Toshiba G 7 User Manual

G7 Adjustable Speed Drive

Operation Manual

Document Number: 51546-009

Date: March, 2005

Introduction

Congratulations on the purchase of the new G7 True Torque Control2 Adjustable Speed Drive (ASD). The G7 True Torque Control2 Adjustable Speed Drive is a solid-state AC drive that features True Torque Control2. TIC’s Vector Control Algorithm enables the motor to develop high starting torque and provide compensation for motor slip, which results in smooth, quick starts and highly efficient operation. The G7 uses digitally-controlled pulse width modulation. The programmable functions may be accessed via the easy-to-use menu or via the Direct Access Numbers (see page 59). This feature, combined with Toshiba’s high-performance software, delivers unparalleled motor control and reliability.

The G7 is a very powerful tool, yet surprisingly simple to operate. The user-friendly Electronic Operator Interface (EOI) of the G7 has an easy-to-read 240 x 64 pixel graphical LCD screen. The EOI provides easy access to the many monitoring and programming features of the G7.

The motor control software is menu-driven, which allows for easy access to the motor control parameters and quick changes when required.

To maximize the abilities of your new G7, a working familiarity with this manual will be required. This manual has been prepared for the G7 ASD installer, user, and maintenance personnel. This manual may also be used as a reference guide or for training. With this in mind, use this manual to develop a system familiarity before attempting to install or operate the device.

Important Notice

The instructions contained in this manual are not intended to cover all details or variations in equipment types, nor may it provide for every possible contingency concerning the installation, operation, or maintenance of this equipment. Should additional information be required contact your Toshiba representative.

The contents of this manual shall not become a part of or modify any prior or existing agreement, commitment, or relationship. The sales contract contains the entire obligation of Toshiba International Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation and any statements contained herein do not create new warranties or modify the existing warranty.

Any electrical or mechanical modifications to this equipment without prior written consent of Toshiba International Corporation will void all warranties and may void the UL/CUL listing or other safety certifications. Unauthorized modifications may also result in a safety hazard or equipment damage.

Misuse of this equipment could result in injury and equipment damage. In no event will Toshiba Corporation be responsible or liable for direct, indirect, special, or consequential damage or injury that may result from the misuse of this equipment.

Contacting Toshiba’s Customer Support

Center

Toshiba’s Customer Support Center can be contacted to obtain help in resolving any Adjustable Speed Drive system problem that you may experience or to provide application information.

The center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free number is US [phone]/Fax [phone] — Canada [phone].

You may also contact Toshiba by writing to:

Toshiba International Corporation

13131 West Little York Road

Houston, Texas 77041-9990

Attn: ASD Product Manager.

For further information on Toshiba’s products and services, please visit our website at www.tic.toshiba.com (right click and select Open Weblink in Browser).

TOSHIBA INTERNATIONAL CORPORATION

G7 Adjustable Speed Drive

Please complete the Warranty Card supplied with the ASD and return it to Toshiba by prepaid mail. This will activate the 12 month warranty from the date of installation; but, shall not exceed 18 months from the shipping date.

Complete the following information and retain for your records.

Model Number: ______________________________________________________________________

Serial Number:______________________________________________________________________

Project Number (if applicable):__________________________________________________________

Date of Installation: __________________________________________________________________

Inspected By:______________________________________________________________________

Name of Application:_________________________________________________________________

About This Manual

This manual was written by the Toshiba Technical Publications Group. This group is tasked with providing technical documentation for the G7 Adjustable Speed Drive. Every effort has been made to provide accurate and concise information to you, our customer.

At Toshiba we’re continuously searching for better ways to meet the constantly changing needs of our customers. Email your comments, questions, or concerns about this publication to

[e-mail].

Manual’s Purpose and Scope

This manual provides information on how to safely install, operate, maintain, and dispose of your

G7 True Torque Control2 Adjustable Speed Drive. The information provided in this manual is applicable to the G7 True Torque Control2 Adjustable Speed Drive only.

This operation manual provides information on the various features and functions of this powerful costsaving device, including

•Installation,

•System operation,

•Configuration and menu options, and

•Mechanical and electrical specifications.

Included is a section on general safety instructions that describe the warning labels and symbols that are used throughout the manual. Read the manual completely before installing, operating, performing maintenance, or disposing of this equipment.

This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review. Dimensions shown in the manual are in metric and/or the English equivalent.

Because of our commitment to continuous improvement, Toshiba International Corporation reserves the right, without prior notice, to update information, make product changes, or to discontinue any product or service identified in this publication.

Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or consequential damages resulting from the use of the information contained within this manual.

TOSHIBA is a registered trademark of the Toshiba Corporation. All other product or trade references appearing in this manual are registered trademarks of their respective owners.

This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form without the prior written consent of Toshiba International Corporation.

© Copyright 2005 Toshiba International Corporation.

All rights reserved.

Printed in the U.S.A.

Table of Contents

CE Compliance Requirements .............................................................................................	10
EMC Installation Guidelines ............................................................................................	10
Motor Characteristics ...........................................................................................................	13
Motor Autotuning .............................................................................................................	13
Pulse Width Modulation Operation ..................................................................................	13
Low Speed Operation .......................................................................................................	13
Overload Protection Adjustment ......................................................................................	13
Operation Above 60 Hz ....................................................................................................	14
Power Factor Correction ..................................................................................................	14
Light Load Conditions .....................................................................................................	14
Motor/Load Combinations ...............................................................................................	14
Load-produced Negative Torque ......................................................................................	15
Motor Braking ..................................................................................................................	15
ASD Characteristics ..............................................................................................................	16
Over-current Protection ....................................................................................................	16
ASD Capacity ...................................................................................................................	16
Using Vector Control ........................................................................................................	16
Local/Remote Operation ..................................................................................................	16
Installation and Connections ................................................................................................	17
Installation Notes ..............................................................................................................	17
Mounting the ASD ...........................................................................................................	18
Connecting the ASD .........................................................................................................	19
I/O and Control .................................................................................................................	22
G7 ASD Control ...............................................................................................................	26
Typical Connection Diagram ...........................................................................................	30
Command Mode and Frequency Mode Control .................................................................	31
Command Control (F003) ................................................................................................	31
Frequency Control (F004) ................................................................................................	32
Override Operation ...........................................................................................................	34
Electronic Operator Interface ..............................................................................................	36
EOI Features .....................................................................................................................	36
EOI Operation ..................................................................................................................	37
System Operation ..................................................................................................................	38
Initial Setup ......................................................................................................................	38
Operation (Local) .............................................................................................................	38
Default Setting Changes ...................................................................................................	39
Startup Wizard Requirements .............................................................................................	40
System Configuration and Menu Options ...........................................................................	43
Root Menus ......................................................................................................................	43
Direct Access Parameter Information .................................................................................	59
Direct Access Parameters/Numbers .................................................................................	59

G7 ASD Operation Manual

i

Alarms, Trips, and Troubleshooting ..................................................................................	173
Alarms and Trips ............................................................................................................	173
Alarms ............................................................................................................................	174
User Notification Codes .................................................................................................	176
Trips/Faults .....................................................................................................................	176
Enclosure Dimensions and Conduit Plate Information ...................................................	182
Enclosure Dimensions/Weight .......................................................................................	182
Conduit Plate Information ..............................................................................................	187
Conduit Extender Box (option) ......................................................................................	189
EOI Remote Mounting ........................................................................................................	190
Current/Voltage Specifications ...........................................................................................	193
Cable/Terminal Specifications ............................................................................................	195
Dynamic Braking Resistor Wire/Cable Specifications ..................................................	198
Link Reactor Information ..................................................................................................	199
G7 Optional Devices ............................................................................................................	200
G7 ASD Spare Parts Listing ...............................................................................................	201

ii	G7 ASD Operation Manual

General Safety Information

DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information and directions that are contained in this manual.

