Toshiba JK Series Instructions Manual

Document: OH01

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Issued:

TOSHIBA

INSTRUCTIONS

OPERATION MAINTENANCE

JK Medium Voltage Controllers Maximum

INTRODUCTION

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READ THIS MANUAL carefully for important information about safety, handling, and
maintenance, for general-purpose NEMA Class E magnetic controllers.

This manual and all accompanying drawings should be considered a permanent part of the
equipment. They should be readily available for review and reference at all times.

DIMENSIONS shown in the manual are in metric and/or their English equivalent.

These instructions are not intended to cover all details, combinations, or variations of the
equipment, storage, or installation.

PROBLEMS OR QUESTIONS should be addressed to:

Field Service Department

Toshiba International Corporation

13131 West Little York Road

Houston, Texas 77041 USA

Telephone:

FAX: [phone]

466-0277
[phone]
(800) 527-l 204 (Canada)

Page 1

Use only Toshiba-authorized replacement parts.

This equipment is designed and built in accordance with applicable
safety standards in effect on the date of manufacture. Unauthorized

modifications can result in severe injury, death and property damage.
Do not make any modifications to this equipment without the written

approval of Toshiba.

TOSHIBA INTERNATIONAL CORPORATION, 1994

Page 2 TABLE OF CONTENTS

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Page

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

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

Overhead Lifting ..................................................

Contactor Carriage Handling ..........................................

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation ..................................................... 10

Indoor Equipment ................................................. 10

Outdoor Equipment ............................................... 10

Routine Inspection ................................................

GENERALDESCRIPTION................................................. 12

Construction .................................................... 12

Controller Compartment ............................................

Isolation Switch .............................................

Withdrawable Contactor Carriage ................................. 14

Service Drawer

Load Receptacle and Current Transformers .......................... 15

Outgoing Load Connections ..................................... 16

Control Power Transformer ..................................... 18

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

Interlocks

Interlocks

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

Main Bus Compartment ............................................ 22

Prepared Spaces ................................................. 23

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

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

Horsepower Table ................................................ 26

Mechanical ........................................ 19

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

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

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

Electrical .........................................

Control Power Interlock

Test Power Interlock .................................

.............................................

...............................

1 0

11

15

21
21
21

7
7
8
8
9

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rating Verification ................................................ 27

Location ....................................................... 27

Service Conditions ................................................ 27

Installation Site Preparation .......................................... 28

Mounting ...................................................... 28

TABLE OF CONTENTS

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Grounding ......................................................

Connections .................................................... 31

Incoming Line ................................................... 33

Outgoing Load ...................................................

PRE-ENERGIZATIONCHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Page 3

Page

29

33

General ........................................................

Wiring.. ....................................................... 35

Devices

Electrical Checks ................................................. 37

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contactor Installation .............................................. 38

Initial Energization ................................................ 39

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance Record ...............................................

General Inspection ................................................ 42

Electrical Joints .................................................. 43

Contactor Carriage ................................................

Isolation Switch ..................................................

Switch Handle Mechanism .......................................... 45

Interlocks ...................................................... 46

Load Receptacle ..................................................

Control Power Transformer .......................................... 47

MAINTENANCE AFTER A FAULT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Mechanisms .............................................

34

36

38

41

43
44

46

Enclosure ...................................................... 48

Isolation Switch ..................................................

Fuse Clips ...................................................... 48

Terminals and Internal Conductors ..................................... 48

Overload Relays ..................................................

Vacuum Contactor ................................................

Return to Service ................................................. 49

WARRANTY AND LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

48

48
49

Page 4

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IMPORTANT MESSAGES

Read this manual and follow its instructions. Signal words such as DANGER, WARNING

and CAUTION will be followed by important safety information that must be carefully
reviewed.

NOTE Gives you helpful information

SAFETY

Indicates a situation which will result in death, serious injury, and severe
property damage if you do not follow instructions.

means that you might be seriously injured or killed if you do not follow
instructions. Severe property damage might also occur.

means that you might be injured if you do not follow instructions.
Equipment damage might also occur.

READ SAFETY SIGNS

To avoid injury,
You must read and follow
all safety signs.

Keep the safety signs visible
and in good shape. Never
remove or cover any safety signs.

DANGER

NOT REMOVE. DESTROY OR THIS LABEL I

READ THE INSTRUCTION MANUAL CAREFULLY BEFORE

INSTALLING, THIS

HAZARDOUS VOLTAGE In This Compartment.

I I Cause Injury, Death, Fire,

Exp I

! Turn Off And Lock Out Pr mat-y And

! Door Unless Isolation

! Keep A I I Panels And Covers

! Never Defeat, O r Bypass

! Dual if Operators Only.

And Property Damage.

I Circuit Power Servicing

Switch

In Place.

Safety Inter locks

OFF And Contactor Is OPEN.

Safety sign on front cover of
controller unit.

