Toshiba 48-1250 A User Manual

INSTRUCTION MANUAL

INSTALLATION - OPERATION - MAINTENANCE

TX SERIES

Low Voltage Digital Solid State Starter

DOCUMENT : NBZ0002

48 - 1250 A

Issued: 11/04 Manufactured in the USA

SAFETY

DANGER

WARNING

CAUTION

DANGER

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 apart of or modify the warranty policy , the terms of which are set forth at the end of this manual.

READ SAFETY SIGNS

T o 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 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.

SAFETY

WARNING

SAFETY CODES

T oshiba 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 (NFP A 70) st andards and instructions provided

in this manual.

HAZARDOUS VOL TAGE will cause severe injury , death, fire, explosion and

property damage.

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

• Keep all panels and covers securely in place.

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

• Qualified Operators only.

Never attempt to install, operate, maintain or dispose of this equipment until you have first read and understood all of the relevant product warnings and user directions that are contained in this Instruction Manual.

Use only T oshiba-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: T oshiba International Corporation

Field Service Department 13131 West Little York Road Houston, T exas 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: _________________________

TX Series

TX Series 48 - 1250A

Digital Solid State Soft Starter 48 - 1250A

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

1.1 General

1.2 Specifications

1.3 Theory of Operation

1.4 General Protection

1.5 Thermal Overload Protection

Installation & Operation Manual

Chapter 2: Installation .......................................................................................................8

2.1 Receiving and Unpacking

2.2 Initial Unit Inspection

2.3 Location

2.4 Mounting & Cleaning

2.5 Power Wire Range and Tightening Torque

2.6 Dimensions

2.7 Power Connections

2.8 Control Connections

2.9 CPU Board Connections

2.10 Communications Board

2.11 RTD Board (Optional)

Chapter 3: Start-Up.......................................................................................................... 16

3.1 Preliminary Start-up Check List

3.2 Introduction

3.3 Acceleration Adjustments

3.4 Deceleration Adjustments

3.5 Sequence of Normal Operation

Chapter 4: User Interface and Menu Navigation.............................................................20

4.1 Keypad/Operator Interface

4.2 Menu Navigation

Chapter 5: Setpoint Programming..................................................................................23

5 .1 Setpoints Page List

5.2 Setpoint Menu

SP.1 Basic Configuration ................................................................................................33

SP.2 Starter Configuration...............................................................................................34

SP.3 Phase & Ground Settings .......................................................................................37

SP.4 Relay Assignment ...................................................................................................40

SP.5 Relay Configuration ...............................................................................................42

SP.6 I/O Configuration ....................................................................................................43

SP.7 Custom Acceleration Curve...................................................................................46

SP.8 Overload Curve Configuration............................................................................... 49

SP .9 R TD Configuration..................................................................................................50

SP.10 Set Password .......................................................................................................52

SP .1 1 Communications ....................................................................................................53

SP.12 System Setpoints ..................................................................................................54

SP.13 Calibration & Service ............................................................................................56

Chapter 6: Metering Pages ..............................................................................................57

6 .1 Metering Page List

Chapter 7: Maintenance and Troubleshooting/Disposal/Storage.................................. 67

7.1 Failure Analysis

7.2 SCR Testing Procedure

7.3 Replacing SCR devices

7.4 Replacing the Main Control Board

7.5 Interconnect Drawing

7.6 Maintenance Program

7.7 Disposal/Storage

Appendix A: Reference Section....................................................................................... 78

Appendix B: Record of Setpoint Adjustments .................................................................81

Warranty Policy .................................................................................................................89

TOSHIBA- 95

TX Series 48 - 1250A

TOSHIBA - 96

TX Series 48 - 1250A

Full horsepower rated contactor included as standard in all Type 12, 3R, 4 & 4X

Chapter 1 - Introduction

This chapter is a brief introduction to the TX Series soft starter and describes product operation and unit features.

1.1 - General

The TX Series is a high-end digitally programmable solid state reduced voltage soft starter. This heavy duty starter provides reduced voltage, stepless soft starting of 3-phase AC induction motors, protecting mechanical components from excessive torque stress and electrical systems from the effects of high motor inrush currents. The TX Series includes advanced motor and load protection features just like those found in expensive motor protection relays. These include retentive thermal memory, dynamic reset capacity, true thermal modeling, separate trip curves for start and run protection, overload alarm, etc. In the case of the TX Series, these features are built in as standard features, providing a cost effective and reliable motor starting and protection scheme for your critical motor applications.

The TX Series features an easy to use interface operator for programming and status indication. It includes a large tactile feedback keypad, LED status indicators and a 2 line x 20 character backlit display using plain English text readout. In addition to programming the standard parameters such as starting torque, ramp time, current limit, dual ramp and decel control, other features like programmable overload trip curves (NEMA/UL Classes 5 - 30), starts-per-hour, time between starts and coast down/back spin lockout protection can also be programmed for your specific application needs.

