G7 Adjustable Speed Drive
`Operation Manual
`
`Document Number: 51546-009
`Date: March, 2005
`
`HALLIBURTON EXHIBIT 1006
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`Introduction
`
`Congratulations on the purchase of the new G7 True Torque Control2 Adjustable Speed Drive (ASD).
`The G7 True Torque Control2 Adjustable Speed Drive is a solid-state AC drive that features True
`Torque Control2. TIC’s Vector Control Algorithm 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 G7 uses digitally-controlled pulse width modulation. The programmable functions may be accessed
`via the easy-to-use menu or via the Direct Access Numbers (see page 59). This feature, combined with
`Toshiba’s high-performance software, delivers unparalleled motor control and reliability.
`
`The G7 is a very powerful tool, yet surprisingly simple to operate. The user-friendly Electronic Operator
`Interface (EOI) of the G7 has an easy-to-read 240 x 64 pixel graphical LCD screen. The EOI provides
`easy access to the many monitoring and programming features of the G7.
`
`The motor control software is menu-driven, which allows for easy access to the motor control parameters
`and quick changes when required.
`
`To maximize the abilities of your new G7, a working familiarity with this manual will be required. This
`manual has been prepared for the G7 ASD installer, user, and maintenance personnel. This manual may
`also be used as a reference guide 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 your Toshiba
`representative.
`
`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.
`
`Misuse of this equipment could result in injury and equipment damage. In no event will Toshiba
`Corporation be responsible or liable for direct, indirect, special, or consequential damage or injury
`that may result from the misuse of this equipment.
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`HALLIBURTON EXHIBIT 1006
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`Contacting Toshiba’s Customer Support
`Center
`
`Toshiba’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 center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free
`number is US (800) 231-1412/Fax (713) 466-8773 — Canada (800) 527-1204.
`
`You may also contact Toshiba by writing to:
`
`Toshiba International Corporation
`
`13131 West Little York Road
`
`Houston, Texas 77041-9990
`
`Attn: ASD Product Manager.
`
`For further information on Toshiba’s products and services, please visit our website at
`www.tic.toshiba.com (right click and select Open Weblink in Browser).
`
`TOSHIBA INTERNATIONAL CORPORATION
`G7 Adjustable Speed Drive
`
`Please complete the Warranty Card supplied with the ASD 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:_________________________________________________________________
`
`HALLIBURTON EXHIBIT 1006
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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 G7 Adjustable Speed Drive. Every effort has been made to
`provide accurate and concise information to you, our customer.
`
`At Toshiba we’re continuously searching for better ways to meet the constantly changing needs of our
`customers. Email your comments, questions, or concerns about this publication to
`Technical-Publications-Dept@TIC.TOSHIBA.COM.
`
`Manual’s Purpose and Scope
`
`This manual provides information on how to safely install, operate, maintain, and dispose of your
`G7 True Torque Control2 Adjustable Speed Drive. The information provided in this manual is
`applicable to the G7 True Torque Control2 Adjustable Speed Drive only.
`
`This operation manual provides information on the various features and functions of this powerful cost-
`saving device, including
`
`Installation,
`
`System operation,
`
`Configuration and menu options, and
`
`(cid:127) Mechanical and electrical specifications.
`
`Included is a section on general safety instructions that describe the warning labels and symbols that are
`used throughout the manual. 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. Dimensions shown in the manual are in metric
`and/or the English equivalent.
`
`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.
`
`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.
`
`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 2005 Toshiba International Corporation.
`
`All rights reserved.
`
`Printed in the U.S.A.
