Appendix2.

Disassembly & Assembly Guide

유2
Appendix2. Disassembly & Assembly Guide

Contents

1. A Frame (5.5kw)
2. B Frame (7.5~11kw)
3. C Frame (15~18.5kw)
4. D Frame (22~30kw)
5. E Frame (37~55kw)
6. F Frame (75~90kw)
7. G Frame (110~160kw)
8. H Frame (220~280kw)
9. Loader ASS’Y Common
유2

1/196
*SV055IP5A-2/4 Disassembly A Frame

유2

2/196
 *SV055iP5A-2/4 Disassembly A Frame

1. Unfasten the bolt ①, Pull the Loader

forward and get the loader and Cable.

② ③

2. Unfasten the bolt ②③④ and pull forward

and get the Cover Ass’y.

유2

3/196
 *SV055iP5A-2/4 Disassembly A Frame

3. Unfold the “L”locks and get the ⑥ CON-POW

Wire Connector. Unfasten the bolt,①②③④⑤
④ and get the Control PCB.
①

③ ⑤

4. Unfasten the bolt ⑦⑧⑨ and get SHIELD

PLATE.

⑨
⑧

유2

4/196
 *SV055iP5A-2/4 Disassembly A Frame

5.Unfasten bolt ①②③ and unfasten the

3 SPACERs and get the Power PCB.
①

SPACER

② ③

SPACER

<Warning>
*When getting POWER PCB, be cautious not
to let unnecessary strength.
④ ⑤

6.Unfasten bolt ④⑤, and get the Bracket.

유2

5/196
*SV055iP5A-2/4 Disassembly A Frame

7. Separate the ① IGBT Module. When

separating, be cautious not to happen faulty
by the compound.

② ④ 8. Unfasten bolt ②③④⑤ and get the FAN.

③ ⑤

유2

분해완료

6/196
*SV075~110iP5A-2/4 Disassembly B Frame

유2

7/196
 *SV075~110iP5A-2/4 Disassembly B Frame

①
1. Unfasten the bolt ①, Pull the Loader
forward and get the loader and Cable.

② ③

2. Unfasten the bolt ②③④ and pull forward

and get the Cover Ass’y.

유2

8/196
*SV075~110iP5A-2/4 Disassembly B Frame

3. Unfold the “L”locks and get the ⑥ CON-POW

① ④ Wire Connector. Unfasten the bolt,①②③④⑤
and get the Control PCB.
⑥

③ ⑤

4. Unfasten the bolt ⑦⑧⑨ and get SHIELD

PLATE.

⑨
⑧

유2

9/196
 *SV075~110iP5A-2/4 Disassembly B Frame

5.Unfasten bolt ①②③ and unfasten the

3 SPACERs and get the Power PCB.

① ②

③ ④
SPACER

SPACER

<Warning>
*When getting POWER PCB, be cautious not
to let unnecessary strength.
⑤ ⑥

6.Unfasten bolt ⑤⑥, and get the Bracket.

유2

10/196
*SV075~110iP5A-2/4 Disassembly B Frame

7. Separate the ① IGBT Module. When

separating, be cautious not to happen faulty
by the compound.

② ③ ④ ⑤

8. Unfasten bolt ②③④⑤⑥⑦⑧⑨ and get

the FAN.

⑥ ⑦ ⑧ ⑨

유2

분해완료

11/196
*SV150~185iP5A-2/4 Disassembly C Frame

유2

12/196
*SV150~185iP5A-2/4 Disassembly C Frame
①

1. Unfasten the bolt ①, Pull the Loader

forward and get the loader and Cable.

②
③

2. Unfasten the bolt ②③④ and pull forward

and get the Cover Ass’y.

유2

13/196
*SV150~185iP5A-2/4 Disassembly C Frame

3. Unfold the “L”locks and get the ⑥ CON-POW

Wire Connector. Unfasten the bolt,①②③④⑤
and get the Control PCB.
① ④

③ ⑤

4. After unfasten the bolt ⑦⑧⑨⑩ and

separate the SUPPORTER and get the CON-
⑦ ⑨ SPS PCB by separating the wire ⑪⑫⑬.

