8 Maintenance and Inspection. YASKAWA F7 Drive
광고
광고
Maintenance and
Inspection
This chapter describes basic maintenance and inspection for the Inverter.
Maintenance and Inspection........................................8-2
Maintenance and Inspection
8
-2
Outline of Free Warranty
The free warranty period of the Inverter is as follows:
Free warranty Period: This product is warranted for twelve months after being delivered to Yaskawa’s customer or if applicable eighteen months from the date of shipment from Yaskawa’s factory whichever comes first.
Daily Inspection
Check the following items with the system in operation.
• The motor should not be vibrating or making unusual noises.
•
•
There should be no abnormal heat generation.
The ambient temperature should not be too high.
•
•
The output current value shown on the monitor displays should not be higher than normal.
The cooling fan on the bottom of the Inverter should be operating normally.
Periodic Inspection
Check the following items during periodic maintenance.
Always turn OFF the power supply before beginning inspection. Turn OFF the main circuit power supply, wait for the time indicated on the front cover, and make sure the CHARGE indicator light has gone out, and then perform maintenance and inspection. Be sure not to touch terminals right after the power has been turned off. Doing so can result in electric shock.
Item
External terminals, mounting bolts, connectors, etc.
Table 8.1 Periodic Inspections
Inspection
Are all screws and bolts tight?
Are connectors tight?
Corrective Procedure
Tighten loose screws and bolts firmly.
Reconnect the loose connectors.
Heatsinks
PCBs
Are the fins dirty or dusty?
Is there any conductive dirt or oil mist on the PCBs?
Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2 x 10
4
to 58.8 x 10
4
Pa
(4 to 6 kg•cm
2
).
Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2 x 10
4
to 58.8 x 10
4
Pa
(4 to 6 kg•cm
2
).
Replace the boards if they cannot be made clean.
Cooling fan
Power elements
Smoothing capacitor
Is there any abnormal noise or vibration or has the total operating time exceeded
20,000 hours?
Replace the cooling fan.
Is there any conductive dirt or oil mist on the elements?
Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2 x 10
4
to 58.8 x 10
4
Pa
(4 to 6 kg•cm
2
).
Are there any irregularities, such as discoloration or odor?
Replace the capacitor or Inverter.
Maintenance and Inspection
Periodic Maintenance of Parts
The Inverter is configured of many parts, and these parts must be operating properly in order to make full use of the Inverter functions.
Among the electronic components, there are some that require maintenance depending on their usage conditions. In order to keep the Inverter operating normally over a long period of time, it is necessary to perform period inspections and replace parts according to their service life.
Periodic inspection standards vary depending the Inverter's installation environment and usage conditions.
The Inverter's maintenance periods are noted below. Keep them as reference.
Refer to Cooling Fan Replacement Outline (Page 8-5) for replacing a cooling fan and Circulation Fan
Replacement Outline (Page 8-14) for replacing a circulation fan.
To replace other parts, contact your Yaskawa representative or YASKAWA ELECTRIC ENGINEERING
CORPORATION for details on preventive maintenance for Inverters.
Cooling fan
Breaker relays
Fuses
Part
Smoothing capacitor
Aluminum capacitors on PCBs
Table 8.2 Part Replacement Guidelines
Standard Replacement Period
2 to 3 years
Replacement Method
Replace with new part.
5 years
-
Replace with new part. (Determine need by inspection.)
Determine need by inspection.
10 years
5 years
Replace with new part.
Replace with new board. (Determine need by inspection.)
Note The standard replacement period is based on the following usage conditions:
Ambient temperature:Yearly average of 30 ° C
Load factor: 80% max.
Operating rate: 12 hours max. per day
Types and Number of Cooling Fans Used in the Drive
Cooling fans used for the Drive has two types; Heatsink cooling fan and heatsink circulation fan. Heatsink cooling fan blows air to the Drive cooling fin. Heatsink circulation fan stirs up the air inside the Drive unit.
