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G3 Applications

Workbook

Summary of Contents for G3

Page 1: ...1 G3 Applications Workbook ...

Page 2: ...2 G3 Applications Workbook 2006 Toshiba International Corporation Industrial Division 13131 West Little York Road Houston Texas 77041 Phone 800 231 1412 Fax 713 896 5242 www toshiba com ind ...

Page 3: ...9 Cyclic Overhauling Load 31 True Torque Control 35 Acc Dec Time Switching Frequency 36 Direction Change with RX Input 37 Half Speed Command 39 Analog Outputs 40 Output Contacts 44 PID 48 Master Follower Pulse Output 56 Independent Dancer Control 59 Trim Dancer Control 62 120 Hz Constant Torque Operation of a 60 Hz Motor 65 Overspeed 67 Drooping 70 Carrier Frequency Derating 72 Load Sharing Applic...

Page 4: ...horted to CC the will change to ON Use this as a troubleshooting tool S6 S7 and S8 exist only on option card RCH LOW FLT OUT FAN MC ON As these output terminals close the will change to ON Use this as a troubleshooting tool OUT exists only on option card MC always says ON FAN shows ON when the drive s muffin fan is on CUMULATIVE RUN TIME 0 00 01 represents one hour The timer is not resettable An o...

Page 5: ...ssing RUN or resetting drive Drive keeps track of both 16 Peak input voltage of these values even when not programmed to display as one of the four monitors Programming The following example will make the monitors one through four frequency reference torque current peak input voltage and peak output current respectively Group Parameter New Value UTILITY PARAMETERS Status Monitor 1 Display Select 2...

Page 6: ...s 10 through 5 respectively Binary bits 10 through 5 have reference values of MOF 21 MOF 22 MOF 23 MOF 24 MOF 25 and MOF 26 respectively In this example these values are 32 16 8 4 2 and 1 Connections F CC ST S1 S2 S3 S4 RES R CC Example of input combinations and corresponding drive outputs with MOF 64 Hz S1 CC 32 S2 CC 16 S3 CC 8 S4 CC 4 RES CC 2 R CC 1 Frequency Command closed open open open open...

Page 7: ...unction 27 TERMINAL SELECTION PARAMETERS S1 Input Terminal Function 32 TERMINAL SELECTION PARAMETERS S2 Input Terminal Function 31 TERMINAL SELECTION PARAMETERS S3 Input Terminal Function 30 TERMINAL SELECTION PARAMETERS S4 Input Terminal Function 29 TERMINAL SELECTION PARAMETERS RES Input Terminal Function 28 FREQUENCY SETTING PARAMETERS Frequency Priority Selection 1 5 FUNDAMENTAL PARAMETERS 1 M...

Page 8: ...and volts hertz pattern with each preset speed Any seven of the fifteen preset speeds can be strung together to create a pattern the G3 stores four such patterns The number of times a pattern repeats is programmable from one to infinity Pattern Run Diagram Forward Speed 2 time 6 sec 30 Hz ACC2 used DEC1 used 15 Hz Speed 1 time 3 sec time 11 Hz Speed 3 time time ACC1 used change in HZ 3 sec Max Out...

Page 9: ...TTERN RUN CONTROL PARAMETERS Pattern Group 1 Speed 2 2 PATTERN RUN CONTROL PARAMETERS Pattern Group 1 Speed 3 3 PATTERN RUN CONTROL PARAMETERS Pattern Group 1 Number Of Cycles 2 PATTERN RUN CONTROL PARAMETERS Speed 1 Continue Mode 2 PATTERN RUN CONTROL PARAMETERS Speed 1 Drive Time 3 PATTERN RUN CONTROL PARAMETERS Speed 2 Continue Mode 2 PATTERN RUN CONTROL PARAMETERS Speed 2 Drive Time 6 PATTERN ...

Page 10: ...umes the pattern run at the speed after the speed at which it was running when the STOP was given Note opening and reclosing ST CC is not considered a STOP RUN command in this scenario the pattern s clock keeps ticking The continue signal must be active when the pattern is started for correct Continue operation Speed 0 in any pattern is only run on the initial pass of the pattern repeats of patter...

