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Toshiba VF010H05 Remote Starter User Manual

1. 3SVHd P 3341 5 OVAOZT 8 1291 55 4 JKSSS Series 87 S3NIA NIVd T31sIAL JAY SABVINDO3S 12 lt 2 ASVHd 8 ASVHd V 3SVHd SdWV S SABVINDO3S 12 AlddNS 399170 WnIT3A 35 4 Spare Parts List SER Unit Voltage Quantity Description Part Number ER Req Unit Current Contact Factory Specify model number MVC STK23200 2300204 7 3 MVC3 STK23400 MVC3 STK23600 MVG3 STK41200 MVC3 STK41400 1 Phase MVC3 STK41600 MVC3 STK72200 MVC3 STK72400 MVC3 STK72600 25 0200 6500 23 25 0400 6500 23 25 0600 3500 23 SCR s Clamped 25 0200 6500 41 in Heat Sink 25 0400 6500 41 Alone 25 0600 3500 41 25 0200 6500 72 25 0400 6500 72 25 0600 3500 72 6000 7200 600 3 10 0000 2300 200 amp 400 7 3 10 000 2300600 6 10 0090 7 3300 4160 200 amp 400 6 10 0000 6000 7200 2004 amp 400 9 10 000 6000 7200 600h 9 Temperature amp Current Board MVC3 Temp CT PS All models PCB Mounting Order DVDT MOV Gate Drive Board Board Board WHITE WIRES toe op et
2. 5 30 Range 1 0 30 0 SEC overcurrent condition must exist before an alarm Increments of 1 Increments of 0 1 will occur UNDERVOLTAGE TRIP UNDERVOLTAGE TRIP LEVEL 15 DELAY 2 0 SEC Range 5 30 OFF Range 1 0 30 0 SEC Increments of 1 Increments of 0 1 LINE FREQUENCY TRIP LINE FREQUENCY TRIP WINDOW DISABLED DELAY 1 0 SEC Range 0 6 Disabled Range 1 0 20 0 SEC Increments of 1 Increments of 0 1 JKSSS Series 50 SP3 6Phase Loss JKSSS Series SP 3 Phase amp Ground Settings Setpoint Page 3 E SP3 5Overcurrent Trip Level Typically used to indicate the motor is severely overloaded and at which point a trip occurs Overcurrent Trip Delay The amount of time the overcurrent condition must exist before a trip will occur Over Current Trip Setting 250 FLA Trip When enabled the soft starter will trip the motor off line upon a loss of phase power Phase Loss Trip Delay The amount of time the phase loss condition must exist before a trip will occur SP3 7 Phase Rotation Detection The soft starter is continuously monitoring the phase rotation Upon a start command a trip will occur if it detects a change in the phase rotation Phase Rotation There are two possible phase rotation options ABC or ACB This setpoint monitors the wiring to ensure that the phase rotation is correct To view the present phase rotation go to Metering Page1 screen number 4 SP3 8
3. 99 WHITE WIRES K CATHODE G GATE JKSSS Series 88 JKSSS Series T Unit Voltage Quantity MVC3 GDFP 2300600 6 Gate Drive MVC3 GDF 7 3300 4160 V 200 8404 6 Boards MVC3 MOV 2300604 6 T 3300 4760 v 200884008 6 MVC3 DvDt 230604 6 MVC3 DvDt 3300 4160 V 200 8404 6 dv dt Board MVC3 Dv Dt 3300 4160 V 600A ce Dv Dt MN 7200 200 amp 400 wesowp Dv Dt 6000 7200v 7200 600 Main board CPU board amp digital controller assembly MVC3 MB CPU KIT All models with lexan cover and harness Control Board MVC3 TCB All models RTD Board DSS1000 RTD All models Ground fault Option MVC3 GECT Option 1 Contact Medium Voltage Fuses Contact Factory Specify FLA 2 3 4 2KV JKSSS Series 89 JKSSS Series 2 3 4 2KV 7 7 Instructions for Stack Replacement For Reference Only TEMP CT Board Gate Drive Board MOV Board ajh 12 tn DV DT Board PCB Mounting Order Gate Drive Board we dines K 1 l Heh SS 11 8 y mn g i e e o WHITE WIRES K CATHODE JKSSS Series 90 JKSSS Series 2 3 4 2KV 7 7 Instructions for Stack Replacement DANGER HAZARDOUS VOLTAGE Disconnect all power supplying this equipment prior to working
4. Bypass AUX START 4 Coil Green Coil x DELAY TIMED gt NM Q gt N OO A TA DN 0o N U aA DN do N U a DN Aux Start Output 120 VAC Neutral E s optional Interlocks x xp ERA 120 VAC Source x FACTORY WIRED DO NOT USE Emergency Bypass 2 gt AUX Contacts amp 5H Emergency Bypass Ehe Full Voltage Start C NO NC Fault C NO NC Lock Out C NC C NO NC NO NC P F C CAP C NO NC Time Delay C NC 2 3 4 2KV JKSSS Series 85 JKSSS Series 2 3 4 2KV 7 5 Typical Wiring Diagram RS 485 Medium Voltage Customer 3 Phase Medium CPT Connect Voltage Suppl lt OPTIONAL gt COMM 9 pply Phose A Phase B Phase C Phase A Phase B BOARD TRANSFORMER Located In Medium 2551000 Voltage Note This Is Section The Rear View 1 Df This Board source 2 WIRE OR 3 WIRE START ty CONTROL WIRING sTART 4F MAIN BDARD ZERO SEQUENCE is d RTD BOARD CT 05 CT Secondary Twisted Pairs Note MVC3 MB m Upon M o FFFFFFF 896 zi GROUND FAULT BOARD 2 MVC3 GF CT E DS NOTE 1 SEE CHAPTER 2 DF MANUFACTURER S MANUAL FOR TCB CIRCUIT BOARD CONNECTION DETAILS Fiber Optic Harness JKSSS Seri
5. 8 LN TB2 2 3 3 E lt lt a Note Install program jumper to enable setpoint programming Jumper must be removed after programming or for prolonged storage to preserve settings JKSSS Series 28 JKSSS Series Chapter 3 Start up AWARNING THE JKSSS UNIT DEALS WITH POTENTIALLY LETHAL VOLTAGE LEVELS YOU MUST BE CERTAIN THAT PERSONNEL ARE THOROUGHLY TRAINED IN THE APPLICABLE SAFETY PRECAUTIONS BEFORE PROCEEDING WITH THIS SECTION 3 1 Preliminary Start Up Check List Please make the following checks before applying power to the unit Qualified personnel have hi potted the line and load wiring before connecting to the soft start Typically 1 5 x Rated Voltage Verify that all wiring is completed and all connections are tightened Check the motor nameplate and confirm the unit is programmed with the correct motor FLA Note It is necessary to connect the line power to L1 L2 and L3 or the Phase Rotation Protection will be activated Verify control logic via 120V test switcher available on standard JKSSS NEMA Class E2 Starters only Aseparate 120Vac test receptacle can be supplied to the control logic without powering up the medium voltage section for control logic testing It also allows isolation of the 120Vac from back feeding the control power transformer Connect control supply Optional Soft Start Only Package only The and Stop LEDs will ligh
6. OFF Range STATOR PHASE 1 lt gt Range STATOR PHASE C2 TYPE OFF lt gt Range END BEARING TYPE OFF Range SHAFT BEARING TYPE OFF Range RTD 9 TYPE OFF Range RTD 10 TYPE je Range RTD 11 TYPE Range RTD 12 erem Range STATOR PHASE 1 a RTD 2 DESCRIPTION STATOR PHASE A2 Range Range Range aes PHASE A2 TYPE lt gt Range RTD 3 DESCRIPTION STATOR PHASE B1 Range Range Range RTD 4 DESCRIPTION STATOR PHASE B2 Range Range Range lt gt RTD 5 DESCRIPTION STATOR PHASE C1 STATOR PHASE C2 Range Range Range RTD 7 DESCRIPTION lt gt END BEARING ALARM END BEARING Range Range Range RTD 8 DESCRIPTION SHAFT BEARING ee RTD 9 DESCRIPTION lt gt RTD 9 ALARM RTD 10 DESCRIPTION lt gt RTD 10 ALARM RTD 10 RTD 11 DESCRIPTION RTD 12 DESCRIPTION RTD 12 ALARM RTD 12 p Ranges 120 OHM NICKEL NI 100 OHM NICKEL NI 10 OHM COPPER CU 100 OHM PLATINUM PT OFF OFF or 0 240C 32 464F Example C F Increments of 1 STATOR A1 STATOR A2 STATOR B1 STATOR B2 STATOR C1 STATOR C2 FRONT BEARING BACK BEARING BEARING BOX AMBIENT NONE 1 DESCRIPTION lt lt STATOR PHASE A1 ALARM
7. Facto 200 1000 600 36 600 3000 2200 Consult Facto Consult Facto ah Facts jm me ae 2 5 Mounting 36 600 3000 2200 200 1500 1000 600 5000 3750_ 720 5500 4000 Note Dimensions are for reference only and subject to change Contact factory for exact dimensions 4160 Each shipping section must be leveled and firmly secured to its supporting foundation Steel shims may be used for final leveling Fig 3 if necessary When three or more shipping sections are to be arranged in one continuous line up the center shipping section should normally be the first located C moma zd Follow the equipment outline drawings to determine the location of the mounting bolt holes and any conduit locations Sill channels may or may not be furnished depending on order specifica tions Referto outline drawings furnished for location SHIM IF NECESSARY of sill channels if furnished TO LEVEL CUBICLE Various methods may be used to anchor the enclosure to the foundation 7777777 7 j FLOOR including expandable inserts or J bolts embedded in concrete The recommended size for anchor bolts is 1 2 Fig 4 AWARNING Heavy Equipment Enclosure must be securely anchored to prevent tipping over Fig 3 Leveling Using Shims FLOOR 2 6 Additional Ca
8. MAX TEMP SINCE CLEAR 5 C Screen 14 MAX TEMP SINCE CLEAR RTD 6 Screen 15 Screen 16 END BEARING MAX TEMP SINCE RTD 7 C CLEAR RTD 7 C Screen 17 Screen 18 SHAFT BEARING MAX TEMP SINCE RTD 8 CLEAR RTD 8 C Screen 19 Screen 20 RTD 9 MAX TEMP SINCE RTD 9 C CLEAR RTD 9 C Screen 21 Screen 22 RTD 10 MAX TEMP SINCE RTD 10 C CLEAR RTD 10 C Screen 23 Screen 24 RTD 11 MAX TEMP SINCE RTD 11 CLEAR RTD 11 C Screen 26 MAX TEMP SINCE CLEAR RTD 12 Screen 25 RTD 12 RTD 12 C HH F Screen 27 PRESS ENTER TO CLEAR MAX TEMP REGS Screen 28 MEASURED RUN COOL TIME MIN Screen 29 MEASURED STOPPED COOL TIME MIN JKSSS Series 75 JKSSS Series 2 3 4 2KV MP4 Status Metering Page 4 Displays the present status of the soft start Screen 1 Displays the present state of the unit as CURRENT STATUS follows EIU Screen 1 Note Screen 2 CURRENT STATUS Screens include O L TRIP LEFT TO MOTOR STOPPED TRIP SEC READY TO START STARTING MULT OF FLA MOTOR RUNNIN AT 1HHE SHE X FLA Screen 5 1 2 3 4 RIP NONE or trip cause 5 TIME BETWEEN STARTS 6 0 3 THERM INH TIME LEFT Screen 4 COAST DOWN TIMER TIME LEFT MIN SETPOINTS TIME MIN
9. lt STATOR PHASE A1 TRIP STATOR PHASE A1 Range Range Range LEVEL OFF LEVEL OFF STATOR PHASE A2 ALARM LEVEL OFF STATOR PHASE A2 TRIP LEVEL OFF STATOR PHASE B1 ALARM gt STATOR PHASE B1 TRIP LEVEL OFF LEVEL OFF STATOR PHASE B2 ALARM LEVEL OFF STATOR PHASE B2 TRIP LEVEL OFF STATOR PHASE C1 ALARM STATOR PHASE C1 TRIP LEVEL OFF LEVEL OFF Range Range Range RTD 6 DESCRIPTION STATOR PHASE C2 ALARM STATOR PHASE C2 TRIP LEVEL OFF lt gt LEVEL OFF END BEARING TRIP LEVEL OFF LEVEL OFF SHAFT BEARING ALARM SHAFT BEARING TRIP LEVEL OFF LEVEL OFF Range Range RTD 9 TRIP LEVEL OFF LEVEL OFF Range Range Range RTD 10 TRIP LEVEL OFF LEVEL OFF Range Range RTD 11 ALARM LEVEL OFF RTD 11 TRIP LEVEL OFF Range Range Range RTD 12 TRIP LEVEL OFF LEVEL OFF Range Range JKSSS Series 63 JKSSS Series SP 9 RTD Configuration Setpoint Page 9 Security Level 3 The soft starter comes with an RTD card that provides 12 programmable RTDs which are individually programmable for type The available types are 100 ohm platinum 100 ohm nickel 120 ohm nickel and 10 ohm copper Each RTD can be identified with a description name of up to 15 characters including spacing Also each individual RTD has it own alarm and trip level SP9 1 Use NEMA Temp for RTD Value When this setpoi
10. 0 60 SEC Normally Closed Increments of 1 oe eR ERES RAMP EE RAMP TYPE NORMALLY OPEN TIME DELAY EE SEC Options Normally Open or Range 0 60 SEC Normally Closed Increments of 1 lt THERMOSTAT lt gt NAME EXT INPUT 4 lt gt THERMOSTAT THERMOSTAT SELECT ENABLED THERMOSTAT TYPE NORMALLY CLOSED TIME DELAY 1 SEC Options Normally Open or Range 0 60 SEC Normally Closed Increments of 1 External Input 3 The setup screens and setpoints for External Input 3 includes the option of being configured for Dual Ramp In Dual Ramp mode the initial contact setting is the same as the START RAMP 1 Upon a change in input contact state the controller will switch over to START RAMP 2 and use that setting for start control mode Note The start RAMP types should only be switched while the motor is stopped In Setpoint Page 4 Relay Assignments do not assign any output relay to this function The controller will ship with External input 3 programmed for dual ramp If it is not needed disable the dual ramp External Input 4 This input screens are for the thermostat input and can be enabled or disabled Note It is recommended that this function remain enabled If the thermostat indicates an over temperature condition the controller will trip the motor JKSSS Series SP 7 Custom Acceleration Curve Setpoint Page 7 Security Level 3 Hit DOWN ARROW six times PAGE7 CUSTOM c ACCELERATION CURV
11. 5 o en o 2 a o g o DV DT Boards JKSSS Series 83 7 3 Overload Curve Definition 1000 100 1 SS T Overload Class 30 Overload Class 25 Overload Class 20 Overload Class 15 JKSSS Series 84 JKSSS Series 7 4 TCB Diagram F1 Control Fuses for TB1 1 9 Part ACG1A250VAC or equivalent F2 Contactor and relay output fuses Part ACG4A250VAC or equivalent F3 TB2 Pin 6 Part ACG4A250VAC or equivalent Customer Provided Momentary or Maintained Start Stop Switching Maintained START ca STOP Li rs tsb BEN 12ovac oe Neutral D 2 12V TB2 Delayed Start Green 4 x Wu Fuse Blown 5 TB6 12V START Disconnect Open 6 7 Dual Ramp 5 ON oF JP4 H 9 Remove JP1 for electronic Bypass Status DUAL ADS motor overload protection 10 during emergency bypass operation 1 TCB TB3 3 CPU AUX1 Fault 4 TB7 At Speed 5 D 7 Fuse Blown Disconnect qp Green Interlock Input D 2 LED oy 3 External Overload TB8 PFC 4 TIMED 7654321 7654321 7654321 OUT Bypass Aux Contact T TT 2 ole
12. EXTERNAL INPUT 2 1ST NONE 1ST NONE DUAL RAMP 1ST NONE KW DEMAND ALARM 1ST NONE THERMOSTAT 1ST TRIP O L WARNING KVA DEMAND ALARM 1ST NONE 1ST ALARM KVAR DEMAND ALARM 1ST NONE OVERCURRENT ALARM 1ST ALARM SCR FAIL SHUNT ALARM 1ST NONE GROUND FAULT ALARM 1ST ALARM UNDERCURRENT ALARM 1ST NONE AMPS DEMAND ALARM 1ST NONE TIMED OUTPUT 1ST NONE RUN DELAY TIME 1ST NONE MOTOR RUNNING AT SPEED 1ST AUX4 1ST AUX3 JKSSS Series 53 JKSSS Series SP 4 Relay Assignment Setpoint Page 4 Security Level 2 2 3 4 2KV The protection functions are user programmable to an output relay Factory setting for the trip functions assigned to TRIP AUX1 relay and alarm functions to ALARM AUX2 relay AUX1 4 are Factory Set and should not be changed SP4 1 The following is a list of the user programmable functions FUNCTIONS OVERLOAD TRIP IMBALANCE TRIP SHORT CIRCUIT TRIP OVERCURRENT TRIP STATOR RTD TRIP NON STATOR RTD TRIP GROUND FAULT HI SET TRIP GROUND FAULT LO SET TRIP PHASE LOSS TRIP ACCEL TIME TRIP START CURVE TRIP OVER FREQUENCY TRIP UNDER FREQUENCY TRIP I I T START CURVE LEARNED START CURVE PHASE REVERSAL OVERVOLTAGE TRIP UNDERVOLTAGE TRIP POWER FACTOR TRIP TACH ACCEL TRIP INHIBITS TRIP SHNT TRIP BYPASS DISCREPANCY TCB FAULT EXTERNAL INPUT 2 DUAL RAMP THERMOSTAT OVERLOAD WARNING OVERCURRENT ALARM SCR FAIL SHUNT ALARM GROUND FAULT ALA
13. Excessive number of stans perro 5 6 1 5 Event Recorder Metering Page 5 Metering Page Description of Display Screen Displays the event with date and time Up to 60 events Displays Phase current values Ground Fault Option at time of trip Displays Vab Vbc Vca and Power Factor at time of trip 6 1 6 Last Trip Metering Page 6 Metering Page Description of Display Screen Measured votage and imbalance percentage the honest stator RTD temperature honest ron stator RTD temperature 6 6 1 7 Statistics Metering Page 7 Metering Page Page 6 Last Trip Description of Display Screen Total megawatt hours EE Clear the toia Tmdmmberohps Number of start and run overload trips since the last statistical data 5 clearing Number of requency tips ard mane ups o Stator andron satorRTD wes 5 F Ground faut Fail shunt trip trips Page 7 n 7 o Phase loss trip trips Tach accel trip trips Undervoltage and Overvoltage trips Power Factor trips Phase reversal trips Ext Inp 1 Ext Inp 22 Ext Inp 3 Ext Inp 4 Press enter to clear statistics JKSSS Series 71 JKSSS Series 2 3 4 2KV 6 2 Metering Menu Push MENU key to toggle the screens between Setpoint Menu and Metering Menu and follow the arrow keys to
14. F name Ext impute UsDelmeWuptoiSChaudes JKSSS Series 40 JKSSS Series 2 3 4 2 5 1 7 Custom Acceleration Curve Setpoint Page 7 Setpoint Security Page Level Factory Setting Default Custom Accel Curve Disabled Disabled Curve A B or C Curve A Voltage Level 1 0 100 SP7 1 Description Range Section Curve A Ramp Time 6 2 sec 1 60 sec Curve A Voltage Level 7 0 100 Curve A Ramp Time 7 1 60 sec Curve A Voltage Level 8 0 100 Custom Curve B Same Programmable Data Points and Ranges as Custom Curve A Custom Curve Same Programmable Data Points and Ranges as Custom Curve A 5 1 8 Overload Curve Configuration Setpoint Page 8 Custom Acceleration Curve Password Protection Setpoint Security Page Level Factory Setting Default SP8 1 Description Section 9 S c 5 a Y 9 o D gt O Learned Start Curve Bias 5 40 Time for Sampling 1 300 sec JKSSS Series 41 JKSSS Series 2 3 4 2KV 5 1 9 RTD Configuration Setpoint 9 Setpoint Security Page Level Factory Setting Description Default Section Enabled or Disabled SP9 1 Disabled Enabled or Disabled SP9 3 Disabled of 0 240 32 464 Off User defined Up to 15 Characters 0 240C 32 464F Off Xx RTD Configuration
15. Ground Fault Alarm Typically used to warn of low level ground current leakage Ground Fault Alarm Delay The amount of time that the ground fault condition must exist before an alarm will occur SP3 9 Ground Fault Loset Trip Level Typically used to trip the motor on a low level of ground current leakage This setpoint is intended to detect high impedance faults Ground Fault Loset Trip Delay The amount of time that the ground fault condition must exist before a trip will occur Ground Fault Option must be installed 2 3 4 2KV Hit DOWN ARROW two times PAGE 3 PHASE amp lt gt GROUND SETTINGS POWER FACTOR LEAD P F LEAD ALARM P F ALARM OFF DELAY 1 SEC Range 01 1 00 OFF 1 Range 1 120 SEC Increments of 01 Increments of 1 POWER FACTOR LEAD P F TRIP OFF Range 01 1 00 OFF Increments of 01 P F LEAD TRIP DELAY 1 0 SEC Range 1 120 SEC Increments of 1 POWER FACTOR LAG P F ALARM OFF Range 01 1 00 OFF Increments of 01 P F LAG ALARM DELAY 1 0 SEC Range 1 120 SEC Increments of 1 P F LAG TRIP DELAY 1 0 SEC Range 1 120 SEC Increments of 1 POWER FACTOR LAG TRIP OFF Range 01 1 00 OFF Increments of 01 POWER DEMAND PERIOD 10 MINUTES Range 1 60 Minutes Increments of 1 KW DEMAND ALARM PICKUP OFF KW Range OFF 1 100000 1 Increments of 1 KVA DEMAND ALARM PICKUP OFF KVA Range
16. JKSSS Series 4 200 amp 400 Amps Units Series Tota Voltage Pairs Number PIV Rating of SCRs 2300 o se eov 3300 4160 V 600 Amps Units Series Total Voltage Pairs Number PIV Rating of SCRs 2 00 2 12 3300 4160V 4 24 14000V Unit PIV Ratings JKSSS Series 2 3 4 2KV e Contactors Vacuum contactors are provided for both In Line Isolation and SCR Bypass The contactor voltage ratings are 7 2kV for 2300 6900V units A sequencing feature controls the contactors Under normal operating conditions this ensures that both contactors make and break under no load conditions to maximize contactor life Vacuum contactors are rated for the maximum starting requirement of the unit design The Bypass Contactor is rated to be capable of emergency start For further information on the vacuum contactor see the instruction manual on the vacuum contactor supplied with the equipment and also either VF010H01 400A Drawout Type or VF010H03 Fixed Type e Soft Start Only Option The JKSSS Series is also offered an optional Soft Start Only package for use in retrofitting behind an existing customer supplied line start controller In this configuration the Disconnect Switch Fuses and Line Isolation Vacuum Contactor are NOT included in the JKSSS unit so proper interlocking of sections containing medium voltage becomes the install er s responsibility retrofit Soft St
17. JKSSS Series 61 JKSSS Series SP 8 Overload Curve Configuration Setpoint Page 8 Security Level 3 Hit DOWN ARROW seven times CURVE CONFIGURATION OVERLOAD CURVE Configures the unit s start and run protection mode The unit has independent start and run curve protection and the settings can be based on the OL Class or set by the motor s locked rotor current and time BASIC START OVERLOAD CURVE SP8 1 Basic Run Overload Curve Run Curve Locked Rotor Time Set the locked rotor time to the OL Class default chosen in Setpoint Page 1 or set the time in seconds This is the time the locked rotor condition exists before a trip occurs Run Locked Rotor Current The current the motor draws with full voltage on the windings and no rotor movement as a percent of motor FLA Refer to the nameplate data or contact the motor manufacturer Coast Down Timer If enabled this prevents the motor from restarting for the programmed amount of time after a stop command is given Options DISABLED LEARN SP8 2Basic Start Overload Curve or ENABLED Start Curve Locked Rotor Time The locked rotor time can be set to the OL Class default chosen in Setpoint Page 1 or to a specific time The overload condition must exist for the programmed amount of time before a trip occurs Start Locked Rotor Current The current the motor draws with full voltage on the windings and no motor movement as a percent of motor FLA Refer
18. LEVEL 2 Password required JKSSS Series 79 JKSSS Series 2 3 4 2KV Chapter 7 Maintenance and Troubleshooting The soft starter is designed to be a maintenance free product However as with all electronic equipment the unit should be checked periodically for dirt moisture or industrial contaminants These can cause high voltage arc over carbon tracking or prevent proper cooling of the SCR heat sinks All bolts should be checked annu ally for proper tightness using an accurate torque wrench According to the manufacturer s manual check the contactor for air gap spacing of the vacuum bottles Note If the unit is installed in a contaminated environment and forced air cooling is used blower filters must be checked and cleaned regularly to insure proper air flow and cooling of the enclosure 7 1 Failure Analysis When a fault occurs the LCD will display the fault error and the listed LED and AUX Relay will be lit Please clear all faults before attempting to restart the unit Note If the problem persists after the required programming changes have been made and all corrective action has been taken please contact the factory for assistance Problem CPU LCD Display LED Possible Cause Solutions rip One of the main Short circuit between the fuses blows or inputs Locate and remove short circuit breaker hos when He IRIE Remove power test SCR s Refer to PONOS appe Faulty SCRs Section 7 1 1 for the SC
19. Page 2 1 11 Page 3 1 29 Page 4 1 6 Class 5 30 4 40 second time delay Motor Design Run Temperature 80 Max 50 100 of Motor Stator Max Temp Motor Stator Max Temp INS CLS INS CLS 10 240 C Input to Thermal Register Enabled Enabled or Disabled Use Calculated K or Assign 1 50 On 5 1 13 Calibration and Service Setpoint Page 13 Setpoint Security Page Level Description Range Section System Setpoints Password Protection Factory Setting Default Set Date and Time FACTORY SET DDMMYY HHMM FACTORY SET 1 1 P13 1 Enter Date DDMMYYYY D 1 31 1 12 Y 1970 2069 FACTORY SET z us Enter Time HH MM 00 23 0 59 FACTORY SET Firmware REV d Hit Display Only Cannot be changed SP13 2 22 t0 Access Factory 1 Available to Qualified Factory Personnel SP13 3 Setpoint Security Page Level Description Range Section FACTORY USE ONLY gt e 2 JKSSS Series 44 JKSSS Series 2 3 4 2KV 5 2 Setpoint Menu Note 1 Push MENU key to toggle the screens between Setpoint Menu and Metering Menu 1 2 Follow the arrow keys to get to different screens Example For Page 3 PHASE amp GROUND SETTINGS press the MENU key and 1 BASIC the DOWN ARROW two times CONFIGURATION LEVEL 1 2 STARTER CONFIGURATION PAGE3 PHASE amp