Table 8.3
shows the number of cooling fans used in the Drive. For more information on models and specifications of cooling fans, contact your Yaskawa representative or YASKAWA ELECTRIC ENGINEERING COR-
PORATION.
When replacing the fan, use the specified type of the fan. If the inapplicable fans are used, performance of the
Drive will not be fully obtained.
Maximum Motor
Capacity
(kW)
0.4
0.75
1.5
2.2
3.7
Table 8.3 Number of Cooling Fans to be Used
200 V Class
Heatsink Cooling
Fan
Heatsink Circulation
Fan
-
-
-
-
400 V Class
Heatsink Cooling
Fan
Heatsink Circulation
Fan
-
-
-
-
1
-
-
-
-
1
1
-
-
-
8-
3
8
-4
Maximum Motor
Capacity
(kW)
5.5
7.5
11
15
18.5
22
30
90
110
132
160
37
45
55
75
185
220
300
Table 8.3 Number of Cooling Fans to be Used (Continued)
200 V Class
Heatsink Cooling
Fan
Heatsink Circulation
Fan
1 -
Fan
1
400 V Class
Heatsink Cooling Heatsink Circulation
Fan
-
2
2
2
2
-
1
-
1
2
2
2
2
-
1
-
1
2
2
2
2
2
2
-
-
1
1
1
1
2
2
2
2
2
2
2
2
-
-
-
-
-
1
1
1
-
4
4
2
2
5
2
2
1
1
2
Maintenance and Inspection
Cooling Fan Replacement Outline
200 V and 400 V Class Inverters of 18.5 kW or Less
A cooling fan is attached to the bottom of the Inverter.
If the Inverter is installed using the mounting holes on the back of the Inverter, the cooling fan can be replaced without removing the Inverter from the installation panel.
Removing the Cooling Fan
1. Press in on the right and left sides of the fan cover in the direction of arrows 1 and pull the fan out in the direction of arrow 2.
2. Pull out the cable connected to the fan from the fan cover and disconnect the relay connector.
3. Open the fan cover on the left and right sides and remove the fan cover from the fan.
Mounting the Cooling Fan
1. Attach the fan cover to the cooling fan. Be sure that the airflow direction indicated by the arrows above faces into the Inverter.
2. Connect the relay connector securely and place the relay connector and cable into the fan cover.
3. Mount the fan cover on the Inverter. Be sure that the tabs on the sides of the fan cover click into place on the Inverter.
1
Airflow direction
2
1
Fan cover
Fig 8.1 Cooling Fan Replacement (200 V Class Inverters of 5.5 kW)
8-
5
8
-6
200 V and 400 V Class Inverters of 22 kW or More
A cooling fan is attached to the top panel inside the Inverter.
The cooling fan can be replaced without removing the Inverter from the installation panel.
200 V Class Inverters of 22 kW, 30kW and 400 V Class Inverters of 22 kW to 55 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Remove the control board bracket to which the boards are mounted. Remove all cables connected to the control board. The cables connected to the control circuit terminals can be removed at the same time by removing them together with the control circuit terminal board. This procedure is not required for 400 V
Class Inverters of 37 kW, 45 kW, and 55 kW. (Refer to page 8-18.)
3. Remove the cooling fan power cable connector (CN26 and CN27) from the gate drive board positioned at the back of the controller.
4. Remove the fan cover screws and pull out the fan cover from the Inverter.
5. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components. Refer to the next page for attaching the fan cover.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Control b oard b racket
Control b oard
Air flo w direction
Fan co v er
Connector
Gate dri v e b oard
Fig 8.2 Cooling Fan Replacement (200 V Class Inverters of 22 kW)
Maintenance and Inspection
Attaching the Fan Cover
1. Tilt the fan cover toward the bottom of the Inverter as shown in Fig 8.3 and insert it to the mounting hole until it meets with A.
F an cover
A
B ottom I nverter
Coo li ng fan
T op I nverter
Fig 8.3
2. Push the fan cover toward the top of the Inverter.
Fig 8.4
3. Make sure that there is no gap between the fan cover and A. Then screw it in place with the three screws.
M a k e sure that there i s no gap .