Safety Alert Symbol

The Safety Alert Symbol indicates that a potential personal injury hazard exists. The symbol is comprised of an equilateral triangle enclosing an exclamation mark.

Signal Words

Listed below are the signal words that are used throughout this manual followed by their descriptions and associated symbols. When the words DANGER, WARNING and CAUTION are used in this manual they will be followed by important safety information that must be carefully adhered to.

The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous situation exists that, if not avoided, will result in death or serious injury to personnel.

DANGER

The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous situation exists that, if not avoided, could result in death or serious injury to personnel.

WARNING

The word CAUTION preceded by the safety alert symbol indicates that a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury.

CAUTION

The word CAUTION without the safety alert symbol indicates a potentially hazardous situation exists which, if not avoided, may result in equipment and property damage.

CAUTION

G7 ASD Operation Manual

1

Special Symbols

To identify special hazards, other symbols may appear in conjunction with the DANGER, WARNING and CAUTION signal words. These symbols indicate areas that require special and/or strict adherence to the procedures to prevent serious injury to personnel or death.

Electrical Hazard Symbol

A symbol which indicates a hazard of injury from electrical shock or burn. It is comprised of an equilateral triangle enclosing a lightning bolt.

Explosion Hazard Symbol

A symbol which indicates a hazard of injury from exploding parts. It is comprised of an equilateral triangle enclosing an explosion image.

Equipment Warning Labels

DO NOT attempt to install, operate, perform maintenance, or dispose of this equipment until you have read and understood all of the product labels and user directions that are contained in this manual.

Shown below are examples of safety labels that may be found attached to the equipment. DO NOT remove or cover any of the labels. If the labels are damaged or if additional labels are required, contact your Toshiba sales representative for additional labels.

Labels attached to the equipment are there to provide useful information or to indicate an imminently hazardous situation that may result in serious injury, severe property and equipment damage, or death if the instructions are not followed.

Figure 1. Examples of labels that may be found on the equipment.

!DANGER

DO NOT REMOVE, DESTROY, OR COVER THIS LABEL.

READ THE INSTRUCTION MANUAL CAREFULLY BEFORE ENTERING THIS COMPARTMENT.

HAZARDOUS VOLTAGE Behind These Panels.

Contact With Energized Main Bus Will Cause

Severe Injury, Death, Fire, Explosion, Or

Property Damage.

Turn Off And Lockout Primary And

Control Circuit Power Before Opening

These Panels.

Qualified Operators Only.

!DANGER

DO NOT REMOVE, DESTROY, OR COVER THIS LABEL.

READ THE INSTRUCTION MANUAL CAREFULLY BEFORE INSTALLING, OPERATING, OR SERVICING THIS EQUIPMENT.

HAZARDOUS VOLTAGE

Can Cause Severe Injury, Death, Explosion,

Fire, Or Property Damage.

Only Qualified Personnel Should Be Permitted

To Operarate or Service This Equipment.

Disconnect And Lockout Primary And Control

Circuit Power Before Servicing.

Keep All Panels And Covers Securely In Place.

Never Defeat, Modify, Or Bypass Safety

Interlocks.

Foreign Voltage May Be Present At Interface

Terminals. Isolate Before Performing Service

Or Repairs.

Unauthorized Modifications To This Equipment

Will Void The Warranty.

	!	CAUTION	!	DANGER
	Excessive Loading of Operating Shaft		DO NOT OPEN THIS DOOR WHILE THE UNIT IS RUNNING.
			THIS DOOR IS INTERLOCKED WITH ASD OPERATION.
	Can Prevent Contactor From Closing
				HAZARDOUS VOLTAGE MAY BE PRESENT.
	Properly Resulting In Major Damage.
				Capacitors Are Charged. Wait
	Do Not Use Contactor Shaft To Drive			At Least 5 Minutes Before Entry.
				Check For Charged Voltage
	Accessories Such As Mechanical Interlocks
	Which Require More Than 5 Kgf-cm Of			To Dissipate To A Safe Level
				Before Opening The Equipment.

Torque To Operate.

2	G7 ASD Operation Manual

Qualified Personnel

Installation, operation, and maintenance shall be performed by Qualified Personnel Only. A Qualified Person is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements).

Qualified Personnel shall:

•Have carefully read the entire operation manual.

•Be familiar with the construction and function of the ASD, the equipment being driven, and the hazards involved.

•Able to recognize and properly address hazards associated with the application of motor-driven equipment.

•Be trained and authorized to safely energize, de-energize, ground, lockout/tagout circuits and equipment, and clear faults in accordance with established safety practices.

•Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety practices.

•Be trained in rendering first aid.

For further information on workplace safety visit www.osha.gov.

Equipment Inspection

•Upon receipt of the equipment inspect the packaging and equipment for shipping damage.

•Carefully unpack the equipment and check for parts that were damaged during shipping, missing parts, or concealed damage. If any discrepancies are discovered, it should be noted with the carrier prior to accepting the shipment, if possible. File a claim with the carrier if necessary and immediately notify your Toshiba sales representative.

•DO NOT install or energize equipment that has been damaged. Damaged equipment may fail during operation resulting in equipment damage or personal injury.

•Check to see that the rated capacity and the model number specified on the nameplate conform to the order specifications.

•Modification of this equipment is dangerous and must not be performed except by factory trained representatives. When modifications are required contact your Toshiba sales representative.

•Inspections may be required before and after moving installed equipment.

•Keep the equipment in an upright position.

•Contact your Toshiba sales representative to report discrepancies or for assistance if required.

G7 ASD Operation Manual

3

Handling and Storage

•Use proper lifting techniques when moving the ASD; including properly sizing up the load, getting assistance, and using a forklift if required.

•Store in a well-ventilated covered location and preferably in the original carton if the equipment will not be used upon receipt.

•Store in a cool, clean, and dry location. Avoid storage locations with extreme temperatures, rapid temperature changes, high humidity, moisture, dust, corrosive gases, or metal particles.

•The storage temperature range of the G7 ASD is 14° to 104° F (-10 to 40° C).

•Do not store the unit in places that are exposed to outside weather conditions (i.e., wind, rain, snow, etc.).

•Store in an upright position.

Disposal

Never dispose of electrical components via incineration. Contact your state environmental agency for details on disposal of electrical components and packaging in your area.

Installation Precautions

Location and Ambient Requirements

•The Toshiba ASD is intended for permanent installations only.

•Installation should conform to the 2002 National Electrical Code — Article 110 (NEC) (Requirements For Electrical Installations), all regulations of the Occupational Safety and Health Administration, and any other applicable national, regional, or industry codes and standards.

•Select a mounting location that is easily accessible, has adequate personnel working space, and adequate illumination for adjustment, inspection, and maintenance of the equipment (refer to 2002 NEC Article 110-13).

