TOSHIBA P3 410K (01) PDF Document

The following safety precautions must be followed when installing the TOSHIBA P3 410K:

1) Always ground the unit to prevent electrical shock and to help reduce electrical noise. A separate ground cable should be run inside the conduit with the input, output, and control power cables (See Grounding page 4-7). THE METAL OF CONDUIT IS NOT AN ACCEPTABLE GROUND.

2) Only qualified personnel should install this equipment (see General Safety Instructions on page iii).

3) Installation of drive systems should conform as a minimum, to the 1999 NEC National Electrical Code Article 110 “Requirements For Electrical Installations”, to all all regulations of the Occupational Safety and Health Administration, and to any other applicable national, regional or industry codes and standards.

4) Install in a secure and upright position in a well ventilated location that is out of direct sunlight. The ambient temperature should be between -10° C and 40° C.

5) Allow clearance space to insure adequate ventilation. Do not obstruct any of the ventilation openings.

6) Avoid installation in areas where vibration, heat, humidity, dust, fibers, steel particles, explosive mists, gasses or sources of electrical noise are present.

7) Adequate working space and illumination must be provided for adjustment, inspection and maintenance of the drive (see 1999 NEC Article 110-16).

8) A noncombustible insulating floor or mat should be provided in the area immediately surrounding the electrical system where maintenance is required.

9) Use lockout/tagout procedures on branch circuit disconnect before drive installation.

10) Connect three phase power of the correct voltage to input terminals L1, L2, L3 (R, S, T) and connect three phase power from output terminals T1, T2, T3 (U, V, W) to a motor of the correct voltage and type for the application. Size the branch circuit conductors in accordance with Selection of Main Circuit Wiring Equipment and Standard Cable Sizes Page 4-2.

11) If conductors of a smaller than recommended size are used in parallel to share current then the conductors should be kept together in sets i.e. U1, V1, W1 in one conduit and U2, V2, W2 in another (see 1999 NEC Article 300-20 and Article 310-4). National and local electrical codes should be checked for possible cable derating factors if more than three power conductors are run in the same conduit (see 1999 NEC Article 310 adjustment factors on page 70-196).

12) Install a molded case circuit breaker (MCCB) between the power source and the inverter. Size the MCCB to clear the available fault current of the power source (see 1999 NEC Article 430 Article 102 through Article 111).

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

14) If the factory provided door or NEMA 1 enclosure is removed from the drive, then it must be provided with an alternate enclosure before operating. The alternate enclosure should be a minimum of NEMA 1.

15) Do not connect control circuit terminal block return connections marked CC to inverter earth ground terminals marked GND(E). See Standard Connection Diagrams page 4-1 and Terminal Connections and Functions page 5-3.

16) If a secondary Magnetic Contactor (MC) is used between the inverter output and the load, it should be interlocked so the ST-CC terminals are disconnected before the output contactor is opened. If the output contactor is used for bypass operation, it must also be interlocked so that commercial power is never applied to the inverter output terminals (U,V,W).

17) Power factor improvement capacitors or surge absorbers must not be installed on the inverter’s output.

The following safety precautions must be observed when operating the TOSHIBA P3 410K:

1) Do not touch any internal part with power applied to the inverter; first remove the power supply from the drive and wait until charge LED (see page 5-1 for location) is no longer illuminated. Charged capacitors can present a hazard even if source power is removed.

2) DO NOT OPERATE THIS UNIT WITH ITS CABINET DOOR OPEN.

3) Only qualified personnel should have access to the adjustments and operation of this equipment. They should be familiar with the drive operating instructions and with the machinery being driven.

4) Only properly trained and qualified personnel should be allowed to service this equipment. See page iii.

5) Follow all warnings and precautions. Do not exceed equipment ratings.

6) Do not power up the inverter until this entire operation manual is reviewed.

7) The input voltage must be within +/-10% of the specified input Voltage. Voltages outside of this permissible tolerance range may cause internal protection devices to turn on or can cause damage to the unit. Also, the input frequency should be within +/-2 Hz of the specified input frequency.

8) Do not use this inverter with a motor whose rated input is greater than the rated inverter output.

9) This inverter is designed to operate NEMA B motors. Consult the factory before using the inverter for special applications such as an explosion proof motor or one with a repetitive type piston load.

10) Do not apply commercial power to the output terminals T1 (U), T2 (V), or T3 (W) even if the inverter source power is off. Disconnect the inverter from the motor before megging or applying bypass voltage to the motor.

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

12) Do not open and then re-close a secondary magnetic contactor (MC) between the drive and the load unless the drive is OFF (output frequency has dropped to zero) and the motor is not rotating. Abrupt re-application of the load while drive is on or while motor is rotating can cause drive damage.

13) Use caution when setting output frequency. Overspeeding a motor can decrease its torque-developing ability and can result in damage to the motor and/or driven equipment.

14) Use caution when setting the acceleration and deceleration time. Unnecessarily short times can cause tripping of the drive and mechanical stress to loads.

Prior to releasing an electrical drive system for regular operation after installation, the system should be given a start-up test by qualified personnel. This assures correct operation of the equipment for reasons of reliable and safe performance. It is important to make arrangements for such a check and that time is allowed for it.

When power is applied for the first time, the drive automatically starts up in the frequency monitor function of standard monitor mode with the ‘default’ parameters set as shown in the “FACTORY SETTING” column of the parameter tables starting on page 8-1. If these settings are not optimal for the application, program the desired settings before initiating a run. The drive can be operated with no motor connected. Operation with no motor connected or use with a small trial motor is recommended for initial adjustment or for learning to adjust and operate the drive.

