Preventive Maintenance Checklist of Industrial Control and Drive System Equipment
Inspect and clean the power section components (IGBTs, SCRs, and capacitors) as part of the annual clean and
inspection cycle (as access allows). Do not remove the whole drive assembly to gain access to the components. The life
expectancy of the power section components is designed to last for the life of the drive for wall-mounted drives. The
actual life is dependent on ambient and environmental conditions, load, variation of load, power system configuration,
output and carrier frequency configuration, cooling system, and other application-related factors.
The design life expectanc
y of the over
all components nor
mally exceeds 10 years (
in some cases can last 20 years or more)
in normal operating environments.
The PowerFlex® 755T product line has true predictive maintenance capabilities for many components that include all
fans, IGBTs, LCL filter capacitors, and bus capacitors. This drive technology determines the remaining life of the
product or maintenance components that are based on actual usage of the product and is updated in real time. This
patented methodology is an advanced approach to predictive and preventative maintenance solution to achieve high
levels of production uptime and apply maintenance or replacement only as needed. The intention is to use these
predicative and preventative maintenance features with the other practices and recommendations in this manual.
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Bus Capacitors
For drives that are in storage and do not have voltage applied, maintenance of the capacitors in the drive can be required.
Follow these requirements and the guidelines listed in Tabl e 3
for bus capacitor maintenance and reforming:
• The reforming voltage must be 1.35…1.45 times the rated AC system voltage
• During the reforming process, the power supply current draw must not exceed 500 mA
• For PowerFlex 753 and 755 frame 6 and 7 drives disconnect all internal stirring fans before applying voltage to the
bus capacitors.
Table 2 - Recommended Cooling Devices Replacement Interval – PowerFlex 4-Series, PowerFlex 520-Series
Drive Series
(2)
(2) For unlisted drives family, refer to their specific user manual.
Interval
(1)
(1) Recommendation is based on designed lifespan, interval to be reduced for harsh ambient conditions.
PowerFlex 4M PowerFlex 4 PowerFlex 40 PowerFlex40P PowerFlex 400 PowerFlex 523 PowerFlex 525 PowerFlex 527
2 years upon startup — — — — — — — —
3 years upon startupXXXXXXXX
4 years upon startup — — — — — — — —
5 years upon startup — — — — — — — —
Table 3 - Drive Storage Duration and Reforming Recommendations
Duration Reforming Guideline
Under 2 years No reforming required.
2 …3 years Apply rated voltage, per the normal method, for 30 minutes under no load.
Over 3 years
Using
a DC power supply conn
ected
directl
y to the DC
terminals of the product, ramp-up the voltage from 0…100% of DC bus voltage (as per Tab le 4) in
increments of 50%, 75%, and 100% rated voltage, under no load, for 30 minutes at each increment. See Figure 5 on page 4 for an illustration of this method.
Table 4 - DC Bus Voltage Ramp-up Values
AC Input Voltage Voltage Across the DC Bus
230V 325V DC
400/480V 680V DC
600V 848V DC
600/690V 976V DC