Toshiba T300MVi MEDIUM VOLTAGE Instruction Manual

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T300MVi

ADJUSTABLE SPEED MOTOR DRIVE

INSTRUCTION MANUAL

TOSHIBA INTERNATIONAL CORPORATION

Document Number: IF08CZ00 June, 2009

MEDIUM VOLTAGE

TOSHIBA INTERNATIONAL CORPORATION 13131 WEST LITTLE YORK HOUSTON, TEXAS 77041 Tel: 1-713-466-0277 1-800-231-1412

Printed in U.S.A.

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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 either indirect or consequential damage or injury that may result from the misuse of this equipment.

TOSHIBA INTERNATIONAL CORPORATION

Adjustable Spe ed D rive

Please complete th e Warra nty Card suppl ied w ith the ASD and retu r n it to Tos h iba by prep aid ma il. This w ill activate the 12 month warranty from the date of installation; but, shall not exceed 18 months from the date of purchase.

Complete the following information about the drive and r etain it for your records.

Model Number:

Serial Number:

Project Number (if applicable):

Date of Installation:

Inspected By: Name of Application:

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Manual’s Purpose and Scope

This manual provides information on how to safely install, operate, and maintain your TIC power electronics product. This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual. Read the manual completely before installing, operating, or performing maintenance on this equipment.

This manual and the accompanying drawings should be considered a permane nt 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.

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 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.

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.

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 (800) 231-1412/Fax (713) 466-8773 — Canada (80 0) 527-1204.

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.toshiba.com/ind

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General Safety Instructions

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 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

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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 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.

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Equipment Labels (Safety, Rating, Information)

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 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.

SAFETY labels that will be found on the equipment are shown below:

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RATING labels that will be found on the equipment are shown below:

Input Controller Rating Label Note: If no input controller is

supplied, this label will not be present. Refer to label on upstream equipment for rating data.

Adjustable Speed Drive Rating Label

Inverter Power Module Rating Label

Note: The above labels are shown blank. The labels affixed to the equipment will be filled in with rating data

specific to the actual unit(s) furnished. Complete rating data is also provided on the rating sheet included in the supplementary drawing packet. Ensure that all rating data matches the power system and the driven load connected to the equipment.

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INFORMATION labels that will be found on the equipment are shown below:

Torque Label

LISTED

Service Label

USC

UL Label (for UL Listed drives)

CE Label (for drives designed for use in the

ean Union)

Euro

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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. In the U.S., refer to the latest edition of NFPA 70E for additional safety requirements. Outside the U.S., follow all applicable national and local safety practices.

Qualified Personnel shall:

• Have 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 in the U.S. visit www.osha.gov

refer to your existing plant safety regulations.

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 from 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 representative.

• DO NOT install or energize equipment that has been damaged. Damaged equipment may fail

during operation resulting in further 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 Toshib a representative.

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

. Outside the U.S.,

• Keep the equipment in an upright position as indicated on the shipping carton.

• Contact your Toshiba representative for assistance if required.

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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.

• 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 as indicated on the shipping carton.

• Include any other product-specific requirements.

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

• Adequate personnel working space and adequate illumination must be provided for adjustment,

inspection, and maintenance of the equipment. In the U.S., refer to NEC Article 110-34 for

requirements. Outside the U.S., follow applicable local electrical code requirements.

• Avoid installation in areas where vibration, heat, humidity, dust, fibers, steel particles, explosive/

corrosive mists or gases, or sources of electrical noise are present.

• Do not install the ASD where it may be exposed to flammable chemicals or gasses, water,

solvents, or other fluids.

• 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 recommended minimum installation dimensions as shown on the enclosure outline drawings.

• The ambient operating temperature shall be between 0 and 40

Mounting Requirements

• Only Qualified Personnel should install this equipment.

C (32 and 105 oF).

• Install the unit in a secure 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.

• Equipment should be installed according to all applicable national, regional, and industry codes

and standards. In the U.S., installation of the equipment should conform to NEC Article 110

Requirements For Electrical Installations and to OSHA requirements..

• In the U.S., installation practices should conform to the latest revision of NFPA 70E Electrical

Safety Requirements for Employee Workplaces. Outside the U.S., applicable national and local

installation safety practices should be followed.

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Conductor Routing and Grounding

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

• A separate ground cable should be run inside the conduit with the input power, output power, 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 all applicable national

and local electrical codes (in the U.S. refer to the 2005 NEC).

WARNING

The Metal Of Conduit Is Not An Acceptable Ground.

Connections

WARNING

Contact With Energized Wiring Will Cause Severe Injury Or Death.

• 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. In the U.S., refer to NEC Article 300 – Wiring Methods and Article 310 –

Conductors For General Wiring and size the branch circuit condu ctors in acco rdance with NEC

Table 310.16. Outside the U.S., follow your national and local electrical codes.

• 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 for U.S. requirements). National and local

electrical codes should be referenced if three or more power conductors are run in the same conduit

(in the U.S. refer to 2002 NEC Article 310 adjustment factors on page 70-142). Outside the U.S.,

consult your national and local electrical codes for additional requirements for running multiple

conductors.

• 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).

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

• Ensure the correct phase sequence and the desired direction of motor rotation in the Bypass

mode (if applicable).

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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, if supplied, 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.

Note: A supplemental emergency stopping system should be used with the ASD.

Emergency stopping should not be a task of the ASD alone.

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 Toshiba for application-specific

information and for training support.

• The Toshiba ASD is part of a larger system and the safe operation of the device 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 Toshiba 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.

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• 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.

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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 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 is a requirement to use this product.

• 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, and 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.

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Operational and Maintenance Precautions

• 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 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.

• 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.

• 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.

• 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.

WARNING

• 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.

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

• Retry or Reset settings may allow the motor to start unexpectedly. Warnings to this effect should

be clearly posted near the ASD and motor.

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.

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CONTENTS

INTRODUCTION................................................................................................................ 1

INITIAL COMMISSIONING................................................................................................ 2

Confirmation of Wiring..................................................................................................... 2

Start-Up and Test............................................................................................................ 2

Cautions on Changing Setting Parameters..................................................................... 3

INSPECTIONS AND MAINTENANCE............................................................................... 4

Daily Inspections............................................................................................................. 4

Regular Inspections ........................................................................................................ 4

Main Components............................................................................................................5

Cautions on Handling Printed Wiring Boards .............................................................. 5

Parts to be Regularly Renewed....................................................................................... 6

Recommended Spare Parts............................................................................................ 7

Preparations for Inspection and Maintenance of Equipment (Powering-Off)................... 8

Recovery after Inspection and Maintenance of Equipment (Powering-On)..................... 9

OVERVIEW................................................................................................................... 10

Display/Keypad (MVi-EOi) ............................................................................................ 10

MVi-EOI Diagram.......................................................................................................... 10

How to Handle Faults....................................................................................................... 12

Description of Terminology ........................................................................................... 12

General Specifications (Structure) .................................................................................13

Altitude and Temperature De-rating.............................................................................. 14

Motor Cable Length....................................................................................................... 14

General Specifications (Electrical) .................................................................................15

General Specifications (Control) ....................................................................................16

Rating Specifications..................................................................................................... 18

Protective Functions...................................................................................................... 19

General Cubicle Structure............................................................................................. 21

Cubicle Structure and Dimensions.................................................................................21

Dimensions and Weights of Equipment ........................................................................ 22

INTERFACE..................................................................................................................... 24

Power Supply Interface and Ground............................................................................. 24

Motor Interface.............................................................................................................. 25

Speed Sensor Interface (Option)................................................................................... 25

Resolver.........................................................................................................................25

PG (Pulse Generator) ....................................................................................................25

Pulse Signal Output ...................................................................................................... 26

Digital Input...................................................................................................................26

Digital Output ................................................................................................................ 29

Analog Input.................................................................................................................. 29

Analog Output............................................................................................................... 30

General-purpose Analog Output ....................................................................................30

Additional Analog Outputs..............................................................................................31

Motor Mounted Fan Circuit............................................................................................ 31

CIRCUIT OPERATION .................................................................................................... 32

Main Circuit Configuration............................................................................................. 32

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Control .......................................................................................................................... 34

Vector Control Block Diagram........................................................................................34

Speed Reference...........................................................................................................35

Speed Control................................................................................................................36

Simulator Follower Control (SFC, optional control used with a speed sensor)...............37

Torque Reference and Current Reference.....................................................................37

IQ Limit (Torque current limit).........................................................................................38

D-Q Axis Current Control ...............................................................................................39

Output Voltage References............................................................................................40

Speed Feedback (Option)..............................................................................................41

Resolver.................................................................................................................... 41

PG............................................................................................................................. 41

Control Board Configuration.......................................................................................... 42

OPERATION.................................................................................................................... 43

Pre-Operation Check Points ......................................................................................... 44

Powering-On................................................................................................................. 44

Operation...................................................................................................................... 44

Normal Operation...........................................................................................................44

Powering-Off................................................................................................................. 44

DATA CONTROL............................................................................................................. 45

Setting Data .................................................................................................................. 45

FAULT AND RECOVERY................................................................................................ 45

Cautions when Handling Faults..................................................................................... 45

Repair ........................................................................................................................... 46

Cautions on Repair ........................................................................................................46

DRIVE INSTALLATION DRAWINGS............................................................................... 47

Frame 0 4160V module lifting and installation .............................................................. 47

Frame 1 4160V drive lifting and assembly .................................................................... 47

Frame 1 drive lifting and assembly (cont’d)................................................................... 48

Frame 1 2400V module lifting and installation .............................................................. 49

Frame 1 4160V module lifting and installation .............................................................. 49

Frame 2 drive lifting and assembly................................................................................ 50

Frame 2 drive main cable installation............................................................................ 51

Frame 2 module lifting................................................................................................... 52

Frame 2 4160V module installation............................................................................... 53

Frame 3 drive lifting and assembly................................................................................ 54

Frame 3 drive main cable installation............................................................................ 55

Frame 3 2400V module installation............................................................................... 57

Frame 3 4160V module installation............................................................................... 58

Frame 4 drive lifting and assembly................................................................................ 59

Frame 4 drive main cable installation............................................................................ 60

Frame 4 module lifting................................................................................................... 61

Frame 4 2400V module installation............................................................................... 62

Frame 4 4160V module installation............................................................................... 63

Frame G4P drive lifting and assembly .......................................................................... 64

Frame G4P drive main cable installation....................................................................... 65

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Frame G4P module lifting and installation..................................................................... 66

Frame G4P module lifting and installation continued.................................................... 67

Frame H4P drive lifting and assembly........................................................................... 68

Frame H4P drive main cable installation....................................................................... 69

Frame H4P module lifting and installation..................................................................... 70

Frame H4P module lifting and installation continued .................................................... 71

Frame B2 2400V module lifting and installation Type 1................................................ 72

Frame B2 2400V module lifting and installation Type 2................................................ 73

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INTRODUCTION

Thank you for purchasing the T300MVi Medium Voltage ASD. This adjustable frequency, solidstate AC drive features a 3φ input isolation transformer with a 24-pulse converter design, a 32 -bit CPU, and a three-unit power module inverter section providing a 5 level output for 4160/3300V drives and 3 level output for 2400V drives. The T300MVi also features as standard, an 8 key Control Panel with a LCD screen and 2 discrete LED lamps to indicate Ready, Run, Local, Remote and Alarm/Fault.

On most power systems, this drive will meet IEEE-519-1992 harmonic regulation guidelines without installing additional harmonic filters. The input power factor is typically 0.95. The multi-level output produces a more sinusoidal voltage and reduces stress on the motor win ding insulation. This drive uses high capacity 3300V IGBTs to improve reliability, reduce switching losses, and improve control performance. The PP7 control processor and 6-layer control board achieves high integration a nd reliability.

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INITIAL COMMISSIONING

The drive should be commissioned by qualified personnel only. Below are some general steps

required for commissioning.

CAUTION

Confirmation of Wiring

Make the following final checks before applying power to the unit:

1) Confirm that source power is connected to terminals L1, L2, L3 (R, S, T). Connection of

incoming source power to any other terminals will damage the drive. Other control voltages

may be required. Consult your custom equipment diagrams shipped with the drive for any

other requirements.

2) Verify that the power modules are properly installed and that there was no damage during

shipping or handling.

3) Verify that there are no loose connections or wires and that all of the required shipping split

connections have been made.

4) Verify all external control circuit wiring is complete and properly connected.

5) The 3-phase source power should be within the correct voltage and frequency tolerances.

6) The motor leads must be connected to terminals T1, T2, T3 (U, V, W).

7) Make sure there are no short circuits or inadvertent grounds and tighten any loose connector

terminal screws.

CAUTION

Start-Up and Test

Prior to releasing the drive system for regular operation after installation, the system must be adjusted and tested by qualified personnel. This assures correct operation of the equipment for

reasons of reliable and safe performance. It is important to make arrange ments for such a check and that time is allowed for it.

CAUTION

- 2

Cautions on Changing Setting Parameters

The setting data of the T300MVi MV is saved in an EEPROM, non-volatile memory. When the micro controller initializes at power-up, it reads the EEPROM data and copie s it to the RAM (Rando m Access Memory). From then on, the micro controller controls the drive using the values in the RAM.

