Toshiba JK 400 Series Instruction Manual

Document: VF010H03 Rev. 5

INSTRUCTION MANUAL

INSTALLATION – OPERATION – MAINTENANCE

JK Series 400 Ampere Medium Voltage Controllers
Fixed Type

7.2kV Maximum

Issued: 9/19

Basic Installation and Operation Guide
JK Series 400 Series Fixed Controllers

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

Important Notice

The instructions contained in this manual are not intended to cover all details or variations in equipment
types nor may it provide for every possible contingency concerning the installation, operation, or
maintenance of this equipment. Should additional information be required, contact your Toshiba
Customer Support Center.

The contents of this manual shall not become a part of or modify any prior or existing agreement,
commitment, or relationship. The sales contract contains the entire obligation of Toshiba International
Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba
International Corporation and any statements contained herein do not create new warranties or modify
the existing warranty.

Any electrical or mechanical modifications to this equipment without the prior written consent of
Toshiba International Corporation may void all warranties or other safety certifications.
Unauthorized modifications may also result in safety hazard or equipment damage.

Misuse of this equipment could result in injury and equipment damage. In no event will Toshiba
International Corporation be responsible or liable for direct, indirect, special, or consequential
damage or injury that may result from the misuse of this equipment.

About This Manual

Every effort has been made to provide accurate and concise information to you, our customer.

At Toshiba International Corporation we are continuously striving for better ways to meet the constantly
changing needs of our customers. E-mail your comments, questions, or concerns about this publication
to [e-mail]

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

Purpose and Scope of Manual

This manual provides information on how to safely install, operate, maintain, and dispose of your JK
controller/starter. The information provided in this manual is only applicable to the fixed type 400A JK
Controller.

This manual provides information on the various features and functions of this powerful device,
including:

• Installation

• Operation

• Mechanical and electrical specifications

Included is a section on general safety instructions that describe the warning labels and symbols that
are used on the device and throughout the manual. Read the manual completely before installing,
operating, performing maintenance, or disposing of this equipment.

This manual and the accompanying drawings should be considered a permanent part of the equipment
and should be readily available for reference and review. Dimensions shown in the manual are in
imperial units and/or the metric equivalent. Connection drawings within this document convey the typical
topology of the JK 400 controller.

Because of our commitment to continuous improvement, Toshiba International Corporation reserves the
right, without prior notice, to update information, make product changes, or to discontinue any product or
service identified in this publication.

Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or
consequential damages resulting from the use of the information contained within this manual.

This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form
without the prior written consent of Toshiba International Corporation.

© Copyright 2019 Toshiba International Corporation.

TOSHIBA® is a registered trademark of Toshiba Corporation. All other product or trade references
appearing in this manual are registered trademarks of their respective owners.

All rights reserved.

Printed in the U.S.A.

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

Contacting TIC’s Customer Support Center

Toshiba International Corporation’s Customer Support Center can be contacted to obtain help in
resolving any system problem that you may experience or to provide application information.

The Support Center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Center’s toll free
number is US [phone]/Fax [phone] CAN [phone] MEX 01 [phone].
For after-hours support follow the directions of the outgoing message when calling. You may also
contact Toshiba International Corporation by writing to:

Toshiba International Corporation

13131 West Little York Road

Houston, Texas 77041-9990

For further information on Toshiba International Corporation’s products and services, please visit our

website at www.toshiba.com/tic

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TOSHIBA INTERNATIONAL CORPORATION

JK Series Controller

Complete the following information and retain for your records.

Model Number: _____________________________________________________________________

Serial Number: _____________________________________________________________________

Project Number (if applicable):_________________________________________________________

Date of Installation: _________________________________________________________________

Inspected By: _____________________________________________________________________

Name of Application: ________________________________________________________________

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

DANGER

WARNING
CAUTION

General Safety Information

DO NOT attempt to install, operate, maintain, or dispose of this equipment until you have read and understood

all of the product safety information and directions that are contained in this manual.

Safety Alert Symbol

The Safety Alert Symbol is comprised of an equilateral triangle enclosing an exclamation mark. This indicates
that a potential personal injury hazard exists.

Signal Words

Listed below are the signal words that are used throughout this manual followed by their descriptions and
associated symbols. When the words DANGER, WARNING, and CAUTION are used in this manual, they will be
followed by important safety information that must be carefully followed.

The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous situation exists
that, if not avoided or if instructions are not followed precisely, will result in serious injury to personnel or loss of
life.

