Toshiba G9 ASD Installation and Operation Manual

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G9 ASD Installation and Operation

Manual

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<![endif]>Drive Speed Adjustable G9

Document Number: 58681-003

Date: October, 2009

G9 ASD Installation and Operation

Manual

Document Number: 58681-003

Date: October, 2009

Introduction

Congratulations on the purchase of the new G9 True Torque Control2 Adjustable Speed Drive!

The G9 True Torque Control2 Adjustable Speed Drive (ASD) is a solid-state AC drive that features True Torque Control2. Toshiba’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 G9 ASD uses digitally-controlled pulse width modulation. The programmable functions may be accessed via the easy-to-use menu selections or via the Direct Access Numbers (see page 76). This feature, combined with Toshiba’s high-performance software, delivers unparalleled motor-control and reliability.

The G9 ASD is a very powerful tool, yet surprisingly simple to operate. The user-friendly Electronic Operator Interface (EOI) of the ASD has an easy-to-read LCD Screen. There is also a read-only LED Screen with enhanced visibility that can be read from a greater distance. The EOI provides easy access to the many monitoring and programming features of the ASD.

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 G9 ASD, a working familiarity with this manual will be required. This manual has been prepared for the 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 Sales 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 may 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.

About This Manual

This manual was written by the Toshiba Technical Publications Group. This group is tasked with providing technical documentation for the G9 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. E-mail 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 G9 Adjustable Speed Drive. The information provided in this manual is applicable to the

G9 Adjustable Speed Drive only.

This manual provides information on the various features and functions of this powerful cost-saving 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.

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 2009 Toshiba International Corporation.

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

TOSHIBA Leading Innovation® is a registered trademark of Toshiba International Corporation. All rights reserved.

Printed in the U.S.A.

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 Support Center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Center’s toll free number is US [phone]/Fax [phone] — Canada [phone]. For after-hours support follow the directions in the outgoing message when calling.

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 web site at www.toshiba.com/ind/.

TOSHIBA INTERNATIONAL CORPORATION

G9 Adjustable Speed Drive

Please complete the Warranty Card supplied with the G9 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:_________________________________________________________________

Table of Contents

General Safety Information ....................................................................................................	1
Safety Alert Symbol ...........................................................................................................	1
Signal Words ......................................................................................................................	1
Special Symbols .................................................................................................................	2
Equipment Warning Labels ................................................................................................	2
Qualified Personnel ............................................................................................................	2
Equipment Inspection .........................................................................................................	3
Handling and Storage .........................................................................................................	3
Disposal ..............................................................................................................................	3
Installation Precautions ...........................................................................................................	4
Location and Ambient Requirements .................................................................................	4
Mounting Requirements .....................................................................................................	4
Conductor Routing and Grounding ....................................................................................	5
Power Connections .............................................................................................................	6
Protection ............................................................................................................................	6
System Integration Precautions ..............................................................................................	7
Personnel Protection ...........................................................................................................	7
System Setup Requirements ...............................................................................................	8
Operational and Maintenance Precautions ...........................................................................	9
Motor Characteristics ............................................................................................................	10
Motor Autotuning .............................................................................................................	10
Pulse Width Modulation Operation ..................................................................................	10
Low-Speed Operation .......................................................................................................	10
Overload Protection Adjustment ......................................................................................	10
Operation Above 60 Hz ....................................................................................................	10
Power Factor Correction ...................................................................................................	11
Light Load Conditions ......................................................................................................	11
Motor/Load Combinations ...............................................................................................	11
Load-Produced Negative Torque ......................................................................................	12
Motor Braking ..................................................................................................................	12
G9 ASD Characteristics ........................................................................................................	13
Over-Current Protection ...................................................................................................	13
ASD Capacity ...................................................................................................................	13
Using Vector Control ........................................................................................................	13
Installation and Connections ................................................................................................	14
Installation Notes ..............................................................................................................	14
Mounting the ASD ............................................................................................................	15

