REPAIR MANUAL - CONTENTS Altistart 48

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1 REPAIR MANUAL REPAIR MANUAL - CONTENTS Altistart General 1.1. Objective 1.2. Products concerned- References- Sizes 1.3. Product design and manufacture 1.4. Exchange and repair 1.5. Assistance 2. Required skills Training 2.1. Required skills 2.2. Training 3. Documentation 3.1. Catalogue 3.2. User's manual 3.3. M.I.T. Intranet 3.4. Vantive RGSA-Return Good Service Agreement- (formerly known as BEST) 4. Repair service equipment 4.1. Equipment needed for repairs 4.2. Dialogue and diagnostics tool 4.3. Test bench 5. Replacement parts list 6. Software 6.1. Starter software 6.2. Remote terminal software 6.3. Power Suite software workshop for motor starters 7. Installation diagnostics 7.1. The motor is turning but does not reach its nominal speed 7.2. The motor is not turning, even though there is current 7.3. The motor does not turn in the required direction 7.4. The ATS 7-segment displays are off 7.5. The display does not change when the keys are pressed 7.6. The motor speed is unstable 8. Help with troubleshooting 8.1. Preambule 8.2. Thyristor test 8.3. List of error codes displayed by the ATS 8.4. Troubleshooting based on the fault displayed Contents - 1/2

2 REPAIR MANUAL 9. Changing the faulty component 9.1. Safety instructions and precautions 9.2. ATS48 size A 9.3. ATS48 size B 9.4. ATS48 size C 9.5. ATS48 size D 9.6. ATS48 size E 9.7. ATS48 size F 10. Procedure for validation after repair Manual validation Validation with test bench 11. Installation diagrams for electronic boards Control board (all ratings) Power boards Filter boards Firing circuit boards 12. Parts lists for assembled products 13. Product wiring Wiring for product sizes A-B-C-D Wiring for size E products Wiring for size F products 14. ATS48 layouts and block diagrams ATS48 block diagram Isolation of size A-B-C products Isolation of size D products Isolation of size E-F products Control board: Block diagram and isolation Contents - 2/2

3 REPAIR MANUAL 1. General 1.1. Objective This document defines the policy and methods to be put in place in each country-based organization for repairing the Altistart 48 locally. Repairs are carried out using replacement parts supplied by SCHNEIDER. This comes solely within the framework of the service agreement. Once this agreement has been signed, a country will have a local representative responsible for this offer Products concerned- References- Sizes This document applies to the new generation of starters known as Altistart 48. ATS48 reference ATS48D17 Q/Y ATS48D22 Q/Y ATS48D32 Q/Y ATS48D38 Q/Y ATS48D47 Q/Y ATS48D62 Q/Y ATS48D75 Q/Y ATS48D88 Q/Y ATS48C11 Q/Y ATS48C14 Q/Y ATS48C17 Q/Y ATS48C21 Q/Y ATS48C25 Q/Y ATS48C32 Q/Y ATS48C41 Q/Y ATS48C48 Q/Y ATS48C59 Q/Y ATS48C66 Q/Y ATS48C79 Q/Y ATS48M10 Q/Y ATS48M12 Q/Y Size A A A A A B B B B C C D D D E E E E F F F 1.3. Product design and manufacture All the modules, accessories and software are designed and developed by Schneider Electric or in collaboration with their associates. They are manufactured and tested at the Pacy Blanchet STIE factory (EURE). The products are subject to continuous monitoring in order to achieve a high level of quality Exchange and repair The Altistart 48 is a category APV4 repairable product for the SBS: - Local repair for country-based organizations that have signed the service agreement - Repair at the factory for other country-based organizations The purpose of this document is to help you repair these products. Section 1-1/4

4 REPAIR MANUAL customer APV4 repaired products faulty products national sales office faulty products repaired products Standard replacement local technical service centre SRES factory Standard subassembly replacement For repair at the factory or for expert advice, consult the Intranet site: ( Technical support and Training/About support/what to do menu) Reminder of after-sales category APV4: This category concerns repairable products. These are identified in the 'Standard Commercial Products' file by a code with the suffix TA. The stated price corresponds to the repair cost if the product is returned to the factory (net price) Assistance Work carried out on site The customer will be provided with on-site assistance by technicians and engineers from the SCHNEIDER service teams in the customer s country Technical support The first level of technical support is provided by the level 1 and 2 forums that the customer can access. The third level of technical support is provided by the Schneider Vantiv Intranet: self-service vantiv (http:// /services/iservices4.nsf/fhomepage?readform&l=e&c=&) or, in the event of an emergency, by the direct line at the Global Help Desk: Tel.: +33 (0) Fax: +33 (0) Customer returns Faulty equipment (complete products or sub-assemblies) may be returned according to the terms of the SCHNEIDER warranty policy. Section 1-2/4