1) Use power lockout/tagout procedures on the disconnecting means in accordance with applicable electrical codes (see 1999 NEC Article 430-101) before performing any drive maintenance.

2) Periodically check the operating drive for cleanliness.

3) Do not use liquid cleaning agents.

4) Keep the heatsink free of dust and debris.

5) Periodically check electrical connections for tightness (with power off, locked out, and with charge LED extinguished (see page 5-1 for location)).

For the purpose of this manual and product labels, a Qualified Person is one who is familiar with the installation, construction, operation and maintenance of the equipment and the hazards involved (see 1999 NEC (National Electric Code) Article 100 – Definitions). This person must:

1) Carefully read the entire operation manual (see 1999 NEC Article 110-3 “Installation and Use”).

2) Be trained and authorized to safely energize, de-energize, clear faults, ground, lockout and tag circuits and equipment in accordance with established safety practices.

3) 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.

4) Be trained in rendering first aid.

Warnings in this manual appear in either of two ways:

1) Danger warnings – The danger warning symbol is an exclamation mark enclosed in a triangle which precedes the 3/16″ high letters spelling the word “DANGER”. The Danger warning symbol is used to indicate situations, locations, and conditions that can cause serious injury or death:

2) Caution warnings – The caution warning symbol is an exclamation mark enclosed in a triangle which precedes the 3/16″ high letters spelling the word “CAUTION”. The Caution warning symbol is used to indicate situations and conditions that can cause operator injury and/or equipment damage:

Other warning symbols may appear along with the Danger and Caution symbol and are used to specify special hazards. These warnings describe particular areas where special care and/or procedures are required in order to prevent serious injury and possible death:

1) Electrical warnings – The electrical warning symbol is a lighting bolt mark enclosed in a triangle. The Electrical warning symbol is used to indicate high voltage locations and conditions that may cause serious injury or death if the proper precautions are not observed:

2) Explosion warnings – The explosion warning symbol is an explosion mark enclosed in a triangle. The Explosion warning symbol is used to indicate locations and conditions where molten, exploding parts may cause serious injury or death if the proper precautions are not observed:

The following notes should be considered:

1) Contacts used to connect drive terminals should be capable of switching low current signals (i.e. 5 mA).

2) The drive has internal motor overload protection which has been functionally certified by Underwriters Laboratories Inc. and no additional external motor overload protection is required (see 1999 NEC Article 430-2, 430-32 and 430-39).

3) When wiring with parallel conductors, the conductors should be kept together in phase sets to avoid heating the surrounding metal by induction. Install U1, V1, W1 conductors in one conduit and parallel conductors U2, V2, W2 in another conduit. The ground conductor must be run in the same conduit. See 1999 NEC Article 300-20(a), 310-4, 310-5. Size the grounding conductor in accordance with 1999 NEC Table 250-122.

4) Twisted pair wiring should be used for external meters connected to AM and FM terminals.

5) For multiple motor applications, a thermal-magnetic circuit breaker must be installed between the drive and each motor. The thermal circuit is for overload sensing and the magnetic coil is for abnormal conditions such as short circuits. Select the MCCB (molded case circuit breaker) in accordance with 1999 NEC Article 430-51 through 430-53, 430-152, and 240-6.

Turn off power to the drive before making any wiring changes to the analog output circuits.

Use separate conduits for routing incoming power, power to motor, and control conductors. Use no more than three power conductors and a ground conductor per conduit.

The suggested maximum output lead distance for the TOSHIBA P3 410K when operating at 460 V is:

Conduit is not a suitable ground for the inverter.

The terminal printed wiring board is shown in the detail below. This board is used in all inverter sizes.

The components are:

• Fused Resistor for P24 (part no. 40980)

• Charge LED

• Terminal Block

• Jumper JP3 is used to set AM terminal and Jumper JP4 is used to set FM terminal.

• 0-1 mA and 4-20 mA selections for JP3 and JP4

Turn off power to the inverter before connecting or disconnecting any wiring to the terminal block.

The control printed wiring board is shown in the detail below. This control board is used in all drive sizes.

The components and functions are:

• Ribbon cable connector (back side)

• Option board connector (40-pin)

• Operation panel connector

• Option ROM socket

• RS-232 Communication connector

• Ribbon cable connector

• Dip Switch SW1 (Detail): When a 0-1 mA reference signal is input to terminal “IV”, set switch SW1 to I. When a 0-10 volt reference signal is input to terminal “IV”, set SW1 to V. When a +/- 0-5 volt reference signal is input to terminal “RX”, set SW1 to 5. When a +/- 0-10 volt reference signal is input to terminal “RX”, set SW1 to 10.

Make connections to this board only with power off.

The operating panel enables the user to enable or disable the keypad, input commands from the keypad, and monitor drive operation. The keys and their functions are:

The LED displays include:

1. 4 seven-segment LED character display:

• In standard monitor mode: displays the current output frequency
• In status monitor mode: monitors the status conditions and frequency command value setting
• In setup mode: displays setup parameter titles and values
• In program mode: displays parameter group titles, individual parameter names, and parameter values
• During a trip: displays the trip title

2. Local/Remote LEDs:

• The appropriate local/remote LED which is inset into the speed control key is lit when the unit is in local or remote mode.

3. Manual/Auto LEDs:

• The appropriate manual/auto LED which is inset into the run mode key is lit when the unit is manual or auto mode.

4. Units LEDs:

• When numeric data is being displayed on the LED display, the corresponding unit indication LED will be lit. If no unit indication LED is lit, the current data has no unit or the corresponding unit does not exist on the display panel.

The 7 segment LED display has a limited number of output characters, therefore the following figures and letters will be used for the display.

