ACV 700 Frequency Converters Service Instructions Code: 3AFY 58054496 R0125 REV B

ACV 700 Frequency Converters
Service Instructions
Code: 3AFY 58054496 R0125 REV A
C 7 .1 V1 4
V 24
A4
R7 V4
C 1.1 V 15
V 21
A1
C 7 .2 C 1 .2
L1 A5
V 11 V1 V25
A 1.1
V5
C 2 .1 V 16
V 22 A2
A6
C 7 .3 C 2 .2 A 2 .1
V12 V 26
V2
V6
V 23 C 3 .1
L2
V3
C 3 .2
V 13
C h opp er
F11
T1
M1 U3
(Option)
U2
U1
Error: Reference source not found 3AFY 58054496
Issued by: FIDRI/ERM

Date: 07.06.23
File: ACVSERIN.DOC
Created with: Word for Windows 2.0
Designer 3.1
Table of revisions:
Date: Code: Remark:

1993-04-28 3AFE58054496 First issue
1995-05-05 3AFY 58054496 R0125 REV A Correction
Table of references:
For information on: See Document:
Description of the firmware Firmware Manual 1.0
Detailed description of the Firmware Manual for Engineering

firmware
The technical data and specifications are valid at the time of printing.
We reserve the right to subsequent alterations.
2
3AFY 58054496 Error: Reference source not found
Contents Page
1. Fault-tracing and repair.......................................................................................5

1.1. Safety.......................................................................................................5
1.1.1. General....................................................................................5
1.1.2. Operation................................................................................5
1.1.3. Maintenance work..................................................................5
1.1.4. WARNINGS!...........................................................................6
1.2. Principle of fault-tracing............................................................................6
1.3. Working methods.....................................................................................8
1.3.1. Reading of fault codes............................................................9
1.3.2. Installation of memory circuits................................................9
1.3.3. Positions of Drive Section Switch.........................................10
2. Fault Indicators....................................................................................................11
2.1. Fault diagnostics messages.....................................................................11
2.1.1. Alarm/Status Signals............................................................14
2.2. HW-Fault Indications................................................................................16
2.2.1. SNAT 603 CNT Motor Control Board...................................16
2.2.2. SNAT 609 TAI Tacho and Interface Board..........................17
2.2.3. SNAT 7261 INT Main Circuit Interface Board......................18
2.2.4. SNAT 607 MCI Main Circuit Interface Board.......................19
2.2.5. SNAT 63_ PAC Pulse Amplifier Board.................................20
2.2.6. SNAT 617 CHC Chopper Control Boards............................21
2.2.7. SAFT 11_ POW Power Supply Board..................................22
2.3. Other fault conditions and repair..............................................................23
2.3.1. Main fuses are blown...........................................................23
2.3.2. Checking the GTO inverter by simulating its operation.......24
2.3.3. Fan control failures...............................................................25
2.3.4. Frame sizes of IGBT type.....................................................26
2.3.5. Replacing the fan for IGBT INU in frame sizes R4 and R5. 27
2.3.6. Replacing the fan for IGBT INU in frame sizes R7 and R9. 27
2.3.7. Replacing the fan for GTO INU............................................28
3. Fault Tracing by diagnostics messages..............................................................30
3.1. Fault signal codes....................................................................................30
4. Replacing the GTO Inverter unit.........................................................................41
3
Page
5. Checking and replacement of the power semiconductors..................................42

5.1. IGBT Power Semiconductors...................................................................42
5.1.1. IGBT handling precautions...................................................42
5.1.2. Measuring of IGBT...............................................................43
5.1.3. Diode measuring of busbar assembly..................................46
5.1.4. Faulty IGBT detected...........................................................47
5.1.5. Location of main circuit components....................................49
5.2. Replacement of IGBT...............................................................................51
5.2.1. Getting access to the module...............................................51
5.2.2. Installation of IGBT...............................................................52
5.3. GTO power semiconductors....................................................................55
5.3.1. General.................................................................................55
5.3.2. GTO measurements.............................................................55
5.3.3. Measuring of Snubber Diodes and the Chopper components57
5.3.4. Free Wheeling Diode measurements..................................61
5.4. Replacement of "Hockey-Puck" power semiconductors.........................61
5.4.1. Comparing of Power Semiconductors..................................61
5.4.2. Preparation of the heat sink and busbar..............................62
5.4.3. Procedure for handling a semiconductor.............................62
5.4.4. Tightening of the press clamp..............................................62
5.4.5. Final cleaning.......................................................................63
6. Fault tracing and repair of supply section...........................................................66
6.1. General.....................................................................................................66
6.2. Fault diagnostics of supply section..........................................................66
6.2.1. Diode bridge rectifier............................................................66
6.2.2. SAFUK 63...250 Braking chopper........................................67
6.2.3. Thyristor braking unit SAFUX...............................................70
6.2.4. Other fault conditions in SAFUX...........................................71
6.2.5. Measurements in SAFUX.....................................................73
6.3. Measuring of power semiconductors from Supply section......................77
6.3.1. Measurement of power semiconductors..............................77
6.3.2. Line supply units SAFUS or Line rectifier unit SAFUD........77
6.3.3. Line converter unit SAFUC...................................................78
6.3.4. Thyristor braking unit SAFUX...............................................78
6.4. Replacing the power semiconductors from Supply section.....................79
6.4.1. Hockey-puck types power semiconductors..........................79
6.4.2. Module type of power semiconductors................................79
6.4.3. Electrical connections of module type power semiconductors80
6.4.4. Bolt-type power semiconductor............................................80
7. Glossary...............................................................................................................81
4
1 Fault-tracing and repair
2 Safety
W arning!
3 General
The ACV 700 Drive System consists of electrical equipment which use
dangerous voltages, and the system may cause danger to health and
property if handled improperly. When sited, installed and used in
accordance with instructions, it causes no risk to its associated
environment.
All relevant safety regulations must be observed in the installation,

commissioning and maintenance work.
It is absolutely necessary to read this safety instruction before opening

the door of the ACV 700 cabinet.
4 Operation
The operation of the ACV 700 Drive System can be entrusted to a

person who is not familiar with its internal function. The operator
should, however, be informed about the significance of the diagnostics.
In case of an alarm possibly followed by tripping, he should be able to
decide whether part of the system should be taken out of operation or
restarted after resetting the fault. (The ACV 700 is not damaged e.g. by
repeated tripping on overcurrent.)
5 Maintenance work
All maintenance of the ACV 700 must be carried out by a competent

electrician, who shall also have custody of keys to the doors, unless the
ACV 700 is located in an electrical equipment room.
In most cases, the diagnostic displays can be used for preliminary

tracing of the fault location and the fault resetting can be done without
opening the door of the ACV 700.
The following points must be observed before any work is begun on the
ACV 700.
5
6 WARNINGS!
Dangerous Voltage!
There is a dangerous voltage inside the cabinet. After the DC voltage

is disconnected by means of the Drive Section Switch, there
remains a high voltage on the capacitor bank of ACV 700, which is
discharged through discharge resistors within five minutes. Always
ensure by voltage measurement that the voltage has dropped before
performing any service or making main circuit connections. Measure
between terminals UDC+ and UDC-. The meter must be capable of
withstanding 1000 VDC.
The motor terminals are live even if the motor is not running, if the main
circuit of inverter unit is live!
There are still live terminals inside the drive cabinet after the DC Bus is
disconnected by means of the Drive Section Switch of ACV 700, due to
the auxiliary voltage supply from the supply section. See the circuit
diagrams of supplies before any action. Note also the possible UPS
supply!
Do not connect or disconnect the Drive Section Switch when power is

applied.
Do not make any voltage withstand tests on any part of the unit.
Disconnect motor cables before taking any measurements in motor or
motor cables.
Do not touch the CMOS IC-circuits on the printed circuit boards. Static
discharge voltage may destroy the circuits. In general, avoid touching
any of the components within ACV 700.
7 Principle of fault-tracing
The fault-tracing method presented here is based on systematic tracing

of the fault location. If spare circuit boards are available, the fault-
tracing is done by systematically replacing boards. Any notes
systematically made on fault messages, and operations and repair
actions taken (e.g. replacement of boards), will be most useful in fault
tracing.
In preliminary fault-tracing, the possible fault location is traced mainly

on the basis of the fault message on the control panel either to a
source outside the ACV 700 module.
6
Outside fault sources are, for example:
- Control circuit connections

- Supply
- Motor and pulse encoder cables
- Motor
- Load of the motor
- Application controller APC-communication fault
- Pulse encoder
Inside fault sources are, for example:
- Circuit boards
- Power semiconductors
- Flat cables
- Cooling fan
In most cases, it is possible to reset the fault message on the control

panel and try to restart ACV 700 before proceeding to a more accurate
fault tracing. If the fault has been removed, the ACV 700 will resume
normal operation. If the fault has not been removed, the ACV 700 will
trip again.
Before the fault is assumed to lie in ACV 700, it must be checked

carefully that the fault code is not due to outside faults or disturbances.
In case of a fault or an alarm occurrence an error code is indicated.

These codes are transferred through a Latest fault buffer (100 error
codes). Previous fault and alarm occurrences can be examined to find
out previous fault and alarm occurrences. If the original fault indication
has been reset, this can be ascertained by means of the
LATEST_FAULT fault buffer (100 error codes). The date and time is
also saved into the buffer at the fault and alarm occurrences. Fault
buffer memory information is protected against the supply
disconnections by means of a giant capacitor.
There is also a way to diagnose a fault situation by using dataloggers.

See the ACV 700 Firmware Manual.
The fault diagnostics messages can be indicated by panel or PC-based

Tool Program.
A fault can be reset by pressing the RESET-button from Panel, using

PC-based Tool Program or switching the mains voltage off for a while.
If the fault has been removed, the ACV 700 will resume normal
operation.
7
8 Working methods
The CMOS circuits used on the control circuit boards and the IGBT
power semiconductors can be damaged by electrostatic charges
discharged to them. Static charges are generated e.g. by friction of
materials made of synthetic fibres.
In order to avoid damage, the following rules must be followed when
handling the circuit boards, IGBT power semiconductors and making
measurements on them:
- Check that there is no voltage in the INU.

