Services note

Cut ACS600 drive operating costs with

preventive maintenance and reconditioning services
ABB recommends its preventive maintenance and
reconditioning services to help control and cut operating
costs associated with its drives. On-site preventive
maintenance is designed around drive maintenance
schedules and significantly reduces the risk of failure
while increasing the lifetime of a drive. Reconditioning
in an authorized ABB drive service workshop should
be considered when major components need replacing
according to the maintenance schedule. Both services
contribute to higher reliability of the installed plant which
in turn helps maintain high productivity.
The importance of maintenance
The failure probability of industrial products equipped with
electronic components, such as drives, increases over time.
The main reason for failure is aging of components, but
it is also greatly affected by the operational conditions. A
demanding environment, such as high ambient temperature,
humidity, dirt, dust and cyclic heavy loads, can shorten
component lifetime as well as maintenance and component
replacement intervals.
A component failure may cause consequential damage to
other parts of the drive, including power semiconductors.
A maintenance schedule provides a systematic and functional
means of maintaining a specific drive type and is based on
ABBs extensive experience and know-how of manufacturing
and maintaining electric drives.
Preventive maintenance the lifeblood of a drive
Drive preventive maintenance consists of annual drive
inspections and component replacements according to
the product specific maintenance schedule. Specifications
of component suppliers are carefully observed, while the
environmental and operational conditions of the drive are
also considered.
Preventive maintenance is carried out during planned
production shutdowns. It should be planned well in advance
and the required resources and service parts reserved. Parts
and materials used in preventive maintenance are bundled
into preventive maintenance kits which are delivered to a
lead-time, unlike normal spare parts.
The success of preventive maintenance depends on the
information recorded in the service reports provided by the
end-user. The more thorough the information provided, the
greater the benefit.
Years from startup
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Startup P
Cooling
Air cooled unit:
Cooling fan (MD and SD R8, R9, IP54) I I R I I R I I R I I R I I R I I R I I R
Cooling fan (SD R2-R7) I I I I I R I I I I I R I I I I I R I I I
DSU, TSU cooling fan (B1-B5) I I R I I R I I R I I R I I R I I R I I R
DC reactor cooling fan (B4-B5) I I R I I R I I R I I R I I R I I R I I R
Water cooled unit:
Cooling fans I I R I I R I I R I I R I I R I I R I I R
Add coolant inhibitor I P I P I P I P I P I P I P I P I P I P I
Heat exchanger I I I I I I I I I I I I I I I I I I I I I
Cooling water pump I I I I I R I I I I I R I I I I I R I I I
Cooling water pipe connections I I I I I I I I I I I I I I I I I I I I I
Aging
Electrolytic capacitors (DC circuit) (R) R (R)
Electrolytic capacitors (NGDR) (R) R (R) R
DSU, TSU RC resistors, capacitors I I I
Connections and environment
Flat cables (NINT, NXPP) (R) R (R) R
Tightness of terminals I I I I I I I
Door filters I I I I I I I I I I I I I I I I I I I I I
Condition of contactors I I I I I I I
Fiber optic cables (connections) I I I I I I I
Dustiness, corrosion and temperature I I I I I I I I I I I I I I I I I I I I I
Quality of supply voltage I I I I I I I I I I I I I I I I I I I I I
Improvements
Based on product notes I I I I I I I I I I I I I I I I I I I I I
Measurements
Basic measurements with supply voltage P P P P P P P P P P P P P P P P P P P P P
Spare Parts
Spare parts I I I I I I I I I I I I I I I I I I I I I
DC circuit capacitor reforming P P P P P P P P P P P P P P P P P P P P P
Note! Recommended maintenance intervals and component replacements
are based on specified operational and environmental conditions. ABB
recommends annual drive inspections to ensure the highest reliability and
optimum performance. More detailed maintenance information can be found
in maintenance instructions, product manuals and on the Internet.
Legend:
I = Inspection (visual inspection and maintenance action if needed)
P = Performance of on/off-site work (commissioning, tests, measurements
or other work)
R = Replacement of component
(R) = Replacement if high ambient temperature or cyclic heavy load
2 Services note | Cut ACS600 drive operating costs with preventive maintenance and reconditioning services
All labor and service parts included
The preventive maintenance service includes labor, if not
agreed otherwise, and the service parts to perform the work
according to the maintenance schedule.
Included are inspections of the:
electric drive and its environmental conditions
connections
ribbon and fiber optic cables
fan and cooling system
emergency stop circuit
circuit to prevent unexpected startup
fault logger
parameters
Tests include:
functional testing of the drive under normal conditions
basic measurements with supply voltage
In addition, the following can be purchased as options:
ESD protected cleaning of the drive
reforming of the spare module capacitors
drive spare part inventory
A detailed service report, including recommendations for
future actions, is provided once the maintenance work is
completed and the inspection data fully analyzed.
Cut ACS600 drive operating costs with preventive maintenance and reconditioning services | Services note 3
Preventive maintenance kits
Preventive maintenance kits contain all the necessary
replacement parts for a scheduled maintenance. The content
of each kit is carefully selected to match the maintenance
schedule and the size and other characteristics of a specific
drive.
Preventive maintenance kits can be selected and ordered
according to the number of drives in use and their age,
ensuring that all the required parts are available for
maintenance.
The parts contained within a preventive maintenance kit cost
less than parts sourced individually. Therefore, engaging in
a proactive preventive maintenance plan will prove more cost
effective than sourcing spares as a result of an emergency or
general repair job. Preventive maintenance kits are available
from www.abb.com/partsonline for component replacements
marked R in the maintenance schedule. The local ABB
representative can define, select and deliver the correct parts
and help plan preventive maintenance. Visit www.abb.com/
drives to nd your nearest ABB representative.
A preventive maintenance kit is a selected package of parts needed for preventive maintenance of ABB drives.
3-, 6- and 9-year preventive maintenance kits for ACS600 are shown above.
Preventive maintenance kits for Every
3rd
year
Every
6th
year
Every
9th
year
Every
12th
year
Cooling fan
(MD and SD R8, R9, IP54, ACW600)
X
DSU, TSU cooling fan (B1-B5) X
DC reactor cooling fan (B4-B5) X
Cooling fan (SD R2-R7) X
Cooling water pump (ACW600) X
Electrolytic capacitors (NGDR) X
Flat cables (NINT, NXPP) X
Electrolytic capacitors (DC circuit) X
S
P
6
2