SUPPORTER
⑪

⑭
⑫
유2
⑬

⑧ ⑩

<When separate the SUPPORTER,

LONGNOSE is required.

14/196
 *SV150~185iP5A-2/4 Disassembly C Frame
③
① 5. Unfasten the bolt ①②③④,and get SHIELD
PLATE.

⑦⑧

6. After unfasten ⑤⑥⑦⑧⑨⑩, unfasten all

bolts of ⑪ and get BUSBAR ASS’Y.

유2
⑥

⑪ ⑨ ⑩

15/196
 *SV150~185iP5A-2/4 Disassembly C Frame

7. Unfasten Spacer ①② and separate the

① corresponding wires and get DM-CT PCB,
SNUBBER PCB by unfastening bolt ③.

② ③

SPACER

8. Unfasten bolt ④⑤⑥ and get SMPS PCB.

④ ⑥

유2

16/196
 *SV150~185iP5A-2/4 Disassembly C Frame
9. Unfasten bolt ①②③④ and get IGBT
MODULE, unfasten ⑤⑥ and get DIODE
MODULE.

① ③

② ④

⑤ ⑥

10. Unfasten bolt ⑦ and get the WIRE NTC

ASS’Y.
⑦

유2

17/196
 *SV150~185iP5A-2/4 Disassembly C Frame

11. Unfasten ①②, separate POWER T/B and

get Bracket Back by unfastening ③④.

①
②

③ ④
12. Unfasten ⑤⑥⑦⑧⑨⑩⑪⑫ and get FAN.

⑤ ⑥ ⑦ ⑧

유2

⑨ ⑩ ⑪ ⑫

18/196
*SV150~185iP5A-2/4 Disassembly C Frame

Completed
disassembly

유2

19/196
*SV220~300iP5A-2/4 Disassembly D Frame

유2

20/196
 *SV220~300iP5A-2/4 Disassembly D Frame
①
1. Unfasten the bolt ①, Pull the Loader
forward and get the loader and Cable.

② ③

2. Unfasten the bolt ②③④ and pull forward

and get the Cover Ass’y.

유2

21/196
 *SV220~300iP5A-2/4 Disassembly D Frame

3. Unfold the “L”locks and get the ⑥ CON-SPS

Wire Connector. Unfasten the bolt,①②③④⑤
① ④
and get the Control PCB.

③ ⑤

4. After unfasten the bolt ⑦⑧⑨⑩ and

⑦ ⑨ separate the SUPPORTER and get the CON-
SPS PCB by separating the wire ⑪⑫⑬.
SUPPORTER
⑪

⑭
⑫

⑬
유2

⑧ ⑩

<When separate the SUPPORTER,

LONGNOSE is required.

22/196
 *SV220~300iP5A-2/4 Disassembly D Frame

③ 5. Unfasten bolt ①②③④ and get SHIELD PLATE.

①

⑦ ⑧

6. After unfasten ⑤⑥⑦⑧⑨⑩, unfasten all

bolts of ⑪ and get BUSBAR ASS’Y.

⑤
유2
⑩

23/196
 *SV220~300iP5A-2/4 Disassembly D Frame
7. Unfasten Spacer ①② and separate the
corresponding wires and get DM-CT PCB,
① SNUBBER PCB by unfastening bolt ③④.

③
④
②

SPACER

8. Unfasten bolt ⑤⑥⑦ and get SMPS PCB.

⑤ ⑦

유2

24/196
 *SV220~300iP5A-2/4 Disassembly D Frame
9. Unfasten bolt ①②③④ and get IGBT
MODULE, unfasten ⑤⑥⑦⑧ and get DIODE
MODULE.

③
①

② ④

⑤ ⑦

⑥ ⑧

10. Unfasten bolt ⑨ and get the WIRE NTC

ASS’Y.
⑨

유2

25/196
 *SV220~300iP5A-2/4 분해방법 D Frame

11. Unfasten ①②, separate POWER T/B and

get Bracket Back by unfastening ③④.