Page 11: ... speeds from 5 Hz for Preset Speed 1 to 75 Hz for Preset Speed 15 in steps of 5 Hz In this scenario the terminals are assigned a value of a power of two This value is the number of the preset speed that is active With the following programming S4 S3 S2 and S1 have values of 23 22 21 and 20 which are 8 4 2 and 1 respectively Connections TERMINAL STRIP ST CC F CC S1 S2 S3 S4 CC Preset speed selected...

Page 12: ... FREQUENCY SETTING PARAMETERS Preset Speed 5 Operating Mode 0 FREQUENCY SETTING PARAMETERS Preset Speed 6 Frequency 30 FREQUENCY SETTING PARAMETERS Preset Speed 6 Operating Mode 0 FREQUENCY SETTING PARAMETERS Preset Speed 7 Frequency 35 FREQUENCY SETTING PARAMETERS Preset Speed 7 Operating Mode 0 FREQUENCY SETTING PARAMETERS Preset Speed 8 Frequency 40 FREQUENCY SETTING PARAMETERS Preset Speed 8 O...

Page 13: ...ociated with that preset speed is determined solely by the Preset Speed n Operating Mode FREQUENCY SETTING PARAMETERS group as seen in the manual A F CC or R CC closure must still be made to run preset speeds but the direction the closure represents is ignored TIP If you have from two to four preset speeds use speeds 1 3 7 and 15 This reduces the number of contact openings closings that have to ta...

Page 14: ...t maintains the current frequency A closure of the momentary reset contact ramps the drive down to zero hertz Do not use this control scenario with ACCEL and or DECEL times greater than 10 seconds Connections TERMINAL STRIP ST CC F CC S1 CC S2 CC S3 CC Increase Decrease Reset Programming Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Terminal Selection Param...

Page 15: ...t is made When the increase contact is made the drive increases its output frequency until the contact is released at which point it maintains the current frequency When the decrease contact is made the drive decreases its output frequency until the contact is released at which point it maintains the current frequency A closure of the momentary reset contact ramps the drive down to zero hertz Do n...

Page 16: ...meters Blind 1 UTILITY PARAMETERS Frequency Setting Parameters Blind 1 TERMINAL SELECTION PARAMETERS Input Terminal Selection 1 TERMINAL SELECTION PARAMETERS S1 Input Terminal Function 34 TERMINAL SELECTION PARAMETERS S2 Input Terminal Function 35 TERMINAL SELECTION PARAMETERS S3 Input Terminal Function 36 FREQUENCY SETTING PARAMETERS Frequency Priority Selection 1 5 FREQUENCY SETTING PARAMETERS F...

Page 17: ...Parameter New Value UTILITY PARAMETERS Command Mode Selection 1 UTILITY PARAMETERS Frequency Mode Selection 2 UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Terminal Selection Parameters Blind 1 TERMINAL SELECTION PARAMETERS Input Terminal Selection 1 TERMINAL SELECTION PARAMETERS S1 Input Terminal Selection 37 TERMINAL SELECTION PARAMETERS S2 Input Terminal Selection 38 TERMINAL...

Page 18: ...the keypad 3 RS485 option board frequency command is received via a communications option board 4 Local Remote control Local Remote light must be off The following programming makes STOP active upon opening S2 CC This programming should only be performed if a normally closed momentary switch is to be used for STOP KEYSTROKE RESULTING DISPLAY PRG OUTPUT FREQUENCY 0 0 Hz LOCAL REMOTE OUTPUT FREQUENC...

Page 19: ...ERS Communication Parameters Blind 1 COMMUNICATION SETTING PARAMETERS Communication Selection 1 COMMUNICATION SETTING PARAMETERS RS485 Baud Rate 0 COMMUNICATION SETTING PARAMETERS Master Slave Selection 2 Enter a 1 to follow the master s output frequency Enter a 2 to follow the master s frequency reference Programming for the follower s Group Parameter New value UTILITY PARAMETERS Blind Function S...

Page 20: ...1 off off 9600 38400 on off 4800 19200 off on 2400 9600 on on 1200 4800 The maximum baud rate on the INV3 COM B card is 19200 The maximum baud rate on the INV3 COM C card is 38400 Adjust jumpers appropriately so that all drives have same baud rate Each slave may be separately trimmed up or down from the master reference by a local speed pot see Application Guideline 11 Trim Pot Slaves are still st...