The fundamental operation of the TOSHIBA P3 410K LED display/keypad is as follows:

1. Standard monitor mode (Local/Remote, Manual/Auto, Host, Option) (Mode selection level) When the drive is initially powered up, it is in standard monitor mode. The drive will display the current output frequency, trip code, or warning code. The drive will accept run/stop and frequency commands from the sources selected by the panel buttons or parameter settings. All appropriate panel LEDs will be lit to indicate frequency units, command mode, and frequency mode.

2. Setup mode

2a. parameter selection

2b. data selection

Drive SETUP parameters are read and modified in this mode. Setup parameters are the most fundamental parameters that nearly all users must edit to operate the drive.

3. Program Mode

3a. group selection

3b. parameter selection

3c. data selection

All parameters can be read and modified in this mode. Parameters are grouped according to functions. The parameter groups can be blinded/unblinded.

4. Status monitor mode

Displays operating conditions (frequency, current, voltage, etc.), terminal status, version, past error conditions, etc.

5. Meter adjustment

Allows the adjustment of an external analog output frequency or current meter.

In standard monitor mode, the following key operations will allow switching between forward and reverse operation:

However, this switching can be done only while in manual control mode. The motor direction LED message is displayed while the key sequence is pressed and held. When the key sequence is released the display returns to standard monitor mode with output frequency displayed. Reverse run can be disabled using the parameter d 1Sr which is described in section “Fundamental Parameters #1” on page 8-2.

In standard monitor mode, there are five alarm conditions that will cause alarm messages to be displayed. The alarm message and the output frequency will be displayed simultaneously if possible and flashed alternately if not. The following five conditions will cause warning messages to be displayed: overload, overvoltage, overcurrent, overheat, and communication timeout. The alarm indicators will be displayed either singularly or in combination with other alarm indicators if multiple alarm conditions exist simultaneously. If the alarm condition(s) is removed, the alarm message will automatically be removed from the display.

If the S/P/M key is pressed while in standard monitor mode, the mode selection menu is displayed. This menu contains 3 selections: setup mode, program mode, and status monitor mode. It is possible to scroll through the menu selections until the desired mode is displayed. The mode is selected by pressing the R/W key.

The following menu selections are available in the mode selection menu:

Example of changing the setting for acceleration time #1 to 20s (assuming power has just been applied to the inverter):

The parameter group Gr.U contains only those parameters which the user has changed from the default factory settings. The messages displayed when viewing parameters in this group are identical to those displayed when viewing the parameters in their standard groups with one exception. When viewing parameters in standard groups, there is no delay when moving from one parameter title display to the next parameter title display. However, when viewing the user changed parameter group, there can be a time delay between parameter title displays. During this time delay the inverter will flash Gr.U on the LED display to indicate that the inverter is searching for user changed parameters. The following is an example of viewing parameters in Gr.U when only the FH setting and RnSL are changed from the factory default settings.

The AM and FM programmable analog output terminals have a coefficient that can be adjusted by the user to obtain the desired output voltage (current) corresponding to the selected input variable. The following adjustment procedure can be used to adjust the output of the FM terminal to 5Vdc at base frequency.

For all parameters, if the setting value exceeds the parameter’s maximum value, the maximum value alarm is activated. For example, if the user attempts to increase the maximum output frequency above 400Hz, the following message will be displayed:

Minimum value alarm – For all parameters, if the setting value exceeds the parameter’s minimum value, the warning “L 0” and the minimum value will be alternately displayed for two cycles as in the case for the maximum warning.

It is possible to disable all key input by setting the parameter PnOd to 0. To cancel this condition, use the following procedure to enter the pass number which is selectable from 0 – 99 (see page 8-33 Item 314 (PRSS) in Utility Parameters Gr.Ut. Assume starting in panel operation disabled condition:

In status monitor mode, it is possible to monitor the inverter status (frequency command, output voltage, current, terminal information, etc.). Status monitor mode is entered by pressing the S/P/M key, then selecting nOn at the mode selection menu and pressing the R/W key. The following example details the procedure for entering status monitor mode (from standard monitor mode) and viewing all the monitored status variables. The present output frequency (which, just after power is applied, is 0.0) is displayed. (If the ST-CC terminals are not shorted, “OFF” will be displayed).

During pattern run, the following pattern run status elements will appear as the first 4 monitor elements in status monitor mode.

Before pattern run has been started or once pattern run has been completed, the displays of the pattern run monitor elements in status monitor mode will revert to the following:

When the drive is tripped, the first item displayed in status monitor mode is the output frequency at the time of the trip. The message is displayed as follows:

When the drive is initially powered on, two additional LED test (LED test) displays exist in status monitor mode. After any TYP reset, these two test displays cease to exist. The test displays appear as follow:

JOG run mode can be entered only when the drive is in local frequency and manual run/stop control mode and the JOG frequency is set to a value not equal to zero. JOG mode can be entered with the following procedure (assume starting in local control mode from standard monitor mode and JOG frequency equal to 5.0Hz):

The TOSHIBA P3 410K drive series allows operating mode switching anytime (it is not necessary to stop the drive). Operating mode switching is performed with the LOCAL/REMOTE and MANUAL/AUTO keys. When power is applied to an inverter, if the command mode selection is not changed from its default setting, the drive will default to terminal (frequency and run/stop) control mode. To change from local frequency control to remote frequency control, or vise versa, press the L/R key.

CAUTION: If the inverter is running at 0 Hz, and the Local/Remote key is pushed, the frequency command input will be switched to a source that may be set for a none-zero frequency command, and the motor may begin turning without any other key pressed.

