Toshiba 48-1250 A Bedienungsanleitung

INSTRUCTION MANUAL

TD SERIES

Low Voltage

Digital Solid State Starter

48 - 1250 A

Issued: 9/03

Manufactured in the USA

INSTALLATION - OPERATION - MAINTENANCE

DOCUMENT: NBZ0001

SAFETY

WARNING

SAFETY CODES

Toshiba motor control is designed and built in accordance with the latest applicable provisions of

NEMA and the National Electrical Code. Installations must comply with all applicable state and local

codes, adhere to all applicable National Electric Code (NFPA 70) standards and instructions provided

in this manual.

HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion and

property damage.

• Turn off and lock out Primary and Control Circuit Power before servicing.

• Keep all panels and covers securely in place.

• Never Defeat, Modify, or Bypass any Safety Interlocks.

• Qualified Operators only.

Never attempt to install, operate, maintain or dispose of this equipment until

you have first read and understood all of the relevant product warnings and

user directions that are contained in this Instruction Manual.

Use only Toshiba-authorized replacement parts.

This equipment is designed and built in accordance with applicable safety

standards in effect on the date of manufacture. Unauthorized modifications

can result in voiding the warranty, severe injury, death and property

damage. Do not make any modifications to this equipment without

the written approval of Toshiba.

For assistance, address correspondence to:

Toshiba International Corporation

Field Service Department

13131 West Little York Road

Houston, Texas 77041 USA

or call: (713) 466-0277 Fax: (713) 466-8773

(800) 231-1412

(800) 527-1204 (Canada)

Please complete the following information for your records and retain with this manual:

Model: ___________________________________

Serial Number: _____________________________

Date of Installation: _________________________

Inspected by: ______________________________

Reference Number: _________________________

SAFETY

DANGE

WARNING

CAUTION

IMPORTANT MESSAGES

Read this manual and follow its intructions. Signal words such as DANGER, WARNING

and CAUTION will be followed by important safety information that must be carefully reviewed.

Indicates a situation which will result in death, serious injury, and severe property damage if you

do not follow instructions.

Means that you might be seriously injured or killed if you do not follow instructions. Severe

property damage might also occur.

Means that you might be injured if you do not follow instructions. Equipment damage might

also occur.

Give you helpful information.

NOTE

READ SAFETY SIGNS

To avoid injury, you must read and follow all safety signs.

Keep the safety signs visible and in good shape. Never remove or cover any safety sign.

DANGE

QUALIFIED OPERATORS ONLY

Only qualified persons are to install, operate, or service this equipment according to all applicable

codes and established safety practices.

A qualified person must:

1) Carefully read the entire instruction manual.

2) Be skilled in the installation, construction or operation of the equipment and aware of

the hazards involved.

3) Be trained and authorized to safely energize, de-energize, clear, ground, lockout and

tag circuits in accordance with established safety practices.

4) Be trained and authorized to perform the service, maintenance or repair of this equip-

ment.

5) Be trained in the proper care and use of protective equipment such as rubber gloves,

hard hat, safety glasses, face shield, flash clothing, etc. in accordance with estab-

lished practices.

6) Be trained in rendering first aid.

Note: The contents of this manual will not become a part of or modify the warranty

policy, the terms of which are set forth at the end of this manual.

