g DEH-40417 ASTAT ®-IBP Plus Solid State Starters Service Instructions
DEH-40417 WARNINGS, CAUTIONS, AND NOTES AS USED IN THIS PUBLICATION WARNINGS Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury are present in this equipment or may be associated with its use. Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.
ASTAT ®-IBP Plus Service Instructions Table of Contents Cover Removal and Replacement ............................................................................................1 Logic Board Replacement .......................................................................................................2 Power Supply Board Replacement ...........................................................................................3 Protection Board Replacement ..................................................
ASTAT ®-IBP Plus Service Instructions WARNING: Power must be removed from the ASTATIBP before any servicing operation. AVERTISSEMENT: Le courant doit être enlevé du ASTAT-IBP avant de procéder à toute opération de service. Terminal Connector Cover Removal and Replacement 1. Remove the two 12-point terminal connectors by inserting a flat-head screwdriver between the terminal connector and the ASTAT-IBP cover, as illustrated in Figure 1. Do not remove the wiring from the terminal connectors.
ASTAT ®-IBP Plus Service Instructions Logic Board Replacement Logic Board Screws CAUTION: Always handle circuit boards by their edges and do not distort the parts on the circuit boards. ATTENTION: Il faut toujours manipuler les plaques de circuits par leurs côtés et ne pas déformer les pièces sur les plaques de circuits. 1. Remove the ASTAT-IBP cover as described in steps 1–2 of Cover Removal and Replacement. 2. Unplug the two ribbon cables from the Logic Board, as shown in Figure 3. 3.
ASTAT ®-IBP Plus Service Instructions Power Supply Board Replacement Power Supply Board Ribbon Cable The Power Supply Board is located as shown in Figure 5. It contains gray and orange transformers visible from the sides. 1. Remove the following components: a. The cover, as described in steps 1–2 of Cover Removal and Replacement. b. The Logic Board, as described in steps 2–3 of Logic Board Replacement. 2.
ASTAT ®-IBP Plus Service Instructions 7. Reconnect the red and white gate wires to the fourpoint Terminal Boards, one on the component side and two on the solder side of the Power Supply Board, as illustrated in Figures 8, 9, and 10. 8. Secure the Power Supply Board with the four screws removed earlier. 9. Reinstall the following components: a. The Logic Board, as described in steps 4–5 of Logic Board Replacement. d. The cover, as described in steps 3–4 of Cover Removal and Replacement. Figure 9.
ASTAT ®-IBP Plus Service Instructions Protection Board Replacement 1. Remove the following components: a. The cover, as described in steps 1–2 of Cover Removal and Replacement. b. The Logic Board, as described in steps 2–3 of Logic Board Replacement. c. The Power Supply Board, as described in steps 2– 5 of Power Supply Board Replacement. Six-Point Terminal Board 2. Remove the six wire connectors from the Protection Board, as shown in Figure 11. Note the locations of these terminals for reassembly.
ASTAT ®-IBP Plus Service Instructions SCR Module Replacement (Sizes K, L, and Y) This procedure requires the following tools and materials: • #2 Philips-head screwdriver, torque wrench 3/16" Allen wrench, • Scotchbrite or equivalent abrasive • Mild solvent to clean mounting surfaces • Electrolube 2GX or equivalent thermal grease 1. Loosen the screws holding the MOVs and bus bars to the SCR Module to be replaced, as illustrated in Figure 12, and remove the MOVs and bus bars. 2.
ASTAT ®-IBP Plus Service Instructions SCR Module Replacement (Sizes M, Z, and N) This procedure requires the following tools and materials: • #2 Philips-head screwdriver, torque wrench 3/16" Allen wrench, • Scotchbrite or equivalent abrasive • Mild solvent to clean mounting surfaces • Electrolube 2GX or equivalent thermal grease 1. Loosen the screws holding the MOVs and bus bars to the SCR Module to be replaced, shown in Figure 14, and remove the MOVs and bus bars. Figure 14.
ASTAT ®-IBP Plus Service Instructions SCR Module Replacement (Sizes P, Q, and R) This procedure requires the following tools and materials: • 1 /2 " wrench, 3/16" Allen wrench, torque wrench • Scotchbrite or equivalent abrasive • Mild solvent to clean mounting surfaces • Electrolube 2GX or equivalent thermal grease 1. Disconnect the control wiring harness for the SCRs to be replaced. If necessary, disconnect the wiring harness of the CTs. 2.
ASTAT ®-IBP Plus Service Instructions SCR Module Replacement (Size S) This procedure requires the following tools and materials: • 9 /16" wrench, torque wrench 11/16" wrench, 3/16" Allen wrench, • Scotchbrite or equivalent abrasive • Mild solvent to clean mounting surfaces • Electrolube 2GX or equivalent thermal grease 1. Disconnect the control wiring harness for the SCRs to be replaced. If necessary, disconnect the wiring harness of the CTs. 2.
ASTAT ®-IBP Plus Service Instructions 7. Lift out the SCR Module, as shown in Figure 21. Retain all parts and hardware for reassembly with the replacement Module. 8. Remove the threaded stud from the SCR Module and attach it to the new Module. Tighten to 200 inlb torque. 9. Clean the heat sink surface of the replacement Module with a fine abrasive, such as Scotchbrite. Remove all particles from the heat sink surface and wipe the SCR mounting surface with a mild solvent.
ASTAT ®-IBP Plus Service Instructions Troubleshooting Guide This guide is provided for troubleshooting and isolating common problems. It does not cover every possible situation. Contact the Customer Support Center at 800-843-3742 if any problem is not resolved by these procedures.
ASTAT ®-IBP Plus Service Instructions Renewal Parts List The following parts and assemblies are available as replacement parts for ASTAT-IBP Solid State Starters. Renewal parts as furnished may not be identical to the original parts since design changes may have been made in the interim. The parts supplied will, however, be interchangeable with the original parts.
These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency that may be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the GE Company. g GE Industrial Systems General Electric Company 41 Woodford Ave.
