Control Module Replacement

Control Module Assembly Replacement Procedures For ALSPAMV3000 MicroCubicles™

Instruction Sheet T1932EN Rev. 0001 (01/01)Page 1 of 20

Introduction and Safety Instructions

Page 1

Replacement Of The Control ModuleAssembly

Page 3

Box Contents

This instruction sheet (T1932).

One Control Module Assembly, S41Y7784/40.

Ribbon Cable Mounting Kit (Bagged).

Safety Instructions

WARNING• Wait at least 5 minutes after isolating supplies and check that voltage

between DC+ and DC– has reduced to a safe level before workingon this equipment.

• This equipment may be connected to more than one live circuit.Disconnect all supplies before working on the equipment.

CAUTIONThis equipment contains solid state devices which may be affected byelectrostatic discharge. Observe static handling precautions.


Instruction Sheet T1932EN Rev. 0001 (01/01)Page 2 of of of of 20

The items described in this instruction sheet must only be used as spare parts in existing equipment. They mustonly be used as a direct replacement for an item of the same number, unless otherwise stated. The prefix “S”on some item numbers denotes “spare” and should be ignored when considering the replacement of an item.

The instructions in this instruction sheet and in the manual for the original product must be observed. Localsafety laws and regulations must always be observed. Failure to do so will invalidate product approvals andcertifications on the original equipment.

Persons working on the product must be suitably skilled and should have been trained in that work for theseproducts.

Related Documents

Failure to comply with any of the general requirements for installation, operation and maintenanceprovided in the technical manuals will significantly increase the risk of maloperation, fire or electricshock.

T1676 ALSPA MV3000 Getting Started Manual for AC-fed Drives

T1684 ALSPA MV3000 Dynamic Braking Units, MV3DB Series

T1925 Spares Replacement Procedures for ALSPA MV3000 Frame Size 3 MicroCubicles™




T2002 ALSPA MV3000 Getting Started Manual for Bi-directional Converters

Definitions

PCB Printed Circuit Board

SMPS Switch Mode Power Supply

CDC Common Drive Controller (Control Module Assembly)

Introduction

This instruction sheet contains procedures for the removal and replacement of the Control Module Assembly inall ALSPA MV3000 MicroCubicles™.

Tool Requirements

Anti-static Wriststrap

Medium Cross Point Drive Screwdriver

Medium Flat Blade Screwdriver

Drive Data Manager™

24V DC Power Supply



REPLACEMENT OF THE CONTROL MODULE ASSEMBLY (S41Y7784)

This Instruction Sheet is concerned with the replacement of the Control Module Assembly only. However, if theControl Module Assembly and the SMPS PCB are to be replaced at the same time, the followingsequence must be used:

• Save the Drive Identity (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).

• Replace the SMPS PCB (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).

• Copy the Drive Identity from the original Control Module to the replacement SMPS PCB (see“Reprogramming the Drive Identity” in the relevant Instruction Sheet).

• Replace the Control Module Assembly as described below.

• Recover the Drive Identity into the replacement Control Module as described below.

If these procedures are not followed fully or are followed in the wrong sequence, this could lead toincorrect identification of the drive type and consequently incorrect drive operation.

Saving User Edits

• This procedure is common to all MicroCubicle™ sizes.

• Ensure that all mains supplies to the drive are isolated.

• Open the yellow Control Door.

• Energise the drive using the 24V Auxiliary supply. This is applied to TB2, located on the front of the CDC(Common Drive Controller).

When the Drive is powered in this manner, some or all of the following trips will be present :

DC Undervolts (Fault Code 4)

Instantaneous Overcurrent (Fault Code 7)

Instantaneous Overcurrent on U-Phase (Fault Code 8)

Hardware Overtemperature on U-Phase (Fault Code 9)

Instantaneous Overcurrent on V-Phase (Fault Code 10)

Hardware Overtemperature on V-Phase (Fault Code 11)

Instantaneous Overcurrent on W-Phase (Fault Code 12)

Hardware Overtemperature on W-Phase (Fault Code 13)

DB Trip (Fault Code 151)

Scroll through all the trips to verify these. For the purposes of these procedures, they can be ignored.

