51729_-_Advanced_PM_Report_-_Pump_#2_VFD_-_Cody_Barrett.pdf

PDF 5 MB Posted Mar 3, 2025

Attached to: Preventive Maintenance of Toshiba VFDs (Bid Discount)
Solicitation number: 25-P-00141
Issued by: Hillsborough County, Florida

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Written by GovTribe AI · Jun 27, 2025

This document is a Toshiba International Corporation Advanced Preventive Maintenance (PM) Report for a medium voltage Variable Frequency Drive (VFD) located at the Sulphur Springs wastewater plant. The report, completed by field engineer Cody Barrett on 5/4/2023 with task number 51729, documents a comprehensive inspection of a T-300 series VFD system for a pump application. The inspection covers multiple system sections including input, transformer, rectifier, inverter, and control sections, with detailed checks on electrical components, voltage measurements, resistance tests, and operational functionality.

The report includes several key recommendations from Toshiba, notably suggesting advanced reconditioning of power modules (which have been in operation for over 7 years), replacement of the power supply (in operation for over 5 years), and upgrading the control system to MV2. The technician was unable to run the VFD during the inspection as the site was using alternative pumps, with the customer planning to operate the VFD at a later date. Specific technical observations include passing all voltage and control circuit checks, verifying DC bus values, and confirming that most system components were in acceptable condition. The report also notes the firmware is specific to a synchronous motor, which prevented firmware upgrades during this maintenance visit.

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MV VFD Preventive Maintenance Page 1 of 15

Advanced PM Report

Task Number Field Engineer

Insert Picture of VFD

Site Name

Cody Barrett

Sulphur Springs wastewater plant

51729

MV VFD Preventive Maintenance Page 2 of 15

T-300 series VFD system

VFD DATA

Project Number

Serial Number

Typeform

Application

Description

MOTOR DATA

Manufacturer

Model

Serial Number

Rotation (DE, ODE)

Voltage Current

RPM Pole

Hz HP

TRANSFORMER DATA

Manufacturer

MFG. P/N

Serial Number KVA Tertiary KVA

Primary Secondary Tertiary Voltage Current

Pump

111777

090400390

059505-0001

873 30

M3A4410ESAAXA

Motor

HITRAN

ZI0135-00

MV VFD Preventive Maintenance Page 3 of 15

Place a check mark next to each step once completed.

I. Save Setfile & Tracesave File

A) Save current setfile

1. Compare with setfile from commissioning, previous PM or from default. If there are any changed parameters, make a record, and investigate potential/possible reasons for the parameter change.

B) Save Tracesave

1. Review Trace back data and explain any new faults since last PM visit.

2. Download data from any peripheral devices i.e. Multilin 869, etc.

3. Analyze Trace back/trouble record data and record firmware version.

Firmware Version Date of last save to EEPROM

II. System Overview

A) Site and Building condition(s)

1. VFD room and environment pass inspection.

C) Motor Inspection

1. Motor physical connection and terminals pass inspection.

2. There are no capacitors or surge arresters in the motor junction box.

III. Visual Inspection & Cleaning All wire/cable/bus condition(s) and connection(s) should be checked, secured, re-torqued, and marked as necessary. Verify all foreign material (dust, metal, bolts etc.) is removed from the cubicle(s). Vacuum the cabinet as required, and clean the air filters.

A3TS03A

MV VFD Preventive Maintenance Page 4 of 15

Figure 1: Typical Frame 1 4160V T300MVi (1000 to 2000HP)

A) Input Section

1. Input terminals

• Input terminals have been checked and are tight.

2. Cables

• There is appropriate spacing between the cable(s).

3. Switch Gear (JK)

• Switchgear has been checked for tracking and damage.

4. Pre-charge Reactor

• Reactor has been visually inspected and it is confirmed that coils have not shifted.

Figure 2: Typical Frame 1 Pre-Charge Reactor

MV VFD Preventive Maintenance Page 5 of 15

5. Input PT and CT

• PTs and CTs have passed visual inspection.

Figure 3: Typical Control Power Transformer

6. Isolation Switch

• Isolation switch is functioning properly.

