Toshiba 18 - 1250 A User Manual

DOCUMENT: NBZ0003

INSTRUCTION MANUAL

INSTALLATION - OPERATION - MAINTENANCE

TE SERIES

Low Voltage
Digital Solid State Starter

18 - 1250 A

Issued: 10/09
Manufactured in the USA

SAFETY

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.

NOTE

Give you helpful information.

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.

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.

QUALIFIED OPERATORS ONLY

Only qualifi ed persons are to install, operate, or service this equipment according to all applicable
codes and established safety practices.

A qualifi ed 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
equipment.

5) Be trained in the proper care and use of protective equipment such as rubber gloves,
hard hat, safety glasses, face shield, fl ash clothing, etc. in accordance with estab-
lished practices.

6) Be trained in rendering fi rst aid.

SAFETY

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, fi re, 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.

• Qualifi ed Operators only.

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

you have fi rst 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 modifi cations
can result in voiding the warranty, severe injury, death and property
damage. Do not make any modifi cations 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: [phone] Fax: [phone]
[phone]
[phone] (Canada)

Please complete the following information for your records and retain with this manual:
Model: ___________________________________
Serial Number: _____________________________
Date of Installation: _________________________
Inspected by: ______________________________
Reference Number: _________________________
© TOSHIBA INTERNATIONAL CORPORATION, 2009

TE Series Digital Solid State Soft Starters 18 – 1250A

Table of Contents

TE Series Digital Solid State Soft Starter
18 – 1250A

Chapter 1: Introduction

Chapter 2 - Installation

Chapter 3 - Motor Overload Protection

Chapter 4 – Connections

Chapter 5 – Programming

Chapter 6 - Start-up

Chapter 7 - Fault Conditions
Appendices

Appendix 1 - Ramp Profile Details ……………………………………………………………….. 66
Appendix 2: Pump-Flex
Appendix 3: Parameter Lock / User Password Instructions …………………………………… 72
Appendix 4: Process Control Timer Functions …………………………………………………. 74
Appendix 5: External Over Load Relay Applications ……………………………….…………. 82
Appendix 6: Soft Starter Settings Record ………………………….…………….……………… 87
Warranty Information ………………………………………………….…………………………… 92

®

Decel Mode Application Considerations ……………………………

1.1 General Description …………………… 1

1.2 Sizes and Ratings ……………………… 4

2.1 Receiving and Unpacking …………….. 5

2.2 Choosing a Location …………………... 5

2.3 Initial Unit Inspection …………………... 5

2.4 SERVICE WARNING! …………………. 6

2.5 Mounting and Cleaning ……………….. 6

2.6 Power Terminations …………………… 7

2.7 Remote Keypad Mounting 9

2.8 Dimensions ……………………………... 10

3.1 Solid State Overload Protection ……… 11

3.2 NEMA Class Trip Curves ……………... 13

4.1 Power Connections ……………………. 15

4.2 Control Connections …………………… 16

5.1 Introduction ……………………………... 23

5.2 Digital Interface ………………………… 23

5.3 Display Modes …………………………. 24

5.4 Program Mode …………………………. 25

5.4.5 Fault Mode ………………………… 28

5.5 The TE Function List ………………... 30

5.6 Function Descriptions …………………. 36

5.6.1 Motor and Overload Functions …. 36

5.6.2 Starting Mode ……………………. 38

5.6.3/4 Jog Mode / Kick Start Mode ……. 42

5.6.5 Pump-Flex Decel Mode ………… 43

5.6.6 Restart Delay ……………………. 44

5.6.7 Process Timer Control Mode …… 45

5.6.8 Current and Ground Fault Protection 47

5.6.9 Lockouts, Reset & Internal Protection 49

5.6.10 Output Relays ……………………. 56

5.6.11 Communications …………………. 57

5.6.12 System Settings …………………. 58

5.6.13 Fault History and Statistical Data 60

6.1 Basic Startup …………………………… 62

6.2 Start-up Check List …………………….. 63

6.3 Sequence of Operation …… ………….. 63

6.4 Testing with a smaller motor ………….. 64

7.1 Fault Codes and Numbers ……………. 64

Page

69

2

TE Series Digital Solid State Soft Starters 18 – 1250A

Chapter 1 - Introduction

1.1 General Description

The TE 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 350% for 30 seconds and up to 600%
for 10 seconds. The TE Series features smooth, stepless ramp control,
which reduces motor inrush current and excessive wear on the
mechanical drive train components. The TE Series includes a
programmable keypad for setting operating parameters for the ideal
starting cycle and protection features, plus easy to understand
diagnostic LEDs. Starting torque, ramp time, current limit, dual ramp,
and Decel control are standard features on the TE Series, as well as
the integrated Batch Process Timer and Time Clock Controller used for
automated applications. 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 TE Series includes solid-state electronic overload protection in
addition to numerous other protective features. It requires 120VAC
(240VAC optional) control power and uses dry contact inputs for Start /
Stop control. Programmable auxiliary contacts and provisions for
interlocking are also included.

1.1.1 Control Features

Programmable Ramp Types:
Voltage Ramp (VR) or closed loop Current Ramp (CR)

Acceleration Adjustments

Dual Ramp Settings

Deceleration Adjustments

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)

4 Options:
Ramps 1 & 2 = VR,
Ramp 1 = VR, Ramp 2 = CR,
Ramps 1 & 2 = CR;
Ramp 1 = CR, R amp 2 = VR
Dual Ramp Control:
Ramp #1 = Default,
Ramp = #2 selectable via dry contact input

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

Kick Start Settings

Process Timer
(2 modes)

Real Time Clock (RTC)
Controller

Jog function selected via dry contact closure input.
Voltage Jog: 5 - 100%
Time of Voltage Jog: 1 - 20 seconds
Current Jog: 100 - 500%

Kick Voltage: 10 - 100%
Kick Time: 0.1 - 2 seconds

Minimum Batch Timer: Runs until timer expires
Maximum Batch Timer: Runs unless timer expires
Range: 0 - 9999 minutes

24/7 Time Clock Controller
Range: 1-24 hours, and 1- 7 days per week,
1 - 7 start events per day, works with Process Timer for run time

1

TE Series Digital Solid State Soft Starters 18 – 1250A

1.1.2 Advanced Motor Protection Features

Thermal Model Electronic
Overload Protection

Two Stage
Overload Curves

Overload Reset Manual (default) or automatic

Retentive Thermal Memory

Dynamic Reset Capacity

Current Imbalance Trip

PTC Input Trip

Over Current Trip
(Electronic Shear Pin)

Phase Loss

Equipment Ground Fault
Protection

A sophisticated Thermal Model of the motor operation is created in the
microprocessor to accurately track all starting, stopping and running conditions
to provide maximum motor protection.

