ABB PSTX210 Service Manual Download

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1SFC13105M0201 | Service Manual |

Service PSTX210...370

3 Service PSTX210...370

3.1 Introduction

3.1.1 Earth the Softstarter

3.1.2 How to access service parameters

3.2 Configuring the HMI

3.2.1 Update Firmware

3.2.2 Set the ID

3.2.3 Reset to factory defaults

3.3 Change the HMI, Disconnect/Connect the main power cables and
the control cables

3.3.1 Change the HMI

3.3.2 Place the new HMI

3.3.3 Disconnect the main power cables and the control cables

3.3.4 Connect the main power cables and the control cables

3.4 Service of the PCBA

3.4.1 Change the PCBA

3.5 Change the Fans, Bypass contactor and Current transformers

3.5.1 Change the fans

3.5.2 Change the Bypass contactor

3.5.3 Change the Current transformers

3.6 Change the SCR

3.6.1 Change the SCR

3.7 Instructions for testing the SCR

3.7.1 Test the SCR

Summary of Contents for PSTX210

Page 1: ...Softstarter type PSTX210 370 and PSTX470 570 Service manual Service manual en rev A 1SFC13105M0201 ...

Page 2: ...any errors he is kindly asked to notify us as soon as possible The data contained in this manual is intended solely for the product description and is not to be deemed to be a statement of guaranteed properties In the interests of our customers we constantly seek to ensure that our products are developed to the latest technological standards As a result there may be some differences between the So...

Page 3: ...y WARNING Warning symbol indicates the presence of hazardous voltage which could result in personal injury Electrostatic sensitive devices warning Electrostatic discharge is needed to not damage the equipment WARNING HAZARDOUS VOLTAGE Symbol indicates that only authorized and appropriately trained personnel are allowed to do the installation operation and maintenance of the product It should be do...

Page 4: ......

Page 5: ...1 1 3 5 2 6 4 1 Introduction 2 Description 3 Service PSTX210 370 4 Service PSTX470 570 5 Wiring Diagrams 6 Revisions Softstarter type PSTX210 370 and PSTX470 570 Service manual ...

Page 6: ......

Page 7: ...3105M0201 Service Manual Introduction 7 1 1 1 Service manual 1 1 1 Intended audience 8 1 1 2 Revision notes and related documents 8 1 1 3 Acronyms and abbreviations 8 1 1 4 Chapters included 8 1 Introduction ...

Page 8: ...he SCR Assemble the Softstarter Test the SCR Change the Stays 4 Revision Shows revisions of this manual 1 1 Service manual This manual contains step by step instructions on how to perform service and maintenance on Softstarter range PSTX210 370 and PSTX470 570 Service and maintenance should be performed in accordance with this instruction to ensure product functionality and to prevent that the lif...

Page 9: ...n 2 1 1 Regular maintenance 10 2 1 2 Tools required 10 2 1 3 Service and repair 10 2 1 4 Weights 10 2 1 5 Dimension prints PSTX30 105 PSTX142 170 11 2 1 6 Dimension prints PSTX210 370 PSTX470 570 12 2 1 7 Markings and connections 14 2 1 8 Identification of Softstarter type 15 ...

Page 10: ...cal equipment room the area should be kept cleaned of dirt and or dust on a regular basis The top of the Softstarter should be examined for evidence of water seepage The source of the water should be immediately identified and corrective measures taken to permanently correct the condition Check the By pass Contactor Inspect for loose broken or worn parts Examine for excessive wear of moving parts ...

Page 11: ...n 178 8 mm 7 in 13 mm 0 5 in 6x 119 mm 4 7 in 298 5 mm 11 7 in 7 5 mm 0 3 in 314 mm 12 4 in 258 mm 10 2 in 30 mm 1 2 in 4x Ø14 2x 1SFC132095M0201 219 6 mm 8 6 in 238 3 mm 9 3 in 377 mm 14 8 in 165 mm 6 5 in 7 5 mm 0 3 in 360 5 mm 14 1 in 199 mm 7 8 in 35 mm 1 3 in 4x 6 6 mm 0 2 in 4x 303 mm 11 9 in 107 6 mm 4 2 in 5 mm 0 2 in 17 5 mm 0 7 in 6x Ø18 2x 1SFC132095M0201 2 ...