Page 21: ...hen running at frequency under DC Inj Start Freq short terminal to CC to inject activate FUNDAMENTAL PARA 1 group open or FUNDAMENTAL PARA 2 group closed PID OFF closed or ON open select Pattern Run 1 2 select Pattern Run 2 2 select Pattern Run 3 2 select Pattern Run 4 2 Pattern Run continue signal 2 Pattern Run step signal 2 JOG forward includes forward command 7 JOG reverse includes reverse comm...

Page 22: ...terlock one of these with your ESTOP circuit Programming example Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Terminal Selection Params Blind 1 TERMINAL SELECTION PARAMETERS Input Terminal Selection 1 TERMINAL SELECTION PARAMETERS F Input Terminal Function 43 TERMINAL SELECTION PARAMETERS Potential Terminal Function 7 The above example programs the fol...

Page 23: ... terminal preset speed or RS485 board SOME TRIM SOURCES ALLOWED Speed pot RR terminal trim or RX terminal trim only 4 20 mA IV CC terminals trim only or panel trim only This example will illustrate the connections and programming necessary to follow a 4 20 mA speed reference while trimming the reference with a trim from a pot connected to the RR terminal Connections TERMINAL STRIP ST CC F CC IV CC...

Page 24: ...RR input is 10 volts maximum potentiometer setting the drive outputs 44 hertz 40 40 x 0 10 Greater trim bandwidth can be achieved by increasing the Override Change Multiplier Instead of connecting a speed pot to the RR input for continuous speed trim a user could connect a switch with fixed resistances to give discrete levels of trim Another method that requires no external connection requires set...

Page 25: ...ST CC LOW A LOW C RCH A RCH B To customer To customer This works in either panel or remote mode In remote remember to include a direction reference Programming Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Terminal Selection Params Blind 1 TERMINAL SELECTION PARAMETERS Low Contacts Function 4 TERMINAL SELECTION PARAMETERS Low Speed Signal Output Freq 40 TER...

Page 26: ... will be visible Cycle drive power after programming Connections TERMINAL STRIP ST CC PP RR CC Programming Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Feedback Control Parameters Blind 1 UTILITY PARAMETERS Protection Function Parameters Blind 1 UTILITY PARAMETERS Terminal Selection Parameters Blind 1 FUNDAMENTAL PARAMETERS 1 Volts per Hertz Pattern 5 FEED...

Page 27: ... arrow until 03AF READ WRITE 05 up arrow until 45 READ WRITE 03AF alternating with 45 then 03AF PRG OUTPUT FREQUENCY 0 0 Hz Cycle power to the drive after programming Drooping Control Amount determines how fast the output frequency and torque changes as the RR input is changed Increase the value in this parameter for faster response You may want to program one of the monitors i e Status Monitor 1 ...

Page 28: ... Terminal Selection Parameters Blind 1 UTILITY PARAMETERS Special Control Parameters Blind 1 UTILITY PARAMETERS Frequency Setting Parameters Blind 1 UTILITY PARAMETERS Protection Function Parameters Blind 1 UTILITY PARAMETERS Pattern Run Control Parameters Blind 1 UTILITY PARAMETERS Feedback Control Parameters Blind 1 UTILITY PARAMETERS AM FM Adjustment Blind 1 UTILITY PARAMETERS Motor Parameters ...

Page 29: ...ections Notes The contacts are shown in an unenergized coil state An additional contactor may be included to isolate the drive thereby allowing the cycling of drive power while in bypass ST S2 F CC 3 C4 C3 MCCB Enable Inverter Bypass M G3 RCH C LOW C RCH A LOW A V CONTROL R2 R1 R4 C2 V C1 R3 Overload Relay An overload relay OLR is necessary in a bypass scenario because the drive s built in motor t...

Page 30: ... overload relay trips control power is interrupted and all contactors drop out If drive trips the drive opens RCHA RCHC and closes LOWA LOWC The end result is that the bypass contactor closes and the output contactor opens The motor is now on utility power Upon closure of S2 CC the drive increases its output frequency until Commercial Power Inv Switch Freq CPISF is reached If S2 CC is unmade befor...

Page 31: ... This causes the DC bus capacitors to charge and reach a high voltage that will trip the drive on overvoltage Typically dynamic braking resistors are employed to take the regenerative energy and dissipate it as heat With the G3 inverter these resistors may no longer be necessary because the drive can detect negative torque current and responds to it by increasing the output frequency to eliminate ...