- Use the working mat on a table near the unit and connect the
mat's earth cord to the unit's frame.
- Put the conducting wrist band on your wrist and connect its
earth cord to the unit's frame.
- Only in emergency situation, if you don't have a wrist band,
discharge your own static charge by touching an unpainted
point e.g. on the rack before you touch the boards.
- Keep new boards and semiconductors for as long as possible
in their original packages.
Wrist band
Components
in box
Earth Card
Working mat
Figure 1. Wrist band and earthing mat (61034811.drw).
8
9 Reading of fault codes
Occurred error codes can be read from the LATEST_FAULT_BUFFER

by means of panel, PC-based Tool Program or via APC (Application
Controller). PC-based Tool Program needs the HDLC protocol (1.5
Mbits/s) communication board installed into the computer. Connection
is done by optic fibre link between the PC and Maintenance input of the
ACV 700. If control panel is used, it is connected to the APC.
10 Installation of memory circuits
If you have to change the memory circuits, remember to install the new
circuit to the right position into the board. Use always the special tool to
install or remove the circuits. Remember to check the pins after the
installation.
Mark Memory circuit
Mark Pin1
IC-socket
1 Printed card
Figure 2. Memory circuit installation into the IC-socket

(61034820.drw).
9
11 Positions of Drive Section Switch
There are two types of Drive Section Switches in ACV 700. The IGBT
type of ACV 700 has a switch which consists of charging contacts in
addition to main and auxiliary contacts. The turning angle between
positions 0 and 1 is 180°. Another type of Drive Section Switch is in the
GTO type of ACV 700; its turning angle is 90°. See the figures and note
the position of the handle in switch position 1 in each type (next page).
P ositio n 0 P ositio n 1
C harge C ha rge
0 0 1
1
A C V 700 Drive Section Switch of IGBT type

P o sition 0 P os itio n 1
1 1
0 0
A C V 7 00 Drive Section Switch of

GTO type
Figure 3. Handle positions of Drive Section Switches

(61034838.drw).
10
12 Fault Indicators
13 Fault diagnostics messages
14Fault signals
There are three different types of signal:

- Fault trips or always prevents the run,
- Alarm warns about the fault but does not prevent or stop the run.
- Status tells the state of the drive.
Every fault and alarm/status signal is coded as an individual error code.
The first eight faults (signal codes 1...8) of the list are in common with
AC and DC drives. For more information about the parameters, see the
ACV 700 Firmware Manuals for Parameter descriptions.
Signal Definition Type of Mode of Reset

Code Signal Action Method
0 No faults or alarms
99 Reset, resets all resettable faults Reset
1 Auxiliary voltage fault Fault Trips Can not be
[Auxil. under voltage] reset
2 Overcurrent Fault Trips To be reset
3 DC intermediate circuit overvoltage Fault Trips To be

[DC overvoltage] reset
4 Measured overtemperature of converter Fault Trips Self reset/ to

[Converter overtemp.] be reset
5 Earth fault Fault Trips To be reset
6 Measured overtemperature of motor Fault Trips Self reset/ to

[Motor overtemp.] be reset
(See param. 16 05, MOT_TEMP_M1_ALARM_LIM
and 16 10, MOT_TEMP_M2_ALARM_LIM)
7 Calculated overtemperature of motor Fault Trips To be reset
[Motor overtemp.]
(See param. 15 05, MOT_TEMP_C_ALARM_LIM)
8 A fault that is caused by some hardware Fault Trips Cannot be
malfunction reset
[Control Unit fault]
11
Fault signals continued...

9 Undervoltage of chopper Fault Trips To be reset
[Chopper undervoltage]
10 Overvoltage of chopper Fault Trips To be reset

[Chopper overvoltage]
11 DC intermediate circuit undervoltage Fault Trips Self reset

[DC undervoltage]
12 Output short circuit Fault Trips To be reset
13 Semiconductor fault in inverter unit Fault Trips Cannot be

[Power stage fault] reset
14 Speed measurement fault Fault Trips To be reset

[Speed meas. fault]
(if param. 18 03, TachoDelay is active)
15 Current measurement fault Fault Trips To be reset
[Current meas. fault]
16 Calibration of Uc measurement Fault Trips Cannot be

[UC measurement fault] reset
17 Matching board fault Fault Trips Cannot be

reset
18 Write or read error in EEPROM Fault Trips Cannot be

[EEPROM fault] reset
19 Analog input overlimit fault Fault Trips Self reset/ to

[Analog input fault] be reset
(See param. 16 05, MOT_TEMP_M1_TRIP_LIM and
16 10, MOT_TEMP_M2_TRIP_LIM if other than motor
temperature measurement is selected)
20 APC-Link communication error Fault Parameter Self reset
[APC-Link comm. error] depend.
(See param. 19 01, APC_COM_TIMEOUT and
param. 19 02, APC_COM_BREAKRESP)
21 APC wath-dog error Fault Parameter Self reset
(See param. 19 03, APC_WATCHDOG_MODE and depend.
param. 19 04, APC_WATCHDOG_BREAKRESP)
22 A) Motor parameters are not set Fault Prevents A) Param. to
B) Identification procedure fault start up be set
[Motor param. fault] B)
(See param. 11 04, DriveMode) Param. 11 04
(See signal 101 06, Commis_Start, for further fault
detection information)
to be set 0
23 Motor stalled Fault Trips To be reset
(see param. 15 07, StallProtSel)
12
Fault signals continued...

24 Tripping of thermal model supervision for Fault Trips Self reset
INU
(IGBT clamp resistors or GTO chokes)
[INU therm.curr.fault]
25 Commutation fault Fault Trips To be reset
(with GTO INUs only)
26 Thermal supervision of GTO INUs based Fault Trips To be reset
on calculation <|5Hz| of sliding mean of
instantaneous total actual current
[Powerstage overcurr.]
45 Fan stalled fault Fault Trips To be reset
(See param. 18 08, GTO_FAN_TIME)
13
15 Alarm/Status Signals

101 Inhibition of false start switch has been Status Prevents Resets when
switched start up released
[Start inhibition]
102 Emergency stop button has been pushed Status Prevents Resets when
[Emergency stop] start up released
103 Alarm of Motor temperature measurement Alarm Alarm Self reset
[Motor temp. alarm] indicator
and 16 09, MOT_TEMP_M2_ALARM_LIM)
104 Indication for calculated motor Alarm Alarm Self reset
temperature alarm indicator
(See param. 15 04, MOT_TEMP_C_ALARM_LIM)
105 Alarm of inverter unit temperature Alarm Alarm Self reset
measurement indicator
[INU overtemp. alarm]
106 TC unit address not in limits Alarm Alarm Address to be
[TC address alarm] indicator set in limits
107 Indication for magnetizing current table Alarm Alarm Self reset
being empty if vector control was selected indicator
[Im Table alarm]
(if param. 11 02, ControlMode = 4)
108 Backup failure of RAM memory Alarm Alarm Self reset
[RAM-backup failed] indicator
109 Alarm for analog input limit Alarm Alarm Self reset
[Analog input alarm] indicator
and 16 09, MOT_TEMP_M2_ALARM_LIM if other
than motor temperature measurement is selected)
110 System restart, indication for fault logger Status Status Self reset
remark indicator after init.
[System restart]
111 Motor temperature measurement selected Alarm Alarm Self reset
but input connector not connected or indicator
supply current out of range/selected
incorrect or current source not in use
[Curr. gen. meas. alarm]
(if param. 16 01, AN_INP1_SEL = {1...4} or 16 06,
AN_INP2_SEL = {...4})
112 Master/Follower index is incorrect Alarm Alarm Self reset
[Mas.Foll.index alarm] indicator
(see param. 20 02, MASTER SIGNAL and 20 03,
FOLLOWER_SIGNAL)
14
Alarm/Status signals continued...

113 Alarm of thermal model supervision for Alarm Alarm Self reset
INU indicator
(IGBT Clamp resistors or GTO chokes)
[INU therm.curr.alarm]
114 APC connection OK Status Status
indicator
115 Actual earth fault alarm Alarm Alarm Self reset
[Act earthflt alarm] indicator
(See param. ACTUAL_EF_DETECT(11 16))
116 UC not in limits duting stand by Alarm Prevents Self reset
[UC limit in stand by] start up
131 Fan stalled alarm Alarm Alarm Self reset
(See param. 18 08, GTO_FAN_TIME) indicator
15
16 HW-Fault Indications
17 SNAT 603 CNT Motor Control Board

The board consists of green "READY" LED indicator and it is
illuminated in normal condition. Indication consists of the following
interlockings and diagnostics.
- Fault of GTO-unit (only in GTO-INU)

- +5 V auxiliary power supply monitoring
- Clock frequency monitoring of SNAT 603 CNT
- +/- 15 V auxiliary power supply monitoring
- Inhibition of false start
- Monitoring of braking at Emergency Stop situation.
V 1 R eady
X403
X401 EEPROM EPROM

D8 D10
Terminal X405 is
wired for Inhibition X406 X408
of false start
1 1
X405
EPROM
+24 V auxiliary
X402 D15
supply terminal 1
for tacho meter
X404
SNAT 603 CNT
Figure 4. SNAT 603 CNT terminals and memory circuits

(61034846.drw).
If SNAT 603 CNT board must be changed, remove the EEPROM D8

from old board and install it to new one. Thus there is no need to do
parameter settings. Check also that the new board consists of EPROM
D10 and D15. The program version must be the same as in the old
board or a newer version. Version identification is written on the label of
EPROM.
There are no adjustable trimmer potentiometers on the board. All
tunings are done automatically in control program.
16
18 SNAT 609 TAI Tacho and Interface Board
Auxiliary voltages can be measured with a multimeter at terminal X1.
Au xilia ry vo lta g e
IN 3 Inverter m e a s u rin g p o in ts
O U T3 number
-1 5 V +15V
Current 35 36
X1
X1
IN 2
APC
O UT2
IN 1
Maintenance
O UT1
tool GND +5V
3 4
S N AT 6 0 9 T AI 1 2
+2 4 V GND
X2
Figure 5. SNAT 609 TAI Auxiliary voltage measurement

(61034854.drw).
If SNAT 609 TAI board must be changed, check that the switches
INVERTER NUMBER and CURRENT are set to the same position as in
the original. Inverter numbers must be coded because of APC
controller can control 1 to 4 inverter units. See Figure 5.
S T R AP S E T
STRAP O PEN
U N IT S E L EC T IO N
IN VE R T E R N U M B E R 1 IN V E R T E R N U M B E R 2 IN VE R T E R N U M B E R 3 IN V E R T E R N U M B E R 4
C O N S T AN T C U R R E N T S E LE C T IO N
CURR ENT CURRENT

1HI 1HI
C HANNEL 1, I = 9 m A C HANNEL 1, I = 9 m A
1LO 1LO
2HI 2HI
CHANNEL 2, I = 9 m A C H A N N E L 2 , I = 1 .6 m A
2LO 2LO
CURR ENT CURRENT

1HI 1HI
C H A N N E L 1 , I = 1 .6m A C H A N N E L 1 , I = 1 .6m A
1 LO 1 LO
2HI 2HI
C HANNEL 2, I = 9 m A C H A NN E L 2 , I = 1.6 m A
2LO 2LO
Figure 6. Strapping of the tacho & I/O board SNAT 609 TAI
(61034862.drw).
17
19 SNAT 7261 INT Main Circuit Interface Board
WARNING! Part of this board is at the main circuit's potential and

so a lethally dangerous voltage is present between the control
board and cabinet frame of ACV 700.
By opening the front cover of the IGBT Converter Module, you will see
the Main Circuit Interface Board SNAT 7261. This board consists of:
- Pulse amplifier to each power semiconductor
- UC-voltage measurement
- Auxiliary power supply
- Current actual buffer amplifiers
- Matching board unit.
There is a seven-segment LED digit on the bottom part of that board. In

normal operation +15 V and +24 V leds are illuminated.
These hatched areas are in
potential of Main Circuit!
T1
X3 06
S e ve n s e g m e nt d is pla y
F1 F2 ind ic a tio ns :
X301
R e d LE D
D ischarge
Ma tc h in g c a rd Power
a = none
S NAT 7 4XX S C L b = none
X318 G re en LE D
c = none
X3 07 X3 1 7 Fuse s d = none
e = none
X3 0 4 f = none
X3 1 6 g = +15 V ok
p o in t = + 2 4 V o k
X3 05
K1
a
X3 09
X3 1 3 SNAT 7261 X3 10
UH f b
UL Main Circuit g
Interface Card
e c
X3 1 4 X3 0 2 X3 11
VL VH d
p o in t
X3 1 5 V30 4 X3 12
WL s e ve n s e g m e n t WH
dis pla y
Figure 7. SNAT 7261 Main Interface board of IGBT INU