A
N G
A
Fig 8.5
8-
7
8
-8
200 V Class Inverters of 55 kW, 75 kW and 400 V Class Inverters of 75 kW, 90 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Pull the cooling fan power cable connector that extends from the fan cover cable hole out of the cooling fan power relay board.
3. Only for 400 V Class Inverters of 75 kW and 90 kW, loosen the resistor unit mounting screws and slide the resistor unit to remove it. Take care as the resistor unit is hot.
4. Remove the fan cover screws and pull out the fan cover from the Inverter.
5. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Front cover mounting screws
Front cover
Terminal cover
Terminal cover mounting screws
Fan support
Fan support mounting screws
Circulation fan
Circulation fan mounting screws
Fan cable pullout position
Airflow direction
Fan support
Airflow direction
Cooling fans
Resistor unit
Fan power relay board
Cooling fans
Resistor unit mounting screws
Cooling fan mounting screws
Cooling fan mounting screws
Fan power cable pullout position
Fig 8.6 Cooling Fan Replacement (400 V Class Inverters of 75 kW and 90 kW)
Maintenance and Inspection
200 V Class Inverters of 37 kW and 45 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Remove the panel to which the control board, the gate drive board, and the cooling fan power relay board are mounted. Remove any cables that are connected to the control board, the gate drive board, and the cooling fan power relay board. The cable that is connected to the control circuit terminals can be removed together with the control circuit terminal board. (Refer to page 8-18.)
3. Remove the fan cover screws and pull out the fan cover from the Inverter.
4. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Fan support mounting screws
Front cover mounting screws
Fan cover Panel mounting screws
Cooling fan power relay board
Gate drive board
Front cover
Panel mounting screws
Capacitor
Terminal cover
Terminal board
Terminal cover mounting screws
Pay attention to the protruding part of the fan cable.
Circulation fan mounting screws
Circulation fan
Cooling fans
Airflow direction
Cooling fan mounting screws
Fan cover
Fig 8.7 Cooling Fan Replacement (200 V Class Inverters of 37 kW and 45 kW)
8-
9
8
-10
400 V Class Inverters of 110 kW and 132 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Remove any cables that are connected to the cooling fan power relay board. The cable that is connected to the control circuit terminals can be removed together with the control circuit terminal board. (Refer to page
8-18.)
3. Remove the fan cover screws and pull out the fan cover from the Inverter.
4. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Front cover mounting screws
Front cover
Terminal cover
Terminal cover mounting screws
Cooling fan power relay board
Fan cover mounting screws
Circulation fan
Airflow direction
Circulation fan mounting screws
Circulation fan
Circulation fan power connector
Cooling fan mounting screws
Fig 8.8 Cooling Fan Replacement (400 V Class Inverters of 110 kW)
Maintenance and Inspection
400 V Class Inverters of 160 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Remove any cables that are connected to the cooling fan power relay board. The cable that is connected to the control circuit terminals can be removed together with the control circuit terminal board. (Refer to page
8-18.)
3. Remove the fan cover screws and pull out the fan cover from the Inverter.
4. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Front cover mounting screws Fan cover Fan cover mounting screws
Fan power relay board
Gate drive board
Front cover
Control board
Terminal cover
Terminal cover mounting screws
Circulation fan
Circulation fan mounting screws
Fan cover mounting screws
Circulation fan airflow direction
Fan cover
Fan cover
Fan airflow direction
Fan power relay board
Fan mounting screws
Finger guard
Cooling fan
*1
Fan ground cable *2
* 1. There is no finger guard mounted to the fan for some capacities. (There is a guard on the Inverter side.)
* 2. There is no fan ground cable for the capacities without a finger guard.
