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: (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: _________________________
© 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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TD Series Digital Solid State Soft Starter 48 - 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 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.
WARNING
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.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
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 the area and reinspect the unit for foreign material. Make
sure there is sufficient clearance (six inches) all around the unit for cooling,
wiring and maintenance purposes. T o maximize effective air flow and cooling,
the unit must be installed with its heat sink ribs oriented vertically and running
parallel to the mounting surface.
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.
T o remove surface dust use 80 to 100 psi, clean, dry compressed air only . A
three inch, high quality , dry paint brush is helpful to loosen up the dust prior
to using compressed air on the unit.
2.6 Power Terminal Wire Range and Tightening Torque
Model Number Wire range Torque lbs/in
TD005 #18 - #4 20
TD006 #14 - #2 50
TD007
TD008
TD009
TD010
TD011
TD012
TD013
TD014
TD015
TD016
TD017
#6 - 250 kcmil 325
375(2) #2 - 600 kcmil
375(2) #2 - 600 kcmil
375(3) #2 - 600 kcmil
(4) #2 - 600 kcmil 375
Note: All wiring must be sized according to NEC standards.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
2.7 Dimensions
TD CHASSIS (PANEL MOUNT) DIMENSIONS
Overall Dimensions Mounting Dimensions
Model Number (inches) (inches)
AB CDEF
TD005A - TD007A
TD008A
TD009A - TD010A
TD011A - TD013A
TD014A - TD015A
TD016A - TD017A
16.5 10 10 15.9 9 0.28
20 20. 1 12 18.5 17.5 0.44
27 20. 1 11.2 25.5 17.5 0.44
29.5 20.1 11.5 25.5 17.5 0.44
45 33 12.8 43.3 31.3 0.44
33 33 15.2 31.2 31.2 0.44
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
Chapter 3 - Motor Overload Protection
3.1 Solid State Overload Protection
The TD Series Starter provides true U.L. listed I2T Thermal Overload Protection
as a built-in function of the main digital processor. For maximum protection it
simulates the tripping action of a bimetallic overload relay, with the accuracy and
repeatability of a digital control system, yet is adjustable over a wide range and
can be easily programmed for different trip curves.
3.1.1 Thermal Memory
The TD Series microprocessor uses a sophisticated “Thermal Register” to keep
track of motor heating and cooling over time regardless of the starter’s power
status. The TD Series does not “forget” that the motor has been running even if
power to the starter is turned off and 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 thermal capacity. The percentage value begins at 100, showing that
the motor is cool. 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 will provide maximum
protection yet eliminates nuisance tripping.
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: If F001 is left at the factory default, the unit will not operate. If the
user attempts to start the TD without entering the motor nameplate
FLA into this Function, the TD will Fault, and the display will read
“nFLA” (for no Full Load Amps).
3.1.3 Disabling the Overload Protection
The Overload Protection feature can be disabled if absolutely necessary. When
using external devices such as Motor Protection Relays or when the TD Series
is wired downstream from an existing starter, this feature can be disabled to
prevent conflicts with external overload protection devices. When the TD Series
is controlling multiple motors, Overload Protection must be disabled. Individual
thermal overload relays must be installed on the motor leads going to each
motor. To disable the Overload Protection function, use F005. (See Section 5.)
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. 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.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
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 TD Series has reset itself after the cool
down period.
Two-wire control systems may restart without warning when Auto Reset
is selected. Extreme caution should be exercised. To prevent automatic
restarting with two-wire control systems, use external interlocking to
provide sufficient warning and safety to operators. A Warning Label (such
as the one provided in the packet with this manual) must be placed to be
visible on the starter enclosure and/or the equipment as required by local
code.
WARNING
MOTOR CONNECTED TO THIS EQUIPMENT MAY
START AUTOMATICALLY WITHOUT WARNING
3.2 NEMA Class Trip Curves
The TD Series Soft Starter provides six NEMA Class trip curve options: 5, 10,
15, 20, 25, and 30. Program the appropriate curve according to the characteristics
of your motor and load.
NEMA Class trip curves are based on a common tripping point of 600% of rated
current. 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%. The factory default setting of
Class 10 will trip in 10 seconds at 600%.
3.2.1 Dual Overload Trip Curves
The TD Series Soft Starter provides two separate Overload Trip Protection Curves,
one for starting and one for running conditions. Programming a higher NEMA
Class overload during start (ramp-up) will eliminate nuisance tripping in higher
inertia or high friction loads.
The starter’s At-Speed detection circuit determines when the motor has reached
full speed based on closed loop feedback signals. 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 for programming details.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
C
30
Class 25
Class 20
Class 15
Class 10
Class 5
e
Seco
ds
TD Series
Overload Trip Curves
n
in
Tim
lass
Note: Factory default setting is Class 10 for both Start and Run Overload Protection
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
Chapter 4 - Connections
4.1 Power Connections
Connect appropriate power lines to the unit input terminals marked L1, L2, L3.
Avoid routing power wires near the control board. Connect the motor leads to the
unit terminals marked T1, T2, T3. Refer to NEC standards for wire length and
sizing. Never interchange input and output connections to the unit. This could
cause excessive voltage in the control logic circuit and may damage the unit.
WARNING
4.1.1 Grounding
4.2 Control Connections
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.
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. Note that line voltage will appear across the output terminals if
there is no motor or load connected to the unit. In areas where lightning is a
significant problem, stationary air gap lightning arrestors should be considered
and utilized on the input power source.
TD Series Unit
Power Connections
Connect the ground cable to the ground terminal as labeled on the unit. Refer to
the National Electrical Code for the proper ground wire sizing and be sure that
the ground connector is connected to earth ground.
TB1
120V
Control
Power
Unit comes standard with
120VAC control. Order 240VAC
control as an option if required.
4.2.1 Control Power Connections
Separate 120VAC supply is required (order 240 VAC if required). The control
voltage should be connected to pins 1 and 6 of TB1. This control voltage must be
customer supplied, unless an optional control power transformer has been supplied
with the unit. The terminal block TB1 is located on the main power board.
However, on units rated 150 Amps and above, TB1 us brought out to a duplicate
120V
Control
Power
Return
terminal block on the back panel assembly.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
4.2.2 Three-Wire Connection
For standard 3-wire control connect 120VAC to pins 1 and 6 of TB1. Connect
N.C. (normally closed) stop button between pins 3 and 4 of TB1. Connect N.O.
(normally open) start button between pins 4 and 5 of terminal block TB1.
4.2.3 Two-Wire Connection
An alternate connection for unattended operation replaces start/stop push buttons
TB1
Three-Wire Connection
by connecting a maintained contact closure between pins 3 and 5 on TB1. When
the maintained contact is used for start/stop it is necessary 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.
WARNING
When two-wire connection method is used, the user’s control circuit
must be interlocked to prevent automatic restart when protective
devices reset. Refer to section 3.1.3.b.
TB1
Two-Wire Connection
4.2.4 Relay Contacts
All the relay contacts are FORM C common (N.O., N.C.), except the optical
triac output. TOSHIBA recommends fusing all contacts with external fuses. TB2
is the terminal block for all auxiliary contacts. Each contact is explained in the
following sections. See Chapter 9 for main control board layout.
4.2.5 Programmable Relays
Three programmable relays are on TB2 which is located on the main control
board. The relays are rated for 240 VAC, 5 A and 1200 VA.
Factory settings for these relays are:
AUX 1 - Run / Stop (F050 = 1)
AUX 2 - At Speed / Stop (F051 = 2)
AUX 3 - Any Trip (F052 = 14)
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
1 2 3
Common
1 2 3
Common
TB4
TB4
Jog
Dual
Ramp
TB2
12345678910
C NO NC C NO NC C NO NC
Programmable
Relay
AUX 1
Fn F050
Programmable Programmable
Relay Relay
AUX 2
Fn F051 Fn F052
AUX 3
Optical Triac
4.2.6 Fault Signal
An optical AC switch triac driver is used for fault indication. This signal energizes
with the fault LED. The optical output is rated for 240 VAC, 50 mA (maximum).
4.2.7 Resetting Faults
To reset faults, press the RESET key on the keypad.
4.2.8 Enabling the Jog Function
Closing TB4 Pins 1 and 2 will enable the Jog feature. 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. See chapter 9 for main control board layout.
4.2.9 Enabling the Dual Ramp Feature
Closing TB4 Pins 1 and 3 will enable ramp 2. The dual ramp feature is useful in
instances where a load changes such as 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.
11 12
Fault
Signal
Driver
240Vac
50mA240Vac / 5A / 1200VA
TB1
123456
Interlock
4.3 Interlock Connection
TB1 provides a connection point for an external user N.C. (normally closed)
interlock device between pins 2 and 3. (Examples of the use of this interlock
connection would be for conditions such as low oil, high temperature, or excess
vibration from user supplied devices).
A factory installed jumper is provided which allows the TD unit to operate if
external interlocks are not used. If this jumper is removed and an interlock is not
used, the TD unit will not function.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
f
Chapter 5 - Programming
5.1 Introduction
It is best to operate the motor at its full load starting condition to 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).
MOTOR FLA (F001)
must be programmed
for unit to operate.
5.2 Digital Interface
The TD Soft Starter includes an intuitive, digital keypad with eight LEDs, seven
command keys, and an LED display with four alphanumeric digits.
Reset Clears the trip indicator and releases the trip relay.
Fn Enters or exits the program mode.
Keys
Green
LEDs
Yellow
LEDs
Up Arrow
Right Arrow
Down Arrow
Left Arrow
Read Enter Selects and stores the value of a function.
Power On Control power is present.
At Speed
Shunt Trip
Shorted SCR
Over Current
Navigates through the Status Display Mode, scrolls up through the list
of functions, increases the value of an active (flashing) digit, and scrolls
through the history of fault conditions.
Each keypress shifts the active (flashing) digit to the right one position,
use to change function number or value.
Navigates through the Status Display Mode, scrolls down through the
list of functions, decreases the value of an active (flashing) digit, and
scrolls through the history of fault conditions.
Each keypress shifts the flashing digit to the left one position, use to
change function number or value.
Motor is at full speed and power.
(The SCRs have phased fully on.)
Two or more power poles are shorted and current is passing to the
motor while in the off mode. For positive motor protection, an auxiliary
relay should be be programmed for "Shunt Trip" and should be
interlocked with a shunt trip breaker or in-line contactor. (In the event o
a shunt trip, do not re-power the unit without repairing the power poles.)
Shorted SCR has been detected in the unit. Refer to section 8.2 for
instructions on checking SCRs.
Over Current LED illuminates for two sets of fault conditions: over
current and short circuit.
If unit experiences output current (of any phase) in excess of the value
programmed in F034 (over current trip %) for the time period specified
in F035 (over current trip delay), this LED will illuminate and either
oCA, oCC, or oCd will be displayed.
If unit experiences a short circuit fault condition, the Over Current LED
illuminates and either SCA, SCC, or SCd will be displayed. This trip is
fixed at 10 times the full load motor current and is not adjustable.
Phase Loss
Over Temp Motor starter has tripped due to heat sink over temperature.
Over Load
Display 8888
One or more of the phase currents is low or has been lost while the
motor was starting or running.
Starter's motor overload has tripped. The overload must be reset
before the fault can be cleared
4 digit 7 segment display
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TD Series Digital Solid State Soft Starter 48 - 1250A
5.3 Display Modes
There are three modes of display: the Status Display mode, the Program mode,
and the Fault mode.
5.3.1 Status Display Mode
The Status Display Mode displays three phase motor current information and the
thermal capacity remaining.
Status mode:
• [0000.] The initial display on power up is four digits and the decimal. This
indicates the motor current for Phase A of the motor.
• [0000] Scroll up to display four digits only (no decimal). This indicates
the motor current for either Phase B or C. While viewing Phase A, press
the UP arrow once to view Phase B or twice to view Phase C current.
• [H000] Scroll up to display the “H”. This indicates that this value is the
remaining thermal capacity of the motor (as a percentage i.e. H070 =
70% remaining thermal capacity)
Reading Phase Current and Thermal Capacity (See Example)
[0120.] Indicates that Phase A is
drawing 120 amps.
Press the UP arrow.
[0121] Indicates that Phase B is
drawing 121 amps.
Press the UP arrow.
NOTE: Decimal points are not
present in the readouts
for Phase B and Phase C.
[0120] Indicates that Phase C is
drawing 120 amps.
Press the UP arrow.
[H051] Indicates that the motor has
51% of its thermal capacity
remaining.
5.3.2 Program Mode
Use the Program Mode to view or change Function (Fn) settings.
To enter the Program Mode, press the [Fn] key once. The first time you enter
Program Mode after power has been cycled to the starter, the initial function
[F001] should display with the selected digit flashing. If the TD Soft Starter has
been programmed and power to the unit has not been cycled, the readout will
display the last function viewed or changed.
To change to a different function, use the arrow keys.
Program Mode:
Press
Reading Phase Current
Thermal Capacity
• [F001] The “F” indicates the programmable function.
• [0000] This is the present setting of the applicable function. This display
may include decimals between digits depending on the function setting’s
range and incremental step.
0 120.
0 121
0 120
H05 1
and
Display
Phase A
Phase B
Phase C
Remaining Thermal
Capacity
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TD Series Digital Solid State Soft Starter 48 - 1250A
Viewing a Function’s Set Value (See Example)
NOTE: If password protection has been enabled, operator will need to obtain
password access before function settings can be changed.
[0000.] Indicates that Phase A is
drawing no current.
Press the Fn key.
[F001] Indicates that this is (function
001) Motor FLA.
To view the F001’s value, press
Read Enter.
[0306] Indicates that the
programmed motor FLA
is 306 Amps.
Press the Fn key to return to the
function.
[F001] Press the Fn key again to
return to the Status Display Mode.
Viewing a Function’s
0000.
F00 1
0306
F00 1
0000.
Set Value
Enabling Password Protection / Parameter Lock
The TD Series Soft Starter is shipped with the Customer password disabled
(F060 = 0). If it is necessary to prevent parameters from being changed
inadvertently, set the password in function F060. See Appendix 4 for details.
The display of a customer password is encrypted. If you do not have a record of
the password and need to gain access, contact TOSHIBA Tech Support. Be
ready to provide the TD Series serial number and the four digits in the encrypted
display. If the display reads “Err” when the READ/ENTER key is pressed, the
parameter lock is enabled.
Changing a Function’s Set Value
Use the UP arrow key to increment the value of the flashing digit. Use the DOWN
arrow key to decrement the value of the flashing digit. Use the LEFT or RIGHT
arrow to select the next digit to be altered. Values can only be changed within
the Adjustment Range of the function parameter.
Storing the Altered Value of a Function
Once the desired value is displayed, press the READ/ENTER key. This stores
the value in memory. The readout momentarily displays [ END] and then returns
to another function code.
NOTE: If the Fn key is pressed BEFORE the READ/ENTER key is pressed, the TD Series
Starter will not store the selected value in memory.
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TD Series Digital Solid State Soft Starter 48 - 1250A
Setting Motor FLA and Overload Class During Start (See Example)
Setting
mFLA
During Start
Setting
OL Class
During Start
5.3.3 Fault Mode
The Fault Display Mode provides information to the operator when a fault occurs
or when the operator wishes to review fault history. Refer to Section 7 for details.
Fault codes are three-digits in length and are displayed in alpha characters. The
first and second characters (reading left to right) are the initials for the applicable
English-language fault name. The third or right-most character can be either A,
C, or D to denote when the fault occurred. A denotes Acceleration. C denotes
Constant speed. D denotes Decel.
Reading Fault Code (See Example)
[ PLC.] Indicates a Phase Loss fault was
detected while at Constant Speed. The
decimal point (to the right of the C)
denotes that this is the most recent fault
condition.
Once a fault condition has been corrected, pressing the Reset key will return the
readout to the Status Display mode. Fault History can be accessed during a
fault condition. While the current fault number is being displayed, use the Up
and Down Arrow keys to scroll through the Fault History. Access Fault History
via Functions F075 through F083.
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Reading Fault Code
PLC.
TD Series Digital Solid State Soft Starter 48 - 1250A
5.4 The TD Function List
5.4.1 Motor FLA, Service Factor and Overload Protection Functions
Fn Group Function
F001
F002 Motor Nameplate Service Factor 1.00 - 1.30 0.05 1.0 SF 5.5.1
F003 Overload Class During Start
F004 Overload Class During Run
F005 Overload Reset
F006-
F009
Motor Nameplate FLA
Motor FLA must be programmed
for proper unit operation.
Motor and Overload
Reserved Reserved Reserved Reserved
50-100% of starter Max. Amp rating
Upper limit of range automatically
adjusts downward as Service
Factor is increased
5 - 30 NEMA / UL Class
Overload Time / Trip Curve
5 - 30 NEMA / UL Class
Overload Time / Trip Curve
0=Manual
1=Auto
2=Disabled Overload
Adjustment
Range
Setting
Increments
1 amp0(Starter disabled
5 Class 10 5.5.1
5 Class 10 5.5.1
1 0 (Manual) 5.5.1
Factory
Setting
until set to FLA)
5.4.2 Starting Mode Functions
Fn Group Function
Ramp Select
F010
F011 Initial Voltage of Ramp 1 0-100% 1% 60% 5.5.2
F012 Initial Current of Ramp 1 0-600% (note1) 1% 200% 5.5.2
F013 Accel Ramp Time of Ramp 1 1-120 seconds 1 second 10 seconds 5.5.2
F014 Max Current Limit of Ramp 1 200 - 600% (note1) 1% 350% 5.5.2
F015 Initial Voltage of Ramp 2 0-100% 1% 60% 5.5.2
F016 Initial Current of Ramp 2 0-600% (note1) 1% 200% 5.5.2
F017 Accel Ramp Time of Ramp 2 1-120 seconds 1 second 10 seconds 5.5.2
F018 Max Current Limit of Ramp 2 200 - 600% (note1) 1% 350% 5.5.2
VR = Voltage Ramp,
CR = Current Ramp
Starting Mode
Range is 1 - 4
Setting to #1: Ramp 1 = VR, Ramp 2 = VR
Setting to #2: Ramp 1 = CR, Ramp 2 = C R
Setting to #3: Ramp 1 = VR, Ramp 2 = CR
Setting to #4: Ramp 1 = CR, Ramp 2 = VR
Adjustment
Range
Setting
Increments
1 1 (VR1-VR2) 5.5.2
Factory
Setting
Section
5.5.1
5.5.1
Section
5.4.3 Jog Mode Functions
Fn Group Function
F019 Voltage Jog 5 - 100% 1% 50% 5.5.3
F020 Time of Voltage Jog 1 - 20 Seconds 1 second 10 seconds 5.5.3
F021 Current Jog 100 - 500% 1% 150% 5.5.3
Jog
Mode
Adjustment
Range
Note 1: Current percentages are based on Motor Full Load Amps (FLA) as entered in F001.
TD - Series
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Setting
Increments
Factory
Setting
Section
TD Series Digital Solid State Soft Starter 48 - 1250A
5.4.4 Kick Start Mode Functions
Fn Group Function
F022 Kick Start
F023 Kick Voltage 10 - 100% 1% 65% 5.5.4
F024 Kick Time 0.1 - 2 Seconds 0.1 second 0.8 seconds 5.5.4
Kick Start
Mode
0=Disabled
1=Enabled
Adjustment
Range
Setting
Increments
1 0 (Disabled) 5.5.4
Factory
Setting
5.4.5 Decel Mode Functions
Fn Group Function
0=Disabled / Coast to Stop
F025 Deceleration Ramp
F026 Begin Decel Level (BDL) 0 - 100 % 1% 60% 5.5.5
Mode
F027 Decel Shut Off Voltage 0 to (BDL minus 1)% 1% 30% 5.5.5
F028 Decel Ramp Time 1 - 60 Seconds 1 second 10 seconds 5.5.5
F029 Reserved Reserved Reserved Reserved 5.5.5
Decel
1=Enabled (except in event of OL Trip)
2=Enabled (continued Decel on OL Trip)
Adjustment
Range
Setting
Increments
1 0 (Disabled) 5.5.5
Factory
Setting
5.4.6 Protection Features
Fn Group Function
F030 Current Imbalance Trip
F031 Current Imbalance Trip % 5 - 30% 1% 10% 5.5.6
F032 Current Imbalance Trip Delay 1 - 20 seconds 1 second 2 seconds 5.5.6
F033 Over Current / Shear Pin Trip
F034 Over Current / Shear Pin Trip % 50 - 300% (note1) 1% 125% 5.5.6
F035 Over Current Trip Delay 1 - 20 seconds 1 second 1 second 5.5.6
F036 Under Current Trip
F037 Under Current Trip % 10 - 90% (note1) 1% 40% 5.5.6
F038 Under Current Trip Delay 1 - 60 seconds 1 second 2 seconds 5.5.6
F039 Coast Down Lockout Timer
F040 Coast Down Lockout Time 1 - 60 minutes 1 minute 5 minutes 5.5.6
Protection Features
F041 Starts per Hour Lockout
F042 Maximum Starts per Hour 1 - 10 1 2 5.5.6
F043 Time Between Starts Lockout
F044 Minimum Time Between Starts 1 - 60 minutes 1 minute 15 minutes 5.5.6
F045 Coast Down Timer Value 1 - 3600 Seconds View Only 0 5.5.6
F046 Starts per Hour Timer Value 1 - 3600 Seconds View Only 0 5.5.6
F047 Starts per Hour Count Value 1 - 10 Starts View Only 0 5.5.6
F048 Time Value Between Starts 1 - 3600 Seconds View Only 0 5.5.6
F049 Thermal Capacity to Start 0 - 100 % Thermal Capacity View Only 0 5.5.6
0=Disabled
1=Enabled
0=Disabled
1=Enabled
0=Disabled
1=Enabled
0=Disabled
1=Enabled
0=Disabled
1=Enabled
0=Disabled
1=Enabled
Adjustment
Range
Setting
Increments
1 0 (Disabled) 5.5.6
1 0 (Disabled) 5.5.6
1 0 (Disabled) 5.5.6
1 0 (Disabled) 5.5.6
1 0 (Disabled) 5.5.6
1 0 (Disabled) 5.5.6
Factory
Setting
Section
Section
Section
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
5.4.7 Relays
Fn Group Function
F050 Aux Relay 1 setting Operation # 1 - 18 (note2) 1 1 5.5.7
F051 Aux Relay 2 setting Operation # 1 - 18 1 2 5.5.7
F052 Aux Relay 3 setting Operation # 1 - 18 1 14 5.5.7
F053-
F054
Relays
Note 2: Auxiliary relays can be programmed for any of the following operations.
# 1 - Run / Stop (Signal) # 7 - Shunt Trip # 13 - Under Current Trip
# 2 - At Speed / Stop (Signal) # 8 - OL Trip # 14 - Any Trip (# 5 - #13)
# 3 - At Speed / End of Decel (SCRs Off) # 9 - OT Trip # 15 - Coastdown Time
# 4 - Start / End of Decel # 10 - Short Circuit Trip # 16 - Starts Per Hour
# 5 - Short SCR Trip # 11 - Current Imbalance Trip # 17 - Time Between Starts
# 6 - Phase Loss Trip # 12 - Over Current Trip # 18 - Any Lockout (#15 -17)
Adjustment
Range
Setting
Increments
Factory
Setting
ReservedReserved Reserved Reserved
5.4.8 Communications
Fn Group Function
F055 Communications
F056 Baud Rate 9.6 - 38.4 KB 9.6 KB 9.6 KB 5.5.8
F057 Modbus Address 1 - 247 1 1 5.5.8
F058-
F059
Communications
Reserved Reserved Reserved Reserved 5.5.8
0=Disabled
1=Enabled
Adjustment
Range
Setting
Increments
105.5.8
Factory
Setting
Section
5.5.7
Section
5.4.9 System Settings
Fn Group Function
Range is 0 - 999
F060
F061 Reset Factory Default Settings
F062-
F064
F065 Year 2000 - 2047 1 Year Date of Mfg. 5.5.9
F066 Month 1 - 12 1 Month Date of Mfg. 5.5.9
F067 Day 1 - 31 1 Day Date of Mfg. 5.5.9
F068 Hour 0 - 23 1 Hour Date of Mfg. 5.5.9
F069 Minute 0 - 59 1 Minute Date of Mfg. 5.5.9
F070 Second 0 - 59 1 Second Date of Mfg. 5.5.9
F071 Revision # - View Only Factory Setting 5.5.9
F072-
F074
Parameter Lock/
User Password
Reserved Reserved Reserved Reserved 5.5.9
System Settings
Reserved Reserved Reserved Reserved 5.5.9
0 = Disabled
Any Other Number = Password
Protected
Range is 0 - 2
0=Disabled
1=Clear Thermal Register and
Lockout Timers
2 = Reset to Factory Default
Settings
Adjustment
Range
Setting
Increments
1 0 (Disabled) 5.5.9
105.5.9
Factory
Setting
Section
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TD Series Digital Solid State Soft Starter 48 - 1250A
5.4.10 Fault History and Run Time
Fn Group Function
F075 Fault History #1, Latest Fault
F076 Time Stamp, Fault #1
F077 Date Stamp, Fault #1
F078
F079 Time Stamp, Fault #2
F080 Date Stamp, Fault #2
F081 Fault History #3, Oldest Fault
F082 Time Stamp, Fault #3
F083 Date Stamp, Fault #3
Fault History #2,
Previous Fault
Fault History and Run Time
Adjustment
Range
0, 1 - 27 (Fault #: see Fault
code list; 0: No fault history)
00.00-23.59 (hh.mm)
[hh = 00-23; mm = 00-59]
01.01 - 12.31 (MM.DD)
[MM = 01-12; DD = 01-31]
0, 1 - 27 (Fault #: see Fault
code list; 0: No fault history)
00.00-23.59 (hh.mm)
[hh = 00-23; mm = 00-59]
01.01 - 12.31 (MM.DD)
[MM = 01-12; DD = 01-31]
0, 1 - 27 (Fault #: see Fault
code list; 0: No fault history)
00.00-23.59 (hh.mm)
[hh = 00-23; mm = 00-59]
01.01 - 12.31 (MM.DD)
[MM = 01-12; DD = 01-31]
Setting
Increments
View Only 0 5.5.10
View Only 00.00 EST 5.5.10
View Only 01.01 5.5.10
View Only 0 5.5.10
View Only 00.00 EST 5.5.10
View Only 01.01 5.5.10
View Only 0 5.5.10
View Only 00.00 EST 5.5.10
View Only 01.01 5.5.10
Factory
Setting
Section
F084 Run Time, Hours 000.0 - 999.9 (hours) View Only 0 5.5.10
F085 Run Time, K Hours 0000 - 9999 (thousand hours) View Only 0 5.5.10
F086 Run Counts 0000 - 9999 (times) View Only 0 5.5.10
F087 Run Counts, 10K times 0000 - 9999 (10 thousand times) View Only 0 5.5.10
5.5 Function Descriptions
The unit is set at the factory with typical starting characteristics that perform well
in most applications.
Note: Customer must program motor FLA (F001) for unit to operate.
5.5.1 Motor and Overload Function Descriptions
F001 = Motor FLA
Factory Setting = 0
Range = 50 - 100% of Unit Max. Current.
Set the value of this function to the motor nameplate Full Load Amps
(FLA). Adjustments for service factor are not necessary when
programming this function. (See note below). If the motor nameplate
FLA is not available, use typical values as shown in NEC, NEMA
standard MG-1 or other reputable third party source (motor manufacturer,
etc.).
Note: To prevent adjusting the settings beyond the starter Max Amp rating, the range
of adjustment for the Motor Nameplate FLA will vary to reflect the Service
Factor as programmed into F002. At the default setting of 1.0SF, the full range
of adjustment from 50 - 100% of the Max Amp rating is available. For example
F002 = 1.15 to reflect a 1.15SF, the maximum FLA programmable into F001 will
be limited to 85% of the starter Max. Amp rating (100% - 15%).
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
F002 = Service Factor
Factory Setting = 1.0 S.F.
Range = 1.00 - 1.30
Set value according to the Service Factor (SF) data provided on the
motor’s nameplate. This value affects several protection features so it
must be accurate. Setting the SF too high may result in motor damage
in overload conditions. Setting SF too low may cause nuisance trips.
F003 = Overload Class During Start
Factory Setting = 10 (Class 10)
Range = 5 - 30 NEMA / UL Class
Set value to the motor protection overload class required for the
application. It is recommended that you try the factory setting first. (If
possible, keep values for F003 and F004 the same.) Increase F003
above F004 only if nuisance tripping occurs during start. See Section
3.2 for details on trip curves.
F004 = Overload Class During Run
Factory Setting = 10 (Class 10)
Range = 5 - 30 NEMA / UL Class
Set value according to the instructions provided by your motor /
equipment manufacturer. This trip curve will not be enabled until the
motor has reached full speed.
F005 = Overload Reset
Factory Setting = 0 (Manual)
Range = 0 - 2
Set value to determine starter behavior after an overload condition has
cleared.
When set to 0 = Manual, the operator must press the Reset key
before restarting the motor. Once the motor windings have cooled
sufficiently AND the Reset key is pressed, the unit will accept a restart
command.
When set to 1 = Automatic mode, and once sufficient time has elapsed
allowing motor windings to cool, the motor will be restarted upon a
start command.
WARNING
F006 - F009 = Reserved
Setting F005 = 1 (Automatic) may present significant
operational risk.
When set to 2 = Disabled Overload, a separate external thermal
overload protection device must be in the circuit.
TD - Series
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TD Series Digital Solid State Soft Starter 48 - 1250A
5.5.2 Starting Mode
The TD is capable of several different starting modes, but is set from the factory
for the most common applications. A second ramp profile is available for use
should you need it but unless wired to do so, the TD defaults to Ramp 1. This
section describes functions for Ramp 1, with references to function numbers that
do the same thing for Ramp 2 if required. Refer to Appendix 2 for a detailed
description of the differences in Ramp Profiles and their uses.
F010 = Ramp Profile Selection
Factory Setting = 1
Range = 1 - 4
This Function selects the type of Ramp Profile desired. Ramp profiles
can be either Voltage Ramp or Current Ramp. See Appendix 2 for
details. Each Ramp Profile consists of 3 settings:
Initial Torque, Ramp Time and Maximum Current Limit
Because there are two ramps available, there are 4 settings to cover
the combinations of profiles possible. If you are not using the 2nd
ramp, the TD will ignore all settings in reference to Ramp 2.
Select Voltage Ramp by setting F010 = 1 (factory default)
When Voltage Ramp is selected,
Set Initial Torque with F011 (see below)
Set Ramp with F013 (see below)
Set Maximum Current Limit with F014 (see below)
Or;
Select Current Ramp by setting F010 = 2
When Current Ramp is selected,
Set Initial Torque with F012 (see below)
Set Ramp Time with F013 (see below)
Set Maximum Current Limit with F014 (see below)
F010
Ramp
Profile
Selection
Setting
1 Voltage Ramp Voltage Ramp
2 Current Ramp Current Ramp
3 Voltage Ramp Current Ramp
4 Current Ramp Voltage Ramp
Ramp 1 Ramp 2
F011 = Initial Voltage of Ramp 1
Factory Setting = 60%
Range = 0 - 100%
Sets the initial voltage of ramp 1 when F010 = 1 or 3. The initial torque
level should be set to provide just enough torque to make the motor
shaft begin to rotate while preventing torque shock damage to
mechanical components.
F012 = Initial Current of Ramp 1
Factory Setting = 200%
Range = 0 - 600%
Sets the initial current of ramp 1 (when F010 = 2 or 4). Current
percentages are based on the Motor FLA as set in F001. The initial
torque level should be set to provide just enough torque to make the
motor shaft begin to rotate while preventing torque shock damage to
mechanical components.
TD - Series
- 22 -
Ramp Type
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