5 REPAIR MANUAL When returning products, complete and attach the 'ATS48 additional information' form (enclosed). This form will shortly be available on the Intranet Updating the installed base If there is a major fault or new functions have been added, it may be necessary to update the products. In this case, advice will be sent to all the SCHNEIDER networks. Section 1-3/4

6 Date s Submitted by This sheet is associated with case VANTIVE N ATS48 Additional information form Customer name: Agency/Official distributor: Country: PRODUCT CHARACTERISTICS Reference: ATS48 Software version: V Serial number: Install. date: Option : Software version: V Serial number: Other options: CUSTOMER APPLICATION Fan Pump Compressor Other machine: MOTOR CHARACTERISTICS Asynchronous motor Wound rotor motor Other motor: Nominal power kw = Motor voltage V = Downstr. contact. Shielded cable Nominal speed rpm = Cos Phi shift = Motor current A = Frequency Hz = Cable length Motor connection SUPPLY Measured voltage min/max Frequency 50/60 Hz = Neutral point connection TT IT TN DESCRIPTION OF THE FAULT When did the fault occur? At first Continuous fault On a new machine Intermittent fault After reconditioning Frequency: During adjustment During operation Ambient temperature C: Daily operating time IMPORTANT: Please specify the conditions (pollution, humidity, etc) under which the starter is operating, who observed the fault, the state of the installation and any modifications made to it, the stage in the sequence that the fault occurred (Acc, Dec, Speed, Load, etc), the nature of the non-conformity. If possible, please attach the configuration file (Powersuite), the fault history log, diagrams and photos if necessary. ON-SITE SOLUTIONS Have you changed the starter? Yes No By the same By another, which? Have you changed a part in the starter? Yes No Which? After the change, has the fault recurred? Yes No

7 02/12/02 REPAIR MANUAL 2. Required skills - Training 2.1. Required skills An Altistart should be repaired by technicians with the following experience: Knowledge of the operation of rotating machines driven by electronic starters or variable speed drives Principle of power switching and electronic control Experience in using the following tools: PCs, oscilloscopes, multimeters, etc. For the protection of equipment and personnel, the qualified maintenance technician should implement the procedure detailed in this manual. Read, interpret and follow the instructions and precautions described in this manual as well as in other reference material Use the necessary tools in a professional manner 2.2. Training Internal training The I.S.F. (Schneider Training Institute) organizes training courses on ATS48 starters and ATV28 and ATV58 variable speed drives for people to become familiar with these products and learn how to install them. -The reference for this course is VMEX and its name is 'Operating and maintaining machines fitted with electronic drives for asynchronous motors'. -Specific training courses can also be set up for the ATS48 although these do not have product references For further information, please contact the I.S.F: Tel.: +33 (0) Fax: +33 (0) Internal training Several courses concerning selection and setup of starters are available. Descriptions of their content are attached to this document. For further information, please refer to the IC SBS training guide After-sales training This course is reserved for personnel working on-site. It requires a good knowledge of the product as well as associated applications (pumping, cooling, etc). For further information, please contact the IC SBS training representative Training support Training support is available from the following sources: Intranet: Connect to the IC SBS server: "Technical support and Training" menu CDROM labelled "CIFOR" Section 2-1/2

8 02/12/02 REPAIR MANUAL To be ordered from Schneider Comm. Services - Meylan / France Tel: +33 (0) or +33 (0) Fax: +33 (0) Schneider Training Institute Intranet site Section 2-2/2