SAFETY

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QUALIFIED OPERATORS ONLY

Only qualified persons are to install, operate, or service this equipment according to all
applicable codes and established safety practices.

A qualified person must:

Page 5

Carefully read the entire instruction manual.

Be skilled in the installation, construction or operation of the equipment and aware

of the hazards involved.

Be trained and authorized to safely energize, deenergize, clear, ground, lockout and

tag circuits in accordance with established safety practice.

Be trained and authorized to perform the service, maintenance or repair of this

equipment.

Be trained in the proper care and use of protective equipment such as rubber
gloves, hard hat, safety glasses, face shield, flash clothing, etc. in accordance with
established practices.

Be trained in rendering first aid.

SAFETY CODES

Toshiba medium voltage controllers are general purpose, Class E, magnetic controllers
designed and built in accordance with the latest applicable provisions of NEMA ICS 2-324,

UL 347 and the National Electrical Code. Installations must comply with all applicable
state and local codes, adhere to all applicable National Electric Code
and instructions provided in this manual.

standards

Page 6

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SAFETY

HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion and
property damage.

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

Do not open door unless Isolation Switch is OFF and Contactor is OPEN.

Keep all panels and covers securely in place.

Never Defeat, Modify, or Bypass any Safety Interlocks

Qualified Operators only

RECEIVING AND HANDLING

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RECEIVING AND UNPACKING

Upon receipt of the equipment, do the

following:

Make an immediate inspection for any

damage which might have occurred
during shipment (Fig. 1). If damage is
found, it should be noted with the
carrier prior to accepting the shipment,

if possible.

Carefully unpack the equipment

sufficiently to check for concealed
damage and to determine that the
shipment is complete and correct.

Keep the equipment upright. If the

controller is not upright upon receipt,

notify the carrier of possible damage.
Upright the unit as soon as possible.

Page 7

Fig. 1 Inspect The Controller

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

File a claim with the carrier for any

damaged or missing item and

immediately notify the nearest Toshiba
Representative.

Do not install or energize
equipment that has been
damaged.

HANDLING AND MOVING

Medium voltage motor controllers should be
handled with care, t o avoid damage to
components and to the frame or its finish

(Fig. 2).

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

Fig. 2 Moving The Controller

Page 8

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movement and placement operations to

prevent dropping, or tipping.

Do not place any part of

your body beneath

equipment being lifted.
Improperly secured
equipment can fall or tip
over quickly and without
notice.

Do not attempt

installation or removal of

the contactor carriage

using the lifting methods
described in this section.

Always use a Toshiba JK

LIFTING DEVICE for the
installation or removal of

the contactor carriage.

USING A FORKLIFT

RECEIVING AND HANDLING

Fig. 3 Use of Spreader Bar-Single Section

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.

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. 3) 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. 4). Ropes
or cables should not pass through the holes in

LIFT

Fig. 4 Lifting Multiple Sections

RECEIVING AND HANDLING

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Page 9

lifting angles or eye-bolts. Slings with safety
hooks or shackles of adequate
should be used.

CONTACTOR CARRIAGE

GENERAL DESCRIPTION, page
normally shipped inside their respective
controller compartments. During initial
installation, the contactor carriages must be
removed from their compartments to allow
access for anchoring the enclosure to the floor,
and for pulling and terminating load cables.

Removal of the contactor carriage is facilitated
by the use of a Toshiba JK carriage lifting

attachment (Fig.
lifting device. The lifting attachment is
furnished with all JK medium voltage
controllers.

Details on the operation of the service drawer

which supports the contactor carriage may be

and a suitable overhead

load rating

NG

(refer toWithdrawable contactor carriage

are

found in the OPERATION section, page 38.
Two shipping brackets securing the carriage to
the service drawer must be removed before

attempting to lift the carriage from the drawer.
These brackets are used only for transportation

and may be discarded.

To attach the lifting attachment to the

carriage:

1.

2.

3.

4.

Position lifting attachment on top of
carriage.
Swing side support arms down to meet
carriage base.

Securely screw lift bolts into base.
Attach overhead lifter to eye bolt on
top of lifting attachment and lift from

drawer.

Maximum weight of

is

carriage
equipped with double
barrel fuses. Verify that
lifter used as adequate
load capacity.

135 Ibs

LIFTER HERE

Fig. 5 Contactor Carriage Lifting Attachment

Page 10 STORAGE

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PREPARATION

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. 6) 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

(NEMA Type 1, 12) which 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 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:

materials should be removed before energizing
space heaters.

OUTDOOR EQUIPMENT

An unenergized controller designed for outdoor
installation (NEMA Type
etc.) should be kept dry internally by installing
electrical heating or by energizing self-heaters,
if provided.

All openings, either used or unused should be
covered or sealed to prevent the entry of rain,
vermin, insects, etc.

All loose packing or flammable

EPIC building,

Fig. 6 Storage

STORAGE Page 11

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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.

