All you ever wanted to know about the hardware of Siemens Masterdrives:

Dear All old and new users of this forum,

Based on my 13 years of hardware repairs experience I had written a 7 part series on the hardware of the
masterdrives in this forum earlier. I had received many feedbacks also for the same. I recd a very imp.
suggestion saying that such good piece of information will be lost in this forum.
I this thread i am providing links for all the 7 parts so that the users can get this information in one place. I
would really be happy to get your valuable feedbacks and Ratings for these postings.

https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=75031&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=75410&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=75883&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=76850&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=78250&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=78642&Lan
guage=en#top
https://www.automation.siemens.com/WW/forum/guests/PostShow.aspx?PageIndex=1&PostID=78754&Lan
guage=en#top

Thanks.
Diwa
Part 2:

We will start with the very basic of Decoding the type no (order no.) of the drive.

For e.g. 6SE7016-1EA61 is decoded as below.

6SE70 means this is a simovert MASTERDRIVE.

1 is the multiplier 1= 1* 10-1

2= 1* 100
3= 1* 10+1
4= 1* 10+2

61 is the o/p current identifier

(this has to be multiplied by the multiplier to get the rated o/p current of the drive)
In the above case 61 * 0.1(1 = 1 * 10-1) = 6.1A

E is the i/p supply code C = 3phase 200 to 230v ac

E = 3phase 380 to 480v ac
F = 3phase 500 to 600v ac
H= 3phase 660 to 690v ac
R = dc 270 to 310v dc
T = dc 510 to 650v dc
U = dc 675 to 810v dc
W= dc 890 to 930v dc
A is the size of the drive

6 denotes the type of controller card in the drive.

1 is the hardware version of the drive.

The above code (6SE7016-0EA61) decodes as

SIMOVERT MASTERDRIVE
VECTOR CONTROL
6.1A o/p current
380 to 480 v ac i/p voltage
A size drive.

Next will be Part 2 which will consist of the hardware components of the Compact
Drives.
Part 3:

CHASIS 1

In this part we will discuss about the CHASIS 1 type of drives i.e. from frame size E to H
ratings 45kw to 200kw.

Like we have seen the compact drives have either 2 or 3 boards in it. The PEU board has
all the circuits other than the controller card.

In the chasis drives the circuit on the peu board is divided into many individual boards.

Here I would like to inform that the controller board of a masterdrive remains
same for all the ratings.

So in a CHASIS 1 drive from 45kw to 200kw you will see the following boards

CUVC / CUMC /CU1 / CU2 / CU3

IVI

ABO

PSU1

PCC

PCU

IGD

SMU and SML

Again here the CUVC is common in all the ranges.

The IVI and IGD board changes with the rating of the drive and also with the hardware
version of the drive.

The ABO and the PCU board changes with the rating of the drive.

The PSU1 and the PCC are common throughout the range.
The SMU and SML boards change with the rating and are not available in some small
ratings.

Imp. Point here is that the hardware version of the drive is mentioned on the type
sticker of the drive and is very very imp. to know which spares are there in your
drive. In case of failure and a siemens engineer is being called, this information is
very important so that correct spares are carried by the engineer to solve the
problem.

Other than the boards mentioned above the drives will have the following components.

The 3 phase bridge rectifier made up of 3 thyristor modules.

The 3 phase inverter ckt made up of either 6 or 12 igbt modules.

The pre charging resistor.

The o/p Current Transformers.

The capacitor bank.

The fan and its ckt.

Next part will be CHASIS 2 drives.

Part 4:

CHASIS 2
In this part we will discuss about the CHASIS 2 type of drives i.e. from frame size J
onwards ratings 250kw onwards.

CHASIS 2 drive you will see the following boards

CUVCIVI / IPI / IMPIABO
PSU2
TDB
IGD
SMU and SML

The CUVC , TDB and the PSU2 boards are common throughout the range.
The drive will have either a IVI , IPI or IMPI depending on the configuration.
IVI for single drives
IPI for parallel connected inverters
IMPI for multi parallel connected drives (i.e Master slave units)
The ABO , IGD and the SMU and SML changes with the rating of the drive.

Other than the boards mentioned above the drives will have the following components.
The 3 phase bridge rectifier made up of 3 thyristor modules.
The 3 phase inverter ckt made up of either 6 or 12 igbt modules.
The pre charging resistor.
The o/p Current Transformers. (hall effect type)
The capacitor banks ( 3nos ).
The fan and its ckt.

In some ratings you will find 3 IGD boards. Here 1 IGD board will control the IGBT’s of
1 phase( i.e. 2 igbt’s).
The next part will be a bit more interesting where I will talk about the functions of each
of the boards used in the chasis drives.
Part 5:

In this part and the next I will brief about functions of the different boards in the chasis
drive

CUVC / CUMC /CU1 / CU2 / CU3

This is the heart of the drive. The main controller card (CPU). All the analog and digital
i/p’s and o/p’s from the field are also connected to this card. You can connect a pc and
communicate with the drive by connecting a cable to 1 of the port on this card. It has 2
ports with rs232 and rs485 protocol. The display unit called the PMU is also connected
to this card.

IVI / IPI / IMPI

This is the interface card between the power ckt and the control ckt(cuvc). This can be a
optical fibre type or flat band type. In optical fibre type the 6 pulses and the 3 feed back
signals are send/ recd using the optical fibre cables so no electrical connection between
the ivi and the igd board (power and control isolated). In a flatband type ivi the 6+3
signals are thru the copper cables i.e. a flat ribbon cable is used for connection between
ivi and the igd board.