G9 ASD Installation and Operation Manual

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Connecting the ASD .........................................................................................................	16
Lead Length Specifications ..............................................................................................	20
I/O and Control .................................................................................................................	21
Electronic Operator Interface ..............................................................................................	28
EOI Operation ...................................................................................................................	28
EOI Remote Mounting .....................................................................................................	28
EOI Features .....................................................................................................................	29
Keypad Remote Mounting ................................................................................................	33
Command Mode and Frequency Mode Control .................................................................	36
Command Control (F003) ................................................................................................	36
Frequency Control (F004) ................................................................................................	37
Override Operation ...........................................................................................................	38
System Configuration and Menu Options ...........................................................................	41
Root Menus .......................................................................................................................	41
System Operation ...................................................................................................................	70
Initial Setup .......................................................................................................................	70
Startup Wizard Parameters ...............................................................................................	70
Operation (Local) ..............................................................................................................	73
Default Setting Changes ...................................................................................................	74
Save User Settings ............................................................................................................	75
Direct Access Parameter Information .................................................................................	76
Direct Access Parameters/Numbers .................................................................................	76
Alarms, Trips, and Troubleshooting ..................................................................................	244
Alarms and Trips ............................................................................................................	244
User Notification Codes .................................................................................................	245
Alarms .............................................................................................................................	246
Trips/Faults .....................................................................................................................	248
Enclosure Dimensions and Conduit Plate Information ....................................................	254
Enclosure Dimensions ....................................................................................................	255
Conduit Plate Dimensions ..............................................................................................	260
Current/Voltage Specifications ...........................................................................................	263
Cable/Terminal/Torque Specifications ..............................................................................	265
Dynamic Braking Resistor Wire/Cable Specifications .....................................................	267
Short Circuit Protection Recommendations .....................................................................	269
Optional Devices ..................................................................................................................	270

ii	G9 ASD Installation and 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 contained in this manual.

Safety Alert Symbol

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

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 serious injury to personnel or loss of life.

DANGER

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

WARNING

The word CAUTION preceded by the safety alert symbol indicates that a potentially hazardous situation exists that, 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 that, if not avoided, may result in equipment and property damage.

CAUTION

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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 loss of life.

Electrical Hazard Symbol

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

Explosion Hazard Symbol

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

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 user directions contained in this manual.

Warning labels that are attached to the equipment will include the exclamation mark within a triangle. DO NOT remove or cover any of these labels. If the labels are damaged or if additional labels are required, contact your Toshiba Sales Representative.

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 loss of life if safe procedures or methods are not followed as outlined in this 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 G9 ASD, the equipment being driven, and the hazards involved.

•Be 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.

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

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Equipment Inspection

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

•Carefully unpack the equipment and check for damaged parts, missing parts, or concealed damage that may have occurred during shipping. 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 injury to personnel.

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

•Modification of this equipment is dangerous and is to be performed by factory trained representatives. When modifications are required contact your Toshiba Sales Representative.

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

•Contact your Toshiba Sales Representative to report discrepancies or for assistance if required.

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 G9 ASD is -13° to 149° F (-25° to 65° 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.

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Installation Precautions

Location and Ambient Requirements

•The Toshiba ASD is intended for permanent installations only.

•Installation should conform to the 2008 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 2008 NEC Article 110-13).

•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, metal 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. 14 for further information on ventilation requirements.

•The ambient operating temperature range of the G9 ASD is 14° to 104° F (-10° to 40° C).

•See the section titled Installation and Connections on pg. 14 for additional information on installing the drive.

Mounting Requirements

•Only Qualified Personnel should install this equipment.

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

•As a minimum, the installation of the equipment should conform to the 2008 National Electrical Code — Article 110 (NEC), OSHA, as well as any other applicable national, regional, or industry codes and standards.

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

•It is the responsibility of the ASD Installer/Maintenance personnel to ensure that the unit is installed into an enclosure that will protect personnel against electric shock.

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Conductor Routing and Grounding

WARNING

•Use separate metal conduits for routing the input power, output power, and control circuits.

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

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

•DO NOT connect CC to earth ground.

•Use IICC terminal as the return for the VI/II (V/I) input.

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

•It is the responsibility of the ASD Installer/Maintenance personnel to provide proper grounding and branch circuit protection in accordance with the 2008 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 —

Grounding Capacitor Switch

The ASD is equipped with noise reduction capacitors which are used to reduce the EMI leakage via the 3-phase power-input circuit and for compliance with the Electromagnetic Compatibility Directive (EMC).

The effective value of the capacitor may be increased, reduced, or removed entirely via the Selector Switch, Switching Bar, or the Switching Screw — the type used is typeform-specific.