(61029907.drw).
If segment +24 V or +15 V is dark, the corresponding internal auxiliary

voltage has dropped too low. The green led (Power) on upper part of
the board is illuminated when power supply is operating normally. If you
disconnect the mains, the red LED (Discharge) above the green one
will turn on for a while, as the DC-bus is being discharged.
18
20 SNAT 607 MCI Main Circuit Interface Board

board and ACV 700 frame.
This board consists of GTO fault indication LEDs. LEDs are located at
the upper part of the board. Leds are U1, V1, W1, U2, V2 and W2
according to location in the main circuit. The board has fuses in 12V
and 24V circuits.
SNAT 607 MCI board consists of following functions:

- Inverter fault detection circuits
- UC-voltage measurement
- Auxiliary power supply
- Current actual buffer amplifiers
- Matching Board Unit
- Earth fault detection
- Inhibition of false start
- Fan control relay K1
X6
X13 K5 K4 K3
X16 X20 S1
U1 V1 W1
Phase fault
1 2 1-2 = SIMULATION 575-690 V
X18 X3
4 3 4-3 = NORMAL
K6 U2 V2 W2 1-4 = SIMULATION 380-500 V
S2
X12
K2
X10 X19 X9 S2
X2
X11
a 0.3V EARTH FAULT DETECTION
b 0.5V
K1
X14 c 1.1V
d 2.6V
SNAT
V48 V49 V50 V51 V52
xxxx-VB SCL
e 4.7V
X15 Matching X1
Card
S1 F1 F2 F3
F4
SNAT 607 MCI
Main Interface Board This hatched area is in
for ACV 700 GTO type potential of Main Circuit!
C2
T1
X8 X7 X6
X4
Figure 8. SNAT 607 MCI Main Interface Board for GTO type of
ACV 700 (61029915.drw).
19
21 SNAT 63_ PAC Pulse Amplifier Board

board and ACV 700 frame.
This board is used to produce required control pulses to GTO thyristors

in the main circuit.
Green LEDs H1 and H2 indicate that power is supplied to the pulse

amplifiers and the fuses are intact. There are three pulse amplifier
boards in GTO INUs. Each pulse amplifier board of GTO-INU contains
two pulse amplifiers. Power supply for boards is 42 V 80kHz.
Construction of board depends on the type of ACV 700.
This hatched area is

in potential of main circuit!
X2
XA1 XA2
T2 T3
X1 XK2
XK1
GTO GTO
V11, XG1 XG2 V14,
V12, C41 C44 V15,
V13 V16
H1 H2
T1
F1 F2
X3 SAFT 63_ PAC
Figure 9. SNAT 63_ PAC Pulse Amplifier board (61029923.drw).
In case of damaged GTO thyristor, change also the SNAT 63_ PAC
pulse amplifier board after the replacement of GTO because the pulse
amplifier may damage in the same situation.
20
22 SNAT 617 CHC Chopper Control Boards
WARNING! This board is at the main circuit's potential and so a

lethally dangerous voltage is present between the control board
and the ACV 700 frame.
The Chopper Control Board controls the gating of the chopper GTO
V17 in GTO inverter units. Energy from the commutation of the GTO
appears across the clamping capacitor C9 and it is fed back to the DC
bus through GTO V17. The amount of energy transferred is determined
by the duty cycle of V17.
The green LED V42 on the chopper control board is on when the
required power is supplied to the board and fuse F1 is intact.
In the event of a shorted device, fuse F1 will open, protecting the

amplifier circuit.
V17
Chopper
Thyristor
X2 X5 X3
X1
V42 X4
XK XG
T1
C41
F1 Warning!
This Board is in potential
of Main Circuit.
SNAT 617 CHC S1

Chopper Control Board
Figure 10. SNAT 617 CHC Chopper Control Board (61029931.drw)
21
23 SAFT 11_ POW Power Supply Board

and ACV 700 frame.
The Power Supply is used to supply voltages to both the Control Board
and the Pulse Amplifier Boards in the GTO INU. The DC voltages used
for control are derived directly from a +300 V DC input from the SNAT
607 MCI Main Circuit Interface Board. DC voltages produced are +14
V, -14 V and + 5 V. In addition to DC voltages, the Power Supply
produces a 42 V, 80 kHz square wave which is used in the Pulse
Amplifier boards SNAT 63_ PAC.
The green LED V40 on the Power Supply Board is lit when the auxiliary
voltage board receives the required power supply and can supply +5 V
to the output. If LED is dark, check first the fuses.
X2
X4 X3 S2 X1
T3 F4 F3 F2
F1 T1A T4A T1A
1A, 1.2 kV
S1
L1
Warning!
This card is in potential
of Main Circuit.
V4 SAFT 11_ POW
V40
Figure 11. SAFT 11_ POW board (61029940.drw).
22
24 Other fault conditions and repair
25 Main fuses are blown
In case of burned main fuses there is a high possibility of short circuit in

the main circuit.
DANGER!
By opening the drive section switch in the IGBT inverter to

position 0 (zero) via charging position, it is possible to blow the
charging fuses as a consequence of short circuit in the main
circuit. If short circuit is suspected, open the main breaker from the
supply section to prevent the burning of charging fuses.
Measure the main circuit to find out the fault source. Never change the
fuses without measuring the condition of main circuit!
Main and charging fuses can be changed only in a situation where

the drive section switch is in zero (off) position and the zero voltage is
measured with a voltage meter from the fuses.
Figure 12. Function of drive section switch in IGBT type.
23
26 Checking the GTO inverter by simulating its operation
The operation of the GTO inverter control circuits can be examined by

simulation without damaging the power semiconductors or blowing of
the fuses in the main circuit in case of fault.
In simulated operation the main circuit voltage is disconnected by

isolating the intermediate DC circuit terminals from the power supply. In
Common DC Bus Drives in which each inverter has its own isolator, the
main circuit voltage is disconnected by taking out the DC fuses of the
inverter.
Simulation procedure
1. Ensure that the circuits have no voltage.
2. Isolate the intermediate DC circuit from the power supply by

removing the DC fuses from the Drive Section Switch.
3. To simulate a Chopper undervoltage change the switch S2

from normal position A-B to position A-C on the board SAFT
11_ POW and change the SNAT 607 MCI board switch S1 from
normal position 3-4 to simulation position 1-2.
4. After the control circuits have been set up for simulation, you
can switch on the Drive Section Switch to get the 220 V AC
supply to the ACV 700. The control panel or system should now
indicate that the inverter is ready to start.
5. Change the parameter CTRLMODE from the group 11 to mode

1 (mode 1 = u/f control without speed feedback).
6. Ready to run test in simulation mode.
7. After the tests remember to return the switch S2 back to

position A-B on the board SAFT 11_ POW and S1 to 3-4 on the
board SNAT 607 MCI. Reconnect the DC circuit to ACV 700.
Change parameter CTRLMODE back to original value.
When the operation of the inverter unit is simulated, an oscilloscope, for

example, can be used for measurements as the main circuit is isolated
from the power supply and the 220 V required by the inverter are
generated galvanically isolated by the auxiliary voltage transformer T1.
24
27 Fan control failures
Fan runs normally
- During a one minute period after the Drive Section Switch is switched
on.
- When the inverter is started.
- When measured heat sink temperature is above +45蚓.
Fan stops
After modulation is stopped and measured heat sink temperature is

below +40蚓.
If fan doesn't start the way mentioned above, check:
1. Fan motor protection switch F11 in GTO type.
2. Check 220 V AC auxiliary voltage.
3. Check the +24 V auxiliary voltages.
4. Check if relay K1 in Main Circuit Interface Board is energized

after the main power is switched on? If not, change the Main
Circuit Interface Board according to ACV type.
5. Fan motor insulation level and connection.
6. Fan motor bearings by rotating the motor manually. Replace

the fan by a spare if required.
7. Temperature measuring NTC sensor (4.7 kW at 25蚓) of heat

sink and its wiring.
8. Connection of terminal X11 on the SNAT 607 MCI (GTO INU)

or terminal X309 (IGBT INU) on SNAT 7261 INT Main Circuit
Interface Board.
9. Change the SNAT 603 CNT Motor Control Board.
25
28 Frame sizes of IGBT type
There are different frame sizes according to output current and voltage.
Following table shows the frame sizes of ACV 700.
Table 13. Frame sizes of IGBT types.
Frame Size Type IN (A)

Rated output
current
R4 ACV701-0009-3 13
Dimensions: ACV701-0016-3 24
W*H*D (mm) ACV701-0025-3 38
300*546*311 ACV701-0010-5 13
ACV701-0020-5 24
ACV701-0032-5 38
R5 ACV701-0050-3 76
W*H*D (mm)
353*640*324
R7 ACV701-0070-3 112
W*H*D (mm) ACV701-150-3 215
336*1041*412 ACV701-0100-5 112
ACV701-0115-5 135
ACV701-0170-5 200
R9 ACV701-0215-3 315
W*H*D (mm) ACV701-0330-3 480
432*1638*442 ACV701-0260-5 300
ACV701-0315-5 365
ACV701-0400-5 460
26
29 Replacing the fan for IGBT INU in frame sizes R4 and R5
The Inverter Unit must be removed from the cabinet before it is

possible to change the fan in frame size R4 and R5. If you have an INU
module as a spare, replace the faulty INU by the spare INU to save
time. Parameter memory circuit EEPROM D8 must be removed from
the original SNAT 603 CNT board and be installed on the spare
module's SNAT 603 CNT board.
Replacing IGBT inverter unit
1. Disconnect the main power supply by opening the Drive

Section Switch of ACV 700. Wait five minutes and confirm your
safety by measuring the voltage of DC and AC before you start
the work.
2. Remove all cables and wires around the INU. Mark the wires to
help reinstallation if required.
3. Remove the INU from the cabinet.
4. Remove the fan motor cable from terminals X10.
5. Open the rear cover of INU and remove the fan by opening the
installation screws.
6. Install the new fan to the INU.
7. Reinstall the rear cover and reconnect the fan motor cable.
8. Install INU back to the cabinet and reconnect the wires.
30 Replacing the fan for IGBT INU in frame sizes R7 and R9
Following instruction is for ACV 700 frame types R7 and R9.

Section Switch of ACV 700. Wait five minutes and confirm your
safety by measuring the voltage of DC and AC before you start
the work.
2. Remove all cables and wires around the INU. If needed, mark
the cables to make it esier to reinstall.
3. Remove the front cover of ACV 700 unit.
4. Remove the fan motor cable.
5. Remove two mounting screws of fan. Screws are located at the
front of the unit.
6. Remove the fan.
7. Confirm the type of faulty fan and spare one.
8. Install the spare fan to the unit.
9. Reinstall and tighten installation screws of fan.
27
Figure 14. Fan motor of IGBT type in frame size R7 and R9

(61029958.drw).
10. Reconnect the motor cable.

11. Remount the front cover.
12. Reconnect the cables to the boards.
31 Replacing the fan for GTO INU
There are two different way to change the fan in GTO INU. Replacing
can done either by removing the fan with installation plate from the front
side or rear side of cubicle. However the replacement from the rear
side is possible only in case where rear side has enough free area to
do the replacing work.
Replacing of fan from the front side

Section Switch and motor protection switch F11 of ACV 700.
Wait five minutes and confirm your safety by measuring the
voltage of DC and AC before you start the work.
2. Remove the busbars or the motor cable from output terminals
of INU, because the fan is located behind the busbars or motor
cable.
3. If the fan motor type is 9.5 kg (see the part list of section),
remove the frame bars of INU under and front of the fan.
4. Remove the fan motor cable from the terminal side.
5. Remove the installation plate of motor by opening four screws
on both sides of INU.
6. Pull out the installation plate with motor.
7. Remove the faulty fan motor and replace it by a new one.
8. Reconnect the motor cable to the motor terminal box.
9. Push the installation plate back to the INU and tighten the four
installation screws of plate.
28
10. Reconnect the fan motor cable to the terminals of INU.

