Maintenance masterdrive siemens

Equipment and materials Scoop fluke Testbox siemens multimeter fluke screwdrivers torque wrench 0-10 Nm torque wrench 10-40 Nm socket spanner/wrench small and big brakleen fine steel wool 2X grease filter cloths cleaning duds rubber pads tyraps powersupply bridge plug

Safety instruction before maintenance

Safety instruction before maintenance Push the emergency stop Turn off all three main switches on the AFE to zero and turn off the UPS in AFE Check DC voltage on the DC bus. How: push ‘P’ (parameter) on display push arrow ‘up’ till you see r 006 push again ‘P’ the number on screen = voltage on DC bus. this has to be under 12V

Safety instruction before maintenance Remove plastic cover of the DC fuses Measure DC voltage on DC fuses

Disassemble of the drive Remove main fan of drive Disconnect the power plug of the main fan Remove the fan (caution: very heavy!)

Disassemble of the drive Remove the three capacitors banks Disconnect the power plug of all capacitor banks Number each bank Remove the 4 bolts that keep the bank in place

Disassemble of the drive Remove the capacitor bank from drive Turn the bank 90 deg to the right Lift the bank up Pull the bank out its pivot point Place it on the ground 2. 1. 3.

Removing master drive circuit boards Removing the connections First take out the connector –X9 out. This to make sure there is no power on panel Remove the display panel and unplug it from the print board

Removing master drive circuit boards Remove al the connectors on all 3 pcb’s Make sure that you remember where to put them back

Removing master drive circuit boards By-pass the safety relay Remove the X533 connector Put the bridge plug on the X533 connector

Removing master drive circuit boards Remove the pcb’s Remove the 6 screws Take out all 3 boards without touching the printed circuit Place the boards on an isolated table or plate Make sure that you know the right position of each board

Cleaning the masterdrive Main fan With the use of brakleen you clean the entire fan Open the front cover and clean the inside of the cover Check for loose connections and burn marks

Cleaning the masterdrive Cleaning the capacitor banks Clean all dust and dirt from the capacitor with brakleen Remove the old grease on the copperplates Cleaning of copperplates with fine steel wool

Cleaning the masterdrive Check all the screws with a torque wrench at 8 Nm Cleaning the inside of the masterdrive Remove al the dust and dirt on the IGBT boards Clean the isolation panel Remove the old crease between the copper slidingplates

Cleaning the masterdrive If everything is clean you check the bolts on IGBT boards at 9Nm Check the bolts (M8) on the copper plates at 12Nm and the bolts (M10) at 18Nm

Cleaning the masterdrive Check the connection bolts (M12) on the copper plates at 70Nm Check if there are rubber pads between the wires and metal guiders

Cleaning the masterdrive substitute the filter cloths by new ones Clean the outer side of the electrical cabinet

Checking for loose contacts

Testing of the masterdrive placing the parts necessary for testing place the mainfan and connect the powerplug Mount the capacity banks in the corresponding slot (don’t shut them) Put grease (SGB 2X contact treatment) on the copper bars. Not on the isolation material

Testing of the masterdrive testbox Place now the test board on the most left side Connect the testbox on the test board Reconnect the plug on the –X09 connection

Testing of the masterdrive Powersupply Connect the + and – wires on the DC-bus Short circuit the copper connection bars of the motor with a wire Adjust the powersupply up to 24V DC and max 2A current

Testing of the masterdrive Testing with testbox Check if all leds light up Measure the voltage on the testbox with a scoop 5V  4.9 and 5.3V (-)15V  14.25 and 15.75V 24V  20 and 27V

Testing of the masterdrive Testing the IGBT,s Pull the first switch up when the led lights up it means that the testbox receives the feedback from the IGBT Pull the third switch down and check if the lower led lights up Check the power supply if the voltage drops down and the current rise

Testing of the masterdrive Put all switches in neutral position ‘0’ Check if power supply is at 24 volts Now do the same for all combination: 1 2 3 ok up down  

Testing of the masterdrive Testing the current coils of masterdrive Measure with scoop between ground and IRN / ISN / ITN Measurement has to be between -50mV and +50mV

Testing of the masterdrive Measure the temperature probe of radiator box Connect the scoop between ground and TWRN Measuring of the voltage should be between 4.53V and 5.29V at ambient temperature of 20dgr

Testing of the masterdrive Measuring the differential DC voltage Turn of the power supply on the DC bus DC bus must be approximately 0 Volt Measure with scoop between ground and UZKN Voltage should be between - 50mV and +50mV

Testing of the masterdrive Testing the main contactor and contactor of fan Turn on the main contactor switch and listen if fan works normal Turn on the pre-load contactor and listen if the contactor is activated If test is ok bring both switches to zero position

Testing of the masterdrive Ending the testing fase Turn of the powersupply and remove all testing equipment of the masterdrive

Testing of the masterdrive Disconnect the plug from –X9 to make sure there is no voltage present on the drive Remove the testbox and connection board

Assembly of the masterdrive Remove brigeplug from X533 connector Plug back the correct plug in to X533 connector Place back the boards in the right order

Assembly of the masterdrive Reconnector all the connector on the electronic boards if it’s a master slave configuration please check the fiber optic link

Assembly of the masterdrive Close the 3 capacitor banks of the masterdrive fasten the bolds of the banks (12 pieces)

Assembly of the masterdrive Reconnect the plugs of capacitor banks Reconnect the display panel Place all plastic covers on there original position Connect the powerplug on the –X9

Updating drivemonitor Accessing the drive Open the S7 simatic manager Go to the right masterdrive. For example: ‘h1inv/masterdrives’ Right click ‘PLC/drive/parameterization’ Click ‘ok’ when warnings shown Open ‘direct to parameter list’

Updating drivemonitor Cleaning the history faults Double click on ‘P952’ Change the value in the right side to ‘0’ and press ‘OK’ Repeat step 1 till 4 of page 36

Updating drivemonitor Uploading parameters from the drive Open ‘save drive parameters to a file’ make sure ‘basic device complete…’ is the only one who is active Press OK

Updating drivemonitor choose an object name according to the drive If file name allready exists,overwrite it Check if upload starts

Updating drivemonitor Wait a few minutes till it is uploaded When done press ‘OK’ and close ‘DriveMon’

Testing the quay crane Put the power back on Undo the emergency stop Turn the UPS back on of all 3 AFE’s Put the switch of the AFE back on

Testing the quay crane Resetting Push the ‘fault reset’ button check fault list  all faults that prevent starting the crane are reset

Testing the quay crane starting up crane Push the ‘control on’ button check if crane is on Check if there are fault generated