ABB PSTX 30***105 Service Manual
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ABB PSTX 30***105 Service Manual

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Service manual en, rev B 1SFC132115M0201
Softstarter type PSTX720...840
Service manual

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Summary of Contents for ABB PSTX 30***105

  • Page 1 Service manual en, rev B 1SFC132115M0201 Softstarter type PSTX720...840 Service manual...
  • Page 2 As a result, there may be some differences between the Softstarter and the information in this manual. Author’s address: ABB AB Control Products Low Voltage Products SE-721 61 Västerås, Sweden Telephone: +46 (0) 21 32 50 00 www.abb.com/lowvoltage...
  • Page 3 Service and repair shall be done in accordance damage to equipment or property. with existing laws and regulations. ABB personnel must under all circumstances, as a WARNING minimum, follow the ABB CISE 15.4 instruction. Warning symbol indicates the presence of hazardous voltage which could result in personal injury.

  • Page 5: Description

    Softstarter type PSTX720...840 Service manual 1 Introduction 2 Description 3 Service PSTX720...840 4 Circuit Diagrams 5 Revisions...
  • Page 7 1 Introduction 1.1 Service manual 1.1.1 Intended audience 1.1.2 Revision notes and related documents 1.1.3 Acronyms and abbreviations 1.1.4 Chapters included | Service Manual | Introduction 1SFC13105M0201...
  • Page 8 Reprint • Connect main power cables and control Reprinting of this service manual is only promoted on cables approval. Reprint for internal use is permitted only for ABB • Change the PCBA service engineers. • Change the fans •...

  • Page 9: Table Of Contents

    2 Description 2.1 Description 2.1.1 Regular maintenance 2.1.2 Tools required 2.1.3 Service and repair 2.1.4 Weights 2.1.5 Dimension prints PSTX30...105, PSTX142...170 2.1.6 Dimension prints PSTX210...370, PSTX470...570 2.1.7 Dimension prints PSTX720...840, PSTX1050...1250 2.1.8 Markings and connections 2.1.9 Identification of Softstarter type | Service Manual | Description 1SFC13105M0201...

  • Page 10: Regular Maintenance

    In case the Softstarter has to be repaired, a spare parts • Make sure that the cooling airways are free from dirt and dust. list and necessary instructions are available at: www.abb.com/lowvoltage. • Make sure that all LED lamps are working. • Spare part list 1SFC001013C0201 •...

  • Page 11: Dimension Prints Pstx30

    2.1.5 Dimension prints PSTX30...105, PSTX142...170 • PSTX30...105 30 mm (1,2 in) 4x Ø14 (2x) 13 mm (0,5 in) 6x 150 mm (5,9 in) 119 mm (4,7 in) • PSTX142...170 Ø18 (2x) 35 mm (1,3 in) 4x 7,5 mm (0,3 in) 6.6 mm (0,2 in) 4x 17,5 mm (0,7 in) 6x 199 mm (7,8 in)

  • Page 12: Dimension Prints Pstx210

    2.1.6 Dimension prints PSTX210...370, PSTX470...570 • PSTX210...370 10,5 mm (0,4 in) 43,7 mm (1,7 in) 4x 19,6 mm (0,8 in) 6x 200 mm (7,9 in) 258 mm (10,2 in) • PSTX470...570 336 mm (13.2 in) 2x 7 mm (0.2 in) 4x 63 mm (2.5 in) 4x 9 mm (0.3 in) 25 mm (0.9 in) 6x...

  • Page 13: Dimension Prints Pstx720

    2.1.7 Dimension prints PSTX720...840, PSTX1050...1250 • PSTX720...840 Ø12.5 (6x) 72 mm 40mm 7 mm (0.276 in) 4x (2.8 in) (1.57 in) Ø6.5 (12x) 55.8 mm (2.2 in) 435 mm (17.126 in) Ø 13 (4x) 408.9 mm (16.1 in) • PSTX1050...1250 133.5 mm (5.2 in) 2x 301.5 mm (11.8 in)

  • Page 14: Markings And Connections

    2.1.8 Markings and connections Terminal marking of control circuits Supply voltage Us Line side connection 100-250V 50/60 Hz Start Stop In1 In2 DGND +24V PSTX Display Order code Ready (Green) Protection (Yellow) Ready Protection Fault Run (Green) Fault (Red) Keypad Mini USB Technical data according to...

  • Page 15: Identification Of Softstarter Type

    The label shows the Softstarter and the serial number. Ready Protection Fault Com1 Com2 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 PPPP...
  • Page 16 Description | Service Manual | 1SFC13105M0201...
  • Page 17 3 Service PSTX720...840 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 Remove the HMI 3.3.2 Place the new HMI...

  • Page 18: Introduction

    Introduction This service instruction contains step-by-step service of the PSTX720...840 Softstarter. The earthing cable length MAX 50 cm. Not a protective earth 3.1.1 Earth the Softstarter Maximum cable length of the earthing The Softstarter should be earthed from terminal 22. The earthing cable length must not be longer Start Stop In1 In2 DGND +24V...

  • Page 19: Configuring The Hmi

    This chapter describes how update firmware, set the ID and how to reset the Softstarter to default. 3.2.1 Update Firmware Firmware needs to be updated when changing the HMI. Please contact your ABB sales office for information. See Figure 1. 3.2.1_1 3.2.2 Set the ID The ID of the Softstarter has to be changed when the PCBA has been changed and after updating firmware.

  • Page 20: Reset To Factory Defaults

    3.2.3 Reset to factory defaults Switch on the power supply (terminal 1 and 2). Press ”Menu” to reach Menu. to navigate to Settings and then press ”Select”. to navigate to Reset to defaults and then press ”Select”. to navigate to Reset all parameters and then press ”Select”.

  • Page 21: Change The Hmi, Disconnect/Connect The Main Power Cables And The Control Cables

    Change the HMI, Disconnect/ Connect the main power cables and the control cables This chapter describes how to change the HMI, disconnect or connect the main power cables and the control cables prior to performing service on the softstarter. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter.

  • Page 22: Remove The Hmi

    Dock the HMI module by pushing the rear end downwards and carefully snap the module into position. Procedures after HMI replacement Firmware needs to be updated when changing 3.3.2_2 the HMI. Please contact your ABB sales office for information. Service PSTX720...840 | Service Manual | 1SFC13105M0201...

  • Page 23: Disconnect The Main Power Cables And The Control Cables

    3.3.3 Disconnect the main power cables and the control cables CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the...

  • Page 24: Connect The Main Power Cables And The Control Cables

    3.3.4 Connect the main power cables and the control cables CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the...

  • Page 25: Service Of The Pcba

    Service of the PCBA This chapter describes changing of the PCBA. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the...

  • Page 26: Change The Pcba

    3.4.1 Change the PCBA CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the Softstarter.
  • Page 27 Place new PCBA on PCBA bracket Note that rubber bushings shall be mounted on the PCBA prior to assembly. Position the bracket so that ABB:s logotype appears upside down on the upper end. 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.
  • Page 28 Set the ID of the Softstarter after changing the PCBA, as described in chapter 3.2.2, step 1-6. 3.4.1_11 Firmware needs to be updated when changing the HMI. Please contact your ABB sales office for information. Service PSTX720...840 | Service Manual | 1SFC13105M0201...

  • Page 29: 3.5 Change The Fans, Bar Holders And Current Transformers

    Change the Fans, Bar holders and Current transformers This chapter describes changing of the Fans, Current transformers and Bar holders. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used.

  • Page 30: Change The Fans

    3.5.1 Change the Fans DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control cables as described in chapter 3.3.3, step 1-3. Tx 20 M4 x 8 Remove HMI cover and PCBA Dismantle the HMI cover, all cables and the PCBA as described in chapter 3.4.1, step 1-5.

  • Page 31: Change The Bar Holders

    3.5.2 Change the Bar holders DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control cables as described in chapter 3.3.3, step 1-3. Remove HMI cover and PCBA Dismantle the HMI cover, all cables and the PCBA as described in chapter 3.4.1, step 1-4.
  • Page 32 Remove screws from bottom bar holder Loosen (2x) Torx 30 M6x16 from the lower Tx 30 corners of the bar holder. M6 x 16 Loosen (6x) Torx 30 M6x16 to disengage the bar holder from the phase bars. Tx 30 M6 x 16 3.5.2_4 Remove bottom bar holder...

  • Page 33: Change The Current Transformers

    3.5.3 Change the Current transformers Remove screws from bottom bar holder Loosen (2x) Torx 30 M6x16 from the lower Tx 30 corners of the bar holder. M6 x 16 Loosen (6x) Torx 30 M6x16 to disengage the bar holder from the phase bars. Tx 30 M6 x 16 3.5.3_1...
  • Page 34 Remove screws from top bar holder Loosen (2x) Torx 30 M6x16 from the lower corners of the bar holder. Tx 30 M6 x 16 Loosen (6x) Torx 30 M6x16 to disengage the bar holder from the phase bars. Tx 30 M6 x 16 3.5.3_5 Remove top bar holder...

  • Page 35: Assemble The Softstarter

    3.5.4 Assemble the Softstarter CAUTION Use protective gloves when working with cover plates to prevent cutting injuries. Place side- and front covers Make sure to position side covers with dual locking rails facing upwards prior to assembly. Interlock the side covers to rails and slide them sideways into position.
  • Page 36 Change the Bypass contactor This chapter describes how to change of the By-pass Contactor. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the...
  • Page 37 3.6.1 Change the Bypass contactor DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control cables as described in chapter 3.3.3, step 1-3. Remove cover and PCBA Dismantle the HMI cover, all cables and the PCBA as described in chapter 3.4.1, step 1-5.
  • Page 38 Remove phase screws Loosen (6x) Hexagon no. 10 M12x40 from the phases of the bypass contactor. Removing the Hexagon n.10 M12x40 screws will also loosen the square nuts located under each phase bar. Loosen (4x) Hexagon no. 5 M5x100 from Hexagon n.5 the bypass contactor.
  • Page 39 Remove bypass contactor Remove the bypass contactor from base plate. Dispose of expended bypass contactor. 3.6.1_8 Place new bypass contactor Place the new bypass contactor on the base plate with terminals 2T1, 4T2 and 6T3 facing downwards. 3.6.1_9 | Service Manual | Service PSTX720...840 1SFC13105M0201...

  • Page 40: Assemble The Softstarter

    3.6.2 Assemble the Softstarter Please don’t forget to vacuum clean the Softstarter from dirt and dust when reassembling. CAUTION Use protective gloves when working with cover plates to prevent cutting injuries. Place cooling towers Place all three cooling towers on the base plate and align to screw holes.
  • Page 41 Place side- and front covers Make sure to position side covers with dual locking rails facing upwards prior to assembly. Interlock the side covers to rails and slide them sideways into position. Attach side covers to support brackets mounted on cooling towers. Place the front cover on the unit and interlock to rails.
  • Page 42 Change the SCR This chapter describes how to change the SCR. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING • SCR and heat sinks must be handled carefully to avoid scratches and other marks.
  • Page 43 3.7.1 Change the SCR DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control cables as described in chapter 3.3.3, step 1-3. Remove HMI cover and PCBA Dismantle the HMI cover, all cables and the PCBA as described in chapter 3.4.1, step 1-4.
  • Page 44 INFORMATION It is important to untighten the hexagon screw- nuts while the cooling tower is still mounted to the unit through the internal phase bar. This prevent the cooling tower from being bent due to torque forces. Untighten screw-nuts from cooling tower Untighten (2x) Hexagon n.
  • Page 45 Remove heat sinks and SCR from cooling tower Remove the upper heat sink and upper SCR unit by lifting them upwards from stud bolts. Remove the middle heat sink and lower SCR unit by lifting them upwards from stud bolts. Do not remove the insulation plastic pipes from stud bolts.

  • Page 46: Assemble The Softstarter

    3.7.2 Assemble the Softstarter Please don’t forget to vacuum clean the Softstarter from dirt and dust when reassembling. CAUTION Use protective gloves when working with cover plates to prevent cutting injuries. INFORMATION It is important that the cooling tower is mounted to the unit through the internal phase bar before tightening the hexagon screw-nuts.
  • Page 47 Place bottom side bar holder Place the bar holder (with phase bars mounted) to the unit and fasten (2x) Torx 30 M6x16 Hexagon n. 10 M12x40 (8Nm) to the lower corners of the bar holder. (45Nm) Fasten the phase screws, (3x) Hexagon no.
  • Page 48 Place top cover Fasten the top cover to the unit with (10x) Torx 20 M4x8 (2,9Nm). Tx 20 M4 x 8 (2,9Nm) 3.7.2_9 REASSEMBLE THE SOFTSTARTER Place PCBA, cables and HMI cover Place the PCBA, connect all cables and install the HMI cover as described in chapter 3.4.1, step 6-11.

  • Page 49: 3.8 Instructions For Testing The Scr

    Instructions for testing the SCR IMPORTANT NOTE Only perform the SCR-test if the Softstarter displays one of the following commandos: “Short circuit fault” or “Open circuit thyristor fault”. Replace SCR if the result of the test shows under 1 Mohm. CAUTION Always make sure that the power supply is switched off before doing maintenance on the...

  • Page 50: Test The Scr

    3.8.1 Test the SCR IMPORTANT NOTE Only perform the SCR-test if the Softstarter displays one of the following commandos: “Short circuit fault” or “Open circuit thyristor fault”. Replace SCR if the result of the test shows under 1 Mohm. DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control...
  • Page 51 Switch Megger cables Switch the connection according to figure 4: Connect the red megger contact to the main 250V 500V terminal 1L1 on the Softstarter. 1000V Connect the black megger contact to the main terminal 2T1 on the Softstarter. Set the megger on 500V. Press and hold the 250V 500V 1000V...
  • Page 52 Change the Stays This chapter describes how to change the Stays. CAUTION Always make sure that the power supply is switched off before doing maintenance on the Softstarter. WARNING When performing maintenance on the Softstarter, an antistatic strap must be used. The antistatic strap should be worn on the wrist, and be connected to an electrical ground, to prevent electrostatic discharge (ESD) damage to the...
  • Page 53 3.9.1 Change the Stays DISMANTLE THE SOFTSTARTER Remove main power cables and control cables Disconnect the main power cables and the control cables as described in chapter 3.3.3, step 1-3. CAUTION Use protective gloves when working with stays to prevent cutting injuries. Remove left and right stays Rotate the Softstarter to the right.
  • Page 54 Service PSTX720...840 | Service Manual | 1SFC13105M0201...
  • Page 55 4 Circuit Diagrams 4.1 Circuit diagram PSTX 4.1.1 Circuit diagram PSTX30...PSTX1250 (IEC version) 4.1.2 Circuit diagram PSTX30...PSTX1250 (UL version) | Service Manual | Circuit Diagrams 1SFC13105M0201...
  • Page 56 Circuit diagram PSTX 4.1.1 Circuit diagram PSTX30...PSTX1250 (IEC version) CAUTION Terminal 22 is a function earth, it is not a protection earth. It shall be connected to the mounting plate. +24V Internal control voltage DGND Stop Start 20, 21 Low Voltage Board Stop Start Internal control voltage...
  • Page 57 | Service Manual | Circuit Diagrams 1SFC13105M0201...
  • Page 58 5 Revisions The following revisions is done on this document: Table 5 Document number Revision Chapter Description Date First release 2015-12-18 1SFC132115M0201 Updates 2017-06-30 1SFC132115M0201 Revisions | Service Manual | 1SFC13105M0201...
  • Page 59 | Service Manual | Revisions 1SFC13105M0201...
  • Page 60 Contact us ABB AB Control Products Low voltage Products SE-721 61 Västerås, Sweden Telephone: +46 (0) 21 32 50 00 www.abb.com/lowvoltage © Copyright 2017, All rights reserved. Specification subject to change without notice.

This manual is also suitable for:

Pstx 142***170Pstx 210***370Pstx 720***840Pstx 470Pstx 1250Pstx 1050 ... Show all

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