Version 1.

Troubleshooting Guide

Contents

1. Troubleshooting Procedures
2. Troubleshooting Situations
3. Hardware Inspection & Repair
4. Repair Practice

2012. 4. 16

J.D Seo, Assistant Manager

Global Support Team, Automation Business Division

!Caution
This content is subject to change due
to various conditions.
 Chapter 1.
Troubleshooting
Procedures
1. Troubleshooting Procedures

Contents
I. Fault List ----------------------------------------------------------------- 5

II. Protective Function Procedure ----------------------------------------- 6

1) Over Current -------------------------------------------------------------------- 6

2) Over Load ----------------------------------------------------------------------- 7
3) Ground Fault -------------------------------------------------------------------- 8
4) Over Voltage -------------------------------------------------------------------- 9
5) Low Voltage ------------------------------------------------------------------- 10
6) Over Heat ---------------------------------------------------------------------- 11
7) Fuse Open --------------------------------------------------------------------- 12
8) NTC Open --------------------------------------------------------------------- 12
9) H/W diag ---------------------------------------------------------------------- 13
10) CPU/COM ERR --------------------------------------------------------------- 13

III. KEYPAD panel does not light ------------------------------------------ 14

IV. Abnormal Operation --------------------------------------------------- 15

1) Motor does not run ----------------------------------------------------------- 15

2) Motor runs but does not change speed ------------------------------------- 16
3) Motor stalls during acceleration ---------------------------------------------- 17
4) Motor generates abnormal heat --------------------------------------------- 18
1. Troubleshooting Procedures
I. Fault List
Classification IC5 IG5A IP5A IS7

Over Load O O O O

Over Current (Over Current1) O O O O

Over Current2 X O O O

Inverter OLT O O O O

E-Thermal O O O O

Over Voltage O O O O

Low Voltage O O O O

Ground Trip O O O O

NTC Open X O O O

Fuse Open X X O O

Over Heat O O O O

H/W diag O O O O

5 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

1) Over Current
Over Current

On Accelerating On Decelerating At constant Speed On a constant Check

hardware

YES Reduce load or

Is the load higher than the inverter rating? increase
NO NO NO inverter
capacity
Check YES
hardware Check if IGBT works out of order

NO NO NO
• Be sure to follow recommended
Remove short Check if there is a short or ground fault detected in
YES specs for motor wiring (Length,
and ground the output wiring and wiring inside the motor thickness, etc)
fault, and
check motor NO NO NO

Is the mechanical brake of the motor

operating too fast?
Adjust brake
YES NO NO
operation time
Is the inverter monitoring current equal to NO Check
the actual current level? hardware
YES YES YES

YES Is a static condenser or Is the load Reduce load variation

Remove surge killer, etc used on YES
changing or increase inverter
the output side? YES
significantly? capacity
NO NO
NO YES Is acceleration / deceleration Adjust ACC &
Set correct Value Is torque boost moderate? NO
time moderate? DEC time

6 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

2) Over Load
Over Load

On Accelerating On Decelerating At constant Speed On a constant Check

hardware

YES
Is the load higher than the inverter rating? Reduce load or
increase
NO NO NO inverter
Check YES capacity
hardware Check if IGBT works out of order

NO NO NO

Adjust brake YES Is the mechanical brake of the motor

operation time operating too fast?
NO NO
NO
Is OLT-related parameter moderate? Set correct Value

YES YES YES

Reduce load
NO Is the load variation or Check
Set correct Value Is V/F pattern set properly? YES
changing increase inverter hardware
significantly? capacity
YES YES YES
NO
NO
Set correct Value Is torque boost moderate?
Is acceleration / deceleration NO Adjust ACC &
YES time moderate? DEC time

7 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

3) Ground Fault
Is a ground fault detected in the wiring on the YES Remove
Ground Fault inverter output side (Disconnect output wiring
ground fault
to judge if a ground fault occurs)
NO

NO Examine motor wiring

Does the length of the motor wiring
(Ex. 3-core cable shall
comply with product specifications?
not be used)
YES

Is a short detected in the wiring inside YES

the motor (Disconnect output wiring Check motor
and judge if a ground fault occurs)? and wiring

NO

Check if foreign substances are YES

Eliminate the
detected around the CT or if the
defects
connector is loose
NO

Is there any noise detected in the YES

Carrier Frequency ↓
peripherals?

NO

Replace control PCB with a new one YES Change

and check if it works properly control PCB

8 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

4) Over Voltage
Over Voltage

On Accelerating On Decelerating At constant Speed On a constant Check

hardware
Adjust input NO
voltage Is the power supply voltage within specification?

YES YES YES

Is the actual DC link voltage reading equal to NO

Even when ACC
time is extended the displayed value?
in ACC section,
motor needs YES YES YES
checkup at NO
occurrence of OV While DC link is in operation, does the voltage of the
DC link exceed protection level?
YES YES YES

Control YES Is load Check

Can ACC time Can DEC time NO
ACC/DEC changing hardware
be extended? be extended?
time significantly?
(Extend) YES
NO YES
NO Control ACC/DEC
NO time and increase
Consider using Is the braking device used? INV capacity
braking device NO
YES YES YES
Check braking Check braking
Adjust NO Is the braking device installed
resistance device
combination correctly? YES
NO NO
Are there any YES Does braking device
YES
abnormal signs in operate properly?
braking resistance?

9 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

5) Low Voltage
Low Voltage Is the power supply voltage within NO Adjust input
specification? voltage
YES
Is the actual voltage
Is the DC link voltage of inverter P, N NO reading of DC link
terminal normal? equal to displayed
value?
YES
YES YES
Use speed Do blackout accidents occur?
search function
Check
NO
hardware
NO Is the terminal of the inverter input (R,S,T)
Reconnect
properly connected?
YES
YES
Check NO
Is there open phased input?
power supply Does transformer
YES have moderate
NO capacity?
Does M/C or relay work inside the inverter? NO NO
YES
When LV TRIP
Is any load requiring high initial current in NO occurs, does M/C
the same system? or circuit breaker
YES work on 1st side?

Re-examine the power supply system

10 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure Over Heat

6) Over Heat
Check heat sink temperature of
loader and check trip history

YES

Did TRIP occur at

100˚C or higher
temperature? *1 NO

YES

Examine panel NO Is ambient

cooling temperature of
system INV below 40 ˚C?
YES

NO Is there no abnormal sign

Is FAN connector Does cooling fan YES
in NTC wire or PIM NTC?
inserted correctly? run normally?
*2

YES NO

Does 24V voltage NO Does Control PCB run

NO
occur in FAN Check normally after it is replaced
Connector of SMPS? Hardware with a new one?
YES

Is there any
NO Replace cooling fan
unexpected
materials in FAN? with a new one
*1 – Based on 100 ˚C (IS7), but 85 ˚C exceptionally
YES (other products)
*2 – IG5A and IC5 have NTC inside PIM
Remove unexpected materials

11 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

7) Fuse Open
NO Change fuse &
Fuse Open Is fuse normal? perform checkup on
IGBT
YES

Does limit switch or fuse show any NO Replace limit

abnormal sign? switch or fuse
wiring with a new
YES one
Change
control PCB

8) NTC Open
NO Change fuse and
NTC Open In case of IG5A, is NTC resistance of PIM normal?
perform checkup
In case of IP5A, IS7, is NTC thermistor resistance normal?
on IGBT
YES
YES Change wire
Is NTC wire abnormal?

NO

Is voltage of SMPS delivered normally from NO

Change SMPS
NTC to Control PCB?

YES

Change
control PCB

12 /108
1. Troubleshooting Procedures II. Protective Function Procedure

II. Protective Function Procedure

9) H/W diag

Type Details EEP ROM*

Replace

EEP ROM Memory fault Watch Dog Control PCB

Or Replace
ADC OFFSET Current feedback circuit fault ADC OFFSET Main PCB DM-CT or
CT wire
Watch Dog CPU malfunction
* In case of IG5A, EEP ROM may occur at initial
power input after O/S downloading.

10) CPU/COM ERR

Type Details Model

IC5, Replace Replace

COM/ERR
IG5A Loader
CPU/COM ERR
1) Faulty connection Or Control PCB
Lost
between inverter and keypad IS7 I/O Board Or
Keypad
2) Inverter CPU malfunction Main PCB
Communication
IP5A
Fault

Cf. When CPU is damaged, it is likely that there is strong

noise source in peripherals. Check noise source and
eliminate it.

13 /108
1. Troubleshooting Procedures III. KEYPAD panel does not light

III. KEYPAD panel does not light

KEYPAD panel
does not light
YES

Check YES Is input voltage Replace charge lamp

Power supply normal? with a new one
NO NO

Does LED Charge NO Does Charge Lamp YES Check hardware

Lamp turn ON? work normally? (Charging circuit)

YES

If P1, P2 terminal
block is available, YES Is connector inside YES
is Short Bar inverter tightened Check hardware
tightened properly?
properly?
NO
NO
Tighten
Tighten Short Connector
Bar

* Only if same symptom occurs after keypad is

replaced with a new one in advance

14 /108
1. Troubleshooting Procedures IV. Abnormal Operation

IV. When alarm is not issued but operation is abnormal

1) Motor does not run
Did circuit breaker or Turn on
Is inverter power turned NO NO
Motor does not run M/C on input side turn Circuit breaker
ON?
ON? or M/C
YES
YES
Is RUN signal applied? NO
Is input voltage normal? Adjust input
(ex. KEYPAD, TERMINAL,
voltage
NO RS485, etc.) YES
YES
Check hardware
Check external Is RUN signal applied to
device inverter? (Check FWD, RUN NO
lamp or check input
terminal status when using
terminal)
YES Check
NO hardware (I/O
Does frequency command occur normally? or Control
PCB)
YES

Is frequency command applied normally to INV?

YES
NO Check hardware
Is output (U,V,W) voltage normal?
(IGBT, output gate,
YES etc)
Motor control is activated
NO when load is too high.
Adjust motor Is motor connection normal?
Reduce load or increase
connection capacity of inverter.
YES
When mechanical brake is
NO YES Is Torque Boost input YES
Check motor Is load too heavy? installed, check if brake is
moderately? opened.

15 /108
1. Troubleshooting Procedures IV. Abnormal Operation

IV. When alarm is not issued but operation is abnormal

2) Motor runs but does not change speed
Is maximum frequency YES
Motor runs but Set correct value
does not change set too low?
speed NO Use keypad to
change
YES
Is frequency limit in use? Set correct value frequency

NO
YES
Keypad NO
What is used for Changed by means of
frequency command? keypad?
Multi step
Analog Input Check signal
Are 0~10V, 4~20mA and NO
device or signal
more changed? converter
YES
NO
Is connection correct? Adjust wiring
YES

NO Is wire connected
Adjust wiring
correctly?