TD Series

Digital Solid State Soft Starter

48 - 1250A

Chapter 1: Introduction .....................................................1

1.1 General

1.2 Specifications and Performance Features

Chapter 2: Installation .......................................................4

2.1 Receiving and Unpacking

2.2 Location

2.3 Initial Unit Inspection

2.4 Warning

2.5 Mounting and Cleaning

2.6 Power Terminal Wire Range and Tightening Torque

2.7 Dimensions

Chapter 3: Motor Overload Protection ...........................7

3.1 Solid State Overload Protection

3.2 NEMA Class Trip Curves

Chapter 4: Connections ..................................................10

4.1 Power Connections

4.2 Control Connections

4.3 Interlock Connection

Chapter 5: Programming ................................................13

5.1 Introduction

5.2 Digital Interface

5.3 Display Modes

5.4 Function List

5.5 Function Descriptions

Chapter 6: Start-Up..........................................................32

6.1 Quick Start

6.2 Start-up Check List

6.3 Sequence of Operation

Chapter 7: Fault Conditions ...........................................35

7.1 Fault Codes and Numbers (In History)

Chapter 8: Troubleshooting ...........................................36

8.1 Failure Analysis

8.2 SCR Testing Procedure

8.3 Replacing SCR Devices

8.4 Replacing Printed Circuit Board Assembly

Chapter 9: Printed Circuit Board Layout .......................41

9.1 Power Board and CPU Board (PC Board Assembly)

9.2 Typical Wiriing Diagram

Chapter 10: Maintenance/Disposal/Storage .................43

Appendix 1: Ramp Profile Details

Appendix 2: Decel Mode Application Considerations

Appendix 3: Parameter Lock / User Password Instructions

Appendix 4: Soft Starter Settings

Warranty Policy

Table of Contents

TD - Series

- 1 -

TD Series Digital Solid State Soft Starter 48 - 1250A

1.1 General

The TD Series is a digitally programmable solid state reduced voltage

soft starter. Its six SCR design features a voltage/current ramp with an

anti-oscillation circuit for smooth load acceleration. The SCRs are sized

to withstand starting currents of 500% for 60 seconds (compared to

350% for 30 seconds from other manufacturers). The TD Series features

smooth, stepless ramp control which reduces motor inrush current and

excessive wear on the mechanical drive train components. In addition to

having easy to understand diagnostic LEDs, the TD Series includes a

programmable keypad for setting operating parameters for the ideal

starting cycle. Starting torque, ramp time, current limit, dual ramp, and

decel control are standard features on the TD Series. By simply adjusting

the unit’s starting torque, ramp time and current limit functions, the starting

electrical characteristics of the motor can be matched to the mechanical

characteristics of the drive train for controlled acceleration of the load.

The TD Series includes solid state electronic overload protection in

addition to numerous other protective features. It is factory wired for 120

VAC control voltage and two or three-wire start/stop control (Units can

also be ordered with 240 VAC control voltage if required). Programmable

auxiliary contacts and provisions for interlocking are also included.

Chapter 1 - Introduction

1.2 Specifications and Performance Features

Type of Load Three phase AC induction motor

AC Supply Voltage 208 - 600VAC ±10%, 50/60 Hz

HP Ratings 48 - 1250 Amps, 10 - 1125 HP

Unit Overload Capacity

(Percent of motor FLA)

125% - Continuous

500% - 60 seconds

600% - 30 seconds

Power Circuit 6 SCRs

SCR Diode Ratings

(Peak Inverse Voltage) 1600V

Phase Insensitivity Unit operates with any phase sequence

Transient Voltage Protection RC snubber dv/dt networks on each phase.

Cooling Convection up to 180A, fan assisted 62 - 120A,

Fan ventilated 220 - 1250A

Bypass Contactor

Full horsepower rated contactor included as standard in all

Type 12, 3R, 4 & 4X enclosed units 120A and above.

Ambient Condition Design

Chassis units: 0° to 50 °C (32° to 122°F)

Enclosed units: 0° to 40°C (32° to 104°F)

5 - 95% relative humidity

0 - 3300 ft. (1000m) above sea level without derating

Control 2 or 3 wire 120VAC (customer supplied)

Optional 240VAC control voltage and CPTs are available.

Type / Rating: Form C (SPDT), rated 5 Amps,

240VAC max. (1200VA)

3 Programmable Relays

Fault Indicator: AC triac solid state switch

240VAC, 50mA max.

Approvals UL Listed, Canadian UL (cUL) Listed

Auxiliary Contacts

TD - Series

- 2 -

TD Series Digital Solid State Soft Starter 48 - 1250A

1.2 Specifications and Performance Features Cont’d

Note 1: Enabled via programming

Two Stage Electronic

Overload Curves

Starting: Programmable for Class 5 through 30

Run: Programmable for Class 5 through 30 when "At-Speed"

is detected.

Overload Reset (Note 1) Manual (default) or automatic

Retentive Thermal Memory

Overload circuit retains thermal condition of the motor

regardless of control power status. Unit uses real time clock

to adjust for off time.

Dynamic Reset Capacity

Overload will not reset until thermal capacity available in the

motor is enough for a successful restart. Starter learns and

retains this information by monitoring previous successful

starts.

Phase Current Imbalance

Protection (Note1)

Imbalance Trip Level: 5 - 30% current

between any two phases

Imbalance Trip Delay: 1 -20 seconds

OverCurrent

(Electronic Shear Pin)

Protection (Note 1)

Trip Level: 50 - 300% of motor FLA

Trip Delay: 1 - 20 seconds

Load Loss Trip Protection

(Note 1)

Under Current Trip Level: 10 -90 % of motor FLA

Under Current Trip Delay: 1 - 60 seconds

Coast Down (Back Spin)

Lockout Timer (Note 1) Coast Down Time Range: 1 - 60 minutes

Starts-per-hour Lockout Timer

(Note 1)

Range: 1 - 10 successful starts per hour

Time between starts: 1 - 60 minutes between start attempts

Type / Rating Form C (SPST), Rated 5 amps

240 VAC max, (1200 VA)

Run Indication Start/Stop or Start/End of Decel

At Speed Indication At Speed/Stop or At Speed/End of Decel

Acceleration Adjustments

Programmable Ramp Types: Voltage or Current Ramp

(VR or CR)