Page 32: ...ll result in unstable operation Programming Chart Group Parameter New Value FEEDBACK PARAMETERS DROOPING CONTROL ENABLE 1 FEEDBACK PARAMETERS DROOPING CONTROL AMOUNT 0 1 10 PROTECTION PARAMETERS STALL PROTECTION ENABLE 0 PROTECTION PARAMETERS STALL PROTECTION CURRENT LEVEL 10 20 PROTECTION PARAMETERS STALL PROTECTION CURRENT ENABLE 1 Turn Stall Off with a value of 1 after setting Stall Protection ...

Page 33: ...RITE 05 up arrow until E5 READ WRITE 03AF alternating with E5 then 03AF PRG OUTPUT FREQUENCY 0 0 Hz Cycle power to the drive after programming Additional Super User Programming The frequency value that the drive will phase forward can be adjusted and is set at 8 Hz by default This is set in Super User Mode at address 03B3 with values in chart below This value should only be adjusted when after the...

Page 34: ...til 03B3 READ WRITE 68 ADJUST SEE ValueChart above READ WRITE 03B3 alternating with value then 03B3 PRG OUTPUT FREQUENCY 0 0 Hz Cycle power to the drive after programming Super User Mode involves accessing the machine code of the inverter hence the unusual names for the parameters Extreme caution should be used whenever this mode of programming is utilized Severe damage and or failure of the ASD c...

Page 35: ...OTOR PARAMETERS Load Moment of Inertia 4 Programming for generic motor Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Motor Parameters Blind 1 FUNDAMENTAL PARAMETERS 1 Volts per Hertz Pattern 5 MOTOR PARAMETERS Number of Motor Poles 1 2 MOTOR PARAMETERS Motor Rated Capacity MOTOR PARAMETERS Motor Type 2 1 MOTOR PARAMETERS Motor Rated Voltage 1 MOTOR PARAMETE...

Page 36: ...ramming is completed the drive will take about 10 seconds to ramp from 0 to 29 3 Hertz and about 1 second to ramp from 29 3 to 60 Hertz Programming Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Fundamental Parameters 2 Blind 1 FUNDAMENTAL PARAMETERS 2 Acceleration Time 2 2 7 FUNDAMENTAL PARAMETERS 2 Deceleration Time 2 2 7 FUNDAMENTAL PARAMETERS 2 ACC DEC 1...

Page 37: ...irection change Set SWITCH 1 right of the phone jack on the control board under the keypad to 5 or 10 as appropriate for the voltage you are applying to the RX terminal The I V switch does not apply to the RX terminal Connections for positive only reference TERMINAL STRIP ST CC F CC PP RX CC Example programming for positive only reference Group Parameter New Value UTILITY PARAMETERS Blind Function...

Page 38: ...ion Selection 1 UTILITY PARAMETERS Frequency Setting Parameters Blind 1 FREQUENCY SETTING PARAMETERS Frequency Priority Selection 1 3 FREQUENCY SETTING PARAMETERS RX Terminal Standard or Adjustable 1 FREQUENCY SETTING PARAMETERS RX Reference Setting Point 1 100 default FREQUENCY SETTING PARAMETERS RX Point 1 Frequency 60 FREQUENCY SETTING PARAMETERS RX Reference Setting Point 2 100 default FREQUEN...

Page 39: ...o the right of the phone jack on the control board under the keypad Make sure it is set to the 10 position The I V switch does not apply to this guideline Programming Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Feedback Parameters Blind 1 FEEDBACK PARAMETERS Override Control Selection 7 FEEDBACK PARAMETERS Override Multiplier Input Selection 3 FEEDBAC...

Page 40: ...p board just to the left of the terminal strip JP3 sets the AM terminal s output range and JP4 sets the FM terminal s output range TERMINAL STRIP ST CC FM CC AM CC In general it is best to calibrate any meter at its maximum deflection to minimize its error as a percentage of the total signal metered On the G3 there are two ways of creating a meter maximum deflection condition for use in calibratio...

Page 41: ...rent current 2 7 100 PID feedback value frequency feedback from application represents 8 75 of Maximum Output Frequency Fundamental Parameters 1 group Motor overload ratio example G3 is rated for 150 FLA for 2 mins If 9 Inverter overload ratio G3 is run at 150 for 1 min this output will be 10 100 DBR overload ratio 50 Drive trips when ratio hits 100 11 Input power in KW 12 230 V drive 346 x drive ...