YES

NO Is multispeed-related YES
Set correct Value parameter input NO
Is ACC time too long? Check
correctly?
hardware
YES

Adjust ACC time

16 /108
1. Troubleshooting Procedures IV. Abnormal Operation

IV. When alarm is not issued but operation is abnormal

3) Motor stalls during acceleration

Motor stalls during YES Increase

acceleration Is ACC time short?
Acceleration time
NO

Is moment of inertia or YES Is inverter used for any YES

Contact LSIS
load of motor high? special purpose?

NO NO
Replace inverter output
wire by thick wire or YES Is there output voltage Reduce moment of inertia in
reduce distance drop? load or increase the capacity of
between inverter and inverter
motor NO

Is torque boost value YES Check hardware

input moderately? (Check peripherals for
noise)
NO

Increase
Torque Boost

17 /108
1. Troubleshooting Procedures IV. Abnormal Operation

IV. When alarm is not issued but operation is abnormal

4) Motor generates abnormal heat

Motor generates Is V/F pattern in use NO

Adjust V/F pattern
abnormal heat suitable for motor?

YES

Does motor still run at YES Use dedicated motor for inverter
low speed? or reduce Torque Boost

NO

YES Reduce load or

Is load too high?
increase capacity of
inverter
NO

Is voltage of inverter YES

Check motor
output (U,V,W) balanced?

NO

Check hardware
(Check peripherals for
noise)

18 /108
 Chapter 2.
Troubleshooting
Situations
2. Troubleshooting Situations

Contents
I. Cases Related to Protective Function --------------------------------- 21

II. Cases Related to Damaged Inverters --------------------------------- 32

III. Cases Related to Malfunctioning Peripherals ------------------------ 37

IV. Cases Related to Noise ------------------------------------------------- 40

V. Other -------------------------------------------------------------------- 43

20 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OC TRIP CASE

Model SV075IG5A-4 System

Load PUMP
SV075IG5A-4

Pressure sensor Pressure limit

• OC TRIP occurs during operation.
FX
Problem • TRIP LIST CM
- OCT, 56.00HZ, 8.9A, STD Pressure tank (300L)
INV

• Distance between inverter and motor Ground

is about 120m. Over current TRIP occurs
due to poor insulation of motor under
Cause
the influence (over voltage, over current)
of reflective voltage resulting from long
wiring distance.
About 100m

• Change Parameter FU2-39 Carrier

Resolution
Frequency from 3.0KHZ to 1.0KHZ. Undergrou
Submerge
nd water
d motor

• It is recommended that the distance

between inverter and motor should be
controlled not more than specification.
Tip But if the distance is long, it is
recommended to reduce carrier
Frequency and install MSF (Micro Surge
Filter) or reactor for output.

21 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OC1 TRIP CASE

Model SV055IS5-4 Parameter

CODE SETTING
Load PUMP ACC 5SEC
DEC 5SEC
• OC1 TRIP occurs occasionally. DRV FX/RX-1
• TRIP LIST FRQ V1+I
In pressure sensor,
Problem - OC1,60.0HZ,34.1A,ACC control the
- OC1,60.0HZ,34.1A,DEC System pressure level of
Heater pipe to 4~20mA,
- OC1,60.0HZ.34.1A,STEADY tank and use it for
controlling inverter
speed. I Terminal
• The value of pressure on heater tank is 5G Terminal
shifted to 4~20mA and used as signal for 8. 사진정보
operating valve of water supply pipe.
Cause 0~100% opening time is 20SEC and inverter
ACC/DCC time is 5SEC respectively, so trip Pressure
occurs due to difference of valve operation sensor
from startup time of inverter.
Control the pressure Water
• Modify parameter. level of heater tank supply
- ACC: 5SEC → 10SEC to 4~20mA, so valve pump
works.
- DEC: 5SEC → 10SEC
• Make sure that operating conditions of pipe Pipe MOTO
valve comply with ACC/DCC conditions of R
Resolution inverter.
Pressure
• Frequency current control is independently Pressure sensor
separated from operation sequence. Thus, control
change to one sequence under same conditions, valve
so that valve can work simultaneously with
inverter speed control.

• When overload TRIP occurs, it is

Tip necessary to check any sequence with
other devices such as brake or valve.

22 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

IOL TRIP CASE

Model SV550IS5-4 Waveform

Load Air conditioner

• Failure of re-startup at instantaneous

blackout
Problem • IOLT TRIP occurs
• TRIP LIST
- IOLT,8.23HZ,195A,ACC

-FU2-22: 0110=>1110
-DEC: 40SEC=>60SEC
-ACC: 25SEC=>40SEC
* Change parameter.
• When IOLT TRIP occurs, ACC time is short so
that initial startup current level becomes boosted
up.
• When power is restored after blackout, startup ACC time is short and over current occurs at initial
Cause synchronized with power input is optionally used, startup
so the slip of motor and inverter becomes
increased and load current level gets higher.
Then, the trip of question occurs.

• At forced blackout, FREE RUN status of motor

becomes disabled in about 1 min 45 sec. When
re-starting motor before it stops running, IOLT
TRIP occurs in parallel with current control
operation.
Resolution • Change parameter related to speed search.
- FU2-22 : 0110 → 1110
• Change parameter related to IOLT TRIP.
- ACC : 25SEC → 40SEC
- DEC : 40SEC → 60SEC

• The load with higher inertia may

involve these phenomena, so it is
Tip
necessary to check load and TRIP Load current is stabilized at startup after
conditions. ACC time is changed

23 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OL TRIP CASE

Model SV2800IP5A-4 System

Load PUMP

• ⓐmotor runs normally, but when it is less Normal voltage 440V

used at night than by day, ⓑ motor stops
running for pressure control, and it is
ⓐ MOTOR 230KW,404A

Problem
operated only by inverter. Then, when ⓑ
motor stops running, ETH, OLT occurs in
inverter. SV2800IP5A-4

• Since pump is less used at night, ⓑ motor

stops running when both ⓑ motor and
ⓑ MOTOR 230KW,404A

inverter run simultaneously. It is estimated

that trip occurs if instantaneous load
Cause
(backflow) is received during operation at
lower limit (10Hz) of inverter frequency (a
frequency band with highest load current
level = ca. 320A).
• Modify 10Hz frequency band (lower limit Current 4~20mA Pressure sensor
setting) with high startup current. Then,
change the band so that pump runs below
trip level even with higher load level when
ⓑ motor stops.
Resolution
• Change parameter.
- Lower limit: 10Hz (Load current: ca. 320A)
→ 17HZ (Load current: ca. 170A)
- Torque boost: Manual → auto
- Acc time: 130sec → 200sec
• This situation may occur due to
Tip changing load level depending on
availability of pump.

24 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OC2 TRIP CASE

Model SV300IP5A-4 Picture

• OC2 Trip occurs occasionally.

- Check TRIP history of OC2 (OC2,
Problem
60.0Hz,50A,STD 5 times).
• Trip occurs about twice a day.

• It is estimated that this trip is an

abnormal operation occurring due to
Cause
panel M/C open-close noise (12 units of
DOL System is included inside panel).

• Change carrier frequency to take

Resolution
proper measures for noise (2 → 0.7kHz).

• In case of malfunction resulting from

Tip M/C Noise, it is recommended to use
M/C equipped with noise filter.

25 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OC2 TRIP CASE

Model SV185IP5A-4 System

Load FAN Air supply Air exhaust

• OC2 TRIP occurs occasionally.

• TRIP LIST Painting process lab
Problem - OC2, 3.17Hz, 48.6A, ACC
- OC2, 25.02Hz, 51.9A, ACC Mobile phone cover
- OC2, 24.40Hz, 52.4A, ACC
• Temperature in panel is high, and
temperature level is about 60°C in terms of
inverter parameters. It is estimated that this
trip is a malfunction due to degraded part
characteristics depending on temperature
Cause variation.
• Carrier frequency 5.0KHz → Ca. 58~61°C
• Carrier frequency 1.0KHz → Ca. 48~51°C
• Among parameters, V/F pattern is SQUARE.
Thus, many cases of IOLT TRIP occur due to
load current during acceleration.

• Change parameter.
- ACC: 500SEC → 50SEC
Resolution - DEC: 600SEC → 50SEC
- V/F pattern: SQUARE → V/F
- Carrier Frequency: 5KHz → 1KHz
• OC2 may work out of order due to
temperature gap of IGBT depending on
Tip
temperature gap of heat sink (Cooling
fan failure, etc)

26 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OV TRIP CASE

Model SV185IS5-4 Waveform

Load LIFT

• OV TRIP occurs occasionally when LIFT

is down.
• TRIP LIST Lift-down
Problem
- OVT, 0.56Hz, 14.3A, ACC high speed section
- OVT, 0.50Hz, 100A, ACC
- OVT, 0.56Hz, 15.1A, ACC

• It is found that the contact of M/C for

Lift-down
operating motor brake is smoked due low speed section
to arc. As a result, it is estimated that
Cause motor brake works out of order during
operation and chatters due to poor
contact point, ending up with Lift-up section
malfunction of inverter.

• Additionally connect surge killer to

M/C terminal inside panel.
Resolution • Change parameter.
- Change carrier frequency from 10KHz
to 5KHz.

• Failure of LIFT may occur due to noise

Tip
of panel (M/C open-close surge).

27 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OV TRIP CASE

Model SV550IS5-4 System

Load FAN
Boiler Motor: 45KW
• OVT occurs occasionally when FAN Damper
Problem
stops running.
• Problems due to sequence question
- M/C on the 1st side of inverter and that on the
2nd side of inverter are synchronized when fan
runs and stops, and OVT occurs in free-run status
Cause of motor when re-starting M/C after it stops.
• Site problem of instantaneous blackout
- FAN works out of order by operation of M/C
on 1st and 2nd side of inverter when
instantaneous blackout occurs.
Blower FAN
• Modify sequence: Change sequence to
assure that M/C on 1st side of inverter
remains ON even when trip occurs and Heating: Heated up by burning wastes
stops, and then M/C of 2nd side of inverter
also remains ON (Only when inverter
operates). Moreover, change sequence to
Resolution make sure that FX (RUN) signal always
remains ON before OFF signal input.
• Change parameter.
- ACC: 110SEC → 20SEC
- DEC: 220SEC → 30SEC
- Speed search: 0000 → 1100
- Stop MODE: FREE RUN → DECEL

• It is necessary to check operation

Tip
sequence of M/C on 2nd side of inverter.

28 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

OV TRIP CASE

Model SV055IP5A-4 Picture

Load Air conditioner

• OVT occurs during acceleration at the

frequency of ca. 9~10Hz.
• When starting up air conditioner after
power turns ON, an irregular buzzing noise
Problem in the inverter.
• TRIP LIST
- OV TRIP, 9.35HZ, 4.3A, ACC
- OV TRIP, 10.08HZ, 4.3A, ACC and same on
follow-up

• It is estimated that this OVT is a symptom

due to poor part characteristics of MAIN Poor
Cause
POWER CONDENSOR within POWER PCB
(560UF, 400V).