`
`HALLIBURTON EXHIBIT 1006
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`Table of Contents
`
`CE Compliance Requirements ............................................................................................. 10
`EMC Installation Guidelines ............................................................................................ 10
`
`Motor Characteristics ........................................................................................................... 13
`Motor Autotuning ............................................................................................................. 13
`Pulse Width Modulation Operation .................................................................................. 13
`Low Speed Operation ....................................................................................................... 13
`Overload Protection Adjustment ...................................................................................... 13
`Operation Above 60 Hz .................................................................................................... 14
`Power Factor Correction .................................................................................................. 14
`Light Load Conditions ..................................................................................................... 14
`Motor/Load Combinations ............................................................................................... 14
`Load-produced Negative Torque ...................................................................................... 15
`Motor Braking .................................................................................................................. 15
`
`ASD Characteristics .............................................................................................................. 16
`Over-current Protection .................................................................................................... 16
`ASD Capacity ................................................................................................................... 16
`Using Vector Control ........................................................................................................ 16
`Local/Remote Operation .................................................................................................. 16
`
`Installation and Connections ................................................................................................ 17
`Installation Notes .............................................................................................................. 17
`Mounting the ASD ........................................................................................................... 18
`Connecting the ASD ......................................................................................................... 19
`I/O and Control ................................................................................................................. 22
`G7 ASD Control ............................................................................................................... 26
`Typical Connection Diagram ........................................................................................... 30
`
`Command Mode and Frequency Mode Control ................................................................. 31
`Command Control (F003) ................................................................................................ 31
`Frequency Control (F004) ................................................................................................ 32
`Override Operation ........................................................................................................... 34
`
`Electronic Operator Interface .............................................................................................. 36
`EOI Features ..................................................................................................................... 36
`EOI Operation .................................................................................................................. 37
`
`System Operation .................................................................................................................. 38
`Initial Setup ...................................................................................................................... 38
`Operation (Local) ............................................................................................................. 38
`Default Setting Changes ................................................................................................... 39
`
`Startup Wizard Requirements ............................................................................................. 40
`
`System Configuration and Menu Options ........................................................................... 43
`Root Menus ...................................................................................................................... 43
`
`Direct Access Parameter Information ................................................................................. 59
`Direct Access Parameters/Numbers ................................................................................. 59
`
`G7 ASD Operation Manual
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`Alarms, Trips, and Troubleshooting .................................................................................. 173
`Alarms and Trips ............................................................................................................ 173
`Alarms ............................................................................................................................ 174
`User Notification Codes ................................................................................................. 176
`Trips/Faults ..................................................................................................................... 176
`
`Enclosure Dimensions and Conduit Plate Information ................................................... 182
`Enclosure Dimensions/Weight ....................................................................................... 182
`Conduit Plate Information .............................................................................................. 187
`Conduit Extender Box (option) ...................................................................................... 189
`
`EOI Remote Mounting ........................................................................................................ 190
`
`Current/Voltage Specifications ........................................................................................... 193
`
`Cable/Terminal Specifications ............................................................................................ 195
`Dynamic Braking Resistor Wire/Cable Specifications .................................................. 198
`
`Link Reactor Information .................................................................................................. 199
`
`G7 Optional Devices ............................................................................................................ 200
`
`G7 ASD Spare Parts Listing ............................................................................................... 201
`
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`G7 ASD Operation Manual
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`HALLIBURTON EXHIBIT 1006
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`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.
`
`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 adhered to.
`The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous
`situation exists that, if not avoided, will result in death or serious injury to personnel.
`DANGER
`
`The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous
`situation exists that, if not avoided, could result in death or serious injury to personnel.
`WARNING
`
`The word CAUTION preceded by the safety alert symbol indicates that a potentially hazardous
`situation exists which, if not avoided, may result in minor or moderate injury.
`CAUTION
`
`The word CAUTION without the safety alert symbol indicates a potentially hazardous situation exists
`which, if not avoided, may result in equipment and property damage.
`CAUTION
`
`G7 ASD Operation Manual
`
`1
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`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 death.
`
`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 which indicates a hazard of injury from exploding
`parts. It is comprised of an equilateral triangle enclosing an
`explosion image.
`
`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.
`
`Shown below are examples of safety labels that may be found attached to the equipment. DO NOT
`remove or cover any of the labels. If the labels are damaged or if additional labels are required, contact
`your Toshiba sales representative for additional labels.
`
`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 death if
`the instructions are not followed.
`Figure 1. Examples of labels that may be found on the equipment.
`
`!
`
`DANGER
`
`DO NOT REMOVE, DESTROY, OR COVER THIS LABEL.