Page 42: ... of the AM terminal for output current Adjust jumper 4 for 0 1 or 4 20 mA output Connect meter to AM and CC Programming Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS AM FM Adjustment Parameters Unblind 1 AM FM TERMINAL ADJUSTMENT PARAMETERS AM Terminal Function Selection 14 AM FM TERMINAL ADJUSTMENT PARAMETERS Current Meter Adjustment AM FM TERMINAL ADJ...

Page 43: ...t voltage Adjust jumper 4 for 0 1 or 4 20 mA output Connect meter to AM and CC Run the drive at some high frequency say 60 Hertz Programming Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS AM FM Adjustment Parameters Unblind 1 AM FM TERMINAL ADJUSTMENT PARAMETERS AM Terminal Function Selection 5 AM FM TERMINAL ADJUSTMENT PARAMETERS Frequency Meter Adjustm...

Page 44: ...e programmed with factory default values the above connection example will illuminate the LED when the drive is outputting a non zero frequency P24 is a 24 VDC 50 mA supply that can be used to power coils or control devices Do not connect CC to ground The G3 s output contacts are rated for 30 VDC 1 amp 250 VAC 1 amp inductive 2 amp resistive 24 VDC LED Programming The function associated with the ...

Page 45: ...act closes when drive is at or above Speed Reach Maximum Frequency during an accel or when drive is at or above Speed Reach Minimum Frequency during a decel 9 Contact closes when drive is not at or above Speed Reach Maximum Frequency during an accel or when drive is not at or above Speed Reach Minimum Frequency during a decel 10 Factory default for FLA FLB FLC terminals Contact closes when drive i...

Page 46: ...loses when DC bus is under 200 VDC 230 V G3 or 380 VDC 460 V G3 25 Contact closes when DC bus is not under 200 VDC 230 V G3 or 380 VDC 460 V G3 26 Contact closes when output current is at or greater than the current programmed into Low Current Detection Level TERMINAL SELECTION group for longer than the time programmed in Low Current Detection Time 27 Contact closes when output current is not at o...

Page 47: ...53 Contact closes when drive is not jogging 54 Contact closes when drive is getting RUN STOP command from the keypad 55 Contact closes when drive is not getting RUN STOP command from the keypad 56 Contact closes when drive run time is greater than or equal to time programmed into Cumulative Run Timer Alarm Setting PROTECTION PARAMETERS group 57 Contact closes when drive run time is not greater tha...

Page 48: ...alves close The rate at which the drive responds to changes is adjustable via three parameters Proportional Gain Integral Time and Differential Time and will have to be field tuned Later in this guideline PID applications will be discussed in general Connections Check your transducer s schematic for connection information The above diagram is typical for a loop powered transducer Separately powere...

Page 49: ...se an increase in output frequency the bias gain of the IV terminal should be reversed by programming the following Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Feedback Parameters Blind 1 FREQUENCY SETTING PARAMETERS IV Terminal Standard or Adjustable 1 FREQUENCY SETTING PARAMETERS IV Reference Setting Point 1 20 FREQUENCY SETTING PARAMETERS IV Ref Point ...

Page 50: ...signal Program as appropriate For 10 volt feedback set to 1 For 4 20 mA feedback the default setting 2 is appropriate set SW1 to I position Tuning the PID The idea when tuning this PID is to get fast enough response from the drive that the pressure doesn t drop or increase very much One problem with this is that if the response is too quick the drive can actually overshoot put out a higher frequen...

Page 51: ...ve Proportional Gain Integral Time and Derivative Time Some recommended PID values based on application type Process Variable Proportional Gain Integral Gain Anti Hunting Gain seconds repeat seconds Flow 0 3 0 6 0 0 Levels fast 1 0 8 0 0 0 Levels slow 0 25 16 0 0 0 Pressure fast 2 0 0 5 0 0 Pressure slow 1 0 2 0 0 0 Temperature fast 1 0 2 0 0 0 Temperature slow 1 0 16 0 0 25 Temperature furnace 0 ...

Page 52: ... by the output of the proportional circuit The integral action is therefore influenced by the proportional action The output of the integral circuit represents the area under the Verror vs time graph In the below example if Verror were to remain at the level shown the output of the integral circuit would continue to increase linearly with time integral output is proportional to area of the rectang...

