SERVICE MANUAL - Sigma Motion srl
Contents
1. Before using the soft starter s output relay to switch an electronic contactor coil consult the contactor manufacturer Some contactor manufacturers eg Klockner Moeller state that you cannot use PCB mount relays for direct switching of their electronic contactor coils If this is the case there are two solutions Use the soft starter s output relay to control a slave relay This slave relay can then be used to directly switch the electronic contactor coil circuit 710 02696 00C CSX Series Page 7 AVOIDING DAMAGE SERI Soft starter output relay 2 Slave relay coll Contactor coil KM1 A1 IB A2 A 03300 A gt 2 Ifthe contactor has a volt free electronic input low voltage low current the soft starter s output relay can be wired directly into this input for contactor control er Soft starter output relay Contactor coil A11 A2 03301 A 3 3 Control Inputs CSX Series soft starters can be operated by external two wire or three wire control signals External switches are configured and wired into control input terminals O1 02 e External switches operating the control inputs must be rated for the control voltage being used and a continuous current of 100 mA e Incorrect configuration and wiring of the external contacts switches to the control input terminals may cause damage e Iflong cable runs are used wiring must be twisted pair or shielded cable and must be separa2. S lt R 3 s S 5 PCB revision 00C PCB revision 00D or later 3 x x x Z a 2 O 20 Le O 2 aoa a II IN White _ o White El Black ai T T Yellow II S Red O 6 4 ION O O SEMIKRON EUPEC SEMIKRON EUPEC 03298 B 995 02565 00 995 02566 00 995 02567 00 Se E sha pe 5 5 PCB revision 00C PCB revision 00D or later 2 o x o 3 2 x o H I L eG om mle Se gu TO 7654 765 4 O oO SEMIKRON EUPEC SEMIKRON EUPEC Page 18 CSX Series 710 02696 00C DISPOSAL INSTRUCTIONS Section 6 Disposal Instructions Component Fraction Environmental Dismantling Scrapping Characteristics conditions Aluminium No problems Re melt Separate from the rest to secure high grade of recovery Steel No problems Re melt Separate from the rest to secure high grade of recovery Wires No problems Re melt in copper works with previous The isolation contains softeners shredding if necessary PVC must be gloves are recommended Some incinerated at high temperature followed by of the isolation is made of PVC rapid cooling Printed
3. circuit boards Problems Copper recycling facilities where all precious All printed circuit boards and Current transformers metals are recovered and heavy metals and components with plastics contain SCRs other hazardous substances are bounded in flame retardant The tin solder the remainder fraction contains lead Plastics Problems Controlled incineration or recycling Plastics are polycarbonate or polycarbonate ABS alloy and contain glass and flame retardant Plastic 10 glass reinforced polycarbonate or polycarbonate ABS alloy PCB Cage clamps yellow zinc chromated steel Current transformer SCR Bus bars tin plated copper Heatsink extruded aluminium black anodised Sheet steel brackets zinc plated Spring stainless steel 7 10 02696 00C CSX Series Page 19 Page 20 CSX Series 710 02696 00C INU efor 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
4. or differences with the finished product Page 2 CSX Series 710 02696 00C TROUBLESHOOTING Section 2 Troubleshooting 2 1 Functional Tests Use the tests in this section to identify the cause of problems with the soft starter Basic Functionality Test This procedure tests that the soft starter is receiving control voltage Remove all external wiring from the soft starter control inputs O1 02 2 Connect the soft starter to control voltage A A2 or A2 A3 e The Ready LED should come on If it does not the Main Control PCB is damaged Power Circuit Test This procedure tests the soft starter s power circuit including the SCRs Interface PCB and Main Control PCB Disconnect the soft starter from mains voltage L1 L2 L3 control voltage Al A2 A3 and from the motor T T2 13 2 Use a 500 VDC insulation tester to measure the resistance across LI T 1 L3 T3 TI Ll and T3 L3 The resistance should be between 30 kQ and 500 kQ and equal for all measurements e Ifthe resistance is below 30 kQ for any measurement the SCR or bypass relay on that phase has been damaged and must be replaced e If the resistance is above 500 kQ for any measurement the Main Control PCB or Interface PCB may be faulty or there may be a faulty connection between these two PCBs To isolate the fault perform the PCB integrity test CSX Start Performance Test This procedure tests that the CSX soft starts correct