Starting: Programmable for Class 5 or 10
Run: Programmable for Class 5 through 30 when "At-Speed" is detected.

Overload circuit retains thermal condition of the motor regardless of control
power status. Unit uses real time clock to adjust for off time.

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.

Trip Level: 5 - 30% Imbalance in any two phases
Trip Delay: 1 -20 seconds

Trips on greater than 750 ohms resistance on a dedicated PTC input. Can be
used with an Emergency Stop or any other External Lockout.

Trip Level: 50 - 300% of motor FLA
Trip Delay: 1 - 20 seconds

Trips on any phase current less than 20% of unit rating.
Can be disabled in programming for testing with smaller loads.

Type: Residual Current Trip
Range: 5 – 90% of unit CT ratio
Trip Delay: 1 – 60 seconds

Load Loss Trip

Coast Down (Back Spin)
Lockout Timer

Starts-per-hour Lockout 1 – 10 successful starts per hour

Minimum Time between
Starts Lockout

Restart Delay

Auto Reset

Power Device Monitoring

Under Current Trip Level: 10 –90 % of motor FLA
Trip Delay: 1 – 60 seconds

Prevents restart when motor may be spinning backwards
Coast Down Time Range: 1 – 60 minutes

Range: 1 – 60 minutes between start attempts

Sequential Start Feature for restarting delay after a power outage.
1-999 seconds after a power loss

Can be programmed to attempt resetting after selected faults
0 – 10 Attempts, 0 – 999 minutes delay between attempts

Shorted SCR Lockout (1 shorted SCR) and independent Shunt Trip (multiple
shorted SCRs). Can be disabled in programming.

2

TE Series Digital Solid State Soft Starters 18 – 1250A

1.1.3 Design Specifications

Type of Load: Three phase AC induction motors

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

Power Ratings: 18 - 1250 Amps, 7.5 - 1000 HP @ 460V

Unit Capacity - Continuous Max. Amp rating is UL Listed continuous rating

Unit Capacity - Overload Rating
(Percent of motor FLA)

Power Circuit

SCR Firing Angle Detection
SCR PIV Ratings

(Peak Inverse Voltage)
Phase Rotation

Transient Protection RC snubber dv/dt networks on each phase

Cooling Fan assisted convection

Bypass Contactor Standard on all NEMA 12 enclosed units

350% - 30 seconds
600% - 10 seconds
6 SCRs, full phase angle firing using a hard fire picket firing circuit and “Back

Porch” DC carryover to avoid motor transient problems
6 pulse Independent Locked Phase Tracking with Auto-synchronization,

prevents misfiring on unstable source frequency
1600V
Operates with any phase sequence, or

programmable rotation trip ABC / ACB / Off

Units 160A and less: Standard on all open panel units (-BP versions)

Units 210A and over: Optional on open panel units (-BP versions)

Bypass Contactor Rating Shunt rated or can be sized for Line start rated contactor (see charts)

Bypass Contactor Control Integral control is included, but contactor can be externally controlled as well.

Open panel mount units: 0° to 50 °C (32° to 122°F)

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

Ambient Condition Design

5 - 95% relative humidity

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

Control Power 120VAC (customer supplied), 240VAC optional

Inputs 6 Dry (voltage free) contact inputs using 24VDC from an internal power supply

Programmable Outputs

Output Relay Contact Rating 5 Amps, 240VAC max. (1200VA)

Dedicated Fault Output

Approvals UL Listed, Canadian UL (cUL) Listed, CE Approved

3 relays, 2 each Form C (SPDT), 1 each Form A (SPST).
Can be programmed for 26 functions, with delays or flashing.

AC Triac solid state switch
240VAC/DC, 50mA max.

3

TE Series Digital Solid State Soft Starters 18 – 1250A

1.2 Sizes and Ratings

The Toshiba TE Series starters are current rated controllers. Max. Amp
ratings are for continuous duty and must not be exceeded. Always
check the motor nameplate FLA and Service Factor to ensure proper
sizing.

Each size has an adjustable range of current from 50% to 100% of the
Max Amp rating. Table 1.2 below shows the Current Ratings available.

Current

Model

Number

TE-18-BP 9 - 18
TE-28-BP 14 - 28
TE-39-BP 19 - 39
TE-48-BP 24 - 48
TE-62-BP 36 - 62
TE-78-BP 39 - 78

TE-92-BP 46 - 92
TE-112-BP 56 - 112
TE-150-BP 75 - 150
TE-160-BP 80 - 160

TE-210-BP or -P 105 - 210
TE-275-BP or -P 138 - 275
TE-360-BP or -P 180 - 360
TE-450-BP or -P 225 - 450
TE-550-BP or -P 275 - 550
TE-718-BP or -P 359 - 718

TE-900-BP or -P 450 - 900
TE-1006-BP or -P 503 - 1006
TE-1250-BP or -P 625 - 1250

Table 1.2: TE Series Range

Range

Min. - Max.

"When an induction motor is operated at any service factor

When using this feature, simply program the TE Series

 NOTE:

1.2.1 Selecting for Service Factor Utilization

Many NEMA design motors include a design rating referred to
as Service Factor (SF) that may allow continuous operation
above the nameplate current rating. If using this Service
Factor, the TE Series starter must be sized for the total amps
used. For proper selection of the TE Series starter when using
SF continuously, multiply the nameplate FLA by the stated
Service Factor, or use stated Service Factor Amps (SFA) if
listed on the nameplate. Following is an excerpt from the
NEMA MG-1 standards for AC Motors that describes the
issues concerning the use of Service Factor ratings.

greater than 1.0, it may have efficiency, power factor and
speed different than those at rated load. Locked rotor torque
and current and breakdown torque will remain the same. A
motor operating continuously at any service factor greater than

1.0 will have a reduced life expectancy compared to operating
at its nameplate horsepower."

