DOCUMENT: NBZ0003 INSTRUCTION MANUAL INSTALLATION - OPERATION - MAINTENANCE TE SERIES Low Voltage Digital Solid State Starter 18 - 1250 A Issued: 10/09 Manufactured in the USA
SAFETY IMPORTANT MESSAGES Read this manual and follow its intructions. Signal words such as DANGER, WARNING and CAUTION will be followed by important safety information that must be carefully reviewed. Indicates a situation which will result in death, serious injury, and severe property damage if you do not follow instructions. Means that you might be seriously injured or killed if you do not follow instructions. Severe property damage might also occur.
SAFETY SAFETY CODES Toshiba motor control is designed and built in accordance with the latest applicable provisions of NEMA and the National Electrical Code. Installations must comply with all applicable state and local codes, adhere to all applicable National Electric Code (NFPA 70) standards and instructions provided in this manual. HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion and property damage. • Turn off and lock out Primary and Control Circuit Power before servicing.
TE Series Digital Solid State Soft Starters 18 – 1250A Table of Contents TE Series Digital Solid State Soft Starter 18 – 1250A Page Chapter 1: Introduction Chapter 2 - Installation Chapter 3 - Motor Overload Protection Chapter 4 – Connections Chapter 5 – Programming 1.1 General Description …………………… 1 1.2 Sizes and Ratings ……………………… 4 2.1 Receiving and Unpacking …………….. 5 2.2 Choosing a Location …………………... 5 2.3 Initial Unit Inspection …………………... 5 2.4 SERVICE WARNING! …………………. 6 2.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 1 - Introduction 1.1 General Description The TE Series is a digitally programmable solid-state reduced voltage soft starter. Its six SCR design features a voltage/current ramp with an anti-oscillation circuit for smooth load acceleration. The SCRs are sized to withstand starting currents of 350% for 30 seconds and up to 600% for 10 seconds.
TE Series Digital Solid State Soft Starters 18 – 1250A 1.1.2 Advanced Motor Protection Features Thermal Model Electronic Overload Protection A sophisticated Thermal Model of the motor operation is created in the microprocessor to accurately track all starting, stopping and running conditions to provide maximum motor protection. Two Stage Overload Curves Starting: Programmable for Class 5 or 10 Run: Programmable for Class 5 through 30 when "At-Speed" is detected.
TE Series Digital Solid State Soft Starters 18 – 1250A 1.1.3 Design Specifications Type of Load: Three phase AC induction motors AC Supply Voltage: Universal, 208 - 600VAC ±10%, 50/60 Hz Power Ratings: 18 - 1250 Amps, 7.5 - 1000 HP @ 460V Unit Capacity - Continuous Max.
TE Series Digital Solid State Soft Starters 18 – 1250A 1.2 Sizes and Ratings The Toshiba TE Series starters are current rated controllers. Max. Amp ratings are for continuous duty and must not be exceeded. Always check the motor nameplate FLA and Service Factor to ensure proper sizing. Each size has an adjustable range of current from 50% to 100% of the Max Amp rating. Table 1.2 below shows the Current Ratings available. Model Number 1.2.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 2 - Installation 2.1 Receiving and Unpacking Upon receipt of the product, you should immediately do the following: Carefully unpack the unit from the shipping carton and inspect it for shipping damage (if damaged, notify the freight carrier and file a claim within 15 days of receipt). Verify that the model number on the unit matches your purchase order.
TE Series Digital Solid State Soft Starters 18 – 1250A WARNING 2.4 SERVICE 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 the unit. Warning labels must be attached to terminals, enclosure and control panel to meet local codes. Use Lock Out tags such as the one shown when servicing equipment. 2.
TE Series Digital Solid State Soft Starters 18 – 1250A WARNING 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 any chemicals to clean the unit. To remove surface dust use clean, dry compressed air only, 80 to 100 psi. A three-inch, high quality, dry paintbrush is helpful to loosen up the dust prior to using compressed air on the unit.
TE Series Digital Solid State Soft Starters 18 – 1250A 2.6 Power Connections (cont.) TE-150 TE-160 Line Load ∅ 1.52" (38.58 mm) 2.81" (71.32 mm) (9.64 mm) 1.54" (39.09 mm) 0.60 (15.23 mm) T/L3 U/T1 R/L1 0.14" (3.55 mm) W/T3 S/L2 V/T2 Line Load Figure 2.6.
TE Series Digital Solid State Soft Starters 18 – 1250A 2.6.1 Power Terminals: Connection points for units of 160A and below are saddle clamps suitable for stranded wire. Connection points for units of 210A and above are bus tabs with pre-drilled holes (see below). Use appropriate compression or mechanical lugs for termination to these bus tabs. Suggested wire sizes and tightening torques for factory-supplied connectors when using conductors rated for 75°C are shown in the chart below.