Run/stop commands from the LED operation panel are valid for the following settings of the CMOD parameter (CnOd):

(O=permissible, X=not permissible)

• CnOd = 0 X

• CnOd = 1 X

• CnOd = 2 O

• CnOd = 3 X

• CnOd = 4 O

Run/stop commands are entered with the RUN and STOP keys.

The emergency off command can be executed in auto mode and in local mode. Because this command is compulsory, it cannot be prohibited by setting the CnOd parameter. Since the emergency off command is regarded as a past fault, it will be saved as such.

Emergency off command consists of pressing the STOP/RESET key twice. The procedure and the display message are different for manual and auto mode.

In auto mode, the emergency off command is executed with the following procedure (assume starting in terminal control mode with the inverter running):

If within two seconds, STOP/RESET is not pressed a second time, the emergency off command will be aborted and the display will return to the standard monitor mode.

In manual mode, the emergency off command is similar with that of auto mode. The first time STOP/RESET key is pressed, it will be treated as a regular stop command. Therefore, there is no “EOFF” display. If STOP/RESET key is pressed a second time within one second, the press will be treated as emergency off command and E will be displayed and will be continuously flashing. If STOP/RESET key is not pressed within one second, no emergency off command will be issued.

A trip clear can be performed after the cause of the trip has been removed. To perform a trip clear, either switch off power to the inverter or use the following procedure:

If any key other than the STOP/RESET key is pressed at the trip clear command prompt, the trip clear command is aborted and the display returns to standard monitor mode (where the trip title will be displayed flashing). The trip clear command does not clear the recorded past faults.

Standard setting selections are performed by selecting the TYP parameter in Gr.Ut. By selecting the standard setting mode settings (see below), the inverter parameters will automatically be configured. The TYP parameter has the following options:

TYP = 0 No effect

TYP = 1 50Hz standard operation, maximum output frequency, base frequencies, upper limit frequency, all terminal input reference point #2 frequencies, and commercial power/ inverter switching frequency are set for 50Hz operation.

TYP = 2 60Hz standard operation, maximum output frequency, base frequencies, upper limit frequency, all terminal input reference point #2 frequencies, and commercial power/ inverter switching frequency are set for 60Hz operation.

TYP = 3 Standard factory-shipped conditions (sets all parameters except those in Gr.An to their factory-shipped values). THIS CLEARS ALL PAST TRIPS.

TYP = 4 Trip history clear (only past trips are cleared)

TYP = 5 Saves user-set parameters

TYP = 6 Standard user-set conditions (sets all parameters to the user saved settings)

TYP = 7 Initialize inverter typeform (Used to reset a ECYP error.)

When the TYP command is executed, the display will blank for a short time, after which In It will be displayed. After the settings have been automatically updated, the inverter will return to standard monitor mode.

When the rEcY parameter is set to a value not equal to zero, if an overcurrent, overvoltage, or overload trip occurs during operation, the inverter will trip, and the retry sequence will begin. The retry sequence will repeatedly attempt to restart the motor, and if normal operation can be achieved and last for one second, the inverter will switch to standard monitor mode, and operation will continue from there. However, if within the set number of retry attempts, the inverter cannot be restarted, it will remain tripped, and the standard trip message will be shown. The following sequence is an example of the automatic retry function attempting to restart after an overcurrent during operation trip:

This function is used to turn on the damper before the motor runs and turn off damper after motor stops. The function is selected by both assigning code 55 (damper status input 0:damper closes, 1:damper open) to an input terminal and assigning 64 or 65 (open damper 64/65: positive/negative logic) to an output terminal. Unless both are assigned, the damper function will not work.

If “damper status” is assigned to an input terminal and “open damper” is assigned to an output terminal, damper will work in the following way: Whenever a run command is issued, “open damper” signal is sent out to the assigned output terminal. A wait occurs until “damper status” changes to 1 (means damper open full) and motor turns on. If a stop command is issued, “open damper” will be cleared (means to close damper) after the motor stops. During a deceleration, if another run command is issued, the motor should run immediately because the damper is still open. If “damper status” input becomes 0 (means the damper closes) while the motor is running, it drive trips and flashes “dAnP”. The damper trip is non-retriable. If any inverter trip occurs, after motor stops, the damper will be closed.

This function is used to automatically start a motor at the preset speed and forward direction in case of fire. If fire status input is assigned to an input terminal (default assignment to S1 input terminal) and the inverter is not in trip, then whenever fire is detected, a run command at forward direction and the speed set by Item 131 (FSor) will be issued. Fire speed run command has the highest priority besides drive trip. In a fire situation, the motor can not be stopped by STOP command from anywhere. Before the fire signal goes off, the motor can only be stopped by a drive trip. If the fire signal is not cleared, after trip is cleared, the motor automatically will start to run again at fire speed. If any trip occurs, the motor will stop. Remember that the fire speed run command is only a run command but with the highest priority. If the damper function is also working, after the fire speed run command is issued, the first thing to do is to open the damper. The motor will not run until a “damper open full” signal is received.

Fire speed is selected by default. The default setting for fire status input is input terminal S1. The fire status input can be assigned to any input terminal by setting input terminal function to code 56. Fire speed can be set by Item 131 (FSor). Fire speed is limited by setting the upper and lower limit frequency in Item 4 (LL) and Item 3 (UL)

The following table lists all possible messages that can be displayed regarding drive status monitor items.

The following is a list of all trip messages (trip causes) and a brief description on each.

The following is a list of non-trip causing messages (these items are not recorded in fault history) and a brief description of each.

To run from a pot, the drive must have:

1) Drive enable (“ST” to “CC” made).

2) No emergency off command (“S4” to “CC” made).

