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Toshiba TE Series User Manual

Toshiba TE Series
91 pages
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DOCUMENT: NBZ0003
INSTRUCTION MANUAL
INSTALLATION – OPERATION - MAINTENANCE
TE Series
Low Voltage
Digital
Solid State Soft Starter
18 – 1250A
Issued: 9/12
Firmware Version 4.31
Buy: www.ValinOnline.com | Phone 844-385-3099 | Email: CustomerService@valin.com

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Toshiba TE Series Specifications

General IconGeneral
BrandToshiba
ModelTE Series
CategoryController
LanguageEnglish

Summary

Chapter 1 - Introduction

1.1 General Description

Overview of the TE Series digital programmable solid-state reduced voltage soft starter.

1.1.1 Control Features

Details on programmable ramp types, dual ramp, deceleration, jog, kick start, and RTC features.

1.1.2 Advanced Motor Protection Features

Details on thermal model, overload curves, reset, retentive memory, imbalance, PTC input, phase loss, etc.

1.1.3 Design Specifications

Technical specifications including load type, voltage, power ratings, circuit, SCRs, cooling, inputs, outputs, and approvals.

1.2 Sizes and Ratings

Information on TE Series starter current ratings, max amp ratings, and proper sizing with motor FLA and Service Factor.

1.2.1 Selecting for Service Factor Utilization

Guidance on selecting starters considering NEMA Service Factor ratings for continuous operation.

1.2.2 Selecting for Across the Line Bypass

Considerations for sizing bypass contactors for Across-the-Line starting when TE Series electronics are out of service.

1.2.3 The TE...-BP Series starters

Details on connecting dry contact for bypass contactor coil control circuit for emergency bypass operation.

Chapter 2 - Installation

2.1 Receiving and Unpacking

Procedure for inspecting the unit upon receipt, checking for damage, and verifying model number and ratings.

2.2 Choosing a Location

Guidelines for selecting an installation area considering ambient temperature, humidity, and environmental conditions.

2.3 Initial Unit Inspection

Visual check for damage, loose assemblies, or broken wires. Verify unit and motor ratings match.

2.4 SERVICE WARNING!

Crucial safety warning about disconnecting power before servicing to avoid fatal electrical shocks.

2.5 Mounting and Cleaning

Instructions for mounting and cleaning the unit, including maintaining proper clearances for airflow.

2.5.1 Clearances

Recommended clearances around the unit for cooling, wiring, and maintenance to ensure proper airflow.

2.6 Power Terminations

Instructions for connecting power conductors to bus tabs, including lug types and local code standards.

2.6.1 Power Terminals

Details on connection points, wire sizes, and tightening torques for factory-supplied connectors.

2.7 Remote Keypad Mounting

Information on remote mounting the keypad/operator interface unit using a kit.

2.8 Dimensions

Table and diagram showing overall and mounting dimensions and weights for TE series units.

Chapter 3 - Motor Overload Protection

3.1 Solid State Overload Protection

Details on the built-in I²t Thermal Overload Protection feature for maximum motor protection.

3.1.1 Thermal Memory

Explanation of the sophisticated 'Thermal Register' that tracks motor heating/cooling over time, even without power.

3.1.2 Thermal Capacity

Description of the Thermal Register display as a percentage of motor's remaining thermal capacity.

3.1.2.a Motor Full Load (FLA) Setting

Instructions to enter motor FLA using Function F001; critical for unit operation.

3.1.3 Disabling the Overload Protection

Guidance on disabling built-in overload protection when external devices are used.

3.1.3.a Manual Reset

Explanation of the manual reset function for overload trips, requiring a physical reset after cooling.

3.1.3.b Automatic Reset

Instructions for enabling automatic reset for overload conditions, with caution for 2-wire control.

3.1.3.c Overload Protection During Bypass

Details on overload protection maintenance when using integral bypass contactors.

3.1.3.d Dynamic Reset Capacity

Explanation of the starter's ability to dynamically track thermal capacity needed for successful restart after overload.