• Contactor and isolation switch interlock function correctly.

• Microswitch functions correctly.

• Stabs/blades are properly lubricated

Figure 4: 4160V Isolation Switch

MV VFD Preventive Maintenance Page 6 of 15

7. Vacuum Contactor

• There is no dust or foreign material on the surface of the vacuum interrupter

• Drop-out and closing voltages have been recorded

Contactor Closing Voltage (VAC) Drop-out Voltage (VAC)

• Contact resistance values have been recorded

Contactor A (µΩ) B (µΩ) C (µΩ)

8. Vacuum Breaker

Breaker Model Number Serial Number Counter As Found Counter As Left

• There is no dust or foreign material on the surface of the vacuum interrupter

• Screws on the auxiliary switches are tight

• Primary and secondary disconnects are properly lubricated

• Control circuits, closing, and tripping devices are functional

• Contact resistance values have been recorded

Breaker A (µΩ) B (µΩ) C (µΩ)

74.2

68.1

51.6

64 62

70 61

73.4

MV VFD Preventive Maintenance Page 7 of 15

Figure 5: Typical Vacuum Circuit Breaker

B) Transformer Section

1. Transformer

• Transformer passes visual inspection and is free of foreign objects.

2. Transformer Megger Check

• Transformer - Primary

(> 1GΩ at 5KV) R-S-T to GND Ω

∗ Ground all secondary connections.

∗ Resistance should be greater than 1GΩ at 5000V to pass

• Transformer –Secondary

(> 1GΩ at 5KV) U1* Ω V1* Ω W1* Ω U2* Ω V2* Ω W2* Ω U3* Ω V3* Ω W3* Ω U4* Ω V4* Ω W4* Ω

∗ Ground secondary connections except the winding in check.

∗ Ground primary connections when checking secondary windings

79.2 G

103 G

87.0 G

236 G

29.6 G

181 G

58.6 G

116 G347 G

75.4 G

70.7 G

109 G 112 G

MV VFD Preventive Maintenance Page 8 of 15

• 2400V or 6600V Transformer – Secondary (> 1GΩ at 5KV)

X1* Ω X2* Ω X3* Ω X4* Ω

3. Transformer Low Resistance Checks

• Transformer – Primary

R-S [mΩ] R-T[mΩ] S -T[mΩ]

• Transformer –Secondary R-S [mΩ] R-T[mΩ] S -T[mΩ] U1 U2 U3 U4 V1 V2 V3 V4 W1 W2 W3 W4

*The tests should be performed with all secondary connections in a delta configuration.

4. Airflow Guides

• The baffles and airflow guides are within proper tolerances of the transformer.

198.6 197.9

65.366.8

197.5

64.8

64.6

65.2

68.8

66.1

66.5

65.1

64.7

68.1

66.0

68.6

63.4

67.5 69.1

65.3

63.6

66.5

66.8

66.1

67.1

64.7

66.3

67.6

66.5

66.9

67.8

63.365.0

67.9

63.8

66.3

67.4

63.3

63.8

MV VFD Preventive Maintenance Page 9 of 15

Figure 6: Typical Frame 4 (4000-6000Hp) Input Transformer

5. Cooling FAN

• The fan(s) turn freely.

C) Rectifier Section

1. Discharge Resistor

• The discharge resistor passes static checks and visual inspection.

2. Rectifier Fuses

• Fuses are closed and in good condition.

3. Airflow Guides

• There is no obstruction in or around the airflow guides and heatsink.

D) Inverter Section

1. Power Module

• Modules pass all checks and heatsink is free of debris and obstruction.

• Door switches function as intended.

Power Module Serial Number 1 Serial Number 2 U V W

090500689

090500688

090500667

MV VFD Preventive Maintenance Page 10 of 15

2. GDI Board

• PCB passes inspection.

• Ground Fault Resistor (11R11) reads correct value.

3. Cooling FAN

• The fans turn freely.

E) Control and Output Section

1. Output Reactor and Filter Circuit

• Reactor and filter circuit pass inspection.