Page 12: ... in 10 5 mm 0 4 in 389 mm 15 3 in 5 mm 0 2 in 151 mm 5 9 in Ø18 2x 200 mm 7 9 in 258 mm 10 2 in 43 7 mm 1 7 in 4x 19 6 mm 0 8 in 6x 1SFC132095M0201 361 mm 14 2 in 282 15 mm 11 1 in 262 82 mm 10 3 in 6 mm 0 2 in 6x 58 2 mm 2 3 in 6x 25 mm 0 9 in 6x 336 mm 13 2 in 2x 460 mm 18 1 in 63 mm 2 5 in 4x 493 mm 19 4 in 466 mm 18 3 in 9 mm 0 3 in 7 mm 0 2 in 4x Ø13 4x 1SFC132095M0201 2 ...

Page 13: ...1SFC13105M0201 Service Manual Description 13 2 ...

Page 14: ... 5 1 4 6 2 1 Stop L 100 250V 50 60 Hz K4 K5 K6 Start Stop In1 In2 DGND 24V GND N In0 Ready Run Fault Protection PSTX Symbol for Torque control Anybus connection Com1 Supply voltage Us Order code Technical data according to UL 508 Fieldbus connection Com2 Motor side connection Terminal marking of control circuits Line side connection Display Keypad Mini USB Country of origin Utilization code Approv...

Page 15: ...C Serial number information The ABB Serial number within business unit Control Products has the following structure Table 5 Prefix Register Id Individual identity number part 1S 160 PPPP YY WW NNNN Prefix Defined in ABB Corporate Standard 9AAK100359 Register Id Defined in BAATLV Instruction 1SFD2000 8 Individual identity number part PPPP Identification for product type part of product YY Manufactu...

Page 16: ...16 Description Service Manual 1SFC13105M0201 2 ...

Page 17: ... cables and the control cables 3 3 1 Change the HMI 22 3 3 2 Place the new HMI 22 3 3 3 Disconnect the main power cables and the control cables 23 3 3 4 Connect the main power cables and the control cables 24 3 4 Service of the PCBA 3 4 1 Change the PCBA 26 3 5 Change the Fans Bypass contactor and Current transformers 3 5 1 Change the fans 30 3 5 2 Change the Bypass contactor 31 3 5 3 Change the C...

Page 18: ... 2 How to access service parameters Follow this instruction in order to make the service parameters available on the Softstarter 1 Switch on the power supply terminal 1 and 2 2 1 Push Options to reach Options menu Use or to navigate to Security management and then push Select 3 2 Use or to navigate to Login and then push Select 4 3 Use or to navigate to Service and then push Select 5 4 Use and to ...

Page 19: ... ID The ID of the Softstarter has to be changed when the PCBA has been changed and after updating firmware Choose between 210 370 due to type of Softstarter 1 Switch on the power supply terminal 1 and 2 2 1 Push Menu to reach Menu Use or to navigate to Parameters and then push Select 3 2 Use or to navigate to Complete list and then push Select 4 3 Use or to navigate to 28 Service and then push Sel...

Page 20: ...o navigate to Settings and then push Select 3 2 Use or to navigate to Reset to defaults and then push Select 4 3 Use or to navigate to Reset all parameters and then push Select 5 4 Following message will appear on the display Continue to reset all parameters to their default values Push Yes to reset all parameters or No if you whish to cancel the operation 1 2 3 4 3 ...

Page 21: ...electronics can be affected by damage caused by electrostatic discharge This can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking ...

Page 22: ...1 Connect the RJ45 plug 1 Connect the RJ45 plug to its socket Make sure the plug gets properly connected listen for a clicking sound from the locking clip when mounting the plug 2 Place the new HMI module 1 Place the new HMI module on top of the unit with the front end facing downwards and the rear end facing upwards 2 Dock the HMI module by pushing the rear end downwards and carefully snap the mo...

Page 23: ... cables prior to disconnecting them to enable proper re connection 1 Loosen the M3 screws using a slotted screwdriver and disconnect the control cables from the terminals 2 Mark the main power cables Mark the power cables prior to disconnecting them 1 Mark the main power cables on the top terminals 1L1 3L2 and 5L3 with 1 3 and 5 2 Mark the main power cables on the bottom terminals 2T1 4T2 and 6T3 ...