• Set P1.31 = 2, first noting its original value. This allows access to the Advanced Menus.

• If the functionality of the unit allows, transfer all customised parameter settings to the Drive DataManager™ as follows :

Set P99.16 = 4. This will force the Drive Data Manager™ to store a copy of all user edits.

Continued….

See Page 1



• Alternatively, customised parameter settings can be manually recorded in the following way :

Set P35.03=1. Use the right arrow on the Navigation key to scroll through all current user edits andnote the values.

Reset P35.03 = 0.

• Reset P1.31 to its original value.

• Remove the 24V Auxiliary supply.

Frame Size Specific Instructions

The removal and replacement procedures are related to the Frame Size of the Drive. The table below indicateson which page these instructions start.

Frame Size Drive Model PageNumber

3 MV3058A4A1, MV3071A4A1

MV3052A5A1, MV3065A5A1

MV3071J5A1

5

4 MV3086A4A1, MV3105A4A1, MV3140A4A1

MV3077A5A1, MV3096A5A1, MV3124A5A1

MV3062A6A1, MV3077A6A1, MV3099A6A1

MV3140J5A1, MV3099J6A1

8

6 MV3168A4A1, MV3204A4A1, MV3244A4A1, MV33292A4A1,MV33364A4A1

MV3156A5A1, MV3180A5A1, MV3240A5A1, MV33302A5A1

MV3125A6A1, MV3144A6A1, MV3192A6A1, MV3242A6A1

MV3364J5A1, MV3242J6A1

11

7 MV3449A4A1, MV3503A4A1, MV3566A4A1

MV3361A5A1, MV3414A5A1, MV3477A5A1

MV3289A6A1, MV3336A6A1, MV3382A6A1

MV3566J5A1, MV3482J6A1

14



FRAME SIZE 3

Removing the Original Control Module Assembly


Ref. 1

Ref. 2

Ref. 3

Ref. 4

Ref. 5

Figure 1

• Undo two M5 captive screws (Figure 1,Refs. 2,4).

• Open the grey Power Door.

• Open the shroud over TB1 by looseningthe M5 captive screw (Figure 1, Ref. 3).

• Remove the plantside connections (TB1-TB6) by unplugging the terminal blocks.

• Remove plantside connections to anyoptional modules fitted to the CDC.

• Remove two M5 screws and springwashers (Figure 1, Refs. 1,5). Storethese in a safe place.

• Pull the Control Module Assembly forwards untilthe plug for the Keypad Harbour ribbon is visibleat the top of the CDC PCB (Figure 2).

• Remove the ribbon cable from PL2.

• If a Dynamic Brake Unit (from the MV3DB range)is fitted, its ribbon cable should be removed fromPL8 at this stage.

• If the Drive is from the Bi-directional Converterproduct range, the ribbon cable should beremoved from PL9. This is located directly behindPL2.

Figure 2

Continued….

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• Pull the Control Module Assembly furtherforwards until the back edge of the PCB is visible.

• Unplug the ribbon cables from PL4, PL10 andPL11. See Figure 3.

• Figure 5 shows these plug positions in detail.

Figure 3

• Release both ribbon cables from their supportingclamps on the metalwork as shown in Figure 4.

• The Control Module Assembly can now be

removed by sliding it out.

Figure 4

Note: If optional modules (such as a FIP Module, MVS3002) are fitted to the CDC these should be removedat this stage and refitted to the replacement Control Module Assembly. Refer to the relevant instructionmanuals for fitting procedure.

Continued….

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See Page 1



Fitting the New Control Module Assembly

• Fit cable clamps to the new Control Module Assembly inthe same positions as those on the replaced module.These are supplied with the replacement module.

• To replace the Control Module Assembly, reverse theprocedure described in the Removal instructions.

• Figure 5 shows all of the ribbon cable plugs in detailfor reference only.

PL4 PL10 PL11 PL9 PL2 PL8

Figure 5

Reinitialising the Drive Identity

• Once the new Control Module Assembly is installed, the drive must have its unique identity copied from theSMPS PCB into the replacement CDC. For instructions of how to complete this procedure see‘Reprogramming the Drive Identity’, page 17.

