TRIPHASE + NEUTRAL SUPPLY 525 V TRIPHASE
PC1: ON CABINET
ON CONSOLE ATV NETWORK SUPPLY
DOOR
CONTROL SEQUENCE SUPPLY DOOR
POWER
MOTORS BENCH (380-525 V)
SINGLEPHASE TRIPHASE OPERATION VARIATOR POWER VOLTAGE CHOICE
OPERATION VALIDATION VALIDATION SWITCH ON FOR PLATFORM SUPPLY
PLATFORM
STOP
POWER
STOP
RUN
EMERGENCY
380 V
STOP
POWER
SWITCH ON
CONSOLE
SWITCH ON STOP
VARIATOR
SECURITY
SHUNT
CONTROL
SWITCH ON
RUN
RUN 525 V
220 V
FORWARD
DEBUGGING BACKWARD
BRAKE RESISTANCE
ON CONSOLE ROOF
VOLTAGE
DIVIDER
VOLTMETER
ON CONSOLE FRONT SIDE
OPERATING LEGEND
MOTORS BENCH (380-525 V)
DEVICES OPERATING LEGEND
PAGE
REFERENCE COL
OPERATING DESCRIPTION SUPPLIER EQUIPMENT
WHITE CAP
CONTROL ENERGISED LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
WHITE CAP
POWER ENERGISED LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
380 V LABEL
48 V BULB
LUMINOUS PUSH-BUTTON
525 V LABEL
48 V BULB
INDICATOR LIGHT
BRAKING LABEL
130 V BULB
2.2 K POTENTIOMETER
27 OHMS 700 W RESISTANCE
27 OHMS 280 W RESISTANCE
PIN PLUG
TERMINAL + ACCESSORIES
TERMINAL + ACCESSORIES
BLUE CASING + BASEPLATE
OPERATING LEGEND
2 TERMINALS
BRAKING-R
BRAKING INDUCED-I
15-RECEPTACLE
CONNECTOR RED
GREEN
FRONT VIEW
GREY
UNLOCK
WHITE
YELLOW
BROWN
CABINET-ATV66 CONNECTION
Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes
(400 Volts) (690 Volts)
2-thyristor module VZ3TM2056M14 3 D17 to D32Q VZ3TM2056M18 3 D17 to D32Y A
2-thyristor module VZ3TM2091M14 3 D38 to D47Q VZ3TM2091M18 3 D38 to D47Y A
2-thyristor module VZ3TM2132M14 3 D62 to D75Q VZ3TM2132M18 3 D62 to D75Y B
2-thyristor module VZ3TM2162M14 3 D88 to C11Q VZ3TM2162M18 3 D88 to C11Y B
2-thyristor module VZ3TM2250M14 3 C14 to C17Q VZ3TM2250M18 3 C14 to C17Y C
2-thyristor module VZ3TM2500M14 3 C21to C32Q VZ3TM2500M18 3 C21to C32Y D
2-thyristor plug-in base VZ3TP2600M14 3 C41Q VZ3TP2600M18 3 C41Y E
6 C79Q 6 C79Y F
2-thyristor plug-in base VZ3TP2M12M16 3 C48 to C66Q VZ3TP2M12M18 3 C48 to C66Y E
6 M10 to M12Q 6 M10 to M12Y F
Control unit assembly VX4G481 1 All Q ratings VX4G481 1 All Y ratings
Filter board VX4G48161Q 1 D17 to D47Q VX4G48161Y 1 D17 to D47Y A
Filter board VX4G48162Q 1 D62 to C11Q VX4G48162Y 1 D62 to C11Y B
Filter board VX4G48163Q 1 C14 to C17Q VX4G48163Y 1 C14 to C17Y C
Filter board VX4G48164Q 1 C21 to C32Q VX4G48164Y 1 C21 to C32Y D
Firing circuit boards VX4G48165Q 6 C41 to C66Q VX4G48165Y 6 C41 to C66Y E
12 C49 to M12Q 12 C49 to M12Y F
The control unit contains the connections required for connecting to the power and the unlabelled terminal
For the power sections of ATS48, C41 to M12: the firing circuit board has a reference and should be ordered separately by the customer.
Section 5 - 1/4
REPAIR MANUAL
Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes
(400 Volts) (690 Volts)
Power board VX5G48D17Q 1 ATS48D17Q VX5G48D17Y 1 ATS48D17Y A
Power board VX5G48D22Q 1 ATS48D22Q VX5G48D22Y 1 ATS48D22Y A
Power board VX5G48D32Q 1 ATS48D32Q VX5G48D32Y 1 ATS48D32Y A
Power board VX5G48D38Q 1 ATS48D38Q VX5G48D38Y 1 ATS48D38Y A
Power board VX5G48D47Q 1 ATS48D47Q VX5G48D47Y 1 ATS48D47Y A
Power board VX5G48D62Q 1 ATS48D62Q VX5G48D62Y 1 ATS48D62Y B
Power board VX5G48D75Q 1 ATS48D75Q VX5G48D75Y 1 ATS48D75Y B
Power board VX5G48D88Q 1 ATS48D88Q VX5G48D88Y 1 ATS48D88Y B
Power board VX5G48C11Q 1 ATS48C11Q VX5G48C11Y 1 ATS48C11Y B
Power board VX5G48C14Q 1 ATS48C14Q VX5G48C14Y 1 ATS48C14Y C
Power board VX5G48C17Q 1 ATS48C17Q VX5G48C17Y 1 ATS48C17Y C
Power board VX5G48C21Q 1 ATS48C21Q VX5G48C21Y 1 ATS48C21Y D
Power board VX5G48C25Q 1 ATS48C25Q VX5G48C25Y 1 ATS48C25Y D
Power board VX5G48C32Q 1 ATS48C32Q VX5G48C32Y 1 ATS48C32Y D
Power board VX5G48C41Q 1 ATS48C41Q VX5G48C41Y 1 ATS48C41Y E
Power board VX5G48C48Q 1 ATS48C48Q VX5G48C48Y 1 ATS48C48Y E
Power board VX5G48C59Q 1 ATS48C59Q VX5G48C59Y 1 ATS48C59Y E
Power board VX5G48C66Q 1 ATS48C66Q VX5G48C66Y 1 ATS48C66Y E
Power board VX5G48C79Q 1 ATS48C79Q VX5G48C79Y 1 ATS48C79Y F
Power board VX5G48M10Q 1 ATS48M10Q VX5G48M10Y 1 ATS48M10Y F
Power board VX5G48M12Q 1 ATS48M12Q VX5G48M12Y 1 ATS48M12Y F
The voltage selection jumper (Q or Y) is placed on the power board at the production output + configuration in EEPROM
Section 5 - 2/4
REPAIR MANUAL
Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes
(690 Volts)
Temperature probe VZ3G001 1 D17 to C32Q VZ3G001 1 D17 to C32Y A,B,C,D
Temperature probe VZ3G002 1 C41 to M12Q VZ3G002 1 C41 to M12Y E,F
Fan assembly VZ3V481 1 D32 to D38Q VZ3V481 1 D32 to D38Y A
Fan assembly VZ3V4811 1 D47Q VZ3V4811 1 D47Y A
Fan assembly VZ3V482 1 D62 to C11Q VZ3V482 1 D62 to C11Y B
Fan assembly VZ3V483 1 C14 to C17Q VZ3V483 1 C14 to C17Y C
Fan assembly VZ3V484 1 C21 to C32Q VZ3V484 1 C21 to C32Y D
Fan assembly VZ3V485 1 C41to C66Q VZ3V485 1 C41to C66Y E
2 C79 to M12Q 2 C79Y to M12Y F
Section 5 - 3/4
REPAIR MANUAL
Section 5 - 4/4
REPAIR MANUAL
6. Software
Inversion of the state of the logic outputs (LO) in relation to those of the ATS46
This problem will be corrected in the next version of the software.