①
②

③ ④
12. Unfasten ⑤⑥⑦⑧⑨⑩⑪⑫ and get FAN.

⑤ ⑥ ⑦ ⑧

유2

⑨ ⑩ ⑪ ⑫

26/196
*SV220~300iP5A-2/4 Disassembly D Frame

Completed
Disassembly

유2

27/196
*SV370~550IP5A-4 Disassembly E Frame

유2

28/196
 *SV370~550iP5A-4 Disassembly E Frame

1. Pulling forward the Loader and get the

Loader.

① ③

② ④

2. Unfasten ①②③④ and open the Cover

Ass’y.

유2

29/196
 *SV370~550iP5A-4 Disassembly E Frame
① ② ⑩⑥ ⑪ 3. Unfasten ①②③④⑤ and get the Control PCB
and unfold the ⑥⑦⑧⑨ connectors, unfastenin
⑩⑪⑫⑬ and get Main SMPS PCB.

③
<Control PCB> <Main SMPS PCB>

④ ⑦

⑤⑬ ⑨ ⑫

4. Unfastening ⒶⒷⒸⒹⒺⒻ and get SHIELD

PLATE.

Ⓐ Ⓓ

Ⓑ Ⓔ
유2

Ⓒ Ⓕ

30/196
 *SV370~550iP5A-4 Disassembly E Frame
⑪⑫ ③ ④ ⑤
5. Unfasten ①②③④⑤⑥⑦⑧⑨⑩, separate
⑪⑫ connector and get Drive SPS PCB,
INSULATION PLATE that is on the bottom.
⑥
①

<Drive SPS PCB> <INSULATION PLATE>

⑦
②

⑩ ⑨ ⑧

6. Unfasten bolts ⒶⒷⒸⒹⒺ, separate ⑬⑭⑮

and get FAN SMPS PCB.
⑬ Ⓒ

Ⓐ Ⓓ
⑭
Ⓑ
Ⓔ

유2

31/196
 *SV370~550iP5A-4 Disassembly E Frame

7. Unfasten ①②③④ and get Charge resistor

and Fuse.
① ②
③ ④ <RES,METAL 60W40J>

<FUSE, 660GH 200S>

8. Unfasten⑤⑥⑦⑧⑨⑩⑪ and get Busbar

ASS’Y & CAP,ERA480RL.
<BUSBAR ASS'Y>

⑧
⑤
⑥
⑨
⑦ 유2
⑩

<CAP,ERA480RL>

32/196
 *SV370~550iP5A-4 Disassembly E Frame
9. Unfasten ①②③④ and get SCR Snubber
board and C/T Board.

<SCR SNUBBER PCB>

③
②
④
<C/T BOARD >

⑤⑥⑦ ⑪ ⑫
10. Unfasten ⑤⑥⑦⑧⑨⑩ and get DIODE
SCR. Unfasten ⑪⑫⑬⑭ and get IGBT
MODULE.

<DIODE,SCR> <TR,IGBT>

유2

⑧⑨⑩ ⑬ ⑭

33/196
 *SV370~550iP5A-4 Disassembly E Frame

7. Unfasten ①② and get T/B, unfasten ③④

⑤⑥ and get PLATE T/B.

<PLATE,T/B>

<T/B,OK-0100,9P>
③ ⑤

① ②

④ ⑥

8. Unfasten ⑦⑧⑨⑩⑪⑫⑬⑭ and get CAP

BOARD.

유2
< CAP BOARD >

⑦ ⑪
⑧ ⑫

⑨ ⑬
⑩ ⑭

34/196
 *SV370~550iP5A-4 Disassembly E Frame

7. Unfasten ①②③④ and separate BRACKET

CAPACITOR with CONDENSOR.

<BRACKET CAPACITOR>

<CONDENSOR>

① ③

② ④

8. Unfasten ⑤⑥⑦⑧⑨⑩⑪⑫ and get FAN

& FAN FG.