Page 24: ...charge ESD damage to the Softstarter 1 Connect main power cables 1 Fasten the main power cables according to previously made markings 1 3 or 5 to top terminals 1L1 3L2 and 5L3 Hexagon no 8 M10x30 28Nm Washers and square nuts to be used 2 Fasten the main power cables according to previously made markings 2 4 or 6 to bottom terminals 2T1 4T2 and 6T3 Hexagon no 8 M10x30 28Nm Washers and square nuts t...

Page 25: ...his can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compar...

Page 26: ...he HMI bracket 1 Loosen 4x Torx 20 4 0 x80 10 Remove the front cover by lifting it upwards from unit 2 Disconnect SCR cables from PCBA Mark the SCR cables with 1 2 3 prior to disconnecting them This enables proper re connection 1 Disconnect the three SCR cables from their terminals on the PCBA using a long nose plier 2 Slide out the cables from the cable holders located on bracket 3 Disconnect byp...

Page 27: ...t pegs and lift it upwards from unit Make sure the rubber bushings stays mounted on the PCBA when removed Dispose of expended PCBA 6 Place new PCBA Note that rubber bushings shall be mounted on the PCBA prior to assembly 1 Align the new PCBA to bracket pegs 2 Gently press the PCBA onto the bracket pegs until it is firmly fitted 7 Connect thermal sensor cable and fan cables to PCBA 1 Place the cabl...

Page 28: ...he PCBA 10 Place front cover Place the front cover on the unit and align it to the plastic screw sleeves located on lower housing 1 Fasten the front cover with 4x Torx 20 4 0 x80 10 1 6Nm 2 Fasten 1x Torx 15 M3 5x12 0 5 Nm on the HMI bracket REASSEMBLE THE SOFTSTARTER Connect main power cables and control cables Connect the main power cables and the control cables as described in chapter 3 3 4 ste...

Page 29: ...can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare th...

Page 30: ... the three already disconnected fan cables Dispose of expended fans 3 Place fans 1 Thread the fan cables through the cable inlets 2 Align the fans to the support pegs and attach them into position on fixture 3 Fasten fans with 3x Torx 25 3 5x12 1 3Nm 4 Place PCBA bracket 1 Align the bracket rails to their fixing point to unit and place the PCBA bracket into position REASSEMBLE THE SOFTSTARTER Plac...

Page 31: ...in chapter 3 4 1 step 1 5 1 Remove PCBA bracket 1 Remove the PCBA bracket by lifting it upwards from unit 2 Disconnect flexible bars 1 Loosen 3x Torx 30 M6x25 one screw per phase to disconnect the flexible bars 3 Remove bypass contactor 1 Loosen 4x Torx 25 M3x8 from the bypass contactor 2 Loosen 3x Torx 30 M6x25 from the bypass contactor 3 Remove the bypass contactor including cable by lifting it ...

Page 32: ...rs with 3x Torx 30 M6x25 8Nm 6 Place PCBA bracket 1 Align the bracket rails to their fixing point to unit and place the PCBA bracket into position REASSEMBLE THE SOFTSTARTER Place PCBA cables and front cover Place the PCBA connect all cables and install the front cover as described in chapter 3 4 1 step 6 10 Connect main power cables and control cables Connect the main power cables and the control...

Page 33: ...er phase to disconnect the flexible bars 3 Remove bypass contactor 1 Loosen 4x Torx 25 M3x8 from the bypass contactor 2 Loosen 3x Torx 30 M6x25 from the bypass contactor 3 Remove the bypass contactor including cable by lifting it upwards from unit 4 Remove phase bar and current transformer 1 Loosen 1x Hexagon no 8 M10x60 from the phase bar Also remove sleeve and washer 2 Loosen 1x Torx 25 M5x18 fr...

Page 34: ...105 105 0 025 1SFA899302R1105 PSCT 400 PSTX142 170 175 0 025 1SFA899302R1175 PSCT 500 PSTX210 370 370 0 2 1SFA899302R1370 PSCT 600 6 Place bypass contactor 1 Place the bypass contactor into the unit and align it to screw mounting points 2 Fasten bypass contactor with 4x Torx 25 M3x8 0 5Nm 3 Fasten bypass contactor additionally with 3x Torx 30 M6x25 8Nm 7 Connect flexible bars 1 Connect and fasten ...