Service Factor (F002) to the nameplate rating see section

5.6.1. All other adjustments to protection circuits are done
automatically within the TE Series.

1.2.2 Selecting for Across the Line Bypass
If you need to be able to start the motor Across-the-Line if the
TE Series electronics are out of service, the starter can also
be selected based upon the rating of the Bypass Contactor.
Some users may also elect to size their Bypass Contactors per
NEMA guidelines. Please use the Product Price Catalog

for
details and notes on doing this, and see Appendix 5 for special
considerations regarding Overload Protection.

The TE…-BP Series starters include the ability to connect a dry
contact directly to the Bypass Contactor coil control circuit. These
terminals shipped are covered and should be used ONLY when
necessary for Emergency Bypass operation and

with an external

Overload Relay. See Appendix 5 for additional information.
No field wiring is necessary to these terminals if this feature is not

used.

4

TE Series Digital Solid State Soft Starters 18 – 1250A

Chapter 2 - Installation

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 Choosing a Location

Proper location of the TE Series is necessary to achieve specified
performance and normal operation lifetime. The TE Series should
always be installed in an area where the following conditions exist:

 Ambient operating temperature:

Panel (open chassis) unit: 0 to 50°C (32 to 122°F)
Enclosed unit: 0 to 40°C (32 to 104°F)

 Protected from rain, moisture and direct sun.
 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 and any other components
mounted inside with it.

 Units with –BP Bypass Contactors produce less heat than units

without. Throughout all sizes, maximum heat dissipation of the
TE…-BP Series electronics, contactor coils and fans is less than
50W.

 Units without the –BP Bypass Contactor (optional on 210A and

above), must have ventilation adequate to account for heat
dissipation of the SCRs. This must be estimated at 4.5 watts per
running load amp. For example, on a 200HP 460V motor with
240FLA, the maximum heat dissipation of a starter w/o bypass will
be 240 x 4.5, or 1080 watts of heat. Enclosure ventilation (or air
conditioning) must be capable of dispersing this amount of heat.

 Care should always be taken to maximize the available space

inside of the enclosure. See section 2.5.1 or contact factory for
assistance in sizing enclosures.

2.3 Initial Unit Inspection

Make a complete visual check of the unit for damage that 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 TE

Series unit are rated for the proper amperage and voltage.

5

TE Series Digital Solid State Soft Starters 18 – 1250A

WARNING

2.4 SERVICE 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. Use Lock Out tags such as the
one shown when servicing equipment.

2.5 Mounting and Cleaning

When drilling or punching holes in the enclosure, cover the electrical
assembly to prevent metal filings from becoming lodged in areas which
can cause clearance reduction or actually short out electronics. After
work is complete, thoroughly clean, vacuum the area, and re-inspect the
unit for foreign material.

2.5.1 Clearances

Make sure there is sufficient clearance all around the unit for cooling,
wiring and maintenance purposes. To conserve panel space, the TE
Series –BP models were designed for close horizontal clearances of
only 1 inch (25mm) on either side. A minimum vertical clearance of 4”
(100 mm) on the top and bottom is necessary to maximize effective
airflow and cooling, and the unit must be installed with its heat sink ribs
oriented vertically and running parallel to the mounting surface. Keep in
mind that these are minimums. Wiring may require more clearance,
particularly on the bottom.

4" minimum ( 100 mm)

TE Series

Starter

4" minimum ( 100 mm)

1" minimum (25 mm)

Figure 2.5: TE minimum mounting clearances

1" minimum (25

mm)

6

TE Series Digital Solid State Soft Starters 18 – 1250A

V

/

/

/

V

WARNING

Remove all sources of power before cleaning the unit.

In dirty or contaminated atmospheres, the unit should be cleaned on a
regular basis to ensure proper cooling. Do not use any chemicals to
clean the unit. To remove surface dust use clean, dry compressed air
only, 80 to 100 psi. A three-inch, high quality, dry paintbrush is helpful to
loosen up the dust prior to using compressed air on the unit. Do not use
wire brushes or other conductive cleaning materials.

2.6 Power Terminations

All line and load power terminations are to be made to tin plated copper
Bus Tabs located on each unit. Bus tabs are pre-drilled to accept
industry standard bolts. Some sizes come with saddle clamp terminals,
however lugs are the responsibility of the user. Toshiba recommends
using crimp-on lugs, although mechanical lugs are suitable as well. The
following diagrams show sizes of the bus tab holes and critical spacing
between them for determining the size of lug that can be used.

NOTE: All wiring must be sized according to local code standards.

TE- 18 ~
TE- 48

Load

Line

Line Load

R/ L1 S/L2 T /L3

/ T2

U/ T1 W

T3

1.50"

(38.07 mm)

0.45"

(11.42 mm)

Figure 2.6.1 Critical clearances for bus tab connections

1.10"

(27.92 mm)

∅

0.19"

(4.82 mm)

TE - 62 ~
TE - 112

Line Load

0.38"

T

∅

(9.64 mm)

1.13"

(28.68

1.82"

(46.19

1.23"

(31.22 mm)

Figure 2.6.2 Critical clearances for bus tab connections

(15.23 mm)

S/L2

R/LT/L3

Line Load

0.60"

1.73"

(43.91

UT W

T

7

TE Series Digital Solid State Soft Starters 18 – 1250A

/

V

2.6 Power Connections (cont.)

TE-150
TE-160

0.14"

(3.55 mm)

Figure 2.6.3 Critical clearances for bus tab connections

NOTE: Consult factory for bus tab critical dimensions for units
210A and above

Line Load

1.52"

(38.58 mm)

T/L3

R/L1

Line Load

S/L2

1.54"

(39.09 mm)

(15.23 mm)

0.60

U/T1

2.81"

(71.32 mm)

/T2

∅

(9.64 mm)

W

T3

8

TE Series Digital Solid State Soft Starters 18 – 1250A

r

r

2.6.1 Power Terminals:

Connection points for units of 160A and below are saddle clamps
suitable for stranded wire. Connection points for units of 210A and
above are bus tabs with pre-drilled holes (see below). Use appropriate
compression or mechanical lugs for termination to these bus tabs.

Suggested wire sizes and tightening torques for factory-supplied
connectors when using conductors rated for 75°C are shown in the
chart below. Always consult local codes and industry standard practices
for proper wires sizes to accommodate voltage drop and ambient
conditions.