PROCEDURE COMPLETE



FRAME SIZE 4



Ref. 6

Ref. 7

Ref. 8

Figure 6

• Undo two M5 captive screws (Figure 6,Refs. 6,8).

• Open the grey Power Door.

• Open the shroud over TB1 by looseningthe M5 captive screw (Figure 6,Ref. 7).

• Remove the plantside connections (TB1-TB6) by unplugging the terminal blocks.


Ref. 9

Ref. 10

Figure 7

• Remove two M5 screws and spring washers.Store these in a safe place (Figure 7,Refs. 9,10).

Continued….

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• Slide the Control Module Assembly forwards until theplug for the Keypad Harbour ribbon is visible at the topof the CDC. See Figure 8.

• Unplug this ribbon cable from PL2.

• If a Dynamic Brake Unit (from the MV3DB range) isfitted, its ribbon cable should be removed from PL8 atthis stage.

• If the Drive is from the Bi-directional Converter productrange, the ribbon cable should be removed from PL9.This is located directly behind PL2.

Figure 8

• Slide the Control Module Assembly forwards until therear edge of the PCB is visible as in Figure 9.

Figure 9

• Unplug the ribbon cables from PL4, PL10 and PL11as shown in Figure 10.

• Figure 11 shows these plug positions in detail.

• Release these ribbon cables from their supportingclamps on the metal work of the Assembly.

• The Control Module Assembly can now be removed bysliding it out. Figure 10

Note: If optional modules (such as a FIP Module, MVS3002) are fitted to the CDC these should be removedat this stage and refitted to the replacement Control Module Assembly. Refer to the relevant instructionmanuals for fitting procedures.

Continued….

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See Page 1

See Page 1







PL4 PL10 PL11 PL9 PL2 PL8

Figure 11





FRAME SIZE 6



Ref. 11

Ref. 12

Ref. 13

Figure 12

• Open the shroud over TB1 by loosening theM5 captive screw (Figure 12, Ref. 12).

• Remove the plantside connections (TB1-TB6)by unplugging the terminal blocks.


• Remove two M5 screws and spring washers(Figure 12, Refs. 11, 13). Store these in asafe place.

• Slide the Control Module Assembly forwardsuntil the plug for the Keypad Harbour ribboncable is visible at the top of the CDC PCB(Figure 13).


• If a Dynamic Brake Unit (from the MV3DBrange) is fitted, its ribbon cable should beremoved from PL8 at this stage.

• If the Drive is from the Bi-directionalConverter product range, the ribbon cableshould be removed from PL9. This is locateddirectly behind PL2. Figure 13

Continued….

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See Page 1



• Slide the Control Module Assembly furtherforwards until the rear edge of the PCB isvisible.

• Unplug the ribbon cables from PL5,6,7,10and 11. See Figure 14.

• Figure 16 shows these plug positions indetail.

Figure 14

• Release the ribbon cables from theirsupporting clamps on the metalwork asshown in Figure 15.

• The Control Module Assembly can now beremoved by sliding it out.

Figure 15


Continued….

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PL5

PL6

PL7

PL10 PL11 PL9 PL2 PL8

Figure 16



PROCEDURE COMPLETE



FRAME SIZE 7



Ref. 15

Ref. 14

TB2

Figure 17

• Open the shroud over TB1 by loosening theM5 captive screw (Figure 17, Ref. 14).

• Remove the plantside connections (TB1-TB6)by unplugging the terminal blocks.


• Remove one M5 screw and spring washer(Figure 17, Ref. 15). Store these in a safeplace.

Ref. 16

Figure 18

• Remove one M5 screw and spring washer(Figure 18, Ref. 16). Store these in a safeplace.

• Slide the Control Module Assembly forwardsby approximately 50mm (2in.) so that theplug for the Keypad Harbour ribbon cable isvisible at the top of the CDC PCB(Figure 19).


