Control Module Replacement

Control Module Assembly Replacement Procedures For ALSPA
MV3000 MicroCubicles™
Introduction and Safety Instructions
Page 1
Replacement Of The Control Module

Assembly
Page 3
Box Contents
This instruction sheet (T1932).
One Control Module Assembly, S41Y7784/40.
Ribbon Cable Mounting Kit (Bagged).
Safety Instructions
WARNING
• Wait at least 5 minutes after isolating supplies and check that voltage
between DC+ and DC– has reduced to a safe level before working
on this equipment.
• This equipment may be connected to more than one live circuit.

Disconnect all supplies before working on the equipment.
CAUTION
This equipment contains solid state devices which may be affected by
electrostatic discharge. Observe static handling precautions.
Instruction Sheet T1932EN Rev. 0001 (01/01)

Page 1 of 20
The items described in this instruction sheet must only be used as spare parts in existing equipment. They must
only be used as a direct replacement for an item of the same number, unless otherwise stated. The prefix “S”
on some item numbers denotes “spare” and should be ignored when considering the replacement of an item.
The instructions in this instruction sheet and in the manual for the original product must be observed. Local
safety laws and regulations must always be observed. Failure to do so will invalidate product approvals and
certifications on the original equipment.
Persons working on the product must be suitably skilled and should have been trained in that work for these
products.
Related Documents
Failure to comply with any of the general requirements for installation, operation and maintenance
provided in the technical manuals will significantly increase the risk of maloperation, fire or electric
shock.
T1676 ALSPA MV3000 Getting Started Manual for AC-fed Drives
T1684 ALSPA MV3000 Dynamic Braking Units, MV3DB Series
T1925 Spares Replacement Procedures for ALSPA MV3000 Frame Size 3 MicroCubicles™
T2002 ALSPA MV3000 Getting Started Manual for Bi-directional Converters
Definitions
PCB Printed Circuit Board
SMPS Switch Mode Power Supply
CDC Common Drive Controller (Control Module Assembly)
Introduction
This instruction sheet contains procedures for the removal and replacement of the Control Module Assembly in
all ALSPA MV3000 MicroCubicles™.
Tool Requirements
Anti-static Wriststrap
Medium Cross Point Drive Screwdriver
Medium Flat Blade Screwdriver
Drive Data Manager™
24V DC Power Supply

Page 2 of 20
REPLACEMENT OF THE CONTROL MODULE ASSEMBLY (S41Y7784)

This Instruction Sheet is concerned with the replacement of the Control Module Assembly only. However, if the
Control Module Assembly and the SMPS PCB are to be replaced at the same time, the following
sequence must be used:
• Save the Drive Identity (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).
• Replace the SMPS PCB (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).
• Copy the Drive Identity from the original Control Module to the replacement SMPS PCB (see
“Reprogramming the Drive Identity” in the relevant Instruction Sheet).
• Replace the Control Module Assembly as described below.
• Recover the Drive Identity into the replacement Control Module as described below.
If these procedures are not followed fully or are followed in the wrong sequence, this could lead to
incorrect identification of the drive type and consequently incorrect drive operation.
Saving User Edits

• This procedure is common to all MicroCubicle™ sizes.
• Ensure that all mains supplies to the drive are isolated.
See Page 1
• Open the yellow Control Door.

• Energise the drive using the 24V Auxiliary supply. This is applied to TB2, located on the front of the CDC
(Common Drive Controller).
When the Drive is powered in this manner, some or all of the following trips will be present :
DC Undervolts (Fault Code 4)
Instantaneous Overcurrent (Fault Code 7)
Instantaneous Overcurrent on U-Phase (Fault Code 8)
Hardware Overtemperature on U-Phase (Fault Code 9)
Instantaneous Overcurrent on V-Phase (Fault Code 10)
Hardware Overtemperature on V-Phase (Fault Code 11)
Instantaneous Overcurrent on W-Phase (Fault Code 12)
Hardware Overtemperature on W-Phase (Fault Code 13)
DB Trip (Fault Code 151)
Scroll through all the trips to verify these. For the purposes of these procedures, they can be ignored.
• Set P1.31 = 2, first noting its original value. This allows access to the Advanced Menus.
• If the functionality of the unit allows, transfer all customised parameter settings to the Drive Data
Manager™ as follows :
Set P99.16 = 4. This will force the Drive Data Manager™ to store a copy of all user edits.
Continued….