20. Page Level Factory Setting Default 50 100 of Unit Max Current Rating Motor Full Load Amps FLA Model dependent Model and Service Factor dependent SP1 1 Description Range Section Cemaes Je 5 1 2 Starter Configuration Setpoint Page 2 Basic Configuration No Passowrd Required gt Setpoint Security Page Level Factory Setting Default Jog Start Ramp 1 Start Ramp 2 Custom SP2 4 Start Control Mode Start Ramp 1 Accel Curve Start Disabled Dual Ramp Tach Ramp Start Ramp 1 Type Voltage Current Voltage Initial Voltage 1 0 100 SP2 3 Description Section Current Limit 1 350 FLA 200 500 Initial Current 1 200 FLA 0 300 Start Ramp 2 Type Disabled Current Voltage Disabled Initial Voltage 2 0 100 Current Limit 2 350 FLA 200 500 2 4 Initial Current 2 200 FLA 0 600 Maximum Current 2 350 FLA 200 500 Kick Start Type Disabled Voltage or Disabled SP2 5 Maximum Current 1 350 FLA 200 500 c 9 5 5 2 o Z 8 N No Passowrd Required At Speed Delay Time 1 30 sec Off SP2 9 JKSSS Series 36 JKSSS Series 5 1 3 Phase and Ground Settings Setpoint Setpoint Security pade Levai Description Imbalance Alarm Level Imbalance Alarm Delay Imbalance Trip Level Imbalance Trip Delay Undercurrent Alarm Level Undercurrent Alarm Delay Overcurrent Alarm Level Overcurrent Alarm Delay Overcurrent Trip Level Overcurrent Trip Delay P
21. AUX7 RELAY lt gt AUX7 RELAY FAIL SAFE NO LATCHED NO AUX8 RELAY lt gt AUX8 RELAY FAIL SAFE NO LATCHED NO JKSSS Series 55 JKSSS Series 2 3 4 2KV SP 6 User I O Configuration Setpoint Page 6 Security Level 2 MENU Hit DOWN ARROW five times ENABLED PAGE6 USER I O o TACHOMETER SCALE MANUAL TACH SCALE CONFIGURATION SELECTION DISABLED 4 0 0 Options ENABLED Range 0 3600 DISABLED Increments of 5 MANUAL TACH SCALE 20 0 mA 2000 RPM Range 0 3600 TACH ACCEL TRIP MODE Increments ofS 20 SEC Range 1 120 SEC Disabled Increments of 1 SELECT DISABLED TACH UNDERSPEED TRIP PT 1650 RPM Range 0 3600 Increments of 5 TACH OVERSPEED TRIP PT 1850 RPM Increments of 5 lt gt TACH ACCEL TRIP DELAY 1 SEC Range 1 60 Increments of 1 ANALOG OUTPUT 1 ANALOG OUTPUT 1 ANALOG OUTPUT 1 gt gt RMS CURRENT 4ma 0 20mA 250 g Range Range 0 65535 Range 0 65535 Analog Output Range Increments of 1 Increments of 1 RPM 0 3600 Hottest Bearing 0 200 Hottest Stator RTD 0 200 C Range 0 3600 Options UNDERSPEED OVERSPEED or DISABLED RMS Current 0 6500A Motor Load 0 1000 KW 0 30000 KW OFF Increments of 1 ANALOG OUTPUT 2 ANALOG OUTPUT 2 lt gt ANALOG OUTPUT 2 Range See Analog Output 1 Range 0 65535 Range 0 6553
22. DC or AC voltage Connect to MVC3 MB Main Firing Board IS present on any of the power Caution Remove the three phase transformer PT fuses and CPT fuses components on panel to prevent backfeed to the Medium Voltage 2 Verify setup of control power transformers for the proper voltage If using 480Vac or 240Vac 3 phase verify transformers are strapped for that voltage See above drawing Configure as an open delta for 3 phase as shown in drawing 3 Verify medium voltage disconnect is open and pull medium voltage fuses including PT and CPT fuses 4 Connect 3 phase power 480 or 240Vac to the down stream side of the fuses Do not connect to disconnect side of fuses Depending on the small test motor used will depend on what size cable or current that is required Also connect the Primaries of the TEST PT in the proper phase sequence of A B C Disconnect medium voltage motor Connect low voltage motor Typically 5 HP or less Connect a wire jumper between TB8 pins 1 and 2 on the TCB con trol board to bypass fuse blown and open disconnect fault The TCB is located in the low voltage compartment 8 Install a switch on TB1 pins 1 and 8 on the TCB control board to bypass all interlocks TEST Switch noo JKSSS Series 94 JKSSS Series 2 3 4 2KV 17 18 19 20 21 22 23 24 25 26 Verify or wire 120Vac plug to the TEST plug supplied the factory Remove all both power fuses on the medium
23. JKSSS Series 16 JKSSS Series 2 3 4 2KV Ensure that safety signs are not covered or obscured by paint AN ARNING Do not remove cover or destroy any safety signs The setting of any adjustable current and voltage trip mechanisms should be verified to the proper values 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 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 func tion as intended for protection of personnel and equipment Overload relay settings should be checked to be sure they are selected and adjusted to the proper settings per the load nameplate data Power circuit fuses were selected and installed in accordance with the application re quirements Fuses must be completely inserted in their holders Instruction on removing and installing the fuses can be found one of the following manuals VF010H093 Fixed VF010H01 Drawout Electrical Checks With incoming power isolated and all loads disconnected electrically the control cir cuit and other mechanisms should be exercised to determine that the devices operate properly An auxiliary source
24. PRESS ENTER TO CLEAR MWH VALUES JKSSS Series 74 JKSSS Series METERING PAGE 3 RTD VALUES MP 3 RTD Values Metering Page 3 Displays the RTD information Screen 1 Displays the hottest stator RTD 1 6 depending upon number of RTDs used for stator Screen 2 Displays the hottest non stator RTD 7 12 if 1 6 is used for stator Screen 3 Displays the temperature of stator phase A1 in C and F Screen 4 Displays the maximum temperature for RTD 1 since the last command to clear the thermal register Screen 5 26 Same as Screens 3 4 for RTDs 22 12 Screen 27 Allows the user to clear the maximum temperature register upon entering the setpoint level 3 password Screen 28 Displays the measured run cool time in minutes Screen 29 Displays the measured stopped cool time in minutes 2 3 4 2KV Screen 1 HOTTEST STATOR RTD Screen 2 HOTTEST NON STATOR RTD Screen 3 t Screen 4 MAX TEMP SINCE CLEAR RTD 1 C STATOR PHASE A1 RTD 1 HH F Screen 5 Screen 6 STATOR PHASE A2 MAX TEMP SINCE RTD 2 1HHEF CLEAR RTD 2 Screen 7 Screen 8 STATOR PHASE B1 MAX TEMP SINCE RTD 3 C CLEAR RTD 3 Screen 9 Screen 10 STATOR PHASE B2 MAX TEMP SINCE RTD 4 C 1HHEF CLEAR RTD 4 Screen 11 1 Screen 12 STATOR PHASE C1 RTD 5 C HH F STATOR PHASE C2 RTD 6 C HH F
25. Single Section 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 A 2 MIN 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 All loose packing or flammable materials should be removed before energizing space heaters Fig 2 Lifting Multiple Sections Outdoor Equipment An unenergized controller designed for outdoor installation NEMA Type 3R EPIC building etc should be kept dry internally by installing electrical heating or by energiz ing self heaters if provided All openings either used or unused should be covered or sealed to prevent the entry of rain vermin insects etc JKSSS Series 13 JKSSS Series Routine Inspection Routine scheduled inspection should be established if storage for
26. TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS STATUTORY AND IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ALL EXPRESS STATUTORY AND IMPLIED WARRANTIES SUCHAS MERCHANTIBILITY AND FITNESS FORAPARTICULAR PURPOSEAPPLICABLE TO ALLREPAIRED OR REPLACED EQUIPMENT AND PARTS FURNISHED PURSUANT TO THEFOREGOING WARRANT Y The total liability of the Company Toshiba Corporation and their suppliers and subcontractors for any loss damage or claim whether in contact tort including negligence and liability without fault or otherwise arising out of connected with or resulting from the equipment and parts described herein or the performance or breach of any contract for the sale or supply of such equipment and parts or from the design manufacture sale delivery resale installation technical direction or supervision of installation inspection testing repair replacement operation maintenance or use of any such equipment or part or any service relating thereto furnished by the Company shall not in any event exceed the price allocable to the equipment part or service which gives claim loss or damage In no event whether as a breach of contract or warranty alleged negligence liability without fault or otherwise shall the Company Toshiba Corporation or their suppliers or subcontractors be liable for indirect incidental special or consequential damages including without limitation property damage l
27. The controller line up must be grounded in accordance with the requirements of the Na tional Electrical Code Proper equipment grounding must be established before making any incoming power connection If a main ground bus is furnished make the ground con nection to this bus If there is no ground bus the sections which are shipped separately should be connected in such a way as to ensure a continuous grounding path Each section contains a vertical ground bus extending from the main ground bus or ground pad to each controller compartment Special attention should be paid to protection for operating personnel to protection of equipment itself i e such as ground fault relays if used 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 seperately 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
28. achieved DO NOT EXCEED THE MOTOR MANUFACTURER S RECOMMENDED AsVARNING NUMBER OF STARTS PER HOUR WHEN CALCULATING THE NUMBER OF STARTS PER HOUR A DECEL CURVE SHOULD BE COUNTED AS A START CURVE FOR EXAMPLE RECOMMENDED NUMBER OF STARTS PER HOUR 6 ALLOWABLE STARTS WITH DECEL CYCLE PER HOUR 3 3 5 Sequence of Normal Operation Apply control power and check that the Power LED comes on Display 1 Apply three phase power to the unit The motor should run only when the start command is applied Apply the start command Display 2 The RUN LED will be lit Display 3 The AUX3 LED will be lit If the motor does not enter run mode in the set time Acceleration time limit see SP8 2 a trip will occur JKSSS Series 34 JKSSS Series When the motor reaches full speed the AUX4 LED At Speed will be lit The POWER RUN AUX3 LEDs will be lit indicating that the contact has energized IA IB IC will display the current setting for Phase A Phase B and Phase C and the G F indicates ground fault Display 4 If the motor decelerates or stops during the acceleration period hit the stop button immediately and open the disconnect line If the unit does not follow this operational sequence please refer to the Troubleshooting Chapter It is best to operate the motor at its full load starting condition to achieve the proper time torque and ramp settings Initial settings are set to accommodate
29. an Q TOHE 2 Coie o C17 U12 _RTD1 RID2 EU _RTD4 _RTDS RTD6 _ _ EU RTD1 d RIDM 7 Signa X Typical RTD Installation JKSSS Series 25 JKSSS Series 2 3 4 2KV 2 116 Communications Board 2 RS422 C TEC vg yg I L I 1 6 1 Note Remove for last unit in modbus string 2 11c Communications Board Connections TB1 2 22 E COMES E lt lt lt 2 RECEIVE TRANSMIT RS485 Connections RS422 Connections Customer Connections Factory Only JKSSS Series 26 JKSSS Series 2 3 4 2KV 2 11d Power Board Board Ground Test Points ZA 7 A Phase 4 B Phase 1 C Phase 2 11e Power Board Connections TB1 TB2 Factory use only Do not reprogram Refer to Setpoint Page 5 for programming information 900000000000000000995 C N O N C C N O C N O N C C NO NC C N O N C NO N C AUX1 AUX2 AUX3 AUX4 AUX5 AUX6 AUX7 AUX8 TRIP ALARM RUN AT SPEED Relay Relay Relay Relay Relay Relay Relay Relay Max Relay Contact Rating is 240 VAC 4A 960VA JKSSS Series 27 JKSSS Series 2 3 4 2KV 2 11f Board Connections Contact factory for remote reset connections Factory wired Do not change bow N a 2 ER 5 os 5 lt 2 S ot ot g 5 5 o o os 2 9o oo a a um aN o
30. 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 AWARNING Do not install equipment found to have damage or deterioration that could affect the unit performance 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 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 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 Temperature or altitude conditions
31. control logic Remove power and repair the control logic Failure of main circuit DNE Replace the main circuit board board Check the motor and the motor Faulty motor connections R d perf the SCR Motor vibrates Faulty SCRs 1 a PARONA Motor growls Trip AUX1 while starting or IMBALANCE TRIP extremely IMBALANCE ALARM unbalanced motor currents run mode Remove power and test SCR s Refer to Section 7 1 1 for the SCR testing procedure Faulty gate cathode on SCRs Faulty main circuit board Replace the main circuit board Faulty motor wirin Troubleshoot and repair replace wirin Ep pairirep 9 Faulty main circuit board the main circuit board 7 1 1 SCR Testing Procedure Perform the SCR Heat Sink Ohm test on each Stack Assembly From Position A to Greater than 10K Ohm Position B Less than 10K Ohm From Position B to Greater than 10K Ohm Position C Less than 10K Ohm Pass Typical 8 to 20 Ohms Less than 10 or greater than 100 Ohms Note Allow 15 minutes after shutdown for DV DT network to discharge DC voltage Gate G to Cathode 8 to 100 Ohms K for each SCR Board K Cathode Red Wire G Gate White Wire JKSSS Series 82 JKSSS Series 2 3 4 2KV 7 2 Typical Block Diagram Voltage L1 L2 L3 Transformer Fiber Optics CPU Digital Controller Main Fiber Optics SCR Assembly Control Board Customer Connections 11 T2 T3 Firing Board MOV Boards o
32. get to different screens METERING PAGE 1 CURRENT METERED DATA METERING PAGE 2 VOLTAGE amp POWER DATA METERING PAGE 3 RTD VALUES METERING PAGE 4 STATUS METERING PAGE 5 EVENT RECORDER METERING PAGE 6 LAST TRIP METERING PAGE 7 STATISTICS JKSSS Series 72 JKSSS Series 2 3 4 2 MP 1 Metering Data Metering Page 1 Displays the basic current metering data Screen1 PhaseA B C and ground fault option current METERING PAGE 1 lt gt 1 1B Screen 1 Screen 2 Displays the average current percent of CURRENT METERED DATA imbalance and the motor s RPM available with tachometer input 1 AVG Screen 3 Displays the motor load in percent of motor 88 venden 2 FLA Screen 4 Displays the line frequency and the present MOTOR LOAD OF FLA Phase Order FLA Sereen Screen 5 Displays the percent of the remaining thermal register In order for the motor to successfully start the percentage must be greater than E 4 the thermal capacity required for a successful 5 Screen 6 Displays the thermal capacity required to THERMAL REGISTER Screen 5 successfully start the motor REMAINING Screen 7 Displays the average time required to start THERMAL CAPACITY amp Screen 8 Displays the average current during start TO START creen Screen 9 Displays the measured required to start t
33. i i i 1 2 7 isolation contactor which starts the motor across the line Noo C No Ne S E No NC See section 3 6 for more details E EMERBYP INTER ICUST POWERI DELAYED Positions 3 4 5 are a FORM C contact This is a dry contact that is i Emergency Bypass Control initiated by the emergency contact being closed It provides indication Figure 2 3 of the emergency bypass mode Positions 6 and 7 is a customer connection for control power Position CAUTION 6 is the 120 Vac supply at 400 VA and position 7 is the return OVERLOAD PROTECTION LOSS Positions 8 9 10 are a FORM C contact The dry contact is a delayed start stop contact The amount of delay is determined by X1 X2 and SW3 See _ When operating the unit in Emergency Bypass Mode 4 MA 4 Y there is no electronic overload protection Switch Positions and Jumper Selection on the next page Note Additional Time Delay to SP2 of the CPU programming External overload protection must be provided for JP1 Motor Protection Jumper Removing jumper JP1 on the TCB Board will continued sare operation allow the soft starter CPU to continue providing electronic motor protection while operating in the Emer gency Bypass Mode If necessary to disable the CPU system during operation in Emergency Bypass be sure JP1 is placed over both pins and an external means of overload protection is used Fault Terminal Block 3 TB3 Positions 1 2 3 and 4 5 6 are set
34. maximum motor current the starter will allow during Ramping As the motor begins to ramp the Current Limit feature sets a ceiling at which the current draw is held Current Limit remains in effect until the following occurs 1 the motor reaches full speed detected by the At Speed detection circuit or 2 the Overload Protection trips on Motor Thermal Overload Once the motor reaches full speed the Current Limit feature becomes inactive In the Voltage Ramp Profile the voltage output is increased until it reaches the Current Limit Ramp time is the maximum amount of time it takes for the voltage to increase until the Current Limit setting takes over With some load conditions the Current Limit is reached before the Ramp Time expires The Current Ramp profile varies the output voltage to provide a linear increase in current up to the Maximum Current setpoint value A closed loop feedback of motor current maintains the Current Ramp profile SP2 4Start Ramp 2 The same options and screen setups as Start Ramp 1 Note CUSTOM ACCEL CURVE overrides the voltage or current start in Ramps 1 and 2 when selected to be the start control mode 2 3 4 2KV SP2 5 Kick Start Used as an initial energy burst applications with high friction loads Kick Start Voltage The initial voltage as percent of full voltage value that is needed to start the motor i e Breakaway or Initial Torque Kick Start Time The time the init
35. most motor conditions TRY INITIAL SETTINGS FIRST See Section 5 1 1 Setpoint Page 2 to make any adjustments lnitial Voltage e Soft Start Curve e Current Limit e Acceleration Time If decel is enabled the following parameters for Deceleration Time Start Decel Volt age see SP2 and Stop Decel Voltage see SP2 must also be programmed 3 6 Emergency Bypass Operation N DANGER HAZARDOUS OPERATION Do not operate the Bypass Contactor with medium voltage power applied to the unit Failure to follow this instruction will cause the motor to start unexpectedly Remove input power using line start section and lock out disconnect e Close the emergency bypass contact e Re close the disconnect on line start panel e integral overload protection is not to be used see JP 1 Motor Protection Jumper then bimetallic or solid state overload protection is required customer supplied if factory emergency overload protection option has not been included IN THE EMERGENCY BYPASS MODE THERE IS NO OVERLOAD PROTECTION UNLESS A SEPARATE OPTIONAL OR CUSTOMER SUPPLIED THERMAL OR SOLID STATE OVERLOAD RELAY IS INSTALLED OR JP 1 MOTOR AWW ARNING PROTECTION JUMPER IS REMOVED FROM THE TCB BOARD The line start panel is operable as a normal across the line starter When power is applied the bypass contactor is energized tying the input terminals directly to its output terminals When the ON OFF con
36. the Thermal Register Capacity Used has exceeded this level Thermal Alarm Delay The amount of time that the Thermal Register Used must exceed the setpoint before an alarm condition will occur Thermal Register Setup Information This setpoint group will configure the thermal register and indicate to the soft starter which inputs to use when thermal modeling Cold Stall Time Enter the time from the motor manufacturer s specification sheet or use the time defined by the OL Class This setpoint is used to define the thermal capacity of the motor Hot Stall Time Enter the amount of time specified by the motor manufacturer or use half of the time defined by the OL Class Stopped Cool Down Time The time the motor requires to cool down after it has stopped Use only the data provided by the motor manufacturer This setpoint is used to configure the cooling rate of the thermal register Running Cool Down Time The amount of time the motor requires for cooling down while running Use only the data provided by the motor manufacturer Relay Measured Cool Rates When RTDs are used the soft starter can be configured to use the measured cool rates from the RTDs instead of the programmed settings This setpoint should only be enabled when RTDs are present JKSSS Series 68 SP12 4 2 3 4 2KV Thermal Register Minimum Sets the value in the thermal register which represents a motor running at the nameplate current with no overhea
37. 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 2 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 2 2 Initial Inspection Make a complete visual check of the unit for damage which may have occurred during shipping and handling Do not uw LIFT POINT attempt to continue installation or start up the unit if it is damaged Checkfor loose mechanical assemblies or broken wires which may have occurred during transportation or handling Loose electrical connections will increase resistance and cause the unit to function improperly Prior to beginning the installation verify that the motor and th jj SPREADER JKSSS unit are rated for the proper amperage and voltage re EYE BOLTS 2 3 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 is removed the top and openings Fig 1 Use of Spreader Bar
38. to the motor nameplate data or contact the motor manufacturer Acceleration Time Limit If the motor does not enter run mode reach at speed within the preset time the unit trips on acceleration time limit Number of Starts per hour If enabled this limits the maximum number of starts permitted per hour This setpoint allows a maximum of 6 starts per hour Contact motor manufacturer Time Between Starts If enabled the soft starter prevents another start attempt until the programmed time has expired JKSSS Series 62 RUN CURVE LOCKED lt ROTOR TIME O LCLAss START CURVE LOCKED ROTOR TIME O L CLASS CURRENT OVER c LEARNED START CURVE CURVE DISABLED BIAS 10 2 3 4 2KV RUN LOCKED ROTOR CURRENT 600 FLA Range 400 80096 Increments of 1 Range 1 30 SEC O L CLASS COAST DOWN TIMER TIME DISABLED Range 1 60 MIN DISABLED Increments of 1 START LOCKED ROTOR CURRENT 600 FLA Range 400 800 Range 1 30 SEC O L CLASS Incremenits of 10 Increments of 1 ACCELERATION TIME LIMIT 30 SEC Range 1 300 SEC DISABLED Increments of 1 NUMBER OF STARTS PER HOUR DISABLED Range 1 6 DISABLED Increments of 1 TIME BETWEEN STARTS TIME 5 MIN Range 1 60 MIN DISABLED Increments of 1 AREA UNDER CURVE Cc START PROTECTION DISABLED 368 FLA FLA SEC Range ENABLED or DISABLED Range 1 2500 FLA Time Sec Increments of 1
