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Toshiba JK Series Instructions Manual Download Page 6

SAFETY

Page  5

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:

Carefully  read  the  entire  instruction  manual.

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

of  the  hazards  involved.

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

tag  circuits  in  accordance  with  established  safety  practice.

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

equipment.

Be  trained  in  the  proper  care  and  use  of  protective  equipment  such  as  rubber

gloves,  hard  hat,  safety  glasses,  face  shield,  flash  clothing,  etc.  in  accordance  with
established 

practices.

Be  trained  in  rendering  first  aid.

SAFETY  CODES

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

UL  347  and  the  National  Electrical  Code.  Installations  must  comply  with  all  applicable

state  and  local  codes,  adhere  to  all  applicable  National  Electric  Code 

 

  standards

and  instructions  provided  in  this  manual.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Summary of Contents for JK Series

Page 1: ...Document OH01 Issued TOSHIBA INSTRUCTIONS OPERATION MAINTENANCE JK Medium Voltage Controllers Maximum Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 2: ...pment storage or installation PROBLEMS OR QUESTIONS should be addressed to Field Service Department Toshiba International Corporation 13131 West Little York Road Houston Texas 77041 USA Telephone 466 0277 800 231 1412 800 527 l 204 Canada FAX 713 466 8773 Use only Toshiba authorized replacement parts This equipment is designed and built in accordance with applicable safety standards in effect on t...

Page 3: ... Load Receptacle and Current Transformers 15 Outgoing Load Connections 16 Control Power Transformer 18 Operating Handle 19 Interlocks Mechanical 19 Door Interlock 19 Handle Interlock 20 Vacuum Contactor Interlock 20 Interlocks Electrical 21 Control Power Interlock 21 Test Power Interlock 21 Low Voltage Compartment 22 Main Bus Compartment 22 Prepared Spaces 23 Contactor Ratings 24 Controller Rating...

Page 4: ...ord 41 General Inspection 42 Electrical Joints 43 Contactor Carriage 43 Isolation Switch 4 4 Switch Handle Mechanism 45 Interlocks 46 Load Receptacle 46 Control Power Transformer 47 MAINTENANCE AFTER A FAULT CONDITION 48 Enclosure 48 Isolation Switch 48 Fuse Clips 48 Terminals and Internal Conductors 48 Overload Relays 48 Vacuum Contactor 49 Return to Service 49 WARRANTY AND LIMITATION OF LIABILIT...

Page 5: ...NOTE Gives you helpful information READ SAFETY SIGNS To avoid injury You must read and follow all safety signs Keep the safety signs visible and in good shape Never remove or cover any safety signs D A N G E R NOT REMOVE DESTROY OR THIS LABEL I READ THE INSTRUCTION MANUAL CAREFULLY BEFORE I N S T A L L I N G T H I S HAZARDOUS VOLTAGE In This Compartment I I Cause Injury Death Fire Exp I And Proper...

Page 6: ...the service maintenance or repair of this equipment Be trained in the proper care and use of protective equipment such as rubber gloves hard hat safety glasses face shield flash clothing etc in accordance with established practices Be trained in rendering first aid SAFETY CODES Toshiba medium voltage controllers are general purpose Class E magnetic controllers designed and built in accordance with...

Page 7: ... Primary and Control Circuit Power before servicing Do not open door unless Isolation Switch is OFF and Contactor is OPEN Keep all panels and covers securely in place Never Defeat Modify or Bypass any Safety Interlocks Qualified Operators only Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 8: ...e equipment on its side or upside down File a claim with the carrier for any damaged or missing item and immediately notify the nearest Toshiba Representative Do not install or energize equipment that has been damaged HANDLING AND MOVING Medium voltage motor controllers should be handled with care to avoid damage to components and to the frame or its finish Fig 2 The capability of the moving equip...

Page 9: ... bottom enclosure OVERHEAD LIFTING When it is necessary to move the equipment between elevations overhead hoisting may be required Lifting angles for multiple controller sections are provided on top of the enclosure for this purpose Spreaders Fig 3 should be used to provide the vertical lift on single controllers to prevent eye bolt failure Always keep the controller upright while lifting Some con...

Page 10: ...rminating load cables Removal of the contactor carriage is facilitated by the use of a Toshiba JK carriage lifting attachment Fig and a suitable overhead lifting device The lifting attachment is furnished with all JK medium voltage controllers Details on the operation of the service drawer which supports the contactor carriage may be T o a t t a c h t h e l i f t i n g a t t a c h m e n t t o t h ...

Page 11: ...quate air circulation and protected from dirt and water Equipment should be stored where it is not subject to mechanical damage especially during building construction An indoor controller that is to be stored outdoors should be securely covered for protection from weather conditions and dirt Temporary electrical heating should be i n s t a l l e d t o prevent condensation Approximately 150 watts ...

Page 12: ...ion corrosion vermin and adequacy of space heating Prior to inspection the equipment should be carefully examined for evidence of physical damage corrosion or other deterioration Do not install equipment found to have damage or deterioration that could a f f e c t t h e u n i t performance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 13: ...compartment contains low voltage components Fig 7 Other variations of this basic arrangement are possible Main horizontal bus is provided when required to supply power to a line up of controllers The main bus is located at the rear of the enclosure midway between the top and bottom A common ground bus is also provided for multiple sections Each controller compartment Fig 8 consists of Fixed mounte...

Page 14: ...g the external handle incoming power is applied to the line side of the power fuses In this position the motor or other load may be switched on and off by operating the vacuum contactor The isolation switch is mechanically interlocked with the vacuum contactor and the compartment door Details of the interlocking are discussed in section H The position of the isolation switch blades can be observed...

Page 15: ...ry for routine maintenance of the contactor or replacement of the power fuses Always use a Toshiba JK Lifting Device Fig 12 for removal or installation of the contactor carriage When the carriage is installed in the controller compartment the following connections are automatically made The line side stabs engage the fixed mounted isolation switch connecting the load side of the switch to the line...

Page 16: ...provide a gripping point D Load Receptacle and Current Transformers Fig 14 The load receptacle is a fixed three phase disconnecting block The vacuum contactor load stabs on the withdrawable carriage engage the load receptacle when the carriage is installed in the controller compartment The load receptacle uses bolted pressure type stab contacts similar to those used in the isolation switch The ope...

Page 17: ... the bottom of the enclosure this should be specified when the equipment is ordered and the termination assembly shown in Fig 17 is then provided This arrangement can accept shielded or non shielded cables up to one 350MCM per phase entering from the bottom A field conversion kit is available to convert from the standard termination assembly Fig 15 and Fig 16 to the arrangement shown in Fig 17 Con...

Page 18: ... a c h c a b l e connectors to bus pads After installation torque hardware to 45 ft After installation check to see that at least three inches clearance is maintained between live parts of opposite polarity and between live parts and ground Fig 17 Shielded Cable Termination Bottom Entry Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 19: ...he two transformers are then connected in an open delta arrangement Another option sometimes supplied is a second control power transformer connected in parallel with the first to increase the available KVA capacity B o t h t h e c o n t r o l a n d o p t i o n a l p o t e n t i a l transformer are used to supply power to the low voltage circuits of the controller This includes power for the vacuu...

Page 20: ...lation switch de energizing all medium voltage incoming power to the controller compartment At the same time an automatic shutter within the switch closes providing an effective barrier between the controller compartment and the incoming supply The opening of the switch also causes the line side of the power fuses to be grounded Fig Operating Handle H Interlocks Mechanical a Door Interlock A mecha...

Page 21: ...ithdrawable carriage are open Fig 23 C Vacuum Contactor Interlock T h e v a c u u m c o n t a c t o r i s m e c h a n i c a l l y interlocked to prevent it from closing unless the switch handle is in the fully ON or fully OFF position The interlock shown in Fig 23 provides this function If the switch handle is in the intermediate position and a closing signal is given to the contactor it is mechan...

Page 22: ... additional load to the isolation switch b Test Power Interlock The test power interlock is a scheme provided to allow simulated operation of the controller from a separate control power test source with power removed from the medium voltage circuit During normal controller operation with the isolation switch closed control power is fed from the control transformer secondary to a receptacle mounte...

Page 23: ...izontal bus which is located directly behind Fig 26 Hazardous Voltage Turn off and lock out all control and primary power before opening this panel Low voltage vertical feed directly into the upper and lower left hand corners of the low voltage compartment A horizontal low voltage is provided at the lower front of each low voltage compartment At each end of the horizontal there is an opening for i...

Page 24: ...re furnished for joining the main bus and ground bus between shipping sections With the low voltage swung open all splice links can be installed from the front of the unit Refer to Installation Section for details PREPARED SPACES Prepared spaces are compartments equipped for future addition of controllers Prepared spaces are supplied with the following components Isolation Switch Service Drawer Lo...

Page 25: ... Permissible Switching Frequency Mechanical Life Tripping Voltage Tripping Current 250 000 Operations Rated DC 4 8 A DC Max Other characteristics of latched contactor same as magnetically held type except number of auxiliary contacts is reduced to 2 N O 3 N C Standard operating voltage is Close l 25VDC Trip Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 26: ...pability 1 Second 6000 A Dielectric Withstand 1 Minute AC 19 DC 26 Impulse Voltage Withstand BIL 60 Enclosure Type Max Continuous Amperes Max Continuous Amperes One High Controller or Upper Controller in a Lower Controller in a High Stacking High Stacking Arrangement Arrangement NEMA 1 Ventilated I 360 I 320 NEMA 1 Non Ventilated I 360 I 280 NEMA 12 3R 310 280 Phone 800 894 0412 Fax 888 723 4773 W...

Page 27: ...0 I 4000 I 3500 280 1000 1250 1000 1750 2250 1750 3000 3500 3000 Maximum Horsepower at Utilization Voltages 2300 Volts 3 Phase I 4000 Volts Phase I 6600 Volts 3 Phase Syn Motors 0 8 1 o PF PF 1500 1750 Ind Motors 1500 Motors 0 8 1 o PF PF 2500 3000 Ind Motors Syn Motors Ind Motors 2500 4000 5000 4000 Motor FLA depends on mfgr speed other factors which must be considered Phone 800 894 0412 Fax 888 ...

Page 28: ...und open enclosure doors to comply with applicable codes SERVICE CONDITIONS Toshiba medium voltage controllers are intended for usual service conditions as defined by NEMA The equipment should not be exposed to corrosive or explosive fumes dusts vapors dripping or standing water abnormal vibration shock tilting or other abnormal operation conditions The temperature of the ambient air surrounding t...

Page 29: ...e shipping sections are to be arranged in one continuous line up the center shipping section should normally be the first located Follow the equipment outline drawings to determine the location of the mounting bolt holes and any conduit locations Sill channels may or may not be furnished depending on order specifications Refer to outline drawings furnished for location of sill channels if furnishe...

Page 30: ...ve transducers or control devices that are electronic in nature The following may be used as a general guide with regard to equipment grounding Controller used as service eauioment for a qrounded svstem or as a main section for a separately derived system a The grounding electrode conductor ground wire sized in accordance with NEC 250 94 should be run from the grounding electrode to the controller...

Page 31: ...o NEC 250 91 a and 250 92 a b If the system is grounded at any point ahead of the controller the grounded conductor should be run to the controller in accordance with NEC 250 23 and connected to the ground bus or ground terminal C Steps a and should effectively connect together the grounding electrode the controller frame all outgoing equipment grounding connectors and grounded conductor which run...

Page 32: ...s should be dressed and terminated as appropriate to the voltage class and cable manufacturer s recommendations Main power bus and horizontal ground bus are supplied with links to join shipping sections together These should be installed in accordance with Fig 34 through Fig 36 All access covers barriers partitions etc that are temporarily removed during installation must be replaced NOTE Covers a...

Page 33: ...FRONT VIEW Fig 35 Main Bus Splice Connections 1200A Main Bus x CLE IT X 1 G R A D E F L A T W A S H E R 5 H E X B O L T V I E W F L A T W A S H E R L O C K HEX NUT M A I N S P L I C E B A R X 4 C O P P E R P A R T N O T W O P E R P H A S E FRONT VIEW 5 CARRIAGE BOLT Fig Main Bus Splice Connections 2000A Main Bus Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 34: ...g 15 through Fig 17 The load cables should be routed through the furnished within the enclosure Typical routing of load cables for a two high controller arrangement is depicted in Fig 37 and Fig 38 for both top and bottom entry of cables Load cable termination arrangments for certain controllers s u c h a s reduced voltage autotransformer types may differ from those shown in this manual In these c...

Page 35: ... t h e information on the two labels agrees completely In particular the following information must agree 1 2 3 4 5 6 Part n u m b e r o f contactor carriage Power fuse type voltage and current rating Control voltage and frequency Contactor type magnetically held or latched Single or dual CPT Any optional features Check connections Although the equipment and devices have been completely tested at ...

Page 36: ...n manuals and diagrams should be collected and filed WIRING CHECK Fig 41 Field wiring should be checked for c l e a r a n c e t o live busses where necessary physically s e c u r e d t o withstand the effects of fault current All grounding connections should be checked Each motor should be connected to its intended controller and phase rotation should be correct prior to startup Shorting jumpers F...

Page 37: ...values as close to minimum as feasible while allowing normal transients All switches relays and other operating mechanisms should be manually exercised to make certain that they are properly aligned and operate freely Operating mechanisms s u c h a s interlocks key switches etc should be checked for function as intended for protection of personnel and equipment Overload relays should be checked to...

Page 38: ... i s t o p e r f o r m a dielectric test at 2 25 times the nominal system voltage plus 2000 volts This should be done phase to ground to phase and phase to neutral if applicable with all switches and circuit breakers opened Disconnect any devices which may have limited dielectric strength and that are not intended for this test The light or buzzer or both used to indicate breakdown should be calib...

Page 39: ...tom of the carriage Installation of contactor carriages in the upper compartments of two and three high stacking arrangements require the use of a Toshiba JK lifting device Manually lifting heavy equipment c a n cause serious injury Use a Toshiba JK lifting device With the carriage properly in place on the service drawer push the drawer f i r m l y all t h e into t h e compartment Then push the re...

Page 40: ... have not been detected in the PRE ENERGIZATION CHECK section major damage including personal injury can result when the power is applied Extra precaution is recommended on initial energization of the equipment Hazardous Voltage Improperly installed or damaged equipment will result in severe injury death and property loss Correct all problems prior to energizing t h i s equipment Only qualified pe...

Page 41: ...atched the devices should be turned on with a firm positive motion Protective devices and switches that are not quick acting should not be teased into the closed or open positions The isolation switch handle should be moved between OFF and ON positions in a single continuous smooth movement Fig After all disconnect devices have been closed may be operated to turn on loads such as motors transforme...

Page 42: ...ent condition Corrective actions or adjustments Date of work Comments The degree of detail will depend on the operating conditions Contact with energized components can cause severe injury or death Turn off and lock out Primary and Control Circuit Power before servicing Improper maintenance can cause severe injury death and extensive property damage Only qualified and authorized persons are to ins...

Page 43: ...cuum contactor maintenance The information presented here is intended to cover preventive maintenance only It does not cover major rework or repair The following MAINTENANCE SHOULD BE PERFORMED AT LEAST ANNUALLY or more frequently depending on operating conditions GENERAL INSPECTION Fig 54 Thoroughly clean the equipment removing all dust dirt and other accumulations Wipe insulators clean using a c...

Page 44: ...e materials used As a general guide use the following table Hardware Size 4 6 6 l 8 IO 15 6 20 30 40 50 The above values apply to metal to metal joints e g copper to copper etc When torquing a bolt threaded into an insert molded into a plastic part use approximately the torque shown WITHDRAWABLE CONTACTOR CARRIAGE C h e c k t h e c o n d i t i o n o f t h e s t a b t e r m i n a l s o n the withdr...

Page 45: ... Isolation Switch Maintenance instructions for the 5HAM vacuum contactor are provided in a separate publication number Radiation Exposure Hazard X Radiation may cause illness or injury Stay at least 1 meter 3 3 feet away from the contactor during potential tests ISOLATION SWITCH The isolation switch Fig 57 provided in each controller is a bolted pressure type device It is designed to maintain prop...

Page 46: ...ace individual parts of this assembly in the field Should it ever become necessary to replace the blade assemblies contact the nearest Toshiba representative SWITCH HANDLE MECHANISM The handle mechanism which operates the isolation switch is adjusted at the factory and under normal operation requires no further adjustment Adjustment can be checked however as follows Fig 58 Move handle to full OFF ...

Page 47: ...o the vacuum contactor operates freely Lubricate with Toshiba B8 grease if necessary Refer to the GENERAL DESCRIPTION section for the location of the handle mechanical interlocks and the CPI electrical interlock LOAD RECEPTACLE The load receptacle requires little maintenance other than periodic cleaning and inspection Using a clean dry cloth wipe off the surfaces of the load receptacle insulator a...

Page 48: ...n of the primary fuses and fuse clips Check all screws for tightness Check that the primary stab clips which mate with the withdrawable contactor carriage are tight and properly aligned with the carriage stabs Fig 60 Inspect Control Power Transformer Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ...

Page 49: ... to the enclosure such as deformation displacement of parts or burning this indicates a problem within the controller which requires major reconditioning or complete replacement of the controller In this event contact the nearest Toshiba representative ISOLATION SWITCH The external operating handle must be capable of opening the switch If the handle fails to open the switch or if visual inspection...

Page 50: ... signs of binding they should be replaced C o n t a c t y o u r T o s h i b a representative Check for any signs of arcing damage to the insulated housing RETURN TO SERVICE Before returning the controller to service repeat the procedure outlined in the ENERGIZATION CHECK section of this manual Fig 62 Check Vacuum Contactor Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr co...

Page 51: ...OREGOING 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 OR INSTALLATION THE COMPANY TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS ...

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