< Position of condenser damaged >

Resolution • Replace condenser with a new one.

• Consumable parts (condenser, relay,

cooling fan, etc) should be inspected on a
Tip regular basis.
• Use of single-phase power in 3-phase
product may cause damages to condenser.

29 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

LV TRIP CASE

Model SV900IV5-4 Picture

Load MIXER

• LV TRIP occurs when cooling fan and

Problem M/C is disabled and when load
operation is in progress.

• The voltage of transformer in inverter

is set as 380V even though site input
Cause voltage is 460V. Then, fuse is damaged
due to over voltage, so the above
problem occurs.

• Replace fuse with a new one and

Resolution
change transformer tap (380V->460V). Input voltage
TAP
• In case of inverter using AC FAN and
M/C, it is necessary to check input voltage
and adjust input voltage TAP of
transformer.
Tip
• If you set transformer tap at lower level
than input voltage, the airflow rate of
cooling fan decreases and OH TRIP may
occur.

30 /108
2. Troubleshooting Situations I. Cases Related to Protective Function

COM/CPU ERR CASE

Model SV110IV5-4 Picture

Load ELEVATOR

• COM/CPU ERROR occurs at power

Problem
input. Contact failure occurs
due to mistaken
selection of OLD/NEW
• CONTROL PCB JP1 SWITCH (OLD/NEW)
is located in the center, so when power
Cause turns ON, RESET signal is not normally
applied to CPU. As a result, CPU/COM
ERROR occurs. < JP1 SWITCH >

• Replace SWITCH or CONTROL PCB with

Resolution
a new one.

• Inverter may work out of order due to

Tip
wrong SWITCH setting of PCB.

31 /108
2. Troubleshooting Situations II. Cases Related to Damaged Inverters

CASE of Input Damaged

Model SV370IP5A-4 <Possible causes of damage on input side>

• When short occurs due to infiltration of foreign
substances or moisture,
Load FAN • When surge voltage is introduced to input power,
• When stress accumulates due to frequent ACC / DCC
• Damage of input M/C and input terminal and overload generation,
Problem
block • When ground fault occurs at power terminal (Higher
• Air flow is created by outdoor unit (of air level of input power),
conditioner) installed 0.8m away forward from Tip • When dielectric breakdown of motor terminal (&
panel, and is immediately input to INV panel. ground fault of output terminal) occurs,
• It is estimated that foreign substances • When stress accumulates due to frequent shift of
Cause
infiltrated into inverter as well as moisture POWER ON/OFF,
condensation could cause short circuit to inter-
• When FAN is used for power supply with high capacity
phase section of inverter input, so that inverter
and input M/C worked out of order. (over 1000KVA), but AC/DC reactor is not used,
• When input voltage is significantly unbalanced, and
• It is necessary to control ambient temperature / • When stress accumulates due to inrush current caused
Resolution humidity of inverter and take proper measures
by frequent occurrences of instantaneous blackout
against infiltration of foreign substances.

Picture

 Front position of outdoor unit  Photo of damaged inverter

for air conditioner
32 /108
2. Troubleshooting Situations II. Cases Related to Damaged Inverters

CASE of input damaged

• While inverter is operated, use M/C of

Model SV1320iP5A-4OL
Resolution inverter input terminal to assure that
power supply is not interrupted.
Load PUMP
• When power supply is interrupted during
Tip operation, the input side of inverter may be
• Input power is turned OFF while damaged due to stress on inverter.
inverter runs by commissioning.
• As soon as input power is turned OFF,
Problem Picture
M/C connected to input side and input
terminal of inverter (GMC-300) becomes
damaged.

• As soon as GMC-300 is turned OFF

during normal operation of inverter, any
energy charged to AC Reactor on input
Cause
terminal of inverter is introduced to
surge on input side of inverter, so that
SCR becomes damaged.
Inverter SCR Input terminal M/C

SV1320IP5A-4
DCL
GMC-300 Main IGBT
SCR
Cap.
ACL M

33 /108
2. Troubleshooting Situations II. Cases Related to Damaged Inverters

CASE of power-insensitiveness

Model SV090IH-4 System

Prime motive Differential
SV090IH-4 SV300IS5-4
Load Centrifuge INV INV
* Surveillance monitor
DCP DCP Only prime motive inverter is
• Braking unit was replaced with new DCN DCN connected for both A,C fault
one by maker after it was damaged, but output signal and 1A,1B (RUN)
Problem RST UVW output signal.
power-insensitive symptom occurs in UVW
inverter.
* Special note
Use DCP, DCN terminal of prime
• Sequence supplies ca. DC 530V from DCP- motive inverter as power source of
DCN terminal of prime motive for inverter differential inverter
to DCP-DCN of inverter differential, and the Differential
braking unit of inverter on differential side
Cause Prime motive
is damaged on site where centrifuge is used.
Then, FUSE OPEN occurs due to rising
current level of DCP-DCN terminal during
operation.

Resolution • Replace FUSE with a new one.

Centrifuge
• When external braking unit is
damaged, charge resistor, fuse and
Tip
more inside inverter may be secondarily
Prime motive turns round in
damaged. opposite direction to
differential.
* Prime motive works as
dehydrator.
* Differential works to push
out sludge. Discharge separated water
Discharge separated sludge

34 /108
2. Troubleshooting Situations II. Cases Related to Damaged Inverters

CASE of inverter parts damaged

Model IG5A Picture

Problem • Melting of current CT mold

Normal Part Damaged Part 1

• When temperature is measured at

high carrier frequency with long output
Cause line, there is a problem found:
Temperature rises over 200℃ and mold
becomes deformed and inflated.

Damaged Part 2 Damaged Part 3

• The higher carrier frequency and the

Tip longer output line may cause damages
to inverter parts including CT.

35 /108
2. Troubleshooting Situations II. Cases Related to Damaged Inverters

CASE of inverter parts damaged

Model SV015IG5A-2/4 Picture

Problem • Charge resistor lead is down.

• Lead is down or resistance is off under

Cause
the influence of impact or vibration.

• Consider whether panel is influenced

Tip
by vibration when installing inverter.

36 /108
2. Troubleshooting Situations III. Cases Related to Malfunctioning Peripherals

CASE of external equipment malfunction

Transformer
Model SV750IS5-4 System

Load Water jet facility

Same system configuration

• Operation is disabled due to TRIP of

Problem ACB 600V 5000A
electric leakage breaker during operation.

• TRIP panel for electric leakage breaker is

a panel to control 7 motors furthest away
ACB 600V 1250A
in terms of bridge position. Here, this trip
is possibly attributed to occurrence of
Cause
unbalanced input voltage due to voltage Same on below Same on below
drop depending on distance (3-phase 4-
wire system, R-N: lighting, S-N: pump, T-N: MCCB 225A
Total 7 units
belt)

INV INV
• Perform re-distribution of single-phase 220V
load when input current is unbalanced. Total 7 units
• After this symptom of TRIP occurred, a panel
system provider upgraded output voltage of SV750IS5-4
Resolution transformer from 380V to 392V (ca. 12V up).
Since the symptom was not repeated at
reproducibility test, it is estimated that the
Total 7 units
question of voltage drop depending on
distance was complemented to certain extent. MOTOR 65KW

• When using 220V load as R-N, S-N, T-N,

Note distribution of load is necessary depending
Water jet facility Water jet facility
on working conditions. (10 nozzles installed) (10 nozzles installed)

37 /108
2. Troubleshooting Situations III. Cases Related to Malfunctioning Peripherals

CASE of external equipment malfunction

Model SV0750IS7-SOD System

Composition of overhead crane

Load CRAIN

Problem • H/W trip (ADC Offset) occurs

• Short to ground occurs at braking

resistance, so that both P and N phase Traversing
are shorted to cause heat generated in
Cause

Hoisting
Charge resistor. And flat cable is
damaged in vicinity of Charge resistor,
so that H/W TRIP occurs.

• Isolate any shorted element of braking

resistance and replace damaged parts Traverse Motor Travel Motor Hoist Motor
Resolution
(flat cable, control, PCB, etc) of inverter
with a new one. (30kW*2) (7.5kW) (90kW)

• Inverter may be damaged due to short

Tip
and open circuit of external equipment.

38 /108
2. Troubleshooting Situations III. Cases Related to Malfunctioning Peripherals

CASE of external equipment malfunction

Model SV220IS5-4 Picture

Load Parking Equipment

• Equipment may be damaged due to

Problem
heat generation of braking resistance.

• This damage is possibly attributed to

occurrence of overheat on braking
Cause resistance side in continuous status of
TURN ON with malfunction of braking
unit.

<Damage of braking unit>

• Replace braking unit and braking
Resolution
resistance with new one.

• Identify restoration rate and

Tip recommend use of braking unit and
resistance (%ED rate)

<Damage of braking
resistance>

39 /108
2. Troubleshooting Situations IV. Cases Related to Noise

NOISE CASE

Model SV110IS5-4 Waveform

Load Air conditioner

Before parameter
• Operating without reaching the speed is changed
After parameter is
Problem changed
as directed

• V/F pattern is set as SQUARE, so functional * Current control operation *

Occurs at ca. 25Hz, 52A
voltage is less distributed at startup and
current level rises to relatively higher level.
Cause Then, current is controlled. Thus, air
conditioner runs without acceleration up to Current controlled
specified speed level, and TRIP occurs after
the symptom is repeated.

• V/F pattern: SQUARE → LINEAR

49/20
• Adjust input voltage: 100%, 440V → 84%, 365V
• Rated voltage of motor: 0V → 380V
Resolution • When same commissioning work is performed < Waveforms measured >
after parameter is changed, it is found that load
current level is decreased about 50~60% than
before.

• V/F pattern must allow for load

characteristics.
Tip
• Current level may be reduced by inputting
input voltage and rated motor voltage.

40 /108
2. Troubleshooting Situations IV. Cases Related to Noise

NOISE CASE

Model SV110IS5-4 Waveform

Load Air conditioner

• Fonts on DISPLAY look distorted during

Problem
operation of air conditioner.
• Due to leakage current introduced in
the ground line, there are problems with
Cause
DC voltage inside CONTROL PCB. As a
result, CPU works out of order.

• Isolate shield-grounded terminal of

REMOTE CABLE between inverter and loader.
Then, air conditioner works normally.
• Change carrier frequency of FU2-38 from
5Khz to 2Khz.
Resolution
• When DC voltage inside CONTROL PCB is
checked before and after change, it is found
that voltage turns from unstable status due < Measured waveform >
to leakage current to stable status (V1-5G
Check)

• This problem can be resolved to certain

extent by reducing carrier frequency when
Tip malfunction occurs due to noise. It is likely
that the problem comes from any fault of
ground.