•A noncombustible insulating floor or mat should be provided in the area immediately surrounding the electrical system.

•Do Not mount the ASD in a location that would produce catastrophic results if it were to fall from its mounting location (equipment damage or injury).

•Do Not mount the ASD in a location that would allow it to be exposed to flammable chemicals or gases, water, solvents, or other fluids.

•Avoid installation in areas where vibration, heat, humidity, dust, fibers, steel particles, explosive/ corrosive mists or gases, or sources of electrical noise are present.

•The installation location shall not be exposed to direct sunlight.

•Allow proper clearance spaces for installation. Do not obstruct the ventilation openings. Refer to the section titled Installation and Connections on pg. 17 for further information on ventilation requirements.

•The ambient operating temperature range of the G7 ASD is 14° to 104° F (-10 to 40° C).

•See the section titled Installation and Connections on pg. 17 for additional information on installing the drive.

4	G7 ASD Operation Manual

Mounting Requirements

•Only Qualified Personnel should install this equipment.

•Install the unit in a secure and upright position in a well-ventilated area.

•A noncombustible insulating floor or mat should be provided in the area immediately surrounding the electrical system at the place where maintenance operations are to be performed.

•As a minimum, the installation of the equipment should conform to the NEC Article 110 Requirements For Electrical Installations, OSHA, as well as any other applicable national, regional, or industry codes and standards.

•Installation practices should conform to the latest revision of NFPA 70E Electrical Safety Requirements for Employee Workplaces.

•It is the responsibility of the person installing the ASD or the electrical maintenance personnel to ensure that the unit is installed into an enclosure that will protect personnel against electric shock.

Conductor Routing and Grounding

WARNING

•Use separate metal conduits for routing the input power, output power, and control circuits and each shall have its own ground cable.

•A separate ground cable should be run inside the conduit with the input power, output power, and and control circuits.

•DO NOT connect control terminal strip return marked CC to earth ground.

•Always ground the unit to prevent electrical shock and to help reduce electrical noise.

•It is the responsibility of the person installing the ASD or the electrical maintenance personnel to provide proper grounding and branch circuit protection in accordance with the 2002 NEC and any applicable local codes.

T h e M e t a l O f C o n d u i t I s N o t A n A c c e p t a b l e G r o u n d .

Power Connections

DANGER

C o n ta c t W i t h E n e r g i z e d W i r i n g W i l l C a u s e S e v e r e I n j u r y O r D e a t h .

•Turn off, lockout, and tagout all power sources before proceeding to connect the power wiring to the equipment.

•After ensuring that all power sources are turned off and isolated in accordance with established lockout/tagout procedures, connect three-phase power source wiring of the correct voltage to the correct input terminals and connect the output terminals to a motor of the correct voltage and type for the application (refer to NEC Article 300 – Wiring Methods and Article 310 – Conductors For General Wiring). Size the branch circuit conductors in accordance with NEC Table 310.16.

•If multiple conductors that are smaller than the recommended sizes are used in parallel for the input or output power, each branch of the parallel set shall have its own conduit and not share its conduit with other parallel sets (i.e., place U1, V1, and W1 in one conduit and U2, V2, and W2 in another) (refer to NEC Article 300.20 and Article 310.4). National and local electrical codes should be

G7 ASD Operation Manual

5

referenced if three or more power conductors are run in the same conduit (refer to 2002 NEC Article 310 adjustment factors on page 70-142).

•Ensure that the 3-phase input power is Not connected to the output of the ASD. This will damage the ASD and may cause injury to personnel.

•Do not install the ASD if it is damaged or if it is missing any component(s).

•Do Not connect resistors across terminals PA – PC or PO – PC. This may cause a fire.

•Ensure the correct phase sequence and the desired direction of motor rotation in the Bypass mode (if applicable).

•Turn the power on only after attaching and/or securing the front cover.

Protection

•Ensure that primary protection exists for the input wiring to the equipment. This protection must be able to interrupt the available fault current from the power line. The equipment may or may not be equipped with an input disconnect (option).

•All cable entry openings must be sealed to reduce the risk of entry by vermin and to allow for maximum cooling efficiency.

•Follow all warnings and precautions and do not exceed equipment ratings.

•If using multiple motors provide separate overload protection for each motor and use V/f control.

•External dynamic braking resistors must be thermally protected.

•It is the responsibility of the person installing the ASD or the electrical maintenance personnel to setup the Emergency Off braking system of the ASD. The function of the Emergency Off braking function is to remove output power from the drive in the event of an emergency. A supplemental braking system may also be engaged in the event of an emergency. For further information on braking systems, see DC Injection Braking Start Frequency on pg. 105 and Dynamic Braking Enable on pg. 112.

Note: A supplemental emergency stopping system should be used with the ASD. Emergency stopping should not be a task of the ASD alone.

•Follow all warnings and precautions and do not exceed equipment ratings.

6	G7 ASD Operation Manual

System Integration Precautions

The following precautions are provided as general guidelines for the setup of the ASD within the system.

•The Toshiba ASD is a general-purpose product. It is a system component only and the system design should take this into consideration. Please contact your Toshiba sales representative for application-specific information or for training support.

•The Toshiba ASD is part of a larger system and the safe operation of the ASD will depend on observing certain precautions and performing proper system integration.

•A detailed system analysis and job safety analysis should be performed by the systems designer and/or systems integrator before the installation of the ASD component. Contact your Toshiba sales representative for options availability and for application-specific system integration information if required.

Personnel Protection

•Installation, operation, and maintenance shall be performed by Qualified Personnel Only.

•A thorough understanding of the ASD will be required before the installation, operation, or maintenance of the ASD.

WARNING

•Rotating machinery and live conductors can be hazardous and shall not come into contact with humans. Personnel should be protected from all rotating machinery and electrical hazards at all times.

•Insulators, machine guards, and electrical safeguards may fail or be defeated by the purposeful or inadvertent actions of workers. Insulators, machine guards, and electrical safeguards are to be inspected (and tested where possible) at installation and periodically after installation for potential hazardous conditions.

•Do not allow personnel near rotating machinery. Warning signs to this effect shall be posted at or near the machinery.

•Do not allow personnel near electrical conductors. Human contact with electrical conductors can be fatal. Warning signs to this effect shall be posted at or near the hazard.

•Personal protection equipment shall be provided and used to protect employees from any hazards inherent to system operation.

•Follow all warnings and precautions and do not exceed equipment ratings.

System Setup Requirements

•When using the ASD as an integral part of a larger system, it is the responsibility of the ASD installer or maintenance personnel to ensure that there is a fail-safe in place, i.e., an arrangement designed to switch the system to a safe condition if there is a fault or failure.

•System safety features should be employed and designed into the integrated system in a manner such that system operation, even in the event of system failure, will not cause harm or result in personnel injury or system damage (i.e., E-Off, Auto-Restart settings, System Interlocks, etc.).

•The programming setup and system configuration of the ASD may allow it to start the motor unexpectedly. A familiarity with the Auto-restart settings are a requirement to use this product.

G7 ASD Operation Manual

7

•Improperly designed or improperly installed system interlocks may render the motor unable to start or stop on command.

•The failure of external or ancillary components may cause intermittent system operation, i.e., the system may start the motor without warning.

•There may be thermal or physical properties, or ancillary devices integrated into the overall system that may allow for the ASD to start the motor without warning. Signs at the equipment installation must be posted to this effect.