Since IPI is used in parallel units, it has 2 sets of signals 1 set for each parallel inverter.
So the IPI has 12 optical transmitters for the 12 igbt’s ( 6 per inverter) and 6 optical
receivers (3 per inverter).

The following signals go out of this card.

6 pulses for the igbt firing.

The enable signal for the firing of the 3 phase i/p thyristor bridge.

The power supply for the o/p ct’s.

The power supply for the igd board.

The following signals come into this card .

The 3 feedback signals from the igbt’s (1 per phase).

The o/p ct feedback.

The dc link voltage sensing feedback.

Temperature sensor connections.

All the power supplies from the PSU card.

ABO

The dc link voltage , the o/p currents and temperature are scaled using op amps on the ivi
board. The gain of the these amplifiers are set by the the i/p and the feedback resistors.
These resistors are mounted on the ABO board. This board has only the resistors
mounted on it an the smallest board in the drive.

PSU1/ PSU2

This is the power supply unit of the drive. All the power supplies required by all the
circuits and boards are generated on this board. The i/p to this board is the dc link
voltage. First the dc link is converted to 24 v by an smps circuit. This 24v is then used to
generate all the other required voltages. The fuses in the fan ckt are mounted on this
board. The dc voltage is also measured on this board , the dropped down voltage is then
given to the cuvc thru the ivi board. The board also has the main contactor control circuit.
The fan control ckt is also on his board.
Part 6:

In this part I will brief about functions of the remaining boards in the chasis drive

PCC
This is the firing card for the i/p thyristor rectifier bridge used in the chasis 1 drives. The
board has the 6 identical ckts for the firing of 6 thyristor and the power supply required
for the same. It gets the power supply and the thyristor firing enable signal from the ivi
board. The enable signal to fire the thyristors are released as soon as the ON command is
given to the drive.
TDB
This is the thyristor driver board used in chasis 2 drives. It has the combine ckts of the
pcc and the pcu boards of the chasis 1 drives.
PCU
This is the pre-charging unit. This board has the high frequency filter ckt and the i/p
diode bridge for the pre-charging of the dc link capacitors The pre-charge resistor is
mounted externally and its connections are brought on this board.
IGD
This is the IGBT gate driver board. It has the 6 identical ckts for the firing of the 6 igbt’s
of the o/p inverter bridge. It gets signals and the power supplies from the ivi board. This
board physically sits directly on the IGBT modules. To switch on the igbt’s a +15v is
given to the gate of the igbt. A -5v at the gate is given to make it off. This board also
senses the functioning of the igbt’s and gives a feedback signal back to the cuvc( 1 signal
per phase).
SMU and SML
These are the the snubber boards used for the protection of the IGBT’s from the dv/dt.
X9 connector.
This is a very important connector in a masterdrive. In compact drives with last digit as
“0” in the type no. there will be a 5 pin x9 conn. And in compact drive with last digit as
“1” in the type no. the connector will be of 9 pin.
All the chasis drives have a 5 pin x9 conn. In chasis drives this connector is on the
PSU1/PSU2 board.
Why this is important is
If you want to check or change any parameter or check the status of digital i/p’s or o/p’s
you need not give the full ac or dc i/p voltage to the drive. You have to just give 24v at
terminals 1 and 2 of this connector x9. Pin 1 is +ve and pin 2 is –ve.

Another importance of this terminal is you can check the o/p pulses at the motor
terminals of the drive again w/o giving the full ac or dc i/p voltage to the drive. This can
be done with something called as simulation mode which I will explain in the next part.
It is a very handy tool for fault finding of masterdrives.
Part 7:

SIMULATION MODE

When it comes to diagnostics I find the master drive to have a very good feature called as
SIMULATION mode. In this mode we can test the drive at a very low voltage say 24v.
This is a very important test when it comes to fault finding in masterdrive and I think
every user of masterdrives should know this.

This test should be done on a drive which has all the power devices ok. i.e. the i/p
rectifier bridge and the o/p inverter bridge components ok. This can be tested with a
multimeter in resistance mode.

First switch off the source of the incoming AC / DC supply. This is very important. Next
remove the X9 connector if any. Connect only 24 volt +ve to pin 1 and –ve to the pin 2 of
the X9 connector of the drive. No other wires should be connected to the X9 connector.

Now connect the +ve of the 24v to the C (L+) terminal and the –ve to the D(L-) terminal
of the drive. The same 24v source can be used which we connected at the X9 conn.

Switch on the 24v source and the display will come.

I will recommend a spare cuvc card to be used for this testing so that we do not
disturb the parameterization of the existing card. You can even use the existing card
if you have the parameter backup with you and you can reload your parameters
back after the test.

First do a factory reseting of the parameters by P60= 2 and then P970 = 0

Now make P372 = 1 By this now we have enabled the SIMULATION mode of the
masterdrive. Now give an “ON” command to the drive from the pmu and increase the
frequency to the max say 50hz. Now you can check the o/p pulses of the drive on a
oscilloscope. You will see the PWM waveform. All the 3 phases should have the same
waveform which will tell us that the CUVC , IVI , IGD and the IGBT’s of the drive
functioning ok. Also the powersupplies are ok. Also you can check the o/p voltage with a
true rms multimeter and will be approximately 18V in all the 3 phases.