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Toshiba GX7R ASD Quick Start Manual

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September, 2014
GX7R ASD
Quick Start Guide

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Summary of Contents for Toshiba GX7R ASD

  • Page 1 September, 2014 GX7R ASD Quick Start Guide...
  • Page 2 GX7R ASD Quick Start Guide DN: 68986-002 September, 2014...
  • Page 3 This feature, combined with Toshiba’s high-performance software, delivers unparalleled motor control and reliability. To maximize the abilities of your GX7R ASD, a working familiarity with this guide will be required. This guide has been prepared for the GX7R ASD installer, user, and maintenance personnel. This guide may also be used as a reference guide or for training.
  • Page 4 The sales contract contains the entire obligation of Toshiba International Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation and any statements contained herein do not create new warranties or modify the existing warranty.
  • Page 5 Dimensions shown in the guide are in imperial units and/or the metric equivalent. Connection drawings within this document convey the typical connectivity of the GX7R ASD system and do not include every possible connection variation. See the drawings received with the system for typeform- and application-specific applicables.
  • Page 6 TOSHIBA INTERNATIONAL CORPORATION GX7R Active Front End Adjustable Speed Drive Please complete the Warranty Card supplied with the GX7R ASD and return it to Toshiba International Corporation by prepaid mail. This will activate the 12-month warranty from the date of installation; but, shall not exceed 18 months from the shipping date.

  • Page 7: Table Of Contents

    Motoring Control Board....................21 CNU1 Pinout........................22 CN7 Pinout........................22 CN8 Pinout........................23 I/O Circuit Configurations .....................24 Regeneration Control Board/Terminal Board..............25 Pre-Startup and Test.......................27 Save User Settings ......................27 Typical Connection Diagram ....................28 GX7R ASD EOI and Front Panel Features .................29 GX7R ASD Quick Start Guide...
  • Page 8 Alarms and Trips ......................56 User Notification Codes ....................57 Alarms ..........................58 Trips/Faults ........................60 Viewing Trip Information ....................64 Clearing a Trip .......................65 Part Numbering Convention ....................66 Ordering Information ......................66 Enclosure Weight/Dimensions ....................67 Voltage/Current Specifications .....................70 Cable/Terminal Specifications ....................71 GX7R ASD Quick Start Guide...

  • Page 9: General Safety Information

    The word CAUTION without the safety alert symbol indicates a potentially hazardous situation exists that, if CAUTION not avoided or if instructions are not followed precisely, may result in equipment and property damage. GX7R ASD Quick Start Guide...

  • Page 10: Special Symbols

    Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety practices. For further information on workplace safety, visit www.osha.gov. GX7R ASD Quick Start Guide...

  • Page 11: Equipment Inspection

    Store in a well-ventilated location and preferably in the original packaging if the equipment will not be used upon receipt. • The storage temperature range of the GX7R ASD is -14° to 104° F (-10° to 40° C). • Store in an upright position.

  • Page 12: Installation Precautions

    • The ambient operating temperature range of the GX7R ASD is 14° to 104° F (-10° to 40° C). Note: Derate the applicable rating by one percent for each degree Celsius above the rated thermal operating capacity.

  • Page 13: Conductor Routing And Grounding Precautions

    300.20 and Article 310.4). National and local electrical codes shall be referenced if three or more power conductors are run in the same conduit (refer to the NEC Article 310 adjustment factors). Note: National and local codes shall be referenced when running more than three conductors in the same conduit. GX7R ASD Quick Start Guide...

  • Page 14: Protection

    Ensure that the phase sequence connection for the device is C-B-A. • Ensure the correct direction of motor rotation in the Bypass mode (if applicable). • The GX7R ASD is designed to operate on utility power ONLY. • DO NOT CONNECT THE GX7R ASD 3-PHASE INPUT TO A GENERATOR. Protection •...

  • Page 15: System Integration Precautions

    A detailed system analysis and job safety analysis shall be performed by the systems designer and/ or systems integrator before the installation of the ASD component. Contact the Toshiba Customer Support Center for options availability and for application-specific system integration information if required.