The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous situation exists
that, if not avoided or if instructions are not followed precisely, could result in serious injury to personnel or loss
of life.

The word CAUTION proceeded by the safety alert symbol indicates that a potentially hazardous situation exists
that, if not avoided or if instructions are not followed precisely, may result in minor or moderate injury.

The word NOTE provides helpful information.

NOTE

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

Equipment Warning Labels

DO NOT attempt to install, operate, perform maintenance, or dispose of this equipment, until you have read and

understood all of the product labels and user directions that are contained in this manual.

Warning labels that are attached to the equipment will include the exclamation mark within a triangle.

DO NOT remove or cover any of these labels. If the labels are damaged or if additional labels are required, contact
the Toshiba Customer Support Center.

Labels attached to the equipment are there to provide useful information or to indicate an imminently hazardous
situation that may result in serious injury, severe property and equipment damage, or loss of life if safe procedures
or methods are not followed as outlined in this manual.

Qualified Personnel

Installation, operation, and maintenance shall be performed by Qualified Personnel ONLY. A Qualified Person
is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of
the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of
NFPA 70E for additional safety requirements).

Qualified Personnel shall:

• Have carefully read the entire manual.

• Become familiar with the construction and function of the starter, the equipment being driven, and the hazards

involved.

• Be able to recognize and properly address hazards associated with the application of motor-driven equipment.

• Be trained and authorized to safely energize, de-energize, ground, lock-out/tag-out circuits and equipment, and

clear faults in accordance with established safety practices.

• Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats,

safety glasses, face shields, flash clothing, etc., in accordance with established safety practices.

For further information on workplace safety, visit www.osha.gov.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

Equipment Inspection

• Upon receipt of the equipment, inspect the packaging and equipment for shipping damage.

• Carefully unpack the equipment and check for parts that may have been damaged during shipping, missing

parts, or concealed damage. If any discrepancies are discovered, it should be noted with the carrier prior to
accepting the shipment, if possible. File a claim with the carrier if necessary and immediately notify your Toshiba
Customer Support Center.

• DO NOT install the starter if it is damaged or if it is missing any component(s).

• Ensure that the rated capacity and the model number specified on the nameplate conform to the order

specifications.

• Modification of this equipment is dangerous and is to be performed by factory trained personnel ONLY. When

modifications are required, contact your Toshiba Customer Support Center.

• Inspections may be required after moving the equipment.

• Contact your Toshiba Customer Support Center to report discrepancies or for assistance, if required.

Handling and Storage

• Use proper lifting techniques when moving the equipment, including properly sizing up the load, getting
assistance, and using a forklift, if required.

• Store in a well-ventilated location, preferably in the original packaging, if the equipment will not be used upon
receipt.

• Store in a cool, clean, and dry location. Avoid storage locations with extreme temperatures, rapid temperature
changes, high humidity, moisture, dust, corrosive gases, or metal particles.

• The storage temperature range of the contactor is 23° to 104° F (-5° to 40° C). If stored at a lower temperature

or where high humidity exists, a cubicle space heater is required, powered from an external 120Vac source.

• DO NOT store the unit in places that are exposed to outside weather conditions (e.g. wind, rain, snow).

• Store in an upright position.

Disposal

Never dispose of electrical components via incineration. Contact your state environmental agency for details on
disposal of electrical components and packaging in your area.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

PAGE

RECEIVING, HANDLING/MOVING, AND UNPACKING ........................................................................ 1

Receiving and Unpacking ........................................................................................................... 1

Handling and Moving .................................................................................................................. 1

Using a Forklift ............................................................................................................................ 1

Overhead Lifting .......................................................................................................................... 2

Initial Inspection .......................................................................................................................... 2

LOCATION ............................................................................................................................................. 2

Storage ....................................................................................................................................... 2

Indoor Equipment ........................................................................................................................ 2

Outdoor Equipment ..................................................................................................................... 3

Routine Inspection ...................................................................................................................... 3

INSTALLATION ..................................................................................................................................... 3

Rating Verification ....................................................................................................................... 3

Location ...................................................................................................................................... 3

Service Conditions ...................................................................................................................... 4

Installation Site Preparation ........................................................................................................ 4

Mounting ..................................................................................................................................... 5

Additional Cabinet Entries ........................................................................................................... 5

Ground Connections ................................................................................................................... 5

Medium Voltage Power Connections .......................................................................................... 7

Incoming Line ............................................................................................................................. 9

Load Connections ....................................................................................................................... 9

