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]

.

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

.

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

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

5

WARNING

Mounting

Each shipping section must be leveled and firmly secured to its

supporting foundation. Steel shims may be used for final leveling (Fig.

6), if necessary. When three or more shipping sections are to be

arranged in one continuous line-up, the center shipping section should
normally be located first.

Follow the equipment outline drawings to determine the location of the

mounting bolt holes and any conduit locations.

Various methods may be used to anchor the enclosure to the foundation,
including expandable inserts or “J” bolts embedded in concrete. The
recommended size for anchor bolts is 1/2” (Fig. 7).

For heavy equipment, enclosure must be
securely anchored to prevent tipping over.

Additional Cabinet Entries

If conduit entry locations are required in areas other than the removable
plates, cover the electrical assemblies to prevent metal filings from
becoming lodged in areas which may cause a reduction in the high
voltage clearances or a short circuit. After the work is completed,
thoroughly clean the area and inspect the unit for foreign material.

Fig. 7 Securely Anchor the Controller
Ground Connections

The controller line-up must be grounded in accordance with the requirements of the National Electrical Code. Proper
equipment grounding must be established before making any incoming power connection. If a main ground bus

Fig. 8a Horizontal Fig. 8b Vertical Ground Bus
Ground Bus in Controller Compartment

(Fig. 8a) is furnished, make the ground
connection to this bus. If there is no ground
bus, the sections which are shipped
separately should be connected to ensure a
continuous grounding path.

Each section contains a vertical ground bus
(Fig. 8b) extending from the main ground bus
or ground pad to each controller
compartment.

TOSHIBA

Fig. 6 Leveling Using Shims

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

6

Special attention should be paid to protection for operating personnel, to protection of equipment itself (e.g. ground
fault relays), and protection of sensitive transducers or control devices that are electronic in nature.

The following may be used as a general guide with regard to equipment grounding.

Controller used as service equipment for a grounded system or as a main section for a separately derived system:

a. The grounding electrode conductor (ground wire) sized in accordance with NEC 250 should be run from the

grounding electrode to the controller ground bus or ground terminal.

b. Unless already done at the factory, a main bonding jumper should be installed from the incoming grounded

connector bus (neutral) to the ground bus or designated grounding point. If a jumper is not furnished, one having
a size in accordance with NEC 250 should be selected.

c. Steps (a) and (b) should effectively connect together the grounding electrode, the controller frame, all outgoing

equipment grounding conductors, and the grounded neutral bus of the system.

d. No connection should be made to ground on the load side of any neutral disconnecting line or any sensor used

for ground fault protection. No connections should be made between outgoing grounding connectors and the
neutral.

e. Where the controller or system is dual-fed (double-ended) and has ground fault protection, special

precautions are necessary to accomplish proper grounding and bonding.

Controller used as service equipment for an ungrounded system or as a main section for a separately derived
system:

a. A grounding electrode conductor (ground wire) sized in accordance with NEC 250 should be run from the

grounding electrode to the controller ground bus or ground terminal.

b. If the system is grounded at any point ahead of the controller, the grounded conductor should be run to the

controller in accordance with NEC 250 and connected to the ground bus or ground terminal.

c. Steps (a) and (b) should effectively connect together the grounding electrode, the controller frame, all outgoing

equipment grounding connectors, and any grounded conductor which runs to the controller.

Controller not used as service equipment or as a main section for a separately derived system, and used on either
a grounded or ungrounded system:

a. The controller frame and any ground bus should be grounded by means of equipment grounding conductors

having a size in accordance with NEC 250 and run with the main supply conductors or by bonding to the
raceway enclosing the main supply conductors in accordance with NEC 250.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

7

Torque at Full

(ft - lbs)

1/4 - 20

6

3/16 - 18

12

3/8 - 16

18

7/16 - 14

30

1/2 - 13

45

9/16 - 12

68

5/8 - 11

90

3/4 - 10

150

7/8 - 9

240

1.0 - 8

245

Torque at Full

(ft - lbs)

1/2 - 13

45

Bus - Bus

28

Bus - Bus

25

Bus - Glastic Ins.

18

Bus - Porcelain Ins.

5/16 - 18

15

M 12

35

b. Ground leads should be
connected to cable
potheads/shields as
specified by the
manufacturer of these
devices.

Fig. 9 Ground Bus Splice

Medium Voltage Power Connections

Use a properly calibrated torque wrench to tighten all MV connections according

to Figures 10a and 10b.

Cable and wire bundles that enter the controller enclosure should be routed to
avoid interference with moving parts. Minimum bending radius for the type of
cable used should be observed.

Power cables should be braced and/or laced to withstand short circuit forces
wherever such cables are unsupported. Power cables should be adequately
sized to carry the motor full load current in accordance with NEC requirements,
and have an adequate voltage rating. Cables should be dressed and terminated
as appropriate to the voltage class and cable manufacturer’s recommendations.

MV Power Connections

Main power bus (when provided) and horizontal ground

bus are supplied with links to join shipping sections
together. These should be installed in accordance with
Fig. 9 through Fig. 12.
partitions, etc., that are temporarily removed during
installation must be replaced.