Page 53: ...y high frequency changes in the system variable including noise if present are picked up by the differential circuit and could lead to instability The longer the derivative time the stronger the derivative action For additional assistance please contact Toshiba Ad Output from Differential Circuit Derivative Time PID Drive Output Hz vs Time in response to pressure drop Time Improve by decreasing In...

Page 54: ...ust PID Lower Limit Frequency in the FEEDBACK PARAMETERS group as desired for a unique PID lower limit Use PID Deviation Upper Limit and PID Deviation Lower Limit in FEEDBACK PARAMETERS group to limit the amplitude of the error signal The values entered here are in percent of Maximum Output Frequency FUNDAMENTAL PARAMETERS 1 group Use on systems that change quickly and drastically PIDDLL applies t...

Page 55: ...st be coming from the terminal strip for the remote PID ON OFF to work a frequency reference can come from keypad if desired PID can be turned ON OFF in this way while the motor is turning As a set up or troubleshooting tool program Status Monitor n Display Select in the UTILITY PARAMETERS group to 8 PID feedback value so that the drive will display the frequency to which the feedback corresponds ...

Page 56: ...mation on G3 option boards Connections On the followers connect the ribbon cable from the INV3 COM D board to the drive s CN6X connector The CN6X connector is to the left of the terminal strip Follower Follower Master FP CC INV3 COM D INV3 COM D CC PGB CC PGB G3 G3 G3 to other followers Programming for the Master Group Parameter Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETER...

Page 57: ...ETERS PG Terminal Standard or Adjustable 1 FREQUENCY SETTING PARAMETERS PG Reference Setting Point 1 0 FREQUENCY SETTING PARAMETERS PG Ref Point 1 Frequency 0 FREQUENCY SETTING PARAMETERS PG Reference Setting Point 2 100 FREQUENCY SETTING PARAMETERS PG Ref Point 2 Frequency 30 The Bias Gain of the PG input is dependent on the drive s Maximum Output Frequency MOF In the above example if the MOF is ...

Page 58: ...ng Dept at 800 872 2192 58 The following are some other ways of configuring a master follower See Application Guideline 11 for information on trimming the slaves Master G3 CC FM Follower G3 IV CC 4 20 mA 2 10 CC IV Follower G3 Follower Follower G3 CC RR Master G3 PP G3 CC RR CC RR ...

Page 59: ... Trim Dancer Control for discussion of the other type of dancer application For this guideline the drive is configured to follow a 4 20 mA reference as a threading speed and will automatically turn on the dancer PID when the drive reaches a programmed output frequency The drive will ignore this 4 20 mA reference when the PID is on See related Guidelines 24 PID and 10 Programmable Inputs for more i...

Page 60: ... 0 5 1 FEEDBACK PARAMETERS Lag Time Constant 0 0 1 1 These are suggestions and will have to be field adjusted See Application Guideline 24 for PID information 2 The following is an example of how to adjust the RX Bias Gain Suppose dancer output is 1 5 volts Set the micro switch next to the phone jack on the control board in the 5 position Suppose that the dancer output voltage when the dancer is i...

Page 61: ...new BCD values will be 1110 0100 which is E4 in hex Use the up arrow to adjust the 64 to read E4 Decimal Binary Hex Digit Decimal Binary Hex Digit Decimal Binary Hex Digit 1 0001 1 6 0110 6 11 1011 B 2 0010 2 7 0111 7 12 1100 C 3 0011 3 8 1000 8 13 1101 D 4 0100 4 9 1001 9 14 1110 E 5 0101 5 10 1010 A 15 1111 F Remove and re apply main power to the drive after the above programming is finished In ...

Page 62: ...e 5 volt or 10 volt position as appropriate for your dancer The other micro switch should be in the I position for this example 5 10 volt dancer position 4 20 mA master line reference Programming Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Frequency Setting Parameters Blind 1 UTILITY PARAMETERS Feedback Parameters Blind 1 FUNDAMENTAL PARAMETERS 1 Maxi...

Page 63: ...age is above 2 5 volts it will decrease its output frequency whenever the dancer voltage is below 2 5 volts If this relationship is the opposite of what is desired for a particular dancer program RX Reference Point 2 Frequency FREQUENCY SETTING PARAMETERS group to 60 Now the drive will increase its output frequency whenever the dancer voltage is below 2 5 volts and decrease its output frequency wh...

