TOSHIBA P3 412K (01) PDF Document

Upon receipt, inspect the drive for shipping damage. After uncrating:

1) Check the unit for loose, broken, bent or otherwise damaged parts due to shipping.

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

1) Store in a well ventilated location and preferably in the original carton if the inverter will not be used immediately after purchase.

2) Avoid storage in locations with extreme temperatures, high humidity, dust, or metal particles.

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.

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.

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.

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

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

4) Make sure there are no short circuits or inadvertent grounds and tighten any loose connector terminal screws.

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)).

The table below lists the recommended specifications for the TOSHIBA P3 412K:

* A disconnect means must be provided in the motor branch circuit which supplies power to the drive. It can be separate for use with fuses or it can be an integral part of a 3-pole circuit breaker (see 1999 NEC Article 430-103 through 430-113). All drives in this series are rated for output short circuit fault currents of 200,000A. The selection of MCCB (molded case circuit breaker) for this table is in accordance with 1999 NEC Article 430-2, 430-51, 430-52, 430-152, and 240-6.

** Wire sizing is based upon NEC table 310-16 or CEC Table 2 using 75 deg C cable, an ambient of 30 deg C, cable runs for less than 300 FT., and copper wiring for not more than three conductors in raceway or cable or earth (directly buried). The customer should consult the NEC or CEC wire Tables for his own particular application and wire sizing.

*** Use two parallel conductors instead of a single conductor (this will allow for the proper wire bending radius within the cabinet). Use separate conduits for routing parallel conductors. This prevents the need for conductor derating (see note 3 this page).

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.

The inverter must be grounded in accordance with Article 250 of the National Electrical Code or Section 10 of the Canadian Electrical Code, Part I and the grounding conductor should be sized in accordance with 1999 NEC Table 250-122 or CEC, Part I Table 16. See Installation Safety Precautions notes 7 and 14.

Conduit is not a suitable ground for the inverter.

For the TOSHIBA P3 412K drive operating at 460 V with a PWM Carrier Frequency greater than or equal to 5 kHz, the suggested maximum output lead distance is 200 ft.

Motors operating from adjustable speed drive power sources tend to operate at higher temperatures which may increase the need for more frequent lubrication cycles.

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

Jumper JP3 can be set to 0-1 mA or 4-20 mA.

Jumper JP4 can be set to 0-1 mA or 4-20 mA.

The terminals L1, L2, L3 are the Line input supply terminals for models P3-4S00 to P3-440K. Connect to either 3φ, 50HZ, 400VAC or 3φ, 60Hz, 400 to 460VAC. Drives can be operated on single phase power when appropriately derated; contact Toshiba distributor for information.

The terminals T1, T2, T3 (U, V, W) are the Motor output terminals. Connect these terminals to a 3-phase induction motor of the proper voltage, current, and horsepower.

The terminals PA, PB (optional) are the Braking resistor output terminals. Connect to an external dynamic braking resistor (DBR).

The terminals FLA, FLB, FLC are Programmable relay contact output. The contact rating is 250VAC – 2A. Default setting closes FLA-FLC and opens FLB-FLC when protective function has been activated.

The terminal P24 is an Unregulated 24Vdc power supply (24Vdc, 50mA maximum). P24 is protected by fused resistor found on the terminal board (see p. 5-1).

The terminals RCH(A & C) are Programmable relay contact output. Standard setting closes contact when an acc/dec is complete, or when the output frequency is within a specified range. Contact rating is 250Vac – 2A.

The terminals LOW(A & C) are Programmable relay contact output. Standard setting closes contact when a preset low speed or a preset lower limit is reached. Contact rating is 250Vac – 2A.

The terminal PP is a 10 VDC supply typically used to drive potentiometers. Wipers from pots typically connected to “RR” or “RX” terminals.

The terminal FM is a Programmable analog output. Outputs 0 – 1 mA current. This terminal can be connected to an external analog meter. Use either an ammeter rated 1 mA DC/20 mA DC at full scale or a voltmeter rated 7.5Vdc at full scale (true analog output). See page 9-31 for programming.

The terminal AM is a Programmable analog output. Outputs 0 – 1 mA current. This terminal can be connected to an external analog meter. Use either an ammeter rated 1 mA DC/20 mA DC at full scale or a voltmeter rated 7.5Vdc at full scale (true analog output). See page 9-31 for programming.

The terminal FP is a Dedicated open-collector output. Pulses that are 48, 96, or 360-times the output frequency are available according to the parameter settings (must connect external supply through pull-up resistor to measure output).

The terminals CC (2-terminals) are the common return for all of the input and output terminals. Do not connect this terminal to ground.

The terminal RR is a Programmable analog input. Default setting allows user to input a 0 – 10VDC signal as a frequency command. Input has bias/gain adjustments.

The terminal IV is a Programmable analog input. User can input a 0 – 10VDC signal or a 4 – 20 mA DC signal as a frequency command (selection of current or voltage done via dipswitch on control board (see page 5-2). Input has bias gain adjustments.

The terminal RX is a Programmable analog input. User can input a +/- 10VDC or a +/- 5VDC signal as a frequency command (see page 5-2). Input has bias/gain adjustments for forward and reverse operation.

The terminal ST is a Programmable digital input. With default setting, shorting terminal to “CC” enables drive. Opening “ST” to “CC” coasts motor.

The terminal F is a Programmable digital input. With default setting, shorting terminal to “CC” gives drive forward run command. Opening “F” to “CC” decels motor to a stop.

The terminal R is a Programmable digital input. With default setting, shorting terminal to “CC” gives drive reverse run command. Opening “R” to “CC” decels motor to a stop.

The terminal S1 is a Programmable digital input. With default setting, shorting “S1” to “CC” enables fire speed run.

The terminal S2 is a Programmable digital input. With default setting, shorting “S2” to “CC” disables feedback control.

The terminal S3 is a Programmable digital input. With default setting, shorting “S3” to “CC” gives drive preset speed frequency reference.

The terminal S4 is a Programmable digital input. With default setting, shorting “S4” to “CC” gives no emergency off command.

The terminal RES is a Programmable digital input. With default setting, shorting “RES” to “CC” resets a tripped drive.

R41/46: Input power selection. Shorting to “RJ” selects 415/460V-50/60Hz.

R40/44: Input power selection. Shorting to “RJ” selects 400/440V-50/60Hz.

R38: Input power selection. Shorting to “RJ” selects 380V-50Hz.

RJ: This is the common return for input power selection terminals R41/46, R40/44, R38. Use only one selection at a time. Do not connect to CC.

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.

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.Rn 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 EcJP error.)

When the EcJP 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.

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 “dRnp”. 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)

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 (Acc1) . 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.

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 It0 = 1 and Input terminal 2 It2 = 2 prior to performing the following programming.

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

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.

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.

See Items 172, RETRY SELECTION r try and Item 173, RETRY TIME SETTING r t to program drive to automatically attempt to reset faults. Drive will display r try “flashing” during retries. See page 9-14 for a list of faults to retry. Retry will not function if Item 172, r try is set to “1” (on).

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 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 OPe (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 OPe. Use stand-ofts 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 UPt.

Comments: Item 184, UNDERVOLTAGE TRIP SELECTION UPSL 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 OCt. 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 Et.yP.

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: LR 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 UPt.

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):

Bit 5: Always (OFF)

Bit 4: Input terminal 5 (S4) : when ON (upper half blank)

Bit 3: Input terminal 4 (S3) : when ON (upper half blank)

Bit 2: Input terminal 3 (S2) : when ON (upper half blank)

Bit 1: Input terminal 2 (S1) : when ON (upper half blank)

Bit 0: Input terminal 1 (R) : when ON (upper half blank)

‘B’ group (input terminals 6 to 11):

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

Bit 9: Input terminal 10 (S6) : when ON (upper half blank)

Bit 8: Input terminal 9 (S5) : when ON (upper half blank)

Bit 7: Input terminal 8 (ST) : when ON (upper half blank)

Bit 6: Input terminal 7 (RES) : when ON (upper half blank)

Bit 5: Input terminal 6 (F) : when ON (upper half blank)

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.

Output terminal information:

Bit 7: Cooling fan ON/OFF status

Bit 6: Main contactor for initial charging circuit status

Bit 4: Output terminal 4 (OUT) : when ON (upper half blank) (Note: Output terminal 4 (OUT): Option PCB)

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

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

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

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.

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.

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.

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).

4) “ST”-“CC” must be made.

5) “S4”-“CC” must be made.

This group contains read/write parameters for the motor connected to the drive:

* Items 345 factory setting depends on inverter rating (1 HP = .746kW).

** Items 349 – 352 are available only when Item 348 Adjustment Range option 2 is selected.