When the setting parameters are changed, by the display-keypad or personal computer ("su pport tool"), only the execution parameters in RAM are changed. If they need to be stored, they must be manually written to the EEPROM. Without this operation, the next initialization or power up will cause them to be replaced by the old data.

When a write to the EEPROM is performed, write processing may take 30 seconds. Turning off the control power supply during write processing will make both the RAM and EEPROM data abnormal. When the power is turned on again, this abnormal data will result in an error ("CHECK ERROR") preventing the drive from running. If such an error occurs, the settings must be reloaded from a saved file. If no setting file exists, the drive must be re-commissioned.

CAUTION

Do not turn off the control power supply under any circumstances while writing data to the EEPROM.

- 3

INSPECTIONS AND MAINTENANCE

Maintenance and inspection is a particularly effective means to help prevent failures an d reduce down time. Creating equipment specific inspection and maintenance check sheets can help to perform maintenance and inspection effectively. Detailed inspections and regular maintenance should be carried out in short cycles initially until a schedule reflecting the site-specific conditions can be determined.

For items that are too high to reach, use a step ladder to gain access. Do not attempt to climb on the equipment.

CAUTION

DANGER

Daily Inspections

Daily inspections consist mainly of visual inspections on the following items. These observations should be made with all of the cubicle doors closed and safety covers installed. Any abnormalities discovered should immediately be repaired.

1) Check the temperature, the humidity, the presence of corrosive or explosive gases, and the

presence of dust in the area.

2) Check for any abnormal sound or vibration of the reactor, transformer, or cooling fans.

3) Check for abnormal odors such as the smell of burning insulating materials.

Regular Inspections

Carry out regular inspections with power off, locked out, and with confirmation that the bus voltage

is completely discharged. Use power lockout/tagout procedure on the disconnecting means in

accordance with applicable local electrical codes (in the U.S., see 2002 NEC Article 430-1 01) before performing any drive maintenance.

The first thing to do in maintenance and inspection is cleaning. Cleaning should be carried out according to the conditions of the equipment. Before starting cleaning, turn off the power supply and check that the main circuit voltage is reduced to 0. Clean dust with a vacuum, dry cloths. Note that excessive air pressure when blowing out equipment may damage parts and wiring. Do not use solvents to clean the drive. Substances stuck to the circuits, which cannot be removed by blowing, should be wiped away using a cloth. As a basic rule, cleaning should start from the upper parts and end at the lower parts. Cleaning of the lower parts last will allow proper removal of substances that could drop from the upper parts.

CAUTION

DANGER

compressed air, and clean dry

- 4

INSPECTIONS AND MAINTENANCE (cont’d)

Main Components

1) Cooling fan - Check to see if there is any abnormality with airflow, increased fan noise, etc.

2) Air filter - Visually check if the air filter is clogged. Gently tap it outside the room to remove loose

dust. To remove caked on dirt use water and a gentle detergent, rinse it with clean water and dry it.

Otherwise replace it with a new one. Cleaning with solvents is not recommended.

3) Main circuit parts and entire cubicle - Check to see if dust is stuck to the cubicl e interior or if there

is any discoloration, heat generation, abnormal sound, leakage, odor or damage with the reactor,

transformer, contactors, cables and connections, fuses, capacitors, lightening arrestor s, and

resistors. Check to see that no wires or mounted parts are broken, disconnected, loose or

damaged. High voltage standoffs, insulators, and cable can be cleaned with isopropyl alcohol.

4) Printed Wiring Boards - The boards, which are made up of ICs and electronic components, must

be protected from dust, corrosive gases and extreme temperatures. Pay attention to the installation

environment of the equipment. Regular inspections, the proper cleaning, and maintenance in an

optimal environment is essential for circuit boards. Since most of the components and parts are

small and vulnerable to external forces, when cleaning them, use a brush to carefully wipe off dust.

Inspect the boards for signs of component damage, heating, and corrosion.

Cautions on Handling Printed Wiring Boards

a) All maintenance work on the board should be carried out at least 15 minutes after all power supplies are turned off to allow the capacitors on the boards to discharge.

b) When removing the board, disconnect all the connectors and wires and remove the mounting screws from the upper part of the board first. At this time, be careful not to drop the boards or screws. When setting the board down, place it on a static free surface. Be careful not to damage any components.

c) When attaching the board, do so in the order opposite to the removing procedure. Be sure that all of the connectors and wires are connected correctly.

d) New boards are shipped in an anti-static bag. Use this bag to store them.

Note that the anti-static coating is only on the inner side of the bag.

5) Check the protection functions for proper operation (Door switches, OH, E-stop...)

6) Check the insulation resistance of the medium voltage circuits.

CAUTION

- 5

INSPECTIONS AND MAINTENANCE (cont’d)

CAUTION

Parts to be Regularly Renewed

To use the T300MVi for a maximum period of time, it is necessary to regularly renew (replace) components whose characteristics have deteriorated. The table below shows the parts used for the inverter equipment whose regular renewal is recommended and their recommended re newal period.

Parts to be Regularly Renewed

Product name Recommended

renewal period

Cooling fan

Air filter 6 months Can also be cleaned. Aluminum Electrolytic

Capacitors On Circuit Boards Oil-filled capacitor Main circuit Control power supply 7 years

Main circuit 7 years Fuse

Control circuit 7 years

3 years Sooner if dust or dirt

7 years

20 years

Remarks

damages bearings

Contact Toshiba for

replacement of these

devices

- 6

Recommended Spare Parts

Spare parts are an important part of downtime reduction. When parts in the drive have failed, onhand spare parts are necessary to shorten the mean time to repair (MTTR). Since repla cement of discrete components is time consuming, it is recommended that entire assemblies be replaced. Recommended spare parts common to all drives are shown in the following tables. The recommende d spare rate and minimum amount can serve as references for the minimum number of spare parts relative to the total number of drives on site. It is recommended that the quantity be determined in accordance with the number drives on site. Many other parts are job specific. It is up to the end user to determine what other parts may be needed.

Recommended Common Spare Parts **

Number of

Product name Model/Rating

CTR Control board ARND-3110(*) 1 each 10% 1 GSD Gate signal distribution board ARND-3126B 1 each 10% 1 OLB Optical gate signal board ARND-8205(*) 3 each 10% 1 XIO External input/output board ARND-8120(*) 1 each 10% 1 VDET Voltage detection board ARND-3127(*) 3 each 10% 1 IPAD Keypad interface board PC61910PP114A 1 each 10% 1 DISP Display/keypad PC61910P116 1 each 10% 1 PS1 Control power supply FYX900/63T-BGEE 1 each 10% 1 GDI Earth fault detection ARND-8126A 1 each 10% 1 TEX Twin expansion board PC61910P123(*) 1/0 10% 1 Control Fuses * * 2 each 10% 2 Main Fuses * * 3 each 10% 3 Pt fuses * * 4 each 10% 4 Rectifier fuses * * 36/12 10% 4/2 Power modules*** * * 3 10% 1 Cooling Fans * * * 10% 1

* This data is job/inverter specific. Check the drawings for the specific inverter for this information.

** This is a general list of spares. Check the specific job drawings for other components that may need to be

spared.

parts per drive

4160V/2300V

*** It is recommended that failed power modules be replaced as a unit and that the failed modules

be returned to Toshiba for repair and testing.

Recommended spare parts

Spare

rate

Recommended

Min Q’ty

- 7

Preparations for Inspection and Maintenance of Equipment (Powering-Off)

Stop the

equipment

Main power

OFF

Control power

OFF

Wait for DC bus

discharge

Voltage check

Grounding

Work

1) Stop the equipment and check that the motor has completely stopped.

2) Press the interlock switch on the operation panel (See Fig. 1 in the next section). The light on the switch should turn on.

3) Turn off

power.

4) Turn off and lock out the control power supply.

5) Turn off an lock out any other job specific power feeding the drive.

6) Wait for 15 minutes or more for the bus to discharge.

7) Verify that all power is removed by measuring the main, the DC bus, the control, and any other external source voltage levels with properly rated measuring equipment.

Note! A meter rated for 5kV is required to safely check the main circuit voltages.

8) Ground the 3-phase input power supply terminal at the main circuit input terminals. (Grounding is automatic when the equipment is supplied with a JK type incoming starter.)

9) Perform the necessary maintenance.

the external main power supply. Disconnect and lockout the main

- 8

Recovery after Inspection and Maintenance of Equipment (Powering-On)

Check for tools.

Remove the

rounding rod

Close the door

Control power

supply ON

Main power

supply ON

Prepare

operation of

equipment

1) Check the drive to make sure no tools or other foreign objects were left in the drive.

2) Remove any grounding devices that may have been attached to the main circuit input terminal.

3) Replace any safety barriers or covers that were removed for maintenance. Close the and latch all doors. Operation of the equipment cannot start when the door of the main circuit related cubicles is open.

4) Turn on

5) Turn on any other external power suppy sources.

6)Turn on

7) After safety checks, prepare for the operation. Press the interlock switch on the operation panel (See Fig. 1 in the next section). (When the LED is turned off, the interlock is off. If the drive is ready, it will start if commanded).)

the control power supply.

the external main power supply.

- 9

OVERVIEW

Display/Keypad (MVi-EOi)

The following figure shows the display/keypad of the equipment. Refer to the keypad operation

manual for more details on its use.

MVi-EOI Diagram

2 4

3 6

13 14 15

Figure 1.

789

11 10

- 10

1. Graphical LCD – Displays user information in text and numerical form.

2. Local/Remote LED – This green LED is illuminated when in local mode, and extinguished while in

remote mode.

3. Status LED:

• Not ready and not running – Both Red and Green off.

• Ready and not running – Green LED only

• Ready and running – Red LED only.

• Fault – Fast blinking Red LED. (2.0 Hz).

• Alarm – Slow blinking red if running or, green if not running. (0.67 Hz).

• Test mode – Alternating red and green when in ready or running condition. (2.0 Hz).

4. LOCAL/REMOTE Key – Toggles between Local and Remote mode while the drive is not running. Press

and hold the key for two seconds to toggle modes.

5. MON/PRG Key – This key will cycle through the tabs (see figure 2).

6. RUN Key – Initiates a start command when the ASD is in local mode, and the MVi-EOI is in the Main

Tab.

7. ENTER Key – Selects a menu item to be changed or accepts and writes the changed data of a selected

field. While in the Main Tab, press and hold this key for two seconds to toggle the direction of the motor.

8. ESCAPE Key – This multi-function Escape key allows the user to cancel changes made to a

programming filed if pressed while the field is selected (highlighted), returns the user to the previous level of the menu tree, and cycles through the display tabs.

9. STOP key – This initiates a stop request when operating in local mode, and is functional in all screens.

When double pressed within 1.5 seconds, it initiates a (gate block) coast to stop. This function always works. The drive must be reset after a double-press stop.

10. UP key – Scrolls up a menu listing and increments a selected field’s parameter data.

11. DOWN key – Scrolls down a menu listing and decrements a selected field’s parameter data.

12. Encoder – This multi-function device scrolls up and down a menu listing, increments/decrements the

data in a selected programming parameter field, and functions as the Enter key when pressed.

13. Commissioning Tool Port – Ethernet port used for communication to the commissioning and support tool

(Wi-Tool).

14. RESET Pushbutton – This pushbutton is used to clear inverter faults and alarms displayed on the LCD.

15. INTERLOCK Pushbutton – This pushbutton is used to disable the inverter via a hard-wired circuit. The

pushbutton is illuminated while the inverter is interlocked, and extinguished for normal operation. Operating the INTERLOCK pushbutton will result in an inverter gate block and free-run deceleration of the load.

- 11

How to Handle Faults

In the event of a fault, the following measures should be taken:

(1) Record the fault message shown on the display on the operation panel.

(2) Collect the trace back data, if the commissioning software package was purchased.

(3) See the Fault and Recovery section.

Description of Terminology

This section describes the special terms used in this manual.

Description of Terminology

Term Meaning Power

module IGD board

OLB board

VDET board

GSD board Gate Signal Distributor. Board that distributes gate signals to each output phase. CTR board Inverter main control board TEX board

EEPROM Electrical Erasable Programmable Read Only Memory IGBT Insulated Gate Bipolar Transistor LCD Liquid Crystal Display LED Light Emitting Diode MCCB Molded Case Circuit Breaker PP7

PSM RAM Random Access Memory Initialize

Interface Means by which this equipment transfers signals to/from external devices. Inverter

Overload Operation at a current output that exceeds the continuos rating of the equipment. Display-

keypad Load Refers to a motor that receives power from this equipment.

A single-phase DC-fed inverter module using IGBTs.

IGBT Gate Driver Board. Converts gate signals sent in optical signal form to electric signals.

Optical Link Board. Converts gate signals from electric to optical signals for isolation.

Voltage Detection Board. Board that measures analog voltage signals and converts them to optical signals.

Twin Expansion Board. Distributes the gate signals to the power modules for twin drives.

Power electronics Processor for Various Inverter control Integration (VII=7). Toshiba dedicated power electronics control 32-bit micro-controller.

Switching power supply that providing ±15 VDC and +5 VDC for boards.

