Toshiba Q9 Series User manual

Document Number: 59492-002
Date: March, 2011
Q9 FlowSaver ASD/Bypass Box
TOSHIBA
Q9 FlowSaver ASD/Bypass Box
Installation and Operation Manual
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Document Number: 59492-002
Date: March, 2011
Q9 FlowSaver/Bypass
Installation and Operation
Manual
Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [email protected]

Introduction
Congratulations on the purchase of the new Q9 F LOW S AVER Adjustable Speed Drive (ASD)/Bypass Box.
The Q9 F
LOW S AVER Adjustable Speed Drive is a solid-state AC drive. The Q9 F LOW S AVER enables the
motor to develop high starting torque and provide compensation for motor slip, which results in smooth,
quick starts and highly efficient operation.
The Q9 F
LOW S AVER provides bypass functionality. Bypass operation allows for the three-phase input
power to be routed around the ASD and applied directly to the motor. During bypass operation, the ASD is
removed from the system electrically via contactors. This feature allows for uninterrupted system
operation during ASD adjustments, modifications, or repairs when required.
The Q9 F
LOW S AVER may be purchased either with or without an ASD included. See the section titled
Mounting and Connections on page 19 for further information on the two versions of the Q9 F
LOW S AVER .
The Q9 F
LOW S AVER uses digitally-controlled pulse width modulation. The programmable functions may
be accessed via the easy-to-use menu or via the Direct Access Numbers. These features, combined with
Toshiba’s high-performance software, delivers unparalleled motor control and reliability.
The Q9 F
LOW S AVER is a very powerful tool, yet surprisingly simple to operate. The user-friendly
Electronic Operator Interface (EOI) of the Q9 F
LOW S AVER has an easy-to-read LCD screen. There is
also a model-specific control panel that provides toggle-switch control of the operating mode with an LED
display array to convey the system operational status.
The EOI and the control panel provide superior monitoring and control of the Q9 F
LOW S AVER and allows
for easy-access programming for quick system changes when required.
The ASD software is menu-driven, simplifying motor control parameter changes when required.
To maximize the abilities of your new Q9 F
LOW S AVER , a working familiarity with this manual will be
required. This manual has been prepared for the Q9 F
LOW S AVER installer, user, and maintenance
personnel. This manual may also be used as a reference manual or for training. With this in mind, use this
manual to develop a system familiarity before attempting to install or operate the device.
Important Notice
The instructions contained in this manual are not intended to cover all details or variations in equipment
types. Nor may it provide for every possible contingency concerning the installation, operation, or
maintenance of this equipment. Should additional information be required contact Toshiba’s Customer
Support Center.
The contents of this manual shall not become a part of or modify any prior or existing agreement,
commitment, or relationship. 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.
Any electrical or mechanical modifications to this equipment without prior written consent of
Toshiba International Corporation will void all warranties and may void the UL/CUL listing or
other safety certifications. Unauthorized modifications may also result in a safety hazard or
equipment damage.
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About This Manual
This manual was written by the Toshiba Technical Publications Group. This group is tasked with
providing technical documentation for the Q9 F
LOW S AVER Adjustable Speed Drive as it pertains to the
bypass functionality of the Q9 F
LOW S AVER system. Every effort has been made to provide accurate and
concise information to you, our customer.
At Toshiba we’re continuously striving for better ways tomeet the constantly changing needs of
our customers. E-mailyour comments, questions, or concerns about this publication to Toshiba.
Manual’s Purpose and Scope
This manual provides information on how to safely install, operate, maintain, and dispose of your
Q9 F
LOW S AVER Adjustable Speed Drive. The information provided in this manual is applicable to the
Q9 F
LOW S AVER Adjustable Speed Drive system only.
This manual is to be used in conjunction with the Q9 ASD Installation and Operation Manual
(P/N 59445).
This manual provides information on the various features and functions of this powerful cost-saving
device, including
• Installation,
• System operation,
• Configuration and Control options, and
• Mechanical and electrical specifications.
Included is a section on general safety instructions that describe the warning labels and symbols that are
used. Read the manual completely before installing, operating, performing maintenance, or disposing of
this equipment.
This manual and the accompanying drawings should be considered a permanent part of the equipment
and should be readily available for reference and review.
Because of our commitment to continuous improvement, Toshiba International Corporation reserves the
right, without prior notice, to update information, make product changes, or to discontinue any product
or service identified in this publication.
Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or
consequential damages resulting from the use of the information contained within this manual.
This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form
without the prior written consent of Toshiba International Corporation.
Copyright ©2011 Toshiba International Corporation.
TOSHIBA®is a registered trademark of the Toshiba Corporation. All other product or trade references
appearing in this manual are registered trademarks of their respective owners.
All rights reserved.
Printed in the U.S.A.
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Contacting Toshiba’s Customer Support
Center
TIC’s Customer Support Center can be contacted to obtain help in resolving any Adjustable Speed
Drive system problem that you may experience or to provide application information.
The Support Center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Center’s toll free
number is US [phone]/Fax [phone] CAN [phone] MEX 01 [phone].
For after-hours support follow the directions in the outgoing message when calling.
You may also contact Toshiba International Corporation by writing to:
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041-9990
Attn: ASD Product Manager.
For further information on TIC’s products and services, please visit our website.
TOSHIBA INTERNATIONAL CORPORATION
Q9 F LOW S AVER ASD/Bypass Box
Please complete the Warranty Card supplied with your system and return it to Toshiba 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.
Complete the following information and retain for your records.
Model Number: ______________________________________________________________________
Serial Number:_______________________________________________________________________
Project Number (if applicable):__________________________________________________________
Date of Installation:___________________________________________________________________
Inspected By:________________________________________________________________________
Name of Application:_________________________________________________________________
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Table of Contents
Q9 FlowSaver Installation and Operation Manual i
General Safety Information ....................................................................................................1
Symbols and Warnings .......................................................................................................1
Safety Alert Symbol.........................................................................................................1
Signal Words....................................................................................................................1
Special Symbols...............................................................................................................2
Equipment Warning Labels .............................................................................................2
Equipment Inspection .........................................................................................................2
Qualified Personnel ............................................................................................................3
Handling and Storage .........................................................................................................3
Disposal ..............................................................................................................................3
Installation Precautions .......................................................................................................4
Location Selection............................................................................................................4
Mounting..........................................................................................................................4
Conductors and Grounding..............................................................................................5
Power Connections ..........................................................................................................5
Protection .........................................................................................................................6
System Integration Precautions ..........................................................................................6
Personnel Protection ........................................................................................................6
System Setup Requirements ...............................................................................................7
Operational and Maintenance Precautions .........................................................................8
CE Compliance Requirements ...............................................................................................9
Using RCD Protection ........................................................................................................9
EMC Installation Guidelines ..............................................................................................9
General EMC Guidelines for Consideration....................................................................9
EMC Compliant Installation Guidelines........................................................................10
Q9 FLOWSAVER Theory of Operation .............................................................................11
Stage 1 Function ...............................................................................................................11
Stage 2 Function ...............................................................................................................11
Stage 3 Function ...............................................................................................................11
Stage 4 Function ...............................................................................................................12
System Protection ..................................................................................................................14
ASD Protection .................................................................................................................14
Motor Protection ...............................................................................................................15
Motor Circuit Protector Adjustment and Setting...........................................................16
Overload Circuit Protector Adjustment and Setting......................................................17
Q9 FLOWSAVER Installation .............................................................................................18
Installation Notes ..............................................................................................................18
Input Power....................................................................................................................18
Control Signal Isolation.................................................................................................18
Jumper Requirements.....................................................................................................18
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ii Q9 FlowSaver Installation and Operation Manual
Output Terminals ...........................................................................................................18
Mounting and Connections ...............................................................................................19
Mounting the Q9 FLOWSAVER...................................................................................19
Mounting the Bypass Box..............................................................................................20
Connecting the Bypass Box...........................................................................................21
Startup and Test .............................................................................................................23
I/O Monitoring and Control .................................................................................................24
I/O Terminal Descriptions ................................................................................................25
Q9 FLOWSAVER Monitoring/Control Interface ............................................................28
Typical Q9 FLOWSAVER Connection Diagram ............................................................29
Q9 FLOWSAVER Control Panel Features ......................................................................33
Panel Item Descriptions .................................................................................................33
Enclosure Dimensional Information and Weights ..............................................................35
Enclosure Dimensions/Weights ........................................................................................37
Cable/Terminal Specifications ..............................................................................................41
Current/Voltage Specifications .............................................................................................43
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Q9 FlowSaver Installation and Operation Manual 1
General Safety Information
DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and
understood all of the product safety information and directions that are contained in this manual.
Note: For all references to the National Electrical Code (NEC), see the latest release of the
National Electrical Code.