Accidental tripping (PhF fault) as soon as the Run command is sent: On control boards with date
codes before 25-2002, a component fault which may cause PhF faults to be triggered accidentally
as soon as the Run command is sent. The component concerned has been replaced in boards
with date codes starting at 25-2002.
Remedies:
-Set the FrC parameter to 50or 60
-Use a V1.1IE07 control board
PhF fault in steady state without bypass on lines subject to significant interference
Notes:
-A number of different faults may occur if ribbon cable J5, which connects the control board to the
power board, is connected incorrectly. Do not forget to lock the ribbon cable using the clamp once
you have inserted it into the connector.
-Precautions to be taken in order to reverse the direction of rotation of the motor with the ATS48
connected to the delta terminal. It is absolutely essential that the motor is wired as specified in the
user's manual. To reverse the direction of rotation of the motor, switch over 2 line phases and not
2 motor phases.
Section 6 - 1/2
REPAIR MANUAL
Section 6 - 2/2
REPAIR MANUAL
7. Installation diagnostics
7.1 The motor is turning but does not reach its nominal speed
-set In=nominal motor current Change the ATS for an ATS Rewire the motor connection
Solutions
-increase ILT,TLI,Tq0 with a higher rating if necessary
Section 7 - 1/6
REPAIR MANUAL
Section 7 - 2/6
REPAIR MANUAL
-Phr parameter
Check -ATS wiring to the supply
-ATS wiring to the motor
Section 7 - 3/6
REPAIR MANUAL
Section 7 - 4/6
REPAIR MANUAL
7.5 The 7-segment displays are but do not respond when the
keys are pressed
Keyboard inoperative or
Probable
disconnected, control card
causes
inoperative
Check
Results
Section 7 - 5/6
REPAIR MANUAL
Results
Section 7 - 6/6
REPAIR MANUAL
8.1. Preamble
On receipt of the product, carefully note down:
-The information on the ID label (label with bar code)
-The information on the control data plate attached to the flanges
-The power data on the rating plate attached to the flanges
-The version of the control unit on the label attached to the control unit
-The voltage on the yellow label attached to the control board terminal (marked DANGER)
If the faulty product is accompanied by a sheet describing the fault observed by the customer, use this
information to locate the faulty component. If not, follow the instructions below:
Examine the product visually (while switched off):
-Check the external physical state of the drive: look for traces of burning or overheating, parts that
have been subjected to knocks
-Check the connectors
-Check the state of the internal screws to determine whether the product has been dismantled
thyristor 1
Thyristor module
thyristor 2
Section 8 - 1/22
REPAIR MANUAL
Schematic diagram for qualitative testing of a thyristor on its plug-in base (sizes E/F)
Calculate R1 in order to obtain the current required to fire the thyristor and limit the gate current
Calculate R in order to limit the current drawn by the power supply but ensure it is sufficient to fire the
thyristor
Example: U=24 V R1=330 ohms R max.=15 ohms
Note: The anode-cathode voltage drop is approximately 1 V when the thyristor is closed.
R1
thyristor 1
mA R
Thyristor module
thyristor 2
+U 0
Test sequence:
1. Switch open => The thyristor circuit is open (lamp off, mA=0)
2. Close switch => The thyristor closes (lamp lights up, mA value no longer equal to 0)
3. Open switch => The thyristor remains closed (lamp on, mA value no longer equal to 0)
4. Reduce the voltage U to extinguish the thyristor
If operation differs from that described above, the thyristor has probably failed (short-circuit or open
circuit or leakage current)
Section 8 - 2/22
REPAIR MANUAL
Section 8 - 3/22
REPAIR MANUAL
Principle:
This fault appears if the ATS rating cannot be recognised (the rating is stored in code format in the
EEPROM on the power board).
This fault is stored in the EEPROM fault log.
Probable causes:
Power board faulty
Procedure, remedy:
Check the connection of the ribbon cables between the control board and the power board
Change the power board
Section 8 - 4/22
REPAIR MANUAL
Principle:
Probable causes:
Impeding short-circuit on starter output
Internal short-circuit on the ATS (thyristor short-circuit, etc.)
The bypass contactor will not open (or the contacts are stuck) or opens subject to a delay in
relation to relay R2
ATS undersized in relation to the motor
Procedure, remedy:
Power the ATS down in order to:
Check the power and motor cable insulation
Check the state of the thyristors (short-circuit)
Check the state of the bypass contactor
Experience to date:
Locked rotor (motor) and ATS undersized in relation to the motor power
Section 8 - 5/22
REPAIR MANUAL
Principle:
Reminder of IEC standards: These motor standards indicate that the motor shaft rotates in a clockwise
direction when motor terminals U, V and W are connected to line terminals L1, L2 and L3 respectively.
The ATS checks the phase rotation direction when the run command is sent. The user may configure
the phase rotation direction (forward or reverse) using parameter Phr. A PIF fault will occur if the line
phase sequence is opposite to that configured in the ATS (Phr parameter).
This fault is stored in the EEPROM fault log.
Probable cause:
The line phase rotation direction and the wiring on the ATS result in a line direction which is opposite
to that configured with the PHR parameter.
Procedure, remedy:
In the event of a PIF fault:
1-Invert the configuration of the PHR parameter
2-Shut down and then restart the ATS in order to acknowledge the PIF fault
3-Send a short run command in order to check the direction of rotation of the motor
There are two possible scenarios:
-The direction of rotation is correct => procedure complete
-The direction of rotation is incorrect => Switch over the 2 line phases (L1-L2 or L1-L3 or L2-L3) and
invert the configuration of the PHR parameter
Section 8 - 6/22
REPAIR MANUAL
Principle:
The EEPROM memory generates a report following a read/write request.
This fault appears if there is a problem (read or write) accessing the power or control EEPROMs.
Probable causes:
Power board EEPROM failed
Control board EEPROM failed
Procedure, remedy:
Disconnect then reconnect the control supply: if the fault does not disappear, replace the
control unit or power board.
Principle:
On power-up, the ATS checks its configuration. If it detects an anomaly, it triggers a CFF fault. The
CFF fault can be reset as soon as it disappears.
This fault is stored in the EEPROM fault log.
Probable causes:
Change in the ATS rating (the control board has been removed then reinstalled with a different
rating)
The electrical environment is subject to interference which has caused the configuration to be
read incorrectly
Procedure, remedy:
Force a factory setting (drive drc menu)
Shut down then restart the product (if the fault is due to electromagnetic interference during
the EEPROM read, it may disappear).
Principle:
If a configuration that has been downloaded (via the RJ45 socket) is inconsistent (invalid parameter
value, the functions configured are incompatible, etc.), the ATS will trigger a CFI fault.
This fault will be reset automatically once a consistent configuration has been downloaded.
This fault is not stored in the EEPROM.
Probable causes:
An inconsistent configuration has been downloaded (parameters outside limits for example)
Procedure, remedy:
Download a consistent configuration
Section 8 - 7/22
REPAIR MANUAL
Principle:
Motor current
Motor freewheeling
Phase fault PHF display flashing
function End of starting relay opens
R1 relay command
3-phase supply
Procedure, remedy:
Modify (increase) the PhL parameter setting
If the line is imbalanced, check the distribution of the loads on the 3 phases
Check that the thyristors are operating (firing) correctly
Experience to date:
Loss of the 3 line phases when the motor is running
Loss of the 3 motor phases when the motor is running or starting up
Loss of a single power phase
Motor rating undersized in relation to the rating of the ATS
Wiring error with the ATS connected in the motor delta winding. Connect the ATS as
recommended in the diagram in the user's manual.
Section 8 - 8/22
REPAIR MANUAL
Principle:
The line frequency (abbreviated to Fr in this document) is checked when the control unit is powered up
by measuring the line period. If Fr is within the permissible tolerances, it will not be checked again
unless the control unit is powered down.