The Grounding Capacitor Switch allows the user to quickly change the value of the leakage-reduction capacitance of the 3-phase input circuit without the use of tools.

See the section titled System Grounding on pg. 18 for more on the Grounding Capacitor.

See figures 4, 5, 6, and 7 on pg. 19 for an electrical depiction of the leakage-reduction functionality of the Grounding Capacitor and the methods used to set the capacitance value.

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Power Connections

DANGER

C o n t a 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 L o s s O f L i f e .

•Turn off, lockout, and tag out 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/tag out procedures, connect the 3-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 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 (i.e., place U1, V1, W1, and a ground wire in one conduit and U2, V2, W2 and a ground wire 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 2008 NEC Article 310 adjustment factors).

•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.

•External dynamic braking resistors must be thermally protected.

•It is the responsibility of the ASD Installer/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 parameters F250 and F304.

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.

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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 upon observing certain precautions and performing proper system integration.

•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).

•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 personnel. 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. 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.

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System Setup Requirements

•When using the ASD as an integral part of a larger system, it is the responsibility of the ASD Installer/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 system damage or injury to personnel (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.

•Power factor improvement/correction 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.

CAUTION

•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 to this effect must be posted at the equipment installation location.

•If a secondary magnetic contactor (MC) or an ASD output disconnect 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, or W).

•When using an ASD output disconnect, the ASD and the motor must be stopped before the disconnect is either opened or closed. Closing the output disconnect while the 3-phase output of the ASD is active may result in equipment damage or injury to personnel.

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Operational and Maintenance

Precautions

WARNING

•Turn off, lockout, and tag out 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 tag out 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 G9 ASD maintain a residual charge for a period of time after turning off the ASD. The required time for each ASD typeform is indicated with a cabinet label and a Charge LED (shown for smaller ASDs in Figure 2 on pg. 16; LED is located on the front panel of larger ASDs). Wait 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 or open the front cover of the G9 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 off the power 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.

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Motor Characteristics

Listed below are some variable speed AC motor-control concepts with which the user of the ASD should become familiar.

Motor Autotuning

Motor production methods may cause minor differences in motor operation. The negative effects of these differences may be minimized by using the Autotune feature of the ASD. Autotuning is a function of the ASD 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 applicationspecific 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.

Pulse Width Modulation Operation

The ASD uses sinusoidal Pulse Width Modulation (PWM) control. 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.

Overload Protection Adjustment

The 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 Motor Overload Protection Level 1 on pg. 182.

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.

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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 Carrier Frequency PWM Carrier Frequency).

Note: When operating in the Vector Control mode the carrier frequency should be set to 2.2 kHz or above.

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: When operating in the Vector Control mode the carrier frequency should be set to 2.2 kHz or above.

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 operating in the Vector control mode, adjust the response time, or

•Switch to the Constant Torque control mode.

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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. See Dynamic Braking on pg. 136 for more information using Dynamic Braking with the ASD.

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 ASD are DC Injection Braking and Dynamic Braking.

For further information on braking systems, see DC Injection Braking on pg. 124 and Dynamic Braking on pg. 136.

12	G9 ASD Installation and Operation Manual

G9 ASD Characteristics

Over-Current Protection

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

However, the G9 ASD may be operated at 115% of the specified output-current range continuously (or 110% continuously if 60 HP for the 230-volt system or if 125 HP for the 460-volt system) or at 150% for a limited amount of time as indicated in the section titled Current/Voltage Specifications on pg. 263. Also, the Stall Prevention Level may be adjusted to help with nuisance over-current trips (see F601).

When using the ASD for an application to control a motor that 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 FLA of the motor. For further information on this parameter, see Motor Overload Protection Level 1 on pg. 182.

ASD Capacity

The ASD must not be used with a motor that has a larger capacity than the ASD, 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.

See F015 on pg. 81 for further information on using Vector Control.

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Installation and Connections

The G9 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 R/L1, S/L2, and T/L3 terminals). The control terminals of the ASD may be used by connecting the terminals of the Terminal Board (P/N 072314P903) to the proper sensors or signal input sources (see the section titled I/O and Control on pg. 21 and Figure 9 on pg. 24).

System performance may be further enhanced by assigning a function to the output terminals of the Terminal Board and connecting the terminals to the proper indicators or actuators (relays, contactors, LEDs, etc.).