Model

Number

TE-18-BP 9 - 18 12
TE-28-BP 14 - 28 10
TE-39-BP 19 - 39 8
TE-48-BP 24 - 48 6
TE-62-BP 36 - 62 4
TE-78-BP 39 - 78 3 35

TE-92-BP 46 - 92 2 35
TE-112-BP 56 - 112 2 50
TE-150-BP 75 - 150 0
TE-160-BP 80 - 160 2/0 70

TE-210-BP or -P 105 - 210 4/0
TE-276-BP or -P 138 - 276 300 kCMIL 150
TE-360-BP or -P 180 - 360 500 kCMIL 300
TE-450-BP or -P 225 - 450 2 x 250 kCMIL 2 x 150
TE-550-BP or -P 275 - 550 2 x 250 kCMIL 2 x 150
TE-718-BP or -P 356 – 718
TE-900-BP or -P 450 – 900

TE-1000-BP or -P 50 - 1000

Table 2.6: TE Series Wire Ranges and Torque Specifications

CF = Consult Factory

2.7 Remote Keypad Mounting
The keypad / operator interface unit can be remotely mounted up to 10’
(3 meters) away from the starter, i.e. on the enclosure door. A remote
mounting kit is necessary, consisting of an adaptor plate, a doorframe
for NEMA 1 or NEMA 12 enclosures and a pre-assembled ribbon cable
available in 1-meter length increments. Detailed assembly instru ct ions
and an enclosure cutout template are included with that kit. See Product
Selection Guide for part numbers of the different kits depending on
NEMA rating and cable lengths.

Current

Range

Min.- Max.

Suggested

Wire Size

AWG

CF CF
CF CF
CF CF

Tightening

Torque
in.-lbs.

35

45

80

200

~ ~

~

Screw / Bolt

Size

1 x M5

(included)

1 x M8

(included)

1 x M8

(included)

1 x 0.38" hole

(M10)

for User

supplied

lugs

CF CF CF
CF CF CF
CF CF CF

NEMA 1 o
NEMA 12
Door Frame

Tightening

Torque

Nm

4

5

9

15

Adaptor Plate

Suggested

Wire Size

ISOmm2

6
10
16
16
25

70

120

Ribbon Cable,
1, 2 or 3 meters

Remote Keypad Mounting Kit

Figure 2.7

Components

TE Starte

9

TE Series Digital Solid State Soft Starters 18 – 1250A

2.8 Dimensions (consult price catalog for enclosed units)

Enclosure Model Number

TE -18-BP thru

TE -48-BP

Panel (open) with

integral bypass

contactor

TE -62-BP thru

TE -112-BP

TE -150-BP and

TE -160-BP

TE -210-BP thru

TE -450-BP

TE-550-BP thru

TE-600-PB

TE-862-BP thru

TE-900-BP

TE-1006-BP thru

TE-1250-BP

Table 2.8: TE Dimensions (subject to change)

14.00 8.00 6.68 12.75 6.75 0.28

19.21 8.00 6.68 18.25 6.75 0.38

28.50 12.5 9.10 27.38 10.75 0.40

43.13 25.5 11.86 43.00 23.00

46.56 28.2 13.00 42.75 23.25 0.50

A

Overall Mounting

A B C D E F

8.75 7.95 6.66 7.56 7.00 0.22

28.5 12.5 9.1 27.38 10.75 0.40

Fdia.

~ ~

~

D

E

B

Figure 2.8: TE Dimensions

C

10

TE Series Digital Solid State Soft Starters 18 – 1250A

Chapter 3 - Motor Overload Protection

MOTOR FLA (F001)

must be programmed

for unit to oper ate!

Examples:

H 100

100% Thermal Capacity

rem a ining a t rest

H 057

57% Thermal Capacity
remaining after starting

(43% u s ed)

3.1 Solid State Overload Protection

The TE Series Starter provides true U.L. listed I
Protection as a built-in function of the main digital processor for
maximum motor protection. It simulates the tripping action of a bi­metallic overload relay, with the accuracy and repeatability of a digital
control system. It is adjustable over a wide range and can be easily
programmed for different trip curves.

3.1.1 Thermal Memory

The TE Series microprocessor uses a sophisticated “Thermal Register”
in the digital memory to keep track of motor heating and cooling over
time regardless of the starter’s power status. By using non-volatile
memory, the TE Series does not “forget” that the motor has been
running even if power to the starter is turned off and turned back on.
Continuous overload protection is provided based on the true thermal
condition of the motor.

3.1.2 Thermal Capacity

The Thermal Register is displayed as a percentage. This percentage is
the motor’s remaining
100, showing that the motor is cool (has 100% of its capacity available).
As the motor heats up or moves toward an overload condition, the
percentage begins to drop. The Thermal Capacity is derived from the
programmed motor nameplate Full Load Amps (FLA) in Function F001,
the Service Factor rating in Function F002, and the Overload Trip Class
in Functions F003 and F004. Setting these functions to the proper
values provides maximum protection and eliminates nuisance tripping.

The Remaining Thermal Capacity can be viewed by using the UP or
DOWN arrow keys when in the Status Display mode. From the default
Phase A Current screen (dot on right side), press the UP arrow key 4
times to display [H100] meaning there is 100% of the Thermal Capacity
(H = Heat capacity) remaining in the motor. After starting or running, the
motor will use this capacity and the display will show a lower number.
For example, after a cold start, the display may read [H065] which
indicates that the motor has 65% of its thermal capacity remaining (35%
used). The Status Display screens cycle back to the beginning, so the
Down arrow keys can get to this display as well.

 3.1.2.a Motor Full Load (FLA) Setting

Use Function F001 to enter motor FLA as indicated on the motor
nameplate. (Do not calculate for service factor, this is programmed
separately in F002).

 NOTE:

All TE Series starters are shipped from the factory with F001 set to
a default value of 0000. If F001 is left at the factory default, the unit
will not operate. If the user attempts to start the TE Series without
entering the motor nameplate FLA, the starter will Fault and the
display will read “nFLA” (no Full Load Amps).

thermal capacity. The percentage value begins at

2

t Thermal Overload

11

TE Series Digital Solid State Soft Starters 18 – 1250A

3.1.3 Disabling the Overload Protection

The Overload Protection feature can be disabled if necessary. When
using external devices such as Motor Protection Relays or when the TE
Series is wired downstream from an existing starter, this feature can be
disabled to prevent conflicts with external overload protection devices.
When the TE Series is controlling multiple motors, the built-in Overload
protection must be disabled and individual thermal overload relays must
be installed on the motor leads going to each motor (see appendix 5 for
additional details). To disable the Overload Protection function, use
F005.