11. Install the frame bars.
12. Reconnect the INU's output busbars or motor cable.
13. Connect the F11 and Drive Section Switch on.
Replacing of fan from the rear side

Section Switch and motor protection switch F11 of ACV 700.
Wait five minutes and confirm your safety by measuring the
voltage of DC and AC before you start the work.
3. Remove the installation screws of the cubicle rear cover.
5. Remove the installation plate of motor by opening four screws
on both sides of INU.
6. Pull out the installation plate with fan motor.
7. Remove the faulty fan motor and replace it by a new one.
8. Reconnect the motor cable to the motor terminal box.
9. Push the installation plate back to the INU and tighten the four
installation screws of plate.
10. Reconnect the fan motor cable to the terminals of INU.
11. Switch the F11 and the Drive Section Switch on.
Mounting plate
Figure 15. Fan motor of GTO INU (61034871.drw).
29
32 Fault Tracing by diagnostics messages
33 Fault signal codes

Table of Fault Tracing
Signal Definition Possible reason/Action

Code [APC Fault Texts]
0 No faults or alarms
99 Reset, resets all resettable Reset

faults
1 Auxiliary voltage fault Try to reset the fault. If the fault message is
[Auxil. undervoltage] repeated, the fault probably lies in the SNAT
7261(IGBT-INU) or SNAT 607 MCI (GTO) Main
Circuit Interface Board.
Measure following auxiliary voltage levels from

SNAT 609 TAI board:
-+5V between X1:4 and X1:2

- + 15 V between X1:36 and X1:2
- - 15 V between X1:35 and X1:2
- + 24 V between X1:1 and X1:2
Terminal X1 is located in the middle of SNAT
609 TAI board.
If +5 V level is low, but +24 V is correct, possible

fault may be in the SNAT 603 CNT board.
Change the board.
If +15 V, -15 V or 24 V voltage levels are not

correct, change the SNAT 7261 (IGBT INU) or
SNAT 607 MCI (GTO INU) Main Circuit Interface
Board :
If there is no voltages at all in IGBT INU, check

the fuses F1 and F2 on the board of SNAT 7261
Main Interface Circuit Board. It they are blown,
change the board.
30

2 Overcurrent Try to reset the fault. If the fault is reset, check

that
Output current of INU has
exceeded the allowed limit - motor is ok.
- motor and inverter are correctly dimensioned.
- motor cables are ok.
- motor load connected to ACV 700 has not
changed.
- possible speed difference reference is correct
compared to other drive sections, if load is
common.
If the fault is repeated several times, the INU can

be overloaded. The torque limits can be
incorrect.
3 DC intermediate circuit over- Try to reset the fault.

voltage [DC overvoltage]
Check whether the braking power is too big.
Reason can be external overvoltage in network,

for example connection of compensation
capacitors. Check the network.
Check the supply unit from the supply section. If

more than one ACV 700 groups trip simulta-
neously by overvoltage tripping, the fault is in
supply section either in SAFUX unit or in Braking
Chopper Unit according to used type.
Check the UC-stabilizer function and

parameters. in case of scalar control. See from
the Firmware Manual section U/f control.
If the fault occurs repeatedly in individual ACV

700, UC-measurement can be faulty. Change
the Main Circuit Interface Board.
4 Measured overtemperature of ACV 700 heatsink temperature is > 85蚓 or less

converter than -10蚓. Restricted air flow caused by dust or
[Converter overtemp.] improper installation; overloading or a
component failure (fan, fuse, power
semiconductors).
- Check ambient temperature < 40蚓

- Check heat-sink fins, remove any dust or dirt.
- Check that the ACV 700 was not overloaded
too long
- Check the fan and air flow.
31

5 Earth fault Earth fault has occurred in output of inverter at

start sequence.
Disconnect the mains of group, wait 5 minutes

and ensure by measurements that the DC-
voltage is zero in UC-circuit.
Disconnect the motor cable from the INU and

check the cable and the motor insulations.
If there is no earth fault or short-circuit between

phases persists, contact the nearest ABB
Service representative.
6 Measured overtemperature of ACV 700 has determined that the motor is

motor (Motor overtemp.) overheated and the tripping limit is exceeded.
Check the motor temperature and reason why

motor temperature has risen.
Check parameters 16 05 and 16 10

MOT_TEMP_M1_TRIP_LIM and (or)
MOT_TEMP_M2_TRIP_LIM values, if other than
PT100 measurement is selected.
If the motor temperature is above rated

temperature, improve motor cooling or resize the
motor.
Wait until the motor has cooled down and try to

start up the ACV 700 again.
If the fault persists, contact the nearest ABB

32

7 Calculated overtemperature of ACV 700 has determined that there is a high

motor (Motor overload) probability that the motor is overheated. Because
the temperature rise is calculated from the motor
current and not measured directly, the motor
may be within the temperature rise specification.
Check the motor temperature and the reason

why motor temperature has risen.
Check the correctness of motor parameters.
See parameter 15 06,

MOT_TEMP_C_TRIP_LIM. Is the tripping
temperature correct?
If the motor temperature is above rated

temperature, improve motor cooling or resize the
motor.
Wait until the motor has cooled down and try to

start up the ACV 700 again.

8 A fault that is caused by a This fault appears when A/D transducer's

hardware malfunction (Control reference voltage is out of range or A/D
Unit fault) conversion time is too long.
Change the SNAT 609 TAI Tacho and I/O

Interface Board.
33

9 Undervoltage of chopper Voltage of the GTO-inverter chopper capacitor

[Chopper undervoltage] has decreased below the alarm limit.
Reset the fault and try to start ACV 700. If the

fault message is repeated, chopper is faulty.
Check that the DC intermediate circuit voltage is

85 to 115 % of rated value. The rated DC voltage
is 1.35 times the r.m.s. value of mains voltage
when a 6-pulse diode bridge is used.
Check the mounting of connector X4 on the

Chopper Control Board. Check if the light-
emitting diode LED of the chopper control board
is lit. If the LED is not lit, check fuse F1 and the
mounting of connector X2. If fuse F1 has blown,
check by measurement the condition of thyristor
V17. Do not dismount the thyristors unless you
are sure that it is faulty. If the fault cannot be
found, replace the chopper control board and
INU愀 control board if necessary.
10 Overvoltage of chopper Voltage of the GTO-Inverter chopper capacitor

[Chopper overvoltage] has increased above the alarm unit.
Reset the fault and try to start ACV 700. If the

fault message is repeated, chopper is faulty.
Actions as above except for the measurement on

thyristor V17. In addition, check connections of
the leads of thyristor V17.
11 DC intermediate circuit under- DC-intermediate circuit voltage has decreased

voltage [DC undervoltage] below the alarm limit 0.6 x Udcn.
The most common reason is a power loss in

network.
The fault probably lies elsewhere, not in the

inverter unit. If the fault message is repeated at
start.
- Check that the main contactor is closed.

- Check the DC intermediate circuit voltage.
If the DC intermediate circuit voltage is too low,

see Chapter 5, 'Fault tracing in supply section'.
34

12 Output short circuit Short circuit at output terminals. This message

occurs only when starting the INU, not while the
INU is running. At the beginning of start, test
program gives a short control pulse for one
power semiconductor of INU. If current flows,
this means a short circuit in output circuit.
Check the motor and motor connection cables.
13 Semiconductor fault in inverter Check the semiconductor fault LEDs on SNAT

unit [Powerstage fault] 607 MCI Main Circuit Interface Board in case of
This function is only in GTO GTO INU.
INU of ACV 700.
Check the power semiconductors. See Chapter
4, 'Checking and replacement of the power
semiconductors'.
If faulty semiconductor is found, replace also its

branch SNAT 63_ PAC Pulse Amplifier Board.
14 Speed measurement fault Tacho pulses are

[Speed meas. fault] - faulty
(if param. 18 03, TachoDelay, - lacking
is active) - tachopulses do not reach the control board
- parameter TACHODELAY group 18 03 is too
low.
Check the TACHODELAY group 18 03 time
within tacho pulses must be generated after the
start command. Delay time is possibly too short.
See also the TACHOPULS_NR parameter
(group 18 02) number of tacho pulses per
revolution.
Continue...
35

...14 (See the previous page too.) Check the auxiliary voltage supply of pulse
encoder from terminal board SNAT 602 TAC.
Speed measurement fault Measure by multimeter:
[Speed meas. fault] - +24 V between X4:11 and X4:10
(if param. 18 03, TachoDelay, - or if +12 V pulse encoder is used between
is active) X4:12
and X4:10.
If auxiliary voltage is missing or it is low, check:

- Terminal X301 is connected in SNAT 7261 INT
Main Circuit Interface Board.
- Terminal X401 is connected in SNAT 603 CNT
board.
- Possible overload in tachocircuit. Check the
cable and pulse encoder.
- Change the SNAT 7261 INT Main Circuit
Interface Board because of auxiliary power
failure.
If auxiliary voltage is OK, rotate the shaft first

manually and measure the tachopulses by
means of oscilloscope from terminal board SNAT
602 TAC:
Single Ended Pulse encoder:

- Tacho channel CHA1 between X4:8 and X4:10
- Tacho channel CHB1 between X4:5 and X4:10.
Differential Pulse encoder:

-Tacho channel CHA1 between X4:8 and X4:10
-Tacho channel CHA2 between X4:7 and X4:10
-Tacho channel CHB1 between X4:5 and X4:10
-Tacho channel CHB2 between X4:4 and X4:10
Waveform must be squarewave when the shaft

of motor rotates. Voltage level must be near 24
V when using 24 V pulse encoder and near 12 V
when using 12 V one. If fault is still on, check the
flat cable between Terminal Board SNAT 602
TAC and SNAT 609 TAI Tacho and I/O Interface
Board.

Interface Board.
36

15 Current measurement fault Operation(s) of ACV 700 output current

[Current meas. fault] transducer is faulty. Offset error has been
detected. See the ACV 700 Maintenance (group
123, signals) parameters IU_FREQ output
frequency of U-phase current measurement and
IV_FREQ output frequency of V-phase current
measurement. Normal value on zero current is
1000 = 1MHz. Maximum positive value is 2000
and negative is 0.
Check first the IU_FREQ and IV_FREQ

parameter values when ACV 700 is stopped.
Value must be near 1000. If not, change the
faulty suspected current transducer unit.
Check the current transducers and terminal

X307 on SNAT 7261 INT (IGBT) or X9, X19 and
X10 on SNAT 607 MCI (GTO) Main Circuit
Interface Board.
Change the SNAT 7261 INT (IGBT) or SNAT

607 MCI (GTO) Main Circuit Interface Board.
16 Calibration of Uc measurement Uc measurement is out of range.

[UC measurement fault]
Change the SNAT 7261 INT board.
17 Matching board fault SNAT 74XX SCL (IGBT) or SNAT 0xxxx MTC
(GTO) scaling board is faulty or missing. The
board is located on the SNAT 7261 INT Main
Interface Board.
Change or add the board. Check that board type

corresponds to the selected ACV 700 type.
18 Write or read error in EEPROM Parameter reading or storing to the EEPROM

[EEPROM fault] has failed.
Switch off the Drive Section Switch for a while

and try to store again. If warning occurs again,
try to restore factory settings.
Change the EEPROM micro circuit in the SNAT

603 CNT board. Remove first the SNAT 609 TAI
board.
If the warning still persists, change the SNAT

603 CNT board.
If the warning persists, contact the nearest ABB

37

19 Analog input overlimit fault This tripping occurs if PT100 temperature

[Analog input fault] measurement is not selected and measurement
(See param. 16 05, signal in analog input(s) exceeds the tripping
MOT_TEMP_M1_TRIP_LIM level (parameter MOT_TEMP_M1_TRIP_LIM or
and 16 10, MOT_TEMP_M2_TRIP_LIM)
MOT_TEMP_M2_TRIP_LIM, if
other than PT100-measure- Check the analog input signal connections and
ment is selected) cabling.
If cabling and input signal are correct, change

the SNAT 609 TAI Tacho and I/O Interface
board.