Note: The optional ASD interface boards may be used to expand the I/O functionality of the ASD.

Installation Notes

CAUTION

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 (U/T1, V/T2, and W/T3).

DO NOT apply commercial power to the ASD output terminals U/T1, V/T2, and W/T3.

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 G9 ASD is on or while the motor is still turning may cause ASD damage.

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 over-voltage and under-voltage stall protection level parameters 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 higher than the rated output of the ASD.

The G9 ASD is designed to operate NEMA B motors. Consult with your Toshiba Sales Representative before using the ASD for special applications such as with an explosion-proof motor or applications with a piston load.

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.

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Not all ASDs are equipped with internal primary power input fuses (typeform dependent). When connecting two or more drives that have no internal fuse to the same power line as shown in Figure 1, it will be necessary to select a circuit-breaking 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 1. Circuit Breaker Configuration.

Mounting the ASD

CAUTION

— The following thermal specifications apply to the 230and the 460-volt ASDs ONLY —

Install the unit securely in a well ventilated area that is out of direct sunlight.

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.

The ambient operating temperature rating of the G9 ASD is 14° to 104° F (-10° to 40° C).

When installing adjacent ASDs horizontally Toshiba recommends at least 5 cm of space between adjacent units. However, horizontally mounted ASDs may be installed side-by-side with no space in between the adjacent units — side-by-side installations require that the top cover be removed from each ASD.

For 150 HP ASDs and above, a minimum of 50 cm of space is required above and below adjacent units and any obstruction.This space is the recommended minimum space requirement for the G9 ASD and ensures that adequate ventilation is provided for each unit. More space will provide a better environment for cooling (see the section titled Enclosure Dimensions and Conduit Plate Information on pg. 254 for additional information on mounting space requirements).

Note: Ensure that the ventilation openings are not obstructed.

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Connecting the ASD

DANGER

Refer to the section titled Installation Precautions on pg. 4 and the section titled Lead Length Specifications on pg. 20 before attempting to connect the ASD and the motor to electrical power.

Power Connections

DANGER

C o n t a c t W i t h 3 - p h a s e I n p u t / O u t p u t T e r m i n a l s M a y C a u s e A n E l e c t r i c a l S h o c k R e s u l t i n g I n I n j u r y O r L o s s O f L i f e .

See Figure 20 on pg. 26 for a system I/O connectivity schematic.

An inductor (DCL) may be connected across the PO and PA/+ terminals to provide additional filtering. When not used, a jumper must be connected across these terminals (see Figure 20 on pg. 26).

PA/+ and PB are used for the DBR connection if using a braking resistor. PC/- is the negative terminal of the DC bus.

R/L1, S/L2, and T/L3 are the 3-phase input supply terminals for the ASD.

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

The location of the Charge LED for the smaller typeform ASD is provided in Figure 2. The Charge LED is located on the front door of the enclosure of the larger ASDs.

Figure 2. Typical G9 ASD Input/output Terminals and the Grounding Capacitor Switch.

Charge LED

Grounding Capacitor Switch — Pull for Small capacitance/push for Large capacitance.

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Power Connection Requirements

Connect the 3-phase input power to the input terminals of the ASD at R/L1, S/L2, and T/L3 (see Figure 3 for the typical electrical connection scheme). Connect the output of the ASD to the motor from the ASD terminals U/T1, V/T2, and W/T3. The input and output conductors and terminal lugs used shall be in accordance with the requirements listed in the section titled Current/Voltage Specifications on pg. 263.

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 2008 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 2008 NEC Article 430.

The ASD is designed and tested to comply with UL Standard 508C. Modifications to the ASD system or failure to comply with the short circuit protection requirements outlined in this manual may disqualify the UL rating. See Table 22 on pg. 269 for typeform-specific short circuit protection recommendations.

As a minimum, the installation of the ASD shall conform to 2008 NEC Article 110, the Occupational Safety and Health Administration requirements, and to any other local and regional industry codes and standards.

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 (U, V, or W) connected to the motor.

Figure 3. G9 ASD/Motor Typical Connection Diagram.

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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 2008 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.

— 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 —

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

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.

•DO NOT install the input power and output power wires in the same duct or in parallel with each other, and do not bind them together.