3) Direction command (“F” or “R” to “CC” made)

4) Frequency reference (wiper from pot is read via “RR” terminal)

5) MANUAL LED off (puts drive in remote mode). Toggle the LOCAL/REMOTE button on keypad to turn LOCAL LED off (with drive stopped).

Notes:

1) Use a 3K ohm pot (1 to 10 K ohms will work).

2) The drive will accel to commanded frequency when “F” or “R” to “CC” is made.

3) The drive will decel to 0.0 Hz when “F” or “R” to “CC” is broken.

4) Motor will coast to a stop if “ST” to “CC” is broken.

5) “E” trip if “S4” to “CC” is broken.

6) The above information applies to a drive with factory default programming.

To follow a 4-20 mA signal, the drive must have:

1) “IV” dipswitch to the right of phone jack on control board (immediately under keypad) set to “I” position. “5/10” dipswitch has no effect in this scenario.

2) No emergency off command (“S4” to “CC” made).

3) Drive enable (“ST”-“CC” made)

4) Direction command (“F” or “R” to “CC” made)

5) Frequency reference ( 4-20 mA signal at “IV” terminal)

6) MANUAL LED off (puts drive in remote mode). Toggle the LOCAL/REMOTE button on keypad to turn LOCAL LED off.

Notes:

1) The drive will accel to commanded frequency when “F” or “R” to “CC” is made.

2) The drive will decel to 0.0 Hz when “F” or “R” to “CC” is broken.

3) Motor will coast to a stop if “ST” to “CC” is broken.

4) “E” trip if “S4” to “CC” is broken.

5) The above information applies to a drive with factory default programming.

6) Do not connect “CC” to ground.

To follow a local (keypad) frequency reference with a auto stop/run, the drive must have:

1) Drive enable (“ST”-“CC” jumpered)

2) No emergency off command (“S4” to “CC” made).

3) Direction command (“F” or “R” to “CC” jumpered)

4) Frequency reference: Adjust on keypad with arrows. Press READ/WRITE to enter.

5) AUTO LED on (puts drive in auto mode)

6) Toggle the LOCAL/REMOTE key on keypad to turn LOCAL LED “on” or Programming: Set Item 312, FREQUENCY MODE SELECTION (FnOd) to Option 2. See page 8-31, 9-33.

Notes:

1) The drive will accel to the commanded frequency when “F” or “R” to “CC” is made.

2) The drive will decel to 0.0 Hz when “F” or “R” to “CC” is broken.

3) Motor will coast to a stop if “ST” to “CC” is broken.

4) “E” trip if “S4” to “CC” is broken.

Pinout for E3 RJ11 RS232 port

Connect DB9 pin 5 to RJ11 pin 3

Connect DB9 pin 3 to RJ11 pin 4

Connect DB9 pin 2 to RJ11 pin 2

Connect DB9 pin 7 to RJ11 pin 6

Connect DB9 pin 8 to RJ11 pin 1

Short DB9 pin 6 to DB9 pin 4

DB9 pin 1 and 9 and RJ11 pin 5 not used

Notes:

1) Free RS232 programming/monitoring software is available from Toshiba. Contact your distributor for a copy and manual.

2) Do not insert/remove the phone plug into/from the P3 port when drive is powered.

3) Common 6 conductor phone cord can be used with an adaptor (6 conductor RJ11 female to DB9 female). The adapter is available from your Toshiba distributor or local electrical supply house.

4) “ST”-“CC” must be made.

5) “S4”-“CC” must be made.

To run from a 0-10 V reference, the drive must have:

1) Drive enable (“ST”-“CC” made).

2) No emergency off command (“S4” to “CC” made).

3) Direction command (“F” or “R” to “CC” made)

4) Frequency reference ( 0-10 V signal applied to “RR” terminal )

5) MANUAL LED off (puts drive in remote mode). Toggle the LOCAL/REMOTE button on keypad to turn LOCAL LED off.

Notes:

1) The drive will accel to commanded frequency when “F” or “R” to “CC” is made.

2) The drive will decel to 0.0 Hz when “F” or “R” to “CC” is broken.

3) Motor will coast to a stop if “ST” to “CC” is broken.

4) The above information applies to a drive with factory default programming.

5) Do not connect “CC” to ground.

6) “E” trip if “S4” to “CC” is broken.

Objective: Set ACCELERATION TIME #1 (ACC 1) to 23.4 seconds. We can change acceleration #1 in SETUP mode or in group FUNDAMENTAL PARAMETERS #1 (Gr.F).

Assume we change the acceleration time #1 in SETUP mode.

Step 1: Press S/P/M key and then R/W key to enter SETUP mode.

Step 2: The first parameter is ACCELERATION TIME #1 (ACC 1) . Press up or down key to adjust the value to 23.4.

Step 3: Press the R/W key to write the new value to EEPROM memory.

To make the drive’s many parameters more manageable, Toshiba employs “blinded” parameters and “blinded” groups.

BLINDED PARAMETERS

Item 13, STALL PROTECTION LEVEL #1 (SEL 1), is an example of a “blinded” parameter. A blinded parameter is identified in the parameter charts (which start on page 8-1) by its gray shading. A “blinded” parameter is preceded by a parameter that has a shaded choice in the Adjustment Range column like Item 12, STALL PROTECTION ENABLE #1 (SEC 1). Item 13, (SEL 1), is visible to the programmer only if Item 12, (SEC 1) has the Option set to 0. Note how Adjustment Range 1 is not shaded to indicate this. There are many other blinded parameters in this drive.

