Frequency Inverter Preventative Maintenance Schedule

An Inverter Preventative Maintenance Schedule prolongs the lifetime of your drives. We have estimated the cost of a preventative maintenance schedule compared to the cost of “Fit and Forget”. When tallying up the cost of unexpected breakdown, loss of production and potential cost of repairs/hire drives, we calculate the preventative maintenance schedule only becomes financially unfeasible in year 19! Little wonder a preventative maintenance schedule is in more demand than ever.

Inverter Preventative Maintenance Schedule

As we know, all electrical and mechanical assets require service and maintenance to make sure they continue to run efficiently and to reduce the risk of failure. An inverter is no different. Just like your car, your central heating boiler or your computers, inverters need to be serviced, maintained and updated. It is key to note that complying with the inverter preventative maintenance schedule insures you maintain your Inverter Warranty.

To increase drive reliability and cut operational costs, Ingress Malaysia has developed a preventive maintenance programme. Drive preventive maintenance consists of annual inspections and component replacements according to drive-specific maintenance schedules. Maintenance schedules are based on manufacturers recommended intervals (from decades of experience of supply, install, repair and maintaining inverter drives). User applications sometimes need customised maintenance schedules and documentation, in which cases Ingress can help the user in question to create an optimised maintenance schedule and documentation for their equipment. For example, components such as a drive’s cooling fan may require yearly inspection, with replacement necessary after six years if in operation under hard conditions, and every three years thereafter. On the other hand, various component connections and cables may only require inspection, without regularly scheduled replacement.

The benefits of scheduled preventive maintenance:

• Reduced risk of failure
• Increased lifetime
• Controlled maintenance cost

Frequency Inverter Preventative9, but what actually happens during these annual maintenance visits?

In addition to the Frequency Inverter Preventative Maintenance Schedule recommendations, Ingress will at every visit:

• Back up the drive parameter settings to the control panel & the Engineers laptop. Send parameters in pdf format to customer.
• Remove the drives main cooling fan & blow out or vacuum the heatsink section to ensure a good airflow through the drive.
• Clean any air filters if present or change these if necessary.
• Make sure all mains & motor connections are tight using torque wrench to check.
• Make sure all controls connections are tight.
• Send service report on condition of drive along with any recommendations & parameter settings to customer.

Frequency Inverter Preventative Maintenance Schedule

To give you an idea of what is included in each visit, below we list the annual maintenance schedule. Below, you will find a 20-year maintenance schedule with our recommendation for each year.

1 Year after Install

• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

 

2 Years after Install

• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

3 Years after Install

• Replacement of Internal/additional cooling fan (IP20, IP21 and IP55)
• Inspection of Cooling fan 
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Inspection of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan
• Inspection of extra cooling fans inside cabinet
• Inspection of extra IP54 cooling fan on roof of cabinet
• Inspection of cooling fans, 50Hz
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Inspection of cooling liquid pump assembly
• Inspection of cooling liquid pipe connections
• Inspection of Power cable connections and quick connectors of the supply, inverter and converter modules

• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

4 Years after Install8

• Inspection of Cooling fan  (mains supply frequency 50Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

5 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

6 Years after Install

• Replacement of Internal/additional cooling fan(IP20, IP21 and IP55)
• Replacement of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Replacement of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan
• Replacement of extra cooling fans inside cabinet
• Replacement of extra IP54 cooling fan on roof of cabinet
• Replacement of cooling fans, 50Hz
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Replace cooling liquid pump assembly
• Visual Inspection of the cooling liquid pipe connections
• Replacement of memory backup battery replacement in APBU-xx unit
• Inspection of ALCL filter capacitor 380 – 415V supply network
• Inspect/Replace ALCL filter capacitor 460V – 690V supply network
• Inspection of power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

 

7 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

8 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

9 Years after Install

• Replacement of Internal/additional cooling fan
• Inspection of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Inspection of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan
• Inspection of extra cooling fans inside cabinet
• Inspection of extra IP54 cooling fan on roof of cabinet
• Inspection of cooling fans
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Inspection of cooling liquid pump assembly
• Change coolant in internal cooling circuit
• Replace expansion tank
• Visual Inspection of the cooling liquid pipe connections
• Replace electrolytic capacitors (DC circuit)
• Inspection/Replacement of ALCL filter capacitor 380 – 415V supply network 
• Inspection of ALCL filter capacitor 460V – 690V supply network
• Replacement of AINT+ flat cables, CINT, NRED, discharging resistors
• Inspection of Power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