39. 0 120 SEC Increments of 1 CURRENT LIMIT 2 350 FLA Range 200 500 Increments of 10 gt 5 TYPE DISABLED Range Voltage or TM KICK START VOLTAGE 65 Range 10 10096 Increments of 5 KICK START TIME 0 50 SEC DECELERATION DISABLED Range Enabled or d Range 0 10 2 00 Increments of 0 10 TIMED OUTPUT TIME OFF Range 1 1000 sec OFF Increments of 1 START DECELERATION VOLTAGE 60 Range 0 100 Increments of 1 STOP DECELERATION VOLTAGE 30 Range 0 5996 Increments of 1 RUN DELAY TIME 1 SEC Range 0 30 sec OFF Increments of 1 DECELERATION TIME 5 SEC AT SPEED DELAY TIME 1 SEC Range 0 30 sec OFF Increments of 1 Range 1 60 Increments of 1 Range 0 300 Increments of 1 RAMP TIME 1 10 SEC Range 0 120 SEC Increments of 1 MAXIMUM CURRENT 1 350 FLA Range 200 500 Increments of 10 INITIAL CURRENT 2 200 FLA will appear Range 0 300 Increments of 1 RAMP TIME 2 10 SEC Range 0 120 SEC Increments of 1 MAXIMUM CURRENT 2 350 FLA Range 200 500 Increments of 10 JKSSS Series 47 JKSSS Series SP 2 Starter Configuration Setpoint Page 2 Provides multiple choices for starting ramps that can be selected for particular loads and applications SP2 1 Start Control Mode Start Ramp 1 Jog Start Disabled Tach Ramp Custom Accel Curv
40. 0 VR or CR 4 Options VR1 VR2 VR1 CR2 CR1 CR2 CR1 VR2 Dual Ramp Control Ramp 1 Default Ramp 2 selectable via dry contact input Begin Decel Level 0 100 of line voltage Stop Level 0 to 1 less than Begin Decel Level Decel Time 1 60 seconds Voltage Jog 5 75 Kick Voltage 10 100 Kick Time 0 1 2 seconds Shorted SCR Phase Loss Shunt Trip Phase Imbalance Trip Overload Overtemp Overcurrent Short Circuit Load Loss Undervoltage or Any Trip Coast Down Time Starts Per Hour Time Between Starts and Any Lockout Event History Data includes cause of event time date voltage power factor and current for each phase and ground fault current at time of event JKSSS Series 2 3 4 2KV 1 2 Specifications continued Metering Functions Motor Load Percent of FLA Current Data A B C Phase Current Avg Current Ground Fault Option Thermal Data Remaining thermal register thermal capacity to start Start Data Start Time Avg Start Current Measured Capacity to start time since last RTD Data Option Temperature readings from up to 12 RTDs 6 stator RTDs Voltage Metering kW kVAR PF kWH Serial Communications Modbus Signal RS 485 RS 422 or RS232 Network Up to 247 devices per mode Functionality Full operation status view and programming via communications port Operator Interface LCD Readout Alpha numeric LCD display Keypad 8 function keys with tactile feed
41. 0000 ff ff ff 1 0 sec 1 120 sec ff ff ff JKSSS Series 37 JKSSS Series 2 3 4 2KV 5 1 4 Relay Assignments Setpoint Page 4 Factory Setting 1st 2nd 3rd Trip None Trip None SIC Trip Trip Only None Overcurrent Trip None Stator RTD Trip None Non Stator RTD Trip None G F Hi Set Trip None G F Lo Set Trip None Phase Loss Trip None Accel Time Trip None Start Curve Trip None Over Frequency Trip None Under Frequency Trip None I T Start Curve None Learned Start Curve None Setpoint Security Level Seain Description Phase Reversal None Overvoltage Trip None Undervoltage Trip None None Power Factor Trip None Trip AUX1 Tach Accel Trip None Alarm AUX2 Inhibits Trip None AUX3 i AUX5 8 Bypass Discrepancy None None None Only Available in 8 Relay TCB Fault Trip None System External Input 2 None Notes Dual Ramp None AUX1 to AUX4 are for Factory Thermostat None Use only Do not change O L Warning None Only AUX 5 8 are used in the Overcurrent Alarm None 2nd amp 3rd relay assignments SCR Fail Shunt Alarm None Ground Fault Alarm None Under Current Alarm None Motor Running None Alarm None Stator RTD Alarm None Non Stator RTD Alarm None RTD Failure Alarm None Self Test Fail None Thermal Register None U V Alarm None Alarm None Power Factor Alarm None KW Demand Alarm None KVA Demand Alarm None KVAR Demand Alarm None Amps Demand Alarm None Ti
42. 1 7 Line Frequency The user may choose either 50 Hz or 60 Hz JKSSS Series 46 MOTOR FULL LOAD AMPS 200 AMPS Range 50 100 of Unit MAX CURRENT AMPS Increments of 1 SERVICE FACTOR 1 15 XFLA 1 00 1 3 Increments of 0 01 OVERLOAD CLASS 10 Range 5 30 Increments of 5 NEMA DESIGN B Range A INSULATION CLASS B Range A S LINE VOLTAGE INPUT 4160 VOLTS Range 100 7200 LINE FREQUENCY HZ 60 Range 50 or 60 JKSSS Series SP 2 Starter Configuration Setpoint Page 2 Hit DOWN ARROW one time PAGE 2 STARTER CONFIGURATION i START CONTROL MODE START RAMP 1 JOG START RAMP 1 START RAMP 2 DUAL RAMP CUSTOM ACCEL CURVE START DISABLED lt gt If VOLTAGE JOG VOLTAGE selected 50 these screens Range 5 75 or Off 5 Increments 5 will appear VOLTAGE 1 20 2 3 4 2KV If CURRENT selected these screens will appear START RAMP 1 TYPE INITIAL VOLTAGE INITIAL CURRENT 1 200 FLA Options Voltage Current or Off Range 0 100 Increments of 1 RAMP TIME 1 10 SEC Range 0 120 SEC Increments of 1 CURRENT LIMIT 1 350 FLA Range 200 500 Increments of 10 gt If VOLTAGE selected INITIAL VOLTAGE these screens 2 60 will appear Range 0 100 Increments of 1 START RAMP 2 TYPE DISABLED Options Voltage Current or Off RAMP TIME 2 10 SEC Range
43. 120VAC Max rated dry contacts LEDs provided on the TCB board for low voltage testing only 12 VDC power supply 12 VDC power supply Start start is initiated to TCB board Fault any fault has occurred Fuse Blown disconnect open or blown fuse has activated On Power Factor Correction Capacitor contacts have energized Timed Out Auxiliary time delay contacts have energized Jumper Selection BEC 2 For the following please refer to Figure 2 6 AUX C X3 DLY C X1 Start Delay ME i This is a selectable delay period between the intiation of the start command and when the CPU actually receives the start signal Selecting Jumper X1 or X2 deter Jumper Selection on TCB Board mines the method by which this delay in cycles or seconds is calculated See SW3 Figure 2 6 below for instructions on setting the actual delay time X1 7 DLY C Start time delay in cycles X2 DLY S Start time delay in seconds Factory setting Auxiliary Start Delay from the time the start input is given Selecting jumper X3 or X4 determines the method by which this delay is calculated cycles or seconds See SWA below for instructions on setting delay time AUX C Auxiliary time delay in cycles X4 AUX S Auxiliary time delay in seconds Factory setting Power Factor Correction PFC Capacitor Contactor Delay From the time the bypass closes to when contacts change state Jumper selection determines the me
44. 5 Increments of 1 Increments of 1 Increments of 1 USER PROGRAMMABLE lt EXTERNAL INPUTS Continued JKSSS Series 56 JKSSS Series SP 6 User I O Configuration Setpoint Page 6 Security Level 2 The controller can be configured to accept a tachometer feedback signal through the 4 20mA input SP6 1 The first screen of setpoint page 6 is TACHOMETER SCALE SELECTION When this is set to ENABLED the user will need to input the tachometer scale of the 4 20mA input range Manual Tach Scale 4 0 mA The unit is looking for an RPM value to assign to the lowest point on the scale This value should represent the motor at zero speed Manual Tach Scale 20 0 mA The unit is looking for an RPM value to assign to the highest point on the scale This value should represent the motor at full speed SP6 2 Tach Accel Trip Mode Select When enabled the underspeed or overspeed must be selected for the Tach Accel Trip If underspeed is selected only the Tach Underspeed Trip Point will be used If overspeed is selected only the Tach Overspeed Trip Point will be used Tach Ramp Time This is the duration of time before the tachometer begins to sample Tach Underspeed Trip The minimum value of motor RPM which must be achieved before the Tach Ramp Time sample is taken Tach Overspeed Trip The maximum motor RPM allowed when the Tach Ramp Time sample is taken Tach Accel Trip Delay The duration of time that the Tac
45. AGE 27 LEVEL for the proper cooling time i L TIME 3 4 Deceleration Adjustments Pump Control E AMBAE Decel extends the stopping time on loads that would otherwise stop too quickly if allowed to coast to stop Decel control provides smooth deceler ation until the load comes to a stop Three adjustments optimize the deceleration curve to meet the most demanding requirements The unit is shipped from the factory with the decel feature disabled Deceleration Applications The unit is shipped from the factory with the decel feature disabled Apply power and adjust the soft start before enabling or modifying the deceleration adjustments Both acceleration and deceleration adjust ments should be made under normal load conditions Coasting Stop using Electro Mech starter Check Valve Open The deceleration feature provides a slow decrease in the output voltage accomplishing a gentle decrease in motor torque during the stopping mode This is the OPPOSITE OF BRAKING in that it will take longer to come to a stop than if the starter were just turned off The primary use of this function is to reduce the sudden changes in pressure that are associated with Water Hammer and slamming of check valves with centrifugal pumps Decel control in pump applications is often referred to as Pump Control Check Valve Closed In a pump system liquid is being pushed uphill The force exerted by gravity on the column of liquid as it goes up h
46. ATISTICS MP7 Statistics Metering Page 7 Displays the statistical trip information Screen 1 Screen 2 Screen 3 Screen 4 Screen 5 Screen 6 Screen 7 Screen 8 Screen 9 Screen 10 Screen 11 Screen 12 Screen 13 Screen 14 Screen 15 Screen 16 Screen 17 Screen 18 Screen 19 Screen 20 Screen 21 Screen 22 Screen 23 Screen 24 Screen 25 Displays the total of megawatt hours Displays the accumulated total running hours Clears the total running hour count Displays the total number of trips since the last clearing the statistical data and the total number of short circuit trips Displays the numbers of start overload and run overload trips since the last clearing of the statistical data Displays the number of frequency trips and Imbalance trips Displays the number of overcurrent trips Displays the number of Stator and non Stator RTD Trips Displays the number of Ground Fault Hi and Lo Set trips Displays the number of acceleration time trips Displays the number of start under curve trips Displays the number start over curve trips Displays the number of start curve trips Displays the number of learned start curve trips Displays the number of fail shunt trips Displays the number of phase loss trips Displays the number of tachometer acceleration trips Displays the number of undervoltage and overvoltage trips Displays the number of power factor trips Dis
47. Custom Acceleration Curve Setpoint Page 7 Security Level 3 SP7 1Setpoint Page 7 allows the user to custom design the acceleration curve start curve to the specific application The user can custom design up to three different curves in the soft starter Only one curve can be active enabled at a time Each of the three curves has eight voltage levels with corresponding ramp times and a current limit setting Note Each successive voltage level must be programmed to a voltage level equal to or greater than the previous level All eight levels of voltages must be programmed and the eighth level has been preset at 10096 If Custom Accel Curve has been set to curve A B or C on this page the soft starter will override the Start Control Mode selected in Setpoint Page 2 even if Start Control Mode in Setpoint Page 2 has not been set to Custom Accel Curve Note Setpoint Page 7 has a security level 3 requirement CUSTOM CURVE C CURVE C VOLTAGE LEVEL 6 67 Range 0 100 Increments of 1 CURVE C RAMP TIME 6 2 SEC Range 1 60 SEC Increments of 1 CURVE C VOLTAGE LEVEL 7 82 Range 0 10096 Increments of 1 CURVE C RAMP TIME 7 2 SEC Range 1 60 SEC Increments of 1 CURVE C VOLTAGE LEVEL 8 100 Range 0 100 Increments of 1 CURVE C RAMP TIME 8 2 SEC Range 1 60 SEC Increments of 1 CURVE C CURRENT LIMIT 350 FLA Range 200 600 Increments of 10
48. E SP7 1Setpoint Page 7 allows the user to custom design the acceleration curve start curve to the specific application The user can custom design up to three different curves in the soft starter Only one curve can be active enabled at a time Each of the three curves allow for eight voltage plotting points with corresponding ramp times and a current limit setting Note Each successive voltage level must be programmed to a voltage level equal to or greater than the previous level All eight levels of voltages must be programmed and the eighth level has been preset at 10096 f Custom Accel Curve has been set to curve A B or C on this page the soft starter will override the Start Control Mode selected in Setpoint Page 2 even if Start Control Mode in Setpoint Page 2 has not been set to Custom Accel Curve Note Setpoint Page 7 has a security level 3 requirement CUSTOM ACCEL CURVE DISABLED Range DISABLED CURVE A Bor C CUSTOM CURVE A 2 3 4 2KV CURVE A VOLTAGE LEVEL 1 25 Range 0 100 Increments of 1 CURVE A RAMP TIME 1 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 2 30 Range 0 10096 Increments of 1 CURVE A RAMP TIME 2 2 SEC Range 1 60 SE Increments of 1 ae CURVE A VOLTAGE LEVEL 3 37 Range 0 100 Increments of 1 CURVE A RAMP TIME 3 2 SEC Range 1 60 SEC 1 Increments of 1 CURVE A VOLTAGE LEVEL 4 45
49. EC 2 3 4 2KV Range 2 4 4 8 9 6 19 2 38 4 KB SEC SET MODBUS BAUD RATE 9 6 KB SEC Range 2 4 4 8 9 6 19 2 38 4 KB SEC MODBUS ADDRESS NUMBER 247 Range 1 247 Increments of 1 SET ACCESS CODE CODE 1 Range 1 999 Increments of 1 SET LINK BAUD RATE 38 4 KB SEC Range 2 4 4 8 9 6 19 2 38 4 KB SEC REMOTE START STOP DISABLED Option Enabled or Disabled JKSSS Series 2 3 4 2KV SP 12 System Setpoints Setpoint Page 12 Security Level 3 Hit DOWN ARROW eleven times PAGE 12 SYSTEM DEFAULT DISPLAY SETPOINTS SCREEN ALARMS THERMAL REGISTER SETUP INFORMATION METERING DATA METERING DATA lt gt PAGE 1 lt SCREEN 1 Enter Metering Page 1 4 Enter Metering Number for display Screen Number for display RTD FAILURE ALARM ALARM DISABLED Enabled or Disabled THERMAL REGISTER lt gt THERMAL ALARM ALARM 90 DELAY 10 SEC Range Off 40 9596 Range 1 20 SEC Increments of 1 Increments of 1 COLD STALL TIME OIL CLASS Range O L CLASS 4 40 SEC Increments of 1 HOT STALL TIME 1 2 O L CLASS Range 1 2 O L CLASS 4 40 SEC Increments of 1 STOPPED COOL DOWN TIME 30 MIN Range 10 300 MIN Increments of 1 RUNNING COOL DOWN TIME 15 MIN Range 10 300 MIN Increments of 1 RELAY MEASURED COOL RATES DISABLED Range ENABLED or DISABLED THERMAL REGISTER MINIMUM 15 Range 10 5096 OFF Incr
50. GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT LEVEL 2 5 RELAY CONFIGURATION PAGE6 USER I O CONFIGURATION PAGE7 CUSTOM ACCELERATION CURVE PAGE8 OVERLOAD CURVE CONFIGURATION LEVEL 3 PAGE 10 SECURITY SET PASSWORD PAGE 11 COMMUNICATIONS LEVEL amp SERVICE PAGE9 RTD CONFIGURATION PAGE 12 SYSTEM SETPOINTS JKSSS Series 45 SP 1 Basic Configuration Setpoint Page 1 In Setpoint Page 1 the starter is looking for the following basic nameplate data of the motor SP1 1 Motor Full Load Amps Allows the user to enter the motor s FLA rating Range of adjustment is 50 100 less programmed service factor SP1 2 Service Factor Sets the pickup point on the overload curve as defined by the programmed motor full load current Ex If the motor FLA is 100 and the service factor is 1 15 the overload pickup point will be 115 Amps SP1 3 Overload Class Choose the motor protection overload class range from 5 30 Ex Overload Class 10 will trip in 10 seconds at six times FLA Overload Class 30 Overload Class 25 Overload Class 20 Overload Class 15 Overload Class 10 Overload Class 5 SP1 4 NEMA design The motor design maximum allowed slip Select from Class A through F SP1 5 Insulation Class The motor insulation temperature class Select E F H K Nor S SP1 6 Line Voltage Input Applied Voltage SP
51. HHH GIF HEHE HHHHE P F HHHH All events will be viewed from oldest event in buffer to most recent event The events are listed from oldest to most recent Screen 1 Displays the event i e Imbalance Trip with the date and time it occurred Screen 1a Displays the current of Phase A B C and the ground fault at the time of the trip Screen 1b Displays the Vab Vbc Vca and power factor at the time of trip JKSSS Series 77 JKSSS Series MP 6 Last Trip Metering Page 6 Displays the information regarding the last trip Screen 1 Displays the cause of the last trip Screen 2 Displays the measured phase current at the time of the trip Screen 3 Displays the Vab Vbc Vca and power factor at the time of trip Screen 4 Displays the imbalance percentage the frequency and the kW at the time of the trip Screen 5 Displays the hottest stator RTD temperature at time of the trip Screen 6 Displays the hottest non stator RTD temperature at the time of the trip JKSSS Series 78 METERING PAGE 6 H 2 3 4 2 Screen 1 cause of trip lt gt value at time of trip Screen 2 la Ib HHEE lc HHHE GIF fHHELE Screen 3 Vab Voc THHHHEL Vca P F Screen 4 VB Hz KW IHEHHHHEL Screen 5 HOTTEST STATOR RTD st Screen 6 1 HOTTEST NON STATOR RTD C JKSSS Series J METERING PAGE 7 lt gt ST
52. IMOTOR A UNKNOWN STATE displays relay state upon error Screen 6 STARTS PER HOUR TIME 3HE THE IHE THE THE IHE HEHE Screen 2 Displays the amount of time remaining before an overload trip will occur Screen 3 Displays the amount of time remaining from a thermal inhibit The inhibit time comes from the amount of thermal register remaining versus the amount of thermal capacity required to start Screen 4 Displays the coast down time remaining Backspin time The time remaining depends upon the user setting in Setpoint Page 8 Coast Down Time Screen 5 Displays the amount of time remaining before a start command can be given Screen 6 If the number of starts per hour has exceeded the setting JKSSS Series 76 JKSSS Series 2 3 4 2 MP 5 Event Recorder 60 Events Metering Page 5 MENU Screen 1 Screen 1a Screen 1b METERING PAGE 5 lt cause of event lt gt HHHH 1B lt Vab IHHHHHE Event Recorder 60 event ist HHEH HEHH GIF THEHHE Vca PIF Event lt of event gt lt gt Vab THHHHHE HEHEHEHEHE PIF HHHH lt of event gt HHHHHE 1B lt gt Vab HHHHHE Vbc E HHHH GIF 995 Vea PIF HHHE lt cause of event gt IA HHHHHE 1B 9558 lt gt Vab Vbc THHHHBE SITE HEHE H
53. Low Voltage section in order to satisfy UL termination require ments and does not connect directly to the medium voltage components other than the contactor coils This board contains the user terminal blocks output relays duplicated inputs and control power connections It also contains ad ditional timed relays for interfacing with Power Factor Correction contactors if used and other external devices Please note Power Factor Capacitor warn ings in Section 2 8 Gate Drive Boards located directly on the SCR stacks These boards com municate to the Main Power board via fiber optic cables They amplify the gate pulse signals with power from the Ring Transformers to create the Sustained Pulse Firing of the SCRs There is one Gate Drive board for each pair of SCRs in each stack Temp CT Boards are attached to the Gate Drive boards on the SCR stacks and provide the heat sink temperature and current signals back to the Main Power Board via fiber optic cables MOV Boards are attached to standoffs mounted on the SCR heat sinks and are mounted directly below the Gate Drive boards The MOV boards are used to protect the gate cathode section of the SCRs Boards are also attached to standoffs mounted on the SCR heat sinks and are mounted below the MOV boards The DV DT boards are used to re duce voltage transients across the stack assemblies JKSSS Series 11 JKSSS Series 2 3 4 2KV Chapter 2 Installation For a
54. ND TIME ENTER DATE DDMMYYYY ENTER TIME hh mm Range D 1 31 1 12 Range 00 23 0 59 1970 2069 Increments of 1 Increments of 1 MODEL HHHHE FIRMWARE REV PRESS ENTER TO ACCESS FACTORY SETTINGS SP 13 Calibration amp Service Setpoint Page 13 Certain screens are displayed for user information only such as Current date and time Model number and Firmware revision number Setpoint changes in this page will only be accessible to factory personnel SP13 1 Set Date and Time Displays the date and time Enter Date DDMMYYYY Allows the factory personnel to program the date for the soft starter in the format shown Enter Time hh mm Allows the factory personnel to program the time for the soft starter SP13 2 Model amp Firmware Displays the model number and firmware revision in the soft starter SP13 3 Press Enter to Access Factory Settings Available to qualified personnel JKSSS Series 69 JKSSS Series Chapter 6 Metering Pages The soft starter offers performance metering which gives the user the ability to view information about the motor and the JKSSS unit 6 1 Metering Page List The following charts list each Metering Page and the functions within that page The applicable section of the manual is also referenced 6 1 1 Metering Menu amp Data Metering Page 1 Metering Page Description of Display Phase A B C and Ground Fault Option Avera
55. OFF 1 100000 Increments of 1 KVAR DEMAND ALARM PICKUP OFF KVAR Range OFF 1 100000 Increments of 1 AMPS DEMAND ALARM PICKUP OFF AMPS Range OFF 1 100000 Increments of 1 SP3 10 Ground Fault Hiset Trip Level Used to trip the motor within milliseconds upon detecting a high level of ground current leakage This setpoint is intended to detect low impedance faults Ground Fault Hiset Trip Delay The amount of time that the ground fault condition must exist before a trip will occur SP3 11 Overvoltage Alarm Level Typically used to indicate when the line voltage is too high This is an alarm level Overvoltage Alarm Delay The amount of time that the overvoltage condition must exist before a trip will occur JKSSS Series 51 JKSSS Series SP3 12 SP3 13 SP3 14 SP3 15 SP3 16 SP3 17 Overvoltage Trip Level Typically used to indicate that the line voltage is too high and at which point a trip occurs Overvoltage Trip Delay The amount of time that the overvoltage condition must exist before a trip will occur Undervoltage Alarm Level Typically used to indicate when the line voltage is too low This is an alarm level Undervoltage Alarm Delay The amount of time that the overvoltage condition must exist before a trip will occur Undervoltage Trip Level Typically used to indicate that the line voltage is too low and at which point a trip occurs Undervoltage Trip Delay T
56. OM CURVE C LEVEL 1 25 0 100 Increments of 1 lt CURVE C RAMP TIME 1 2 SEC Range 1 60 SEC Increments of 1 CURVE C VOLTAGE LEVEL 2 30 Range 0 100 Increments of 1 CURVE C RAMP TIME 2 2 SEC Range 1 60 SEC Increments of 1 lt CURVE C VOLTAGE LEVEL 3 37 Range 0 100 Increments of 1 CURVE C RAMP TIME 3 2 SEC Range 1 60 SEC Increments of 1 CURVE C VOLTAGE LEVEL 4 45 Range 0 100 Increments of 1 CURVE C RAMP TIME 4 2 SEC Range 1 60 SEC Increments of 1 CURVE C VOLTAGE LEVEL 5 55 Range 0 100 Increments of 1 lt CURVE C RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 CURVE B VOLTAGE LEVEL 2 30 Range 0 100 Increments of 1 lt CURVE B RAMP TIME 2 2 SEC Range 1 60 SEC Increments of 1 CURVE B VOLTAGE LEVEL 3 37 Range 0 100 1 Increments of 1 lt CURVE B RAMP TIME 3 2 SEC Range 1 60 SEC Increments of 1 CURVE B VOLTAGE LEVEL 4 45 Range 0 100 Increments of 1 lt CURVE B RAMP TIME 4 2 SEC Range 1 60 SEC Increments of 1 CURVE VOLTAGE LEVEL 5 55 Range 0 100 Increments of 1 CURVE RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 CURVE B VOLTAGE LEVEL 6 67 Range 0 100 Increments of 1 lt CURVE B RAMP TIME 6 2 SEC Range 1 60 SEC Increments of 1 JKSSS Series 60 JKSSS Series 2 3 4 2 SP 7