⑤ ⑥⑦ ⑧

유2

< FAN >

⑨ ⑩ ⑪ ⑫

< FAN FG >

35/196
 *SV370~550iP5A-4 Disassembly E Frame

7. Unfasten ①②③④ and get BACK CASE.

① ③

<BODY,BACK CASE>
② ④

유2

분해완료

36/196
*SV750~900iP5A-4 Disassembly F Frame

유2

37/196
 *SV750~900iP5A-4 Disassembly F Frame

1. Pull the Loader forward and get the Loader..

① ④
② ⑤

③ ⑥

2. Unfasten ①②③④⑤⑥ and open the

Cover Ass’y.

유2

38/196
 *SV750~900iP5A-4 Disassembly F Frame
① ② ⑩⑥ ⑪
3. Unfasten ①②③④⑤ and get the Control PCB
and unfold the ⑥⑦⑧⑨ connectors, unfastenin
⑩⑪⑫⑬ and get Main SMPS PCB.

③
<Control PCB> <Main SMPS PCB>

④ ⑦

⑤⑬ ⑨ ⑫

4. Unfasten ⒶⒷⒸⒹ and get SHIELD PLATE.

Ⓐ Ⓒ

유2
Ⓑ Ⓓ

39/196
 *SV750~900iP5A-4 Disassembly F Frame
③ ④ ⑤
5. Unfasten ①②③④⑤⑥⑦⑧⑨⑩, separate
⑪⑫ ⑬ connector and get Drive SPS PCB,
① INSULATION PLATE that is on the bottom.
⑥
<Drive SPS PCB>
⑦
②

⑪⑫ ⑩ ⑬ ⑨ ⑧

<INSULATION PLATE>

Ⓧ Ⓒ
6. Unfasten bolts ⒶⒷⒸⒹⒺ, separate ⓧⓨⓩ
connector and get FAN SMPS PCB.
Ⓐ Ⓓ
Ⓩ
Ⓑ
Ⓔ

유2

40/196
 *SV750~900iP5A-4 Disassembly F Frame

7. Unfasten ①②③④ and get Charge resistor

and Fuse.
① ②

③ ④ <RES,METAL 60W40J>

<FUSE, 660GH 200S>

8. Unfasten⑤⑥⑦⑧⑨⑩⑪ and get Busbar

ASS’Y & CAP,ERA480RL.
<BUSBAR ASS'Y>

⑤
⑧

⑥
⑨
⑦ 유2
⑩

<CAP,ERA480RL>
⑪

41/196
 *SV750~900iP5A-4 Disassembly F Frame
9. Unfasten ①②③④ and get SCR Snubber
board and C/T Board.

<SCR SNUBBER PCB>

①
③
② ④

<C/T BOARD >

10. ⑤⑥⑦⑧⑨⑩ 의 Bolt를 풀고. DIODE

SCR 과 IGBT MODULE을 분리한 후,
⑪⑫⑬⑭ 의 Bolt 를 풀고, Body
Support
⑤ 를 분리한다. ⑨
10. Unfasten ⑤⑥⑦⑧⑨⑩ and get DIODE
SCR & IGBT MODULE. Unfasten ⑪⑫⑬⑭
and get Body support.

<DIODE,SCR> <TR,IGBT>

⑥
⑦

유2

⑪ ⑬
<BODY,SUPPORT PLATE>

⑫ ⑭

⑧ ⑩

42/196
 *SV750~900iP5A-4 Disassembly F Frame

7. Unfasten ①②③ and get CAP BOARD.

<CAP BOARD>

8. Unfasten ④⑤⑥⑦ and separate

CONDENSOR with BRACKET,CAPACITOR.

① ② ③ < CONDENSOR >

< BRACKET,CAPACITOR >

유2

④ ⑥

⑤ ⑦

43/196
 *SV750~900iP5A-4 Disassembly F Frame
③ ⑤
7. Unfasten ①②③④⑤⑥⑦⑧ and get FAN
& FAN FG.