TE Series Digital Solid State Soft Starters 18 – 1250A 2.8 Enclosure Dimensions (consult price catalog for enclosed units) Overall Model Number TE -18-BP thru TE -48-BP TE -62-BP thru TE -112-BP Panel (open) with integral bypass contactor TE -150-BP and TE -160-BP TE -210-BP thru TE -450-BP TE-550-BP thru TE-600-PB TE-862-BP thru TE-900-BP TE-1006-BP thru TE-1250-BP Mounting A B C D E F 8.75 7.95 6.66 7.56 7.00 0.22 14.00 8.00 6.68 12.75 6.75 0.28 19.21 8.00 6.68 18.25 6.75 0.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 3 - Motor Overload Protection MOTOR FLA (F001) must be programmed for unit to operate! 3.1 Solid State Overload Protection The TE Series Starter provides true U.L. listed I2t Thermal Overload Protection as a built-in function of the main digital processor for maximum motor protection. It simulates the tripping action of a bimetallic overload relay, with the accuracy and repeatability of a digital control system.
TE Series Digital Solid State Soft Starters 18 – 1250A 3.1.3 Disabling the Overload Protection The Overload Protection feature can be disabled if necessary. When using external devices such as Motor Protection Relays or when the TE Series is wired downstream from an existing starter, this feature can be disabled to prevent conflicts with external overload protection devices.
TE Series Digital Solid State Soft Starters 18 – 1250A 3.1.3.c Overload Protection During Bypass When an integral Bypass Contactor is used to shunt power around the SCRs in the TE Series (as in the TE…-BP version), overload protection is maintained as long as the TE Series is directly controlling the contactor. No additional Overload Relay is necessary for normal operation. CAUTION If a Bypass Contactor is added by the user in the field (i.e.
TE Series Digital Solid State Soft Starters 18 – 1250A 3.2.3 Running Overload Curve During the Run mode, Overload trip curves are selectable from NEMA Class 5, 10, 15, 20, 25, and 30. Program the appropriate curve according to the characteristics of your motor and load. 3.2.4 Overload Trip Curve Chart Figure 3.2.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 4 – Connections Disconnect or Circuit Breaker R/ L1 S/ L2 T/ L3 TE Starter . Solid State. Over Load. 4.1 Power Connections Connect appropriately sized power conductors to the unit input terminals marked L1, L2, L3 (R, S, T for IEC users). Connection points for units of 160A and below are saddle clamps suitable for stranded wire. Connection points for units of 210A and above are bus tabs with pre-drilled holes (see section 2).
TE Series Digital Solid State Soft Starters 18 – 1250A 4.1.4 Testing The TE Series can be tested with a load smaller than the motor it was originally selected to control, however additional steps must be taken to avoid tripping on Phase Current Loss. See section 5.6.9.a under “Phase Loss Protection” for additional details on performing this task. NOTE: The unit cannot be tested without a motor or other test load connected to the load side of the unit.
TE Series Digital Solid State Soft Starters 18 – 1250A Figure 4.2: Control Terminal Blocks 4.2.1 AC Control Power Supply Connection 120VAC Supply 1 NC NO. C 2 NC NO. C 3 NO. C 1A1 A2 Figure 4.2.1 Control Pow er Supply Connection TB-2 Separate AC Control Power supply is required to power the electronics of the TE Series starter. 120VAC is standard, order 240 VAC (optional) if necessary for your line power supply configuration.
TE Series Digital Solid State Soft Starters 18 – 1250A NC 1 2 RAMP2 PTC OPTO 3 Figure 4.2.2 3 Wire Control Connection TB-1 Connect 3 wire control here as shown NC 1 JOG 2 RAMP2 JOG PTC OPTO 3 Figure 4.2.3 2 Wire Control Connection TB-1 Connect 2 wire control / PLC output here 4.2.2 Three-Wire Control Connection For standard 3-wire control, connect dry (voltage free) contacts of the Stop / Start buttons as shown on the diagram directly above the terminal strip.
TE Series Digital Solid State Soft Starters 18 – 1250A 4.2.5 Enabling the Dual Ramp and Jog Features TB1 includes provisions for enabling the Dual Ramp and Jog functions by using external contact closures. Both features use a common +24VDC from Terminal # 7, however they can be used independently of each other or together. See sections 5.6.2 and 5.6.3 for full function descriptions and setup. NC RAMP2 6 RAMP 1 JOG 7 PTC OPTO 8 RAM P 2 4.2.5.