• If a Dynamic Brake Unit (from the MV3DBrange) is fitted, its ribbon cable should beremoved from PL8 at this stage.

• If the Drive is from the Bi-directionalConverter product range, the ribbon cableshould be removed from PL9. This is locateddirectly behind PL2.

Figure 19

Continued….

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• Slide the Control Module Assembly forwardsas shown in Figure 20.

• Unplug the ribbon cables from PL5,6,7,10and 11.

• Figure 21 shows these plug positions indetail.

• Release the ribbon cables from theirsupporting clamps on the Assembly chassis.

• The Control Module Assembly is now fullydisconnected from the Drive.

Figure 20


Continued….

See Page 1







PL5

PL6

PL7

PL10 PL11 PL9 PL2 PL8

Figure 21



PROCEDURE COMPLETE



REPROGRAMMING THE DRIVE IDENTITY

At each power up, drive identity information is retrieved by the Firmware from the drive power bridge. Thisinformation is stored in the SMPS on MV3000 MicroCubicle™ units, (a shadow copy is also stored in the CDC ifthe Firmware is V3.01 or later). To ensure the power bridge data is transferred to the new PCB, it is necessaryto follow the instructions as detailed in the flowchart on the following page.

However, if the Control Module Assembly and the SMPS PCB are to be replaced at the same time, thefollowing sequence must be used:

• Save the Drive Identity (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).

• Replace the SMPS PCB (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).

• Copy the Drive Identity from the original Control Module to the replacement SMPS PCB (see“Reprogramming the Drive Identity” in the relevant Instruction Sheet).

• Replace the Control Module Assembly as described in this Instruction Sheet.

• Recover the Drive Identity into the replacement Control Module as described in this Instruction Sheet.

If these procedures are not followed fully or are followed in the wrong sequence, this could lead toincorrect identification of the drive type and consequently incorrect drive operation.

When one of the PCB’s have been replaced with a spare and the drive is powered using the 24V Auxiliarysupply, the Firmware will produce a combination of the following Fault Codes :-

Fault Code Number Fault Code Description Details

19 New Drive PCB (see P10.35) Either the CDC or the SMPS have beenreplaced

68 Unknown Drive Size (see P10.35) The critical data is not present in the SMPS.This PCB has been replaced.

4 DC Undervolts

7 Instantaneous Overcurrent

8 Instantaneous Overcurrent on U-Phase

9 Hardware Overtemperature on U-Phase

10 Instantaneous Overcurrent on V-Phase

11 Hardware Overtemperature on V-Phase

12 Instantaneous Overcurrent on W-Phase

13 Hardware Overtemperature on W-Phase

151 DB Trip

These trips are due to the Drive beingpowered with the Auxiliary 24V.

For the purposes of spares replacement, theycan be ignored.

The flowchart on the following page shows the procedures to reinitialise the Drive Identity.



Power up Drive withAux 24V

Trip Codes 19 or 68,with a combination of

4, 7-13, 151

Set P10.35 = 2

19 / 68 Trips Reset

Drive Reboots.Returned to Factory

Defaults

Re-install All UserEdits

Set P99.16 = 5 Type in Edits

Remove Aux 24V

Verify Drive Operatesas Expected

Via Keypad Manual Entry



Customer Support and Training

Please refer to your local technical support centre if you have any queries about this product. Contact telephonenumbers are shown on the back page.



ALSTOM Power Conversion

France9, rue Ampère91345 Massy CedexSales Tel: +33 (0) 8 25 02 11 02Support Tel (International):

+33 (0) 3 84 55 33 33Support Tel. (National):

08 25 02 11 02

GermanyCulemeyerstraße 1D-12277 BerlinSales Tel: +49 (0) 30 74 96 27 27Support Tel (International):

+49 (0) 69 66 99 831Support Tel (National):

01 80 3 23 45 72

UKBoughton Road, RugbyWarwickshire, CV21 1BUSales Tel: +44 (0) 1788 563625Support Tel: +44 (0) 1788 547490

USA610 Epsilon DrivePittsburgh, PA 15238Sales Tel: +1 412 967 0765Support Tel: +1 800 800 5290

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