•If a secondary magnetic contactor (MC) is used between the ASD and the load, it should be interlocked to halt the ASD before the secondary contact opens. If the output contactor is used for bypass operation, it must be interlocked such that commercial power is never applied to the ASD output terminals (U, V, W).

•Power factor improvement capacitors or surge absorbers must not be installed on the output of the ASD.

•Use of the built-in system protective features is highly recommended (i.e., E-Off, Overload Protection, etc.).

•The operating controls and system status indicators should be clearly readable and positioned where the operator can see them without obstruction.

•Additional warnings and notifications shall be posted at the equipment installation location as deemed required by Qualified Personnel.

•Follow all warnings and precautions and do not exceed equipment ratings.

Operational and Maintenance Precautions

WARNING

•Turn off, lockout, and tagout the main power, the control power, and instrumentation connections before inspecting or servicing the drive, or opening the door of the enclosure.

•Turn off, lockout, and tagout the main power, the control power, and instrumentation connections before proceeding to disconnect or connect the power wiring to the equipment.

•The capacitors of the ASD maintain a residual charge for a period of time after turning the ASD off. The required time for each ASD typeform is indicated with a cabinet label and a Charge LED. Wait for at least the minimum time indicated on the enclosure-mounted label and ensure that the Charge LED has gone out before opening the door of the ASD once the ASD power has been turned off.

•Turn the power on only after attaching (or closing) the front cover and Do Not remove the front cover of the ASD when the power is on.

•Do Not attempt to disassemble, modify, or repair the ASD. Call your Toshiba sales representative for repair information.

•Do not place any objects inside of the ASD.

•If the ASD should emit smoke or an unusual odor or sound, turn the power off immediately.

•The heat sink and other components may become extremely hot to the touch. Allow the unit to cool before coming in contact with these items.

•Remove power from the ASD during extended periods of non-use.

•The system should be inspected periodically for damaged or improperly functioning parts, cleanliness, and to ensure that the connectors are tightened securely.

8	G7 ASD Operation Manual

•Ensure that the Run functions (F, R, Preset Speed, etc.) of the ASD are off before performing a Reset. The post-reset settings may allow the ASD to start unexpectedly.

•Retry or Reset settings may allow the motor to start unexpectedly. Warnings to this effect should be clearly posted near the ASD and motor.

•In the event of a power failure, the motor may restart after power is restored.

•Follow all warnings and precautions and do not exceed equipment ratings.

DO NOT install, operate, perform maintenance, or dispose of this equipment until you have read and understood all of the product warnings and user directions. Failure to do so may result in equipment damage, operator injury, or loss of life.

Service Life Information

	Part Name	Service Life	Remarks
	Large Capacity Electrolytic	5 Years	When not used for long periods,
	Capacitor		charge semi-annually.
	Cooling Fan	26,000 Hours
	CN Connectors	100 Connects/Disconnects
	On-board Relays	500,000 Actuations

G7 ASD Operation Manual

9

CE Compliance Requirements

In addition to the local and regional safety requirements, this section describes additional criteria that must be met to qualify for European Conformity (CE) certification. All relevant apparatus placed on the European market is required to comply to the European Community directive on electromagnetic compatibility (EMC). The following instructions provide a means of compliance for the 7-series of ASDs. A Technical Construction File (TFC) indicates the rationale used to declare compliance and is on file at Toshiba International Corporation, Houston, Texas U.S.A.

EMC Installation Guidelines

All systems placed on the European market are required to comply with the European Community directive regarding electromagnet compatibility (EMC). Toshiba ensures that all systems deployed in the European market have been screened and are in 100% compliance with the following standards:

•Radiated Interference: EN 55011 Group 1 Class A

•Mains Interference: EN 55011 Group 1 Class A

•Radiated Susceptibility: IEC 801-3 1984

•Conducted RFI Susceptibility: prEN55101-4 (prIEC801-6) Doc 90/30270

•Electrostatic Discharge: IEC801-2 1991

•Electrical Fast Transient: IEC 801-4 1988

•Surge: IEC1000-4-5 1995 2 KV line-to-line, 4 KV line-to-earth

•Voltage Interruption: IEC 1000-4-11

General EMC Guidelines for Consideration

•Input filters of the appropriate rating shall be used.

•Proper grounding is a requirement.

•Grounds shall be kept to the minimum length to accomplish the connection.

•Grounds shall have low RF impedance.

•A central ground shall employed in a complex system.

•Paint or corrosion can hamper good grounding; remove as required.

•Keep control and power cabling separated. Minimize exposed (unscreened) cable.

•Use 3600 screened connections where possible.

CE Compliant Installation Guidelines

ASDs should be installed in accordance with the following guidelines.

1.Filtering — An input filter shall be used with the ASD. A Schaffner FN258 series input filter of the appropriate rating shall be mounted next to the ASD.

2.Mechanical — The ASD and the associated equipment shall be mounted on a flat metallic backplane. A minimum space of 5 cm (2 inches) shall be between the ASD and the filter to allow for ventilation. The filter output cable is to be connected from the bottom of the filter to the ASD power input and is to be the minimum length required for a connection. See Table 1 on page 11 for filter selection assistance.

10	G7 ASD Operation Manual

Units received as an Open Chassis shall not be placed into operation until being placed into an approved enclosure that will protect personnel against electrical shock.

Opening and closing of enclosures or barriers should be possible only with the use of a key or a tool.

3.Cabling — The power, filter, and motor cables shall be of the appropriate current rating. The cables shall be connected in accordance with the guidelines of the manufacturer and the applicable local and national agencies. A 4-core screened cable (such as RS 379-384) is to be used for the power and earth connections to minimize RF emissions. Control cabling must be screened using P/N RS 367-347 or a similar component.

4.Grounding — The mains (input) ground shall be connected at the ground terminal provided on the filter. The filter and motor shall be grounded at the ground terminals provided in the ASD.

5.Screening — The mains (input) screen is to be connected to the metallic back-plane at the filter; remove any finish coating as required. The screen over the filter output cables, the motor cable screen, and the control wire screens must be connected to the ASD case using glands or conduit connectors. The motor cable screen shall be connected to the motor case. When using a braking resistor, the cabling between the resistor and ASD shall also be screened. This screen shall connect to both the ASD enclosure and the resistor enclosure.

6.Where residual-current-operated protective device (RCD) is used for protection in case of direct or indirect contact, only RCD of type B is allowed on the supply side of this Electronic Equipment (EE). Otherwise, another protective measure shall be applied, such as separation of the EE from the environment by double or feinforced insulation, or isolation of the EE and the supply system by a transformer.

See the G7 Filter Selection below for the recommended input filters for a given typeform.

Table 1.

