51729_-_Advanced_PM_Report_-_Pump_#4_VFD_-_Cody_Barrett.pdf

PDF 6 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 Field Service Advanced Preventive Maintenance (PM) Report for a variable frequency drive (VFD) located at the Sulphur Springs wastewater pump station, performed by field engineer Cody Barrett on 5/4/2023. The report details a comprehensive inspection of a T-300 series 4160V VFD system, including assessments of the input, transformer, rectifier, inverter, and control sections. The maintenance check involved multiple detailed evaluations such as visual inspections, electrical measurements, megger tests, voltage checks, and functional tests of various system components.

The report includes several critical recommendations for the VFD system, including advanced reconditioning of power modules (which have been in operation for over 7 years), replacement of the power supply (in operation over 5 years), and upgrading the control system to MV2. The technician noted that the firmware was upgraded to A3TF09G0 and recommended replacement of the pre-charge contactor due to dropout voltage being outside the recommended range. Notably, the VFD could not be run during the inspection as the site was using alternative pumps, with the customer planning to operate the VFD at a later date. The maintenance report provides a comprehensive technical overview of the system's condition and suggested improvements to maintain optimal performance.

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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 pump station

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

111780

091201723

M3А4410ESAAXA

Motor

N/A transformer nameplate not legible

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.

A3TF09C

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)

73.3

75.3

59.6

65 75

63 59

77.0

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

310 G

131 G

80.6 G

102 G

26.4 G

51.4 G

16.2 G138 G

132 G

44.8 G

279 G 26.6 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.

189.4 187.1

69.568.4

187.4

69.6

68.6

67.4

72.8

73.6

73.3

68.5

69.1

74.3

72.9

72.7

67.5

73.8 74.2

68.6

68.3

70.1

72.0

73.5

72.7

70.7

73.8

73.9

71.5

73.0

73.6

68.068.5

74.1

67.3

68.8

74.5

68.4

67.2

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

091003976

091201724

091201726

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.

422 milli

3.94 G, 3.38 G, 3.24 G

422 milli

N/AN/A N/A

422 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

122.4

Pass

-14.80

453.6

123.2

Pass

5.140

122.9

14.82

451.2

Pass

452.8

Pass

24.02

123.0

Pass

5.084

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

- Upgraded the firmware to A3TF09G0

- Toshiba recommends replacement of the Pre-charge contactor, the dropout voltage is not within the recommended range

- 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

Low voltage cabinet after inspection and cleaning

V & W phase input fuses installed backwards, fuse blown indicator is facing the back.

10ACL upon initial inspection, No coils found shifted

Customers input cables after inspection and cleaning

Power modules reinstalled after inspection, testing and cleaning

Input and rectifier section after inspection, testing and cleaning

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