57. Password Protection 0 240C 32 464F Off E ff x pr of pr SamssSeorPhseM 0 240C 32 464F Off 0 240C 32 464F Off 0 240C 32 464F Off 120 OHM NI 100 OHM NI 100 OHM PT 10 OHM CU 0 240C 32 464F Off or Off 32 ff Off Off Off Off ff ff ff SP9 4 ff ff ff ff ff ff ff ff ff ff ff ff ff ff JKSSS Series 42 JKSSS Series 2 3 4 2KV 5 1 9 RTD Configuration Page 9 Cont d Setpoint Security Page Level Factory Setting Default Romie Description Range Section J 5 1 10 Security Set Password 10 RTD Configuration Password Protection Setpoint Security Page Level Factory Setting Default Set Level 2 Password 000 999 Three Digits SP10 1 Set Level 3 Password 1000 0000 9999 Four Digits SP10 2 5 1 11 Communications Page 11 Description Section Setpoint Security Page Level Factory Setting Default Modbus Numer sens 28 Remote Start Stop Disabled Enabled or Disabled SP11 6 Description Range Section Password Protection 9 5 9 5 JKSSS Series 43 JKSSS Series 2 3 4 2KV 5 1 12 System Setpoint Page 12 Factory Setting Default Metering Data Page Enter Metering Page 1 4 Enter Metering Screen Page 1 1 10 Metering Data Screen
58. R testing or disconnect is procedure open Short circuit or ground fault in motor cabling Phase Loss Repair cause of phase loss Branch circuit protection Verify correct sizing of branch circuit Short Circuit Trip SHORT CIRCUIT TRIP not correctly protection Faulty main circuit board 22 power and replace main circuit Remove power and test SCR s Refer to Faulty SCRs Section 7 1 1 for the SCR testing procedure Locate and remove short or ground Single phase incoming Correct problem with incoming power SINGLE PHASE TRIP power Single Phase Trip Check LCD display for possible fault indicators Faulty SCRs Section 7 1 1 for the SCR testing procedure Remove power and test SCR s Refer to If fans have power remove power and replace fan s If fans do not have power find cause of power loss and repair Fan s not functioning If supplied Remove power and clean heatsink with Heatsink coated with dirt high pressure air 80 100 psi max clean and dry air Thermostat trips EXTERNAL TRIP ON Overcurrent on unit Verf that running current does not during run THERMOSTAT exceed unit rating Environment temperature over 122 F ambient temperature for chassis units or over 104 F ambient temperature for enclosed version Bypass failed to close bypass contactor and wiring Place unit in environment temperature less than 122 F for panel version or less than 104 F for enclosed ver
59. RM UNDERCURRENT ALARM MOTOR RUNNING IMBALANCE ALARM STATOR RTD ALARM NON STATOR RTD ALARM RTD FAILURE ALARM SELF TEST FAIL THERMAL REGISTER U V ALARM O V ALARM POWER FACTOR ALARM KW DEMAND ALARM KVA DEMAND ALARM KVAR DEMAND ALARM AMPS DEMAND ALARM TIMED OUTPUT RUN DELAY TIME AT SPEED Ground fault option must be installed JKSSS Series 54 RELAY ASSIGNMENTS 15 2nd TRIP ONLY NONE TRIP AUX1 NONE TRIP ONLY NONE TRIP AUX1 NONE NONE NONE NONE NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP ONLY NONE TRIP ONLY NONE NONE NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP AUX1 NONE TRIP AUX1 NONE NONE NONE NONE NONE TRIP AUX1 NONE NONE NONE NONE NONE TRIP AUX1 NONE NONE NONE NONE NONE TRIP AUX1 NONE ALARM AUX2 NONE ALARM AUX2 NONE ALARM AUX2 NONE ALARM AUX2 NONE NONE NONE AUX3 NONE ALARM AUX2 NONE NONE NONE NONE NONE NONE NONE TRIP AUX1 NONE ALARM AUX2 NONE ALARM AUX2 NONE ALARM AUX2 NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE AUX4 NONE 3rd NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE NONE JKSSS Series SP 5 Relay Configuration Setpoint Page 5
60. Range 0 100 Increments of 1 CURVE A RAMP TIME 4 2 SEC Range 1 605 Increments of 1 ITI OJ CURVE A VOLTAGE LEVEL 5 55 Range 0 100 Increments of 1 lt gt CURVE A RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 6 67 Range 0 100 Increments of 1 CURVE A RAMP TIME 6 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 7 82 Range 0 100 Increments of 1 CURVE A RAMP TIME 7 2 SEC Range 1 60 SEC Increments of 1 JKSSS Series 59 A SP 7 Custom Acceleration Curve Setpoint Page 7 Security Level 3 Y CURVE A VOLTAGE CURVE B VOLTAGE CUSTOM CURVE A LEVEL 8 100 CUSTOM CURVE B VEVEL 7 82 Range 0 100 Increments of 1 Range 0 10096 Increments of 1 CURVE A RAMP CURVE B RAMP TIME 8 2 SEC TIME 7 2 SEC Range 1 60 SEC Range 1 60 SEC Increments of 1 Increments of 1 lt CURVE CURRENT LIMIT 350 FLA Range 200 500 Increments of 10 CURVE B VOLTAGE LEVEL 8 100 Range 0 100 Increments of 1 CURVE B RAMP TIME 8 2 SEC Range 1 60 SEC Increments of 1 lt CURVE B VOLTAGE CUSTOM CURVE B LEVEL 1 25 Range 0 100 Increments of 1 lt CURVE B CURRENT LIMIT 350 FLA Range 200 500 Increments of 10 lt CURVE B RAMP TIME 1 2 SEC Range 1 60 SEC Increments of 1 i CURVE C VOLTAGE CUST
61. Security Level 2 In Setpoint Page 5 the user can configure the four output relays as either fail safe or 5 RELAY non fail safe and latching or CONFIGURATION lt _ non latching SP5 1 When a relay has been configured as fail safe and power is applied the relay will be energized The relay will then de energize when an event occurs or if the power fails Note The relays in the soft starter will not prevent a start sequence unless they are wired in as interlocks If power is lost the motor power is also lost Do not change the programming for AUX 1 4 These are for factory use only AUX 5 8 are user defined outputs SP5 2A relay configured as non latching will reset itself when the cause of the trip event is not continuous The TRIP AUX1 relay should always be programmed for latching because this trip should require a visual inspection of the motor and starter before issuing a manual reset to release the relay after a trip has been stored Hit DOWN ARROW four times 2 3 4 2 AUX1 RELAY TRIP AUX1 RELAY FAIL SAFE NO LATCHED YES Options Yes or No ALARM AUX2 RELAY lt gt ALARM AUX2 RELAY FAIL SAFE LATCHED AUX 3 RELAY AUX3 RELAY FAIL SAFE NO LATCHED NO AUX4 RELAY lt gt AUX4 RELAY FAIL SAFE NO LATCHED NO AUX5 RELAY lt _ AUX5 RELAY FAIL SAFE LATCHED NO AUX6 RELAY AUX6 RELAY FAIL SAFE LATCHED
62. TOSHIBA Document VF010H05 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE JKSSS Plus Series Medium Voltage Solid State Starters Firmware Rev 6 96 Issued 9 09 Manufactured in the USA SAFETY IMPORTANT MESSAGES Read this manual and follow its intructions Signal words such as DANGER WARNING and CAUTION will be followed by important safety information that must be carefully reviewed Indicates a situation which will result in death serious injury and severe property damage if you do not follow instructions Means that you might be seriously injured or killed if you do not follow instructions Severe Ay ARNING property damage might also occur ACAUTION Means that you might be injured if you do not follow instructions Equipment damage might also occur NOTE Give you helpful information Note The contents of this manual will not become apart of or modify the warranty policy The terms of which are set forth at the end of this manual READ SAFETY SIGNS To avoid injury you must read and follow all safety signs Keep the safety signs visible and in good shape Never remove or cover any safety sign ADANGER QUALIFIED OPERATORS ONLY Only qualified persons are to install operate or service this equipment according to all applicable codes and established safety practices A qualified person must 1 Carefully read the entire instruction manual 2 Be skilled in the inst
63. a current imbalance condition Normal Cooling Provided when the motor current drops below the pick up point or the motor is off line The cooling rate is lower for motors that are off line such as after a trip since cooling fans are also inoperative 2 3 4 2KV JKSSS Series 9 JKSSS Series 2 3 4 2KV RTD Input Will bias the register in either direction based on real time input of the motor bearing and even ambient temperature conditions Dynamic Reset is another feature that adds reliability and consistency to the performance of the soft starter If a motor overload condition occurs and the soft starter trips it cannot be reset until sufficient cool down time has elapsed This cool down time is determined by the thermal state of the motor when it tripped i e hot motors cool more quickly due to additional convection The cool down time is also biased by RTD measurements when used Retentive Memory provides continuous overload protection and real time reset even if power is lost Upon restoration of power the soft starter will read the Real Time Clock and restore the thermal register to what it should be given the elapsed time Learned Reset Capacity is a feature that is unique to the JKSSS Series sampling the amount of thermal capacity used in the previous three successful starts the soft starter will not allow a reset until a sufficient amount of thermal capacity has been regained in the motor This prev
64. age is for an extended period The unit should be checked for condensation moisture corrosion and vermin Prior to installation the starter should be carefully examined for evidence of physical damage corrosion or other deterioration The MAINTENANCE section of this manual describes various types of inspections recommended for this starter during the operation period JKSSS Series 2 3 4 2 WARRANTY AND LIMITATION OF LIABILITY Toshiba International Corporation Company warrants that all equipment and parts described herein will be free from defects in materials and workmanship THIS WARRANTY WILL EXPIRE TWENTY FOUR 24 MONTHS AFTER SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE PLACED IN OPERATION OR THIRTY 30 MONTHS AFTER THE DATE ON WHICH SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE SHIPPED TO THE INITIAL PURCHASER WHICHEVER PERIOD FIRST EXPIRES THERE ARE NO OTHER WARRANTIES WHETHER EXPRESS IMPLIED STATUTORY OR OTHER WISE INCLUDING THEIMPLIED WARRANTIES ORMERCHANTABILITYAND FITNESS FORAPARTICULAR PURPOSE The Company will at its option repair or replace or refund the purchase price paid for such equipment or part which is defective under the terms of the foregoing warranty free of charge provided the purchaser 1 promptly notifies the Company in writing of such def
65. allation construction or operation of the equipment and aware of the hazards involved 3 Be trained and authorized to safely energize de energize clear ground lockout and tag circuits in accordance with established safety practices 4 Be trained and authorized to perform the service maintenance or repair of this equipment 5 Be trained in the proper care and use of protective equipment such as rubber gloves hard hat safety glasses face shield flash clothing etc in accordance with estab lished practices 6 Be trained in rendering first aid SAFETY SAFETY CODES Toshiba motor control is designed and built in accordance with the latest applicable provisions of NEMA and the National Electrical Code Installations must comply with all applicable state and local codes adhere to all applicable National Electric Code NFPA 70 standards and instructions provided in this manual HAZARDOUS VOLTAGE will cause severe injury death fire explosion and property damage Turn off and lock out Primary and Control Circuit Power before servicing Keep all panels and covers securely in place Never Defeat Modify or Bypass any Safety Interlocks Qualified Operators only AWARNING Never attempt to install operate maintain or dispose of this equipment until you have first read and understood all of the relevant product warnings and user directions that are contained in this Instruction Manual Use only Tosh
66. anent record of all maintenance work Ata minimum this record should include information on Items inspected Reports of any testing Equipment condition Corrective actions or adjustments Date of work Comments The degree of detail of the record will depend somewhat on the operating conditions SERVICING EQUIPMENT For your safety turn off and lock out main and control circuit power before servicing the starter Certain minimum safety procedures must be followed 1 Only qualified personnel should attempt this service 2 Never perform service on or next to exposed components energized with line voltage Failure to adhere to these safety procedures can result in severe injury death and property damage JKSSS Series 97 JKSSS Series JKSSS Series 98 2 3 4 2 DISPOSAL Contact your state environmental agency for details on disposal of electrical components and packaging in your particular area STORAGE If the starter is to be stored for any length of time prior to installation the following precautions should be taken 1 The original packing should be restored if possible 2 Do not subject the equipment to moisture or sun rays Store in cool clean and dry location 3 Place a dust cover over the starter packaging to protect against dirt and moisture 4 Store in an upright position INSPECTION DURING STORAGE Routine scheduled inspection is necessary if stor
67. anging Motor FLA A Press MENU button to display Setpoint Page 1 Basic Configuration B Press the RIGHT ARROW you will view the screen Motor Full Load Amps C Press the ENTER button for edit mode Note the asterisk in the top right corner of the LCD screen that indicates Edit Mode D To change the value select the UP ARROW or DOWN ARROW E To accept the new value press the ENTER button The unit will accept the changes and will leave the edit mode Note the is no longer in the top right corner of the LCD Display MENU PAGE1 BASIC MOTOR FULL LOAD AMPS CONFIGURATION 140 AMPS MOTOR FULL LOAD 2x 142 AMPS ENTER MOTOR FULL LOAD AMP 142 AMPS JKSSS Series 35 JKSSS Series 2 3 4 2KV Chapter 5 Setpoint Programming The JKSSS Series has thirteen programmable setpoint pages which define the motor data ramp curves protection I O configuration and communications In Section 5 1 the setpoint pages are outlined in chart form In Section 5 2 the setpoint pages are illustrated and defined for easy navigation and programming Note Setpoints can only be changed when the starter is in the Ready Mode Also the soft start will not start when it is in programming mode 5 1 Setpoints Page List These charts list the Setpoint Page the programmable functions and the section 5 1 1 Basic Configuration Setpoint Page Setpoint Security
68. art Only packages must be used with complete line isola tion using a contactor or other air gap device The Optional Soft Start Only includes overload protection in normal operation mode and will sequence the isolation contactor so all logic control should be done at the JKSSS control unit Avoid turning the JKSSS on and off using the isolation device 1 4 Structure and Power Bus The JKSSS Series is a heavy duty design Special consideration has been given to the enclosure and unit design to ensure that it is suitable for most applications and environments e Structure 11 gauge frame with 16 gauge side back and top sheets Doors are 12 gauge steel The enclosure assembly is NEMA EEMAC type 1 as standard Type 12 and 3R are available as an option e Sections In a typical arrangement each enclosure is divided vertically into three major compartments each with a separate door In the JK400 the upper most and lowermost compartments contain medium voltage controller compo nents gt 600 while the middle compartment contains low voltage components 600V Other variations of this basic arrangement are possible The Main Incoming Power Compartment houses the main disconnect switch amain power fuses and input isolation contactor A viewing window provides clear indication of the switch position without opening the compartment Main Bus Compartment contains the horizontal bus bars if provided Top bottom or side cable entry ca
69. artment AVARNING Do not install or energize equipment that has been damaged ACAUTION Do not lay the equipment on its side or upside down Handling and Moving Medium voltage motor controllers should be handled with care to avoid damage to components and to the frame or its finish 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 equipment being lifted Improperly secured equipment can fall or tip over quickly and without notice AsV ARNING 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 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 1 should be used to provide the vertical lift on single controllers to prevent eye bolt failure JKSSS Series 12 JKSSS Series 2 3 4 2KV Always keep
70. ation 5 2 Setpoint Page 10 Displays Set Password 5 2 Setpoint Page 11 Displays Communications 5 2 setpoint Page 12 Displays System 67 68 Setpoints 52 Setpoint Page 13 Displays Calibration amp Service Metering Page List 70 71 Metering Page 1 Displays Metering Data Metering Page 2 Displays Metering Metering Page 3 Displays RTD Values 73 Overload Curve Definition sa Typical Wiring Diagram 86 87 Spare Parts List 88 89 PCB Mounting Order Stack Replacement amp PCB Mounting 90 93 Instructions for Low Voltage Test 97 98 JKSSS Series 2 3 4 2 Chapter 1 Introduction This chapter is an introduction to the Toshiba Series reduced voltage solid state starter for medium voltage AC motors It describes the basic configuration operation and unit features It is highly recommended that new users read this section thoroughly to gain a basic understanding of the starter system before attempting to start up a unit If you are already familiar with the JKSSS Series starter you may begin setup procedures immediately by proceeding to Chapter 2 Installation 1 1 Overview The standard JKSSS Series solid state starter is a complete NEMA Class E 2 motor controller designed for the starting protection and control of AC medium voltage motors It contains the motor disconnect switch motor circuit fuses control power transformer a line isolation contactor SCR stack assemblie
71. ays Pis communicates to the CPU via a serial link and if necessary be remotely mounted up to 1000 from the soft starter 59 CPU Board where the microprocessor and communications coprocessor reside It is attached to the main power board and communicates to it and the Keypad Operator Interface via serial links The CPU determines operating functions stores user programming and acts upon feedback signals for faults metering and historical data This board also contains the flash EPROM and SRAM memory as well as the Analog I O and terminations Keypad Operator Interface Main Power Board is also referred to as the Firing Board It contains the Digital I O relays and interfaces to the TCB board see below for user inter face It also controls the sequencing of the Isolation and Bypass contactors with the SCR firing This board generates all firing signals for the SCR stacks and receives feedback signals from fiber optic transmitters It converts analog levels to digital signals for the CPU These firing pulses are via fiber optic signals to isolate them from the Medium Voltage environment Control Electronics are located in the medium voltage and low voltage sections of the soft starter The main line power must be disconnected before these electronics can be accessed They include the TCB Gate Drive and Temp CT boards TCB Terminal and Control Board is the user connection interface board It is located in the
72. back Status Indicators 12 LEDs include Power Run Alarm Trip Aux Relays Remote Mount Capability e ug circuit feet from chassis use twisted shielded wire amp power Clock and Memory Operating Memory SRAM loaded from EEPROM at initialization Factory Default Storage Flash EPROM field replaceable Customer Settings and Status Non volatile EEPROM no battery backup necessary Real Time Clock Lithium ion battery for clock memory only JKSSS Series 3 JKSSS Series 1 3 Design Features The standard JKSSS configuration is a complete NEMA Class E 2 motor controller which includes the following features Isolation Switch 2 3 4 2KV An isolation switch is provided in the incoming power section of the starter assembly The maximum voltage is 7200V Power is switched on and off to the controller by a fixed mounted externally operated three pole isolation switch When the switch is in the opened 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 opened This allows any stored energy in the controller load circuit to be discharged by closing the contactor using test power A viewing window in the Main Incoming Power Compartment allows visual inspection of the disconnect blade status with the medium voltage door closed The external operating handle for the isolation swit
73. binet Entries Bonum If conduit entry locations are required in areas other than the BOTTOM PLATE y removable plates cover the electrical assemblies to prevent 2 metal filings from becoming lodged areas which may cause a reduction in the high voltage clearances or a short circuit Yes Yj After the work is completed thoroughly clean the area and reinspect the unit for foreign material FOR ANCHOR BOLT LOCATIONS SEE FLOOR PLAN DRAWINGS FURNISHED WITH EQUIPMENT 2 7 Pre energization Check 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 Fig 4 Securely Anchor the Controller JKSSS Series 15 JKSSS Series 2 3 4 2KV There is rating data label on the inside of each medium voltage compartment door Verify that the controller ratings properly match the system data by checking the follow ing 1 Verify agreement of full load current locked rotor current and acceleration time with motor 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 c
74. c HELP setpoint or action Will scroll up through the setpoint and metering menu page It will scroll to the top of the setpoint page or a Button UP ARROW section In edit mode it will increase a setpoint in an incremental step or toggle through the available options in the setpoint Keypad Operator Interface In the main menu the RIGHT ARROW button provides access to the setpoint page For setpoint pages with RIGHT ARROW multiple columns the RIGHT ARROW will scroll the setpoint page to the right When in edit mode it will shift one character to the right Will scroll down through the setpoint pages and down through the setpoints In edit mode it will decrement through values and toggle available options in the setpoint Will move to the left through setpoint pages with multiple columns When in edit mode it will become the backspace key and will shift one character to the left Power Indicates control power is present Run Indicates unit motor is running Lights in conjunction with AUX 2 to indicate event or warn of possible critical condition Lights in conjunction with AUX 1 to indicate critical Trip condition has occurred AUX1 8 Auxilary relays Note The directional arrow buttons are sensitive In edit mode if the buttons are held for a long period the scrolling speed will increase DOWN ARROW LEFT ARROW JKSSS Series 33 JKSSS Series 2 3 4 2KV 4 2 Menu Navigatio