5. 00 995 02536 00 CSX xxx V6 xx 995 02539 00 995 02540 00 CSX Interface PCB Each soft starter requires one Interface PCB 995 02543 00 995 045 6 00 995 03874 00 2 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 27 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 710 02696 00C CSX Series Page 13 En PARTS Bypass Relays Soft starter models 007 030 and 075 1 10 require one bypass relay per starter Models 037 055 require two relays per starter 995 02568 00 CSX 037 CSX 045 995 045 5 00 CSX 055 CSX 075 CSX 090 995 03873 00 2 CSX 1 10 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 earlier versions 995 02568 00 995 045 5 00 995 03873 00 HE Fe SH 03755 B ELO 8rOI VZU VOrZ 10375 B Page 14 CSX Series 710 02696 00C DK R PARTS 5 2 CSXi Main Control PCB Each soft starter requires o
6. Figure 2 Bypass relay control pins 37 kW 55 kW models 740A R2A C048 012 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 owes 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 710 02696 00C CSX Series Page 5 TROUBLESHOOTINS Figure 5 MOV location on Interface PCB 7 kW 30 kW models Figure 7 MOV location on Interface PCB 75 kW 110 kW models Page 6 CSX Series 710 02696 00C AVOIDING DAMAGE Section 3 Avoiding Damage 3 1 SCRs SCR damage is generally caused by overcurrent overvoltage or overtemperature To prevent future damage check that the soft starter has been installed properly Common causes of SCR problems include Overcurrent e cable fault on soft starter output e motor fault e start current and or start time exceeds the soft starter s rating e starts per hour exceed the soft starter rating Overvoltage e power supply transient or surge e lightning strike direct or indirect on power supply e motor fault e loose connection in power circuit before or after the starter e power factor correction connected to the output of the soft starter e over corrected bulk power factor correction on a lightly load
7. aves one phase connected to the motor The soft starter should not be used as a safety switch NOTE It is the responsibility of the user or person installing the soft starter to provide proper grounding and branch circuit protection according to local electrical safety codes 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 NM Many electronic components are sensitive to static electricity Voltages so low that they cannot be felt 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 void the product warranty 2003 2008 AuCom Electronics Ltd All Rights Reserved As AuCom is continuously improving its products it reserves the right to modify or change the specification of its products at any time without notice The text diagrams images and any other literary or artistic works appearing in this document are protected by copyright Users may copy some of the material for their personal reference but may not copy or use material for any other purpose without the prior consent of AuCom Electronics Ltd AuCom endeavours to ensure that the information contained in this document including images is correct but does not accept any liability for error omission
8. e check whether the soft starter now operates correctly 2 Verify that the Main Control PCB is sound remove and e chec replace the Main Control PCB whether the soft starter now operates correctly 3 Verify that the Interface PCB is sound refit the original Mal n Control PCB e remove and replace the Interface PCB e chec whether the soft starter now operates correctly If the fault cannot be traced to either the Main Control PCB or the Interface PCB replace both PCBs Bypass Relay Integrity Test This procedure further isolates a fault with the soft starter s bypass circuitry Verify that the connections between the Main Control PCB and the Interface PCB and between the Interface PCB and the bypass relay are sound e remove the Main Control PCB e remove the Interface PCB e refit the Interface PCB to the bypass relays e refitthe Main Control PCB e check whether the soft starter now operates correctly 2 Verify that the bypass relay is sound e remove the Main Control PCB and Interface PCB e momentarily apply 24 VDC to the bypass relay control pins The bypass relay should change state The bypass relays are latching so behaviour must be checked by applying voltage in both directions If the bypass relay does not change state correctly it must be replaced Figure I Bypass relay control pins 7 kW 30 KW models Page 4 CSX Series 7 0 02696 00C O i BLESHOOTING