G7 Filter Selection Table

	230V		VT130G7U4110B	FN258-30
VT130G7U2010B		FN258-7	VT130G7U4160B
VT130G7U2015B			VT130G7U4220B	FN258-42
VT130G7U2025B		FN258-16	VT130G7U4270B	FN258-55
VT130G7U2035B			VT130G7U4330B
VT130G7U2055B		FN258-30	VT130G7U4400B	FN258-75
VT130G7U2080B			VT130G7U4500B	FN258-100
VT130G7U2110B		FN258-42	VT130G7U4600B
VT130G7U2160B		FN258-75	VT130G7U4750B	FN258-130
VT130G7U2220B		FN258-100	VT130G7U410KB	FN258-180
VT130G7U2270B			VT130G7U412KB	FS5236-300
VT130G7U2330B		FN258-130	VT130G7U415KB

G7 ASD Operation Manual

11

G7 Filter Selection Table

	460V		VT130G7U420KB
					FS5236-500
VT130G7U4015B			VT130G7U425KB
VT130G7U4025B		FN258-7	VT130G7U430KB
VT130G7U4035B				600V
VT130G7U4055B		FN258-16	VT130G7U6015B
VT130G7U4080B			VT130G7U6025B		FN258-7
VT130G7U4110B		FN258-30	VT130G7U6035B
VT130G7U4160B			VT130G7U6055B
VT130G7U4220B		FN258-42	VT130G7U6080B		FN258-16
VT130G7U4270B		FN258-55	VT130G7U6110B
VT130G7U4330B			VT130G7U6160B		FN258-30
VT130G7U4400B		FN258-75	VT130G7U6220B		FN258-42
VT130G7U4500B		FN258-100	VT130G7U6270B
VT130G7U4600B			VT130G7U6330B		FN258-55
VT130G7U4750B		FN258-130	VT130G7U6400B
VT130G7U410KB		FN258-180	VT130G7U6500B		FN258-75
VT130G7U412KB		FS5236-300	VT130G7U6600B		FN258-100
VT130G7U415KB			VT130G7U6750B
VT130G7U420KB			VT130G7U610KB		FN258-130
VT130G7U425KB		FS5236-500	VT130G7U612KB		FS5236-180
VT130G7U430KB			VT130G7U615KB
VT130G7U4015B			VT130G7U620KB		FS5236-300
VT130G7U4025B		FN258-7	VT130G7U625KB		FS5236-500
VT130G7U4035B			VT130G7U630KB
VT130G7U4055B		FN258-16
VT130G7U4080B

12	G7 ASD Operation Manual

Motor Characteristics

Listed below are some variable speed AC motor control concepts with which the user of the

G7 Adjustable Speed Drive should become familiar.

Motor Autotuning

Motor production methods may cause minor differences in the motor operation. The negative effects of these differences may be minimized by using the Autotune feature of the G7 ASD. Autotuning is a function of the G7 that measures several parameters of the connected motor and places these readings in a stored table. The software uses the information in the table to help optimize the response of the ASD to application-specific load and operational requirements. The Autotuning function may be enabled for automatic tuning, configured manually at F400, or disabled.

The measured parameters include the rotor resistance, the stator resistance, the required excitation inductance, rotational inertia values, and leakage inductance values.

The G7 ASD is also equipped with a factory-loaded table of motor parameters that fit several different types of motors. To use this function, disable Autotune and select a motor type at F413.

Pulse Width Modulation Operation

The G7 ASD uses a sinusoidal Pulse Width Modulation (PWM) control system. The output current waveform generated by the ASD approaches that of a perfect sine wave; however, the output waveform is slightly distorted. For this reason, the motor may produce more heat, noise, and vibration when operated by an ASD, rather than directly from commercial power.

Low Speed Operation

Operating a general-purpose motor at lower speeds may cause a decrease in the cooling ability of the motor. Reducing the torque requirement of the motor at lower speeds will decrease the generated heat at lower speeds.

When the motor is to be operated at low speed (less than 50% of full speed) and at the rated torque continuously, a Toshiba VF motor (designed for use in conjunction with an ASD) is recommended. When the ASD is used with a VF motor, the VF Motor overload protection setting must be enabled (see Program Protection Parameters Overload V/f Motor Enable/Disable).

Overload Protection Adjustment

The G7 ASD software monitors the output current of the system and determines when an overload condition occurs. The overload current level is a percentage of the rating of the motor. This function protects the motor from overload.

The default setting for the overload detection circuit is set to the maximum rated current of the ASD at the factory. This setting will have to be adjusted to match the rating of the motor with which the ASD is to be used. To change the overload reference level, see Electronic Thermal Protection #1 on pg. 154.

G7 ASD Operation Manual

13

Operation Above 60 Hz

A motor produces more noise and vibration when it is operated at frequencies above 60 Hz. Also, when operating a motor above 60 Hz, the rated limit of the motor or its bearings may be exceeded; this may void the motor warranty.

Contact the motor manufacturer for additional information before operating the motor above 60 Hz.

Power Factor Correction

DO NOT connect a power factor correction capacitor or surge absorber to the output of the ASD.

If the ASD is used with a motor that is equipped with a capacitor for power factor correction, remove the capacitor from the motor.

Connecting either of these devices to the output of the ASD may cause the ASD to malfunction and trip, or the output device may cause an over-current condition resulting in damage to the device or the ASD.

Light Load Conditions

When a motor is operated under a continuous light load (i.e., at a load of less than 50% of its rated capacity) or it drives a load which produces a very small amount of inertia, it may become unstable and produce abnormal vibration or trips because of an over-current condition. In such a case, the carrier frequency may be lowered to compensate for this undesirable condition (see Program Special Control Parameters Carrier Frequency).

Note: For proper operation, the carrier frequency must be 2.2 kHz or above except when operating in the Constant Torque, Variable Torque, or the 5-Point Setting modes.

Motor/Load Combinations

When the ASD is used in combination with one of the following motors or loads, it may result in unstable operation.

•A motor with a rated capacity that exceeds the motor capacity recommended for the ASD.

•An explosion-proof motor.

When using the ASD with an explosion-proof motor or other special motor types, lower the carrier frequency to stabilize the operation. DO NOT set the carrier frequency below 2.2 kHz if operating the system in the vector control mode.

Note: For proper operation, the carrier frequency must be 2.2 kHz or above except when operating in the Constant Torque, Variable Torque, or the 5-Point Setting modes.

•If the motor that is coupled to a load that has a large backlash or a reciprocating load, use one of the following procedures to stabilize its operation.

•Adjust the S-pattern acceleration/deceleration setting,

•If in the Vector control mode, adjust the response time, or

•Switch to the Constant Torque control mode.

14	G7 ASD Operation Manual

Load-produced Negative Torque

When the ASD is used with a load that produces negative torque (an overhauling load), the over-voltage or over-current protective functions of the ASD may cause nuisance tripping.

To minimize the undesirable effects of negative torque the dynamic braking system may be used. The dynamic braking system converts the regenerated energy into heat that is dissipated using a braking resistor. The braking resistor must be suitably matched to the load. Dynamic braking is also effective in reducing the DC bus voltage during a momentary over-voltage condition.

CAUTION

If under extreme conditions the dynamic braking system or a component of this system were to fail, the dynamic braking resistor may experience an extended over-current condition. The DBR circuit was designed to dissipate excessive amounts of heat and if the extended over-current condition were allowed to exceed the circuit parameters, this condition could result in a fire hazard.

To combat this condition, the 3-phase input may be connected using contactors that are configured to open in the event of an extended DBR over-current condition or an internal circuit failure. Using a thermal sensor and/or overload protection as the 3-phase input contactor drive signal, the contactors will open and remove the 3-phase input power in the event of an extended DBR over-current or system over-voltage condition.

Motor Braking

The motor may continue to rotate and coast to a stop after being shut off due to the inertia of the load. If an immediate stop is required, a braking system should be used. The two most common types of motor braking systems used with the G7 ASD are DC Injection Braking and Dynamic Braking.