Symbols and Warnings
Safety Alert Symbol
The Safety Alert Symbol indicates that a potential personal injury hazard exists. The symbol is
comprised of an equilateral triangle enclosing an exclamation mark.
Signal Words
Listed below are the signal words that are used throughout this manual followed by their descriptions
and associated symbols. When the words DANGER, WARNING and CAUTION are used in this
manual they will be followed by important safety information that must be carefully followed.
The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous
situation exists that, if not avoided or if instructions are not followed precisely, will result in serious
injury to personnel or loss of life.
The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous
situation exists that, if not avoided or if instructions are not followed precisely, could result in serious
injury to personnel or loss of life.
The word CAUTION preceded by the safety alert symbol indicates that a potentially hazardous
situation exists which, if not avoided or if instructions are not followed precisely, may result in minor or
moderate injury.
The word CAUTION without the safety alert symbol indicates a potentially hazardous situation exists
which, if not avoided or if instructions are not followed precisely, may result in equipment and property
damage.
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2 Q9 FlowSaver Installation and Operation Manual
Special Symbols
To identify special hazards, other symbols may appear in conjunction with the DANGER, WARNING
and CAUTION signal words. These symbols indicate areas that require special and/or strict adherence
to the procedures to prevent serious injury to personnel or loss of life.
Electrical Hazard Symbol
A symbol which indicates a hazard of injury from electrical
shock or burn. It is comprised of an equilateral triangle
enclosing a lightning bolt.
Explosion Hazard Symbol
A symbol that is comprised of an equilateral triangle enclosing
an explosion indicates a hazard of injury from exploding parts.
Equipment Warning Labels
DO NOT attempt to install, operate, perform maintenance, or dispose of this equipment until you have
read and understood all of the product labels and user directions that are contained in this manual.
Warning labels that are attached to the equipment will include the exclamation mark within a triangle.
DO NOT remove or cover any of these labels. If the labels are damaged or if additional labels are
required, contact your TIC Sales Representative.
Labels attached to the equipment are there to provide useful information or to indicate an imminently
hazardous situation that may result in serious injury, severe property and equipment damage, or loss of
life if safe procedures or methods are not followed as outlined in this manual.
Equipment Inspection
• Upon receipt of the equipment inspect the packaging and equipment for shipping damage.
• Carefully unpack the equipment and check for parts that may have been damaged during shipping,
missing parts, or concealed damage. If any discrepancies are discovered, it should be noted with the
carrier prior to accepting the shipment, if possible. File a claim with the carrier if necessary and
immediately notify your Toshiba sales representative.
•DO NOT install or energize equipment that has been damaged. Damaged equipment may fail
during operation resulting in equipment damage or personal injury.
• Check to see that the rated capacity and the model number specified on the nameplate conform to
the order specifications.
• Modification of this equipment is dangerous and must not be performed except by factory trained
representatives. When modifications are required contact Toshiba’s Customer Support Center.
• Inspections may be required before and after moving installed equipment.
• Keep the equipment in an upright position.
• Contact Toshiba’s Customer Support Center to report discrepancies or for assistance if required.
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Q9 FlowSaver Installation and Operation Manual 3
Qualified Personnel
Installation, operation, and maintenance shall be performed by Qualified Personnel Only. A Qualified
Person is one that has the skills and knowledge relating to the construction, installation, operation, and
maintenance of the electrical equipment and has received safety training on the hazards involved (Refer
to the latest edition of NFPA 70E for additional safety requirements).
Qualified Personnel shall:
• Have read the entire installation and operation manual.
• Be familiar with the construction and function of the Q9 F
LOW S AVER , the equipment being driven,
and the hazards involved.
• Be able to recognize and properly address hazards associated with the application of motor-driven
equipment.
• Be trained and authorized to safely energize, de-energize, ground, lockout/tagout circuits and
equipment, and clear faults in accordance with established safety practices.
• 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 osha website.
Handling and Storage
• Use proper lifting techniques when moving the Q9 F LOW S AVER ; including properly sizing up the
load, getting assistance, and using a forklift if required.
• Store in a well-ventilated covered location and preferably in the original carton if the equipment
will not be used upon receipt.
• Store in a cool, clean, and dry location. Avoid storage locations with extreme temperatures, rapid
temperature changes, high humidity, moisture, dust, corrosive gases, or metal particles.
• The storage temperature range of the Q9 F
LOW S AVER is 14° to 104° F (-10° to 40° C).