Page 12

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Toshiba medium voltage controllers are AC
general-purpose NEMA Class E controllers
designed for applications at utilization voltages
ranging from 2.3 through 6.6
normally used to control motor loads, although
other types of loads such as transformers and
capacitors are possible.

CONSTRUCTION

They are

GENERAL DESCRIPTION

The standard enclosure size is
36” deep by 90” high. In a typical two-high
arrangement, each enclosure is divided
vertically into three major compartments, each
with a separate door. The uppermost and
lowermost compartments contain medium
voltage controller components
the middle compartment contains low voltage
components
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.

Each controller compartment (Fig. 8) consists
of:

Fixed mounted non-load break isolation
switch.
Withdrawable contactor carriage with
power fuses.

Built-in service drawer for removing
contactor carriage from compartment.
Current transformers for metering.
Control power transformer and optional
potential transformer.

Load cable terminations.

(Fig. 7). Other

wide by

while

Fig. 7 Typical Controller Arrangements

Fig. 8 Controller Compartment

GENERAL DESCRIPTION

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CONTROLLER COMPARTMENT

Page 13

A.

Power is switched on and off to each

individual controller compartment by a

mounted, externally-operated, three-pole
isolation switch. When the switch is in the
open position, incoming power is isolated from
the compartment interior by an automatic
shutter. Also, the load terminals of the switch
are automatically grounded in the open
position for additional safety.

The isolation switch is designed to accept a
direct connection from the line stabs of the
withdrawable contactor carriage.
connection is automatically made when the
contactor carriage is installed in the medium
voltage compartment.
closed by operating the external handle,
incoming power is applied to the line side of
the power fuses. In this position, the motor or
other load may be switched on and off by
operating the vacuum contactor.

Isolation Switch (Fig. 9)

This

When the switch is

Fig. 9 Isolation Switch

is

The isolation switch
interlocked with the vacuum contactor and the
compartment door. Details of the interlocking
are discussed in section H.

The position of the isolation switch blades can

be observed through a window in the medium
voltage compartment door. 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. IO).

The isolation switch has a maximum
interrupting capacity of 0.4 amperes.

Do n o t connect

additional load to the
isolation switch.

mechanically

Fig. 10 Isolation Switch Lockout

Page 14

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Withdrawable Contactor Carriage

(Fig. 11)

The withdrawable contactor carriage is a

removable assembly which contains the
following components:

Vacuum contactor

Power fuse housing assembly.

Set of line and load power stab
terminals.
Auxiliary contacts for vacuum

contactor.

Control wiring disconnect plug.

Set of wheels to facilitate moving the

is

carriage when it

controller.

The withdrawable contactor carriage is
normally shipped installed in the controller. It

may be removed for access to the medium
voltage compartment during initial installation,
connection of motor cables, etc. Periodically,

removal of the carriage may also be necessary
for routine maintenance of the contactor or

replacement of the power fuses.

outside the

GENERAL DESCRIPTION

Fig. 11 Withdrawable Contactor Carriage

Always use a Toshiba JK

Lifting Device (Fig. 12)
for removal or installation
of the contactor carriage.

When the carriage is installed in the controller

compartment, the following connections are
automatically made:

The line side stabs engage the fixed-

mounted isolation switch connecting

the load side of the switch to the line

side of the power fuses.

The load side stabs engage the fixed-

mounted load receptacle connecting the

load side of the vacuum contactor to
the current transformers.
The control transformer primary stabs

engage fixed-mounted clips connecting

the load side of the power fuses to the

primary side of the control

transformer(s).

Fig. 12 Lifting Device

GENERAL DESCRIPTION

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In addition, when the withdrawable contactor

is

carriage
compartment, it becomes interlocked with the
isolation switch so that the switch may not be
opened or closed unless the contacts of the
vacuum contactor are opened.

C. Service Drawer (Fig. 13)

The withdrawable contactor carriage is moved
in and out of the controller compartment on a

built-in sliding service drawer. The drawer has
four locating pins on top of it. When the
contactor carriage is placed on the drawer,
these pins engage four holes in the bottom of
the carriage which serve to align it properly.

The drawer moves in and out of the controller
compartment on sliding ball
rails. There is a handle on the front of the
drawer to provide a gripping point.

inserted into the controller

bearing type

Page 15

Fig. 13 Service Drawer

D.

The load receptacle is a fixed three-phase
disconnecting block. The vacuum contactor

load stabs on the withdrawable carriage
engage the load receptacle when the carriage

is installed in the controller compartment.

The load receptacle uses bolted pressure type

stab contacts similar to those used in the

isolation switch.

The operation of the bolted pressure contact

mechanism in the load receptacle is controlled

by a release lever located at the front of the

compartment be low t he ser vic e drawer.

Further details on the operation of the release
lever can be found in the OPERATION section
of this manual.

Power from the load receptacle is fed through
three current transformers located just behind
it. Current transformers furnished may be
either wound primary (bar) type, or window

Load Receptacle and Current

Transformers (Fig. 14)

Fig. 14 Load Receptacle