BLINDED GROUPS

Of the twenty groups available in the drive, ten are accessible when the drive is programmed with factory defaults and ten are blinded. To adjust a parameter that is not in one of the visible groups, that parameter’s group must first be added to the group list. This is done by turning “on” or “off” the BLIND FUNCTION SELECTION (bLnd) parameter located in group UTILITY PARAMETERS (Gr.Ut), which is an always visible group.

When GROUP: PARAMETERS CHANGED FROM FACTORY DEFAULT (Gr.U) is displayed and READ/WRITE is pressed, the drive will flash Gr.U and display any parameters that have been changed to a value different from the Toshiba factory set defaults. Press READ/WRITE to see the value of the parameter. The parameter can be modified with the up/down arrows. Pressing READ/WRITE again resumes the drive’s search.

The following example uses “S1” and “S2” terminals to access three preset speeds of 11.0 Hz (close “S1”-“CC”), 55.0 Hz (close “S2”-“CC”), and 33.7 Hz (close “S1” and “S2” to “CC”). “F”-“CC” and “ST”-“CC” must be made on the drive’s terminal strip. This example assumes Input terminal 1 I t 1=1 and Input terminal 2 I t 2 = 2 prior to performing the following programming.

This example uses the “RX” terminal to trim a reference (i.e. a 4-20 mA input) +7/-5 Hz.

The following programming allows a drive to emulate motor operated pot control. Momentarily shorting “S1”-“CC” increases frequency reference. Momentarily shorting “S2”-“CC” decreases frequency reference. Momentarily shorting “S3”-“CC” erases frequency reference. “F”-“CC” and “ST”-“CC” must be made on the drive’s terminal strip. This example assumes drive is defaulted to factory settings prior to the following programming is done.

These parameters must be adjusted to use TTC with a TOSHIBNHOUSTON motor.

* Enter appropriate value from motor’s nameplate. KW = 0.746 X HP.

** Enter “0” for an EQPIII or “1” for a high efficiency motor.

The following parameters must be adjusted to use TTC for a GENERIC motor.

* Enter appropriate value from motor’s nameplate. KW = 0.746 X HP.

** Enter “0” for an EQPIII or “1” for a high efficiency motor.

**** The drive will auto tune the next time a run is initiated. This parameter is then reset to “0” by the drive’.

A fault can be cleared by:

1. Cycling power

2. Pressing the STOP/RESET button twice

3. Closing “RES”-“CC” on the terminal strip (with default drive programming).

If Item 191, FAULT TRIP SAVING b-CL is set to option “1”, the drive will power up with the fault display, but the fault monitor and any fault contacts will be reset. On OVERLOAD trips, reset can occur only after a cooling time; see explanation for Item 14, OVERLOAD SELECTION OLn. No cooling time for reset is required when power is cycled.

In order to obtain the best performance and to get the maximum service life from the drive it is necessary to perform timely maintenance repairs on some parts of the system even though the equipment may still be functioning with no apparent problems.

Use the following service life chart as a guide for major part periodic replacement when the equipment is used in a standard installation service environment.

If the drive faults, the following questions may help to pinpoint the reason for the trip:

1. Does the drive trip when accelerating, running, decelerating, or when not running?

2. Can the drive make it to commanded frequency?

3. Does the drive trip without the motor attached?

4. Does drive trip with an unloaded motor?

Drive data at the time of trip is saved in the monitor and can be read until the trip is cleared. Before clearing the trip, make a note of this information. A history of past faults can be viewed by pressing the MON button and then the down arrow until PAST FAULTS are displayed. Some trips are the result of improper programming; resetting the drive to factory settings may be a solution (see Item 17, STANDARD SETTING MODE SELECTION TYP).

Cause: Drive current exceeded 145% of its rated FLA (190% above 100 HP).

Comments: Check for phase-phase short. ACCELERATION TIME ACC 1 or ACC2 may be too small. VOLTAGE BOOST ub 1 or ub2 may be too high. Is motor/machine jammed? Is mechanical brake engaged while drive is running? If drive is starting into a rotating motor, see Item 176, AUTO-RESTART R-SE. If there is a contactor between motor and drive, wire so that contactor changes state only when drive is outputting 0.0 Hz. Drive will automatically adjust accel time with Item 30, ACC/DEC PATTERN #1 SCu 1 set to option “1”.

Cause: Drive current exceeded 145% of its rated FLA.

Comments: Check for phase-phase short. DECELERATION TIME dEC 1 or dEC2 may be too small. Is motor/machine jammed? Is mechanical brake engaged while drive is running? Adding appropriate braking resistor across “PA” and “PB” terminals may solve problem (see page 9-20). Drive will automatically adjust decel time with Item 30, ACC/DEC PATTERN #1 SCu 1 option set to “1”.

Cause: Drive current exceeded 145% of its rated FLA.

Comments: Check for phase-phase short. Is motor/machine jammed? Is mechanical brake engaged while drive is running? Adding appropriate dynamic braking resistor across “PA” and “PB” terminals may solve problem (see page 9-20). If there are severe load fluctuations, adding mechanical dampening or an output line reactor may help to electrically dampen.

Cause: Drive detected short-circuit in transistor.

Comments: Replace transistor. Contact your Toshiba distributor for authorized repair.

Cause: Drive detected short-circuit on output.

Comments: Check for phase-phase short. Meg motor/leads with leads disconnected from drive. Remove any power factor correction caps on motor. See Item 169, OUTPUT SHORT-CIRCUIT DETECTION SELECT.

Cause: Bus exceeded 787 VDC (460 volt drive).

Comments: Incoming AC may have gone high or spiked (verify with Item 319,320, 321, or 322 set to option “16”); a line reactor or a lower tap on transformer may help. Motor may be mechanically forced to run faster than drive is commanding; install appropriate dynamic braking resistor (see page 9-20). On eccentric cyclic loads like presses or pump jacks, contact your Toshiba distributor for special programming instructions that may make a DBR unnecessary.

