Toshiba TOSVERT VF-AS1 Series User manual

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TOSVERT VF-AS1/PS1/AS3
PB unit Option
( PB7-4200K / 4400K )
( PB7-6300K / 6400K )
Instruction Manual
NOTICE
1. Make sure that this instruction manual is delivered to the end user of PB unit.
2. Read this manual before installing or operating PB unit, and store it in a safe place for
reference.
3. All information contained in this manual will be changed without notice.

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Ⅰ. Safety precautions
The items described in these instructions and on the inverter itself are very important.
Read these precautions and warnings to prevent injury to yourself and other people
around you as well as prevent damage to property in the area.
Thoroughly familiarize yourself with all safety precautions and etc. on the
instruction manual of the VF-AS1/PS1/AS3, and then continue to read the
manual. Make sure that you observe all warnings given.
■General Operation
Warning
Disassembly
prohibited
▼Never disassemble, modify or repair. This can result in electric shock, fire
and injury. For repairs, call your sales agency.
Prohibited
▼Never remove the front cover when power is on or open door if enclosed in
a cabinet. The unit contains many high voltage parts and contact with them
will result in electric shock.
▼Don't stick your fingers into openings such as cable wiring hole and cooling
fan covers. This can result in electric shock or other injury.
▼Don't place or insert any kind of object into the inverter (electrical wire
cuttings, rods, wires). This can result in electric shock or fire.
▼Do not allow water or any other fluid to come in contact with the inverter.
This can result in electric shock or fire.
Mandatory
▼Wiring must be done after turning off all input power to the VF-AS1/PS1/AS3.
▼If the inverter begins to emit smoke or an unusual odor, or unusual sounds,
immediately turn power off. If the equipment is continued to operate in such
a state, the result may be fire. Call your local sales agency for repairs.
■Transportation & installation
Warning
Prohibited
▼Do not install or operate the inverter if it is damaged or any component is
missing. This can result in electric shock or fire. Please consult your local
sales agency for repairs.
▼Do not place any inflammable objects nearby. If a flame is emitted due to
malfunction, it may result in a fire.
▼Do not install in any location where the inverter could come into contact
with water or other fluids. This can result in electric shock or fire.
Mandatory
▼Must be used in the environmental conditions prescribed in the instruction
manual. Use under any other conditions may result in malfunction.
Caution
Prohibited
▼Do not install in any area where the unit would be subject to large amounts
of vibration. That could result in the unit falling, resulting in injury.

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■Wiring
Warning
Mandatory
▼The following steps must be performed before wiring.
(1) Turn off all input power to the inverter.
(2) Wait at least 15 minutes and check to make sure that the charge
lamp of the VF-AS1/PS1/AS3 is no longer lit.
(3) Use a tester that can measure *1)DC voltage 800VDC or more, and
check to make sure that the voltage to the DC main circuits (between
PA and PC) is 45V or less.
If these steps are not properly performed, the wiring will cause electric
shock.
▼Tighten the screws on the terminal board to specified torque.
If the screws are not tightened to the specified torque, it may lead to fire.
*1) In case of 690V inverter, use a tester of DC voltage 1400VDC or more.
■Operations
Warning
Prohibited
▼Do not touch inverter and option unit terminals when electrical power is
applied to the inverter even if the motor is stopped.
Touching the inverter terminals while power is connected to it may result
in electric shock.
▼Do not touch switches when hands are wet and do not try to clean the
inverter with a damp cloth. Such practices may result in electric shock.
▼Do not pull the cable. This can result in damage or malfunction.
■Disposal
Caution
Mandatory
▼If you throw away this product, have it done by a specialist in industry
waste disposal*. If the collection, transport and disposal of industrial
waste is done by someone who is not licensed for that job, it is a
punishable violation of the law. (Laws in regard to cleaning and
processing of waste materials)
(*)Persons who specialize in the processing of waste and known as
“industrial waste product collectors and transporters”or “industrial waste
disposal persons”.

