ABB PSTX370 User manual

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

This is the Service manual for Softstarter type PSTX210...370
and PSTX470...570.
Document number: 1SFC13105M0201
Revision: A
Issue date: 2015-12-07
Data subject to change without notice.
We reserve all rights to this document, even in the event that a
patent is issued and a different commercial proprietary right is
registered. Improper use, in particular reproduction and
dissemination to third parties, is not permitted.
This document has been carefully checked. If the user
nevertheless detects 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
Softstarter and the information in this manual.
Author’s address:
ABB AB
Control Products
Low Voltage Products
SE-721 61 Västerås, Sweden
Telephone: [phone]
www.abb.com/lowvoltage
© Copyright 2015. All rights reserved. Specication subject to
changes without notice.
Original instruction

This chapter describes warning and information signs used in
this manual, which the user should pay attention to.
• The service of the Softstarter shall be performed by
authorized personnel only.
• This manual should always be accessible to authorized
personnel working with service of Softstarters
PSTX210...370 and PSTX470...570.
• The manual shall always be read through before
performing any service tasks.
Usage of warnings and notes
There are two types of safety instructions throughout this
manual: warnings and notes. Warnings caution you about
conditions which can result in serious injury or death and/
or damage to the equipment, and advise on how to avoid
the danger. Notes draw attention to a particular
condition or fact, or give information on a subject.
The warning symbols are used as follows:
WARNING. HAZARDOUS VOLTAGE
General warning symbol indicates the presence of
a hazard which could result in personal injury and
damage to equipment or property.
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 done in accordance, with
existing laws and regulations.
INFORMATION
Information sign tells the reader important facts
and conditions.
Electrostatic sensitive devices warning
The printed circuit boards contain components
sensitive to electrostatic discharge. Wear a grounding
wrist band when handling the boards. Do not touch
the boards unnecessarily.
Personal safety
WARNING. HAZARDOUS VOLTAGE
Service and repair shall be performed by
authorized personnel only.
Service and repair shall be done in accordance
with existing laws and regulations.
ABB personnel must under all circumstances, as a
minimum, follow the ABB CISE 15.4 instruction.
WARNING
Use protective gloves when working with cover
plates to prevent cutting injuries.
Safety
Warning and information

11
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

1SFC13105M0201 | 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

8 Introduction | Service Manual | 1SFC13105M0201
1.1.4 Chapters included
Table 3
Chapter Description
1. Introduction Introduces the reader to this manual.
2. Description Describes the maintenance in general.
3. Service
PSTX210...370
This chapter describes how to perform service on the
Softstarter step-by-step.
The chapter contains:
• Earth the Softstarter
• How to enter the password code
• Update rmware
• Set the ID
• Reset to factory defaults
• Remove the HMI
• Place new HMI
• Disconnect main power cables and control
cables
• Connect main power cables and control
cables
• Change the PCBA
• Change the fans
• Change the bypass contactor
• Change the current transformers
• Change the SCR
• Test the SCR
4. Service
PSTX470...570
This chapter describes how to perform service on the
Softstarter step-by-step.
The chapter contains:
• Earth the Softstarter
• How to enter the password code
• Update rmware
• Set the ID
• Reset to factory defaults
• Remove the HMI
• Place new HMI
• Disconnect main power cables and control
cables
• Connect main power cables and control
cables
• Change the PCBA
• Change the fans
• Change the bar holders
• Change the current transformers
• Assemble the Softstarter
• Change the bypass contactor
• Assemble the Softstarter
• Change the 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 lifetime of the product is shortened.
1.1.1 Intended audience
General
The service manual is intended for internal use and for
the maintenance personnel responsible for service within
ABB.
Reprint
Reprinting of this service manual is only promoted on
approval. Reprint for internal use is permitted only for ABB
service engineers.
1.1.2 Revision notes and related
documents
For latest information on revisions and other documents
related to the Softstarters, please check www.abb.com/
lowvoltage.
Table 1
Document Document name
Spare parts catalogue 1SFC001013C0201
1.1.3 Acronyms and abbreviations
Acronyms and abbreviations used in this manual.
Table 2
Acronym/
Abbreviation
Description
PCBA Printed circuit board assembly
ESD Electrostatic sensitive device
LED Light Emitting Diode
LCD Liquid Crystal Display
SCR Silicon Controlled Rectifier (Thyristor)
HMI Human-Machine Interface
FBP Fieldbusplug
PCBA Printed Circuit Board Assembly
CT Current Transformer
R\L-key Remote or Local
i-key Information key
1

1SFC13105M0201 | Service Manual | Description 9
2
2 Description
2.1 Description
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