75. ch is designed to accept up to three external padlocks in the OFF position For additional information on the isolation switch see instruction manual VF010H01 VF010H02 or VF010H03 Power Fuses As a NEMA Class E2 controller current limiting primary power fuses are provided for each incoming phase Typically the fuses are ANSI class R for units rated up to 4800V The fuses are sized according to motor locked rotor current and are coordinated with the solid state overload relay The fuse and overload coordination is designed to allow the controller and contactor to clear low and medium level faults This prevents exceeding the contactor interrupt ratings Fuses interrupt high level faults that exceed the contactor interrupt ratings Fuse holders include blown fuse indicators wired to the isolation contactor circuit to disconnect all three phases if any one of the fuses clears see section 2 7 SCR Power Modules For each phase the SCRs are matched devices arranged in inverse parallel pairs and in series strings as indicated in the chart to facilitate sufficient PIV ratings for the applied voltage RC Snubber Networks Provide Transient Voltage Protec tion for SCR Power Modules in each phase to reduce dv dt damage Firing Circuit The SCRs are gated turned on using a Sustained Pulse Firing Circuit This circuitry is amplified and isolated from the control voltage by means of fiber optics for current and ring transformers
76. 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 b Ground leads should be connected to cable potheads shields as specified by the manufacturer of these de vices CUBICLE SPLIT TOP VIEW 3 8 16 NUT 3 8 LOCK WASHER SPLICE LINK 1 4 X 2 COPPER PART PC18598P115 5 8 FLAT WASHER 3 8 FLAT WASHER 3 8 HEX SPIN LOCK NUT 1 3 4 FULL THREAD FRONT VIEW Er BoE Fig 7 Ground Bus Splice JKSSS Series 21 JKSSS Series 2 10 Control Connections TCB Terminal and Control Board Avarninc THIS SECTION INVOLVES POTENTIALLY LETHAL VOLTAGE LEVELS USE EXTREME CAUTION TO PREVENT INJURY Do not bypass the electrical or mechanical interlocks This will cause severe equipment damage and possible fatal injury Fuses F1 Control Fuses for TB1 1 9 Customer Provided 2 3 4 2KV Momentary or Maintained Start Stop S witching Maintained START STOP 2 10 1 JKSSS Plus TCB Board The JKSSS Plus TCB board provides interconnections between the main power and CPU boards and the customer s control logic connections It is a 120Vac control board with several auxiliary dry control contacts built in time delay circuits and emergency bypass func tions It also controls the se
77. d onto the center pin of the heat sink assembly Place the next level of heat sink bar on the mounted SCRs Note There is a difference in the heat sink bars The center bar has more holes drilled in it for mounting the circuit boards on it Now replace the other two 2 SCRs by repeating steps 10 and 11 Next carefully sandwich the SCRs and turn the stack over so the heat sink bars are vertical and run the center bolt through the springs and hand tighten the nut on the center bolt assembly Then make approximately 3 and 75 full revolutions on the nut to create the appropriate amount of compression force You can tell if there is enough compression force applied to the heat sink by the fact that the force needed to turn the nut will suddenly increase Finally reinstall all boards in the same manner in which they were removed Refer to drawing PCB for disassembling and reassembling the stack assembly JKSSS Series 92 2 3 4 2KV JKSSS Series 2 3 4 2KV Reinstallation 1 Hold the rebuilt or new stack assembly in the vertical position with the Temp CT board on top only the top stack assembly will have this board in a multi stack phase and place the stack on the positioning studs that protrude from the isolation standoffs While pressing on the stack to hold it on the positioning studs place the feed through bolt through the heat sink and finger tighten the top bolt Then repeat the process with the bottom feed through b
78. dditional information on the equipment refer to the following additional instruction manuals For fixed type input isolation contactor JK Series Medium Voltage Controllers Fixed Type manual number VF010H03 or JK Series 720 Ampere Medium Voltage Controllers manual number VF010H02 For drawout type input isolation contactor JK Series Medium Voltage Controllers manual number VF010H01 2 1 Receiving Handling Moving and Unpacking Upon receipt of the equipment do the following All JKSSS 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 unit as soon as possible Immediately notify the nearest Toshiba representative e Carefully unpack the unit and make an immediate inspection for any 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 Carefully unpack the equipment sufficiently to check for concealed damage and to 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 If is located on stickers in the medium voltage incoming comp
79. duplex piece with a mating tab that faces away from the stack If the tab is broken off refer to an adjacent stack s labels to see how the labels should be positioned when install ing a duplex connector with a broken tab Again caution should be taken not to touch the fiber connector end or force it in with the tab facing down JKSSS Series 93 JKSSS Series 2 3 4 2KV 7 8 Instructions for Low Voltage Test A DANGER HAZARDOUS VOLTAGE Disconnect all power supplying this equipment prior to working on it Failure to follow this instruction will result in death or serious injury Tools Phillips screwdriver Medium voltage fuse pullers if available Two control power transformer Test PT 500 VA minimum 120Vac control power Test plug Low voltage motor strapped for the proper voltage typically 5 HP or less Oscilloscope if available Wire jumper Test switch single pole i e light switch 480 or 240 VAC 3 Phase Supply A DANGER A Ensure proper HAZARDOUS VOLTAGE the MVC for low voltage testing phase sequence Remove all medium voltage fuses to prevent back Minimum of 500VA each H2 H1 H1 H2 feeding transformers PTs Failure to follow this instruction will result in death 1 or serious injury X1 x2 2 Manual reference drawing above Low Voltage Panel TB1 Terminal 1 1 Terminal 3 1 Terminal 5 Procedure 120 VAC 3 Phase Output 1 Verify that no
80. e Dual Ramp Start Ramp 2 Dual Ramp The dual ramp mode works in conjunction with External Input 3 This allows the user to switch between the two start ramps without having to reconfigure the start mode For details on configuring External Input 3 for DUAL RAMP see Setpoint Page 6 Custom Accel Curve Allows the user to custom design the acceleration start curve to the application See setpoint page 7 for configuration setup Note If Custom Accel Curve has not been enabled in setpoint page 7 the soft starter will ignore the start control mode and read this setpoint as disabled setup of tachometer input SP2 2 Jog Voltage The voltage level necessary to cause the motor to slowly rotate SP2 3 Start Ramp 1 Type The ramp type can be setup for either Voltage or Current If Voltage is selected initial voltage ramp time and current limit are adjustable If Current is selected initial current ramp time and maximum current are adjustable Start Ramp 1 Type Voltage method because the starter will eventually reach an output voltage high enough to draw full current and 1 Jog Voltage develop full torque Setting This method is useful for applications where 9 load conditions E change frequently and Time i dog i where different levels Button of torque are required Held Typical applications Start Control Mode include material handling S Mam Jog te conveyors positive disp
81. eas where lightning is a significant problem The arrestors should be mounted on the nearest utility pole 2 9 Medium Voltage Power Connections Use a properly calibrated torque wrench to tighten all MV connections Bolt Torque at Full according to the chart Size ft Ibs Connections 14 20 6 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 916 12 6 wherever such cables are unsupported Power cables should be adequately sized 58 11 90 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 240 appropriate to the voltage class and cable manufacturer s recommendations 245 Torque Specs for 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 5 through Fig 7 All access covers barriers partitions etc that are temporarily removed during installation must be replaced JKSSS Series 18 JKSSS Series 2 3 4 2KV NOTE Covers and braces supplied only for protection during shipment should not be replaced All debris and tools should be removed
82. eck phase to phase voltages on T1 T2 and T3 motor leads The voltages should be bal anced If the motor doesn t spin up smoothly the soft starter is malfunction ing Proceed to step 27 for troubleshooting If the motor starts and runs smoothly then repeat this procedure in reverse to remove all test connect and reinstall all fuses Low Voltage Troubleshooting Tools Ungrounded Oscilloscope 2f 28 29 30 31 Open test switch and stop motor Change Setpoint Page 5 AUX4 is set at non fail safe Change it to fail safe Observe bypass contactor closes immediately Place the Oscilloscope on the 2msec time scale and 1 Volt per division Connect the Oscilloscope probe to the Gate and Cathode of the SCRs JKSSS Series 95 JKSSS Series 2 3 4 2KV 32 The gate and cathode leads are the white wires on the gate drive board in the medium voltage cabinet See drawing below 33 If waveform is inverted swap Oscilloscope connections for proper polarity Close the temporary Start switch and allow the test motor to reach full speed 34 Then verify all gating signals to each SCR two gating signals on every gate drive board See drawing below for correct waveform 35 Once the bad signal s are found write down the location and call the factory for further guidance Run 50kS s Sample Waveform is the gating signal as measured with an ungrounded oscilloscope at the gate to cathode of the SCR The wave
83. ect and 2 furnishes the Company satisfactory proof thereof and 3 establishes that the equipment or part has been properly installed maintained and operated within the limits of rated capacity and normal usage and in accordance with current operating and maintenance instructions and 4 has not been altered or modified in any manner without the written consent of the Company and 5 if requested by the Company returns the defective equipment or part to the Company and pays all expenses incurred in connection with such return The repaired or replacement equipment or part will be delivered free of charge to the purchaser F O B the Company s warehouse or at the Company s option F O B a Company authorized service shop not loaded on truck or other carrier The purchaser will pay the costs applicable to the equipment or part following such delivery including without limitation all handling transportation assembly insurance testing and inspection charges THE FOREGOING OBLIGATION TO REPAIR OR REPLACE EQUIPMENT PARTS SHALL BE THE SOLE AND EXCLUSIVE REMEDY OF THE PURCHASER ITS CUSTOMERS AND USERS OF THE EQUIPMENT AND PARTS FOR BREACH OF THE FOREGOING WARRANTY THE COMPANY WILL HAVE NO OBLIGATIONS TO DISASSEMBLE ANY EQUIPMENT OR PART WHICH IS DEFECTIVE WITHIN THE TERMS OF THE ABOVE WARRANTY OR TO INSTALLANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAY ANY COSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION THE COMPANY
84. ed the soft starter will end the Decel cycle and turn itself off Another common application for decel control is on material handling conveyors as a means to prevent sudden stops that may cause products to fall over or to bump into one another In overhead crane applications soft stopping of the Bridge or Trolley can prevent loads from beginning to over swing on sudden stops ACCELERATION RUNNING MODE DECELERATION START DECELERATION MODE 42 FS STARTING TORQUE i STOP LEVEL VOLTAGE LEVEL ACCELERATION DECELERATION 4 RAMP TIME STOP DECELERATION MODE 3 4 1 Start Deceleration Voltage Factory Setting 60 of line voltage Range 0 100 of line voltage The step down voltage adjustment eliminates the dead band in the deceleration mode that is experienced while the voltage drops to a level where the motor deceleration is responsive to decreased voltage This feature allows for an instantaneous drop in volt age when deceleration is initiated 3 4 2 Stop Deceleration Voltage Factory Setting 20 of line voltage Range 0 100 of line voltage The stop voltage level setpoint is where the deceleration voltage drops to zero 3 4 3 Deceleration Time Factory Setting 5 sec Range 0 60 sec The deceleration ramp time adjusts the time it takes to reach the stop voltage level set point The unit should be restarted and stopped to verify that the desired deceleration time has been
85. effectively connect together the grounding electrode the controller frame all outgoing equipment grounding conductors and the grounded neutral bus of the system d Noconnection 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 JKSSS Series 20 JKSSS Series 2 3 4 2 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
86. ements of 1 MOTOR DESIGN AMBIENT TEMPERATURE 40C Range 10 90C Increments of 1 MOTOR DESIGN RUN TEMPERATURE 80 MAX Range 50 100 of Motor Stator Max Temp Increments of 196 MOTOR STATOR MAX TEMPERATURE INS CLS Range Insulation Class 1 40C Increments of 1 V B INPUT TO THERMAL REGISTER ENABLED Options ENABLED or DISABLED USE CALCULATED K OR ASSIGN 7 Range 1 50 ON PRESS ENTER TO CLR THERMAL REGISTER JKSSS Series 67 JKSSS Series SP 12 System Setpoints Setpoint Page 12 Security Level 3 SP12 1 SP12 2 SP12 3 Default Display Screen This setpoint group allows the user to choose the default screen the soft starter displays while the motor is running Select the metering page number 1 3 then select the metering screen number The range varies depending on the selected page To display a default screen program the following two setpoints Metering Data Page Range is Page 1 3 Metering Data Screen If Page 1 is selected as the default page then Screens 1 10 are available If Page 2 Screens 1 29 are available If Page 3 is selected then Screens 1 6 are available See Metering Menu MP 1 for screen number assignment Alarms Configures the RTD failure alarm and the thermal register alarm RTD Failure Alarm If enabled and an RTD shorts or open an alarm occurs Thermal Register Alarm Sets a level in the thermal register to generate an alarm when
87. ents nuisance tripping and insures that unsuccessful start attempts which would otherwise use up the starts per hour capacity of the motor are not counted 1 8 Firing Circuit The SCR gate firing circuit is critical to performance and stability of the system The firing circuit includes several unique features which enhance the ruggedness noise immunity and flexibility for maximized performance In most applications this performance is attained without the need for reactors or field installed devices These features include Auto Synchronizing of the gate timing pulses match each phase firing angle to their respective phases The starter actively tracks minor shifts in the line fre quency avoiding nuisance tripping that may happen with conventional gate firing Systems This is especially useful on portable or backup generator supplies allowing the starter to be used confidently in applications that have unstable power Sustained Pulse firing keeps the firing signal active for 270 electrical degrees ensuring that the DC gate pulse causes the SCR to fire even if line noise is present at a critical moment This provides the soft starter with superior noise immunity and protects against misfiring enhancing the system reliability Closed Loop Firing Control is a method of balancing the SCR firing pattern based on the desired output The CPU uses feedback signals from both the output current and voltage providing smooth output and preventing
88. er Type Rating Run Indication At Speed Indication Acceleration Adjustments Dual Ramp Settings Deceleration Adjustments Jog Settings Kick Start Settings Fault Display Lockout Display Up to 60 Events JKSSS Series 2 2 3 4 2KV Advanced Motor Protection Starting Programmable for Class 5 through 30 Run Programmable for Class 5 through 30 when At Speed is detected Manual default or automatic Overload circuit retains thermal condition of the motor regardless of control power status Unit uses real time clock to adjust for off time Overload will not reset until thermal capacity available in the motor is enough for a successful restart Starter learns and retains this information by monitoring previous successful starts Imbalance Trip Level 5 3096 current between any two phases Imbalance Trip Delay 1 20 seconds Trip Level 100 30096 of motor FLA Trip Delay 1 20 seconds Under Current Trip Level 10 90 96 of motor FLA Under Current Trip Delay 1 60 seconds Coast Down Time Range 1 60 minutes Range 1 6 successful starts per hour Time between starts 1 60 minutes between start attempts Programmable Outputs Form C DPDT Rated 5 amps 240 VAC max 1200 VA Programmable Programmable Programmable Ramp Types Voltage or Current Ramp VR or CR Starting Torque 0 100 of line voltage VR or 0 600 of motor FLA CR Ramp Time 1 to 120 seconds Current Limit 200 50
89. es 86 m 2 WD AX m 3 ONIS 3C AX d p4o0g aAlug 2409 p4oog 93 dua j p4oog pa 4 087 w n eec x SONIA a aaa Rf aaa N ADHS A ISA3SSV 05 62 5 62 LIOA WOIdAL 2 z a a E LEN AR 212 K n 819 74 1 18 ay o 4 li T 2 mem um 09 E9AN c Bei 1 SI DNINIA C38 Fek AIWADASNYAL TY 7 3 ge ge
90. form should be 1 7 to 2msec off time and approximately 1 5 to 3 This signal is only present at full conduction or the motor is at speed Each SCR gating signal should be checked in accordance with the low voltage test procedure WED 2ms iine 7 103V Correct Waveform JKSSS Series 96 JKSSS Series 2 3 4 2KV 7 9 Maintenance Program Servicing Equipment Disposal Storage AD ANGER av ARNING Av ARNING Av ARNING MAINTENANCE PROGRAM 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 usually dictate the frequency of inspection required NFPA Publication 70B Electrical Equipment Maintenance may be used as a guide for setting up the maintenance program Contact with energized components can cause severe injury death and property damage Turn off and lock out primary and control circuit power before servicing Improper maintenance can cause severe injury death and property damage Only qualified and authorized persons are to install operate or service this equipment Grease is conductive Do not allow grease or any other substances to contaminate insulating materials Contaminated insulators can allow a short circuit or ground fault to occur NOTE Refer to the SAFETY section of this manual for important information MAINTENANCE RECORD Keep a perm
91. from each compartment as cabling is completed CUBICLE SPLIT 3 B FLAT WASHER 3 8 LOCK WASHER 5 8 16 Y 1 1 4 GRADE 5 BOLT TOP VIEW MUN SPLICE RiR 1 8 Y 4 COPPER PART 0 PCTS5SEPDGE FRONT VIEW 3 8 16 Y 1 1 4 GRADE 5 CARRIAGE HOLT 3 8 FLAT WASHER 2 8 LOCK WASHER 3 B 18 Fig 5 Main Bus Splice Connections 1200A Bus CUBICLE SPLIT 3 6 FLAT WASHER 3 8 LOCK WASHER 3 6 16 Y 1 3 4 GRADE 5 BOLT TOP VIEW MAIN SPLICE 1 4 4 COPPER PART NO 18596 068 TWO PER PHASE FRONT WEW 3 8 16 Y 1 3 4 GRADE 5 CARPIAGE BOLT 3 9 FLAT WASHER 326 LOCK WASHER 378 18 HEX NLT Fig 6 Main Bus Splice Connections 2000A Main Bus JKSSS Series 19 JKSSS Series 2 3 4 2KV 2 9 1 Incoming Line On the Standard JKSSS incoming power cable connections should be made at the points shown on the wiring diagram furnished with the equipment Note Proper phase sequence must be observed when connecting the input power For example phase A must lead phase B which in turn must lead phase C by 120 respectively If the phase rotation is not correct a fault light and the LCD display will indicate the problem The SCR output will be clamped 2 9 2 Load Connections The load cables should be routed through the wireways furnished within the enclosure Load cable termination arrangements refer to the drawings furnished with the equip ment 2 9 3 Ground Connections
92. ge current of the of imbalance and the motor s RPM Motor load as a percentage of motor FLA Line frequency and present phase sequence Percentage of remaining Thermal Register Thermal capacity required to start the motor Average time required to start Page 1 Metering Menu amp Data Average current during start Measured required to start the motor Amount of time required to start the motor during the last successful start 6 1 2 Metering Metering Page 2 Metering Page Description of Display Phase A B C currents and Power Factor SS O DsslyekWangA WAR and Displays Peak ON ard iw Demand Peak ON and kVA Demand Jo Displays Peak ON and Amps Demand clears 6 1 3 RTD Values Metering Page 3 Metering Page Description of Display Hottest stator RTD 1 6 Hottest non stator RTD 7 12 2 5 22 Cc oF 4 Temperature Measured running thermal stabilization time of motor in minutes Measured stopped cooling time to ambient of motor in minutes JKSSS Series 70 2 3 4 2KV JKSSS Series 2 3 4 2KV 6 1 4 Status Metering Page 4 Metering Page Description of Display Screen Current status Amount of time remaining before overload trip occurs coast
93. gs 2 9 Medium Voltage Power Connections 2 10 Control Connections and JKSSS TCB 2 11 Reference Section Chapter 3 Start Up s ccccccccsciccccccsececnecscncsescicacecessetsnsceatecsactessndvacessnccennectanisanadscaesstedenesene 29 3 1 Preliminary Start up Check List 3 2 Introduction 3 3 Acceleration Adjustments 3 4 Deceleration Adjustments 3 5 Sequence of Normal Operation 3 6 Emergency Bypass Operation Chapter 4 Programming csnteccesseesscnsecesnscnecascerssuocesescceessscerssnnestedoccesscterssnsces 33 4 1 Keypad Operator Interface 4 2 Menu Navigation Chapter 5 Setpoint and Programming eese nnne 36 5 1 Setpoints Page List 5 2 Setpoint Menu Basie CODfIQUFaliODi murieron hit eee npa dors 46 SP2 Starter GonfigutatioDi 47 SPB Phase amp GroubdSettihgs ee con irm emm Eee 50 SP 4 Relay Assignment SB 5 Relay GOMMGURATOM 55 SO I OUG OIG UI AMON ea ae con cet 56 SP 7 Custom Acceleration Curve ccccececsecceseceeeeeeeeeeseeeeeeaeeaeeeaesaeeeaeeaeeeeeeaeenaeeatenee 59 SP 8 Overload Curve Configuration 62 SES RIDGOORIQUIAtlOly 63 OP O SOT EE 65 EE 66 SPAA OVSE OSDO SE e TEE 67 SP 13 Calibration amp sess