The fault thresholds are determined by the value of the FRC parameter:
-FRC =50: fault indicating that Fr is outside the range [40-60Hz] (tolerance at 50 Hz: +/- 20%)
-FRC =60: fault indicating that Fr is outside the range [48-72Hz] (tolerance at 60 Hz: +/- 20%)
-FRC =AUT: fault for [Fr< 47.5 Hz] or [52.5 Hz< Fr< 57 Hz] or [Fr> 63 Hz]
Probable causes:
Line supply outside the tolerances permitted by the ATS
Use of a generating set with a frequency that varies outside the limits permitted by the ATS
and/or ATS configured for automatic detection (FRC parameter = AUT)
The start command for the motor is being sent as soon as the control unit is powered up
Procedure, remedy:
Configure FRC=50 or FRC=60 as the tolerance is too broad for these configurations
Check the line frequency and its stability on control power-up
Section 8 - 9/22
REPAIR MANUAL
Principle:
Line supply
No line supply USF display flashing
function End of starting relay opens
Run command R1 relay command
When a run command is sent, the ATS checks that the line voltage is present on the power part (L1;
L2; L3).
Trip threshold: Loss of all three line phases simultaneously for 350 ms following the run command.
This fault is stored in the EEPROM fault log.
Procedure, remedy:
Check the power supply sequence
Disconnect then reconnect the control supply for the ATS without sending a run command: heck
that the ATS shows nLP
Connect the power part and check that the ATS shows RDY
Experience to date:
Loss of the 3 line phases when the run command is sent
Section 8 - 10/22
REPAIR MANUAL
Principle:
The ATS monitors the control voltage via the 2 terminals (CL1-CL2) on the 'control unit'
This fault is encountered very infrequently as it is usually transient. The voltage must rise again in
order for the switch mode power supply to be present during operation.
CLF fault trip threshold:
- Voltage less than approx. 40% of 220 V for the ATS48Q (threshold = 88 V)
- Voltage less than approx. 40% of 110 V for the ATS48Y (threshold = 44 V)
Probable causes:
Loss of the line voltage for at least 200 ms on terminals CL1-CL2
Voltage thresholds exceeded
Procedure, remedy:
Check the value of the voltage at terminals CL1-CL2: if the voltage is within the tolerances,
replace the power board
Check the quality of the line supply
Section 8 - 11/22
REPAIR MANUAL
Principle:
The ATS can communicate with the following devices via the RJ45 socket:
-The remote terminal
-A PC (Power Suite software)
-A PPC (Power Suite software)
-A PLC
Probable causes:
Incorrect wiring between the ATS (RJ45 socket) and the peripheral device
Inconsistent communication protocol (incompatible communication parameters)
Procedure, remedy:
Check the wiring between the ATS (RJ45 socket) and the peripheral device
Check the minimum configuration required on the PC for communication
Check the consistency of the configuration of the serial link (protocol, speed, parity, etc.)
Section 8 - 12/22
REPAIR MANUAL
Principle:
Line/Local configuration
This function enables the user to apply an external command to the ATS in order to switch it to fault
mode.
Trip conditions:
- Local mode: One terminal logic input assigned to the function (active on level)
- Line mode (via the RJ45 socket): Using a PC/PPC/communication module, write the bit
corresponding to this fault
This fault is stored in the EEPROM fault log.
Probable causes:
An 'external fault' command has been sent to the ATS by a PC (via the RJ45 socket)
A terminal logic input has been assigned to the 'external fault' function (active)
Procedure, remedy:
This operation only affects the management of the ETF fault for the application.
Section 8 - 13/22
REPAIR MANUAL
Principle:
R1 relay opens
Excessive starting time End of starting relay opens
Run command
function StF display flashing
Probable causes:
Excessive resistive torque during starting
Parameter setting In lower than the nominal motor current indicated on the rating plate
TLS parameter setting too low
ILT parameter setting (limiting current) too low
Drive parameters configured incorrectly (ILT,TLI , tq0, LSC parameters)
ATS undersized
Procedure, remedy:
Modify the following settings (depending on the application):
Increase ILT
Increase tq0 (initial torque)
Increase TLI (torque limit)
Experience to date:
Motor overloaded during starting
Section 8 - 14/22
REPAIR MANUAL
Principle:
The overload event is controlled in continuous operation (whether the ATS is bypassed or not)
The 'overload' event is processed depending on the configuration of the OIL parameter:
- OIL = Off: event ignored
- OIL = ALA: switch to alarm mode
- OIL = DEF: switch to alarm mode and to OLC fault
The overload time can be adjusted using the TOL parameter (increment = 0.1 second)
The current threshold can be set using the LOC parameter. Threshold =(LOC*In)/100 where LOC is a
% of In
Probable causes:
-Nominal motor current setting too low (In parameter)
-Motor overloaded in continuous operation
-ATS rating too low
Procedure, remedy:
-Set In > nominal motor current (nominal current on motor rating plate)
-Use an ATS with a higher rating
Section 8 - 15/22
REPAIR MANUAL
Principle:
Thresholds for changing to thermal fault mode: Cu thermal state > 200% or Fe thermal state > 125%
Threshold for changing to alarm mode: iron thermal state > 110%
Only the iron thermal state appears on the display (thr parameter)
In the event of a power failure, the downtime is measured by the ATS and used to estimate the motor
thermal state when the power is restored.
This fault can only be reset if the copper thermal state < 170% and the iron thermal state < 110%.
This fault is stored in the EEPROM fault log.
Probable causes:
Motor overloaded
Starting cycles too severe (number of starts, duration, etc.)
Selected protection class too severe
Procedure, remedy:
Change the thermal protection class by increasing the value of the tHp parameter.
Section 8 - 16/22
REPAIR MANUAL
Principle:
Delay=2 s
On range Y ATS products (fitted with a current transformer for each phase), the total of the 3 motor
phase currents is measured in continuous operation.
Fault trip threshold: I motor > 1.25 * I nominal motor for 2 seconds
This fault is stored in the EEPROM fault log.
Note: The fault code associated with the insulation fault is identical to the motor thermal fault
code (OLF).
Probable causes:
Motor not insulated correctly
Motor cables not insulated correctly
ATS insulation fault (filter board on sizes A/B/C/D)
Procedure, remedy:
Check the insulation of the cables, the motor and the ATS (filter board on sizes A/B/C/D)
Section 8 - 17/22
REPAIR MANUAL
Principle:
Heatsink temperature
measurment Fan command (*)
(PTC probe) Starter thermal R1 relay opens
function End of starting relay opens
Motor current OhF display flashing
measurement (Lcr param)
Procedure, remedy:
-Check the supply voltage to the fans (12 V DC)
-Check the fan connections
-Ventilate the ATS
-Bypass the ATS
-Derate the ATS
-Choose an ATS with a higher rating
Section 8 - 18/22
REPAIR MANUAL
Principle:
Probable causes:
Ambient temperature too high (above 40C)
PTC probe short-circuit or open circuit
PTC characteristics incorrect (ohmic value, operating curve)
Motor not ventilated correctly
Motor overloaded
Section 8 - 19/22
REPAIR MANUAL
Principle:
The ATS monitors the motor load in continuous operation (bypassed or not)
ULL = Off adjustment parameters not visible on the HMI
ULL <> Off adjustment parameters visible on the HMI
The underload threshold (% of Cn) and the detection time (seconds) can be adjusted.
Hysteresis: +10% in relation to the trip threshold
The 'underload' event is processed depending on the configuration of the ULL parameter:
- ULL = Off : the event is ignored
- ULL = ALA: switch to alarm mode
- ULL = DEF: switch to alarm mode and to ULF fault
Experience to date:
Motor underloaded (below the ULL parameter threshold) in continuous operation
Section 8 - 20/22
REPAIR MANUAL
Principle:
In parameter
R1 relay opens
Motor current Locked rotor in
End of starting relay opens
(Lcr param) continuous operation
function
LrF display flashing
Procedure, remedy:
-Increase (if possible) the value of the In parameter (nominal motor current)
-Check that the rating of the ATS and the motor are sufficient for the application.