Fig. 10b Torque Specs for Bus Connections

All access covers, barriers,

Bolt Size

3/8 - 16

Engagement

Bolt Size

Fig. 10a Torque Specs for

Engagement

Type of Connection

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

8

Fig. 11 Main Bus Splice Connections - 1200A Main Bus

NOTE:

Remove part number identification or any label on the splice bus before installation.
Tighten and torque the bolts for all bus splice connections and other bus if loosened
during installation of the bus splice.

Covers and braces supplied only for protection during shipment should not be replaced.

All debris and tools should be removed from each compartment as cabling is completed.

Fig. 12 Main Bus Splice Connections - 2000A
(Consult Factory for 3000A Main Bus Splice)

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

9

WARNING

Incoming Line

On the standard JK, incoming power cable connections should
be made at the points shown on the wiring diagram furnished
with the equipment.
a separate incoming compartment to bus lugs, an incoming load
interrupter switch, or a vacuum circuit breaker. If the equipment is
a single controller (e.g. 1-High, JKSSS, RVAT) and no incoming
section is provided, the incoming main power terminations are in
the rear bus compartment (Fig. 13), behind the low voltage
compartment swing out panel. The terminations can be accessed
through this compartment or by removing the enclosure rear cover.
The bottom incoming cable entrance location is also shown in
Figure 13.

Load Connections

Outgoing load connections are made in the controller

compartment to the three lugs or copper pads located as shown in
Figure 14a and 14b. Fig. 13 Single Controller Incoming Wiring,
Bottom Entry

Load cable termination arrangements for
certain controllers, such as reduced voltage
autotransformer and solid state types, may
differ from those shown in this manual. In
these cases, refer to the drawings furnished
with the equipment.

To access cable termination areas, remove
fuse barriers as shown in Fig. 45, then
remove fuses (see Power Fuses section).

After completing the cable termination and
re-installation of the fuses, re-install the four
vertical and one angle shaped horizontal
fuse barriers and position them per Fig. 45
and 46.

These connections will normally be made in

Failure to properly

install fuse barriers
can result in major
equipment damage
and possible
personnel injury.

Fig. 14a Controller Load Wiring Fig. 14b Controller Load Wiring

When routing and terminating load cables, observe the following:

- Use listed compression connectors suitable for the cable being used.

- Use the 1/2" hardware provided with the controller to attach cable connectors to bus pads. After installation,
torque hardware to 45 ft-lbs.

- After installation, check to see that the minimum clearance (per NEC) is maintained between live parts and
between live parts and ground.

TOSHIBA

Bar Type CTs Window Type CTs

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

10

POWER FUSE CARTRIDGES (Fig. 15a & 15b)

To remove power fuse cartridge:

1. Loosen the front two sems bolts (Fig. 15c).

2. Lift up the front end then slowly slide out of the
compartment.

To install power fuse cartridge:

1. Position the cartridge on top of the vacuum
contactor (Fig. 15d).

2. Slowly slide the cartridge in until the back bus stab

engages inside the isolation switch opening slot (Fig.

15e).

3. Lower the front end bus into the two sems bolts then
tighten and torque the sems bolts to 10-15 ft-lbs.

Fuse Cartridges

Fig. 15d Installing Fuse Cartridge

Fig. 15c Removing Fuse Cartridge

Fig. 15e Installing Fuse Cartridge

Fig. 15a Double Barrel Fuse Cartridge

Fig. 15b Installed Single Barrel

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

11

PRE-ENERGIZATION CHECK

General

AFTER INSTALLATION, BUT BEFORE ENERGIZING THE CONTROLLER for the first time, follow the procedure
below to verify that the equipment is properly installed and functional.

There is a rating data label (Fig. 16) on the inside of each medium
voltage compartment door. Verify that the controller ratings properly
match the system data by checking the following:

1. Verify agreement of load current (e.g. motor full load &
locked rotor current with nameplate).

2. Verify that system voltage, number of phases, and
frequency matches controller rating.

3. Verify that available short circuit current of power system
is less than rated short circuit capacity of controller.

Check connections - Although the equipment and devices have been
completely tested at the factory, a final field check should be made
that all electrical wiring and bus bar connections are correct and have
not become loose in transportation (Fig. 17). Refer to the
MAINTENANCE Section for electrical joint specification.

All blocks or other temporary braces used for shipment must be
removed.

Before closing the enclosure, all metal chips, scrap wire, and
other debris left over from installation must be cleaned out. If
there is an appreciable accumulation of dust or dirt, the
enclosure should be cleaned by using a brush, vacuum
cleaner, or clean, lint free brush.

The integrity of all bus bar supports must be checked to confirm
they are secured and without damage.

Care should be exercised that when covers are installed and
doors closed, no wires are pinched, and that all enclosure parts
are properly aligned and tightened.

Fig. 17 Check Connections

A supply of spare parts, fuses, etc. should be established.
Instruction manuals and diagrams should be collected and filed.

Fig. 16 Data Label on Controller

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

12

Wiring Check

Field wiring (F i g . 18) should be checked for clearance to live busses,
where necessary, physically secured to withstand the effects of fault
current.

All grounding connections should be checked.

Each load should be connected to its intended controller, and phase
rotation should be corrected prior to startup.

Shorting jumpers (Fig. 19) for current transformer secondary
windings must be removed once the secondary circuit is
completed. A circuit transformer must not be operated with its
secondary windings
open.

Changes made to circuit diagrams during installation should be
recorded.