41 /108
2. Troubleshooting Situations IV. Cases Related to Noise

NOISE CASE

Model SV220IS5-2 Waveform

Load LIFT

• LIFT trembling occurs. Forward torque rate FU1-27 : Forward torque rate FU1-27 :
Change sequence,
• LIFT works normally when it moves down by its 2% 4%
parameter
Reverse torque rate FU1-28 : Reverse torque rate FU1-28 :
load, but it trembles significantly only when it
Problem moves up.
2% 4%
Brake operates when FX/RX Brake operates when AXA-AXC
• This problem occurs when RUN signal is OFF ON operates. operates.
during high speed operation at 60HZ.

• In general, AXA-AXC terminal is used

for operation signal of brake when
inverter is started up. However, while
FX/RX RUN signal is alternatively used
Cause
as operation signal of brake, LIFT is
trembled due to current control
operation in the operation of brake
during deceleration at stop.
Time point of RUN Time point of RUN signal OFF while
Current
signal OFF while LIFT LIFT moves UP (60Hz)
• Change sequence. control
moves UP (60Hz)
operation
• Change brake operation signal from RUN
signal to AXA-AXC terminal signal. < Waveform of output current >
Resolution
• Change parameter.
- Forward torque boost: 2% → 4% changed.
- Reverse torque boost: 2% → 4% changed.

• It is recommended to use versatile

Tip output terminal for operation signal of
brake.

42 /108
2. Troubleshooting Situations V. Other

CASE of AM output problem

Model IG5A and more Picture

• If RPM meter is connected to AM

Problem output terminal, scores of RPM are
displayed even during stop.

• Offset (50mV) occurs under the

influence of minimum pulse input and
Cause hardware of IG5A where digital RPM
meter displays scores of RPM due to
occurrence of AM output offset.

• If AM output is used, minute value

Tip may be output under the influence of
offset value.

43 /108
 Chapter 3.
Hardware
Inspection & Repair
3. Hardware Inspection & Repair

Contents
I. Major Parts on Main Circuit of Inverter----------------------------- 46

II. Major Parts and Functions--------------------------------------------- 48

III. Preventive Maintenance----------------------------------------------- 53

IV. Basic Matters for Inspection------------------------------------------- 56

1) Visual Inspection ---------------------------------------------------- 56

2) Load Test ------------------------------------------------------------ 57

V. POWER CIRCUIT ------------------------------------------------------- 58

1) Checkup of I/O MODULE ------------------------------------------ 58

2) Instruction for replacement of IGBT ------------------------------- 59

VI. Checkup by Content of iS7 Fault -------------------------------------- 61

VII. Checkup by Content of iG5A Fault ------------------------------------ 70

VIII. Checkup by Content of iP5A Fault ----------------------------------- 82

IX. Checkup by Content of iC5 Fault -------------------------------------- 98

45 /108
3. Hardware Inspection & Repair I. Major Parts on Main Circuit of Inverter

I. Major Parts on Main Circuit of Inverter

MAIN condenser BUSBAR

Contactor

Snubber Condenser

Motor

CT

Charge Diode Module IGBT Module

Resistor

46 /108
3. Hardware Inspection & Repair I. Major Parts on Main Circuit of Inverter

I. Major Parts on Main Circuit of Inverter

Braking IGBT
Charge Resistor MAIN FUSE

BUSBAR IGBT Module

SCR Module
Snubber Condenser

Down Trans

Diode Module

Electronic
CT contactor

47 /108
3. Hardware Inspection & Repair II. Major Parts and Functions

II. Major Parts and Functions

Name of parts Functions

Diode Module Rectifies AC to DC.

Controls inrush current into condenser at the time of power

Charge Resistor
input.

Contactor (or thyristor) Shorts resistor when charge is finished.

Main Condenser Smoothes power.

IGBT Creates random AC by PWM control.

Absorbs surge voltage by switching of IGBT (Protection of

Snubber Condenser
IGBT).

CT Detects current and uses it to control and protect feedback.

48 /108
3. Hardware Inspection & Repair II. Major Parts and Functions

II. Major Parts and Functions

1. Diode
1) Usage： To rectify AC power into DC power
2) Structure： A structure insulated with ceramics
3) Precautions： DO NOT strike or impact diode (If it is
dropped, DO NOT USE IT).

2. Charge Resistor

1) Function: To control any inflow of inrush current into condenser

when introducing power source
2) Precautions
Resistance wire is solidified with cement. If cement is cracked,
insulation cannot be assured at all. DO NOT strike or impact it.
The following type of resistor is likely to turn away from its right
place under the influence of impact. Thus, be careful to handle it.

3. Electronic Contactor

1) Usage: To short charge resistor after charging is finished

49 /108
3. Hardware Inspection & Repair II. Major Parts and Functions

II. Major Parts and Functions

4. Main Condenser
1) Function: To flatten power source rectified by diode
2) Precautions
This type of condenser takes considerable and high capacity
in large inverter, so be careful to avoid potential risk of
electric shock.

5. Balance Resistor
1) Function
When the electrolytic condenser is connected in series,
voltage balance cannot be maintained just with this
condenser by difference of leakage current. Thus, make sure
that this resistor is connected in parallel to condenser, and
voltage balance is acquired.
2) Precautions
If cracked, insulation of resistor cannot be maintained. Thus,
DO NOT strike or impact it.

6. Hall CT

Detects output current of inverter.

50 /108
3. Hardware Inspection & Repair II. Major Parts and Functions

II. Major Parts and Functions

7. IGBT
1) Function
This is the most important element used to switch DC
power (PWM control) to create pulse voltage.
2) Precautions
① DO NOT apply static electricity.
② DO NOT impact.
③ DO NOT use any powered driver to install IGBT.
④ DO NOT use analog tester to judge if IGBT is accepted
or not.

8. NTC Thermistor

This is used to detect pin temperature. As temperature varies,

resistance value changes continuously. Contrary to thermal
guide, detection level can be set randomly with software when
this thermistor is in use. NTC or PTC type of thermistor is used
to detect temperature of pin.

9. Thermal guide
When temperature exceeds set value, contact point is opened.
Thermal guide is attached to top of pin to protect pin from
overheat. Structurally, thermal guide is susceptible to magnetic
field. When thermal guide is incorrectly installed inside inverter,
it works out of order under the influence of magnetic field.
Therefore, be careful to service and maintain it.

51 /108
3. Hardware Inspection & Repair II. Major Parts and Functions

II. Major Parts and Functions

10. Cooling Fan

Some cooling fan has disabling signal output to cool down the
heat of pin and printed circuit board (PCB) inside inverter.
Cooling fan is a part with limited working life, so it requires
regular replacement.
Some latest cooling fans have long working life over 10 years,
but the working life of cooling fan varies significantly
depending on conditions of use.

11. Transformer for AC FAN, M/C

This transformer is used to drive fan and contactor (200V power)

by 400V-series inverter.

12. HEAT SINK

This is used to carry IGBT and diode and cool down their heat.
It is made by injection molding in form of casting.

52 /108
3. Hardware Inspection & Repair III. Preventive maintenance

III. Preventive maintenance

Frequency of
Checkup
Checkup Measuring
What to Check Regular How to Check Judgment Criteria
Items Instruments
Daily
1 year 2 years
Ambient temperature: -10℃ ~
Thermometer/
Environment Check ambient temperature, +50℃ (No freezing allowed).
Ｏ hygrometer/
al settings humidity and dust. Ambient humidity: Below 50% (No
recorder
dew allowed)

Entire Is there any abnormal vibration

Ｏ Check by visual or auditory sense. No abnormal sign allowed.
system or noise?

Power & Measure voltage among R, S and T 200~230V Tester/

Is main circuit voltage normal? Ｏ
voltage phase of inverter terminal block. 380~460V Digital multi-tester

(1) Mega-check (Between main Ｏ

circuit terminal and contact (1) Unlock inverter connection and
terminal) short R, S, T, U, V and W. Then, use
(1) More than 5MΩ
(2) Is there any fixed part Ｏ mega-check to measure in between Mega-check at the
General missing? this part and contact terminal.
(2) No abnormal sign allowed
grade of DC500V
(3) No abnormal sign allowed
(3) Is there any trace of overheat Ｏ (2) Tighten screw.
in each part? (3) Visually check.
(4) Clean-up Ｏ

(1) Is there any corrosion in Ｏ

Connection
conductor? (1) No abnormal sign allowed
conductor / (2) Is there any coating of electric Ｏ
(1), (2) Visually check.
(2) No abnormal sign allowed
electric wire wire damaged?

Terminal
Is terminal block damaged? Ｏ Visually check. No abnormal sign allowed.
block

Inverter Unlock connection of inverter and

module / Check each resistance between use tester x 1Ω range to set
Ｏ (See the next page) Analog tester
Converter terminals. between terminal R,S,T↔P,W, and
module between U,V,W↔P,N.

(1) Is internal fluid leaked out? Ｏ

(1),(2) Visually check. (1) No abnormal sign allowed.
Smoothing (2) Does safety ball come out? Is Ｏ
(3) Use capacitance meter to (2) No abnormal sign allowed. Capacitance meter
condenser there any swelling?
measure capacitance. (3) Over 85% of rated capacitance.
(3) Measure capacitance. Ｏ

53 /108
3. Hardware Inspection & Repair III. Preventive maintenance

III. Preventive maintenance

Frequency of
Checkup
Checkup Measuring
What to Check How to Check Judgment Criteria
Items Regular Instruments
Daily
1 year 2 years
(1) Is there any chattering sound in Ｏ
operation of relay? (1) Check it by ears. (1) No abnormal sign allowed.
Relay (2) Is there any damage in contact Ｏ (2) Check it by eyes. (2) No abnormal sign allowed.
point?

(1) Visually check (cement resistor,

(1) Is there any damage in Ｏ
wound-type resistor). (2) Make sure that resistance value
insulation of resistor? Tester / Digital
Resistor (2) Check resistor for any open Ｏ
(2) Take off a connection on one is within tolerance of resistance
multi-tester
side and use tester to measure reading ±10%.
circuit?
resistance.

(1) Check if each inter-phase output Ｏ

(1) In case of inverter for inter-
voltage is unbalanced during the
(1) Measure voltage among U, V and phase voltage balance 200V
operation of inverter. Digital multi-tester
Operation W phase of inverter output terminal. (400V), make sure that the voltage
(2) Perform sequence protection Ｏ / Rectification-type
check (2) Short or open inverter protection is less than 4V (8V).
operating test, and make sure that voltmeter
circuit output by force. (2) Check if abnormal circuit works
there is no abnormal sign in
by sequence.
indication circuit.

(1) Is there any abnormal vibration Ｏ

(1) Turn OFF power and manually
or sound? (1) Rotate fan smoothly.
Cooling fan (2) Is there any connection Ｏ
rotate fan.
(2) No abnormal sign allowed.
(2) Tighten connection once again.
loosened?

(1) Here, lamp refers to surface

(1) Is LED lamp turned ON? Ｏ
Indication (2) Clean-up Ｏ
display lamp of panel. (1) Check if LED is turned ON.
(2) Clean up.