• Do not store in places that are exposed to outside weather conditions (i.e., wind, rain, snow, etc.).
• Store in an upright position.
Disposal
Never dispose of electrical components via incineration. Contact your state environmental agency for
details on disposal of electrical components and packaging in your area.
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4 Q9 FlowSaver Installation and Operation Manual
Installation Precautions
Location Selection
•TheToshibaQ9 F LOW S AVER is intended for permanent installations only.
• Select a mounting location that is easily accessible, has adequate personnel working space, and
adequate illumination for adjustment, inspection, and maintenance of the equipment (refer to NEC
Article 110-13).
•Do Not mount the Q9 F
LOW S AVER in a location that would produce catastrophic results if it were to
fall from its mounting location (equipment damage or injury).
•Do Not mount the Q9 F
LOW S AVER in a location that would allow it to be exposed to flammable
chemicals or gasses, water, solvents, or other fluids.
• The ambient operating temperature range of the Q9 F
LOW S AVER is 14° to 104° F (-10° to 40° C).
• The installation location shall not be exposed to direct sunlight.
• Avoid installation in areas where vibration, heat, humidity, dust, fibers, metal particles, explosive/
corrosive mists or gases, or sources of electrical noise are present.
• Allow proper clearance spaces for installation. Do not obstruct the ventilation openings. Refer to
the section titled Installation and Connections of the Q9 ASD Installation and Operation
Manual (P/N 59445) for further information on installation and ventilation requirements.
Mounting
•OnlyQualified Personnel should install this equipment.
• Install the unit in a secure and upright position in a well-ventilated area.
• Installation should conform to the National Electrical Code (NEC) — Article 110 (Requirements
For Electrical Installations), all regulations of the Occupational Safety and Health
Administration, and any other applicable national, regional, or industry codes and standards.
• Installation practices should conform to the latest revision of NFPA 70E Electrical Safety
Requirements for Employee Workplaces.
• It is the responsibility of the person installing the Q9 F
LOW S AVER or the electrical maintenance
personnel to ensure that the unit is installed into an enclosure that will protect personnel against
electric shock.
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Q9 FlowSaver Installation and Operation Manual 5
Conductors and Grounding
• Use separate metal conduits for routing the input power, output power, and control circuits and each
shall have its own ground cable.
• A separate ground cable should be run inside the conduit with the input power, output power, and
and control circuits.
•DO NOT connect the CC terminal of the Terminal Board to earth ground.
• Always ground the unit to prevent electrical shock and to help reduce electrical noise.
• It is the responsibility of the person installing the Q9 F
LOW S AVER or the electrical maintenance
personnel to provide proper grounding and branch circuit protection in accordance with the NEC
and any applicable local codes.
— The Metal Of Conduit Is Not An Acceptable Ground —
Power Connections
Contact With Energized Wiring Will Cause Severe Injury Or Death.
• Turn off, lockout, and tagout all power sources before proceeding to connect the power wiring to
the equipment.
• Ensure the correct supplied voltage, wiring used, and system type for the application (refer to the
NEC Article 300 – Wiring Methods and Article 310 – Conductors For General Wiring). Size the
branch circuit conductors in accordance with NEC Table 310.16.
• Only after ensuring that all power sources are turned off and isolated in accordance with
established lockout/tag out procedures, shall a three-phase power source of the correct voltage be
connected to the input terminals and the system output terminals be connected to a motor.
• Adhere to the recommended conductor sizes listed in the section titled Cable/Terminal
Specifications on pg. 41. If multiple conductors are used in parallel for the input or output power,
each branch of the parallel set shall have its own conduit and not share its conduit with other
parallel sets (i.e., place U1, V1, and W1 in one conduit and U2, V2, and W2 in another) (refer to the
NEC Article 300.20 and Article 310.4). National and local electrical codes should be referenced if
three or more power conductors are run in the same conduit (refer to the NEC Article 310
adjustment factors).
• Ensure that the 3-phase input power is Not connected to the output of the Q9 F
LOW S AVER . This will
damage the system and may cause injury to personnel.
•DO NOT install the Q9 F
LOW S AVER if it is damaged or if it is missing any component(s).
•DO NOT connect resistors across terminals PA – PC or PO – PC. This may cause a fire.
• Ensure the correct phase sequence and the desired direction of motor rotation in the Bypass mode
(if applicable).
• Turn the power on only after attaching and/or securing the front cover.