1.2 Specifications

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 motors or synchronous motors 208 - 600 VAC + 39 - 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 78 - 120A

Fan ventilated 220 - 1250A

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

10%, 50/60 Hz

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) 4 Programmable Relays UL Listed, Canadian UL (cUL)

TOSHIBA- 1

TX Series 48 - 1250A

for a successful restart. Starter learns and retains this information by monitoring

1.2 Specifications (continued)

Advanced Motor Protection

Two Stage Electronic Overload Curves

Overload Reset Retentive Th ermal Memory

Dynamic Reset Capacity

Phase Current Imbalance Protection

Over Current Protection (Electronic Shear Pin)

Load Loss Trip Protection

Coast Down (Back Spin) Lockout Timer

Starts-per-hour Lockout Timer

Starting: programmable for Class 5 - 30 or locked rotor time. Run: Programmable for Class 5 - 30 when "At-Speed" is detected.

Manual (default) or automatic 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

previous successful starts. Imbalance Trip Level: 5 - 30% current between any two phases

Imbalance Trip Delay: 1 -20 seconds Trip Level: 100 - 300% of motor FLA while running not starting or OFF

Trip Delay: 1 - 20 seconds Under Current Trip Level: 10 -90 % of motor FLA or OFF

Under Current Trip Delay: 1 - 60 seconds

Coast Down Time Range: 1 - 60 minutes or OFF

Range: 1 - 6 successful starts per hour Time between starts: 1 - 60 minutes between start attempts

Programmable Outputs

Type / Rating Run Indication At Speed Indication

Acceleration Adjustments

Dual Ramp Settings

Deceleration Adjustments

Jog Settings (Function selected via programming input)

Kick Start Settings

Fault Display Lockout Display

Form C (DPDT), Rated 5 amps 240 VAC max, (1200 VA) Start/Stop or Start/End of Decel At Speed/Stop or At Speed/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

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% or OFF Time of Voltage Jog: 1 - 20 seconds Current Jog: 100 - 500%

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

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

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

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TX Series 48 - 1250A

1.2 Specifications (continued)

Event History

Up to 60 Events

Motor Load Current Data Thermal Data

Start Data RTD Data

Voltage Metering

Protocol Signal Network Functionality

LCD Readout Keypad Status Indicators Remote Mount Capability

Data includes cause of event, time, date, and current for each phase and ground fault current at time of event

Metering Functions

Percent of FLA A, B, C Phase Current, Avg Current, Ground Fault Remaining thermal register; thermal capacity to start Avg Start Time, Avg Start Current, Measured Capacity to start, time since last

start Temperature readings from up to 12 RTDs (6 stators) KW, KVAR, PF, KWH

Serial Communications

Modbus RTU RS-485 or RS-422 Up to 247 devices per mode Full operation, status view, and programming via communications port

Operator Interface

Alpha numeric LCD display 8 function keys with tactile feedback 8 LEDs include Power, Run, Alarm, Trip, Aux Relays Up to 1000 feet from chassis (use twisted, shielded wire)

Clock and Memory

Operating Memory Factory Default Sto rage Customer Settings and Status Real Time Clock

DRAM loaded from EPROM and EEPROM at initialization Flash EPROM, field replaceable Non-volatile EEPROM, no battery backup necessary Lithium ion battery for clock memory only

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TX Series 48 - 1250A

1.3 - Theory of Operation

The power of the TX Series is in the CPU, a microprocessor based protection and control system for the motor and starter assembly. The CPU uses Phase Angle Firing of the SCRs to apply a reduced voltage to the motor, and then slowly and gently increases torque through control of the voltage and current until the motor accelerates to full speed. This starting method lowers the starting current of the motor, reducing electrical stresses on the power system and motor. It also reduces peak starting torque stresses on both the motor and load mechanical components, promoting longer service life and less downtime.

Acceleration: The TX Series comes standard with several methods of accelerating the motor so that it can be programmed to match almost any industrial AC motor application.

The factory default setting applies a Voltage Ramp with Current Limit as this has been proven the most reliable starting method for the vast majority of applications. Using this starting method, the Initial Torque setting applies just enough voltage to the motor to cause the motor shaft to begin to turn. This voltage is then gradually increased over time (as per the Ramp Time setting) until one of three things happen: the motor accelerates to full speed, the Ramp Time expires or a Current Limit setting is reached.

If the motor accelerates to full speed before the ramp time setting has expired, an automatic Anti-Oscillation feature will override the remaining ramp time and full voltage will be applied. This will prevent any surging or pulsation in the motor torque, which might otherwise occur due to the load not being fully coupled to the motor when operating at reduced voltage and torque levels.

If the motor has not reached full speed at the end of the ramp time setting, the current limit setting will proportionally control the maximum output torque. Feedback sensors in the TX Series provide protection from a stall condition, an overload condition or excessive acceleration time.

The Current Limit feature is provided to accommodate installations where there is limited power available (for example, on-site generator power or utility lines with limited capacity). The torque is increased until the motor current reaches the preset Current Limit point and it is then held at that level. Current Limit overrides the ramp time setting so if the motor has not accelerated to full speed under the Current Limit setting, the current remains limited for as long as it takes the motor to accelerate to full speed.