Cause: Bus exceeded 787 VDC (460 volt drive).

Comments: Incoming AC may have gone high or spiked (verify with Item 319 set to option “16”); a line reactor or a lower tap on transformer may help. Item 2, DECELERATION TIME #1 dEC 1/dEC 2 may be too short. Drive will automatically change decel time with Item 31, ACC/DEC PATTERN ADJUST LOW SCL option set to “1”. Make sure Item 164, OVERVOLTAGE STALL PROTECTION OPSS is set to option “0”. Motor may be mechanically forced to run faster than drive is commanding (due to large load inertias mechanical couplings); install appropriate dynamic braking resistor (see page 9-20). On eccentric cyclic loads like presses or pump jacks, contact your Toshiba distributor for special programming instructions that may make a DBR unnecessary.

Cause: Drive exceeded 100% of its rated current for too long of a time.

Comments: This trip indicates that the drive output exceeded its rated current for specific amounts of time. For example, drives can output 110% of their rated current for 60 seconds, and 150% for 0.5 seconds. If using DC Injection, Item 166, DC INJECTION CURRENT dbC or Item 167 DC INJECTION TIME dbt they may be too large. If Item 98, PWM CARRIER FREQUENCY CF is greater than 8 KHz, try carrier frequencies less than 8 KHz. Programming Item 14, OVERLOAD SELECTION OLn to option”1″ or “3” (soft stall on) makes the drive reduce output frequency/voltage to shed load (works best on variable torque applications). Motor or load bearings may have seized. Enabling True Torque Control (see page 10-7) may reduce drive’s current output and solve the problem. Make sure that drive is seeing voltage on all three input phases. Drive may be undersized.

Cause: Motor is in danger of overheating because it drew too much current for too long of a time, as determined by the drive.

Comments: See page 8-14. Check Items 178, 179, 180, and 181. If trip occurred at a low frequency, the setting of Item 179, OVERLOAD REDUCTION START FREQUENCY OLF is probably critical. Motor overload protection can be turned off by placing a “2” or “3” in Item 181. Check value in Item 180, MOTOR 110% OVERLOAD TIME LIMIT OLt.

Cause: IGBT7 (dynamic braking transistor) is damaged

Comments: Check ohm value connected to “PA” and “PB” terminals (see page 9-20 for minimum ohm values). If using multiple resistors, make sure parallel-series combination is wired correctly. Check IGBT7. Check DC bus fuse for continuity; if open, check output transistors. Consult your Toshiba distributor for authorized service.

Cause: Dynamic braking resistor is in danger of overheating (as determined by drive).

Comments: Check that the values entered into Item 162, BRAKING RESISTOR VALUE Pbr and Item 163, BRAKING RESISTOR CAPACITY PbCP are correct.

Cause: Drive’s heatsink exceeded 90°C.

Comments: Check drive’s muffin fans (if any). Clear heatsinks of anything blocking airflow. The enclosure that the drive is installed in may be too small or there may be to many heat sources in the same enclosure. Drive may not have been properly sized for operating altitude. Thermistor on heatsink may be bad.

Cause: Drive received one of the following ESTOP commands:

1. Drive was receiving STOP/RUN command via terminal strip when STOP button on keypad was pressed.

2. One of the drive’s input terminal’s function is set to “10” (see Item codes 0-56 and page 9-11), and terminal is being opened/closed to command ESTOP.

Cause: EEPROM was unable to read/write to peripherals.

Comments: Check for miswiring that may be causing noise (such as “CC” connected to ground, an external 10 volt source connected to “PP” etc.) Control board may need to be replaced. See picture of board on page 5-2.

Comments: Check for miswiring that may be causing noise (such as “CC” connected to ground, an external 10 volt source connected to “PP” etc.). Replace control board. See picture of board on page 5-2.

Comments: Check for miswiring that may be causing noise (such as “CC” connected to ground, an external 10 volt source connected to “PP” etc.). If drive is energized with option ROM installed and is later energized without option ROM installed, this fault will appear. Reset in normal fashion.

Comments: If option ROM or option board is installed or removed when drive is powered, this fault will appear. Reset like any fault. Check for miswiring that may be causing noise (such as “CC” connected to ground, an external 10 volt source connected to “PP” etc.). If the CPU is truly damaged, the fault will not reset and replacement of the control board is necessary. See picture of control board on page 5-2.

Cause: RS232 or RS485 timer did not respond

Comments: Check wiring to RS232 or RS485 ports. Check setting of Item 286, COMMUNICATION SELECTION OPt (should be option “1” for RS485). Check jumpers J1, J2, and J3 on RS485 option board (see RS485 Communications Option Manual). Cable may be broken.

Comments: If drive is energized with an option board installed and is later energized without the board installed, this fault will appear. Check connectors between control board and option board. Check settings of Item 99, FREQUENCY PRIORITY SELECTION #1 Fc 1, Item 100, FREQUENCY PRIORITY SELECTION #2 Fc2, and Item 286, COMMUNICATION SELECTION OPc. Use stand-offs to secure board.

Cause: The drive’s output current went below the current value entered in Item 186, LOW CURRENT DETECT LEVEL LLPC for at least the amount of time entered in Item 187, LOW CURRENT DETECTION TIME LLPt.

Cause: The drive’s DC bus voltage went below 413 VDC (460 V P3), for at least the time entered in Item 185, UNDERVOLTAGE DETECT TIME UPc.