Experience to date:
High resistive torque surge
Section 8 - 21/22
REPAIR MANUAL
Section 8 - 22/22
REPAIR MANUAL
Section 9 - 1/32
REPAIR MANUAL
Reference documents:
-Wiring diagram for size A to D products No. 1494468A42
-Diagram of assembled product (size A) No. 1494408
-Parts lists
3. -Position the control unit then fix it in place using the 4 screws (S1, S2, S3, S4), observing the
tightening torques of 2 Nm.
Section 9 - 2/32
REPAIR MANUAL
Section 9 - 3/32
REPAIR MANUAL
Section 9 - 4/32
REPAIR MANUAL
Section 9 - 5/32
REPAIR MANUAL
Section 9 - 6/32
REPAIR MANUAL
Section 9 - 7/32
REPAIR MANUAL
Reference documents:
- Wiring diagram for size A to D products No. 1494468
- Diagram of assembled product (size B) No. 1494462
- Parts list
3. Position the control unit then fix it in place using the 4 screws (S1, S2, S3, S4), observing the
tightening torques of 2 Nm.
Section 9 - 8/32
REPAIR MANUAL
Section 9 - 9/32
REPAIR MANUAL
Section 9 - 10/32
REPAIR MANUAL
Section 9 - 11/32
REPAIR MANUAL
Reference documents:
- Wiring diagram for size A to D products No. 1494468
- Diagram of assembled product No. 1494463
-Parts lists
3. Position the control unit then fix it in place using the 4 screws (S1, S2, S3, S4), observing the
tightening torques of 2 Nm.
Section 9 - 12/32
REPAIR MANUAL
Section 9 - 13/32
REPAIR MANUAL
Section 9 - 14/32
REPAIR MANUAL
Section 9 - 15/32
REPAIR MANUAL
Section 9 - 16/32
REPAIR MANUAL
Size C product - views of the filter board, thyristors, etc. (view from below)
Section 9 - 17/32
REPAIR MANUAL
Section 9 - 18/32
REPAIR MANUAL
Reference documents:
- Wiring diagram for size A to D products No. 1494468
- Diagram of assembled product No. 1494464
-Parts lists
3. Position the control unit then fix it in place using the 4 screws (S1, S2, S3, S4), observing the
tightening torques of 2 Nm.
Section 9 - 19/32
REPAIR MANUAL
Section 9 - 20/32
REPAIR MANUAL
Section 9 - 21/32
REPAIR MANUAL
Section 9 - 22/32
REPAIR MANUAL
Section 9 - 23/32
REPAIR MANUAL
Reference documents:
- Diagram of assembled product No. 1494465A53 (f 1/2; 2/2)
-Assembly drawing for 'power sub-assembly' No. 149448A53
-Wiring diagram for sizes E and F No. 1494469A42
-Parts lists
Section 9 - 24/32
REPAIR MANUAL
-The ribbon cable (C10) which connects the connector (J10) on the power board to the J4
connectors on the firing circuit boards.
4. Remove the 4 torcx fixing screws (S84 to S87) from the base (27).
5. Remove the 'bases + power board' assembly (27, 2/2) from the product.
9.6.5. Dismantling the 'plug-in power unit + motor, bypass, line rails' power sub-
assembly
1. Dismantle the control unit (section 9.6.1).
2. Dismantle the power board sub-assembly (section 9.6.3).
3. Dismantle the synchronization rail (22) which connects the 3 firing circuit boards and is fixed in
place by 3 screws (S68;S70;S72).
-Do the same for the other synchronization rail (23) which is fixed in place by 3 screws
(S67;S69;S71).
4. Once you have labelled them, disconnect the ribbon cables:
_Fans (connected to J5 on the firing circuit board)
_Current transformer (connected to J3 on the firing circuit board)
_Ribbon cables connected to J1; J4 on the firing circuit board
Section 9 - 25/32
REPAIR MANUAL
7. Remove the 'plug-in base + motor, bypass, line rails' assembly from the product using the 2
extraction lugs provided (03; 05).
8. Remove the bypass and motor power rails (14; 17) which are fixed in place by 2 screws (S33;
S34).
9. Remove the line supply power rail (11) which is fixed in place by 2 screws (15; 16).
9.6.6. Assembling the 'plug-in power unit + motor, bypass, line rails' sub-assembly
1. Fix the line supply power rail (11) in place on the plug-in power unit using the 2 screws (15; 16).
2. Fix the bypass and motor power rails (14; 17) in place on the plug-in power unit using the 2
screws (S33; S34).
3. Insert the 'plug-in power unit + firing circuit + motor power rail + bypass power rail' assembly into
the product using the 2 extraction lugs provided (03; 05).
4. Fix the plug-in power unit in place using the 5 screws (S9;S17;S27;S35;S154), observing the
tightening torque of 9 Nm.
5. Fix the cable clamp(s) in place.
6. Plug the fan, current transformer and power board ribbon cables (labelled when they were
unplugged) into connectors J1-J3-J4-J5 on the firing circuit board.
7. Assemble the synchronization rail (22) which connects the 3 firing circuit boards using the 3
screws (S68;S70;S72), observing the tightening torque of 2 Nm.
8. Assemble the synchronization rail (23) which connects the 3 firing circuit boards and the earthing
strip (32) using the 3 screws (S67;S69;S71), observing the tightening torque of 2 Nm.
9. Assemble the 'power board' sub-assembly (section 9.6.4 no. 4;5;6).
10. Assemble the control unit (section 9.6.2).
Section 9 - 26/32
REPAIR MANUAL
Reference documents:
- Diagram of assembled product (size F) No. 1494466-53 (f 1/3; 2/3;3/3)
-Assembly drawing for 'power sub-assembly' No. 149448-53
-Size E/Size F wiring diagram No. 1494469-42
-Parts lists
Ribbon cable C3: power board-J7 connected to J1-firing circuit board 11 (with ferrite on power
board side)
Ribbon cable C4: power board-J1 connected to J1-firing circuit 1 (with ferrite on power board
side)
Section 9 - 27/32
REPAIR MANUAL
Ribbon cable C5: power board-J8 connected to J1-firing circuit 21 (with ferrite on power board
side)
Ribbon cable C6: power board J2 connected to J1-firing circuit 2 (with ferrite on power board
side)
Ribbon cable C7: power board-J9 connected to J1-firing circuit 31 (with ferrite on power board
side)
Ribbon cable C8: power board J3 connected to J1-firing circuit 3 (with ferrite on power board
side)
-The 3 ribbon cables with ferrites (C11, C12, C13 on the wiring diagram) which connect the
connectors (J13,J14,J15) on the power board with the J6 connectors on the firing circuit boards.
Ribbon cable C11: power board-J13 connected to J6-firing circuit 1 (with ferrite on power
board side)
Ribbon cable C12: power board-J14 connected to J6-firing circuit 2 (with ferrite on power
board side)
Ribbon cable C13: power board-J15 connected to J6-firing circuit 3 (with ferrite on power
board side)
-The 2 ribbon cables (C9, C10 on the wiring diagram) which connect the connectors (J10,J11) on
the power board with the J4 connectors on the firing circuit boards.
5. Remove the 2 screws + washers (S347 to S352, 3/3) and the 4 torcx fixing screws (S219 to S222,
3/3) from the size F power board base (52, 3/3):
6. Remove the size F power board base assembly (52, 2/3) from the product.
Section 9 - 28/32
REPAIR MANUAL
7. Once you have marked the power board side and the top (or bottom) on the machine ground (49,
3/3), remove the machine ground by unscrewing the 4 torcx fixing screws (S209 to S212, 3/3).
8. Once you have marked the assembly direction of the power board (welding panel on the machine
ground side, J16;J11;J10 connectors pointing upwards) on the machine ground (49), remove the
board by unscrewing the 6 fixing screws (S213 to S218, 3/3).
