1. Maintenance masterdrive siemens

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

3. Safety instruction before maintenance

4. 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

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

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

7. 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

8. 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.

9. 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

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

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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

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

19. Checking for loose contacts

20. 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

21. 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

22. 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

23. 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  and 15.75V
24V  20 and 27V

24. 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

25. 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

26. 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

27. 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

28. 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

29. 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

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

31. 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

32. 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

33. 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

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

35. 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

36. 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’

37. 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

38. 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

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

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

41. 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

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

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