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6 Q9 FlowSaver Installation and Operation Manual
Protection
• Ensure that primary protection exists for the input wiring to the equipment. This protection must be
able to interrupt the available fault current from the power line. The equipment may or may not be
equipped with an input disconnect (option).
• All cable entry openings must be sealed to reduce the risk of entry by vermin and to allow for
maximum cooling efficiency.
• If using multiple motors provide separate overload protection for each motor and use V/f control.
• It is the responsibility of the person installing the Q9 F
LOW S AVER or the electrical maintenance
personnel to setup the Emergency Off braking system of the Q9 F
LOW S AVER . The function of the
Emergency Off braking function is to remove output power from the drive in the event of an
emergency. A supplemental braking system may also be engaged in the event of an emergency. For
further information on braking systems, see DC Injection Braking in the Q9 ASD Installation and
Operation Manual.
Note: A supplemental emergency stopping system should be used with the Q9 F
LOW S AVER .
Emergency stopping should not be a task of the Q9 F
LOW S AVER alone.
• Follow all warnings and precautions and do not exceed equipment ratings.
System Integration Precautions
The following precautions are provided as general guidelines for the setup of the Q9 F LOW S AVER
system.
•TheToshibaQ9 F
LOW S AVER is a general-purpose product. It is a system component only and the
system design should take this into consideration. Please contact Toshiba’s Customer Support
Center for application-specific information or for training support.
•TheToshibaQ9 F
LOW S AVER is part of a larger system and the safe operation of the Q9 F LOW S AVER
will depend on observing certain precautions and performing proper system integration.
• A detailed system analysis and job safety analysis should be performed by the systems designer
and/or systems integrator before the installation of the Q9 F
LOW S AVER component. Contact
Toshiba’s Customer Support Center for options availability and for application-specific system
integration information if required.
Personnel Protection
• Installation, operation, and maintenance shall be performed by Qualified Personnel Only.
• A thorough understanding of the Q9 F
LOW S AVER will be required before the installation, operation,
or maintenance of the Q9 F
LOW S AVER .
• Rotating machinery and live conductors can be hazardous and shall not come into contact with
humans. Personnel should be protected from all rotating machinery and electrical hazards at all
times.
• Insulators, machine guards, and electrical safeguards may fail or be defeated by the purposeful or
inadvertent actions of workers. Insulators, machine guards, and electrical safeguards are to be
inspected (and tested where possible) at installation and periodically after installation for potential
hazardous conditions.
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Q9 FlowSaver Installation and Operation Manual 7
•DO NOT allow personnel near rotating machinery. Warning signs to this effect shall be posted at or
near the machinery.
•DO NOT allow personnel near electrical conductors. Human contact with electrical conductors can
be fatal. Warning signs to this effect shall be posted at or near the hazard.
• Personal protection equipment shall be provided and used to protect employees from any hazards
inherent to system operation.
System Setup Requirements
• When using the Q9 F LOW S AVER as an integral part of a larger system, it is the responsibility of the
Q9 F
LOW S AVER installer or maintenance personnel to ensure that there is a fail-safe in place (i.e., an
arrangement designed to switch the system to a safe condition if there is a fault or failure).
• System safety features should be employed and designed into the integrated system in a manner
such that system operation, even in the event of system failure, will not cause harm or result in
personnel injury or system damage (i.e., E-Off, Auto-Restart settings, System Interlocks, etc.).
• The programming setup and system configuration of the Q9 F
LOW S AVER may allow it to start the
motor unexpectedly. A familiarity with the Auto-restart settings is a requirement to use this
product.
• Improperly designed or improperly installed system interlocks may render the motor unable to start
or stop on command.
• The failure of external or ancillary components may cause intermittent system operation (i.e., the
system may start the motor without warning).
• There may be thermal or physical properties, or ancillary devices integrated into the overall system
that may allow for the Q9 F
LOW S AVER to start the motor without warning. Signs at the equipment
installation must be posted to this effect.
• If a secondary magnetic contactor (MC) is used between the ASD and the load, it should be
interlocked to halt the ASD before the secondary contact opens. If the output contactor is used for
bypass operation, it must be interlocked such that commercial power is never applied to the ASD
output terminals (T1, T2, T3).
• Power factor improvement capacitors or surge absorbers MUST NOT BE INSTALLED on the
output of the Q9 F
LOW S AVER .
• Use of the built-in system protective features is highly recommended (i.e., E-Off, Overload
Protection, etc.).
