Home

Toshiba 48-1250 A Remote Starter User Manual

1. i C NO NCi NO NCi N C C NO NCI AUX1 AUC AUG AUXM ALARM SHUNT AT SPEED Relay Contacts on Power Board Rated 240Vac 5A 1200VA TOSHIBA 12 TX Series 2 9 CPU Board Connections There are eight digital inputs on the CPU board Four of the inputs are user programmable There are also two analog outputs a tachometer feedback input 48 1250A Contact factory for remote reset connections N 2 im a amp amp 5 5 5 5 ox SE 2 oo 5 8 5 TB1 amp i TB2 TB3 Note Install program jumper to enable setpoint programming Jumper must be removed after programming or for prolonged storage to preserve settings TOSHIBA 13 Factory wired Do not change N 5 E 8 X Dual Ramp Thermostat TX Series 48 1250A 2 10 Communications Board Full RS422 or half RS485 duplex Modbus communications port is available at TB1 on the communications board No field wiring connections are required for TB2 TB2 RS422 Note Remove for last unit in modbus string 2 10 1 Communication Board Connections TB1 TB2 9 22 lt 1 XY my RECEIVE TRANSMIT RS485 Connections RS422 Connections Customer Connections Factory Only TOSHIBA 14 _ 3 _ 5_ a
2. 9 0555 01 20 Analog Output zomar eo Araig ompun same As arao moan User Programmable External Inputs Disabled _______ EnabedorDeabes Ext meu Exmampugi 71 01 Disabled Embedor eaed 1 1 User Detned upto 15 Graces type Normally J Time oss OvalRamp EmabedorDsabedorDosRam Ea mpu Dual Ramp User Defined upto 15Gharactors J Dual Ramp TimeDeay oss name Ex Thermostat User Defined upto 15 Characters Thermostat Type JO Tine ise osse Description Range Setting Password Protection 5 5 2 c o o E tc Setpoint Level Description Setting Analog Output 1 RMS Current User I O Configuration Passowrd Protection TOSHIBA 84 TX Series Setpoint Page Custom Acceleration Curve Setpoint Page Overload Curve Configuration Security Level Password Protection Securit
3. 5 55 0 lt o gt 3 5 5 8 3 9 413121913 3 3 9 9 gt 2 151315 3 D 5 E o INS CLS INS CLS 10 240 C Input to Thermal Register Enabled Enabled Only 7 80 On 5 1 13 Calibration and Service Setpoint Page 13 Setpoint Security Page Level Factory Setting Default Set Date and Time FACTORY SET DDMMYY HHMM THEHBEHBE HHHH SP13 1 Description Range Section FACTORY SET Enter Date DDMMYYYY 0 1 31 1 12 1970 2069 Enter Time HH MM PAO edi H 00 23 M 0 59 HHHH FACTORY SET Firmware REV dH Display Only Cannot be changed 5 13 2 Available to Qualified Factory Personnel SP13 3 gt 2 0 o 9 0 g 2 E o FACTORY USE ONLY 2 0 n TOSHIBA 31 TX Series 48 1250 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 the DOWN ARROW two times PAGE 1 BASIC CONFIGURATION LEVEL 1 2 STARTER CONFIGURATION PAGE 3 PHASE amp GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT LEVEL 2 5 RELAY CONFIGURATION 6 USERI O CONFIGURATION PAGE7 CUSTOM ACCELERATION CURVE P
4. Use only Toshiba authorized replacement paris 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 2004 TX Series Digital Solid State Soft Starter 48 1250A Installation amp Operation Manual Chapter 1 1 1 1 2 1 3 e 1 General Specifications Theory of Operation 1 4 General Protection 1 5 Thermal Overload Protection Chapter 2 Installation 8 2 1 Receiving and Unpacking 2 2 Initial Unit Inspection 2 3 Location 2 4 Mounting amp Cleaning 25 Power Wire Range and Tightening Torque 2 6 Dimensions 2 7 Power Connections 2 8 Control Connections 2 9 CPU Board Connections 2 10 Communications Board 2 11
5. Range Range Range Range STATOR PHASE B1 TYPE RTD 3 DESCRIPTION STATOR PHASE B1 ALARM STATOR PHASE B1 TRIP 100 OHM PT STATOR PHASE B1 LEVEL HHF LEVEL Range Range Range Range STATOR PHASE B2 TYPE RTD 4 DESCRIPTION STATOR PHASE B2 ALARM STATOR PHASE B2 TRIP 100 OHM STATOR PHASE B2 LEVEL HHF LEVEL Range Range Range Range STATOR PHASE C1 TYPE RTD 5 DESCRIPTION STATOR PHASE C1 ALARM STATOR PHASE C1 TRIP 100 OHM PT STATOR PHASE C1 LEVEL HHF LEVEL HHF Range STATOR PHASE C2 RTD 6 DESCRIPTION STATOR PHASE C2 ALARM STATOR PHASE C2 TRIP 100 OHM PT STATOR PHASE C2 LEVEL LEVEL C Range Range Range Range END BEARING TYPE RTD 7 DESCRIPTION END BEARING ALARM END BEARING TRIP 100 OHM PT END BEARING LEVEL C LEVEL Range Range Range SHAFT BEARING TYPE RTD 8 DESCRIPTION SHAFT BEARING ALARM SHAFT BEARING TRIP 100 OHM PT SHAFT BEARING LEVEL LEVEL HHF Range Range Range Range RTD 9 TYPE RTD 9 DESCRIPTION RTD 9 ALARM RTD 9 TRIP 100 OHM RTD 9 LEVEL HHF LEVEL HHF Range Range Range Range RTD 10 TYPE RTD 10 DESCRIPTION RTD 10 ALARM RTD 10 TRIP
6. Tachometer Feedback Ramp uses a closed loop speed follower method monitoring a tachometer input signal from the motor or load shaft PENDING Deceleration the TX Series provides the user with the option of having the load coast to a stop or controlling the deceleration by slowly reducing the voltage to the motor upon initiating a stop command The Decel feature is the oppo site of DC injection braking in that the motor will actually take longer to come to a stop than if allowed to coast to a stop The most common applica tion for the Decel feature is pumping applications where a controlled stop prevents water hammer and mechanical damage to the system 1 4 General Protection Operation of the TX Series can be divided into 4 modes Ready Start Run and Stop The CPU provides motor and load protection in all four modes Additional details on each protection feature can be found in later chapters Ready Mode In this mode control and line power are applied and the starter is ready for a start command Protection during this mode includes the monitor ing of current for leakage through multiple shorted SCRs Other protection features in effect are Starter Temperature Shorted SCR Phase Reversal if enabled Line Frequency Trip Window External Input Faults Note The Programming Mode can only be entered from the Ready Mode During programming all protection features and start command are disabled Start Mode These
7. er 1 60 5 current limit setting Increments of 1 Note Each successive voltage level must be programmed to a voltage level equal to or greater than the previous level All eight levels of LEVEL 7 82 voltages must programmed and the eighth Renae 0 100 level has been preset at 100 f Custom Accel Curve has been set to curve A or C this page the TX will override the Start Range 1 60 SEC Control Mode selected in Setpoint Page 2 even Increments td if Start Control Mode Setpoint 2 has been set to Custom Accel Curve Note Setpoint Page 7 has a security level 3 Range 0 100 requirement Increments of 1 CURVE C VOLTAGE LEVEL 8 100 CURVE C RAMP TIME 8 2 SEC Range 1 60 SEC Increments 1 LIMIT 350 FLA Range 200 600 Increments of 10 TOSHIBA 48 TX Series 48 1250A SP 8 Overload Curve Configuration Setpoint 8 Security Level 3 Hit DOWN ARROW seven times 8 OVERLOAD BASIC RUN 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 ROTOR TIME O L CLASS CURRENT 600 FLA SP8 1 Basic Run Overload Curve Rangat1 30 BEG OL CUES p
8. TOSHIBA 26 TX Series 48 1250A 5 1 6 User I O Configuration Setpoint Page 6 Setpoint Security Page Level Factory Setting Default Tachometer Scale Selection Disabled Enabled or Disabled Manual Tach Scale 4 0mA ORPM 0 3600 SP6 1 Manual Tach Scale 20 0 mA 2000 RPM 0 3600 Tach Accel Trip Mode Select Disabled Underspeed Overspeed or Disabled SP6 2 Description Section Off RPM 0 3600 Hottest Non Stator RTD 0 200 C Hottest Stator RTD Analog 1 RMS 0 200 C RMS Current 0 7500 Motor Load 0 600 kw 0 30000kw SP6 3 Analog Output 1 4mA __________0 65535 User I O Configuration Passowrd Protection Inputs User Defined up to 15 Characters NO 0 sec 0 60 sec Enabled Disabled Pp Analog Output 2 4mA 0 1000 1 Normally Open Closed Name Ext Input 2 User Defined up to 15 Characters Dual Ramp Dual Ramp Enabled or Disabled or Dual Ramp User Defined up to 15 Characters User Defined up to 15 Characters TOSHIBA 27 TX Series 48 1250A 5 1 7 Custom Acceleration Curve Setpoint Page 7 Setpoint Security Page Level Custom Acceleration Curve Password Protection Factory Setting Default Same Programmable Data Points Ranges Custom Curve B as Custom Curve A Custom Curve Same Programmable Data Points and Ranges as Custom Curve A Description
9. cause of event 59th HEISEI THE HE Event lt of event IA THHHHHE 1B lt gt Vab THHHHBE IC HHHH GIF HHHE HHHHE PIF HHHE lt gt Vab HHHHE Vca PIF HHHH 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 Imbalance Trip with the date and time it occurred Screen 1a Displays the current at Phase A B C and the ground fault at the time of the trip Screen 1b Displays the Vab Vbc and power factor at the time of trip TOSHIBA 64 TX Series 48 1250A MP 6 Last Trip Metering Page 6 Displays the information regarding the last trip Screen 1 Displays the cause of the last trip creen cause of tri Screen 2 Displays the measured phase current at the una UE A time of the trip Screen 2 1 Screen 3 Displays the Vab Vbc Vca and power la HHH 0b HHH factor at the time of trip lc HHHE Screen 3 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 when RTD option present at time of the Hz trip KW Screen 6 Displays the hottest non stator RTD wes EXE temperature when RTD option present at
10. 9999 Four Digits SP10 2 5 1 11 Communications Page 11 Description Section Setpoint Security Page Level Factory Setting Default Modus Address Number 9 Remote Start Stop Disabled Enabled or Disabled SP11 6 Description Section a c 5 9 5 Password Protection TOSHIBA 30 TX Series 48 1250A 5 1 12 System Setpoint Page 12 Setpoint Security Page Level Factory Setting Description Default Section Default Display Screen Metering Data Page Enter Metering Page 1 4 Enter Metering Screen Page 1 1 10 Metering Data Screen 1 Page 2 1 11 Page 3 1 29 Page 4 1 6 Disabled Enabled or Disabled SP12 2 O L Class O L Class 5 30 or 4 40 second time delay O L Class Ve Class 4 40 sec SP12 3 Page 12 System Setpoints 80 50 100 Motor Stator Temp Password Protection 2 9 5 2 17 2 12 5 2 S 8 5 lt 5 5 31313 3 3 8 13 3 2 9 9 2 2 8 2 2 5 5 2 3 2 gt 2 5 9 5 8 5151 0 2 dz 19 3 9 8 gt 2 2 9 9 9 PEL c 3 x 5 1313 9 51912513 4 gt l 2 2 3 5 gt
11. kW THHHHE Screen 6 1 PEAK ON TERETHE KVA Screen 7 PEAK Screen 8 AMPS Screen 9 PRESS ENTER CLEAR DEMAND VALUES Screen 10 1 MWH USED 11 1 PRESS ENTER CLEAR MWH VALUES METERING PAGE 3 RTD VALUES RTD Values Metering Page 3 Displays the RTD information when RTD option is supplied 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 1 in C and 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 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 TOSHIBA 62 HOTTEST STATOR RTD Screen 2 HOTTEST NON STATOR RTD Screen 4 STATOR PHASE A1 MAX TEMP SINCE RTD 1 HH HH F CLEAR RTD 1 Screen 5 Screen 6 STATOR PHASE A2 MAX TEMP SINCE RTD 2 HH HH F CLEAR RTD 2 Screen 7 Screen 8 STATOR PHASE B1 MAX TEMP SINCE RTD 3 C HH F CLE
12. yor yor Thermostat TOSHIBA 75 TX Series ADANGER AMVARNING 48 1250 7 6 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 with energized componenis 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 permanent record of all maintenance work At a minimum this record should include information on Items inspected Reports of any testing Equipment condition Corrective actions or adjustments Date of work Comments 2 0 00102 The degree detail of the record will depend som
13. 1250A SP6 5 The TX provides two 4 20mA analog outputs SP6 6 TOSHIBA 44 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 or Motor Load Analog Output 1 Select a function from the available five 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 TX 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 4mA 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 Analog Output 2 All of the setpoints and setup screens for Analog Output 2 are the same as those for Analog Output 1 TX Series 48 1250A SP User I O Configuration Setpoint 6 Security Level 2 gt PROGRAMMABLE SELECT DISABLED TYPE NORMALLY CLOSED TIME DELAY 0 SEC EXTERNAL Options Enabled or Disabled See text for directions Options Normally Open or Range 0 60 SEC INPUTS Normally Closed Increments of 1 Continued ae Options Enabled or Disabled S
14. Phase Rotation Detection The TX 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 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 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 Pending Ground Fault Loset Trip Delay The amount of time that the ground fault condition must exist before a trip will occur lt gt 5 3 11 TOSHIBA 38 48 1250A Hit DOWN ARROW two times PAGE 3 PHASE amp GROUND SETTINGS POWER FACTOR LEAD P F ALARM OFF Range 01 1 00 OFF Increments of 01 P F LEAD ALARM DELAY 1 SEC Range 1 120 SEC Increments of 1 Y 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 P F LAG ALARM DELAY 1 0 SEC Range 1 120 SEC Increment
15. 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 5 12 2 Alarms Configures the RTD failure alarm when RTD option is included and the thermal register alarm RTD Failure Alarm If enabled and an RTD shorts or open an alarm occurs Only if RTD option is installed Thermal Register Alarm Sets a level in the thermal register to generate an alarm when 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 5 12 3 Thermal Register Setup Information This setpoint group will configure the thermal register and indicate to the TX which inputs to use when thermal modeling 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
16. 61 49 210 183 92 73 259 225 113 90 388 337 169 135 516 449 225 180 2 3 948 84 412 330 71 9 8 59 88 516 46 48 100 2154 1873 97 749 187 108 20 4307 3745 1873 1498 375 215 7 2 3 9 __60 100 375 9363 4682 29 49 73 27 74 337 TOSHIBA 79 Cooling Consideration for Maintaining Ambient Temperature TOSHIBA 80 TX Series 48 1250A Appendix B Record of Setpoint Adjustments Setpoint Security Page Level Factory Setting Default 133 Css o 1 wmm fe 8 amp amp ERRKNS tine Frequency sem 1 0 Description Setting Basic Configuration No Passowrd Required Setpoint Security Page Level Factory Setting Description Default Setting Jog Start Ramp 1 Start Ramp 2 Custom Accel Curve Start Disabled Dual Ramp sian Curren vonage JO 1 1 Type coen voeson Final votage 2 _______ 1 0 oss ose Cramo mmes Maximum kickstart Type e kickstart Tin
17. SP8 3 Area Under Curve Protection If enabled this secondary start protection uses both the SP8 2 Basic Start Overload Curve basic start protection and the area under the Start Curve Locked Rotor Time The locked rotor curve protection I I T Start The maximum allowed during start If the 12 to start exceeds this number then the TX will generate a trip 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 SP8 4 Current Over Curve Learns the motor s starting characteristics and protects the motor motor draws with full voltage on the windings and based upon the learned curve It is useful no motor movement as a percent of motor FLA Refer to the motor nameplate data contact the when commissioning a new motor motor manufacturer See Appendix A Learn The unit reads the motor s starting Acceleration Time Limit If the motor does not characteristics Start the motor and allow it enter run mode reach at speed within the preset to come to full speed The start feedback time the unit trips on acceleration time limit enables the motor protection based on the Number of Starts per hour enabled this limits learned start curve the maximum number starts permitted per hour Learned Start Curve Basis The maximum
18. TOSHIBA 7 TX Series 48 1250A Chapter 2 Installation 2 1 Receiving and Unpacking Upon receipt of the unit Carefully unpack the unit and inspect it for any shipping damage Report any damage immediately and file a claim with the freight carrier within 15 days of receipt Verify that the model number on your unit matches your purchase order Confirm that the ratings label on the unit matches or is greater than the motor s HP and current rating 2 2 Initial Unit Inspection Make a complete visual check of the unit for damage which may have occurred during shipping and handling Do not attempt to continue installation or start up the unit if it is damaged Check for loose mechanical assemblies or broken wires which may have occurred during transportation or handling Loose electrical connections will increase resistance and cause the unit to function improperly Prior to beginning the installation verify that the motor and TX unit are rated for the proper amperage and voltage 2 3 Location The proper location of the unit is an important factor in achieving the unit s specified performance and normal operation lifetime The unit should always be installed in an area where the following conditions exist Ambient Operating Temperature 0 C to 50 C 32 F to 122 F Optional space heaters can be provided for operation in ambient temperature to 20 C Protected from rain and moisture Humidity 596 to 95 non condensin
19. When the output voltage to the Closes Slowly motor is low enough to no longer be needed the TX will end the Decel cycle and turn itself off Check Valve Closed N NO SHOCK WAVE TOSHIBA 17 RUNNING DECELERATION 100 START DECELERATION MODE Do 25 Fs STARTING d TORQUE STOP E STOP LEVEL i VOLTAGE DECELERATION LEVEL ACCELERATION DECELERATION RAMP TIME Another common application for decel control is on material handling convey ors aS a means to prevent sudden stops that may cause products to fall over or to bump into one another In overhead crane applications soft stopping of the Bridge or Trolley can prevent loads from beginning to over swing on sudden stops 3 4 1 Start Deceleration Voltage Factory Setting 60 of line voltage Range 0 100 of line voltage The step down voltage adjustment eliminates the dead band in the deceleration mode that is experienced while the voltage drops to a level where the motor deceleration is responsive to decreased voltage This feature allows for an instantaneous drop in voltage when deceleration is initiated 3 4 2 Stop Deceleration Voltage Factory Setting 20 of line voltage Range 0 100 of line voltage The stop voltage level setpoint is where the deceleration voltage drops to zero 3 4 3 Deceleration Time Factory Setting 5 sec Range 0 60 sec The deceleration ramp time adjusts the time it takes
20. beyond the window before a trip will occur SP3 16 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 SP3 17 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 SP3 18 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 TOSHIBA 39 SP 4 Relay Assignment Setpoint 4 Hit DOWN ARROW three times PAGE 4 RELAY gt O L TRIP ASSIGNMENT 1ST TRIP ONLY Range TRIP AUX1 ALARM AUX2 AUX3 a 1ST TRIP c S C 1ST TRIP ONLY OVERCURRENT TRIP 1ST TRIP STATOR RTD TRIP 1ST TRIP NON STATOR RTD TRIP 1ST TRIP 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 TRIP UNDER FREQUENCY TRIP 1ST TRIP FT START CURVE 1ST TRIP LEARNED START CURVE 1ST TRIP PHASE REVERSAL 1ST TRIP OVERVOLTAGE TRIP 1
21. the time of the trip Screen 6 1 HOTTEST NON STATOR RTD TOSHIBA 65 TX Series 48 1250A 1 METERING PAGE 7 MWH TOTAL MP 7 Statistics Metering Page 7 Sereen 2 Screen 3 an RUNNING HOURS gt PRESS ENTER Displays the TX Series statistical trip information Screen 1 Displays the total of megawatt hours Screen 2 Displays the accumulated total running Screen 4 hours TOTAL TRIPS Screen 3 Clears the total running hour count SIC TRIPS Screen 4 Displays the total number of trips since the Screens Screen 17 last clearing the statistical data and the total START TRIPS UN TRIPS 8 number short circuit trips RUN TRIPS ON TRIPS Screen 5 Displays the numbers of start overload and 1 run overload trips since the last clearing of Screen 6 Screen 18 the statistical data FREQUENCY TRIPS Screen 6 Displays the number of frequency trips and ETRE TRIPS Imbalance trips Screen 7 1 Screen 7 Displays the number of overcurrent trips Screen 19 Screen 8 Displays the number of Stator and non Stator TRIPS TRIPS FTD TRpS Screen 8 Screen 9 Displays the number of Ground Fault Hi and 20 Lo Set trips NON STATOR TRIPS EXT INP 1 Screen 10 Displays the number of acceleration time trips Screen 9 Screen 11 Displays the number of start curve trips ME quaii Screen 21 Sc
22. 2 SP2 3 Start Control Mode Dual Ramp Custom Accel Curve Tach Ramp Jog Voltage Start Ramp 1 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 TX will ignore the start control mode and read this setpoint as disabled Tach Ramp See setpoint page 6 for configuration setup of tachometer input Pending Jog Voltage The voltage level necessary to cause the motor to slowly rotate 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 Voltage Ramping is the most reliable starting method because the starter will eventually reach an output voltage high enough to draw full current and develop full torque This method is useful for applications where the load conditions change frequently and where different levels of torque are required Typical applications
23. Factory Setting Default Set Level 2 Password 000 999 Three Digits Set Level 3 Password 1000 0000 9999 Four Digits Description Range Setting Factory Setting Default Ser Front Baua Rare pasas Ser Modbus Baud Ras 2 Set Link Baud Rate 38 4 KB sec 2 4 4 8 9 6 19 2 38 4 KB sec 71 Remote Start Stop Disabled Enabled or Disabled Description Setting TOSHIBA 87 TX Series 48 1250A Setpoint Security Page Level Factory Setting Description Default Range Setting Default Display Screen o 5 5 5 D o o Metering Data Page Enter Metering Page 1 4 Enter Metering Screen Page 1 1 10 Page 2 1 11 Page 3 1 29 Page 4 1 6 Metering Data Screen Enabled or Disabled Off 40 95 2 O L Class 5 30 or 4 40 second time delay O L Class Ve Class 4 40 sec Page 12 System Setpoints topped Cool Down Time afa ole ola 5 5 2 p 2 o o n Relay Measured Rates Motor Design Ambient Temp 18 Input to TrermalRegser Use Calculated Kor Assign Disabled Enabled or Disabled 50 Relay Measured Cool Rates Motor Design Ambient Temp Motor Design Run
24. OR INSTALLATION THE COMPANY TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS STATUTORY AND IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ALL EQUIPMENT AND PARTS FURNISHED PURSUANT TO THE FOREGOING WARRANTY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY 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 in this manual 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 special or consequential damages including without limitation loss or profits or revenue loss of equipment described herein or any associate
25. Once these inputs are given the TX automatically scales the range of the tachometer feedback to give a linear RPM ramp When this is set to MANUAL the user will need to input the tachometer scale of the 4 20mA input range Press Enter if Motor Speed 0 RPM This setpoint will be displayed when the user has selected Auto Scaling Mode The TX is prompting the user to program when the motor speed is at zero This will be the lowest value on the scale Press Enter if Motor Speed MAX RPM The TX is now prompting the user to program the unit when the motor is at maximum speed This will be the highest value on the scale Press Enter to Scale This is a prompt to the user that the unit has recorded the values of the tachometer input based on input from the user and is now ready to automatically scale the range of the tachometer input 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 Feedback Ramp Time This is the duration of the tachometer ramp time Tach Accel Trip The maximum allowed percentage of slip per NEMA design of the motor Tach Accel Trip Delay The duration of time that the Tach Accel trip condition must persist before a trip is generated 48
26. Range Section 5 1 8 Overload Curve Configuration Setpoint Page 8 Setpoint Page Security Level Password Protection S 5 2 5 gt 9 Factory Setting Default Basic un OveroagGuve Basic OveroadGuve SP8 4 Description Section TOSHIBA 28 TX Series 48 1250A 5 1 9 RTD Option Configuration Setpoint Page 9 Setpoint Security Page Level Factory Setting Default Use NEMA Temp for RTD Values Disabled Enabled or Disabled SP9 1 RTD Voting Disabled Enabled or Disabled SP9 3 4 120 OHM NI 100 OHM NI 100 OHM PT 10 Stator Phase A1 Type Off OHM CU RTD 1 Description Stator A1 User defined Up to 15 Characters Stator Phase A1 Alarm Level 0 240C 32 464F Off Stator Phase Trip Level 0 240C 32 464F Off Stator Phase A2 Type Same as Stator Phase A1 RTD 2 Description Stator A2 User defined Up to 15 Characters SP9 4 Description Section Page 9 RTD Configuration Password Protection TOSHIBA 29 TX Series 48 1250A 5 1 9 RTD Option Configuration 9 Setpoint Security Page Level Factory Setting Default Description Section 5 1 10 Security Set Password Page 10 Page 9 RTD Configuration Password Protection Setpoint Security Factory Setting Page Level Default 8 Set Level 2 Password 000 999 Three Digits SP10 1 4 Set Level 3 Password 1000 0000
27. Required 9 5 5 5 Timed Output Time Off 5 1 3 Phase and Ground Settings Setpoint Page 3 Setpoint Security Page Level Factory Setting Default Imbalance Alarm Level 15 FLA 5 30 Off Imbalance Alarm Delay 1 0 20 0 sec Imbalance Trip Level 5 30 Off Description Section Imbalance Trip Delay 1 0 20 0 sec Undercurrent Alarm Level 10 90 Undercurrent Alarm Delay 1 0 60 0 sec Overcurrent Alarm Level Of 100 300 Off Overcurrent Alarm Delay 1 0 20 0 sec Overcurrent Trip Level 100 300 Overcurrent Trip Delay 1 0 20 0 sec ff ff ff Phase Loss Trip Disabled Enabled or Disabled Phase Loss Trip Delay 0 20 0 sec Phase Rotation Detection Enabled Enabled Only Phase Rotation ABC Ground Fault Alarm Level 5 90 Off Ground Fault Alarm Delay 0 1 20 0 sec Ground Fault Loset Trip Level 5 90 95 Off Ground Fault Loset Trip Delay 0 1 20 sec Ground Fault Hiset Trip Level 5 90 95 Off Ground Fault Hiset Trip Delay 0 008 sec 0 008 0 250 sec Overvoltage Alarm Level 5 30 Overvoltage Alarm Delay 10sec 1 0 30 0 Overvoltage Trip Level Off 5 30 Off ff ff ff ff ff Overvoltage Trip Delay 1 0 30 0 sec Undervoltage Alarm Level 5 30 Off Password Protection o 5 9 a Undervoltage Alarm Delay 1 0 sec 1 0 3
28. TRIP unloaded motor Check load Failed CPU or Main Firing Contact factory Board Check internal wiring connections Troubleshoot and repair generator Contact utilities company Generator Power Problem Main board fail or grid change ain board failure Three phase power removed from Main Board Improper programming Check program setpoints Any wire going to ground l e stator ground motor ground soft start ground High vibration or loose 9 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 Load shorted grounded Remove power and repair faulted Faulty main circuit board the main circuit board Control circuit power locate and remove this fuses blow after shor control power is i h applied Wrong control voltage the correct voltage to the contro Self test Failure SELF TEST FAILURE Line Frequency OVER OR UNDER Trip FREQUENCY TRIP GROUND FAULT HI SET OR LO SET Pending Check with meggar or Hi pot motor leads Any Ground Fault and motor Trip Pending Motor stopped Check for fault indication during run TOSHIBA 68 TX Series 48 1250A CPU LCD Display LED Possible Cause Solutions No control voltage applied Apply control voltage to TB1 pins 1 and 6 to control board on the power board Control power transformer Remove p
29. Temperature 80 Max 50 100 of Motor Stator Max Temp INS CLS 10 240 C Input to Thermal Register Enabled Only Use Calculated K or Assign Press Enter to Clr Thermal Register Nim 2 210 uU 9 a Setpoint Security Page Level Factory Setting Default Set Date and Time FACTORY SET DDMMYY HHMM SHAE AE HE FACTORY SET pu Enter Date DDMMYYYY D 1 31 1 12 1970 2069 Enter Time HH MM 2 SET H 00 23 M 0 59 Model FACTORY SET Firmware REV THHHHBE THHHHHE Enter t0 Access Factory Available to Qualified Factory Personnel Settings Description Setting Page 13 Calibration amp Service Display Only Cannot be changed FACTORY USE ONLY TOSHIBA 88 Warranty Policy 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 EIGHTEEN 18 MONTHS AFTER THE DATE ON WHICH SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE SHIPPED BY THE COMPANY TO THE INITIAL PURCHASER OR TWELVE 12 MONTHS AFTER SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE FIRST PLACED IN OPERATION WHICHEVER PERIOD FIRST EXPIRES The Company will at its option repair or replace such equipment or part whic
30. keypad LED status indica tors and a 2 line x 20 character backlit display using plain English text readout In addition to programming the standard parameters such as starting torque ramp time current limit dual ramp and decel control other features like programmable overload trip curves NEMA UL Classes 5 30 starts per hour time between starts and coast down back spin lockout protection can also be programmed for your specific application needs 1 2 Specifications Type of Load Three phase AC induction motors or synchronous motors AC Supply Voltage 208 600 10 50 60 Hz HP Ratings 39 1250 Amps 10 1125 HP 125 Continuous 500 60 seconds 600 30 seconds Power Circuit 6 SCRs SCR Diode Ratings Peak Inverse Voltage Phase Insensitivity Unit operates with any phase sequence Transient Voltage Protection RC snubber dv dt networks on each phase Convection up to 180A fan assisted 78 120A Fan ventilated 220 1250A Unit Overload Capacity Percent of motor FLA Cooling Full horsepower rated contactor included as standard all Type 12 4 amp 4X enclosed units 120A and above Bypass Contactor Chassis units 0 to 50 32 to 122 F Enclosed units 0 to 40 C 32 to 104 F 5 95 relative humidity 0 3300 ft 1000m above sea level without derating Ambient Condition Design 2 or 3 wire 120VAC customer supplied Optional 240VAC control voltage and CPTs ar
31. mechanical components promoting longer service life and less downtime Acceleration The TX Series comes standard with several methods of accelerating the motor so that it can be programmed to match almost any industrial AC motor application The factory default setting applies a Voltage Ramp with Current Limit as this has been proven the most reliable starting method for the vast majority of applications Using this starting method the Initial Torque setting applies just enough voltage to the motor to cause the motor shaft to begin to turn This voltage is then gradually increased over time as per the Ramp Time setting until one of three things happen the motor accelerates to full speed the Ramp Time expires or a Current Limit setting is reached If the motor accelerates to full speed before the ramp time setting has expired an automatic Anti Oscillation feature will override the remaining ramp time and full voltage will be applied This will prevent any surging or pulsation in the motor torque which might otherwise occur due to the load not being fully coupled to the motor when operating at reduced voltage and torque levels If the motor has not reached full speed at the end of the ramp time setting the current limit setting will proportionally control the maximum output torque Feedback sensors in the TX Series provide protection from a stall condition an overload condition or excessive acceleration time The Current Limit featu
32. personnel to program the time for the TX SP13 2 Model amp Firmware Displays the model number and firmware revision in the TX SP13 3 Press Enter to Access Factory Settings Available to qualified personnel TOSHIBA 56 TX Series 48 1250A Chapter 6 Metering Pages The TX Series offers performance metering which gives the user the ability to view information about the motor and the TX 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 Description of Display Screen 8 Groun Average corent of he of imbalance ard 2 7 Measured Amount of ime required start the motor during the last successiu 10 6 1 2 Metering Metering 2 Metering Page 5 gt 2 Description of Display Screen Phase A B C and Power Facio i i Prase A C and Grouan J gt ___ Displays Peak ON ara KW Demand To Peak ON KVA Displays Peak ON and Amps Demana f 6 1 3 RTD Values Metering Page 3 Metering Page Description of Display Screen Hotestron siatorRTD Te Temperature of star phase rm Te Maximum
33. starts 1 60 minutes between start attempts Programmable Outputs Rating Run Indication At Speed Indication Form C DPDT Rated 5 amps 240 VAC max 1200 VA Start Stop or Start End of Decel At Speed Stop or At Speed End of Decel Acceleration Adjustments Dual Ramp Settings Deceleration Adjustments Jog Settings Function selected via programming input Kick Start Settings Fault Display Lockout Display Programmable Ramp Types Voltage or Current Ramp VR or CR Starting Torque 0 100 of line voltage VR or 0 600 of motor FLA CR Ramp Time 1 to 120 seconds Current Limit 200 600 VR or CR 4 Options VR1 VR2 VR1 CR2 CR1 CR2 CR1 VR2 Dual Ramp Control Ramp 1 Default Ramp 2 selectable via dry contact input Begin Decel Level 0 100 of line voltage Stop Level 0 to 1 less than Begin Decel Level Decel Time 1 60 seconds Programmable to decel or coast to stop upon overload trip Voltage Jog 5 100 or OFF Time of Voltage Jog 1 20 seconds Current Jog 100 500 Kick Voltage 10 100 or OFF Kick Time 0 1 2 seconds Shorted SCR Phase Loss Shunt Trip Phase Imbalance Trip Overload Overtemp Overcurrent Short Circuit Load Loss Undervoltage or Any Trip Coast Down Time Starts Per Hour Time Between Starts and Any Lockout TOSHIBA 2 TX Series 48 1250A 1 2 Specifications continued Event History Data includes cause of event time date and cur
34. 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 specific HELP setpoint action Will scroll up through the setpoint and metering menu page It will scroll to the top of the setpoint page ora Button UP ARROW In edit mode it will increase a setpoint an incremental step or toggle through the available options in the setpoint In the main menu the RIGHT ARROW button provides access to the setpoint page For setpoint pages with 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 DOWN ARROW Will move to the left through setpoint pages with multiple LEFT ARROW 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 condition has occurred AUK Ta Auxiary relays Note The directional arrow buttons are sensitive In edit mode if th
35. to reach the stop voltage level set point The unit should be restarted and stopped to verify that the desired deceleration time has been achieved AAVARNING DO NOT EXCEED THE MOTOR MANUFACTURER S RECOMMENDED NUMBER OF STARTS PER HOUR WHEN CALCULATING THE NUMBER OF STARTS PER HOUR A DECEL CURVE SHOULD BE COUNTED ASA START CURVE FOR EXAMPLE RECOMMENDED NUMBER OF STARTS PER HOUR 6 ALLOWABLE STARTS WITH DECEL CYCLE PER HOUR 3 TOSHIBA 18 TX Series 48 1250A 3 5 Sequence of Normal Operation e Apply control power and check that the Power LED comes 1 MOTOR STOPPED Display 1 READY TO START Apply three phase power to the unit The motor should run only when the 2 MOTOR STARTING start command is applied 00XFLA e Apply the start command Display 2 The RUN LED will be lit Display 3 i OVERLOAD ALARM The AUX3 LEDs will be lit If the motor does not enter run mode in the set 3 C SEC time a trip will occur e The POWER RUN AUX3 LEDs will be lit indicating that the contact has E energized IA IC will display the current setting for Phase A Phase m Ce and Phase and the G F indicates ground fault Display 4 When the motor reaches full speed the AUX4 LED At Speed will be lit e the motor decelerates or stops during the acceleration period hit the stop button immediately and open the disc
36. unit DISCONNECT The SCRs will be seriously damaged if OR CIRCUIT capacitors are located on the load side BREAKER The unit must be tested with a motor or other test load connected to the load side of the unit A load bank can be used if a motor is not available Note that line voltage will appear across the output terminals if there is no motor or load connected to the unit In areas where lightning is a significant problem station type air gap lightning arrestors should be considered and utilized on the input power source Power Connections 2 7 1 Grounding Connect the ground cable to the ground terminal as labeled on the unit Refer to the National Electrical Code for the proper ground wire sizing and be sure that the ground connector is connected to earth ground TB4 2 8 Control Connections Separate 120Vac supply is required 240Vac for 380V and 415V applications The control voltage should be connected to pins 1 and 6 of TB4 on the power board This control voltage must be customer supplied unless an optional control power transformer See chart has been supplied 120 240 120 240 with the unit Control Control Power Power Return Panel NEMA 1 NEMA 12 3R 4 PERILA TX008 50 VA 100 VA 250 VA Unit comes standard with 120Vac control Order 240Vac control as an TX009 50 VA 100 VA 500 VA option if required TX010 250 VA 250 VA 500 VA Transformer size is adequate to power built in bypa
37. 0 0 sec Undervoltage Trip Level 5 30 Off Undervoltage Trip Delay 1 0 30 0 sec Line Frequency Trip Window 0 6 Hz Disabled Line Frequency Trip Delay 1 0 20 0 sec P F Lead P F Alarm 0 1 1 00 P F Lead Alarm Delay 10sec 1 120 P F Lead P F Trip Of 01 00 04 P F Lead Trip Delay 10sec 1 120 P F Lag P F Alarm 01 1 00 Off P F Lag Alarm Delay 1 05 2 1 120 P F Lag P F Trip 01 1 00 Off P F Lag Trip Delay 10sec 1 120 KW Demand Alarm Pickup Off 1 100000 Amps Demand Alarm Pickup Off 1 100000 o o gt e gt o 0 0 0 0 0 0 0 0 0 4 TOSHIBA 24 TX Series 48 1250A 5 1 4 Relay Assignments Setpoint 4 Setpoint Security Page Level Factory Setting 1st 2nd 3rd None Trip AUX1 Alarm AUX2 AUX3 ARAA Description Section 7 10 o E c lt gt Password Protection TOSHIBA 25 TX Series 48 1250A 5 1 5 Relay Configuration Setpoint Page 5 Setpoint Security Page Level Factory Setting Default Trb AUK Fall Saf Trip AUX1 Relay Latched Yes No Yes oro Relay Laced No Yeserie Relay Lathes nod 952 Description Section E 3 2 c gt w tc Password Protection
38. 1 4 turn to ensure that the SCR is not over torqued The gauge reading should be similar to the initial reading taken in step 2 If the clamp uses the spin washer gauge verify that the washer spins freely after clamping TOSHIBA 72 TX Series 48 1250A 7 4 Once proper force is reached make sure that SCR pucks securely held between the heatsinks and aligned evenly Replace any lugs MOVs snubbers power straps printed circuit boards and associated wiring that was removed in step 4 Use the following chart to verify wiring of J5 J6 and J7 Main Circuit ES Destination Load cathode Output Load Lug Ping Line Cathode After verifying that all wiring is correctly connected test the SCR and then test the unit Replacing the Main Control Board The printed circuit board is not intended to be field repaired If the board is faulty the entire board should be replaced using the following procedure See Chapter 6 for the main control board layout Remove three phase power and control power from the unit and lock out Remove plugs and tag plugs with connector numbers Remove control wires from terminals and tag wires with terminal numbers Note the settings of all jumpers Remove the mounting screws Remove the old printed circuit board Mount the new printed circuit board Install the mounting screws Set the jumpers to the same position
39. 100 OHM PT RTD 10 LEVEL HHF LEVEL C Range RTD 11 TYPE RTD 11 DESCRIPTION RTD 11 ALARM RTD 11 TRIP 100 OHM PT RTD 11 LEVEL LEVEL HHF Range Range RTD 12 TYPE RTD 12 DESCRIPTION RTD 12 ALARM RTD 12 TRIP 100 OHM PT RTD 12 LEVEL HHF LEVEL HHF Range Range Range TOSHIBA 50 TX Series 48 1250A 5 9 RTD Configuration Setpoint Page 9 Security Level 3 The TX is available with an optional 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 setpoint is enabled the TX 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 8 Of RTD S Used for Stator Up to six RTDs be assigned to monitor the stator of the motor SP9 3 RTD Voting When this is enabled the TX will not post a trip until 2 RTD s have exceeded the trip level This prevents nuisance RTD tripping SP9 4 All 12 RTDs ar
40. 120 82 144 93 384 53 50 34 49 14 68 232 72 77 620 64 60 32 5 10 63 275 85 72 735 75 75 29 71 10 58 338 90 66 904 79 150 22 133 320 45 60 160 51 1719 140 20 2 172 60 4 831 300 45 2238 265 TOSHIBA 78 TX Series Typical Maximum Locked Rotor Current NEMA amp D NEMA E 48 1250A THREE PHASE SQUIRREL CAGE MOTORS NEMA DESIGNS B C amp D 2300V 4000V 05 23 20 10 8 J 075 29 25 12 40 34 30 15 12 _46 40 20 16 57 50 25 20 J 74 64 32 26 106 92 46 37 J 7 146 127 63 5 J 267 232 116 93 J 333 290 145 16 J 420 365 182 146 500 435 217 174 J 67 52 290 22 __ 834 725 362 290 1 1 5 2 3 5 5 10 15 20 25 30 40 50 7 _15 __2 NE GEN 5 75 10 186 162 8t 65 1 15 20 25 40 50 60 MAXIMUM LOCKED ROTOR CURRENTS THREE PHASE SQUIRREL CAGE MOTORS NEMA DESIGN E RATED VOLTAGE AMPS 200V 230v 460v 5757 2300 4000 05 23 2 8 5 075 29 25 13 1 35 30 15 12 15 46 40 20 16 2 58 50 25 2 84 73 37 29 1140 122
41. 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 CURVE RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 TOSHIBA 47 Increments of 1 lt CURVE B VOLTAGE LEVEL 3 37 Range 0 100 1 Increments 1 CURVE RAMP TIME 3 2 SEC Range 1 60 SEC 1 Increments of 1 lt CURVE B VOLTAGE LEVEL 4 45 Range 0 100 Increments 1 lt CURVE RAMP 4 2 5 1 60 5 Increments of 1 CURVE VOLTAGE LEVEL 5 55 Range 0 100 Increments of 1 CURVE B RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 CURVE B VOLTAGE LEVEL 6 67 Range 0 100 1 Increments 1 CURVE RAMP TIME 6 2 SEC Range 1 60 SEC Increments of 1 TX Series 48 1250A SP 7 Custom Acceleration Curve Setpoint 7 Security Level 3 SP7 1 Setpoint Page 7 allows the user to custom design the acceleration curve start curve to the CUSTOM CURVE C iri specific application user custom Range 0 100 design up to three different curves the TX Increments of 1 Only one curve can be active enabled at a time Each of the three curves has eight voltage CURVE C RAMP levels with corresponding ramp times and a WIECH
42. AGE 8 OVERLOAD CURVE CONFIGURATION PAGE9 RTD CONFIGURATION LEVEL 3 PAGE 10 SECURITY SET PASSWORD PAGE 11 COMMUNICATIONS LEVEL amp SERVICE PAGE 12 SYSTEM SETPOINTS TOSHIBA 32 SP 1 Basic Configuration Setpoint Page 1 In Setpoint Page 1 the TX is looking for the following basic nameplate data of the motor SP1 1 SP1 2 SP1 3 1000 5 1 4 5 1 5 SP1 6 SP1 7 10 1 22 Motor Full Load Amps Allows the user to enter the motor s FLA rating Range of adjustment is 50 100 less programmed service factor 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 TX overload pickup point will be 115 Amps 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 NEMA design The motor design maximum allowed slip Select from Class A through F Insulation Class The motor insulation temperature class Select A B C E F H K N or S Line Voltage Inut Applied system nominal voltage Line Frequency The user may choose either 50 Hz or 60 Hz TO
43. AL VOLTAGE 1 20 Range 0 100 Increments of 1 RAMP TIME 1 10 SEC Range 0 120 SEC Increments of 1 CURRENT LIMIT 1 350 FLA Range 200 600 Increments of 10 these INITIAL VOLTAGE screens 2 60 will appear Range 0 100 Increments of 1 If VOLTAGE selected RAMP TIME 2 10 SEC Range 0 120 SEC Increments of 1 CURRENT LIMIT 2 350 FLA 200 600 Increments of 10 lt gt KICK START VOLTAGE 65 Range 10 100 Increments 5 KICK START TIME 0 50 SEC Range 0 10 2 00 Increments of 0 10 START DECELERATION VOLTAGE 60 Range 0 100 Increments of 1 STOP DECELERATION VOLTAGE 30 Range 0 59 Increments of 1 DECELERATION TIME 5 SEC Range 1 60 Increments of 1 TOSHIBA 34 will appear Range 0 300 INITIAL CURRENT 1 200 FLA Range 0 300 Increments of 1 RAMP TIME 1 10 SEC Range 0 120 SEC Increments of 1 MAXIMUM CURRENT 1 350 FLA Range 200 600 Increments of 10 INITIAL CURRENT 2 200 FLA RAMP TIME 2 10 SEC Range 0 120 SEC If CURRENT selected these screens Increments of 1 Increments of 1 MAXIMUM CURRENT 2 350 FLA Range 200 600 Increments of 10 TX Series SP2 Starter Configuration Setpoint Page 2 Provides multiple choices for starting ramps that can be selected for particular loads and applications SP2 1 SP2
44. AR RTD 3 Screen 9 Screen 10 STATOR PHASE B2 MAX TEMP SINCE RTD 4 HH HH F CLEAR RTD 4 Screen 11 12 TEMP SINCE CLEAR RTD 5 STATOR PHASE C1 RTD 5 C HH F Screen 13 STATOR PHASE C2 RTD 6 C HH F Screen 15 END BEARING RTD 7 HH HH F Screen 14 MAX TEMP SINCE CLEAR RTD 6 Screen 16 MAX TEMP SINCE CLEAR 7 17 18 SHAFT BEARING MAX TEMP SINCE RTD 8 C HH F CLEAR RTD 8 Screen 19 Screen 20 MAX TEMP SINCE CLEAR RTD 9 RTD 9 RTD 9 Screen 21 Screen 22 MAX TEMP SINCE CLEAR RTD 10 RTD 10 RTD 10 1HHEF Screen 23 1 RTD 11 RTD 11 C 25 RTD 12 RTD 12 HH HH F Screen 27 PRESS ENTER TO CLEAR MAX TEMP REGS Screen 28 MEASURED RUN COOL TIME MIN Screen 24 MAX TEMP SINCE CLEAR RTD 11 Screen 26 MAX TEMP SINCE CLEAR RTD 12 Screen 29 MEASURED STOPPED COOL TIME MIN TX Series 48 1250A 4 Status Metering Page 4 Displays the present status of the TX Series soft start Screen 1 Displays the present state of the unit as follows STATUS Screen 2 O L TRIP LEFT TO Screen 2 Displays the amount of time remaining before an overload trip will occur TRIP HHHH SEC Screen 1 Note Screen 3
45. CURRENT STATUS Screens include THERM INH TIME LEFT 1 STOPPED READY TO START 2 STARTING COAST DOWN TIMER MULT OF FLA TIME LEFT MIN 3 MOTOR RUNNING Screen 5 AT HHH HH X FLA TIME BETWEEN STARTS 4 LAST TRIP CAUSE TIME ea MIN NONE or trip cause E 5 IPROGRAMMING STARTS PER HOUR TIME 5 THE THE THE 6 MOTOR STATUS UNKNOWN STATE displays relay state upon error 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 TOSHIBA 63 TX Series 48 1250A MP 5 Event Recorder 60 Events Metering Page 5 MENU Screen 1 1 Screen 1b METERING PAGE 5 e lt cause of event gt lt gt kA HHHH 1B HHBHHHE Vab THHHHHE Event Recorder 60 event HEHEHEHEH TETUER IC GIF HHHH PIF 99 1 lt gt THHHHHE PIF HHHE lt cause of event 2nd TER HH Event
46. Control Board 7 5 Interconnect Drawing 7 6 Maintenance Program 7 7 Disposal Storage Appendix A Reference Section 78 Appendix B Record of Setpoint Adjustments 81 Warranty Policy santoarssasnsansisisnaneasentecdvaasteceateciavacuevsasaessnes 89 TX Series 48 1250A TX Series 48 1250A Chapter 1 Introduction This chapter is a brief introduction to the TX Series soft starter and describes product operation and unit features 1 1 General The TX Series is a high end digitally programmable solid state reduced voltage soft starter This heavy duty starter provides reduced voltage stepless soft starting of 3 phase AC induction motors protecting mechanical components from excessive torque stress and electrical systems from the effects of high motor inrush currents The TX Series includes advanced motor and load protection features just like those found in expensive motor protection relays These include retentive thermal memory dynamic reset capacity true thermal modeling separate trip curves for start and run protection overload alarm etc In the case of the TX Series these features are built in as standard features providing a cost effective and reliable motor starting and protection scheme for your critical motor applications The TX Series features an easy to use interface operator for programming and status indication It includes a large tactile feedback
47. Current Limit select VOLTAGE for the START RAMP 1 setpoint and set CURRENT LIMIT 1 setpoint to a desired lower setting as determined by your application requirements Start Ramp 1 Type Current Current Ramping Closed Loop Torque Ramping is used for smooth linear acceleration of output torque 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 capaci
48. E 7 2 SEC Range 1 60 SEC Increments 1 TOSHIBA 46 5 7 Custom Acceleration Curve Setpoint 7 Security Level 3 CURVE A VOLTAGE CUSTOM CURVE LEVEL 8 100 lt CURVE VOLTAGE CUSTOM CURVE B LEVEL 7 82 Range 0 100 1 Range 0 100 Increments of 1 Increments of 1 CURVE B RAMP TIME 7 2 SEC Range 1 60 SEC Increments of 1 CURVE A RAMP TIME 8 2 SEC Range 1 60 SEC Increments of 1 lt CURVE A CURRENT LIMIT 350 FLA Range 200 600 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 CURRENT LIMIT 350 FLA Range 200 600 Increments of 10 lt CURVE B VOLTAGE CUSTOM CURVE B LEVEL 1 25 Range 0 100 1 Increments of 1 lt CURVE RAMP TIME 1 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 CURVE VOLTAGE CUSTOM CURVE C lt lt LEVEL 1 25 Range 0 10096 Increments of 1 CURVE RAMP TIME 1 2 SEC Range 1 60 SEC Increments of 1 lt 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
49. IRCUIT TRIP OVERCURRENT TRIP STATOR RTD TRIP NON STATOR RTD TRIP GROUND FAULT HI SET TRIP GROUND FAULT LO SET TRIP PHASE LOSS TRIP ACCELERATION TIME 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 SHUNT TRIP BYPASS DISCREPANCY EXTERNAL INPUT 1 EXTERNAL INPUT 2 DUAL RAMP THERMOSTAT OVERLOAD WARNING OVERCURRENT ALARM GROUND FAULT ALARM 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 RELAY ASSIGNMENT TRIP AUX1 TRIP TRIP TRIP TRIP TRIP TRIP AUX 3 NONE NONE NONE NONE TRIP AUX 1 ALARM AUX2 ALARM AUX2 ALARM AUX2 ALARM AUX2 NONE ALARM AUX2 ALARM AUX2 ALARM AUX2 ALARM AUX2 TRIP AUX1 ALARM AUX2 ALARM ALARM ALARM ALARM ALARM ALARM TOSHIBA 41 48 1250A TX Series 48 1250A SP 5 Relay Configuration Setpoint Page 5 Security Level 2 In Setpoint Page 5 the user can configure the four output HE DOWNARROW DINE relays as either fail safe or non fail safe and latching or PAGE 5 RELAY gt TRIP AUX1 RELAY TRIP AUX1 RELAY non latching 4 CONFIGURATIO
50. LAY 2 0 SEC Range 1 0 60 0 SEC Increments of 0 1 OVERCURRENT ALARM DELAY 2 0 SEC Range 1 0 20 0 SEC OFF Increments of 1 Increments of 0 1 OVERCURRENT TRIP LEVEL OFF Range 100 30096 OFF 1 OVERCURRENT TRIP DELAY 2 0 SEC Range 1 0 20 0 SEC Increments of 0 1 Increments of 1 PHASE LOSS TRIP DISABLED Options Enabled or Disabled PHASE LOSS TRIP DELAY 0 1 SEC Range 0 20 0 SEC Increments of 0 1 PHASE ROTATION DETECTION DISABLED Options Enabled or Disabled PHASE ROTATION ABC Options ABC ACB GROUND FAULT ALARM LEVEL OFF Range 5 90 OFF A GROUND FAULT ALARM DELAY 0 1 SEC Range 0 5 20 0 SEC Increments of 0 1 Increments of 1 GROUND FAULT LOSET TRIP LEVEL OFF Range 5 90 OFF GROUND FAULT LOSET TRIP DELAY 0 5 SEC Range 1 0 20 0 SEC OFF Increments of 0 1 Increments of 1 GROUND FAULT HISET TRIP LEVEL OFF Range 5 90 OFF GROUND FAULT HISET TRIP DELAY 0 008 SEC Range 0 008 0 250 SEC SP3 4 alarm will occur Overcurrent Alarm Level Typically used to indicate when the motor is overloaded This feature can be used to either stop the feed to the equipment or warn operators of an overload condition Overcurrent Alarm Delay The amount of time the overcurrent condition must exist before an alarm will occur TOSHIBA 37 Increments of 1 OVERVOLTAGE ALARM LEVEL OFF Ra
51. N FAIL SAFE lt LATCHED YES Options Yes or No SP5 1 When a relay has been configured as fail safe ALARM AUX2 RELAY ALARM AUX2 RELAY and power is applied the relay will be ATARIAN JRE lt gt ARM aura RELAY energized The relay will then de energize when an event occurs or if the power fails NOTE The relays in the TX will not prevent a URS BELAY APOE start sequence unless they are wired in as FAIL SAFE NO LATCHED NO interlocks If power is lost the motor power is also lost AUX4 RELAY lt gt AUX4 RELAY SP5 2 A relay configured as non latching will reset FAIL SAFE NO LATCHED NO 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 TOSHIBA 42 TX Series 48 1250A 5 6 User I O Configuration Setpoint Page 6 Security Level 2 ENABLED 6 USERI O lt gt SELECTION DISABLED SCALE MANUAL SCALE CONFIGURATION SELECTION DISABLED DISABLED lt gt 4 0 mA 0 RPM Options ENABLED or 0 ABLED Range 0 3600 Increments of 5 MANUAL TACH SCALE 20 0 mA 2000 RPM Range 0 3600 TACH ACCEL TRIP MODE Increments of 5 ________ 20 Range 1 120 5 Dis
52. None Trip AUX1 External Input 1 None Alarm AUX2 External Input 2 None AUX3 Dual Ramp None AUX4 Thermostat None O L Warning None None None None None Alarm None Stator RTD Alarm None None None Self Test Fail None Thermal Register None U V Alarm None O V Alarm None None None None None Description Setting Password Protection 7 8 o E c lt gt E o TOSHIBA 83 TX Series 48 1250A Setpoint Security Page Level Factory Setting Default Relay tached vs Yesorno Faise Relay Latched Ne veon Relay Latchea J vesorno Factory Setting Default Tachometer Scale Selecion Disablea Manual Tach Seale soma __ orm Tat Seale Tach Accel Trip Mode Select Underspacd Gverspeed or aon Ramptine asec owo Tach UnderspeeaTinPT wesoneu oso Tam Overpeed tees Off RPM 0 3600 Hottest Non Stator RTD 0 200 C Hottest Stator RTD 0 200 C RMS Current 0 7500 A Motor Load 0 600
53. RTD Board Optional Chapter3 Start Up eire 16 3 1 Preliminary Start up Check List 3 2 Introduction 3 3 Acceleration Adjustments 3 4 Deceleration Adjustments 3 5 Sequence of Normal Operation Chapter 4 User Interface and Menu Navigation 20 4 1 Keypad Operator Interface 4 2 Menu Navigation Chapter 5 Setpoint 23 54 Setpoints Page List 5 2 Setpoint Menu SP 1 Basic Configuration 33 SP 2 Starter Configuration 34 SP 3 Phase amp Ground Settings 37 SP 4 Relay Assignment 40 SP 5 Relay Configuration 42 SP 6 Configuration 438 SP 7 Custom Acceleration Curve 46 SP 8 Overload Curve Configuration 49 SP RTD Configuratio si s toco rere re ertet Re Fr rr eras 50 SP 10 Set Password 52 SP 11 Communications 53 SP 12 System Setpoints 54 SP 13 Calibration amp Service 56 Chapter 6 Metering Pages cansa necem 57 6 1 Metering List Chapter 7 Maintenance Troubleshooting Disposal Storage 67 71 Failure Analysis 7 2 SCR Testing Procedure 7 3 Replacing SCR devices 7 4 Replacing the Main
54. SHIBA 33 PAGE 1 BASIC CONFIGURATION MOTOR FULL LOAD AMPS 200 AMPS MAX CURRENT AMPS Increments of 1 SERVICE FACTOR 1 15 X FLA Range 1 00 1 3 Range 50 100 Unit Increments 0 01 OVERLOAD CLASS 10 Range 5 30 Increments of 5 NEMA DESIGN B Range A INSULATION CLASS B Range 5 LINE VOLTAGE INPUT 480 VOLTS Range 208 600 LINE FREQUENCY HZ 60 Range 50 or 60 TX Series SP 2 Starter Configuration Setpoint Page 2 H PAGE 2 STARTER CONFIGURATION it DOWN ARROW one time lt gt START CONTROL MODE START RAMP 1 JOG START RAMP 1 START RAMP 2 DUAL RAMP CUSTOM ACCEL CURVE START DISABLED JOG VOLTAGE OFF Range 5 75 or Off A Increments 5 START RAMP 1 TYPE VOLTAGE Options Voltage Current or Off gt START RAMP 2 OFF Options Voltage Current or Off gt 5 Range Voltage or DECELERATION DISABLED Range Enabled or 4 TIMED OUTPUT TIME OFF Range 1 1000 sec OFF Increments of 1 RUN DELAY TIME 1 SEC Range 0 30 sec OFF Increments of 1 SPEED DELAY TIME 1 SEC Range 0 30 sec OFF Increments of 1 BYPASS PULL IN CURRENT 100 FLA Range 90 300 Increments of 1 48 1250A If If VOLTAGE CURRENT selected selected these these screens screens will appear will appear INITI
55. SHIBA 85 TX Series 48 1250A Setpoint Security Page Level Factory Setting Default Use NEMA Temp for RTD Values Disabled Enabled or Disabled of RTD Used for Stator RTD Voting Disabled Enabled or Disabled 120 OHM 100 OHM 100 OHM PT 10 Stator Phase A1 Type Off OHM CU Off 0 240C 32 464F Off 020 82 647 01 02400 Of Off 0 240C 32 464F Off Off 0 240C 32 464F Off 020 32 4647 Of 0440 92464 OF Off 0 240C 32 464F Off 0 240C 32 464F Off 0 2400 G2 464F Of 0 2400 8 4648 Of Off 0 240C 32 464F Off Off 0 240C 32 464F 02406 924647 OF 0440 02464 OF Off 0 240C 32 464F Off Off 0 240 32 464F Off 0 Of Description Range Setting 2 5 9 n 5 38 n TOSHIBA 86 TX Series Setpoint Page RTD Configuration Setpoint Page Setpoint Page Communiications Security Level Password Protection Security Level Security Level Password Protection 48 1250 Factory Setting Default Bonome OK O RTD 810 Deserption User definea Upto 15 Graecos Romme o _________ Desorpron useraefned User dened Upto 15 Characters OOO Deserbion dened User defined Upto 15 Characters RTO 2 o O O OO Description Range Setting
56. ST TRIP UNDERVOLTAGE TRIP 1ST TRIP POWER FACTOR TRIP 1ST TRIP TACH ACCEL TRIP 1ST TRIP INHIBITS TRIP 1ST TRIP SHUNT TRIP 1ST AUX 3 BYPASS DISCREPANCY 1ST NONE EXTERNAL INPUT 1 1ST NONE EXTERNAL INPUT 2 1ST NONE DUAL RAMP 1ST NONE THERMOSTAT 1ST TRIP O L WARNING 1ST ALARM OVERCURRENT ALARM 1ST ALARM GROUND FAULT ALARM 1ST ALARM UNDERCURRENT ALARM 1ST ALARM MOTOR RUNNING 1ST NONE TOSHIBA 40 ALARM 1ST ALARM STATOR RTD ALARM 1ST ALARM NON STATOR RTD ALARM 1ST ALARM RTD FAILURE ALARM 1ST ALARM lt gt SELF TEST FAIL 1ST TRIP THERMAL REGISTER 1ST ALARM U V ALARM 1ST ALARM O V ALARM 1ST ALARM POWER FACTOR ALARM 1ST ALARM KW DEMAND ALARM 1ST ALARM KVA DEMAND ALARM 1ST ALARM KVAR DEMAND ALARM 1ST ALARM AMPS DEMAND ALARM 1ST ALARM TIMED OUTPUT 1ST NONE RUN DELAY TIME 1ST NONE AT SPEED 1ST AUX4 TX Series SP 4 Relay Assignment Setpoint Page 4 Security Level 2 All of the protection functions of the TX are user programmable to an output relay The factory will ship with all tripping functions assigned to TRIP AUX1 relay and all alarm functions to ALARM AUX2 relay Note AUX1 4 are Factory Set and should be changed SP4 1 The following is a list of all the user programmable functions Note The Relay Assignments are factory defaults FUNCTIONS IMBALANCE TRIP SHORT C
57. T LEVEL 2 SET PASSWORD PASSWORD 100 Range 000 999 SET LEVEL 3 PASSWORD 1000 Range 0000 9999 TX 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 TX relay SP11 4 Set Access Code Assigns an access code to the Modbus addressing SP11 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 TOSHIBA 53 48 1250A Hit DOWN ARROW ten times PAGE 11 5 SET FRONT BAUD RATE 9 6 KB SEC 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 SP 12 System Setpoints Setpoint Page 12 Security Level 3 Hit DOWN ARROW eleven times 12 SYSTEM DEFAULT DISPLAY METERING DATA METERING DATA SETPOINTS SCREEN lt gt PAGES 1 lt gt SCREEN 1 Enter Metering Page 1 4 Enter Metering N
58. TOSHIBA DOCUMENT 70002 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE TX SERIES Low Voltage Digital Solid State Starter 48 1250A Issued 11 04 Manufactured in the USA 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 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 AV 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 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 B
59. The factory setting of 350 is a good starting 100 point Do not set the current limit too low on variable starting loads This could cause the motor to stall and eventually cause the overload protection to trip 3 4 Deceleration Adjustments Pump Control w Decel extends the stopping time on loads that would otherwise stop 9 too quickly if allowed to coast to stop Decel control provides smooth deceleration until the load comes to a stop Three adjustments STARTING optimize the deceleration curve to meet the most demanding require ments Try factory settings before adjusting Deceleration Applications AIME The unit is shipped from the factory with the decel feature disabled Apply power and adjust the soft start before enabling or modifying the deceleration adjustments Both acceleration and deceleration adjustments should be made under normal load conditions The deceleration feature provides a slow decrease in the output voltage accomplishing a gentle decrease in motor torque during the stopping mode This is the OPPOSITE OF BRAKING in that it will take longer to come to a stop than if the starter were just turned off The primary use of this function is to reduce the sudden changes in pressure that are associated with Water Hammer and slamming of check valves with centrifugal pumps Decel control in pump applications is often referred to as Pump Control Coasting Stop using Electro Mech starter Ch
60. This setpoint allows a maximum of 6 starts per allowed deviation above or below the start hour Contact motor manufacturer curve before a trip is generated Time Between Starts If enabled the TX for Sampling The time ihe prevents another start attempt until the continues to sample the start curve programmed time has expired characteristic during learn the mode TOSHIBA 49 5 9 RTD Configuration Setpoint 9 Security Level 3 Please note this is supplied as an option Contact factory for more information Optional Ranges 120 OHM NICKEL NI PAGE9 RTD lt gt USE NEMA TEMP FOR 100 OHM NICKEL NI CONFIGURATION RTD VALUES DISABLED 10 OHM COPPER CU 100 OHM PLATINUM PT Options ENABLED OR OFF DISABLED 0 240C 32 464F OFF OF RTD S USED FOR Increments of 1 SIM 6 STATOR A1 STATOR 2 STATOR B1 STATOR 82 STATOR C1 STATOR C2 Hit DOWN ARROW eight times a Range 0 6 FRONT BEARING BACK BEARING BEARING BOX AMBIENT NONE Increments of 1 RTD VOTING DISABLED Options ENABLED or DISABLED STATOR PHASE A1 TYPE RTD 1 DESCRIPTION STATOR PHASE A1 ALARM STATOR PHASE 1 TRIP 100 OHM PT STATOR PHASE A1 LEVEL HHF LEVEL Range f Range Range Range STATOR PHASE A2 TYPE RTD 2 DESCRIPTION STATOR PHASE A2 ALARM STATOR PHASE A2 TRIP 100 OHM PT STATOR PHASE A2 LEVEL HHF LEVEL
61. Timer Starts per Hour Time Between Starts External Input Faults 1 5 Thermal Overload Protection The TX Series plays an important role in the protection of your motor in that it monitors the motor for excessive thermal conditions due to starting running or even ambient conditions The TX Series has a Dynamic Thermal Register system in the CPU that provides a mathematical representation of the thermal state of the motor This thermal state information is kept in memory and is monitored for excesses in both value and rate of change Input is derived from current imbalances and optional RTD measurements making it dynamic to all processes involving the motor The TX Series monitors these conditions separately during Start and Run modes to provide proper thermal overload protection at all times Start Mode overload protection is selectable using one of three methods Basic Protection data is accumulated and plotted based on an Overload Curve selected in programming This is programmed per NEMA Class 5 30 standard curves and is based on the Locked Rotor Current from the motor nameplate as programmed into the soft starter Measured Start Capacity the user enters a measured amount of thermal capacity from a pre selected successful start as a setpoint to the Thermal Register for the soft starter to follow Learned Curve Protection the user sets the soft starter to the LEARN mode and starts the motor under normal startin
62. abled 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 Range Range 0 65535 Range 0 65535 Analog Output Range Increments of 1 Increments of 1 RPM 0 3600 Hottest Bearing 0 200 C 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 ANALOG OUTPUT 2 Range See Analog ii Range 0 100096 Range 0 100095 Increments of 1 Increments of 1 Increments of 1 USER PROGRAMMABLE lt gt EXTERNAL INPUTS Continued TOSHIBA 43 TX Series SP 6 User I O Configuration Setpoint Page 6 Security Level 2 The TX can be configured to accept a tachometer feedback signal through the 4 20mA input and has two options available for scaling the tachometer input Note At the time of this printing SP6 1 SP6 4 are pending SP6 1 SP6 2 SP6 3 SP6 4 The first screen of setpoint page 6 is TACHOMETER SCALE SELECTION When this is set to AUTO the display prompts the user to program the TX to sense when the motor speed is zero It will prompt again when the motor speed is at maximum RPM
63. additional protection functions are enabled when the soft starter receives a valid Start command Phase Reversal if enabled Start Curve Acceleration Timer Phase Imbalance Short Circuit Load Pre check Toe in the Water Ground Fault External Input Faults Accumulated Starting FLA Units 1 Protection Overload Protection Thermal Capacity Note Shorted SCR and Shunt Trip protection are no longer in effect once the Soft starter goes into the Start Mode TOSHIBA 5 TX Series 48 1250A Run Mode The soft starter enters the Run Mode when it reaches full output voltage 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 External Input Faults Stop Mode Once a Stop command has been given the TX Series protec tion features change depending on which Stop Mode is selected Decel Mode retains all protection features of the Run Mode At the end of Decel the motor will be stopped and the protection features change as indicated below Coast To Stop Mode power is immediately 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
64. 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 the RTD option is supplied the TX can be configured to use the measured cool rates from the RTDs instead of the programmed settings This setpoint should only be enabled when the RTD option is present TOSHIBA 55 48 1250A Thermal Register Minimum Sets the value the thermal register which represents a motor running at the nameplate current with no overheating or negative sequence currents present Motor Design Ambient Temperature Use the data from the motor manufacturer s specifications When RTD option is supplied 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 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 temper
65. 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 100 CURVE A RAMP TIME 1 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 2 30 Range 0 100 Increments of 1 CURVE A RAMP TIME 2 2 SEC Range 1 60 SEC Increments of 1 If Custom Accel Curve has been set to curve B or C on this page the TX 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 CURVE A VOLTAGE LEVEL 3 37 Range 0 100 Increments of 1 gt CURVE RAMP TIME 3 2 SEC Range 1 60 SEC Increments of 1 i CURVE A VOLTAGE LEVEL 4 45 Range 0 100 Increments of 1 lt gt CURVE A RAMP TIME 4 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 5 55 Range 0 100 Increments of 1 CURVE RAMP TIME 5 2 SEC Range 1 60 SEC Increments of 1 CURVE A VOLTAGE LEVEL 6 67 CURVE A RAMP TIME 6 2 SEC Range 1 60 SEC Increments of 1 lt gt CURVE VOLTAGE LEVEL 7 82 Range 0 100 Increments of 1 CURVE RAMP TIM
66. ango 400 600 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 lt TIME BETWEEN STARTS TIME DISABLED with full voltage on the a SE windings and no rotor increments of movement as a percent of AREA UNDER CURVE MAX START PROTECTION DISABLED gt 368 FLA FLA SEC motor FLA Refer to the Range ENABLED or DISABLED Range 1 2500 FLA Time Sec RUN CURVE LOCKED RUN LOCKED ROTOR lt gt ROTOR TIME O LCLASS lt gt CURRENT 600 FLA Range 1 30 SEC O L CLASS Range 400 800 Increments of 1 COAST DOWN TIMER lt TIME DISABLED Range 1 60 MIN DISABLED Increments of 1 ACCELERATION TIME LIMIT 30 SEC Range 1 300 SEC DISABLED Increments of 1 lt NUMBER OF STARTS PER HOUR DISABLED Range 1 6 DISABLED Increments of 1 t nameplate data or contact the motor manufacturer Increments of 1 Coast Down Timer enabled this prevents the CURRENT OVER LEARNED START CURVE lt gt TIME FOR SAMPLING 0 motor from restarting for the CURVE DISABLED lt gt Bias 10 30 SEC Options DISABLED LEARN Range 5 40 Range 1 300 SEC programmed amount of time or ENABLED Increments of 1 Increments of 1 after a stop command is given
67. aracteristics that perform well in most applications When the system is ready to start try the initial unit settings If the motor does not come up to speed increase the current limit setting If the motor does not start to turn as soon as desired raise the starting voltage adjustment Adjustment description and procedures are described as follows See section 4 5 2 for additional Accel settings 3 3 1 Starting Voltage Factory Setting 20 of line voltage Range 0 100 of line voltage Starting voltage adjustment changes the initial starting voltage level to the motor 3 3 2 Ramp Time Factory Setting 10 sec Range 0 120 sec Ramp time adjustment changes the amount of time it takes to reach the current limit point or full voltage if the current limit point was not reached 3 3 3 Current Limit Factory Setting 350 of unit FLA Range 200 600 of unit FLA The current limit adjustment is factory set for 350 of the unit s rating The range of adjustment is 200 to 600 The main function of current limit is to cap the peak current It may also be used to extend the ramp ing 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 TOSHIBA 16 TX Series 48 1250A The current limit must set high enough to allow the motor to ACCELERATION reach full speed
68. as on the old board Install the control wires onto correct terminals per tag sequence Install the plugs Apply power to the unit and program all parameters to values in old board Test TOSHIBA 73 7 5 Interconnect Drawing TOSHIBA 74 Unit 3 PC Stations Unit 2 2 or 4 wire Modbus 2 or 4 wire Modbus 3 a 5 5 2 5 2 or 4 wire Modbus Communication amp Keypad Board Note J1 can alternately be connected to remote power supply 5 Computer with RS232 Communication Port 111111 00000000 0000000000000000090 C vit ndul sasn c ndu 0050 5 111111 Tm D js 9 asn neg yasay ejqeu3 ejqeu3 C indui zitndino 2 Bojeuy 9 ndino Bojeuy C
69. ature This maximum temperature represents 10096 thermal capacity Input to Thermal Register When enabled it allows the TX 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 TX will calculate the k constant factor for biasing the thermal register or the user may choose to assign the k value Cold Stall Time Enter the time from the motor SP12 4 Press Enter to CLR Thermal Register Allows the level three password user to clear the thermal register for emergency restarts TX Series 48 1250A SP 13 Calibration amp Service Setpoint Page 13 Security Level Factory Use Only Hit DOWN ARROW twelve times PAGE 13 CALIBRATION SET DATE AND TIME ENTER DATE DDMMYYYY ENTER TIME hh mm Range 1 31 M 1 12 Range 00 23 0 59 1970 2069 Increments 1 Increments 1 MODEL 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 TX in the format shown Enter Time hh mm Allows the factory
70. aulty SCRs Section 7 1 1 for the SCR If fans have power remove power 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 AUXI Overcurrent on unit Verify 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 Check bypass contactor and wiring Loss of 1or more phases of ower from utility or Check power source Phase Loss PHASE LOSS Trip pues Bowel Blown power fuses Check for short circuits TOSHIBA 67 Place unit in environment temperature less than 122 F for panel version or less than 104 F for enclosed version TX Series 48 1250A Problem CPU LCD Display Possible Cause Solutions Check motor nameplate versus Proper progra 9 programmed parameters possible load Check motor currents jammed load Improper setting for motor Verify current limit setting load condition Damaged load Check for load failure Check setpoint settings Overload OVERLOAD TRIP Stall prevention ACCEL TIME TRIP Under Current Trip Improper programming or UNDER CURRENT
71. d equipment cost of capital cost of substitute equipment or parts facilities or services down time costs labor costs or claims of customers of the purchaser for such damages
72. e 9 o RTD12 Compensation RTD Typical RTD Installation TOSHIBA 15 TX Series 48 1250A Chapter 3 Start up THE TX 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 Supply voltage matches the rated supply voltage of the unit Horsepower and current ratings of the motor and unit match or the unit has a higher rating Initial ramp time and torque adjustments have been checked Power lines are attached to the unit input terminals marked L1 L2 and L3 Motor leads are connected to the lower terminals marked T1 T2 and T3 Appropriate control power is applied and or control connections have been made The motor s FLA has been programmed The thermal overload parameters are properly set The motor area and equipment are clear of people and parts before start up 3 2 Introduction It is best to operate the motor at its full load starting condition to achieve the proper time torque and ramp settings Initial settings are set to accommo date most motor conditions TRY INITIAL SETTINGS FIRST See Setpoints Page 2 to make any adjustments 3 3 Acceleration Adjustments The unit is set at the factory with typical starting ch
73. e 05022 20 Decio Disabled Enabrdorbeabed Deceieraionvotage SepDecwemonVota sw osa F becoleratonTime 5s ot 1 0 19e 1 mspedDemyTme Se 5smor Start Control Mode Start Ramp 1 Page 2 Starter Configuration No Passowrd Required TOSHIBA 81 Setpoint Security Page Level ma Factory Setting Description Default Setting Imbalance Level sson imbalance Alarm Delay 15s 1020080 Phase Rotation ABC AB Undervoltage Alarm Delay Undervoltage Trip Level _____ Undervoltage Trip Delay Line Frequency Trip Window Password Protection 5 2 ic a Undervoltage Trip Level Off P F Lead P F Alarm Off TOSHIBA 82 Setpoint Security Page Level Factory Setting 1st 2nd 3rd Trip Trip S C Trip Overcurrent Trip Stator RTD Trip Bearing RTD Trip 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 I T Start Curve None None None None Undervoltage Trip None Power Factor Trip None Tach Accel Trip None Inhibits Trip None Shunt Trip None None Bypass Discrepancy
74. e available Type Rating FORM C SPDT rated 5 Amps 240VAC max 1200VA Auxiliary Contacts 4 Programmable Relays Approvals UL Listed Canadian UL cUL TOSHIBA 1 Control TX 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 Protection Coast Down Back Spin Lockout Timer Starts per hour Lockout Timer 48 1250A Advanced Motor Protection Starting programmable for Class 5 30 or locked rotor time Run Programmable for Class 5 30 when At Speed is detected Manual default or automatic Overload circuit retains thermal condition of the motor regardless of control power status Unit uses real time clock to adjust for off time Overload will not reset until thermal capacity available in the motor is enough for a successful restart Starter learns and retains this information by monitoring previous successful starts Imbalance Trip Level 5 30 current between any two phases Imbalance Trip Delay 1 20 seconds Trip Level 100 300 of motor FLA while running not starting or OFF Trip Delay 1 20 seconds Under Current Trip Level 10 90 of motor FLA or OFF Under Current Trip Delay 1 60 seconds Coast Down Time Range 1 60 minutes or OFF Range 1 6 successful starts per hour Time between
75. e buttons are held for a long period the scrolling speed will increase TOSHIBA 20 TX Series 48 1250A 4 2 Menu Navigation 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 PAGE1 BASIC 2 Levels 1 2 and 3 indicate password protection levels for these setpoint pages CONFIGURATION LEVEL 1 2 STARTER CONFIGURATION PAGE 3 PHASE amp GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT LEVEL 2 5 RELAY CONFIGURATION 6 USER I O CONFIGURATION PAGE7 CUSTOM ACCELERATION CURVE PAGE 8 OVERLOAD CURVE CONFIGURATION LEVEL 3 PAGE 10 SECURITY SET PASSWORD PAGE 11 COMMUNICATIONS LEVEL amp SERVICE 9 RTD CONFIGURATION PAGE 12 SYSTEM SETPOINTS TOSHIBA 21 TX Series 48 1250A 4 2 1 Password Access Screens in Level 1 of the setpoint menu can be changed without password access because they list basic motor information Screens in Levels 2 and 3 require passwords because they provide more in depth protection and control of the TX Series unit The password in Levels 2 and 3 can be changed by the user NOTE Setpoints can only be changed when the motor is in Stop Ready Mode The TX will not allow a start if it is still i
76. e 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 2 respectively RTDs 3 amp 4 are named STATOR PHASE and 2 RTDs 586 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 TOSHIBA 51 TX Series SP 10 Set Password Setpoint Page 10 Security Level 3 The TX 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 starter 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 5 10 2 Set Level 3 Password Level three uses 4 digit password The default level 3 password is 1000 TOSHIBA 52 48 1250A Hit DOWN ARROW nine times PAGE 10 SECURITY SE
77. e skilled in the installation construction or operation of the equipment and aware of the hazards involved 3 Be trained and authorized to safely energize de energize clear ground lockout and tag circuits in accordance with established safety practices 4 Be trained and authorized to perform the service maintenance or repair of this equip ment 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 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 covers securely in place Never Defeat Modify or Bypass any Safety Interlocks Qualified Operators only Never attempt to install operate maintain or dispose of this equipment until AW ARNING you have first read and understood all of the relevant product warnings and user directions that are contained in this Instruction Manual
78. eck Valve In a pump system liquid is being pushed uphill The force exerted by gravity on the column of liquid as it goes up hill is called the Head 9 Pressure in the system The pump is sized to provide enough Output PUMP FLOW Pressure to overcome the Head Pressure and move the fluid up the pipe When the pump is turned off the Output Pressure rapidly drops to zero and the Head Pressure takes over to send the fluid back down the hill A Check Valve is used somewhere in the system to prevent this if necessary by only allowing the liquid to flow in one direction The kinetic energy in that moving fluid is suddenly trapped when the valve slams closed Since fluids can t compress that energy is transformed into a Shock Wave that travels through the piping Closed System looking for an outlet in which it dissipates The sound of that shock wave is referred to as Water Hammer The energy in that shock wave can be extremely damaging to pipes fittings flanges seals and mounting systems By using the Soft Stop Deceleration feature of the TX the pump output torque is gradually and gently reduced which slowly reduces the Check Valve Pump Control pressure in the pipe When the Output Pressure is just slightly lower Soft Stop 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 Check Valve fluid and the Shock Wave is avoided
79. ecommended for this starter during the operation period TOSHIBA 77 48 1250A TX Series Appendix A Reference Section Typical Full Load Current for 3 Phase Motors INDUCTION TYPE SQUIRREL CAGE AND WOUND ROTOR AMPERES 48 1250A SYNCHRONOUS TYPE UNITY POWER FACTOR AMPERES 115V 200V 24 22 11 09 2 7s oe 175 72 68 202 359 343 312 156 125 253 552 528 480 20 192 49 400 201 161 40 1 1 f 2 3858 2551 2 pev 2 5 11 55 42 09 1 seo 472 118 For 90 80 percent power factor the figures shall be multiplied by 1 1 1 25 respectively 4 4 8 4 E 13 6 2 5 3 7 4 8 7 8 11 92 85 59 075 150 200 gt Typical Maximum Allowable Start and Stops per hour ALLOWABLE STARTS AND STARTING INTERVALS DESIGN AND MOTORS 6 POLE B 1 291 23 1 5 7 86 38 291 24 7 3 9 35 198 17 40 224 51 46 v 33 34 35 36 37 39 41 2 8 30 99 5 104 10 15 20 48 21 110 96 99 55 109 262 48
80. ee text for directions Options Normally Open or Range 0 60 SEC Normally Closed Increments of 1 cose LETT Options Enabled Disabled See text for directions Options Normally Open or Range 0 60 SEC Dual Ramp Normally Closed Increments of 1 EE ass cose gt ient ose SELECT ENABLED THERMOSTAT TYPE NORMALLY CLOSED TIME DELAY 0 SEC Options Enabled Disabled or See text for directions Options Normally Open or Range 0 60 SEC Thermostat Normally Closed Increments of 1 SP6 7 User Programmable External Inputs The TX External Input 3 The setup screens and provides up to 4 digital external inputs which are setpoints for External Input 3 includes the option individually programmable A description name of being configured for Dual Ramp In Dual can be assigned to each individual input for easy Ramp mode the initial contact setting is the identification same as the START RAMP 1 Upon a change External Input 1 used this setpoint must be in input contact state the TX will switch over to enabled START RAMP 2 and use that setting for start Name Ext Input 1 The user can assign a control mode Note The start RAMP types description name to the input to easily identify the should only be switched while the motor is cause of external trip or alarm Up to 15 stopped In Setpoint Page 4 Relay characters including spaces can be used to Assignments do not assign any output
81. en 9 Displays the measured required to start THERMAL CAPACITY the motor TO START creen Screen 10 Displays the amount of time required to start the motor during the last successful start AVERAGE START TIME TIME SECS AVG START CURENT AMPS FT START Screen 9 LAST START TIME SEC Screen 10 TOSHIBA 60 TX Series MP 2 Metering Metering Page 2 Displays the TX Series statistical voltage metering information Screen 1 Screen 2 Screen 3 Screen 4 Screen 5 Screen 6 Screen 7 Screen 8 Screen 9 Screen 10 Screen 11 Displays Phase A B C and Power Factor Note P F N A Motor stopped P F LG 8488 Lagging P F LD Leading Displays Phase A B C and Ground Fault Current Displays KW and KVA Displays KVAR and Power Factor Displays Peak On and KW demand Displays Peak On and KVA demand Displays Peak On and KVAR demand Note P F N A Motor stopped P F LG Lagging P F LD Leading Displays Peak On and Ampsdemand Clears Demand Values Displays the Megawatts used per hour Press Enter to clear statistics on MWH values 48 2 2 lt gt VOLTAGE amp POWER DATA TOSHIBA 61 1250A Screen 1 Vbc THEE P F THE Screen 2 Screen 4 P F THE 5 ON HHTHE
82. ewhat 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 TOSHIBA 76 TX Series 7 7 DISPOSAL STORAGE 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 cool clean and dry location 3 Place a dust cover over the starter packaging to protect against dirt and moisture 4 Store in upright position INSPECTION DURING STORAGE Routine scheduled inspection is necessary if storage 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 r
83. g Free from metallic particles conductive dust and corrosive gas Free from excess vibration below 0 5G Open panel units must be mounted in the appropriate type of enclosure Enclosure size and type must be suitable to dissipate heat generated by the soft starter Contact factory for assistance in sizing the enclosure aA WARNING Do not service equipment with voltage applied The unit can be the source of fatal electrical shocks To avoid shock hazard disconnect main power and control power before working on ihe unit Warning labels must be attached to terminals enclosure and control panel to meet local codes 2 4 Mounting and Cleaning When drilling or punching holes in the enclosure cover the electrical assembly to prevent metal filings from becoming lodged in areas which can cause clearance reduction or actually short out electronics After work is completed thoroughly clean the area and reinspect the unit for foreign material Make sure there is sufficient clearance six inches all around the unit for cooling wiring and maintenance purposes To maximize effective air flow and cooling the unit must be installed with its heat sink ribs oriented vertically and running parallel to the mounting surface TOSHIBA 8 Remove all sources of power before cleaning the unit In dirty or contaminated atmospheres the unit should be cleaned on a regular basis to ensure proper cooling Do not use a
84. g 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 TOSHIBA 6 TX Series 48 1250A Run Mode overload protection is initiated when the TX Series determines that the motor is At Speed Overload Protection is initiated when the motor RMS current rises above a pick up point as determined by the motor nameplate FLA and service factor Run mode protection is provided by the CPU monitoring the Dynamic Thermal Register Data for the Dynamic Thermal Register is accumulated from calculations and cooling rates trip occurs when the register reaches 100 as determined by the selected Overload Protection Curve NEMA Class 5 30 standard curves and is based on the programmed Locked Rotor Current indicated on the motor nameplate The Dynamic Thermal Register is altered or biased by the following condi tions Current Imbalance will bias the register higher to add protection from additional motor heating during a current imbalance condition Normal Cooling provided when the motor current drops below the pick up point or the motor is off line The c
85. h is defective under the terms of the foregoing warranty free of charge provided the purchaser 1 promptly notifies the Company in writing of such defect 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 this manual and 4 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 the Company s warehouse or at the Company s option 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 INSTALL ANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAY ANY COSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY
86. he SCR clamp Then remove the top clamp holding the SCR stack together Remove the top heatsink Use extreme caution when handling the heat sink so it does not become dented or damaged e Remove the faulty SCR device noting the direction in which the SCR is oriented The new SCR puck must be inserted in the same direction Make sure the SCR mounting surface tools and hands are clean and free from dirt nicks and scratches Do not sand or scrape SCR mounting surface If necessary super fine Scotch Brite pads can be used to clean the heatsink before installing the new SCR Apply athin 3 mil thick layer of thermal grease uniformly along both sides of the SCR Spread the grease to cover the entire surface of both sides of the SCR in a manner that minimizes air pockets The grease must be free of contamination Locate the centering pin in the bottom and top of the heatsink and center it in the SCR hole making sure that the SCR is pointed in the same direction as the SCR that was removed in step 6 Locate the centering pin in the top heatsink and center it in the SCR hole Caution If center pin is not placed correctly it will damage the SCR and the heat sink Hand tighten the clamps evenly so that the same number of threads appear at both ends of the U clamp Tighten the clamp 1 4 turn at a time alternating sides of the U clamp until the correct force is reached Check the gauge or spin washer every time the clamp nuts are tightened
87. he following charts list each Setpoint Page and the programmable functions within that page The applicable section of the manual is also referenced 5 1 1 Basic Configuration Setpoint Page 1 Setpoint Security Page Level Factory Setting Default 50 100 of Unit Max Current Rating Model Motor Full Load Amps FLA Model dependent and Service Factor dependent SP1 1 Description Range Section 5 1 2 Starter Configuration Setpoint Page 2 1 00 1 3 SP1 2 O L Class 5 30 H S 208 10 600 50 60 2 Basic Configuration No Passowrd Required Setpoint Security Page Level Factory Setting Default Jog Start Ramp 1 Start Ramp 2 Custom Start Control Mode Start Ramp 1 Accel Curve Start Disabled Dual Ramp SP2 1 Jog Voltage 5 75 Off SP2 2 Start Ramp 1 Type Voltage Initial Voltage 1 20 Current Voltage Off 0 100 350 FLA 200 600 SP2 3 Description Section 20 Current Voltage Off i 0 100 350 FLA 200 600 SP2 4 200 600 350 FLA 200 600 10 100 SP2 5 0 10 2 00 Kick Start Voltage 65 Kick Start Time 0 50 sec Enabled or Disabled 0 100 SP2 6 0 59 1 60 sec 1 1000 sec Off Start Deceleration Voltage 60 0 Run Delay Time 1 Sec 1 30 sec Off At Speed Delay Time 1 Sec 1 30 sec Off SP2 9 Stop Deceleration Voltage 30 Deceleration Time 5 sec Bypass Pull in Current 100 FLA 90 300 SP2 10 TOSHIBA 23 No Passowrd
88. include material handling conveyors positive displacement 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 60096 the maximum setting Since Jog Voltage Setting Ramp 1 Voltage Ramp New Start Command Jog Start Control Mode Setpoint changed lt Start Ramp 1 Type Voltage TOSHIBA 35 48 1250A this is essentially Locked Rotor Current most motors there is little or no Current Limit effect on the Ramp profile 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 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
89. 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 annually for proper tightness using an accurate torque wrench Note If the unit is installed 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 f 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 Eo Possible Cause Solutions Short circuit or ground fault Locate and remove short or ground in motor cabling Repair cause of phase loss Branch circuit protection Verify correct sizing of branch circuit Short Circuit Trip SHORT CIRCUIT TRIP i not correctly sized Faulty main circuit board Remove power and replace main circuit board Remove power and test SCR s Refer to Faulty SCRs Section 7 1 1 for the SCR procedure Single phase incoming Correct problem with incoming power SINGLE PHASE TRIP power Single Phase Trip Check LCD display for Remove power and test SCR s Refer to possible fault indicators F
90. n control board layout Note the type of color coding of the wires connected to J5 J6 and J7 Toshiba uses two possible configurations Both configurations have 4 wires going to each plug The first configuration consists of 4 wires color coded black yellow grey and white The second configuration consists of 4 wires color coded red white red white The testing procedure for SCRs is comprised of two separate tests The first one tests the anode to cathode integrity of the SCR by performing the following ohm checks Lead Lead Consult factory L1 Lug T1 Lug Greater than 10K ohm Less than 10K ohm L2 Lug Greater than 10K ohm Less than 10K ohm L3 Lug Greater than 10K ohm Less than 10K ohm The second tests the gate to cathode integrity of the SCR The chart below indicates good versus bad readings For wire that is color coded black yellow gray and white Lead Good Black Yellow Between 5 and 90 ohms Less than Or greater than 90 ohms Less than 5 or greater Grey White Between 5 and 90 ohms than 90 ohms For wire that is color coded red white red and white Between 5 90 ohms Bess thans of greater than 90 ohms Rei Between 5 90 ohms Less than 5 or greater than 90 ohms Note If any of the above readings are out of specifications replace the faulty SCR Note The best way to test an SCR is with an SCR Tester and look for leakage current le
91. n the Edit Mode When the unit is in the Edit Mode a is in the top right corner of the display 4 2 2 Changing Setpoints Example 1 Changing Motor FLA A Press MENU button to display Setpoint Page 1 Basic Configuration B Press the RIGHT ARROW you will view the screen Motor Full Load Amps C Press the ENTER button for edit mode Note the asterisk in the top right corner of the LCD screen that indicates Edit Mode D To change the value select the UP ARROW or DOWN ARROW E To accept the new value press the ENTER button The unit will accept the changes and will leave the edit mode Note the is no longer in the top right corner of the LCD Display MENU PAGE1 BASIC MOTOR FULL LOAD AMPS CONFIGURATION 140 AMPS MOTOR FULL LOAD 2x 142 AMPS MOTOR FULL LOAD 142 AMPS TOSHIBA 22 TX Series 48 1250A Chapter 5 Setpoint Programming The TX Series has twelve programmable setpoint pages which define the motor data ramp curves protection I O configuration and communications In Section 5 1 the setpoint pages are outlined in chart form In Section 5 2 the setpoint pages are illustrated and defined for easy navigation and programming Note Setpoints can only be changed when the starter is in the Ready Mode Also the soft start will not start when it is in programming mode 5 1 Setpoints Page List T
92. necting 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 SP3 1 Imbalance Alarm Level This is an advance warning of a phase imbalance problem The problem may not be a fault in the motor but merely caused by imbalanced voltages Imbalance Alarm Delay The amount of time the imbalance condition must exist before an alarm occurs SP3 2 Imbalance Trip Level This will trip the motor on excessive phase imbalance The trip level should be programmed to a higher value than the alarm level Imbalance Trip Delay The amount of time the imbalance condition must exist before a trip will occur SP3 3 Undercurrent Alarm Level Typically used to warn of possible load loss a coupling breaking or other mechanical problems Undercurrent Alarm Delay The amount of time the undercurrent condition must exist before an 48 1250A IMBALANCE ALARM IMBALANCE ALARM LEVEL 15 FLA DELAY 1 5 SEC Range 1 0 20 0 SEC Increments of 0 1 IMBALANCE TRIP DELAY 2 0 SEC Range 1 0 20 0 SEC Increments of 0 1 Increments of 1 IMBALANCE TRIP LEVEL 20 FLA Range 5 30 OFF Range 5 30 OFF Increments of 1 UNDERCURRENT ALARM LEVEL OFF Range 10 90 OFF Increments of 1 OVERCURRENT ALARM LEVEL OFF Range 100 300 OFF 1 UNDERCURRENT ALARM DE
93. nge 5 30 OFF Increments of 1 OVERVOLTAGE TRIP LEVEL OFF Range 5 30 OFF Increments of 1 UNDERVOLTAGE ALARM LEVEL OFF Range 5 30 OFF Increments of 1 UNDERVOLTAGE TRIP LEVEL OFF Range 5 30 OFF Increments of 1 1 LINE FREQUENCY TRIP WINDOW DISABLED Range 0 6 Disabled Increments of 1 Increments of 0 002 OVERVOLTAGE ALARM DELAY 1 0 SEC Range 1 0 30 0 SEC Increments of 0 1 OVERVOLTAGE TRIP DELAY 2 0 SEC Range 1 0 30 0 SEC Increments of 0 1 UNDERVOLTAGE ALARM DELAY 1 0 SEC Range 1 0 30 0 SEC Increments of 0 1 UNDERVOLTAGE TRIP DELAY 2 0 SEC Range 1 0 30 0 SEC Increments of 0 1 LINE FREQUENCY TRIP DELAY 1 0 SEC Range 1 0 20 0 SEC Increments of 0 1 TX Series Phase amp Ground Settings Setpoint Page 3 continued 4 SP 3 Phase amp Ground Settings Setpoint Page 3 Security Level 2 SP3 5 Overcurrent Trip Level Typically used to SP3 6 SP3 7 SP3 8 SP3 9 indicate the motor is severely overloaded and at which point a trip occurs Over Current Trip Setting 1 250 FLA 3 07 Overcurrent Trip Delay The amount of time the overcurrent condition must exist before a trip will occur Time Phase Loss Trip When enabled the TX 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
94. ny chemicals to clean the unit To remove surface dust use 80 to 100 psi clean dry compressed air only Athree inch high quality dry paint brush is helpful to loosen up the dust prior to using compressed air on the unit 2 5 Power Terminal Wire Range and Tightening Torque TX005 TX006 EA 25 2221 RAE CEREK 20 alo ojo 009 m5 258 ELM 2 919 125 200 450 56 BY ojojo 11 18 4 ma 16 250 kcmil 46 600 kcmil 4 2 600 kcmil Fix Note wiring must be sized according to NEC standards 2 6 Dimensions Mode Number 8 c E Txos 165 10 10 59 0 28 PANEL OPEN CHASSIS TYPE TOSHIBA 9 2 7 Power Connections Connect appropriate power lines to the unit input terminals marked L1 L2 L3 Avoid routing power wires near the control board Connect the motor leads to the unit terminals marked T1 T2 T3 Refer to NEC standards for wire length and sizing Never interchange input and output connections to the unit This could cause excessive voltage in the control logic circuit and may damage the unit TX Series Unit AVARNING Never connect power factor correction capacitors on the load side of the
95. onnect 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 most motor conditions TRY INITIAL SETTINGS FIRST See Setpoint Page 2 to make any adjustments e Initial Voltage e Start Curve e Current Limit Acceleration Time If decel is enabled the following parameters for Deceleration Time Start Decel Voltage see SP2 and Stop Decel Voltage see SP2 must also be pro grammed TOSHIBA 19 TX Series 48 1250A 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 TX Series user keypad keypad operator interface consists of 2 row by 20 characters Liquid Crystal Display LCD 12 LEDs 8 pushbuttons DIGITAL DISPLAY Note The TX Series is menu driven and there are three levels of programming programming for two of these levels is password protected Level two requires three digit password and level three requires a four digit password TRIP Toggle between the menu selection for metering setpoint pages Keypad Operator Interface RESET Will clear the trip indicator and release the trip relay In the edit mode press
96. ooling rate is lower for motors that are off line such as after a trip since cooling fans are also inoperative RTD Input requires the optional RTD monitor card will bias the register in either direction based on real time input of the motor bearing and even ambient temperature conditions Dynamic Reset is another feature that adds reliability and consistency to the performance of the TX Series soft starter If a motor overload condition occurs and the soft starter trips it cannot be reset until sufficient cool down time has elapsed This cool down time is determined by the thermal state of the motor when it tripped i e hot motors cool more quickly due to additional convection The cool down time is also biased by RTD measurements when used Retentive Thermal Memory provides continuous overload protection and real time reset even if power is lost Upon restoration of power the TX Series will read the Real Time Clock and restore the thermal register to what it should be given the elapsed time Learned Reset Capacity is a feature that is unique to the TX Series sampling the amount of thermal capacity used in the previous three successful starts the TX Series will not allow a reset until a sufficient amount of thermal capacity has been regained in the motor This prevents nuisance tripping and insures that unsuccessful start attempts which would otherwise use up the starts per hour capacity of the motor are not allowed
97. ower 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 Any fault indication No start command Apply the start command Motor will not start message No phase line voltage Apply 3 phase line voltage to the unit Remove power and test SCR s Refer to Shorted SCR starter Section to 7 1 1 for the SCR testing procedure Faulty control logic power repair the control logic Replace the main circuit board board Check the motor and the motor Faulty motor connections Remove power and perform the SCR Motor growis while starting or extremely Faulty gate cathode on unbalanced motor SCRs currents run mode Remove power and test SCR s Refer to Section 7 1 1 for the SCR 2 Faulty main circuit board Replace the main circuit board Faulty motor wiring Troubleshoot and repair replace wiring Faulty main circuit board Replace the main circuit board TOSHIBA 69 7 2 SCR Testing Procedure Failure to remove both line and control power before starting this procedure may cause personal injury or death Remove both line power and control power from the unit and lock out Disconnect any two motor load leads and any two line leads Disconnect the SCR connections to main control board J5 J6 and J7 Refer the Chapter 6 for the mai
98. re FORM C Com N O N C Toshiba recommends fusing all contacts with external fuses The TX has four programmable relays on TB3 on the power board The relays are rated for 240Vac 5 A and 1200 VA These relays can respond to either a fault condition or an up to speed condition In the TX all tripping functions have been assigned to the TRIP AUX1 relay and all alarm warning condition has been configured to the ALARM AUX2 relay AUX 3 is factory programmed for a SHUNT TRIP indication and can be connected to a shunt trip coil on an incoming circuit breaker or open an input isolation contactor AUX4 is the AT SPEED contact When the motor has reached the end of its acceleration ramp the TX will wait until the AT SPEED programmed time delay has expired Then the relay will energize until a stop command has been received The AT SPEED contact can be used to operate a bypass contactor used for shorting the load current around the SCRs To change AUX3 or AUX4 functions see Setpoint Page 4 TB3 C NO NCi N O NO NCi NO AUX1 AUX2 AUX3 AUX4 TRIP ALARM SHUNT AT SPEED Relay Contacts on Power Board Rated 240Vac 5A 1200VA TOSHIBA 11 TX Series 48 1250A 2 8 4 DC DC1 oro Interlock Start Interlock Stop Start Control Control Control Control Power Contact Power Power Power Three Wire Control Connection Two Wire Control Connection m
99. re is provided to accommodate installations where there is limited power available for example on site generator power or utility lines with limited capacity The torque is increased until the motor current reaches the preset Current Limit point and it is then held at that level Current Limit overrides the ramp time setting So if the motor has not accelerated to full speed under the Current Limit setting the current remains limited for as long as it takes the motor to accelerate to full speed When the motor reaches full speed and the current drops to running levels the TX Series detects an At Speed condition and will close the Bypass Contactor if provided The Bypass Contactor serves to shunt power around the SCR stack assemblies to prevent heat build up NEMA 12 3R 4 and 4X enclosed units due to the slight voltage drop across the SCRs At this point the TX Series has the motor operat ing at full voltage just as any other starter would TOSHIBA 4 TX Series 48 1250A Other starting methods available in the TX Series are Current Ramp uses a closed current feedback PID loop to provide a linear torque increase up to a Maximum Current level Constant Current current is immediately increased to the Current Limit point and held there until the motor reaches full speed Custom Curve gives the user the ability to plot torque and time points on graph The soft starter will then accelerate the motor following these points
100. reen 12 Displays the number of l T start curve trips EXT INP 2 24H Screen 13 Displays the number of learned start curve Screen 10 trips ACCELERATION TIME 22 Screen 14 Displays the number fail shunt trips TRIPS EXT INP 3 Screen 15 Displays the number of phase loss trips Screen 11 Screen 16 Displays the number of tachometer START CURVE acceleration trips TRIPS Screen 17 Displays the number of undervoltage and TINE ie overvoltage trips Screen 12 Screen 18 Displays the number of power factor trips START CURVE Screen 24 Screen 19 Displays the number of phase reversal trips UES PRESS ENTER Screen 20 Displays the number of external input 1 CLEAR 13 LEVEL 2 Password required trips LEARNED START CURVE Screen 21 Displays the number of external input 2 TRIPS trips Screen 22 Displays the number of external input 3 Screen 14 trips FAIL SHUNT TRIP 2227 TRIPS Screen 23 Displays the number external input 4 trips Screen 15 Screen 24 Requires a Security Level 2 password to PHASE LOSS TRIP clear the statistics URIS ees Screen 16 TACH ACCEL TRIP TRIPS TOSHIBA 66 TX Series 48 1250A Chapter 7 Maintenance and Troubleshooting The TX Series is designed to be a maintenance free product However as with all electronic equipment the unit should be checked periodically for dirt moisture or