① ⑦

② ⑧

④ ⑥ < FAN >

>
< FAN

< FAN FG >>

유2

Completed
Disassembly

44/196
*SV1100~1600iP5A-4 Disassembly G Frame

유2

45/196
 *SV1100~1600iP5A-4 Disassembly G Frame

1. Pull the Loader forward and get the Loader..

① ②

2.Unfasten ①② and get Cover Ass’y.

유2

46/196
 *SV1100~1600iP5A-4 Disassembly G Frame
③

3. Unfasten ①②, unfold the connector ③

And get SCR SNUBBER PCB.

<SCR SNUBBER PCB>

②
①

4. Unfasten bolt ③, unfold connector ④ and

get Control PCB.

<CONTROL PCB>

유2
③

47/196
 *SV1100~1600iP5A-4 Disassembly G Frame

5. Unfasten ①②, unfold the connector ③④

And get FAN SPS PCB.

① ②
<FAN SPS PCB>

⑤ ⑦ 6. Unfasten ⑤⑥, unfold connectors ⑦⑧ and

get MAIN SMPS PCB.

<MAIN SMPS PCB>

유2

⑥ ⑧

48/196
 *SV1100~1600iP5A-4 Disassembly G Frame

7. Unfasten ① and get SHIELD PLATE.

<SHIELD PLATE>

8. Separate each connector as like Wire

ASS’Y.

<WIRE ASS'Y>

유2

49/196
 *SV1100~1600iP5A-4 Disassembly G Frame

9. Unfasten ① and get input part BUSBAR.

<Input part BUSBAR>

10. Unfasten ② and get output part BUSBAR.

< Output part BUSBAR>

②
유2

50/196
*SV1100~1600iP5A-4 Disassembly G Frame
①

11. Unfasten ①② and get

CAP,MF,KPF2.00MFD
1250VE3TTL,DC1250V,2UF.

< CAP,MF,KPF2.00MFD 1250VE3TTL,

DC1250V,2UF >

③
12. Unfasten ③④ and get additional
BUSBAR.

⑤ 13. Unfasten ⑤ and get BUS PLATE

ASS’Y,IGBT.
유2

< BUS PLATE ASS’Y,IGBT >

51/196
*SV1100~1600iP5A-4 Disassembly G Frame

①
14. Unfasten① and get PLATE,T/B.

< PLATE T/B >

15. Unfasten ② and get BUS PLATE

ASS’Y, CONDENSER.
②
< BUS PLATE ASS’Y,CONDENSER >

Bolt

※ By unfastening the additional bolts, it

can be separated each ASS’Y.

<CAP,DC400V, <BUS PLATE

68OOUF> ASS’Y,CONDENSER>

유2

<RES,15W30K (31.8MM)>

52/196
*SV1100~1600iP5A-4 Disassembly G Frame

①
16. Unfasten ①② and get PLATE T/B.

<DIODE,SCR,SKKH132/16E>

17. Unfasten ③ and get BUS PLATE

ASS’Y CONDENSER.

<TR,IGBT,SKM300GB128D>

유2

53/196
*SV1100~1600iP5A-4 Disassembly G Frame
18. Unfasten ① and get the FAN(MECH)
① RESISTOR BRACKET by upwarding it.

<FAN(MECH),RESISTOR BRACKET>

19. Unfasten ② and get RES,METAL 400W

②
15J(600MM).
<Back>
<RES,METAL 400W 15J>

20. Unfasten ③④ and separate FAN with

FAN FG.
③
<FAN,DF,FFB1424VHG>
<Front> 유2

< FAN,FG,-33,NMB >

54/196
*SV1100~1600iP5A-4 Disassembly G Frame

21. Completed Disassembly

Competed
Disassembly

유2

55/196
*SV2200~2800iP5A-4 Disassembly H Frame

유2

56/196
 *SV2200~2800iP5A-4 Disassembly H Frame

1. Pull the Loader forward and get the Loader.

① ②

2.Unfasten ①② and get Cover Ass’y.

유2

57/196
*SV2200~2800iP5A-4 Disassembly H Frame

③
3. Unfasten ①②, unfold the connector ③
And get SCR SNUBBER PCB.