Act of initialization. When the control power switch is turned from OFF to ON the inverter equipment initializes data and circuits.

Inverse converter that converts DC power to AC power. (DC → AC conversion)

Operational panel installed on the cubicle surface that is used for data display and basic operations.

- 12

General Specifications (Structure)

The general specifications (structure) of the equipment are shown in the following table. General Specifications (Structure)

Item Standard specification Additional optional

specification

Applicable standard UL, NEMA Ambient conditions

Temperature

0 to 40°C

Humidity Max 95%, no condensation

Altitude 1000 m Max. above sea level Installation

Indoors location Vibration 10 to 50 Hz, 0.5 G or less Corrosive factors

Hydrogen Sulfide (H2S)  0.001 PPM

Sulfur Dioxide (SO2)  0.05 PPM

Chlorine gas (Cl2)  0.1 PPM

Ammonia gas (NH3)  0.1 PPM

Nitrogen Dioxide (NO2)  0.02 PPM

Nitrogen Oxide (NOx)  0.02 PPM

Ozone (O3)  0.002 PPM

)  0.1 mg/m

Paint color Cubicle

Hydrochloric acid mist (HCl

ANSI 61 Gray Consult factory for surface

Cubicle structure Front maintenance,

stand-alone cubicles

NEMA 1,

structure

Forced ventilated

With channel base

Air filter Front mounte d

This is a list of

optional colors

Cubicle protective

Remarks

t no time should the drive be subjected to conditions that would allow condensation to form on the components.

corrosive agents know to attack the drive components. Other agents may also have adverse effects on the drive.

- 13

Altitude and Temperature De-rating

Altitude Derate Chart **

Altitude % Amp Output Derate 3,300’ 0.0%

4,000’ 2.0% 4,500’ 3.3% 5,000’ 4.7% 6,000’ 7.5% 7,000’ 10.2% 8,000’ 12.9% 9,000’ 15.7% 10,000’ 18.4%

** Applications above 5000 feet may also require special magnetics. Consult Toshiba Engineering.

Temperature Derate Chart

Ambient Temperature % Amp Output Derate 40 C 45 C 50 C

0.0%

7.5%

15.0%

Motor Cable Length

Below are cable length guidelines for use with most standard industrial motors.

Suggested Maximum Output Cable Distances

AC Motor Voltage Drive Output Voltage Max lead length

without filter

2300 2400V 0-1000 ft

2300/4000 2400V 0-1000 ft

4000V or 2300/4000 4160V 0-1000 ft

CAUTION

(1) Older motors, or motors with marginal insulation systems, may require filters to help reduce the stress on the insulation system. Consult Toshiba application engineering.

(2) Exceeding the peak voltage and allowable rise time of the motor insulation system will reduce motor life expectancy. To insure good insulation life, consult with the motor supplier to determine motor insulation ratings and allowable maximum output lead distance. Long lead lengths b etween the motor and drive may require that filters be added to the drive output.

- 14

General Specifications (Electrical)

The general (electrical) specifications of the equipment are shown in the following table.

General (Electrical) Specifications Item Standard specification Standard

Optional Specification

Frame Sizes

Motor driven by this equipment Squirrel-cage induction Main

power supply

Control power supply

circuit Others

Input supply voltage and range of fluctuation

Output voltage 0 ~ Rated Voltage Supply voltage frequency

PWM frequency 2048Hz 4160V Regeneration system Not available

Overload capacity 100% - continuous

Ground protection Yes Receptacle No Yes Motor cooling fan control Cabinet space heater No Cabinet internal light No Maximum Sound Level

4160V

2400V

motor Rated Voltage ±10% Rated Frequency ±5%

Internally supplied 480 V, 60 Hz

1024Hz 2400V

110-115% - 60 sec (Depends upon frame size and drive rating)

Less than 80 dBA, measured 3 ft (1 m) from equipment

Frame 0 Frame 1 Frame 2 Frame 3 Frame 4 Frame G4P Frame H4P Frame 0 Frame 1 Frame B2 Frame 3 Frame 4

See ratings

480 V, 60 Hz Voltage fluctuation range: ±10% Main

125%,

dditional Optional Specification

150%, 175%, 200%, 225%, 250%

Remarks

table for specific kVA ratings available

he higher OL ratings require a reduction in continuous capacity

- 15

General Specifications (Control)

The general (control) specifications are shown in the following table.

General Control Specifications Item Standard

specification

Maximum output frequency 75 Hz 120 Hz Speed sensor (PG pulse output) No Yes Basic control performance

Basic control system Volts/Hertz

Operation control range 3%-100% 1%-100% Limited by motor Field weakening control 1:1.5 1:5 Vector Control

Additional optional specification

Sensor Type Vector Sensorless Vector

Remarks

Sensor type vector control uses a resolver or a PG. The maximum PG freq. is 10kHz.

heating

Operation specification

Speed accuracy Speed resolution 1/25000

Acceleration/deceleration time

Restart after instantaneous interruption

±0.5% ±0.01% (Digital setting)

0.1 – 3276.7 sec, acceleration/dec eleration independent setting Possible (more than 5 cycles interruption causes shut down)

Analog setting 1/1000. Isolation transducer recommended. Drive can not

Under-voltage trip at 75% level

regenerate

- 16

General Control Specifications Continued:

General Control Specifications Item Standard specification Option Remarks

Transmission

Cubicle display/ operation

Operation

Connector Personal computer connection Ethernet Analog signal output

Analog signal input

Digital input/output

Commissioning and Maintenance Tool

PC interface None MODBUS

Comissionin g/Maintenan ce Tool LED 1 lamp READY: Operation preparation

LED 2 lamp ON - Keypad control LCD display 128x64 Pixel Graphical LCD display apparatus

Ethernet (with modular jack attached to keypad)

completed (Green) RUN: Inverter in operation (Red) ALARM/FAULT: Alarm slow flashing/Fault fast flashing

OFF - Other than keypad control Backlit type interlock switch: 1

Unlit reset switch: 1 Operation via 8 key keypad and a 15pulse/30detent incremental encoder

modular jack ±10VDC x 3 programmable channels on XIO board ±10VDC x 5 programmable channels on terminal strip ±10VDC x 2 fixed channels on terminal strip ±10VDC x 2 channels

Input: 8 dry contact inputs 7 Programmable: 1 dry contact 24-110Vdc 48-120Vac 6 dry contact 24Vdc 1 Fixed: 1 dry contact 24-110Vdc 48-120Vac Output: Programmable 1 open collector 24VDC-50mA max 5 open collector 24/50VDC-50mA max

Parameter

DEVICE_NET PROFIBUS TL-S20

READY and RUN light colors can be reversed by changing an EIO parameter

Connected

Fixed contact is

24V contact

setting, fault data display, etc.

Requires optional board.

measuring equipment must be isolated from ground

source equipment must be isolated from ground

always used for interlocking control function

always used for internal control functions Optional Software Package

- 17

Rating Specifications

NEMA Type 1 Standard Ratings Table

Standard Model

M3A22030S 300 233 268 64 74 0 M3A22035S 350 272 313 75 86 0 M3A22040S 400 311 357 86 99 0 M3A22045S 450 350 402 97 111 0 M3A22050S 500 389 447 107 124 0 M3A22060S 600 466 536 129 148 1 M3A22070S 700 544 625 150 173 1 M3A22080S 800 622 715 172 198 1 M3A22090S 900 699 804 193 222 1 M3A22100S 1000 777 893 215 247 1 M32A22060S 600 466 536 129 148 B2 M32A22070S 700 544 625 150 173 B2 M32A22080S 800 622 715 172 198 B2 M32A22090S 900 699 804 193 222 B2 M32A22100S 1000 777 893 215 247 B2 M3A22125S 1250 971 1116 269 309 3 M3A22150S 1500 1166 1340 322 371 3 M3A22175S 1750 1360 1563 376 432 3 M3A22200S 2000 1554 1786 430 494 3 M3A22225S 2250 1748 2010 483 556 4 M3A22250S 2500 1943 2233 537 618 4 M3A22300S

M3A44030S 300 233 268 37 43 0 M3A44035S 350 272 313 43 50 0 M3A44040S 400 311 357 50 57 0 M3A44045S 450 350 402 56 64 0 M3A44050S 500 389 447 62 71 0 M3A44060S 600 466 536 74 86 0 M3A44070S 700 544 625 87 100 0 M3A44080S 800 622 715 99 114 0 M3A44090S 900 699 804 112 128 0 M3A4410ES 1000 777 893 124 136 0 M3A44100S 1000 777 893 124 143 1 M3A44125S 1250 971 1116 155 178 1 M3A44150S 1500 1166 1340 186 214 1 M3A44175S 1750 1360 1563 217 249 1 M3A44200S 2000 1554 1786 248 273 1 M3A44225S 2250 1748 2010 279 321 2 M3A44250S 2500 1943 2233 310 356 2 M3A44300S 3000 2331 2680 372 428 3 M3A44350S 3500 2720 3126 434 499 3 M3A44400S 4000 3108 3573 496 570 4 M3A44450S 4500 3497 4019 558 642 4 M3A44500S 5000 3885 4466 620 713 4 M3A44550S 5500 4274 4913 682 784 4

M3A44600S 6000 4663 5359 744 818 4 M3AP44700S 7000 5440 6252 868 998 G4P M3AP44800S 8000 6217 7146 992 1141 H4P M3AP44900S 9000 6994 8039 1116 1283 H4P M3AP4410KS

Specifications subject to change without notice. Inverter performance data is based on a typical 4 pole motor operating at 0.87 pf and 0.96 efficiency.

Input

Voltage

2400 V

4160 V

Motor

10000 7771 8932 1240 1426 H4P

Output

3000 2331 2680 645 741 4

Output

KVA

Output Current

100%

Overload Current

110~115%-60 s. Frame

Output Voltage

& Frequency

0~2400 V 0~75 Hz

0~4160 V 0~75 Hz

- 18

Protective Functions

The main protective functions are shown in the following table. For other faults or more details,

refer to the troubleshooting manual. Protective Function Table

Item Abbreviation

Input main switch open AC_MCCB O O No load connected AC_NL O O Output main switch closed

without signal (Welded) Output main switch opened

during operation Output main switch open timer ACSW_T O O Brake healthy B_HLTY O O External trip from input breaker BLA O O Brake release fault BR_F O O Equipment ventilation fan stop C_FN O O O Equipment ventilation fan stop

timer Current limit timer CL_T O O Current limit alarm CL_TA O O Control power supply loss CPSF O O* CPU error CPU_A or M O O* U or W phase feedback error CURU or W O O* Door open DS_T O O* Encoder feedback error ENCODER_F O O* Rectifier fuse fault FUSE_xP

Ground fault alarm GR_A_ O O O Ground fault trip GR_T_ O O External interlock IL O O Motor cooling fan stop timer M_FN_T O O Motor cooling fan stop M_FN O O O O Motor overheat M_OH O O O O Motor overheat alarm M_OH_A O O O Main power supply loss MPSF O O* Main power supply loss MPSF_MV O O* Motor temperature sensor error MTMP_S O O O AC over-current OCA O O* Power Module phase over-

current Power Module IGBT over-

current

Power Module overheat OH_T_x O O* Transformer over heat OH_TR O O*

ACSW_C

ACSW_F

C_FN_T

FUSE_xN

OCD_x

OCD_xA1 OCD_xA4 OCD_xB1 OCD_xB4

Hardware Detection

O O*

Software Detection

O O

O O*

Heavy Fault Coast

to stop

Decel stop

Medium Fault Stop

request

Light Fault Alarm

Start Interlock

- 19

Overload alarm OL_A O O Overload (5 minutes) OL5 O O Overload (20 minutes) OL20 O O Over speed OSS O O* Output frequency high OSS_F0 O O* DC bus over-voltage

positive/negative Panel safety switch P_SW O O Parameter setting error PARA_ERR O O PLL phase error PHASE_ERR O O

PLD error PLD_ERR O O* PLL error PLL O O* Pre-charge CTT trip PRE_CTT O O Pre-charge CTT alarm PRE_CTT_F O O O Rectifier failure REC_F O O* Reverse rotation failure REV_ROT_F O O* Rotation/start failure ROTATE_FAIL O O* Soft stall SOFT_STL O Speed feedback error SP_ERR O O* Speed feedback error2 SP_ERR2 O O* Speed reference lost SP_LOST O O O Speed reference lost alarm SP_LOST_A O O O Motor turning start interlock SP_SIL O Spare input 1-4 SPA1-4 O O* O O Spare input 1-4 timer SPA1-4_T O O* O O System configuration error SYS_ERR O O Communication error 1-4 TL_F1-4 O O O Main under-voltage UV_MPSF O O DC under-voltage start interlock UV_SIL O O O DC under-voltage trip UVD O O External safety switch UVS O O Input voltage phase loss VAC_PH_LOSS O O Output current phase loss VINV_PH_LOSS O O

OV_xP OV_xN

O O*

(Note 1) Hardware Detection: Items for which all IGBTs are directly turned off by hardware.

Detection: Items for which protective interlock operation is performed by detecting errors via software. (Note 2) "O" marks in the interlock operation fields can be selected by parameter setting. "*" indicates that the equipment outputs the trip signal to input main circuit breaker.