E
N

R
E
V
A

2
0
1
1

#
1
5
4
9
5
For more information contact your local ABB representative
or visit:
www.abb.com/drives
www.abb.com/drivespartners
Copyright 2011 ABB. All rights reserved. Specifications subject to change
without notice.
Reconditioning giving drives a new life
While, within preventive maintenance, component replacements
can be carried out on-site, ABB recommends that, at least
once in the drives lifetime, it is reconditioned to its original
factory condition.
Reconditioning should be considered when major components,
such as electrolytic capacitors, need replacing according to
the maintenance schedule.
The ABB drive reconditioning service is carried out at an
authorized ABB drive service workshop within a clean
environment and with suitable testing facilities. The service
includes a full inspection, thorough cleaning and the analysis
of individual components, as well as part replacements
according to a product specific maintenance schedule. The
reconditioned drive is then fully tested.
With on-site preventive maintenance, only the replaced parts
come with a warranty whereas with reconditioning the entire
module or drive carries a warranty.
Complete reconditioning
When the drive arrives at the ABB workshop, the following is
carried out:
visual inspection
electronic boards are dismantled and cleaned ultrasonically
mechanical parts are washed
after drying, individual components are analyzed and
replaced according to a product specific maintenance
schedule
software is updated
Tests include:
functional testing
a load test, using a minimum 50 percent of nominal load
Once all stages are complete, a service report is compiled
and a 12 months warranty issued for the complete module
or drive.
Exchange units may be available during the reconditioning
period. The ABB service engineer or local sales office will be
able to advice.
Non-repairable drives
Following reconditioning, ABB returns the drive with its
functionality fully restored. However, if at the workshop the
drive is examined and fails to meet ABBs quality standards,
ABB can declare the drive non-repairable. Common reasons
for a drive to be declared non-repairable include heavy
mechanical damage and corrosion.
If an item is declared non-repairable, ABB informs the customer
without delay and offers alternative solutions.
Summary
The advantages and benefits of preventive maintenance
include:
Advantage Benefit
Use of genuine service parts Increased reliability leading to
longer component lifetime
Timely part replacements in
accordance with maintenance
schedule
Increased reliability leading
to reduced drive and plant
operational lifetime costs
Economical kit pricing compared
to individual part price
Lower operational lifetime costs
Maintenance schedules help long
term maintenance budget planning
Schedules help define whether
to continue maintenance or to
upgrade, retrofit or replace a drive
Updating to the latest software
version
Ensures optimum drive
performance
In addition to the above, reconditioning includes the following
advantages and benefits:
Advantage Benefit
Clean service workshop
environment, washing facilities,
ESD protected working conditions
and comprehensive testing
arrangements to maximize the
reconditioning quality
Drive returned to its original
condition and entire drive delivered
with one year warranty