1. Position the power board on the machine ground (49, 3/3) (threaded pin side down) using the 3
plastic centring pins.
2. Fix the power board in place on the machine ground (49, 3/3) using the 6 screws (S213 to S218,
3/3), observing the tightening torque of 2 Nm.
3. Fix the 'machine ground + power board' (49, 3/3) in place on the power board base (52, 3/3),
making sure it is facing the right way (component side of the power board facing the base window
and top of the board pointing upwards).
4. Position the power board base (52, 3/3) on the panels (45;46, 3/3) then fix it in place by tightening
the 2 screws (S347 to S352) to a tightening torque of 3.5 Nm and the 4 torcx screws (S219 to
S222) to a tightening torque of 2 Nm.
5. Connect:
-The 6 ribbon cables (C3,C4,C5,C6,C7,C8 on the wiring diagram) - labelled when they were
disconnected - which connect connector J1 on each firing circuit board to the connectors on the
power board (J1,J2,J3,J7,J8,J9).
-The 3 ribbon cables (C11, C12, C13 on the wiring diagram) which connect the connectors
(J13,J14,J15) on the power board to the J6 connectors on the firing circuit boards.
-The 2 ribbon cables (C9, C10 on the wiring diagram) which connect the connectors (J10,J11) on
the power board to the J4 connectors on the firing circuit boards.
Section 9 - 29/32
REPAIR MANUAL
6. Dismantle the 'balancing choke + motor - bypass + current transformer' sub-assembly (38;41;44,
2/3): screw (S163;S167;S251, 2/3).
7. Remove the line supply power rail (24, 2/3): screw (S62;S66).
8. Remove the 4 fixing screws (S304;S313;S280;S288, 2/3) from the 'plug-in base + motor, bypass,
line rails' assembly.
9. Remove the 'plug-in base + motor, bypass, line rails' assembly from the product using the 2
extraction lugs provided (03; 05, power sub-assembly diagram).
10. Remove the bypass and motor power rails (14; 17) which are fixed in place by 2 screws (S33;
S34).
11. Remove the line supply power rail (11) which is fixed in place by 2 screws (15; 16).
1. Fix the line supply power rail (18) in place on the plug-in power unit using the 2 nuts (S37;S38).
2. Fix the motor side power rail (14; 17) in place on the plug-in power unit using the 2 nuts
(S91;S92).
3. Insert the 'plug-in power unit + firing circuit board + motor power rail + bypass power rail' assembly
into the product using the 2 extraction lugs provided (03; 05 power sub-assembly diagram).
4. Fix the plug-in power unit in place using the 4 screws (S304;S13;S288;S280, 2/3), observing the
tightening torque of 9 Nm.
5. Assemble the 'balancing choke + motor - bypass + current transformer' sub-assembly (38;41;44,
2/3) using the 3 screws (S163;S167;S251, 2/3).
6. Fix the cable clamp(s) in place.
7. Plug the fan, current transformer and power board ribbon cables (labelled when they were
unplugged) into connectors J1-J3-J4-J5 on the firing circuit board.
8. Assemble the synchronization rail (22) which connects the 3 firing circuit boards using the 3
screws (S68;S70;S72), observing the tightening torque of 2 Nm.
9. Assemble the synchronization rail (23) which connects the 3 firing circuit boards and the earthing
strip (32) using the 3 screws (S67;S69;S71), observing the tightening torque of 2 Nm.
10. Assemble the 'power board' sub-assembly (section 9.6.4 no. 4;5;6).
11. Assemble the control unit (section 9.6.2).
Section 9 - 30/32
REPAIR MANUAL
Section 9 - 31/32
REPAIR MANUAL
Section 9 - 32/32
REPAIR MANUAL
Once a device has been repaired, its operation can be checked in several ways.
- Manually (the simplest method)
- Using a PC with Autodiagnostic software
- Test on a test bench
2. Test using a motor with a rating much lower than that of the ATS
Use a no-load or inert motor for the test.
Apply the factory settings then configure the ATS for a small motor (FCS parameter)
Activate a run command on the RUN and STOP logic inputs of the control terminal (+24 V) =>
-The speed of the motor rises then is constant. The bypass relay must close at the end of the starting
phase.
-The diode (LED) connected to logic output LO2 should light up.
Activate a run command on the RUN and STOP logic inputs (0 V) =>
-The bypass relay should open then the motor should stop according to the stop configured (StY
parameter)
-The diode (LED) connected to logic output LO2 should go out once all the current has been
discharged from the motor
Repeat the tests for the 2 other possible stops (modification of the StY parameter)
Section 10 - 1/2
REPAIR MANUAL
Schematic diagram (3-wire control) for a control and monitoring unit for manual testing
STOP
RUN
LI3
LI4
PL (+24V)
LO+
LED 1
R1 R1=2.2 kOhms
LO1
LED 2
LO2 R2 R2=2.2 kOhms
mA
AO1 R3 R3= 500 Ohms max.
COM (0 V)
P1
PTC1
PTC2 P1= 750 Ohms
CL1
CL2 Control supply A.C
R1A (NO)
R1C (NO)
R2A (NO)
R2C (NO)
R3A (NO)
R3C (NO)
Section 10 - 2/2
REPAIR MANUAL
Ratings D17-D22-D32-D38-D47-D62-D75-D88-C11-C14-C17
Diagram no. 1625086
Ratings C21-C25-C32
Diagram no. 1625088
Ratings C41-C48-C59-C66-C79-M10-M12
Diagram no. 1625090
Size A products
Diagram no. 1625092
Size B products
Diagram no. 1625094
Size C products
Diagram no. 1625096
Size D products
Diagram no. 1625098
Section 11-1/1
REPAIR MANUAL
Section 12
CLIC ME !