Fig. 18 Wiring Check

Fig. 19 Removing Current Transformer
Shorting Jumpers

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

13

WARNING

WARNING

Device/Mechanism Checks

All devices should be checked for damage (Fig. 20). All necessary
repairs or replacements should be made.

Do not energize damaged equipment that has

not been repaired and verified.

Ensure that safety signs are not covered or obscured by paint.

Do not remove, cover, or destroy any

safety signs.

Fig. 20 Device/Mechanism Check

The setting of any adjustable current (e.g. motor overload protection relay) and voltage trip mechanisms should
be verified to the proper values.

NOTE:

All switches, relays, and other operating mechanisms should be manually exercised to make certain that they are
properly aligned and operate freely.

Operating mechanisms such as interlocks, key switches, etc. should be checked for function as intended for

protection of personnel and equipment.

The motor/load protection relay should be checked to be sure that proper
settings have been programmed per the motor/load specification sheet and
nameplate (Fig. 21). Check the instruction manual for the specific relay
supplied with your equipment for factory default settings and additional
protection and programming details.

Fig. 21 Protection Relay Setting
Check

Power circuit fuses were selected and installed in accordance with the application requirements. Confirm the proper
fuses were provided. The fuses must be completely inserted in their holders. Instructions on removing and installing
the fuses can be found in this manual page 10.

NOTE:

Damage from faults can be reduced if devices used for short circuit and ground fault protection are

chosen and set to operate at values as close to minimum as feasible, while allowing normal
transients.

Factory settings are per the information provided by the

customer. If not provided, factory settings include CT & PT
ratio, estimated motor/load FLA. Settings like motor
service factor and overload class will be minimum (e.g. 1.0

S.F, Class 10 OL curve) which may cause a nuisance trip

during the initial start unless adjusted for the application.
Most settings are disabled and many should be turned on
at the end of commissioning.

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

14

WARNING

WARNING

Electrical Checks

With incoming power isolated and all loads disconnected electrically, the control circuit and other mechanisms
should be exercised to determine that the devices operate properly. An auxiliary source of control power will be
necessary to provide power to the electrical operators.

Electrical shock hazard. Do not touch energized components during a test
using auxiliary power.

The ground fault protection system (if furnished) should be tested in accordance with the instructions furnished with
the device.

An electrical insulation test should be performed to ensure that the controller and associated field wiring are free
from short circuits and grounds. The preferred method is to perform a dielectric test at 2.25 times the nominal
system voltage plus 2000 volts. This should be done phase-to-ground, phase-to-phase, and phase-to-neutral (if
applicable), with all switches, contactors and circuit breakers opened. Disconnect any devices which may have
limited dielectric strength and that are not intended for this test.

The light or buzzer, or both, used to indicate breakdown should be calibrated to indicate failure with an output
current between 1.5 and 2.0 milliamperes per 1000 volts applied.

Hazardous voltages are present during dielectric testing that can result in
serious injury or death. High potential test should be performed only by
qualified personnel. Refer to safety instructions provided with the test
equipment.

All devices must be set to their normal or OFF position before energizing incoming power.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

15

F F O

N

ISOLATION

POWER

SWITCH

O O F F POWER

ISOLATION

N O SWITCH

STARTER

LOW
VOLTAGE

F F O

SWITCH
POWER

ISOLATION

O

N

BLANK OR

ADDITIONAL

MV

COMPONENTS

F F O

ISOLATION

POWER

SWITCH

N

O

STARTER

STARTER

STARTER

LOW
VOLTAGE

LOW
VOLTAGE

GENERAL DESCRIPTION

Toshiba JK 400 ampere medium voltage controllers are AC

general-purpose NEMA Class E2 controllers designed for

applications at utilization voltages ranging from 2.3 through 6.6

kV. They are normally used to control motor loads, although

other types of loads such as variable frequency drives (VFDs),

transformers and capacitors are possible.

Construction

The standard enclosure size for the 400 ampere controller is

30" wide by 36" deep by 46”, 60” or 90" high. In a typical one-

high arrangement, each section is divided into two isolated

compartments, each with a separate door. The lower

compartment contains medium voltage controller components

(>600V) while the upper compartment contains low voltage

components (<600V) (Fig. 22). In a two-high arrangement,

each enclosure is divided vertically into three major compart- Fig. 22 Typical Controller Arrangements

ments, each with a separate door. The uppermost and lower-

most compartments contain medium voltage controller components while the middle compartment contains low

voltage components. Other variations of this basic arrangement are possible.

Main horizontal bus is provided when required to supply power to a line-up of controllers. The main bus is located at

the rear of the enclosure midway between the top and bottom. A common ground bus is also provided for multiple

sections.

The medium voltage compartment (Fig. 23) consists of:

1) Fix-mounted non-load break isolation switch

2) Fix-mounted vacuum contactor

3) Fix-mounted current-limiting power fuses

4) Current transformers for metering

5) Control power transformer and optional potential transformer

6) Load cable terminations

Fig. 23 Controller Compartment

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

16

WARNING

Controller Compartment

A. Isolation Switch

Power is switched on and off to the controller by a fix-mounted,

externally-operated, three-pole, non-load break, isolation

switch (Fig. 24a). When the switch is in the off position,

incoming power is isolated from the controller compartment

interior by an automatic shutter. For additional safety, the load

terminals of the switch are automatically grounded when the

switch is off.