94. h Accel trip condition must persist before a trip is generated 2 3 4 2KV SP6 3The controller provides two 4 20mA analog outputs Each analog output is independent of the other and can be assigned to monitor different functions The available output ranges are RPM Hottest Non Stator Bearing RTD Hottest Stator RTD RMS current 96 Motor Load or kW Analog Output 1 Select a function from the available options to be transmitted from the 4 20mA output Note If selecting RPM the Tachometer feedback input signal must be present in order for the controller to give proper output If selecting RTD the RTD option must be installed and an RTD input signal must be present for a proper output to be given from the analog output Analog Output 1 4 mA Enter a value that the 4 level will represent for the selected function typically this value should be 0 Analog Output 1 20 mA Enter a value that the 20mA level will represent for the selected function SP6 4Analog Output 2 All of the setpoints and setup screens for Analog Output 2 are the same as those for Analog Output 1 JKSSS Series 57 JKSSS Series SP 6 User I O Configuration Setpoint Page 6 Security Level 2 2 3 4 2KV USER lt gt TCB FAULT lt gt EXT INPUT 1 gt TCB FAULT TCB FAULT PROGRAMMABLE SELECT ENABLED TCB FAULT TYPE NORMALLY OPEN TIME DELAY 1 SEC EXTERNAL Options Enabled or Disabled See text fo
95. hase Loss Trip Phase Loss Trip Delay Phase Rotation Detection Phase Rotation Trip Delay Ground Fault Alarm Level Ground Fault Alarm Delay Ground Fault Loset Trip Level Ground Fault Loset Trip Delay Ground Fault Hiset Trip Level Ground Fault Hiset Trip Delay Overvoltage Alarm Level Overvoltage Alarm Delay Overvoltage Trip Level Overvoltage Trip Delay Undervoltage Alarm Level Phase and Ground Settings Password Protection Undervoltage Alarm Delay Undervoltage Trip Level Undervoltage Trip Delay Line Frequency Trip Window Line Frequency Trip Delay P F Lead P F Alarm P F Lead Alarm Delay P F Lead P F Trip P F Lead Trip Delay P F Lag P F Alarm P F Lag Alarm Delay P F Lag P F Trip P F Lag Trip Delay Power Demand Period KW Demand Alarm Pickup KVA Demand Alarm Pickup KVAR Demand Alarm Pickup Amps Demand Alarm Pickup Ground fault option must be installed Page 3 Factory Setting Default Section 15 FLA 5 30 Off SP3 1 SP3 2 2 0 sec 1 0 60 0 sec 2 0 sec 1 0 20 0 sec SP3 5 Enabled Enabled or Disabled SP3 6 1 0 sec 1 0 20 0 sec 0 1 sec 0 1 20 0 sec SP3 9 SP3 10 0 008 sec 0 008 0 250 sec 5 30 Off 1 0 sec 1 0 30 0 sec SP3 12 1 0 sec 1 0 30 0 sec ff ff ff ff ff SP3 14 Disabled 0 6 Hz Disabled SP3 15 1 0 sec 1 120 sec 1 0 sec 1 120 sec SP3 19 Off KW Off 1 100000 Off KVA Off 1 100000 SP3 20 Off KVAR Off 1 100000 Off Amps Off 1 10
96. he amount of time that the undervoltage condition must exist before a trip will occur Line Frequency Trip Window The acceptable amount of drift above or below the line frequency Hz before a trip is generated Line Frequency Trip Delay The amount of time that the frequency drift condition must exist beyond the window before a trip will occur Power Factor Lead Alarm Typically used to indicate a leading power factor Power Factor Lead Alarm Delay The amount of time that the power factor lead condition must exist beyond the window before a trip will occur Power Factor Lead Trip The acceptable amount of power factor lead before a trip is generated Power Factor Lead Delay The amount of time that the power factor lead condition must exist beyond the window before a trip will occur JKSSS Series 52 SP3 18 SP3 19 SP3 20 2 3 4 2 Power Factor Lag Alarm Typically used to indicate a lagging power factor Power Factor Lag Alarm Delay The amount of time that the power factor lagging condition must exist beyond the window before a trip will occur Power Factor Lag Trip The acceptable amount of power factor lag before a trip is generated Power Factor Lag Delay The amount of time that the power factor lag condition must exist beyond the window before a trip will occur Power Demand Period The soft starter measures the demand of the motor for several parameters current kW kvar kVA The demand va
97. he motor AVERAGE START TIME Screen 7 TIME SECS Screen 10 Displays the amount of time required to start the motor during the last successful start screens AMPS TO START IIT HHBHHHHE LAST START TIME SEC Screen 10 JKSSS Series 73 JKSSS Series 2 3 4 2KV 2 Metering Metering Page 2 Displays the statistical voltage metering informa tion Screen 1 Screen 1 Displays Phase B C and Power Factor VOLTAGE amp POWER DATA Vea P F HHH Note P F N A Motor stopped P F LG Lagging Scree P F LD Leading Screen 2 Displays Phase A B C and Ground Fault Current Screen 3 Displays KW and KVA Screen 4 Screen 4 Displays KVAR and Power Factor PIF 88 Screen 5 Displays Peak and KW demand Screen 5 PEAK HHHH kW Screen 6 Displays Peak On and KVA demand Screen 6 ON HHHH KVA fHHHEE Screen 7 Displays Peak On and KVAR demand Note P F N A Motor stopped P F LG Lagging P F LD Leading Screen 7 PEAK ON HEHH Screen 8 Displays Peak On and Amps demand 8 Screen 9 Clears Demand Values AMPS HHHH Screen 10 Displays the Megawatts used per hour Screen 9 Screen 11 Press Enter to clear statistics on MWH values PRESS ENTER TO CLEAR DEMAND VALUES Screen 10 1 MWH USED HHHH Screen 11
98. his section involves working with potentially lethal voltage levels Use extreme caution to prevent injury Pressing Stop push button does not remove AC mains potential AWARNING Do not service this equipment with voltage applied The unit can be the source of fatal electric shocks To avoid shock hazard disconnect main power and control power before working on the unit Warning labels must be attached to terminals enclosure and control panel to meet local codes ACAUTION not connect the capacitors to the load side motor side TA CAUTION of the solid state starter This will cause di dt damage to the A CAUTION SCR DAMAGE SCRs when they are turned on Do not connect PFC capacitors to the load side of the unit Do not connect the capacitors to the input side of the unit 2 Doing so will cause DI DT damage to the SCRs when If you cannot avoid using capacitors across the power lines they energized must be located as far upstream as possible of the input line contactor In this situation optional power factor correction PFC caps contactor should be specified For additional information and specifications please contact the factory ACAUTION ACAUTION Never interchange the input and output power connections on the unit This will cause excessive voltage to the control circuit logic ACAUTION For bus protection it is strongly recommended to use lightning arrestors in ar
99. ial torque boost is applied SP2 6 Deceleration Allows the motor to gradually come to a soft stop Start Deceleration Voltage The first part of the deceleration ramp The soft starter initially drops to this voltage level upon receiving a STOP command Represented as a percent of voltage value Stop Deceleration Voltage The drop off point of the deceleration ramp Percent of voltage value Deceleration Time Decel ramp time SP2 7 Timed Output Used with an AUX 5 8 relay When enabled and upon a start command it waits until the programmed time plus the run delayed time has expired The relay energizes and remains so until a stop command is received It de energizes upon receiving a stop command SP2 8Run Delay Time Can be used with an AUX 5 8 relay The delay timer begins upon receipt of the start command The relay will then drop out when the time has expired SP2 9 At Speed Delay Time Used with an AUX 4 relay it waits until after the motor reaches the end of ramp and the programmed delay time has expired The relay energizes until a stop command has been received JKSSS Series 49 JKSSS Series 2 3 4 2KV SP 3 Phase amp Ground Settings MENU Setpoint Page 3 Security Level 2 p DOWN ARROW two times IMBALANCE ALARM IMBALANCE ALARM 3 PHASE amp lt gt GROUND SETTINGS LEVEL 15 FLA DELAY 1 5 SEC Range 5 30 OFF f Range 1 0 20 0 SEC Increments of 1 Increme
100. iba authorized replacement parts This equipment is designed and built in accordance with applicable safety standards in effect on the date of manufacture Unauthorized modifications can result in voiding the warranty severe injury death and property damage Do not make any modifications to this equipment without the written approval of Toshiba For assistance address correspondence to Toshiba International Corporation Field Service Department 13131 West Little York Road Houston Texas 77041 USA or call 713 466 0277 Fax 713 466 8773 800 231 1412 800 527 1204 Canada Please complete the following information for your records and retain with this manual Model Serial Number Date of Installation Inspected by Reference Number TOSHIBA INTERNATIONAL CORPORATION 2009 JKSSS Series Medium Voltage Solid State Soft Starters 2 3 4 2KV Installation amp Operation Manual Chapter 1 Introduction 1er tei 1 1 1 Overview 1 2 Specifications 1 3 Design Features 1 4 Structure and Power Bus 1 5 Theory of Operation 1 6 General Protection 1 7 Thermal Overload Protection 1 8 Firing Circuit 1 9 Electronics Chapter 2 Installati n 12 2 1 Receiving and Unpacking 2 2 Initial Unit Inspection 2 3 Location 2 4 Dimensions 2 5 Mounting 2 6 Additional Equipment 2 7 Before Applying Power 2 8 Warnin
101. ill is called the Head Pressure in the system The pump is sized to provide enough Output Pressure to overcome the Head Pressure and move the fluid up the ipe When the pump is turned off the Output Pressure rapidly drops and the Pressure takes over to send the fluid back Pad Pump Control the hill A Check Valve is used somewhere in the system to prevent Soft Stop this if necessary by only allowing the liquid to flow in one direction The kinetic energy in that moving fluid is suddenly trapped when the valve Check Valve slams closed Since fluids can t compress that energy is transformed Closes Slowly into a Shock Wave that travels through the piping system looking for an outlet in which it dissipates The sound of that shock wave is referred to as Water Hammer The energy in that shock wave can be extremely damaging to pipes fittings flanges seals and mounting systems Check Valve By using the Soft Stop Deceleration feature of the soft starter the pump Closed output torque is gradually and gently reduced which slowly reduces the A NO SHOCK WAVE pressure in the pipe When the Output Pressure is just slightly lower than the Head Pressure the flow slowly reverses and closes the Check Valve By this time there is very little energy left in the moving fluid and the JKSSS Series 30 JKSSS Series 2 3 4 2KV Shock Wave is avoided When the output voltage to the motor is low enough to no longer be need
102. imbalances during ramping which prevents unnecessary motor heating Transformer Isolation of the firing signals prevents interference from line noise and EMI RFI signals that may be present Specially designed 120V 3 phase iso lation transformers provide potential measurement firing board power and gate power systems while being isolated from the line voltage High isolation Ring Transformers are used to step this down to 28Vac for the Sustained Pulse firing circuit providing further isolation for the SCR gates Fiber Optic Isolation is provided for all signal interfaces between the Medium Voltage and Low Voltage systems Even the current signals from CTs are con verted to fiber optic signals for maximum isolation and safety JKSSS Series 10 JKSSS Series 2 3 4 2KV 1 9 Electronics The JKSSS Series electronics systems are divided into two categories Low Voltage and Medium Voltage based solely on where they are located in the starter structure Low Voltage electronics include the Keypad Operator Interface CPU and Main Power PC boards are located in an isolated Low Voltage Compartment of the enclosure Keypad Operator Interface a 2 line x 20 character LCD display with backlight ing for low ambient conditions The display reads out in truncated English and DIGITAL DISPLAS can show multiple data points in each screen Also included are 12 LED indica tors which include Power Run Alarm Trip and the status of the 8 Aux Rel
103. inks Note If the unit is a 6000 7200V re move the power strap connecting one side of the stack to the stack directly below it 5 Before removing the fiber optic wiring make a note of the label on the fiber cable to ensure they are placed exactly in the same socket they were removed from Now remove all fiber optic connectors on the stack Gently push on the connector tab and pull with a gentle left to right motion on the connector in the direction away from the fiber optic device Two connectors will be found per gate drive board and one duplex connector will be found on the small Temp CT board on top Caution Do not touch the tip of the connectors or contaminate the connection sockets with any dust or foreign material Remove the wires from the Temp CT board terminal block 3 screws Use a 9 16 socket with a 6 extension to remove the lower bolt that routes through the front face of the heat sink and into the isolation standoff mounted to the white panel Then carefully hold the heat sink in place with one hand and remove the top bolt from the heat sink 8 Ensure the fiber optic connectors and all wires are positioned out of the way and then the heat sink can be gently removed from the unit JKSSS Series 91 JKSSS Series SCR Replacement AcsuTion FAILURE TO PERFORM THIS PROCEDURE 10 11 12 13 14 15 16 CORRECTLY WILL DAMAGE THE SCR AND WILL NOT BE COVERED UNDER WARRANTY Remove whi
104. lacement pumps and drum mixers Voltage is increased from a starting point Initial Torque to full voltage over an adjustable period of time Ramp Time To achieve Voltage Ramping select VOLTAGE for the START RAMP 1 TYPE setpoint and set CURRENT LIMIT 1 setpoint to 500 the maximum setting Since this is essentially Locked Rotor Current on most motors there is little or no Current Limit effect on the Ramp profile JKSSS Series 48 Tach Ramp See setpoint page 6 for configuration Voltage Ramping is the most reliable starting Start Ramp 1 Type Voltage 2 3 4 2KV Voltage Ramping with Current Limit is the most used curve and is similar to voltage ramping However it adds an adjustable maximum current output Voltage is increased gradually until the setting of the Maximum Current Limit setpoint is reached The voltage is held at this level until the motor accelerates to full speed This may be necessary in applications where the electrical power is limited Typical applications include portable or emergency generator supplies utility power near the end of a transmission line and utility starting power demand restrictions Note Using Current Limit will override the Ramp Time setting if necessary so use this feature when acceleration time is not critical To achieve Voltage Ramping with Current Limit select VOLTAGE for the START RAMP 1 setpoint and set CURRENT LIMIT 1 setpoint to a desired lower setting as dete
105. lt TIME FOR SAMPLING 30 SEC Range 1 300 SEC Increments of 1 Range 5 40 Increments of 1 SP8 3 Area Under Curve Protection If enabled this secondary start protection uses both the basic start protection and the area under the curve protection I I T Start The maximum I T allowed during start If the to start exceeds this number then the soft starter will generate a trip SP8 4Current Over Curve Learns the motor s starting characteristics and protects the motor based upon the learned curve It is useful when commissioning a new motor Learn The unit reads the motor s starting characteristics Start the motor and allow it to come to full speed The start feedback enables the motor protection based on the learned start curve Learned Start Curve Basis The maximum allowed deviation above or below the start curve before a trip is generated Time for Sampling The time the soft starter continues to sample the start curve characteristic during learn the mode JKSSS Series 2 3 4 2KV SP 9 RTD Optional Configuration Setpoint Page 9 Security Level 3 Hit DOWN ARROW eight times PAGE9 RTD lt gt USE NEMA TEMP FOR CONFIGURATION RTD VALUES DISABLED DISAB i Options ENABLED OR LED OF RTD S USED FOR STATOR 4 Range 0 6 Increments of 1 RTD VOTING DISABLED Options ENABLED or DISABLED Range STATOR PHASE B1 TYPE lt gt STATOR PHASE 2
106. lues of motors assists in energy management programs where processes may be altered or scheduled to reduce overall demand Demand is calculated by a programmed amount of time where current kW kvar and kva samples are taken and then averaged and stored to assess demand JKSSS Series SP 4 Relay Assignment Setpoint Page 4 Hit DOWN ARROW three times PAGE 4 RELAY gt O L TRIP ASSIGNMENT 1ST TRIP ONLY Range TRIP AUX1 ALARM AUX2 AUX3 AUX4 TRIP 1ST TRIP SIC TRIP 1ST TRIP ONLY OVERCURRENT TRIP 1ST TRIP STATOR RTD TRIP 1ST NONE NON STATOR RTD TRIP 1ST NONE G F HI SET TRIP 1ST TRIP G F LO SET TRIP 1ST TRIP PHASE LOSS TRIP 1ST TRIP ACCEL TIME TRIP 1ST TRIP ONLY START CURVE TRIP 1ST TRIP ONLY OVER FREQUENCY TRIP 1ST NONE UNDER FREQUENCY TRIP 1ST TRIP START CURVE 1ST TRIP LEARNED START CURVE 1ST TRIP TACH ACCEL TRIP 1ST NONE 2 3 4 2KV PHASE REVERSAL 1ST TRIP ALARM 1ST ALARM OVERVOLTAGE TRIP STATOR RTD ALARM 1ST TRIP 4ST NONE NON STATOR RTD ALARM 1ST NONE UNDERVOLTAGE TRIP 1ST TRIP POWER FACTOR TRIP 1ST NONE RTD FAILURE ALARM 1ST NONE t SELF TEST FAIL 1ST TRIP INHIBITS TRIP 1ST TRIP THERMAL REGISTER 1ST ALARM SHUNT TRIP 1ST NONE U V ALARM 1ST ALARM BYPASS DISCREPANCY 1ST NONE O V ALARM TCB FAULT 1ST TRIP POWER FACTOR ALARM
107. med Output None Run Delay Time None At Speed None Password Protection 2 c o E c o lt gt 5 x JKSSS Series 38 JKSSS Series 2 3 4 2KV 5 1 5 Relay Configuration Setpoint Page 5 Setpoint Security Page Level Factory Setting Default Description Trip AUX1 Fail Safe Trip AUX1 Relay Latched Alarm AUX2 Fail Safe Alarm AUX2 Relay Latched AUX3 Relay Fail Safe AUX3 Relay Latched AUXA Relay Fail Safe AUXA Relay Latched AUX5 Relay Fail Safe AUX5 Relay Latched AUX6 Relay Fail Safe AUX6 Relay Latched AUX7 Relay Fail Safe AUX7 Relay Latched AUX8 Relay Fail Safe AUX8 Relay Latched Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No Password Protection z 9 5 5 ao gt 5 a Yes or No Yes or No Yes or No Yes or No Yes or No Yes or No JKSSS Series 39 JKSSS Series 2 3 4 2KV 5 1 6 User I O Configuration Setpoint Page 6 Setpoint Security Page Level Factory Setting Default Tachometer Scale Selection Disabled Enabled or Disabled SP6 1 Description Range Section Tach orem Off RPM 0 3600 Hottest Non Stator RTD Analog Output 1 RMS Current 0 A Motor Load 0 600 Kw SP6 3 User Programmable External Inputs TCB Fault Enabled Enabled or Disabled SP6 5 User I O Configuration Passowrd Protection
108. mediately removed from the motor and the soft starter returns to the Ready Mode Additional protection features activated when the stop command is given include Coast Down Back Spin Timer Starts per Hour Time Between Starts External Input Faults 1 7 Thermal Overload Protection The JKSSS Series plays an important role in the protection of your motor in that it monitors the motor for excessive thermal conditions due to starting running or even ambient conditions The soft starter has a Dynamic Thermal Register system in the CPU that provides a mathematical representation of the thermal state of the motor This thermal state information is kept in memory and is monitored for excesses in both value and rate of change Input is derived from current imbalances and RTD measurements making it dynamic to all processes involving the motor The starter monitors these conditions separately during Start and Run modes to provide proper thermal overload protection at all times Start Mode overload protection is selectable using one of three methods Basic Protection 124 data is accumulated and plotted based on an Overload Curve selected in programming This is programmed per NEMA Class 5 30 standard curves and is based on the Locked Rotor Current from the motor nameplate as programmed into the soft starter Measured Start Capacity The user enters a measured amount of thermal capacity from a pre selected successful start as a setpoi
109. n Notes 1 The MENU keys allow you to toggle the screens between the Setpoint Menu and the Metering Menu Simply use the arrow keys to get to the different screens 1 within each menu Example To access Setpoint Page 3 PHASE amp GROUND SETTINGS press the MENU key once and the DOWN ARROW two times PAGE 1 BASIC 2 Levels 1 2 and 3 indicate password protection levels for these setpoint pages CONFIGURATION LEVEL 1 PAGE2 STARTER CONFIGURATION PAGE 3 PHASE amp GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT LEVEL 2 PAGE5 RELAY CONFIGURATION PAGE6 USERI O CONFIGURATION PAGE7 CUSTOM ACCELERATION CURVE PAGE8 OVERLOAD CURVE CONFIGURATION LEVEL 3 PAGE 10 SECURITY SET PASSWORD PAGE 11 COMMUNICATIONS LEVEL amp SERVICE PAGE9 RTD CONFIGURATION PAGE 12 SYSTEM SETPOINTS JKSSS Series 34 JKSSS Series 2 3 4 2KV 4 2 1 Password Access Screens in Level 1 of the setpoint menu can be changed without password access because they list basic motor information Screens in Levels 2 and 3 require passwords because they provide more in depth protection and control of the unit The password in Levels 2 and 3 can be changed by the user NOTE Setpoints can only be changed when the motor is in Stop Ready Mode The soft starter will not allow a start if it is still in the Edit Mode When the unit is in the Edit Mode an asterisk is in the top right corner of the display 4 2 2 Changing Setpoints Example 1 Ch
110. n be made with minimum bending One or more Starter Power Compartments contain the bypass vacuum con tactors SCR power modules instrument transformers and all other medium voltage devices Adequate room is provided for motor lead connections to be made with minimum conductor bend A Low Voltage Control Compartment houses the digital microprocessor controller and LCD keypad operator interface along with any other low voltage devices This allows the operator to make adjustments without exposure to the line voltages JKSSS Series 5 JKSSS Series 2 3 4 2KV Removable conduit entry plates are provided in the bottom of the enclosure to facilitate drilling and punching of conduit holes without exposing the equip ment to contamination from metal debris Enclosure Finish The enclosure is suitable for use in noncorrosive environ ments The paint is ANSI 61 gray polyurethane powder over a zinc phosphate pretreatment with a minimum thickness of 2 mil 11 gauge steel is used in all enclosures All NEMA 1 amp 12 units have bottom entrance plates e Lifting Provisions Eyes or angles capable of supporting the maximum weight of each shipping split are provided on the top of the enclosure Power Bus Optional main horizontal phase bus bars can be configured to extend the entire length of the starter lineup Bus bar material is tin plated or silver plated copper All bus ratings are per UL Standard 347 e Bracing Bus bars are braced