To print all the
SCHNEIDER TOSHIBA INVERTER EUROPE
document PACY BLANCHET
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S324 S325
S326 S327 S328 S329
S330 S331 S332 S333
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S324 S325
S326 S327 S328 S329
S330 S331 S332 S333
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S324 S325
S326 S327 S328 S329
S330 S331 S332 S333
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S324 S325
S326 S327 S328 S329
S330 S331 S332 S333
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S325 S326
S327 S328 S329 S330
S331 S332 S333
V1631000 ROND M10 AC ZNC GRC P 42 S62 S63 S67 S68 S72
S73 S77 S78 S82 S83
S87 S88 S116 S117
S121 S122 S126 S127
S131 S132 S136 S137
S141 S142 S150 S151
S159 S160 S168 S169
S322 S323 S324 S325
S326 S327 S328 S329
S330 S331 S332 S333
Cable ID From To
on diagram
C Power board-J1 (2 pts) Current transformer motor phase 1
C Power board-J2 (2 pts) Current transformer motor phase 2
C Power board-J3 (2 pts) Current transformer motor phase 3
C1 Power board-J5 (flat cable) Control board
C2 Power board-J6 (6 pts) Control board
C3 Power board-J11 (2 pts) Thyristor phase 1
C3 Power board-J12 (2 pts) Thyristor phase 1
C4 Power board-J21 (2 pts) Thyristor phase 2
C4 Power board-J22 (2 pts) Thyristor phase 2
C5 Power board-J31 (2 pts) Thyristor phase 3
C5 Power board-J32 (2 pts) Thyristor phase 3
C6 Power board-J4 (6 pts) Control board
C7 Power board-J9 (6 pts)
C8 Power board-J8 (4 pts/6 pts depending on size) Fans
No ID Power board-J7 (2 pts) Thermal probe, product heatsink
Section 13 - 1/8
REPAIR MANUAL
Wiring for ribbon cables with 2 connection points (C) which connect J1, J2, J3 on the power board to the current transformers:
J1.1 (CI1.0-white wire) Connected to current transformer motor phase 1 (2T1)
J1.2 (2.5V-black wire) Connected to current transformer motor phase 1 (2T1)
J2.1 (CI2.0-white wire) Connected to current transformer motor phase 2 (4T2) (range Y)
J2.2 (2.5V-black wire) Connected to current transformer motor phase 2 (4T2) (range Y)
J3.1 (CI3.0-white wire) Connected to current transformer motor phase 3 (6T3)
J3.2 (2.5V-black wire) Connected to current transformer motor phase 3 (6T3)
Wiring for the ribbon cable (C1) which connects J5 on the power board to the control board:
Wiring for the ribbon cable with 6 connection points (C2) which connects J6 on the power board to the control board:
J6.1 (0VCL-black wire) Connected to connector J on the control board
J6.2 (24VCL-white wire) Connected to connector J on the control board
J6.3 N.C
J6.4 N.C
J6.5 (0VLS-black wire) Connected to connector J on the control board
J6.6 (10VLS-white wire) Connected to connector J on the control board
Ribbon cable (C3) which connects J11 on the power board to the thyristors
J11.1 Connected to pin 4 on thyristor module phase 1
J11.2 Connected to pin 5 on thyristor module phase 1
Ribbon cable (C3) which connects J12 on the power board to the thyristors
J12.1 Connected to pin 7 on thyristor module phase 1
J12.2 Connected to pin 6 on thyristor module phase 1
Section 13 - 2/8
REPAIR MANUAL
Ribbon cable (C4) which connects J22 on the power board to the thyristors
J22.1 Connected to pin 7 on thyristor module phase 2
J22.2 Connected to pin 6 on thyristor module phase 2
Ribbon cable (C4) which connects J21 on the power board to the thyristors
J21.1 Connected to pin 4 on thyristor module phase 2
J21.2 Connected to pin 5 on thyristor module phase 2
Ribbon cable (C5) which connects J32 on the power board to the thyristors
J32.1 Connected to pin 7 on thyristor module phase 3
J32.2 Connected to pin 6 on thyristor module phase 3
Ribbon cable (C5) which connects J31 on the power board to the thyristors
J31.1 Connected to pin 4 on thyristor module phase 3
J31.2 Connected to pin 5 on thyristor module phase 3
Ribbon cable with 6 connection points (C6) which connects J4 on the power board to the control board
J4.1 (CL1-black wire) Connected to connector J on the control board
J4.2 nc
J4.3 nc
J4.4 nc
J4.5 nc
J4.6 (CL2-white wire) Connected to connector J on the control board
Section 13 - 3/8
REPAIR MANUAL
Wiring for the ribbon cable (C8) which connects J8 on the power board to the fans (product sizes A, B, C):
J8.1 (12VCC-red wire) Connected to the fan on the right-hand side
J8.2 (CMDV1-black wire) Connected to the fan on the right-hand side
J8.3 (12VCC-red wire) Connected to the fan on the left-hand side
J8.4 (CMDV2-black wire) Connected to the fan on the left-hand side
Wiring for the ribbon cable (C8) which connects J8 on the power board to the fans (product size D):
J8.1 (12VL-red wire) Connected to the fan on the right-hand side
J8.2 (12VL-black wire) Connected to the fan on the right-hand side
J8.3 (12VL-red wire) Connected to the fan in the centre
J8.4 (12VL-black wire) Connected to the fan in the centre
J8.5 (12VL-red wire) Connected to the fan on the left-hand side
J8.6 (0VCC-black wire) Connected to the fan on the left-hand side
Wiring for the ribbon cable (no ID) which connects J7 on the power board to the thermal probe
J7.1 (red wire) Connected to thermal probe (fixed on heatsink)
J7.2 (black wire) Connected to thermal probe (fixed on heatsink)
Section 13 - 4/8
REPAIR MANUAL
Section 13 - 5/8
REPAIR MANUAL
Wiring for the ribbon cable which connects J3 on the power board to J1 on firing circuit board no. 3
J3.1 on the power board connected to J1.1 on firing circuit board no. 3 with ferrite on power board side
J3.2 on the power board connected to J1.2 on firing circuit board no. 3 with ferrite on power board side
J3.3 on the power board connected to J1.3 on firing circuit board no. 3 with ferrite on power board side
J3.4 on the power board connected to J1.4 on firing circuit board no. 3 with ferrite on power board side
J3.5 on the power board connected to J1.5 on firing circuit board no. 3 with ferrite on power board side
J3.6 on the power board connected to J1.6 on firing circuit board no. 3 with ferrite on power board side
J3.7 on the power board connected to J1.7 on firing circuit board no. 3 with ferrite on power board side
J3.8 on the power board connected to J1.8 on firing circuit board no. 3 with ferrite on power board side
Wiring for the ribbon cable which connects J10 on the power board to J4 on the firing circuit boards
J10.1 on the power board connected to J4.1 on firing circuit board no. 3
J10.2 on the power board connected to J4.2 on firing circuit board no. 3
J10.3 on the power board connected to J4.1 on firing circuit board no. 2
J10.4 on the power board connected to J4.2 on firing circuit board no. 2
J10.5 on the power board connected to J4.1 on firing circuit board no. 1
J10.6 on the power board connected to J4.2 on firing circuit board no. 1
Wiring for the ribbon cable which connects J13 on the power board to J6 on firing circuit board no. 1
J13.1 on the power board connected to J6.1 on firing circuit board no. 1 with ferrite on power board side
J13.6 on the power board connected to J6.6 on firing circuit board no. 1 with ferrite on power board side
Section 13 - 6/8
REPAIR MANUAL
Section 13 - 7/8
REPAIR MANUAL
Wiring for the ribbon cable (C3) which connects J7 on the power board to J1 on firing circuit board 11:
J7.1 on the power board connected to J1.1-firing circuit board 11
J7.2 on the power board connected to J1.2-firing circuit board 11
J7.3 on the power board connected to J1.3-firing circuit board 11
J7.4 on the power board connected to J1.4-firing circuit board 11
J7.5 on the power board connected to J1.5-firing circuit board 11
J7.6 on the power board connected to J1.6-firing circuit board 11
J7.7 on the power board connected to J1.7-firing circuit board 11
J7.8 on the power board connected to J1.8-firing circuit board 11
Wiring for the ribbon cable (C9) which connects J11 on the power board to J4 on the firing circuit boards
J11.1 on the power board connected to J4.1-firing circuit board 3
J11.2 on the power board connected to J4.2-firing circuit board 3
J11.3 on the power board connected to J4.1-firing circuit board 31
J11.4 on the power board connected to J4.2-firing circuit board 31
J11.5 on the power board connected to J4.1-firing circuit board 2
J11.6 on the power board connected to J4.2-firing circuit board 2
Wiring for the ribbon cable (C10) which connects J10 on the power board to J4 on the firing circuit boards
J10.1 on the power board connected to J4.1-firing circuit board 21
J10.2 on the power board connected to J4.2-firing circuit board 21
J10.3 on the power board connected to J4.1-firing circuit board 1
J10.4 on the power board connected to J4.2-firing circuit board 1
J10.5 on the power board connected to J4.1-firing circuit board 11
J10.6 on the power board connected to J4.2-firing circuit board 11
Section 13 - 8/8
REPAIR MANUAL
Section 14 - 1/1
Line chokes
VZ1 L . . . . . . . .