When the motor reaches full speed and the current drops to running levels, the TX Series detects an At-Speed condition and will close the Bypass Contactor (if provided). The Bypass Contactor serves to shunt power around the SCR stack assemblies to prevent heat build-up NEMA 12, 3R, 4 and 4X enclosed units due to the slight voltage drop across the SCRs. At this point, the TX Series has the motor operat- ing at full voltage, just as any other starter would.

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TX Series 48 - 1250A

Other starting methods available in the TX Series are:

· Current Ramp: uses a closed current feedback PID loop to provide a linear torque increase up to a Maximum Current level.

· Constant Current: current is immediately increased to the Current Limit point and held there until the motor reaches full speed.

· Custom Curve: gives the user the ability to plot torque and time points on a graph. The soft starter will then accelerate the motor following these points.

· Tachometer Feedback Ramp: uses a closed loop speed follower method monitoring a tachometer input signal from the motor or load shaft. (PENDING)

Deceleration: the TX Series provides the user with the option of having the load coast to a stop or controlling the deceleration by slowly reducing the voltage to the motor upon initiating a stop command. The Decel feature is the oppo- site of DC injection braking in that the motor will actually take longer to come to a stop than if allowed to coast to a stop. The most common application for the Decel feature is pumping applications where a controlled stop prevents water hammer and mechanical damage to the system.

1.4 General Protection

Operation of the TX Series can be divided into 4 modes; Ready, Start, Run and Stop. The CPU provides motor and load protection in all four modes. Additional details on each protection feature can be found in later chapters.

Ready Mode: In this mode, control and line power are applied and the starter is ready for a start command. Protection during this mode includes the monitoring of current for leakage through multiple shorted SCRs. Other protection features in effect are:

· Starter Temperature

· Shorted SCR

· Phase Reversal (if enabled)

· Line Frequency Trip Window

· External Input Faults

Note: The “Programming Mode” can only be entered from the Ready Mode. During programming, all protection features and start command are disabled.

Start Mode: These additional protection functions are enabled when the soft starter receives a valid Start command:

· Phase Reversal (if enabled)

· Start Curve

· Acceleration Timer

· Phase Imbalance

· Short Circuit / Load Pre-check (Toe-in-the-Water)

· Ground Fault

· External Input Faults

· Accumulated Starting FLA Units (I2t Protection)

· Overload Protection

· Thermal Capacity

Note: Shorted SCR and Shunt Trip protection are no longer in effect once the soft starter goes into the Start Mode.

TOSHIBA- 5

TX Series 48 - 1250A

Run Mode: The soft starter enters the Run Mode when it reaches full output voltage FLA plus service factor) for a predetermined period of time. During the Run Mode these additional protection features are enabled:

· Running Overload Curve

· Phase Loss

· Under Current / Load Loss

· Over Current / Electronic Shear Pin

· External Input Faults Stop Mode: Once a Stop command has been given, the TX Series protec-

tion features change depending on which Stop Mode is selected.

· Decel Mode: retains all protection features of the Run Mode. At the end of

· Coast-T o-Stop Mode: power is immediately removed from the motor and the

· Coast-Down / Back Spin Timer

· Starts-per-Hour

· Time Between Starts

· External Input Faults

and the motor current drops below the FLA setting (motor nameplate

Decel, the motor will be stopped and the protection features change as indicated below.

soft starter returns to the Ready Mode. Additional protection features activated when the stop command is given include:

1.5 Thermal Overload Protection

The TX Series plays an important role in the protection of your motor in that it monitors the motor for excessive thermal conditions due to starting, running or even ambient conditions. The TX Series has a Dynamic Thermal Register system in the CPU that provides a mathematical representation of the thermal state of the motor. This thermal state information is kept in memory and is monitored for excesses in both value and rate of change. Input is derived from current imbalances and (optional) RTD measurements making it dynamic to all processes involving the motor. The TX Series monitors these conditions separately during Start and Run modes to provide proper thermal overload protection at all times.

Start Mode overload protection is selectable using one of three methods:

· Basic Protection: I2t data is accumulated and plotted based on an Overload Curve selected in programming. This is programmed per NEMA Class 5-30 standard curves and is based on the Locked Rotor Current (from the motor nameplate) as programmed into the soft starter.

· Measured Start Capacity: the user enters a measured amount of thermal capacity from a pre-selected successful start as a setpoint to the Thermal Register for the soft starter to follow.

· Learned Curve Protection: the user sets the soft starter to the “LEARN” mode and starts the motor under normal starting conditions. The CPU then samples and records 100 data points during the start curve, analyzes them and creates a graphical representation in memory. The soft starter is then switched to Curve Follow protection mode and monitors motor performance against this curve. This feature is especially useful in initial commissioning tests to record a base line performance sample (in this case, it is not necessarily used for motor protection).

