Toshiba JKSSS Plus Series Instruction Manual Download Page 1

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jKSSS Plus Series

Medium Voltage Solid State Starters

Document: VF010H05

INSTRUCTION MANUAL

__________________________________________________________________________

INSTALLATION - OPERATION - MAINTENANCE

Firmware Rev 6.96

Issued: 9/09

Manufactured in the USA

Summary of Contents for JKSSS Plus Series

Page 1: ...oltage Solid State Starters Document VF010H05 INSTRUCTION MANUAL __________________________________________________________________________ INSTALLATION OPERATION MAINTENANCE Firmware Rev 6 96 Issued 9 09 Manufactured in the USA ...

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Page 3: ...ATORS ONLY Only qualified persons are to install operate or service this equipment according to all applicable codes and established safety practices A qualified person must 1 Carefully read the entire instruction manual 2 Be skilled in the installation construction or operation of the equipment and aware of the hazards involved 3 Be trained and authorized to safely energize de energize clear grou...

Page 4: ... that are contained in this Instruction Manual Use only Toshiba authorized replacement parts This equipment is designed and built in accordance with applicable safety standards in effect on the date of manufacture Unauthorized modifications can result in voiding the warranty severe injury death and property damage Do not make any modifications to this equipment without the written approval of Tosh...

Page 5: ...mergency Bypass Operation Chapter 4 Programming 33 4 1 Keypad Operator Interface 4 2 Menu Navigation Chapter 5 Setpoint and Programming 36 5 1 Setpoints Page List 5 2 Setpoint Menu SP 1 Basic Configuration 46 SP 2 Starter Configuration 47 SP 3 Phase Ground Settings 50 SP 4 Relay Assignment 53 SP 5 Relay Configuration 55 SP 6 I O Configuration 56 SP 7 Custom Acceleration Curve 59 SP 8 Overload Curv...

Page 6: ...Reference Chart ...

Page 7: ...oceeding to Chapter 2 Installation 1 1 Overview The standard JKSSS Series solid state starter is a complete NEMA Class E 2 motor controller designed for the starting protection and control of AC medium voltage motors It contains the motor disconnect switch motor circuit fuses control power transformer a line isolation contactor SCR stack assemblies a bypass contactor low voltage controls and motor...

Page 8: ...arts per hour Lockout Timer Range 1 6 successful starts per hour Time between starts 1 60 minutes between start attempts Type Rating Form C DPDT Rated 5 amps 240 VAC max 1200 VA Run Indication Programmable At Speed Indication Programmable Acceleration Adjustments 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 t...

Page 9: ...p to 247 devices per mode Functionality Full operation status view and programming via communications port LCD Readout Alpha numeric LCD display Keypad 8 function keys with tactile feedback Status Indicators 12 LEDs include Power Run Alarm Trip Aux Relays Remote Mount Capability Up to 1000 circuit feet from chassis use twisted shielded wire power source Operating Memory SRAM loaded from EEPROM at ...

Page 10: ...e instruction manual VF010H01 VF010H02 or VF010H03 Power Fuses As a NEMA Class E2 controller current limiting primary power fuses are provided for each incoming phase Typically the fuses are ANSI class R for units rated up to 4800V The fuses are sized according to motor locked rotor current and are coordinated with the solid state overload relay The fuse and overload coordination is designed to al...

Page 11: ... the JKSSS on and off using the isolation device 1 4 Structure and Power Bus The JKSSS Series is a heavy duty design Special consideration has been given to the enclosure and unit design to ensure that it is suitable for most applications and environments Structure 11 gauge frame with 16 gauge side back and top sheets Doors are 12 gauge steel The enclosure assembly is NEMA EEMAC type 1 as standard...

Page 12: ...partment and also ties the grounding arm of the disconnect switch to the main ground bus bar see section 2 11 Seismic Qualifications The entire starter assembly when properly installed withstands vertical and horizontal accelerations typical of seismic Zones 1 through 4 as defined in the UBC The assembly will not overturn or show significant lateral movement but cannot be expected to continue oper...

Page 13: ...e to full speed When the motor reaches full speed and the current drops to running levels the soft starter detects an At Speed condition and closes the Bypass Contactor The Bypass Contactor serves to shunt power around the SCR stack assemblies to prevent heat buildup in the starter enclosure due to the slight voltage drop across the SCRs At this point the soft starter has the motor operating at fu...

Page 14: ...the soft starter receives a valid Start command Phase Reversal if enabled Start Curve Acceleration Timer Phase Imbalance Short Circuit Load Pre check Toe in the Water Ground Fault Optional External Input Faults Accumulated Starting FLA Units I2 t Protection Overload Protection Thermal Capacity Note Shorted SCR and Shunt Trip protection are no longer in effect once the soft starter goes into the St...

Page 15: ...rt as a setpoint to the Thermal Reg ister for the soft starter to follow Learned Curve Protection The user sets the soft starter to the LEARN mode and starts the motor under normal starting conditions The CPU then samples and records 100 data points during the start curve analyzes them and creates a graphical representation in memory The soft starter is then switched to Curve Follow protection mod...