Power Fuse Cartridge ............................................................................................................... 10

PRE-ENERGIZATION CHECK ............................................................................................................ 11

General ..................................................................................................................................... 11

Wiring Check ............................................................................................................................ 12

Device/Mechanism Checks ....................................................................................................... 13

Electrical Checks ...................................................................................................................... 14

GENERAL DESCRIPTION ................................................................................................................... 15

Construction .............................................................................................................................. 15

Controller Compartment ............................................................................................................ 16

Isolation Switch ............................................................................................................. 16

Vacuum Contactor ......................................................................................................... 17

Outgoing Load Connections .......................................................................................... 17

Control Power/Potential Transformers ........................................................................... 18

Operating Handle .......................................................................................................... 19

Interlocks - Mechanical .................................................................................................. 19

Door Interlock .................................................................................................... 19

Handle Interlock ................................................................................................. 20

Vacuum Contactor Interlock ............................................................................... 20

Interlocks - Electrical ..................................................................................................... 21

Control Power Interlock (CPI)............................................................................. 21

Test Power Interlock (TPI) ................................................................................. 21

Low Voltage Compartment ........................................................................................................ 22

Main Bus Compartment ............................................................................................................ 23

Contactor Ratings ..................................................................................................................... 24

Controller Ratings ..................................................................................................................... 25

Rating Table ............................................................................................................................. 26

TOSHIBA

Table of Contents

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

OPERATION ..................................................................................................................................... 27

Initial Energization ..................................................................................................................... 27

MAINTENANCE ................................................................................................................................ 28

Maintenance Record ................................................................................................................. 28

General Inspection .................................................................................................................... 29

Electrical Joints ......................................................................................................................... 29

Power Fuses ............................................................................................................................. 30

Vacuum Contactor .................................................................................................................... 30

Isolation Switch ......................................................................................................................... 31

Switch Handle Mechanism ........................................................................................................ 32

Interlocks .................................................................................................................................. 33

Control Power/Potential Transformers ...................................................................................... 33

MAINTENANCE AFTER A FAULT CONDITION ............................................................................... 34

Enclosure .................................................................................................................................. 34

Isolation Switch ......................................................................................................................... 34

Fuse Mounting .......................................................................................................................... 34

Terminals and Internal Conductors ........................................................................................... 34

Overload Relay ......................................................................................................................... 34

Vacuum Contactor .................................................................................................................... 34

Return to Service ...................................................................................................................... 34

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

1

WARNING
CAUTION

WARNING

RECEIVING, HANDLING/MOVING, AND UNPACKING

Receiving and Unpacking

Upon receipt of the equipment, do the following:

• All JK Series units are shipped in the vertical (upright) position and should be handled accordingly when received.
If the controller is not upright upon receipt, notify the carrier of possible damage. Upright the units as soon as
possible and immediately notify the nearest Toshiba representative.

• Carefully unpack the unit and make an immediate inspection for any concealed damage which might have
occurred during shipment. If damage is found, it should be noted with the carrier prior to accepting the shipment,
if possible. Report any damage immediately and file a claim with the freight carrier within 15 days of receipt.

• Verify that the starter description on your unit matches your purchase order. The starter information is located
on stickers in the medium voltage incoming compartment.

• Keep the equipment upright.

Do not install or energize equipment that has been damaged.

Do not lay the equipment on its side or upside down.

Handling and Moving

Medium voltage controllers should be handled with
care to avoid damage to components, frame, and
finish (Fig. 1).

The capability of the moving equipment to handle
the weight of the controller shipping section should
be confirmed. The equipment should remain
secured to the shipping skid to prevent distortion of
the frame during moving and to minimize tipping.
Extreme care should be exercised during any
movement and placement operations to prevent
dropping or tipping.

Do not place any part of your
body beneath the equipment
being lifted. Improperly
secured equipment can fall
or tip over quickly and
without notice.

Using a Forklift

A forklift truck may offer a more convenient method
of handling the controller. A safety strap should be
used when handling with a forklift. The ends of the forks
should not enter the bottom of an open-bottom
enclosure.

Fig. 1 Moving the Controller

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

2

Overhead Lifting

When it is necessary to move the equipment between

elevations, overhead hoisting may be required. Lifting angles
(for multiple controller sections) are provided on top of the
enclosure for this purpose. Spreaders (Fig. 2) should be used to
provide the vertical lift on single controllers to prevent eye-bolt
failure. Always keep the controller upright while lifting. Some
controller sections may contain heavy or special equipment that
will cause the center of gravity to be off-center. Rigging lengths
should be adjusted to maintain the controller in an upright
position. The angle between the lifting cables and vertical should
not be allowed to exceed 45 degrees (Fig. 3). Ropes or cables
should not pass through the holes in lifting angles or eye-bolts.
Slings with safety hooks or shackles of adequate load rating
should be used.