  • Page 16: System Setup Requirements

    When using an ASD output disconnect, the ASD and the motor must be stopped before the disconnect is either opened or closed. Closing the output disconnect while the 3-phase output of the ASD is active may result in equipment damage or injury to personnel. GX7R ASD Quick Start Guide...

  • Page 17: Operational And Maintenance Precautions

    Turn the power on only after attaching (or closing) the front cover. DO NOT open or remove the front cover or any of the enclosure panels of the ASD when the power is on. • DO NOT attempt to disassemble, modify, or repair the ASD. Contact the Toshiba Customer Support Center for repair information.

  • Page 18: Installation And Connections

    Installation and Connections The GX7R ASD may be set up initially by performing a few simple configuration settings. To operate properly, the ASD must be connected to a power source. Connect the 3-phase AC input lines, C-B-A, to the PB1 terminal block terminals A, B, and C, respectively.

  • Page 19: Installing The Asd

    The ASD input voltage should remain within 10% of the specified input voltage. The frequency of the input power should be ±2 Hz of the specified input frequency. The ASD is designed to operate NEMA B motors. Consult with the Toshiba Customer Support Center before using the ASD for special applications such as with an explosion-proof motor or applications with a piston load.

  • Page 20: Connecting The Asd

    The Fuse Open Indicator LED provides an indication that the bus fuse is open and the bus voltage is present (when on). Caution: LED indicators are not to be used for troubleshooting. Figure 1. Typical GX7R ASD Gate Driver PCB. harge ndicator LED Buss Fuse Open +5, +15, -15, &...
  • Page 21 In the event that the motor rotates in the wrong direction when powered up, reverse any two of the three ASD output power leads (U, V, or W) connected to the motor. Figure 2. The GX7R ASD/Motor Typical Connection Diagram. GX7R ASD Quick Start Guide...
  • Page 22 Figure 3. The GX7R ASD Auxiliary Enclosures. Note: 100 HP ASD shown as an example of the GX7R ASD auxiliary enclosures. Auxiliary enclosure specifics are typeform- specific. See the accompanying drawings received with the ASD system. GX7R ASD Quick Start Guide...

  • Page 23: System Grounding

    > 5 kHz 300 ft. 100 ft. Note: Contact Toshiba for application assistance when using lead lengths in excess of those listed. Exceeding the peak voltage rating or the allowable thermal rise time of the motor insulation will reduce the life expectancy of the motor.

  • Page 24: I/O And Control

    I/O and Control The GX7R ASD can be controlled by several input types and combinations thereof, as well as operate within a wide range of output frequency and voltage levels. This section discusses the ASD control methods and supported I/O functions.

  • Page 25: Terminal Board Descriptions

    The ST terminal is activated by connecting CC to this terminal (Sink mode). When deactivated, OFF is displayed on the LCD screen. This input terminal may be programmed to any of the functions listed in the GX7R ASD Install and Op Manual (see F113).
  • Page 26 This output terminal may be programmed to provide an indication that any of the functions listed in the GX7R ASD Install and Op Manual is active or has taken place. This function may be used to signal external equipment or to activate a brake. The OUT2 terminal is rated at 2 A/250 VAC and 2 A/30 VDC (see F131).
  • Page 27 GX7R ASD Install and Op Manual. For further information on this terminal, see F670. FM — This output terminal produces an output current that is proportional to the output frequency of the ASD or of the magnitude of the function assigned to this terminal. The available assignments for this output terminal are listed in the GX7R ASD Install and Op Manual.
  • Page 28 Figure 5. GX7R ASD Terminal Board. CN7A SW1 and SW2 may be switched to change the full-scale range of the AM and FM output terminals, respectively. See F670 and F005 for more information on the FM and AM terminal W1 Terminal 0–1 mA...

  • Page 29: Gx7R Asd Control

    GX7R ASD Control Motoring Control Board The Motoring Control Board (P/N 56000) serves as the primary control source for the GX7R ASD and receives input from the Motoring Terminal Board (see Figure 5. on pg 20), the Voltage Sensor Board, an Option Card, RS232/RS485 Communications, or the EOI.

  • Page 30: Cnu1 Pinout

    26). CN7 connects to CN7A of the Terminal Board. Table 4. CN7 pinout assignments — Default settings listed for the programmable terminals. Pin Number Pin Number Pinout Pinout OUT1 OUT2 — — Note: * Open collector output. GX7R ASD Quick Start Guide...

  • Page 31: Cn8 Pinout

    CN8 Pinout Listed below are the pinouts of the CN8 connector of the Motoring Control Board. The CN8 connector of the Motoring Control Board is not used with the GX7R ASD. Table 5. Pin Number CNU8 Pinout — GX7R ASD Quick Start Guide...

  • Page 32: I/O Circuit Configurations

    Figure 8. RR Input. Figure 9. RX Input. Figure 10. VI/II Input. Figure 11. P24 Output. Figure 12. PP Output. Figure 13. OUT1/OUT2 Output. Figure 14. FP Output. Figure 15. AM/FM Output. Figure 16. Fault Relay (during fault). GX7R ASD Quick Start Guide...

  • Page 33: Regeneration Control Board/Terminal Board

    Regeneration Control Board/Terminal Board The Regeneration Control Board (P/N 64625A) serves as the control source for the GX7R ASD during regeneration. Regeneration is activated during a bus overvoltage condition, as determined by the Voltage Sensor board. The Reset button (SW4) resets a faulted ASD and is effective when faulted only.
  • Page 34 Figure 17. GX7R ASD Control Board for Regeneration. ASD Reset (SW4). To Gate Driver Board (CN2). Power for Voltage Sense (CN8). Voltage Battery/Batt Sensor Jumper Board I/O (Vbat1/ (CN4). JP3). Connector RS232/ RS485 signal I/O (CNU1). Discrete Input Sink/ SW1/SW2.

  • Page 35: Pre-Startup And Test

    Table 7. ASD Parameter Changes by Installer/Maintenance Personnel. ASD ID__________Name:______________________Date:________ Default or Notes Parameter Unit of Parameter Name Previous New Setting Number Measure Setting Note: Settings may also be recorded via Program  Utilities  Type Reset  Save User Parameters. GX7R ASD Quick Start Guide...

  • Page 36: Typical Connection Diagram

    Typical Connection Diagram Figure 18. GX7R ASD Typical Connection Diagram. Note: When connecting multiple wires to a terminal, do not connect a solid wire and a stranded wire to the same terminal. Note: The VI, RX, and RR analog input terminals are referenced to CC.

  • Page 37: Gx7R Asd Eoi And Front Panel Features

    EOI of the ASD remotely. The EOI can be mounted remotely from the ASD as described in the GX7R ASD Install and Op Manual. The dimensional requirements for remote mounting may also be found in this section. Using a screw length that exceeds the specified dimensions may cause deformation of the outer surface of the bezel and should be avoided.

  • Page 38: Eoi Operation

    Up, Down, and Enter key functions. The software used with the GX7R ASD is menu driven; thus, making it a select and click environment. The operating parameters of a motor may be selected and viewed or changed using the EOI.

  • Page 39: Front Panel Features

    On during an overvoltage, overcurrent, MS1 contactor fail, or PWM short circuit condition. On during an active regeneration fault. ASD Run — On when ASD is running. ASD Fault — On when ASD is faulted. GX7R ASD Quick Start Guide...

  • Page 40: System Operation

    GX7R ASD. The GX7R ASD may also be setup by directly accessing each of the individual parameters (see the GX7R ASD Install and Op Manual). See the section titled Default Setting Changes on pg.

  • Page 41: Operation (Local)

    Direct Access menu field (Program  Direct Access  applicable parameter number). A listing of the Direct Access/Parameter Numbers and a description of the associated parameter may be found in the GX7R ASD Install and Op Manual. A listing of all parameters that have been changed from the factory default setting may be viewed sequentially by accessing the Changed From Default screen (Program ...
  • Page 42 Pressing ESC while the system is performing a Changed From Default search terminates the search. Pressing ESC when done searching (or halted at a changed parameter) returns the system to the Program Menu. Figure 21. Changed From Default screen. GX7R ASD Quick Start Guide...

  • Page 43: System Configuration And Menu Options

    System Configuration and Menu Options Root Menus The Mode key accesses the three primary screens of the GX7R ASD: the Frequency Command screen, Monitor screen, and the Program screen. From either screen, press the Mode key to loop through to...
  • Page 44 Accel/Decel profiles is comprised of three user settings: Acceleration, Deceleration, and Pattern. Expanded descriptions of these parameters may be found in the GX7R ASD Install and Op Manual. Feedback in Panel Mode — This feature enables or disables the PID feedback function.

  • Page 45: Monitor Screen

    Monitor Screen Monitor Screen Monitor The Monitor mode allows the user to monitor GX7R ASD/motor performance variables, ASD control settings, and configuration data during motor operation. The monitored parameters are listed and described below. Note: The Monitor mode is a read-only mode. The settings cannot be changed from the Monitor mode.
  • Page 46 Pattern Select — Active Group Number and Speed Number separated by a period (e.g., 2.3). Repeats Left — Number of remaining Speed cycles in the active Group. Pattern — Active Speed Number of the Group. Pattern Time Left — Time remaining in the active Speed. GX7R ASD Quick Start Guide...
  • Page 47 Seconds Between Switch user setting of the Scrolling Monitor screen. If no items are selected, No Items is displayed at the Frequency Command screen. The selected items, along with their real-time values, are displayed (and/or scrolled) on the Frequency Command screen while running. GX7R ASD Quick Start Guide...

  • Page 48: Program Screen Menu Navigation

    53.) TARTUP IZARD HANGED (See the section titled Default Setting Changes on pg. 33.) EFAULT the GX7R ASD Install and Op Manual (See the section titled IRECT CCESS Darker (highlight Darker and press Enter) EOI O PTION ETUPS Contrast (adjustment)
  • Page 49 Auto Setup for 60 Hz Restore Factory Defaults Clear Trip Clear Run Timer Type Reset F007 New Base Drive Board Save User Parameters Restore User Parameters Reload EOI Flash (keypad) Reset EOI Memory (keypad) Comm. Stops During Reset GX7R ASD Quick Start Guide...
  • Page 50 FP Terminal Meter Adjustment F677 ST Signal Selection F103 F/R Priority Selection (w/both on) F105 Input Special Functions Input Terminal Priority (check box) F106 Extended Terminal Function F107 Line Power Switching (Commercial Power Switching) On Trip F354 GX7R ASD Quick Start Guide...
  • Page 51 Jog Run Frequency F260 Jog Settings Jog Stop Control F261 Jog Window (check box) #1 Frequency & Characteristics F018 #2 Frequency & Characteristics F019 Preset Speeds #3 Frequency & Characteristics F020 #4 Frequency & Characteristics F021 GX7R ASD Quick Start Guide...
  • Page 52 F604 Emergency Off Settings Emergency Off Activation of the FL Output (check box) Number of Retries F303 Restart Conditions (check box) F301 Scan Rate F312 Retry/Restart Lock-on Rate F313 Search Method F314 Search Inertia F315 GX7R ASD Quick Start Guide...
  • Page 53 Supply Voltage Compensation (check box) Base Frequency Voltage F307 Output Voltage Limitation (check box) Suppression of Inrush-Current Timing F608 Soft Start Interlock with ST (check box) F609 VI/II F205 ORQUE ETTING F214 Setpoints F220 F226 F232 GX7R ASD Quick Start Guide...
  • Page 54 F368 PG Disconnection Detection Selection F369 Electronic Gear Setting F370 PG Settings Position Loop Gain F371 Positioning Completion Range F372 Frequency Limit at Position F373 Current Control Proportional Gain F374 Current Control Integral Gain F375 GX7R ASD Quick Start Guide...
  • Page 55 #13 Frequency & Characteristics F292 #14 Frequency & Characteristics F293 #15 Frequency & Characteristics F294 Preset Speed Mode Use Preset Speed F380 ASD Number F802 OMMUNICATION Communication Settings Logic (TTL) Baud Rate F800 RS232/RS485 Baud Rate F820 GX7R ASD Quick Start Guide...
  • Page 56 (not used) #4 Scan Transmit F844 #5 Scan Transmit F845 #6 Scan Transmit F846 Communication Error Command Request Disposition on Error F830 (not used) Optional Parameter #1 F890 Optional Parameters (not used) Optional Parameter #2 F891 GX7R ASD Quick Start Guide...
  • Page 57 Motor Set #3 #3 Torque Boost F176 #3 Electronic Thermal Protection Level F177 #4 Base Frequency F178 #4 Max Output Voltage F179 Motor Set #4 #4 Torque Boost F180 #4 Electronic Thermal Protection Level F181 GX7R ASD Quick Start Guide...
  • Page 58 Crane/Hoist Load Switching Load Torque During Forward Run F335 Heavy-Load Torque During Forward F336 Acceleration Heavy-Load Torque During Fixed Speed F337 Forward Run Switching Load Torque During Reverse Run F338 Heavy-Load Torque During Reverse F339 Acceleration GX7R ASD Quick Start Guide...
  • Page 59 Compensation Coefficient for Iron Loss F487 Special Parameters Voltage Compensation Coefficient for Dead Time Dead Time Compensation F489 Dead Time Compensation Bias F489 Switching Frequency Between Current and F491 Voltage Optional Analog Terminal Mark Current Differential Gain F454 GX7R ASD Quick Start Guide...
  • Page 60 Sub Menu Parameter Name Number Exciting Strengthening Coefficient F480 PECIAL ONTROL User Parameter Initialization During Typeform F709 Initialization Enable/Disable Special Parameters % Current Vector Control F482 % Voltage Vector Control F483 % Constant Vector Control F484 GX7R ASD Quick Start Guide...

  • Page 61: Startup Wizard Requirements

    ASD control settings and system operational specifications. The GX7R ASD may also be setup by directly accessing each of the settings via the Program menu or the Direct Access Number for each item (see the GX7R ASD Install and Op Manual for specifics on each parameter).
  • Page 62 This parameter allows the user to input the full-load amperage (FLA) of the motor. This value is used by the GX7R ASD to determine the motor overload protection setting for the motor. The value is found on the nameplate of the motor.
  • Page 63 11 — Pulse Input (option) 9. Wizard Finished! This screen is the final screen of the Startup Wizard. The basic parameters of the GX7R ASD have been set. Click Exit to load the Startup Wizard input and to return to the Frequency Command screen.

  • Page 64: Alarms, Trips, And Troubleshooting

    The operating conditions at the time of the trip may be used to help determine the cause of the trip. Listed below are operating conditions that may be used to assist the operator in correcting the problem or that the ASD operator should be prepared to discuss when contacting the Toshiba Customer Support Center assistance.

  • Page 65: User Notification Codes

    User Notification codes notify the user of active functions that are typically only momentary under normal conditions and are active for the duration of activation only. User notification events are not error conditions and only convey active system functions to the user. Table 9. GX7R ASD User Notification Codes. EOI Display Function Description Atn indicates that the Autotune function is active.

  • Page 66: Alarms

    Alarms Table 10 lists the alarm codes that may be displayed during operation of the GX7R ASD. Each alarm code listed is accompanied by a description and a possible cause. In the event that the source of the malfunction cannot be determined, contact your the Toshiba...
  • Page 67 (increase the difference). each other. Undercurrent Output current of the ASD is • Adjust F611 and F612 to match the application. below the level defined at F611 and remains there for the time set at F612. GX7R ASD Quick Start Guide...

  • Page 68: Trips/Faults

    Faults that may cause a Trip and the possible causes. When a Trip is incurred the system displays the Fault screen. The Fault screen identifies the active Fault. Table 11. GX7R ASD Faults. Fault Screen Display Possible Causes...
  • Page 69 • Load requirement exceeds ability of the motor. • Startup frequency setting adjustment required. No Fault • No active faults. Option Fault • Optional device malfunction. • Improper system settings (at ASD or optional device). • Loose or improper connection. GX7R ASD Quick Start Guide...
  • Page 70 • A torque requirement by the load in excess of the setting of F616 or F617 for a time longer than the setting of F618. • The ASD is improperly matched to the application. • The load is obstructed. GX7R ASD Quick Start Guide...
  • Page 71 • Low impedance at the U lead of the ASD output. V Phase Short Circuit • Low impedance at the V lead of the ASD output. W Phase Short Circuit • Low impedance at the W lead of the ASD output. GX7R ASD Quick Start Guide...

  • Page 72: Viewing Trip Information

    At-trip Recorded Parameters (parameter readings at the time that the trip occurred). Table 12. GX7R ASD Trip History Record Parameters (RTC option required). At-trip Recorded Parameters Trip records that are assigned zero and one are comprised of the full list of monitored parameters (32).

  • Page 73: Clearing A Trip

    • Remotely via the communications channel, • Momentarily connecting terminal RES to CC of the Control Terminal Strip, or • Via Program  Utility Parameters  Type Reset  Clear Trip (clears Trip Monitor From ASD). GX7R ASD Quick Start Guide...

  • Page 74: Part Numbering Convention

    Part Numbering Convention The GX7R ASD is a configurable large-horsepower ASD. The GX7R ASD may be ordered in several different configurations. The typical cabinet configurations will include multiple modules. The modules may be single-phase or three-phase. The part numbering scheme for a given configuration is defined in the following section.

  • Page 75: Enclosure Weight/Dimensions

    Refer to the drawing on pg. 68 for the referenced enclosure figure. Note: All Toshiba ASD enclosures carry at least an IP20 rating — NEMA 1 listed. Table 14. GX7R NEMA 3-R Enclosure Dimensions and Weights Model Number Shipping Weight...
  • Page 76 Figure 23. 480-Volt 30 – 100 HP GX7R ASD. GX7R ASD Quick Start Guide...
  • Page 77 Figure 24. 480-Volt 125 – 150 HP GX7R ASD. GX7R ASD Quick Start Guide...

  • Page 78: Voltage/Current Specifications

    ±2% Frequency 150% 60 Secs. 60.0 78.0 97.5 115.5 480 VAC 0 – 80 Hz (±10%) Note: Derate the applicable rating by one percent for each degree Celsius above the rated thermal operating capacity. GX7R ASD Installation and Operation Manual...

  • Page 79: Cable/Terminal Specifications

    Cable/Terminal specifications are based on the rated current of the ASD and Do Not include the 10% Service Factor. Because the GX7R ASD may be commissioned within a wide range of environments and applications, consider the application with each installation.
  • Page 80 Changed From Default screen, 34 Dynamic Braking Resistor Overload, 61 Changes by Installer, 27 Charge Indicator LED, 9 Clearing a Trip, 65 CM1, 58 CM2, 58 Earth Fault, 61 CN3 Pinout, 23, 25 EEPROM Data Fault, 61 GX7R ASD Quick Start Guide...
  • Page 81 Front End Active Light, 31 Local Remote Key, 40 Front End Fault Light, 31 Local|Remote Key, 29 Front Panel Features, 31 Lockout, 41 Fundamentals, 40 Low Current, 45, 61 Fwd/Rev Disable, 44 Lower Limit Frequency, 53 GX7R ASD Quick Start Guide...
  • Page 82 OUT1 OUT2 FL, 37 Protection Parameters, 44, 45 OUT2, 16, 18 PtSt, 59 Output Current Protection Fault, 62 Output Disconnect, 8 Output Phase Loss, 62 Output Terminal Delays, 43 Output Terminal Functions, 42 Qualified Personnel, 2 GX7R ASD Quick Start Guide...
  • Page 83 Soft Stall Enable, 45 Soft Start, 45 Special Control, 50 Special Parameters, 51, 52 Special Symbols, 2 U Phase Short Circuit, 63 Speed Ref. Setpoint, 43 UC, 59 Speeds, 47 Undervoltage/Ridethrough, 45 ST, 16 Up Key, 29 GX7R ASD Quick Start Guide...
  • Page 84 Volts per Hertz Setting, 54 V Phase Short Circuit, 63 V/f Adjustment, 51 V/f Five Point Setting, 51 W Phase Short Circuit, 63 Vector Motor Model, 49 Warranty Card, 2 Versions, 41 Wizard Finish, 55 GX7R ASD Quick Start Guide...
  • Page 85 TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road, Houston, TX 77041-5807 US (800) 231-1412 CAN (800) 872-2192 MEX 01 (800) 527-1204 FAX: (713) 466-8773 http://www.toshiba.com/ind/ Printed in the U.S.A.

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