TE Series Digital Solid State Soft Starters 18 – 1250A NC RAMP2 JOG PTC 9 OPTO 10 ** PTC Resistor in Motor Figure 4.2.6: PTC Resistor Connection TB-1 + ** Remove factory jumper from Terminals 9 and 10 4.2.6 PTC Thermistor Input The TE Series starter is provided with input terminals for connecting a PTC (Positive Temperature Coefficient) Thermistor that may be imbedded in the motor.
TE Series Digital Solid State Soft Starters 18 – 1250A NC RAMP2 JOG PTC OPTO 11 Control Power or PLC Source 12 R External Fault Relay or PLC Input Figure 4.2.7: Fault Output Opto-Triac Connection TB-1 4.2.7 Fault Signal An optically isolated Triac output is dedicated as a fault indicator on TB1, terminals 11 and 12, labeled “Opto”. The output Triac switch is rated for 10 - 250 VAC/DC, 50 mA (maximum).
TE Series Digital Solid State Soft Starters 18 – 1250A 4.2.9 Bypass Contactor Control On TE…-BP version (and NEMA 12 enclosed) starters, an internal dedicated connection is used at the factory for automatically controlling the Bypass Contactor. Field wiring for Bypass Contactor operation is not required. 4.2.9.a Independent Bypass Contactor Control The TE…-BP Series starters use standard industrial contactors that can be controlled independent of the starter electronics if necessary.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 5 - Programming MOTOR FLA (F001) must be programmed for unit to operate! 5.1 Introduction It is best to operate the motor at its full load starting conditions to achieve the proper time, torque and ramp settings. Initial factory settings are set to accommodate general motor applications and provide basic motor protection. Advanced features must be enabled via programming. The only parameter that MUST be set by the user is motor FLA (F001).
TE Series Digital Solid State Soft Starters 18 – 1250A 5.3 Display Modes There are three modes of display: the Status Display Mode, the Program Mode, and the Fault Mode. 5.3.1 Status Display Mode (Default Display) The Status Display Mode displays seven “screens” of information. Motor Currents (3 phases), Remaining Thermal Capacity, Ground Current, Remaining Time on the Process Timer, and Time Base of the Time Clock Controller. This is also the entry screen for going into the Program Mode.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.4 Program Mode The starter must be OFF in order to enter the Program Mode. Use the Program Mode to view or change Function (Fn) settings. To enter the Program Mode, press the [Fn] key once from the Status Screen described in 5.3.1 above. The first time you enter the Program Mode after power has been cycled to the starter, the initial function [F001] should display with the selected digit flashing.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.4.2 Enabling Password Protection / Parameter Lock The TE Series starter is shipped with the password protection disabled (F070 = 0). If it becomes necessary to prevent parameters from being changed inadvertently, set the password in function F070. See Appendix 3 for details. If the display reads [ Loc] when the [READ/ENTER] key is pressed, the parameter lock is enabled. 5.4.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.4.3.a Changing a Value by Increments Although it may be easier to shift the cursor position, it is also possible to increase or decrease values by pressing the UP or DOWN arrow keys successively. This will change the Function value by the incremental amount associated with that Function. The Function List shows increment values for each Function. Example 2: Figure 5.4.3.a Changing a Function’s Value by Increments [0000.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.4.5 Fault Mode The Fault Mode Display provides information to the operator when a fault occurs and allows the operator to review fault history. Refer to Section 7 for details. Fault codes are three-digits in length and are displayed in alpha characters. The first and second characters (reading left to right) are the initials for the applicable English-language fault name.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.4.5.c Automatic Reset The TE Series starter provides for automatic reset on certain noncritical faults and Over Load. For non-critical fault resets, see section 5.6.9 for program details of F052 and F053. For automatic Over Load reset, see section 3.1 and 5.6.1 for programming details. 5.4.5.d Lockout Functions Lockout functions such as Minimum Time Between Starts and Starts per Hour are not true fault conditions.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5 The TE Function List 5.5.1 Motor FLA, Service Factor and Overload Protection Functions Fn # Group Function Description Motor Nameplate FLA F001 F003 F004 F005 Motor and Overload Info. F002 FLA must be programmed for starter to function. F006 F009 Adjustment / Display Range Setting Increments Factory Setting 50-100% of Max Amp Rating. Upper limit of range automatically adjusts downward as Service factor is increased. 1 amp 0 0.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5.3 F019 F020 F021 Group Jog Modes Fn # Jog Mode Functions Setting Increments Factory Setting 1% 50% 1 second 10 seconds 1% 150% Setting Increments Factory Setting 1% 0 Disabled 0.1second 0.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5.11 Serial Communications Fn # Group F066 F067 F068 Communications F065 F069 Function Description Adjustment / Display Range Setting Increments Factory Setting Section Communications 0 = Disabled 1 = Enabled (11Bit) 2 = Enabled (10Bit) 1 0 Baud Rate 4.8, 9.6 and 19.2 KB 3 rates 9.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.5.13 Fault History and Run Time Fn # Group Function Description Adjustment / Display Range Setting Increments Factory Setting Fault History #1, Latest Fault 0 = No fault history, or Fault # 1 - 27: see Fault code list 1 0 F086 Time Stamp, Fault #1 Based on F078-80 00.00-23.59 (hh.mm) [hh = 00-23; mm = 00-59] 00.01 00.00 F087 Date Stamp, Fault #1 Based on F076-77 01.01 – 12.31 (MM.DD) [MM = 01-12; DD = 01-31] 00.01 01.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6 Function Descriptions Your TE Series starter is set at the factory with typical default settings that perform well in most applications. Following are detailed descriptions of each Function and the factory default settings. 5.6.1 MOTOR FLA (F001) must be programmed for unit to operate! Motor and Overload Function Descriptions F001= Motor FLA Factory Setting = 0 Range = 50 - 100% of Unit Max. Current.
TE Series Digital Solid State Soft Starters 18 – 1250A F004 = Overload Class During Run Factory Setting = 10 (Class 10) Range = 5 - 30 NEMA / UL Class Set value according to the instructions provided by your motor / equipment manufacturer. This trip curve will not be enabled until the motor has reached full speed. F005 = Overload Reset Factory Setting = 0 (Manual) Range = 0 – 2 Set value to determine starter behavior after an overload condition has cleared.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.2 Starting Mode The TE Series is capable of several different starting modes, but is set from the factory for the most common applications. A second ramp profile is available for use should you need it. Unless wired to do so, the TE Series defaults to Ramp 1. This section describes functions for Ramp 1, with references to function numbers that do the same thing for Ramp 2 (if required).
TE Series Digital Solid State Soft Starters 18 – 1250A F011 = Initial Voltage of Ramp 1 Factory Setting = 60% Range = 0 - 100% Sets the initial voltage of ramp 1 when F010 = 1 or 3. The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate while preventing torque shock damage to mechanical components. F012 = Initial Current of Ramp 1 Factory Setting = 200% Range = 0 - 600% Sets the initial current of ramp 1 (when F010 = 2 or 4).
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.2.a Ramp 2 (user-optional ramp) This ramp is selected by closing the input for Ramp 2, TB1 – terminals 5 & 6 (see section 4.2.5). If this input is left open, the TE Series will respond only to Ramp 1 settings as listed above. Since ramp 2 is always used as an alternate to the default Ramp 1, different combinations of ramp profiles can be selected in F010. Refer to Appendix 1 for additional information on ramp profiles.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.3 Jog Mode The Jog Function is another user optional feature and is controlled by closing the input on TB1 Terminals 6 and 7. If this input is left open, the TE Series will ignore all Jog settings. Engaging the Jog feature along with the Start / Run Command provides an output from the SCRs, but will not continue ramping to full acceleration.
TE Series Digital Solid State Soft Starters 18 – 1250A Kick Start Voltage Setting Normal Ramp Torque Kick Time Start Command Time Figure 5.6.4: Kick Start used to check rotation, alignment, or slowly move a load into position. This is not time-limited but should be used cautiously. 5.6.4 Kick Start Mode Kick Start applies a pulse of voltage to the motor producing a momentary “kick” of high torque to break the motor load free from high friction or frozen components. This pulse is limited to 2 seconds.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.5 Pump-Flex® Decel Mode (F025 through F028) Pump-Flex® deceleration is a feature of the TE Series Soft Starter that slowly decreases the applied voltage to the motor when a stop command is given, resulting in a gentle decrease in motor torque. Deceleration provides a way to extend the stopping time so that abrupt stopping does not occur.
TE Series Digital Solid State Soft Starters 18 – 1250A CAUTION Decel is THE OPPOSITE of braking. Enabling the Decel feature will make the motor take LONGER to stop than if it were simply turned off. 5.6.6 Restart Delay The TE Series can be programmed to delay restarting upon restoration of line power after an outage. This allows multiple units to be programmed to restart at staggered times in an effort to avoid causing additional problems with the power supply system.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.7 Process Timer Control Mode (F030 through F039): The following special functions allow the TE Series starter to operate automatically from a Process Control Timer using an internal Real Time Clock. Only brief descriptions of the functions are provided here. REFER TO APPENDIX 4 at the end of this manual for detailed operations and instructions.
TE Series Digital Solid State Soft Starters 18 – 1250A F032 = Real Time Clock Controller Factory Setting = 0 (One Shot) Range = 0 - 8 settings This function is used to select the operating mode of the 24hr / 7 Day Time Clock Controller (TCC). F032 sets the number of days in which the TCC will repeat the Start Event Cycle of up to seven discrete Start Events selected in F033 through F039. After each Start Event, the TE Series will run per the time value set in F030 above.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.8 Current and Ground Fault Protection Features F040 – F050 set extended protection features that may be used in the TE Series starter. Percentages shown are all based automatically upon the Motor FLA setting from F001 (except Ground Fault, F046). No additional calculations are necessary. Over Current Trip Current F042: O. C. Trip Setting F043: O.C. Trip Delay Running Current Time Figure 5.6.8.a: Over Current Trip Current F044: U.C.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.8.a Ground Fault F046 – F047 provides Ground Fault protection for equipment only (a.k.a. Arcing Ground Fault) using the Residual Current method. Trip settings are based on the CT ratio as shown in F074 (see below). A delay time is available in F047 to help prevent nuisance trips. Ground current can always be viewed in the Status Display, shown with a “G” prefix (see section 5.3.1).
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.9 Lockouts, Reset and Internal Protection Features F048 – F050 provide lockout protection for motors and equipment that may have potentially damaging consequences from premature restart or with limited duty cycles. Time and count values for these lockouts can be viewed in F055 – F058. Time values are based on the Real Time Clock and DONOT reset when power is lost or disconnected. Emergency clearing of lockouts can be accomplished in F071.
TE Series Digital Solid State Soft Starters 18 – 1250A F050 = Minimum Time Between Starts Lockout Factory Setting = 0 (Disabled) Range = 1 - 60 minutes, or 0 (Disabled) When F050 is set to 1 through 60, the motor cannot be restarted within the time specified after the first start. Time between starts is calculated from the time of the first start command to the next regardless of run time or off time. Example: If F050 = 15, motor will not be allowed to re-start within 15 minutes of first start.
TE Series Digital Solid State Soft Starters 18 – 1250A Phase Rotation Protection: The TE Series is set up to monitor an expected Phase Rotation and trip if it changes. Control of this is divided into two categories: On-Off and Expected Sequence. The default setting is On, with and Expected Sequence of A-B-C rotation.
TE Series Digital Solid State Soft Starters 18 – 1250A Shunt Trip: Shunt Trip is a feature that will cause an immediate Trip if the TE Series detects current flowing through any phase (or all) when it is supposed to be off. The trip function is typically associated with Aux. Relay setting 7 (see F060-63), wired to a Shunt Trip coil in an upstream circuit breaker or an in-line contactor. This is so that power flow to the motor windings can be interrupted to prevent damage.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.9.a (continued) Function 51: Internal Protection Features Bit # Fault Display Code Protection Function 0 rtd * Phase Rotation Trip 1 ABC Expected Phase Sequence Description Phase Rotation protection. Phase rotation must match selection in Bit #2 below.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.9.b Auto-Reset Programming (F052 – F054) The TE Series can be programmed to automatically attempt to reset after selected faults, provided a Start Command is present (see Section 4.2) and the fault condition has been corrected. The Fault Events to attempt restarting (F052) and number of reset attempts (F053) are programmable as follows. If F053 is set to 0 (default setting), the TE Series will not attempt to restart automatically.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.9.c Timer Value Readouts for Protection Features F054 – F059 provide display of timer or register values for information only. The user cannot alter them. Upon power loss and restoration, these values are updated for time elapsed. F054 = Restart Delay Time Readout Factory Setting = Not Applicable Range = 1 - 999 Seconds Remaining time value readout of F028, the Auto-Restart Delay Timer.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.10 Output Relays There are three programmable relays (rated 240VAC, 5A, 1200 VA) in the TE Series. They can be programmed for change of state indication for any one of the 25 conditions identified in the following chart. F060 = Aux Relay 1: Form C (SPDT) Factory Setting = 1 (Run / Stop) Range = 1 - 26 (See list) Use to program the desired operation for Relay # 1.
TE Series Digital Solid State Soft Starters 18 – 1250A Special Note when using Serial Comm: When F068 = 3, the function of the Jog / Remote Input on TB-1 terminals 7 and 8 will change. Closing the Input will cause the Comm. port control to function as per setting 1. Leaving the input open will cause the Comm. port to function as per setting 0. When F068 = 1, 2 or 3, the Jog function will cease to operate. Since Jogging is a local function, set F068 to 0 when using it.
TE Series Digital Solid State Soft Starters 18 – 1250A F069= Reserved 5.6.12 System Settings The following functions set operator interface controls and unit programming. Also contained here are the Clock settings used for history functions. Change the Clock settings if accurate time values are important. F070 = Parameter Lock / User Password Factory Setting = 0 (disabled) Range = 0 – 999 Use only when necessary to prevent unauthorized access.
TE Series Digital Solid State Soft Starters 18 – 1250A F073 = Unit Frame Rating: Read Only. Reserved for Factory Use F074 = CT Ratio: Read Only. Primary value of the TE Series internal Current Transformers (CTs) for use in determining the GF trip settings (F046). CTs cannot be used for external metering. Alteration is reserved for factory use only. 5.6.12.a Real Time Clock Settings Functions F075 through F080 set the system real time clock.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.13 Fault History and Statistical Data F085 – F097 contain the Fault History and Statistical data about the Run Mode. Fault code: (See Chapter 7) Time Stamp (HH.mm) Date Stamp (MM.DD) 5.6.13.a Fault History Fault codes for each of the three latest events are stored with time and date stamps; see Chapter 7 for a complete list of fault codes and corresponding error displays. Time stamps use the 24hr HH.
TE Series Digital Solid State Soft Starters 18 – 1250A 5.6.13.b Statistical Data F094 - F097 display information from the Run Time / Elapsed Time meter and Run-Cycle counter. Run Time includes Accel, Run, Decel, and Jog operations. Run Cycles are counted only when the starter reaches At-Speed mode. F094 = Run Time, Hours Factory Setting = 0000 Range = 000.9 - 999.9 hours Run counts in excess of 999.9 are recorded in F095.
TE Series Digital Solid State Soft Starters 18 – 1250A Chapter 6 - Start-up 6.1 Basic Startup Your new TE Series Soft Starter is factory preset for a wide variety of applications and often can be used with minimal adjustment. 6.1.1 Three Step Process 1. Connect L1, L2, and L3 to power lines and T1, T2, and T3 to motor. 2. Connect control wires and control power. 3. Program motor FLA (F001). 6.1.
TE Series Digital Solid State Soft Starters 18 – 1250A 6.2 Start-up Check List Supply voltage matches the rated supply voltage of the unit. Horsepower and current ratings of the motor and unit match or the unit is higher rating. Initial ramp time and torque adjustments have been checked. Power lines are attached to the unit input terminals L1, L2 and L3. Motor leads are connected to the lower terminals T1, T2, and T3. Appropriate control power is applied and/or control connections have been made.
TE Series Digital Solid State Soft Starters 18 – 1250A 6.4 Testing with a smaller motor To test the TE Series starter with a motor which will draw less than 20% of the unit Max Amp rating, you must disable the Phase Current Loss (Running) protection as per instructions in section 5.6.9.a. If this feature is not disabled, the TE Series will give a Phase Loss Trip after running for 3 seconds at low currents.
TE Series Digital Solid State Soft Starters 18 – 1250A Fault Display Code Readout Fault Condition Description No Full Load Amps entered into F001 Over Current during Acceleration Over Current during Constant speed Over Current during Deceleration Phase Loss during Acceleration Phase Loss during Constant speed Phase Loss during Deceleration Line Voltage Loss (no 3 phase prior to start) Over Temperature during Acceleration Over Temperature during Constant speed Over Temperature during Deceleration Over Lo
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 1 - Ramp Profile Details The TE Series offers four different types of starting ramp profiles. Simply select the one that best matches your motor / load requirements. In addition, two separate ramps are available that can be selected via contact closure (see section 4.2.5.a), and each one can be set up for any ramp type as shown in the table below.
TE Series Digital Solid State Soft Starters 18 – 1250A Current Limit Current Initial Torque Ramp Time At Speed Time Figure APP 1.3: Current / Torque Ramp Current Initial Torque Current Limit At Speed Time Figure APP 1.4: Current Step Starting 3. Closed Loop Current (Torque) Ramping is good for smooth linear acceleration of output torque. Ramp Time becomes the time from Initial Torque and Current Limit settings.
TE Series Digital Solid State Soft Starters 18 – 1250A Accel Ramp Time. This Function sets the maximum allowable time for ramping from the Initial Torque setting to either of the following: 1) 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 lowering the slope of increase in voltage or current.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 2: Pump-Flex® Decel Mode Application Considerations Coast-to-Stop (using Electro-Mech. starter) Pump On Pump Flow Check Valve Open Pump Off Back Flow Check Valve Slams Pump Off ((( SHOCK WAVE ))) Check Valve Closed Pump-Flex® Soft Stop (using VMX Series starter) Pump Soft Stop Neutralized Flow Check Valve Closes Slowly Pump-Flex® Deceleration (Soft Stop) is a unique feature of Toshiba Solid State Soft Starters.
TE Series Digital Solid State Soft Starters 18 – 1250A Setup and Use Pump systems vary greatly. To accommodate this, the Pump-Flex® Decel control feature is designed to provide complete flexibility in how the deceleration process takes place by using the following settings. Decel begins when a Stop command is given (or the Run command is removed). If there is a Bypass Contactor, it will open immediately, putting the power control back to the SCRs.
TE Series Digital Solid State Soft Starters 18 – 1250A ALWAYS shuts the starter down WITHOUT Decel (as in setting 1 above) even if F025 is set to 2. F025 = Begin Decel Level (BDL) Factory Setting = 60% Range = 0 - 100% of line voltage Use to drop voltage to a level where there is a noticeable effect on motor torque during Decel mode. Generally, systems with high head pressure need to start Decel near the top of the ramp (85-95%). Low head systems can drop to lower settings (5060%).
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 3: Parameter Lock / User Password Instructions Provides users with the ability to prevent unauthorized operators from making changes to the programmed functions. If you do not need to take advantage of this feature, do not enter anything into this function. The factory default is disabled, and no Password is necessary to make changes to the program.
TE Series Digital Solid State Soft Starters 18 – 1250A Example: Figure App 3 Enabling Password Protection / Parameter Lock Starting from the Status Display Mode, no previous function number entered, no existing password... Press the Fn key. Displays F001 to indicate the beginning of the function list. Press the LEFT arrow key Selects the second digit (from the right).
TE Series Digital Solid State Soft Starters 18 – 1250A Ramp 0mofile Appendix 4: Process Control Timer Functions F030 through F039; Overview of Process Timer Control and Time Clock Controller Features: The following special functions allow your TE Series starter to operate automatically from an internal Process Control Timer and Time Clock Controller (TCC) using a real time clock. The Process Control Timer (F030 and F031) can be used independently or together with the TCC feature (F032-39).
TE Series Digital Solid State Soft Starters 18 – 1250A Example: Process Timer for Well Pump Example: Figure App 4.1 Minimum Run (Batch) Timer An irrigation pump needs to come on when called for by a soil moisture control system, and run for ½ hour. If during that ½ hour the well level drops and shuts the pump down, the pump needs to restart when the well recovers and finish the ½ hour pump time. Set F030 to [0001] for Minimum Run Timer.
TE Series Digital Solid State Soft Starters 18 – 1250A F030 = 2: Permissive Run Timer. In this mode, the Process Control Timer engages differently according to the settings of the Time Clock Controller (TCC). When the TCC is set to 0 (using “One Shot” operation), the Process Control Timer begins counting down after the first Start command. Subsequent stop and start commands have no further affect on the timer status and can be used to fully control the starter.
TE Series Digital Solid State Soft Starters 18 – 1250A Example: Figure App 4.2 Permissive Run Timer An air compressor controlled by a pressure switch feeds a large air distribution system that has small normally insignificant leaks. If left on over night when the system is not in use, leaks drop the air pressure and the compressor cycles on and off even though the facility is unoccupied, wasting energy. Set F030 to [0002] for Permissive Run Timer.
TE Series Digital Solid State Soft Starters 18 – 1250A IMPORTANT NOTE: When F030 or F031 is changed in program mode, the timer will not respond to the new settings until after control power has been cycled (off and back on again). F032 = Time Clock Controller (TCC) Factory Setting = 0 (One Shot) Range = 1 - 8 settings This function is used to select the operating mode of the 24hr / 7 Day Time Clock Controller (TCC). F032 = 0 operates the SEC in a “One-Shot” mode (factory default setting).
TE Series Digital Solid State Soft Starters 18 – 1250A F033 = Event #1 Start Time Factory Setting = OFF Range = 00:00 through 23:59, or OFF This function is used to select the start time for Event #1 in the TCC above. Once given a Start command after this event time, the starter will run the motor according to the selections entered into F030 and for the time entered into F031.