Three bolted-in current-limiting power fuses provide primary

short-circuit protection for the controller and load circuit. These

fuses are connected between the isolation switch and the

vacuum contactor. The vacuum contactor load terminals are

cabled through three metering current transformers (plus a

ground sensor, if supplied) to the outgoing load terminals.

Current transformers furnished are of the window (donut) or Fig. 24a Isolation Switch

bar type. The isolation switch is mechanically interlocked with

the vacuum contactor and the compartment door. Details

of the interlocking are discussed in Section F.

The position of the isolation switch blades can be observed

through a window in the medium voltage compartment door,

along with viewing the green OPEN flags (Fig. 24b.). Thus, it

is possible to have visual evidence that the power source is

isolated before entering the medium voltage compartment.

The switch is also provided with lock-out provisions (Fig. 25).

The isolation switch has a maximum interrupting capacity of

0.4 amperes.

Fig. 24b Isolation Switch Open Indication Flags

Do not connect additional load to the
isolation switch.

Fig. 25 Isolation Switch Lockout

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

17

B. Vacuum Contactor

The Type HCV-5HA/7HA vacuum contactor (Fig. 26) used in Toshiba JK

400 ampere controllers is a compact, fix-mounted device. It is mounted to

the floor of the controller compartment, beneath the isolation switch.

Switching occurs entirely within vacuum bottles, which results in long life with

virtually no maintenance. The contactor is mechanically interlocked with the

isolation switch so that the switch may not be opened or closed unless the

contacts of the vacuum contactor are open.

Fig. 26 Type HCV-5HA/7HA
Vacuum Contactor

C. Outgoing Load Connections

Connections for outgoing load cables are located at the rear of vacuum

contactor. Cables may enter the controller from either the top or bottom of

the enclosure, at the points indicated on the outline drawings furnished with

the equipment, through the wireways provided.

The standard cable exit is shown in Fig. 27a. To access cable termination

areas, remove fuse barriers and fuses (see Power Fuse). Non-shielded

cable up to one 350MCM per phase or shielded cable up to one 2/0 per

phase can be accommodated through the window (donut) type current

transformer and terminated at the provided aluminum mechanical lugs

behind the vacuum contactor.

If necessary, the current transformer can be easily removed, to feed load

cables through opening windows, by unscrewing the secondary terminal

wires and two mounting nuts. Fig. 27a Load Cable Connections,

Top Exit

If a ground sensor (optional) is supplied with the equipment as shown in Fig.

27b, route all the load cables through the sensor. Ground wires from

shielded cable terminators must be routed back through the window type

current transformer and ground sensor window before attaching to ground

bus.

After installation, be sure the secondary terminal wires on the current

transformer are re-connected correctly and securely, the load cables are not

pressing on the current transformer excessively, the lugs are torqued at 120

in-lbs for lugs rated for wire ranges from 1/0 to #14 and at 275 in-lbs for lugs

rated for wire ranges from 350MCM to #6, and check to see that at see that

the minimum clearance (per NEC) is maintained between live parts and

between live parts and ground.

For aluminum cable, “DE-OX” inhibitor is recommended at the termination.

Fig. 27b Ground Sensor
Installation

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

18

D. Control Power/Potential Transformers

A control power transformer (Fig. 28a) is fix-mounted on the left

side of the controller compartment. Power is supplied to the fused

primary of the control power transformer from the load side of the

main power fuses.

Optionally, a second transformer (Fig. 28b), normally used as an

instrument transformer, can be mounted in the compartment.

When this option is supplied, the two transformers are normally

connected in an open-delta arrangement.

Another option sometimes supplied is a second control power

transformer connected in parallel with the first to increase the

available KVA capacity.

Both the control and optional potential transformers are used to

supply power to the low voltage circuits of the controller. This

includes power for the vacuum contactor operating coil and

instrumentation. Reference the equipment’s schematic drawing(s)

for details.

Fig. 28a Control Power Transformer

An electrical interlock is provided to ensure that all load is

disconnected from the control power transformer secondary

winding before the power isolation switch can be opened or closed.

Fig. 28b Optional 2

nd

Transformer

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

19

E. Operating Handle

The external operating handle shown in Fig. 29 is used to control the operation

of the isolation switch. Moving the handle upward turns the switch on, thus

applying incoming power to the main current-limiting fuses.

Moving the handle down opens the isolation switch, de-energizing all medium

voltage incoming power to the controller compartment. At the same time, an

automatic shutter within the switch closes, providing an effective barrier between

the controller compartment and the incoming supply. The opening of the switch

also causes the line side of the power fuses to be grounded.

Further details on the isolation switch and external operating handle can be

found in the Maintenance section.

Fig. 29 Operating Handle

F. Interlocks - Mechanical
a. Door Interlock

A mechanical interlock is provided to prevent opening or closing the medium
voltage compartment door unless the switch operating handle is off (Fig. 30).

TOSHIBA

Fig. 30 Door Interlock

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

20

b. Handle Interlock

Two mechanical interlocks are provided to prevent operating the switch

handle improperly.

The first interlock prevents moving the handle from OFF to ON unless the

compartment door is closed (Fig. 31).