Fig 8.9 Cooling Fan Replacement (400 V Class Inverters of 110 kW)
8-
11
8
-12
400 V Class Inverters of 185 kW and 220 kW
Removing the Cooling Fan
1. Remove the terminal cover and top and bottom front covers from the front of the Inverter.
2. Remove any cables that are connected to the cooling fan power relay board.
3. Remove the fan cover screws and pull out the fan covers from the Inverter.
4. Remove the cooling fan from the fan cover and replace it with a new one.
Mounting the Cooling Fan
After attaching a new cooling fan, reverse the above procedure to attach all of the components.
When attaching the cooling fan to the mounting bracket, be sure that the airflow faces the top of the Inverter.
Make sure that the fan cable and the fan ground cable are not tangled or pinched.
F ront cover mount i ng screws
F an cover
F an power re l ay b oard
F an cover
T op front cover
B ottom front cover
T erm i na l cover
T erm i na l cover mount i ng screws
F an cover mount i ng screws
E
n
l
arged v
i
ew
F an ca bl e
F an ground ca bl e
F an cover mount i ng screws
F an a i rf l ow d i rect i on
Co lli ng fan
Coo li ng fan mount i ng screws
Fi nger guard
Fig 8.10 Cooling Fan Replacement (400 V Class Inverters of 185 kW and 220 kW)
Maintenance and Inspection
400 V Class Inverters of 300 kW
Removing the Cooling Fan
1. Remove the terminal cover, Inverter cover, Digital Operator, and front cover from the front of the Inverter.
2. Remove any cables that are connected to the cooling fan power relay board. The cable that is connected to the terminal board can be removed together with the terminal board.
3. Remove the fan unit screws and pull out the fan units from the Inverter.
4. Replace the fan units with new ones.
And, remove the screws for the fan power relay board and attach this board to the new unit.
Mounting the Cooling Fan
After attaching a new cooling fan unit, reverse the above procedure to attach all of the components.
Front cover mounting screws
Fan cover
Fan power relay board
Fan cover
Top front cover
Bottom front cover
Terminal cover
Terminal cover mounting screws
Fan cover mounting screws
Enlarged view
Relay board mounting screws
Fan power relay board
Fan cover mounting screws
Fan units
Fig 8.11 Cooling Fan Replacement (400 V Class Inverters of 300 kW)
Fan airflow derection
8-
13
8
-14
Circulation Fan Replacement Outline
With some capacities, there is a small fan installed inside the Inverter for the purpose of increasing circulation in areas where heat has built up. These fans have built-in fan sensors that output an alarm when the rotation rate of the fan drops to indicate that replacement is necessary.
200 V and 400 V Class Inverters of 11 kW
The circulation fan is installed behind the control circuit terminal board inside the Inverter.
The circulation fan can be replaced by removing the control circuit terminal board.
Removing the Circulation Fan
1. Remove the Digital Operator, the terminal cover, and the front cover.
2. Remove the control circuit terminal board. Remove the cables connected to the terminals if necessary.
3. While pushing the two tabs (A) in direction 1, pull the fan out in direction 2.
4. Remove the relay connector connected to the fan.
Mounting the Circulation Fan
Reverse the above procedure to mount the fan.
Be sure to mount the fan so that the air flows towards the top of the Inverter (direction indicated by the arrow).
Mount the fan securely using the tabs (A).
Confirm that there are no cables in contact with the fan’s rotating parts.
2
Control board
1
Airflow direction
Tabs (A)
Circulation fan
Inverter with Control Circuit Terminal Board Removed
Fig 8.12 Circulation Fan Replacement (200 V and 400 V Class Inverters of 11 kW)
Maintenance and Inspection
200 V and 400 V Class Inverters of 18.5 kW
The circulation fan is installed at the top-left corner of the Inverter interior.
Removing the Circulation Fan
1. Remove the Digital Operator, the terminal cover, and the front cover.
2. While pushing the relay connector tab (A) in direction 1, pull the relay connector out in direction 2.
3. While pushing the fan tabs (B) in direction 3, pull the fan out in direction 2.
4. Remove the relay connector connected to the fan.
Mounting the Circulation Fan
Reverse the above procedure to mount the fan.