Initial 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 load and

JK unit are rated for the proper amperage and voltage.

Fig. 2 Use of Spreader Bar - Single Section

LOCATION

Storage

If the controller is to be stored for any length of time prior to installation, the packing
should be restored for protection during that period. Where conditions permit, the
packing should be left intact until the controller is at the final installation position. If the
packing (Fig. 4) is removed, the top and openings of the controller should be covered
during the construction period to protect it against dust and debris.

Indoor Equipment

Controllers designed for indoor installation (e.g. Type 1, 12) that are not to be installed
and energized immediately should be stored in a clean, dry space where a uniform
temperature prevents condensation. Preferably, the controller should be stored in a
heated building, with adequate air circulation and protected from dirt and water.
Equipment should be stored where it is not subject to mechanical damage, especially

Fig. 4 Storage

TOSHIBA

Fig. 3 Lifting Multiple Sections

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

3

WARNING

DANGER

during building construction. An indoor controller that is to be stored outdoors should be securely covered for
protection from weather conditions and dirt. Temporary electrical heating should be installed to prevent
condensation. Approximately 150 watts per enclosure is usually adequate.

NOTE: All loose packing or flammable materials should be removed before energizing space heaters.

Outdoor Equipment

An un-energized controller designed for outdoor installation (e.g. Type 3R) should be kept dry internally by installing
electrical heating or by energizing provided space heaters. All openings, either used or unused, should be covered
or sealed to prevent the entry of rain, vermin, insects, etc.

Routine Inspection

Routine scheduled inspection should be established if storage for an extended period is anticipated. This is to check
for condensation, corrosion, vermin, and adequacy of space heating. Prior to inspection, the equipment should be
carefully examined for evidence of physical damage, corrosion, or other deterioration.

Do not install equipment found to have damage or deterioration that could affect
the unit performance.

INSTALLATION

Rating Verification - Prior To Installation

The maximum fault capability of the power system at the point of installation should be verified and must not exceed
the short-circuit rating of the controller (see RATINGS section). All system accessories, such as surge suppressers,
lightning arresters, etc., should be checked to verify their ratings capacity.

Do not exceed the ratings specified on the controller nameplate or system accessories.

Location

Overhead should be checked for plumbing condensation, sprinklers, or similar possible sources of trouble. A clearance
of 1/2 inch should be provided between a wall and the rear of the controller for indoor equipment, when rear access
is not required. If rear access is required in either environment, a minimum of 30 inches should be provided. Consult
local codes in case more space is required.

A minimum of 48 inches working space should be allowed in front of the controller. This minimum should be increased
if necessary to accommodate movement around open enclosure doors to comply with applicable codes.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

4

WARNING

WARNING

If the location for installation is damp, space heaters may be
required. If space heaters (Fig. 5) are furnished inside the
controller, they should be connected in accordance with the
wiring diagram furnished.

Do not install this equipment in areas

where unusual service conditions exist,
unless the equipment has been
specially designed for the particular
environment.

Fig. 5 Typical Space Heater

Service Conditions

Toshiba medium voltage controllers are intended for usual service conditions as defined by NEMA. The equipment

should not be exposed to corrosive or explosive fumes, dusts, vapors, dripping or standing water, abnormal
vibration, shock, tilting, or other abnormal operation conditions. The temperature of the ambient air surrounding the
controller should be between the limits of 0°C (32°F) and +40°C (104°F). The altitude of the equipment installed
should not exceed 3300 ft. (1000m).

NOTE:

equipment, such as heating, cooling, or ventilation. Contact Toshiba for further information.

Do not install this equipment in areas where unusual service conditions exist,

Installation Site Preparation

It is recommended that site preparation be completed before the controller is unpacked, so that possible problems
such as headroom, conduit location, cable tray locations, ventilation, etc. can be solved, assuring a proper
installation in compliance with the building plans and codes. The floor on which the controller will be placed must
be level so that the enclosure is not distorted when bolted in place. Ensure the equipment adequately clears any
underground raceways or cables.

Temperature or altitude conditions outside of the usual limits may require derating or other special

unless the equipment has been specially designed for the particular environment.

TOSHIBA