• Resistance of the coils have been recorded.

A (µΩ) B (µΩ) C (µΩ)

2. Output Terminals

• Terminals checked and are tight.

• Output terminals have been meggered.

(> 1GΩ at 5KV) U-V-W to GND Ω

• Resistance of the motor windings have been recorded.

Motor U-V (µΩ) U-W (µΩ) V-W (µΩ)

3. HCT Cable

• HCT and cables are secure and in good condition.

4. Output PT and CT (If there is PT or CT for protection relay on output of VFD)

• PT fuses pass static checks and fuse brackets are secure.

432 milli

1.97 G, 2.10 G, 2.16 G

431 milli

N/AN/A N/A

431 milli

MV VFD Preventive Maintenance Page 11 of 15

Figure 7: Typical Output Reactor and HCT

F) Cabinet Split/Junction Point(s)

1. Connector

• Connector connection(s) are in good condition

2. Main Bus/Cables

• Bus connection(s) are in good condition

3. Ground Bus/Cables

• Wire/cables are in good condition.

G) Low Voltage Cabinet Inspection

1. Power Supply

• Power supply is in good condition and has been replaced if necessary.

2. Device Check

• HCT and VCCT resistors are the correct values.

• Relay and contactor coils are in good condition and operate correctly.

• Fans overload relays function correctly.

MV VFD Preventive Maintenance Page 12 of 15

3. Control Voltage Checks

Voltage Measurement Result Actual Measurement Inverter Converter

Input Voltage Feedback (12R2-2) Input Voltage Feedback (2-12T2) Input Voltage Feedback (12T2-12R2) Control Voltage Feedback (1-2) Control Voltage P5 Control Board P5 Control Voltage P15 Control Voltage N15 Control Voltage P24 Input Voltage (48R2-48S2) Input Voltage (48S2-48T2) Input Voltage (48T2-48R2)

4. Control Circuit Checks

• Voltage readings from PDM board and EOI readings have been verified.

• Protective functions have been tested.

Description Test Result Note 1 Fan Rotation check Check fan transfer and fault detection.

2 Door switch Open door and verify fault detection.

3 Ground detection Simulate ground fault and verify fault detection.

4 Transformer Overheat

Simulate transformer overheat if possible.

5 RTD/Motor Protection relay

Check that external protective relay/RTD monitor will shut the drive down.

5. Motor Heater Check

Voltage Actual Current Calc. Current

Pass

N/A

Pass

122.1

Pass

-14.87

494.3

122.5

Pass

5.140

123.0

14.95

488.2

Pass

492.7

Pass

24.02

122.6

Pass

5.081

MV VFD Preventive Maintenance Page 13 of 15

IV. Final Verification of Program A) Parameter Checks

1. Compare final setfile with original setfile.

2. Set VFD’s clock from EOI.

V. Operation Check

A) DC Voltage Check

1. Review and record the DC bus values

DC Bus Value (%)

VDC_UN

VDC_UP

VDC_VN

VDC_VP

VDC_WN

VDC_WP

B) Output Voltage and Current

1. Output voltage and current waveform(s) are accurate as captured by with Wi Tool.

MV VFD Preventive Maintenance Page 14 of 15

VI. Recommendations and Final notes:

Engineer Signature: ___________________________ Date: _______________________

- Toshiba recommends Advanced reconditioning on all power modules, the modules have been in operation for over 7yrs.

- Toshiba recommends replacement of the power supply, the power supply has been in operation for over 5yrs.

- Toshiba recommends upgrading the control system to MV2

- No output reactor installed in this unit

- Unable to upgrade the firmware as this is firmware for a Synchronous motor

- Unable to Run the VFD after inspection, the site was using other pumps, customer will operate the VFD at a later date

5/4/2023

MV VFD Preventive Maintenance Page 15 of 15

Additional Pictures

Input and rectifier section after inspection, testing and cleaning

Customer added cables to the 10ACL for input exciter

Customers input cables

Power modules after inspection, testing and cleaning

File details come from the government source that posted it. Updated Jun 27, 2025.