Be sure to mount the fan so that the air flows towards the bottom of the Inverter (direction indicated by the arrow).
Mount the fan securely using the fan tabs (B).
Confirm that there are no cables in contact with the fan’s rotating parts.
Circulation fan
4
2 1
Relay connector tab (A)
Fan tabs (B)
3
Airflow direction
Fig 8.13 Circulation Fan Replacement (200 V and 400 V Class Inverters of 18.5 kW)
200 V Class Inverters of 37 kW or More and 400 V Class Inverters of 75 to 160 kW
The circulation fan is installed in front of the fan cover inside the Inverter. Remove the circulation fan using the procedure for replacing the cooling fan and replace it with the new fan. (The installation position for 200 V
Class Inverters of 75 kW is different.)
8-
15
8
-16
400 V Class Inverters of 185 kW and 220 kW
Two circulation fans are installed as described in the following sections.
Removing the Circulation Fan
1. Remove the terminal cover and top and bottom front covers.
2. Unscrew the frame fixing screws and take off the frame.
3. Remove the relay connector connected to the fan.
4. Remove the fan cover mounting screws and pull the fan cover out.
5. Remove the fan from the fan cover and replace it with a new one.
Mounting the Circulation Fan
Reverse the above procedure to mount the fan.
Be sure to mount the fan so that the air flows in the direction indicated by the arrow in the corresponding diagram.
Confirm that there are no cables in contact with the fan’s rotating parts.
Fan cable
Fix the fan cable with lnsulok ties
Frame
Frame fixing screws
Fan airflow direction
Enlarged view
Fan cover mounting screws
Circulation fan
Enlarged view
Fan airflow direction
Fan cover mounting screws
Fan cable
Fig 8.14 Circulation Fan Replacement (400 V Class Inverters of 185 kW and 220 kW)
Maintenance and Inspection
400 V Class Inverters of 300 kW
Two circulation fans are installed as described in the following sections.
Removing the Circulation Fan
1. Remove the terminal cover and top and bottom front covers.
2. Unscrew the frame fixing screws and takeoff the frame.
3. Remove the relay connector connected to the fan.
4. Remove the fan cover mounting screws and pull the fan cover out.
5. Remove the fan from the fan cover and replace it with a new one.
Mounting the Circulation Fan
Reverse the above procedure to mount the fan.
Be sure to mount the fan so that the air flows in the direction indicated by the arrow in the corresponding diagram.
Confirm that there are no cables in contact with the fan’s rotating parts.
Fan cable
Fix the fan cable with Insulok ties
Frame
Frame fixing screws
Fan airflow direction
Enlarged view
Fan cover mounting screws
Circulation fan
Fan airflow direction
Fix the fan cable with Insulok ties
Enlarged view
Fan cable
Fan cover mounting scerws
Fig 8.15 Circulation Fan Replacement (400 V Class Inverters of 300 kW)
8-
17
8
-18
Removing and Mounting the Control Circuit Terminal Board
The control circuit terminal board can be removed and mounted without disconnecting the cables.
Always confirm that the charge indicator is not lit before removing or mounting the control circuit terminal board.
IMPORTANT
Removing the Control Circuit Terminal Board
1. Remove the Digital Operator and front cover.
2. Remove the connecting line connectors connected to FE and NC on the control circuit terminal board.
3. Loosen the mounting screws (1) on the left and right sides of the control terminals until they are free. (It is not necessary to remove these screws completely. They are self-rising.)
4. Pull the terminal board out sideways (in direction 2) with the screws sticking out from the board.
Mounting the Control Circuit Terminal Board
Reverse the removal procedure to mount the terminal board.
Confirm that the control circuit terminal board and the control board properly meet at connector CN5 before pressing in on the board.
The connector pins may be bent if the board is forced into place, possibly preventing correct Inverter operation.
Removing and Mounting the
Control Circuit Terminal Board
FE NC
Fig 8.16 Removing the Control Circuit Terminal Board
다운로드
공개 링크 업데이트됨
문서 공개 링크
광고