Page 35: ...mportant that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare this with the fact that some sensitive components can be destroyed when discharged ...

Page 36: ...hase to disconnect the flexible bars 3 Remove bypass contactor 1 Loosen 4x Torx 25 M3x8 from the bypass contactor 2 Loosen 3x Torx 30 M6x25 from the bypass contactor 3 Remove the bypass contactor including cable by lifting it upwards from unit 4 Remove middle phase bar and current transformer 1 Loosen 1x Hexagon no 8 M10x60 from the middle phase bar Also remove sleeve and washer 2 Loosen 1x Torx 2...

Page 37: ... scratches and other marks Do not scratch the contact surfaces with the guide pins Do not touch the contact surfaces Do not lift the SCR by the wire Make sure that there is no damage to the welding flange or to the contact surface 7 Preparation of heatsink and SCR Clean all polished contact surfaces carefully with Ethanol Use well moistened lint free paper Avoid contact with surface Lubricate dire...

Page 38: ... phase bar additionally with 1x Torx 25 M5x18 3Nm 10 Place middle phase bar and current transformer 1 Place the middle current transformer into the unit with cable side facing toward fans 2 Mount the middle phase bar through the current transformer and fasten phase bar with 1x Hexagon no 8 M10x60 12Nm Sleeve and washer are to be used 3 Fasten middle phase bar additionally with 1x Torx 25 M5x18 3Nm...

Page 39: ...ng point to unit and place the PCBA bracket into position REASSEMBLE THE SOFTSTARTER Place PCBA cables and front cover Place the PCBA connect all cables and install the front cover as described in chapter 3 4 1 step 6 10 Connect main power cables and control cables Connect the main power cables and the control cables as described in chapter 3 3 4 step 1 2 Tx 30 8Nm M6 x 25 12 3 6 1_12 3 13 3 6 1_1...

Page 40: ...life span of electronics can be affected by damage caused by electrostatic discharge This can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A pe...

Page 41: ...sing a long nose plier 2 Slide out the cables from the cable holders located on bracket 3 Connect the Megger to the Softstarter 1 Connect the black megger contact to the main terminal 1L1 on the Softstarter 2 Connect the red megger contact to the main terminal 2T1 on the Softstarter 3 Set the megger on 500V Press and hold the Test button Note the result Also use 500V for 690V softstarters 4 Switch...

Page 42: ... lower housing 1 Fasten the front cover with 4x Torx 20 4 0 x80 10 1 6Nm 2 Fasten 1x Torx 15 M3 5x12 0 5 Nm on the HMI bracket REASSEMBLE THE SOFTSTARTER Connect main power cables and control cables Connect the main power cables and the control cables as described in chapter 3 3 2 step 1 2 8 Examples of SCR for PSTX Figure 8 shows typical types of SCR blocks used in PSTX210 370 The manufacturing t...

Page 43: ...1SFC13105M0201 Service Manual Service PSTX210 370 43 3 ...

Page 44: ...44 Service PSTX210 370 Service Manual 1SFC13105M0201 3 ...

Page 45: ...nd the control cables 51 4 3 4 Connect the main power cables and the control cables 52 4 4 Service of the PCBA 4 4 1 Change the PCBA 54 4 5 Change the Fans Bar holders and Current transformers 4 5 1 Change the Fans 58 4 5 2 Change the Bar holders 59 4 5 3 Change the Current transformers 61 4 5 4 Assemble the Softstarter 62 4 6 Change the Bypass contactor 4 6 1 Change the Bypass contactor 65 4 6 2 ...

Page 46: ... 1 2 How to access service parameters Follow this instruction in order to make the service parameters available on the Softstarter 1 Switch on the power supply terminal 1 and 2 1 Push Options to reach Options menu Use or to navigate to Security management and then push Select 2 2 Use or to navigate to Login and then push Select 3 3 Use or to navigate to Service and then push Select 4 Use and to en...

Page 47: ... ID The ID of the Softstarter has to be changed when the PCBA has been changed and after updating firmware Choose between 470 570 due to type of Softstarter 1 Switch on the power supply terminal 1 and 2 2 1 Push Menu to reach Menu Use or to navigate to Parameters and then push Select 3 2 Use or to navigate to Complete list and then push Select 4 3 Use or to navigate to 28 Service and then push Sel...

