The drive Maintenance Monitors keep track of component wear and tell the user when the end of the estimated performance life is approaching. The Maintenance Monitors prevent the need to shut down the full system for unexpected problems. Users can set alarm notifications for the maintenance periods for these drive components:
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Cooling fan
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Electrolytic capacitor
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Soft charge bypass relay
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IGBT
Contact Yaskawa or your nearest sales representative for more information about part replacement.
Replaceable Parts
You can replace these parts of the drive:
If there is a failure in the main circuit, replace the drive.
You can remove the control circuit board of the drive. When you remove the control circuit terminal block of the drive and install a new terminal block, you can easily replace the control circuit terminal block. Refer to Replace the Drive for more information.
If the drive is in the warranty period, contact Yaskawa or your nearest sales representative before you replace parts. Yaskawa reserves the right to replace or repair the drive as specified by the Yaskawa warranty policy.
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Electrical Shock Hazard
Do not examine, connect, or disconnect wiring on an energized drive. Before servicing, disconnect all power to the equipment and wait for the time specified on the warning label at a minimum. The internal capacitor stays charged after the drive is de-energized. The charge indicator LED extinguishes when the DC bus voltage decreases below 50 Vdc. When all indicators are OFF, measure for dangerous voltages to make sure that the drive is safe.
If you do work on the drive when it is energized, it will cause serious injury or death from electrical shock.
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Part Replacement Guidelines
Table 1 shows the standard replacement period for replacement parts. When you replace these parts, make sure that you use Yaskawa replacement parts for the applicable model and design revision number of your drive.
Table 1. Standard Replacement Period
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Parts
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Standard Replacement Period
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Cooling fan
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10 years
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Electrolytic capacitor 1
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10 years
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Note:
Performance life estimate is based on these use conditions. These conditions are provided for the purpose of replacing parts to maintain performance. Some parts may require more frequent replacement due to poor environments or rigorous use. Operating conditions for performance life estimate: Ambient temperature: Yearly average of 40 °C (IP20/UL Open Type), Load factor: 80%, Operating rate: 24 hours a day
Monitors that Display the Lifespan of Drive Components
The drive keypad shows percentage values for the replacement parts to help you know when you must replace those components. Use the monitors in Table 2 to check replacement periods. When the monitor value is 100%, the component is at the end of its useful life and there is an increased risk of drive malfunction. Yaskawa recommends that you check the maintenance period regularly to make sure that you get the maximum performance life.
Table 2. Performance Life Monitors
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Monitor No.
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Parts
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Description
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U4-03
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Cooling fan
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Shows the total operation time of fans as 0 to 99999 hours. After this value is 99999, the drive automatically resets it to 0.
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U4-04
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Shows the total fan operation time as a percentage of the specified maintenance period.
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U4-05
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Electrolytic capacitor
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Shows the total capacitor usage time as a percentage of the specified maintenance period.
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U4-06
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Soft charge bypass relay
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Shows the number of times the drive is energized as a percentage of the performance life of the inrush circuit.
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U4-07
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IGBT
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Shows the percentage of the maintenance period for the IGBTs.
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Alarm Outputs for Maintenance Monitors
You can use H2-xx [MFDO Function Selection] to send a message that tells you when a specified component is near the end of its performance life estimate. Set the applicable value to H2-xx as shown in Table 3 for your component.
When the specified component is near the end of its performance life estimate, the MFDO terminals set for H2-xx = 2F [Maintenance Notification] will turn ON, and the keypad will show an alarm that identifies the component to replace.
Table 3. Maintenance Period Alarms
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Display
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Alarm Name
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Cause
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Possible Solutions
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MFDO
(Setting Value in H2-xx)
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LT-1
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Cooling Fan Maintenance Time
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The cooling fan is at 90% of its expected performance life.
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Replace the cooling fan, then set o4-03 = 0 [Fan Operation Time Setting = 0 h] to reset the cooling fan operation time.
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2F
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LT-2
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Capacitor Maintenance Time
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The capacitors for the main circuit and control circuit are at 90% of expected performance life.
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Replace the board or the drive.
Contact Yaskawa or your nearest sales representative to replace the board.
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LT-3
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SoftChargeBypassRelay MainteTime
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The soft charge bypass relay is at 90% of its performance life estimate.
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Replace the board or the drive.
Contact Yaskawa or your nearest sales representative to replace the board.
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LT-4
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IGBT Maintenance Time (50%)
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The IGBT is at 50% of its expected performance life.
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Check the load, carrier frequency, and output frequency.
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TrPC
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IGBT Maintenance Time (90%)
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The IGBT is at 90% of its expected performance life.
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Replace the IGBT or the drive.
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10
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Related Parameters
Replace the component, then set o4-03, o4-05, o4-07, and o4-09 [Maintenance Setting] = 0 to reset the Maintenance Monitor. If these parameters are not reset after the corresponding parts have been replaced, the Maintenance Monitor function will continue to count down the performance life from the value that was reached with the old part. If the Maintenance Monitor is not reset, the drive will not have the correct value of the performance life for the new component.
Note:
The maintenance period changes for different operating environments.
Table 4. Maintenance Setting Parameters
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No.
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Name
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Function
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o4-03
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Fan Operation Time Setting
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Sets the value from which to start the cumulative drive cooling fan operation time in 10-hour units.
Note:
When o4-03 = 30 has been set, the drive will count the operation time for the cooling fan from 300 hours and U4-03 [Cooling Fan Ope Time] will show 300 h.
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o4-05
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Capacitor Maintenance Setting
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Sets the value from which to start the count for the main circuit capacitor maintenance period as a percentage.
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o4-07
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Softcharge Relay Maintenance Set
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Sets as a percentage the value from which to start the count for the soft charge bypass relay maintenance time.
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o4-09
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IGBT Maintenance Setting
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Sets the value from which to start the count for the IGBT maintenance period as a percentage.
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