20 APC-Link communication error Communication supervision has detected an

[APC-Link comm. error] error. APC and ACV 700 are not able to
(see param. 1901, communicate.
APC_COM_TIMEOUT and
param. 1902, Check first that:
APC_COM_BREAKRESP) - Opto cables are correctly connected.
- APC seven segment display shows P1 (APC is
in running mode).
- APC indicators V50 (watchdog) red led is dark
and V51 (power ok) green led is lit.
If YPC 111A Optic Link Distributor has been

used, check that:
- Green led is lit in YPC 111A board (Power ok).
If some of these are not right see the APC fault

tracing instructions.

interface board. Change the SNAT 603 CNT
Motor Control Board.

38

21 Uc not in limits when starting up Possible reason is in supply section.

[UC limit fault]
Check the number of this fault from other drive
sections. If more than one drive has this same
fault, the reason is in supply section. See the
fault tracing of supply section.
Otherwise:
- measure the level of UC-voltage by multimeter
- see the parameter UC_FRQ output frequency
of DC-measurement (signal 123 01). When
UC-voltage is zero, parameter value must be
near 290. If not, change the SNAT 7261 INT or
SNAT 607 MCI Main Circuit Interface board
according to the type of ACV 700.
22 a) Motor parameters are not set If any of following tests fails, the ACV 700
b) Identification procedure fault program forbids to use vector and scalar control.
(see parameter 11 04,
DriveMode) Reasons for identification program fails:
[Motor param. fault]
(see signal 106 04, - motor rating plate values are missing or they
Commis_Stat, for further fault are wrong.
detection information) - measured speed is not close to the modulator
frequency reference.
- the saturation curve of motor to be measured
running the motor with 2/3 of the nominal motor
speed. The couplings can be connected if the

load of the motor doesn't rise above 50% of the
nominal.
- stator resistance is to be measured with zero
speed.
Check that the motor parameters are written into

the ACV 700 parameter memory, see the
parameter group 13, Motor Model. More
information about the reason can be seen from
signal 106 04, Commis-Stat. See the Firmware
Manuals.
Check the load, if identication is done with too

heavy a load. Remove the couplings if required
and try again to do the identification.
39

23 Motor stalled Fault message appears when stall protection

operates.
Check if the motor drive is stalled or the motor
load increased.
See the Firmware Manuals parameter 15 07,
StallProtSel.
24 INU thermal current fault / Possible overloaded motor.

alarm, which is based on Check if motor and inverter are correctly
calculation of sliding mean of dimensioned.
instantaneous total filtered
actual current. (I_Act_Filt_Rel)
- clamp resistor protection if
IGBT-INU.
- DC-choke and commutation-
choke protection if GTO-INU.
[INU therm.curr.fault]
25 Commutation fault Hardware recognized fault that is based on the

(with GTO INUs only) motor ASIC-circuit supervision of simultaneous
switching of control pulses.
26 GTO-powerstage and zero- Possible overloaded motor.

diode protection. Thermal Check if motor and inverter are correctly
supervision of GTO INUs dimensioned.
based on calculation <|5Hz| of
sliding mean of instantaneous
total actual current.
(See Parameter 12 10, Pwrstg_Flt_Lim)
[Powerstage overcurr.]
45 Fan stalled fault Fan stalled.

(See param. 18 08, GTO_FAN_TIME) Check the operation of fan.
40
34 Replacing the GTO Inverter unit
Note the Working Methods in chapter 1.3. !
1. Disconnect the main power supply by opening the Drive Section Switch of ACV
700. Wait five minutes and confirm your safety by measuring the voltage of DC
and AC before you start the work.
2. Remove all cables, control wires and DC busbar connection from the Inverter
unit.
3. Open the front cover of the Inverter unit to get access to the installation screws.
4. Open the installation screws of the Inverter unit. GTO Inverter unit is attached to
the cabinet frame through installation bars. Installation bars, 2 pieces, are
located on the upper and lower front part of the Inverter unit. They are attached
to the cabinet frame with total of six screws (2+4) and to the Inverter unit with
total of four screws (2+2). Furthermore, the Inverter unit is attached with two
screws to the cabinet frame trough installation plate which is located back on the
top part of the Inverter unit.
5. Remove the faulty Inverter unit and replace it with the new one.
6. Tighten the installation screws and install the installation parts.
7. Reconnect all cables, control wires and DC busbar connection to the Inverter
unit.
8. Set the jumpers "Inverter number" and "Current" of the SNAT 609 TAI board as
they were on the old replaced board.
When replacing Inverter unit note that Inverter-related parameter values have to be set
into the new Inverter unit.
The Inverter-related parameters are stored in the EEPROM memory and in the backup
disk of the DDC-Tool.
EEPROM memory circuit D8 is mounted on the SNAT 603 CNT Motor Control Board.
The transfer of the parameters can be done by one of the following ways:
- If the old SNAT 603 CNT board is not faulty replace new board with the old one
or,
- replace only the EEPROM circuit D8 from the old board to the new board or,
- when the new Inverter unit is installed switch on the power and download
parameters from the DDC-Tool to the ACV 700 and save the parameters to the
EEPROM.
Replacing the IGBT Inverter unit is descriped in the section "Replacing the fan for IGBT
INU in frame sizes R4 and R5".
41
35 Checking and replacement of the power semiconductors
36 IGBT Power Semiconductors
37 IGBT handling precautions
Base (Gate) - emitter resistance and protection components are

installed between terminals B (base) and E (emitter) in R7 and R9
frame. Do not remove these components unnecessarily because there
is a risk to damage the high impedance base circuit by static charges
from your body. These components are located in frame R4 and R5
into the SNAT 0xx PTR terminal board A4...A6. Remember always to
use a wrist band when handling the IGBT.
Spare part module consists of short cut bridge between terminals B-E.
Folio will be removed just before B - E wiring installation.
C 2E1 E2 C1
E2
B2
E1 E
B1
B
E C
3 4 3 4
frame R4, R5 frame R7, R9
C2E1
E2 C1 E C
E2 E1 E
B2 B1 B
Figure 16. Terminals of IGBT Power Semiconductor (61034889.drw).
42
38 Measuring of IGBT
W arning!
Never use insulation level meter in your measurements in Gate

circuit!
Short circuits and diode fault can be detected by a digital multimeter
measurement. If gate circuit has broken, the only way to check function
is to do the test in which a positive gate (base) control is given and
collector circuit has a test load with indicators. Partly gate injured IGBT
will operate correctly for a short period before a permanent injury. A
partly gate injury can be caused by careless handling of IGBT.
Before going on with repair, make sure there is evidence of an IGBT

failure. Multimeter measurements on the Converter Module according
to instructions can give adequate indication of a failed IGBT. If any one
of the measured values differs substantially from the one given, there is
a reason to start repair.
Do also the visual inspection for power semiconductors. Sometimes

the shell of the IGBT may be broken in the case of damage, when a
high current has flown through the IGBT. In this case check also
clamping resistors R1...R6 and diodes V1...V6 of power stage and
replace if required. Number of clamping resistors and diodes varies
according to type of ACV 700. See the Main Circuit diagram.
Before starting the measurement, remove the corresponding connector

X310...X315 from the SNAT 7261 INT board. Thus the pulse amplifier
circuit is out of the measuring circuit. Measuring can be done from
these terminal plugs in frame types R7 and R9.
ACV 700 frame sizes R4 and R5 collector wires are not wired into the
terminal plugs X310...X315. In addition, R4 and R5 gate wiring consists
of Protection Board SNAT 0xx PTR. Measure gate circuit directly at
semiconductor module. Collector measurement must be done from
+UDC, U2, V2, W2 busbars. See the main circuit diagrams. Measured
ohmic values depend on the digital multimeter type.
ACV 700 frame size R9 has two IGBTs connected in parallel. Therefore
terminal plug X310...X315 has in numbers 3 and 4 wires for second
IGBT gate circuit.
43
Term inal connector T erm inal connector Term inal connector

X 3 10 ...X 31 5 X 31 0 ...X 31 5 X 31 0 ...X 3 15
in fram e R 4 , R 5 in fra m e R 7 in fram e R 9
1 G 1 G 1 G
2 E IG B T 2 E IG B T 2 E
3 m od u le 3 m od ule 3 G IG B T
4 4 4 E m od u le s
5 5 5
6 6 C 6 C
Figure 17. X310-X315 terminal plug types (61034897.drw).
Following example measurements are shown on ACV 700 frame R7
1. Diode measurement of IGBT
Measured value must be approximately 0.3 V. Compare measurement

result with other power semiconductor measurements.
Term inal connector

X 3 1 0 ...X 3 1 5
1 G
+ 2 E IG B T
- m o d u le
6 C
Figure 18. Diode measurement of IGBT (61034901.drw).
2. Collector - Emitter resistance measurement
Measured value must be within range 5 kW...1MW depending on the

digital multimeter. Compare measurement result with other power
semiconductor measurements.
Term inal connector

X 3 1 0 ...X 3 1 5
1 G
+ 2 E IG B T
- m o d u le
6 C
Figure 19. Collector - Emitter resistance measurement

(61034919.drw).
3. Gate - Emitter resistance measurement
44
Measures the possible short circuit between Gate - Emitter due to the
power semiconductor or VxZ1 protection component connected
between B and E.
Measured value must be 10 kW in frame types R7 and R9 according to

base resistance in both measurements. Compare measurement result
with other power semiconductor measurements. Frame types R4 and
R5 have IGBT protection board. Gate circuit has resistor in series and
therefore resistance is a sum of protection board components R1 + R2
and R3 + R4. See the main circuit diagram.
T erm inal connector

X 3 1 0 ...X 3 1 5
1 G
+ 2 E IG B T
- m od u le
6 C

X 3 10...X 3 15
1 G
+ 2 E IG B T
- m od u le
6 C
Figure 20. Gate - Emitter resistance measurement (61034927.drw).
4. Gate - Collector resistance measurement
Measured value must be within range 10 kW...1 MW depending on the

digital multimeter. Compare measurement result with other power
semiconductors measurements.
45

X 3 1 0 ...X 3 1 5
1 G
+ 2 E IG B T
- m o d u le
6 C

X 3 1 0 ...X 3 1 5
1 G
+ 2 E IG B T
- m o d u le
6 C
Figure 21. Gate - Collector resistance measurement (61034935.drw).
39 Diode measuring of busbar assembly
There are several diodes, resistors and capacitors mounted in busbar

assembly and heat-sink. See the layout figures of power stages.
Diodes can be measured by digital multimeter in diode test measuring
range as diode measurement of IGBT. If short circuit is suspected,
busbar assembly must be removed before measurements. If +UDC and
-UDC busbars are in short circuit, possible fault might be in these
busbar assembly components.
Note!
Be careful with bolt type of diodes during the installation
and removing. Non-bolt side connection must be
installed carefully to prevent the mechanical damaging of
the diode during the installation.
46
40 Faulty IGBT detected
If damaged IGBT has been detected, measure also other components

of Main Circuit. Diodes and clamping resistors can be injured too.
Frame sizes R4 and R5 have B - E resistor and overvoltage protector in
SNAT 0xx PTR board located on terminal board A4...A6. In case of
damaged IGBT, change always this board.
B1 E1 B2 E2
R2
R1 R3
V1
V2 R4
Figure 22. IGBT Protection Board SNAT 0xx PTR in R4 and R5

frame (61034943.drw).
47
A 2 /X 3 0 7
A 2 /X 30 7
Figure 23. Typical Main Circuit diagram of IGBT INU