9 REPAIR MANUAL 3. Documentation 3.1. Catalogue User's manual Reference VVDED ART M.I.T. Intranet All the user's manuals and technical information sheets regarding VSD products (software versions, application sheets, etc.) are available on the Intranet. These documents can be consulted on the IC SBS Intranet site. Address: Select: MIT, Technical Information VSD 3.4. Vantive RGSA -Return Good Service Agreement- (formerly known as BEST) This database is accessed via the SCHNEIDER Intranet. Industrial control site/technical support/help desk: This database allows users: To ask a specific question and receive a personalized response from the SBS In country-based organizations, to consult their portfolio of current or answered questions in order to find out their status at any moment, whether or not the SBS is available To search the database for all the questions that the SBS has already been asked in order to find a possible suitable response or search avenue Section 3-1/2

10 REPAIR MANUAL Section 3-2/2

11 REPAIR MANUAL 4. Repair service equipment 4.1. Equipment required for repairs General equipment -Thermal junction for semi-packs and temperature probe. Schneider reference for thermal joint: 1LUB Wire clamp -Adhesive tape for repairing interconnecting ribbon cables (the ribbon cables are not identified in the products) -Wire cutter (for removing the wire clamps) -PIF (small electrical torch) for testing electrical continuity, thyristors Tools for dismantling the control unit (all sizes) - Recessed screwdriver torcx 89 TX.10 - Pliers for disconnecting the interconnecting ribbon cables ATS48 all sizes -Allen key (hexagonal) no. 3 -Flat screwdriver size 1.2 x 6.5 -Flat screwdriver size 5 mm -Flat screwdriver size 4 mm -Recessed screwdriver torcx no. 89TX.20 - Socket wrench no. 7 Tools (additional) for ATS size B 1 Allen key (hexagonal) no. 4 Tools (additional) for ATS size C 1 socket wrench no socket wrench no. 13 Tools (additional) for ATS size D 1 socket wrench no. 16 Tools (additional) for ATS size E 1 spanner no socket wrench no. 10 with extension Tools (additional) for ATS size F 1 spanner no spanner no socket wrench no. 17 with extension Section 4-1/3

12 REPAIR MANUAL 4.2. Dialogue and diagnostics tool 'Power Suite' software First-level diagnostics can be carried out using the Power Suite software. Power Suite can be used specifically to: -Check the state of the I/O at the control unit terminal -Read the fault log -Save or transfer the starter configurations Section 4-2/3

13 REPAIR MANUAL 4.3. Test bench In order to test the ATS38 after repair, a document is attached showing how to build a test bench. It corresponds to that used to test Altivar 66 and 38 drives. Only the cable linking the Altistart 48 connectors to the 15-pin Sub-D connector is different. Wiring for the cable connecting the test bench to the control terminal of the ATS48: 15-way female Sub-D connector (front view) ATS48 connector COM (0 V) STOP RUN LI3 LI4 LO+ PL (+24V) Section 4-3/3

14 CONSTRUCTION OF THE TEST PLATFORM

15

16 PAGE DESIGNATION EVOLUTION INDEX PAGE DESIGNATION EVOLUTION INDEX FLYLEAF RECAPITULATION PAGE POWER CONTROL SEQUENCE CONTROL SEQUENCE CONTROL SEQUENCE CONTROL SEQUENCE OPERATING LEGEND OPERATING LEGEND DOOR AND CABINET CABINET-ATV66 CONNECTION

17 SUPPLY 380V TRIPHASE + NEUTRAL SUPPLY 220 V TRIPHASE ATV MOTOR TEST BENCH PC2: ON CABINET RIGHT SIDE ATV OUTPUT SUPPLY CONTROL SEQUENCE SUPPLY ON CONSOLE DOOR PC1: ON CABINET DOOR ATV NETWORK SUPPLY POWER

18 SINGLEPHASE OPERATION VALIDATION TRIPHASE OPERATION VALIDATION VARIATOR POWER SWITCH ON VOLTAGE CHOICE FOR PLATFORM SUPPLY PLATFORM STOP POWER STOP EMERGENCY STOP RUN 380 V RUN 220 V SWITCH ON CONSOLE STOP POWER SWITCH ON CONTROL SWITCH ON VARIATOR SECURITY SHUNT RUN 220 V RUN 380 V SINGLEPHASE RUN TRIPHASE RUN