10 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

11 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

12 Years after Install

• Replacement of Internal/additional cooling fan (IP20, IP21 and IP55)
• Replacement of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Replacement of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan
• Replacement of extra cooling fans inside cabinet
• Replacement of extra IP54 cooling fan on roof of cabinet
• Replacement of cooling fans
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Replace cooling liquid pump assembly
• Visual Inspection of the cooling liquid pipe connections
• Replacement of memory backup battery replacement in APBU-xx unit
• Inspection of ALCL filter capacitor 380 – 415V supply network
• Inspect/Replace ALCL filter capacitor 460V – 690V supply network
• Inspection of power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming 

13 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reformin 

14 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

15 Years after Install

• Replacement of Internal/additional cooling fan
• Inspection of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Inspection of cooling fan  (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan 
• Inspection of extra cooling fans inside cabinet 
• Inspection of extra IP54 cooling fan on roof of cabinet
• Inspection of cooling fans 
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Inspection of cooling liquid pump assembly
• Visual Inspection of the cooling liquid pipe connections
• Inspection of ALCL filter capacitor 380 – 415V supply network
• Inspection of ALCL filter capacitor 460V – 690V supply network
• Inspection of power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

16 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

17 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

18 Years after Install

• Replacement of Internal/additional cooling fan (IP20, IP21 and IP55)
• Replacement of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Replacement of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan 
• Replacement of extra cooling fans inside cabinet
• Replacement of extra IP54 cooling fan on roof of cabinet
• Replacement of cooling fans
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Check pH of coolant
• Add coolant corrosion inhibitor
• Heat exchanger cleaning
• Check expansion tank air pressure
• Replace cooling liquid pump assembly
• Change coolant in internal cooling circuit
• Replace expansion tank
• Visual Inspection of the cooling liquid pipe connections
• Replace electrolytic capacitors (DC circuit)
• Replace memory backup battery replacement 
• Inspection/Replacement of ALCL filter capacitor 380 – 415V supply network
• Inspection/Replacement of ALCL filter capacitor 460V – 690V supply network 
• Replacement of AINT+ flat cables, CINT, NRED, discharging resistors
• Inspection of Power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

19 Years after Install

• Inspection of Cooling fan (mains supply frequency 50Hz)
• Visual Inspection of the cooling liquid pipe connections
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Check performance: DC circuit capacitors reforming

20 Years after Install

• Replacement of Internal/additional cooling fan (IP20, IP21 and IP55)
• Inspection of Cooling fan
• Replacement of DOL Cooling fan (mains supply frequency 60Hz)
• Inspection of cooling fan (mains supply frequency 50Hz)
• Replacement of cooling fan for TSU
• Replacement of enclosure extension cooling fan
• Inspection of extra cooling fans inside cabinet
• Inspection of extra IP54 cooling fan
• Inspection of cooling fans
• Replacement of DOL cooling fan (mains supply frequency 60Hz)
• Inspection of cooling liquid pump assembly
• Visual Inspection of the cooling liquid pipe connections
• Inspection of ALCL filter capacitor 380 – 415V supply network
• Inspection of ALCL filter capacitor 460V – 690V supply network
• Inspection of power cable connections and quick connectors of the supply, inverter and converter modules
• Inspection of Air filters (IP20 to IP42)
• Replacement of Air filters (IP54 and IP54R)
• Inspection: Cleanliness check (dustiness, corrosion and temperature) and/or heat sink cleaning
• Inspection of improvements, based on product notes
• Check performance: DC circuit capacitors reforming

If you have any questions regarding an Frequency Inverter Preventative Maintenance Schedule for your inverters please contact our repair engineers on +60361855121 or email info@ingress.com.my

www.ingress.com.my 

By Mr. Nathan Sanmugom

Founder of Ingress Malaysia who have 20 years experience in Electrical and Electronic Engineering. Believe strongly in hardwork and teamwork. Creating a Malaysian company which can provide the best repair services to the client around the world.