WARNING

Do NOT disable Overload Protection unless another Thermal Overload Protection
device exists in the circuit for all three phases. Running a motor without Overload

Protection presents serious risk of motor damage or fire.

 3.1.3.a Manual Reset

The factory default setting is Manual Reset. This means that when
the Overload Trip is activated, the starter cannot be restarted
without pressing the Reset key. The Overload Trip will not reset
until the motor cools down (see 3.1.3.d). The Manual Reset function
is also “trip free”. Holding in the Reset key will not prevent the
Overload Trip from activating and protecting the motor.

 NOTE:

When the Overload Trip activates, the Overload LED will glow solid.
When the motor cools down, the LED will begin to flash, indicating
that the Overload Trip can be reset.

 3.1.3.b Automatic Reset

If Automatic Reset is necessary, change from Manual Reset to
Automatic Reset by using Function F005. (See Section 5 for
details). In this mode, a 3-wire control circuit will be capable of
restart when the TE Series has reset itself after the cool down
period.

WARNING

Two-wire control systems may restart without warning when Auto
Reset of the overload protection is selected. Extreme caution
should be exercised. To prevent automatic restarting with 2-wire
control systems, use external interlocking to provide sufficient
warning and safety to operators. A Warning Label similar to that
shown below (and the one provided in the packet with this manual)
must be located where visible (on the starter enclosure and/or the
driven equipment) as required by local code.

WARNING: MOTOR CONNECTED TO THIS EQUIPMENT

MAY START AUTOMATICALLY WITHOUT WARNING

12

TE Series Digital Solid State Soft Starters 18 – 1250A

 3.1.3.c Overload Protection During Bypass

When an integral Bypass Contactor is used to shunt power around
the SCRs in the TE Series (as in the TE…-BP version), overload
protection is maintained as long as the TE Series is directly
controlling the contactor. No additional Overload Relay is

necessary for normal operation.

CAUTION

If a Bypass Contactor is added by the user in the field (i.e. 210A units and above), care
must be taken to ensure proper power routing to ensure functioning of the Overload
protection. Consult factory for assistance.

 When the Bypass Contactor on a TE…-BP Series has been

selected to be used for Across-the-Line restart (reference section

1.2.3), supplemental overload protection may be necessary. For this
application, refer to the External Overload Relay Applications
supplement and wiring diagram in Appendix 5 and section 4.2.6.a.

 3.1.3.d Dynamic Reset Capacity

The TE Series includes the ability to dynamically track the Thermal
Capacity needed for a successful restart after an overload trip. It
averages the Thermal Capacity consumed in the previous three
successful starts, and calculates a Thermal Capacity to Start
(viewed in Function F059). After tripping on Overload, the Thermal
Register must have regained the amount recorded in F059 before a
Reset will be allowed. If the display reads [ Inh] when attempting to
reset an overload trip, it is indicating that the starter is Inhibited from
being reset.

Refer to details of Function F071 for information on emergency
override of lockouts such as this.

3.2 NEMA Class Trip Curves

NEMA Class trip curves are based on a common tripping point of 600%
of motor Full Load Amps (FLA). Curves vary by the amount of time
before the unit trips. As an example, a Class 20 curve will trip in 20
seconds at 600% of FLA. The factory default setting of Class 10 will trip
in 10 seconds at 600% of FLA.

3.2.1 Dual Overload Trip Curves

The TE Series Soft Starter provides two separate Overload Trip
Protection Curves, one for starting and one for running conditions. The
starter’s At-Speed detection circuit determines when the motor has
reached full speed. When the At-Speed condition is reached, the
overload trip curve will shift from the Start to the Run level, as
programmed in Functions F003 and F004. See Section 5.6.1 for
programming details.

3.2.2 Starting Overload Trip Curve

During the start mode, Overload Trip Curves are selectable from NEMA
Class 5 through Class 20 only. The default setting of Class 10 allows
protection for the overload capacity of the soft starter as well as the
motor. Use a higher Trip Class only if nuisance tripping occurs with the
default setting.

13

TE Series Digital Solid State Soft Starters 18 – 1250A

3.2.3 Running Overload Curve

During the Run mode, Overload trip curves are selectable from NEMA
Class 5, 10, 15, 20, 25, and 30. Program the appropriate curve
according to the characteristics of your motor and load.

3.2.4 Overload Trip Curve Chart

Figure 3.2.4: TE Series Overload Trip Curves

14

TE Series Digital Solid State Soft Starters 18 – 1250A

r

r

r

/

/T3V

Chapter 4 – Connections

Disconnect

o

Circuit

Breake

R /

S /

L1

L2

T

TE Starte

L3

Solid State.

Over Load .

4.1 Power Connections

Connect appropriately sized power conductors to the unit input
terminals marked L1, L2, L3 (R, S, T for IEC users). Connection points
for units of 160A and below are saddle clamps suitable for stranded
wire. Connection points for units of 210A and above are bus tabs with
pre-drilled holes (see section 2). Use appropriate compression or
mechanical lugs for termination to these bus tabs. Avoid routing power
wires over the control board or display. Connect the motor leads to the
unit terminals marked T1, T2, T3 (U, V, W for IEC users). Refer to local

.

code standards for wire sizing and length.
If control power is present, but line power is disconnected from L1, L2,

L3, the display will show [n3PH] indicating “no 3 Phase”.

Integral
Bypass

Contactor*

U /
T1

W

/

T2

MTR

Figure 4.1:

TE Power Connections

*Larger units (210A and above) can
be ordered with fan cooling instead of
Bypass Contactors, but are intended
for use in NEMA 1 ventilated
enclosures only. Do not use the TE
starter in a sealed enclosure without a
bypass contactor.

CAUTION

Never interchange input and output connections to
the unit. This could cause excessive voltage in the
control logic circuit and may damage the unit.

G

4.1.1 Bypass Contactor

Bypass Contactors are integral (built-in) on all TE…-BP (panel mount),
and all TE…–E (NEMA 12 enclosed) versions. See sections 3.2.1.c and

4.2.5 for more details on contactor control and overload protection
details.

4.1.2 Power Factor Correction Capacitors

Power factor correction capacitors can be connected to motors
controlled by TE Series starters, however they must be off-line during
ramping. Connect PFC capacitors to the Line side of the starter with a

separate capacitor control contactor.

WARNING

Never connect power factor correction capacitors on
the load side of the unit. The SCRs will be seriously
damaged if capacitors are located on the load side.