• The operating controls and system status indicators should be clearly readable and positioned
where the operator can see them without obstruction.
•TheDynamic Braking function is not used with the Q9 ASD.
•DO NOT attempt to configure or connect the DBR function to the Q9 ASD.
• Attempts to configure or adapt the Q9 ASD to use the Dynamic Braking function may result in
system damage or injury to personnel.
• Additional warnings and notifications shall be posted at the equipment installation location as
deemed required by Qualified Personnel.
• Follow all warnings and precautions and do not exceed equipment ratings.
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8 Q9 FlowSaver Installation and Operation Manual
Operational and Maintenance Precautions
• Turn off, lockout, and tagout the main power, the control power, and instrumentation connections
before inspecting or servicing the drive, or opening the door of the enclosure.
• Turn off, lockout, and tagout the main power, the control power, and instrumentation connections
before proceeding to disconnect or connect the power wiring to the equipment.
• The capacitors of the Q9 F
LOW S AVER maintain a residual charge for a period of time after turning
the off the Q9 F
LOW S AVER . The required wait time for each system typeform is indicated with a
cabinet label and a Charge LED. Wait for at least the minimum time indicated on the enclosure-
mounted label and ensure that the Charge LED has gone out before opening the door of the Q9
F
LOW S AVER once the power has been turned off.
• Turn the power on only after attaching (or closing) the front cover and DO NOT remove the front
cover of the Q9 F
LOW S AVER when the power is on.
•DO NOT attempt to disassemble, modify, or repair the system. Call your Toshiba sales
representative for repair information.
•DO NOT place any objects inside of the Q9 F
LOW S AVER .
• If the system should emit smoke or an unusual odor or sound, turn the power off immediately.
• The heat sink and other components may become extremely hot to the touch. Allow the unit to cool
before coming in contact with these items.
• Remove power from the Q9 F
LOW S AVER during extended periods of non-use.
• The system should be inspected periodically for damaged or improperly functioning parts,
cleanliness, and to ensure that the connectors are tightened securely.
• Ensure that the Run functions (F, R, Preset Speed, etc.) of the Q9 F
LOW S AVER are off before
performing a Reset. The post-reset settings may allow the motor to start unexpectedly.
•Retry or Reset settings may allow the motor to start unexpectedly. Warnings to this effect should
be clearly posted on or near the Q9 F
LOW S AVER and the motor.
• In the event of a power failure, the motor may restart after power is restored.
• Use caution when setting the output frequency. Over speeding a motor decreases its ability to
deliver torque and may result in damage to the motor and/or the driven equipment.
•TheQ9 F
LOW S AVER is designed to operate NEMA B motors. Consult with your sales representative
before using the Q9 F
LOW S AVER for special applications such as with an explosion-proof motor or
applications with a piston load.
DO NOT install, operate, perform maintenance, or dispose of this equipment until you have read and
understood all of the product warnings and user directions. Failure to do so may result in equipment
damage, operator injury, or loss of life.
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Q9 FlowSaver Installation and Operation Manual 9
CE Compliance Requirements
In addition to the local and regional safety requirements, this section describes additional criteria that
must be met to qualify for European Conformity (CE) certification. All relevant apparatus placed on
the European market is required to comply to the European Community directive on electromagnetic
compatibility (EMC). The following instructions provide a means of compliance for the Q9
F
LOW S AVER . A Technical Construction File (TCF) indicates the rationale used to declare compliance and
is on file at Toshiba International Corporation, Houston, Texas, U.S.A.
Using RCD Protection
Where a residual-current-operated protective device (RCD) is used to guard against direct or indirect
contact, only an RCD of Type B is allowed on the supply side of this Electronic Equipment.
Otherwise, another protective measure shall be applied, such as separation of the Electronic Equipment
from the environment by double or reinforced insulation, or isolation of the Electronic Equipment and
supply side by a transformer.
EMC Installation Guidelines
All systems placed on the European market are required to comply with the European Community
directive regarding electromagnet compatibility (EMC). Toshiba ensures that all systems deployed in
the European market have been screened and are in 100% compliance.
General EMC Guidelines for Consideration
• Input filters of the appropriate rating shall be used.
• Proper grounding is a requirement.
• Grounds shall be kept to the minimum length to accomplish the connection.
• Grounds shall have low RF impedance.
• A central ground shall be employed in a complex system.
• Paint or corrosion can hamper good grounding; remove as required.