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Ⅱ. Introduction
Thank you for your purchase of the PB unit option (called the PB unit after this) for
the inverter “TOSVERT VF-AS1/PS1/AS3”.
This PB unit is the separate dynamic braking unit to use with the inverter
“TOSVERT VF-AS1/PS1/AS3”.
Before using the PB unit, read this manual and refer to the instruction manual of the
pairing inverter, after that use it appropriately.

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- Contents -
Ⅰ．Safety precautions 1
Ⅱ．Introduction 3
1. Read first 5
2. Names, specifications and dimensions 6
3. Standard connections 8
4. Installation 9
5. Set parameters 15
6. Replacement of expendable parts 17
7. Warranty 17

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１.Read first
■Check product purchase
Before using the product you have purchased, check to make sure that it is exactly
what you ordered.
[Check the accessories]
This PB unit option is composed of PB unit and following accessories.
Unpack a parcel and check to make sure the contents.
○Instruction manual : This manual
○Bus bars for connecting the BU terminals :
Parts (B) in this manual, see page 10, 12 and 13
○Cover of DC choke chassis : Parts (E) in this manual, see page 11 (PB7-4200K only)
○Screw for connecting PB unit
[Check the name plate]
The name plate is put on the left-hand side of the PB unit on the position of figure below.
[ Contents of the product ]
Explanation of the type and form written on the label.
ＰＢ７－４２００Ｋ
Modelname Voltageclass Regenerativebrakingcapacity
PB unit Type
Input Voltage (DC)
threshold Voltage
Maximum braking power
Maximum continuous power
Minimum allowableresistance
Name plate

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2. Names, specifications and dimensions
■Specifications
PB unit type
PB7-4200K
PB7-4400K
PB7-6300K
PB7-6400K
threshold voltage
(note2)
758V (at F626=134)
1090V(at F626=134)
Maximum DC bus
voltage
825V
1170V
Maximum braking power
at threshold voltage
420kW-12s
750kW-12s
450kW-7s
900kW-7s
Maximum continuous
power
200kW
400kW
300kW
400kW
% ED
5% - 420kW
5% - 750kW
5% - 450kW
5% - 900kW
15% - 320kW
15% - 550kW
15% - 400kW
15% - 600kW
50% - 250kW
50% - 440kW
50% - 350kW
50% - 500kW
cycle time
240 second or less
140 second or less
Braking poweron a
vertical movement
Protective function
(note1)
overheat protection, overcurrent protection,
overheat protection for AC fan (PB7-4400K, 6300K, 6400K)
Minimumallowable
resistance
1.0Ω
0.7Ω
2.0Ω
1.0Ω
Ambient temperature
-10 to +50 ℃
Storage temperature
-25 to +70 ℃
Relative humidity
20 to 93 % (free from condensation)
Vibration
5.9m/s2{0.6G} or less (10 to 55Hz)
Protective method
IP00 Open type
Calorific values
550W
1050W
650W
1150W
Forced ventilation
3.2m3/min
6.0m3/min
3.7m3/min
6.6m3/min
Color
RAL9006
(German
standard)
RAL7016 (German standard)
Installation position
mountcloselyon
theleft-handsideof
theinverter
mount on the left-hand side of the inverter
Approx weight
30kg
80kg
note1) When each protective functions are detected, the alarm is outputted from the
inverter main unit.
note2) Threshold voltage can be adjusted using the inverter parameter F626.
10s
440kW
110s
120s
0kW
750kW
15s
500kW
65s
60s
0kW
900kW
10s
250kW
110s
120s
0kW
420kW
15s
350kW
65s
60s
0kW
450kW