4.1.3 Grounding

Connect the ground cable to the ground terminal as labeled on the unit.
Refer to the National Electrical Code or your local Code for the proper
ground wire sizing and be sure that the ground connector is connected
to earth ground. In ungrounded systems, it is not necessary to connect
a ground to the unit however local codes should always be consulted.

15

TE Series Digital Solid State Soft Starters 18 – 1250A

4.1.4 Testing
The TE Series can be tested with a load smaller than the motor it was

originally selected to control, however additional steps must be taken to
avoid tripping on Phase Current Loss. See section 5.6.9.a under “Phase
Loss Protection” for additional details on performing this task.

 NOTE:

The unit cannot be tested without a motor or other test load
connected to the load side of the unit. It may be necessary to use a
load bank to test the unit without a motor.

 Line voltage will appear across the output terminals if there is no

motor or load connected to the unit.

 IMPORTANT NOTE:

Fault code SSd may display if there is no output load connection
when control power is applied!

4.1.5 Lightning Protection

As with all electronic power controllers, protection from damage by
lightning surges is recommended in areas where lightning is a
significant problem. Stationary air gap lightning arrestors should be
considered and utilized on the input power source. The best method of
protection is to have an Isolation Contactor in front of the starter that is
open when the soft starter is not in use.

4.2 Control Connections

Control connections on the TE Series starter are divided into 2 groups.
With the unit oriented vertically, TB1 is a 12-point DC terminal block (on
the left), and TB2 is a 10 point AC terminal block (on the right side).
These are removable terminal blocks
servicing, and are provided with different spacing (pitch) between the
header pins so they are not interchangeable. Following are descriptions
of control connection points.

 NOTE:

Terminal numbers are shown on the side of the first and last
terminal of each block. An additional 3 point terminal on the far left
side is for serial communication connections (see section 5.6.11).

TB1: 12 terminals, #1-12

N C

RAM P2

JOG

PTC

OPTO

1 2 3 .................................. ........ ..... 11 12

24VDC from internal supply

= Factory instal led ju mp er s

Opt o-Isolated Triac Swit ch

10-250VAC/D C 50mA max.

TB2: 10 Terminals, #13-22

1

NC NO. C

2

NC NO. C3NO. C

13 14 ...........................19 20

240VAC max. fr om

customer source

for ease of connection and

1

A1 A2

120VAC Contr ol Power
(or 240VAC if ordered)

16

TE Series Digital Solid State Soft Starters 18 – 1250A

Figure 4.2: Control Terminal Blocks

4.2.1 AC Control Power Supply Connection

1

NC NO. C

2

NC NO. C3NO. C

Control Pow er Supply Connection

Figure 4.2.1

TB- 2

120VAC

Supply

1

A1 A2

AC Control Power VA Requirements

TE-18 to 48 48 (inc. in PCB) 95 9 100
TE-62 to 112 48 (inc. in PCB) 220 17 250
TE-150 to 160
TE- 210 to 276*
TE-360 to 450*
TE-550 to 900*
TE-1006 to 1250* 48 200 1900 48 2000

Table 3: TE Series Control Power Requirements
NOTE: * - P versions (w/o bypass) still require PCB and fans, plus user supplied bypass (if any).

Separate AC Control Power supply is required to power the electronics
of the TE Series starter. 120VAC is standard, order 240 VAC (optional)
if necessary for your line power supply configuration. The control
voltage must be connected to terminals marked A1 and A2 of TB-2 as
shown in figure 4.2.1 (these are also Terminal #s 21 and 22). This
control voltage must be customer supplied, unless an optional control
power transformer (see table below) has been supplied with the unit.

TE …-BP

Model

PC

Boards

Fans

-BP: Bypass
Contactor

Inrush

-BP: Bypass
Contactor

Sealed

Recommended

minimum

48 72 298 12.3 500
48 100 380 11.6 500
48 150 571 14 750
48 200 600 3.3 750

 4

.2.1.a Control Power Requirements

When sizing a control power transformer for the TE…-BP Series
starter use the above chart for minimum sizes or supply capacity.
Any additional control devices powered by the same CPT must be
added to the above figures to ensure proper operation of the
Bypass Contactor.

 NOTE:

TE-210 and larger units are available without the Bypass Contactor,
but fans are still included. CPT can be sized for fan loads only if
used in NEMA 1 ventilated enclosures.

 4.2.1.b Control Fusing

Output relays in TB2 must be protected from currents in excess of
5A, either with a fuse or with other suitable current protection
devices.

 A dedicated fault output for use in PLC or interposing relay control

is available on TB1. This opto-isolated Triac switch is rated for
50mA max., 10-250V AC/DC. Any circuit connected to it must be
fused accordingly.

CPT

Rating

17

TE Series Digital Solid State Soft Starters 18 – 1250A

4.2.2 Three-Wire Control Connection

For standard 3-wire control, connect dry (voltage free) contacts of the

OPTO

Stop / Start buttons as shown on the diagram directly above the terminal
strip. Connect the NO contact of the Start button to Terminal #1 (far left
terminal), the common point between the Stop and Start to Terminal #2

nd

(2

from left) and the NC from the Stop button to Terminal #3 (3rd from

left).
 4.2.2.a Seal In Contact

The TE Series uses an internally pre-wired “seal-in” contact around
the Start button (Terminals 1 and 2). No external relay or auxiliary
output connection is necessary.

4.2.3 Two Wire Control: Relay / PLC Connection

An alternate connection for automated or unattended operation replaces

OPTO

start/stop push buttons by connecting a dry (voltage free) maintained
contact closure between terminals 1 and 3 as shown in Figure 4.2.3.
When this contact is closed, the TE Series starter will start and run.
When it is opened, it is the same as a Stop command.

 4.2.3.a Automatic Functions and 2 Wire Control

If using the Time Clock functions (F032-F039) or Auto Reset
functions (F052 – F053), special consideration must be given to
using 2 wire control. Refer to Appendix 3 for additional details and
information on time clock functions, and section 5.6.9 for details on
using Auto-Reset functions.



NOTE:

When a maintained contact is used for start/stop it is advisable to
set the overload relay to the manual reset position. This will prevent
the motor from restarting if the thermal overload trips and then cools
off.

CAUTION

Control Terminals 1-10 of TB1 are a 24VDC circuit from an internal
power supply of the TE Series.

Use dry (unpowered) contact closures only. Applying any voltage
to these terminals will result in damage to the TE Series control
board.