Software

“x” indicates the phase (U,V,W).

- 20

General Cubicle Structure

The configuration and dimensions of the equipment are described below.

Cubicle Structure and Dimensions

The equipment is made up of one or more cabinets containing the transformer, incoming terminals,

converter section, and the inverter section. All components can all be accessed from the front.

This outline is for the standard Frame 1 model. For details of this and other ratings, see the outline

drawing of each product.

POWER ISOLATION SWITCH

O N

O F F

HEIGHT

TRANSFORMER/CONVERTER CUBICLEINVERTER/CONTROL

WIDTH DEPTH

Dimensional Outline of 4160V- Frame 1 Cubicle (See the following page for dimensions)

General structure

1) All cubicles have a structure that allows maintenance from the front. Rear maintenance access is not required. The cubicles may be placed within 1" of the rear wall.

2) Provide a maintenance space of at least 72 inches (1829 mm) in front of the cubicles.

3) Provide a clearance of at least 24 inches (610 mm) above the exhaust fans.

4) The following are not included in the dimensions on the next page: a) Handle projections b) Door mounted device projections c) Fastener projections

- 21

Dimensions and Weights of Equipment

Dimensions and weights of the complete drive, including the power modules

Standard Model Number

M3A22030-050S 103.7 (2634) M3A22060-100S 103.7 (2634)

M32A22060-100S 103.7 (2634)

M3A22125-200S 103.7 (2634)

M3A22250-300S 103.7 (2634) M3A44030-10ES 103.7 (2634) M3A44100-200S 103.7 (2634) M3A44225-250S 103.7 (2634) M3A44300-350S 103.7 (2634) M3A44400-600S 103.7 (2634)

M3AP44700S 103.7 (2634)

M3AP44800-10KS 103.7 (2634)

Standard Model

M3A22030-050S N/A 6000 (2722) M3A22060-100S

M32A22060-100S

M3A22125-200S M3A22250-300S M3A44030-10ES M3A44100-200S M3A44225-250S M3A44300-350S M3A44400-600S

M3AP44700S

M3AP44800-10KS

“*” Inverter and converter sections combined into one cubicle. “**” Maximum weight for the frame size with the standard transformer and no options. Consult the factory for weights for non-standard inverters, as they are job specific.

Number

Input

Sect

N/A N/A N/A N/A N/A N/A N/A N/A N/A

N/A 51 (1295) 51 (1295)

Weight

Input

lbs (kg)

N/A N/A N/A N/A N/A N/A N/A N/A

N/A 3000 (1364) 3100 (1409)

Dimensions – inches (mm)

Conv

Sect 1

74 (1880) N/A *

74 (1*(880)

74 (1880) 90 (2286)

111 (2819)

74 (1880) 74 (1880) 90 (2286) 90 (2286)

111 (2819)

118.5 (3010)

92.5 (2350) 100 (2540) 111 (2819)

Weight

Conv1**

lbs (kg)

6500 (2949)

6000 (2722) 10500 (4763) 13000 (5897)

7600 (3447) 10500 (4763) 12000 (5443) 14000 (6350)

24000 (10909) 23500 (10682) N/A 8300 (3772) 3000 (1364)

20500 (9318) 20500 (9318) 9600 (4364) 3500 (1591)

Conv

Sect 2

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Inv

Sect

48 (1219)

84 (2134)

111 (2819)

* 48 (1219) 74 (1880) 84 (2134)

111 (2819)

90 (2286)

Weight

Conv2**

lbs (kg)

N/A * N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

2500 (1134)

4500 (2041) 6000 (2722)

2500 (1134) 4500 (2041) 6000 (2722) 6300 (2858)

Output

Sect

N/A N/A N/A N/A N/A N/A N/A N/A N/A

N/A 48 (1219) 48 (1219)

Weight

Inv**

lbs (kg)

74 (1880) 43.4 (1102)

122 (3099) 43.4 (1102)

74 (1880) 43.4 (1102) 174 (4420) 49.5 (1257) 222 (5639) 49.5 (1257)

74 (1880) 43.4 (1102) 122 (3099) 43.4 (1102) 164 (4166) 49.5 (1257) 174 (4420) 49.5 (1257) 222 (5639) 49.5 (1257)

307.5 (7811) 60 (1524)

402.5 (10224) 60 (1524)

Weight Output

lbs (kg)

total

N/A N/A N/A N/A N/A N/A N/A N/A N/A

- 22

Dimensions and weights of the inverter power modules

Drive Model Number

Module Dimensions – inches (mm)

Width Depth Height

M3A22030-050S 9.64 (245) 27.00 (686) 24.21 (615) 120 (54) M3A22060-100S 11.60 (295) 30.18 (767) 31.55 (801) 235 (107) M32A22060-100S 9.88 (251) 26.75 (679) 11.13 (283) 71 (32) M3A22125-200S 24.00 (610) 38.00 (965) 35.34 (898) 512 (232) M3A22250-300S 31.20 (792) 35.40 (899) 38.61 (981) 650 (295) M3A44030-090S 9.64 (245) 27.00 (686) 24.21 (615) 140 (64) M3A44100-200S 11.60 (295) 30.18 (767) 31.55 (801) 260 (118) M3A44225-250S 16.65 (423) 35.40 (899) 38.61 (981) 400 (181) M3A44300-350S 24.00 (610) 38.00 (965) 35.34 (898) 580 (263) M3A44400-600S 31.20 (792) 35.40 (899) 38.61 (981) 800 (363) M3AP44700S 24.00 (610) 38.00 (965) 35.34 (898) 580 (263) M3AP44800-10KS 31.20 (792) 35.40 (899) 38.61 (981) 800 (363)

Weight

lbs (kg)

- 23

Speed sensor

Temperature sensor

INTERFACE

The interface between the drive system and external devices is divided into two categori es: power

supply system and control system.

Power Supply Interface and Ground

The power supplies required are the main circuit input of 2400/4160V and (option al) control power

supply of AC480V-60 Hz.

The following figure shows a recommended grounding circuit for the related equipment. Grounding is intended not only for safety but also to reduce noise problems. The control ground bus is mounted on insulated standoffs. It may be separated from the power ground and run separately to the earth ground with insulated cable if noise problems are encountered with auxiliary control devices.

Grounding must follow local and national codes by attaching a properly sized ground conductor to the drive equipment.

Recommended Ground Circuit

Input transformer

Grounding

Earth Ground

Inverter main circuit Primary Secondary

Drive Power/Chassis Ground

Speed Sensor

Motor

PLC

Control Ground

- 24

INTERFACE (cont’d)

Motor Interface

If armored and shielded cables are to be used, be sure to connect the shield drain or armor to the ground bus provided in the drive equipment near the motor terminals (U, V, W). Ensure that the motor is connected properly at the junction box and properly insulated to protect against accidental shorting or grounding.

Speed Sensor Interface (Option)

In addition to open loop control, it is also possible to use a speed sensor to perform high precision speed control. Speed sensor selection explained below

Resolver

The drive is capable of accepting both 1x and 4x resolver feedback. The excitation can be either 1 or 4kHZ. For resolver feedback, the following parameters need to be set:

CS_RES_TYPE=1or4 (Set to match the resolver)

CS_PG_OUT= Set to desired PG output count. (Minimum setting for reslover use is 64)

(See parameter manual for exact settings)

CS_PG_CNT=64

FLG_RES_EX4= 0 for 1kHz, 1 for 4kHz

PG (Pulse Generator)

This drive can only read single ended PG signals. The maximum frequency that the PG input can read is 10kHz. The PG should be selected so that this limit is never exceeded. It is recommended that a 10% margin be allowed for overspeed. The following is an example of how to select your PG.

PG pulse count (ppr) = (maximum frequencyx0.9)/ (application top motor speed (min

<Example> When 100% speed is 1800 min

Max PG pulse count = (10000x0.9)/(1800/60) = 300 ppr

Therefore, PG of 300 ppr or less is used. The following settings should be used:

CS_RES_TYPE=1 CS_PG_OUT=0

CS_PGCNT = 256 (Set to the PPR of the PG.)

-1

) / 60)

- 25

INTERFACE (cont’d) Pulse Signal Output

If a speed sensor is used, speed feedback signals can be output as pul se signals. The PG pulse output circuit is shown in the following figure. The power supply for the pulses should supplied from an outside source in a range of 12 V to 24 V. The number of pulses per revolution output can be set using the parameter CS_PGOUT when a resolver is used. See the parameter setting manual for exact settings. Otherwise, set to zero when using a PG. With a PG, the number of pulses out equals the number of pul ses in. This output is limited to 10kHz.

The PG pulse output consists of two phases of PGA and PGB at 90° separation. These pulse signals (at the level of the power supplied from an outside source) are isolated from the control power supply of the drive through photo-couplers.

Pulse Output Circuit

PGB PGA

TB1-18

+12V~48V 100mA max

TB1-19

TB1-20

TB1-21

TB1-22

TB1-23

Digital Input

A total of 7 programmable digital inputs (DI1 to DI7) are provided. Only DI1 is capable of accepting an external voltage input (24VDC) DI2-7 are hard connected to the drive’s internal 24VDC power supply and should only be connected to dry contacts. These input signals can be individually assigned to bits in the DI_EX1, 2, 3, or 4 words. The available input assignments are shown below. For more detail refer to the parameter setting manual.

Digital Input Options

Bit DI_EX1 DI_EX2 DI_EX3 DI_EX4 15 IL * QSTOP MV_JOG_B3 14 UVS * UVS MV_JOG_B2 13 EXT0 * EXT0 MV_JOG_B1 12 SPA1 SPA4 * MV_JOG_B0 11 BRTST SPA3 * EX_LMT_I1 10 ST SPA2 ST EX_LMT_TR 9 F BLA F SP_UP_DI 8 R M_FN ** R SP_DN_DI 7 3S OH_ACL 3S SEL_DI 6 2S E_DRIVE 2S DIR0_DI 5 B HOLD * DIR1_DI 4 FLD QSTOP FLD START0_DI

3 BC F_LMT LATCH_PG_POS START1_DI 2 SPA0 R_LMT SPA0 STOP0_DI 1 EXRST B_HLTY EXRST STOP1_DI 0 R_TEN BA R_TEN EXT1

“*” Not used “**” Available with 03C and up software only

- 26

INTERFACE (cont’d)

Digital Input Descriptions **

Name Description B Brake release command issued 1:Brake release sent, 0:Brake release not sent

(Use when open command sent by other equipment) BA Brake answer back 1: Brake is open, 0: Brake is closed BC Brake closed 1: Brake function normal, 0:Brake forced closed BLA Input breaker state 0:Breaker open, 1:Breaker closed (“a” aux contact) BRTST Brake test 1:Brake forced open, 0:Brake function normal B_HLTY Brake healthy 1:Healthy, 0:Not healthy

DIR0_DI Direction select 0 DIR1_DI Direction select 1 EXRST External reset 1:External reset (Momentary input must be used)

EXT0 Two wire start/stop 0 1:Start, 0: Stop (Refer to SEL_DI) EXT1 Two wire start/stop 1 1:Start, 0: Stop (Refer to SEL_DI) EX_LMT_I1 Total output current limit selection 0:Use LMT_I1, 1:Use LMT_I1_EX EX_LMT_TR Torque reference limit selection 0:Use LMT_TRQ & LMT_TRQ_INV

E_DRIVE Drive emergency command 0:Normal operation, 1:Emergency operation F Forward jogging command (F,R)=(1,0) :Forward jogging start

R Reverse jogging command See above FLD Field current command 1:Field current on when READY

F_LMT Forward speed limit 1:Use LMT_SP_F, 0:Set for ward speed limit to 0 R_LMT Reverse speed limit 1:Use LMT_SP_R, 0:Set reverse speed limit to 0 HOLD Emergency speed hold 0:Normal operation, 1:Maintain speed reference IL Interlock 1:Interlock released, 0: Interlocked LATCH_PG_POS Latch the PG/shaft position input Stores the PG/shaft position at the time the input goes to

MV_JOG_B3 Speed select bit 3 MV_JOG_B2 Speed select bit 2 MV_JOG_B1 Speed select bit 1 MV_JOG_B0 Speed select bit 0

M_FN Motor cooling fan state 1:Cooling fan running, 0:Cooling fan stopped OH_ACL AC reactor overheat 1:Not overheated, 0:Overheated

0:Forward, 1:Reverse

(Operates only when keypad is in remote mode.)

0:No reset

1:Use LMT_TRQ_EX & LMT_TRQ_INV_EX

(F,R)=(0,0) :Forward jogging stop

(F,R)=(0,1) :Reverse jogging start

(F,R)=(0,0) :Reverse jogging start

(F,R)=(1,1) :First received jogging start

(EXT must be off)

0:Field current off until start command received

1in PG_POS_RLATCH and in PG_POS_FLATCH at the

time the input goes to 0.