• Keep control and power cabling separated. Minimize exposed (unscreened) cable.
• Use 360° shielded connections where possible.
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10 Q9 FlowSaver Installation and Operation Manual
EMC Compliant Installation Guidelines
The Q9 F LOW S AVER should be installed in accordance with the following guidelines.
1. Filtering — An input filter shall be used with the ASD. A Schaffner FN258 series input filter of the
appropriate rating shall be used and mounted adjacent to the ASD.
2. Mechanical — The ASD and the associated equipment shall be mounted on a flat metallic
backplane. A minimum space of 5 cm (2 inches) shall exist between the ASD and the filter to allow
for ventilation. The filter output cable is to be connected from the bottom of the filter to the ASD
power input and is to be the minimum length required for a connection.
Units received as an Open Chassis shall not be placed into operation until being placed into an
approved enclosure that will protect personnel against electrical shock.
Opening and closing of enclosures or barriers should be possible only with the use of a key or a
tool.
3. Cabling — The cables of the input power, filter, and motor shall be of the appropriate current
rating. The cables shall be connected in accordance with the guidelines of the manufacturer and the
applicable local and national agencies. A 4-core screened cable (such as RS 379-384) is to be used
for the power and earth connections to minimize RF emissions. Control cabling must be screened
using P/N RS 367-347 or a similar component.
4. Grounding — The mains (input) ground shall be connected at the ground terminal provided on the
filter. The filter and motor shall be grounded at the ground terminals provided in the ASD.
5. Screening — The mains (input) screen is to be connected to the metallic back-plane at the filter;
remove any finish coating as required. The screen over the filter output cables, the motor cable
screen, and the control wire screens must be connected to the ASD case using glands or conduit
connectors. The motor cable screen shall be connected to the motor case. When using a braking
resistor, the cabling between the resistor and ASD shall also be screened. This screen shall connect
to both the ASD enclosure and the resistor enclosure.
See the Q9 F
LOW S AVER Filter Selection below for the recommended input filters for a given typeform.
Q9 F LOW S AVER Filter Selection Table
230V Filter
Number 460V Filter Number 460V Filter Number
Q92015I FN258-7 Q94015I
FN258-7
Q94500 FN258-100
Q92025I FN258-16 Q94025I Q94600
Q92035I Q94035I Q94750 FS5236-130
Q92055I FN258-30 Q94055I FN258-16 Q9410K FS5236-180
Q92080I Q94080I Q9412K FS5236-300
Q92110I FN258-42 Q94110I FN258-30 BYP4-070E FN258-100
Q92160I FN258-75 Q94160I BYP4-080E
Q92220I FN258-100 Q94220I FN258-42 BYP4-100E FN258-130
Q92270I Q94270I FN258-55 BYP4-125E FN258-180
Q92330I FN258-130 Q94330I BYP4-160E FS5236-300
Q92400I FN258-180 Q94400I FN258-75
BYP2-100E FN258-130
BYP2-125E FN258-180
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Q9 FlowSaver Installation and Operation Manual 11
Q9 F LOW S AVER Theory of Operation
The Q9 F LOW S AVER ASD system is available in three configurations. The system configuration type is
defined by the suffix A, C, or Eas shown in the part numbering convention on pg. 35.
In the description below, system operation for the Q9 F
LOW S AVER Aand Ctypes differ from the Etype
where the referenced function is not supported by the Aor Ctypeform. The following explanation
targets the Q9 F
LOW S AVER Econfiguration.
Note: Reference Figure 1 on pg. 13 and Figure 7 on pg. 29 for the following explanation.
Note: The 200-volt 30 HP and 40 HP Q9 F
LOW S AVER ASD systems are designed with the
ASD component and the Bypass Box provided and mounted as separate items
(e.i., the ASD is sold separately). The same is true for the 400-volt 50 – 100 HP Q9
F
LOW S AVER ASD Systems.
The Integrated Enclosure and the BYP Series systems operate in the same manner —
as described below.
Initially all switches are open and the normal states of all relays are as indicated in Figure 1 on pg. 13.
Stage 1 Function
Power is applied to stage one via the Control Power Transformer (CPT). The 120 VAC signal is
applied to the Shunt Trip circuit and LED 5 (Control Power). LED 5 illuminates and if the LS switch
is open (enclosure door is closed), the system is enabled for normal operation.