Remote console
+
or cable
VW3G48101
P.C. software
+
or cable, CD, Diskettes
VW3A 8 . . .
connection
RJ45
P.P.C. offer
or +
cables, CD, Diskettes
VW3A 8 . . . .
or Communication module
CL1
Customer Current and voltage Polarity of motor
terminal Switch mode power supply Firing circuits
synchronisation stator voltages
Power supply
CL2
Temperature
Heatsink
Sensor(s)
Fans
A2
1L1 TC 1 2T1
B2
3L2 TC 2 4T2
C2
5L3 TC 3 6T3
PE
PE
RC Thyristor + Filter Element RC Thyristor + Filter Element RC Thyristor + Filter Element
Phase L1- U - PE Phase L2- V- PE Phase L3 -W - PE
Appendix 2
Customer terminals Customer terminals Connector
I/O - motor PTC Relays - Control circuit supply Serial link + remote terminal
Control Board
J4 (5-pin) J6 (6-pin) J7 (6-pin) J5 (30-pin)
Connection
Power supply connection
Keypad power board-control board (micro zone)
power board-control board
connection ( Power supply - Current, voltage feedbacks, PTC-
supply
(customer zone) and (L-S zone)
Thyristor commands, fan-EEPROM)
Control circuit
J4 (5-pin) J6 (6-pin) J5 (30-pin)
Fan
Sensor
Temperature
connection
Connection
connection
connection
Gate-Cathode
Gate-Cathode
Fans
connection
connection
connection
Gate-Cathode
Gate-Cathode
Temperature
connection
connection
Gate-Cathode
Gate-Cathode
1, 2 and 3
U phase curent sensor
Heatsink
connection
Sensor
W phase current sensor
Appendix 3
Customer terminals Customer terminals Connector
I/O - motor PTC Relays - Control circuit supply Serial link + remote terminal
Control Board
J4 (5-pin) J6 (6-pin) J7 (6-pin) J5 (30-pin)
Connection
Power supply connection
Keypad power board-control board (micro zone)
power board-control board
connection ( Power supply - Current, voltage feedback, PTC-
supply
(customer zone) and (L-S zone)
Thyristor commands, fan-EEPROM)
Control circuit
J4(5-pin) J6 (6-pin) J5 (30-pin)
L1-T1
feedback and temperature sensors Connection thyristor commands,
synchro.
current feedback and temperature Connection thyristor commands,
L2-T2
V1-V2-V3 TE & F
synchro.
sensors fan current feedback and
J1 (8-pin) J6 (6-pin) V4-V5-V6 TF
temperature sensors
Filter Element
J2 (2-pin)
L3 -T3 synchro.
Phase L1- U PE
J1 (8-pin) J6 (6-pin)
Firing circuit board + RC thyristor
Filter Element
J7,J8 J9,J10 J2 (4-pin)
J3 (2-pin) Phase L2- V J1 (8-pin) J6 (6-pin)
(2x1-pin) (2x1-pin) A2
Firing circuit board + RC thyristor
Filter Element
J7,J8 J2 (4-pin)
J9,J10 (2x1pt) J3 (2-pin) Phase L3- W
(2x1pt)
B2
Thyristor Thyristor Current Firing circuit board + RC thyristor
TH11 TH12 feedback 1
1L1 J7,J8(2x1pt) J9,J10 (2x1pt) J3 (2-pin) TC 1 2T1
Temperature sensors Thyristor Thyristor Current
Fans J4 (4-pin), J5,J6 (2x2-pin)
TH21 TH22 feedback 2 4T2
3L2
J5 (2-pin) Plug-in base 1 J4 (2-pin) V1 Temperature sensors Thyristor Thyristor Current
TH11 TH12 feedback 2
5L3 Fans J4 (4-pin), J5,J6 (2x2-pin) TC 3 6T3
J5 (2-pin) Plug-in base 2 J4 (2-pin) V2 Temperature sensors
Appendix 4
Customer terminals Customer terminals Connector
I/O - motor PTC Relays - Control circuit supply Serial link + remote terminal
Control Board
J4(5-pin) J6 (6-pin) J7 (6-pin) J5 (30-pin)
Connection
Power supply connection Keypad power board-control board (micro zone)
power board-control board connection ( Power supply - Current, voltage feedback, PTC-
supply
(customer zone) and (L-S zone)
Thyristor commands, fan-EEPROM)
Control circuit
J4 (5-pin) J6 (6-pin) J5 (30-pin)
PE
Plug-in base
Ls1 1 A2
1L1
Plug-in base
11 TC 1 2T1
Ls11
Plug-in base
Ls2 2 B2
3L2
Plug-in base
21 4T2
Ls21
Plug-in base
Ls3 3 C2
5L3
Plug-in base
31 TC 3 6T3
PE Ls31
ATS48 architecture TE-TF a
Appendix 5
Customer terminals Customer terminals Customer terminals
I/O Relays Communication
(E/SCL) (CRCL) (RSCL)
OVC III
Current values
(MCO)
Microcontroller
(MCO)
(ALP)
Current and voltage Polarity of motor
Firing circuits
synchronisation stator voltages
(MCO)
(MCO) (MCO)
(CL1)
CL1 Rectifier and
Switch mode power
filtering
supply
Current and voltage Polarity of motor
CL2 Firing circuits
(CL2) synchronisation stator voltages
Protective bar
Protective bar Protective bar
(ALM)
(X)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(L1)
(L2)
(L3)
(L1)
(L2)
(L3)
Temperature
Sensors
(MCO)
Fans
(MCO) (T1)
A2
(L1) (T1)
1L1 TC 1 2T1
(T2)
B2
(L2) (T2)
3L2 TC 2 4T2
(T3)
C2
(L3) (T3)
5L3 TC 3 6T3
PE
PE
Filter Filter Filter
(L1) (X) (L2) (X) (L3)
(X)
(X)
ATS48 isolation for TA to TC
Appendix 6
Customer terminals Customer terminals Customer terminals
I/O Relays Communication
(E/SCL) (CRCL) (RSCL)
OVC III
Current values
(MCO)
Microcontroller
(MCO)
(ALP)
Current and voltage Polarity of motor
Firing circuits
synchronisation stator voltages
(MCO)
(MCO) (MCO)
(CL1)
CL1 Rectifier and
Switch mode power
filtering
supply
Current and voltage Polarity of motor
CL2 Firing circuits
(CL2) synchronisation stator voltages
Protective bar
Protective bar Protective bar
(ALM) Fans
(X) (MCO)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(L1)
(L2)
(L3)
(L1)
(L2)
(L3)
Temperature
Sensors
(MCO)
Fan power supply
Fan control
(MCO) (T1)
A2
(L1) (T1)
1L1 TC 1 2T1
(T2)
B2
(L2) (T2)
3L2 TC 2 4T2
(T3)
C2
(L3) (T3)
5L3 TC 3 6T3
PE
PE
Filter Filter Filter
(L1) (X) (L2) (X) (L3)
(X)
(X)
ATS48 isolation for TD
Appendix 7
Customer terminals Customer terminals Customer terminals
I/O Relays Communication
(E/SCL) (CRCL) (RSCL)
OVC III
Current values
(MCO)
Microcontroller
(MCO)
(ALP)
Current and voltage Polarity of motor
Firing circuits
synchronisation stator voltages
(MCO)
(MCO) (MCO)
(CL1)
CL1 Rectifier and
Switch mode power
filtering
supply
Current and voltage Polarity of motor
CL2 Firing circuits
(CL2) synchronisation stator voltages
Protective bar
Protective bar Protective bar
(ALM) Fans
(X)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(T1)
(T2)
(T3)
(L1)
(L2)
(L3)
(L1)
(L2)
(L3)
Temperature
Sensors
(MCO)
Fan power supply
Fan control
(MCO) (T1)
A2
(L1) (T1)
1L1 TC 1 2T1
(T2)
B2
(L2) (T2)
3L2 TC 2 4T2
(T3)
C2
(L3) (T3)
5L3 TC 3 6T3
PE
PE
Filter Filter Filter
(L1) (X) (L2) (X) (L3)
(X)
(X)
ATS48 isolation for TE & TF
Appendix 8
Power EEPROM
Customer port EEPROM
3-pin J5
Connector
RJ45- 8-pin J3
Elapsed time "RESET"
Control Clock circuit
circuit circuit (MCO)
circuit
5VDC-0VDC Alpha and Gamma
5VDC-0VDC 5VDC-0VDC
(RSCL) synchro.