(B3,B2,B1,B0)=(0000): Speed0 select

(B3,B2,B1,B0)=(0001): Speed1 select

(B3,B2,B1,B0)=(0010): Speed2 select

(B3,B2,B1,B0)=(0011): Speed3 select

(B3,B2,B1,B0)=(0100): Speed4 select

(B3,B2,B1,B0)=(0101): Speed5 select

(B3,B2,B1,B0)=(0110): Speed6 select

(B3,B2,B1,B0)=(0111): Speed7 select

(B3,B2,B1,B0)=(1000): Speed8 select

(B3,B2,B1,B0)=(1001): Speed9 select

(B3,B2,B1,B0)=(1010): Speed10 select

(B3,B2,B1,B0)=(1011): Speed11 select

(B3,B2,B1,B0)=(1100): Speed12 select

(B3,B2,B1,B0)=(1101): Speed13 select

(B3,B2,B1,B0)=(1110): Speed14 select

(B3,B2,B1,B0)=(1111): Speed15 select

(Used in conjunction with F and R inputs and CR_SP0-15)

- 27

QSTOP Quick stop command 1:Quick stop, 0:Normal stop R-TEN Reverse tension command 1:Revers e tension control on,

0:Forward tension control on SEL_DI Start/Stop/Reference/direction select 0:Use EXT0,START0,STOP0,SP_REF_AIN1,DIR0_DI

1:Use EXT1,START1,STOP1,SP_REF_AIN2,DIR1_DI SPA0 Spare 0 Spare 0 (For future use) SPA1 Spare 1 Spare 1 SPA2 Spare 2 Spare 2 SPA3 Spare 3 Spare 3 SPA4 Spare 4 Spare 4 SP_UP_DI Raise speed reference 0:no change, 1:Raise speed reference

(Operates only when keypad is in remote mode. Use in

conjunction with CR_RATE_MRH) SP_DN_DI Lower speed reference 0:No change, 1:Lower speed reference

(Operates only when keypad is in remote mode. Use in

conjunction with CR_RATE_MRH) START0_DI Start command for three wire control 0 START1_DI Start command for three wire control 1 STOP0_DI Stop command for three wire control 0 STOP1_DI Stop command for three wire control 1 ST_CLUTCH Torque control selection

UVS Operation interlock 1:Interlock released, 0: Interlocked 3S 3rd jogging speed command 2S 2nd logging speed command

“**” The function of many operation signals can be reversed via settings for SGN_DI1-8 or SGN_DI_EX4 if need ed.

0:No start, 1:Start

(Must be momentary. Refer to SEL_DI)

0:No stop, 1:Stop

(Refer to SEL_DI)

1:Tension control,

0: Speed control (when torque control is selected)

(3S, 2S)=(0,0) :Jog speed 1 used

(3S, 2S)=(0,1) :Jog speed 2 used

(3S, 2S)=(1,0) :Jog speed 3 used

(3S, 2S)=(1,1) :No jog speed used

- 28

INTERFACE (cont’d) Digital Output

There are 6 programmable digital outputs (DO0-5). DO5 is used internally for control of the input contactor and should not be changed. The other 5 outputs are available for optional control or indication functions. These relays can be programmed to any bit in any word in the drive. The most commonly used bits can be found in the SSEQ_OUT1 and SSEQ_OUT2 words. The word assignment is made via DO0_AS

- DO4_AS parameters. The bit number is set via DO0_BN – DO4BN.

Analog Input

The drive has two general-purpose analog input channels (AIN1, AIN2). They are fixed at ± 10VDC. The analog signals are converted to digital values through a 12-bit A/D converter. A ±10 Vdc input is converted to counts by software and is stored in the target data register. Since this signal is directly connected to the control circuit, it is recommended that an isolation transducer be used. The data register, the gain and the offset are set with the following parameters:

AIN#_AS Target register – set by symbol name

AIN#_GS Gain setting – defines the number of counts for 10V input

AIN#_OS Offset setting – offsets the input The "#" of each parameter name denotes the AD channel number. The following figure shows the input

circuit:

TB2-1 TB2-2

TB1-30

TB1-31

AIN1

AIN2

Analog Input Circuit

Gain AIN1_GS

Offset AIN1_OS

Gain AIN2_GS

Offset AIN2_OS

Data storage destination AIN1_AS

Data storage destination AIN2_AS

- 29

INTERFACE (cont’d)

[Setting examples]

• Example 1: When a 0~8V (0 to 100%) speed reference is input to AIN1.

Set the input jumpers as per the drawings for single ended voltage input. Set a 0 to 100% (count 0 to 25000) speed reference signal at 0 to +8 V so that it is stored in SP_REF_AIN1.

The input characteristic is shown in the right hand figure.

Set as follows:

AIN1_GS = [25000count x 10v/(10v-2v)] = 31250

AIN1_OS = 0

AIN1_AS = SP_REF_AIN1 or 2

AIN1_TYPE = 1

Input Characteristic Example

Example 2 When a 4~20 mA (0 to 100%) speed reference is input to AIN1, it is recommended that a 4-20mA/0-10VDC transducer be used. If the source is isolated, a 510Ohm burden resistor may also be used. This would give 2V at 4mA. In this case an offset would need to be set in the drive as follows:

AIN1_GS = [25000count x 10v/(10v-2v)] = 31250

AIN1_OS = -[31250counts x 2v/10v] = -6250

AIN1_AS = SP_REF_AIN1 or 2

AIN1_TYPE = 1 When using 4-20mA input and a burden resistor, it is possible that the reference will become

negative if the input falls below 4mA. If this happens, the drive could run in reverse. To stop this, the reverse speed limit (LMT_SP_R) should be set to zero, if possible. If this can not be done due to the need for reverse jogging, the parameter LMT_SP_MIN should be set to 0 or higher. This limit fixes the speed reference from the keypad or the analog inputs to a minimum value.

Input Count

25000

-8V 8V

-25000

Input Volta

Analog Output

General-purpose Analog Output

Three channels (AOUT1, 2, and 3) are provided as general-purpo se, ±10VDC analog output from the XIO board. These outputs are directly output from the control board. The device reading these signals must be isolated. To insure this, it is recommended that signal isolators be used. The output can be selected from a list shown in the parameter setting manual by using the parameters AOUT1-3_CODE. They may also be set to any function in the drive by the use of the parameters AOUT1-3_OP_AS, AOUT13_OP_GS, and AOUT1-3_OP_OS. When using the optional settings, care must be taken to set the output up so that the output signal does not exceed ±10V. Exceeding this value will cause overflow problems.

- 30

INTERFACE (cont’d) Additional Analog Outputs

Six channels (D/A1 to D/A5 and Amp A) are provided as additional analog outputs. These outputs are wired out to terminal block TB-AO. Channel A is direct current feedback from the U phase Hall CT. The other five channels are programmable ±10vDC outputs. The data to be output, the gain, and the offset, can be set from the display/keypad or a personal computer by use of the parameters DA1-5_AS, DA15_GS, and DA1-5_OS.

Motor Mounted Fan Circuit

A main motor may require a motor mounted blower fan circuit as an option. When using an external motor fan, be sure to check the rotation direction of the fan and change its phase rotation if necessary.

You can make a fan interlock for the operation of the drive by connecting an “a” auxiliary contact of the fan MCCB/starter to one of the digital inputs on the XIO board and programming it as M_FAN.

This function is available in drives with 03C and up software versions only. If the drive has software version 03A, one of the spare inputs must be used instead.

- 31

CIRCUIT OPERATION

Main Circuit Configuration

The following circuit shows the configuration of the T300MVi 4160V drive. Input AC is supplied through an input controller to transformer T1. The transformer has four (4) isolated secondary windings per output phase, each feeding a 3-phase full wave rectifier bridge. The output of the rectifiers is connected to three inverter power modules that produce 3-phase AC power at the frequency and voltage required by the motor.

ONE PHASE LEG OF 3 LEGS SHOWN

Integral

disconnect

Option

Main Power

7.2 kV class or below

Integral

Transformer

Integral

Pre-charge

circuit

24 Pulse

Source

Phase Leg

ssembly

Optiona l Integral

dv/dt Filter

Output bypass

disconnect

Option

Integral

Lightning

arrestor

ux & Control

Power

460 std., others avail

Sensing PT's

120 output

120 v sec

Power Supply

(15PS1)

Standard

E.S. Shield

Phase Detection

+5V dc

+15V dc

-15V dc 0V dc

+24V dc

0V dc

460 Vac

Control power

feed option

Fan Fan Fan Fan

Module

Main Controller

External I/O

Voltage

Detection

Module

Gate Signal

Distributor

Optical

Link

Module

optional

redundan t fans

shown dotted

Current

Feedback

T300MVi Circuit Configuration

Optional

Input bypass

disconnect

Power Bridge Topology-2.vsd Jan-24-

- 32

CIRCUIT OPERATION (cont’d)

The AC output voltage of the each inverter power module is 2400V line to neutral. With phase voltages shifted 120° from one other, an output voltage of 4160V between phases is generated. The output voltage closely approximates a sine wave. This is shown in the output waveform below. This produces a sine wave motor current with low distortion.

Generation of High Voltage by Wye Connection

2400V

1 phase inverter

Output Voltage and Current Waveforms

4160V

Motor

- 33

CIRCUIT OPERATION (cont’d) Control

The following figure shows the T300MVi Vector Control block diagram.

Vector Control Block Diagram

Speed reference

Speed

control

SFC

Torque reference limit

Tension control

D/q axis current reference

ld/lq current detection

Speed detection (Option)

Voltage reference

PWM control

- 34

CIRCUIT OPERATION (cont’d) Speed Reference

An external speed reference with count 25000/100% weighting is input by serial transmission or analog input and subjected to rate processing and limit processing to output an SP_R signal. The sign of the speed reference signal is "+" for normal rotation and "-" for reverse rotation.

SEL_DI=1

25000 count/100%

SP_REF_AIN1

SP_REF_AIN2

Jogging (option) JOG_R

LMT_SP_MIN

EXT=1

CR_RATE_ACC CR_RATE_DEC CR_RATE_QSTOP

SP_R

SP_REF1 SP_REF2

LMT_SP_F LMT_SP_R

Speed

Reference

1. Speed references SP_REF1 or SP_REF2 can be used when the drive speed is to be controlled from one location only. When using local and remote control or there is a need for selection between two separate inputs SP_REF_AIN1 and SP_REF_AIN2 should be used. To select between references, one of the digital inputs should be programmed as SEL_DI and the selection switch connected.

SP_REF_AIN1 is used when the SEL_DI input is 0 (Open). SP_REF_AIN2 is used when SEL_DI is 1 (Closed). The start commands (EXT) are also different for this application. When SEL_DI is 0, EXT0 should be used and when SEL_DI is 1, EXT1 should be used.

2. LMT_SP_MIN LMT_SP_MIN is used as a minimum speed. The drive will run at this speed anytime the start command is on and the speed reference is less than LMT_SP_MIN.

- 35

CIRCUIT OPERATION (cont’d) Speed Control

The following figure shows the speed control block diagram.

The speed reference signal SP_R and the filtered speed feedback are input and the deviation between these two is subjected to proportional/integral operations and output. After this signal is subjected to torque filtering and torque limit processing, a torque reference SFC_T_R is output.

Control response is performed with the following parameter settings.

ASPR_A: Anti-overshoot gain

ASPR_AT: Anti-overshoot gain time constant

ASPR_P: Proportional gain

ASPR_W1: Response target

Note that if the GD

of the machine is extremely large compared to GD2 of the motor or if there is

torsional resonance, the control response may need to be slow.

FLT_T_R

Speed control gain switching (option) Switching of a Minimum of 4 stages ASPR_G_SEL

<Anti-over>

<Limit>

Limit Block

4000/100%

SFC_T_R

SFC_DATA

Speed Control

Speed reference SP_R

Speed feedback SP_F

<Anti-over> <Speed control> ASPR_A: Anti-overshoot ASPR_AT: Anti-overshoot time constant ASPR_P: Proportional gain ASPR_W1: Response target

SFC (option) Simulator

FLT_SFC OP_SFC_J

d/dt

OP_SFC_P: Proportional gain OP_SFC_D: Differential gain OP_SFC_A: Anti-over gain LMT_SFC_D: Differential limit

- 36

CIRCUIT OPERATION (cont’d)

Simulator Follower Control (SFC, optional control used with a speed sensor)

When the machine has torsional resonance, the (SFC) function may be used to try to reduce the torsional vibration and increase the speed response.

With SFC, the speed regulator output signal is input to an inertia compensation block. This block produces an estimated speed signal. The speed feedback is then subtracted from this value to create a speed deviation signal. This signal is then sent through a proportional block and added to the output of the speed regulator. The speed deviation signal is also sent through an anti-overshoot block and subtracted from the speed regulator output. The combination of these two functions can be used to help improve the recovery of the system during shock loading.

The speed deviation signal is also sent to a differential block and added to the torque reference (see below). This signal is effective for torsional vibration control. When the SFC function is not used, set all of the gains to 0.

Torque Reference and Current Reference

Signal SFC_T_R, the result of speed control, which is equivalent to the torque reference is input and subjected to torque limit operation and di/dt processing. The differential output of the SFC control is then added (if used). This is the torque reference that is sent to the current regulator.

T_R

Torque reference speed control output

SFC T R

Torque Reference

SFC_DATA

<Limit>

Limit block LMT_DIDT

<di/dt>

- 37

CIRCUIT OPERATION (cont’d) IQ Limit (Torque current limit)

The IQ limit has a flat characteristic from 0 to base speed and tapers from base to top speed. The following settings are used to adjust the limits.

