Old Version Siemens Inverter Ivi Board 6SE7038-6GL84-1BG2 6SE70386GL841BG2 6SE7O38-6GL84-1BG2 6SE7 038-6GL84-1BG2

Siemens 6SE7038-6GL84-1BG2 | SIMOVERT MASTERDRIVES IVI Inverter Interface Board — 380–690V 3AC, Large Chassis

Part Number: 6SE7038-6GL84-1BG2

Manufacturer: Siemens AG (Germany)

Product Type: IVI — Inverter Interface Board (Spare Part)

Product Range: SIMOVERT MASTERDRIVES (6SE70 Series)

Overview

The 6SE7038-6GL84-1BG2 is the IVI (Inverter Interface board) for large-chassis SIMOVERT MASTERDRIVES converters and inverters covering the 380–690V three-phase voltage range. The IVI board sits physically and electrically between the drive's main control unit (CUD1) and the IGBT inverter power stage.

It is the signal routing and translation layer that converts the digital PWM commands from the CUD into gate drive signals for the IGBT modules, while simultaneously routing current feedback, temperature data, and fault signals back to the CUD for closed-loop control and protection.

The SIMOVERT MASTERDRIVES is Siemens' established fully digital modular AC drive platform, widely deployed across heavy industry in converters, inverters, and rectifier/regenerative units.

The 6SE7038 base designation identifies units in the higher-power bracket of the 6SE70 series — the GL designation indicates the large-frame chassis variants that deliver the current capacity needed for multi-hundred-kilowatt drive applications.

These drives power rolling mills, large extruder lines, ship propulsion systems, heavy hoists, paper and board machines, test stands, and compressor trains.

The BG2 revision of the IVI board is the successor to BG0 and BG1 and is the current production version.

It maintains full physical and functional compatibility with earlier IVI board revisions in the same drive type.

Key Specifications

IVI Board — The Signal Bridge in a Large Drive

In a SIMOVERT MASTERDRIVES chassis unit, the drive architecture separates the intelligence (the CUD1 control board) from the muscle (the IGBT power modules). The CUD runs the control algorithms — speed, torque, and current loops — and outputs a set of six PWM switching commands at any given moment.

These commands specify exactly when each of the six IGBTs in the three-phase inverter bridge should turn on and turn off.

The 6SE7038-6GL84-1BG2 IVI board receives these commands and routes them to the gate drive boards (IGD boards) that physically drive the IGBT gates.

This routing is not passive — the IVI board handles the timing logic, processes the interlock signals that prevent upper and lower IGBTs in the same phase leg from conducting simultaneously (a shoot-through condition that would cause immediate catastrophic failure), and coordinates the gate signals across multiple parallel IGBT assemblies in the GL series large-frame units.

In the return direction, the IVI board collects motor phase current measurements from the drive's current sensors, processes temperature data from multiple heatsink NTC thermistors, and aggregates fault signals from across the power stage.

All of this data flows back to the CUD through the IVI board's interface connectors. 

The CUD uses these signals to close its control loops and to trigger protective shutdowns when any parameter exceeds its safe operating limit.

Wide Voltage Coverage — One Board for Multiple Drive Variants

A notable feature of the 6SE7038-6GL84-1BG2 is its voltage range coverage. The single IVI board covers SIMOVERT MASTERDRIVES large-chassis converters operating on 380–460V, 500–575V, and 660–690V three-phase supplies.

In a site with a mixed fleet of SIMOVERT MASTERDRIVES units across different supply voltage specifications, a single IVI board spare can serve multiple drive types. 

This reduces the spare parts inventory required and simplifies procurement — a significant practical benefit for maintenance teams managing large drive fleets.

The board's internal design accommodates the different DC bus voltage levels associated with each supply voltage range — approximately 530–650V DC for the 380–480V supply range, and up to approximately 975V DC for 690V supply.

The gate drive isolation and component voltage ratings on the 6SE7038-6GL84-1BG2 are designed to handle the full spread.