Page 3 of 20
• Alternatively, customised parameter settings can be manually recorded in the following way :
Set P35.03=1. Use the right arrow on the Navigation key to scroll through all current user edits and
note the values.
Reset P35.03 = 0.
• Reset P1.31 to its original value.
• Remove the 24V Auxiliary supply.
Frame Size Specific Instructions

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

Number
3 MV3058A4A1, MV3071A4A1
5
MV3052A5A1, MV3065A5A1
MV3071J5A1
4 MV3086A4A1, MV3105A4A1, MV3140A4A1

8
MV3077A5A1, MV3096A5A1, MV3124A5A1
MV3062A6A1, MV3077A6A1, MV3099A6A1
MV3140J5A1, MV3099J6A1
6 MV3168A4A1, MV3204A4A1, MV3244A4A1, MV33292A4A1,

MV33364A4A1
11
MV3156A5A1, MV3180A5A1, MV3240A5A1, MV33302A5A1
MV3125A6A1, MV3144A6A1, MV3192A6A1, MV3242A6A1
MV3364J5A1, MV3242J6A1
7 MV3449A4A1, MV3503A4A1, MV3566A4A1

14
MV3361A5A1, MV3414A5A1, MV3477A5A1
MV3289A6A1, MV3336A6A1, MV3382A6A1
MV3566J5A1, MV3482J6A1

Page 4 of 20
FRAME SIZE 3
Removing the Original Control Module Assembly
See Page 1
• Undo two M5 captive screws (Figure 1,

Refs. 2,4).
Ref. 1
• Open the grey Power Door.
Ref. 2
Ref. 3 • Open the shroud over TB1 by loosening
the M5 captive screw (Figure 1, Ref. 3).
• Remove the plantside connections (TB1-
TB6) by unplugging the terminal blocks.
• Remove plantside connections to any
optional modules fitted to the CDC.
Ref. 4 • Remove two M5 screws and spring

washers (Figure 1, Refs. 1,5). Store
Ref. 5 these in a safe place.
Figure 1
• Pull the Control Module Assembly forwards until

the plug for the Keypad Harbour ribbon is visible
at the top of the CDC PCB (Figure 2).
• Remove the ribbon cable from PL2.
See Page 1
• If a Dynamic Brake Unit (from the MV3DB range)

is fitted, its ribbon cable should be removed from
PL8 at this stage.
• If the Drive is from the Bi-directional Converter
product range, the ribbon cable should be
removed from PL9. This is located directly behind
PL2.
Figure 2
Continued….

Page 5 of 20
• Pull the Control Module Assembly further

forwards until the back edge of the PCB is visible.
• Unplug the ribbon cables from PL4, PL10 and
PL11. See Figure 3.
• Figure 5 shows these plug positions in detail.
See Page 1
Figure 3
• Release both ribbon cables from their supporting

clamps on the metalwork as shown in Figure 4.
See Page 1
• The Control Module Assembly can now be

removed by sliding it out.
Figure 4
Note: If optional modules (such as a FIP Module, MVS3002) are fitted to the CDC these should be removed
at this stage and refitted to the replacement Control Module Assembly. Refer to the relevant instruction
manuals for fitting procedure.
Continued….

Page 6 of 20
Fitting the New Control Module Assembly
PL4 PL10 PL11 PL9 PL2 PL8
• Fit cable clamps to the new Control Module Assembly in

the same positions as those on the replaced module.
These are supplied with the replacement module.
• To replace the Control Module Assembly, reverse the
procedure described in the Removal instructions.
• Figure 5 shows all of the ribbon cable plugs in detail
for reference only.
Figure 5
Reinitialising the Drive Identity

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

Page 7 of 20
FRAME SIZE 4
See Page 1
• Undo two M5 captive screws (Figure 6,

Refs. 6,8).
• Open the grey Power Door.
Ref. 6
• Open the shroud over TB1 by loosening
the M5 captive screw (Figure 6,
Ref. 7).
Ref. 7 • Remove the plantside connections (TB1-
TB6) by unplugging the terminal blocks.
Ref. 8
Figure 6
• Remove two M5 screws and spring washers.

Store these in a safe place (Figure 7,
Refs. 9,10).
Ref. 9
Ref. 10
Figure 7
Continued….

Page 8 of 20
• Slide the Control Module Assembly forwards until the
plug for the Keypad Harbour ribbon is visible at the top
of the CDC. See Figure 8.
• Unplug this ribbon cable from PL2.
See Page 1
• If a Dynamic Brake Unit (from the MV3DB range) is

fitted, its ribbon cable should be removed from PL8 at
this stage.
• If the Drive is from the Bi-directional Converter product

range, the ribbon cable should be removed from PL9. Figure 8
This is located directly behind PL2.
• Slide the Control Module Assembly forwards until the

rear edge of the PCB is visible as in Figure 9.
See Page 1
Figure 9
• Unplug the ribbon cables from PL4, PL10 and PL11

as shown in Figure 10.
• Figure 11 shows these plug positions in detail.
• Release these ribbon cables from their supporting
clamps on the metal work of the Assembly.
See Page 1
• The Control Module Assembly can now be removed by

sliding it out. Figure 10
manuals for fitting procedures.
Continued….