Comments: Item 184, UNDERVOLTAGE TRIP SELECTION UPSt turns the ability to undervoltage trip on/off. On some models, turning on Item 174, REGENERATION POWER RIDE-THROUGH UUc and adjusting Item 175, REGENERATION RIDE-THROUGH TIME UUct may keep bus up during brown out if there is sufficient regen energy from the load.

Cause: The drive’s torque current went above the current value programmed in Item 190, OVERTORQUE TRIP LEVEL OtL. The drive can be programmed to torque current limit; contact your Toshiba distributor and request the torque limit application guideline.

Cause: Drive detected some current to ground. Depending on rating, drive senses ground fault via ZCT (hard fault) or HCT (soft fault).

Comments: With leads disconnected from drive, meg motor and leads. Look for any moisture that may provide current path to ground. Make sure that control wiring is separated from power wiring. Adding noise supressors on coils of starters on same line as drive may snub noise picked up by ZCT. RF/EMI filter may help remove noise generated by SCR rectifiers in the vicinity. Make sure drive chassis and motor are grounded.

Cause: Motor’s physical characteristics are not within the window of allowable values for modeling.

Comments: Try a different inertia setting in Item 353, LOAD MOMENT OF INERTIA Mt.iH. Motor must be at rest to perform auto-tuning. Motor must be one HP size within the drive’s HP size. Auto-tuning is best done with motor at full-load temperature (if temperature is very cold, auto-tune error may appear).

Comments: Replace control board.

Comments: Occurs when drive is stopped but CPU detects current flowing. This fault could be caused by plugging in RS232 cable with drive powered (resulting in damage to control board). Adding a RF/EMI filter may remove noise spikes from nearby SCR rectifiers. If the control board is damaged, the drive must be serviced.

Cause: Control board is not configured to drive’s rating.

Comments: Enter option “7” into Item 310, STANDARD SETTING MODE SELECTION TYP.

Cause: Damper function is selected (one input terminal is assigned to 56 and one output terminal is assigned to 64). Every time a run command is issued, the output terminal will output a signal to open damper. Then waiting for the damper open full signal from the input terminal. After getting the damper open full signal from the input terminal, the motor will start to run. If the damper is closed while the motor is running, go damper trip.

Comments: Check the input damper status signal.

Cause: L R IS = 3 and IV input voltage is less than 1 volt.

Comments: Check IV input voltage.

Cause: The drive’s DC bus voltage went below approximately 413 VDC (460 volt drive), for at least the time entered in Item 184, UNDERVOLTAGE DETECT TIME UPc.

Comments: Item 164, UNDERVOLTAGE TRIP SELECTION turns the ability to undervoltage trip on/off.

Control Power low warning voltage levels are sensed on DC bus and are set slightly less than DC BUS UNDERVOLTAGE nOFF levels.

A flashing overcurrent display means that the drive is outputting more than 110% of its rated current. If Item 14, OVERLOAD SELECTION OLn is set to “1” or “3” (soft stall on), the drive’s output frequency will automatically decrease in an effort to reduce current. See suggestions for remedying an inverter overload trip on page 11-4. Setting one of the monitor’s functions (Items 319-322) to “10” will give an indication of how close a drive is to tripping.

A flashing overcurrent display means that the drive is stalling. (Stall level is set by Item 13, STALL PROTECTION CURRENT LEVEL SEL 1). The drive’s output frequency will automatically decrease.

A flashing overvoltage display means that the drive’s DC bus has exceeded 720 VDC (460 volt drive).

A flashing overheat display means that the drive’s heat sink temperature has exceeded 84°C. Display dissappears when heatsink temperature reaches 80°C.

A flashing comm display means that the drive has momentarily lost communications. Display will clear when follower receives valid reference. Cycling power or reinitializing drive will clear warning.

The eleven input terminals correspond to the following bits.

‘A’ group (input terminals 1 to 5)

Always : (OFF)

Input terminal 5 (S4): when ON, when OFF (upper half blank)

Input terminal 4 (S3): when ON, when OFF (upper half blank)

Input terminal 3 (S2): when ON, when OFF (upper half blank)

Input terminal 2 (S1): when ON, when OFF (upper half blank)

Input terminal 1 (R): when ON, when OFF (upper half blank)

‘B’ group (input terminals 6 to 11)

Input terminal 10 (S7): when ON, when OFF (upper half blank)

Input terminal 10 (S6): when ON, when OFF (upper half blank)

Input terminal 9 (S5): when ON, when OFF (upper half blank)

Input terminal 8 (ST): when ON, when OFF (upper half blank)

Input terminal 7 (RES): when ON, when OFF (upper half blank)

Input terminal 6 (F): when ON, when OFF (upper half blank)

Output terminal information (Including status display of colling fan and main contactor for initial charging circuit)

The four output terminals correspond to the following bits. The operating status of the cooling fan and main contactor for the initial charging circuit are also displayed.

Cooling fan ON/OFF status

Main contactor for initial charging circuit status

Output terminal 4 (OUT): when ON, when OFF (upper half blank)

Output terminal 3 (FL): when ON, when OFF (upper half blank)

Output terminal 2 (LOW): when ON, when OFF (upper half blank)

Output terminal 1 (RCH): when ON, when OFF (upper half blank)

Note: Output terminal 4 (OUT): Option PCB

When GROUP: PARAMETERS CHANGED FROM FACTORY DEFAULT (Gr.U) is displayed and READ/WRITE is pressed, the drive will flash Gr.U and display any parameters that have been changed to a value different from the Toshiba factory set defaults. Press READ/WRITE to see the value of the parameter. The parameter can be modified with the up/down arrows. Pressing READ/WRITE again resumes the drive’s search.