9. ed system causing severe ringing voltages Overtemperature e blocked heatsinks or restricted ventilation e inadequate ventilation e excessive ambient temperatures e bypass relay fails to close during running Protecting SCRs Modern SCRs are generally rugged and reliable However the risk of SCR damage can be reduced by using semiconductor fuses and or a main contactor e Semiconductor Fuses Semiconductor fuses reduce the potential for SCR damage caused by short circuits on the output of the starter Protection systems such as circuit breakers or HRC fuses do not operate quickly enough to protect SCRs from short circuits e 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 eliminates the risk of SCR damage due to overvoltage 3 2 Output Relays CSX Series soft starters have one fixed output relay terminals 13 14 and CSX soft starters have one fixed and one programmable output relay terminals 13 14 and 23 24 These relays are often used to control the main contactor The electronic contactor coils used in many contactors have a high initial inrush current which can damage the soft starter s internal relays if the contactor coil is switched directly Using the Soft Starter to Switch a Contactor
10. ly Connect the CSX to mains voltage and to a motor 2 Measure the voltage across LI TI and L3 T3 This should be close to the nominal 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 LI T and L3 T3 The voltage should fall to less than 2 VAC just before the CSX reaches Run mode e Ifthe voltage remains near nominal mains voltage the SCR is not firing correctly This can be caused by a faulty Main Control PCB a faulty Interface PCB or a poor connection between these two PCBs To isolate the fault perform the PCB integrity test CSXi Start Performance Test This procedure tests that the CSX soft starts correctly Calculate the expected motor start current by multiplying the CSX current rating by the Motor FLC setting and the Current Limit setting Connect the CSX to mains voltage and to a motor 3 Command the CSX to start While the CSX is starting measure the current on Ll and L3 e Ifthe current does not stabilise at expected level the SCR is not firing correctly This can be caused by a faulty Main Control PCB a faulty Interface PCB or a poor connection between these two PCBs To isolate the fault perform the PCB integrity test Bypass Relay Test CSX Series soft starters incorporate internal bypass relays This procedure tests the operation of the internal bypass relays Connect the
11. ne Main Control PCB CI Models C2 Models CSXi xxx V4 xx 995 02537 00 995 02538 00 CSXi xxx V6 xx 995 0254 00 995 02542 00 CSXi Interface PCB Each soft starter requires one Interface PCB 995 045 18 00 995 03875 002 995 03876007 995 03877 002 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 soft starter requires two SCRs Bypass Relays Soft starter models 007 030 and 075 1 10 require one bypass relay per starter Models 037 055 require two relays per starter 995 02568 00 CSXi 037 CSXi 045 995 045 15 00 CSXi 055 CSXi 075 CSXi 090 995 03873 00 2 CSXi 1 10 710 02696 00C CSX Series Page 15 SPAREPARTS PARTS 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 earlier versions 995 02568 00 995 045 15 00 995 03873 00 I HD Fe SH eLO 8P0D 7u VOrL 037558 CSXi Current Transf
12. ormers Each soft starter requires two current transformers 995 0257 00 995 02572 00 995 02573 00 995 0257 00 995 02572 00 995 02573 00 o 5 8 Page 16 CSX Series 710 02696 00C O SPAREPARTS PARTS 5 3 Finding the Batch Number The soft starter s batch number can be identified from a label on each PCB For boards with a barcode the batch number is on the For boards with no barcode the batch number is a six digit barcode label number on a separate label 8980 02398 fa u P gt i AJ990 02388 a lt ban 04348 890 02400 5 4 SCR Connections 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 0247 00x 340 02472 00x 340 02473 00x Connect the firing looms according to the diagrams below 995 02557 00 995 02558 00 995 02559 00 995 02560 00 995 02561 00 NOTE A Spare part kits may include either Semikron or Eupec SCRs These SCRs are fully interchangeable in CSX si PCB revision 00C PCB revision 00D or later 23 28 5 23 23 S Lo S da gas ease IJ nn a 1 76 54 76 54 76 54 76 54 SEMIKRON EUPEC SEMIKRON EUPEC 710 02696 00C CSX Series Page 17 SPAREPARTS PARTS 995 02562 00 995 02563 00 995 02564 00 t TRAI rer lt gt ql Le a
