Chapter 7
Maintenance
This chapter describes basic maintenance and inspection of the Drive. Please refer to these instructions to ensure that the Drive receives the proper maintenance to maintain overall performance.
Periodic Inspection ..............................................................7-2
Preventive Maintenance ......................................................7-3
Heatsink Cooling Fan Replacement ...................................7-4
Removing and Mounting the Terminal Card ........................7-6
Maintenance 7 - 1
Periodic Inspection
•
•
Check the following items during periodic maintenance.
•
•
The motor should not be vibrating or making unusual noises.
There should be no abnormal heat generation from the Drive or motor.
The ambient temperature should be within the Drive specification of -10
°
C to 40
°
C (14
°
F to 104
°
F).
The output current value shown in parameter U1-03 should not be higher than the motor rated current for an extended period of time.
•
The cooling fan in the Drive should be operating normally.
Always turn OFF the input power before beginning inspection. Confirm that the digital operator indicators on the front cover have all turned OFF, and then wait an additional five minutes before beginning the inspection. Be sure not to touch terminals immediately after the power has been turned off. Doing so can result in electric shock. Please refer to Warnings on page i.
WARNING
Prior to removing any protective cover or wiring any part of the Drive, remove all power sources, including main input power and control circuit power. Wait a minimum of 5 minutes after power removal, before removing any cover. The charge lamp located within the Drive should be off prior to working inside. Even if the charge lamp is off, one must measure the AC input, output, and DC Bus potential to insure safe levels prior to resuming work. Failure to adhere to this warning may result in personal injury or death.
Item
External terminals, mounting bolts, connectors, etc.
Cooling fins
Control PCB
Terminal PCB
Power PCB
Gate Drive PCBs
Input Diodes
IPMs
Output Transistors
DC bus capacitors
Table 7.1 Periodic Inspections With no Power Applied
Inspection Corrective Action
Are all screws and bolts tight?
Tighten loose screws and bolts firmly.
Are connectors tight?
Are the fins dirty or dusty?
Reconnect the loose connectors.
Clean off any dirt and dust with an air gun using clean and dry air at a pressure between 55-85 psi.
Is there any conductive dirt or oil mist on the
PCBs?
Clean off any dirt and dust with an air gun using clean and dry air at a pressure between 55-85 psi.
Replace the boards if they cannot be made clean.
Is there any conductive dirt or oil mist on the modules or components?
Are there any irregularities, such as
discoloration or odor?
Clean off any dirt and dust with an air gun using clean and dry air at a pressure between 55-85 psi.
Replace the capacitors or Drive.
Apply power to the Drive and conduct the following inspection.
Item
Cooling fan(s)
Table 7.2 Periodic Inspections With Power Applied
Inspection Corrective Action
Is there any abnormal noise or vibration, or has the total operating time exceeded 20,000 hours.Check U1-40 for elapsed cooling fan operation time.
Replace Cooling Fan
Maintenance 7 - 2
Preventive Maintenance
Inspection Points
General
AC Power Circuit &
Devices
Control Circuits
Cooling System
Keypad/Display
Item
Environment
Equipment
AC Power Supply
Conductors & Wire
Connections
Transformers & Reactors
Terminal Blocks
DC Bus Capacitors
Relays & Contactors
Soft Charge Resistors
Operation
Digital Operator
Table 7.3 Preventive Maintenance
Cooling Fans/Fins & Heatsink
Check Points
Ambient Temperature
Humidity
Dust
Harmful Gas
Oil Mist
Abnormal vibration or noise
Main circuit & control voltage
Loose lugs, screws & wires
Hot spots on parts
Corrosion
Bent conductors
Breakage, cracking or discoloration
Check spacing
Discoloration or Noise
Loose, damaged
Leakage
Ruptures, broken, expansion
Capacitance & insulation resistance
Noisy
Contact discoloration
Cracked
Discoloration
Speed reference voltage/current
I/O contact operation
Abnormal fan noise
Loose connectors
Free of accumulation
LEDs
Monitor display values
Key functionality
Clean
Every 3-6 Months
X
X
X
X
X
X
X
Yearly
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
If the Drive is used under the following conditions, it may be necessary to inspect more often:
•
High ambient temperatures, humidity or altitudes above 3,300 feet
•
Frequent starting and stopping
•
Fluctuations of the AC power supply or load
•
Excessive vibration and/or shock loading
•
Poor environment, including dust, metal particles, salt, sulfuric acid, chlorine
Maintenance 7 - 3
Heatsink Cooling Fan Replacement
!
Models CIMR-P7U20P4 thru 2018 and 40P4 thru 4018
A cooling fan is attached to the bottom of the Drive.
If the Drive is installed using the mounting holes on the back of the Drive heat sink, the cooling fan can be replaced without removing the Drive from the enclosure panel.
If the Drive is mounted with the heatsink external to the enclosure, the cooling fan can only be replaced by removing the Drive from the enclosure.
"
Removing the Heatsink Cooling Fan
1.
Always turn OFF the input power before removing and installing the heatsink cooling fan.
2.
Press in on the right and left sides of the fan cover in the direction of arrows “1” and then pull the fan out in the direction of arrow “2”.
3.
Pull out the cable connected to the fan from the fan cover and disconnect the power connector. See Figure 7.1
4.
Open the fan cover on the left and right sides in the direction of arrows “3” and remove the fan cover from the fan.
3
3
Power
Connector
Fig 7.1 Cooling Fan Replacement Procedure
"
Installing the Heatsink Cooling Fan
1. Attach the fan cover to the cooling fan. Be sure that the air flow direction indicated by the arrows above faces into the
Drive.
2. Connect the power connector securely and place the power connector and cable into the fan cover.
3. Mount the fan cover on the Drive. Be sure that the tabs on the sides of the fan cover click into place on the Drive.
Maintenance 7 - 4
"
Models CIMR-P7U2022 thru 2110 (30HP to 150HP @ 208V/240V) and 4030 thru 4300
(40HP to 500HP @ 480V)
A cooling fan assembly is attached to the top inside the Drive. The cooling fan assembly includes the heat sink cooling fans and the internal cooling fan. The cooling fan(s) can be replaced without removing the Drive from the enclosure panel.
Removing the Cooling Fan Assembly
1.
Always turn OFF the input power before removing and installing the heatsink cooling fan assembly.
2.
Remove the terminal cover, Drive cover, Digital Operator, and front cover from the front of the Drive.
3.
Remove the Control PCB bracket (if necessary) to which the cards are mounted. Remove all cables connected to the
Control PCB and remove the cooling fan power connector from the fan board (13 PCB) positioned near the top of the
Drive.
4.
Remove the cooling fan power connectors from the gate drive board (3PCB) positioned at the back of the Drive.
5.
Remove the fan assembly screws and pull out the fan assembly from the Drive.
6.
Remove the cooling fan(s) from the fan assembly.
Mounting the Cooling Fan Assembly
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 air flow goes toward the top of the Drive.
Control PCB bracket
Control PCB
Air flow direction
Fan cover
Connector
Gate driver
Fig 7.2 Cooling Fan Assembly Replacement Procedure
Maintenance 7 - 5
Removing and Mounting the Terminal Card
The terminal card can be removed and mounted without disconnecting the control wiring.
IMPORTANT
Always confirm that input power is removed and the Charge LED is not lit before removing or mounting the terminal card.
"
Removing the Terminal Card
1. Remove the terminal cover on the Drive.
1. Remove the Digital Operator and front cover on the Drive.
2. Remove the wires connected to FE and NC on the terminal card.
3. Loosen the mounting screws on the left and right sides of the terminal card until they are free. It is not necessary to remove the mounting screws completely. They are captive and self-rising.
4. Pull the terminal card out in the direction of the block arrow.
"
Mounting the Terminal Card
Reverse the removal procedure to mount the terminal card.
Confirm that the terminal card and the Control PCB properly meet at connector CN8 before insertion.
The connector pins may be bent if the terminal card is forced into place, possibly preventing correct Drive operation.
CN8
FE NC
Mounting Screw Mounting Screw
Fig 7.3 Terminal Card Removal Procedure
Maintenance 7 - 6