For further information on braking systems, see DC Injection Braking on pg. 105 and Dynamic Braking Enable on pg. 112.

G7 ASD Operation Manual

15

ASD Characteristics

Over-current Protection

Each G7 ASD model was designed for a specified operating power range. The ASD will incur a trip if the design specifications are exceeded.

However, the ASD may be operated at 110% of the specified output-current range continuously or at 150% for a limited amount of time as indicated in the section titled Current/Voltage Specifications on pg. 193. Also, the Overcurrent Stall Level may be adjusted to help with nuisance over-current trips (see

F601).

When using the ASD for an application that controls a motor which is rated significantly less than the maximum current rating of the ASD, the over-current limit (Thermal Overload Protection) setting will have to be changed to match the application. For further information on this parameter, see Electronic Thermal Protection #1 on pg. 154.

ASD Capacity

The G7 ASD must not be used with a motor that has a significantly larger capacity, even if the motor is operated under a small load. An ASD being used in this way will be susceptible to a high-output peak current which may result in nuisance tripping.

Do not apply a level of input voltage to an ASD that is beyond that which the ASD is rated. The input voltage may be stepped down when required with the use of a step-down transformer or some other type of voltage-reduction system.

Using Vector Control

Using Vector Control enables the system to produce very high torque over the entire operating range even at extremely low speeds. Vector Control may be used with or without feedback. However, using feedback increases the speed accuracy for applications requiring precise speed control. Enabling the Automatic Energy Savings further increases the efficiency of the G7 ASD while maintaining its robust performance.

Vector Control is not capable of operating multiple motors connected in parallel.

See F015 on pg. 64 for further information on using Vector Control.

Local/Remote Operation

While running in the Local mode at a non-zero speed, if the RJ45 connector is removed from the EOI and then reinserted, the ASD remains in the Local mode even though the Local LED is off (press Run to illuminate the Local LED). The ASD output remains at the frequency of the Frequency Command field at the time of the disconnect so long as the connector is disconnected.

Once reinserted, the reference frequency that was loaded into the EEPROM (not RAM) before the disconnect will be the frequency to which the ASD output will return.

To prevent this condition, before disconnecting the RJ45 connector ensure that the ASD is off.

16	G7 ASD Operation Manual

Installation and Connections

The G7 True Torque Control2 Adjustable Speed Drive may be set up initially by performing a few simple configuration settings. To operate properly, the ASD must be securely mounted and connected to a power source (3-phase AC input at the L1/R, L2/S, and L3/T terminals). The control terminals of the ASD may be used by connecting the terminals of the Control Terminal Strip to the proper sensors or signal input sources (see the section titled I/O and Control on pg. 22).

Note: The optional ASD-Multicom boards may be used to expand the I/O functionality of the ASD. See the section titled G7 Optional Devices on pg. 200 for further information on the available options.

The output terminals of the ASD (T1/U, T2/V, and T3/W) must be connected to the motor that is to be controlled (see Figure 18 on pg. 30).

As a minimum, the installation of the ASD shall conform to Article 110 of the 2002 NEC, the Occupational Safety and Health Administration requirements, and to any other local and regional industry codes and standards.

Upon initial system powerup, the Startup Wizard starts automatically. The Startup Wizard assists the user with the initial configuration of the G7 True Torque Control2 Adjustable Speed Drive. See the section titled Initial Setup on pg. 38 for additional information on the Startup Wizard.

Installation Notes

When a brake-equipped motor is connected to the ASD, it is possible that the brake may not release at startup because of insufficient voltage. To avoid this, Do Not connect the brake or the brake contactor to the output of the ASD.

If an output contactor is used for bypass operation, it must be interlocked such that commercial power is never applied to the output terminals of the ASD (T1/U, T2/V, or T3/W).

If a secondary magnetic contactor (MC) is used between the output of the ASD and the motor, it should be interlocked such that the ST – CC connection is disconnected before the output contactor is opened.

Do Not open and then close a secondary magnetic contactor between the ASD and the motor unless the ASD is off and the motor is not rotating.

Note: Re-application of power via a secondary contact while the ASD is on or while the motor is still turning may cause ASD damage.

On some devices the ST-to-CC connection is further enhanced by the operation of the MS1 AUX relay circuit. The MS1 AUX relay circuit is normally open and closes the ST-to-CC connection (via ST1) only after normal system power is available. The MS1 AUX relay circuit prohibits the ST-to-CC connection in the event that the MS1 contactor fails to close during start up or if MS1 opens while the ASD is running. For the 230 volt ASD this feature is available on the 30 HP system, on the 460 volt ASD this feature is available on the 75 HP and above systems, and on the 600 volt ASD it is available on the 60 HP and above systems.

Figure 2. ST activation using the MS1 AUX circuit configuration.

G7 ASD Operation Manual

17

The ASD input voltage should remain within 10% of the specified input voltage range. Input voltages approaching the upper or lower limit settings may require that the overvoltage and undervoltage stall protection level parameters, F626 and F629, be adjusted. Voltages outside of the permissible tolerance should be avoided.

The frequency of the input power should be ±2 Hz of the specified input frequency.

Do not use an ASD with a motor that has a power rating that is higher than the rated output of the ASD.

The ASD is designed to operate NEMA B motors. Consult with your sales representative before using the ASD for special applications such as with an explosion-proof motor or applications with a piston load.

Do Not apply commercial power to the output terminals T1/U, T2/V, or T3/W.

Disconnect the ASD from the motor before megging or applying a bypass voltage to the motor.

Interface problems may occur when an ASD is used in conjunction with some types of process controllers. Signal isolation may be required to prevent controller and/or ASD malfunction (contact your Toshiba sales representative or the process controller manufacturer for additional information about compatibility and signal isolation).

Use caution when setting the output frequency. Over speeding a motor decreases its ability to deliver torque and may result in damage to the motor and/or the driven equipment.

All G7 ASDs are equipped with internal DC bus fuses. However, not all G7 ASDs are equipped with internal primary power input fuses (HP dependent). When connecting two or more drives that have no internal fuse to the same power line as shown in Figure 3, it will be necessary to select a circuitbreaking configuration that will ensure that if a short circuit occurs in ASD 1, only MCCB2 trips, not MCCB1. If it is not feasible to use this configuration, insert a fuse between MCCB2 and ASD 1.

Figure 3. Circuit breaker configuration.

Mounting the ASD

CAUTION

Install the unit securely in a well ventilated area that is out of direct sunlight using the mounting holes on the rear of the ASD.

The ambient temperature rating for the G7 ASD is from 14 to 104° F (-10 to 40° C). The process of converting AC to DC, and then back to AC produces heat. During normal ASD operation, up to 5% of the input energy to the ASD may be dissipated as heat. If installing the ASD in a cabinet, ensure that there is adequate ventilation.

Do Not operate the ASD with the enclosure door open.

18	G7 ASD Operation Manual

When installing multiple ASDs, ensure that there is a clearance space of at least 8 inches (20 cm) from the top and the bottom of adjacent units. There should be at least 2 inches (5 cm) on either side of adjacent units. For the models below 50 HP the top and bottom clearance specifications may be reduced to 4 inches (10 cm). This space ensures that adequate ventilation is provided (see the section titled Enclosure Dimensions and Conduit Plate Information on pg. 182 for additional information on mounting space requirements).