LMT_IQ_BAS: Base speed torque current limit. Set 110%, 115%, etc. according

to OL specification of the drive.

LMT_IQ_TOP: Top speed torque current limit. Set as required by the application

or set the same as the base limit when field weakening is not used.

LMT_IQ_INV: Regeneration torque current limit. Set to 1 or 2%. This Drive

cannot regenerate.

LMT_SP_BASE: The upper speed of the drive at which LMT_IQ_BASE is used.

Set 125% for applications that do not use field weakening. Otherwise set as required by the application. LMT_TRQ: Torque reference motoring absolute limit. The maximum motoring torque reference allowed regardless of speed. Set to the base speed torque current limit. LMT_TRQ_INV: Torque reference regeneration absolute limit. The maximum regeneration torque reference allowed regardless of speed. Set to 2%.

Speed

feedback

IQ Limit

-100%

SPEED

LMT_IQ_TOP

IQ limit

LMT_IQ_INV

calculation

LMT_IQ_BAS LMT_IQ_TOP

LMT_IQ_INV

LMT_SP_BASE

+IQ

LMT_IQ_BAS

LMT_SP_BASE

LMT_SP_INV

LMT_IQ_BAS

LMT_IQ_INV

-IQ

LMT_IQ_TOP

+100% SPEED

Flux reference

ID limit

calculation

limit

Torque reference limit

- 38

CIRCUIT OPERATION (cont’d) D-Q Axis Current Control

The figure on the following page shows the block diagram of D-Q axis curre nt control.

This system controls the current of an induction motor by separating it into a magnetic flux (Field) component and a torque component. This drive controls the current on the D-Q coordinates. It can control the current to an AC motor as a DC value, achieving high performance control irrespective of output frequencies.

(1) ID (Field current) control

A magnetic flux reference is generated based upon the speed reference. This and the field current setting (MI_ID_BASE) are used to generate an ID reference. This ID reference and the ID feedback signal are input into a PI controller. The output of this controller is the ED_R (Field voltage reference). Optional Inductance (L) compensation can also be used (ACR_WL). If used, this value is combined with the PI controller output to create the ED_R.

(2) IQ (Torque current) control

The torque reference, which is the result of the previously mentioned speed control, is input and divided by magnetic flux to obtain an IQ reference. This IQ reference and IQ feedback signal are input into a PI controller. The output of this controller is the EQ_R (Torque voltage reference). An induction voltage compensation (ACR_E2) and L compensation (ACR_WL) may also be used. If used these values are combined with the output of the PI controller to create the EQ_R.

Magnetic flux

refe re nce

FL_R

Torque

refere n ce

T_R

Field current

setting

MI_ID_BASE

Flux fu n ctio n

D-Q Axis Current Control

ACR_E2

Frequency

lim it

lim it

IQ_ R

ID_ R

IQ_ F

ID_ F

<Anti-overshoot>

ACR_A: Anti-overshoot ACR_P: Proportional ACR_W1: Response target

<Anti-overshoot>

Frequency

ID_ R

IQ_ R

+++

ACR_WL

EQ_R

ED_R

- 39

CIRCUIT OPERATION (cont’d) Output Voltage References

(1) Output voltage references

ED_R and EQ_R (the results of the current regulator) and the flux angle are input into a two to three

phase conversion block. This block outputs the phase voltage references to the PWM (pulse width

modulation) controller.

(2) PWM control

The PWM control section outputs gate pulse signals to the gate board based on the voltage

reference of each phase.

(3) Gate Signal Distribution board (GSD)

The GSD board receives the gate signals from the control board and sends them to the individual

power modules.

D-axis voltage reference ED_R

Q-axis voltage reference ED_R

Magnetic flux location Q0CMP_V

Voltage Reference

Two to three phase convertor

X=DCos(Theta)-QSin(Theta) Y=DSin(Theta)-QCos(Theta)

U=X W=-[(X/2)+Sqrt(3/2)Y] V=-(U+W)

Theta

VU_REF

VV_REF

VW_REF

PWM

Controller

GSD

OLBs

IGBTs

- 40

CIRCUIT OPERATION (cont’d) Speed Feedback (Option)

As an option, a Resolver or a Pulse Generator (PG) can be selected for speed feedback. Speed control with a Tach Generator is not available because Tach Generator perform ance is poor.

Resolver

A resolver is an analog feedback device that used for speed feedback. Two sinewave excitati on signals (sine and cosine) are sent to the resolver and two signals (sine and cosine) are returned to the drive. The use of these two phase shifted signals allows the direction rotation to be determined. The position of the motor rotor is determined by the phase difference between the excitation and return signals. The speed is found from the change in this position over time.

A signal is detected from a single ended PG attached to the motor and converted to a speed. Detection is performed according to the pulse interval measurement system. This system converts a signal to a speed based on the fact that the interval (time) between pulses input is inversely proportional to the speed. The maximum input frequency is 10kHz.

PGA

PGB

PG Speed Detection

Speed Detection

Pulse count Pulse interv al Rotation direction

CS_RES_TYPE = 1 CS_PG_CNT = PG PPR FLG_DIFF_PG = 0

Speed feedback

Position feedback

- 41

CIRCUIT OPERATION (cont’d)

Control Board Configuration

The boards in the following table are used in the drive. The figure below shows the control board configuration.

Boards Used

Board Name Device Main function

ARND-3110(*) CTR Main control circuit ARND-3126B GSD3+ Gate signal distribution circuit ARND-8205(*) OLB Optical gate signal circuit (electrical/optical signal

conversion) ARND-3127(*) VDET Voltage detection circuit ARND-8120(*) XIO External I/O signal circuit PC61910P116 DISP Drive operation PC61910P114A IPAD PC communication/Reset and Interlock functions PC61910P075(*) IGD IGBT gate driver circuit PC61910P106A RGM Resistor voltage divider circuit PC61910P107A PDM Potential transformer circuit ARND-8126A GDI Ground fault detector circuit

‘*’ This data is job/inverter specific. Check the drawings for the specific inverter for this information.

4.16kV/2.3kV

120V

In case of

no control PS feeder

PDM

In case

control PS feeder is available

120,240,460V

120V

Control Board Configuration

PS1

FAN

6Vac

VR,VT

120Vac

PN15

CPS

P24

P15

PM×3

GDI

120Vac

XIO

RGM

PS3

6Vac

Vacx 2 Vdcx 2

P15

CTR

TB-AO

Thermal

VDET

GSD3+

P15

OLB

IPAD

DISP

HCT

IGD

Optical

Link

Electrical

Link

- 42

OPERATION

The powering-on operation must follow a certain sequence. Failing to observe the powering-on

sequence described here may cause unnecessary stress on the equipm ent. Be sure to observe the

powering-on sequence.

WARNING

While the equipment is in operation and the motor is running, do not turn off the main circuit power supply or control power supply under any circumstances. Do not open the cubicle doors.

When the operation of the equipment is completely stopped, use the following basic procedure to turn on/off the power.

NOTE: On some drives, the control power supply is internally derived from the main circuit power supply. In this case, disregard the steps below involving the 480 Vac control power supply.

General power-on and power-off sequence.

Powering-on sequence

Powering-off sequence

Turn on control power supply.

480 VAC-50/60 Hz

Turn on main circuit power supply.

Check that operation is stopped.

Turn off main circuit power supply.

Turn off control power supply.

480VAC-50/60 Hz

- 43

OPERATION (cont’d)

Pre-Operation Check Points

Check the following points before starting the operation.

1) Wiring is correct.

2) A voltage of 2400 V, or 4160 V, ±10% can be supplied as the input power supply voltage.

3) A voltage of 480 VAC ±10% can be supplied as the control power supply voltage.

4) The ground bus and any shielded wires are grounded.

5) The motor frame is also grounded.

6) The motor main circuit wire is not grounded.

Powering-On

The power should be turned on when the motor is completely stopped.

1) Turn on the control power supply MCCB "CONTROL."

2) Interlock the drive with the interlock switch on the keypad.

3) Turn on the main power supply.

4) Release the interlock switch on the keypad.

Operation

This section shows a typical operation procedure. You are also required to obse rve your own safety rules to prevent accidents.

Normal Operation

When carrying out a normal operation using the digital interface (refer to the keypad manual for keypad operation), check that the necessary interface signals are correctly connected and then follow the procedure below.

1) Set the frequency command signal.

2) Turn on the IL (interlock) input signal if used.

3) Turn on the UVS input.

4) Turn on the EXT (start command) input signal.

5) Vary the frequency command as needed. Do not run the drive at zero speed unless you have a

speed sensor.

6) Turning off the EXT signal during operation ramps the motor to a stop.

7) Removing the UVS signal or the IL signal during operation turns off the output of the drive and

the motor coasts to a stop. If these signals are removed during operation, the EXT command must

be removed and the UVS and/IL restored before the drive will restart.

Powering-Off

1) Stop the motor by removing the EXT, the IL, or the UVS command.

2) After the motor has stopped, interlock the drive with the interlock button on th e keypad.

3) Turn off the external main power supply.

4) Turn off the control power supply MCCB "CONTROL."

- 44

DATA CONTROL

Setting Data

The parameter setfile is stored in the EEPROM on the main control board. This is non-volatile memory and will not generally be lost when the drive is powered down. However, this data could be lost if there is a board failure. If this data is lost, the drive will need to be re-commissioned. For this reason, it is recommended that the parameter setfile data be backed up in a file stored on a personal computer. This requires the use of the optional commissioning software. The software and training is available through Toshiba.

FAULT AND RECOVERY

Cautions when Handling Faults

When a fault occurs, before resetting, understand the fault code. It may be unsafe to restart if a component or motor has failed. Every effort should be made to determine the cause of the fault and to correct any problems before attempting to restart the drive.

To do this, it is necessary to record and evaluate the phenomena and conditions of the fault in detail from both electrical and mechanical standpoints. Collect as much data as possible on the following items to determine the operation situation when the fault occurred.

1) Record the fault message (fault display) shown on the display/keypad at the moment the fault

occurred.

2) Collection of trace back data. Record the trace back data by PC(option).

3) Operation different from ordinary operation

Check if there was anything that affected the input power supply of the equipment at the moment

the fault occurred (for example, powering-on of large-capacity equipment which is connected to the

common AC power supply or short-circuits, etc.).

4) Power failure

Check if the input power supply of the equipment was disconnected at the time of the fault (for

example, if the line of the AC power supply was switched or if the breaker was turned on or off).

5) Load condition

Check if the load was drastically changed at the time of the fault.

6) Operation

Check to see if any changes in the process or load machinery were made by the operator at the

time of the fault.

7) Installation environment

Check if there was any abnormal ambient conditions present in the electrical room at the time of the

CAUTION

- 45

fault or before the fault. (Fault of air-conditioner or ventilation system, water leakage into the room,

intrusion of dirt or chemicals, etc…)

8) Changes

Check if there were any recent changes to other equipment around the drive or load machinery.

For example, if some electrical work was carried out on or around the equipment.

9) Lightning

Check if there were any lightning strikes in the area.

10) Abnormal sound, odor

Check if there was any odor or abnormal sound around the equipment at the time of the fault or

after.

Understanding the conditions before and during the fault can help to determine whether the fault is attributable to factors inside or outside of the drive. Further, this information becomes an important clue to determine the cause of intermittent faults. It is important to keep a precise record.

Repair

Cautions on Repair

• Be sure to use only the renewal parts specified by Toshiba. Parts other than those specified by Toshiba may not only not demonstrate the stipulated performance but also affect the safety. If spare parts are not available, contact Toshiba to order them or ask for replacement of parts.

• This equipment includes parts that need to be replaced periodically. It takes time to deliver parts, so order them as early as possible.

1) The power modules have been designed for easy replacement as a unit. They are sold as units

and should be replaced as units. Individual parts should not be removed from or installed on the

power module assemblies. Modules that have failed or are believed to have failed should be

returned to the factory for evaluation, repair, and testing. Refer to the information label on the inside

of the power module compartment door for instructions on replacing a power module.

2) Prepare necessary tools and drawings, etc. before starting the work.

3) Be careful not to damage other parts when removing some parts.

4) Do not make wrong connections when changing parts. Put markings, etc., if necessary.

5) Before restarting after changing any part verify all connections are correct.

6) Use the right tools (torque wrench, etc.) when handling screws and bolts.

7) Special care is required when handling heavy articles.

8) When the work is completed, make sure that no tools or other foreign material is left in the drive.

CAUTION

- 46

DRIVE INSTALLATION DRAWINGS

Frame 0 4160V module lifting and installation

WARNINGS Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power module.

Use module lifting attachment GCI6720G055 and a lifting device rated 250 lbs minimum for removal and installation of modules.