`READ THE INSTRUCTION MANUAL CAREFULLY BEFORE
` ENTERING THIS COMPARTMENT.
`HAZARDOUS VOLTAGE Behind These Panels.
`Contact With Energized Main Bus Will Cause
`Severe Injury, Death, Fire, Explosion, Or
`Property Damage.
`Turn Off And Lockout Primary And
`Control Circuit Power Before Opening
`These Panels.
`Qualified Operators Only.
`
`!
`
`DANGER
`
`DO NOT REMOVE, DESTROY, OR COVER THIS LABEL.
`
`READ THE INSTRUCTION MANUAL CAREFULLY BEFORE
`INSTALLING, OPERATING, OR SERVICING THIS EQUIPMENT.
`
`HAZARDOUS VOLTAGE
`Can Cause Severe Injury, Death, Explosion,
`Fire, Or Property Damage.
`Only Qualified Personnel Should Be Permitted
`To Operarate or Service This Equipment.
`Disconnect And Lockout Primary And Control
`Circuit Power Before Servicing.
`Keep All Panels And Covers Securely In Place.
`Never Defeat, Modify, Or Bypass Safety
` Interlocks.
`Foreign Voltage May Be Present At Interface
`Terminals. Isolate Before Performing Service
`Or Repairs.
`Unauthorized Modifications To This Equipment
`Will Void The Warranty.
`
`!
`
`CAUTION
`
`Excessive Loading of Operating Shaft
`Can Prevent Contactor From Closing
`Properly Resulting In Major Damage.
`
`Do Not Use Contactor Shaft To Drive
`Accessories Such As Mechanical Interlocks
`Which Require More Than 5 Kgf-cm Of
`Torque To Operate.
`
`!
`
`DANGER
`
`DO NOT OPEN THIS DOOR WHILE THE UNIT IS RUNNING.
`THIS DOOR IS INTERLOCKED WITH ASD OPERATION.
`
`HAZARDOUS VOLTAGE MAY BE PRESENT.
`Capacitors Are Charged. Wait
`At Least 5 Minutes Before Entry.
`Check For Charged Voltage
`To Dissipate To A Safe Level
`Before Opening The Equipment.
`
`2
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`G7 ASD Operation Manual
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`HALLIBURTON EXHIBIT 1006
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`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 carefully read the entire operation manual.
`
`Be familiar with the construction and function of the ASD, the equipment being driven, and the
`hazards involved.
`
`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.
`
`Be trained in rendering first aid.
`
`For further information on workplace safety visit www.osha.gov.
`
`Equipment Inspection
`
`Upon receipt of the equipment inspect the packaging and equipment for shipping damage.
`
`Carefully unpack the equipment and check for parts that were 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.
`
`(cid:127) Modification of this equipment is dangerous and must not be performed except by factory trained
`representatives. When modifications are required contact your Toshiba sales representative.
`
`Inspections may be required before and after moving installed equipment.
`
`Keep the equipment in an upright position.
`
`Contact your Toshiba sales representative to report discrepancies or for assistance if required.
`
`G7 ASD Operation Manual
`
`3
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`Handling and Storage
`Use proper lifting techniques when moving the ASD; including properly sizing up the load, getting
`assistance, and using a forklift if required.
`Store in a well-ventilated covered location and pref erably 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 G7 ASD is 14° to 104° F (-10 to 40° C).
`Do not store the unit 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.
`
`Installation Precautions
`Location and Ambient Requirements
`The Toshiba ASD is intended for permanent installations only.
`
`Installation should conform to the 2002 National Electrical Code — Article 110 (NEC)
`(Requirements For Electrical Installations), all regulations of the Occupational Safety and
`Health Administration, and any other applicable national, regional, or industry codes and
`standards.
`
`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 2002
`NEC Article 110-13).
`
`A noncombustible insulating floor or mat should be provided in the area immediately surrounding
`the electrical system.
`
`Do Not mount the ASD 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 ASD in a location that would allow it to be exposed to flammable chemicals or
`gases, water, solvents, or other fluids.