19 DEBUGGING RELAY INTERMEDIARY RELAY FORWARD RELAY BACKWARD RELAY BRAKE RELAY DEBUGGING FORWARD BACKWARD

20 ELECTRIC SUPPLIES SINGLEPHASE RUN TRIPHASE

21 S10: LOCKING-UNLOCKING SWITCH BRAKE RESISTANCE ON CONSOLE ROOF VOLTAGE DIVIDER VIEW ON SEAM SIDE PC3 SUB D 56 PIN CONNECTION ON CONSOLE FRONT SIDE VOLTMETER ON CONSOLE FRONT SIDE

22 DEVICES OPERATING LEGEND REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT CONTACT BREAKER PROTECTION MODULE COIL 240 V 50 HZ HANDLE + DRILL-PLATE MOTOR CIRCUIT BREAKER ADDITIONAL CONTACT START-STOP EXTERIOR CONTROL NEUTRAL FUSE SUPPORT FUSE SUPPORT FUSE CARTRIDGE am FUSE SUPPORT FUSE CARTRIDGE gl FUSE SUPPORT FUSE CARTRIDGE am FUSE SUPPORT FUSE CARTRIDGE am SINGLEPHASE TRANSFORMER VOLTMETER BRAKING LABEL VOLTAGE DIVIDER AMMETER 0-40 A MOTOR I LABEL INTENSITY TRANSFORMER MARTIN LUNEL PLUG 16-25A P17 CONNECTOR 16A 3P + E 380 V PE BLANKING PLUG AR TERMINAL (BRAKING R) AR TERMINAL AR TERMINAL COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK AUXILIARY CONTACTOR AUXILIARY CONTACTOR TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART INDICATOR LIGHT 48 V BULB ENERGISED LABEL PUSH-BUTTON EMERGENCY STOP OPENING CONTACT 60 MM LABEL EMERGENCY STOP PUSH-BUTTON EMERGENCY STOP CASING PUSH-BUTTON LABEL CONTROL STOP COMMUTATOR BODY COMMUTATOR HEAD LABEL 220 V 380 V PUSH-BUTTON LABEL POWER STOP COMMUTATOR BODY COMMUTATOR HEAD LABEL SINGLE TRI COMMUTATOR LABEL SHUNT SA SB 0-1 PUSH-BUTTON LABEL PLATFORM STOP COMMUTATOR LABEL DEBUGGING 0-1 COMMUTATOR LABEL FW 0 RV COMMUTATOR LABEL BRAKE 0-1 COMMUTATOR LABEL RUN 0-1 LUMINOUS PUSH-BUTTON OPERATING LEGEND

23 DEVICES OPERATING LEGEND REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT WHITE CAP CONTROL ENERGISED LABEL 48 V BULB LUMINOUS PUSH-BUTTON WHITE CAP POWER ENERGISED LABEL 48 V BULB LUMINOUS PUSH-BUTTON 380 V LABEL 48 V BULB LUMINOUS PUSH-BUTTON 220 V LABEL 48 V BULB INDICATOR LIGHT BRAKING LABEL 130 V BULB 2.2 K POTENTIOMETER 27 OHMS 700 W RESISTANCE 27 OHMS 280 W RESISTANCE PIN PLUG TERMINAL + ACCESSORIES TERMINAL + ACCESSORIES BLUE CASING + BASEPLATE OPERATING LEGEND

24 BRAKING RESISTANCE 2 TERMINALS CHOICE FOR RESISTANCE VALUE BRAKING-R BRAKING INDUCED-I 380 V 220 V MOTOR Emergency Stop DOOR AND CABINET

25 CABINET 15-RECEPTACLE CONNECTOR BLUE RED VZ3N006 TYPE CONNECTOR (BLADES CONNECTOR) TOP VIEW UNLOCK FRONT VIEW GREEN GREY WHITE STEP BY STEP ROSE YELLOW BROWN CABINET-ATV66 CONNECTION

26 MOTORS BENCH ( V)

27 PAGE DESIGNATION EVOLUTION INDEX PAGE DESIGNATION EVOLUTION INDEX FLYLEAF RECAPITULATION PAGE POWER CONTROL SEQUENCE CONTROL SEQUENCE CONTROL SEQUENCE CONTROL SEQUENCE OPERATING LEGEND OPERATING LEGEND DOOR AND CABINET CABINET-ATV66 CONNECTION

