TMEIC TMdrive-30 frequency converter

Detailed explanation of fault handling, maintenance, and parameter management of TMEIC TMdrive-30/TMdrive-P30 IGBT drive system

Product Overview

TMdrive-30 is a fully digital, vector controlled sine wave PWM inverter launched by Toshiba Mitsubishi Electric Industrial Systems (TMEIC), mainly used for precision variable speed control of small and medium-sized AC motors; TMdrive-P30 is a matching IGBT rectifier that converts AC power into the DC power required by IGBT frequency converters. Due to the use of sine wave PWM control for input current, P30 has strong ability to suppress harmonics in the power grid, and its power factor can be controlled close to 1, making it a power system friendly device.

TMdrive-30 covers single transmission of 1500kVA and 2000kVA, as well as dual transmission structures of 2 × 1500kVA and 2 × 2000kVA; TMdrive-P30 covers 1700kW single rectifier and 2 × 1700kW dual rectifier. The entire system is used in conjunction with the Common Bus, and is powered by P30 to multiple TMdrive-30s connected to the common bus. The regenerated energy can be fed back to the grid through the common rectifier, achieving energy-saving operation.

Key points of main circuit and control structure

The main circuit of TMdrive-30 consists of a capacitor unit and a three-level IGBT power unit, with a DC bus voltage of 2 × 900Vdc and an output AC voltage of 1250Vac. The control circuit is based on PP7 (Toshiba 32-bit power electronic control microprocessor), and is calculated step by step through speed control (5.4.2), torque reference (5.4.3), D-Q axis current control (5.4.4), voltage reference, and PWM control (5.4.5). Finally, the IGBT is driven by the gate driver board (GDM). It should be noted that the three-level inverter outputs three levels of P potential, 0 potential, and N potential through the combination of four IGBTs (Q1~Q4), which are fundamentally different from the PWM principle of the two-level circuit. They should not be confused during maintenance.

The speed detection can be selected from PLG (pulse encoder) or high-resolution brushless rotary transformer (Resolver), and also supports sensorless vector control and V/f control. When using PLG, the pulse frequency must meet the constraint condition of 3300Hz ≤ (rated speed/60) × PLG pulse number ≤ 100000Hz, otherwise the pulse cannot be recognized, resulting in control failure. When using a rotary transformer, it is important to avoid changing the feedback polarity by modifying the wiring. The direction of rotation should be determined by the parameters FLG WVU and FLG W

The polarity settings of VU and CSVNet RPM must be turned off and restarted (MCCB "Control" on/off) to take effect after the change.

Protection function system

This series of devices has a complete software and hardware dual protection system, with the main protection items including:

Current class: AC overcurrent OCA (action level automatically set according to CS_SRAME-Size, CS-EQUIP_CURR, CS_VOLT_RANK, approximately 50%~100% of overload rating), IGBT overcurrent OCD, 5-minute/20 minute overload OL5/OL20 and OL_S alarm, current limit timing CL_T/CL_TA, low-frequency overload STALL.

Voltage category: DC overvoltage OVP/OVN (120% rated automatic setting), DC undervoltage UVP/UVN (detected level 50%).

Speed category: overspeed OSS ($CP_SP=115%), overclocking OSS-FO, speed detection anomaly SP-ERR/SP-ERR2.

Power and Control Category: Control Power Supply Voltage Loss CPSF, Gate Power Supply Abnormal GDM-F, CPU Failure CPU_ A/CPU_ M, Transmission Errors TL_f1~TL_f4.

Motor and brake category: motor overheating ($CP∝OH=155 ℃, mOH_S alarm low by 10 ℃), motor temperature sensor fault MTMP_S, cooling fan shutdown (mFN/MFN_T), electromagnetic brake circuit fault BR_S.

P30 dedicated: Pre charge fault PRE-F, ground detection GR/GR_T (TIME_CR=0.1s), and ground fuse F_GND.

When a fault occurs, the standard operation panel displays a three digit code "FI-XXX", and the first fault displays the top ten faults in the order they occurred; Please note that after a fault occurs, wait for at least 30 seconds before performing a fault reset to avoid the reset being ineffective.

Fault handling and recovery process

After a malfunction occurs, it is recommended to follow the following steps for troubleshooting:

Record the fault information displayed on the panel (FI code or fault symbols and comments on the high-performance panel);

Collecting Traceback Data - The non-volatile memory of the device stores high-speed, standard, and long-term three-stage traceability data of the last 6-7 faults, which can be played back and analyzed in conjunction with PC maintenance tools;

Check the appearance and operation status: environmental temperature, abnormal noise and odor, dust, lightning strikes, sudden load changes, power supply switching, recent surrounding electrical operations, etc., and form a complete fault record;

According to the manual for maintenance: To replace the IPU (IGBT power unit), refer to Unit Replacement Manual 6F3A4795. Before replacement, be sure to follow the power-off confirmation process - stop the machine, disconnect the main circuit power supply, wait for more than 5 minutes, confirm that the charging indicator light is off, measure the HIGH-LOW and P-CTR-OV-CTR terminal voltage of the GDM board to confirm safety;

If "PI-183" is displayed, it indicates that the EEPROM parameters may be damaged and the settings need to be reloaded from the PC tool (Access level 9 full access). After writing, power off and restart initialization.

At the same time, it should be clarified that the TMdrive-30 DC bus voltage is above 1800Vdc, the circuit voltage is above 1250Vac, and it is strictly prohibited to open the cabinet door, touch internal components, or work with wet hands when it is live; Never cut off the main circuit or control power during operation.

Maintenance and regular replacement

Daily inspection: environmental temperature and humidity, dust, abnormal noise and vibration of reactors/transformers/fans, insulation odor, etc. Any abnormalities found should be dealt with immediately.

Regular maintenance: cabinet cleaning, filter cleaning, capacitor and resistor discoloration, deformation and leakage inspection, substrate cleaning, wiring thermochromism inspection, bolt tightening inspection. Cleaning follows the principle of top-down approach.

Regular replacement parts (recommended cycle): 3 years for large cooling fans; Air filter for 6 months; Main circuit and aluminum electrolytic capacitors inside the board for 7 years; Control power supply device for 7 years; Main circuit/control circuit/door plate fuse for 7 years. The replacement of fuses requires the use of Toshiba designated spare parts, as non designated parts may pose performance and safety hazards.

Communication interface and special operating mode

The device supports four types of communication: TOSLINE-S20, ISBus, DeviceNet, and PROFIBUS. Scanning transmission uses the Common Memory mechanism, and the master and slave stations mutually check the health of the link through Heartbeat signals. TL-F3 is detected when the heartbeat timeout is abnormal. In addition, the equipment also has practical on-site functions such as JOG jog (F/R command combined with 2S/3S multi-stage speed), emergency operation (E-DRIVE bypass transmission signal only uses P I/O), E-HOLD speed maintenance, and shared motion (Shared Motion, switching EEPROM A/B motor parameters through 2S signal).