The second interlock prevents the switch handle from being moved in

either direction unless the contacts of the vacuum contactor are open

(Fig. 32).

c. Vacuum Contactor Interlock

The vacuum contactor is mechanically interlocked to prevent it from

closing unless the switch handle is in the fully ON or fully OFF

position. The interlock shown in Fig. 32 provides this function.

If the switch handle is in an intermediate position, and a closing

signal is given to the contactor, it is mechanically prevented from

operating.

TOSHIBA

Fig. 31 Handle Interlock to Door

Fig. 32 Handle Interlock to Vacuum

Contactor

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

21

WARNING

G. Interlocks - Electrical

a. Control Power Interlock (CPI)

The control power interlock (CPI) is a microswitch which is directly driven

by the operation of the switch handle (Fig. 33). This normally open switch

is closed only when the handle is fully ON. It ensures that all load is

disconnected from the control power transformer secondary winding

before the isolation switch can be operated.

As the switch handle is moved from ON to OFF, the CPI opens before

the main contacts of the power isolation switch. Conversely, during

closing of the switch, the CPI contacts do not close until the switch

contacts have fully closed. The isolation switch is therefore only

subjected to making and breaking currents equal to the no-load

magnetizing current of the transformer. More than one CPI may be

present. Reference the equipment’s schematic drawings to confirm

number of CPIs in the equipment.

Do not connect any additional load to the

isolation switch.

b. Test Power Interlock (TPI)

The test power interlock (TPI) is a scheme provided to allow simulated

operation of the controller from a separate control power (test) source

with power removed from the medium voltage circuit. During normal

controller operation with the isolation switch closed, control power is fed

from the control transformer secondary to a receptacle mounted on the

low voltage wireway (Fig. 34). A plug inserted into this receptacle

supplies power to the controller's low voltage compartment.

For testing purposes, the isolation switch must be turned off and the

controller door must be opened. The plug is then removed and inserted

into an ordinary extension cord. Plugging the extension cord into a

conventional outlet provides 120VAC power

circuit operational tests while the medium voltage circuit is de-energized.

The CPI(s) prevent the high voltage back feeding on the CPT (PT)

primary.

for performing control

Fig. 33 Control Power Interlock

Fig. 34 Test Power Receptacle

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

22

DANGER

WARNING

Low Voltage Compartment

The low voltage compartment contains controller components rated 600 volts maximum,

which may include such items as overload relays, pilot devices, control relays, etc.

Hazardous Voltage. Turn off and lock out control circuit

power before servicing.

The location and size of the low voltage compartment will vary depending on the

particular controller arrangement. In the standard one-high controller, the low voltage

compartment is located in the upper half of the enclosure. In a typical two-high controller,

the low voltage compartment is located in the center of the enclosure. A subpanel is

located behind the low voltage door, which is used to mount various relays and other

control devices. The low voltage subpanel is hinged in such a way that it can be swung

open (Fig. 35a), if necessary, to gain access to the main horizontal bus by removing

barriers (Fig. 35b) located directly behind the panel.

Hazardous Voltage. Turn off and
lock out all control and primary
power before opening this panel.

Fig. 35a Low Voltage
Swing-out Panel

Fig. 35a Access to Main Bus
Through LV Compartment

A low voltage vertical wireway (Fig. 36) feeds directly into the lower left hand corner
of the low voltage compartment. This wireway provides isolation for control wires
entering the bottom of the enclosure. Control wires entering the top of the enclosure
feed directly into the low voltage compartment. A horizontal low voltage wireway is
provided at the lower front of the low voltage compartment. At each end of the
horizontal wireway there is an opening for inter-cubicle control wiring.

Fig. 36 Typical Low Voltage
Vertical Wiring Route

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

23

DANGER

Main Bus Compartment

Main bus bars extending horizontally throughout a line-up are

located in an isolated compartment located in the rear center of

the enclosure (Fig. 36a & 36b). From the main bus, riser bars

supply power to the controller. Standard main bus bars are copper

with tin plating.

Access to the main bus compartment can be obtained either by

removing the enclosure back sheet or by swinging open the

hinged low voltage subpanel and then removing a fixed barrier

that covers the main bus.

Hazardous Voltage. Turn off and lock out

all control and primary power before
accessing this compartment.

Bus splice links (Fig. 37) are furnished for joining the main bus

and ground bus between shipping sections. With the low voltage

subpanel swung open and the main bus barrier removed, all splice

links can be installed from the front of the unit. Refer to Installation

Section for details. Fig. 36a Main Bus (1200A & 2000A)

Compartment

A copper ground bus, located in front of the main bus

compartment and above the isolation switch, is used to provide a

common ground between cubicles. The ground bus also provides

a termination point for grounding the enclosure and for

connecting the ground wires from shielded cable terminators.