28 SUPPLY 380V TRIPHASE + NEUTRAL SUPPLY 525 V TRIPHASE ATV MOTOR TEST BENCH ELECTRIC SUPPLY FOR POWER CABINET TRANSFORMER PC2: ON CABINET RIGHT SIDE ATV OUTPUT SUPPLY CONTROL SEQUENCE SUPPLY ON CONSOLE DOOR PC1: ON CABINET DOOR ATV NETWORK SUPPLY POWER MOTORS BENCH ( V)

29 SINGLEPHASE OPERATION VALIDATION TRIPHASE OPERATION VALIDATION VARIATOR POWER SWITCH ON VOLTAGE CHOICE FOR PLATFORM SUPPLY PLATFORM STOP POWER STOP EMERGENCY STOP RUN 380 V SWITCH ON CONSOLE STOP POWER SWITCH ON CONTROL SWITCH ON VARIATOR SECURITY SHUNT RUN 220 V RUN 525 V MOTORS BENCH ( V)

30 DEBUGGING RELAY INTERMEDIARY RELAY FORWARD RELAY BACKWARD RELAY BRAKE RELAY DEBUGGING FORWARD BACKWARD MOTORS BENCH ( V)

31 ELECTRIC SUPPLIES SINGLEPHASE RUN TRIPHASE MOTORS BENCH ( V)

32 S10: LOCKING-UNLOCKING SWITCH BRAKE RESISTANCE ON CONSOLE ROOF VOLTAGE DIVIDER VIEW ON SEAM SIDE PC3 SUB D 56 PIN CONNECTION ON CONSOLE FRONT SIDE VOLTMETER ON CONSOLE FRONT SIDE MOTORS BENCH ( V)

33 DEVICES OPERATING LEGEND REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT CONTACT BREAKER PROTECTION MODULE COIL 240 V 50 HZ HANDLE + DRILL-PLATE MOTOR CIRCUIT BREAKER ADDITIONAL CONTACT START-STOP EXTERIOR CONTROL NEUTRAL FUSE SUPPORT FUSE SUPPORT FUSE CARTRIDGE am FUSE SUPPORT FUSE CARTRIDGE gl FUSE SUPPORT FUSE CARTRIDGE am FUSE SUPPORT FUSE CARTRIDGE am SINGLEPHASE TRANSFORMER VOLTMETER BRAKING LABEL VOLTAGE DIVIDER AMMETER 0-40 A MOTOR I LABEL INTENSITY TRANSFORMER MARTIN LUNEL PLUG 16-25A P17 CONNECTOR 16A 3P + E 380 V PE BLANKING PLUG AR TERMINAL (BRAKING R) AR TERMINAL AR TERMINAL COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR POWER ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK COMMUTATOR SWITCH ADDITIONAL CONTACT BLOCK AUXILIARY CONTACTOR AUXILIARY CONTACTOR DE-ENERGISED TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART AUXILIARY CONTACTOR ENERGISED TIMER ADDITIONAL PART INDICATOR LIGHT 48 V BULB SWITCH ON LABEL PUSH-BUTTON EMERGENCY STOP OPENING CONTACT 60 MM LABEL EMERGENCY STOP PUSH-BUTTON EMERGENCY STOP CASING PUSH-BUTTON LABEL CONTROL STOP COMMUTATOR BODY COMMUTATOR HEAD LABEL 220 V 525 V PUSH-BUTTON LABEL POWER STOP COMMUTATOR LABEL SHUNT SA SB 0-1 PUSH-BUTTON LABEL PLATFORM STOP COMMUTATOR LABEL DEBUGGING 0-1 COMMUTATOR LABEL FW 0 RV COMMUTATOR LABEL BRAKE 0-1 COMMUTATOR LABEL RUN 0-1 LUMINOUS PUSH-BUTTON OPERATING LEGEND MOTORS BENCH ( V)

34 DEVICES OPERATING LEGEND REFERENCE PAGE COL OPERATING DESCRIPTION SUPPLIER EQUIPMENT WHITE CAP CONTROL ENERGISED LABEL 48 V BULB LUMINOUS PUSH-BUTTON WHITE CAP POWER ENERGISED LABEL 48 V BULB LUMINOUS PUSH-BUTTON 380 V LABEL 48 V BULB LUMINOUS PUSH-BUTTON 525 V LABEL 48 V BULB INDICATOR LIGHT BRAKING LABEL 130 V BULB 2.2 K POTENTIOMETER 27 OHMS 700 W RESISTANCE 27 OHMS 280 W RESISTANCE PIN PLUG TERMINAL + ACCESSORIES TERMINAL + ACCESSORIES BLUE CASING + BASEPLATE OPERATING LEGEND MOTORS BENCH ( V)