If existing 120VAC or other powered control circuit must be
interfaced, use interposing relays or control the TE Series wit h 2
wire control as shown above.

4.2.4 Interlock Connection

TB1 provides a connection point for an external dry (voltage free) N.C.

OPTO

(Normally Closed) interlock device between terminals 4 and 5.
Examples where this interlock connection would be used include low oil,
high temperature, or excess vibration dropout from user supplied
devices. A factory-installed jumper is provided which allows the TE
Series unit to operate if external interlocks are not used. If this jumper is
removed and an interlock is not

used, the TE Series unit will not

function.

1 2 3

Connect 3 w ire

control here

as shown

1 2 3

Connect 2 wire

control / PLC

output her e

RAM P2

N C

N C

N C

4 5

External Interlock Connection

JOG

Figure 4.2.2

3 Wire Control Connection

TB-1

RAM P2

JOG

Figure 4.2.3

2 Wire Control Connection

TB-1

RAM P2

JOG

Remove factory jumper

and connect external
interlock device here

Figure 4.2.

TB-1

PTC

PTC

PTC

18

TE Series Digital Solid State Soft Starters 18 – 1250A

4.2.5 Enabling the Dual Ramp and Jog Features

TB1 includes provisions for enabling the Dual Ramp and Jog functions
by using external contact closures. Both features use a common
+24VDC from Terminal # 7, however they can be used independently of
each other or together. See sections 5.6.2 and 5.6.3 for full function
descriptions and setup.

RAM P2

N C

6 7 8

RAMP 1 RAMP 2

Figure 4.2.5.a:

Dual Ramp Connections

TB-1

RAM P2

N C

6 7 8

Figure 4.2.5.b:

Jog Connections

TB-1

RAM P2

N C

6 7 8

JOG

JOG

RUN JOG

JOG

RUN JOG

PTC

PTC

PTC

RAMP 2

OPTO

 4.2.5.a Dual Ramp Command

Closing a dry (voltage free) contact between TB1, terminals 6 and 7
will enable Ramp 2, and the TE Series starter will respond to the
settings for Ramp 2 in F015 - F018. If no contact closure is present,
the TE Series starter defaults to the Ramp 1 parameters (F011 –
F014). See Section 5.6.2.a for setup of the Dual Ramp Feature.

The Dual Ramp feature is useful in instances where the load
changes significantly. Example: a loaded or unloaded conveyor belt.
The characteristics for starting an unloaded conveyor can be
programmed for ramp 1. The characteristics for starting a loaded
conveyor can be programmed for ramp 2. Ramp 2 can also be
programmed for Full Voltage / Across-the-Line starting by setting
the ramp time to 0 and Current to 600%.

Dual Ramp is also useful in 2-speed motor applications. Simply use
an auxiliary contact from one of the speed contactors to select
Ramp 2 so that separate ramp profiles can be used.

 4.2.5.b Jog / Remote Command

OPTO

Connecting a dry (voltage free) contact between TB1, Terminals 7
and 8 will enable the Jog feature. A Start command (Run Command
or Start button) is required to activate the Jog feature. See Section

5.6.3 for setup of the Jog Function.
The Jog feature can be used for tasks such as lining up machines

for blade or bit changes or inching belts along to check tracking.
This input is also used to change the function of the Serial

Communications port control through F068. For additional
information, see instructions of that function in section 5.6.11.

 4.2.5.c Using Both Commands

OPTO

It may be useful to initialize the Ramp 2 and Jog command
simultaneously when jogging. If this is the case, terminals 6 and 8
can be jumped together and controlled with one contact closure to
Terminal 7 (the common 24VDC).

Figure 4.2.5.c:

Dual Ramp / Jog Connections

TB-1

19

TE Series Digital Solid State Soft Starters 18 – 1250A

4.2.6 PTC Thermistor Input

RAM P2

N C

Figure 4.2.6:

PTC Resistor Connection

TB-1

JOG

PTC

9 10

**

PTC Resistor in Motor

+

** Remove factory jumpe r
from Terminals 9 and 10

RAM P2

N C

Optional

Emergency Stop PB

JOG

PTC

9 10

**

External OL Re lays

OLR 1 OLR 2

Figure 4.2.6.a:

Extern al Overload Relay(s)

and/or E-Stop PB Connect ion

TB-1

** Remove f actory jumpe r
from Terminals 9 and 10

The TE Series starter is provided with input terminals for connecting a

OPTO

PTC (Positive Temperature Coefficient) Thermistor that may be
imbedded in the motor. These are specialized resistors imbedded in
some motor windings that increase resistance as the temperature
increases. When the TE Series detects that the PTC input resistance is
too high, it initiates a PTC trip, and displays it on the readout as
[ PTc ]. This is independent of the Thermal Register overload current
protection and provides supplemental protection for high motor ambient
temperature applications. Terminals for this input are provided with a
factory jumper that must be removed if the PTC input is used. These
terminals are located on TB1, Terminals 9 and 10.

PTC resistors are also found in other devices such as bearings, air
receivers, oil or coolant reservoirs and air discharge systems that may
require shutdown of the motor.

PTC Resistor Values:

Resistance must be greater than or equal to 750 Ω at 25ºC. If multiple
resistors are used in the motor, the sum of all resistors in series must
equal or exceed this value.

 4.2.6.a External Over Load Relay Connection

OPTO

If an external Over Load Relay (OLR) is used (see Section 3.1.3.c
and Appendix 5), connect the NC aux. contact of the OLR to the
PTC input after removing the jumper. When the external OLR trips,
the contact will open, opening the resistance input to the PTC circuit
(the resistance goes to infinity). This indicates an immediate Over
Load to the starter, which trips and displays it on the readout as

 [ PTc ] to differentiate from the internal Thermal Over Load trip. If

multiple OLRs are used, i.e. multiple motors controlled by the same
TE Series starter, simply wire the Aux Contacts in series as shown
in Figure 4.2.6.a. See Appendix 5 for additional information.



NOTE:

An Emergency Stop Push Button or any other field device may be
wired to the PTC input using NC contacts. When the contacts open,
the starter will detect it as a PTC trip. Even if a PTC is used in the
motor, field devices can still be added as long as the total circuit
resistance is not exceeded.



This feature is especially useful when using Decel Control because

it will immediately shut off power to the motor even if Decel is
active. If used this way, instruct the users as to the trip indication
issues (i.e. the display will show [ PTc ] and the Overload LED will
be on).