•DO NOT install the input/output power wires 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.

Grounding Capacitor

The Grounding Capacitor plays a role in minimizing the effects of leakage current through the ASD system and through ground paths to other systems. Leakage current may cause the improper operation of earth-leakage current breakers, leakage-current relays, ground relays, fire alarms, and other sensors

— and it may cause superimposed noise on CRT screens.

The Grounding Capacitor Switch allows the user to quickly change the value of the leakage-reduction capacitance of the 3-phase input circuit. See figures 4, 5, 6, and 7 on pg. 19 for an electrical depiction of the leakage-reduction functionality and the methods used to change the capacitance value. The method used is typeform-specific.

If using a 460-volt 5 HP ASD or a 460-volt ASD that is in the range of 7.5 HP to 25 HP, and the U/T1, V/T2, and W/T3 connections to the motor are 100 meters or more in length, the ASD Carrier Frequency must be set to 4 kHz or less when activating or deactivating the Grounding Capacitor Switch. ASD overheating may occur if the Carrier Frequency is set above 4 kHz when activating or deactivating the Grounding Capacitor Switch.

See pg. 5 for more information on the Grounding Capacitor Switch and pg. 16 for the location of the switch.

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Figure 4. The Grounding Capacitor Switch is used on typeforms 230-volt 0.5 HP to 10 HP and the 25 and 30 HP/ 460-volt 1.0 HP to250 HP.

The value may be set to Maximum (default setting) or to Zero by pushing or pulling the switch actuator, respectively.

Figure 5. The Grounding Capacitor Switch is used on typeforms 230-volt 15 HP to 20 HP and the 40 HP to

60 HP/460-volt 30 HP to 100 HP. The value may be set to Large (default setting) or Small by pushing or pulling the switch actuator, respectively.

Figure 6. The Grounding Capacitor Bar is used on typeforms 230-volt 75 HP and the 100 HP/460-volt 125 HP and the 150 HP.

The value may be set to Large or Small (default setting) by connecting or disconnecting the switching bar, respectively.

Figure 7. The Grounding Capacitor Screw is used on typeforms 460-volt 175 HP and above.

The value may be set to Large or Small (default setting) by placing the screw in the A position or by placing the screw in the B position, respectively.

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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 1 may require filters to be added to the output of the ASD. Table 1 lists the suggested maximum lead lengths for the listed motor voltages.

Table 1. Lead Length Recommendations.

	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

Note: Contact the Toshiba Customer Support Center 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.

When operating in the Vector Control mode the carrier frequency should be set to 2.2 kHz or above.

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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 Terminal Board supports discrete and analog I/O functions and is shown in Figure 9 on pg. 24. Table 2 lists the names, descriptions, and default settings (of programmable terminals) of the input and output terminals of the Terminal Board.

Note: To use the input lines of the Terminal Board to provide Run commands the Command Mode setting must be set to Terminal Block.

Figure 20 on pg. 26 shows the basic connection diagram for the G9 ASD system.

Table 2. Terminal Board Default Assignment Terminal Names And Functions.

