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SERVICE MANUAL

AuCom Electronics Ltd

123 Wrights Road

PO Box 80208

Christchurch 8440

New Zealand

T +64 3 338 8280

F +64 3 338 8104

E [email protected]

W www.aucom.com

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Summary of Contents for CSX-007

Page 1: ...SERVICE MANUAL ...

Page 2: ...7 3 3 Control Inputs 8 Section 4 Service Instructions 9 4 1 Exploded View CSX 007 CSX 030 9 4 2 Exploded View CSX 037 CSX 055 9 4 3 Exploded View CSX 075 CSX 110 10 4 4 Exploded View CSXi 007 CSXi 030 11 4 5 Exploded View CSXi 037 CSXi 055 11 4 6 Exploded View CSXi 075 CSXi 110 12 Section 5 Spare Parts 13 5 1 CSX 13 5 2 CSXi 15 5 3 Finding the Batch Number 17 5 4 SCR Connections 17 Section 6 Dispo...

Page 3: ...w that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components When performing service proper ESD equipment should be used to prevent possible damage from occurring NOTE The CSX Series soft starter is not user serviceable The unit should only be serviced by authorised service personnel Unauthorised tampering with the unit will ...

Page 4: ...mains voltage If the voltage is zero the SCR or bypass relay on that phase may have failed 3 Command the CSX to start While the CSX is starting measure the voltage across L1 T1 and L3 T3 The voltage should fall to less than 2 VAC just before the CSX reaches Run mode If the voltage remains near nominal mains voltage the SCR is not firing correctly This can be caused by a faulty Main Control PCB a f...

Page 5: ...starter now operates correctly 2 Verify that the Main Control PCB is sound remove and replace the Main Control PCB check whether the soft starter now operates correctly 3 Verify that the Interface PCB is sound refit the original Main Control PCB remove and replace the Interface PCB check whether the soft starter now operates correctly If the fault cannot be traced to either the Main Control PCB or...

Page 6: ...models PCB Visual Inspection Damage to the MOV on the Main Control PCB may indicate that incorrect control voltage has been applied to the unit Figure 4 Location of MOV on Main Control PCB Damage to the MOVs and or surrounding circuitry on the Interface PCB may indicate that the soft starter has suffered overvoltage This usually also damages the SCRs ...

Page 7: ...OTING Page 6 CSX Series 710 02696 00C Figure 5 MOV location on Interface PCB 7 kW 30 kW models Figure 6 MOV location on Interface PCB 37 kW 55 kW models Figure 7 MOV location on Interface PCB 75 kW 110 kW models ...

Page 8: ... Protection systems such as circuit breakers or HRC fuses do not operate quickly enough to protect SCRs from short circuits Main Contactors SCRs are most vulnerable to overvoltage damage when voltage is applied to their input terminal while they are off In this condition the SCR is blocking the full line voltage Using a main contactor to remove voltage from the SCR input when the starter is off el...

Page 9: ...ee wire control signals External switches are configured and wired into control input terminals 01 02 External switches operating the control inputs must be rated for the control voltage being used and a continuous current of 100 mA Incorrect configuration and wiring of the external contacts switches to the control input terminals may cause damage If long cable runs are used wiring must be twisted...

Page 10: ...e PCB 3 Bypass relays 4 SCRs 5 SCR bus bar connection tighten to 4 Nm 6 SCR heatsink connection tighten to 4 Nm 4 2 Exploded View CSX 037 CSX 055 1 Main Control PCB 2 Interface PCB 3 Bypass relays 4 SCRs 5 SCR bus bar connection tighten to 5 Nm 6 SCR heatsink connection tighten to 4 Nm Section 4 Service Instructions ...

Page 11: ...UCTIONS Page 10 CSX Series 710 02696 00C 4 3 Exploded View CSX 075 CSX 110 1 Main Control PCB 2 Interface PCB 3 Bypass relays 4 SCRs 5 SCR bus bar connection tighten to 9 Nm 6 SCR heatsink connection tighten to 4 Nm ...