Page 64: ...amming is finished The G3 can be programmed to change the state of one of its output contacts based on dancer travel by programming PID Deviation Upper Limit and PID Deviation Lower Limit in the FEEDBACK PARAMETERS group and programming 38 or 39 into an output contact s function TERMINAL SELECTION PARAMETERS group To set PIDDLL or PIDDUL to change a contact s state whenever the dancer voltage chan...

Page 65: ...or the motor The motor will run on 460V power but is wired for 230V This can be done because the insulation systems of low voltage motors are good for 600 volts The drive will put 230V to the motor at 60HZ which the motor winding will need for proper operation At this time the motor can deliver nameplate horsepower and torque As the inverter continues to increase frequency AND voltage motor horsep...

Page 66: ... sure the machine pulleys or gearbox are sized for 3600 RPM Both of the following motors have the same torque rating of 150 ft lbs at 60 Hz 50HP 230V 326T frame 1800 RPM 122 amps will be run up to 480V 120 Hz 3600 RPM 100HP 460V 405TS frame 3600 RPM 120 amps will be run up to 480V 60 Hz 3600 RPM A 100 HP G3 would be used with either motor Notice that the 50 HP motor is in a smaller frame Programmi...

Page 67: ...Z Item 2 BASE FREQUENCY 1 typically 60 Hz Rated Torque Rated Voltage Volts and HP Torque Many users would like to run motors at speeds higher than the motor design speed The G3 has no problem outputting up to 400 Hz contact Inverter Marketing for information on 800 Hz operation Over 60 Hz however the G3 cannot make voltage to keep the V Hz ratio constant voltage becomes fixed at the line value of ...

Page 68: ...he breakdown torque which decreases as the square of speed increase has crossed over the full load torque and is now the limiting factor for torque development Recommendations On applications requiring output frequencies up to 90 Hz derate the motor s rated full load torque by the ratio of base frequency to maximum operating frequency On applications requiring output frequencies greater than 90 Hz...

Page 69: ...or constant HP is Torque 5250 x HP 5250 x 3 1 75 ft lbs RPM 9000 This number is greater than the 1 08 ft lbs calculated as the motor s torque ability at 300 Hz Therefore the motor cannot provide constant HP at up to 300 Hz In fact the maximum HP the motor can develop at 300 Hz is HP Torque x RPM 1 08 x 9000 1 85 HP 5250 5250 ...

Page 70: ...edding load and encouraging a lightly loaded motor to pick up the slack The goal of drooping control is to have the same torque ratios actual torque rated torque for both motors Example System Programming Common frequency reference G3 2 G3 1 Motor 1 CONVEYOR Motor 2 Group Parameter New Value UTILITY PARAMETERS Blind Function Selection 1 UTILITY PARAMETERS Feedback Parameters Blind 1 FEEDBACK PARAM...

Page 71: ... overrides Droop Contact drive marketing for information on how to change the Droop reaction time Contact drive marketing for inforamtion on how to increase droop amount larger than 10 Contact drive marketing for information concerning positive droop Common Frequency Reference The drives used in a drooping system share a frequency reference use the G3 s RS485 master follower board see application ...

Page 72: ...t squared times time I2 t For a fixed amount of current the longer the transition time the more heating that will occur inside the transistor In addition the more times that the transistor turns on or off within a period of time the more heating that will occur This means that the higher the carrier frequency the more the heating in the drive and consequently the lower the full load current value ...

Page 73: ...plier High carrier frequencies in the range of 10 12KHz have the benefit of shifting a motor s audible noise to a frequency that is not heard by the human ear It can also have some benefits in reduced output filter costs The downsides include increased thermal stress on the transistors or a required drive derate increased stress on motor insulation and increased opportunity for common mode bearing...

Page 74: ... pass of the belt either drive may trip over voltage fifteen or twenty times because it was pulled too fast from the other motor Common DC bus is recommended for this application but was not allowed by the user for perceived safety reasons Surges in speed are so fast the pump jack software was not effective in all cases although it did reduce tripping 2 This conveyer is hanging from the ceiling of...