20

TE Series Digital Solid State Soft Starters 18 – 1250A

4.2.7 Fault Signal

RAM P2

N C

Control Power or PLC Source

Fault Outp ut Opto-Triac Connection

1

NC NO. C

13 14 15 16 17 18 19 20

Figure 4.2.7:

Internal Connections

K3

AUX.

RELAY #1

Auxiliary Relay Connections

TB-1

2

NC NO. C3NO. C

RELAY #2

JOG

AUX.

Figure 4.2.8

TB-2

PTC

External Fault Relay

K5K4

AUX .

RELAY #3

11 12

or PLC Input

1

A1 A2

An optically isolated Triac output is dedicated as a fault indicator on

OPTO

TB1, terminals 11 and 12, labeled “Opto”. The output Triac switch is
rated for 10 - 250 VAC/DC, 50 mA (maximum). If the three
programmable Output Auxiliary Relays are being used for other
functions, this output can easily be hooked up to a PLC or small
external relay to provide a Fault signal. This Fault Output operation is

R

permanently fixed at “Any Trip”, duplicating the Relay setting #16 as
shown in Table 5.6.10.

This output is permanently set to this function and is not
programmable.

4.2.8 Output (Auxiliary) Relay Contacts

Three programmable auxiliary relays are on TB2. The TE Series starter
comes with three programmable dry relay output contacts. Outputs #1
and #2 are Form C (SPDT), with a Common, N.O. and N.C. Output #3
is a Form A, (SPST), N.O. contact. It is not necessary to use the
programmable output auxiliary relays in the Start / Stop circuit. An
internal seal-in relay is provided elsewhere (see 4.2.2.a above). Toshiba
recommends fusing all contacts with external fuses.

The relays are rated for 240 VAC, 5 A and 1200 VA.
Factory default settings for these relays are as follows:
 AUX 1 – Run / Stop (see F060) This contact changes state upon a

Start command, returns to normal on Stop (or Begin Decel if active).

 AUX 2 – At-Speed / Stop (see F061) This contact changes state

upon the TE Series detecting At-Speed, and returns to normal on
Stop. At-Speed is determined by the TE Series detecting the
current dropping after reaching End-of-Ramp, or a maximum of 30
seconds after Start.

 AUX 3 – Any Trip (see F062) This contact closes when any trip

condition # 5 – 15 (as defined in Table 5.6.10) occurs.

All relays can be reprogrammed for a wide variety of functions.
See Section 5.6.10 for additional relay programming details.

21

TE Series Digital Solid State Soft Starters 18 – 1250A

4.2.9 Bypass Contactor Control

On TE…-BP version (and NEMA 12 enclosed) starters, an internal
dedicated connection is used at the factory for automatically controlling
the Bypass Contactor. Field wiring for Bypass Contactor operation is not
required.

 4.2.9.a Independent Bypass Contactor Control

The TE…-BP Series starters use standard industrial contactors that
can be controlled independent of the starter electronics if
necessary. When doing so, it is necessary to size the starter based
upon the ATL (Across-the-Line) selection chart so that the
contactors are rated for ATL duty instead of the normal Shunt Duty
(see section 1.2.3). Supplemental overload protection will be
required (see section 3.1.3.c).

Units have external terminal blocks marked for this purpose (see
Appendix 5 for drawings). A dry (voltage free) contact closure
between these terminals will close the bypass contactor
immediately. The Bypass Contactor coil voltage is the same as the
control voltage (120VAC unless the optional 240VAC control is
specified), and the potential on these terminals is the same as the
coil voltage.

No field wiring is necessary to these terminals if this feature is
not used.

For all other styles of TE Series, the At-Speed signaling can be
programmed into any of the three Output relays above (section 4.2.8
and Table 5.6.10).

22

TE Series Digital Solid State Soft Starters 18 – 1250A

Chapter 5 - Programming

5.1 Introduction

It is best to operate the motor at its full load starting conditions to

MOTOR FLA (F001)

must be programmed

for unit to oper ate!

Figure 5.2: Digital Interface

achieve the proper time, torque and ramp settings. Initial factory settings
are set to accommodate general motor applications and provide basic
motor protection. Advanced features must be enabled via programming.
The only parameter that MUST be set by the user is motor FLA (F001).

5.2 Digital Interface

The TE Series Soft Starter includes an intuitive, digital keypad with
eight LEDs, seven command keys, and an LED display with four
alphanumeric digits.

Keys

Green

LEDs

Yellow

LEDs

Display 8888.

Table 5.2: TE Series Display Features

Reset Clears the Trip indication and releases the Trip Relay.

Fn Enters or exits the Program Mode.

Navigates through the Status Display Mode, scrolls up

Up and

Down

Arrows

Right

and Left

Arrows

Power

On

At

Speed

Shunt

Trip

Shorted

SCR

Over

Current

Phase

Loss

Over

Temp

Over
Load

and down through the Function List, increases or
decreases the value of the active (flashing) digit and
scrolls through the fault history. When entering values,
holding the key down for more than 2 seconds will
activate Auto-step, which increases its rate the longer
the key is held down.

Each key press shifts the active (flashing) digit to the
right or left by one position, allowing you to change
higher values of functions without waiting to Auto-step
though large numbers.

Control power is available at A1 and A2
The motor is at full power and the Bypass Contactor

has been commanded to pull in.
The SCRs are at full conduction and current has

dropped.
Two or more SCRs in opposing phases have shorted,

and power is flowing to the motor in the Off mode. See
section 8 for additional concerns.

There is no voltage drop across at least one SCR
phase assembly, indicating that at least one SCR is
shorted. See section 8 for additional concerns

Overcurrent LED lights for three sets of fault conditions:

1) During start, the unit saw current exceed the
normal rate of increase in the first 250ms.

2) During Run, current exceeded either the OC setting
in F042 for the delay set in F043. This LED will be
accompanied by oCA, oCC or oCd on the display.

3) The unit has seen a Short Circuit exceeding 10x
FLA for 12.5ms. This LED will be accompanied by
SCA, SCC or SCD display.

One or more of the phase currents dropped below the
threshold during starting or running.

Starter has tripped due to excess heat sink
temperature. This will automatically reset.

Starter has tripped due to the Thermal Register
reaching 0000. The Overload must reset before this
fault can be cleared.

4 digit 7 segment display with a decimal point on the
right side indicating Phase A.

23