Page 48: ...vigate to Settings and then push Select 3 2 Use or to navigate to Reset to defaults and then push Select 4 3 Use or to navigate to Reset all parameters and then push Select 5 4 Following message will appear on the display Continue to reset all parameters to their default values Push Yes to reset all parameters or No if you whish to cancel the operation 1 2 3 4 4 ...

Page 49: ...ctronics can be affected by damage caused by electrostatic discharge This can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on ...

Page 50: ...lace RJ45 plug 1 Connect the RJ45 plug to its socket Make sure the plug gets properly connected listen for a clicking sound from the locking clip when mounting the plug 2 Place new HMI 1 Place the new HMI module on top of the unit with the front end facing downwards and the rear end facing upwards 2 Dock the HMI module by pushing the rear end downwards and carefully snap the module into position P...

Page 51: ...r to disconnecting them to ensure proper re connection 1 Loosen the M3 screws using a slotted screwdriver and disconnect the control cables from the terminal block 2 Mark main power cables Mark the power cables prior to disconnecting them 1 Mark the main power cables on the top terminals 1L1 3L2 and 5L3 with 1 3 and 5 2 Mark the main power cables on the bottom terminals 2T1 4T2 and 6T3 with 2 4 an...

Page 52: ...D damage to the Softstarter 1 Connect main power cables 1 Fasten the main power cables according to previously made markings 1 3 or 5 to top terminals 1L1 3L2 and 5L3 Hexagon no 8 M10x40 35Nm Washers and square nuts to be used 2 Fasten the main power cables according to previously made markings 2 4 or 6 to bottom terminals 2T1 4T2 and 6T3 Hexagon no 8 M10x40 35Nm Washers and square nuts to be used...

Page 53: ...appen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare this wi...

Page 54: ...nt still mounted on bracket to facilitate continued service 2 Disconnect SCR cables from PCBA Mark the SCR cables with 1 2 3 prior to disconnecting them to ensure proper re connection Note that markings are to be made in accordance with existing data available on the PCBA bracket 1 Disconnect the three SCR cables from their terminals on the PCBA using a long nose plier 2 Pull out the three SCR cab...

Page 55: ...expended PCBA 6 Place new PCBA on PCBA bracket Note that rubber bushings shall be mounted on the PCBA prior to assembly 1 Position the bracket so that ABB s logotype appears upside down on the upper end 2 Place the new PCBA on the bracket by sliding it onto bracket from the right direction until attached to the peg in the lower left corner 3 Gently press the PCBA onto the bracket peg in the upper ...

Page 56: ...BA 10 Place new PCBA and PCBA bracket 1 Place the new PCBA mounted to bracket on the unit Make sure cables do not get stuck in between the bracket frame and Softstarter when mounted 11 Place front cover Place the front cover on the unit and align it to the plastic screw sleeves located on lower housing 1 Fasten the front cover with 4x Torx 20 4 0 x80 10 1 6Nm 2 Fasten 1x Torx 15 M3 5x12 0 5 Nm on ...

Page 57: ...l or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare this with the fact that some ...

Page 58: ...d fans 3 Fasten fans to fan cover Note that fans are to be mounted with regards to air flow directions 1 Fasten 8x Torx 20 M4x12 1 3Nm to attach the four fans on the fan cover Screws are to be mounted diagonally with two screws per fan 4 Place fan cover 1 Thread the fan cables through the cable inlets 2 Fasten the fan cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each co...

Page 59: ...g injuries 1 Remove fan cover 1 Loosen 6x Torx 20 M4x8 from the fan cover Screws are located in each corner and on the center bracket of the fan cover 2 Pull the fan cover outwards from unit with the fans still mounted to fan cover 2 Remove top cover 1 Loosen 6x Torx 20 M4x8 and pull the top cover outwards from unit Screws are located in each corner and on the center bracket of the top cover 3 Rem...

Page 60: ...xagon no 8 M10x40 2 Loosen 2x Torx 30 M6x16 and pull the bar holder outwards from unit Dismantle assemble current transformers from to bar holders as described in chapter 4 4 4 7 Place new bar holder 1 Place the new bar holder to the unit and align it correctly to phases and screw holes Fasten with 2x Torx 30 M6x16 8Nm 2 Fasten the middle phase bar screw Hexagon no 8 M10x40 28Nm REASSEMBLE THE SOF...