Fig. 37 Bus Splice Links Fig. 36b Main Bus (3000A) Compartment

PREPARED SPACES

Prepared spaces are compartments equipped for future addition of controllers and are supplied with the following
components:

- Isolation Switch

- Riser bus

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

24

To convert a prepared space to a functional controller, the following must be added:

- Vacuum Contactor and interlock - Handle mechanism for Isolation Switch

- Power fuse cartridges and barriers - Current and control power transformers

- Low voltage controls - Load protect relay

CONTACTOR RATINGS

Table 1 Contactor Type HCV-5HA/7HA (Magnetically Held)

Maximum Voltage 7200 Volts

Rated Operational Current 400 Amps

Rated Thermal Current 450 Amps

Interrupting Capacity (NEMA Class E1) 5HA: 7.0kA RMS Sym. (4.5kA @ 7.2 kV Max)

7HA: 7.2kA

Permissible Switching Frequency 1200/Hour

Mechanical Life 2,500,000 Operations

Electrical Life 250,000 Operations

Pick-Up Voltage AC or DC 85% (Hot) – 70% (Cold)

Drop-Out Voltage AC or DC 70% (Hot) – 60% (Cold)

Rated Control Voltage AC 120 V 50/60 Hz

Optional Control Voltage DC 125 V

Coil Circuit Inrush 5.4A Peak @ 120Vac (670VA AC – 700W DC)

Coil Circuit Holding 0.12A Average @ 120Vac (85VA AC – 85W DC )

Auxiliary Contact Arrangement 3 N.O. - 3 N.C.

Auxiliary Contact Rating 10 A, 48-600Vac Max. (NEMA Class A600)

Contactor Type HCV-5HAL/7HAL (Latched Type)

Permissible Switching Frequency 300/Hour

Mechanical Life 250,000 Operations

Tripping Voltage 60% or less of Coil Rating DC (Cold)

Tripping Current 4.8A Peak @ 125Vdc

A latched contactor is the same as magnetically-held type, except number of auxiliary contacts is reduced
to 2 N.O. - 2 N.C. Standard operating voltage is 120Vac Close/125Vdc Trip.

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

25

CONTROLLER RATINGS

Table 2 Short-Circuit & Withstand Capability

Interrupting

Capacity

(Sym.

Amperes)

50,000 RMS

@2.3-6.6kV
(7.2kV Max)

Enclosure Type Max. Continuous

Type-1

Ventilated

Type-1 Non-

Ventilated

Type-12, 3R 310 310 280

Interrupting

Capacity

(Sym. MVA)

200@2.3kV
350@4.0kV
400@4.6kV
570@6.6kV

Amperes

One-High Controller

360 360 320

320 320 280

Short Time

30 Seconds

Table 3 Continuous Current Rating

Short Time

Capability

2400 A

Max. Continuous Amperes
Lower Controller in a Two-

High Stacking Arrangement

Capability

1 Second

6,000 A

Dielectric

Withstand

1 Minute

AC 19 kV

DC 26kV

Max. Continuous Amperes

Upper Controller in a Two-High

Stacking Arrangement

Impulse
Voltage

Withstand

60 kV BIL

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Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

26

Induction

Induction

Induction

0.8

P.F.

1.0

P.F.

0.8

P.F.

1.0

P.F.

Table 4 Approximate Maximum Rating Based On Continuous Current

Maximum Horsepower Rating Maximum Horsepower Rating

Enclosed

Maximum

Continuous

Current

(Amperes)*

360 1500 1750 1500 2500 3000 2500 4000 5000 4000

320 1250 1500 1250 2250 2500 2250 3500 4500 3500

310 1250 1500 1250 2000 2500 2000 3500 4000 3500

2300V, 3-Phase 4200V, 3-Phase 6600V, 3-Phase

Synchronous

Motors

Motors

Synchronous

Motors

Motors

Synchronous Motors

0.8 P.F. 1.0 P.F.

Motors

280 1000 1250 1000 1750 2250 1750 3000 3500 3000

* – Motor FLA depends on manufacturer, speed, and other factors which must be considered.

Note: Consult factory with your specific application requirements.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

27

OPERATION

Initial Energization

Energizing a medium voltage controller or line-up of controllers

for the first time is potentially dangerous. Therefore only qualified

personnel, as defined in the SAFETY section of this manual,

should energize the equipment (Fig. 38). If equipment damage or

poor installation practices have escaped detection in the PRE-

ENERGIZATION CHECK, major damage, including personal

injury, can result when the power is applied. Extra precaution is

recommended on initial energization of the equipment.

Hazardous Voltage. Improperly
installed or damaged equipment will
result in severe injury, death, and
property loss. Correct all problems
prior to energizing this equipment.

Only qualified personnel should
energize this equipment.

In order to minimize the risk of injury or damage, there should be

no load on the controller or group of controllers when incoming

power is first turned on. All downstream loads, including

distribution equipment and other remote devices, should be

turned off. The isolation switch ahead of each controller should

be in the off position.

The equipment should be energized in sequence by starting at

the source end of the system and working towards the load end.

First, the main devices, then the feeder devices, and then the

branch circuit devices should be closed.

With all removable barriers in place and all doors closed and

latched, the devices should be turned on with a firm, positive

motion. Protective devices and switches that are not quick-acting

should not be "teased" into the

isolation switch handle should be moved between the OFF and

ON positions in a single continuous smooth movement (Fig. 39).

After all disconnect devices have been closed, contactors may be

operated to turn on loads such as motors, transformers, variable

frequency drives, etc.

closed (or open) positions. The

Fig. 38 Preparing for Initial Energization

TOSHIBA

Fig. 39 Closing Isolation Switch

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

28

WARNING

WARNING

WARNING

MAINTENANCE

In order to ensure continued reliable and safe operation of the equipment, a

program of periodic maintenance must be established. Operating and

environmental conditions will dictate the frequency of inspections required.

NFPA Publication 70B "Electrical Equipment Maintenance" (Fig. 40) may be

used as a guide for setting up the maintenance program.