Page 16: ...cations this performance is attained without the need for reactors or field installed devices These features include Auto Synchronizing of the gate timing pulses match each phase firing angle to their respective phases The starter actively tracks minor shifts in the line fre quency avoiding nuisance tripping that may happen with conventional gate firing systems This is especially useful on portabl...

Page 17: ...gital signals for the CPU These firing pulses are via fiber optic signals to isolate them from the Medium Voltage environment Control Electronics are located in the medium voltage and low voltage sections of the soft starter The main line power must be disconnected before these electronics can be accessed They include the TCB Gate Drive and Temp CT boards TCB Terminal and Control Board is the user...

Page 18: ...rter information is located on stickers in the medium voltage incoming compartment Keep the equipment upright If is located on stickers in the medium voltage incoming compartment Do not install or energize equipment that has been damaged Do not lay the equipment on its side or upside down Handling and Moving Medium voltage motor controllers should be handled with care to avoid damage to components...

Page 19: ...permit the packing should be left intact until the controller is at the final installation position If the packing is removed the top and openings of the controller should be covered during the construction period to protect it against dust and debris Indoor Equipment Controllers designed for indoor installation NEMA Type 1 12 which are not to be installed and energized immediately should be store...

Page 20: ...xplosive fumes dusts vapors dripping or standing water abnormal vibration shock tilting or other abnormal operation conditions The temperature of the ambient air surrounding the controller should be between the limits of 0 C 32 F and 40 C 104 F The altitude of the equipment installed should not exceed 3300 ft 1000m NOTE Temperature or altitude conditions outside of the usual limits may require der...

Page 21: ...ing expandable inserts or J bolts embedded in concrete The recommended size for anchor bolts is 1 2 Fig 4 Heavy Equipment Enclosure must be securely anchored to prevent tipping over 2 6 Additional Cabinet Entries If conduit entry locations are required in areas other than the removable plates cover the electrical assemblies to prevent metal filings from becoming lodged in areas which may cause a r...

Page 22: ...wire and other debris left over from installation must be cleaned out If there is an appreciable accumulation of dust or dirt the enclosure should be cleaned by using a brush vacuum cleaner or clean lint free brush The integrity of all bus bar supports must be checked for secureness and damage Care should be exercised that when covers are installed and doors closed no wires are pinched and that al...

Page 23: ...ically the control cir cuit and other mechanisms should be exercised to determine that the devices operate properly An auxiliary source of control power will be necessary to provide power to the electrical operators Electrical shock hazard Do not touch energized components during a test using auxiliary power The ground fault protection system if furnished should be tested in accordance with the in...

Page 24: ... lightning arrestors in areas where lightning is a significant problem The arrestors should be mounted on the nearest utility pole 2 9 Medium Voltage Power Connections Use a properly calibrated torque wrench to tighten all MV connections according to the chart Connections Cable and wire bundles that enter the controller enclosure should be routed to avoid interference with moving parts Minimum ben...

Page 25: ...plice Connections 1200A Main Bus Fig 6 Main Bus Splice Connections 2000A Main Bus NOTE Covers and braces supplied only for protection during shipment should not be replaced All debris and tools should be removed from each compartment as cabling is completed ...

Page 26: ...partment Special attention should be paid to protection for operating personnel to protection of equipment itself i e such as ground fault relays if used and protection of sensitive transducers or control devices that are electronic in nature The following may be used as a general guide with regard to equipment grounding Controller used as service equipment for a grounded system or as a main secti...

Page 27: ...should effectively connect together the grounding electrode the controller frame all outgoing equipment grounding connectors and any grounded conductor which runs to the controller Controller not used as service equipment or as a main section for a separately derived system and used on either a grounded or ungrounded system a The controller frame and any ground bus should be grounded by means of e...

Page 28: ...ate start stop contact TCB Terminal and Control Board Figure 2 2 See page 85 for larger version Start Stop Control Figure 2 1 C 4 6 A1 A2 Main Coil 10 9 A2 A1 Bypass Coil 8 7 PFC TB 4 TIME D OUT S TART AUX DE L AY Green LED NO T ime Delay 1 C 2 4 3 C NC 5 6 NO C NC BOARD Bypass Aux Contact 4 5 External Overload Fuse Blown Disconnect Interlock Input 3 2 1 5 7 6 1 4 3 2 TB 8 AUX S PFC S PFC C AUX C ...

Page 29: ...will change state after a delay when the Start contact is initiated X3 X4 and SW4 determine the amount of delay Switch Position and Jumper Selection on following page Positions 7 8 9 and 10 11 12 are sets of FORM C contacts These are power factor correction capacitor PFC contacts to pull in an isolation con tactor for the capacitors if required by the application These will change state when the A...

Page 30: ...Selecting jumper X3 or X4 determines the method by which this delay is calculated cycles or seconds See SW4 below for instructions on setting delay time X3 AUX C Auxiliary time delay in cycles X4 AUX S Auxiliary time delay in seconds Factory setting Power Factor Correction PFC Capacitor Contactor Delay From the time the bypass closes to when contacts change state Jumper selection determines the me...

Page 31: ...JKSSS Series 25 JKSSS Series 2 3 4 2KV 2 11 Reference Section 2 11a RTD Board RTD1 RTD Typical RTD Installation Signal Compensation Power RTD2 RTD3 RTD4 RTD5 RTD6 RTD7 RTD8 RTD9 RTD10 RTD11 RTD12 Shield ...

Page 32: ...SS Series 2 3 4 2KV 2 11b Communications Board RS422 Connections Factory Only RS485 Connections Customer Connections 2 11c Communications Board Connections RS485 RS422 Note Remove for last unit in modbus string REAR VIEW ...

Page 33: ...5 6 7 8 9 10 11 12 GF CT CI BT BI AT AI 2 11e Power Board Connections 1 2 4 3 5 6 7 8 10 9 11 12 C N O N C C N O N C C N O N C Relay Relay C N O N C Max Relay Contact Rating is 240 VAC 4A 960VA AUX1 TRIP AUX2 ALARM AUX3 RUN Relay AUX4 AT SPEED Relay 13 14 16 15 17 18 19 20 22 21 23 24 C N O N C C N O N C C N O N C Relay Relay C N O N C AUX5 AUX6 AUX7 Relay AUX8 Relay TB1 Factory use only Do not re...

Page 34: ...ermostat TB2 1 2 4 3 5 6 7 8 Tach Input Analog Output 1 4 20 mA Analog Output 2 4 20 mA Program Enable Input Contact factory for remote reset connections Note Install program jumper to enable setpoint programming Jumper must be removed after programming or for prolonged storage to preserve settings Factory wired Do not change 2 1 19 20 2 1 19 20 ...

Page 35: ... the motor s Check for any loose mechanical parts or metal debris in the enclosure Check the motor strapping and connections Verify that the unit is properly grounded Remove tie straps from Blown Fuse Indicator Connect line voltage to line terminals 3 2 Introduction It is best to operate the motor at its full load starting condition to achieve the proper time torque and ramp settings Initial setti...

Page 36: ...celeration 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 valve...

Page 37: ... Stop Deceleration Voltage Factory Setting 20 of line voltage Range 0 100 of line voltage The stop voltage level setpoint is where the deceleration voltage drops to zero 3 4 3 Deceleration Time Factory Setting 5 sec Range 0 60 sec The deceleration ramp time adjusts the time it takes to reach the stop voltage level set point The unit should be restarted and stopped to verify that the desired decele...

Page 38: ...ut disconnect Close the emergency bypass contact Re close the disconnect on line start panel If integral overload protection is not to be used see JP 1 Motor Protection Jumper then bimetallic or solid state overload protection is required customer supplied if factory emergency overload protection option has not been included In the emergency bypass mode there is no overload protection unless a sep...

Page 39: ...indicator list such as alarms or trips HELP Provides general help information about a specific setpoint or action UP ARROW Will scroll up through the setpoint and metering menu page It will scroll to the top of the setpoint page or a section In edit mode it will increase a setpoint in an incremental step or toggle through the available options in the setpoint RIGHT ARROW In the main menu the RIGHT...

Page 40: ...nd the DOWN ARROW two times 2 Levels 1 2 and 3 indicate password protection levels for these setpoint pages MENU PAGE 1 BASIC CONFIGURATION PAGE 2 STARTER CONFIGURATION PAGE 3 PHASE GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT PAGE 5 RELAY CONFIGURATION PAGE 6 USER I O CONFIGURATION LEVEL 1 LEVEL 2 FACTORY LEVEL 1 PAGE 7 CUSTOM ACCELERATION CURVE PAGE 8 OVERLOAD CURVE CONFIGURATION PAGE 9 RTD CONFIGURA...

Page 41: ...n asterisk 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...

Page 42: ...tial Current 1 200 FLA 0 300 Ramp Time 1 10 sec 0 120 sec Maximum Current 1 350 FLA 200 500 Start Ramp 2 Type Disabled Current Voltage Disabled Initial Voltage 2 60 0 100 Ramp Time 2 10 sec 0 120 sec Current Limit 2 350 FLA 200 500 Initial Current 2 200 FLA 0 600 Ramp Time 2 10 sec 0 120 sec Maximum Current 2 350 FLA 200 500 Kick Start Type Disabled Voltage or Disabled Kick Start Voltage 65 10 100...

Page 43: ...evel Off 5 90 Off Ground Fault Hiset Trip Delay 0 008 sec 0 008 0 250 sec Overvoltage Alarm Level Off 5 30 Off Overvoltage Alarm Delay 1 0 sec 1 0 30 0 sec Overvoltage Trip Level 10 5 30 Off Overvoltage Trip Delay 2 0 sec 1 0 30 0 sec Undervoltage Alarm Level Off 5 30 Off Undervoltage Alarm Delay 1 0 sec 1 0 30 0 sec Undervoltage Trip Level 15 5 30 Off Undervoltage Trip Delay 2 0 sec 1 0 30 0 sec ...

Page 44: ...None None None Dual Ramp None None None Thermostat Trip None None O L Warning Alarm None None Overcurrent Alarm Alarm None None SCR Fail Shunt Alarm None None None Ground Fault Alarm Alarm None None Under Current Alarm None None None Motor Running AUX3 None None I B Alarm Alarm None None Stator RTD Alarm None None None Non Stator RTD Alarm None None None RTD Failure Alarm None None None Self Test ...

Page 45: ...JKSSS Series 39 JKSSS Series 2 3 4 2KV 5 1 5 Relay Configuration Setpoint Page 5 ...

Page 46: ...Same As Analog Input 1 Analog Output 2 4mA 0 0 65535 Analog Output 2 20mA 1000 0 65535 User Programmable External Inputs TCB Fault Enabled Enabled or Disabled Name Ext Input 1 TCB Fault User Defined up to 15 Characters TCB Fault Type NO Normally Open or Closed TCB Fault Time Delay 1 sec 0 60 sec External Input 2 Disabled Enabled or Disabled Name Ext Input 2 User Defined up to 15 Characters Externa...

Page 47: ... FLA 200 500 Custom Curve B Same Programmable Data Points and Ranges as Custom Curve A Custom Curve C Same Programmable Data Points and Ranges as Custom Curve A Page 7 Custom Acceleration Curve Level 3 Password Protection SP7 1 Setpoint Page Security Level Description Factory Setting Default Range Section Basic Run Overload Curve Run Curve Locked Rotor Time O L Class 1 30 sec O L Class Run Locked ...

Page 48: ...on Stator B2 User defined Up to 15 Characters Stator Phase B2 Alarm Level Off 0 240C 32 464F Off Stator Phase B2 Trip Level Off 0 240C 32 464F Off Stator Phase C1 Type Off Same as Stator Phase A1 RTD 5 Description Stator C1 User defined Up to 15 Characters Stator Phase C1 Alarm Level Off 0 240C 32 464F Off Stator Phase C1 Trip Level Off 0 240C 32 464F Off Stator Phase C2 Type Off Same as Stator Ph...

Page 49: ...ption User defined User defined Up to 15 Characters RTD 12 Alarm Level Off 0 240C 32 464F Off RTD 12 Trip Level Off 0 240C 32 464F Off Page 9 RTD Configuration Level 3 Password Protection SP9 4 Setpoint Page Security Level Description Factory Setting Default Range Section Set Level 2 Password 100 000 999 Three Digits SP10 1 Set Level 3 Password 1000 0000 9999 Four Digits SP10 2 Page 10 Level 3 Set...

Page 50: ...10 300 Min Relay Measured Cool Rates Disabled Enabled or Disabled Thermal Register Minimum 15 10 50 Motor Design Ambient Temp 40C 10 90C Motor Design Run Temperature 80 Max 50 100 of Motor Stator Max Temp Motor Stator Max Temp INS CLS INS CLS 10 240 C I B Input to Thermal Register Enabled Enabled or Disabled Use Calculated K or Assign 7 1 50 On Press Enter to Clr Thermal Register SP12 4 Page 12 Sy...

Page 51: ...N ARROW two times 5 2 Setpoint Menu MENU PAGE 1 BASIC CONFIGURATION PAGE 2 STARTER CONFIGURATION PAGE 3 PHASE GROUND SETTINGS PAGE 4 RELAY ASSIGNMENT PAGE 5 RELAY CONFIGURATION PAGE 6 USER I O CONFIGURATION LEVEL 1 LEVEL 2 FACTORY LEVEL 1 PAGE 7 CUSTOM ACCELERATION CURVE PAGE 8 OVERLOAD CURVE CONFIGURATION PAGE 9 RTD CONFIGURATION PAGE 10 SECURITY SET PASSWORD PAGE 11 COMMUNICATIONS PAGE 12 SYSTEM...

Page 52: ...ose the motor protection overload class range from 5 30 Ex Overload Class 10 will trip in 10 seconds at six times FLA SP1 4 NEMA design The motor design maximum allowed slip Select from Class A through F SP1 5 Insulation Class The motor insulation temperature class Select A B C E F H K N or S SP1 6 Line Voltage Input Applied Voltage SP1 7 Line Frequency The user may choose either 50 Hz or 60 Hz ME...

Page 53: ...FLA Range 0 300 Increments of 1 Range 0 120 SEC Increments of 1 Range 200 500 Increments of 10 If VOLTAGE selected these screens will appear If CURRENT selected these screens will appear INITIAL VOLTAGE 2 60 RAMP TIME 2 10 SEC CURRENT LIMIT 2 350 FLA Range 0 100 Increments of 1 Range 0 120 SEC Increments of 1 Range 200 500 Increments of 10 INITIAL CURRENT 2 200 FLA RAMP TIME 2 10 SEC MAXIMUM CURRE...

Page 54: ... maximum current output Voltage is increased gradually until the setting of the Maximum Current Limit setpoint is reached The voltage is held at this level until the motor accelerates to full speed This may be necessary in applications where the electrical power is limited Typical applications include portable or emergency generator supplies utility power near the end of a transmission line and ut...

Page 55: ...urrent 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 t...

Page 56: ...LTAGE TRIP DELAY 2 0 SEC Range 5 30 OFF Increments of 1 Range 1 0 30 0 SEC Increments of 0 1 UNDERVOLTAGE ALARM LEVEL OFF UNDERVOLTAGE ALARM DELAY 1 0 SEC Range 5 30 OFF Increments of 1 Range 1 0 30 0 SEC Increments of 0 1 UNDERVOLTAGE TRIP LEVEL 15 UNDERVOLTAGE TRIP DELAY 2 0 SEC Range 5 30 OFF Increments of 1 Range 1 0 30 0 SEC Increments of 0 1 LINE FREQUENCY TRIP WINDOW DISABLED LINE FREQUENCY...

Page 57: ...hat the ground fault condition must exist before a trip will occur Ground Fault Option must be installed SP3 10 Ground Fault Hiset Trip Level Used to trip the motor within milliseconds upon detecting a high level of ground current leakage This setpoint is intended to detect low impedance faults Ground Fault Hiset Trip Delay The amount of time that the ground fault condition must exist before a tri...

Page 58: ...te 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 ...

Page 59: ...TRIP 1ST TRIP PHASE LOSS TRIP 1ST TRIP DUAL RAMP 1ST NONE O L WARNING 1ST ALARM ACCEL TIME TRIP 1ST TRIP ONLY START CURVE TRIP 1ST TRIP ONLY OVERCURRENT ALARM 1ST ALARM G F LO SET TRIP 1ST TRIP THERMOSTAT 1ST TRIP UNDER FREQUENCY TRIP 1ST TRIP GROUND FAULT ALARM 1ST ALARM I I T START CURVE 1ST TRIP UNDERCURRENT ALARM 1ST NONE OVER FREQUENCY TRIP 1ST NONE SCR FAIL SHUNT ALARM 1ST NONE MOTOR RUNNING...

Page 60: ...1 NONE NONE PHASE REVERSAL TRIP AUX1 NONE NONE OVERVOLTAGE TRIP TRIP AUX1 NONE NONE UNDERVOLTAGE TRIP TRIP AUX1 NONE NONE POWER FACTOR TRIP NONE NONE NONE TACH ACCEL TRIP NONE NONE NONE INHIBITS TRIP TRIP AUX1 NONE NONE SHNT TRIP NONE NONE NONE BYPASS DISCREPANCY NONE NONE NONE TCB FAULT TRIP AUX1 NONE NONE EXTERNAL INPUT 2 NONE NONE NONE DUAL RAMP NONE NONE NONE THERMOSTAT TRIP AUX1 NONE NONE OVE...

Page 61: ...y AUX 5 8 are user defined outputs SP5 2A relay configured as non latching will reset itself when the cause of the trip event is not continuous The TRIP AUX1 relay should always be programmed for latching because this trip should require a visual inspection of the motor and starter before issuing a manual reset to release the relay after a trip has been stored PAGE 5 RELAY CONFIGURATION TRIP AUX1 ...

Page 62: ...UT 1 4ma 0 ANALOG OUTPUT 2 MOTOR LOAD ANALOG OUTPUT 2 4mA 0 ENABLED Range 1 120 SEC Disabled Increments of 1 Range 0 3600 Increments of 5 Range 0 3600 Increments of 5 Range RPM 0 3600 Hottest Bearing 0 200 C Hottest Stator RTD 0 200 C RMS Current 0 6500A Motor Load 0 1000 KW 0 30000 KW OFF Increments of 1 Analog Output Range Range See Analog Output 1 Increments of 1 ANALOG OUTPUT 1 20mA 250 ANALOG...

Page 63: ... of motor RPM which must be achieved before the Tach Ramp Time sample is taken Tach Overspeed Trip The maximum motor RPM allowed when the Tach Ramp Time sample is taken Tach Accel Trip Delay The duration of time that the Tach Accel trip condition must persist before a trip is generated SP6 3The controller provides two 4 20mA analog outputs Each analog output is independent of the other and can be ...

Page 64: ...AMP types should only be switched while the motor is stopped In Setpoint Page 4 Relay Assignments do not assign any output relay to this function The controller will ship with External input 3 programmed for dual ramp If it is not needed disable the dual ramp External Input 4 This input screens are for the thermostat input and can be enabled or disabled Note It is recommended that this function re...

Page 65: ...of 1 Range 0 100 Increments of 1 Range 1 60 SEC Increments of 1 Range 0 100 Increments of 1 Range 1 60 SEC Increments of 1 Range 0 100 Increments of 1 Range 1 60 SEC Increments of 1 SP7 1Setpoint Page 7 allows the user to custom design the acceleration curve start curve to the specific application The user can custom design up to three different curves in the soft starter Only one curve can be act...

Page 66: ... 60 SEC Increments of 1 Range 0 100 Increments of 1 Range 1 60 SEC Increments of 1 CUSTOM CURVE B CURVE B VOLTAGE LEVEL 1 25 Range 0 100 Increments of 1 CURVE B RAMP TIME 7 2 SEC CURVE B VOLTAGE LEVEL 8 100 CURVE B RAMP TIME 8 2 SEC CURVE C VOLTAGE LEVEL 1 25 CURVE C VOLTAGE LEVEL 2 30 CURVE C RAMP TIME 2 2 SEC CURVE C VOLTAGE LEVEL 3 37 CURVE C RAMP TIME 1 2 SEC CURVE C VOLTAGE LEVEL 4 45 CURVE C...

Page 67: ...vels of voltages must be programmed and the eighth level has been preset at 100 If Custom Accel Curve has been set to curve A B or C on this page the soft starter will override the Start Control Mode selected in Setpoint Page 2 even if Start Control Mode in Setpoint Page 2 has not been set to Custom Accel Curve Note Setpoint Page 7 has a security level 3 requirement CURVE C VOLTAGE LEVEL 6 67 CURV...

Page 68: ... 60 MIN DISABLED Increments of 1 Range 1 2500 FLA Time Sec Increments of 1 Range 5 40 Increments of 1 START LOCKED ROTOR CURRENT 600 FLA TIME FOR SAMPLING 30 SEC Range 400 800 Increments of 10 Range 1 300 SEC Increments of 1 Range 400 800 Increments of 1 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 ...

Page 69: ...E A1 TRIP LEVEL OFF STATOR PHASE C1 TRIP LEVEL OFF Range Range Range Range Range END BEARING TYPE OFF SHAFT BEARING TYPE OFF RTD 9 TYPE OFF STATOR PHASE C2 TYPE OFF RTD 10 TYPE OFF Range Range Range Range Range RTD 7 DESCRIPTION END BEARING RTD 8 DESCRIPTION SHAFT BEARING RTD 9 DESCRIPTION RTD 9 RTD 6 DESCRIPTION STATOR PHASE C2 RTD 10 DESCRIPTION RTD 10 Range Range Range Range Range END BEARING A...

Page 70: ...Of RTD S Used for Stator Up to six RTDs can be assigned to monitor the stator of the motor SP9 3RTD Voting When this is enabled the soft starter will not post a trip until 2 RTD s have exceeded the trip level This prevents nuisance RTD tripping SP9 4All 12 RTDs are configured in the following manner The first column is the RTD type the second column is the RTD description the third column is the a...

Page 71: ...quire a three digit password to configure the protection schemes Level three setpoint screens require a four digit password to access the full range of protection and starter schemes SP10 1 Set Level 2 Password This level uses a 3 digit password The default level 2 password is 100 SP10 2 Set Level 3 Password Level three uses a 4 digit password The default level 3 password is 1000 MENU PAGE 10 SECU...

Page 72: ...es the RS422 communications baud rate between the keypad operator and the CPU board For applications with remote keypad only SP11 6 Remote Start Stop Allows the RS485 Modbus communications to start and stop the motor Contact factory for details MENU PAGE 11 COMMUNICATIONS SET FRONT BAUD RATE 9 6 KB SEC Hit DOWN ARROW ten times Range 2 4 4 8 9 6 19 2 38 4 KB SEC SET MODBUS BAUD RATE 9 6 KB SEC MODB...

Page 73: ...ABLED Enabled or Disabled Range Off 40 95 Increments of 1 Range O L CLASS 4 40 SEC Increments of 1 Range 1 2 O L CLASS 4 40 SEC Increments of 1 Range 10 300 MIN Increments of 1 Range 10 300 MIN Increments of 1 Range ENABLED or DISABLED THERMAL ALARM DELAY 10 SEC Range 1 20 SEC Increments of 1 Enter Metering Screen Number for display MOTOR DESIGN AMBIENT TEMPERATURE 40 C MOTOR DESIGN RUN TEMPERATUR...

Page 74: ...tering 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 assi...

Page 75: ... Date DDMMYYYY Allows the factory personnel to program the date for the soft starter in the format shown Enter Time hh mm Allows the factory personnel to program the time for the soft starter SP13 2 Model Firmware Displays the model number and firmware revision in the soft starter SP13 3 Press Enter to Access Factory Settings Available to qualified personnel MENU PAGE 13 CALIBRATION SERVICE SET DA...

Page 76: ...g start 8 Measured I 2 T required to start the motor 9 Amount of time required to start the motor during the last successful start 10 Page 1 Metering Menu Data Metering Page Description of Display Screen Phase A B C currents and Power Factor 1 Phase A B C currents and Ground Fault Option 2 Displays kW and kVA 3 Displays kVAR and Power Factor 4 Displays Peak ON and kW Demand 5 Displays Peak ON and ...

Page 77: ...A Displays Vab Vbc Vca and Power Factor at time of trip 1B Page 5 Event Recorder Metering Page Description of Display Screen Accumulated total running hours 2 Clear the total running hour count 3 Total number of trips 4 Number of start and run overload trips since the last statistical data clearing 5 Number of frequency trips and imbalance trips 6 Overcurrent trips 7 Stator and non stator RTD trip...

Page 78: ...en Setpoint Menu and Metering Menu and follow the arrow keys to get to different screens MENU METERING PAGE 1 CURRENT METERED DATA METERING PAGE 2 VOLTAGE 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 ...

Page 79: ... thermal capacity required for a successful start Screen 6 Displays the thermal capacity required to successfully start the motor Screen 7 Displays the average time required to start Screen 8 Displays the average current during start Screen 9 Displays the measured I2 T required to start the motor Screen 10 Displays the amount of time required to start the motor during the last successful start MEN...

Page 80: ...s Peak On and KVA demand Screen 7 Displays Peak On and KVAR demand Note P F N A Motor stopped P F LG Lagging P F LD Leading Screen 8 Displays Peak On and Amps demand Screen 9 Clears Demand Values Screen 10 Displays the Megawatts used per hour Screen 11 Press Enter to clear statistics on MWH values Vab Vbc Vca P F IA IB IC G F kW kVA P F PEAK ON kW PEAK ON PEAK ON kVAR PEAK ON AMPS PRESS ENTER TO C...

Page 81: ...n 21 Screen 22 Screen 23 Screen 24 Screen 25 Screen 27 Screen 28 Screen 29 Screen 26 PRESS ENTER TO CLEAR MAX TEMP REGS MEASURED RUN COOL TIME MIN MEASURED STOPPED COOL TIME MIN RTD 10 RTD 10 C F MAX TEMP SINCE CLEAR RTD 10 C RTD 11 RTD 11 C F RTD 12 RTD 12 C F MAX TEMP SINCE CLEAR RTD 11 C MAX TEMP SINCE CLEAR RTD 12 C MP 3 RTD Values Metering Page 3 Displays the RTD information Screen 1 Displays...

Page 82: ...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 CURRENT STATUS O L TRIP LEFT TO TRIP SEC THERM INH TIME LEFT MIN COAST DOWN TIMER TIME LEFT MIN TIME BETWEEN STARTS TIME MIN STARTS PER HOUR TIME MENU METERING PAGE 4 STATUS S...

Page 83: ...ound fault at the time of the trip Screen 1b Displays the Vab Vbc Vca and power factor at the time of trip cause of event cause of event cause of event cause of event IA IB IC G F IA IB IC G F IA IB IC G F IA IB IC G F All events will be viewed from oldest event in buffer to most recent event 2nd Event 1st Event 60th Event 59th Event MENU METERING PAGE 5 Event Recorder 60 event Screen 1 Screen 1a ...

Page 84: ...factor at the time of trip Screen 4 Displays the imbalance percentage the frequency and the kW at the time of the trip Screen 5 Displays the hottest stator RTD temperature at time of the trip Screen 6 Displays the hottest non stator RTD temperature at the time of the trip MENU cause of trip value at time of trip Ia Ib Ic G F I B Hz KW HOTTEST STATOR RTD C HOTTEST NON STATOR RTD C METERING PAGE 6 L...

Page 85: ...the number of tachometer acceleration trips Screen 18 Displays the number of undervoltage and overvoltage trips Screen 19 Displays the number of power factor trips Screen 20 Displays the number of phase reversal trips Screen 21 Displays the number of external input 1 trips Screen 22 Displays the number of external input 2 trips Screen 23 Displays the number of external input 3 trips Screen 24 Disp...

Page 86: ...ng procedure Short circuit or ground fault in motor cabling Locate and remove short or ground Phase Loss Repair cause of phase loss Branch circuit protection not correctly sized Verify correct sizing of branch circuit protection Faulty main circuit board Remove power and replace main circuit board Faulty SCRs Remove power and test SCR s Refer to Section 7 1 1 for the SCR testing procedure Single p...

Page 87: ...e phase power rem oved from Main Board Im proper program m ing Check program setpoints Any wire going to ground I e stator ground m otor ground soft start ground Check with m egger or Hi pot m otor leads and m otor High vibration or loose connections Check internal connections Load shorted grounded faulted Rem ove power and repair Faulty m ain circuit board Replace the m ain circuit board Short in...

Page 88: ...aulty control logic Remove power and repair the control logic Failure of main circuit board Replace the main circuit board Faulty motor Check the motor and the motor connections Faulty SCRs Remove power and perform the SCR device checks Faulty gate cathode on SCRs Remove power and test SCR s Refer to Section 7 1 1 for the SCR testing procedure Faulty main circuit board Replace the main circuit boa...

Page 89: ... CPU Digital Controller Main Firing Board Fiber Optics SCR Assembly B C A L2 L3 L1 T2 T3 T1 Fiber Optics Ring Transformer Voltage Transformer Temp CT Board Gate Drive Boards MOV Boards DV DT Boards Control Board Customer Connections 1 2 3 CT 4 1 2 3 CT 4 1 2 3 CT 4 ...

Page 90: ...JKSSS Series 84 JKSSS Series 2 3 4 2KV 7 3 Overload Curve Definition ...

Page 91: ... NC NO 12 10 11 C NC NO 2 1 C NO 3 4 C NC TB3 TCB START 10 7 5 6 C NC 8 9 C Fault NC NO 11 12 NO NC 2 1 NO C 120VAC Delayed Start Neutral 3 2 HEATSINK Line 1 12V LED Green LED Green HEATSINK T1 E2 E1 E4 E3 Inter F2 LED Green TB2 F3 F1 8 4 5 3 NO NC 6 7 S C N 9 10 NC NO 2 1 Source AC Lock TB1 FAULT FUSE LED Red LED Red 8 5 4 3 Lock Inter 6 7 Start Stop NO 9 10 Neut AC C 12 11 NC Maintained Momentar...