Starting Torque: 0 - 100% of line voltage (VR)

or 0 - 600% of motor FLA (CR)

Ramp Time: 1 to 120 seconds

Current Limit: 200 - 600% (VR or CR)

Dual Ramp Settings

4 Options: VR1+VR2; VR1+CR2; CR1+CR2; CR1+VR2

Dual Ramp Control: Ramp #1 = Default,

Ramp = #2 selectable via dry contact input

Deceleration Adjustments

Begin Decel Level: 0 - 100% of line voltage

Stop Level: 0 to 1% less than Begin Decel Level

Decel Time: 1 - 60 seconds

Programmable to decel or coast to stop upon overload trip

Jog Settings

Jog function selected via

dry contact closure input)

Voltage Jog: 5 - 100%

Time of Voltage Jog: 1 - 20 seconds

Current Jog: 100 - 500%

Kick Start Settings

(Note 1)

Kick Voltage: 10 - 100%

Kick Time: 0.1 - 2 seconds

Fault Indications

Shorted SCR, Phase Loss, Shunt Trip, Phase Imbalance

Trip, Overload, Overtemp, Overcurrent, Short Circuit, Load

Loss, or Any Trip

Lockout Indicator Coast Down Time, Starts Per Hour,

Time Between Starts, and Any Lockout

Programmable Outputs

Advanced Motor Protection

TD - Series

- 3 -

TD Series Digital Solid State Soft Starter 48 - 1250A

1.2 Specifications and Performance Features Cont’d

Phase Currents 0 - 9999 Amps, Phase A, B, or C

Remaining Thermal Capacity 0 - 100% of available motor thermal capacity

Elapsed Time 0 - 1,000,000.0 hours, non resetable

Run Cycle Counter 0 - 10,000,000 run commands non resetable

Lockout Time Values Remaining time of any enabled lockout timer

Fault Codes Abbreviated fault codes, indicating trip and operating mode

Fault History Last 3 faults with Time and Date Stamps

Protocol Modbus RTU

Signal RS-485

Network Up to 247 devices per mode

Functionality Full operation, status view, and programming

via communications port

LED Readout 4 digit alpha numeric, high brightness, 7 segment display

Keypad 8 functions keys with tactile feedback

Status Indicators 8 LEDs

Remote Mount Capability Up to 10 feet (3 meters) from chassis

Operating Memory DRAM loaded from EPROM and EEPROM at initialization

Factory Default Storage Flash EPROM, field replaceable

Customer Settings and Status Non-volatile EEPROM, no battery backup necessary

Real Time Clock Lithium ion battery for clock memory only,

10+ years life span

Operator Interface

Clock and Memory

Metering Functions

Serial Communications

TD - Series

- 4 -

TD Series Digital Solid State Soft Starter 48 - 1250A

2.1 Receiving and Unpacking

Upon receipt of the product you should immediately do the following:

•Carefully unpack the unit from the shipping carton and inspect it for

shipping damage (if damaged, notify the freight carrier and file a

claim within 15 days of receipt).

•Verify that the model number on the unit matches your purchase

order.

•Confirm that the ratings sticker on the unit matches or is greater

than the motor’s HP and current rating.

2.2 Location

Proper location of the TD Series is necessary to achieve specified

performance and normal operation lifetime. The TD Series should

always be installed in an area where the following conditions exist:

•Ambient operating temperature:

Chassis unit: 0 to 50°C (32 to 122°F)

Enclosed unit: 0 to 40°C (32 to 104°F)

•Protected from rain and moisture

•Humidity: 5 to 95% non-condensing

•Free from metallic particles, conductive dust and corrosive gas

•Free from excessive vibration (below 0.5G)

•Open panel units must be mounted in the appropriate type of

enclosure. Enclosure size and type must be suitable to dissipate

heat generated by the soft starter. Contact factory for assistance in

sizing enclosures.

2.3 Initial Unit Inspection

• Make a complete visual check of the unit for damage which may

have occurred during shipping and handling. Do not attempt to continue

installation or start up the unit if it is damaged.

• Check for loose mechanical assemblies or broken wires which may

have occurred during transportation or handling. Loose electrical

connections will increase resistance and cause the unit to function

improperly.

• Prior to beginning the installation, verify that the motor and TD unit

are rated for the proper amperage and voltage.

2.4 Warning!

Do not service equipment with voltage applied! The unit can be

the source of fatal electrical shocks! To avoid shock hazard,

disconnect main power and control power before working on

the unit. Warning labels must be attached to terminals, enclosure

and control panel to meet local codes.

Chapter 2 - Installation

WARNING

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