8-pin J5
Connector
Thyristor
RS485 serial link control
5VLS interface
5-pin J5
Isolation
Connector
10VLS-0VLS circuit
5VDC-0VDC
Current
Display unit feedback
circuit Microcontroller circuit
5-pin J5
Connector
+Vref(2.5V)
5VDC-0VDC 5VCAN-0VCAN
12VDC-0VDC
Heatsink P.T.C.
6-pin J4
Connector
Keypad circuit 5VDC-0VDC + Fan control
2-pin J5
Connector
circuit
5VDC-0VDC
5VDC-0VDC
Isolation Isolation Isolation Isolation
15VDC
5VDC
USF
4-pin J5
Connector
24VCL-0VCL
Connector
(CRCL)
0VLS
Customer port ( 12-pin) J1 Customer port (8-pin) J2
Appendix 9
(MCO) (L1) L1 / K11 (L1)
Gamma 1 Gamma 1
Thyristor TH11 Thyristor TH11
synchronisation synchronisation
firing circuit firing circuit
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J11
Connector
Connector
Connector
circuit circuit U / K12
5VDC-0VDC (T1) 15VS1-0VS1 (MCO) 12VDC-0VDC
1-pin J5
Isolation
Isolation
2-pin J12
Connector
Connector
Connector
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J21
Connector
Connector
Connector
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J22
Connector
Connector
Connector
circuit circuit L3 / K31
5VDC-0VDC (L3) 15VS2-0VS2 (MCO) 12VDC-0VDC
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J31
Connector
Connector
Connector
circuit (T3)
circuit W / K32
5VDC-0VDC 15VS3-0VS3 (MCO) 12VDC-0VDC
(T3)
Current
Thyristor TH32 Thyristor TH32
feedback scaling
3x2-pin
firing circuit firing circuit
1-pin J5
5-pin J5
Isolation
2-pin J32
J1 -J2-J3
Connector
Connector
Connector
circuit
Connectors
(MCO) 2,5V (MCO) 12VDC-0VDC
Temperature (T1)
sensor interface Motor voltage Motor voltage
(T2)
2-pin J5
2-pin J7
measurement
Connector
Connector
circuit (T3)
measurement
3-pin J5
(MCO) 5VDC-0VDC
Isolation
circuit
Connector
circuit
15VS1-0VS1 / 15VS2-0VS2 / 15VTM-0VTM (MCO) 5VDC-0VDC
Power EEPROM 15VS3-0VS3 / 15VTM-0VTM
(MCO)
circuit
2-pin J5
5-pin J4
6-pin J9
Connector
Connectors
(MCO) supply
Fan control
5VDC-0VDC
J8
4-pin
12VDC-5VDC-0VDC circuit
1-pin J5
Connector
Connectors
24VCL-0VCL / 10VLS-0VLS
12VDC-0VDC
Connector Connector
3-pin J5 6-pin J6
PTC1 block diagram and isolation
Appendix 10
(MCO) (L1) L1 / K11 (L1)
Gamma 1 Gamma 1
Thyristor TH11 Thyristor TH11
synchronisation synchronisation
firing circuit firing circuit
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J11
Connector
Connector
Connector
circuit circuit U / K12
5VDC-0VDC (T1) 15VS1-0VS1 (MCO) 15VDC-0VDC
1-pin J5
Isolation
Isolation
2-pin J12
Connector
Connector
Connector
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J21
Connector
Connector
Connector
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J22
Connector
Connector
Connector
circuit circuit L3 / K31
5VDC-0VDC (L3) 15VS2-0VS2 (MCO) 12VDC-0VDC
1-pin J5
1-pin J5
Isolation
Isolation
2-pin J31
Connector
Connector
Connector
circuit (T3)
circuit W / K32
5VDC-0VDC 15VS3-0VS3 (MCO) 12VDC-0VDC
(T3)
Current
Thyristor TH32 Thyristor TH32
feedback scaling
3x2-pin
firing circuit firing circuit
1-pin J5
5-pin J5
Isolation
2-pin J32
J1 -J2-J3
Connector
Connector
Connector
circuit
Connectors
(MCO) 2,5V (MCO) 12VDC-0VDC
Temperature (T1)
sensor interface Motor voltage Motor voltage
(T2)
2-pin J5
2-pin J7 measurement
Connector
Connector
circuit (T3)
measurement
3-pin J5
(MCO) 5VDC-0VDC
Isolation
Connector
circuit circuit
15VS1-0VS1 / 15VS2-0VS2 / 15VTM-0VTM (MCO) 5VDC-0VDC
Power EEPROM 15VS3-0VS3 / 15VTM-0VTM
circuit
2-pin J5
5-pin J4
6-pin J9
Connector
Connectors
Isolation
Connector
Connectors
24VCL-0VCL / 10VLS-0VLS
12VDC-0VDC
Connector Connector (CL2) (MCO)
3-pin J5 6-pin J6
PTC2 block diagram and isolation
Appendix 11
(MCO) (L1) L1 / K11
Gamma 1 Gamma 1 Thyristor TH11
synchronisation synchronisation and TH111
1-pin J5
1-pin J5
Isolation
2-pin J7
2-pin J1
Connector
Connector
Connector
6-pin J13
circuit circuit firing circuit
Connector
5VDC-0VDC (T1) 15VS1-0VS1 U / K12 (MCO) 12VDC-0VDC
2-pin J7
2-pin J1
1-pin J5
1-pin J5
Isolation
Connector
Connector
Connector
1-pin J5
2-pin J8
2-pin J2
1-pin J5
Isolation
6-pin J14
Connector
Connector
Connector
Connector
1-pin J5
2-pin J8
2-pin J2
1-pin J5
Isolation
Connector
Connector
Connector
circuit circuit L3 / K31
firing circuit
5VDC-0VDC (L3) 15VS2-0VS2 (MCO) 12VDC-0VDC
6-pin J15
2-pin J9
2-pin J3
1-pin J5
1-pin J5
Connector
Isolation
Connector
Connector
Connector
circuit (T3)
circuit W / K32
firing circuit
5VDC-0VDC 15VS3-0VS3 (MCO) 12VDC-0VDC
(T3)
Current Thyristor TH32
feedback scaling and TH321
2-pin
2-pin J9
2-pin J3
1-pin J5
5-pin J5
J1 -J2-J3
Connector
Connector
Connector
Connectors
(MCO) 2,5V (MCO) 12VDC-0VDC
Temperature (T1)
sensor interface Motor voltage Motor voltage
2-pin
(T2)
J8-J9
2-pin J5
measurement
Connector
circuit measurement
Connectors
J1-J2-J3-J7-
(T3)
3-pin J5
(MCO) 5VDC-0VDC
Isolation
Connector
circuit circuit
15VS1-0VS1 / 15VS2-0VS2 / 15VTM-0VTM (MCO) 5VDC-0VDC
Power EEPROM 15VS3-0VS3 / 15VTM-0VTM
circuit
2-pin J5
5-pin J4
Connector
Connector
circuit
J10-J11
Isolation
Connector
Connectors
24VCL-0VCL / 10VLS-0VLS
12Vvent-0Vvent 12VDC-0VDC
Connector Connector (CL2) (MCO)
3-pin J5 6-pin J6
PTC3 block diagram and isolation
Appendix 12
(N) (X)
(L1)
6-pin J6
(T1)
Connector
(L1)
J7-J8
2x1-pin
firing circuit firing circuit
2-pin J1
Isolation
Connector
Connector
(MCO) 12VDC-0VDC
(T1)
Thyristor THx2 Thyristor THx2
J9-J10
2x1-pin
firing circuit firing circuit
2-pin J1
Isolation
Connector
Connector
(MCO) 12VDC-0VDC
Temperature
sensor 2-pin J1
2-pin J2
Connector
Connector
(MCO)
Current
feedback
2-pin J1
2-pin J3
Connector
Connector
(MCO)
Fan power
supply
2-pinJ5
4-pin J4
Connector
Connector
(CL2)
Appendix 13