`
`Avoid installation in areas where vibration, heat, humidity, dust, fibers, steel particles, explosive/
`corrosive mists or gases, or sources of electrical noise are present.
`
`The installation location shall not be exposed to direct sunlight.
`
`Allow proper clearance spaces for installation. Do not obstruct the ventilation openings. Refer to
`the section titled Installation and Connections on pg. 17 for further information on ventilation
`requirements.
`
`The ambient operating temperature range of the G7 ASD is 14° to 104° F (-10 to 40° C).
`
`See the section titled Installation and Connections on pg. 17 for additional information on installing
`the drive.
`
`4
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`G7 ASD Operation Manual
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`HALLIBURTON EXHIBIT 1006
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`Mounting Requirements
`Only Qualified Personnel should install this equipment.
`
`Install the unit in a secure and upright position in a well-ventilated area.
`
`A noncombustible insulating floor or mat should be provided in the area immediately surrounding
`the electrical system at the place where maintenance operations are to be performed.
`
`As a minimum, the installation of the equipment should conform to the NEC Article 110
`Requirements For Electrical Installations, OSHA, as well as 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 ASD or the electrical maintenance personnel to
`ensure that the unit is installed into an enclosure that will protect personnel against electric shock.
`
`Conductor Routing and Grounding
`
`WARNING
`
`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 control terminal strip return marked CC 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 ASD or the electrical maintenance personnel to
`provide proper grounding and branch circuit protection in accordance with the 2002 NEC and any
`applicable local codes.
`
`T h e M e t a l O f C o n d u i t I s N o t A n A c c e p t a b l e G r o u n d .
`
`Power Connections
`DANGER
`C o n t a c t W i t h E n e r g i z e d W i r i n g W i l l C a u s e S e v e r e I n j u r y O r D e a t h .
`
`Turn off, lockout, and tagout all power sources before proceeding to connect the power wiring to
`the equipment.
`
`After ensuring that all power sources are turned off and isolated in accordance with established
`lockout/tagout procedures, connect three-phase power source wiring of the correct voltage to the
`correct input terminals and connect the output terminals to a motor of the correct voltage and type
`for the application (refer to NEC Article 300 – Wiring Methods and Article 310 – Conductors For
`General Wiring). Size the branch circuit conductors in accordance with NEC Table 310.16.
`
`If multiple conductors that are smaller than the recommended sizes 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 NEC Article 300.20 and Article 310.4). National and local electrical codes should be
`
`G7 ASD Operation Manual
`
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`referenced if three or more power conductors are run in the same conduit (refer to 2002 NEC
`Article 310 adjustment factors on page 70-142).
`
`Ensure that the 3-phase input power is Not connected to the output of the ASD. This will damage
`the ASD and may cause injury to personnel.
`
`Do not install the ASD 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.
`
`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.
`
`Follow all warnings and precautions and do not exceed equipment ratings.
`
`If using multiple motors provide separate overload protection for each motor and use V/f control.
`
`External dynamic braking resistors must be thermally protected.
`
`It is the responsibility of the person installing the ASD or the electrical maintenance personnel to
`setup the Emergency Off braking system of the ASD. 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 Start Frequency on pg. 105 and Dynamic Braking
`Enable on pg. 112.
`
`Note:
`
`A supplemental emergency stopping system should be used with the ASD. Emergency
`stopping should not be a task of the ASD alone.
`
`Follow all warnings and precautions and do not exceed equipment ratings.
`
`6
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`G7 ASD Operation Manual
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`System Integration Precautions
`
`The following precautions are provided as general guidelines for the setup of the ASD within the
`system.
`
`The Toshiba ASD is a general-purpose product. It is a system component only and the system
`design should take this into consideration. Please contact your Toshiba sales representative for
`application-specific information or for training support.
`
`The Toshiba ASD is part of a larger system and the safe operation of the ASD 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 ASD component. Contact your Toshiba sales
`representative 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 ASD will be required before the installation, operation, or
`maintenance of the ASD.
`
`WARNING
`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.
`
`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.
`
`Follow all warnings and precautions and do not exceed equipment ratings.
`
`System Setup Requirements
`(cid:127) When using t