10 Description | Service Manual | 1SFC13105M0201
2.1 Description
This chapter outlines general information and procedures
necessary for performing maintenance on Softstarters
PSTX210...370 and PSTX470...570.
CAUTION
Do not open the Softstarter or touch any live parts
when the main and supply voltage is connected.
WARNING
If using the Rated Operational Voltage Ue (Phase
/N) as source for Control Supply Voltage Us, make
sure to not exceed Us250V AC,50/60Hz.
2.1.1 Regular maintenance
Check screws
• Check that all mounting screws are fastened.
Tighten if necessary.
• Check that all connections of main-, control- and
supply circuits are fastened.
• Tighten the terminal screws and screws on the
connection bars, if necessary.
• Check that the cooling airways are free from dirt and
dust.
• Check that all the LED lamps are working.
• Check that the text in the HMI display is working.
Keep Softstarter clean from dirt
• Clean all dust and dirt from the products exterior
using a vacuum cleaner. Any buildup of dirt or other
contaminates that will not come off with vacuuming
should be cleaned with lint free rags.
• All vents are to be cleaned of all dust and/or dirt.
Ensure that ventilation openings are not obstructed.
Dust and/or dirt in the Softstarter could lead to a short
circuit.
• In environments where there is an extreme exposure to
adverse conditions, the frequency of regular
maintenance for Softstarters should be increased.
If the Softstarter is installed in an electrical 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. Observe that
operating mechanisms function properly without
binding, hanging, or without delayed action. Ensure
mechanisms are clean, and all screws and screws are
properly secured. Repair or replace if necessary.
• Check contacts on Softstarters for signs of wear and
replace as required.
Service for By-pass Contactors
See the following operating instructions:
For PSTX470…570 1SFC 380023-en.
2.1.2 Tools required
• Slotted screwdriver
• Slotted screwdriver M3
• Long-nose plier
• Torx 15
• Torx 20
• Torx 25
• Torx 30
• Hexagon no. 4 Screwdriver
• Hexagon no. 8 Screwdriver
• Hexagon M10 socket wrench
• Abrasive cloth P600
• Ethanol
• Silicone oil
• Megger to set on 500V
2.1.3 Service and repair
In case the Softstarter has to be repaired, a spare parts
list and necessary instructions are available at:
www.abb.com/lowvoltage.
• Spare part list 1SFC001013C0201
Service and repair shall be performed by
authorized personnel only. Note that unauthorized
service and/or repair affects the safety and the
warranty.
2.1.4 Weights
CAUTION
Pay attention to the weight when handling the
Softstarter. Heavy lifting could result in personal
injury.
Table 4
Type Weight in kg Weight in lbs
PSTX 30...105 6,1 13,5
PSTX 142...170 9,6 21,2
PSTX 210...370 12,7 27,9
PSTX 470 25,5 56,2
PSTX 570 27,5 60,6
2

1SFC13105M0201 | Service Manual | Description 11
2.1.5 Dimension prints PSTX30...105, PSTX142...170
• PSTX30...105
• PSTX142...170
197.5 mm (7,7 in)
150 mm (5,9 in)
90,5 mm (3,6 in
)
3 mm (0,1 in)
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

12 Description | Service Manual | 1SFC13105M0201
• PSTX210...370
• PSTX470...570
2.1.6 Dimension prints PSTX210...370, PSTX470...570
260 mm (10,2 in)
279.1 mm (10,9 in)
470 mm (18,5 in)
451.2 mm (17,7 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

1SFC13105M0201 | Service Manual | Description 13
2

14 Description | Service Manual | 1SFC13105M0201
2.1.7 Markings and connections
Table 4
Position Key
1Selection soft keys
2Navigation keys
3R\L-key = Remote or Local control
4i-key = Information
5Stop key
6Start key
L
100-250V
50/60 Hz K4 K5 K6
StartStopIn1 In2 DGND +24VGND
N
In0
Ready
RunFault
Protection
PSTX
Start
Options Menu
3
5
1
4
6
2
1
Stop
L
100-250V
50/60 Hz K4 K5 K6
StartStopIn1 In2DGND +24VGND
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
Approvals
Terminal marking of
control circuits
Protection (Yellow)
Fault (Red)
Technical data
according to
IEC 60 947-4-2
Ready (Green)
Run (Green)
2