(61034951.drw).
48
41 Location of main circuit components
Components can be seen in following figure.
A3
V 1C 1
C4 C1
V 4C 1
U 21
V 4Z1 V 1Z1
V4 V1
R 4.1 R 1.1
C 4.1 C 1.1
C 4.2 A7 C 1.2
R7
C5 C2
V 5C 1
V 2C 1
U 22
R2 R5
V 5Z1 V 2Z1
V5 V2
R 5.1 R 2.1
C5.1 C 2.1
C 5.2 C 2.2
C6 C3
V 6C 1
V3C1
R1 R4
V 6Z1 V 3Z1
V6 V3
R 6.1 R 3.1
C6.1 C 3.1
C6.2 C 3.2
400V
(5 00V ) C 14.1
C 15.1 C 15 .3
(C 1 6.1 ) (C 15.1) (C 14 .1)
4 00V
(500V ) C 15.2 C 14.3 C14.2
(C 1 6.2 ) (C 15.2) (C 1 4.2 )
Figure 24. Layout of main circuit components in frame R7

(61034960.drw).
49
V 4Z2 C 4.3 V 1Z2 C 1.3

C 4.4 C 1.4
V 4C2
V 1C 2
R 4.2 R 1.2
V4.2 V1.2
R7 R1
U 21 C4 C1 R4
A3
V 4Z2 V 1Z1
V 4.1 V1 .1
V4C1
V1C1
R 4.1 C 4.1 R 1.1 C 1.1
C 4.2 C 1.2
V 5Z2 C 5.3 V 2Z2 C 2.3
C 5.4 A7 C 2.4
V5C2
V2C2
R 5.2 R 2.2
V 5 .2 V 2 .2
R2
U 22 C5 C2 R5
V 5Z2 V 2Z1
V 5 .1 V5C1
V2 .1
V2C1
R 5.1 C 5.1 R 2.1 C 2.1
C 5.2 C 2.2
V 6Z2 C 6.3 V3Z2 C 3.3

C 6.4 C 3.4
V6C2
V3C2
R 6.2 R 3.2
V 6 .2 V 3 .2
R3
C6 C3 R6
V 462 V 3Z 1
V 6 .1 V 3.1
V6C1
V3C1
R 6.1 C 6.1 R 3.1 C 3.1

C 6.2 C 3.2
400V
(500V ) C 15.1 C 15.5 C 14.1
(C 16.1) (C 15.1) (C 14.1)
400V
(500V ) C 15.2 C 15.6 C 14.2
(C 16.2) (C 15.2) (C 14.2)
400V
(500V ) C 15.3 C 14.6 C 14.3
(C 16.3) (C 15.3) (C 14.3)
400V
(500V ) C 15.4 C 14.5 C 14.4
(C 16.4) (C 15.4) (C 14.4)
(500V )
(C 16.5) (C 15.5) (C 14.5)
Figure 25. Layout of main circuit components in frame R9

(61034978.drw).
50
42 Replacement of IGBT
43 Getting access to the module
Clean a suitable place out of immediate work area to place removed

screws, bolts, components and subassemblies so that you do not
accidentally loose or damage them.
Read the chapter Safety and disconnect the main supply. Wait five
minutes and measure the DC-voltage between +UDC and -UDC.
Voltage must be zero before you continue the work.
1. Install the wrist band and earthing mat according to chapter

Working methods. Put the wrist band on your wrist.
2. Remove the terminals from SNAT 603 CNT and SNAT 609 TAI
board.
3. Remove the front cover of ACV 700 module.
4. Now we can see SNAT 7261 INT board. Remove the terminals
and mounting plate screws. Remove the SNAT 7261 INT with
mounting plate.
5. Open the screws of busbar assembly and remove it.
6. Now we can see the IGBT semiconductors. If the IGBT to be

replaced is next to the current transducer, remove the four
mounting screws of transducer and pull out the transducer
about 5 cm from the mounting plate. Now it is possible to open
the IGBT assembly screws which are under the transducer
(only in R7 and R9 frames).
7. Remove the Base - Emitter wiring by opening the screws.
8. Remove the faulty IGBT.
51
44 Installation of IGBT
Semiconductor components are precision products. All unnecessary

tools and articles constitute a needless danger to the easily dented and
scratched mounted surfaces and to the semiconductors in general.
1. Keep new semiconductors as long as possible in their original

packages.
2. Use protective gloves if necessary.
3. Clean table and hands frequently.
4. Use good lighting.
In order to keep the operating temperature of the semiconductor

module low, the joint between the heat sink and the module should
have a good heat conducting ability. The electrical conductivity of the
connectors must also be good. For this reason the following
instructions must be observed with particular care.
1. Compare that new and old components have the same type
designation or that the new component can replace the old
one. The IGBT semiconductor can be replaced also by the
different manufactorer's compatible semiconductor according to
the code in part list appendix of ACV 700 section.
Note!
There are two pieces of IGBT semiconductors

connected parallel in each branch of the bridge in frame
size R9. Following rules must be observe:
1. Both semiconductors are made by the same

manufactorer.
2. The mark letter (A...) printed on the label or
the shell of the IGBT, is same. Mark letter
means the certain group of the Collector -
Emitter saturation voltage Vce(sat).
3. If the semiconductor manufacturer is Siemens,
there is no limitation with mark letter.
2. Preparation of the heat sink. If the area is clean, spread out the
remaining heat-conducting compound with a rubber spatula. If
the area is dirty, wipe the heat sink surface clean with tissue
paper.
52
1 2 1 2
C 2E1 E2 C1
E2
B2
E
E1
B1
B
E C
3 4 3 4
frame R4, R5 frame R7, R9
Figure 26. Terminals and mounting screws of IGBT module

(61034986.drw).
3. Clean the mounting surfaces with an appropriate solvent (for

example Grafol fluid) and spread heat transfer grease on the
base of the module.
4. Mount the module on the heat sink and tighten the clamping
screws until the screw heads touch the bottom of the module.
5. Then tighten the screws to pretorque according to table 27 in

order 1, 4, 3, 2. See Figure 26.
6. Tighten the screws to the final torque according to the table 27.
53
Table 27. Torques for the installation and connection screws.
Assembling Torque
screw type
Pretorque Final torque
Module assembling
screws
M5 (Æ 5 mm) 1.5 Nm 3.0 Nm
M6 (Æ 6 mm) 1.5 Nm 3.0 Nm
Main circuit C - E
terminals
M6 (Æ 6 mm) 3.0 Nm
M8 (Æ 8 mm) 10.0 Nm
Control circuit B - E 1.5Nm

terminal screws M4
(only frame types
R7 and R9 )
Diodes of busbar 2.5 Nm
assembly (bolt-
side)
Capacitor bank 3.0 Nm
terminal screws
54
45 GTO power semiconductors
46 General
The construction of the "hockey-puck" semiconductor components is

such that they require a certain compression force to operate. To
prevent overheated of component depends essentially on how well the
heat dissipated in the semiconductor is conducted to the heat sink. It is
thus important that all joints have good thermal and electrical
conduction.
Strict observance of the mounting instruction given below is therefore of

utmost importance.
Different press clamps are used, depending on the size of the

semiconductors. The type of press clamp and its code are given in the
part list immediately under the appropriate semiconductor. The
necessary compression force is also given in the part list of ACV 700.
Spare part kit includes the installation kit for semiconductor because of
differences of mechanical dimensions between the manufactorers.
Spare part kit is delivered with spare part GTO. Compression
force/deflection curves of the Dial Gauge are shown at the end of this
chapter.
47 GTO measurements
If you suspect a GTO power semiconductor fault, proceed as follows:

1. Check no voltage state.
2. Disconnect the motor cables.
3. Disconnect the thyristor control wires A , G and K from the flat
terminal of the pulse amplifier boards A4...A6 and the control wires
G and K of the chopper's thyristor from the flat terminals of the
chopper's pulse amplifier board A7.
4. Measure the resistance between the inverter's output terminal U2,
V2 and W2 and the input terminal L+ as well as between the input
terminal L- and the unit's output terminal U2, V2 and W2. A total of
six measurements should be made. With the positive measurement
wire in the first three measurements in the input terminal L+ and in
the last three measurements in the output terminal the meter must
show tens of kiloohms.
55
5. Measure the forward voltage in the diode range between the

inverter's output terminal U2, V2 and W2 and the input terminal L+
as well as between the input terminal L- and unit's output terminal
U2, V2 and W2. A total of six measurements should be made. With
the positive measuring wire in the first three measurements in the
output terminal and in the last three measurements in the input
terminal L- the multimeter must show a conducting diode
connection, about 0.5 V.
thyristor's control wires G and K. A total of six + one measurements
should be made. With the positive measuring wire in the G-wire the
multimeter must show a conducting diode connection, about 0.5 V.
7. Measure the resistance between the thyristor's control wires K and
G. A total of six + one measurements should be made. With the
positive measuring wire in the K-wire the meter must show tens of
kiloohms.
A K
G
G K
Figure 28. Case and symbol of GTO thyristor (61034994.drw).
The resistances must clearly deviate from a short (the resistance

value depends on the measuring instrument used and on the power
semiconductor). First measurement will take some time, because the
intermediate circuit must charge upto the measuring voltage.
56
48 Measuring of Snubber Diodes and the Chopper components
Commutation energy of the GTOs are collected by means of Snubber

Diodes (V21...V26) to the Chopper circuit. In case of faulty GTO there
is also possibility for faulty Snubber Diode(s). Therefore is also
important to measure the Snubber Diodes and The Chopper Circuit
(see the Main Circuit Diagram).
Note!
Be careful with bolt type of diodes during the installation
and removing. Non-bolt side connection must be
installed carefully to prevent the mechanical damaging of
the diode during the installation.
57
Figure 29. Typical Main Circuit Diagram of GTO INU

(61035001.drw).
58
C 7 .1 V 14
V 24
A4
R7 V4
C 1.1 V 15
V 21
A1
C 7 .2 C 1 .2
L1 A5
V 11 V1 V 25
A 1.1
V5
C 2 .1 V 16 A2
V 22
A6
C 7 .3 C 2 .2 A 2 .1
V12 V 26
V2
V6
V 23 C 3 .1
L2
V3
C 3 .2
V 13
C h opp er
F11
T1
M1 U3
(Option)
U2
U1
Figure 30. Lay out of GTO INU module. The chopper module is not
shown in the figure. (61035010.drw).
59
Measuring goes as follows:
1. Remove the other sides of Snubber Diodes from the Main

Circuit and measure the resistances across the diodes:
2. Positive measuring wire connected to the Anode and negative

one connected to Cathode.
3. Negative measuring wire connected to the Anode and the

positive one to Cathode.
4. To confirm the condition of non-conducting direction of the

Diodes, check by measuring with Insulation Level Meter the
condition of non-conducting direction. Connect the positive
measurement wire to Cathode and negative measurement wire
to Anode.
The resistances must clearly deviate from a short circuit (the

resistance value depends on the measuring instrument used and on
the power semiconductor).
C9.10
C9.2 R2.7
R2.6
C9.13 R2.5 R3.4
C9.1
C9.5 R2.4
C9.8 R2.3
C9.4 R2.2 R3.3 A7
C9.3 C9.9 R2.1 R3.2
R4 A3
C9.12 C9.7 R3.1
C9.6 R1.3
C9.11 V28 R1.2
R1.1
V29
V27
V17 V30
C8
Figure 31. Typical lay out of the Chopper in GTO INU