Page 61: ...Torx 30 M6x16 from the middle phase bar in order to pull out the phase bar and remove the current transformer Dispose of expended current transformer 4 Place new current transformer on top bar holder Make sure that the ratio value of the new current transformer correspond to previously installed current transformer Verify the ratio according to Table 7 below Make sure cable of new current transfor...

Page 62: ...outer screws of each bracket are mounted to cooling towers 3 Place first internal phase bar 1 Fasten phase bar to unit with 2x Torx 30 M6x25 8Nm Note that one screw is mounted on cooling tower 4 Place side and front covers Make sure to position side covers with dual locking rails facing upwards prior to assembly 1 Interlock the side covers to rails and attach them to support brackets mounted on co...

Page 63: ...cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each corner and on the center bracket of the top cover REASSEMBLE THE SOFTSTARTER Place PCBA cables and front cover Place the PCBA connect all cables and install the front cover as described in chapter 4 4 1 step 6 10 Connect main power cables and control cables Connect the main power cables and the control cables as describe...

Page 64: ...ore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare this with the fact that some sensitive components can be destroyed ...

Page 65: ...ting injuries 1 Remove fan cover 1 Loosen 6x Torx 20 M4x8 from the fan cover Screws are located in each corner and on the center bracket of the fan cover 2 Pull the fan cover outwards from unit with the fans still mounted to fan cover 2 Remove top cover 1 Loosen 6x Torx 20 M4x8 and pull the top cover outwards from unit Screws are located in each corner and on the center bracket of the top cover 3 ...

Page 66: ...6 Remove bottom bar holder 1 Slightly untighten screw from the middle phase Hexagon no 8 M10x40 2 Loosen 2x Torx 30 M6x16 and pull the bar holder outwards from unit 7 Loosen screws from bypass contactor 1 Loosen 6x Hexagon no 8 M10x40 from the phases on the bypass contactor 2 Remove phase rails by pulling them outwards from bypass contactor 3 Loosen 4x Hexagon no 4 M5x100 from the bypass contactor...

Page 67: ...tactor 1 Remove the bypass contactor by lifting it outwards from unit Dispose of expended bypass contactor 9 Place new bypass contactor 1 Place the new bypass contactor in the unit with terminals 1L1 3L2 and 5L3 facing inwards Align to phase rails 8 4 6 1_8 1 9 4 6 1_9 1 4 ...

Page 68: ...Fasten bypass contactor to unit with 4x Hexagon no 4 M5x100 2 9Nm 2 Place bottom bar holder 1 Place the bar holder to the unit and align it correctly to phases and screw holes Fasten with 2x Torx 30 M6x16 8Nm 2 Fasten the middle phase bar screw Hexagon no 8 M10x40 28Nm 3 Place angle brackets 1 Fasten the two angle brackets to unit with 4x Torx 30 M6x25 8Nm Note that outer screws of each bracket ar...

Page 69: ...ten fan cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each corner and on the center bracket of the fan cover 7 Place top cover 1 Fasten top cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each corner and on the center bracket of the top cover REASSEMBLE THE SOFTSTARTER Place PCBA cables and front cover Place the PCBA connect all cables and instal...

Page 70: ... very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be charged with up to fifteen thousand volt 15000V Compare this with the fact that some sensitive components can be destroyed when disc...

Page 71: ...juries 1 Remove fan cover 1 Loosen 6x Torx 20 M4x8 from the fan cover Screws are located in each corner and on the center bracket of the fan cover 2 Pull the fan cover outwards from unit with the fans still mounted to fan cover 2 Remove top cover 1 Loosen 6x Torx 20 M4x8 and pull the top cover outwards from unit Screws are located in each corner and on the center bracket of the top cover 3 Remove ...

Page 72: ... screws Dispose of expended SCR WARNING SCR s and heatsinks must be handled with care to avoid scratches and other marks Do not scratch the contact surfaces with the guide pins Do not touch the contact surfaces Do not lift the SCR by the wire Ensure there is no damage to the welding flange or to the contact surface 7 Preparation of heatsink and SCR Clean all polished contact surfaces carefully wit...