1SFC13105M0201 | Service Manual | Description 15
2.1.8 Identification of Softstarter type
NOTE
The service kits and spare parts varies depending on
the type and serial number of the Softstarter. It is essential
that the corresponding service kits and spare parts is
used. Always refer to the spare parts catalogue when
ordering service kits and spare parts. The spare parts
catalogue, 1SFC001013C0201, is to be found on
www.abb.com/lowvoltage.
Identification
The Softstarter is identified by the front label A.
Terminal marking of main circuit B.
AFront label
Order code 2.
Technical data according to IEC 60947-4-2 3.
Technical data according to UL 508 4.
The label shows the Softstarter and the serial number.
CSerial 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 = Manufacturing year. Two digits.
(e.g. 02 for year 2002)
WW = Manufacturing Week. Two digits.
NNNN = Running number with week. Minimum four digits,
starting with 1000 each week.
Com1 Com2
2
3
4
A
B
B
1SFA 894 007 R1002
Ie: 37-72A
UL 508
Uc: 100-250V AC/DC
FLA: 37-68A
Ue 208 220-240 440-480 V
In line 20 20 50 Hp
Overload Capacity 115% of Continuous
1234567891011121314151617181920
100-250V
LN
Stop Start In1VcVn Vp Vp K4
In0
50/60 Hz K5 K6
PTCKeypad Fieldbus
1L1
2T14T2 6T3
B1 B2 B3
3L25L3
LISTED
IND. CONT. EQ
7F39
IEC 947-4-2
Us: 100-250V AC/DC Ue: 220-230 380-400 500 V
72: AC-53a: 8-1.6: 80-6
In line 18,5 37 45 kW
LISTED 7F39
IND. CONT.EQ
.
Ie: 37-72A
Us: 100-250V AC/DC
UL
Uc: 100-250V AC/DC
FLA: 37-68A
Ue: 220-230 380-400 500 V
In line 18,5 3745 kW
Ue 208 220-240 440-480 V
In line 20 2050 Hp
CAUTION
Fuse 250ATYPOWER ZILOX
Max short circuit current 65kAat Wire 1-8Al Cu75C only, 35lb-in
Overload Capacity 115%of Continuous
PTC
Keypad Fieldbus
1S160100103020123
12345678910111213
Bypass connection
(PST30...300 only)
Terminal marking
of control circuits
Control voltage U
e
For identification of Softstarter, see chapter
2.1.9 Identification of Softstarter type
Line side
connection
Power on ProtectionFault
1 2
3
4
Figure 1:
1 Status indication LEDs
2 LCD display
3 Selection keys for selecting, changing and storing parameters
4 Navigation keys for navigating in the menus
* Arrows shown in the display indicate that the value/menu is
possible to change or scroll
5
L
100-250V
50/60 Hz K4 K5 K6
StartStopIn1 In2DGND+24VGND
N
In0
Ready
Run Fault
Protection
PSTX
1S160100103020123
12345678910111213
C
2

16 Description | Service Manual | 1SFC13105M0201
2

1SFC13105M0201 | Service Manual | Service PSTX210...370 17
3
3 Service PSTX210...370
3.1 Introduction
3.1.1 Earth the Softstarter 18
3.1.2 How to access service parameters 18
3.2 Configuring the HMI
3.2.1 Update Firmware 19
3.2.2 Set the ID 19
3.2.3 Reset to factory defaults 20
3.3 Change the HMI, Disconnect/Connect the main power 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 Current transformers 33
3.6 Change the SCR
3.6.1 Change the SCR 36
3.7 Instructions for testing the SCR
3.7.1 Test the SCR 41

18 Service PSTX210...370 | Service Manual | 1SFC13105M0201
3.1 Introduction
This service instruction contains step-by-step service of
the PSTX210...370 Softstarter.
Lock/Unlock parameters
Push and hold the Options-key, Menu-key and
i-key simultaneous for 2 seconds in order to lock/
unlock the keypad. This prevents accidental
changes of parameters. Parameters are read-only.
Still Start/Stop and R/L is active.
3.1.1 Earth the Softstarter
1. Maximum cable length of the earthing
The Softstarter should be earthed from terminal
22. The earthing cable length must not be longer
than 50 cm. Note that the earthing is not a
protective earth.
3.1.2 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).
2. 1Push ”Options” to reach Options menu.
Use or to navigate to Security
management and then push ”Select”.
3. 2Use or to navigate to Login and then
push ”Select”.
4. 3Use or to navigate to Service and then
push ”Select”.
5. 4Use , and , to enter the
Password for service.
Enter the following password: 73758,and then
push ”Enter”.
6. When the message Service login OK appears, the
password is set.
INFORMATION
To login as Advanced User you must set the
parameter 28.45 to “Yes”. Then follow the same
password procedure as Service but use 00000
for password.
K4 K5 K6
StartStopIn1 In2DGND +24VGNDIn0
PSTX
The earthing cable length
MAX 50 cm.
Not a protective earth
1
2
3
4
3

1SFC13105M0201 | Service Manual | Service PSTX210...370 19
3.2 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.
3.2.2 Set the 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. 1Push ”Menu” to reach Menu.
Use or to navigate to Parameters and then
push ”Select”.
3. 2Use or to navigate to Complete list
and then push ”Select”.
4. 3Use or to navigate to 28 Service and
then push ”Select”.
5. 4Use or to navigate to 28.01 ID and then
push ”Edit”.
6. 5Use , to set 28.01 ID to 105
and then push ”Save”.
1
3.2.2_3
1
2
3
4
5
3

20 Service PSTX210...370 | Service Manual | 1SFC13105M0201
3.2.3 Reset to factory defaults
1. Switch on the power supply (terminal 1 and 2).
2. 1Push ”Menu” to reach Menu.
Use or to navigate to Settings and then
push ”Select”.
3. 2Use or to navigate to Reset to
defaults and then push ”Select”.
4. 3Use or to navigate to Reset all
parameters and then push ”Select”.
5. 4Following 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