Page 9 of 20
PL4 PL10 PL11 PL9 PL2 PL8

for reference only.
Figure 11


Page 10 of 20
FRAME SIZE 6
See Page 1
• Open the shroud over TB1 by loosening the

M5 captive screw (Figure 12, Ref. 12).
Ref. 11
• Remove the plantside connections (TB1-TB6)
by unplugging the terminal blocks.
Ref. 12
• Remove two M5 screws and spring washers
(Figure 12, Refs. 11, 13). Store these in a
safe place.
Ref. 13
Figure 12
• Slide the Control Module Assembly forwards

until the plug for the Keypad Harbour ribbon
cable is visible at the top of the CDC PCB
(Figure 13).
See Page 1
• If a Dynamic Brake Unit (from the MV3DB

range) is fitted, its ribbon cable should be
removed from PL8 at this stage.
• If the Drive is from the Bi-directional
Converter product range, the ribbon cable
should be removed from PL9. This is located
directly behind PL2. Figure 13
Continued….

Page 11 of 20
• Slide the Control Module Assembly further

forwards until the rear edge of the PCB is
visible.
• Unplug the ribbon cables from PL5,6,7,10
and 11. See Figure 14.
See Page 1
• Figure 16 shows these plug positions in

detail.
Figure 14
• Release the ribbon cables from their

supporting clamps on the metalwork as
shown in Figure 15.
See Page 1
• The Control Module Assembly can now be

removed by sliding it out.
Figure 15
Continued….

Page 12 of 20
PL10 PL11 PL9 PL2 PL8

for reference only.
PL5
PL6
PL7
Figure 16

PROCEDURE COMPLETE

Page 13 of 20
FRAME SIZE 7
See Page 1
• Open the shroud over TB1 by loosening the

M5 captive screw (Figure 17, Ref. 14).
Ref. 15
• Remove the plantside connections (TB1-TB6)
by unplugging the terminal blocks.
Ref. 14
TB2 • Remove one M5 screw and spring washer
(Figure 17, Ref. 15). Store these in a safe
Figure 17 place.
• Remove one M5 screw and spring washer

(Figure 18, Ref. 16). Store these in a safe
place.
Ref. 16
Figure 18

by approximately 50mm (2in.) so that the
plug for the Keypad Harbour ribbon cable is
visible at the top of the CDC PCB
(Figure 19).
See Page 1
• If a Dynamic Brake Unit (from the MV3DB

range) is fitted, its ribbon cable should be
removed from PL8 at this stage. Figure 19
• If the Drive is from the Bi-directional
Converter product range, the ribbon cable
should be removed from PL9. This is located
directly behind PL2.
Continued….

Page 14 of 20
as shown in Figure 20.
• Unplug the ribbon cables from PL5,6,7,10
and 11.
See Page 1
• Figure 21 shows these plug positions in

detail.
• Release the ribbon cables from their
supporting clamps on the Assembly chassis.
Figure 20
• The Control Module Assembly is now fully
disconnected from the Drive.
Continued….

Page 15 of 20
PL10 PL11 PL9 PL2 PL8

for reference only.
PL5
PL6
PL7
Figure 21

PROCEDURE COMPLETE

Page 16 of 20
REPROGRAMMING THE DRIVE IDENTITY

At each power up, drive identity information is retrieved by the Firmware from the drive power bridge. This
information is stored in the SMPS on MV3000 MicroCubicle™ units, (a shadow copy is also stored in the CDC if
the Firmware is V3.01 or later). To ensure the power bridge data is transferred to the new PCB, it is necessary
to follow the instructions as detailed in the flowchart on the following page.
However, if the Control Module Assembly and the SMPS PCB are to be replaced at the same time, the
following sequence must be used:
• Save the Drive Identity (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).
• Replace the SMPS PCB (see “Replacement of the SMPS PCB S20X432x” in the relevant Instruction Sheet).
• Copy the Drive Identity from the original Control Module to the replacement SMPS PCB (see
“Reprogramming the Drive Identity” in the relevant Instruction Sheet).
• Replace the Control Module Assembly as described in this Instruction Sheet.
• Recover the Drive Identity into the replacement Control Module as described in this Instruction Sheet.
If these procedures are not followed fully or are followed in the wrong sequence, this could lead to
incorrect identification of the drive type and consequently incorrect drive operation.
When one of the PCB’s have been replaced with a spare and the drive is powered using the 24V Auxiliary
supply, the Firmware will produce a combination of the following Fault Codes :-
Fault Code Number Fault Code Description Details

19 New Drive PCB (see P10.35) Either the CDC or the SMPS have been
replaced
68 Unknown Drive Size (see P10.35) The critical data is not present in the SMPS.
This PCB has been replaced.
4 DC Undervolts
7 Instantaneous Overcurrent
8 Instantaneous Overcurrent on U-
Phase
9 Hardware Overtemperature on U- These trips are due to the Drive being
Phase powered with the Auxiliary 24V.
10 Instantaneous Overcurrent on V- For the purposes of spares replacement, they
Phase can be ignored.
11 Hardware Overtemperature on V-
Phase
12 Instantaneous Overcurrent on W-
Phase
13 Hardware Overtemperature on W-
Phase
151 DB Trip
The flowchart on the following page shows the procedures to reinitialise the Drive Identity.