TE Series Fn# Function Type Digital Solid State Soft Starters 18 – 1250A Setting 0 1 F030 Process Control Timer Mode Timer Motor Initiated Starts By… When… No Process Control Timer operation (default setting from factory) Function Description / Range Minimum (Batch) Run Timer (works the same with or without TCC control) Start command and/or TCC Permissive Run Timer, without TCC (F032 =0, “One Shot”) Start command Permissive Run Timer, with TCC (F032 = 2 thru 8) TCC Start Event only Timer value
TE Series Digital Solid State Soft Starters 18 – 1250A Example: Figure App 4.3 Time Clock Controller with Minimum Run Timer An irrigation pump fed from a well with a single float level control needs to come on every other day at 5:30 PM, and run for ½ hour. If during that ½ hour the well level drops and shuts the pump down, the pump needs to restart when the well recovers and finish the ½ hour pump time. Set F030 to [0001] for Minimum Run Timer.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 5 – External Overload Relay Applications Your TE Series starter comes equipped with a very intelligent internal electronic overload protection system, and does not need an external Over Load Relay (OLR). There are instances however where external OLRs are needed or desired because of the application. These fall into three categories; Higher Level Protection systems, Redundant Backup applications and Special Motor applications.
TE Series Digital Solid State Soft Starters 18 – 1250A TE Bypass Control Terminal Location Diagrams Bypass Control Terminals 18 - 48A Units Bypass Control Terminals 62 - 160A Units NOTE: Use these terminals only when separate control of the Bypass Contactor is necessary Bypass Control Terminals: 210 – 550A with or without integral bypass 83
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 5 (cont.) External OL Relay Applications Across-the-Line (Direct-on-Line) Bypass A suggested control schematic is shown below for using the TE …-BP Series rated for Across-the-Line Bypass with an External Overload: AC CONTROL POWER Start / Run Command Disconnect or Circuit Breaker CR (2-wire or 3-wire) 97 R/ L1 S/ L2 T/ L3 TE Starter Off SS . A-T-L 98 External OL CR Solid State. Over Load.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 5 (cont.) External OL Relay Applications SPECIAL MOTOR APPLICATIONS Multiple Motors When more than one motor is connected downstream from the TE Series starter, the internal electronic overload protection cannot provide proper protection of the individual motors. Codes require the use of separate OLRs for each motor, which would need to be external devices.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 5 (cont.) External OL Relay Applications SPECIAL MOTOR APPLICATIONS 2S2W Motors 2 speed / 2 winding motor applications require a separate OLR sized for each set of windings. These would need to be external OLRs. 120VAC CONTROL POWER A1 Disconnect or Circuit Breaker R/ L1 S/ L2 MS 2S2W Starter (Logic not shown for clarity) MF T/ L3 TE Starter . MF Solid State. Over Load.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 6 - Soft Starter Settings Record The following chart may be used to record the changes made to the factory settings. Fn # Group Function Description Motor Nameplate FLA F002 F003 F004 F005 Motor and Overload Info. F001 FLA must be programmed for starter to function. Setting Increments Factory Setting 50-100% of Max Amp Rating. Upper limit of range automatically adjusts downward as Service factor is increased. 1 amp 0 0.05 1.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 6 (cont.
TE Series Fn # Group Digital Solid State Soft Starters 18 – 1250A Function Description Adjustment / Display Range Setting Increments Factory Setting 1% 0 Disabled 1 second 2 seconds 1% 0 Disabled 1 second 1 second 1% 0 Disabled 1 second 2 seconds 1% 0 Disabled Current Imbalance Trip 0 = Disabled, or 5 - 30% imbalance Current Imbalance Trip Delay 1 - 20 seconds Over Current Trip 0 = Disabled, or 100 - 300% of motor FLA Over Current Trip Delay 1 - 20 seconds Under Current Trip 0 =
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 6 (cont.) Soft Starter Settings Record Fn # Group F066 F067 F068 Communications F065 Function Description Adjustment / Display Range Setting Increments Factory Setting Communications 0 = Disabled 1 = Enabled (11Bit) 2 = Enabled (10Bit) 1 0 Baud Rate 4.8, 9.6 and 19.2 KB 3 rates 9.
TE Series Digital Solid State Soft Starters 18 – 1250A Appendix 6 (cont.) Soft Starter Settings Record Fn # Group Function Description Adjustment / Display Range Setting Increments Factory Setting Fault History #1, Latest Fault 0 = No fault history, or Fault # 1 - 27: see Fault code list 1 0 F086 Time Stamp, Fault #1 Based on F078-80 00.00-23.59 (hh.mm) [hh = 00-23; mm = 00-59] 00.01 00.00 F087 Date Stamp, Fault #1 Based on F076-77 01.01 – 12.31 (MM.DD) [MM = 01-12; DD = 01-31] 00.
TE Series Digital Solid State Soft Starters 18 – 1250A LIMITED WARRANTY AND LIMITATION OF LIABILITY Toshiba International Corporation (“Company”) warrants that all equipment and parts described herein will be free from defects in materials and workmanship.