	Terminal	Input/Output	Default Function	Circuit Config.
	Name		(Also See Terminal Descriptions on pg. 22)
	ST		Standby — Multifunctional programmable discrete input. Activation required for
			normal ASD operation.
	RES	Discrete Input	Reset — Multifunctional programmable discrete input. Resets the ASD.
	F		Forward — Multifunctional programmable discrete input.
	R	Connect to CC to	Reverse — Multifunctional programmable discrete input.	Figure 10 on pg. 25.
		activate (Sink
	S1		Preset Speed 1 — Multifunctional programmable discrete input.
		mode).
	S2		Preset Speed 2 — Multifunctional programmable discrete input.
	S3		Preset Speed 3 — Multifunctional programmable discrete input.
	S4		Preset Speed 4 — Multifunctional programmable discrete input.
	O1A/B (OUT1)		Low Speed — Multifunctional programmable discrete output.	Figure 16 on pg. 25.
	O2A/B (OUT2)		Reach Frequency — Multifunctional programmable discrete output.
	FLA	Switched Output	Fault relay (N.O.).
				Figure 19 on pg. 25.
	FLB		Fault relay (N.C.).
	FLC		Fault relay (common).
	RR		Multifunction programmable analog input. (0.0 to 10 VDC input).	Figure 11 on pg. 25.
	RX		Multifunctional programmable analog input (-10 to +10 VDC input).	Figure 12 on pg. 25.
		Analog Input	Unassigned — V — Multifunctional programmable isolated analog voltage input
			(0 to 10 VDC input)
	V/I			Figure 13 on pg. 25.
			Frequency Mode 2 (default SW301 setting) — I —Multifunctional
			programmable isolated analog current input (4 [0] to 20 mADC input — 0 Hz to
			Maximum Frequency).
			Output Current — Current output that is proportional to the output current of the
	AM		ASD or to the magnitude of the function assigned to this terminal (see Table 6 on
		Analog Output	pg. 237 for assignment listing).	Figure 18 on pg. 25
			Output Frequency — Current or Voltage output that is proportional to the output
	FM		frequency of the ASD or to the magnitude of the function assigned to this
			terminal (see Table 6 on pg. 237). Select Current or Voltage at F681.
	SU+	DC Input	Externally-supplied 24 VDC backup control power (1.1 A min.).
	P24	DC Output	24 VDC output (200 mA max.).	Figure 14 on pg. 25.
	PP		10.0 VDC/10 mA voltage source for the external potentiometer.	Figure 15 on pg. 25.
	FP	Pulsed Output	Frequency Pulse — Multifunctional programmable output pulse train of a	Figure 17 on pg. 25.
			frequency based on the output frequency of the ASD (see Table 6 on pg. 237).
	IICC	—	Return for the V/I input terminal (see IICC Note: on pg. 105).	DO NOT
				connect to
	CCA	—	Return for the RR, RX, P24, and the PP terminals.
				Earth Gnd or to each
	CC	—	Return for the AM, FM, SU+, and the discrete input terminal.
				other.
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Terminal Descriptions

Note: The programmable terminal assignments may be accessed and changed from their default settings as mapped on pg. 46 or via the Direct Access method: Program Direct Access Applicable Parameter Number. See the section titled Program Mode Menu Navigation on pg. 46 for the applicable Direct Access parameter numbers.

For further information on terminal assignments and default setting changes, see the sections titled Terminal on pg. 47 and Default Setting Changes on pg. 74.

Note: See the section titled Cable/Terminal/Torque Specifications on pg. 265 for the G9 ASD conductor and terminal electrical specifications.

Note: Programmable terminals will not retain their settings indefinitely in the event of a power loss. Connect an external +24 VDC supply to the SU+ terminal to retain the programmable settings in the event of Control Power loss (see Figure 20 on pg. 26).

ST — The default setting for this terminal is the Standby mode controller. As the default setting, this terminal must be activated for normal system operation. The ST terminal is activated by connecting CC to this terminal (Sink mode). When deactivated, OFF is flashed on the LED Screen and the Not-Ready- to-Run indicator is displayed on the LCD Screen (see Figure 22. on pg. 31). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F113).

RES — The default setting for this terminal is Reset. The RES terminal is activated by connecting CC to this terminal (Sink mode). A momentary connection to CC resets the ASD and any fault indications from the display. Reset is effective when faulted only. This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F114).

F — The default setting for this terminal is Forward run command. The F terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F111).

R — The default setting for this terminal is Reverse run command. The R terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F112).

S1 — The default setting for this terminal is Preset Speed 1 (see Preset Speed 1 on pg. 83). The S1 terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F115).

S2 — The default setting for this terminal is Preset Speed 2 (see Preset Speed 2 on pg. 83). The S2 terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F116).

S3 — The default setting for this terminal is Preset Speed 3 (see Preset Speed 3 on pg. 84). The S3 terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F117).

S4 — The default setting for this terminal is Preset Speed 4 (see Preset Speed 4 on pg. 84). The S4 terminal is activated by connecting CC to this terminal (Sink mode). This input terminal may be programmed to any of the functions listed in Table 5 on pg. 234 (see F118).

RR — The default function assigned to this terminal is the Frequency Mode 1 setting. The RR terminal accepts a 0 – 10 VDC input signal that is used to control the function assigned to this terminal. This input terminal may be programmed to control the speed or torque of the motor via an amplitude setting or regulate by setting a limit. The gain and bias of this terminal may be adjusted for applicationspecific suitability (see F210 – F215).

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