Power Module Removal

1. Disconnect and remove AC neutral bus.

2. Disconnect power cables ACL, P, C & N.

3. Remove control wiring cover (two "A" bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

5. Free slide tray by removing bolt "B".

6. Pull slide tray out until slides lock.

7. Remove four "C" bolts which secure module to tray.

Power Module Removal (cont'd)

8. Using module lifting attachment and lifter, lift module from tray.

Power Module Installation

1. Pull slide tray out until slides lock.

2. Using module lifting attachment and lifter, place module on tray.

3. Secure module to tray with four "C" bolts.

4. Press slide release buttons and slide module into compartment (use caution).

5. Reinstall bolt "B" to secure tray in position.

6. Reconnect control signal cable and 120VAC supply cable to module connectors.

7. Reinstall control wiring cover and secure with two "A" bolts.

8. Reconnect power cables ACL, P, C & N.

9. Reinstall AC neutral bus.

10. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

AC NEUTRAL BUS

ACN

N C P

PINCH AREA USE CAUTION

PRESS BUTTON (INSIDE OF DRAWER) TO SLIDE TRAY BACK

CONTROL WIRING COVER

LIFTING ATTACHMENT

CONTROL SIGNAL & 120VAC CABLES

LIFT HERE

PINCH AREA

ACL

USE CAUTION

PRESS BUTTON (INSIDE OF DRAWER) TO SLIDE TRAY BACK

Frame 1 4160V drive lifting and assembly

...... .....

DANGER

...... ..... When the service drawer is withdrawn, the power modules

have sufficient weight to tip over the Frame 1 inverter cabinet if it is not firmly anchored to the mounting floor, resulting in severe injury or death.

...... ..... DO NOT attempt to install or withdraw the Frame 1 power

modules before first securely anchoring the cabinet to the floor.

PC94060P007

- 47

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 1 drive lifting and assembly (cont’d)

TO MOVE THE SECTIONS USE A FORKLIFT OF ADEQUATE CAPACITY LIFT FROM THE SLOTS IN THE CHANNEL BA SE ON THE TRANSFORMER SECTION. THE INVERTER SECTION IS SHIPPED WITH 4x4 POSTS ATTACHED TO BOTTOM. MAKE SURE THE FORKS EXTEND ENTIRELY THROUGH THE SECTION. NOTE: OVERHEAD LIFTING PROVISIONS ARE PROVIDED ONLY FOR THE INVERTER SECTION. AFTER THE SECTIONS ARE IN PLACE BOLT TOGETHER WITH WITH 1/2" HARDWARE. THEN INSTALL AND WIRE THE FAN ASSEMBLIES. CONNECT THE DC BUS CABLES TO THE MODULES AND PLUG IN THE CONTROL CONNECTOR ASSEMBLE THE GROUND BUS SPLICE.

FAN CONTROL / POWER WIRE CONNECTOR AND MOUNTING HOLES

CONTROL WIRE CONNECTOR AND DC BUS CABLES

1/2 INCH HOLES FOR JOINING CABINETS

LIFTING EYES

TOW MOTOR SLOTS

- 48

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 1 2400V module lifting and installation

ARNINGS Inverter cabinet is top heavy. Cabinet must be anchored to floor before withdrawing power modules to prevent tipping .

Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power modul e .

Use module lifting attachment GCI6721G055 and a lifti ng device rated 350 lbs minimum for removal and installation o modules.

Power Module Removal

1. Disconnect power cables

ACL, P, C & N (P, C & N on right-hand module only).

2. Disconnect and remove bus bars P, C & N.

3. Remove control wiring

cover (two "A" bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

5. Free slide tray by

removing bolt "B".

Power Module Removal (cont'd)

6. Pull slide tray out until slides lock.

7. Remove four "C" bolts which secure module to tray.

8. Using module lifting attachment and lifter, lift module from tray.

Power Module Installation

1. Pull slide tray out until slides lock.

2. Using module lifting attachment and lifter, place module on tray.

3. Secure module to tray with four "C" bolts.

4. Press slide release buttons and slide module into compartment (use caution).

5. Reinstall bolt "B" to secure tray in position.

6. Reconnect control signal cable and 120VAC supply cable to module connectors.

7. Reinstall control wiring cover and secure with two "A" bolts.

8. Reinstall bus bars P, C & N.

9. Reconnect power cables ACL, P, C & N (P, C & N on right-hand module only).

10. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

USE CAUTION

Frame 1 4160V module lifting and installation

WARNINGS Inverter cabinet is top hea vy. Cabinet must be anchored to floor before withdrawing power modules to prevent tipping.

Disconnect power and wait 15 minutes to ensure capacitor s are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power module.

Use module lifting attachment GCI6721G055 and a lifting device rated 350 lbs minimum for removal and installation of modules.

Power Module Removal

1. Disconnect and remove AC neutral bus.

2. Disconnect power cables ACL, P, C & N.

3. Remove control wiring cover (two "A" bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

5. Free slide tray by removing bolt "B".

Power Module Removal (cont'd)

6. Pull slide tray out until slides lock.

7. Remove four "C" bolts which secure module to tray.

8. Using module lifting attachment and lifter, lift module from tray.

Power Module Installation

1. Pull slide tray out until slides lock.

2. Using module lifting attachment and lifter, place module on tray.

3. Secure module to tray with four "C" bolts.

4. Press slide release buttons and slide module into compartment (use caution).

5. Reinstall bolt "B" to secure tray in position.

6. Reconnect control signal cable and 120VAC supply cable to module connectors.

7. Reinstall control wiring cover and secure with two "A" bolts.

8. Reconnect power cables ACL, P, C & N.

9. Reinstall AC neutral bus.

10. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

AC NEUTRAL BUS

USE CAUTION

PINCH AREA

PRESS BUTTON TO SLIDE TRAY BACK

CONTROL WIRING COVER

PINCH AREA

PRESS BUTTON TO

SLIDE TRAY BACK

CONTROL WIRING COVER

LIFTING ATTACHMENT

ACN

N C P

CONTROL SIGNAL & 120VAC CABLES

LIFT HERE

ACL

PRESS BUTTON TO SLIDE TRAY BACK

BUS BAR (3)

PINCH AREA

USE CAUTION

ACL

PINCH AREA USE CAUTION

- 49

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 2 drive lifting and assembly

FAN CONTROL/POWER WIRE CONNECTOR

AND MOUNTION HOLES

INV TOP LIFT

USE LIFTING ANGLE - ONLY WITHOUT CELLS INSTALLED

XFMR TOP LIFT

USE XFMR LIFTING EYES THRU ROOF

FAN ASSEMBLY

CONNECT

(3) 3 PHASE

(1) GROUND

(9) DC BUSSES

WITH BUS SPLICES

1/2" BOLT TOGETHER HOLES (6)

LOWER CONTROL

WIRE ACCESS

TO MOVE THE SECTIONS USE A FORKLIFT OF ADEQUATE CAPACITY

WITH 1/2" HARDWARE.

THEN INSTALL AND WIRE THE FAN ASSEMBLIES.

AFTER THE SECTIONS ARE IN PLACE BOLT TOGETHER WITH

NOTE : OVERHEAD LIFTING PROVISIONS ARE ALSO PROVIDED

MAKE SURE THE FORKS EXTEND ENTIRELY THROUGH THE SECTION.

LIFT FROM THE SLOTS IN THE CHANNEL BASE ON EACH SECTION.

TOW MOTOR SLOTS

CUBICLES BOTTOM LIFT

- 50

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 2 drive main cable installation

TERMINALS

W/COVERS

TERMINALS

INCOMING

LOCATIONS

PLUG

CONTROL

INVERTER SECTION INVERTER SECTION INVERTER SECTION

TERMINALS

OUPUT OUPUT

INCOMING

TERMINALS

W/COVERS

INNER

CELL WITH

COVER

REMOVED

COVER

CELL WITH

OUTER

REMOVED

- 51

COVERS

ALL

CELL WITH

INSTALLED

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 2 module lifting

LIFTING PROVISIONS

2 LIFTING PROVISIONS ARE AVAILABLE

Lift Here

Lifting Attachment

1. Load or remove power module from truck GCI6723G055 using lifting attachment GCI6722G055 and a lifting device rated for 750 lbs or more.

Secure lifting attachment to power module using (4) 3/8-16 bolts provided.

2. Load or remove power module from truck GCI6723G055 using ramp assembly GCI6723G053.

Lock truck to ramp by inserting truck pins into ramp holes.

Set brakes on truck before carefully rolling power module up or down ramp.

- 52

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 2 4160V module installation

Control Wiring Cover

Bus Link Assembly

WARNINGS Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power module.

Front Barrier

POWER MODULE DISCONNECTION POWER MODULE REMOVAL

Control Signal Cable & 120VAC Supply Cable

Power Module Disconnection

1. Remove front barrier (four bolts).

2. Loosen ten nuts and remove bus link assembly by sliding sideways and off.

3. Remove control wiring cover (two bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

Engage Latch

Set Wheel Brakes

Power Module Removal

1. Align truck GCI6723G055 with front of cubicle.

2. Secure truck to cubicle by inserting two studs into holes in base.

3. Set wheel brakes on truck.

4. Roll power module onto truck until front latch engages.

5. Refer to additional instruction label for moving power module on and off of truck.

Secure Truck to Cubicle

Power Module Truck GCI6723G055

Power Module Reinstallation

1. Reverse the procedure followed during disconnection and removal of power module.

2. Ensure that control signal cable and 120VAC supply cable are properly reconnected.

3. Reinstall all hardware previously removed.

4. Torque bus link connections (5/16-18 hdwr) to 10-15 ft-lbs.

- 53

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 3 drive lifting and assembly

FAN CONTROL/POWER WIRE CONNEC TOR

AND MOUNTING HOLES

FAN ASSEMBLY

FOR LIFTING USE THE LIFTING ANGLES

(WITH C E L LS REMOVED)

1/2" BOLT TOGETHER HOLES (6)

MAIN AND DC BUS L INKS

CONTR O L CONNECTOR

FOR LIFTING TH E SEC TIO N U SE TH E TRANSFORMER LIFTING EYES.

TO MOVE THE SECTIONS US E A FO RKLIFT OF ADEQUATE CAPACITY

LIFT FROM THE SLO TS I N THE CHANNEL BASE ON EACH SECTION.

MAKE SURE THE FOR KS EXTEN D ENTIRELY THROUGH THE SECTION.

NOTE :OVERHEAD LIFTING PRO VISIONS ARE ALSO PROVIDED

AFTER T HE SECT I O NS ARE I N PLAC E , BOLT TOGETHER WITH WITH 1/2" HARDWARE.

INSTALL THE MAIN AND DC BUS LINKS AND THE CONTROL CONNECTOR

THEN INSTALL AND WIRE THE FAN ASSEMBLIES.

TOW MOTOR SLOTS

- 54

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 3 drive main cable installation

OUTPUT CABLE CONNECTIONS

ACN ACLCP N ACN P C N ACL

1 2 3

INVERTER SECTION

INPUT CABLE CONNECTIONS

1 2 3

- 55

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 3 module lifting

LIFTING PROVISIONS

LIFT HERE

2 LIFTING PROVISIONS ARE AVAILABLE

LIFTING

ATTACHMENT

1. LOAD OR REMOVE POWER MODULE FROM TRUCK GCI6723G055 USING LIFTING ATTACHMENT GCI6723G054 AND A LIFTING DEVICE RATED FOR 1000 LBS. OR MORE.

SECURE BRACKET TO POWER MODULE USING (4) 1/2-13 BOLTS.

2. LOAD OR REMOVE POWER MODULE FROM TRUCK USING RAMP ASSEMBLY GCI6723G053.

LOCK TRUCK TO RAMP BY INSERTING TRUCK PINS INTO RAMP HOLES.

SET BRAKE ON TRUCK BEFORE CAREFULLY ROLLING POWER MODULE UP OR DOWN RAMP

PC94060P093

- 56

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 3 2400V module installation

WARNINGS

Disconnect power and

wait 15 minutes to

ensure capacitors are

discharged before

performing inspection

or maintenance.

Improper handling of the fiber optic cables

and connectors may

cause drive failure due

to problems

transmitting signals.

Take care not to

disturb fiber optic

cables when handling

power module.

Use Truck

GCI6723G055 for

removal & installation

of modules.

Power Module Removal

1. After capacitor discharge, open upper Power Module cover.

2. Disconnect Control Cable from PCB 'A' and lay in wireway above Power Module.

3. Disconnect Control Power Cable 'B', lay in wireway above Power Module.

4. Remove (4) bolts 'C' from bus stabs P, C, N & ACL

5. Remove (1) bolt 'D' from back of Power Module cableway.

6. Lock Truck GCI6723G055 to enclosure, insert truck pins into holes in front edge of lower pan 'E'. Set truck brake.

7. Withdraw Power Module by handles onto truck until latch engages 'F'. Unlock truck.

WIREWAY

PCNACL

FRONT VIEW

PM CABLEWAY

D C

TRUCK BRAKE

Power Module Installation

1. Load Power Module onto Truck. Engage truc k latch 'F'.

2. Lock Truck GCI6723G055 to front of enclosure, inserting truck pins into holes in front edge of lower pan 'E'.

3. Unlatch Power Module 'F'. Roll Power Module by handles from truck onto enclosure rail until enclosure and Power Module bus stabs touch.