101. relay to assign the name this function The TX will ship with External External Input 1 Type The external input can input 3 programmed for dual ramp If it is not be set as either a normally open or normally needed disable the dual ramp closed contact External Input 4 These input screens are for External Input 1 Time Delay Upon a change in the thermostat input and can be enabled or contact setting the unit will wait the programmed disabled Note Toshiba recommends that this amount of time before generating an output If function remain enabled If the thermostat no delay is needed then input 0 seconds The indicates an over temperature condition the TX TX will post an event upon seeing a change in Will trip the motor state External Input 22 The setup screens and setpoints for External Input 42 includes the option of programming the unit for Under Voltage Phase Rotation TOSHIBA 45 SP 7 Custom Acceleration Curve Setpoint 7 Security Level 3 Hit DOWN ARROW six times PAGE7 CUSTOM c CUSTOM ACCEL CURVE ACCELERATION CURVE DISABLED Range DISABLED CURVE Bor C SP7 1 Setpoint Page 7 allows the user to custom CURVE A VOLTAGE CUSTOM CURVE LEVEL 1 25 design the acceleration curve start curve to the specific application The user can custom design up to three different curves in the TX Only one curve can be active enabled at a time Each of the three curves
102. rent for each phase and ground fault current at of event Metering Functions Motor Load Percent of FLA Current Data A B C Phase Current Avg Current Ground Fault Thermal Data Remaining thermal register thermal capacity to start Start Data Time Avg Start Current Measured Capacity to start time since last RTD Data Temperature readings from up to 12 RTDs 6 stators Voltage Metering KW KVAR PF KWH Serial Communications Protocol Signal Network Functionalty Operator Interface LCD Readout 722 Status Indicators Remote Mount Capability Clock and Memory Operating Memory DRAM loaded from EPROM and 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 TOSHIBA 3 TX Series 48 1250A 1 3 Theory of Operation The power of the TX Series is in the CPU a microprocessor based protection and control system for the motor and starter assembly The CPU uses Phase Angle Firing of the SCRs to apply a reduced voltage to the motor and then slowly and gently increases torque through control of the voltage and current until the motor accelerates to full speed This starting method lowers the starting current of the motor reducing electrical stresses on the power system and motor It also reduces peak starting torque stresses on both the motor and load
103. ries 48 1250A 6 2 Metering Menu 1 Push MENU key to toggle the screens between Setpoint Menu and Metering Menu and follow the arrow keys to get to different screens 4 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 TOSHIBA 59 TX Series 48 1250A 1 Metering Menu amp Data Metering Page 1 Displays the basic current metering data Screen 1 Phase A and ground fault current Screen 2 Displays the average current of the of imbalance and the motor s RPM available with tachometer in Screen 3 Displays the motor load in percent of motor FLA AVG 344 Screen 4 Displays the line frequency and the present VB 4 RPM Hf 2 Phase Order Screen 5 Displays the percent of the remaining thermal MOTOR LOAD OF FLA register In order for the motor to successfully FLA 88 Screen 3 start the percentage must begreater than the thermal capacity required for a successful start LINE FREQUENCY 202204 PHASE ORDER Screen 6 Displays the thermal capacity required to successfully start the motor Screen 7 Displays the average time required to start THERMAL REGISTER 5 REMAINING Screen 8 Displays the average current during start Scre
104. s needed to start the motor i e Breakaway or Initial Torque Kick Start Time The time the initial torque boost is applied Deceleration Allows the motor to gradually come to a soft stop Start Deceleration Voltage The first part of the deceleration ramp The TX 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 Timed Output Used with an AUX relay When enabled and upon a start command it energizes the assigned relay for the programmed time At the end of the programmed time the relay de energizes See Setpoint Page 4 Run Delay Time Used with an AUX3 relay When enabled and upon a start command it waits until the programmed time has expired The relay energizes and remains so until a stop command is received It de energizes upon receiving a stop command See Setpoint Page 4 At Speed Delay Time Used with an AUXA 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 See Setpoint Page 4 TX Series i Hit DOWN ARROW two times je GROUND SETTINGS SP 3 Phase amp Ground Settings Setpoint Page 3 Security Level 2 lt Proper phase sequence must be observed when con
105. s of 1 P F LAG TRIP DELAY 1 0 SEC Range 1 120 SEC Increments of 1 Increments of 01 POWER FACTOR LAG P F TRIP OFF Range 01 1 00 OFF Increments of 01 POWER DEMAND PERIOD 10 MINUTES Range 1 60 Minutes Increments of 1 gt KW DEMAND ALARM PICKUP OFF KW Range OFF 1 100000 Increments of 1 KVA DEMAND ALARM PICKUP OFF KVA 2 5 m m 2 5 5 8 2 a s 5 lt gt 4 Increments of 1 AMPS DEMAND ALARM PICKUP OFF AMPS 2 5 R Increments 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 Pending Ground Fault Hiset Trip Delay The amount of time that the ground fault condition must exist before a trip will occur 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 TX Series 48 1250A SP3 12 Overvoltage Trip Level Typically used to SP3 19 Power Factor Lag Trip The acceptable indicate that the line voltage i
106. s too high and at amount of power factor lag before a trip is which point a trip occurs generated Overvoltage Trip Delay The amount of time Power Factor Lag Delay The amount of time that the overvoltage condition must exist before a that the power factor lag condition must exist trip will occur beyond the window before a trip will occur SP3 13 Undervoltage Alarm Level Typically used to SP3 20 Power Demand Period The TX Series indicate when the line voltage is too low This is measures the damand of the motor for several an alarm level parameters current kvar KVA demand values of motors assists in energy Undervoltage Alarm Delay The amount of management programs where processes may time that the overvoltage condition must exist be altered or scheduled to reduce overall before a trip will occur demand Demand is calculated by a programmed amount of time where current kW SP3 14 Undervoltage Trip Level Typically used to kvar and kva samples are taken and then indicate that the line voltage is too low and at averaged and stored to assess demand which point a trip occurs Undervoltage Trip Delay The amount of time that the undervoltage condition must exist before a trip will occur SP3 15 Line Frequency Trip Window The acceptable amount of drift above or below the line frequency before a trip is generated Line Frequency Trip Delay The amount of time that the frequency drift condition must exist
107. se the following chart to verify the wiring of J5 J6 and J7 After verifying that all wiring is correctly connected test the SCR Destination Main Circuit Board Pin Load cathode Output Load Lug Pine Line Cathode BUSBAR CONNECTION 4 Isolated SCR Configuration TOSHIBA 71 TX Series 48 1250A 7 3 2 Changing a Hockey Puck Type SCR Remove both line and control power from unit tag and lock out Failure to remove both line and control power before starting this procedure may cause personal injury or death AMWVARNING Toshiba uses two types of clamps with gauges for reading the amount of force on the device The first type of force gauge uses a spin washer When the proper force is applied the washer will be free to spin The second type of gauge uses a step indicator on the end of the lever Before proceeding note the type of clamp used and if the clamp has a step indicator document the position of the indicator before removing the clamp to facilitate proper mounting of the new SCR device Label the location of the wires connected to the SCR e Remove lugs snubbers printed circuit boards refer to section X and associated wiring that may get in the way of reaching the faulty SCR Document the location and wiring of all parts before removing them to facilitate the reinstallation of the devices later e Document the position of the indicator on t
108. ss contactors on these models Recommended Transformer Sizes for Control Power Note TB4 1 If power is used for additional accessory items Lights fans etc contact factory for sizing 2 8 1 Three Wire Connection 519 Interlock Stop Start For standard 3 wire control connect 120Vac or 240Vac for 415 and Control Control 380V applications to pins 1 and 6 Connect N C normally Power Power closed stop button between pins 3 and 4 of TB4 Connect N O source Return normally open start button between pins 4 and 5 of terminal block Three Wire Connection TOSHIBA 10 TX Series 48 1250A 4 2 8 2 Two Wire Connection An alternate connection for unattended operation replaces start stop push buttons by connecting a maintained contact closure between pins 3 and 5 on TB4 When the maintained contact is used for start stop it is Interlock Start necessary to set the overload setpoint to the manual reset position Control Contact Control This will prevent the motor from restarting if the thermal overload trips Power Power and then cools off Source Return Two Wire Connection ANVARNING When two wire connection method is used the start circuit must be interlocked to prevent automatic restart when either of the two protective devices overload or thermostat reset Thermostats always automatically reset on cool down 2 8 3 Programmable Relays Relay Contacts All the relay contacts a
109. ss than the manufacturer specified values TOSHIBA 70 TX Series 48 1250A 7 3 Replacing SCR Devices Two types of SCRs are used in the TX Series depending on the horsepower amperage rating of the unit Isolated SCRs are used in smaller units and hockey puck type SCRs are used in larger units Refer to Chapter 9 for the main control board layout 7 3 1 Changing an Isolated SCR Remove both line and control power from unit tag and lock out Failure to remove both line and control power before starting this procedure may cause personal injury or death Label the location of wires connected to the SCR Remove the mounting screws lugs and associated wiring from the existing SCR Make sure the surface to which the power module mounts is clean and free from dirt nicks and scratches Apply thermal grease uniformly along the mounting surface of the SCR Spread the grease thinly 3 mil thick to completely cover the base of the power module and minimize air pockets The grease must be free of contamination Replace the screws and tighten down firmly All mounting screws should be 44 Ib in Units with a maximum amperage rating of up to 48A should use 26 Ibs in busbar and power lugs Units with a maximum amperage of 78A 120A should use 44 Ibs in busbar and power lugs Reconnect all busbars lugs and wires Check to make sure the gate and cathode are wired correctly U
110. temperatureforTD T 5 o TOSHIBA 57 TX Series 48 1250A 6 1 4 Status Metering Page 4 Metering Page Description of Display Screen Current status aa Amount of time remaining before an overload trip occurs Ea Amount of remaining from a thermal inhibit signal Ea m Coast down time remaining Amount of remaining before start command can given 5 Excessive number starts per hour 6 6 1 5 Event Recorder Metering 5 Metering RECE Description of Display Screen Displays the event with date and time Up to 60 events Displays Phase A B C and the Ground Fault at the time of the trip Displays Vab and Power Factor at the time of trip 6 1 6 Last Trip Metering Page 6 Metering Page Description of Display Screen Tt 121 Memwedvolapoendpower dor 3 Imbalance percentage tne frequency andine w Hotteststator RTD temperare OO O O non stator RTD temperature 6 1 7 Statistics Metering Page 7 Metering Page Ip s n Last Tri Description of Display Screen Number of start and run overload trips since the last statistical data clearing F statorand non staorATD Wes Ground taut hisetandiosettips 2 TOSHIBA 58 8 a 8 0 TX Se
111. ty is barely adequate stall condition or overloading occurs or if other starting modes fail Since ramp times are set to zero 0 START RAMP 1 TYPE is set to TX Series either VOLTAGE or CURRENT Initial Torque Initial Voltage 1 or Initial Current 1 Sets the initial start point of either 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 d
112. ue to insufficient torque Current Limit Sets the 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 TOSHIBA SP2 4 SP2 5 SP2 6 SP2 7 SP2 8 SP2 9 48 1250A Start 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 Kick Start Used as an initial energy burst in applications with high friction loads Kick Start Voltage The initial voltage as a percent of full voltage value that i
113. umber for display Screen Number for display ALARMS RTD FAILURE ALARM ALARM DISABLED Enabled or Disabled THERMAL REGISTER gt THERMAL ALARM ALARM 90 DELAY 10 SEC Range Off 40 95 Range 1 20 SEC Increments of 1 Increments of 1 THERMAL REGISTER TIME SETUP INFORMATION 5 4 40 Range CLASS 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 50 OFF Increments of 1 MOTOR DESIGN AMBIENT TEMPERATURE 40 C Range 10 90 C Increments of 1 MOTOR DESIGN RUN TEMPERATURE 80 MAX Range 50 100 of Motor Stator Temp Increments of 1 MOTOR STATOR MAX TEMPERATURE INS CLS 1 40 Range Insulation Class 0 2 Increments of 1 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 TOSHIBA 54 TX Series 12 System Setpoints Setpoint Page 12 Security Level 3 SP12 1 Default Display Screen This setpoint group allows the user to choose the default screen the TX displays while the motor is running Select the metering page number
114. y Level Password Protection 48 1250A Factory Setting Default custom Accel uve AVotage pex une AVotage Level poa pooo ooo 2 AVotage Level be m poo EuveATampTmes AVotage Levels 1 ARampTimes AVotage eves Jom ese AVotage Level o Same Programmable Data Points and Ranges Custom Curve B as Custom Curve A Same Programmable Data Points and Ranges Factory Setting Default Basic Run Overoadcune 117277 un Curve Locked Ror Time OL Gass raose onces OOo coast Down Time sexes 1 0 Stat Curve Locked RotorTime OL Gass Lass o Acceleration Time 30 JOO umber of Perho sexes Time Between Stans Time sexes rreo min area Under Curve Protection Disabled Disabled OOO current Over Cave psa Disabled Learn teamed Sian poe sax Time orSamping Description Range Setting Description Setting TO

Toshiba 48-1250 A Remote Starter User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents