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    Maintenance Preventive 104 Module

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    zinou

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    © All Rights Reserved
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    Maintenance Preventive 104 Module

    Uploaded by

    zinou
    3 views8 pages

    Original Title

    Maintenance preventive 104 module

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    © © All Rights Reserved

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    Copyright:

    © All Rights Reserved
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    3 views8 pages

    Maintenance Preventive 104 Module

    Uploaded by

    zinou

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 8

    105

    Maintenance

    What this chapter contains


    This chapter contains preventive maintenance instructions, and a description of the
    LEDs of the drive.

    Safety instructions
    Only a qualified electrician is allowed to perform the maintenance.
    Before starting work on the drive system,
    • isolate the drive system from the main supply
    • open the switch-disconnectors and lock them out in the open position
    • switch off any voltages connected to the I/O terminals
    • wait for 5 minutes to let the intermediate circuit capacitors discharge
    • ensure there is no dangerous voltage present by measuring the voltage on the
    input, I/O and intermediate circuit terminals.

    Inverter module replacement

    WARNING! When replacing an inverter module, make sure the replacement module
    has exactly the same type designation (see the type designation label) as the old
    module. If it does not, consult ABB for more information.

    Maintenance
    106

    Maintenance intervals
    This table lists the routine maintenance intervals recommended by ABB.

    Maintenance Interval Instructions

    Capacitor reforming Every year when stored See Capacitor reforming.

    Depending on the dustiness of


    Heatsink temperature check
    the environment, every 6 to 12 See Heatsinks.
    and cleaning
    months

    Cabinet air filter check; See Checking and replacing


    Every year
    replacement if necessary the air filters.

    Frame R4i and R5i inverter


    modules: Change of Every 3 years See Cooling fans.
    additional cooling fan

    Frame R8i inverter modules:


    Check and cleaning of power Every 3 years See Power connections (R8i).
    connections

    Main cooling fan change Every 6 years See Cooling fans.

    Units with parallel- Locate the APBU unit. Switch


    connected inverter off the power to the unit.
    modules: APBU branching Every 6 years Remove cover. Replace
    unit – Memory backup battery battery with a new CR 2032
    renewal battery.

    Frame R4i and larger


    inverter modules: capacitor Every 10 years See Capacitors.
    renewal

    Consult your local ABB Service representative for more details on the maintenance.
    On the Internet, go to http://www.abb.com/drivesservices and select Drive Services
    – Maintenance and Field Services.

    Reduced run capability

    Note: This section applies to drives equipped with the APBU branching unit only.

    If one of the parallel-connected inverter modules of an inverter unit must be taken


    out of the cabinet for service, it is possible to continue operation at reduced power
    using the remaining modules. Follow the steps below.
    1. Read and repeat the steps in the safety instructions above.
    2. Extract the module to be serviced from the cabinet.
    3. Block the airflow through the empty module bay with an air baffle made of sheet
    metal.

    Maintenance
    107

    4. Units with DC switch fuses only: On the ASFC switch fuse controller, set the fibre
    optic link to the absent module to “disabled” using the appropriate switch (S1, S2
    or S3).

    Fibre optic links to 1 to 3 inverter modules

    5. Make the necessary parameter adjustments in the drive firmware. Refer to the
    appropriate Firmware Manual.
    6. Reconnect the module after service in reverse order.

    Checking and replacing the air filters


    Before replacing the air filters of the cabinet, read and repeat the steps in the safety
    instructions above.

    Heatsinks
    Heatsink fins pick up dust from the cooling air. Inverter modules run into
    overtemperature warnings and faults if the heatsink is not clean. In a “normal”
    environment (not dusty, not clean) the heatsink should be checked annually, in a
    dusty environment more often.
    Clean the heatsink as follows (when necessary):
    1. Remove the cooling fan as described in section Cooling fans elsewhere in this
    chapter.
    2. Blow clean, dry compressed air from bottom to top and simultaneously use a
    vacuum cleaner at the air outlet to trap the dust.

    Note: Prevent the dust from entering the adjoining equipment.

    3. Refit the cooling fan.

    Maintenance
    108

    Cooling fans
    The lifespan of the cooling fan depends on the drive usage and ambient
    temperature. See the appropriate Firmware Manual for an actual signal which
    indicates the hours of usage of the fan.
    Fan failure can be predicted by the increasing noise from fan bearings and the
    gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
    operated in a critical part of a process, fan replacement is recommended once these
    symptoms start appearing. Replacement fans are available from ABB. Do not use
    other than ABB-specified spare parts.

    Fan replacement (R2i, R3i)


    To remove the fan, release the retaining clips. Disconnect the cable. Install the fan in
    reverse order.

    Bottom view

    Fan replacement (R4i)


    1. Loosen the screws that fasten the fan mounting plate to the frame.
    2. Shift the fan mounting plate to the left and pull the fan assembly out.
    3. Disconnect the fan power cable.
    4. Undo the screws that fasten the fan to the fan mounting plate.
    5. Install the new fan in reverse order.

    2 2
    1 1 4 4
    4 4

    Maintenance
    109

    Fan replacement (R5i)


    To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan
    in reverse order.

    Bottom view

    Additional fan
    If you have an additional fan installed in your module, see the instructions below for
    its replacement.
    Replacement (R2i, R3i)
    Remove the front cover. To remove the fan, release the retaining clip (1). Disconnect
    the cable (2, detachable terminal). Install the fan in reverse order.
    Top view

    1
    2

    Replacement (R4i, R5i)


    Remove the front cover. The fan is located on the lower right-hand side of the unit
    (R4) or on the right-hand side of the control panel (R5). Lift the fan out and
    disconnect the cable. Install the fan in reverse order.

    Maintenance
    110

    Fan replacement (R7i)


    1. Disconnect the wire plug.
    2. Remove the two screws holding the fan unit.
    3. To free the fan, pull it slightly outwards, then downwards.
    4. Install new fan in reverse order.

    Maintenance
    111

    Fan replacement (R8i)


    1. Read and repeat the steps in the safety instructions above.
    2. Open the inverter cubicle doors.
    3. Disconnect the fan wiring plug (1).
    4. Remove the locking screws (2).
    5. Pull the fan out along its sliding rails (3).
    6. Install a new fan in reverse order.

    Maintenance
    112

    Power connections (R8i)


    1. Read and repeat the steps in the safety instructions above.
    2. Open the cabinet doors.
    3. Extract one inverter module from the cabinet.
    4. Check the tightness of the cable connections at the quick connector. Use the
    tightening torque table in Technical data.
    5. Clean all contact surfaces of the quick connector and apply a layer of suitable
    joint compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
    6. Re-insert the inverter module.
    7. Repeat steps 3 to 6 for all remaining R8i inverter modules.

    Capacitors
    The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
    depends on drive loading and ambient temperature. Capacitor life can be prolonged
    by lowering the ambient temperature.
    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
    a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
    Replacements are available from ABB. Do not use other than ABB-specified spare
    parts.

    Capacitor reforming
    Reform (re-age) spare part capacitors once a year according to Converter modules
    with electrolytic DC capacitors in the DC link, Capacitor reforming instructions
    (3BFE64059629 [English]).

    LEDs
    This table describes LEDs of the drive.

    Where LED When the LED is lit

    RMIO board (not visible in frame Red The drive is in fault state
    sizes R2i to R5i)
    Green The power supply on the board is OK.
    Control panel mounting platform Red The drive is in fault state
    Green The main +24 V power supply for the control panel and the
    RMIO board is OK.
    APBU board TXD (Yellow) Data is being sent by the APBU to the drive control unit.
    RXD (Yellow) Data is being received by the APBU from the drive control unit.
    PWR (Green) APBU logic voltage is OK.
    BAT (Green) The memory backup battery is OK. The LED is off if the battery
    is disabled.

    Maintenance

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