4. Install (1) bolt 'D' at back of cableway. Unlock, remove truck.

5. Install (4) bolts 'C' through bus stabs P, C, N & ACL. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

6. Connect Control Power Cable from wireway as shown at 'B'.

7. Connect Control Cable from wireway to PCB as shown at 'A'.

8. Close upper Power Module cover. Secure with 2 bolts.

9. Replace outside filter cover.

R.H. SIDE VIEW

PC94060P100

- 57

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 3 4160V module installation

WARNINGS

Disconnect power and

wait 15 minutes to

ensure capacitors are

discharged before

performing inspection

or maintenance.

Improper handling of

the fiber optic cables

and connectors may

cause drive failure due

to problems

transmitting signals.

Take care not to

disturb fiber optic

cables when handling

power module.

Use Truck

GCI6723G055 for

removal & installation

of modules.

Power Module Removal

1. After capacitor discharge, open upper Power Module cover.

2. Disconnect Control Cable from PCB 'A' and lay in wireway above Power Module.

3. Disconnect Control Power Cable 'B', lay in wireway above Power Module.

4. Remove (5) bolts 'C' from bus stabs ACN, P, C, N & ACL

5. Remove (1) bolt 'D' from back of Power Module cableway.

6. Lock Truck GCI6723G055 to enclosure, insert truck pins into holes in front edge of lower pan 'E'. Set truck brake.

7. Withdraw Power Module by handles onto truck until latch engages 'F'. Unlock truck.

WIREWAY

ACN P C N ACL

FRONT VIEW

PM CABLEWAY

D C

TRUCK BRAKE

Power Module Installation

1. Load Power Module onto Truck. Engage truck latch 'F'.

2. Lock Truck GCI6723G055 to front of enclosure, inserting truck pins into holes in front edge of lower pan 'E'.

3. Unlatch Power Module 'F'. Roll Power Module by handles from truck onto enclosure rail until enclosure and Power Module bus stabs touch.

4. Install (1) bolt 'D' at back of cableway. Unlock, remove truck.

5. Install (5) bolts 'C' through bus stabs ACN, P, C, N & ACL. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

6. Connect Control Power Cable from wireway as shown at 'B'.

7. Connect Control Cable from wireway to PCB as shown at 'A'.

8. Close upper Power Module cover. Secure with 2 bolts.

9. Replace outside filter cover.

R.H. SIDE VIEW

PC94060P092

- 58

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 4 drive lifting and assembly

FAN ASSEMBLY

CONNECT

(3) 3 PHASE

(1) GROUND

(9) DC BUSSES

FAN CONTROL/POWER WIRE CONNECTOR

AND MOUNTION HOLES

WITH BUS SPLICES

1/2" BOLT TOGETHER HOLES (6)

INV TOP LIFT

USE LIFTING ANGLE - ONLY WITHOUT CELLS INSTALLED

XFMR TOP LIFT

USE XFMR LIFTING EYES THRU ROOF

LOCATIONS

CONTROL

PLUG

TO MOVE THE SECTIONS USE A FORKLIFT OF ADEQUATE CAPACITY

WITH 1/2" HARDWARE.

THEN INSTALL AND WIRE THE FAN ASSEMBLIES.

AFTER THE SECTIONS ARE IN PLACE BOLT TOGETHER WITH

NOTE : OVERHEAD LIFTING PROVISIONS ARE ALSO PROVIDED

MAKE SURE THE FORKS EXTEND ENTIRELY THROUGH THE SECTION.

LIFT FROM THE SLOTS IN THE CHANNEL BASE ON EACH SECTION.

TOW MOTOR SLOTS

CUBICLES BOTTOM LIFT

- 59

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 4 drive main cable installation

OUTPUT CABLE CONNECTIONS

ACN ACLCP N ACN P C N ACL

1 2 3

INVERTER SECTION

INPUT CABLE CONNECTIONS

1 2 3

- 60

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 4 module lifting

Lift Here

LIFTING PROVISIONS

2 LIFTING PROVISIONS ARE AVAILABLE

Lifting Attachment

1. Load or remove power module

from truck GCI6724G054 using lifting attachment GCI6724G055 and a lifting device rated for 1000 lbs or more.

Secure lifting attachment to power module using (4) 1/2-13 bolts provided.

2. Load or remove power module from truck GCI6724G054 using ramp assembly GCI6724G053.

Lock truck to ramp by inserting truck pins into ramp holes.

Set brakes on truck before carefully rolling power module up or down ramp.

- 61

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 4 2400V module installation

Control Wiring Cover

Bus Link

Assembly

Front Barrier

POWER MODULE DISCONNECTION POWER MODULE REMOVAL

WARNINGS Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power module.

Control Signal Cable &

120VAC Supply Cable

Power Module Disconnection

1. Remove front barrier (six bolts).

2. Loosen eight nuts and remove bus link assembly by sliding sideways and off.

3. Remove control wiring cover (two bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

Engage Latch

Set Wheel Brakes

Power Module Removal

1. Align truck GCI6724G054 with front of cubicle.

2. Secure truck to cubicle by inserting two studs into holes in base.

3. Set wheel brakes on truck.

4. Roll power module onto truck until front latch engages.

5. Refer to additional instruction label for moving power module on and off of truck.

Secure Truck to Cubicle

Power Module Truck GCI6724G054

Power Module Reinstallation

1. Reverse the procedure followed during disconnection and removal of power module.

2. Ensure that control signal cable and 120VAC supply cable are properly reconnected.

3. Reinstall all hardware previously removed.

4. Torque bus link connections (5/16-18 hdwr) to 10-15 ft-lbs.

- 62

DRIVE INSTALLATION DRAWINGS (cont’d) Frame 4 4160V module installation

Control Wiring Cover

Bus Link Assembly

Front Barrier

POWER MODULE DISCONNECTION POWER MODULE REMOVAL

WARNINGS Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care not to disturb fiber optic cables when handling power module.

Control Signal Cable & 120VAC Supply Cable

Power Module Disconnection

1. Remove front barrier (six bolts).

2. Loosen ten nuts and remove bus link assembly by sliding sideways and off.

3. Remove control wiring cover (two bolts)

4. Disconnect control signal cable and 120VAC supply cable from module.

Engage Latch

Set Wheel

Brakes

Power Module Removal

1. Align truck GCI6724G054 with front of cubicle.

2. Secure truck to cubicle by inserting two studs into holes in base.

3. Set wheel brakes on truck.

4. Roll power module onto truck until front latch engages.

5. Refer to additional instruction label for moving power module on and off of truck.

Secure Truck to Cubicle

Power Module Truck

GCI6724G054

Power Module Reinstallation

1. Reverse the procedure followed during disconnection and removal of power module.

2. Ensure that control signal cable and 120VAC supply cable are properly reconnected.

3. Reinstall all hardware previously removed.

4. Torque bus link connections (5/16-18 hdwr) to 10-15 ft-lbs.

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame G4P drive lifting and assembly

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame G4P drive main cable installation

- 65

DRIVE INSTALLATION DRAWINGS (cont’d) Frame G4P module lifting and installation

D C

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame G4P module lifting and installation continued

Pin in front

edge of lift

tray

Power

Module

support pan

Power Module Installation

1. Lower lifter tray to ground. Roll Power Module onto tray. Secure with chains.(F)

2. Raise tray above Power Module support pan. Lower tray, inserting pins into holes in front edge of support pan. (E) Set truck brake.

3. Unlatch chains. Roll Power Module by handles from truck onto enclosure rail until enclosure and Power Module bus stabs touch.

4. Install (1) bolt 'D' at back of cableway. Unlock, remove truck.

5. Install (5) bolts 'C' through bus stabs ACN, P, C, N & ACL. Torque all power connections (5/16-18 hdwr) to 10-15 ft-lbs.

6. Connect Control Power Cable from wireway as shown at 'B'.

7. Connect Control Cable from wireway to PCB as shown at 'A'.

8. Close upper Power Module cover. Secure with 2 bolts.

9. Replace outside filter cover.

Lifting

Attachment

For lifting the Power Module after it is out of

the Cubicle use Lifting Attachment GCI6723G054 and a lifting device rated at 1000 lbs. or more.

Secure Lifting Attachment to Power Module

with (4) ½-13 Bolts.

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame H4P drive lifting and assembly

- 68

DRIVE INSTALLATION DRAWINGS (cont’d) Frame H4P drive main cable installation

- 69

DRIVE INSTALLATION DRAWINGS (cont’d) Frame H4P module lifting and installation

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame H4P module lifting and installation continued

Pin in front

edge of lift tray

Power Module support pan

Power Module Installation

1. Lower lifter tray to ground. Roll Power Module onto tray. Secure Power Module.(B)

2. Raise tray above Power Module support pan. Lower tray, inserting pins into holes in front edge of support pan. (A) Set truck brake.

3. Unlatch Power Module (B). Roll Power Module from truck onto enclosure rails.

Power Module Reconnection

1. Reverse the procedure followed during disconnection and removal of Power Module.

2. Ensure that control signal cable and 120VAC supply cable are properly reconn ected.

3. Reinstall all hardware previously removed.

4. Torque bus link connections (5/16-18 hdwr) to 10-15 ft-lbs.

Lifting Attachment

Power Module Lifting

For lifting the Power Module after it is out of the Cubicle use Lifting Attachment GCI6724G055 and a lifting device rated at

1000 lbs. or more.

Secure Lifting Attachment to Power Module with (4) ½ -13 Bolts.

PC94060P194

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame B2 2400V module lifting and installation Type 1

WARNINGS

Power Module Removal

1. Lift latch and lower shelf to service position.

2. Disconnect ACL power cable.

3. Disconnect control plug.

4. Disconnect P, C & N bus bars by removing hardware "A".

5. Remove bolt "B".

6. Slide module out of comp artment and onto shelf.

7. Disconnect four (4) fiber optic cables from module.

8. Using module lifting attachment and lifter, lift module from shelf.

Power Module Installation

1. Lower shelf to service position.

2. Using module lifting attachment and lifter, place module on shelf.

3. Reconnect four (4) fiber optic cables to module.

4. Align module and push into compartment until it stops.

5. Reinstall bolt "B".

6. Install previously removed hardware "A" to connect P, C & N bus bars.

7. Reconnect control plug.

8. Reconnect ACL power cable.

9. Torque P, C, N & ACL connections (5/16-18 hdwr) to 10-15 ft-lbs.

10. Push shelf back up and latch in stowed position.

Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

LIFTING ATTACHMENT GCI673BG055

SHELF IN LOWERED (SERVICE) POSITION

FIBER OPTIC CONNECTORS (2 - FRONT)

CONTROL PLUG

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care when handling fiber optic cables.

LIFT HERE

ACL

Use module lifting attachment GCI673BG055 and a lifting device rated 125 lbs minimum for removal and installation of modules.

LATCH TO HOLD SHELF IN STOWED POSITION

FIBER OPTIC CONNECTORS (2 - REAR)

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DRIVE INSTALLATION DRAWINGS (cont’d) Frame B2 2400V module lifting and installation Type 2

WARNINGS

Power Module Removal

1. Disconnect ACL power cable.

2. Disconnect control plug.

3. Disconnect P, C & N bus bars by removing hardware "A".

4. Remove bolt "B".

5. Slide lifting attachment into module extension guide and fasten lifting attachment using bolt "C".

6. Pull module out into lifting attachment.

7. Latch module (see "LATCH DETAIL").

8. Disconnect four (4) fiber optic cables from module.

9. Couple lifting device to lifting attachment.

10. Unfasten bolt "C".

11. Using lifting device, slide power module and lifting attachment together out of module extension guide.

Power Module Installation

1. Using lifting device, insert module

with lifting attachment into module extension guide.

2. Fasten bolt "C".

3. Reconnect four (4) fiber optic

cables to module.

4. Lift latch, align module and push into

compartment until module bus bars are flush with P, C, & N bus bars.

5. Unfasten bolt "C".

6. Remove lifting attachment by

sliding it out of module extension guide.

7. Reinstall bolt "B".

8. Install previously removed hardware

"A" to connect P, C & N bus bars.

9. Reconnect control plug.

10. Reinstall previously removed

ACL cable.

11. Torque P, C, N & ACL connections

(5/16-18 hdwr) to 10-15 ft-lbs.

Disconnect power and wait 15 minutes to ensure capacitors are discharged before performing inspection or maintenance.

MODULE EXTENSION GUIDE

LATCH DETAIL

LATCH

ACL

FIBER OPTIC CONNECTORS (2 - FRONT)

A A A

CONTROL PLUG

LIFTING ATTACHMENT GCI673BG055 STORED POSITION

Improper handling of the fiber optic cables and connectors may cause drive failure due to problems transmitting signals. Take care when handling fiber optic cables.

LIFTING ATTACHMENT GCI673BG055

N C

LIFT HERE

Use module lifting attachment

GCI673BG055 and a lifting device

rated 125 lbs minimum for removal

and installation of modules.

Lifting attachment is stored inside

the Power Module Compartment.

FIBER OPTIC CONNECTORS (2 - REAR)

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TOSHIBA INTERNATIONAL CORPORATION 13131 WEST LITTLE YORK HOUSTON, TEXAS 77041 USA

www.toshiba.com/ind

Telephone: 713-466-0277 800-231-1412

800-527-1204 (Canada)

Fax: 713-466-8773 Printed in U.S.A.

- 74

Toshiba T300MVi MEDIUM VOLTAGE Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual