Toshiba VF-A7 instruction manual

Instruction Manual

The new generation

high-performance inverter

TOSVERT VF-A7

NOTICE

1. Make sure that this instruction manual is delivered to the end user of

the inverter unit.

2. Read this manual before installing or operating the inverter u nit, and

store it in a safe place for reference.

200V class 0.4 90kW

400V class 0.75 280kW

Preface

Safety

precautions

Read this

section first

Contents

Operating

the inverter

Connection

Basic

parameters

Basic

Operation

with external

signal

Peripheral

units

Monitoring

operation

status

Specification

Table o

parameters

Regular

inspection

and

maintenance

Prior to

service call

Warranty

Precautions

of disposal

Extended

parameters

Contents

Main Instruction Manual TOSVERT VF-A7 Safety precautions Marking Precautions Danger Warning Handling in general Transportation Installation Wiring Warning even after source power is removed About operation When selecting the retry mode (Applicable to inverters) About inspection and maintenance About disposal of inverters Sticking warning labels Warning Preface Features A-1 1.1 Checking the purchase Make sure that the inverter delivered is exactly what you ordered. Read this section first Warning Mandatory 1.3 Names and functions 1.3.1 Panel description Panel indication Page Page Page Page 1.3.3 Detaching the terminal board front cover 1.4 Notes on the application of inverters 1.4.1 Notes on motors combined with inverters Keep in mind the following notes when using the VF-A7 in combination with a motor. Page 1.4.2 Notes on inverters Over-current protective function Inverter capacity Power factor improving capacitor Use of an inverter at a voltage other than the rated one 1.4.3 Influences of leakage currents and measures against it Measures to be taken: (2) Influences of a current leaking from a cable into other cables 1.4.4 Notes on installation Installation environment Page Installation Installation place Calorific values of inverters and amount of air to be ventilated Control panel designed in consideration of possible influences of noise Notes on the installation of two or more inverters in a single cabinet Heat-sink going out attachment(simple type) 2. Connection 2.1 Cautions as to wiring Prevention of radio noise Notes on wiring B-3 2.2 Standard connection Prohibited 200V class: 0.4 22kW 400V class: 0.75 22kW Motor B-4 200V class: 30 55kW 400V class: 30 75kW B-5 200V class: 75 90kW 400V class: 110 280kW * 2.3 Explanation of terminals 2.3.1 Main circuit terminals IM Connecting a power source and a motor Connecting peripheral devices Fig.3 Fig.1 Fig.2 2.3.2 Control circuit terminals (sink logic(mi nus common)) F RX II VI FM AM OUT2 OUT1 CC Sink logic (minus common)/source logic (plus co mmon) ... Switching I/O terminal Switching logic 2.3.3 Serial RS485 communication connector RXA 4 RXB 5 TXA 3 TXB 6 SG 2,8 3. Operating the inverter Sensor vector control (Optional) Pre-operation check the following check again before starting operation C-3 3.2 Simple operation of the VF-A7 [1] [Speed control mode] Slowdown stop Example of typical connection 3.2.1Operation from the terminal(external signals) Terminal operation Start/Stop Frequency Frequency setting Setting the operation frequency with an exter nal volume control Speed setting mode selection parameter at . Setting the frequency by voltage signals (0 t o 10 V) Speed setting mode selection parameter at . Setting the frequency by voltage signals ( 0 to 10 Vdc) Speed setting mode selection parameter at . Setting the frequency by voltage signals (0 to +/-10Vdc) Speed setting mode selection parameter at Ex.: To set the frequency by current signal (4 to 20 mAdc) through the terminal] 3.2.2 Operation from the control panel Example of control panel operation RUN STOP Selecting a stop mode with the control panel 3. 3 Simple operation of the VF-A7 [2] [Torque control mode] [Operating panel operation] : [Operating panel+terminal operation] : 3.3.1 Setting a control mode [Torque control mode] Page 3.3.2 Polarity of torque command 3.3.3 Operation from the terminal(e xternal signal) [Torque control mode] S t a r t / s t o p Torque command Torque setting by means of voltage signals (0 to 10 Vdc) Set the torque reference selection at 3) Torque setting by means of voltage signals (0~10 Vdc) Set the torque reference selection parameter at Torque setting by means of voltage signals (0~10 Vdc) voltage signals 0-10Vdc Torque setting by means of a volume control 5) Others 3.3.4 Operation from the control panel [Torque control mode] Setting the start and stop modes Selecting a torque command mode Torque command Example of control panel operation 1. Set the torque command. 2 Starts the motor 3. Stops the motor RUN STOP [Normal monitor mode] 4. Basic operation of the VF-A7 4.1.1 How to set basic parameters [Basic parameter] ENT D-3 [Basic parameter list] 4.1.2 How to set extended parameters [Procedure for setting an extended parameter] Example of parameter setting 4.1.3 Searching for changed parameters and changing their settings again Notes on operation Searching for a parameter and changing its setting 4.1.4 Parameters that cannot be changed during operation 4.1.5 Note on operation D-8 Title Function 5.1 Setting the acceleration and deceleration times Set the parameter (automatic acceleration/deceleration) at (enabled). 5. Explanation of the basic parameters 5.1.2 Manually setting the acceleration and deceleration times (Manual setting) 5.2 Increasing starting torque/ energy-saving operation mode Automatic V/f mode setting To automatically increase the torque according to the load condition Set the automatic V/f mode setting at (automatic torque boost + auto-tuning). 2) To operate the inverter in energy-saving mode If you fail to make the setting for vector control ..., Set the motor control mode selection parameter at (constant torque) 5.3 Selecting an operation mode : Operation command mode selection : Speed setting mode selection Function Preset speed operation E-8 1) Setting the start, stop and operation frequencies with the operating panel E-9 RUN STOP r mode selection mode selection 5.4 Setting and calibrating meters selection FM Terminal meter selection FM Terminal meter adjustment AM Terminal meter selection AM Terminal meter adjustment [Terminal FM-related parameters] Title Function Adjustment range Adjustment level Default setting Resolution Calibrating a meter when the inverter is out of operation Page 5.5 Factory default setting Standard setting mode selection [Set value] [ 50 Hz standard setting ( = ) ] [ 60 Hz standard setting ( = ) ] Page 5.6 Forward/reverse run selection (for the panel control only) Forward/reverse selection 5.7 Maximum frequency Maximum frequency 5.8 Upper and lower limit frequencies Upper limit frequency Lower limit frequency 5.9 Base frequency Base frequency #1 5.10 Control mode selection Motor control mode selection 1) Constant torque characteristic (Normal way of use) [Set the motor control mode selection at (Constant torque characteristic)] 2) Setting suitable for fans and pumps [Set the motor control mode selection at (Variable torque mode).] 3) To increase the starting torque [Set the V/F control selection parameter at (Automatic torque boost).] This control mode involves the setting of the motor constant. 4) To increase starting torque and the accuracy of operation - Vector control [Set the V/f control selection parameter at (Sensorless vector control).] 7) To set the V/F characteristic arbitrarily [ 9) Notes on the vector control 5.11 Switching between speed control and torque control Motor control mode selection Input terminal selection #1 to #8 [Torque reference] 5.12 Manual torque boost - Increasing the torque produced at low speeds Manual torque boost [A general-purpose motor (other than motors intended for use with inverters)] Explanation of terms [Example of setting: VF-A7 2007PL with a 0.4 kW motor (rated current: 2A)] [VF motor (motor intended for use with an inverter)] 2) Motor 150%-overload time limit 3) Inverter overload characteristic Inverter's overload protective characteristic 5.14 Preset-speed operation (15 speeds) 3) Use of a preset-speed comman d in combination with another speed command 4) Setting the operation mode 6. Extended parameters 6.1 Frequency signals Ry 6.1.1 Low-speed signal 6.1.2 Putting out signals of arbitrary frequencies 1) If detection frequency band + Speed reach setting frequency < Reference frequency 6.2 Selection of input signals 6.2.1 Changing standby signal function 1) Standard 2) Always-ON 3) Interlocked with terminal F (forward)/R (reverse) 6.2. 3 Assigning pr iority to the terminal board in panel operation mode Priority command from terminal board (Operation command) 6.2.4 Binary/BCD signal selection(Expansion TB option unit) Binary/BCD signal selection(Expansion TB option unit) 6.3 Selection of terminal functions 6.3.1 Keeping an input terminal function always active (ON) 6.3.2 Changing input terminal functions 6.3.3 Signal on completion of acceleration/deceleration (OUT 2) Page 6.4 Basic parameters #2 6.4.1 6.5 V/f 5-point setting 6.6 Speed/torque command gain and bias 6.6.1 Using two types of frequency (speed) commands Frequency reference 6.6.2 Setting frequency command characteristics 6.6.3 Setting torque reference characteristics 6.7 Operation frequency 6.7.1 Start-up frequency and End frequency 0Hz dead band frequency Start-up frequency Stop frequency 6.7.2 Operating by means of reference signals 6.8 DC injection braking 6.8.1 DC injection braking F-16 [D.C. braking under normal conditions] (Forward/reverse DC braking priority control =[OFF]) 6.8.2 Motor shaft fixing control Motor shaft fixing control 6.8.3 Zero-speed stop mode selection Zero-speed stop mode selection 6.9 Jog run Jog run frequency Jog stop control 6.10 Jump frequency 6.11 Preset-speed #8 15 Preset-speed #8 #15 6.12 PWM carrier frequency PWM carrier frequency 6.13 Trip-less enhancement 6.13.1 Auto-restart (restart during free-run (coast)) Warning Step 1: Set the control method of Auto-restart 1) Restart after a momentary power failure 2) Restart of coasting motor (Motor speed search function) Step 2: Set the mode of Auto-restart Caution! Step 3: Set the property of Auto-restart 1) Case = / 6.13.2 Regenerative power ride-through control / Deceleration stop Deceleration stop Ride-through time Deceleration time 6.13.3 Retry function Retry selection 6.13.4 Dynamic (regenerative) braking - To urgently stop the motor 1) An internal braking resistor (for 3.7kW model and smaller) 2) An external braking resistor (optional) Page F-28 3) Selection of braking resistor option and braking unit Type 4) Connectable braking resistors and their minimum resistances 6.13.5 Avoiding over-voltage trip 6.13.6 Adjusting the output voltage and voltage compensation F-30 = ] [ 6.13.7 Prohibiting the reverse operation Reverse-run prohibition [Parameter setting] Caution! 6.14 Drooping control 6.15 Function for crane/hoist 6.16 Commercial power/inverter switching Page 6.17 PID control 6.18 Speed feedback/positioning control 6.19 Preset speed operation mode 6.20 Setting motor constants Warning [Selection 1: Setting by the automatic V/f mode] [Selection 2: Individually setting the vector control and the auto-tuning] Set the auto-tuning (Automatic tuning execution) [Selection 3: Individually setting the vector control and the manual tuning] Step 2 for the adjustment of . Step 1: Setting the rating of the motor Step 2: Setting motor constants Examples of setting auto-tuning 6.21 Torque control 6.21.1 Torque reference 6.21.2 Torque reference filter Torque reference filter 6.21.3 Speed limits in torque control mode Setting by means of external signals 6.21.4 Torque bias and load sharing gain Page 6.22 Torque limit Setting (1) Power running /regenerative torque limit Page (2) Positive/negative torque limits [Positive torque limit] [Negative torque limit] Page 6.23 Secondary acceleration/deceleration 6.23.2 Switching of acceleration/deceleration #1, 2, 3 and 4 3) Switching with terminals - Switching acc/dec times by means of external terminals Acceleration/deceleration patterns 6.23.3 Minimum acceleration/deceleration times Acceleration/deceleration lower limit 6.24 Pattern run F-55 Basic operating Monitor displayed during pattern run Note) To put out the signals to the terminal OUT2, select the parameter . Page 6.25 Protection functions 6.25.1 Motor over road protection level adjust / motor types Motor over road protection level #1 Overload reduction start-up frequency 6.25.2 Setting of current stall Stall prevention level 6.25.4 Emergency stop Emergency stop Emergency DC injection braking control time 1) Emergency stop by terminal operation 2) Emergency stop by panel operation 6.25.5 Overload reduction start-up frequency 6.25.7 Action at low currents Low-current trip Low-current detection level Low-current detection time 6.25.8 Detection of output phase failure Detection of output short-circuit during start-up Adjustment of detection pulse for output short-circuit during start-up 6.25.10 Cooling fan control mode selection Cooling fan control mode 6.25.11 Cumulative operation time alarm Cumulative operation time alarm setting 6.25.12 Over-voltage stall protection level Over-voltage stall protection level(high response) Over-voltage stall protection level 6.25.13 Under-voltage trip Under-voltage trip mode Under-voltage detection time 6.25.14 UV stall level 6.26 Special analog input 6.27 Over-ride Over-ride addition input selection Over-ride multiplication input selection Output frequency = Reference + Over-ride (VI input [Hz]) Output frequency = Reference + Over-ride(VI input [Hz]) Output frequency = Reference {1 + Over-ride(VI input [%] / 100)} Output frequency = Reference {1 + Over-ride( [%] / 100)} 6.28 Meter output 6.28.1 Setting of meter outputs AM terminal meter selection AM terminal meter adjustment 6.28.2 Setting of optional meter outputs 6.28.3 Pulse output to meters 6.29.5 Changing items displayed in status monitor mode 6.29.6 Switching basic parameters Selection of panel V/f1, 2, 3 or 4 6.29.7 Selecting a control panel stop pattern Panel stop pattern 1) Slowdown stop 2) Free-run stop 6.29 .8 Resetting the inverter from the control panel 6.29.10 Canceling PID control in panel operation mode Panel PID control OFF 6.29 .11 Setting a torque command in panel operation mode Panel torque reference 6.29.12 Drooping control in panel operation mode 6.29.14 Restricting or prohibiting key operation Panel operation prohibition Setting Canceling methods 6.30 Communication function (RS485/common serial) 6.30.1 Common serial optional device Page 6.30.2 Using the RS485 port fitted as standard Page Page G-1 7. 1. External Operation 7. OPERATION WITH EXTERNAL SIGNAL 7. 2 Applied operation with input and output signals (operation by the terminal board) 7. 2. 1 Functions of input terminals (in case of sink logic) Inverter Page 7. 2. 2 Functions of output terminals (in case of sink logic) G-6 Output terminal function(open collector, relay outputs) settings and detection levels Table of output terminal functions and detection levels G-7 G-8 7. 2. 3 Setup of input/output terminal operation time Setup of response time 7. 2. 4 Analog input filter Response time setting 7. 3 Setup of external speed command (analog signal) [Control terminal board] Setting of analog input terminal functions G-11 7. 3. 1 Setup by analog input signals (RR terminal) Title Function Adjustment range Default value Setup value Speed setting mode selection (RR) (RR) G-12 7. 3. 2 Setup by analog input signals (VI/II terminal) Speed setting mode selection (RR) (VI/II) G-13 7. 3. 3 Setup by analog input signals (RX terminal) Setup value Speed setting mode selection (RR) (RX) * Motor 8. Monitoring operation status MON Information on input terminals Information on output terminals Type of connected option Total (accumulated) operation hours 8. 2 Changing status monitor function Changing indication of status with power on Standard monitor mode Standard monitor indication selection Changing contents of status monitor indication Page 8. 3 Indication in trip status Details of indications of trip status Examples of reading out trip data 8. 4 Indication of alarm, pre-alarm, etc... 9. Selection of peripheral devices I-1 Mandatory 9. 1 Selection of wiring equipment I-2 Selection of wiring equipment Inverter model 9. 2. Installation of electromagnetic contactor Electromagnetic contactor in the primary circuit Note on wiring Electromagnetic contactor in the secondary circuit Note on wiring 9. 3. Installation of overload relay I-5 9. 4 Application and functions of options IM N.F. Separate type options shown below are prepared for the inverter VF-A7 Sorts of separate-type options I-6 I-7 I-8 Option should be used under the condition of 9600 bps or less (). I-9 Selection table of separate-type options I-10 9. 5 Optional add-on cassettes Table of optional add-on cassettes Table of optional add-on cassettes Functions of optional add-on cassettes Vector option unit Page I-12 9. 6 Board options Table of board options Option name Function, purpose Model Remarks VEC002Z PG feedback board VEC003Z 9.7 Before installing optional add-on cassette or board option 9.7.1 Case 1 9.7.1 Case 1 Mandatory 9.7.2 Case 2 9.7.3 Case 3 10. Table of parameters J-1 1. Basic parameters (1/2) J-2 1. Basic parameters (2/2) J-3 2. Extended parameters [1] Frequency signal [2] Input signal selection [3] Terminal function selection (1/2) J-4 [3] Terminal function selection (2/2) [4] Terminal response time setup J-5 [5] Basic parameters #2 [6] V/f 5-point setting J-6 [7] Speed/torque reference gain/bia s setup (1/2) J-7 [7] Speed/torque reference gain/bias setup (2/2) [8] Operation frequency [9] DC injection braking [10] Jogging operation J-8 [11] Jumper frequency [12] Preset speed operation frequency (8- to 15-stage speed) [13] PWM carrier frequency [14] Tripless intensification setup (1/2) J-9 [14] Tripless intensification setup (2/2) [15] Drooping control [16] Functions for lift (1/2) J-10 [16] Functions for lift (2/ 2) [17] Commercial/inverter switching function [18] PID control [19] Speed feedback/positioning control J-11 [20] Vector control [21] Preset-speed operation mode J-12 [22] Motor constant [23] Torque control J-13 [24] Torque limit [25] Speed/torque reference gain/bias setup #2(1/2) J-14 [25] Speed/torque reference gain/bias setup #2(2/2) [26] Secondary acceleration/deceleration J-15 [27] Pattern run (1/2) J-16 [27] Pattern run (2/2) J-17 [28] Protection functions J-18 [29] Special analog input [30] Over-ride [31] Meter output (1/2) J-19 [31] Meter output (2/2) [32] Control panel parameters J-20 [33] Communication function(1/2) J-21 [33] Communication function(2/2) [34] Reservation area (reference section): Refer to the designated section of the inverter's individual manual. J-22 Contents of monitor indications J-23 Monitor FM/AM/pulse output function selection J-24 Input terminal function setting (1/2) J-25 Input terminal function setting (2/2) J-26 Output terminal function setting (1/2) J-27 Output terminal function setting (2/2) J-28 [Default settings] E6580988 11. Specifications by types K-1 11. 1 Standard specifications by types 1) Standard specifications by types (small/medium capacity types) K-2 2) Standard specifications by types (large capacity types) K-3 4) Common specifications (Contin ued on the following page) K-4 11.2 External dimensions and mass External dimensions and mass K-6 Outline drawings Note)VFA7-2004PL and -2007PL have no cooling fan. Drawing A Drawing B Note)VFA7-2185P, -2220P, -4185P, -4220P have cooling fan in the upper part. Drawing C Drawing D Dimensions for heat-sink going out attachment(simple type) 12. Trip information and countermeasures Prior to service call 12. 1 L-1 L-2 (Continued on the following page) L-3 L-4 [Message] The following are messages only. No trip is developed. Same as (over-voltage) Overload alarm Same as / (overload) Overheat alarm Same as (overheat) 12. 2 Method of resetting causes of trip 12. 3 In the case motor does not run in spite of no trip message appearing ... L-7 12. 4 How to check other troubles Measures against trouble with parameter setting 13. Regular inspection and maintenance 13.1 Regular inspection Check points 13. 2 Periodical inspection Points of inspection Replacement of expendable parts Standard period of years to replace main component parts 13. 3 When making a service call 13. 4 When retaining the inverter out of operation 14. Warranty 15. When disposing the inverter