Note: Ensure that the ventilation openings are not obstructed.

ASDs produce high-frequency noise — steps must be taken during installation to avoid the negative effects of noise. Listed below are some examples of measures that will help to combat noise problems.

•Separate the input and output power conductors of the main circuit. Do not install the input and output wires in the same duct or in parallel with each other, and do not bind them together.

•Do not install the input or output power conductors of the main circuit and the wires of the control circuit in the same duct or in parallel with each other, and do not bind them together.

•Use shielded wires or twisted wires for the control circuits.

•Ensure that the grounding terminals (G/E) of the ASD are securely connected to ground.

•Connect a surge suppressor to every electromagnetic contactor and every relay installed near the ASD.

•Install noise filters as required.

Connecting the ASD

DANGER

Refer to the section titled Installation Precautions on pg. 4 and the section titled Lead Length Specifications on pg. 21 before attempting to connect the ASD and the motor to electrical power.

System Grounding

Proper grounding helps to prevent electrical shock and to reduce electrical noise. The ASD is designed to be grounded in accordance with Article 250 of the 2002 NEC or Section 10/Part One of the

Canadian Electrical Code (CEC).

The grounding conductor shall be sized in accordance with Article 250-122 of the NEC or Part OneTable 6 of the CEC.

Note: The metal of conduit is not an acceptable ground.

The input, output, and control lines of the system shall be run in separate metal conduits and each shall have its own ground conductor.

Power Connections

DANGER

L1/R, L2/S, and L3/T are the 3-phase input supply terminals for the ASD. The ASD may be operated from a single-phase supply. When operating using a single-phase supply, use the L1 and L3 terminals.

T1/U, T2/V, and T3/W are the output terminals of the ASD that connect to the motor.

G7 ASD Operation Manual

19

An inductor may be connected across terminals PA and PO to provide additional filtering. When not used, a jumper is connected across these terminals (see Figure 18 on pg. 30).

Connect the input and output power lines of the ASD as shown in Figure 4.

Note: In the event that the motor rotates in the wrong direction when powered up, reverse any two of the three ASD output power leads connected to the motor.

Figure 4. ASD/Motor connection diagram.

Connect the 3-phase input power to the input terminals of the ASD at L1/R, L2/S, and L3/T. Connect the output of the ASD to the motor from terminals T1/U, T2/V, and T3/W. The input and output conductors and terminal lugs used shall be in accordance with the requirements listed in the section titled Cable/Terminal Specifications on pg. 195.

If multiple conductors are used in parallel for the input or output power and it is necessary to use separate conduits, each parallel set shall have its own conduit and not share its conduit with other parallel sets (i.e., place U1, V1, and W1 in one conduit and U2, V2, and W2 in another) (refer to NEC Article 300.20 and Article 310.4). National and local electrical codes should be referenced if three or more power conductors are run in the same conduit (refer to 2002 NEC Article 310 adjustment factors).

Note: National and local codes should be referenced when running more than three conductors in the same conduit.

Install a molded case circuit breaker (MCCB) or fuse between the 3-phase power source and the ASD in accordance with the fault current setting of the ASD and 2002 NEC Article 430.

CAUTION

For 600 volt ASDs, the 15 HP or less ASDs (P/N VT130G7U6015B – 6160B) require a class-J fuse rated at 600 Volts/30 A.

A phase-shifting transformer (or other means) must be supplied by the user when configured for 12pulse operation.

External fuses are required on the ASDs listed below when configured for 12-pulse operation.

VT130G7U2600B(DR)

VT130G7U2750B(DR)

VT130G7U412KB(DR)

VT130G7U415KB(DR)

VT130G7U610KB(DR)

VT130G7U612KB(DR)

VT130G7U615KB(DR)

Use either the Ferraz Shawmut Semiconductor fuse (P/N A70QS200) and fuse block P234C, or the Toshiba ASD-FUSEKIT-12P. The Toshiba kit includes the required fuses and the mounting hardware for the fuses.

20	G7 ASD Operation Manual

Lead Length Specifications

Adhere to the NEC and any local codes during the installation of ASD/Motor systems. Excessive lead lengths may adversely effect the performance of the motor. Special cables are not required. Lead lengths from the ASD to the motor in excess of those listed in Table 2 may require filters to be added to the output of the ASD. Table 2 lists the suggested maximum lead lengths for the listed motor voltages.

			Table 2.
	Model	PWM Carrier	NEMA MG-1-1998 Section IV Part 31
		Frequency	Compliant Motors2
	230 Volt	All	1000 feet
	460 Volt	< 5 kHz	600 feet
		≥ 5 kHz	300 feet
	600 Volt	< 5 kHz	200 feet
		≥ 5 kHz	100 feet

Note: Contact Toshiba for application assistance when using lead lengths in excess of those listed.

Exceeding the peak voltage rating or the allowable thermal rise time of the motor insulation will reduce the life expectancy of the motor.

For proper operation, the carrier frequency must be 2.2 kHz or above except when operating in the Constant Torque, Variable Torque, or the 5-Point Setting modes.

Startup and Test

Perform the following checks before turning on the unit:

•L1/R, L2/S, and L3/T are connected to the 3-phase input power.

•T1/U, T2/V, and T3/W are connected to the motor.

•The 3-phase input voltage is within the specified tolerance.

•There are no shorts and all grounds are secured.

G7 ASD Operation Manual

21

I/O and Control

The ASD can be controlled by several input types and combinations thereof, as well as operate within a wide range of output frequency and voltage levels. This section discusses the ASD control methods and supported I/O functions.

The Control Terminal Strip PCB (P/N 48570) supports discrete and analog I/O functions and is shown in Figure 6 on pg. 25. Table 3 lists the names, the default settings, and the descriptions of the input and output terminals of the Control Terminal Strip PCB.

Note: To use the input control lines of the Control Terminal Strip the Command Mode setting must be set to Use Control Terminal Strip (Program Fundamental Parameters Standard Mode Selection Command Mode Use Control Terminal Strip).

Figure 18 on pg. 30 shows the basic connection diagram for the G7 system.

Table 3. Control Terminal Strip default assignment terminal names and functions.