If the LS switch is closed (enclosure door is open), the Motor Circuit Protector (MCP) is opened via
the Shunt Trip function (see Motor Protection on pg. 15) and the 3-phase input voltage to the system is
terminated. The LS switch may be connected to an ancillary circuit that can perform a system shutdown
in the event of a system malfunction or an ancillary circuit status change (e.g., door opens, etc.). The LS
switch is used as a door interlock in this example.
Stage 2 Function
Stage two has two operating modes: Test operation and INV operation (K2 energized).
If the Test switch (SW1) is closed or if K2 is energized via SW2 (SW2 to INV, OL closed [open =
overload], and CIA-to-B closure required) the K1 relay is energized and the states of the K1 contacts
change.
LED1 illuminates (if in the Test mode) and the 1M contactor energizes which closes the 1M contacts
(see Figure 7 on pg. 29; 3-phase input is applied to the ASD).
Stage 3 Function
The closures of the OL contacts of the motor overload relay and the CIA/B (Customer Interface)
contacts are required to provide 120 VAC to stage 3.
The CIA/B contacts are configured by the user such that the system is disabled in the event that any
user-selected function changes state (i.e., alarm is initiated, door is opened, etc.). CIA/B contacts may
be jumpered if unused.
The three positions of SW2; Off, INV, and BYP, are described below.
Off — K2 and K3 remain in the normal state.
INV — Energizes K2 which turns off LED 1 (Test Mode) (if on), illuminates LED 2 (INV Mode),
opens K2 at stage 3, closes K2 at stage 4, and completes the ST terminal path via PCB 11. The
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12 Q9 FlowSaver Installation and Operation Manual
resulting closure of K2 at stage 4 energizes the 2M contactor (jumper or open-damper signal at DRA/
B required) which allows the ASD output to be applied to the motor (see 2M at Figure 7 on pg. 29).
BYP — Energizes K3 which turns off LED 2 (INV Mode) (if on), illuminates LED 3 (Bypass
Mode), opens K2 at stage 4 (which opens 2M if closed), and closes K3 at stage 4. The resulting
closure of K3 at stage 4 energizes the 3M contactor (jumper or open-damper signal at DRA/B
required) which allows the utility power to be applied directly to the motor bypassing the ASD (see
3M at Figure 7 on pg. 29).
Note: Ensure that the phase relationship of the L1, L2, and L3 connections to the motor for
the Bypass mode of operation and for the ASD-driven operation are consistent. The
Reverse and Forward functions will be reversed if not properly connected (see
diagram in Figure 7 on pg. 29).
The Damper Response feedback circuit (DRA/DRB) may be used to prevent a motor from attempting
to force air flow through a duct that has a closed damper.
Damper motor power (120 VAC) is provided from an external source and is applied via the switched
DSA/DSB circuit (OUT1 contacts). The 120 VAC is switched via the OUT1 contacts while operating in
the INV mode or switched via the K3 contacts while operating in the Bypass mode.
Note: OUT1 contacts are labeled DSA and DSB on the terminal board.
Stage 4 Function
In the INV mode, the OUT1 closure (set to Damper Command) occurs upon receiving a Run command
and allows power to be applied to the damper motor. Once the damper-mounted DRA-to-DRB contacts
are closed (open damper required), K4 is energized.
LED 4 (System Interlock) illuminates and the K4 contacts close the S3-to-CC connection (JP1 jumper
required) completing the Damper Feedback circuit requirement for ASD operation. The DRA-to-DRB
closure also provides power to the 2M coil allowing for the ASD output to be applied to the motor.
If no discrete input terminal is assigned the function Damper Feedback, this permissive
in no longer a requirement for normal system operation.
With all other permissives configured to run, the motor will run without activating a
Damper Feedback discrete input terminal.
In the Bypass mode, switching SW2 to the Bypass operating mode energizes K3. The K3 contact
closure at PCB 11 applies power to the damper motor (Terminal Board [P/N 53750] jumpers JPDS1 and
JPDS2 are required). Once the damper-mounted DRA-to-DRB contacts are closed (open damper
required), the 3M coil is energized providing utility power to the motor, bypassing the ASD.
The DRA-to-DRB contacts are provided via a reversible damper-mounted switch. The switch
terminates power to the damper motor once the damper is fully opened or closed (reversible means that
only the opposite function is available once reaching the fully opened or closed position).
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Q9 FlowSaver Installation and Operation Manual 13
Figure 1. Simplified depiction (Ladder Logic) of the Q9 F LOW S AVER Bypass operation.
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