3.2 NEMA Class Trip Curves

Explanation of NEMA Class trip curves based on tripping point and time before trip.

3.2.1 Dual Overload Trip Curves

Description of two separate overload trip curves for starting and running conditions.

3.2.2 Starting Overload Trip Curve

Selection of NEMA Class trip curves from 5 to 30 for the start mode.

3.2.3 Running Overload Curve

Selection of NEMA Class trip curves from 5 to 30 for the run mode.

3.2.4 Overload Trip Curve Chart

A chart illustrating the TE Series Overload Trip Curves for various NEMA classes.

Chapter 4 – Connections

4.1 Power Connections

Instructions for connecting power conductors to L1, L2, L3 and motor leads to T1, T2, T3.

4.1.1 Bypass Contactor

Information on integral bypass contactors and their control for TE versions.

4.1.2 Power Factor Correction Capacitors

Guidance on connecting PFC capacitors to the line side only, with a warning against load-side connection.

4.1.3 Grounding

Instructions for connecting the ground cable to the unit's ground terminal per local codes.

4.1.4 Testing

Procedure for testing the TE Series with a smaller motor, noting Phase Current Loss considerations.

4.1.5 Lightning Protection

Recommendations for protecting against lightning surges using arrestors or isolation contactors.

4.2 Control Connections

Description of control connection points on TB1 (DC) and TB2 (AC) terminal blocks.

4.2.1 AC Control Power Supply Connection

Details on connecting the 120VAC or 240VAC control power supply to TB-2 terminals A1 and A2.

4.2.1.a Control Power Requirements

Guidance on sizing control power transformers for TE...-BP Series starters.

4.2.1.b Control Fusing

Recommendations for protecting output relay contacts and fault output with fuses.

4.2.2 Three-Wire Control Connection

Wiring instructions for standard 3-wire control using Stop/Start push buttons on TB1.

4.2.2.a Seal In Contact

Explanation of the internal pre-wired seal-in contact for the Start button.

4.2.3 Two Wire Control: Relay / PLC Connection

Alternative connection for automated operation using a maintained contact closure between terminals 1 and 3.

4.2.3.a Automatic Functions and 2 Wire Control

Considerations for using 2-wire control with Auto-Reset functions.

4.2.4 Interlock Connection

Connection point for external normally closed interlock devices between terminals 4 and 5.

4.2.5 Enabling the Dual Ramp and Jog Features

Provisions for enabling Dual Ramp and Jog features using external contact closures on TB1.

4.2.5.a Dual Ramp Command

Connecting a contact between TB1 terminals 6 and 7 to enable Ramp 2.

4.2.5.b Jog / Remote Command

Connecting a contact between TB1 terminals 7 and 8 to enable the Jog feature.

4.2.5.c Using Both Commands

Wiring terminals 6 and 8 together to control Ramp 2 and Jog simultaneously.

4.2.6 PTC Thermistor Input

Input terminals for connecting a PTC thermistor for motor winding temperature protection.

4.2.6.a External Overload Relay Connection

Connecting an external OLR's NC aux contact to the PTC input for fault indication.

4.2.7 Fault Signal

Optically isolated Triac output on TB1 for fault indication, usable with PLCs or external relays.

4.2.8 Output (Auxiliary) Relay Contacts

Description of three programmable auxiliary relays on TB2 and their factory default settings.

4.2.9 Bypass Contactor Control

Internal connection for automatic bypass contactor control on TE...-BP starters.

4.2.9.a Independent Bypass Contactor Control

Controlling bypass contactors independently of starter electronics, requiring specific sizing and wiring.

Chapter 5 - Programming

5.1 Introduction

Importance of operating the motor at full load starting conditions and programming motor FLA (F001).

5.2 Digital Interface

Description of the digital keypad, LEDs, command keys, and display features of the soft starter.

5.3 Display Modes

Overview of the three display modes: Status, Program, and Fault.

5.3.1 Status Display Mode (Default Display)

Details on the seven screens of information displayed in Status Mode.

5.4 Program Mode

Procedure for entering Program Mode to view or change Function settings.

5.4.1 Viewing Function Programming and Values

How to view function programming and values without making changes.

5.4.2 Enabling Password Protection / Parameter Lock

Instructions for enabling password protection to prevent unauthorized changes to parameters.

5.4.3 Changing a Function's Set Value

Step-by-step guide on how to alter function values using the keypad.

5.4.3.a Changing a Value by Increments

Method for changing function values by successively pressing UP or DOWN arrow keys.

5.4.4 Storing the Altered Value of a Function

Procedure for storing changed function values by pressing the READ/ENTER key.

5.4.5 Fault Mode

Information on reviewing fault history and codes displayed in Fault Mode.

5.4.5.a Resetting Faults

Methods for resetting faults, including keypad reset and power cycling.

5.4.5.b Remote Reset

How to accomplish remote reset using a NC remote contact or push-button.

5.4.5.c Automatic Reset

Details on automatic reset for non-critical faults and overloads.

5.4.5.d Lockout Functions

Explanation of lockout functions like Minimum Time Between Starts and Starts per Hour.

5.4.5.e Changing to Default Screen During Fault

Procedure to access Status Screen from a Fault Screen to enable programming.

5.6 Function Descriptions

Detailed descriptions of all functions, including motor, starting, protection, and communication features.

5.6.1 Motor and Overload Function Descriptions

Detailed descriptions of functions F001-F005 for motor FLA, service factor, and overload protection.

5.6.2 Starting Mode

Descriptions of functions for selecting ramp type, initial torque, ramp time, and current limit.

5.6.2.a Ramp 2 (user-optional ramp)

Details on using the secondary ramp profile selected via contact closure.

5.6.3 Jog Mode

Descriptions of functions for setting voltage, time, and current for the Jog mode.

5.6.4 Kick Start Mode

Descriptions of functions for setting kick start voltage and time.

5.6.4.a "Dwell” operation using Kick Start

Guidance on using Kick Start for slow slack take-up in drive chains.

5.6.5 Pump-Flex®Decel Mode (F025 through F028)

Descriptions of functions for Pump Flex Decel control, including begin level and ramp time.

5.6.6 Restart Delay

Description of function F028 for setting restart delay time after a power loss.

5.6.7 Current and Ground Fault Protection Features

Descriptions of functions F040-F047 for current imbalance, over/under current, and ground fault protection.

5.6.7.a Ground Fault

Details on Ground Fault protection using residual current method and CT ratio.

5.6.8 Lockouts, Reset and Internal Protection Features

Descriptions of functions F048-F059 for lockouts, reset, and internal protection features.

5.6.8.a Internal Protection Features

Explanation of built-in protection features like Phase Rotation, SCR Lockout, and Shunt Trip.

5.6.8.b Auto-Reset Programming (F052 – F054)

Programming for automatic reset based on selected faults and number of attempts.

5.6.8.c Timer Value Readouts for Protection Features

Readout functions F054-F059 for timer and register values for information only.

5.6.9 Output Relays

Descriptions of functions F060-F064 for programming auxiliary relays and delay timers.

5.6.10 Communications

Descriptions of functions F065-F069 for setting communications parameters and remote control.

5.6.11 System Settings

Descriptions of functions F070-F084 for parameter lock, system clear, frame rating, CT value, and clock settings.

5.6.11.a Real Time Clock Settings

Functions F075-F080 for setting the system real time clock used for fault history stamping.

5.6.12 Fault History and Statistical Data

Descriptions of functions F085-F097 for viewing fault history and statistical data like run time.

5.6.12.a Fault History

Details on storing fault codes with time and date stamps for the three latest events.

5.6.12.b Statistical Data

Information on run time and run cycle counter data displayed via functions F094-F097.

Chapter 6 - Start-up

6.1 Basic Startup

Overview of the basic startup procedure for the TE Series Soft Starter.

6.1.1 Three Step Process

The three essential steps for basic startup: power connections, control wiring, and FLA programming.

6.1.2 Start-up Parameters and Factory Defaults

Guidance on initial testing using factory presets and adjusting advanced features.

6.2 Start-up Check List

A checklist to verify correct supply voltage, ratings, connections, and programming before startup.

6.3 Sequence of Operation

Step-by-step description of the expected motor operation sequence during startup and running.

Chapter 7 - Fault Conditions

7.1 Fault Codes and Numbers (in History)

Explanation of three-character fault codes displayed and their corresponding numeric codes in history.

7.2 Fault Explanation - Probable Cause - Solution

Detailed explanations of fault codes, probable causes, and recommended solutions for troubleshooting.

Appendix 1 - Ramp Profile Details

1. Voltage Ramping

Description of voltage ramping as a reliable starting method for varying load conditions.

2. Voltage Ramping with Current Limit

Voltage ramping with adjustable maximum current output, useful for limited power applications.

3. Closed Loop Current (Torque) Ramping

Smooth linear acceleration of output torque using PID feedback for applications with rapid torque changes.

4. Current Limit Only (Current Step)

Uses current limit exclusively for starting, useful for difficult loads or limited power supplies.

Appendix 2: Pump-Flex®Decel Mode Application Considerations

Setup and Use

Guidance on configuring the Pump-Flex Decel feature for flexible deceleration process control.

F024 = Deceleration Ramp

Function to enable or disable deceleration, with options for overload trip behavior.

F025 = Begin Decel Level (BDL)

Sets the voltage level for noticeable motor torque effect during initial Decel mode.

F026 = Decel Shut Off Voltage

Sets the voltage level where the starter turns off, corresponding to effective motor torque.

F027 = Decel Ramp Time

Sets the maximum time for deceleration ramp from Begin Decel Level to Shut Off Voltage.

Appendix 3: Parameter Lock / User Password Instructions

Changing passwords:

Instructions for changing or disabling the parameter lock and user password feature.

Appendix 4 – External Overload Relay Applications

HIGHER LEVEL PROTECTION SYSTEMS

Using external coordinated protection systems instead of internal TE Series overload protection.

REDUNDANT BYPASS STARTER APPLICATIONS:

Providing independent starting means using bypass contactors if TE Series starter becomes inoperable.

Across-the-Line (Direct-on-Line) Bypass

Suggested control schematic for using TE...-BP Series with external overload relay for bypass operation.

SPECIAL MOTOR APPLICATIONS

Considerations for special motor applications requiring external overload relays.

Multiple Motors

Using separate external OLRs for each motor when connected downstream from the TE Series starter.

2S-2W Motors

Requirements for external OLRs for 2-speed/2-winding motor applications.

Appendix 5 - Soft Starter Settings Record

Motor and Overload Info.

Record of settings for Motor FLA, Service Factor, and Overload Class.

Starting and Stopping Modes

Record of settings for Ramp Type, Initial Torque, Ramp Time, and Current Limit.

Jog Modes

Record of settings for Voltage Jog, Time of Voltage Jog, and Current Jog.

Kick Mode

Record of settings for Kick Start Voltage and Kick Start Time.

Pump Flex Decel Mode

Record of settings for Pump Flex Control, Begin Decel Level, Shut Off Voltage, and Ramp Time.

Restart

Record of setting for Restart Delay Time.

Current and Ground Fault Protection

Record of settings for Current Imbalance, Over/Under Current, and Ground Fault protection.

Lockouts, Reset and Internal Protection

Record of settings for Lockouts, Auto Reset, and Internal Protection features.

Output Relays

Record of settings for Auxiliary Relay programming and delay timers.

Communications

Record of settings for Communications, Baud Rate, Modbus Address, and Remote Control.

System Settings

Record of settings for Parameter Lock, System Clear, Frame Rating, CT Value, and Clock settings.

Fault History and Run Data

Record of settings for Fault History and Statistical Data like run time and counts.

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