	Default		Default Function
	Term.	Input/Output		Circuit Config.
			(also see Terminal Descriptions on pg. 23)
	Setting
			Standby (jumper to CC to operate the unit) — Multifunctional
	ST	Discrete Input	programmable discrete input (see Installation Notes on pg. 17 for further
			information on this terminal).
	RES	Discrete Input	Reset — Multifunctional programmable discrete input.
	F	Discrete Input	Forward — Multifunctional programmable discrete input.	Figure 8 on pg. 29.
	R	Discrete Input	Reverse — Multifunctional programmable discrete input.
	S1	Discrete Input	Preset Speed 1 — Multifunctional programmable discrete input.
	S2	Discrete Input	Preset Speed 2 — Multifunctional programmable discrete input.
	S3	Discrete Input	Preset Speed 3 — Multifunctional programmable discrete input.
	S4	Discrete Input	Emergency Off — Multifunctional programmable discrete input.
	RR	Analog Input	RR — Multifunction programmable analog input	Figure 9 on pg. 29.
			(0.0 to 10 volt input — 0 to 80 Hz output). Reference CC.
	RX	Analog Input	RX — Multifunctional programmable analog input	Figure 10 on pg. 29.
			(-10 to +10 VDC input — -80 to +80 Hz output). Reference CC.
			II — Multifunctional programmable analog input (4 [0] to 20 mADC
	II	Analog Input	input — 0 to 80 Hz output) (see Figure 6 on pg. 25 for the location of
			the II terminal). Reference CC.	Figure 11 on pg. 29.
	VI	Analog Input	VI — Multifunctional programmable analog input
			(0 to 10 VDC input — 0 to 80 Hz output). Reference CC.
	P24	DC Output	24 VDC @ 50 mA output.	Figure 12 on pg. 29.
	PP	DC Output	PP — 10.0 VDC voltage source for the external potentiometer.	Figure 13 on pg. 29.
	OUT1	Discrete Output Low Frequency — Multifunctional programmable discrete output.		Figure 14 on pg. 29.
	OUT2	Discrete Output Reach Frequency — Multifunctional programmable discrete output.
	FP	Output	Frequency Pulse — an output pulse train that has a frequency which is	Figure 15 on pg. 29.
			based on the output frequency of the ASD.
	AM	Output	Produces an output current that is proportional to the magnitude of the	Figure 16 on pg. 29
			function assigned to this terminal (see Table 7 on page 61).
	FM	Output
	FLC	Output	Fault relay (common).
	FLB	Output	Fault relay (N.C.).	Figure 17 on pg. 29.
	FLA	Output	Fault relay (N.O.).
	CC	—	Control common (Do Not connect to Earth Gnd).

Discrete Input Terminals Connect to CC to activate.

Analog Input Terminals reference CC.

22	G7 ASD Operation Manual

Terminal Descriptions

Note: The programmable terminal assignments may be accessed and changed from their default settings as mapped on pg. 47 or via the Direct Access method: Program Direct Access applicable parameter number. See the section titled Program Mode on pg. 47 for the applicable Direct Access parameter numbers.

For further information on terminal assignments and default setting changes, see the section titled Output Terminal Functions on pg. 49 and CHANGED FROM DEFAULT on pg. 47.

ST — The default setting for this terminal is ST. The function of this input as ST is a Standby mode controller (system is in Standby when on). As the default setting, this terminal must be connected to CC for normal operation. If not connected to CC, Off is displayed on the LCD screen. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F113).

RES — The default setting for this terminal is RES. The function of this input as RES is a system Reset. A momentary connection to CC resets the ASD and any fault indications from the display. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F114). Reset is effective when faulted only.

F — The default setting for this terminal is F. The function of this input as F is Forward Run. A connection to CC runs the motor in the Forward direction when it is on. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F111).

R — The default setting for this terminal is R. The function of this input as R is Reverse Run. A connection to CC runs the motor in the Reverse direction when it is on. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F112).

S1 — The default setting for this terminal is S1. The function of this input as S1 is to run the motor at Preset Speed #1 (see Preset Speed #1 on pg. 66) when it is on. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F115).

S2 — The default setting for this terminal is S2. The function of this input as S2 is to run the motor at Preset Speed #2 (see Preset Speed #2 on pg. 66) when it is on. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F116).

S3 — The default setting for this terminal is S3. The function of this input as S3 is to run the motor at Preset Speed #3 (see Preset Speed #3 on pg. 67) when it is on. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F117).

S4 — The default setting for this terminal is Emergency Off (normally closed). The function of this input as Emergency Off is to remove power from the output of the ASD and may apply a supplemental braking system using the method selected at F603. This input terminal may be programmed to any 1 of the 68 possible functions that are listed in Table 8 on page 76 (see F118).

RR — The default function assigned to this terminal is to carry out the Frequency Mode #1 setting. The RR terminal accepts a 0 – 10 VDC input signal that controls the function assigned to this terminal. This input terminal may be programmed to control the speed or torque of the motor. It may also be used to regulate (limit) the speed or torque of the motor. The gain and bias of this terminal may be adjusted for application-specific suitability (see F210 – F213).

RX — The RX terminal accepts a ±10 VDC input signal that controls the function assigned to this terminal. This input terminal may be programmed to control the speed, torque, or direction of the motor. It may also be used to regulate (limit) the speed or torque of the motor. The gain and bias of this terminal may be adjusted for application-specific suitability (see F216 – F219).

G7 ASD Operation Manual

23

II — The function of the II input is to receive a 4 – 20 mA input signal that controls a 0 – 80 Hz output. This input terminal may be programmed to control the speed or torque of the motor and may not be used when using the VI input. Also, the gain and bias of this terminal may be adjusted (see F201 – F204).

VI — The function of the VI input terminal is to receive a 0 – 10 VDC input signal that controls a

0 – 80 Hz output. This input terminal may be programmed to control the speed or torque of the motor and may not be used when using the II input. Also, the gain and bias of this terminal may be adjusted (see

F201 – F204).

P24 — +24 VDC @ 50 mA power supply for customer use.

PP — The function of output PP is to provide a 10 VDC output that may be divided using a potentiometer. The tapped voltage is applied to the RR input to provide manual control of the RR programmed function.

OUT1 — The default setting for this output terminal is the Output Low Speed indicator. This output terminal may be programmed to provide an indication that 1 of 60 possible events has taken place. This function may be used to signal external equipment or to activate the brake (see F130). The OUT1 contact is rated at 2A/250 VAC.

OUT2 — The default setting for this output terminal is the ACC/DEC Complete indicator. This output terminal may be programmed to provide an indication that 1 of 60 possible events has taken place. This function may be used to signal external equipment or to activate the brake (see F131). The OUT2 contact is rated at 2A/250 VAC.

FP — The default function of this output terminal is to output a series of pulses at a rate that is a function of the output frequency of the ASD. As the output frequency of the ASD goes up so does the FP output pulse rate. This terminal may be programmed to provide output pulses at a rate that is a function of the output frequency or the magnitude of any 1 of the 31 the functions listed in Table 7 on pg. 61 (see F676).

AM — This output terminal produces an output current that is proportional to the output frequency of the ASD or of the magnitude of the function assigned to this terminal. The available assignments for this output terminal are listed in Table 7 on page 61. For further information on this terminal see F670 on pg. 163.

FM — This output terminal produces an output current that is proportional to the output frequency of the ASD or of the magnitude of the function assigned to this terminal. The available assignments for this output terminal are listed in Table 7 on page 61. For further information on this terminal see F005 on pg. 60.

FLC — FLC is the middle leg of a single-pole double-throw (relay) switch. This FLC contact of the relay is switched between FLB and FLA. This contact may be programmed to switch between FLB and FLA as a function of any 1 of the 60 conditions listed in Table 9 on page 81 (see F132 and Figure 5 on pg. 24).

FLB — One of two contacts that, under user-defined conditions, connect to FLC (see Figure 5 on pg. 24).

FLA — One of two contacts that, under user-defined conditions, connect to FLC (see Figure 5 on pg. 24).

Note: The FLA and FLC contacts are rated at 2A/250 VAC. The FLB contact is rated at 1A/ 250 VAC.

CC — Control common (Do Not connect to Earth Gnd).

Figure 5. FLA, FLB, and FLC switching contacts shown in the de-energized state.

Note: The relay is shown in the Faulted or de-energized condition. During normal system operation the relay connection is FLC-to-FLA.

24	G7 ASD Operation Manual