Maintenance Record

A permanent record of all maintenance work should be kept.

As a minimum, this record should include information on:

1) Items inspected

2) Test reports

3) Equipment condition Fig. 40 NFPA 70B

4) Corrective actions or adjustments Electrical Equipment

5) Date of work Maintenance

6) Comments

The degree of detail will depend on the operating conditions.

Contact with energized components can cause severe injury or death.

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

Improper maintenance can cause severe injury, death, and extensive property

damage. Only qualified and authorized persons are to install, operate, or
service the equipment.

This equipment utilizes both low and high voltage for operation. Verify that

all test equipment is suitable for the voltage being checked.

NOTE: Refer to the SAFETY section of this manual for important information.

After disconnecting and locking out incoming power and before performing
any maintenance, it is recommended that a safety ground be connected to
the main power bus (Fig. 41). After maintenance is complete, perform the
checks in the PRE-ENERGIZATION CHECK section of this manual before
restoring power.

The following pages detail maintenance procedures recommended for
Toshiba JK 400 ampere medium voltage controllers. In general, the
following items should be included on the maintenance checklist:

- Cleaning

- Checking and tightening of electrical connections

- Checking of fuses and fuse connections

- Proper installation of any removable barriers

- Vacuum contactor maintenance

Fig. 41 Attaching Safety Ground

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

29

Torque at Full

(ft - lbs)

1/4 - 20

6

3/16 - 18

12

3/8 - 16

18

7/16 - 14

30

1/2 - 13

45

9/16 - 12

68

5/8 - 11

90

3/4 - 10

150

7/8 - 9

240

1.0 - 8

245

WARNING

The information presented here is intended to cover preventive maintenance only. It does not cover major

rework or repair. The following MAINTENANCE SHOULD BE PERFORMED AT LEAST ANNUALLY or more

frequently depending on operating conditions.

General Inspection

Thoroughly clean the equipment, removing all dust, dirt, and other accumulations. Wipe insulators clean using

a clean, dry cloth. Do not use petroleum-based solvents or cleaners.

Check for any signs of moisture inside the enclosure. If there are signs of dripping water entering the

enclosure, eliminate the source. Thoroughly dry any insulation which shows signs of wetness and repeat the

dielectric test procedure given in the PRE-ENERGIZATION CHECK. Replace insulators, if necessary.

Check for any signs of rusted or corroded parts.

Check for free movement of all moving parts and mechanisms. Lubricate, if necessary, with Toshiba B9

grease.

Grease is conductive. Do not apply grease to electrical insulation.

Electrical Joints

Examine all visible terminals and joints for signs of

overheating (Fig. 42). An overheated connection will

appear discolored. Be suspicious of any conducting joint

which has a darker color than other similar joints.

Check all bolted connections for tightness. The proper

torque is dependent on the size of the hardware and the

materials used. As a general guide, use the following

Fig. 43. The values apply to metal-to-metal joints (e.g.
copper-to-copper). When applying torque to a bolt
threaded into an insert, molded into a plastic part, use
approximately 2/3 the torque shown.

Fig. 43 Torque Specs for
MV Power Connections

Fig. 42 Check Electrical Joints

Bolt Size

Engagement

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

30

CAUTION

Power Fuses

The power fuses supplied in Toshiba JK 400 ampere controllers are

of the bolt-in or clamp-in type, therefore overheating due to loss of

fuse clip pressure is not a problem. The tightness of the fuse

clamping bolts (Fig. 44a) should, however, be periodically checked

and maintained within a range of 4-6 ft-lbs.

Check the condition of the back stab terminals on the cartridge for

any signs of damage or discoloration (Fig. 44b). Check the power

fuses for any signs of discoloration. A fuse barrel which appears

darker than others indicates overheating. Possible causes of fuse

overheating, other than load problems, are misapplication (fuse

current rating too small), loose fuse connections, or a damaged

fuse.

If there is any excessive build-up of dirt or other foreign material, Fig. 44a Checking Power Fuse

wipe clean and lubricate with a light coat of Toshiba B9 grease, Clamping Bolt Torque
making sure that no grease gets on the insulated fuse housing.

Check the fuse barriers for cleanliness and proper positioning, as
shown in Fig. 45. There are three vertical barriers, two located
between adjacent fuses and a third between the right hand fuse and
the operator mechanism. A fourth angle-shaped barrier is
positioned in front of the isolation switch (Fig. 46).

Vacuum Contactor

Maintenance instructions for the HCV-5HA/7HA vacuum contactor
are provided in a separate publication, number
VF010H08A/VF00W104. Contact the equipment supplier or the
factory if this publication is needed and was not provided with the
equipment.

Radiation Exposure Hazard. X-Radiation

may cause illness or injury. Stay at least Fig. 44b Checking Stab on Power
1 meter (3.3 feet) away from the contactor Fuse Cartridge
during high-potential tests.

Fig. 46 Angled Barrier In
Front of The Isolation Switch Fig. 45 Fuse Barrier Placement

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

31

WARNING

Isolation Switch

The isolation switch provided in each controller is a bolted pressure type device. It is designed to maintain

proper adjustment and contact pressure over its mechanical life of 10,000 close-open cycles. Under normal

operating conditions, no maintenance is required other than periodic inspection and cleaning.