13. soft Starter SERVICE MANUAL Contents Section Caution Statements ii A a aqiaih ias 2 I Sac AA Aa 2 Section 2 Troubleshooting 4 sale Eee 3 2 1 Functional Mes a Eee 3 2 2 FaultDiagn sist dd did 4 Section 3 Ayaldinge DAM iaa 7 3 Eta A 3 2 Output RELAYS ia i n 7 3 3 NT 8 Section 4 Service OU Si a a aa aaa Ana 4 1 Exploded View CSX 007 CSX 030 4 2 Exploded VieWiG S203 72 CS 05 e 43 Exploded View CSX 0 7 52 CS Xe O HE EEE 44 Exploded View GSXEO00 72 TENSO Di ata ll 4 5 Exploded VIEWIESTEOSTFESXEOID cin ll 4 6 BpHlsded vieWESXE07IFESXE Os ak 12 Section 5 Spare Parts s 5 1 GSX aon ano a ce o a a a a ala carci ena 5 2 EA A A E 5 3 Finding the Batch Number weld 5 4 SCR CONNECTIONS ii A Aa 17 Section 6 Disposal SUCIO rra ao AA AA A 19 710 02696 00C CSX Series Page CAUTION STATEMENTS Section Caution Statements WARNING ELECTRICAL SHOCK HAZARD CSX Series soft starters contain dangerous voltages when connected to mains voltage Only a competent electrician should carry out the electrical installation Improper installation of the motor or the soft starter may cause equipment failure serious injury or death Follow this manual and local electrical safety codes 1 1 Safety Regulations Disconnect the soft starter from mains voltage before carrying out repair work Stopping the soft starter does not disconnect the equipment from mains voltage and le
14. soft starter to mains voltage and to a motor 2 Measure the voltage across LI T and L3 T3 This should be close to the nominal mains voltage e Ifthe voltage is zero the SCR or bypass relay on that phase may have failed 3 Command the soft starter to start When the Run LED stops flashing you should hear the bypass relay close 710 02696 00C CSX Series Page 3 TROUBLESHOOTINS 2 2 If the bypass re there may be a ay does not close the bypass relay Main Control PCB or Interface PCB may be faulty or faulty connection between these components To isolate the fault perform the bypass relay integrity test 4 When the soft starter is running measure the voltage across LI T and L3 T3 This should be less than 0 5 VAC If the voltage remains near nominal mains voltage the bypass relay did not close This can be caused by a faulty relay fa PCBs To isola ulty Main Control PCB a faulty Interface PCB or a poor connection between these two te the fault perform the bypass relay integrity test 5 Command the soft starter to stop You should hear the bypass relay open If the bypass re Fault Diagnosis ay does not open perform the bypass relay integrity test PCB Integrity Test This procedure further isolates a fault with the soft starter s control circuitry Verify that the connection between the Main Control PCB and the Interface PCB is sound remove and refit the Main Control PCB
15. ted from AC power cables by at least 300 mm NOTE Applying voltage to the control inputs will damage the soft starter Damage to the control inputs is not covered by warranty Page 8 CSX Series 710 02696 00C SERVICE INSTRUCTIONS Section 4 Service Instructions 4 1 Exploded View CSX 007 CSX 030 A 6 SCR heatsink connection tighten to 4 Nm Ei Man Coma 6 SCR heatsink connection tighten to 4 Nm 7 10 02696 00C CSX Series Page 9 SERVICE INSTRUCTIONS INSTRUCTIONS 4 3 Exploded View CSX 075 CSX 110 Man comarca O Interface PCB 6 SCR heatsink connection ighten to 4 Nm Page 10 CSX Series 710 02696 00C u INSTRUCTIONS 4 4 Exploded View CSXi 007 CSXi 030 EA Main Control PCB a 4 5 Exploded View CSXi 037 CSXi 055 Pra Comps 6 SCR pus bar connection ghten to 7 Nm 7 710 02696 00C CSX Series Page SERVICE INSTRUCTIONS INSTRUCTIONS 4 6 Exploded View CSXi 075 CSXi 1 10 in Control PCB Interface PCB Bypass relays Rs rrent transformers 710 02696 00C Page 12 CSX Series SPARE PARTS Section 5 Spare Parts NOTE The numbers shown indicate the quantity required for each starter Unless otherwise indicated spare part kits contain only one of each item 5 1 CSX Main Control PCB Each soft starter requires one Main Control PCB CI Models C2 Models CSX xxx V4 xx 995 02535
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