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TCM FB15-7 inverters.

Number of messages: 7

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jason_t
Hampshire, United Kingdom

Hi all, I have been lurking on these forums for a while now, and now have a valid tech question. I look after 12 TCM FB15-7 trucks with AC drive motors. One truck has blown two inverters, one about two months ago, and the other this week(controller has 3 seperate inverters). I have had the motor out and tested but it came back with a clean bill of health, does anyone have any ideas, as its costing £3,500 each time this happens!

Posted 9 Feb 2007 07:13 AM

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justinm
New York, United States

check the temperature sensors
make sure the operators are not operating them in a manner that will overheat them (such as pushing loads on the ground)
check the brake adjustments and make sure they arnt binding
make sure they are charging the machine properly (low volts = high amps and can damage circuits)
i see youre in the uk so im assuming they are 36 volt or higher
if they are 24 volts some ac inverters have overheating issues at this low of a voltage (we sell em cause americans like 24 volts mainly because of cost savings upfront.. we make alot of money from decisions made solely on upfront cost savings lol)
check for shorts and make sure all spike suppressors are working and installed (on horns fans relays etc)

"have a good luck"

Modified 13 Feb 2007 01:28 PM
by poster.

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jason_t
Hampshire, United Kingdom

I have had the motor stripped and inspected with no faults found. The truck is 48v,controller has a current limit of 394A. I do suspect the operators are pushing the loads instead of lifting, but I would have liked to see heat damage in the motor? I look after a fleet of 12, all in the same place, but its only this machine thats failing (so far!)

Posted 14 Feb 2007 04:51 AM

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Drlifttruck

Please advise wich inverter(s) failed.

With this tcm drive controller, I doubt you would see overheating damage in drive motors.

If the motor stall due to pushing product this high current surge would burn the MOSFET circuit in the inverter to an open position.

Additionally could you verify your voltage threshold for lift interrupt and drive interupt.

I will assume that you have the current TCM service manual for this unit.

If not advise so I may be of assistance to you

Regards

-------------------------
Lift Trucks all the same, just painted different colors Regards, Doc My Email is: Ulsh1@aol.com

Posted 25 Mar 2007 00:32 AM

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jason_t
Hampshire, United Kingdom

Two of the drive inverters failed, one of which has a current sensor in line. I am slightly worried as the MOSFETS are burning up, the last one that blew totalled all 44 FETs! I have since repaired the inverter and replaced it back into the truck, all tests prove ok. I have done stall current tests, and running current tests, all prove equal current readings between all 3 phases. I am unsure of the thresholds for lift interupt as my manual does not make this clear!!
Hope you can help, I am sure the 3rd inverter will pop next.

Kind regards Jason

Posted 27 Mar 2007 07:21 AM

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Drlifttruck

Jasom, all of the mosfet inverters(3) have a current detecting device. My question is Drive (right) Drive (left) or Pump?

If you email me at my signature address, I will endeavor to help you

Regards,

Doc

-------------------------
Lift Trucks all the same, just painted different colors Regards, Doc My Email is: Ulsh1@aol.com

Posted 27 Mar 2007 12:31 AM

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justinm
New York, United States

i agree with kevin 2 posts back where you wont see the damage in the motors
the mosfet circuits are way more sensitive to overload
ive seen abused trucks fry mosfets and its usually a fiery death

are all the machines about the same age? or was this the demo or something?
does it have an assigned operator (check the machine hes using now lol)
is the battery in good shape and do they use distilled water when they check the cells when it comes off charge?
acid buildup?
do they charge the machines on their lunch breaks (tea time opportunity charges???)
are there bad connections in the power circuits? (you might want to just take it all apart and wire brush the connections while youre this deep into the machine by now)

something overloaded the heck outta that control it could be internal in the control itself (defect of some sort but im sure that would have reared its head in a few other units out of a dozen) but replacing parts doesnt always solve the problem it just makes u have to buy new parts again
when u burn something like that it stinks of operator abuse

or
1 bum machine outta 12 aint bad lol (jk)

also ur slightly unclear
did you blow the same controller or two differnt ones?(ie traction twice or traction and pump)
it helps to know to pinpoint possible bad circuits

check all the settings compared to a truck that seems to be working fine and verify every parameter
check for firmware updates and see if this has an older version than the rest
ask the dealer for any service bulletins for your truck
(i dont wanna say who but i had a 100 page rework program for an ac series it wasnt pretty)

maybe you want to try a lower rated power circuit fuses hopefully to spare another controller but id contact tcm 1st and get their opinion

Modified 27 Mar 2007 01:45 PM
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