Page 17 of 20
Power up Drive with

Aux 24V
Trip Codes 19 or 68,

with a combination of
4, 7-13, 151
Set P10.35 = 2
19 / 68 Trips Reset
Drive Reboots.
Returned to Factory
Defaults
Re-install All User

Edits
Via Keypad Manual Entry
Set P99.16 = 5 Type in Edits
Remove Aux 24V
Verify Drive Operates

as Expected

Page 18 of 20
Customer Support and Training

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

Page 19 of 20
The logo ALSTOM and their frameworks are trademarks and service trademark applications of ALSTOM.
ALSTOM Power Conversion
France
9, rue Ampère
91345 Massy Cedex
Sales Tel: +33 (0) 8 25 02 11 02
Support Tel (International):
+33 (0) 3 84 55 33 33
Support Tel. (National):
08 25 02 11 02
Germany
Culemeyerstraße 1
D-12277 Berlin
Sales Tel: +49 (0) 30 74 96 27 27
Support Tel (International):
+49 (0) 69 66 99 831
© ALSTOM - 2000 - Publication No. T1932EN.
Support Tel (National):

01 80 3 23 45 72
UK
Boughton Road, Rugby
Warwickshire, CV21 1BU
Sales Tel: +44 (0) 1788 563625
Support Tel: +44 (0) 1788 547490
USA
610 Epsilon Drive
Pittsburgh, PA 15238
Sales Tel: +1 412 967 0765
Support Tel: +1 800 800 5290

Page 20 of 20
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Control Module Assembly Replacement Procedures For ALSPA

Introduction and Safety Instructions

Replacement Of The Control Module

• This equipment may be connected to more than one live circuit.

Instruction Sheet T1932EN Rev. 0001 (01/01)

Instruction Sheet T1932EN Rev. 0001 (01/01)

REPLACEMENT OF THE CONTROL MODULE ASSEMBLY (S41Y7784)

Saving User Edits

• Open the yellow Control Door.

Instruction Sheet T1932EN Rev. 0001 (01/01)

Frame Size Specific Instructions

Frame Size Drive Model Page

4 MV3086A4A1, MV3105A4A1, MV3140A4A1

6 MV3168A4A1, MV3204A4A1, MV3244A4A1, MV33292A4A1,

7 MV3449A4A1, MV3503A4A1, MV3566A4A1

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Undo two M5 captive screws (Figure 1,

Ref. 4 • Remove two M5 screws and spring

• Pull the Control Module Assembly forwards until

• If a Dynamic Brake Unit (from the MV3DB range)

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Pull the Control Module Assembly further

• Release both ribbon cables from their supporting

• The Control Module Assembly can now be

Instruction Sheet T1932EN Rev. 0001 (01/01)

PL4 PL10 PL11 PL9 PL2 PL8

• Fit cable clamps to the new Control Module Assembly in

Reinitialising the Drive Identity

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Undo two M5 captive screws (Figure 6,

• Remove two M5 screws and spring washers.

Instruction Sheet T1932EN Rev. 0001 (01/01)

• If a Dynamic Brake Unit (from the MV3DB range) is

• If the Drive is from the Bi-directional Converter product

• Slide the Control Module Assembly forwards until the

• Unplug the ribbon cables from PL4, PL10 and PL11

• The Control Module Assembly can now be removed by

Instruction Sheet T1932EN Rev. 0001 (01/01)

PL4 PL10 PL11 PL9 PL2 PL8

• Fit cable clamps to the new Control Module Assembly in

Reinitialising the Drive Identity

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Open the shroud over TB1 by loosening the

• Slide the Control Module Assembly forwards

• If a Dynamic Brake Unit (from the MV3DB

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Slide the Control Module Assembly further

• Figure 16 shows these plug positions in

• Release the ribbon cables from their

• The Control Module Assembly can now be

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Fit cable clamps to the new Control Module Assembly in

Reinitialising the Drive Identity

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Open the shroud over TB1 by loosening the

• Remove one M5 screw and spring washer

• Slide the Control Module Assembly forwards

• If a Dynamic Brake Unit (from the MV3DB

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Figure 21 shows these plug positions in

Instruction Sheet T1932EN Rev. 0001 (01/01)

• Fit cable clamps to the new Control Module Assembly in

Reinitialising the Drive Identity