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TX Series 48 - 1250A

Run Mode overload protection is initiated when the TX Series determines that the motor is At-Speed. Overload Protection is initiated when the motor RMS current rises above a “pick-up point” (as determined by the motor nameplate FLA and service factor). Run mode protection is provided by the CPU monitoring the Dynamic Thermal Register. Data for the Dynamic Thermal Register is accumulated from I trip occurs when the register reaches 100% as determined by the selected Overload Protection Curve (NEMA Class 5-30 standard curves) and is based on the programmed Locked Rotor Current indicated on the motor nameplate. The Dynamic Thermal Register is altered, or “biased”, by the following conditions:

· Current Imbalance: will bias the register higher to add protection from additional motor heating during a current imbalance condition.

· Normal Cooling: provided when the motor current drops below the pick-up point or the motor is off line. The cooling rate is lower for motors that are offline (such as after a trip) since cooling fans are also inoperative.

· RTD Input: (requires the optional RTD monitor card): will bias the register in either direction based on real-time input of the motor, bearing and even ambient temperature conditions.

t calculations and cooling rates. A

· Dynamic Reset is another feature that adds reliability and consistency to the performance of the TX Series soft starter. If a motor overload condition occurs and the soft starter trips, it cannot be reset until sufficient cool down time has elapsed. This cool down time is determined by the thermal state of the motor when it tripped (i.e. hot motors cool more quickly due to additional convection). The cool down time is also biased by RTD measurements when used.

Retentive Thermal Memory provides continuous overload protection and real time reset even if power is lost. Upon restoration of power, the TX Series will read the Real Time Clock and restore the thermal register to what it should be given the elapsed time.

· Learned Reset Capacity is a feature that is unique to the TX Series. By sampling the amount of thermal capacity used in the previous three successful starts, the TX Series will not allow a reset until a sufficient amount of thermal capacity has been regained in the motor. This prevents nuisance tripping and insures that unsuccessful start attempts (which would otherwise use up the starts-per-hour capacity of the motor) are not allowed.

TOSHIBA- 7

TX Series 48 - 1250A

WARNING

Chapter 2 - Installation

2.1 Receiving and Unpacking

Upon receipt of the unit:

• Carefully unpack the unit and inspect it for any shipping damage. Report any damage immediately and file a claim with the freight carrier within 15 days of receipt.

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

• Confirm that the ratings label on the unit matches or is greater than the motor’s HP and current rating.

2.2 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 TX unit are rated for the proper amperage and voltage.

2.3 Location

The proper location of the unit is an important factor in achieving the unit’s specified performance and normal operation lifetime. The unit should always be installed in an area where the following conditions exist:

• Ambient Operating Temperature: 0° C to 50° C (32° F to 122° F) (Optional space heaters can be provided for operation in ambient temperature to -20° C.)

• Protected from rain and moisture.

• Humidity: 5% to 95% non-condensing.

• Free from metallic particles, conductive dust and corrosive gas.

• Free from excess 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 the enclosure.

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.

2.4 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 completed, 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. To 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.

TOSHIBA - 8

TX Series 48 - 1250A

Model

W ire

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.

2.5 Power Terminal Wire Range and Tightening Torque

230V 400V

Ran ge

Torque

lbs/in

Model

Number

Max

Am p s

Max HP

208V 230V 480V 600V

TX005 TX006 TX007 TX008 TX009 TX010 TX011 TX012 TX013 TX014 TX015 TX016 TX017

48 10 15 30 40 11 22 #18 - #4 20

78 20 25 50 60 22 37 #14 - #2 50 120 30 40 75 100 30 55 180 50 60 125 150 55 90 220 60 75 150 200 110 288 75 100 200 250 75 132 414 125 150 300 350 200 476 - - 350 400 132 250 550 150 200 400 500 160 718 200 250 500 600 200 315

1006 300 350 700 800 400 1150 350 400 800 900 1250 450 500 1000 1125

Note: All wiring must be sized according to NEC standards

2.6 Dimensions

TX DIME NSIONS

Enclosure

PANEL

(OPEN

CHASSIS

TYPE)

Number

TX005 to TX007

TX008 TX009 to TX010 TX011 to TX013 TX014 to TX015 TX016 to TX017

Overall Dimensions Mounting Dimensions ABCDEF

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

#6 - 250 kc m il 3 25

(2) #6 - 600 kcm i l 375

(2) #2 - 600 kcm i l 375

(3) #2 - 600 kcm i l 375

(4) #2 - 600 kcm i l 375

TOSHIBA- 9

TX Series 48 - 1250A

WARNING

2.7 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.

TX Series Unit

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 must be tested with a motor or other test load connected to the load side of the unit. (A load bank can be used if a motor is not available). 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, station-type air gap lightning arrestors should be considered and utilized on the input power source.

2.7.1 Grounding

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.

2.8 Control Connections

Separate 120Vac supply is required (240Vac for 380V and 415V applications). The control voltage should be connected to pins 1 and 6 of TB4 on the power board. This control voltage must be customer supplied, unless an optional control power transformer (See chart) has been supplied with the unit.

Recommended Transformer Sizes

TX Model

Panel NEMA Type 1 NEMA Type 12/3R/4

TX008 50 VA 100 VA 250 VA* TX009 50 VA 100 VA 500 VA* TX010 250 VA 250 VA 500 VA*

TX011 to TX013 250 VA 250 VA 750 VA*

Power Connections

TB4

Control

Power

Source

Unit comes standard with 120Vac control. Order 240Vac control as an option if required.

Control

Power

Return

2.8.1 Three-Wire Connection

TX014 500 VA 500 VA 1 KVA*

TX015 to TX016 500 VA 750 VA 1.5 KVA*

TX017 500 VA 750 VA 1.5 KVA*

* Transformer size is adequate to power built-in bypass contactors on these models.

Recommended Transformer Sizes for Control Power

Note:

1. If power is used for additional accessory items (Lights, fans, etc.) contact factory for sizing.

For standard 3-wire control connect 120V ac (or 240Vac for 415V and 380V applications) to pins 1 and 6 of TB4. Connect N.C. (normally closed) stop button between pins 3 and 4 of TB4. Connect N.O. (normally open) start button between pins 4 and 5 of terminal block TB4.

TOSHIBA - 10

Three-Wire Connection

TX Series 48 - 1250A

WARNING

2.8.2 Two-Wire Connection

An alternate connection for unattended operation replaces start/stop push buttons by connecting a maintained contact closure between pins 3 and 5 on TB4. When the maintained contact is used for start/stop it is necessary to set the overload setpoint to the manual reset position. This will prevent the motor from restarting if the thermal overload trips and then cools off.

Two-Wire Connection

When two-wire connection method is used, the start circuit must be interlocked to prevent automatic restart when either of the two protective devices (overload or thermostat) reset. Thermostats always automatically reset on cool down.

2.8.3 Programmable Relays/Relay Contacts

All the relay contacts are FORM C (Com, N.O., N.C.). Toshiba recommends fusing all contacts with external fuses. The TX has four programmable relays on TB3 on the power board. The relays are rated for 240Vac, 5 A and 1200 VA. These relays can respond to either a fault condition or an up-to-speed condition. In the TX all tripping functions have been assigned to the TRIP (AUX1) relay, and all alarm (warning) condition has been configured to the ALARM (AUX2) relay. AUX 3 is factory programmed for a SHUNT TRIP indication and can be connected to a shunt trip coil on an incoming circuit breaker or open an input isolation contactor. AUX4 is the AT SPEED contact. When the motor has reached the end of its acceleration ramp, the TX will wait until the AT SPEED programmed time delay has expired. Then, the relay will energize until a stop command has been received. The AT SPEED contact can be used to operate a bypass contactor (used for shorting the load current around the SCRs. To change AUX3 or AUX4 functions, see Setpoint Page 4.

Relay Contacts on Power Board

Rated 240Vac, 5A, 1200VA

TOSHIBA- 11

TX Series 48 - 1250A

2.8.4 Power Board

2.8.4a Power Board Connections

TB4

Three-Wire Control Connection

TB4

Two-Wire Control Connection

Relay Contacts on Power Board

Rated 240Vac, 5A, 1200VA

TOSHIBA - 12

TX Series 48 - 1250A

2.9 CPU Board Connections

There are eight digital inputs on the CPU board. Four of the inputs are user programmable. There are also two analog outputs, a tachometer feedback input.

TB1

Tach Input

1 2 43 5 6 7 8 9

Analog Output #1

4 - 20 mA

Analog Output #2

4 - 20 mA

Contact factory for remote

reset connections

Input

TB2

1 2 43 5 6 7 8

Program Enable

Factory wired. Do not change

TB3

External Input #1

1 2 43 5 6 7 8

External Input #2

Dual Ramp

Thermostat

+ -

Note: Install program jumper to enable setpoint programming. Jumper must be removed after programming or for prolonged storage to preserve settings.

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2.10 Communications Board

Full (RS422) or half (RS485) duplex Modbus communications port is available at TB1 on the communications board. No field wiring connections are required for TB2.

(RS485)

Note: Remove for last unit in modbus string

2.10.1 Communication Board Connections

REAR

VIEW

(RS422)

TB1 TB2

RS485 Connections

(Customer Connections)

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RS422 Connections

(Factory Only)

TX Series 48 - 1250A

2.1 1 Optional RTD Board

RTD1

Compensation

Signal

Power

RTD

Typical RTD

Installation

Shield

RTD2

RTD3

RTD4

RTD5

RTD6

RTD7

RTD8

RTD9

RTD10

RTD11

RTD12

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TX Series 48 - 1250A

WARNING

Chapter 3 - Start-up

THE TX UNIT DEALS WITH POTENTIALLY LETHAL VOL T AGE LEVELS. YOU MUST BE CERT AIN THA T PERSONNEL ARE THOROUGHL Y TRAINED IN THE APPLICABLE SAFETY PRECAUTIONS BEFORE PROCEEDING WITH THIS SECTION!

3.1 Preliminary Start-Up Check List

Please make the following checks before applying power to the unit:

• Supply voltage matches the rated supply voltage of the unit.

• Horsepower and current ratings of the motor and unit match or the unit has a higher rating.

• Initial ramp time and torque adjustments have been checked.

• Power lines are attached to the unit input terminals marked L1, L2 and L3.

• Motor leads are connected to the lower terminals marked T1, T2 and T3.

• Appropriate control power is applied and/or control connections have been made.

• The motor’s FLA has been programmed.

• The thermal overload parameters are properly set.

• The motor area and equipment are clear of people and parts before start-up.

3.2 Introduction

It is best to operate the motor at its full load starting condition to achieve the proper time, torque and ramp settings. Initial settings are set to accommodate most motor conditions. TRY INITIAL SETTINGS FIRST. See Setpoints Page 2 to make any adjustments.

3.3 Acceleration Adjustments

The unit is set at the factory with typical starting characteristics that perform well in most applications. When the system is ready to start, try the initial unit settings. If the motor does not come up to speed, increase the current limit setting. If the motor does not start to turn as soon as desired, raise the starting voltage adjustment. Adjustment description and procedures are described as follows (See section 4.5.2 for additional Accel settings):

3.3.1 Starting Voltage

Factory Setting = 20% of line voltage Range = 0% - 100% of line voltage

Starting voltage adjustment changes the initial starting voltage level to the motor.

3.3.2 Ramp Time

Factory Setting = 10 sec. Range = 0 - 120 sec.

Ramp time adjustment changes the amount of time it takes to reach the current limit point or full voltage if the current limit point was not reached.

3.3.3 Current Limit

Factory Setting = 350% of unit FLA Range = 200% - 600% of unit FLA

The current limit adjustment is factory set for 350% of the unit’s rating. The range of adjustment is 200% to 600%. The main function of current limit is to cap the peak current. It may also be used to extend the ramping time if required. The interaction between the voltage ramp and the current limit will allow the soft start to ramp the motor until the maximum current is reached and the current limit will hold the current at that level.

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TX Series 48 - 1250A

The current limit must be set high enough to allow the motor to reach full speed. The factory setting of 350% is a good starting point. Do not set the current limit too low on variable starting

loads. This could cause the motor to stall and eventually cause the overload protection to trip.

3.4 Deceleration Adjustments (Pump Control)

Decel extends the stopping time on loads that would otherwise stop too quickly if allowed to coast to stop. Decel control provides smooth deceleration until the load comes to a stop. Three adjustments optimize the deceleration curve to meet the most demanding requirements. Try factory settings before adjusting.

Deceleration Applications The unit is shipped from the factory with the decel feature disabled. Apply power and adjust the soft start before enabling or

modifying the deceleration adjustments. Both acceleration and deceleration adjustments should be made under normal load conditions.

The deceleration feature provides a slow decrease in the output voltage, accomplishing a gentle decrease in motor torque during the stopping mode. This is the OPPOSITE OF BRAKING in that it will take longer to come to a stop than if the starter were just turned off. The primary use of this function is to reduce the sudden changes in pressure that are associated with “Water Hammer” and slamming of check valves with centrifugal pumps. Decel control in pump applications is often referred to as Pump Control.

In a pump system, liquid is being pushed uphill. The force exerted by gravity on the column of liquid as it goes up hill is called the “Head Pressure” in the system. The pump is sized to provide enough Output Pressure to overcome the Head Pressure and move the fluid up the pipe. When the pump is turned off, the Output Pressure rapidly drops to zero and the Head Pressure takes over to send the fluid back down the hill. A “Check Valve” is used somewhere in the system to prevent this (if necessary) by only allowing the liquid to flow in one direction. The kinetic energy in that moving fluid is suddenly trapped when the valve slams closed. Since fluids can’t compress, that energy is transformed into a “Shock Wave” that travels through the piping system looking for an outlet in which it dissipates. The sound of that shock wave is referred to as “Water Hammer”. The energy in that shock wave can be extremely damaging to pipes, fittings, flanges, seals and mounting systems. By using the Soft Stop/Deceleration feature of the TX, the pump output torque is gradually and gently reduced, which slowly reduces the pressure in the pipe. When the Output Pressure is just slightly lower than the Head Pressure, the flow slowly reverses and closes the Check Valve. By this time there is very little energy left in the moving fluid and the Shock Wave is avoided. When the output voltage to the motor is low enough to no longer be needed, the TX will end the Decel cycle and turn itself off.

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TX Series 48 - 1250A

WARNING

Another common application for decel control is on material handling conveyors as a means to prevent sudden stops that may cause products to fall over or to bump into one another. In overhead crane applications, soft stopping of the Bridge or Trolley can prevent loads from beginning to over swing on sudden stops.

3.4.1 Start Deceleration Voltage

Factory Setting = 60% of line voltage Range = 0% - 100% of line voltage

The step down voltage adjustment eliminates the dead band in the deceleration mode that is experienced while the voltage drops to a level where the motor deceleration is responsive to decreased voltage. This feature allows for an instantaneous drop in voltage when deceleration is initiated.

3.4.2 Stop Deceleration Voltage

Factory Setting = 20% of line voltage Range = 0% - 100% of line voltage

The stop voltage level setpoint is where the deceleration voltage drops to zero.

3.4.3 Deceleration Time

Factory Setting = 5 sec. Range = 0 - 60 sec.

The deceleration ramp time adjusts the time it takes to reach the stop voltage level set point. The unit should be restarted and stopped to verify that the desired deceleration time has been achieved.

DO NOT EXCEED THE MOTOR MANUF ACTURER’S RECOMMENDED NUMBER OF ST ARTS PER HOUR. WHEN CALCULA TING THE NUMBER OF ST ARTS PER HOUR, A DECEL CURVE SHOULD BE COUNTED AS A START CUR VE. FOR EXAMPLE: RECOMMENDED NUMBER OF ST ARTS PER HOUR = 6, ALLOW ABLE ST ARTS WITH DECEL CYCLE PER HOUR = 3.

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3.5 Sequence of Normal Operation

• Apply control power and check that the “Power” LED comes on. (Display 1)

• Apply three phase power to the unit. The motor should run only when the start command is applied.

• Apply the start command. (Display 2). The RUN LED will be lit. (Display 3) The AUX3 LEDs will be lit. If the motor does not enter run mode in the set time, a trip will occur.

• The POWER, RUN, AUX3 LEDs will be lit, indicating that the contact has energized. IA, IB, IC will display the current setting for Phase A, Phase B, and Phase C and the G/F indicates ground fault. (Display 4)

• When the motor reaches full speed, the “AUX4” LED (At Speed) will be lit.

• If the motor decelerates, or stops, during the acceleration period, hit the stop button immediately and open the disconnect line. If the unit does not follow this operational sequence, please refer to the Troubleshooting Chapter.

• Initial Voltage

• Soft Start Curve

• Current Limit

• Acceleration Time

MOTOR STOPPED

READY TO START

MOTOR STARTING

00 X FLA

OVERLOAD ALARM

TIME TO TRIP: XXX SECS.

IA: _ _ _ IB: _ _ _

IC: _ _ _ G/F: _ _ _

If decel is enabled, the following parameters for Deceleration Time, Start Decel Voltage (see SP2) and Stop Decel Voltage (see SP2) must also be programmed.

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Chapter 4 - User Interface & Menu Navigation

This chapter explains the keypad operator interface, the LCD descriptions and the programming features

4.1 Keypad/Operator Interface

The TX Series user keypad/keypad operator interface consists of:

• 2 row by 20 characters Liquid Crystal Display (LCD)

• 12 LEDs

• 8 pushbuttons

Note: The TX Series is menu driven and there are three levels of programming. The programming for two of these levels is password protected. Level two requires a three digit password and level three requires a four digit password.

Button

RESET

ENTER

HELP

UP ARROW

RIGHT ARROW

DOWN ARROW

Toggle between the menu selection for metering and setpoint pages.

Will clear the trip indicator and release the trip relay.

In the edit mode, press the ENTER pushbutton so the unit will accept the new programming information. Whe not in the edit mode, the ENTER pushbutton will toggle through the event in dicator list (such as alarms or trips)

Provides general help information about a specific setpoint or action.

Will scroll up through the setpoint and metering menu page. It will scroll to the top of the setpoint page or a section. In edit mode it wil l increase a setpoint in an incremental step or toggle through the available options in the setpoint.

In the main menu the RIGHT ARROW button provides access to the setpoint page. For setpoint pages with multiple columns, the RIGHT ARROW will scroll the setpoint page to the right. When in edit mode it will shift one character to the right.

Will scroll down through the setpoint pages and down through the setpoints. In edit mode, it will decrement through values and toggle available options in the setpoint.

Keypad Operator Interface

Will move to the left through setpoint pages with multipl columns. When in edit mode it will become the backspace key and will shift one character to the left.

Indicates unit/motor is running Lights in conjunction with AUX 2 to indicate event or

warn of possible critical condition. Lights in conjunction with AUX 1 to indicate a critical

condition has occurred. Auxilary relays

LED

LEFT ARROW

Power Indicates control power is present

Run

Alarm

Trip

AUX 1-4

Note: The directional arrow buttons are sensitive. In edit mode, if the buttons

are held for a long period, the scrolling speed will increase.

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TX Series 48 - 1250A

4.2 Menu Navigation

PAGE 1 BASIC CONFIGURATION

LEVEL 1

PAGE 2 STARTER CONFIGURATION

PAGE 3 PHASE & GROUND SETTINGS

PAGE 4 RELAY ASSIGNMENT

LEVEL 2

PAGE 5 RELAY CONFIGURATION

(1)

Notes:

1. The MENU keys allow you to toggle the screens between the Setpoint Menu and the Metering Menu. Simply use the arrow keys to get to the different screens within each menu. Example: To access Setpoint Page 3: PHASE & GROUND SETTINGS, press the MENU key once and the DOWN ARROW two times.

2. Levels 1, 2 and 3 indicate password protection levels for these setpoint pages.

LEVEL 3

PAGE 6 USER I/O CONFIGURATION

PAGE 7 CUSTOM ACCELERATION CURVE

PAGE 8 OVERLOAD CURVE CONFIGURATION

PAGE 9 RTD CONFIGURATION

PAGE 10 SECURITY SET PASSWORD

PAGE 11 COMMUNICATIONS

PAGE 12 SYSTEM SETPOINTS

FACTORY

LEVEL

PAGE 13 CALIBRATION & SERVICE

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TX Series 48 - 1250A

4.2.1 Password Access

Screens in Level 1 of the setpoint menu can be changed without password access because they list basic motor information. Screens in Levels 2 and 3 require passwords because they provide more in-depth protection and control of the TX Series unit. The password in Levels 2 and 3 can be changed by the user.

NOTE: Setpoints can only be changed when the motor is in Stop/

Ready Mode! The TX will not allow a start if it is still in the Edit Mode. When the unit is in the Edit Mode, a “*” is in the top right corner of the display .

4.2.2 Changing Setpoints

Example 1: Changing Motor FLA

A. Press MENU button to display Setpoint Page 1, Basic Configuration B. Press the RIGHT ARROW you will view the screen Motor Full Load

Amps.

C. Press the ENTER button for edit mode. Note the asterisk (*) in the

top right corner of the LCD screen that indicates Edit Mode. D. To change the value, select the UP ARROW or DOWN ARROW. E . To accept the new value, press the ENTER button. The unit will

accept the changes and will leave the edit mode. Note the * is no

longer in the top right corner of the LCD Display.

PAGE 1 BASIC CONFIGURATION

MOTOR FULL LOAD AMPS : 140 AMPS

ENTER

MOTOR FULL LOAD AMP : 142 AMPS

MOTOR FULL LOAD AMP* : 142 AMPS

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TX Series 48 - 1250A

50 - 100% of Unit Max Curr ent Rati ng (Model

Chapter 5 - Setpoint Programming

The TX Series has twelve programmable setpoint pages which define the motor data, ramp curves, protection, I/O configuration and communications. In Section 5.1, the setpoint pages are outlined in chart form. In Section 5.2 the setpoint pages are illustrated and defined for easy navigation and programming. Note: Setpoints can only be changed when the starter is in the Ready Mode. Also the soft start will not start when it is in programming mode.

5.1 Setpoints Page List

The following charts list each Setpoint Page and the programmable functions within that page. The applicable section of the manual is also referenced.

5.1.1 Basic Configuration (Setpoint Page 1)

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range Section

Motor Full Load Amps (FLA) Model dependent Service Factor 1.15 1.00 – 1.3 SP1.2

Overload Class 10 O/L Class 5-30 SP1.3

Page 1

Basic Configuration

Level 1

NEMA Design B A-F SP1.4 Insulation Class B A, B, C, E, F, H, K, N, S SP1.5 Line Voltage 480 208 to 600V SP1.6

No Passowrd Required

Line Frequency 60 50 or 60 HZ SP1.7

5.1.2 Starter Configuration (Setpoint Page 2)

Setpoint

Page

Page 2

Starter Configuration

Security

Level

Level 1

Description

Start Control Mode Start Ramp 1

Jog Voltage Off 5-75%, Off Start Ramp #1 Type Voltage Current, Voltage, Off Initial Voltage #1 20% 0-100% Ramp Time #1 10 sec 0-120 sec Current Limit #1 350% FLA 200-600 % Initial Current #1 200% FLA 0-300% Ramp Time #1 10 sec 0-120 sec Maximum Curre nt #1 350% FLA 200-600 % Start Ramp #2 Type Off Current, Voltage, Off Initial Voltage #2 60% 0-100 % Ramp Time #2 10 sec 0-120 sec Current Limit #2 350 % FLA 200-600 % Initial Current #2 200% FLA 0-600 % Ramp Time #2 10 sec 0-120 sec Maximum Curre nt #2 350% FLA 200-600 %

No Passowrd Required

Kick Start Type Off Voltage or Off Kick Start Voltage 65% 10-100 % Kick Start Time 0.50 sec 0.10-2.00 Deceleration Disabled Enabled or Disabled Start Deceleration Voltage 60% 0-100 % Stop Decel eration Voltage 30% 0-59 % Deceleration Time 5 sec 1-60 sec Timed Output Time Off 1-1000 sec, Off Run Delay Time 1 Sec 1-30 sec, Off At Speed Delay Time 1 Sec 1-30 sec, Off Bypass Pull-in Current 100% FLA 90 - 300%

Factory Setting

Default

and Service Factor dependent)

Range Section

Jog, Start Ramp 1, Start Ramp 2, Custom Accel Curve, Start Disabled, Dual Ramp

SP1.1

SP2.1

SP2.2

SP2.3

SP2.4

SP2.5

SP2.6

SP2.7 SP2.8 SP2.9

SP2.10

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