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■Outline drawing
■Selection of braking resistor
Standard braking resistors and recommended wire size are listed in the table below.
PB7-4200K
PB7-4400K
VFAS1-4200KPC,
4220KPC
VFAS3-4200KPC,
4220KPC
Rating : 8.7kW –1.9Ω
PA, PB terminal : 150mm2
-
VFAS1-4280KPC
VFPS1-4250KPC
4280KPC
4315KPC
VFAS3-4280KPC
Rating : 14kW –1.4Ω
PA, PB terminal : 150mm2
-
VFAS1-4355KPC,
4400KPC
VFPS1-4400KPC
-
Rating : 17.4kW –0.95Ω
PA, PB terminal : 185mm2 x2
G/E terminal : 150mm2 x2
VFAS1-4500KPC
VFPS1-4500KPC
4630KPC
-
Rating : 28kW –0.7Ω
PA, PB terminal : 185mm2 x2
G/E terminal : 150mm2 x2
(for 4630KPC 185mm2 x2)
Maximum cable length between the PB unit and the braking resistor is 50m.
Refer to the specifications (page 6 of this manual) for minimum allowable resistance
value of braking resistor.
Note1) The recommended wire size is that of the wire with continuous maximum
permissible temperature of 75 oC, ambient temp is 40 oC or less and the
wiring distance is 30m or less.
Note2) This wire size is conformity to IEC60364-5-52 (IEC60364-5-54 for grounding
wire)
VFAS1-4200KPC ～4280KPC
（VFPS1-4250KPC～4315KPC）
＋DCL1-4200K，4280K
＋PB7-4200K
or
VFAS3-4200KPC～4280KPC
(DCL1 is included in the package)
＋PB7-4200K
VFAS1-4200KPC ～4280KPC/
（VFPS1-4250KPC～4315KPC）
＋PB7-4200K
PB7-4400K, -6300K, 6400K
note) (1),(2) of below figure are
the dimensions of
(1) with the screws and (2) without the screws
VF-AS1/PS1
or AS3
DCL1
PB7-4200K
note) PB7-4400K, -6300K, 6400K are mechanically
mounted on the wall or the bottom of an enclosure
on the left of the inverter VF-AS1/PS1, and must be
placed 110mm (±5mm) from the inverter.

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3. Standard connections
Fuse
IM
Motor
TC
MC
R/L1
S/L2
T/L3
U/T1
V/T2
W/T3
BU+
FLB
BU-
F
FLC
FLA
R
CC
external braking resistor (optional)
[Note 1]
MC
MCCB
Three-phase
main circuit
power supply
Power supply
Surge killer
Forward run/stop
Reverse run/stop
* If no power supply is
provided for the control circuit
Inverter
Step-Down
transformer
200V
TH - Ry
PA
PB
Dynamic braking unit
PB7
[Note 2]
[Note 3]
Note 1: Connection when using a MCCB with a top coil instead of a MC.
Note 2: A Step-Down transformer is required for 400V/690V models but not for 200V models.
Note 3: As a last resort to prevent fire, be sure to connect a thermal relay (TH-Ry).
Select and connect a thermal relay (TH-Ry) appropriate to the capacity
(Wattage) of the braking resistor.
［Position of terminals］
acasetousethePBunit
G/E terminal
(2xM12 screw)
PB7-4200K
PB7-4400K, -6300K, -6400K
PA terminal
(M10 screw)
PB terminal
(M10 screw)
PA terminal
PB terminal
BU+ terminal
(2xM12 screw)
BU- terminal
(2xM12 screw)
PA terminal
(2xM12 screw)
PB terminal
(2xM12 screw)