Page 92: ...JKSSS Series 86 JKSSS Series 2 3 4 2KV 7 5 Typical Wiring Diagram ...

Page 93: ...JKSSS Series 87 JKSSS Series 2 3 4 2KV ...

Page 94: ... 600A 3 25 0200 6500 23 2300V 200A 3 25 0400 6500 23 2300V 400A 3 25 0600 3500 23 2300V 600A 3 25 0200 6500 41 3300 4160V 200A 3 25 0400 6500 41 3300 4160V 400A 3 25 0600 3500 41 3300 4160V 600A 3 25 0200 6500 72 6000 7200V 200A 3 25 0400 6500 72 6000 7200V 400A 3 25 0600 3500 72 6000 7200V 600A 3 10 0090 2300V 200A 400A 3 10 0090 2300V 600A 6 10 0090 3300 4160V 200A 400A 6 10 0090 3300 4160V 600A...

Page 95: ...JKSSS Series 89 JKSSS Series 2 3 4 2KV ...

Page 96: ...ies 90 JKSSS Series 2 3 4 2KV 7 7 Instructions for Stack Replacement For Reference Only Gate Drive Board TEMP CT Board MOV Board DV DT Board DVDT Board MOV Board Gate Drive Board Temp CT Board PCB Mounting Order ...

Page 97: ...s 4 Use the 9 16 wrench and carefully unbolt all of the line and load power con nections attached to the heat sinks Note If the unit is a 6000 7200V re move the power strap connecting one side of the stack to the stack directly below it 5 Before removing the fiber optic wiring make a note of the label on the fiber cable to ensure they are placed exactly in the same socket they were removed from No...

Page 98: ... same direction 9 Clean the heat sink surface area thoroughly and reapply some thermal heat sink grease sparingly to the SCRs mating surfaces 10 Please note that replacement SCRs are in matched sets of four and as such please try to keep the matched sets within the same phase 11 Now take any two SCRs from a set and place them on the heat sink in the same direction as the old SCRs were ensuring tha...

Page 99: ...ck reattach TB4 1 to X3 TB4 3 to X4 TB1 3 to X2 and TB1 1 to X1 Verify all X wires are reconnected to their original position on the gate drive boards Otherwise the SCRs will misfire 6 Reconnect thermostat wires on TB1 positions 2 and 3 of the Temp CT board 7 Reconnect the main CT black wire to TB1 1 Then feed the white wire through the board mounted CT and connect to TB1 1 on the Temp CT board Pl...

Page 100: ...s required Also connect the Primaries of the TEST PT in the proper phase sequence of A B C 5 Disconnect medium voltage motor 6 Connect low voltage motor Typically 5 HP or less 7 Connect a wire jumper between TB8 pins 1 and 2 on the TCB con trol board to bypass fuse blown and open disconnect fault The TCB is located in the low voltage compartment 8 Install a switch on TB1 pins 1 and 8 on the TCB co...

Page 101: ...480 or 240 volt three phases 19 Use the multimeter on the AC scale and verify 3 phase 120Vac phase to phase at TB1 pins 1 3 and 5 of the main firing board 20 If all 120Vac 3 phase is present then de energize low voltage of 480 or 240Vac 21 Re energize the low voltage of 480 or 240Vac 22 Now all test voltages should be present 480 or 240Vac and three phase 120Vac TEST PT and 120Vac single phase for...

Page 102: ...als to each SCR two gating signals on every gate drive board See drawing below for correct waveform 35 Once the bad signal s are found write down the location and call the factory for further guidance Waveform is the gating signal as measured with an ungrounded oscilloscope at the gate to cathode of the SCR The waveform should be 1 7 to 2msec off time and approximately 1 5 to 3 Vdc This signal is ...

Page 103: ...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 1 Items inspected 2 Reports of any ...

Page 104: ...sun rays Store in cool clean and dry location 3 Place a dust cover over the starter packaging to protect against dirt and moisture 4 Store in an upright position INSPECTION DURING STORAGE Routine scheduled inspection is necessary if 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 exami...

Page 105: ...OING WARRANTY THE COMPANY WILL HAVE NO OBLIGATIONS TO DISASSEMBLE ANY EQUIPMENT OR PART WHICH IS DEFECTIVE WITHIN THE TERMS OF THE ABOVE WARRANTY OR TO INSTALLANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAYANY COSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION THE COMPANY TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS STATUT...

Page 106: ...INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Rd Houston Texas 77041 Tel 713 466 0277 Fax 713 466 8773 US 800 231 1412 Can 800 872 2192 Mex 95 800 527 1204 World Wide Web http www toshiba com ind ...

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Summary of Contents for JKSSS Plus Series

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Toshiba JKSSS Plus Series, Instruction Manual, Page: 1 / 106

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Summary of Contents for JKSSS Plus Series

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