Wipe off any dust or dirt which may have accumulated on the

switch housing, the insulating blade drive links (Fig. 47), and

the shutter.

Open and close the switch and verify that no excessive force

is required. Observe that the line terminal shutter opens and

closes properly. Lubricate the moving parts of the handle

mechanism and, if necessary, apply a light coat of Toshiba

B9 grease to the inside contact surfaces of the switch blades.

Contact the equipment supplier or the factory to obtain B9

grease, if required.

Grease is conductive. Do not allow
grease to contact the switch
housing or the insulated shutter.

Fig. 47 Checking Isolation Switch

Examine the current-carrying switch blades for any sign of discoloration due to overheating.

Each bolted pressure switch blade assembly is pre-torqued and adjusted to the proper settings at the factory.
DO NOT attempt to change the torque settings or replace any individual parts of this assembly in the field.

If it is necessary to replace the blade assemblies, contact the nearest Toshiba representative.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

32

Switch Handle Mechanism And Interlock

The handle mechanism which operates the isolation switch is adjusted at the factory and under normal

operation requires no further adjustment. Alignment can be checked, however, as follows (Fig. 48):

Hazardous Voltage. Turn off and lock out primary power.

Opening barriers will expose medium voltage.

1) Move the handle to the full OFF position.

2) Observe that the isolation switch blades are in contact with the ground pads.

3) If adjustment is required, loosen lock nut securing yoke on handle end of connecting rod. Remove pin
which attaches yoke to handle drive lever. Turn yoke in required direction to achieve adjustment
defined in step 2. Attach yoke and pin to drive lever and tighten yoke lock nut.

Fig. 48 Switch Mechanism and Interlock Adjustment

4) Check the position of the handle interlock with the vacuum contactor in the OFF position. The tab

extending from the interlock should clear the notch in the handle, allowing the handle to be moved freely
between OFF and ON. Operate the contactor on test power and check that there is no binding and that the
contactor is able to reach its full travel in both directions.

The moving joints of all linkages should be occasionally lubricated with a light coat of Toshiba B9 grease.

TOSHIBA

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

33

Interlocks

Circumvent the handle interlock by pushing a screwdriver through the slot and operate the handle several times.

Hazardous Voltage. Turn off and lock out Primary and Control power.

Check that the CPI electrical interlock (microswitch) operates each time the handle is moved. The CPI (control

power interlock) should close approximately 10° before the handle reaches the full ON position. As the handle
is moved from ON to OFF, the CPI switch should open by the time the handle has moved approximately 10° or
one inch (Fig. 49).

Refer to the GENERAL DESCRIPTION section for the location of the handle mechanical interlocks and the CPI

electrical interlock.

Fig. 49 Interlock Sequence Check

Control Power/Potential Transformers

Wipe off the surface of the transformers (Fig. 50).

Check the condition of the primary fuses and fuse clips. Check all screws
for tightness.

TOSHIBA

Fig. 50 Inspect Transformer(s)

Basic Installation and Operation Guide
JK 400 Series Fixed Controllers

34

WARNING

MAINTENANCE AFTER A FAULT CONDITION

The following covers procedures to return to service a medium voltage controller, which has been required to
interrupt a load side short-circuit or ground fault. These procedures are not intended to cover devices such as wiring
and motors, which may also require attention.

In an installation which has been properly coordinated and in service prior to a fault, the opening of the current­limiting power fuses in the controller indicates a fault condition in excess of operating overload. This fault condition
must be corrected and necessary repairs made to the load circuit before re-energizing the controller.

The following inspection and repair procedures should be carried out by qualified personnel.

Hazardous Voltage. Turn off and lock out Primary and Control Circuit Power

before any inspection or testing.

Enclosure

Check the condition of the enclosure for any signs of bowing or deformation. Check the condition of the doors and
latches for damage.

If substantial damage has occurred to the enclosure, such as deformation, displacement of parts, or burning, this
indicates a problem within the controller that requires major reconditioning or complete replacement of the controller.
In this event, contact the nearest Toshiba representative.

Isolation Switch

The external operating handle must be capable of opening the switch. If the handle fails to open the switch or if
visual inspection after opening indicates deterioration beyond normal wear and tear such as overheating or pitting
of blades, insulation breakage, or charring, contact your Toshiba representative.

Fuse Mounting

Check the condition of the power fuse mounting hardware, clamps, and insulating bases. Any deterioration of these
components requires replacement of the damaged parts.

Terminals and Internal Conductors

Indication of arcing damage, overheating, or both, such as discoloration and melting of insulation, requires
replacement of the damaged parts.

Overload Relay

The overload relay must be checked to verify that it will still trip properly. Follow the test instructions provided with
the overload device for verifying trip characteristics.

Vacuum Contactor

Operate the vacuum contactor electrically from test power and observe that it opens and closes freely. If the vacuum

bottles show any sign of binding, they should be replaced. Contact your Toshiba representative. Check for any
sign of arcing damage to the insulated housing.

Return to Service

Before returning the controller to service, repeat the procedure outlined in the PRE-ENERGIZATION CHECK
section of this manual.

TOSHIBA

Motors and Drives Division

Power Apparatus & Components
13131 West Little York Road | Houston, TX 77041
Tel: [phone] | US: 800-231-1412 | CAN: 800-872-2192

www.toshiba.com/tic

Printed in USA