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4. Installation
Show below about how to connect between PB7 unit and VF-AS1/PS1/AS3, and
installation environment.
●Applicable inverter
PB7-4200K is mechanically mounted on the left-hand side of the inverter
VF-AS1/PS1/AS3.
PB7-4400K, -6300K, -6400K are mechanically mounted on the wall or the back of an
enclosure on the left of the inverter VF-AS1/PS1, and must be placed 110mm
(±5mm) from the inverter.
After the mechanical installation of PB unit, connect the bus bars and each cables
between the inverter and the PB unit.
■How to connect between PB7-4200K and VF-AS1/PS1/AS3
1. Mechanically install the VF-AS1/PS1/AS3.
2. Remove the cover of VF-AS1/PS1/AS3 in accordance with the safety instructions given
in this document. (Figures shown in following instruction is VF-AS1)
3. Detach removable part (A) from the left-hand side of the VF-AS1/PS1/AS3.
VFAS1
VFPS1
VFAS3
PB7-4200K
-4200KPC, -4220KPC
-4280KPC
-4250KPC, -4280KPC
-4315KPC
-4200KPC, -4220KPC
-4280KPC
PB7-4400K
-4355KPC, -4400KPC
-4500KPC
-4400KPC, -4500KPC
-4630KPC
PB7-6300K
-6200KPC, -6250KPC
-6315KPC
-6250KPC, -6315KPC
-6400KPC
PB7-6400K
-6400KPC, -6500KPC
-6630KPC
-6500KPC, -6630KPC

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4. Mount the PB7-4200K on the left-hand side of the VF-AS1/PS1/AS3.
There are 5 fixing points (5xM8).
5. Connect the bus bars (B) between terminals BU- and BU+ on the VF-AS1/PS1/AS3
and terminals BU- and BU+ on the PB7-4200K.
6. Connect the braking resistor to PA and PB terminals on the PB7-4200K.
BU-BU+
X3
BU-
BU+
BU+ BU-
BU+BU-
X3
BU-
BU+
BU+ BU-
BU+
BU-
B
B

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7. Connect the control cables:
- Connect control cable X20 on the PB7-4200Ktocable X20on the VF-AS1/PS1/AS3.
- ConnectcontrolcableX92onthePB7-4200KtoconnectorX92ontheVF-AS1/PS1/AS3.
- Disconnect cable X3 on the VF-AS1/PS1/AS3 from connector X3 on the PCBA of
the VF-AS1/PS1/AS3.
- Connect disconnected cable X3 to cable X3B on the PB7-4200K.
-ConnectcableX3AonthePB7-4200KtoconnectorX3onthePCBAoftheVF-AS1/PS1/AS3.
(The following is the case when use with DC choke option.)
8. Mount the DC choke chassis (C) on the wall or on the bottom of the enclosure.
Refer to the attached installation manual of DC choke option.
9. Detach removable part (D) from DC choke chassis.
10. Mount the PB7-4200K cover (E) on the DC choke chassis.
11. Install the DC chokes in accordance with the installation manual of DC choke
option.

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■How to connect between PB7-4400K, -6300K, -6400K and VF-AS1/PS1
1. Mechanically install the VF-AS1/PS1 and the PB7 unit.
2.Remove the cover of VF-AS1/PS1 in accordance with the safety instructions given
in this document.
3. Detach removable part (A) located inside the VF-AS1/PS1.
4. Connect the bus bars (B) between terminals BU- and BU+ on the VF-AS1/PS1
and terminals BU- and BU+ on the PB7 unit.
A
B
B
PB7-4400K
110 +/- 5
A
B
B
PB7-6300K

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110,50
5. Connect the each cables:
- Connect the X1 control cable from the PB7 unit to the X1 connector on the
VF-AS1/PS1 via the control cable hole.
- Connect the fan power supply cable from the PB7 unit to the connector X2
on the VF-AS1/PS1.
X2 X1
PB7-6400K
PB7-4400K