35 BRAKING RESISTANCE 2 TERMINALS CHOICE FOR RESISTANCE VALUE BRAKING-R BRAKING INDUCED-I 380 V 525 V MOTOR Emergency Stop DOOR AND CABINET MOTORS BENCH ( V)

36 CABINET 15-RECEPTACLE CONNECTOR BLUE RED VZ3N006 TYPE CONNECTOR (BLADES CONNECTOR) TOP VIEW UNLOCK FRONT VIEW GREEN GREY WHITE STEP BY STEP ROSE YELLOW BROWN CABINET-ATV66 CONNECTION MOTORS BENCH ( V)

37 REPAIR MANUAL 5. Replacement parts list for ATS48 Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes (400 Volts) (690 Volts) 2-thyristor module VZ3TM2056M14 3 D17 to D32Q VZ3TM2056M18 3 D17 to D32Y A 2-thyristor module VZ3TM2091M14 3 D38 to D47Q VZ3TM2091M18 3 D38 to D47Y A 2-thyristor module VZ3TM2132M14 3 D62 to D75Q VZ3TM2132M18 3 D62 to D75Y B 2-thyristor module VZ3TM2162M14 3 D88 to C11Q VZ3TM2162M18 3 D88 to C11Y B 2-thyristor module VZ3TM2250M14 3 C14 to C17Q VZ3TM2250M18 3 C14 to C17Y C 2-thyristor module VZ3TM2500M14 3 C21to C32Q VZ3TM2500M18 3 C21to C32Y D 2-thyristor plug-in base VZ3TP2600M C41Q C79Q VZ3TP2600M C41Y C79Y E F 2-thyristor plug-in base VZ3TP2M12M C48 to C66Q M10 to M12Q VZ3TP2M12M C48 to C66Y M10 to M12Y E F Control unit assembly VX4G481 1 All Q ratings VX4G481 1 All Y ratings Filter board VX4G48161Q 1 D17 to D47Q VX4G48161Y 1 D17 to D47Y A Filter board VX4G48162Q 1 D62 to C11Q VX4G48162Y 1 D62 to C11Y B Filter board VX4G48163Q 1 C14 to C17Q VX4G48163Y 1 C14 to C17Y C Filter board VX4G48164Q 1 C21 to C32Q VX4G48164Y 1 C21 to C32Y D Firing circuit boards VX4G48165Q 6 12 C41 to C66Q C49 to M12Q VX4G48165Y 6 12 C41 to C66Y C49 to M12Y E F The control unit contains the connections required for connecting to the power and the unlabelled terminal For the power sections of ATS48, C41 to M12: the firing circuit board has a reference and should be ordered separately by the customer. Section 5-1/4