Fault Diagnosis — When the IVI Board Fails

IVI board failure in a large SIMOVERT MASTERDRIVES unit typically manifests as one of several fault patterns. The drive's CUD reports a gate drive fault — the IGBT gate drive circuits are not responding to the CUD's switching commands as expected. In some cases, the fault appears on only one phase, identifying which IGBT leg or gate drive circuit is affected.

In others, all phases are affected simultaneously, suggesting the IVI board's interface to the CUD has failed.

A second presentation is asymmetric motor current — one phase carries significantly different current than the other two.

This can indicate that one IGBT leg is not switching correctly, either firing late, not firing at all, or firing continuously.

All of these conditions can trace to the IVI board's gate signal routing failing for one phase channel.

Before replacing the IVI board, check the gate drive board (IGD) for the affected phase — the IGD is a more commonly failed component and is easier to replace than the IVI board. If the IGD is confirmed functional, the IVI board is the next replacement candidate.

Large Drive Safety — High-Voltage Precautions

SIMOVERT MASTERDRIVES GL-series units are large, high-power drives operating at potentially 660–690V AC supply and DC bus voltages close to 1000V.

All internal work must follow the mandatory discharge procedure: isolate AC supply, wait minimum five minutes, measure DC bus voltage below 50V before opening the drive cabinet. 

These drives store substantial energy in their DC bus capacitors — the discharge time must be respected, not estimated.

Work must be performed by trained and authorised electrical personnel only.

FAQ

Q1: The SIMOVERT MASTERDRIVES large-chassis unit reports a gate drive fault on phase U but phases V and W are operating correctly. Is the 6SE7038-6GL84-1BG2 IVI board the cause?

A single-phase gate drive fault is more likely to be a failed gate drive board (IGD) for that phase rather than the IVI board itself.

The IVI board routes signals to all three phases through separate channels — a failure that affects only one phase usually originates at the IGD for that phase, not at the IVI routing board. Check and replace the phase-U IGD board first. 

If the fault persists after IGD replacement, the IVI board's phase-U output channel has failed, making the 6SE7038-6GL84-1BG2 the next replacement candidate.

Q2: The BG0 revision IVI board is installed. The only available replacement is the BG2. Is this a direct swap?

Yes. The BG2 is a direct replacement for BG0 and BG1 in the same drive type. Siemens maintains revision compatibility for IVI boards within the same drive design range.

No parameter changes or drive reconfiguration is needed after swapping from BG0 to BG2. 

The BG2 incorporates component updates relative to BG0 but is functionally and interfacially identical.

Q3: After installing the 6SE7038-6GL84-1BG2, the drive shows an overcurrent fault on first run at no load. Cabling and motor are confirmed good. What should be checked?

Check the current feedback connector seating on the new IVI board. If the current sensor signals are not reaching the CUD correctly — due to a connector not fully seated — the CUD may calculate incorrect motor currents and trip on overcurrent.

Power down, discharge the DC bus, reseat all current sensor and IVI-to-CUD interface connectors, then retry. If the fault remains after confirmed connector seating, verify the current sensors in the power stage themselves are functional.

Q4: The 6SE7038-6GL84-1BG2 has been discontinued by Siemens. How reliable is the aftermarket supply for this board?

The SIMOVERT MASTERDRIVES installed base is large, and the aftermarket supply chain for IVI boards is well established. Specialist drive repair companies test and certify refurbished IVI boards from drives taken out of service.

For critical production equipment running SIMOVERT MASTERDRIVES, holding one spare IVI board on site eliminates the risk of a multi-week sourcing delay in the event of board failure.

Exchange programs — where a refurbished board is provided and the failed unit is returned for reconditioning — are a common sourcing model for discontinued boards like this one.

Q5: Can the 6SE7038-6GL84-1BG2 be used across all three voltage ranges (380–460V, 500–575V, and 660–690V) without any hardware modification or configuration?

Yes. The board is designed to cover the full voltage range without modification.

The gate drive isolation and component ratings accommodate the different DC bus levels associated with each supply voltage. 

No jumper setting, no component change, and no configuration step is needed to adapt the board between voltage ranges.

The drive's voltage-specific parameters are managed through the CUD's software configuration, not through the IVI board hardware.