<SCR SNUBBER PCB>

②
①

4. Unfasten bolt ③, unfold connector ④ and

get Control PCB.

<CONTROL PCB>

유2
③

58/196
 *SV2200~2800iP5A-4 Disassembly H Frame

5. Unfasten ①②, unfold the connector ③④

And get FAN SPS PCB.

②
①
<FAN SPS PCB>

6. Unfasten ⑤⑥, unfold connectors ⑦⑧ and

⑤ ⑦ get MAIN SMPS PCB.

<MAIN SMPS PCB>

유2

⑥ ⑧

59/196
 *SV2200~2800iP5A-4 Disassembly H Frame

7. Unfasten ① and get SHIELD,PLATE.

<SHIELD PLATE>

8. Unfold each connectors and get WIRE

ASS’Y.

<WIRE ASS'Y>

유2

60/196
 *SV2200~2800iP5A-4 Disassembly H Frame

9. Unfasten ① and get input part BUSBAR.

<Input part BUSBAR>

10. Unfasten ② and get output part BUSBAR.

<Output part BUSBAR>

②
유2

61/196
 *SV2200~2800iP5A-4 Disassembly H Frame

11. Unfasten ①②③④⑤ and get the BUSBAR

ASS’Y.
①

< BUSBAR ASS’Y >

12. FUSE & CAP,MF,PM91W3

C155K,DC1600V,1.5UF can be separated.
②
< FUSE,PF,660GH 315S UL >

유2

④ ⑤ < CAP,MF,PM91W3C155K >

62/196
*SV2200~2800iP5A-4 Disassembly H Frame
①

13. Unfasten ①②, Unfold connector ③ and

get IGBT GATE WIRE and IGBT INTERFACE
PCB.

<WIRE ASS'Y,IGBT GATE>

<PCB ASS'Y,IGBT INTERFACE>

14. Unfasten ④⑤⑥ and get output

MODULE. 유2
<TR,IGBT,CM1400DU-24NF>
④ ⑤ ⑥

63/196
 *SV2200~2800iP5A-4 Disassembly H Frame
①

15. Unfasten ①② and get DIODE SCR.

<DIODE,SCR,SKKH330/16E>

16. Unfasten ③④ and get the PLATE T/B.

<PLATE,T/B>

유2

③ ④

64/196
*SV2200~2800iP5A-4 Disassembly H Frame
17. Unfasten ① and get the FAN ASS’Y
① BRACKET by up warding it.

<FAN ASS’Y BRACKET>

③ ② ④ 18. Unfasten ② and get RES,METAL 400W

15J(300MM).

<RES,METAL 400W 15J>

19. Unfasten ③④⑤ and separate FAN with

FAN FG.

<FAN,DF,FFB1424VHG> <FAN,DF,F9225X24B>

⑤ 유2

<FAN,FG,G92-16A>
< FAN,FG,-33,NMB >

65/196
*SV2200~2800iP5A-4 Disassembly H Frame
20. Unfasten ① and get the BUS PLATE
① ASS’Y CONDENSER by up warding it.

< BUS PLATE ASS'Y,CONDENSER >

21. Unfasten ②③ as picture below, separate

the RES,RW,RQC15W30K with
CAP,CE,LNX2G 822MSEAZH,DC400V,8200UF.

< BUS PLATE ASS'Y,CONDENSER >

②

< RES,RW,RQC15W30K > 유2

③ <CAP,8200UF, DC400V>

66/196
*SV2200~2800iP5A-4 Disassembly H Frame

22. Completed disassembly

Completed
Disassembly

유2

67/196
*LCD LOADER Disassembly (Common)

unit: mm

유2

68/196
 *LCD LOADER Disassembly

1. Unfasten ①② and get the COVER BASE.

① ②

유2

69/196
*LCD LOADER Disassembly

2. After separating COVER BASE, LOADER

COVER can be get without any problem.

Completed
disassembly
유2

70/196
LS Industrial Systems Co,. Ltd

IP5A 5.5~ 450KW

Publishing date: 2010. July
Version : 1.0