Make sure that indication

Check indication of meters on panel Voltmeter /
Meter Is indication normal? Ｏ
surface.
complies with value of
ammeter, etc
specification and management.

(1) Is there any abnormal vibration Ｏ (1) Check by ears, hands and eyes.
Motor or sound? (2) Check if there is any abnormal (1),(2) No abnormal sign allowed.
(2) Is there any odd odor? Ｏ signs like overheat and damage.

Motor
(1) Mega-check (Between output (1) Unlock connection of U, V and W (1) Make sure that resistance is
insulation terminal and ground terminal)
Ｏ
and bind up motor wiring. read over 5MΩ.
500V Mega
resistance

54 /108
3. Hardware Inspection & Repair III. Preventive maintenance

III. Preventive maintenance

Standard
Name of Parts Years of How to Change ᆞ Others
Conversion
Cooling fan 2 ~ 3 years Replace fan with a new one.
Replace condenser with a new
Smoothing condenser 5 years
one (Determine by CHECK).
Brake relay Determine by CHECK.
Determine by CHECK on
Timer
working time.
Fuse 10 years Replace fuse with a new one.
Replace condenser with a new
Aluminum condenser on PCB plate 5 years
one (Determine by CHECK).

 Years of replacement may vary depending on working

environment (ambient temperature, ventilation conditions)
and utilization (Load factor, voltage application hour rate).
 Consider reduction of replacement frequency if inverter
falls into the following items:

① Place of high temperature and humidity or place of significantly changing

temperature and humidity
② Frequent repetition of operation and stop
③ Significant variation of power (voltage, frequency and waveform distortion) and
load
④ Installation on any place of high vibration and impact
⑤ Use in poor environments such as wear, salt, harmful gas (sour gas and hydrogen
sulfide) and oil dust
⑥ Poor storage conditions and long-term storage before use
⑦ When power capacity is much higher than capacity of inverter (10 times or more)

55 /108
3. Hardware Inspection & Repair IV. Basic matters of inspection

IV. Basic matters of inspection

1) Visual Inspection
⑴ Visual Inspection: When a report about any hardware problem due to product
malfunction and failure is received, perform an initial visual inspection to check
hardware for mounting status and any abnormal sign in outer appearance.

Visual Inspection

* Mounting status * * Appearance *

- Check if mounted parts are - Check PCB and each part for
identical with those on the PART LIST. introduction of unexpected materials
- Check if any parts with polarity (IC, (water, dust, oil, metallic substances, gas,
TR, diode, condenser, etc) show etc) as well as corrosive conditions.
change of polarity. - Check if each part is damaged.
- Check if there is any part missing - Check if the legs of each part are cut
(not mounted). properly.
- Check if the height of mounted - Check connectors and cables for
parts is constant. engagement status.
- Check bolts for tightening status.
- Check if there is any inferior soldering.

56 /108
3. Hardware Inspection & Repair IV. Basic matters of inspection

IV. Basic matters of inspection

2) Load Test
⑵ Load Test: When any proper measures are taken normally during checkups on
malfunctioning products, perform a final load test to check if inverter works
normally.

Checkup on
• There are different terminal layouts depending on capacity. So pay special attention to
power
check input power specification (220V/440V). Then,
specification and
• Connect input power (R,S,T) with motor wiring (U,V,W).
POWER terminal

• Introduce input power (R,S,T) and connect motor wiring (U,V,W) in the following manner:
Connection of • Determine, install and use braking resistor depending on its purpose of use, and connect
POWER input power with inverter output terminal (U,V,W).
terminal • When power is introduced or braking resistance terminal (P(+), B) or (P(+), N(-)) is
randomly shorted, inverter may be damaged.

• When wiring is properly finished, set operation command and frequency command by
each parameter to perform startup of motor.
• When inverter is operated by means of DMM, check output voltage of each phase (U,V,W)
(Within inter-phase voltage balance rate + 3%) to monitor normal output (Note that the
Load test value of output voltage may vary depending on input voltage and operation frequency).
• Use SCOPMETER and current PROBE to check output current at each phase (U, V, W)
when motor is started up (Within inter-phase current balance rate ±10%) to monitor
normal output (Note that the value of output current may vary depending on working
frequency and load).

57 /108
3. Hardware Inspection & Repair V. POWER CUIRCUIT

V. Checkup of POWER CUIRCUIT Module

Test Polarity Check
Number
Test Polarity Check
+ - Value + - Value
1) Checkup of I/O MODULE
R DCP+ Closed R N Open
D1 D4
DCP+ R Open N R Closed

S DCP+ Closed S N Open

Diode D2 D5
DCP+ S Open N S Closed

T DCP+ Closed T N Open

D3 D6
DCP+ T Open N T Closed

U DCP Closed U N Open

Tr1 Tr4
DCP U Open N U Closed

V DCP Closed V N Open

IGBT Tr2 Tr6
DCP V Open N V Closed

W DCP Closed W N Open

DIODE TYPE Tr3 Tr2
DCP W Open N W Closed

Test Polarity Check Test Polarity Check

Module Number
+ - Value + - Value

R DCP+ Closed R N Open

D1 D4
DCP+ R Open N R Closed
Diode
S N Open T N Open
D5 D6
N S Closed N T Closed

U DCP Closed U N Open

Tr1 Tr4
DCP U Open N U Closed

V DCP Closed V N Open

IGBT Tr3 Tr6
DCP V Open N V Closed

SCR TYPE Tr5

W DCP Closed
Tr2
W N Open

DCP W Open N W Closed

58 /108
3. Hardware Inspection & Repair V. POWER CUIRCUIT

V. Checkup of POWER CUIRCUIT

2) Instruction for replacement of IGBT

In the following procedure, check if IGBT is damaged:

1) Check if power supply is completely turned OFF, and check if voltage at terminal P, N of inverter drops
within 25V.
Simple 2) Completely disconnect inverter output wire.
examination 3) Refer to preceding page to check if circuit is short or open.
4) Check diode value of gate section.
5) If there is any abnormal sign detected by checkup, it is certain that IGBT is damaged. Even if there is any
abnormal sign, it is likely that IGBT is damaged. Therefore, disconnect FUSE and check it up again.
(Even if only one phase of IGBT is damaged, be sure to consider that the damage affects other phases as
properly. )

Decision of ※ If one phase or two phases are damaged, consider period of use and diode value to judge if whole of
replacement IGBT is replaced with a new one.

1) Disconnect any damaged IGBT and wipe out any compound remaining in the heat sink etc.
2) Apply a uniform thickness of compound to new IGBT.
Replacement 3) For screws, engage them all loosely 2 to 3 times at first and tighten them with same torque in the
procedure (recommended) of right figure, so that there is no gap formed.
work
4) BE CAREFUL TO apply soldering to avoid unfinished or inferior soldering. For contact-type screws, tighten
them so that they reach the surface of contact correctly.

59 /108
 3. Hardware Inspection & Repair V. POWER CUIRCUIT

V. Checkup of POWER CUIRCUIT

2) Instruction for replacement of IGBT 1

How to apply compound Module

▶ Make sure that there is no foreign substances left on surface of coating and
contact. Compound
- Before work, use brush to clearly wipe out any surface of coating.

▶ Make sure that there is no compound smeared on screw hole and screw.
Heat Sink
▶ Apply compound so that it comes out slightly from the vicinity of module.
1

Procedure of assembly Procedure of assembly BE SURE TO tighten

(Screw engagement) (Screw engagement) screw.

Temporary tightening: ①→② Temporary tightening: ①→③→②→④

Final tightening: ②→① Final tightening: ④→②→③→①

Temporary tightening: ①→③→②→④ Temporary tightening: ①→⑤→④→⑧→②→③→⑥→⑦

Final tightening: ④→②→③→① Final tightening: ⑦→⑥→③→②→⑧→④→⑤→①
▶ BE SURE TO use screw to assemble BE SURE TO lock up
▶ Temporarily assemble one side of IGBT before complete assembly.
immovable region of contact surface – screw.
▶ For assembly, apply moderate torque fit for screw – Prevent
Avoid any poor contact by vibration,
occurrence of shift.
etc.

60 /108
3. Hardware Inspection & Repair VI. iS7

VI. Checkup of iS7 by Nature of Failure

1) OVER CURRENT1 TRIP ( IOLT, GFT )
Checkup of I/O MODULE Proper measures
for abnormal cases
※ Even when check value is normally measured, it is likely that there is any abnormal
problem. In terms of soldering method, check if soldering is inferior or unfinished. In ※ Replace PIM, IGBT with a
terms of contact method, check if there is any foreign substance or damage in contact. new one.

Checkup of CT

* How to perform measurement in case of any abnormal conditions: Proper measures

1) CT consists of 4 parts such as 15P, 15N, 5G and OUT. Check CT operation voltage for abnormal cases
(15P-DCN, 15N-DCN) and check OUT voltage at load operation (OUT voltage may vary - For small capacity, replace
depending on type of CT). POWER PCB with a new one.
2) When voltage is generated over reference level without any load current, it is likely that For middle or high capacity,
replace CT Board with a new
C/T is in poor conditions. one.
※ When CT works out of order, H/W TRIP (ADC OFFSET) may occur in addition to OC.

SV0110IS7-4 SV0750IS7-4 Reference

Circuit CHECKPOINT
Value
C70 both
50mV (Offset voltage)
IU Terminal
at load current of 0A
CT1:3-4
C73 both
50mV (Offset voltage)
IV Terminal
at load current of 0A
CT2:3-4
C76 both
CT3-3PIN CT3-4PIN CT2-3PIN CT2-4PIN 50mV (Offset voltage)
IW Terminal
at load current of 0A
CT1-3PIN CT1-4PIN CT3:3-4

C74 both C77 both C80 both

terminal terminal terminal

61 /108
3. Hardware Inspection & Repair VI. iS7
Proper measures for abnormal
cases

Checkup of SMPS (POWER PCB or SMPS PCB) ※ Replace POWER or SMPS

PCB with a new one.
* How to perform measurement in cases of abnormal conditions:
1) If all of circuit output voltages are abnormal
Place of
: Consider that there may be any abnormal sign on TRANS and switching part. measurement
2) If only output voltage of certain circuit is abnormal Allowable
No. Items
range (V)
: Check relevant circuit. TEST
PAD
※ In case of product with 30kW or higher power consumption, H/W TRIP (Gate Power Loss) or D11:2-
equivalent problems may occur when 15V circuit works out of order. 1 5P 4.8~5.2V 5P-5G
Q10:4