111. ne voltage Starting voltage adjustment changes the initial starting voltage level to the motor 3 3 2 Ramp Time Factory Setting 10 sec Range 0 120 sec Ramp time adjustment changes the amount of time it takes to reach the current limit point or full voltage if the current limit point was not reached Note Refer to your motor manual for the maximum number of starts per hour allowed by the manufacturer and do not exceed the recommended number 2 3 4 2KV JKSSS Series 29 JKSSS Series 2 3 4 2KV 3 3 3 Current Limit Factory Setting 350 of unit FLA Range 200 500 of unit FLA The current limit adjustment is factory set for 350 of the unit s rating The range of adjustment is 200 to 500 The main function of cur ACCELERATION rent limit is to cap the peak current It may also be used to extend the 100 ramping time if required The interaction between the voltage ramp and the current limit will allow the soft start to ramp the motor until the maximum current is reached and the current limit will hold the current at that level The current limit must be set high enough to allow the motor to reach full speed The factory setting of 350 is a good start ing point Do not set the current limit too low on variable starting loads This could cause the motor to stall and eventually cause the overload protection to trip STARTING Note If the motor does stall refer to the motor manufacturer s motor data VOLTAGE TORQUE VOLT
112. nt is enabled the soft starter will use the NEMA design insulation class to limit the maximum allowed range of the alarm and trip level The maximum allowed temperature range is 240 C or 464 F SP9 2 Of RTD S Used for Stator Up to six RTDs can be assigned to monitor the stator of the motor SP9 3RTD Voting When this is enabled the soft starter will not post a trip until 2 RTD s have exceeded the trip level This prevents nuisance RTD tripping SP9 4All 12 RTDs are configured in the following manner The first column is the RTD type the second column is the RTD description the third column is the alarm level and the fourth column is the trip level The first six RTDs have been pre programmed with a description name for the STATOR with two RTDs per phase RTDs 1 amp 2 have been named STATOR PHASE 1 and A2 respectively RTDs 3 amp 4 are named STATOR PHASE 1 and B2 RTDs 5 amp 6 are named STATOR PHASE C1 and C2 If other description names are required press the right arrow button from the RTD Type screen to go the RTD description screen If no alarm or trip level is required these setpoints can be turned off JKSSS Series 64 2 3 4 2KV JKSSS Series SP 10 Set Password Setpoint Page 10 Security Level 3 The soft starter has three levels of user programmable setpoint screens Level one setpoints do not require a password because the data contained in level one is basic nameplate data and star
113. nt to the Thermal Reg ister for the soft starter to follow Learned Curve Protection The user sets the soft starter to the LEARN mode and starts the motor under normal starting conditions The CPU then samples and records 100 data points during the start curve analyzes them and creates a graphical representation in memory The soft starter is then switched to Curve Follow protection mode and monitors motor performance against this curve This feature is especially useful in initial commissioning tests to record a base line performance sample in this case it is not necessarily used for motor protection Run Mode overload protection is initiated when the starter determines that the motor is At Speed Overload Protection is initiated when the motor RMS current rises above a pick up point as determined by the motor nameplate FLA and service factor Run mode protection is provided by the CPU monitoring the Dy namic Thermal Register Data for the Dynamic Thermal Register is accumulated from 1 calculations and cooling rates A trip occurs when the register reaches 10096 as determined by the selected Overload Protection Curve NEMA Class 5 30 standard curves and is based on the programmed Locked Rotor Current indicated on the motor nameplate The Dynamic Thermal Register is altered or biased by the following conditions Current Imbalance Will bias the register higher to add protection from ad ditional motor heating during
114. nts of 0 1 IMBALANCE TRIP IMBALANCE TRIP LEVEL 20 FLA DELAY 2 0 SEC Range 5 30 OFF 1 Range 1 0 20 0 SEC Increments of 1 Increments of 0 1 PHASE ROTATION PHASE ROTATION TRIP DETECTION ABC DELAY 1 0 SEC SP3 2 Imbalance Trip Level This will trip the motor on Options ABC ACB or Range 1 0 20 0 SEC excessive phase imbalance The trip level should Disabled be programmed to a higher value than the alarm UNDERCURRENT ALARM UNDERCURRENT ALARM Note Proper phase sequence must be observed when LEVEL OFF DELAY 2 0 SEC 10 90 Range 1 0 60 0 SEC connecting the input power For example phase A incremente of 1 Inerements of 0 1 must lead phase B which in turn must lead phase C by 120 respectively If the phase rotation is not correct a fault light and the LCD display will Range 100 300 OFF Range 1 0 20 0 SEC OFF indicate the problem Increments of 1 Increments of 0 1 OVERCURRENT OVERCURRENT TRIP SP3 1 Imbalance Alarm Level This is an advance warning LEVEL OFF DELAY 2 0 SEC of a phase imbalance problem The problem may Range 100 300 OFF Range 1 0 20 0 SEC not be a fault in the motor but merely caused by Increments of 1 Increments of 0 1 imbalanced voltages PHASE LOSS TRIP PHASE LOSS TRIP ENABLED DELAY 0 1 SEC i Options Enabled or Disabled Range 0 20 0 SEC Imbalance Alarm Delay The amount of time the imbalance condition mu
115. nts on graph The soft starter will then accelerate the motor following these points Tachometer Feedback Ramp Uses a closed loop speed follower method monitoring a tachometer input signal from the motor or load shaft Deceleration The soft starter provides the user with the option of having the load coast to a stop or controlling the deceleration by slowly reducing the voltage to the motor upon initiating a stop command The Decel feature is the opposite of DC injection braking in that the motor will actually take longer to come to a stop than if allowed to coast to a stop The most common ap plication for the Decel feature is pumping applications where a controlled stop prevents water hammer and mechanical damage to the system JKSSS Series 7 JKSSS Series 2 3 4 2KV 1 6 General Protection The soft starter is provided with a built in motor protection relay that can be programmed for primary protection of the motor load system Operation of the soft starter can be divided into 4 modes Ready Start Run and Stop Ready Mode In this mode control and line power are applied and the starter is ready for a start command Protection during this mode includes the monitoring of current for leakage through multiple shorted SCRs or welded contacts on the Bypass Contactor Other protection features in effect are Starter Temperature Shorted SCR Phase Reversal if enabled Line Frequency Trip Window External Input Fault
116. ocean rr yon Rye ER Es er uu e iden EYE Fe vu ge s n Peta fra nidi 69 Chapter 6 Metering Pages nee 70 6 1 Metering Page List Chapter 7 Maintenance and Troubleshooting Disposal Storage 80 7 1 Failure Analysis 7 2 Typical Block Diagram 7 3 Overload Curve Definition 7 4 Typical Wiring Diagram for TCB Board 7 5 Typical Internal Wiring Diagram 7 6 Spare Parts List 7 7 Instructions for Stack Replacement 7 8 Instructions for Low Voltage Test 7 9 Maintenance Program Servicing Equipment Disposal Storage Warranty and Limitations of Liability 41 11111 ener 99 Reference Chart section Table or Drawing ee C ti Board C tions setpoints Pagers 36 44 Setpoint Page 1 Displays Basic Configuration Overload Class Trip Curves 46 setpoint Page 2 Displays Starter Configuration 52 Jog voltageRamp 48 5 2 Setpoint Page 3 Displays Phase amp 50 51 Ground Settings section Table or Drawing Sae Overcurrent Trip Delay Graph Setpoint Page 4 Displays Relay Assignment 52 Setpoint Page 5 Displays Relay 55 Configuration 52 setpoint Page 6 Displays User I O 56 58 Configuration 5 2 Setpoint Page 7 Displays Custom 59 61 Acceleration Curve 5 2 Setpoint Page 8 Displays Overload 62 Curve Configuration 5 2 setpoint Page 9 Displays RTD 63 64 Configur
117. of control power will be necessary to provide power to the electrical operators ANVARNING 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 asso ciated 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 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 which can result in serious injury or death High potential tests should be performed only by qualified personnel Refer to safety instructions provided with the test equipment AVARNING All devices must be set to their normal or OFF position before energizing incoming power JKSSS Series 17 JKSSS Series 2 3 4 2KV 2 8 Warnings amp Cautions ARNING T
118. olt to ensure the stack is held against the isolation standoffs After verifying no wires or fibers have been pinched between the stack assembly and isolation standoffs tighten the top bolt completely then repeat the process for the bottom bolt Now the stack assembly should be held firmly in place Using the 9 16 wrench reinstall the line and load power cables and tighten If needed refer to the appropriate drawing to reconnect red transformer wires on each gate drive board As an example for the 4160V stack reattach TB4 1 to 4 3 to X4 TB1 3 to X2 and TB1 1 to X1 Verify all wires are reconnected to their original position on the gate drive boards Otherwise the SCRs will misfire Reconnect thermostat wires on TB1 positions 2 and 3 of the Temp CT board Reconnect the main CT black wire to TB1 1 Then feed the white wire through the board mounted CT and connect to TB1 1 on the Temp CT board Please note that one each of the thick white wires from the encapsulated CT must be connected with the Main CTs wiring Ensure the same fiber optic routing is used as before If the fiber optic wiring is positioned close to a heat source such as the 25 watt resis tors on the gate drive board melting or distortion of the plastic fiber may occur Minimum distance is a inch with a minimum bend radius of 2 inches All gate drive boards require 2 single connectors per board and the Temp CT connector is a
119. on it Failure to follow this instruction will result in death or serious injury Note All power sources must be removed and a waiting period of at least 15 minutes must be observed before initiating any repairs to the unit s because DC voltage may still be present immediately after turning off power to the unit Note It is good practice to disassemble and reassemble one stack at a time so you can have an assembled and wired stack in the unit as a reference Note Toshiba recommends that the order include the SCR with the heat sink assembly at a minimum Only an experienced technician should attempt to replace the SCRs Tools Phillips screwdriver 3 8 12 point socket set 2 9 16 wrenches wrench AC DC Multimeter JKSSS manual refer to drawings in this section Procedure 1 Verify that no DC or AC voltage is present on any of the power compo nents 2 Disconnect all four wires connected to TB 1 positions 1 3 the tempera ture CT board 3 Disconnect the 4 red transformer wires on each of the gate drive boards These would be TB1 positions 3 and 5 for each gate drive board Typically the 2300V unit will have only 4 wires per phase to disconnect a 4160V unit will have 8 wires per phase and a 6000 7200V unit will have 12 wires per phase Note the 7200 600 unit will also have 24 wires 4 Use the 9 16 wrench and carefully unbolt all of the line and load power con nections attached to the heat s
120. onnections are correct and have not become loose in transportation Refer to MAINTE NANCE 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 for secureness and 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 A supply of spare parts fuses etc should be established Instruction manuals and diagrams should be collected and filed WIRING CHECK Field wiring 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 motor should be connected to its intended controller and phase rotation should be correct prior to startup Changes made to circuit diagrams during installation should be recorded DEVICE MECHANISM CHECKS devices should be checked for damage All necessary repairs or replacements should be made HV ARNING Do not energize damaged equipment that has not been repaired ARNING and verified
121. oss of profits or revenue loss of information or data loss of equipment described herein or any associated equipment cost of capital cost of substitute equipment or parts facilities or services down time costs labor costs or claims of customers ofthe purchaser for such damages even if Company has been advised of the possibility of such damages Purchaser shall provide this Limited Warranty and Limitation of Liability to its customers and users of the equipment and parts described herein prior to any sale to or use of the equipment and parts by such customer or user Company does not authorize anyone to make any representations or warranties other than the express warranties contained herein JKSSS Series 99 TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Rd Houston Texas 77041 Tel 713 466 0277 Fax 713 466 8773 US 800 231 1412 Can 800 872 2192 Mex 95 800 527 1204 World Wide Web http www toshiba com ind
122. outside of the usual limits may require derating or other special equipment such as heating cooling or ventilation Contact Toshiba for further information If the location for installation is damp space heaters may be required If space heaters are furnished inside the controller they should be connected in accordance with the wir ing 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 AWARNING 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 ven tilation 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 JKSSS Series 14 2 3 4 2KV JKSSS Series 2 3 4 2KV 2 4 Dimensions Ratings Standard JKSSS Class E2 Soft Starter a Type 1 Dimen in NEMA Type 12 3R Type 12 Dimen in Type 3R Dimen in Nominal ae HP Hi 48 59 1250 100 72 Volts 2300 600 2500 1900 600 2500 1900 3000 2250 Consi
123. plays the number of phase reversal trips Displays the number of external input 1 trips Displays the number of external input 2 trips Displays the number of external input 3 trips Displays the number of external input 4 trips Requires a Security Level 2 password to clear the statistics Screen 1 MWH TOTAL 2 RUNNING HOURS TOTAL TIME HOURS Screen 4 TOTAL TRIPS SIC TRIPS Screen 5 START TRIPS RUN TRIPS Screen 6 FREQUENCY TRIPS TRIPS 7 OVERCURRENT TRIPS Screen 8 STATOR TRIPS NON STATOR TRIPS Screen 9 G F HISET TRIPS Y G F LOSET TRIPS Screen 10 ACCELERATION TIME TRIPS Screen 11 START UNDER CURVE TRIPS Screen 12 START OVER CURVE TRIPS Screen 13 START CURVE TRIPS Screen 14 LEARNED START CURVE TRIPS Screen 15 FAIL SHUNT TRIP TRIPS Screen 16 PHASE LOSS TRIP TRIPS Screen 17 TACH ACCEL TRIP TRIPS Y 2 3 4 2KV Screen 3 PRESS ENTER TO CLEAR RUN HOURS Screen 18 U V TRIPS ON TRIPS Screen 19 i POWER FACTOR TRIPS Screen 20 t PHASE REVERSAL TRIPS Screen 21 i EXT INP 1 Screen 22 i EXT INP 2 Screen 23 4 EXT INP 3 Screen 24 EXT INP 4 Screen 25 PRESS ENTER TO CLEAR STATISTICS
124. quence of the inline isolation and bypass contactor and provides provisions for shutdown interlocks see section 2 10 2 TB1 Start Stop Control Figure 2 1 2 10 2 Description of Terminal Connections Start Stop Control Terminal Block 1 1 Positions 1 and 9 are the 120 Vac control power Positions 2 3 and 4 5 are factory jumpers installed and can be removed for customer s normally closed dry shutdown contacts See Fig 2 1 above Positions 6 7 8 are for either two wire or three wire start stop logic Two wire is connected to positions 6 and 8 with a N O dry maintained start stop contact Three wire control connects to 6 with 7 as the stop push button and the start push button is connected to 7 and 8 Positions 10 11 12 is a dry FORM C contact The contact is an immediate start stop contact JKSSS Series 22 Part ACG1A250 VAC or equivalent F2 Contactor and relay output fuses Part ACG4A250 VAC or equivalent F3 TB2 Pin 6 Part ACG4A250 VAC or equivalent d ai Start E2 ES E4 Output is Red max 120 VAC CREE EHE 20 VA x FUSE 716 T1 Red TB1 pm 6 LED E Xx SEEN FAULT 4
125. r directions INPUTS Continued Options Enabled or d See text for directions lt gt DUAL RAMP gt NAME EXT 22250291 3 SELECT DUAL RAMP 22250291 RAMP Options Enabled Disabled or See text for directions Dual Ramp Options Enabled or Disabled See text for directions SP6 5 User Programmable External Inputs The controller provides up to 4 digital external inputs which are individually programmable A description name can be assigned to each individual input for easy identification External Input 1 Factory programmed for TCB Trip External Input 2 If used this setpoint must be enabled Name Ext Input 2 The user can assign a description name to the input to easily identify the cause of external trip or alarm Up to 15 characters including spaces can be used to assign the name External Input 2 Type The external input can be set as either a normally open or normally closed contact External Input 2 Time Delay Upon a change in contact setting the unit will wait the programmed amount of time before generating an output If no delay is needed then input 0 seconds The controller will post an event upon seeing a change in state JKSSS Series 58 lt gt EXTERNAL INPUT 2 lt gt NAME EXT INPUT 2 Options Normally Open or Range 0 60 SEC Normally Closed Increments of 1 EXTERNAL INPUT 2 EXTERNAL INPUT 2 TYPE NORMALLY OPEN TIME DELAY 0 SEC Options Normally Open or Range
126. rmined by your application requirements Start Ramp 1 Type Current Current Ramping Closed Loop Torque Ramping is used for smooth linear acceleration of output torque This ramp is only used on some conveyor systems long haul or down hill Output voltage is constantly updated to provide the linear current ramp and therefore the available torque is maximized at any given speed This is for applications where rapid changes in torque may result in load damage or equipment changes Typical applications include overland conveyors if belt stretching occurs fans and mixers if blade warping is a problem and material handling systems if stacked products fall over or break This feature can be used with or without the Maximum Current Limit setting To achieve Current Ramping select CURRENT for START RAMP 1 TYPE setpoint and the MAXIMUM CURRENT 1 setpoint to the desired level Current Limit Only Current Step start uses the Current Limit feature exclusively This method of starting eliminates the soft start voltage current ramp and instead maximizes the effective application of motor torque within the limits of the motor In this mode setpoint RAMP TIME 1 is Set to zero 0 so the output current jumps to the current limit setting immediately Typically used in with a limited power supply when starting a difficult load such as a centrifuge or deep well pump when the motor capacity is barely adequate stall condition or overloading occ
127. round motor Check with megger or Hi pot motor HI SET OR LO SET nd motor ground soft start ground SRUS RUM High vibration Check internal connections connections Warning This is a serious fault condition Ensure that the fault condition is cleared on the load before attempting to restart the motor AUX1 Load shorted grounded Remove power and repair faulted Faulty main circuit board the main circuit board Remove power locate and remove Short in control circuit 2 this short None Apply the correct voltage to the control Wrong control voltage E 9 JKSSS Series 81 Any Ground Fault Trip Motor stopped Check for fault indication during run Control circuit fuses blow after control power is applied JKSSS Series 2 3 4 2KV Aux Relay No control voltage applied Apply control voltage to TB1 pins 1 and 6 to control board on the power board Control power transformer Remove power and replace the power failure or CPT fuse failure transformer or the CPT fuse Start circuit wired Remove power and correct the start incorrectly circuit wiring AUX1 Possible Cause Solutions Problem CPU LCD Display LED Materno ela Any fault indication message No start command Apply the start command No 3 phase line voltage 3 phase line voltage to the unit Remove power and test SCR s Refer to Shorted SCR in starter Section 7 1 1 for the SCR testing procedure Faulty
128. s Note The Programming Mode can only be entered from the Ready Mode During programming all protection features and start command are disabled Start Mode These additional protection functions are enabled when the soft starter receives a valid Start command Phase Reversal if enabled Start Curve Acceleration Timer Phase Imbalance Short Circuit Load Pre check Toe in the Water Ground Fault Optional External Input Faults Accumulated Starting FLA Units 121 Protection Overload Protection Thermal Capacity Note Shorted SCR and Shunt Trip protection are no longer in effect once the Soft starter goes into the Start Mode Run Mode The soft starter enters the Run Mode when it reaches full output voltage and the motor current drops below the FLA setting motor nameplate FLA plus service factor for a predetermined period of time During the Run Mode these additional protection features are enabled Running Overload Curve Phase Loss Under Current Load Loss Over Current Electronic Shear Pin Jam protection External Input Faults Stop Mode Once a Stop command has been given the protection features change depending on which Stop Mode is selected Decel Mode Retains all protection features of the Run Mode At the end of Decel the motor will be stopped and the protection features change as indicated below JKSSS Series 8 JKSSS Series Coast To Stop Mode Power is im