38 REPAIR MANUAL Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes (400 Volts) (690 Volts) Power board VX5G48D17Q 1 ATS48D17Q VX5G48D17Y 1 ATS48D17Y A Power board VX5G48D22Q 1 ATS48D22Q VX5G48D22Y 1 ATS48D22Y A Power board VX5G48D32Q 1 ATS48D32Q VX5G48D32Y 1 ATS48D32Y A Power board VX5G48D38Q 1 ATS48D38Q VX5G48D38Y 1 ATS48D38Y A Power board VX5G48D47Q 1 ATS48D47Q VX5G48D47Y 1 ATS48D47Y A Power board VX5G48D62Q 1 ATS48D62Q VX5G48D62Y 1 ATS48D62Y B Power board VX5G48D75Q 1 ATS48D75Q VX5G48D75Y 1 ATS48D75Y B Power board VX5G48D88Q 1 ATS48D88Q VX5G48D88Y 1 ATS48D88Y B Power board VX5G48C11Q 1 ATS48C11Q VX5G48C11Y 1 ATS48C11Y B Power board VX5G48C14Q 1 ATS48C14Q VX5G48C14Y 1 ATS48C14Y C Power board VX5G48C17Q 1 ATS48C17Q VX5G48C17Y 1 ATS48C17Y C Power board VX5G48C21Q 1 ATS48C21Q VX5G48C21Y 1 ATS48C21Y D Power board VX5G48C25Q 1 ATS48C25Q VX5G48C25Y 1 ATS48C25Y D Power board VX5G48C32Q 1 ATS48C32Q VX5G48C32Y 1 ATS48C32Y D Power board VX5G48C41Q 1 ATS48C41Q VX5G48C41Y 1 ATS48C41Y E Power board VX5G48C48Q 1 ATS48C48Q VX5G48C48Y 1 ATS48C48Y E Power board VX5G48C59Q 1 ATS48C59Q VX5G48C59Y 1 ATS48C59Y E Power board VX5G48C66Q 1 ATS48C66Q VX5G48C66Y 1 ATS48C66Y E Power board VX5G48C79Q 1 ATS48C79Q VX5G48C79Y 1 ATS48C79Y F Power board VX5G48M10Q 1 ATS48M10Q VX5G48M10Y 1 ATS48M10Y F Power board VX5G48M12Q 1 ATS48M12Q VX5G48M12Y 1 ATS48M12Y F The voltage selection jumper (Q or Y) is placed on the power board at the production output + configuration in EEPROM Section 5-2/4

39 REPAIR MANUAL Component Symbol Qty Starter reference Symbol Qty Starter reference Sizes (690 Volts) Temperature probe VZ3G001 1 D17 to C32Q VZ3G001 1 D17 to C32Y A,B,C,D Temperature probe VZ3G002 1 C41 to M12Q VZ3G002 1 C41 to M12Y E,F Fan assembly VZ3V481 1 D32 to D38Q VZ3V481 1 D32 to D38Y A Fan assembly VZ3V D47Q VZ3V D47Y A Fan assembly VZ3V482 1 D62 to C11Q VZ3V482 1 D62 to C11Y B Fan assembly VZ3V483 1 C14 to C17Q VZ3V483 1 C14 to C17Y C Fan assembly VZ3V484 1 C21 to C32Q VZ3V484 1 C21 to C32Y D Fan assembly VZ3V C41to C66Q C79 to M12Q VZ3V C41to C66Y C79Y to M12Y E F The fan assemblies are supplied with fixing screws Section 5-3/4

40 REPAIR MANUAL Section 5-4/4

41 REPAIR MANUAL 6. Software 6.1. Starter software The software version currently on the market is V1.1IE07. Known bugs to date Inversion of the state of the logic outputs (LO) in relation to those of the ATS46 This problem will be corrected in the next version of the software. Accidental tripping (PhF fault) as soon as the Run command is sent: On control boards with date codes before , a component fault which may cause PhF faults to be triggered accidentally as soon as the Run command is sent. The component concerned has been replaced in boards with date codes starting at Remedies: -Set the FrC parameter to 50 or 60 -Use a V1.1IE07 control board Connecting the ATS in the motor delta winding The ATS 48 Q range does not trigger a PhF fault if the branch corresponding to the one without isolated earth in the ATS is disconnected. For the 2 other branches, the ATS does detect the break and triggers a PhF fault. PhF fault in steady state without bypass on lines subject to significant interference Notes: -A number of different faults may occur if ribbon cable J5, which connects the control board to the power board, is connected incorrectly. Do not forget to lock the ribbon cable using the clamp once you have inserted it into the connector. -Precautions to be taken in order to reverse the direction of rotation of the motor with the ATS48 connected to the delta terminal. It is absolutely essential that the motor is wired as specified in the user's manual. To reverse the direction of rotation of the motor, switch over 2 line phases and not 2 motor phases Remote terminal software The software for the remote terminal (ref. VW3G48101) is the same as that for the ATV28. The only difference between the 2 terminals is the keypad: the keypad for the ATS48 has 4 keys (Escape, Enter, Up, Down). The menus for the remote terminal are identical to those for the ATS48 with the addition of a switch to lock access to the menus. Section 6-1/2

42 REPAIR MANUAL 6.3. 'Power Suite' software workshop for motor starters The Power Suite software can be operated on PCs with different versions of Windows and requires a minimum PC configuration (memory for example). The current version of the Power Suite software is V1.40. Section 6-2/2