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X2
X1
PB7-6300K
PB7-6400K

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■Installation environment
Install the PB unit in a well-ventilated indoor place
and mount in portrait orientation.
As PB unit uses a built-in cooling fan, at least leave
a space of 100mm or more above and below the
PB unit.
note) Do not install in any location where there is
high humidity or high temperatures and where
there are large amounts of dust and metallic
fragments. If you are going to install the
equipment in any area that presents a
potential problem, please consult with your
supplier before doing so.
5. Set parameters
Set parameters of the inverter after installation the PB unit. Refer to instruction
manual of the VF-AS1 (E6581301 or E6581442 or E6581528) VF-PS1(E6581386 or
E6581531) section 5.19, VF-AS3 (E6582062 section 6.15.4) about how to set
parameters.
[Parameter setting]
Title
Function
Adjustment range
Default setting

Dynamic braking
selection
note1), note2)
Setting
Braking
function
ST-off
Overload
detect


Disabled
―
―

Enabled (It is
effective in trip
condition.) The
state of  trip
is excluded.
Enabled
protect

not protect

Disabled
protect

not protect

Enabled (It isn't
effective in trip
condition )
Enabled
protect

not protect

Disabled
protect

not protect

Dynamic braking
resistance
~ Ω
According to
inverter model

Dynamic braking
resistor capacity
~ kW
According to
inverter model

Overvoltage limit
operation level
(Regenerative
braking level)
~%
note3)


Braking resistance
overload time
~ sec.


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１６
Note1)  is set to or more when PB unit is used.
And set  (Overvoltage limit operation) to .
Note2) =3 to 8 is available only for inverter software version 152 or more
(VFAS1), 652 or more (VFPS1).
Note3) When PB unit is used,  setting is recommended in the table below.
model
Inverter line supply (AC)
recommended range
PB7-4200K
PB7-4400K
380V/400V
112% to 145%
440V
123% to 145%
460V
129% to 145%
480V
134% to 145%
PB7-6300K
PB7-6400K
500V
113% to 150%
575V
113% to 144%
690V
113% to 120%

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6. Replacement of expendable parts
The PB unit is composed of a large number of electronic parts including
semiconductor devices. The following parts deteriorate with the passage of time
because of their composition or physical properties. The use of aged or deteriorated
parts leads to degradation in the performance or a breakdown of the equipment. To
avoid such trouble, the PB unit should be checked periodically.
note) Generally, the life of a part depends on the ambient temperature and the
conditions of use. The life spans listed below are applicable to parts when used
under normal environmental conditions.
1) Cooling fan
The fan, which cools down heat-generating parts, has a service life of about 10
years (average ambient temperature : 40℃, operation time : 12 hours per day).
The fan also needs to be replaced if it makes a noise or vibrates abnormally.
2) Smoothing capacitor (for PB7-4400K, 6300K, 6400K)
The smoothing aluminum electrolytic capacitor in the main circuit DC section
degrades in performance because of ripple current, etc. It becomes necessary to
replace the capacitor after it is used for about 5 years under normal conditions
(average ambient temperature : 40℃, load factor : not more than 80%, operation
time : 12 hours per day).
note) When it becomes necessary to replace expendable parts, contact your
supplier. For safety’s sake, never replace any part on your own.
7. Warranty
Any part of the PB unit that proves defective will be repaired and adjusted free of
charge under the following conditions:
1. Any part of the PB unit which fails or is damaged under normal installation and
use within 1 year from the date of delivery shall be repaired free of charge.
2. This warranty applies only to the PB unit option main unit.
3. For the following kinds of failure or damage, the repair cost shall be borne by the
customer even within the warranty period.
a) Failure or damage caused by improper or incorrect use or handling, or
unauthorized repair or modification of the PB unit
b) Failure or damage caused by the PB unit falling or an accident during
transportation after the purchase
c) Failure or damage caused by fire, salty water or wind, corrosive gas, earthquake,
storm or flood, lightning, abnormal voltage supply, or other natural disasters
d) Failure or damage caused bythe use of the PB unit for any purpose or application
other than the intended one
4. Unless a service contract is signed beforehand between the customer and Toshiba,
in which case the service contract has priority over this warranty.
©Toshiba Schneider Inverter Corporation 2006