5P(D11:2) 15P(D12:2) 15N(D13:1) P24(C14:1-C14:2) D12:2-

2 15P 15.1~17.6V 15P-5G
Q10:4

D13:1-
3 15N -15.1~-17.6V 15N-5G
Q10:4

TR1:3- PSCR-
4 PSCR 5.8~7.0V
PC1:3 GSCR

D18:2-
5 /PP15 17.1~18.9V /PP15-E
ZD8:1

ZD8:2-
6 /NN10 -4.8~-5.8V E-/NN5
ZD8:1

D14:2-
7 PU 17.1~18.9V PU-GEU
ZD5:2

ZD5:2-
8 NU -4.8~-5.8V GEU-NU
ZD5:1

D16:2-
9 PV 17.1~18.9V PV-GEV
ZD6:1

ZD6:2-
10 NV -4.8~-5.8V GEV-NV
ZD6:1

D17:2-
5G(Q10:4) Common 11 PW 17.1~18.9V PW-GEW
ZD7:2

ZD7:2- GEW-
EX. SMPS PCB (18.5~22KW) 12 NW -4.8~-5.8V
ZD7:1 NW

C14:1-
13 P24I 22.0~26.0V P24I-CM
C14:2

62 /108
3. Hardware Inspection & Repair VI. iS7

Allowable Place of measurement

Checkup of SMPS (POWER PCB or SMPS PCB) No. Items
range (V) TEST PAD
15N(D10:1) 1 5P 4.8~5.2V D13:2-Q10:4 5P-5G

2 15P 15.1~17.6V D11:2-Q10:4 15P-5G

3 15N -15.1~-17.6V D10:1-Q10:4 15N-5G

4 PSCR 5.5~7.5V TR3:3-PC7:3 PSCR-GSCR

5 P15 14.85~15.15V C75:2-C75:1 P15-G15

6 P15G 19~21V C80:2-C80:1 P15G-G15

5P(D13:2)
7 PU 14~17V PC6:13-ZD12:2 PU-MU
15P(D11:2)
8 NU 11~15V PC6:10-ZD12:2 NU-MU

9 /PU 14~17V PC3:13-ZD6:2 /PU-/MU

5G(Q10:4)
Common 10 /NU 11~15V PC3:10-ZD6:2 /NU-/MU

11 PV 14~17V PC5:13-ZD10:2 PV-MV

12 NV 11~15V PC5:10-ZD10:2 NV-MV

13 /PV 14~17V PC2:13-ZD4:2 /PV-/MV

14 /NV 11~15V PC2:10-ZD4:2 /NW-/MV

15 PW 14~17V PC4:13-ZD8:2 PW-MW

P24I(C84:1-C84:2)
16 NW 11~15V PC4:10-ZD8:2 NW-MW

17 /PW 14~17V PC1:13-ZD2:2 /PW-/MW

18 /NW 11~15V PC1:10-ZD2:2 /NW-/MW

EX. SMPS PCB (75~90KW) 19 P24I 23~27V C84:2-C84:1 P24I-CM

20 P24F 22.0~26.0V R28:1-R28:2 P24F-24N

63 /108
3. Hardware Inspection & Repair VI. iS7

Checkup of CONTROL PCB

* How to perform measurement in cases of abnormal conditions:

- If there is any problem in the relevant circuit, it is likely that current display shakes on
keypad or abnormal trip (e.g. GFT) occurs when load operation of finished product is in Proper measures
progress. for abnormal cases
- For small capacity, replace
※ When CPU failure occurs, there may be occurrence of various malfunctions. POWER PCB with a new one.
- For middle or high capacity,
replace CT Board with a new
one.
U3 IC #9

U2
U3
IC
IC Circuit Checkpoint Reference Value
#2
#2

50mV (Offset voltage)

IU IN U3 IC 2PIN-5G
at load current of 0A

50mV (Offset voltage)

IV IN U3 IC 9PIN-5G
at load current of 0A
5G
50mV (Offset voltage)
IW IN U2 IC 2PIN-5G
at load current of 0A

64 /108
3. Hardware Inspection & Repair VI. iS7

VI. Checkup of iS7 by Nature of Failure

2) OVER VOLTAGE TRIP ( LOW VOLTAGE TRIP )
Checkup of I/O MODULE

Measurement of DC LINK Voltage

POWER PCB

* How to perform measurement in cases of abnormal conditions:

1) Check if both terminal DC voltage of DCP-DCN is normal.
2) Check if voltage value of U6 #4 -5G is output within 0~5.0V depending on the value of Proper measures
input voltage (See Table 1-1). for abnormal cases

※ Replace POWER PCB with

a new one

VDC ④ ① 5G
(U6 IC #④ PIN) ⑤ ② (U6 IC #② PIN)
③
Circu Reference
CHECKPOINT
it Value
See Table
VDC VDC-5G
1-1.

400V TYPE 200V TYPE

Items
(DC V) (DC V)
LV
460±20V 230±10V
Recovery
Ex. SV0075IS7-4 LV 360±20V 180±10V
POWER PCB
OVT 820±20V 400±10V

65 /108
3. Hardware Inspection & Repair VI. iS7

Measurement of DC LINK Voltage

POWER or SMPS PCB

DCL DCL
Ex. SV0185IS7-4
VDC_AD(V) Proper measures
(220V TYPE) (440V TYPE) POWER PCB for abnormal cases
65.7V 131.4V 0.5V ※ Replace POWER PCB or
SMPS with a new one.
131.4V 262.8V 0.9V

197.2V 394.4V 1.7V

262.9V 525.8V 2.5V

328.6V 657.2V 3.3V ④ ①

⑤ ②
394.3V 788.6V 4.1V ③
433.7V 867.4V 5.0V
Table 1-1

Ex. SV0750IS7-4
MAIN SMPS PCB Circu Reference
CHECKPOINT
it Value
See Table
VDC VDC-5G
1-1.
VDC(U5 IC 4PIN) 5G(U5 IC 2PIN)

400V TYPE 200V TYPE

Items
(DC V) (DC V)
5G(R72, Right)
LV
460±20V 230±10V
recovery
VDC(U6 IC 1PIN) LV 360±20V 180±10V

OVT 820±20V 400±10V

66 /108
3. Hardware Inspection & Repair VI. iS7
Proper measures
for abnormal cases
- In case of VDC-5GA →
Measurement of DC LINK Voltage
Replace POWER PCB
CONTROL PCB with a new one.
- In case of VDCOUT-5GA
* How to perform measurement in cases of abnormal conditions: → Replace CONTROL
- Check VDC circuit inside CONTROL PCB to see if there is almost no difference between PCB with a new one.
input value and output value (Input value is voltage value of U5 #1 -5G). Table 2-1
DCL DCL
VDC-5GA VDCOUT-5GA VDC_AD(V)
(220V TYPE) (440V TYPE)
(C61 both terminal) (C51 both terminal)
65.7V 131.4V 0.5V

131.4V 262.8V 0.9V

197.2V 394.4V 1.7V

262.9V 525.8V 2.5V

328.6V 657.2V 3.3V

394.3V 788.6V 4.1V

433.7V 867.4V 5.0V

Table 2-2
DCL DCL
VDC_AD(V)
(220V TYPE) (440V TYPE)

65.7V 131.4V 0.5V

131.4V 262.8V 1.0V

Reference Reference 197.2V 394.4V 1.5V
Circuit Checkpoint Circuit Checkpoint
value value
262.9V 525.8V 2.0V
C61 both See Table U6 IC 4PIN- See Table
VDCOUT VDCOUT 328.6V 657.2V 2.5V
terminal 2-1. 5G 2-2.
394.3V 788.6V 3.0V

433.7V 867.4V 3.3V

67 /108
3. Hardware Inspection & Repair VI. iS7

V. Checkup of iS7 by Nature of Failure

3) In case of Power-insensitiveness Proper measures
for abnormal cases
Checkup of I/O MODULE
※ Replace PIM, IGBT with a
new one.
Checkup of Charge Resistor

R56/ R60/ R54/ R67/ R72/ R66/ R1~ R1~ R

Classification Classification
R57 R61 R55 R68 R73 R72 R4 R8 pre
Proper measures
for abnormal cases
5W
SV0008~ SV0110~ 10W
0015iS7-2
200J
0150iS7-4 50J*2 - If only Charge Resistor is
*1
damaged
→ Replace only Charge
5W
SV0008~ SV0185~ 10W Resistor with a new
200J
0015iS7-4
*1
0220iS7-2 20J*4 one.
- If PCB is damaged twice
5W → Replace PCB with a new
SV0022~ SV0185~ 5W
200J one.
0037iS7-2 0220iS7-4 20J*8
*2

5W
SV0022~ 60W
200J SV0300iS7-4
0037iS7-4 60J*1
*2

10W
SV0055~ SV0370~ 60W
100J
0075iS7-2 0450iS7-4 40J*1
*2

10W 150
SV0055~ SV0550~
100J W
0075iS7-4 0750iS7-4
*2 30J*1

10W 400
SV0110~ SV0900~
20J* W
0150iS7-2 1600iS7-4
2 15J*1

68 /108
3. Hardware Inspection & Repair VI. iS7

Measurement of DC LINK Voltage

CONTROL PCB

POWER or SMPS PCB

Measurement of CONTROL PCB Power Level Voltage

* How to perform measurement in cases of abnormal conditions:

1) Check if working voltage (5P-5G) of IC (U1) is 5V. Proper measures
for abnormal cases
2) Unless only certain voltage (3.3V, 1.9V) is output, perform checkup on relevant circuits.
3) Unless neither 3.3V nor 1.9V is output, it is likely that U1 IC and CPU IC work out of - In case that 3.3P, 1.9P,
order. 3.3PA are abnormal
→ Replace CONTROL PCB
with a new one.
- In case that 5P is abnormal
→ Replace POWER or SMPS
PCB with a new one.

Circuit Checkpoint Reference

Value (V)
3.3P C3 both 3.23~3.37
terminal
1.9P C6 both 1.86~1.94
terminal
5P(C2:1-C2:2) 3.3PA C7 both 3.23~3.37
1.9P(C6:1-C6:2) terminal
3.3PA(C7:1-C74:2)
5P C2 both 4.93~5.07
3.3P(C3:1-C3:2)
terminal

69 /108
3. Hardware Inspection & Repair VII. iG5A

VII. Checkup of iG5A by Nature of Failure

1) OVER CURRENT1 TRIP( IOLT, GFT )
Checkup of I/O MODULE

Checkup of Shunt Resistance

Class.. SHUNT R CHARGE R

004-2 MPS-2 21mm[1] 5W 200Ω [1]

008-2 MPS-2 10mm[1] 5W 200Ω [1]

R57 (SHUNT 004-4 MPS-2 30mm[2] 5W 200Ω [1]

resistance)
008-4 MPS-2 20mm[2] 5W 200Ω [1]

015-2 MPS-2 15mm [1] 5W 200Ω Proper measures

R54,59
(SHUNT for abnormal cases
Ex. SV008iG5A-4 015-4 MPS-2 20mm [1] 5W 200Ω
resistance) ※ Replace SHUNT R or
POWER PCB
022-2 MPS-2 10mm [2] 5W 200Ω [2] POWER or MAIN PCB with
a new one.
037-2 MPS-2 6mm [3] 5W 200Ω [2]

022-4 MPS-2 10mm [1] 5W 200Ω [2]

037-4 MPS-2 6mm [1] 5W 200Ω [2]

055-2 MPS-2 4mm [2] 10W 40Ω [2]

075-2 MPS-2 4mm [3] 10W 40Ω [2]

055-4 MPS-2 8mm [2] 10W 100Ω [2]

Ex. SV075iG5A-4
MAIN PCB 075-4 MPS-2 6mm [2] 10W 100Ω [2]

70 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of OCT Detection Circuit

SV008IG5A-4 MAIN PCB & SV075IG5A-4 MAIN PCB

Proper measures
for abnormal cases

※ Replace MAIN PCB with a

new one.

Circuit Checkpoint Reference Value

LOW output (0V)

OCT(C43 both terminal) U2 IC 4PIN-
Itrip-DCN at load current of
U2 IC 7PIN
0A
SV075iG5A-4
LOW output (0V)
MAIN PCB OCT-DCN
C43 both
at load current of
terminal
0A
DCN(U2 IC 4PIN) Itrip(U2 IC 7PIN)

SV008iG5A-4
MAIN PCB

71 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of OCT Detection Circuit

SV220IG5A-4 POWER PCB

Proper measures
for abnormal cases

※ Replace CT or POWER
PCB with a new one.

IW (C77 both
terminal)

IU (C72 both
terminal)

Circuit Checkpoint Reference Value

C72 both 50mV at load

IV (C74 both IU
terminal current of 0A
terminal)
C77 both 50mV at load
IV
terminal current of 0A
C74 both 50mV at load
IW
terminal current of 0A

72 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of OCT Detection Circuit

SV220IG5A-4 CONTROL PCB

Proper measures
for abnormal cases

※ Replace CONTROL PCB

with a new one.

OCT (C46 both

terminal)

Circuit Checkpoint Reference Value

High output (3.3V)

OCT- C46 both
at load current of
G3.3A terminal
0A

73 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of SMPS

SV008IG5A-4 MAIN PCB

N15 (CN1:1) Proper measures

for abnormal cases
P15 (CN1:2) P24I (D1:2)
※ Replace MAIN PCB with a
new one.
P3.3 (CN1:4) CM(U5:2
Common)

Reference
Circuit Checkpoint
Value (V)

P3.3 CN1;4-CN1:17 3.23~3.37

DCN (CN1:17 CN1;2-CN1:17

Common) P15 15.7~16.8

N15 CN1;1-CN1:17 -14.5~-15.5

P24I D1:2-U5:2 23.0~25.0

①②③
P5I U5:3-U5:2 4.9~5.2
P5I (U5:3)

74 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of SMPS

SV075IG5A-4 MAIN PCB

Proper measures
for abnormal cases

※ Replace MAIN PCB with a

new one.

Reference
Circuit Checkpoint
DCN(Common) Value (V)
P15(R87) N15(D19:1)
C2 both
P3.3 3.23~3.37
terminal
R87 both
P15 14.7~15.8
terminal
P3.3(C2 both
terminal) N15 D19:1-DCN -14.7~-15.8

①②③ P5I U6:3-CM 4.9~5.2

P24I D2:2-CM 23.0~25.0

CM(U6:2 Common)
P5I(U6:3) P24(D2:2)

75 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of SMPS

SV220IG5A-4 POWER PCB

Proper measures
for abnormal cases

※ Replace POWER PCB with

a new one.

Reference
Circuit Checkpoint
Value (V)
P24I(C6 both
terminal) C112 both
P3.3 3.23~3.37
terminal
C105 both
15P 14.7~15.8
P3.3(C112 15P(C105 terminal
15N(C111 both
both terminal) both terminal)
terminal) C111 both -14.7~-
15N
terminal 15.8
①②③ U16:2-
P5I 4.9~5.2
U16:3
C6 both
P24I 23.0~25.0
terminal

CM(U16:2) P5I(U16:3)

76 /108
3. Hardware Inspection & Repair VII. iG5A

VII. Checkup of iG5A by Nature of Failure

2) OVER VOLTAGE TRIP( LOW VOLTAGE TRIP )
Checkup of I/O MODULE

Measurement of DC LINK Voltage

SV008IG5A-4 MAIN PCB & SV075IG5A-4 MAIN PCB

VDC_AD(R4 both
terminal)
Proper measures
DCL DCL for abnormal cases
VDC_AD(V)
(220V TYPE) (440V TYPE)
※ Replace MAIN PCB with a
65.7V 131.4V 0.5V new one
131.4V 262.8V 1.0V

197.2V 394.4V 1.5V

262.9V 525.8V 2.0V

328.6V 657.2V 2.5V

394.3V 788.6V 3.0V

433.7V 867.4V 3.3V Reference

Circuit Checkpoint
Value
R4 both
VDC_AD See Table.
terminal
R50 both
VDC_AD See Table.
terminal

VDC_AD(R50
both terminal)

77 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of DC LINK Voltage

SV220IG5A-4

POWER PCB Proper measures

VDC (C8 both for abnormal cases
terminal) ※ Replace POWER PCB with
DCL DCL a new one.
VDC_AD(V)
(220V TYPE) (440V TYPE)

65.7V 131.4V 0.5V

131.4V 262.8V 1.0V

197.2V 394.4V 1.5V

262.9V 525.8V 2.0V

328.6V 657.2V 2.5V

394.3V 788.6V 3.0V

433.7V 867.4V 3.3V

CONTROL PCB

Reference
Circuit Checkpoint
Value
C8 both
VDC See Table.
terminal
VDC_AD C15 both
See Table.
terminal
VDC_AD(C15 both
terminal)

78 /108
3. Hardware Inspection & Repair VII. iG5A

VII. Checkup of iG5A by Nature of Failure

3) Power-insensitiveness
Checkup of I/O MODULE

Measurement of DC LINK Voltage

Checkup of SMPS

Proper measures
for abnormal cases

※ Replace MAIN PCB with a

new one.

Reference
P15 (C45 both Circuit Checkpoint
P15 (C20 both Value (V)
terminal)
terminal)
C20 both
P15 14.7~15.8
terminal
C45 both
P15 14.7~15.8
terminal

79 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of CONTROL PCB (11kW or higher)

SV220IG5A-4

Proper measures
for abnormal cases

※ Replace CONTROL PCB

with a new one.

Reference
Circuit Checkpoint
Value (V)
P24I (C11 both P5I (C12 both terminal)
terminal) P3.3 (C8 both C8 both
terminal) P3.3 3.23~3.37
terminal
G3.3 CP2 both
P15 (CP2, Right) P15 15.7~16.8
Common terminal
CP3 both
N15 -14.5~-15.5
terminal
C11 both
P24I 23.0~25.0
terminal
C12 both
P5I 4.9~5.2
terminal

N15 (CP3,
Right)

80 /108
3. Hardware Inspection & Repair VII. iG5A

Checkup of I/O BOARD

Proper measures for abnormal

cases

※ Replace I/O BOARD with

P5I (TEST PIN) a new one.

P24I (TEST PIN)

Reference
Circuit Checkpoint
Value (V)

P5I P5I-CM 4.9~5.2

P24I P24I-CM 23.0~25.0

CM Common

81 /108
3. Hardware Inspection & Repairing VIII. iP5A

VIII. Checkup of iP5A by Nature of Failure

1) OVER CURRENT1 TRIP ( IOLT, GFT )
Checkup of I/O MODULE

Checkup of CT

SV055~110IP5A-2/4 POWER PCB

Proper measures
for abnormal cases

※ Replace POWER PCB with

a new one.

IUIN(R38 top)

IVIN(R36 top)

IWIN(R34 top)

Reference
Circuit Checkpoint
Value (V)
5G(C21 Right) R38 top under
Common IUIN-5G
-C21 Right 50mV
R36 top under
IVIN-5G
-C21 right 50mV
R34 top under
IWIN-5G
-C21 right 50mV

82 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of CT

SV150~300IP5A-2/4 DM-CT

* How to perform measurement in cases of abnormal conditions: Proper measures

- OUT voltage may vary depending on type of CT. Check CT operation voltage for abnormal cases
(15P-DCN, 15N-DCN) and check OUT voltage at load operation according to following ※ Replace DM-CT PCB with
formula. a new one.
ex) when 8.2A current flows at rated 15A 4V CT, (8.2*1.414+0.5)*4/15=3.22528V

Circuit Checkpoint Reference Value (V)

OUT-5G
50mV at load current
IU
of 0A
④③②① CT1:3-4
OUT-5G
50mV at load current
IV
of 0A
CT2:3-4
OUT-5G
50mV at load current
IW
of 0A
5G OUT 15N 15P CT3:3-4

83 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of CT

SV370~900IP5A-2/4 MAIN SMPS

Proper measures
for abnormal cases

※ Replace MAIN SMPS PCB

with a new one.

Circuit Checkpoint Reference Value (V)

IUIN(R96 right)
IVIN(R99 left) 5G common IUIN-
R96:right-5G OFFSET under 50mV
5G
IWIN(R102 left)
IVIN-
R99:left-5G OFFSET under 50mV
5G
IWIN-
R102:left-5G OFFSET under 50mV
5G

84 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of Charge Resistor

SV150~300IP5A-2/4 DM-CT

Class. SHUNT R

055-2 13.3KF, 1/8W

055-4 14.7KF, 1/8W

075~110-2 14.3KF, 1/8W

075-4 13.3KF, 1/8W

110-4 11.5KF, 1/8W

150~185-2/4 13.3KF, 1/8W Proper measures

for abnormal cases
220~300-2/4 17.8KF, 1/8W
※ Replace DM-CT PCB or
370-4 15.4KF, 1/10W
Shunt Resistance with
450-4 20.0KF, 1/10W a new one.
550-4 16.9KF, 1/10W

750-4 20.0KF, 1/10W

900-4 19.1KF, 1/10W

1100-4 13.7KF, 1/10W

1320~1600-4 16.5KF, 1/10W

2200-4 18.2KF, 1/10W

2800-4 16.2KF, 1/10W

SHUNT R(RM1, RM2, RM3) 3150-4 11.5KF, 1/10W

3750~4500-4 14.7KF, 1/10W

85 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of SMPS

V055~110IP5A-2/4 POWER PCB

Proper measures
for abnormal cases

※ Replace POWER PCB with

a new one.

Reference
Circuit Checkpoint
Value (V)

5P-5G 5P-5G 4.9~5.2V

15N 15P

15P-5G 15P-5G 14~16V

15N-5G 15N-5G -14~-16V

DCN 24P 24G
5P 5G 공통
24P-24G 24P-24G 23.0~26.0V

PP15-DCN PP15-DCN 14.0~16.0V

NN10-DCN NN10-DCN 9.0~11.0V

NN10 PP15

86 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of SMPS
Proper measures
SV150~300IP5A-2/4 DRV-SMPS PCB for abnormal cases

※ Replace DRV-SMPS PCB

with a new one.