(61035044.drw).
60
49 Free Wheeling Diode measurements
If it is suspected that the free-wheeling diode connected in parallel with

the thyristor has been damaged, remove the thyristor by undoing its
clamp and measure the condition of the diode.
Note that the condition of a "hockey-puck" power semiconductor

which is not pressed in position cannot be measured!
Figure 32. Individual GTO and Free Wheeling Diode in main circuit
(61035028.drw).
If the measurements show a short circuit, the power semiconductor has

been damaged.
50 Replacement of "Hockey-Puck" power semiconductors
To avoid confusion with "good" components, always mark clearly

suspected damaged components after removing them from the circuit.
When dismounting the damaged semiconductor, note which way it

was installed in the heat sink.
Handle power semiconductors with care, do not lift power

semiconductors by taking in your hand only the control wires!
51 Comparing of Power Semiconductors
The GTO semiconductor can be replaced also by the different

manufacturer's compatible semiconductor according to the code in part
list appendix of ACV 700 section.
Check that the new component can replace the old one. Check that the
measuring range of the dial indicator used is suitable for the clamp, i.e.
deflection is measured at exactly the correct points (see the figures at
the end of this chapter). At this stage, go over the phases of the
replacement procedure and consider which way the component is to be
installed in the heat sink.
61
52 Preparation of the heat sink and busbar
If the area is clean, spread out the remaining heat-conducting

compound with a rubber spatula. If the area is dirty, wipe the heat sink
surface and the busbar clean with tissue paper. Do not clean the
surfaces too thoroughly of all grease, because the ground aluminium
surface will oxidise in a few seconds.
53 Procedure for handling a semiconductor
Rub the mounting surface carefully with a polishing pad (for example,
3M Scotchbrite) using a circular motion. The polishing must be carried
out with enough care to assure that the copper is not exposed. Cleanse
the polished surface of the semiconductor with an appropriate solvent
(for example, Grafol fluid) as well as with a lint-free cloth and spread a
thin layer of heat conducting paste (for example General Electric
G 322 L) on the mounting surface using a rubber spatula.
54 Tightening of the press clamp
Place the spigot shaft in position and check that it is not too long. Place
the semiconductor under the press clamp and turn it +/- 90° left and
right, leaving it in a position where the connecting leads are not
subjected to any stresses or sharp bends.
Dial gauge
Press clamp
Figure 33. The dial gauge for the press clamp spring
(61035036.drw).
Set the flexion gauge of the spring bar at the center point of the press
clamp's spring as shown in Figure 33 and reset it to zero. Tighten the
spring clamp to finger tightness (screws tight but no deflection of the
spring bar). Ensure that the bar is parallel with the heat sink surface.
62
Find the required compression force from the parts list and read the
corresponding bar deflection from the figure 34 or 35. Tighten the
screws alternatively 1/4 turn at a time until the indicator reads the
desired deflection.
55 Final cleaning
Clean the insulator of the semiconductor and its surroundings with a

piece of tissue paper moistened with solvent. Check that the insulator
and the connections are intact.
63
DIAL GAUGE CODE 5719802-8
COMPRESSION
FORCE kN
DEFLECTION / mm
(1 k N = 1 0 0 k p)
5 0 0 .2 0 0 .2 5 0 .3 0 0 .3 5 0 . 4 0 0 . 4 5 0 .5 0 0 .5 5 0 .6 0 0 .6 5 0 .7 0
48
46
44
42
40
38
36
34
32
30
28
CODE
26
24 5719866 4
22 5719278 0
20
18
16
14
12
Figure 34. Compression force/deflection curves, compression force

12-50 kN.
64
DIAL GAUGE CODE 57269324
COMPRESSION
FORCE kN
(1kN = 100kp) DEFLECTION / mm
0.06 0.08 0 .10 0.12 0.14 0 .16 0.1 8 0.20 0.22 0.2 4 0.26
30
29 CODE
28 57168455
27
26 CODE
25 CODE 57168471
24 57419709
57860847 CODE
23 57915455
22
21
20
19 CODE
18 57860839
17 57168463
16
15 CODE
14 57861444
13 CODE
12 57168480
11 57860821
10
CODE
9
5786954-2
8
7
6
5
4 CODE
3 57172321
2 57196815
1
0.0 6 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.24 0.26
DEFLECTION / mm
Figure 35. Compression force/deflection curves, compression force

1-30 kN.
65
56 Fault tracing and repair of supply section
57 General
There are two main types of supply section:

- Supply section with a diode bridge rectifier
- Supply section with a thyristor bridge rectifier
58 Fault diagnostics of supply section
59 Diode bridge rectifier
On the supply section's controller and supervision board SAFT 136

CTS there are five LED units that indicate the unit's state. In a normal
situation green LED units glow and the reds do not. Operating
protections lead to the opening of the main contactor.
LED glows Explanation

V7, green The charging contactor of the
capacitor bank unit is closed, the
capacitor bank unit is being
charged. The charging contactor is
closed only during the charging
before closing of main contactor.
V8, green The main contactor is closed. The
DC-intermediate circuit is under
voltage. Charging contactor is open.
V9, red The temperature of either the
capacitors of the capacitor bank unit
or the diodes in the line converter
unit is too high.
V10, red DC-intermediate circuit has
overvoltage.
V11, green The protection chain, keeping the
emergency stop relay closed, is
intact.
The green LED units on the supervision board SAFT 132 CBS of the
capacitor bank unit glow when the voltage of the capacitors has been
evenly distributed.
66
60 SAFUK 63...250 Braking chopper
Braking chopper is used with diode rectifier supply section to resistor

braking in situation when the intermediate DC voltage rises over 15 %
above the nominal voltage. This kind of situation is possible for
example during the fast speed deceleration.
The braking chopper consists of the braking chopper control board
SAFT 135 BCC or SAFT 193 BCC and the main circuit components.
Control board opens or closes thyristor V11 connecting the braking
resistance parallel with intermediate circuit. Braking energy from motor
circuits is supplied to the braking resistor, if voltage of intermediate
circuit rises 15% above the nominal voltage.

and the ACV 700 frame.
S1 V22
Voltage selector LED
switch Red LED is lit in normal
condition
SAFT 135 BCC

or
X1
SAFT 193 BCC
XG Gate and Cathode

terminals for V11
XK
Figure 36. Braking control board SAFT 135 BCC or SAFT 193 BCC
(61035052.drw).
Braking resistor unit and heat-sink of braking chopper consist of the

overtemperature switch which is wired to control circuit of supply
section. Sensor prevents overtemperature of braking resistance in fault
situation when braking chopper is faulty and thus thyristor V11 is
always open or in short circuit.
67
There are a selector switch S1 according to the nominal voltage of

network and a red LED. The LED is lit when the braking chopper unit
receives the intermediate voltage and the auxialiry voltage circuit is
under normal load on the control board.
If braking chopper control takes place without overvoltage in

intermediate circuit, possible fault may be in overvoltage peaks in
network. Measure the voltage of network continuously by means of
recorder equipped with trigger function. If network is clean, change the
Braking Control Board.
68
Figure 37. Braking Chopper main circuit diagram.
69
61 Thyristor braking unit SAFUX
A regenerating thyristor bridge rectifiers the supply voltage to the DC

voltage of the intermediate circuit and in a braking state supplies
(inverts) the energy, accumulated in the intermediate circuit, back to the
line. A choke filters the current peaks of intermediate circuit.
The control section of the thyristor braking unit SAFUX includes six
printed boards:
- Bridge controller board SAFT 185 TBC

- Unit's auxiliary power supply SAMC 11 POW
- Connection boards SAMC 19 INF and SAFT 181 INF
- Pulse amplifier board SAMT 11
- Voltage measurement board SAFT 183 VMC
External faults
The cause of the blowing of the main circuit fuses is most likely a
disturbance in the supply network.
- If the supply voltage fails while SAFUX operates in regenerative

mode, a commutation failure occurs in the regenerative bridge
and the main-circuit fuses blow.
- This can also happen when starting under no-load condition, if
the supply voltage is cut off by means other than the main
circuit breaker/contactor of the Line Supply Unit. When the
voltage fails, the discontinuous current becomes continuous.
This can be prevented by controlling the SAFUX operating
under no load to the diode bridge mode.
External faults are indicated by a lamp or a LED lit until the cause of the
fault has been eliminated, e.g:
- Overtemperature; the temperature switch mounted on the

heatsink has opened the fault circuit and the SAFUX is
stopped.
- Fan fault; the protection switch of the fan has tripped due to
overcurrent causing the fault circuit to open, and the SAFUX is
stopped.
- Power supply fault; when a fault occurs in the SAMC 11 POW
power supply board, the LED H1 on it goes out and turning on
of the thyristors is inhibited.
70
Internal faults
Internal faults are indicated by blinking of the lamp on the cabinet door
and of the LED V1 on the SAFT 185 TBC board. Internal faults are:
1. Turn-on interruption FIRP is late.

2. Counter circuit D3/L0,L1 does not count correctly (D3 SAFT
185 TBC).
5. RAM fault (D5 SAFT 185 TBC).
6. EPROM fault, the checksum is wrong (D2 SAFT 185 TBC).
7. Phase-locked loop PLL or counter circuit D3 fault.
8. Counter circuit D3 reading or loading error.
11. A/D-converter fault (D16 SAFT 185 TBC).
12. Synchronization fault.
The numerical fault codes specified above indicate how many times the
lamp or the LED blinks. The blinking interval is 0.3 second and there is
a break of two seconds between the messages.
FAULT CODE OBSERVED
RESET the SAFUX by disconnecting the auxiliary supply for a moment.

If fault is disappered, possible reason was the disturbance in the net. If
the fault appears again, change the SAFUX boards systematically
starting first from the SAFT 185 TBC board. In case of error codes 1
and 12 the possible reason can be in the synchronizing signal
connection circuits. Check also the synchronizing transformer.
62 Other fault conditions in SAFUX
1. Synchronization fault; if the phase-locked loop on the SAMC 19

INF board cannot be synchronized to the supply voltage, the
SAFUX is stopped.
2. Supply voltage failure; a supply voltage failure during

regenerative operation may cause the fuses to blow. Supply
voltage failures of short duration do not cause the SAFUX to
stop. The LED on the SAFT 185 TBC board is lit during a
supply voltage failure.
When the supply voltage fails during motor operation, the
SAFUX is immediately stopped. When the supply voltage fails
during regenerative operation, the SAFUX is stopped when the
line current has become discontinuous.
71
3. Wrong charging mode selected:

- Charging with a 50° constant firing angle even though there are
no charging resistors (selector S3: b-c on SAFT 181 INF
board).
Depending on the power rating of SAFUX, fuses may be blown
because of too high a charging current.
- Charging by variation of the firing angle even though charging
resistors are used in the supply section (S3: a-b).
Charging takes so long that the voltage supervision circuit of
the capacitor bank unit trips the main contactor.
4. Control of SAFUX continues in diode bridge mode and the

control signal for changeover to normal mode is not transmitted
to the control board. Braking causes an overvoltage trip in the
drive section(s).
5. The intermediate circuit voltage decreases when load is

connected, leading to an undervoltage alarm which causes the
drive sections to trip. SAFUX probably changes over to
charging mode because either:
- UC-measuring data is faulty,
- One of the thyristors in the rectifier bridge will not turn on, or
- SAFUX is not receiving information on the line current (HOLE
signal) and does not change the firing angle of the thyristors.
6. The intermediate circuit voltage UC is unsettled during no-load:

- Synchronization is tuned to take place too early. The normal
phase difference tuned during synchronization between
synchronizing voltage and UV phase-to-phase voltage is 150
microseconds. If synchronization is tuned shorter than 150 ms ,
it has a smoothing effect on the UC voltage under no-load
conditions but, at the same time, the commutation margin is
reduced.
- The UC voltage also varies in the diode bridge mode. Other
thyristor drives cause mains voltage distortion which cannot be
corrected by tuning of SAFUX control. Thyristor drive
acceleration/deceleration may show in UC-voltage variations.
When replacing SAFUX boards only selector plug settings are normally
needed. If the need for other tuning (synchronization, current limit etc.)
arises, separate instructions are available. Instructions for electrical
testing of the Thyristor Braking Unit, code EN VE 5812 0766.
72
63 Measurements in SAFUX
Figure 38. Pulse Amplifier Board. (5721 1377)

Current and synchronization measurement and one
thyristor control channel.
73
Figure 39. Main circuit diagram of supply section equipped with a

switch fuse.
74
Note!
For measurements use a measuring instrument with isolated

neutral system.
Note!
Measurements should not be made at the main-circuit voltage

side of the galvanic isolation transformers of the pulse amplifier
when the main-circuit voltages are connected (the main circuit
breaker/main contactor closed). They should be made instead at
the control voltage side only.
Control signals transmitted from the control board can be checked at
the pulse amplifier measuring points.
When only control voltages are on in SAFUX, it is possible to check

from the pulse amplifier SAMT 11 that all rectifier bridge thyristors
receive a control pulse (e.g. V1 control MP1 and MP24). The
regenerative bridge thyristors do not then receive control pulses,
because SAFUX control is in charging mode.
MP24 is the earth point.
A current probe can be used to measure current in the gate lead to

ensure that current is actually flowing into the gate circuit of the
thyristor. However, due to small current (approx. 2 A), a sensitive
measuring instrument is needed. The current pulse can be measured
also with an oscilloscope through the pulse amplifier channel across
power resistors (e.g. thyristor V1 control, resistors R128 and R129).
This is not, however, the final gate current entering the thyristor.
The voltage connected to the gate circuit can be measured direct from
the gate and cathode leads through the pulse amplifier terminals
(e.g. V1 voltage, terminals X2:1-2).
75
Note!
These terminals are at the main circuit potential when the main
circuit breaker/main contactor is closed.
The regenerative bridge thyristor controls can also be examined by

means of control voltages only, when simulation of UC measurement is
selected on the SAFT 183 VMC board. DBMODE control must also be
removed, because, when the main circuit breaker is open, bridge
control is in the diode bridge mode (relay K1 on the SAFT 181 INF
board must be made to energize). Control pulses are then transmitted
to both bridges.
Bridge current can be measured between the measuring points 20 and
21 of the pulse amplifier. The voltage between the measuring points is
4.36 V at 1 A rated secondary current of the current transformers. The
current signal is rectified and it cannot directly be used to conclude
which bridge (rectifier/regenerative) is conducting. However, it is
possible to see from the pulse train that all thyristors in the controlled
bridge are turned on and current is flowing through them.
The matched synchronizing voltage can be measured from the
measuring points 22 to 23 of the pulse amplifier.
76
64 Measuring of power semiconductors from Supply section
65 Measurement of power semiconductors
1. Make sure that the supply section does not have a live voltage.
2. Open the Drive Section Switch of the supply section equipped

with a load-break switch or, alternatively, the main circuit
breaker of the supply section equipped with a circuit breaker
and the Drive Section Switch of the auxiliary power supply.
3. Do not close the earth switch.
4. If a short-circuit occurs in subsequent measurements the

measured branch has a faulty power semiconductor.
5. Before removing the faulty power semiconductor write down

which way it was fixed to the heat-sink.
66 Line supply units SAFUS or Line rectifier unit SAFUD
In the diode bridge of the line supply unit and the line rectifier unit bolt-
type diodes are used.
1. Disconnect the diode bridge of the line supply units or the line
rectifier unit from the unit's output terminals L+ and L-
(capacitor bank unit).

unit's input terminal U1, V1 and W1 and the diode bridge's
negative terminal and the unit's input terminal U1, V1 and W1.
A total of six measurements should be made. With the positive
measuring wire in the first three measurements in the input
terminal and in the last three measurements in the bridge's
negative terminal the multimeter must show a conducting diode
connection, about 0.5 V.
3. Measure the resistance between the unit's input terminal U1,
V1 and W1 and the diode bridge's positive terminal as well as
the diode bridge's negative terminal and the unit's input
terminal U1, V1 and W1. A total of six measurements should be
made. With the positive measuring wire in the first three
measurements in the bridge's positive terminal and in the last
three measurements in the input terminal the multimeter must
show tens of kiloohms.
77
67 Line converter unit SAFUC
In the line converter unit's diode bridge diodes of the hockey-puck type
are used.
Note! The condition of the hockey -puck diode cannot be measured if it

is not under pressure.
1. Disconnect the unit from the DC-busbars L+ and L-.

unit's input terminal U1, V1 and W1 and the output terminal L+
as well as between the output terminal L- and the unit's input
terminal U1, V1 and W1. A total of six measurements should be
made. With the positive measuring wire in the first three
measurements in the input terminal and in the last three
measurements in the output terminal the multimeter must show
a conducting diode connection, about 0.5 V.
3. Measure the resistance between the unit's input terminal U1,

V1 and W1 and the output terminal L+ as well as between the
output terminal L- and the unit's input terminal U1, V1 and W1.
A total of six measurements should be made. With the positive
measuring wire in the first three measurements in the output
terminal L+ and in the last three measurements in the input
terminal the meter must show tens of kiloohms.
68 Thyristor braking unit SAFUX
In the thyristor bridge of the thyristor braking unit either thyristor

modules or hockey-puck thyristors are used, depending on the size of
the bridge.
Note! The condition of the hockey -puck diode cannot be measured if it

is not under pressure.
1. Disconnect the unit from the DC-busbars L+ and L-.
2. Disconnect the thyristor control wires G and K from the flat

terminals of the pulse amplifier board A1A5.
3. Measure the resistance between the unit's input terminal U, V

and W and the , output terminal L+ as well as between the
output terminal L- and the unit's input terminal U, V and W. A
total of six measurements should be made. The resistance
should be tens of kiloohms.
thyristor's control wires G and K. A total of 12 measurements
should be made. With the positive measuring wire in the G-wire
78
the multimeter must show a conducting diode connection,

about 0.5 V.
5. Measure the resistance between the thyristor's control wires G

and K. A total of 12 measurements should be made. With the
positive measuring wire in the K-wire the meter must show tens
of kiloohms.
69 Replacing the power semiconductors from Supply section
70 Hockey-puck types power semiconductors
See the instruction from Chapter 4.4 Replacement of Hockey-Puck

power semiconductors.
71 Module type of power semiconductors
1. Fix the semiconductor module by screws first lightly to the heat

sink. Check that the module's contact surface touches evenly
the surface of the heat-sink.
2. Tighten the screws of the module by 1/8 round at a time until

the torque is the same as that given in the parts list.
3. Clean the semiconductor module and the heat-sink element
from excessive heat conducting compound with tissue paper,
dipped into the solvent.
79
72 Electrical connections of module type power semiconductors
1. Check that the semiconductor's insulator and electric

connections are intact.
2. Check that the installation screws of the wires of the modular
semiconductor are not too long.
3. Fix the wires and the busbars to the terminals of the
semiconductor, using following torques:
Table 40. Tightening torques for modular and bolt semiconductors.
Screw turn Torque

Modular Bolt
M4 (Æ 4 mm) 1.5 Nm
M5 (Æ 5 mm) 2.0 Nm 3.0 Nm
M6 (Æ 6 mm) 3.0 Nm 6.0 Nm
M8 (Æ 8 mm) 8.0 Nm
73 Bolt-type power semiconductor
Fix a bolt-type semiconductor first lightly to the heat-sink element.

Check that the surface of the semiconductor touches evenly the
surface of the heat-sink.
Tighten the semiconductor with the torque specified in the parts list.
Clean the semiconductor and the heat sink from surplus conducting
compound with tissue paper, dipped into the solvent.
80
74 Glossary
Abbreviations used for the ACV 700 units:
APC Application Controller is

flexible, compact and efficient
system for controlling AC- or
DC-drives.
EEPROM Electrically Erasable

Programmable Read Only
Memory.
EPROM Ultraviolet erasable and

Electrically Programmable
Read Only Memory.
GTO INU Inverter Unit implemented by

means of GTO thyristor
techniques.
IGBT INU Inverter Unit implemented by

means of IGBT transistor
techniques.
INU Inverter Unit (module).
LED Light Emitting Diode.
LSU Line Supply Unit which

includes main contactor, line
rectifier bridge and voltage
source intermediate circuit
equipment.
UC Means the DC voltage of

intermediate circuit.
81

ACV 700 Frequency Converters Service Instructions Code: 3AFY 58054496 R0125 REV B

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ACV 700 Frequency Converters

Code: 3AFY 58054496 R0125 REV A

Issued by: FIDRI/ERM

Date: Code: Remark:

For information on: See Document:

Description of the firmware Firmware Manual 1.0

Detailed description of the Firmware Manual for Engineering

1. Fault-tracing and repair.......................................................................................5

5. Checking and replacement of the power semiconductors..................................42

1 Fault-tracing and repair

All relevant safety regulations must be observed in the installation,

It is absolutely necessary to read this safety instruction before opening

The operation of the ACV 700 Drive System can be entrusted to a

All maintenance of the ACV 700 must be carried out by a competent

In most cases, the diagnostic displays can be used for preliminary

There is a dangerous voltage inside the cabinet. After the DC voltage

Do not connect or disconnect the Drive Section Switch when power is

The fault-tracing method presented here is based on systematic tracing

In preliminary fault-tracing, the possible fault location is traced mainly

Outside fault sources are, for example:

- Control circuit connections

Inside fault sources are, for example:

In most cases, it is possible to reset the fault message on the control

Before the fault is assumed to lie in ACV 700, it must be checked

In case of a fault or an alarm occurrence an error code is indicated.

There is also a way to diagnose a fault situation by using dataloggers.

The fault diagnostics messages can be indicated by panel or PC-based

A fault can be reset by pressing the RESET-button from Panel, using

- Check that there is no voltage in the INU.

Figure 1. Wrist band and earthing mat (61034811.drw).

9 Reading of fault codes

Occurred error codes can be read from the LATEST_FAULT_BUFFER

10 Installation of memory circuits

Mark Memory circuit

Figure 2. Memory circuit installation into the IC-socket

11 Positions of Drive Section Switch

A C V 700 Drive Section Switch of IGBT type

A C V 7 00 Drive Section Switch of

Figure 3. Handle positions of Drive Section Switches

13 Fault diagnostics messages

There are three different types of signal:

Every fault and alarm/status signal is coded as an individual error code.

Signal Definition Type of Mode of Reset

2 Overcurrent Fault Trips To be reset

3 DC intermediate circuit overvoltage Fault Trips To be

4 Measured overtemperature of converter Fault Trips Self reset/ to

5 Earth fault Fault Trips To be reset

6 Measured overtemperature of motor Fault Trips Self reset/ to

Fault signals continued...

Signal Definition Type of Mode of Reset

10 Overvoltage of chopper Fault Trips To be reset

11 DC intermediate circuit undervoltage Fault Trips Self reset

12 Output short circuit Fault Trips To be reset

13 Semiconductor fault in inverter unit Fault Trips Cannot be

14 Speed measurement fault Fault Trips To be reset

16 Calibration of Uc measurement Fault Trips Cannot be

17 Matching board fault Fault Trips Cannot be