43 REPAIR MANUAL 7. Installation diagnostics 7.1 The motor is turning but does not reach its nominal speed Probable causes -resistive torque too high -drive parameters incorrectly set -ATS under-sized Incorrect motor connection (star/delta) for the line voltage Check -read (Lcr), measure motor current -ATS at current limit (display flashing) -In setting = motor Inom -ILT,Tq0,TLI settings -check the motor connection (star/delta) and the power supply Results -In< motor I nom -ILT,TLI,tq0 too low ATS at current limit (display flashing) with ILT=max TLI=max Solutions -set In=nominal motor current -increase ILT,TLI,Tq0 Change the ATS for an ATS with a higher rating Rewire the motor connection if necessary Section 7-1/6

44 REPAIR MANUAL 7.2 The motor is not turning, even though there is current (The preheating function is not active) Probable causes -Resistive torque (starting) too high -ATS under-sized The motor connection is inappropriate (star instead of delta) The brake remains engaged Unknown Check -Measure the motor current in the 3 phases -ATS at current limit (display flashing) Results The brake remains engaged Solutions -set In=nominal motor current -increase In, ILT, Tq0,TLI -fit an ATS with a higher rating Rewire the motor connection Review the brake operating sequence Connect the motor direct to the line supply to check starting Section 7-2/6

45 REPAIR MANUAL 7.3 The motor does not turn in the required direction (See forward/reverse supply voltage convention) Probable causes -supply voltage direction of rotation (forward or reverse) -ATS wiring to the supply -ATS wiring to the motor Check -Phr parameter -ATS wiring to the supply -ATS wiring to the motor Results Phr parameter=no Phr parameter=123 or 321 Solutions Switch 2 supply phases Switch 2 motor phases Section 7-3/6

46 REPAIR MANUAL 7.4 The ATS48 7-segment displays are off Probable causes Voltage in CL1-CL2 of control terminal too low No voltage in CL1-CL2 on the control terminal -Power card inoperative -Problem with internal connections Check Measure voltage U in CL1- CL2 Check the 24 VDC voltage on the contol terminal Measure voltage U in CL1- CL2 Check the voltage in CL1- CL2 on the control terminal Check the 24 VDC voltage on the control terminal Results Voltage U < 30% approx. 24 VDC voltage present No voltage in CL1-CL2 Voltage in CL1-CL2 : OK No 24 VDC voltage Solutions The CL1-CL2 supply voltage is too low Supply the ATS with its nominal voltage Supply CL1-CL2 with the ATS nominal voltage -Check the connections: J4/ J5 cables, presence of J9 strap -Change the power card Section 7-4/6

47 REPAIR MANUAL 7.5 The 7-segment displays are but do not respond when the keys are pressed Probable causes Keyboard inoperative or disconnected, control card inoperative Check Results Solutions Change the control unit Section 7-5/6

48 REPAIR MANUAL 7.6 The motor speed is unstable Probable causes The motor used has excessive slip The ATS is wired to the motor's delta windings Check Check the slip (see motor rating plate) Results Solutions -Reduce the LSC parameter -Adjust the value of the tig parameter -Reduce the LSC parameter -Adjust the value of the tig parameter Section 7-6/6

49 REPAIR MANUAL 8. Help with troubleshooting 8.1. Preamble On receipt of the product, carefully note down: -The information on the ID label (label with bar code) -The information on the control data plate attached to the flanges -The power data on the rating plate attached to the flanges -The version of the control unit on the label attached to the control unit -The voltage on the yellow label attached to the control board terminal (marked DANGER) If the faulty product is accompanied by a sheet describing the fault observed by the customer, use this information to locate the faulty component. If not, follow the instructions below: Examine the product visually (while switched off): -Check the external physical state of the drive: look for traces of burning or overheating, parts that have been subjected to knocks -Check the connectors -Check the state of the internal screws to determine whether the product has been dismantled 8.2. Thyristor test Equipment: - Small incandescent torch and 4.5 V battery for sizes A, B, C, D ma DC supply max. + milli-ammeter for sizes E and F Recommended diagram for testing a thyristor (sizes A/B/C/D) 4.5 V battery Incandescent bulb + - thyristor 1 thyristor 2 Thyristor module Section 8-1/22

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