Page 73: ...ing tower Align to guide pin 3 Place the upper SCR unit and upper heatsink onto mounting screws on cooling tower Align to guide pin 2 Place screw nuts and tension bars to cooling tower 1 Place the distance bar onto mounting screws on cooling tower 2 Place the two torque washers and tension bar onto mounting screws on cooling tower 3 Place 2x Hexagon M10 Screw nut and the two spring washers onto mo...

Page 74: ...e inlets opening in the front cover 6 Place fan cover 1 Thread the fan cables through the cable inlets 2 Fasten fan cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each corner and on the center bracket of the fan cover 7 Place top cover 1 Fasten top cover to the unit with 6x Torx 20 M4x8 2 9Nm Screws are to be mounted in each corner and on the center bracket of the top cov...

Page 75: ... electronics can be affected by damage caused by electrostatic discharge This can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking...

Page 76: ...rom unit at this point still mounted on bracket to facilitate continued service 2 Disconnect SCR cables from PCBA Mark the SCR cables with 1 2 3 prior to disconnecting them to ensure proper re connection Note that markings are to be made in accordance with existing data available on the PCBA bracket 1 Disconnect the three SCR cables from their terminals on the PCBA using a long nose plier 2 Pull o...

Page 77: ...e markings 1 2 or 3 to their terminals on the PCBA 7 Place front cover 1 Place back the PCBA and the bracket on the Softstarter Place the front cover on the unit and align it to the plastic screw sleeves located on lower housing 2 Fasten the front cover with 4x Torx 20 4 0 x80 10 1 6Nm 3 Fasten 1x Torx 15 M3 5x12 0 5 Nm on the HMI bracket REASSEMBLE THE SOFTSTARTER Connect main power cables and co...

Page 78: ... affected by damage caused by electrostatic discharge This can happen if a charged tool or person touches a component Therefore it is very important that all tools and personnel are discharged by touching an earthed point before the PCBA or any of the components are touched It is equally important to discharge the package with the new component before opening it A person walking on a carpet can be...

Page 79: ...ight 2 Loosen 2x Torx 30 M6x12 and remove the left stays 3 Loosen 2x Torx 30 M6x12 and remove the right stays 2 Place the Stays 1 Place the new left stays on the Softstarter Fasten the left stays with 2x Torx 30 M6x12 8Nm 2 Place the new right stays on the Softstarter Fasten the right stays with 2x Torx 30 M6x12 8Nm 3 Rotate the Softstarter to the left REASSEMBLE THE SOFTSTARTER Connect main power...

Page 80: ...80 Service PSTX470 570 Service Manual 1SFC13105M0201 4 ...

Page 81: ...1SFC13105M0201 Service Manual Wiring Diagrams 81 5 5 Wiring Diagrams 5 1 Circuit diagram PSTX 5 1 1 Circuit diagram PSTX30 PSTX1250 IEC version 82 5 1 2 Circuit diagram PSTX30 PSTX1250 UL version 82 ...

Page 82: ...s 23 24 25 26 27 28 2 1 29 30 Anybus External control voltage 24V DC 18 13 14 Stop Start M U V W 2T1 4T2 6T3 1L1 3L2 5L3 V5 V6 K2 V4 V3 V2 V1 Ct1 Ct2 Ct3 2T1 1L1 K5 K4 12 11 10 9 8 7 6 5 4 K6 3 Only on PSTX470 PSTX1250 4T2 3L2 6T3 5L3 5 1 2 Circuit diagram PSTX30 PSTX1250 UL version A C B INCOMING LINES CXFU CHFU CCT CHFU START STOP 20 21 19 18 16 17 15 22 28 29 30 24 23 13 14 2 1 L N GND Start St...

Page 83: ...1SFC13105M0201 Service Manual Wiring Diagrams 83 5 ...

Page 84: ... Revisions Service Manual 1SFC13105M0201 The following revisions is done on this document Table 5 Document number Revision Chapter Description Date 1SFC13105M0201 A First release 2015 12 07 6 6 Revisions ...

Page 85: ...1SFC13105M0201 Service Manual Revisions 85 6 ...

Page 86: ...ubject to change without notice ABB AB Control Products Low voltage Products SE 721 61 Västerås Sweden Telephone 46 0 21 32 50 00 www abb com lowvoltage Softstarter Type PSTX210 370 and PSTX470 570 Service Manual 1SFC13105M0201 2015 12 07 ABB AB Control Productsl ...

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