129. s a bypass contactor low voltage controls and motor terminal blocks in that order An optional soft start only version is also available which is supplied without the control power transformer the disconnect switch and line isolation contactor The soft start only model must be used with a customer supplied mechanically interlocked line start panel 1 2 Specifications Unit Overload Capacity 500 60 seconds Percent of motor FLA 1 Cycle up to 14 x FLA internally protected by programmable short circuit Frequency 50 or 60Hz 2Hz hardware selectable Power Circuit 6 SCRs 12 SCRs or 18 SCRs model dependent SCR Peak Inverse Voltage Ratings 6500 13000V model dependent see page 4 Phase Insensitivity User selectable phase sequence detection Transient Voltage Protection RC snubber dv dt networks one per SCR module Enclosed units 0 to 40 C 32 to 104 F 5 95 relative humidity 0 3300 ft 1000m above sea level without derating Ratings for ambient conditions external to unit Contro Auxiliary Contacts BIL Rating Ambient Condition Design JKSSS Series 1 JKSSS Series 1 2 Specifications continued Two Stage Electronic Overload Curves Overload Reset Retentive Thermal Memory Dynamic Reset Capacity Phase Current Imbalance Protection Over Current Protection Electronic Shear Pin Load Loss Trip Protection Coast Down Back Spin Lockout Timer Starts per hour Lockout Tim
130. s of FORM contacts These dry contacts that operate when a blown fuse indication is given or discon nect is 1 2 3 4 5 6 7 48 9 10 11 12 Positions 7 8 9 and 10 11 12 are sets of FORM C contacts These are C No NCC NC C NO NC C NO NC fault contacts that change state if any fault condition occurs Lockout Fault Contacts Figure 2 4 Optional Relay Terminal 4 TB4 Positions 1 2 3 and 4 5 6 are sets of FORM C contacts These are aux TB4 iliary time delay contacts that will change state after a delay when the Start contact is initiated X3 X4 and SW4 determine the amount of delay Switch Position and Jumper Selection on following page Positions 7 8 9 and 10 11 12 are sets of FORM C contacts These are power factor correction capacitor PFC contacts to pull in an isolation con 2 5 9 0 1 2 tactor for the capacitors if required by the application These will change bd pu NM state when the At Speed contact is initiated X5 X6 and SW5 determine the TMEDELAY amount of delay See Switch Positions and Jumper Selection on E the following Note This delay is in addition to SP2 of the CPU programming Figure 2 5 Terminal Block 6 TB6 Positions 1 and 2 are 120 VAC power supply to the Main and CPU circuit boards Positions 3 and 4 are the start input connections to the Main and CPU circuit boards Positions 5 and 6 are the fuse blown input connection
131. s to the Main and CPU circuit boards Positions 7 and 8 are the Dual Ramp input connections to the Main and CPU circuit boards Positions 9 and 10 are the Bypass Status input connections to the Main and CPU circuit boards Terminal Block 7 TB7 Positions 1 and 2 are the Run contacts AUX 3 from the Main and CPU circuit boards to the TCB board This signal is used to hold the Main Contactor closed during deceleration Positions 3 and 4 are the Main and CPU circuit board output connections to the TCB that signal the AUX1 Fault Status Positions 5 and 6 are the At Speed contacts AUX 4 from the Main and CPU circuit boards that signal the Bypass Contactor to close Position 7 has no connection Terminal Block 8 TB8 Positions 1 and 2 accept dry normally closed contacts from blown fuse indicators and or disconnect inter lock contact Positions 3 and 4 accept dry normally closed contacts from an external overload protection device re quired if emergency bypass is used JKSSS Series 23 JKSSS Series 2 3 4 2KV e Positions 5 and 6 accept dry normally closed contact from the bypass contac tor for an At Speed indication Factory wired s Positions 7 and 8 are wired to the coil of the bypass contactor and energizes and de energizes the contactor Factory wired s Positions 9 and 10 are wired to the coil of the inline isolation contactor and energizes and de energizes the contactor Note All customer contacts are 960VA
132. sion JKSSS Series 80 JKSSS Series 2 3 4 2KV Problem CPU LCD Display s Possible Cause Solutions Relay Loss of 1 ormore phases of power from Check power source Phase Loss PHASE LOSS AUX1 utility or generated power Blown power fuses Check for short circuits Check motor nameplate versus proper prog 9 programmed parameters Overload OVERLOAD TRIP AUX1 Possible load Check motor currents jammed load 2 Verify current limit setting Stall prevention ACCEL TIME TRIP AUXI TUIS So Rd Damaged load Check for load failure Improper programming Check setpoint settings Wrong position of Check disconnect or open breaker disconnected breaker AUXI Under Voltage UNDER VOLTAGE TRIP Trip Main contactor failed to Check internal connections close Reduce current limit setting saturation Transformer too small or sagging power supply transformer Improper programming Check setpoint settings AUX1 Unloaded motor Check load Failed CPU or Main Firing AUXI Board Contact factory Vibration Check internal wiring connections AUXI Gerierator Power Main board failure Problem or grid change Three phase power removed from Main Board Improper programming Check program setpoints Any wire going to ground AUX1 Under Current UNDER CURRENT TRIP Trip Self test Failure SELF TEST FAILURE Line Frequency OVER OR UNDER Trip FREQUENCY TRIP GROUND FAULT Le stator g
133. sors in the Series provide protection from a stall condi tion an overload condition or excessive acceleration time The Current Limit feature is provided to accommodate installations where there is limited power available for example on site generator power or utility lines with limited capacity The torque is increased until the motor current reaches the preset Current Limit point and it is then held at that level Current Limit overrides the ramp time setting so if the motor has not accelerated to full speed under the Current Limit setting the current remains limited for as long as it takes the motor to accelerate to full speed When the motor reaches full speed and the current drops to running levels the Soft starter detects an At Speed condition and closes the Bypass Contactor The Bypass Contactor serves to shunt power around the SCR stack assemblies to prevent heat buildup in the starter enclosure due to the slight voltage drop across the SCRs At this point the soft starter has the motor operating at full voltage just as any other starter would Other starting methods available in the soft starter are Current Ramp Uses a closed current feedback PID loop to provide a linear torque increase up to a Maximum Current level Constant Current Current is immediately increased to the Current Limit point and held there until the motor reaches full speed Custom Curve Gives the user the ability to plot torque and time poi
134. st exist before an alarm GROUND FAULT ALARM GROUND FAULT ALARM i level LEVEL OFF DELAY 0 1 SEC Range 5 90 OFF Range 0 1 20 0 SEC Imbalance Trip Delay The amount of time the Increments of 1 Increments of 0 1 imbalance condition must exist before a trip will Emna TRIP LEVEL OFF TRIP DELAY 0 5 SEC Range 5 90 OFF Range 0 1 20 0 SEC Increments of 1 1 Increments of 0 1 SP3 3 Undercurrent Alarm Level Typically used to warn of possible load loss a coupling breaking or other GROUND FAULT HISET mechanical problems TRIP LEVEL OFF 0 GROUND FAULT HISET TRIP DELAY 0 008 SEC ange 0 008 0 250 SEC FF 9 Increments of 1 Increments of 0 002 Undercurrent Alarm Delay The amount of time the undercurrent condition must exist before an OVERVOLTAGE ALARM OVERVOLTAGE ALARM alarm will occur LEVEL OFF DELAY 1 0 SEC Range 5 30 OFF Range 1 0 30 0 SEC Increments of 1 Increments of 0 1 P3 4 Overcurrent Alarm Level Typically used to indicate SP3 pedi is y d d OVERVOLTAGE TRIP OVERVOLTAGE TRIP when the motor is overloaded This feature can be LEVEL 10 DELAY 2 0 SEC used to either stop the feed to the equipment or Range 5 30 OFF Range 1 0 30 0 SEC warn operators of an overload condition UNDERVOLTAGE ALARM UNDERVOLTAGE ALARM Overcurrent Alarm Delay The amount of time the DECA Od OSE js
135. t up Review all parameters and readjust as required See Chapter 5 Programming for de tailed instructions Try factory settings first Verify that the interlocks for the system are installed and working properly Verify that the feed transformer is correctly sized for the motor s Check for any loose mechanical parts or metal debris in the enclosure Check the motor strapping and connections Verify that the unit is properly grounded Remove tie straps from Blown Fuse Indicator Connect line voltage to line terminals 3 2 Introduction It is best to operate the motor at its full load starting condition to achieve the proper time torque and ramp settings Initial settings are set to accommodate most motor conditions TRY INITIAL SETTINGS FIRST See Setpoint 5 1 2 Starter Confiuration Setpoint Page 2 to make any adjustments 3 3 Acceleration Adjustments The unit is set at the factory with typical starting characteristics that perform well in most applications When the system is ready to start try the initial unit settings If the motor does not come up to speed increase the current limit setting If the motor does not start to turn as soon as desired raise the starting voltage adjustment Adjustment description and procedures are described as follows See Setpoint 5 1 2 Starter Configuration Set point Page 2 for additional Accel settings 3 3 1 Starting Voltage Factory Setting 20 of line voltage Range 0 100 of li
136. tact is closed the main contactor is energized and the motor line starts When the ON OFF contact is opened the motor is disconnected from the line via the main in line vacuum contactor JKSSS Series 32 Display 1 Display 2 Display 3 Display 4 2 3 4 2KV MOTOR STOPPED READY TO START MOTOR STARTING 00 XFLA OVERLOAD ALARM TIME TO TRIP XXX SECS A 22 ee NN IB GIF _ JKSSS Series 2 3 4 2KV Chapter 4 User Interface amp Menu Navigation This chapter explains the keypad operator interface the LCD descriptions and the programming features 4 1 Keypad Operator Interface The user keypad keypad operator interface consists of 2 row by 20 characters Liquid Crystal Display LCD e 12 LEDs 8 pushbuttons 1 Note The soft start is menu driven and there are three levels of programming The POWER ENTER programming for two of these levels is password protected Level two requires a 1 e three digit password and level three requires a four digit password Alea Toggle between the menu selection for metering and setpoint pages RESET Will clear the trip indicator and release the trip relay In the edit mode press the ENTER pushbutton so the unit will accept the new programming information When not in the edit mode the ENTER pushbutton will toggle through the event indicator list such as alarms or trips Provides general help information about a specifi
137. te jumper wires on the gate drive board and make a note of their placement Remove both 7 16 bolts and the singular 10 32 screw at the top of gate drive board and lift off the board To remove the MOV board remove the SCR gate cathode leads thin red and white wires and the white jumper wires attached to them Make a note as to how they were connected Unbolt the 72 fasteners as well At this point all boards should now be removed from the aluminum heat sink assembly Make a note or drawing of how each of the SCRs are oriented within the heat sink If factory supplied replacement SCRs and heatsinks are used the following steps are not required Loosen and carefully remove the 72 feed through bolt and two black springs that hold the assembly together and turn it on its side Remove the two 2 SCRs in the top layer making certain to note that the SCRs are not facing the same direction Remove the two 2 SCRs in the bottom layer also making certain to note that the SCRs are not facing the same direction Clean the heat sink surface area thoroughly and reapply some thermal heat sink grease sparingly to the SCRs mating surfaces Please note that replacement SCRs are in matched sets of four and as Such please try to keep the matched sets within the same phase Now take any two SCRs from a set and place them on the heat sink in the same direction as the old SCRs were ensuring that the dimple in the center of the SCR is properly place
138. tek L7 Optional Interlocks SUA pter 2 Lock 120 VAC m X Source E F1 10 ee B FACTORY WIRED Green F3 B DO NOT USE LED F3 Eh 120VAC Line Op x Neutral 0 2 12V TB2 aa jg 7 Ql T 4 Bypass Delayed Start Dl d LED 3 Eh AUX Contacts Fuse Blown A START Bypass Disconnect Open Dle B6 1 EMT Full Voltage Start 0 7 Dual Ramp ON 1 1 swi bypass DU Remove for eleconie EBL o Qo during emergency 5 bypass operation 1 TCB Dis CPU AUX1 Fault ae 4 TB7 BOARD 5 5 At Speed 8 Qs Fuse Blown o E Disconnect 329320 Interlock Input Ql OR RARE LED a x 3 External Overload 8 5 4 TIMED 7654321 7654321 7654321 hd Bypass Aux Contact o s DADON Bypass PFC AUX sTarT TB4 Coil A2 Ds gt Main 9 5 A2 10 LED 9 DELAY TIMED OUT TCB Terminal and Control Board Figure 2 2 See page 85 for larger version JKSSS Series 2 3 4 2KV Emergency Bypass Control Terminal Block 2 TB2 TB2 Positions 1 and 2 are for an emergency bypass contact If a dry contact closes position 1 and 2 this causes the CPU to be shut off so there is no display Then when a start is initiated it pulls in the inline i
139. ter control Level two setpoint screens require a three digit password to configure the protection schemes Level three setpoint screens require a four digit password to access the full range of protection and starter schemes SP10 1 Set Level 2 Password This level uses a 3 digit password The default level 2 password is 100 SP10 2 Set Level 3 Password Level three uses a 4 digit password The default level 3 password is 1000 2 3 4 2KV Hit DOWN ARROW nine times PAGE 10 SECURITY SET PASSWORD SET LEVEL 2 PASSWORD 100 Range 000 999 SET LEVEL 3 PASSWORD 1000 Range 0000 9999 JKSSS Series 65 JKSSS Series SP 11 Communications Setpoint Page 11 Security Level 3 SP11 1 Set Front Baud Rate Configures the RS232 communications baud rate SP11 2 Set Modbus Baud Rate Configures the Modbus communications baud rate SP11 3 Modbus Address Number Assigns a Modbus address to the soft starter relay SP11 4 Set Access Code Assigns an access code to the Modbus addressing This is typically not used 11 5 Set Link Baud Rate Configures the RS422 communications baud rate between the keypad operator and the CPU board For applications with remote keypad only SP11 6 Remote Start Stop Allows the RS485 Modbus communications to start and stop the motor Contact factory for details JKSSS Series 66 Hit DOWN ARROW ten times PAGE 11 c SET FRONT BAUD COMMUNICATIONS RATE 9 6 KB S
140. thod by which this delay is calculated See SW5 for instructions X5 PFC C Time delay in cycles X6 PFC S Time delay in seconds Factory setting Switch Positions Switch Positions o n Please refer to Figure 2 7 m um LL SW1 ON Dual Adjustment 12 3 4 5 6 7 8 OFF Disabled Time 1 2 A SW2 Not used Switches SW3 SW4 and SW5 are 7 position dip switches seconds cycles that use binary code to count up to 127 seconds cycles see Jumper Selec tion above SW3 Start Delay 7 position dip switch uses binary count up to 127 seconds cycles see jumper selection above Factory setting 1 second SWA Auxiliary Start Delay 7 position dip switch uses binary count up to 2 4 3 to 19294 7 seconds 127 seconds cycles see jumper selection above Factory setting 1 second total time Note This example ap SW5 PFC time delay 7 position dip switch uses binary count up to 127 plies to SW3 SW4 amp SW5 seconds cycles see jumper selection above Factory setting 1 second Note This switch interacts with the CPU programming when the Decel function is enabled Note These times are in addition to SP2 in the CPU setpoints Figure 2 7 Example Switch settings are cumulative Setting dip switch positions 1 2 JKSSS Series 24 JKSSS Series 2 3 4 2KV 2 11 Reference Section 2 11a RTD Board pa aj E Sa 5 2 C37
141. ting or negative sequence currents present Motor Design Ambient Temperature Use the data from the motor manufacturer s specifications When RTDs are used this setpoint will be the base point for the RTD biasing of the Thermal Register Motor Design Run Temperature Use the data from the motor manufacturer s specifications This setpoint defines the operating temperature rise of the motor at full load amps or 100 load Motor Stator Max Temperature This represents the maximum temperature the stator insulation will withstand The user may choose to use the temperature setting of the insulation class selected in Setpoint Page 1 or enter a specific maximum temperature This value should not exceed the stator s insulation temperature This maximum temperature represents 10096 thermal capacity Input to Thermal Register Always enabled It allows the soft starter to use the line current imbalance information to bias the Thermal Register User Calculated K or Assign When the setpoint is set to ON the controller will calculate the k constant factor for biasing the thermal register or the user may choose to assign the k value Press Enter to CLR Thermal Register Allows the level three password user to clear the thermal register for emergency restarts JKSSS Series 2 3 4 2KV SP 13 Calibration amp Service Setpoint Page 13 Security Level Factory Use Only Hit DOWN ARROW twelve times PAGE 13 CALIBRATION SET DATE A
142. urs or if other starting modes fail Since ramp times are set to zero 0 START RAMP 1 TYPE is set to either VOLTAGE or CURRENT Initial Torque Initial Voltage 1 or Initial Current 1 Sets the initial start point of either JKSSS Series the Voltage Ramp or the Current Ramp Every load requires some amount of torque to start from a standstill It is inefficient to begin ramping the motor from zero every time since between zero and the WK2 break away torque level no work is being performed The initial torque level should be set to provide enough torque to start rotating the motor shaft enabling a soft start and preventing torque shock damage Setting this start point too high will not damage the starter but may reduce or eliminate the soft start effect Ramp Time 1 Sets the maximum allowable time for ramping the initial voltage or current torque setting to either of the following 1 the Current Limit setting when the motor is still accelerating or 2 full output voltage if the Current Limit is set to maximum Increasing the ramp time softens the start process by gradually increasing the voltage or current Ideally the ramp time should be set for the longest amount of time the application will allow without stalling the motor Some applications require a short ramp time due to the mechanics of the system i e centrifugal pumps because pump problems can occur due to insufficient torque Current Limit Sets the
143. voltage CPT single phase control power transformer if present Remove 3 fuses from the medium voltage potential transformer PT Verify the 120 volt test switch is in the NORMAL position Connect test power to test plug connector and place the 120 volt test switch to the TEST position The keypad should be energized with the Power LED Stop LED Close the temporary Start switch which is connected to the control board The Main Vacuum contactor should close and the keypad should trip on Under Voltage Open temporary TEST switch and reset CPU fault Connect the Secondary of the TEST PT to Panel TB1 positions 1 phase A position 3 phase B and position 5 phase C on the main firing board JKSSS MB It is physically located behind the low voltage compartment door Screw terminal block Verify all connections are good and then energize the low voltage of either 480 or 240 volt three phases Use the multimeter on the AC scale and verify 3 phase 120Vac phase to phase at TB1 pins 1 3 and 5 of the main firing board If all 120Vac phase is present then de energize low voltage of 480 or 240Vac Re energize the low voltage of 480 or 240Vac Now all test voltages should be present 480 or 240Vac and three phase 120Vac TEST PT and 120Vac single phase for control power Close the temporary Start switch and the test motor should spin up smoothly Use the Multimeter on the AC scale and ch
144. with non tracking fire resistant non hygroscopic insulation supports and have a minimum fault current rating of 50 000 Amps e Connections All bus connections use 2 bolts minimum with Belleville spring washers to ensure tightness Splice kits for each shipping split are included along with specific installation instructions Ground Bus A continuous ground bus bar with a minimum rating of 400 Amps extends the entire length of the starter near the bottom of each enclo sure A grounding strap connects each vertically adjacent compartment and also ties the grounding arm of the disconnect switch to the main ground bus bar see section 2 11 e Seismic Qualifications The entire starter assembly when properly installed withstands vertical and horizontal accelerations typical of seismic Zones 1 through 4 as defined in the UBC The assembly will not overturn or show significant lateral movement but cannot be expected to continue operating during or after a seismic event 1 5 Theory of Operation The power of the JKSSS Series is in the CPU a microprocessor based protection and control system for the motor and starter assembly The CPU uses Phase Angle Firing of the SCRs to apply a reduced voltage to the motor and then slowly and gently increases torque through control of the voltage and current until the motor accelerates to full speed This starting method lowers the starting current of the motor reducing electrical stresses on the power S
145. ystem and motor It also reduces peak starting torque stresses on both the motor and load mechanical components promoting longer service life and less downtime Acceleration The JKSSS Series comes standard with several methods of accelerating the motor so that it can be programmed to match almost any industrial AC motor application The factory default setting applies a Voltage Ramp with Current Limit as this has been proven the most reliable starting method for the vast majority of applications Using this starting method the Initial Torque setting applies just enough voltage to the motor to cause the motor shaft to begin to turn This voltage is then gradually increased over time as per the Ramp Time setting JKSSS Series 6 JKSSS Series 2 3 4 2KV until one of three things happen the motor accelerates to full speed the Ramp Time expires or a Current Limit setting is reached If the motor accelerates to full speed before the ramp time setting has expired an automatic Anti Oscillation feature will override the remaining ramp time and full voltage will be applied This will prevent any surging or pulsation in the mo tor torque which might otherwise occur due to the load not being fully coupled to the motor when operating at reduced voltage and torque levels If the motor has not reached full speed at the end of the ramp time setting the current limit setting will proportionally control the maximum output torque Feedback sen

Toshiba VF010H05 Remote Starter User Manual

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