Page 12: ... Bypass relays 4 SCRs 5 Current transformers 6 SCR bus bar connection tighten to 4 Nm 7 SCR heatsink connection tighten to 4 Nm 4 5 Exploded View CSXi 037 CSXi 055 1 Main Control PCB 2 Interface PCB 3 Bypass relays 4 SCRs 5 Current transformers 6 SCR bus bar connection tighten to 7 Nm 7 SCR heatsink connection tighten to 4 Nm ...

Page 13: ...12 CSX Series 710 02696 00C 4 6 Exploded View CSXi 075 CSXi 110 1 Main Control PCB 2 Interface PCB 3 Bypass relays 4 SCRs 5 Current transformers 6 SCR bus bar connection tighten to 12 Nm 7 SCR heatsink connection tighten to 4 Nm ...

Page 14: ... 037 CSX 045 995 04516 00 1 CSX 055 CSX 075 CSX 090 995 03874 00 2 CSX 110 1 This part is suitable for use with CSX Series units of version 10 or later serial number xxxxx 10 Please contact AuCom for assistance with earlier versions 2 This part is suitable for use with CSX Series units of version 7 or later serial number xxxxx 07 Please contact AuCom for assistance with earlier versions SCRs Each ...

Page 15: ...995 04515 00 1 CSX 055 CSX 075 CSX 090 995 03873 00 2 CSX 110 1 This kit is suitable for use with CSX Series units of version 10 or later serial number xxxxx 10 batch number 060227 Please contact AuCom for assistance with earlier versions 2 This kit is suitable for use with CSX Series units of version 7 or later serial number xxxxx 07 batch number 050602 Please contact AuCom for assistance with ea...

Page 16: ...or later serial number xxxxx 10 Please contact AuCom for assistance with earlier versions 2 This part is suitable for use with CSX Series units of version 7 or later serial number xxxxx 07 Please contact AuCom for assistance with earlier versions SCRs Each soft starter requires two SCRs CSXi 007 995 02557 00 CSXi 015 995 02558 00 CSXi 018 995 02559 00 CSXi 022 995 02560 00 CSXi 030 995 02561 00 CS...

Page 17: ...table for use with CSX Series units of version 7 or later serial number xxxxx 07 batch number 050602 Please contact AuCom for assistance with earlier versions 995 02568 00 995 04515 00 995 03873 00 CSXi Current Transformers Each soft starter requires two current transformers CSX 007 CSX 015 CSX 018 995 02571 00 CSX 022 CSX 030 CSX 037 CSX 045 995 02572 00 CSX 055 CSX 075 CSX 090 995 02573 00 CSX 1...

Page 18: ...te label 5 4 SCR Connections NOTE Spare part kits may include either Semikron or Eupec SCRs These SCRs are fully interchangeable in CSX Series units and can be mixed within the same soft starter The connections between the Interface PCB and SCR depend on the revision of the Interface PCB 340 02471 00x 340 02472 00x 340 02473 00x Connect the firing looms according to the diagrams below 995 02557 00...

Page 19: ...RE PARTS Page 18 CSX Series 710 02696 00C 995 02562 00 995 02563 00 995 02564 00 PCB revision 00C PCB revision 00D or later 995 02565 00 995 02566 00 995 02567 00 PCB revision 00C PCB revision 00D or later ...

Page 20: ... circuit boards Current transformers SCRs Problems Copper recycling facilities where all precious metals are recovered and heavy metals and other hazardous substances are bounded in the remainder fraction All printed circuit boards and components with plastics contain flame retardant The tin solder contains lead Plastics Problems Controlled incineration or recycling Plastics are polycarbonate or p...

Page 21: ...NOTES Page 20 CSX Series 710 02696 00C ...

Page 22: ...AuCom Electronics Ltd 123 Wrights Road PO Box 80208 Christchurch 8440 New Zealand T 64 3 338 8280 F 64 3 338 8104 E enquiry aucom com W www aucom com ...

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