Toshiba 48-1250 A User Manual

INSTRUCTION MANUAL

INSTALLATION - OPERATION - MAINTENANCE

TD SERIES

Low Voltage
Digital Solid State Starter

DOCUMENT: NBZ0001

48 - 1250 A

Issued: 9/03
Manufactured in the USA

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, 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

WARNING

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: [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, 2003

SAFETY

R

R

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.

DANGE

WARNING

CAUTION

NOTE

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: 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.

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 equip­ment.

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 estab­lished practices.

6) Be trained in rendering first aid.

Table of Contents

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

TD Series Digital Solid State Soft Starter 48 - 1250A

Chapter 1 - Introduction

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.

1.2 Specifications and Performance Features

Type of Load

AC Supply Voltage

HP Ratings

Unit Overload Capacity
(Percent of motor FLA)

Power Circuit

SCR Diode Ratings
(Peak Inverse Voltage)

Phase Insensitivity

Transient Voltage Protection

Cooling

Bypass Contactor

Ambient Condition Design

Three phase AC induction motor

208 - 600VAC ±10%, 50/60 Hz

48 - 1250 Amps, 10 - 1125 HP

125% - Continuous
500% - 60 seconds
600% - 30 seconds

6 SCRs

1600V

Unit operates with any phase sequence

RC snubber dv/dt networks on each phase.

Convection up to 180A, fan assisted 62 - 120A,
Fan ventilated 220 - 1250A

Full horsepower rated contactor included as standard in all

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

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

Auxiliary Contacts

Approvals

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.

UL Listed, Canadian UL (cUL) Listed

TD - Series

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TD Series Digital Solid State Soft Starter 48 - 1250A

1.2 Specifications and Performance Features Cont’d

Advanced Motor Protection

Two Stage Electronic
Overload Curves

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

Retentive Thermal Memory

Dynamic Reset Capacity

Phase Current Imbalance
Protection (Note1)

OverCurrent
(Electronic Shear Pin)
Protection (Note 1)

Load Loss Trip Protection
(Note 1)

Coast Down (Back Spin)
Lockout Timer (Note 1)

Starts-per-hour Lockout Timer
(Note 1)

Type / Rating

Run Indication

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

Acceleration Adjustments

Dual Ramp Settings

Starting: Programmable for Class 5 through 30
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.

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

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

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

Coast Down Time Range: 1 - 60 minutes

Range: 1 - 10 successful starts per hour
Time between starts: 1 - 60 minutes between start attempts

Programmable Outputs

Form C (SPST), Rated 5 amps
240 VAC max, (1200 VA)

Start/Stop or Start/End of Decel

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)

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

Jog Settings
Jog function selected via
dry contact closure input)

Kick Start Settings
(Note 1)

Fault Indications

Lockout Indicator

Note 1: Enabled via programming

TD - Series

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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

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

Shorted SCR, Phase Loss, Shunt Trip, Phase Imbalance
Trip, Overload, Overtemp, Overcurrent, Short Circuit, Load
Loss, or Any Trip

Coast Down Time, Starts Per Hour,
Time Between Starts, and Any Lockout

TD Series Digital Solid State Soft Starter 48 - 1250A

1.2 Specifications and Performance Features Cont’d

Metering Functions

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

Remaining 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

Fault Codes

Fault History Last 3 faults with Time and Date Stamps

Protocol

Signal

Network Up to 247 devices per mode

Functionality

LED Readout

Keypad 8 functions keys with tactile feedback

Status Indicators 8 LEDs

Remote Mount Capability

Operating Memory DRAM loaded from EPROM and EEPROM at initialization

Factory Default Storage

Customer Settings and Status

Real Time Clock

0 - 100% of available motor thermal capacity

Remaining tim e of any enabled lockout timer

Abbreviated fault codes, indicating trip and operating mode

Serial Communications

Modbus RTU

RS-485

Full operation, status view, and programming
via communications port

Operator Interface

4 digit alpha numeric, high brightness, 7 segment display

Up to 10 feet (3 meters) from chassis

Clock and Memory

Flash EPROM, field replaceable

Non-volatile EEPROM, no battery backup necessary

Lithium ion battery for clock memory only,
10+ years life span

TD - Series

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