Page 75: ...ference Slave is a pulse follower of the main drive for frequency synchronization Slave runs 06Hz slower than master to exactly load share probably due to roll size differences A 10KW 3 6 ohm resistor was added to each drive Resistors run cool but do fire infrequently while drive is running System runs 10 lighter load with coal than without indicating a slight decline Conveyer coasts about 10 12 s...

Page 76: ...s binary 1111 therefore 4 parameters are output Command Mode 3 Lets the G3 get its command input from Tosline F10 Frequency Mode 3 Lets the G3 gets its frequency from Tosline F10 T2 Settings I O Allocation Perform auto I O allocation Put Link into System Information I O Allocation Network Settings TL F10 CH1 Set the following MS211 DIP switch ON DSO left bank switch 4 Put all others OFF The rotary...

Page 77: ... Monitoring a different parameter in the G3 using super user mode This is an example of setting up the G3 to output the present fault 1 Go to super user mode Only those who have been trained in the use of super user mode should do this Severe damage to the drive and motor can result from improper use of super user mode The keystrokes used to enter super user mode are not described here 2 Go to EEP...

Page 78: ...Four standoffs are used to mount the G3 Tosline F10 option card If additional standoffs are needed please contact inverter marketing and reference standoff number 42645 9 16 When using the above super user mode settings at least 6 LW registers will be used by the G3 Even if a parameter is not being monitored zero will be stored in the register Therefore if it is necessary to minimize the number of...

Page 79: ...oise immune fiber optic connection Tosline S20 supports 1024 Registers across 64 stations Connections 2 Mbaud Very Fast 1024 Words Fiber Optic Noise Immune In the T2 the Tosline S20 fiber optic module is needed This module has two sets of fiber optic communication ports In the G3 the S20 option card is used in this system This card mounts under the LCD display It has one set of communicaton ports ...

Page 80: ... Tosline S20 Manual Detailed Information on the Tosline S20 G3 Connection Follows T PDS Programming Software To enable communication use T PDS Toshiba Program Development System to configure the set up options type O Check that the computer link parameters and COM port settings are correct and remember the settings for future reference For example 9600 BPS odd parity 8 data bits 1 stop bit on COM1...

Page 81: ...e addresses in the S 20 system to designate the send and receive registers bearing in mind that each station must have unique send transmit registers Refer to example table NOTE Before attempting communications use Station Connect S in the main loader menu to check if communication settings are formatted correctly If Station Connect has problems communications will not execute Send Register Set Up...

Page 82: ...ary Speed Base Value bit 3 External Current Limit Value bit 4 Drooping on line gain value Note that 3 in decimal is equal to 0011 in binary The S20 Monitor Output parameter will choose which drive data are available through the S20 network bit 0 Status bit 1 Speed Feedback Value bit 2 Output Current Value bit 3 Excitation Current Value bit 4 Torque Current Value A setting of 31 which is equal to b...

Page 83: ...us address from the G3 decode the register using the following table bit 0 1 0 stop run 1 run stop 2 reverse rotation forward rotation 3 acc dec 1 acc dec 2 4 not used keep at 0 5 failed gate block normal 6 not used 7 normal operation jog operation 8 feedback available no feedback 9 no dc braking dc braking A VF1 VF2 B run coast stop C run emergency stop D to F not used ...

Page 84: ...n coast stop C run emergency stop D reset trigger turn to 1 E not used F Command Input Speed Base Value 0 27500 Set max frequency FH to 275 1 Auxiliary Speed Base 0 27500 FH as above 110 27500 External Current Limit 0 10200 Stall protect level 100 4000 Drooping Online Gain 0 127 Drooping Control Value 10 100 Monitor Output Speed FeedBack Value 0 27500 Max freq FH 110 27500 Output Current Value 0 1...

Page 85: ...TOSLINE S20 Freq Ref Address 42 TOSLINE S20 Com Err Mode 0 TOSLINE S20 Com Option Reset 0 Sending and Reading Information ie with MMI using the addresses set in the continuous example S 20 Adr G3 T2 W0000 status register W0001 feedback speed W0002 output current W0003 excitation curr W0004 torque current W0040 command run W0041 speed ref W0042 aux speed W0043 current limit W0044 drooping gain From...

Page 86: ... the G3 LCD Display to German Press and release Local Remote Press and release MON Press and release PROG Press all three at the same time Local Remote MON PROG Select GERMAN from the menu that appears Other language options also appear on this menu but the only languages implemented at this time are German and English ...

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