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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