Reference
Circuit Checkpoint
Value (V)

5P-5G PC2:3PIN-4PIN 4.9~5.2V

PP15-5G PC6:12PIN-PC2:4PIN 14~16V

NN10(PC6:9PIN) PP15(PC6:12PIN)
5G(PC2:4PIN)공통 5P(PC2:3PIN) NN10-5G PC6:9PIN-PC2:4PIN -9.0~-11.0V

87 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of SMPS

SV150~300IP5A-2/4 CON-SMPS PCB

Proper measures
for abnormal cases

※ Replace CON-SMPS PCB

15P(C38 both terminal)
with a new one.

5P(C35 both terminal)

15N(C39 both terminal)

Reference
Circuit Checkpoint
Value (V)

24P-24G C41 both terminal 23~25V

24PF-24GF C42 both terminal 23~25V

24P(C41 both terminal) 24PF(C42 both C38 both terminal

terminal) 15P-5G (pay attention to 14~16V
the polarity)
C39 both terminal
15N-5G (pay attention to -14~-16V
the polarity)
C35 both terminal
5P-5G (pay attention to 4.9~5.2V
the polarity)

88 /108
3. Hardware Inspection & Repairing VIII. iP5A

Checkup of SMPS

SV370~900IP5A-2/4 MAIN SMPS PCB

Proper measures
for abnormal cases

※ Replace MAIN SMPS PCB

with a new one.

Reference
Circuit Checkpoint
Value (V)

5P-5G 5P-5G 4.9~5.2V

15P-5G 15P-5G 14~16V

5P 15p 5G Common 15N
P15 G15 15N-5G 15N-5G -14~-16V

P15-G15 P15-G15 14.0~16.0V

P15A-24G P15-DCN 14.0~16.0V

N15A-24G N15-DCN 14.0~16.0V

24P-24G 24P-24G 23.0~26.0V

24P 24G P15A N15A

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of SMPS

SV370~900IP5A-2/4 DRV-SMPS PCB

Proper measures
for abnormal cases

※ Replace DRV-SMPS PCB

with a new one.

Reference
Circuit Checkpoint
Value (V)
PC2:3PIN-
5P-5G 4.9~5.2V
PC2:4PIN
5G(PC2:4PIN) Common P15(U1:13PIN) P15:13PIN-
P15-5G 14~16V
PC2:4PIN
5P(PC2:3PIN) G15(R47)

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of CONTROL PCB

SV055~300IP5A-2/4 CONTOL PCB & SV370~900IP5A-2/4 CONTOL PCB

Proper measures
for abnormal cases

※ Replace CONTROL PCB

OCT(C25 both terminal) with a new one.

Reference
Circuit Checkpoint
Value (V)
LOW
C25 both
OCT-5G About under
terminal
0.5V

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3. Hardware Inspection & Repairing VIII. iP5A

VIII. Checkup of iP5A by Nature of Failure

2) OVER VOLTAGE TRIP( LOW VOLTAGE TRIP )
Checkup of I/O MODULE

Checkup of VDC Circuit

SV055~110IP5A-2/4 POWER PCB

Proper measures
for abnormal cases

※ Replace POWER PCB with

a new one.

DCL DCL
VDC_AD(V)
(220V TYPE) (440V TYPE)

65.7V 131.4V 0.5V

131.4V 262.8V 0.9V

197.2V 394.4V 1.7V

VDC(R46 bottom) 5G(C34 (-)terminal)
262.9V 525.8V 2.5V

Circuit Checkpoint Reference Value (V) 328.6V 657.2V 3.3V

394.3V 788.6V 4.1V

VDC-5G R46 bottom -C34 (-) terminal See table.
433.7V 867.4V 5.0V

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of VDC Circuit

SV370~900IP5A-2/4 MAIN SMPS

Proper measures
for abnormal cases

※ Replace MAIN SMPS PCB

with a new one.
5G

Reference Value
Circuit Checkpoint
(V)
U5:1PIN
VDC-5G See table.
-5G

DCL DCL
VDC_AD(V)
(220V TYPE) (440V TYPE)

65.7V 131.4V 0.5V

131.4V 262.8V 0.9V

VDC(U5:1PIN) 197.2V 394.4V 1.7V

262.9V 525.8V 2.5V

328.6V 657.2V 3.3V

394.3V 788.6V 4.1V

433.7V 867.4V 5.0V

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of CONTROL PCB

SV055~300IP5A-2/4 & SV370~900IP5A-2/4 CONTROL PCB

Proper measures
for abnormal cases

※ Replace CONTROL PCB

with a new one.

DCL DCL
VDC_AD(V)
(220V TYPE) (440V TYPE)

5G(D4 2PIN) VDCOUT(D4 3PIN) 5G(D14 2PIN) VDCOUT(D14 3PIN) 65.7V 131.4V 0.5V

131.4V 262.8V 1.0V

197.2V 394.4V 1.5V

Circuit Checkpoint Reference Value (V)
262.9V 525.8V 2.0V
VDCOUT-5G D4 3PIN-D4 2PIN See table. 328.6V 657.2V 2.5V

394.3V 788.6V 3.0V

433.7V 867.4V 3.3V

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3. Hardware Inspection & Repairing VIII. iP5A

VIII. Checkup of iP5A by Nature of Failure

3) Power-insensitiveness
Checkup of I/O MODULE

See the previous page.

Measurement of DC LINK Voltage

See the previous page.

Checkup of SMPS Output Voltage

See the previous page.

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of loader operating Voltage

Proper measures
SV055~300IP5A-2/4 CONTROL PCB for abnormal cases

- In case that 3.3P, 5P are

abnormal
→ Replace CONTROL PCB
with a new one.
- In case that VCC-5G is
abnormal
→ Replace loader with a new
one.

3.3P(D2 1PIN) 5G(D2 2PIN) Common

5P(L1 Left)
Reference
Circuit Checkpoint
Value (V)
LOADER
3.3P-5G D2 1PIN-D2 2PIN 3.1~3.5V

5P-5G L1 Left-D2 2PIN 4.9~5.1V

VCC-5G C11 both terminal 4.9~5.1V

VCC-5G(C11 both terminal)

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3. Hardware Inspection & Repairing VIII. iP5A

Checkup of loader operating Voltage

Proper measures
SV370~900IP5A-2/4 CONTROL PCB for abnormal cases

- In case that 3.3P, 5P are

abnormal
→ Replace CONTROL PCB
with a new one.
- In case that VCC-5G is
abnormal
→ Replace loader with a new
one.

5G(D2 2PIN) 3.3P(D2 1PIN) Common

5P(L1 Left) Reference

LOADER Circuit Checkpoint
Value (V)

3.3P-5G D2 1PIN-D2 2PIN 3.1~3.5V

5P-5G L1 Left-D2 2PIN 4.9~5.1V

VCC-5G C11 both terminal 4.9~5.1V

VCC-5G(C11 both terminal)

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3. Hardware Inspection & Repair IX. iC5

IX. Checkup of iC5 by Nature of Failure

1) OVER CURRENT1 TRIP (IOLT, GFT)
Checkup of I/O MODULE

Checkup of Shunt Resistance

SV004~008iC5-1/2
MOTHER PCB
Class.. SHUNT R (R1)

200V MPS-2 12m 1%

0.4kW 2W 12m-ohm 1%
200V MPS-2 8m 1%
0.8kW 2W 12m-ohm 1%
Proper measures
For abnormal cases
Shunt R
※ Replace SHUNT R or
SV015~022iC5-1 MAIN PCB with a new one.
POWER PCB
Class.. SHUNT R (R1,R100)

200V R1:2W 12m-ohm

1.5kW R100:2W 12m-ohm
200V R1:2W 8m-ohm
2.2kW R100:2W 8m-ohm

Shunt R

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3. Hardware Inspection & Repair IX. iC5

Checkup of OCT Detection Circuit

Proper measures
for abnormal cases

- In case of A FRAME
→ Replace MOTHER PCB
with a new one.
- In case of B FRAME,
→ Replace POWER PCB with
a new one.

SV004~008iC5-1/2 C18 (+) SV015~022iC5-1

MOTHER PCB terminal POWER PCB
Itrip(U1:14) Place of Reference
Items
measurement value
DCN(U1:18)
OCT Itrip ~DCN 0.24V~0.25V

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3. Hardware Inspection & Repair IX. iC5

Measurement of Current Detection OFFSET

Proper measures for abnormal

cases

- In case of A FRAME
→ Replace MOTHER PCB
with a new one.
- In case of B FRAME,
→ Replace POWER PCB with
a new one.

SV004~008iC5-1/2 IDC(U2:1) IDC(U2:1) SV015~022iC5-1

MOTHER PCB POWER PCB
DCN(U2:4)
DCN(U2:4) Place of Reference
Items
measurement value
IDC
Idc ~DCN 1.6V~1.7V
OFFSET

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3. Hardware Inspection & Repair IX. iC5

Checkup of SMPS Output Voltage

Proper measures for abnormal

cases
C30
- In case of A FRAME
→ Replace MOTHER PCB
with a new one.
- In case of B FRAME,
→ Replace CONTROL PCB
C31 C33 with a new one.

SV004~008iC5-1/2
Allowable
MOTHER PCB No. Items
range (V)
TEST PAD

1 P3.3~DCN 3.23~3.37 C33 #1 ~ DCN

SV015~022iC5-1
C26
CONTROL PCB 2 P15~DCN 16~17.5 C31 #1 ~ DCN

3 P5I~CM 4.9~5.2 C30 #1 ~ CM

4 P24I~CM 23.0~25.0 C26 #1 ~ CM

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3. Hardware Inspection & Repair IX. iC5

IX. Checkup of iC5 by Nature of Failure

2) OVER VOLTAGE TRIP( LOW VOLTAGE TRIP )
Checkup of I/O MODULE

Measurement of DC LINK Voltage

Proper measures for abnormal

cases

- In case of A FRAME
→ Replace MOTHER PCB
with a new one.
- In case of B FRAME,
→ Replace POWER PCB with
a new one.

DCL DCL
VDC_AD(V)
(220V TYPE) (440V TYPE)

65.7V 131.4V 0.5V

131.4V 262.8V 1.0V

SV004~008iC5-1/2 SV015~022iC5-1 R3 (+) 197.2V 394.4V 1.5V
MOTHER PCB POWER PCB terminal
262.9V 525.8V 2.0V

328.6V 657.2V 2.5V

394.3V 788.6V 3.0V

Checkup of SMPS Output Voltage
433.7V 867.4V 3.0V

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3. Hardware Inspection & Repair IX. iC5

IX. Checkup of iC5 by Nature of Failure

3) Power-insensitiveness
Checkup of I/O MODULE

Measurement of DC LINK Voltage

Checkup of SMPS Output Voltage

Judgment of CPU Failure

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Chapter 4.
Repair
Practice
4. Repair Practice
I. Disassembly Process

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4. Repair Practice
II. Checkup Process

106 /108
4. Repair Practice
III. Reassembly Process

107 /108
Q&A

108 /108