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Toshiba 18 - 1250 A Remote Starter User Manual

1. lt 120VAC CONTROL POWER gt A1 A2 5 VMX TB 2 Disconnect or Circuit Breaker External External A oF Ti Start Run or One L1 L2 L3 TE Starter Command A K7 Solid State Over Load 1 2 3 9 10 _ TE TB 1 TE TB 1 24VDC PTC Input VAVAYVA TE BP Series Control Wiring Bypass Contactor BP U v w Ti T2 T3 G External External Over Load 1 Over Load 2 A gt A a E K MTR _ MTR XN lt 85 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 lt 120VAC CONTROL POWER gt A1 A2 7 VMX TB 2 Disconnect pan or MS Circuit 2S2W Starter Logic not shown for clarit S Breaker Log y a T l TE Starter MF Solid State Slow Fast Over Load OL OL MS MFO rT VAVAYVA 1 2 3 6 7 9 10 TE TB1 TE TB1 TE TB1 24VDC Ramp 2 PTC Input Bypass Contactor BP TE BP Series U vi w 3 Control Wiring T1 T2 T3 G External 2 Speed 2 Winding 2S2W Starter MS MF Slow Fa
2. lt AC CONTROL POWER gt Start Run Command Disconnect ECR or 2 wire or 3 wire Circuit Breaker 97 98 Off External i TE Starter ss att OL Solid State CR Over Load x CR YAYAYA 1 2 3 B1 B2 A1 A2 TE TB 1 TE TE Bypass 24VDO TB 4 TB 2 Contactor t AA pp 4 Control Power f U v w Potential gt T1 T2 T3 G a HY BP Internal Bypass g External i Bypass Over Load __ Pilot Relay Contactor Coil 7 x TE BP Series N Internal Wiring A Figure APP5 2 TE Wiring for Across the Line Bypass Operation with External Overload Relay Only the terminals necessary for this operation are shown In this example The Start Run command 2 wire or 3 wire energizes a control Relay CR If the selector Switch is in the SS Soft Start position the contact of CR closes the 24VDC control signal to TB1 terminals 1 and 3 of the TE Series which begins ramping When At Speed status is reached an internal Bypass Pilot Relay is used to close the Bypass Contactor While in this mode the TE Series CPU provides full motor protection even when the Bypass Contactor closes When the Selector Switch is placed in the A T L Across the Line position a 2 isolated contact of CR is used to close the circuit between B1 and B2 of TB4 which are internally connected in parallel to the Bypass Pilot Relay contact in the Bypass Contactor co
3. ABV ARNING 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 Deceleration is useful with centrifugal pumps material handlers and conveyors where abrupt stopping could be damaging to the equipment and or load SEE APPENDIX 2 AT THE END OF THIS MANUAL for typical Pump Flex Decel feature applications and more detailed descriptions of the following functions F024 Deceleration Ramp Factory Setting 0 Disabled Range 0 2 When F024 0 the deceleration feature is disabled When F024 1 the deceleration feature is enabled AND the overload protection feature from F003 F005 remains active power off on OL trip When F024 2 the deceleration feature is enabled and deceleration will continue even when an overload condition trips Setting F025 2 presents significant risk of over heating the motor beyond its design limits which could result in motor damage and fire hazard Do this only in circumstances where the potential for mechanical damage outweighs the risk of motor damage Stop Command Bypass Contactor Opens F025 Begin Decel Level Immediate step d
4. Process Control Timer Mode 0 No Process Control Timer operation default setting from factory Minimum Batch Run Timer works the same with or without TCC control Start command and or TCC Start command Permissive Run Timer without TCC F032 0 One Shot Permissive Run Timer with TCC F032 2 thru 8 Start command TCC Start Event only Start command Process Timer Value 24 hr 7 day Time Clock Controller Timer value setting used by F030 Range 1 9999 minutes 166 65 hours One Shot follows Start command only Loop the Start Even Cycle SEC daily Loop the 24hr SEC every other day Loop the 24hr SEC every 3 day Loop the 24hr SEC every 4 day Loop the 24hr SEC every 5 day Loop the 24hr SEC every 6 day Loop the 24hr SEC one day per week Single 24hr SEC without repeating until programmed again Start command 24hr Real Time Clock on day of program change Event 1 24hr TCC Start Time for Event 1 Event 2 24hr TCC Start Time for Event 2 Event 3 24hr TCC Start Time for Event 3 Event 4 24hr TCC Start Time for Event 4 Event 5 24hr TCC Start Time for Event 5 Event 6 24hr TCC Start Time for Event 6 Event 7 Chart APP 4 1 24hr TCC Start Time for Event 7 Process Timer and TCC Operations Logic Chart NOTE Start command Per F0
5. control voltage must be customer supplied unless an optional control Figure 4 2 1 power transformer see table below has been supplied with the unit Control Power Supply Connection TB 2 AC Control Power VA Requirements Recommended minimum CPT Rating TE 18 to 48 48 inc in PCB 95 100 TE 62 to 112 inc in PCB TE 150 to 160 72 TE 210 to 276 100 TE 360 to 450 150 TE 550 to 900 200 TE 1006 to 1250 200 BP Bypass BP Bypass Fans Contactor Contactor Inrush Sealed TE BP PC Model Boards Table 3 TE Series Control Power Requirements NOTE P veigions w o bypass still require PCB and fans plus user supplied bypass if any 2 1 a Control Power Requirements When sizing a control power transformer for the TE BP Series starter use the above chart for minimum sizes or supply capacity Any additional control devices powered by the same CPT must be added to the above figures to ensure proper operation of the Bypass Contactor NOTE TE 210 and larger units are available without the Bypass Contactor but fans are still included CPT can be sized for fan loads only if used in NEMA 1 ventilated enclosures 4 2 1 b Control Fusing Output relays in TB2 must be protected from currents in excess of 5A either with a fuse or with other suitable current protection devices A dedicated fault output for use in PLC or interposing relay control is available on
6. Sequence Rotation PLa or Phase Phase Current Loss any phase current reading is 2 x Current less than 20 of unit max amp rating after 3 1 On 4 PLe Loss seconds from Start command 3 ss Shorted At least one SCR has shorted there is no voltage 1 On SCR drop across the SCR phase assembly Phase rtd Rotation Trip Shunt Trip of the main Circuit Breaker or Isolation Shunt Contactor if provided and wired to an Aux relay 4 ST Trip in FO60 F061 2 or more SCRs have shorted in 1 On 16 opposing phases so current was flowing to the motor while the TE was in the Off state PTC Input PTC Trip function This can be disabled so that a jumper is not required across the PTC inputs 19n Protection against loss of input line voltage 1 On Disable when using an In Line Isolation Contactor erie ae a or any other system that normally removes line 64 P power from the starter Resets automatically when line voltage returns 7 Reserved Reserved for factory use 0 Off Operating Mode designation See Fault Code List for description Table 5 6 9 a Function 51 table of Hardware Protection Features NOTE To restore all settings back to the factory default enter a value of 127 If you see a numeric value other than the default value of 127 one or more features has already been altered If you do not know which one or ones are changed the simplest thing to do is determine what combination of settings you want no
7. The energy in that shock wave can be extremely damaging to pipes fittings flanges seals and mounting systems SOLUTION By using the Pump Flex Decel feature of the TE Series the pump output torque is gradually and gently reduced which slowly reduces the pressure in the pipe When the Pump Output Pressure is just slightly lower than the System Head Pressure the flow slowly reverses and closes the Check Valve By this time there is very little energy left in the moving fluid and the Shock Wave is avoided When the output voltage to the motor is low enough to no longer be needed the TE Series will end the Pump Flex Decel cycle and turn itself off ACAUTION 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 69 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 Stop Command Bypass Contactor Opens Full Speed F025 Begin Decel Level Immediate step d Check Valve Closes F027 Decel Ramp Time E Motor Torque Pump Out
8. 0 1 2 This function enables a Process Control Timer which may be used alone or in conjunction with the Time Clock Controller feature FO32 F039 This timer offers two operating modes selected by entering 1 or 2 into the function parameter Setting 1 Minimum Batch Run Timer After a Start Command the starter runs until the batch timer expires If stopped and restarted it will complete that batch time sequence Setting 2 Permissive Run Timer After a Start Event from the TCC the starter can be started and stopped as necessary until the timer expires Process Timer Value Factory Setting 1 Range 1 9999 minutes This function loads a value into the Process Timer above When initialized the value counts down towards 0 NOTE The above Process Control Timer in F030 F031 works in conjunction with the Time Clock Controller in F032 F039 When the TCC is set to One Shot F032 0 this timer will activate whenever a Start Command is given When F032 any other setting this timer activates according to that schedule 45 TE Series F032 F033 F034 F035 F036 F037 F038 F039 Digital Solid State Soft Starters 18 1250A 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 Star
9. Increments Setting Section Fn Group Function Description Adjustment Display Range 0 999 0 Disabled Any Other Numbers Password displays encrypted code Parameter Lock Customer Password 0 Disabled System Clear Reset 1 Clear THR and Lockout Timers 2 Reset to Factory Default Settings Reserved for Factory Use defaults Frame Rating 18 550 to 48 By Model CT Value 40 1200 5 defaults to 40 Reserved for factory use Table 5 5 12 System Settings Function Group ae iw e mi w lt By Model System Settings 1 7 7 Factory Setting 34 TE Series Fn Group 6 S a c 5 oc 3 G gt d o a x 5 fo re Digital Solid State Soft Starters 18 1250A 5 5 13 Fault History and Run Time Function Description Fault History 1 Latest Fault Time Stamp Fault 1 Based on F078 80 Date Stamp Fault 1 Based on F076 77 Fault History 2 Previous Fault Date Stamp Fault 3 Run Time Hours Run Time 1000 Hour Overflow Run Cycle Counter Run Cycle Counter 10K overflow Table 5 5 13 Fault History and Run Data Group Adjustment Display Range 0 No fault history or Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12 31 MM DD MM 01 12 DD 01 31 0 No fault history or Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12
10. Provides a time delay to prevent nuisance trips from short duration transients Using default setting if the output current of any phase drops below F044 for more than 2 seconds the starter will trip 47 TE Series AMV ARNING 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 THIS IS NOT INTENDED TO BE USED AS PERSONNEL PROTECTION GROUND FAULT This feature is only intended to provide a level of equipment protection against damaging ground currents Ground faults are potentially dangerous conditions and must be corrected immediately for safety of operating personnel F046 Ground Fault Trip Factory Setting 0 Disabled Range 5 90 of CT value or 0 Disabled When a value other than 0 is entered for F046 the starter will trip if current to ground exceeds this percentage of the unit CT value The CT value is shown in F074 see section 5 6 12 This value is different from the Unit Rating or FLA setting To calculate actual ground current multiply the CT value of F074 by the setting of F046 Example 210A starter desired
11. F039 and for date time stamping of the Fault History The clock automatically adjusts for leap years and is backed up with a Li battery for long life NOTE Time clock does not automatically adjust for daylight savings time F075 Year Factory Setting Year of manufacture Range 2000 to 2047 F076 Month Factory Setting Month of manufacture Range 1 12 F077 Day Factory Setting Day of manufacture Range 1 31 F078 Hour Factory Setting Actual EST Range 0 23 12 00 midnight is hour 0 F079 Minute Factory Setting Actual EST Range 0 59 F080 Second Factory Setting Actual EST Range 0 59 F081 Firmware revision number for Factory Use F082 F084 Reserved 59 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 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 MM format so for example 3 19 PM would display as 15 19 Date stamps use the MM DD format so for example September 3 would display 09 03 Fault 1 Fault 2 Fault 3 Latest Fault Previous Fault Oldest Fault Fault code See Chapter 7 Time Stamp HH mm Date Stamp Table 5 6 13 a Fault
12. First Digit x o S bess EA key Cursor flashing Position Shift New Value of Second Digit x lt N Kez N 03 fies that a password Cursor flashing Position Shift Key 4 eb F New Value of Second Digit N c Value Accepted flashes once Press Key READ READ m key 0 Return to Function Display Figure App 3 Entering a Password Changing passwords To change an existing password the steps are essentially the same as outlined above except you must first enter the existing password At F070 press the READ ENTER key to reveal the encoded password you must know that password before it can be changed Use the Arrow keys to enter the password As soon as you press the first Arrow key the display will change to 0000 and start showing the actual value of your entry When you get to the existing password press the READ ENTER key again The display will flash PASS to indicate that the password was accepted If it flashes Err you have entered the wrong password Resetting to Factory Defaults using F071 will NOT reset the password Disabling Password Protection Parameter Lockout Changing function F070 to 0000 will disable the user password If the initial display reads 3552 the password is already set to 0000 73 TE Series Digital Solid State Soft Starters 18 1250A Appendix 4 Process Control Timer Functions F
13. and will only reset after the Run command has been cycled opened and reclosed Use this function in without the Time Clock Controller One Shot mode to ensure that a load only operates for a maximum of the programmed amount of time beginning with the first Start command Examples would be Pumps where the failure of a stop float may lead to dry run conditions if allowed to operate too long or when the pump only needs to run when someone is present but operate automatically via float switched pump out for service Ventilation Blowers where operation is controlled by a manual switch but may be inadvertently left on when someone leaves When the TCC is set for 1 through 8 using Start Event Cycles the timer begins counting down immediately when a Start Event is activated Any Start Stop Command that is given to the starter during this time will work normally When the timer finishes F031 0000 the starter will shut off and Start Stop commands will no longer function until the next Start Event Cycle SEC In 2 wire control systems If a Run command is already present when the SEC occurs it will make no difference and the starter will start Reset of the Permissive Run Timer will occur only when the next Start Event Cycle is activated by the Time Clock Controller or when changes are made to programming see NOTE on programming changes see Important NOTE on page 80 Loss of control power without program chang
14. 0000 9999 Run counts in excess of 9999 are recorded in F097 F097 Run Counts 10K Times Factory Setting 0000 Range 0000 9999 10 thousand times 0001 in readout means a run count of 10 000 operations Overflow Basic Examples Value Value A F095 F094 Run Time 23 047 Hours 0002 3047 F097 F096 Run Counts 18 702 Starts Table 5 5 15 Statistical Data Examples 61 TE Series Chapter 6 Start up Digital Solid State Soft Starters 18 1250A 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 2 Start up Parameters and Factory Defaults Try the initial presets first and then adjust or enable the more advanced features to meet your specific starting needs Fn Function Factory Name Setting FLA must be programmed for Motor Nameplate Motor Nameplate Change only if necessary AND F002 1 0 SF motor is rated over 1 0SF Overload Class F003 During Start Class 10 NEMA UL Class 10 Overload Class F004 During Run Class 10 NEMA UL Class 10 F005 Overload Reset 0 Manual 0 Manual i Ramp 1 and Ramp 2 ie Hees eke i Voltage Ramp with Current Limit F011 Initial Torque 60 Initial Voltage F014 Current Limit 350 of pro
15. 30 Bypass Discrepancy during Constantspeed BPe 32 PTC Trip during Acceleration Pa 34 PTC Trip during Constant speed Pte 35 Over Load PTC Trip during Deceleration Pa 3 Rotation Trip during Acceleration mta 37 Rotation Trip during Constantspeed rte 38 Rotation Trip during Deceleration ond 39 Table 7 1 Fault code List LED Fault Condition Description indicator 65 TE Series Digital Solid State Soft Starters 18 1250A Appendix 1 Ramp Profile Details Ramp 1 Settings Initial Ramp nae Torque Time yp from from Voltage from 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 Ramp 2 Settings from from from Current Ramp yi ype Initial Ramp Current Limit Selection Ramp Torque Time Limit from F010 Type q Voltage Current Voltage Current Current Current Voltage Table APP 1 1 Ramp Selection Choices and Settings Initial Torque Full Speed oes eke a Ramp Time gt Voltage Time Figure APP 1 1 Voltage Ramp w o Current Limit Initial Torque Full Speed Limit Setting gt R
16. 6 Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 6 in the TCC above Event 7 Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 7 in the TCC above 46 TE Series Current Current Over Current Trip F042 O C Trip Setting Running Current Time Figure 5 6 8 a Over Current Trip F044 U C Trip Setting Under Current 2 Normal Running Current Time Figure 5 6 8 b Under Current Trip 5 6 8 Digital Solid State Soft Starters 18 1250A 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 F040 F041 F042 F043 F044 F045 NOTE All of these features are disabled at the factory and must be enabled via user programming as follows Current Imbalance Trip Factory Setting 0 Disabled Range 5 30 or 0 Disabled Use to set the trip level for when current imbalance between any two phases exceeds this amount for the time specified with F041 Current Imbalance Trip Delay Factory Setting 2 seconds Range 1 20 seconds Provides a time d
17. AND EXCLUSIVE REMEDY OF THE PURCHASER ITS CUSTOMERS AND USERS OF THE EQUIPMENT AND PARTS FOR BREACH OF THE FOREGOING WARRANTY THE COMPANY WILL HAVE NO OBLIGATIONS TO DISASSEMBLE ANY EQUIPMENT OR PART WHICH IS DEFECTIVE WITHIN THE TERMS OF THE ABOVE WARRANTY OR TO INSTALL ANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAY ANY COSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION THE COMPANY TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS STATUTORY AND IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ALL EXPRESS STATUTORY AND IMPLIED WARRANTIES SUCH AS MERCHANTIBILITY AND FITNESS FOR A PARTICULAR PURPOSE APPLICABLE TO ALL REPAIRED OR REPLACED EQUIPMENT AND PARTS FURNISHED PURSUANT TO THE FOREGOING WARRANTY The total liability of the Company Toshiba Corporation and their suppliers and subcontractors for any loss damage or claim whether in contact tort including negligence and liability without fault or otherwise arising out of connected with or resulting from the equipment and parts described herein or the performance or breach of any contract for the sale or supply of such equipment and parts or from the design manufacture sale delivery resale installation technical direction or supervision of installation inspection testing repair replacement operation maintenance or use of any such equipment or part or any service relating thereto furnished by the Company s
18. Control connections on the TE Series starter are divided into 2 groups With the unit oriented vertically TB1 is a 12 point DC terminal block on the left and TB2 is a 10 point AC terminal block on the right side These are removable terminal blocks for ease of connection and servicing and are provided with different spacing pitch between the header pins so they are not interchangeable Following are descriptions of control connection points NOTE Terminal numbers are shown on the side of the first and last terminal of each block An additional 3 point terminal on the far left side is for serial communication connections see section 5 6 11 gt lt TB2 10 Terminals 13 22 gt inc no c nc no c JNO c At a B e max from customer source Factory installed jumpers Opto Isolated Triac Switch 120VAC Control Power 10 250VAC DC 50mA max or 240VAC if ordered 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 Separate AC Control Power supply is required to power the electronics m of the TE Series starter 120VAC is standard order 240 VAC optional if necessary for your line power supply configuration The control Nc No cfc no c No c At a voltage must be connected to terminals marked A1 and A2 of TB 2 as ra G shown in figure 4 2 1 these are also Terminal s 21 and 22 This
19. F050 are used with 2 wire control the starter may re start automatically when time has expired Adequate warnings similar to those in Section 3 1 3 b should be observed 1 Run Time 1 Coast Down Time 1 D a a a I I 1 On Begin d PSS Figure 5 6 9 Coast Down Lockout Timer F048 F049 Coast Down Lockout Timer Back Spin Timer Factory Setting 0 Disabled Range 1 60 minutes or 0 Disabled When F048 1 through 60 this sets the number of minutes that the starter must be off before a restart can be attempted This function is useful in applications such as pump motor backspin protection where you need to prevent the pump motor from restarting if it is spinning backwards 2 speed operations where speed changes require a minimum disconnect spin down timer or reversing applications to prevent plugging anti plugging timer Maximum Starts per Hour Lockout Factory Setting 0 Disabled Range 1 10 or 0 Disabled If F049 1 through 10 this feature will count the number of start commands within a 1 hour period If the setting maximum starts per hour is exceeded starting is prohibited until sufficient time has expired This timer initiates upon the first start in an hour It resets after 1 hour from that start and waits until another subsequent start to initiate again Often used in conjunction with F050 NOTE Consult the motor manufacturer for a Starts per Hour or Startin
20. Full Speed F026 Stop Level VMX Output Off F027 Decel Ramp Time Determines slope Voltage Time Figure 5 6 5 Pump Flex Decel Ramp Settings 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 initial Decel mode F026 Decel Shut Off Voltage Factory Setting 30 Range 0 to BDL 1 Sets the level where the starter is turned off corresponding to where motor torque during Decel is no longer effective Always set this function lower than the setting of F026 F027 Decel Ramp Time Factory Setting 10 seconds Range 1 60 seconds Sets the maximum time for the deceleration ramp to go from the Begin Decel Level setting F026 to the Decel Shut Off Voltage F027 NOTE When using the Decel function count these cycles as additional starts when determining maximum starts per hour of the motor 43 TE Series ACAUTION Digital Solid State Soft Starters 18 1250A 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 su
21. History Configuration F085 Latest Fault Code Fault 1 Factory Setting 0 No Fault Range 0 27 This Function displays the Fault Code of the latest fault event F086 Time Stamp of the Latest Fault Factory Setting 00 00 No Fault Range 00 00 23 59 24hr time format This Function displays the time of the latest fault event F087 Date Stamp of the Latest Fault Factory Setting 00 00 No Fault Range 01 01 12 31 This Function displays the date of the latest fault event F088 Same as F085 except for the Previous Fault Fault 2 F089 Same as F086 except for the Previous Fault F090 Same as F087 except for the Previous Fault F091 Same as F085 except for the Oldest Fault Fault 3 F092 Same as F086 except for the Oldest Fault F093 Same as F087 except for the Oldest Fault 60 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 F095 Run Time K Hours Factory Setting 0000 Range 0000 9999 K hours 0001 in readout means a run time of 1 000 hours F096 Run Counts Factory Setting 0000 Range
22. Hour are not true fault conditions They are based on the internal Real Time Clock RTC When control power is removed the RTC value is quickly stored Upon return of power the timer values are updated from the RTC for elapsed time If the Lockout Time has not expired the TE Series cannot be started To reset the Lockout Times for emergency restart see section 5 6 12 under FO71 5 4 5 e Changing to Default Screen During Fault In some cases it may be necessary to alter programmed parameters in order to test or make changes to clear a fault such as Phase Loss or to view the more detailed fault history in F085 F097 To accomplish this you must get to the Status Screen so the Fn button becomes active When in a Fault Screen pressing the Right or Left Arrow buttons will take you to the Status Screen From there you can hit the Fn key to enter the Programming Mode and move to different functions 29 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 Setting Factory Increments Setting Section Fn Group Function Description Adjustment Display Range Motor Nameplate FLA 50 100 of Max Amp Rating Upper limit of range automatically FLA must be programmed for adjusts downward as Service factor starter to function is increased Motor Nameplate i Overload Class During Start NEMA UL Class 5 20 5 Class 10 a Overload Cl
23. Kick Start Settings Kick Time 0 1 2 seconds Process Timer 2 modes Real Time Clock RTC Controller Minimum Batch Timer Runs until timer expires Maximum Batch Timer Runs unless timer expires Range 0 9999 minutes 24 7 Time Clock Controller Range 1 24 hours and 1 7 days per week 1 7 start events per day works with Process Timer for run time TE Series Digital Solid State Soft Starters 18 1250A 1 1 2 Advanced Motor Protection Features 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 Starting Programmable for Class 5 or 10 Overload Curves Run Programmable for Class 5 through 30 when At Speed is detected Overload Reset Manual default or automatic A Overload circuit retains thermal condition of the motor regardless of control PICO e POET ial MetoLy power status Unit uses real time clock to adjust for off time Overload will not reset until thermal capacity available in the motor is enough for Dynamic Reset Capacity a successful restart Starter learns and retains this information by monitoring previous successful starts A Trip Level 5 30 Imbalance in any two phases Current Imbalance Trip Trip Delay 1 20 seconds A Trips on greater than 750 ohms resistance on a dedicated PTC input Can be HAREM Se Ul used with an Emergency Stop or any other External
24. Lockout Over Current Trip Trip Level 50 300 of motor FLA Electronic Shear Pin Trip Delay 1 20 seconds Phase Loss Trips on any phase current less than 20 of unit rating Can be disabled in programming for testing with smaller loads Type Residual Current Trip Range 5 90 of unit CT ratio Trip Delay 1 60 seconds Under Current Trip Level 10 90 of motor FLA Leed Less wip Trip Delay 1 60 seconds Coast Down Back Spin Prevents restart when motor may be spinning backwards Lockout Timer Coast Down Time Range 1 60 minutes Starts per hour Lockout 1 10 successful starts per hour Minimum Time between Starts Lockout Range 1 60 minutes between start attempts Sequential Start Feature for restarting delay after a power outage Rese Daey 1 999 seconds after a power loss Auto Reset Can be programmed to attempt resetting after selected faults 0 10 Attempts 0 999 minutes delay between attempts E ee Shorted SCR Lockout 1 shorted SCR and independent Shunt Trip multiple ower Device Monnornig shorted SCRs Can be disabled in programming Thermal Model Electronic Overload Protection Equipment Ground Fault Protection TE Series Digital Solid State Soft Starters 18 1250A 1 1 3 Design Specifications Type of Load AC Supply Voltage Power Ratings Unit Capacity Continuous Unit Capacity Overload Rating Percent of motor FLA Power Circuit SCR Firing Angle Detection SC
25. Mode no previous function Using Password 123 number entered no existing password Press the Fn key Displays F001 to indicate the beginning of the function list Display Means Press the LEFT arrow key Selects the second digit from the right order because F000 would not have been a valid number Press the UP arrow key seven times 7X Changes the function code to F071 Press the RIGHT arrow key Selects the first digit from the right Press the DOWN arrow key Changes the function code to F070 Press the Read Enter The default display will show 3552 as long as no password has been previously entered This is the default code for 0000 meaning that there is no password As soon as you press the first Arrow key the display will change to 0000 and begin showing the actual value of your password entry Any initial display other than 3552 signi already exists This means that you will need to change rather than enter a new one see below Use the UP arrow and the LEFT arrow keys to display the password you desire Valid range is 0000 to 0999 In this example 0123 has been selected Press the Read Enter The display will flash End to confirm you have entered a password Then it will return to displaying thee Function 7 Phase A Current no oF J 3 NOTE do it in this Select Function 70 El 3 NI Default Setting of Function 70 2 5 O01 New Value of
26. Previous Setting of Function 1 New Value of First Digit Cursor flashing Position Shift i 4 Or New Value of Second Digit Key O1 LON I y Q Value Accepted flashes once Rey 0049 Return to Function Display E Figure 5 4 3 Changing a Function Value 26 TE Series Digital Solid State Soft Starters 18 1250A 5 43 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 Example 2 Setting the OL Curve 0000 Indicates that Phase A is drawing no current During Start unit is in Off mode Press the Fn key Change from Class 10 to Class 20 F001 Indicates that this is Function 001 Motor FLA The farthest left digit 1 is flashing indicating this Display Means is the digit that you will alter cursor position Shows Press the UP Arrow key twice 0000 Phase A to increase this digit value to 3 K Current F003 Indicates that this is Function 003 a FG Functions OL Class During Start Fn F001 Displayed Press READ ENTER key to view the F003 value 2 New Value of 0010 Indicates that the prog
27. 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 The ability to turn this feature ON or OFF is useful in applications where the TE Series starter is going to be used downstream from an existing reversing contactor starter or to avoid conflicts with other protection devices Rotation Trip On Off Control Numeric value 1 If this feature is On default setting and you want to turn it Off Subtract 1 from F051 If this feature is Off and you want to turn it On add 1 to F051 When set to On a trip will occur when the Expected Sequence see below is wrong On large motors where large multiple conductors are used it may be easier to change the Expected Sequence in the TE Series starter rather than swap the conductors Expected Phase Rotation Sequence Numeric Value 2 If A B C rotation is the expected sequence default setting and you want it to be A C B subtract 2 from F051 If A C B rotation is the expected sequence and you want it to be A B C add 2 to F051 If Rotation Trip is set to Off see above this setting is ignored Phase Current Loss Running Protection This feature will cause a Trip if current in any phase or all 3 is less than 20 of the unit maximum amp rating after 3 seconds from a Start Command note tha
28. TB1 This opto isolated Triac switch is rated for 50mA max 10 250V AC DC Any circuit connected to it must be fused accordingly TE Series Digital Solid State Soft Starters 18 1250A 4 2 2 Three Wire Control Connection L L PE or For standard 3 wire control connect dry voltage free contacts of the Stop Start buttons as shown on the diagram directly above the terminal Seeeeeeeeeee strip Connect the NO contact of the Start button to Terminal 1 far left terminal the common point between the Stop and Start to Terminal 2 Connect 3 wire GWie ee eis 2 from left and the NC from the Stop button to Terminal 3 3 from anon TB 1 left 4 2 2 a Seal In Contact The TE Series uses an internally pre wired seal in contact around the Start button Terminals 1 and 2 No external relay or auxiliary output connection is necessary 4 2 3 Two Wire Control Relay PLC Connection l aE ae An alternate connection for automated or unattended operation replaces c start stop push buttons by connecting a dry voltage free maintained contact closure between terminals 1 and 3 as shown in Figure 4 2 3 1T 2 3 When this contact is closed the TE Series starter will start and run When it is opened it is the same as a Stop command y Figure 4 2 3 2 Wire Control Connection ERTA 4 2 3 a Automatic Functions and 2 Wire Control control PLC If using the Time Clock functions F032 F039 or A
29. after determining that all 3 phases have voltage applied The voltage level at which this feature activates is fixed at approximately 100VAC but is not adjustable and should not be used as Under Voltage protection Line Phase Loss Stopped Trip Numeric Value 64 If this feature is On default setting and you want to turn it Off Subtract 64 from F051 If this feature is Off and you want to turn it On add 64 to F051 NOTE 1 When using an In Line Isolation Contactor it may be necessary to defeat this protection by subtracting a numeric value of 64 from F051 in order to avoid nuisance tripping whenever the In Line Contactor opens 2 This protection will automatically reset itself when line voltage is present on all 3 phases When using 3 wire control the TE Series will not attempt restarting unless the Start Command is reinitiated ACAUTION When using 2 wire control the starter will restart when this feature resets itself after all 3 phases are present 52 TE Series Digital Solid State Soft Starters 18 1250A 5 6 9 a continued Function 51 Internal Protection Features Fault F Default Display eerie Description Bit Code Setting Decimal Value Phase Rotation protection Phase rotation must match selection in Bit 2 1 On below Setting to Off 0 will make the TE insensitive for use behind a reversing contactor ABC aie 2 A B C Phase Rotation Sequence Only mee 0 A C B Phase Rotation Sequence Only
30. changes in torque may result in load damage or equipment changes Examples would be Long overland conveyors where belt stretching may occur Low pressure pumps where slight surges at the end of ramp may pose mechanical problems Fans and mixers where blade warping is a problem Material handling systems where stacked products may fall over or break This feature can be used with or without the Maximum Current Limit setting To achieve Torque Ramping with the TE Series set the Ramp Profile F010 to 0002 or 0004 Current Ramp and the Maximum Current Limit setting F014 to the desired level Initial Torque setting comes from the Initial Current function F012 4 Current Limit Only Current Step starting means using the Current Limit feature exclusively without the benefit of soft starting by ramping the voltage or current first also known as Pedestal Starting This will maximize the effective application of motor torque within the limits of the motor In this mode Initial Torque is set to maximum and Ramp Time is set to minimum so the output current jumps to the Current Limit setting immediately Examples of when to use this mode are Applications with a severely limited power supply When starting a difficult load such as a centrifuge or deep well pump When the motor capacity is barely adequate without stalling or overloading It is a good choice when other starting modes fail Since ramp times are set t
31. designed and built in accordance with applicable safety standards in effect on the date of manufacture Unauthorized modifications can result in voiding the warranty severe injury death and property damage Do not make any modifications to this equipment without the written approval of Toshiba For assistance address correspondence to Toshiba International Corporation Field Service Department 13131 West Little York Road Houston Texas 77041 USA or call 713 466 0277 Fax 713 466 8773 800 231 1412 800 527 1204 Canada Please complete the following information for your records and retain with this manual Model Serial Number Date of Installation Inspected by Reference Number TOSHIBA INTERNATIONAL CORPORATION 2009 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 1 1 General Description 00cccces0e 1 1 2 Sizes and Ratings eseeeeeeee ee 4 Chapter 2 Installation 2 1 Receiving and Unpacking 5 2 2 Choosing a Location eeeeeee 5 2 3 Initial Unit Inspection n 5 2 4 SERVICE WARNING oaeen 6 2 5 Mounting and Cleaning 08 6 2 6 Power Terminations 000 7 2 7 Remote Keypad Mounting 9 2 8 DIMENSIONS eritir uatre tect ks 10 Chapter 3 Motor Overload Prot
32. equipment as required by local code WARNING MOTOR CONNECTED TO THIS EQUIPMENT MAY START AUTOMATICALLY WITHOUT WARNING TE Series ACAUTION 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 If a Bypass Contactor is added by the user in the field i e 210A units and above care must be taken to ensure proper power routing to ensure functioning of the Overload protection Consult factory for assistance When the Bypass Contactor on a TE BP Series has been selected to be used for Across the Line restart reference section 1 2 3 supplemental overload protection may be necessary For this application refer to the External Overload Relay Applications supplement and wiring diagram in Appendix 5 and section 4 2 6 a 3 1 3 d Dynamic Reset Capacity The TE Series includes the ability to dynamically track the Thermal Capacity needed for a successful restart after an overload trip It averages the Thermal Capacity consumed in the previous three successful starts and calculates a Thermal Capacity to Start viewed in Function F059 After tripping on Overload the Thermal Register must have regained the a
33. moisture control system and run for 1 2 hour If during that 1 2 hour the well level drops and shuts the pump down the pump needs to restart when the well recovers and finish the 1 2 hour pump time Set F030 to 0001 for Minimum Run Timer This will ensure that when the well level recovers and resets the run command the starter will finish the time sequence Set F031 to 0030 minutes This is the Run Time that ensures the proper amount of irrigation getting to the crop Not Shown Ensure F032 is set to 0000 for One Shot This will allow the Start command provided by the external control system to engage the starter at any time it is required Another example of this function used with the Time Clock Controller is provided further on NOTE on interaction with other functions Display Shows oto f i O O l eN N J Noy Ea ENTER End READ ENTER olo F CO F OJo x lt ao wy a d Q Digital Solid State Soft Starters 18 1250A Example Process Timer for Well Pump Means Starting at Function 30 Default Setting of Function 30 Set F030 1 Minimum Run Timer Value Accepted flashes once Change to F031 Default Setting of Function 31 Change Setting to 30 minutes Value Accepted flashes once Return to Function Display Cycle Control Power to Accept Changes Figure App 4 1 Programming the Minimum Run Timer Functions Whe
34. power applied or if the Pump Flex Decel function was enabled it was engaged in the Soft Stop routine set up by F024 27 IMPORTANT NOTE Fault code SSd may display if there is no output load connection when control power is applied In addition to these fault display codes each trip condition has a corresponding numeric code that is stored in the Fault History see section 5 6 13 a These numeric codes follow the display codes exactly The following Table 7 1 shows Fault Display Codes Fault Number Codes LED indicators that would come on with them and descriptions Additional details are available in the Service and Troubleshooting Guide Example If Function F003 starting overload protection is set too low for the size of the load and causes a trip the code oLA will be displayed Its corresponding number will be entered into the fault history In this case the number 0010 will be available for display in the window of function F085 Fault History The time the fault was detected is available in Function F086 It is expressed as hh mm Therefore if the oLA fault occurred at 10 00 am F086 would display 10 00 The date the fault occurred is available in Function F087 The date is expressed as mm dd If the oLA fault occurred on March 1 F077 would display 03 01 If there were no fault conditions in history the display in F085 would read 0000 64 TE Series Digital Solid State Soft Starters 18 1250A Fau
35. running parallel to the mounting surface Keep in mind that these are minimums Wiring may require more clearance particularly on the bottom 1 minimum 25 mm 4 minimum 100 mm TE Series Starter 4 minimum 100 mm 1 minimum 25 mm Figure 2 5 TE minimum mounting clearances TE Series a AMV ARNING Line Rai si2 m3 oo o oO Digital Solid State Soft Starters 18 1250A 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 Do not use wire brushes or other conductive cleaning materials 2 6 Power Terminations All line and load power terminations are to be made to tin plated copper Bus Tabs located on each unit Bus tabs are pre drilled to accept industry standard bolts Some sizes come with saddle clamp terminals however lugs are the responsibility of the user Toshiba recommends using crimp on lugs although mechanical lugs are suitable as well The following diagrams show sizes of the bus tab holes and critical spacing between them for determining the size of lug that can be
36. segment display with a decimal point on the Display spe right side indicating Phase A Table 5 2 TE Series Display Features 23 TE Series 5 3 Display Modes Digital Solid State Soft Starters 18 1250A 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 Status mode 0000 The initial display on power up is four digits and the decimal This indicates the motor current for Phase A of the motor 0000 Scroll UP to display four digits only no decimal This indicates the motor current for Phase B While viewing Phase B press the UP arrow again to view Phase C current GO00 Scroll UP to display the G This indicates that this value is the current flowing to ground on the motor leads H000 Scroll UP to display the H This indicates that this value is the remaining thermal capacity percentage of the motor i e HO70 70 remaining thermal capacity 0000 Scroll UP again to display the Process Batch Timer described in Section 5 6 7 If this entire screen is flashing the Timer is active 00 00 Scroll UP to display two pairs of digit
37. setting 1 above Use this function if it is necessary to have a return to local start stop control should the communications system fail or become disconnected 57 TE Series ABVARNING Digital Solid State Soft Starters 18 1250A FO69 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 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 See Appendix 3 at the end of this manual for detailed instructions on using and altering the Parameter Lock User Password feature F071 Emergency Clear Reset Factory Setting 0 disabled Range 0 2 This Function serves two purposes It can clear the memory values used for lockouts and overload protection and it can reset all functions to the factory default settings This is a One Shot feature so when another value is entered as shown below this function automatically returns to the default st
38. starter s power status By using non volatile memory the TE Series does not forget that the motor has been running even if power to the starter is turned off and turned back on Continuous overload protection is provided based on the true thermal condition of the motor 3 1 2 Thermal Capacity The Thermal Register is displayed as a percentage This percentage is the motor s remaining thermal capacity The percentage value begins at 100 showing that the motor is cool has 100 of its capacity available As the motor heats up or moves toward an overload condition the percentage begins to drop The Thermal Capacity is derived from the programmed motor nameplate Full Load Amps FLA in Function F001 the Service Factor rating in Function F002 and the Overload Trip Class in Functions F003 and F004 Setting these functions to the proper values provides maximum protection and eliminates nuisance tripping The Remaining Thermal Capacity can be viewed by using the UP or DOWN arrow keys when in the Status Display mode From the default Phase A Current screen dot on right side press the UP arrow key 4 times to display H100 meaning there is 100 of the Thermal Capacity H Heat capacity remaining in the motor After starting or running the motor will use this capacity and the display will show a lower number For example after a cold start the display may read H065 which indicates that the motor has 65 of its thermal capacity remain
39. timer has expired If using the TCC F032 reset is automatic when completed and no other Run command is present If a Stop Command power failure or Fault trip occurs during timed operation the Process Control Timer is suspended and maintains its value When the starter is then restarted the timer resumes counting down to ensure that the motor has run for the programmed amount of time finishes the batch Use this function to ensure that a load operates for a minimum amount NOTE of time regardless of other circumstances Examples would be Irrigation pumps where a specific amount of pumping time is required even if the pump is shut down on a low level alarm and then resets or power fails and returns Mixers that need to agitate for a specific amount of time yet may be shut down when power fails or as product is added Aeration Blowers that must be run for minimum amounts of time to ensure that proper aeration contact time has been provided to a tank In 2 wire control systems where the Run command is maintained the starter will automatically restart after a power failure or a Trip is reset Use appropriate warnings as mentioned in section 3 1 3 6 see the following F032 description for an exception to this In 3 wire control systems a new Start command will be required to restart the starter 74 TE Series Example Figure App 4 1 Minimum Run Batch Timer An irrigation pump needs to come on when called for by a soil
40. used NOTE All wiring must be sized according to local code standards TE 62 TE 112 Load o 1 50 38 07 mm Figure 2 6 1 Critical clearances for bus tab connections 0 45 11 42 mm 71 10 0 19 27 92 mm 4 82 mm allel aku _ 80 38 1 73 9 64 mm 60 15 23 mm a i 1 1 23 31 22 mm Figure 2 6 2 Critical clearances for bus tab connections TE Series Digital Solid State Soft Starters 18 1250A 2 6 Power Connections cont 38 58 mm _ _ 71 32 mm 1 52 2 81 9 64 mm 39 a aii 0 60 15 23 mm Figure 2 6 3 Critical clearances for bus tab connections NOTE Consult factory for bus tab critical dimensions for units 210A and above TE Series Model Number TE 18 BP TE 39 BP TE 48 BP TE 78 BP TE 112 BP TE 150 BP TE 160 BP TE 210 BP or P TE 276 BP or P TE 360 BP or P TE 450 BP or P TE 550 BP or P TE 718 BP or P TE 900 BP or P TE 1000 BP or P 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 tighte
41. 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 50 60 System conditions vary greatly by pump type pipe size and system head Some experimentation with settings may be necessary Decel Shut Off Voltage Factory Setting 30 Range 0 to BDL 1 Sets the level where the starter is turned off corresponding to where motor torque during Decel is no longer effective Always set this function lower than the setting of F026 Begin Decel Level this function is restricted from being less than F026 minus 1 This function is used to shut the motor off once the check valve closes Again because systems vary greatly this setting may require adjustment several times If you cannot hear or see the check valve close observe fluid pressure or flow if available Decel Ramp Time Factory Setting 10 seconds Range 1 60 seconds Sets the maximum time for the deceleration ramp to go from the Begin Decel Level setting F026 to the Decel Shut Off Voltage F027 This function is used to dampen the effect of reducing pump torque as much as possible If the check valve still slams at the end of ramp try extending this time function a little Since motor heating increases as voltage is lowered the setting should not exceed the time necessary to achieve the deceleration effect NOT
42. 030 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 The TCC requires using the Process Control Timer to provide for Start commands depending on the selected mode Time progression and clock values can be read in the Status Screen see section 5 3 1 A convenient chart at the end of this appendix shows all settings and interactions Vi a INA F030 Process Control Timer Selection Factory Setting 0 Disabled Range 0 1 2 This function enables a Process Control Timer which offers two operating modes Minimum Batch Run Timer and Permissive Run Timer selected by entering 1 or 2 here F030 1 Minimum Batch Run Timer In this mode the Process Control Timer engages that the motor will run for a minimum amount of time regardless of whether someone stops it intentionally or power fails and returns When selected to Minimum Run Timer it begins counting down after a Start command The Time Value is set in F031 When the time value reaches 0000 the starter will turn off even if the Start command is still closed and without a Stop command To Reset the timer in this mode give a Stop command after the
43. 1 second No Delay 89 TE Series Digital Solid State Soft Starters 18 1250A Appendix 6 cont Soft Starter Settings Record Setting Factory Increments Setting 0 Disabled Communications 1 Enabled 11 Bit 1 2 Enabled 10Bit 0 Disabled 1 Enabled w Start button Remote Starter Control 2 Enabled w o Start button d 3 Enabled by Jog Remote Input 0 999 ae Parameter Lock 0 Disabled 1 displays Customer Password Any Other Numbers Password encrypted code 0 Disabled System Clear Reset 1 Clear THR and Lockout Timers 1 2 Reset to Factory Default Settings By Model Frame Rating 18 550 1 defaults to 48 By Model CT Value 40 1200 5 defaults to 40 ECAN me a Fn Group Function Description Adjustment Display Range Setting Setting Communications System Settings 0 D lt Hour Bp Factory Reserved for factory use 90 TE Series Appendix 6 cont Soft Starter Settings Record Fn Group Function Description Adjustment Display Range 0 No fault history or Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12 31 MM DD MM 01 12 DD 01 31 Fault History 1 Latest Fault Time Stamp Fault 1 Based on F078 80 Date Stamp Fault 1 Based on F076 77 Fault History 2 Previous 0 No fault history or Fault Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12 31 MM
44. 1250A 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 Overload Reset Factory Setting 0 Manual Range 0 2 Set value to determine starter behavior after an overload condition has cleared When set to 0 Manual the operator must press the RESET key before restarting the motor Once the motor windings have cooled sufficiently AND the RESET key is pressed the unit will accept a restart command When set to 1 Automatic mode and once sufficient time has elapsed allowing motor windings to cool the motor will be restarted upon a start command If 2 wire control is used the unit will restart immediately When set to 2 Disabled Overload the TE Series will not trip on Motor Thermal Overload This is provided for applications where either an external Overload Relay or Motor Protection Relay is used or where multiple motors are connected and each one requires having an individual Overload Relay See Appendix 5 for more details Setting F005 1 Automatic may present significant operational risk When F005 2 Disabled Overload a separate external thermal overload protection device must be in the circuit NOTE Because of the risk of fire or equipment damage cycling control power will NOT reset an Overlo
45. 250A Time in Seconds 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 1 10 1000 100 Class 30 Class 25 Class 20 Class 15 10 MFLA Note Factory default setting is Class 10 for both Start and Run Overload Protection Figure 3 2 4 TE Series Overload Trip Curves TE Series Digital Solid State Soft Starters 18 1250A Chapter 4 Connections 4 1 Power Connections Disconnect ee or Connect appropriately sized power conductors to the unit input Circuit 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 Breaker wire Connection points for units of 210A and above are bus tabs with pre drilled holes see section 2 Use appropriate compression or mechanical lugs for termination to these bus tabs Avoid routing power wires over the control board or display Connect the motor leads to the U i TE Starter unit terminals marked T1 T2 T3 U V W for IEC users Refer to local code standards for wire sizing and length pinnae If control power is present but line power is disconnected from L1 L2 L3 the display will show
46. 30 setting Time Expires Trip or Stop Command Per F030 setting Per F030 setting Time Expires Stop command only Time Expires Next SEC only Per F030 setting Per F030 setting Continuous unless program is changed Change of Program Continuous unless program is changed These functions may interact with the Coast Down Lockout F048 Stars per Hour Lockout F049 Minimum Time Between Starts F050 Auto Reset F052 and Restart Delay Time F028 functions if enabled Be sure to read and understand descriptions of those functions then check settings before using the Process Control Timer 80 TE Series 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 1 2 hour If during that 1 2 hour the well level drops and shuts the pump down the pump needs to restart when the well recovers and finish the 1 2 hour pump time Set F030 to 0001 for Minimum Run Timer This will ensure that when the well level recovers and resets the run command the starter will finish the time sequence Set F031 to 0030 minutes This is the Batch Time that ensures the proper amount of irrigation getting to the crop Set F032 to 0002 for Every 2 Day This will begin the Start Even Cycle on the day of programming and every other day from then on Se
47. 31 MM DD MM 01 12 DD 01 31 0 No fault history or Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12 31 MM DD MM 01 12 DD 01 31 000 0 999 9 hours 0000 9999 thousand hours 0000 9999 times 0000 9999 10 thousand times 35 Setting Factory Increments Setting EE 00 01 01 01 N ra 00 01 Section 0 1 hours mee 10k times 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 and Overload Function Descriptions F001 Motor FLA Factory Setting 0 Range 50 100 of Unit Max Current MOTOR FLA F001 Set the value of this function to the motor nameplate Full Load must be programmed Amps FLA Adjustments for service factor are not necessary for unit to operate when programming this function See note below If the motor nameplate FLA is not available use typical values as shown in NEC NEMA standard MG 1 or other reputable third party source motor manufacturer etc NOTE To prevent adjusting the settings beyond the starter Max Amp rating the range of adjustment for the Motor Nameplate FLA will vary in accordance with the Service Factor as programmed into F002 At t
48. Application Considerations 0 ccceeeeeeeees 69 Appendix 3 Parameter Lock User Password Instructions cceceeeee eee eee eee eee ee 72 Appendix 4 Process Control Timer Functions eeceeeeeeeeeeeeeeeeeeneeeeeeeeeeeaeeenes 74 Appendix 5 External Over Load Relay Applications ceceeeeeseeeeeeeeeeeeeeeeeneeeneees 82 Appendix 6 Soft Starter Settings Record ceeeceeecneeeeeeeeeeeeeeeeeaeeeeeeeeeaeeeaeeeeeeeaes 87 Warranty Informatio Mssari entice ais deia aut E tee ei ae eal a a 92 TE Series Digital Solid State Soft Starters 18 1250A Chapter 1 Introduction Acceleration Adjustments Dual Ramp Settings Deceleration Adjustments Jog Settings 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 The TE Series features smooth stepless ramp control which reduces motor inrush current and excessive wear on the mechanical drive train components The TE Series includes a programmable keypad for setting operating parameters for the ideal starting cycle and protection features plus easy to understand diagnostic LEDs Starting torque ramp time current limit dual ramp and Decel control are standard featu
49. B 9 6 KB or 19 2 KB and match the setting of the host device Modbus Address Factory Setting 1 Range 1 247 The Modbus communications protocol allows each node to have up to 247 connected devices but each must have a unique address Two devices with the same address will result in a communications error Remote Starter Control Factory Setting 0 disabled Range 0 3 Use this to program how the TE Series starter is to be controlled when using serial communications When F068 0 the starter can be monitored by the Comm port but not controlled When F068 1 the starter will be controlled by the comm port In addition the Start Stop inputs are altered as follows The hard wired Start command is put in AND logic with the Comm port both Start commands must be on for the TE to start The Stop function is put in OR logic either the Comm port Stop command OR the hard wired Stop will cause the TE to stop When F068 2 the TE starter is in full control of the Comm port only Local Start Stop inputs become completely inactive Use this function only when controlled shutdown is a priority When F068 3 the TE starter will change the function of the Jog Remote Input to cause a switch between the functions of setting 0 and setting 1 as listed above When the input is open the starter will respond to the Comm port as per setting 0 above When the Jog Remote Input is closed the starter will respond as per
50. DC 50 mA maximum If the three programmable Output Auxiliary Relays are being used for other functions this output can easily be hooked up to a PLC or small external relay to provide a Fault signal This Fault Output operation is permanently fixed at Any Trip duplicating the Relay setting 16 as shown in Table 5 6 10 This output is permanently set to this function and is not programmable 4 2 8 Output Auxiliary Relay Contacts Three programmable auxiliary relays are on TB2 The TE Series starter comes with three programmable dry relay output contacts Outputs 1 and 2 are Form C SPDT with a Common N O and N C Output 3 is a Form A SPST N O contact It is not necessary to use the programmable output auxiliary relays in the Start Stop circuit An internal seal in relay is provided elsewhere see 4 2 2 4 above Toshiba recommends fusing all contacts with external fuses The relays are rated for 240 VAC 5 A and 1200 VA Factory default settings for these relays are as follows AUX 1 Run Stop see F060 This contact changes state upon a Start command returns to normal on Stop or Begin Decel if active J AUX2 At Speed Stop see F061 This contact changes state upon the TE Series detecting At Speed and returns to normal on Stop At Speed is determined by the TE Series detecting the current dropping after reaching End of Ramp or a maximum of 30 seconds after Start AUX 3 Any Trip see F062 Th
51. DD MM 01 12 DD 01 31 Time Stamp Fault 2 Date Stamp Fault 2 0 No fault history or Fault 1 27 see Fault code list 00 00 23 59 hh mm hh 00 23 mm 00 59 01 01 12 31 MM DD MM 01 12 DD 01 31 Fault History 3 Oldest Fault Time Stamp Fault 3 Fault History and Run Data Date Stamp Fault 3 Run Time Hours 000 0 999 9 hours Run Time 1000 Hour Overflow Run Cycle Counter Run Cycle Counter 10K overflow 91 0000 9999 thousand hours jtiehour fo 0000 9999 times i fo Digital Solid State Soft Starters 18 1250A Setting Increments E e ki wo for E en 00 01 00 00 coor foro fo Factory Setting Setting Setting 00 01 00 00 00 01 01 01 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 THIS WARRANTY WILL EXPIRE TWENTY FOUR 24 MONTHS AFTER SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE PLACED IN OPERATION OR THIRTY 30 MONTHS AFTER THE DATE ON WHICH SUCH EQUIPMENT AND PARTS EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY ARE SHIPPED TO THE INITIAL PURCHASER WHICHEVER PERIOD FIRST EXPIRES THERE ARE NO OTHER WAR
52. E When using the Decel function count these cycles as additional starts when determining maximum starts per hour Other Applications Another common application for Decel control is on material handling conveyors as a means to prevent sudden stops that may cause products to shift fall over or to bump into one another In overhead crane applications Soft Stopping of the Bridge or Trolley can prevent loads from beginning to over swing on sudden stops 71 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 When any value other than 0000 is entered into this Function the Parameter Lock is enabled and that number becomes the User Password From that point forward it will be necessary to enter the User Password in this Function prior to making changes in any programmed function including this one When the Parameter Lock has been enabled attempts to alter the program will result in the display reading Err whenever the READ ENTER key is pressed To alter the program after the Parameter Lock has been enabled go to Function F070 and enter the correct user Password T
53. Ground Fault Trip level is 20A On this unit the CT value reading from F074 will be 250 250 5 20 250 0 08 8 Set F046 to 8 F047 Ground Fault Trip Delay Factory Setting 2 seconds Range 1 60 seconds Provides a time delay to prevent nuisance trips from short duration transients Using default setting if the Ground Fault current exceeds the level set in F046 for more than 2 seconds the starter will trip ACAUTION This method of Ground Fault sensing may not provide adequate equipment protection in resistance grounded systems We recommend providing external GF protection using a core balanced Zero Sequence CT for those types of applications Consult factory for additional assistance 48 TE Series AMV ARNING 5 6 9 Digital Solid State Soft Starters 18 1250A 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 NOTE When F048 through F050 are used with 3 wire control systems a Start command will not seal in during lockout time When time has expired a new Start command will be necessary When F048 through
54. R PIV Ratings Peak Inverse Voltage Phase Rotation Transient Protection Cooling Bypass Contactor Units 160A and less Units 210A and over Bypass Contactor Rating Bypass Contactor Control Ambient Condition Design Control Power Programmable Outputs Output Relay Contact Rating Dedicated Fault Output Three phase AC induction motors Universal 208 600VAC 10 50 60 Hz 18 1250 Amps 7 5 1000 HP 460V Max Amp rating is UL Listed continuous rating 350 30 seconds 600 10 seconds 6 SCRs full phase angle firing using a hard fire picket firing circuit and Back Porch DC carryover to avoid motor transient problems 6 pulse Independent Locked Phase Tracking with Auto synchronization prevents misfiring on unstable source frequency 1600V Operates with any phase sequence or programmable rotation trip ABC ACB Off RC snubber dv dt networks on each phase Fan assisted convection Standard on all NEMA 12 enclosed units Standard on all open panel units BP versions Optional on open panel units BP versions Shunt rated or can be sized for Line start rated contactor see charts Integral control is included but contactor can be externally controlled as well Open panel mount units 0 to 50 C 32 to 122 F Factory enclosed units 0 to 40 C 32 to 104 F 5 95 relative humidity 0 3300 ft 1000m above sea level without derating 120VAC customer supplied 240VAC option
55. RANTIES WHETHER EXPRESS IMPLIED STATUTORY OR OTHERWISE INCLUDING THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE The Company will at its option repair or replace or refund the purchase price paid for such equipment or part which is defective under the terms of the foregoing warranty free of charge provided the purchaser 1 promptly notifies the Company in writing of such defect and 2 furnishes the Company satisfactory proof thereof and 3 establishes that the equipment or part has been properly installed maintained and operated within the limits of rated capacity and normal usage and in accordance with current operating and maintenance instructions and 4 has not been altered or modified in any manner without the written consent of the Company and 5 if requested by the Company returns the defective equipment or part to the Company and pays all expenses incurred in connection with such return The repaired or replacement equipment or part will be delivered free of charge to the purchaser F O B the Company s warehouse or at the Company s option F O B a Company authorized service shop not loaded on truck or other carrier The purchaser will pay the costs applicable to the equipment or part following such delivery including without limitation all handling transportation assembly insurance testing and inspection charges THE FOREGOING OBLIGATION TO REPAIR OR REPLACE EQUIPMENT PARTS SHALL BE THE SOLE
56. Setting 0 Disabled No timer operation 0 Run Timer Selection 1 Minimum Batch Run Timer 1 Disabled 2 Permissive Run Timer Sexe Run Timer Time 1 9999 minutes after a Start 1 1 for use in F030 above Command or Start Event from TCC SEC Start Event Cycle SEC Settings 24hr Time Clock Controller TCC 1 Loop SEC every day Start Event Mode 2 Loop SEC every 2 day 3 Loop SEC every 3 day Chose One Shot 4 Loop SEC every 4 day 0 or 1 to 7 Start Events 5 Loop SEC every 5 day 1 One Shot from F033 F039 6 Loop SEC every 6 day NESO 7 Loop SEC one day per week Run time for this mode comes 8 Single 24hr SEC from F030 above until programmed again 0 One Shot Start Event comes from Start command only 1 00 00 23 59 hh mm or OFF a 00 00 23 59 hh mm or OFF 00 00 23 59 hh mm or OFF i Fn Group Function Description Adjustment Display Range Section Run Timer and Time Clock Controller Modes 00 00 23 59 hh mm or OFF 00 00 23 59 hh mm or OFF 1 00 00 23 59 hh mm or OFF O Table 5 5 7 Run Timer and Time Clock Controller Function Group OFF OFF OFF OFF OFF OFF FF 5 5 8 Current and Ground Fault Protection Features Setting Factory Increments Setting 0 Disabled or 0 Current Imbalance Trip 5 30 imbalance Disabled Current Imbalance Trip Delay 1 20 seconds 1 second E seconds 0 Disabled or 0 Over Current Trip 100 300 of motor FLA Disabled Over Curr
57. TE Series unit will not External interlock Connection function 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 4 2 5 a Dual Ramp Command Closing a dry voltage free contact between TB1 terminals 6 and 7 will enable Ramp 2 and the TE Series starter will respond to the settings for Ramp 2 in F015 F018 If no contact closure is present the TE Series starter defaults to the Ramp 1 parameters F011 F014 See Section 5 6 2 a for setup of the Dual Ramp Feature L RAMP2 JOG opto Seeeeeeeeeee RAMP 1 RAMP 2 ore azsa The Dual Ramp feature is useful in instances where the load Dual Ramp Connections changes significantly Example a loaded or unloaded conveyor belt The characteristics for starting an unloaded conveyor can be programmed for ramp 1 The characteristics for starting a loaded conveyor can be programmed for ramp 2 Ramp 2 can also be programmed for Full Voltage Across the Line starting by setting the ramp time to 0 and Current to 600 Dual Ramp is also useful in 2 speed motor applications Simply use an auxiliary contact from one of the
58. TOSHIBA 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 Means that you might be injured if you do not follow instructions Equipment damage might also occur Give you helpful information NOTE The contents of this manual will not become a part of or modify the warranty policy the terms of which are set forth at the end of this manual READ SAFETY SIGNS To avoid injury you must read and follow all safety signs Keep the safety signs visible and in good shape Never remove or cover any safety sign i ANGER QUALIFIED OPERATORS ONLY Only qualified persons are to install operate or service this equipment according to all applicable codes and established safety practices A qualified person must 1 Carefully read the entire instruction manual 2 Be skilled in the installation construction or operation of the equipme
59. ad Trip If F005 2 Automatic Reset cycling control power will allow reset ONLY IF the Thermal Register has determined that the motor has regained sufficient thermal capacity to allow it to restart successfully F006 F009 Reserved 37 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 Refer to Appendix 2 for a detailed description of the differences in Ramp Profiles and their uses All current percentages are based on the Motor FLA as programmed in F001 F010 Ramp Profile Selection Factory Setting 1 Range 1 4 This Function selects the type of Ramp Profile desired Ramp profiles can be either Voltage Ramp or Current Ramp See Appendix 2 for details Each Ramp Profile consists of 3 settings Initial Torque Ramp Time and Maximum Current Limit Because there are two ramps available there are 4 settings to cover the combinations of profiles possible If you are not using the 2 ramp the TE Series will ignore all settings in reference to Ramp 2 Ramp 1 Ramp 2 Dual Ramp Input Open Dual Ramp Input Closed F010 Settin
60. al 6 Dry voltage free contact inputs using 24VDC from an internal power supply 3 relays 2 each Form C SPDT 1 each Form A SPST Can be programmed for 26 functions with delays or flashing 5 Amps 240VAC max 1200VA AC Triac solid state switch 240VAC DC 50mA max Approvals UL Listed Canadian UL cUL Listed CE Approved TE Series Current Model Rande Number Min Max TE 18 BP 9 18 TE 28 BP 14 28 TE 39 BP 19 39 TE 48 BP 24 48 TE 62 BP 36 62 TE 78 BP 39 78 TE 92 BP 46 92 TE 112 BP 56 112 TE 150 BP 75 150 TE 160 BP 80 160 TE 210 BP or P 105 210 TE 275 BP or P 138 275 TE 360 BP or P 180 360 TE 450 BP or P 225 450 TE 550 BP or P 275 550 TE 718 BP or P 359 718 TE 900 BP or P 450 900 TE 1006 BP or P 503 1006 TE 1250 BP or P 625 1250 Table 1 2 TE Series Range 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 1 2 1 Selecting for Service Factor Utilization Many NEMA design motors include a design rating referred to as Service Factor SF that may allow continuous operation abov
61. amp Timep Time Figure APP 1 2 Voltage Ramp with Current Limit Following are descriptions of the four types of Ramp Profiles 1 Voltage Ramping is the most reliable starting method since at some point the starter will reach an output voltage high enough to allow the motor to draw full current and develop full torque This method is useful for applications where the load conditions change frequently and significantly enough to require different levels of starting torque Examples where this is effective are Material handling conveyers Positive displacement pumps Drum mixers grinders etc Voltage is increased from a starting point Initial Torque to full voltage over an adjustable time period Ramp Time To achieve Voltage Ramping set the Ramp Profile F010 to 0001 or 0003 Voltage Ramp and the Maximum Current Limit setting F014 to maximum 600 Since this is essentially Locked Rotor Current on most motors there will be little or no Current Limit effect on the Ramp profile Initial Torque setting comes from the Initial Voltage function F011 2 Voltage Ramping with Current Limit works similarly to the above except adds an adjustable maximum current output Voltage is increased gradually until the Maximum Current Limit setting F014 is reached then held at this level until the motor accelerates to full speed Then as the current drops below the limit setting voltage is automatically increased to m
62. ass During Run NEMA UL Class 5 30 5 Class10 3 0 Manual Overload Reset 1 Auto 2 Disabled Overload Motor and Overload Info Manual Reserved for factory use Table 5 5 1 Motor and Overload Function Group 5 5 2 Starting Mode Functions Setting Factory Increments __ Settin Section Fn Group Function Description Adjustment Display Range Ramp Type Selection Setting 1 VR1 VR2 Setting 2 CR1 CR2 Setting 3 VR1 CR2 Setting 4 CR1 VR2 VR Voltage Ramp CR Current PID Ramp 1 Ramp 1 2 Ramp 2 VR1 VR2 Initial Torque VR of Ramp 1 0 100 Line Voltage 1 Initial Torque CR of Ramp 1 0 600 Motor Current 1 Accel Ramp Time of Ramp 1 1 120 seconds 1 second Max Current Limit of Ramp 1 200 600 Motor Current 1 Initial Torque VR of Ramp 2 0 100 Line Voltage 1 Initial Torque CR of Ramp 2 0 600 Motor Current 1 60 200 seconds 350 TI oO a oa 60 N ge D a Qa Foi3 2 n me e D c is Ss n 200 Accel Ramp Time of Ramp 2 1 120 seconds 1 second Max Current Limit of Ramp 2 200 600 Motor Current 1 Table 5 5 2 Starting Mode Function Group seconds 350 ak E oO oO KQ T oO a o 30 TE Series Digital Solid State Soft Starters 18 1250A 5 5 3 Jog Mode Functions Setting Factory Increments Setting Voltage Jog 100 Line Voltage Fn Group Function Description Adjustment Disp
63. ate When F071 0 the feature is disabled When F071 1 the values stored in the Thermal Register and all of the Lockout Timers will be cleared This will allow an emergency restart without having to wait for proper cool down time or lockout timers to expire Clearing the Thermal Register to allow restarting without proper cool down time after an Overload Trip will risk motor damage and fire Use only where emergency restart is necessary with knowledge of these potential hazards When F071 2 the values of all functions will be reset to the factory default settings Use this feature when settings conflict or have been tampered with This is also useful when you lose track of experimental settings and wish to start over It will also be used to clear the Fault History NOTE This will not reset F070 Parameter Lock User Password See Appendix 3 for resetting this feature F072 Reserved 58 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 The time clock is used in the 24hr Time Clock Controller operation F032
64. aximize torque until the TE Series is At Speed This may be necessary in applications where the electrical power is limited Examples would be Portable or emergency generator supplies Utility power near the end of a transmission line or other starting power demand restrictions Using Current Limit will override the Ramp Time setting if necessary so use this feature when acceleration time is not critical The Ramp Time setting however still determines the slope of the ramp up to the Current Limit setting to apply the softest possible acceleration To achieve Voltage Ramping with Current Limit set the Ramp Profile F010 to 0001 or 0003 Voltage Ramp and the Maximum Current Limit setting F014 to a desired lower setting as determined by your application requirements 66 TE Series Current Current Limit Initial Torque Time Figure APP 1 3 Current Torque Ramp Current Limit Initial Torque one Time Figure APP 1 4 Current Step Starting Digital Solid State Soft Starters 18 1250A 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 Output torque is constantly updated using an internal PID feedback loop to provide a linear ramp and therefore the available torque is maximized at any given speed The best use of this feature is for applications where rapid
65. cel Ramp Time 1 60 Seconds 1 second 10 seconds 0 Disabled or Restart Delay Time 0 1 999 seconds after a Power Loss 1 second p ORN Se paca Status an Re reaa In 1054 e one na 0 Disabled No timer operation 2 Permissive Run Timer Ee e for use in F030 above Command or Start Event from TCC Start Event Cycle SEC Settings 0 One Shot Start Event comes from Start command only 1 Loop SEC every day 2 Loop SEC every 2 day 3 Loop SEC every 3 day 4 Loop SEC every 4 day 5 Loop SEC every 5 day 6 Loop SEC every 6 day 7 Loop SEC one day per week 8 Single 24hr SEC until programmed again Fn Group Function Description Adjustment Display Range Setting Setting o 3 5 O a x iL 2 E a 24hr Time Clock Controller TCC Start Event Mode Chose from One Shot or 1 to 7 Start Events in F033 F039 Run time for this mode comes from F030 above Start Event 1 Start Time 00 00 23 59 hh mm or OFF Start Event 2 Start Time 00 00 23 59 hh mm or OFF Run Timer and Time Clock Controller Modes Start Event 3 Start Time 00 00 23 59 hh mm or OFF Start Event 4 Start Time 00 00 23 59 hh mm or OFF Start Event 5 Start Time 00 00 23 59 hh mm or OFF Start Event 6 Start Time 00 00 23 59 hh mm or OFF Start Event 7 Start Time 00 00 23 59 hh mm or OFF 88 TE Series Digital Solid State Soft Starters 18 1250A Setting Factory Inc
66. ched before the Ramp Time has expired Inthe Current Ramp Profile output voltage varies to provide a linear increase in current up to the Current Limit setting and Ramp Time is the time that it will take to get there A closed loop feedback of motor current allows continuous updating of the output to maintain this ramp profile Because most AC induction motors will not start below 200 current the current limit set point is adjustable down to only 200 ACAUTION While in the Start mode there is no maximum Current Limit time Excessive start time may lead to motor stalling causing an Overload Trip If this happens try raising the Current Limit setting to accommodate your load conditions If the Current Limit setting cannot be increased try using Current Limit without ramping features Current Limit Only as described previously 68 TE Series Digital Solid State Soft Starters 18 1250A Appendix 2 Pump Flex Decel Mode Application Considerations Coast to Stop using Electro Mech starter GO rA y Pump Flow N 4 Check Valve gt Open Pump Off _ la Back Flow E Oo N Check Valve E Siams Pump Off k j Check Valve P n Closed Pump Flex Soft Stop using VMX Series starter Pump Soft Stop tana i Neutralized Flow Q Check Valve Closes Slowly Pump Off yale sowe l e Check Valve Dod Closed Pu
67. cor Esiop PR Connecilon TE Series starter simply wire the Aux Contacts in series as shown in Figure 4 2 6 a See Appendix 5 for additional information Optional External OL Relays Emergency Stop PB ATN OLR 1 OLR 2 Remove factory jumper from Terminals 9 and 10 NOTE An Emergency Stop Push Button or any other field device may be wired to the PTC input using NC contacts When the contacts open the starter will detect it as a PTC trip Even if a PTC is used in the motor field devices can still be added as long as the total circuit resistance is not exceeded This feature is especially useful when using Decel Control because it will immediately shut off power to the motor even if Decel is active If used this way instruct the users as to the trip indication issues i e the display will show PTc and the Overload LED will be on 20 TE Series Ll Control Power or PLC Source NC RAMP2 JOG PTC OPTO ad ZOLA gt Figure 4 2 7 External Fault Relay Fault Output Opto Triac Connection TB 1 or PLC Input Internal Connections RELAY 1 RELAY 2 RELAY 3 Figure 4 2 8 Auxiliary Relay Connections TB 2 Digital Solid State Soft Starters 18 1250A 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
68. damage to mechanical components F013 Accel Ramp Time of Ramp 1 Factory Setting 10 seconds Range 1 120 seconds Sets the time between the initial torque set with F011 or F012 and either the Max Current Limit set with F014 or full output voltage Set time to enable soft starts without stalls Also consider your motor s application For example centrifugal pumps may require a shorter ramp time NOTE Ramp time is affected by the following conditions 1 Current limit will extend the ramp time if the motor does not reach full speed while in current limit mode 2 Anti oscillation circuit may shorten the ramp time if the motor reaches full speed before end of ramp F014 Max Current Limit of Ramp 1 Factory Setting 350 Range 200 600 Sets the maximum motor current that the TE Series starter will allow during Ramp 1 This limit applies to both voltage and current type ramping Current will be limited to this setting until either the motor reaches full speed or the over load protection feature trips F003 39 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 amp 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 profi
69. e 1 10 Attempts or 0 Disabled If F052 1 through 10 the TE Series will attempt to restart if the Start Command is present for this number of times If set to Zero the starter will not attempt to reset automatically 54 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 F055 F056 F057 F058 F059 Restart Delay Time Readout Factory Setting Not Applicable Range 1 999 Seconds Remaining time value readout of F028 the Auto Restart Delay Timer Coast Down Backspin Timer Value Factory Setting Not Applicable Range 1 3600 Seconds Remaining time value readout of F048 the Coast Down Lockout Timer Starts per Hour Timer Value Factory Setting Not Applicable Range 1 3600 Seconds Remaining time value readout of F049 the Starts per Hour Lockout Timer Starts per Hour Counter Readout Factory Setting Not Applicable Range 1 10 Starts Incremental counter value readout of F050 the Starts per Hour Lockout Time Value Between Starts Readout Factory Setting Not Applicable Range 1 3600 Seconds Remaining time value readout of F050 the Minimum Time Between Starts Timer Thermal Capacity to Start Readout Factory Setti
70. e right or left by one position allowing you to change higher values of functions without waiting to Auto step though large numbers Control power is available at A1 and A2 The motor is at full power and the Bypass Contactor At has been commanded to pull in Speed The SCRs are at full conduction and current has dropped Shunt Two or more SCRs in opposing phases have shorted Trip and power is flowing to the motor in the Off mode See section 8 for additional concerns Shorted There is no voltage drop across at least one SCR SCR phase assembly indicating that at least one SCR is shorted See section 8 for additional concerns Overcurrent LED lights for three sets of fault conditions 1 During start the unit saw current exceed the normal rate of increase in the first 250ms Over 2 During Run current exceeded either the OC setting Current in F042 for the delay set in F043 This LED will be accompanied by oCA oCC or oCd on the display Right and Left Arrows 3 The unit has seen a Short Circuit exceeding 10x FLA for 12 5ms This LED will be accompanied by SCA SCC or SCD display Phase One or more of the phase currents dropped below the Loss threshold during starting or running Over Starter has tripped due to excess heat sink Temp temperature This will automatically reset Over Starter has tripped due to the Thermal Register toad reaching 0000 The Overload must reset before this fault can be cleared gt 4 digit 7
71. e sure that the ground connector is connected to earth ground In ungrounded systems it is not necessary to connect a ground to the unit however local codes should always be consulted TE Series TB1 12 terminals 1 12 aaa from internal supply 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 It may be necessary to use a load bank to test the unit without a motor Line voltage will appear across the output terminals if there is no motor or load connected to the unit IMPORTANT NOTE Fault code SSd may display if there is no output load connection when control power is applied 4 1 5 Lightning Protection As with all electronic power controllers protection from damage by lightning surges is recommended in areas where lightning is a significant problem Stationary air gap lightning arrestors should be considered and utilized on the input power source The best method of protection is to have an Isolation Contactor in front of the starter that is open when the soft starter is not in use 4 2 Control Connections
72. e the nameplate current rating If using this Service Factor the TE Series starter must be sized for the total amps used For proper selection of the TE Series starter when using SF continuously multiply the nameplate FLA by the stated Service Factor or use stated Service Factor Amps SFA if listed on the nameplate Following is an excerpt from the NEMA MG 1 standards for AC Motors that describes the issues concerning the use of Service Factor ratings When an induction motor is operated at any service factor greater than 1 0 it may have efficiency power factor and speed different than those at rated load Locked rotor torque and current and breakdown torque will remain the same A motor operating continuously at any service factor greater than 1 0 will have a reduced life expectancy compared to operating at its nameplate horsepower When using this feature simply program the TE Series Service Factor F002 to the nameplate rating see section 5 6 1 All other adjustments to protection circuits are done automatically within the TE Series 1 2 2 Selecting for Across the Line Bypass If you need to be able to start the motor Across the Line if the TE Series electronics are out of service the starter can also be selected based upon the rating of the Bypass Contactor Some users may also elect to size their Bypass Contactors per NEMA guidelines Please use the Product Price Catalog for details and notes on doing this and see Appendix 5 for
73. e this digit value Indicates you have increased the 2 to left digit to a value of 5 10 s place Press READ ENTER key to store the new value The word End will flash briefly to indicate that the new value has been entered and accepted After flashing once the display will revert to showing the Function number 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 3 Changing a Function s Set Value From the instructions above after hitting the READ ENTER key the display will show the value of that function with one digit flashing usually the rightmost digit Flashing indicates this is the digit to be altered similar to cursor position Use the UP arrow key to increment the value of the flashing digit Use the DOWN arrow key to decrement the value of the flashing digit Use the LEFT or RIGHT arrow to select the next digit to be altered Values can only be changed within the Adjustment Range of the function parameter Example 1 Setting the Motor FLA Change FLA from 48 to 59A Display Means Shows Phase A Current Function 1 Selected
74. ection 3 1 Solid State Overload Protection 11 3 2 NEMA Class Trip Curves 6 08 13 Chapter 4 Connections 41 Power Connections 06 0eeee 15 4 2 Control Connections 0 eeeee eee 16 Chapter 5 Programming 5 1 INtrOdUCTION nsere Ea ainin 23 5 2 Digital Interface ee 23 5 3 Display Modes e cece ees 24 5 4 Program Mode sses 25 5 4 5 Fault Mode ees 28 5 5 The TE Function List 30 5 6 Function Descriptions 36 5 6 1 Motor and Overload Functions 36 5 6 2 Starting Mode n 38 5 6 3 4 Jog Mode Kick Start Mode 42 5 6 5 Pump Flex Decel Mode 43 5 6 6 Restart Delay ee 44 5 6 7 Process Timer Control Mode 45 5 6 8 Current and Ground Fault Protection 47 5 6 9 Lockouts Reset amp Internal Protection 49 5 6 10 Output Relays eee 56 5 6 11 Communications 0 57 5 6 12 System Settings eee 58 5 6 13 Fault History and Statistical Data 60 Chapter 6 Start up 6 1 Basic Startup ccccccssseeeeceeeeeeeee 62 6 2 Start up Check List ee 63 6 3 Sequence of Operation 008 63 6 4 Testing with a smaller motor 64 Chapter 7 Fault Conditions 7 1 Fault Codes and Numbers 64 Appendices Appendix 1 Ramp Profile Details cccecscceessecseceetesceceeetecesceeesceeeeeenseoeeeeeeeees 66 Appendix 2 Pump Flex Decel Mode
75. elay to prevent nuisance trips from short duration transients Using default settings if the difference in output current between two phases exceeds 10 of FLA for more than 2 seconds the starter will trip Over Current Trip Shear Pin Trip Factory Setting 0 Disabled Range 100 300 0 Disabled When a value other than 0 is entered for F042 the starter will trip when the output current of any phase exceeds the amount set and the time specified in F043 This is also referred to as a Shear Pin Trip and can be used to protect mechanical components from breaking due to jammed loads Over Current Trip Delay Factory Setting 1 second Range 1 20 seconds Provides a time delay to prevent nuisance trips from short duration transients For example using default settings if the output current of any phase exceeds F042 for more than 1 second the starter will trip Under Current Trip Factory Setting 0 Disabled Range 10 90 or 0 Disabled When a value other than 0 is entered for F044 the starter will trip when the output current of any phase drops below the amount set and the time specified in F045 This fault condition is often referred to as a Load Loss Trip and can be used to detect a broken shaft V belt or other mechanical drive system component In pumping applications this can be used as a Loss of Prime trip Under Current Trip Delay Factory Setting 2 seconds Range 1 60 seconds
76. ent Trip Delay 1 20 seconds 0 Disabled 0 a Disabled or Under Current Trip 10 90 of motor FLA Disabled Under Current Trip Delay 1 60 seconds 0 Disabled or 0 Ground Fault Trip 5 90 of CT ratio from Fn 74 Disabled Ground Fault Trip Delay 1 60 seconds Table 5 5 8 Current and Ground Protection Features Group Fn Group Function Description Adjustment Display Range Section c e O 2 d o 3 f re lt 3 e 6 ao J G c o b 3 8 32 TE Series Digital Solid State Soft Starters 18 1250A 5 5 9 Lockouts Reset and Internal Protection Functions Setting Factory Increments Setting Coast Down Back Spin ay k 0 Lockout Timer 0 Disabled or 1 60 minutes 1 minute Disabled i 0 Maximum Starts per Hour 0 Disabled or 1 10 starts Disabled 5 6 9 1 Fn Group Function Description Adjustment Display Range Section Minimum Time Between F i 0 Starts 0 Disabled or 1 60 minutes 1 minute Disabled 127 Enable all 4 Phase Loss only 5 6 9 b Section i 1 127 Internal Protection Settings See F051 Definition Table Auto Reset Fault Preferences 1 12 See Table 5 6 8 on Selected Faults Auto Reset Selected Faults Auto Reset Attempts 0 Disabled or 1 10 attempts Restart Delay Time Value 3 Readout for F028 OR aus Coast Down Timer Value for F048 1 3600 Seconds Starts Per Hour Timer Value for F049 1 3600 Seconds Star
77. eries protection even though most of the features are the same or better In these instances the TE Series Over Load protection can simply be turned off deferring protection to the external devices Care should be taken however to ensure that the external device is properly wired into the starter control circuit to facilitate shutdown of the motor The TE Series provides a PTC input that can be wired to the NC aux contact of the external device so that a trip will still shut down the TE Series and be annunciated on the display See section 4 7 2 a for more details on using the PTC input REDUNDANT BYPASS STARTER APPLICATIONS In some applications it may be necessary to provide an independent means of starting and protecting the motor should be TE Series starter become inoperable If this were the case the Bypass Contactor could be used for Across the Line D O L starting of the motor The TE BP version with Integral Bypass Contactors is designed for that possibility as long as the starter is properly selected when ordered To do so select the starter based upon the ATL Across the Line selection chart so that the contactor is rated for ATL duty instead of the normal Shunt Duty see section 1 2 3 for Selection charts Under normal operations the Bypass Contactor is controlled internally by the TE Series PC board and an internal pilot relay For redundant backup purposes however terminals B1 and B2 of TB4 are provided for field connecti
78. es will NOT reset the time Use this function in conjunction with the Time Clock Controller to ensure that a load only operates during the programmed amount of time beginning with the Start Event Cycle Examples would be Air compressors where leaking of air lines during normal downtime causes the compressor to run unnecessarily Irrigation pumps where operation during parts of the day is undesirable Energy Savings to prevent operation when Time of Use TOU metering discounts are provided to promote conservation 76 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 This will ensure that if nobody remembers to shut the compressor off it will not run when the facility is shut down Set F031 to 0600 minutes 10 hours This is the longest Run Time after which the starter will automatically shut down This ensures that it will not restart after the time expires and until a new Start Event occurs Not Shown Ensure F032 is set to 0001 for Every Day and F033 is set to correspond to work start time or 5 minutes prior This will al
79. etting 3 VR1 CR2 1 CR Current PID Ramp Setting 4 CR1 VR2 VR1 VR2 1 Ramp 1 2 Ramp 2 ital Torque VA of Ramp 1 0 100 Line Vaage E Initial Torque CR of Ramp 1 0 600 Motor Current 200 fT 10 Max Current Limit of Ramp 1 200 600 Motor Current 350 az ital Torque VA of Ramp 2 0 100 Line Vaage eS IIE Initial Torque CR of Ramp 2 0 600 Motor Current 200 fT 5 10 Max Current Limit of Ramp 2 200 600 Motor Current 350 fT Time of Voltage Jog 1 20 Seconds en _ F021 Current Jog 100 500 Motor Current 150 0 Disabled or 19 pene KickStart voltage 10 100 Line Voltage enbia EEE F023 Kick Kick Stat Time Time 0 1 0 1 2 Seconds o 2 0 1 2 Seconds o 0 1second 1second osse Fn Group Function Description Adjustment Display Range Motor and Overload Info T oO re A TT Q wo Starting and Stopping Modes a Oo o 1 E arg oO pa 2 N a Oo 1 Oo arg o Jog Modes F020 87 TE Series Digital Solid State Soft Starters 18 1250A Appendix 6 cont Soft Starter Settings Record Setting Factory Increments Setting 0 Disabled coast to stop Pump Flex Control 1 Enabled except after OL trip A 0 Deceleration Ramp 2 Enabled continued Decel even Disabled if there is an OL trip Begin Decel Level BDL Immediate Drop Down Torque 0 100 of Output Voltage 1 60 Decel Shut Off Voltage 0 to BDL minus 1 Voltage pom fame fof De
80. g B E Enclosure Model Number TE 18 BP thru TE 48 BP TE 62 BP thru TE 112 BP TE 150 BP and TE 160 BP Panel open with TE 210 BP thru integral bypass 12 5 10 75 contactor TE 450 BP TE 550 BP thru TE 600 PB TE 862 BP thru TE 900 BP TE 1006 BP thru TE 1250 BP Table 2 8 TE Dimensions subject to change 7 95 7 00 8 00 6 75 8 00 6 75 12 5 10 75 25 5 23 00 28 2 23 25 __Fdia S Figure 2 8 TE Dimensions 10 TE Series Digital Solid State Soft Starters 18 1250A Chapter 3 Motor Overload Protection MOTOR FLA F001 must be programmed for unit to operate H100 100 Thermal Capacity remaining at rest H057 57 Thermal Capacity remaining after starting 43 used 3 1 Solid State Overload Protection The TE Series Starter provides true U L listed I t Thermal Overload Protection as a built in function of the main digital processor for maximum motor protection It simulates the tripping action of a bi metallic overload relay with the accuracy and repeatability of a digital control system It is adjustable over a wide range and can be easily programmed for different trip curves 3 1 1 Thermal Memory The TE Series microprocessor uses a sophisticated Thermal Register in the digital memory to keep track of motor heating and cooling over time regardless of the
81. g Duty Cycle rating Larger motors tend to have lower starts per hour ratings When using the Decel function F025 or an electronic braking option count these cycles as additional starts when determining maximum starts per hour 49 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 This function is useful as a Short Cycle Timer in preventing excessive wear on motors where automatic demand control may occasionally cycle on and off too quickly such as compressors or sump pumps 5 6 9 a Internal Protection Features The TE Series starter contains additional protection features that are built into the hardware and factory preset Function F051 is provided to alter these settings via numerical preset programming For maximum protection all of these features are turned On as a factory default and should be left that way unless changes are necessary for service purposes testing or to accommodate non standard applications Factory default settings are as follows Phase R
82. g Ramp Profile Ramp Profile Voltage Voltage Current Current Voltage Current Current Voltage Table 5 6 2 Ramp Type selection Settings Select Voltage Ramp by setting F010 1 factory default When Voltage Ramp is selected Set Initial Torque Voltage with F011 see below Set Ramp Time with F013 see below Set Maximum Current Limit with F014 see below Or Select Current Ramp by setting F010 2 When Current Ramp is selected Set Initial Torque Current with F012 see below Set Ramp Time with F013 see below Set Maximum Current Limit with F014 see below NOTE When either Ramp is set to Voltage Ramp the corresponding Initial Torque Current setting is ignored Conversely when set to Current Ramp the Initial Torque Voltage is ignored 38 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 The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate while preventing torque shock
83. grammed FLA Description Factory Setting 10 Second Ramp Ramp 1 Ea Ramp 2 settings Inactive unless Ramp 2 Input is closed Software protection aes and control features Internal hardware Foa protection features tar F054 Timer and counter F059 value readouts Fo60 Aux Relay 1 Run Stop F061 Aux Relay 2 At Speed Stop F062 Aux Relay 3 Any Trip F063 Aux Relay Delay No Delay F065 ee F070 Parameter Lock ies a User password disabled F071 Reset Function fo Use to reset to default values Inactive unless selected All active Read only Not Used unless without optional Comm Adaptor F073 System settings F080 and time clock F085 F093 Fault History Table 6 1 2 Factory Presets User choice to adjust clock Read only 62 TE Series 6 2 6 3 Digital Solid State Soft Starters 18 1250A 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 Power On light located on the front of the unit turns on when control power is applied Four 7 segment LED readouts are visible The mo
84. hall not in any event exceed the price allocable to the equipment part or service which gives claim loss or damage In no event whether as a breach of contract or warranty alleged negligence liability without fault or otherwise shall the Company Toshiba Corporation or their suppliers or subcontractors be liable for indirect incidental special or consequential damages including without limitation property damage loss of profits or revenue loss of information or data loss of equipment described herein or any associated equipment cost of capital cost of substitute equipment or parts facilities or services down time costs labor costs or claims of customers of the purchaser for such damages even if Company has been advised of the possibility of such damages Purchaser shall provide this Limited Warranty and Limitation of Liability to its customers and users of the equipment and parts described herein prior to any sale to or use of the equipment and parts by such customer or user Company does not authorize anyone to make any representations or warranties other than the express warranties contained herein 92
85. he default setting of 1 0SF the full range of adjustment from 50 100 of the Max Amp rating is available As the Service Factor is increased the FLA range will drop by an equal ratio For example if F002 1 15 a 1 15 Service Factor the maximum FLA programmable into F001 will be limited to 85 of the starter Max Amp rating 100 15 F002 Service Factor Factory Setting 1 0 S F Range 1 00 1 30 Set value according to the Service Factor SF data provided on the motor s nameplate This value affects several protection features so it must be accurate Setting the SF too high may result in motor damage in an overload condition Setting SF too low may cause nuisance trips however a 1 0 SF setting is safest if SF is unknown NOTE The combination of F002 and F001 FLA x SF cannot exceed the Unit Max Amp rating If when programming F002 you are not allowed to raise the setting the combined total has been exceeded F003 Overload Class During Start Factory Setting 10 Class 10 Range NEMA UL Class 5 20 Set value to the motor protection overload class required for the application It is recommended that you try the factory setting first If possible Keep values for F003 and F004 the same Increase F003 above F004 only if nuisance tripping occurs during start See Section 3 2 for details on trip curves 36 TE Series F004 F005 AMV ARNING Digital Solid State Soft Starters 18
86. he display will read an encoded value representing the existing password As soon as you press the first Arrow key the display will change to 0000 and start showing the actual value of your password entry When the READ ENTER button is pressed the display will read PASS indicating that the User Password is correct and the system is unlocked You will have 5 minutes in which to make a change in the program This 5 minute window resets whenever any key is pressed so it floats to give you 5 minutes after the last entry After 5 minutes of no keypad activity the Parameter Lock is reinstated with the current user Password Subsequent changes will require re entering the User Password To change the User Password or to disable the Parameter Lock function enter the programmed User Password first and then set Function F070 to 0 disabling the Parameter Lock If you do not re enter the Password or enter a new user password the Parameter Lock feature will remain disabled If you enter a different number into this Function the new number becomes your new User Password Existing passwords are encoded to hide them in the display ACAUTION DO NOT LOSE YOUR PASSWORD If the password has been lost or forgotten contact Toshiba for assistance 72 TE Series Example Figure App 3 Enabling Password Protection Parameter Lock Digital Solid State Soft Starters 18 1250A Example Setting a Password Starting from the Status Display
87. il circuit Since the TE Series electronics may be out of service an External Overload is added which only works in this mode and protects the motor by dropping out the connection between B1 and B2 ACAUTION The circuit on TB 4 is at the same potential as the AC control voltage but should not be directly connected to it PC board damage may result 84 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 In these instances the TE Series Over Load protection should be turned off deferring protection to the separate OLRs Care should be taken to ensure that the External OLR is properly wired into the starter control circuit to facilitate shutdown of the motor The TE Series provides a PTC input that can be wired to the NC auxiliary contact of the external OLR so that a trip will still shut down the TE Series and be annunciated on the display Multiple OLRs would then be wired in series for the same effect See section 4 7 2 a for details on using the PTC input
88. ing 35 used The Status Display screens cycle back to the beginning so the Down arrow keys can get to this display as well 3 1 2 a Motor Full Load FLA Setting Use Function F001 to enter motor FLA as indicated on the motor nameplate Do not calculate for service factor this is programmed separately in F002 NOTE All TE Series starters are shipped from the factory with F001 set to a default value of 0000 If F001 is left at the factory default the unit will not operate If the user attempts to start the TE Series without entering the motor nameplate FLA the starter will Fault and the display will read nFLA no Full Load Amps TE Series AMV ARNING 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 When the TE Series is controlling multiple motors the built in Overload protection must be disabled and individual thermal overload relays must be installed on the motor leads going to each motor See appendix 5 for additional details To disable the Overload Protection function use F005 Do NOT disable Overload Protection unless another Thermal Overload Protection device exists in the circuit for a
89. ion 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 RAMP2 JOG OPTO L SEEE Local Figure 5 6 11 Local Remote Control Connections to TB 1 Only when F068 3 5 6 11 Digital Solid State Soft Starters 18 1250A Communications The TE Series starter is shipped from the factory ready to accept RS 485 Serial Communications using Modbus RTU protocol Additional detailed instructions on accomplishing communications are available in a Serial Communication Supplement to this manual F065 F067 are used to set the communications parameters in the starter for use by the adaptor module F068 determines how the Start Stop functions work through the comm port F065 F066 F067 F068 Communications Factory Setting 0 Disabled Range 0 2 This enables serial communications with remote monitoring and control systems and sets the format for Modbus RTU protocol Once Enabled the local start stop inputs are altered to avoid inadvertent starting See F068 for details When F065 0 communications are disabled When F065 1 uses the std 11 bit Modbus format w parity bit When F065 2 a non standard 10 bit format without a parity bit is used to accommodate some systems using this method Baud Rate Factory Setting 9 6 KB Range 4 8 to 19 2 KB Set value to either 4 8 K
90. is contact closes when any trip condition 5 15 as defined in Table 5 6 10 occurs All relays can be reprogrammed for a wide variety of functions See Section 5 6 10 for additional relay programming details 21 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 When doing so it is necessary to size the starter based upon the ATL Across the Line selection chart so that the contactors are rated for ATL duty instead of the normal Shunt Duty see section 1 2 3 Supplemental overload protection will be required see section 3 1 3 c Units have external terminal blocks marked for this purpose see Appendix 5 for drawings A dry voltage free contact closure between these terminals will close the bypass contactor immediately The Bypass Contactor coil voltage is the same as the control voltage 120VAC unless the optional 240VAC control is specified and the potential on these terminals is the same as the coil voltage No field wiring is necessary to these terminals if this feature is
91. lay Range Section Time of Voltage Jog 1 20 Seconds Le Table 5 5 3 Jog Mode Function Group 5 5 4 Kick Start Mode Functions Setting Factory EZ Setting ee Disabled or EJ EA 100 Line ee EA o F023 Kick Start Time 0 1 2 Seconds seconds Table 5 5 4 Kick Start Mode Function Group Fn Group Function Description Adjustment Display Range Section F022 Kick Kek SiatVotage Wik SiatVotage 5 5 5 Decel Mode Functions Setting Factory Increments Setting 0 Disabled coast to stop Pump Flex Control 1 Enabled except after OL trip 1 0 Deceleration Ramp 2 Enabled continued Decel even Disabled if there is an OL trip Begin Decel Level BDL 7 5 E Immediate Drop Down Torque 0 100 of Output Voltage 1 60 Decel Shut Off Voltage 0 to BDL minus 1 Voltage Decel Ramp Time 1 60 Seconds 1 second 19 seconds Table 5 5 5 Pump Flex Decel Mode Function Group Fn Group Function Description Adjustment Display Range Section Pump Flex Decel Mode 5 5 6 Restart Function Setting Factory Increments Setting Section Fn Group Function Description Adjustment Display Range 0 Disabled or Restart Delay Time F028 1 999 seconds after a Power Loss 1 second Sequential Start Delay Status can be read in F054 Ea verge Ee Table 5 5 6 Restart Function Group 31 TE Series Digital Solid State Soft Starters 18 1250A 5 5 7 Process Timer Features Setting Factory Increments
92. les can be selected in F010 Refer to Appendix 1 for additional information on ramp profiles F015 F016 F017 F018 Initial Torque Voltage of Ramp 2 Factory Setting 60 Range 0 100 Sets the initial voltage of Ramp 2 when F010 1 or 4 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 Initial Torque Current of Ramp 2 Factory Setting 200 Range 0 600 Sets the initial current of Ramp 2 when F010 2 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 Accel Ramp Time of Ramp 2 Factory Setting 10 seconds Range 1 120 seconds Sets the time between the initial torque set with F015 or F016 and either the Max Current Limit set with F018 or full output voltage Set time to enable soft starts without stalls Also consider your motor s application For example centrifugal pumps may require a shorter time See NOTE under F013 for more details Max Current Limit of Ramp 2 Factory Setting 350 Range 200 600 Sets the maximum motor current that the TE Series starter will allow during ramp 2 This limit applies to both voltage and current type ramping Current will be limited to this setting until either the motor reaches full speed or the ove
93. ll three phases Running a motor without Overload Protection presents serious risk of motor damage or fire 3 1 3 a Manual Reset The factory default setting is Manual Reset This means that when the Overload Trip is activated the starter cannot be restarted without pressing the Reset key The Overload Trip will not reset until the motor cools down see 3 1 3 d The Manual Reset function is also trip free Holding in the Reset key will not prevent the Overload Trip from activating and protecting the motor NOTE When the Overload Trip activates the Overload LED will glow solid When the motor cools down the LED will begin to flash indicating that the Overload Trip can be reset 3 1 3 b Automatic Reset If Automatic Reset is necessary change from Manual Reset to Automatic Reset by using Function F005 See Section 5 for details In this mode a 3 wire control circuit will be capable of restart when the TE Series has reset itself after the cool down period AMV ARNING Two wire control systems may restart without warning when Auto Reset of the overload protection is selected Extreme caution should be exercised To prevent automatic restarting with 2 wire control systems use external interlocking to provide sufficient warning and safety to operators A Warning Label similar to that shown below and the one provided in the packet with this manual must be located where visible on the starter enclosure and or the driven
94. llic particles conductive dust and corrosive gas Free from excessive vibration below 0 5G Open panel units must be mounted in the appropriate type of enclosure Enclosure size and type must be suitable to dissipate heat generated by the soft starter and any other components mounted inside with it Units with BP Bypass Contactors produce less heat than units without Throughout all sizes maximum heat dissipation of the TE BP Series electronics contactor coils and fans is less than 50W Units without the BP Bypass Contactor optional on 210A and above must have ventilation adequate to account for heat dissipation of the SCRs This must be estimated at 4 5 watts per running load amp For example on a 200HP 460V motor with 240FLA the maximum heat dissipation of a starter w o bypass will be 240 x 4 5 or 1080 watts of heat Enclosure ventilation or air conditioning must be capable of dispersing this amount of heat Care should always be taken to maximize the available space inside of the enclosure See section 2 5 1 or contact factory for assistance in sizing enclosures 2 3 Initial Unit Inspection Make a complete visual check of the unit for damage that may have occurred during shipping and handling Do not attempt to continue installation or start up the unit if it is damaged Check for loose mechanical assemblies or broken wires which may have occurred during transportation or handling Loose electrical connec
95. low the Run command provided by the pressure switch to engage the starter any time it is required after the shift begins With this setting the compressor will start whenever the pressure switch calls for it after the Start Event set by the Time Clock Controller but if forgotten it will shut itself off after 10 hours If power is turned off or lost during those 10 hours the timer is not cleared or reset so even if it is turn back on 1 minute before the timer expires it still shuts off at the end of that 10 hour period NOTE the new one Example Process Timer for Compressor Display Means Shows Starting at Function 30 Default Setting of Function 30 Set F030 2 Permissive Run Timer x N Value Accepted flashes once Change to F031 Default Setting of Function 31 Change Setting to 600 minutes Value Accepted flashes once Return to Function Display F030 End 0600 F031 Cycle Control Power to Accept Changes Figure App 4 2 Programming Permissive Run Timer Functions If the Process Control Timer F030 is set for Minimum Batch Timer value of 1 and the next Start Event Cycle passes without a Start command the previous event will be ignored in favor of If a Process Control Timer setting from F031 is so long that it overlaps a Start Event Cycle setting in F032 F039 the original timer value becomes invalid The new Start Event Cycle reloads the value of F031 and begins cou
96. lt Number Fault DiSplay Code used in Code 3 History Readout F085 F088 and F091 Over Current during Acceleration e Over Current during Gonstantspeed oce 2 curent Over Current during Deceleration oa 3 Phase Loss during Acceleration PLA 4 Phase Loss during Constant speed Ple S Phase Phase Loss during Deceleration Pld Loss Line Voltage Loss no 3 phase prior to star n3Ph 6 Over Temperature during Constantspeed ote 8 Sy emp Over Temperature during Deceleration otd 9 Over Load Shorted SCR during Acceleration SSA 13 Shorted Shorted SCR during Constant speed SSe 14 SCR Shorted SCR during Deceleration or Stop ssd __ 15 nO toad Shunt Trip during Acceleration s 16 Shunt Trip during Constant speed st 17 Shunt Trip Shunt Trip during Deceleration s 18 Current Imbalance during Acceleration IBA 19 Current Imbalance during Constant speed IBe 20 Current Imbalance during Deceleration Bd 29 Under Current during Acceleration Uea 22 Under Current during Constant speed Uee 23 Under Current during Deceleration Ued 24 Short Circuit during Acceleration Sea 235 Short Circuit during Gonstant speed See 26 Cnt Short Circuit during Deceleration Sed 27 Ground Fault during Acceleration GFA 28 Ground Fault during Constantspeed GPe 29 Ground Fault during Deceleration GFd
97. mount recorded in F059 before a Reset will be allowed If the display reads Inh when attempting to reset an overload trip it is indicating that the starter is Inhibited from being reset Refer to details of Function F071 for information on emergency override of lockouts such as this 3 2 NEMA Class Trip Curves NEMA Class trip curves are based on a common tripping point of 600 of motor Full Load Amps FLA Curves vary by the amount of time before the unit trips As an example a Class 20 curve will trip in 20 seconds at 600 of FLA The factory default setting of Class 10 will trip in 10 seconds at 600 of FLA 3 2 1 Dual Overload Trip Curves The TE Series Soft Starter provides two separate Overload Trip Protection Curves one for starting and one for running conditions The starters At Speed detection circuit determines when the motor has reached full speed When the At Speed condition is reached the overload trip curve will shift from the Start to the Run level as programmed in Functions F003 and F004 See Section 5 6 1 for programming details 3 2 2 Starting Overload Trip Curve During the start mode Overload Trip Curves are selectable from NEMA Class 5 through Class 20 only The default setting of Class 10 allows protection for the overload capacity of the soft starter as well as the motor Use a higher Trip Class only if nuisance tripping occurs with the default setting TE Series Digital Solid State Soft Starters 18 1
98. mp Flex Deceleration Soft Stop is a unique feature of Toshiba Solid State Soft Starters It 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 with centrifugal pumps as a means to reduce the sudden changes in pressure that are associated with Water Hammer and slamming of check valves Decel control in pump applications is often referred to as Pump Control In a pump system liquid is being pushed uphill The force exerted by gravity on the column of liquid as it goes up hill is called the Head Pressure in the system The pump is sized to provide enough Output Pressure to overcome the Head Pressure and move the fluid up the pipe When the pump is turned off the Output Pressure rapidly drops to zero and the Head Pressure takes over to send the fluid back down the hill A Check Valve is used somewhere in the system to prevent this if necessary by only allowing the liquid to flow in one direction Kinetic energy in that moving fluid is suddenly trapped when the valve slams closed Since fluids can t compress that energy is transformed into a Shock Wave that travels through the piping system looking for an outlet in which to dissipate The sound of that shock wave is referred to as Water Hammer
99. n additional Fault History complete with Time and Date stamps is also available for viewing at any time in F085 through F093 54 5 a Resetting Faults Once a fault condition has been corrected pressing the Reset key will return the readout to the Status Display mode To reset faults aa press the RESET key on the keypad Alternatively most faults will Emote Poset Conhoclio reset upon removal and return of control power Over Load trips will TB 2 NOT be reset in this way unless sufficient time has passed for the Thermal Register to regain sufficient capacity for a successful Nc no c nc no c no c at a2 restart see section 3 1 Remote Reset 54 5 b Remote Reset Because most trips can be reset by removing control power remote reset can be accomplished this way A NC remote contact or push button can be placed in the control power supply to A1 or A2 and opened to facilitate a trip reset See figure 5 4 5 b for a suggested connection Control Power Supply 28 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 non critical 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
100. n used with F028 Auto Restart Delay the Minimum Batch Timer will not resume counting down until F028 has expired and the starter has restarted When used with 3 wire control it may be necessary to maintain a Start Command until after F028 has expired or repeat it if momentary When used with F049 F050 Lockout Protection features the Minimum Batch Timer will not resume counting down until those settings have been satisfied and the TE Series starter has restarted When used with 3 wire control it may be necessary to maintain a Start Command until after they are satisfied or repeat it if momentary When used with the Pump Flex Decel feature the Decel Time F027 is counted as part of the Batch Run time for this feature 75 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 When the timer finishes F031 0000 the starter will shut off Upon the next Start command the timer will reset and begin counting down again In 2 wire control systems the starter will shut off even if the Run command is still closed
101. n3PH indicating no 3 Phase VAYVAYVA ACAUTION Never interchange input and output connections to the unit This could cause excessive voltage in the Integral control logic circuit and may damage the unit Bypass Contactor U v wi T1 T2 T3 G 4 1 1 Bypass Contactor Bypass Contactors are integral built in on all TE BP panel mount Dvo o Os and all TE E NEMA 12 enclosed versions See sections 3 2 1 c and A 4 2 5 for more details on contactor control and overload protection MTR details l fias 4 1 4 1 2 Power Factor Correction Capacitors TE Power Connections Power factor correction capacitors can be connected to motors controlled by TE Series starters however they must be off line during ramping Connect PFC capacitors to the Line side of the starter with a separate capacitor control contactor Larger units 210A and above can be ordered with fan cooling instead of Bypass Contactors but are intended Av ARNING for use in NEMA 1 ventilated enclosures only Do not use the TE Never connect power factor correction capacitors on starter in a sealed enclosure without a the load side of the unit The SCRs will be seriously bypass contactor damaged if capacitors are located on the load side 4 1 3 Grounding Connect the ground cable to the ground terminal as labeled on the unit Refer to the National Electrical Code or your local Code for the proper ground wire sizing and b
102. ng Not Applicable Range 0 100 Thermal Capacity Readout only for user s viewing of the motor Thermal Capacity percentage required to allow a Reset after an Overload Trip Use this function in conjunction with the Remaining Thermal Capacity in the Status Screen group to be able to predict when a restart will be allowed This value is automatically updated by the TE Series CPU whenever a successful start sequence has been accomplished The TE Series essentially learns how much Thermal Capacity is needed in the motor in order to successfully restart and stores the information at this Function Upon power loss and restoration this value is updated for elapsed time 55 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 FO60 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 F061 Aux Relay 2 Form C SPDT Factory Setting 2 At Speed Stop Range 1 26 See list Use to program the desired operation for Relay 2 F062 Aux Relay 3 Form A SPST N O Factory Setting 16 Any Trip 5 15 Range 1 26 See list Use to program the desired operation for Relay 3 F063 Aux Relay Delay Timer fo
103. ning torques for factory supplied connectors when using conductors rated for 75 C are shown in the chart below Always consult local codes and industry standard practices for proper wires sizes to accommodate voltage drop and ambient conditions Current Suggested Tightening Screw Bolt Tightening Range Wire Size Torque Size Min Max in lbs 1x M8 included 1x eae eae l Pacem for User supplied lugs Suggested Wire Size included Table 2 6 TE Series Wire Ranges and Torque Specifications CF Consult Factory 2 7 Remote Keypad Mounting The keypad operator interface unit can be remotely mounted up to 10 3 meters away from the starter i e on the enclosure door A remote mounting kit is necessary consisting of an adaptor plate a doorframe for NEMA 1 or NEMA 12 enclosures and a pre assembled ribbon cable available in 1 meter length increments Detailed assembly instructions and an enclosure cutout template are included with that kit See Product Selection Guide for part numbers of the different kits depending on NEMA rating and cable lengths NEMA 1 or Adaptor Plate NEMA 12 Door Frame Pai Aliy ww COLETTI rrr rrr Ave VAN Ribbon Cable 1 2 or 3 meters Figure 2 7 Remote Keypad Mounting Kit TE Starter Components TE Series Digital Solid State Soft Starters 18 1250A 2 8 Dimensions consult price catalog for enclosed units Overall Mountin
104. nore this command until the input is cycled Off and back On terminals TB1 1 and 3 are opened and reclosed For automatic operations F032 can also set the number of days in which the TCC will repeat a Start Event Cycle SEC Each Start Event Cycle consists of from 1 to 7 Start Events as programmed in F033 through F039 below Start Events can be non sequential see NOTE below F032 1 operates the SEC every day of the week F032 2 operates the SEC every 2 days every other day F032 3 operates the SEC every 3 day F032 4 operates the SEC every 4 day F032 5 operates the SEC every 5 day F032 6 operates the SEC every 6 day F032 7 operates the SEC 1 day per week F032 8 operates the SEC for a single 24HR event non repeating Use this for testing or for walk away operations that need to run after you leave but not again Start Event Cycles allow the use of a Start Command 2 wire or 3 wire ONLY AFTER the time of the Start Event has passed logic state AND In a 3 wire control system this is similar to having an Enable switch in series with the Stop button In a 2 wire control system this is similar to having and Enable contacts in series with the Run contact The Stop Button or opening the Run contact will always work to shut down the TE Series starter If F032 is set to anything other than 0 the normal Start Stop functions will no longer work except as shown above Each Start Event is a timed ope
105. not used For all other styles of TE Series the At Speed signaling can be programmed into any of the three Output relays above section 4 2 8 and Table 5 6 10 22 TE Series Digital Solid State Soft Starters 18 1250A Chapter 5 Programming MOTOR FLA F001 must be programmed for unit to operate S Tip Shori i H Powar Figure 5 2 Digital Interface 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 5 2 Digital Interface The TE Series Soft Starter includes an intuitive digital keypad with eight LEDs seven command keys and an LED display with four alphanumeric digits Clears the Trip indication and releases the Trip Relay Enters or exits the Program Mode Navigates through the Status Display Mode scrolls up and down through the Function List increases or Up and decreases the value of the active flashing digit and Down scrolls through the fault history When entering values Arrows holding the key down for more than 2 seconds will activate Auto step which increases its rate the longer the key is held down Each key press shifts the active flashing digit to th
106. nt 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 The usual cause is multiple shorted SCRs or a welded Bypass Contactor The only time this should be turned off is for troubleshooting by Service personnel Shunt Trip Numeric Value 16 If this feature is On default setting and you want to turn it Off Subtract 16 from F051 If this feature is Off and you want to turn it On add 16 to F051 PTC Trip This feature controls the inclusion of the PTC Input see Section 4 2 7 When ON default setting a jumper wire or other circuit must be installed on the PTC input if a PTC resistor is not included in the motor Turn this feature to OFF for troubleshooting or if you do not want to worry about the jumper wire PTC Trip Numeric Value 32 If this feature is On default setting and you want to turn it Off Subtract 32 from F051 If this feature is Off and you want to turn it On add 32 to F051 Line Phase Loss Stopped Trip This feature will prevent the TE Series starter from attempting to start if voltage in one or more of the incoming lines is not present This can be used to detect a blown fuse or power supply loss as long as control power is still available It differs from the Phase Loss Running Trip above in that it is based upon line voltage so does not require that a Start Command be given This trip function resets itself
107. nt and aware of the hazards involved 3 Be trained and authorized to safely energize de energize clear ground lockout and tag circuits in accordance with established safety practices 4 Be trained and authorized to perform the service maintenance or repair of this equipment 5 Be trained in the proper care and use of protective equipment such as rubber gloves hard hat safety glasses face shield flash clothing etc in accordance with estab lished practices 6 Be trained in rendering first aid SAFETY 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 Feri ae AZARDOUS VOLTAGE will cause severe injury death fire explosion and property damage Turn off and lock out Primary and Control Circuit Power before servicing Keep all panels and covers securely in place Never Defeat Modify or Bypass any Safety Interlocks e Qualified Operators only deren Never attempt to install operate maintain or dispose of this equipment until LET you have first read and understood all of the relevant product warnings and user directions that are contained in this Instruction Manual Use only Toshiba authorized replacement parts This equipment is
108. nting down again from the beginning F031 Process Timer Value Factory Setting 1 Range 1 9999 minutes This function loads a value into the Process Control Timer above When initialized the value counts down towards 0 F030 sets the operating mode and reset functions for this timer The value of this timer can be read directly in the main Status Screen see section 5 3 1 When the Process Control Timer has been enabled in F030 the Status Screen display for the value will flash once per second while timing When completed it will stop flashing and read 0000 77 TE Series and back on again ACAUTION 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 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 When set to 0 the Process Timer F030 responds only to each NEW hard wired START input command Use this setting to allow the Process Control Timer to operate without the TCC For safety purposes when using 2 wire control systems in this mode only if power fails and the START RUN command is present when power is restored the starter will ig
109. o minimum this mode functions in either Voltage Ramp or Current Ramp setting Ramp Parameter Descriptions Following are detailed descriptions of the individual settings that make up each ramp profile Initial Torque Initial Voltage or Initial Current These functions set the initial start point of either the Voltage Ramp or Current Ramp as programmed in F010 Every load requires at least some amount of torque to start from a standstill It is not efficient to begin ramping the motor from zero every time since between zero and the WK2 breakaway torque level no useful work is being performed The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate enabling the softest possible start and preventing torque shock damage to the mechanical components Setting this function too high will not damage the starter but may reduce or eliminate the soft start advantages 67 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 This should be set to provide the softest possible start without stalling unless you have de
110. on of a dry contact closure in parallel to the pilot relay contact allowing control even if the electronics are out of service AC control power must still be applied to TB2 terminals A1 and A2 but no other electronics or power supplies need to be functioning It is in this instance that an external OLR must be added to the motor power circuit and wired into that coil control circuit TB4 is located in different areas of each frame size in the TE Series Refer to the following diagram for the location on your unit 82 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
111. otation Protection is ON expected rotation sequence is set for A B C Phase Current Loss Running Protection is ON trips at lt 20 of unit Max amps after 3 seconds of acceleration and at full speed Shorted SCR Protection is ON unit will lock out if one SCR is shorted no voltage drop across the SCR Shunt Trip Protection is ON unit trips if current flows in any phase while in OFF mode PTC Trip Protection is ON unit will trip if PTC Input resistance exceeds set value or open Line Phase Loss Stopped Protection is ON unit will trip if any line voltage is not present while the unit is not accelerating or stopped F051 Internal Protection Features Factory Setting 127 all enabled Range 1 127 Numeric value representing bit locations F051 represents the numeric value of a byte 8 bits of memory which enables or disables these features Each bit within that byte acts like a dip switch to alter the associated feature but instead of having to open the starter case changes can be done via the keypad Each function has a fixed numeric decimal value associated with it Adding or subtracting decimal values to this function changes the binary On Off status of each bit and is simply done by entering the new value into F051 The Factory Default value is F051 0127 which has all features On Numeric values for each feature are as follows 50 TE Series Digital Solid State Soft Starters 18 1250A Phase
112. p Settin Jog Command Max Jog New Start Time Command Voltage Time Figure 5 6 3 1 Voltage Jog and Jog Time Jog Current Current Ramp Setting Jog Command New Start Command Current Time Figure 5 6 3 2 Current Jog motor damage or nuisance tripping F019 Voltage Jog Factory Setting 50 Range 5 100 Sets the voltage level of the Jog feature and is typically used to check rotation alignment or to slowly move a load into position Jogging at a set voltage has no current control so the duration of the applied voltage must be limited to prevent excessive motor heating F020 Time of Voltage Jog Factory Setting 10 seconds Range 1 20 seconds Set to minimize motor heating during a voltage jog This setting is the maximum allowable time for jogging the motor using voltage only F021 Current Jog Factory Setting 150 Range 100 500 Sets output of a current Jog The current jog feature is typically 41 TE Series Kick Start Normal Ramp Voltage Setting Torque Time Figure 5 6 4 Kick Start Kick Start j ea Voltage Setting oltage Hamp Ramp Initial Voltage Setting Torque Time Figure 5 6 4 a Dwell Start Using Kick Start 5 6 4 Digital Solid State Soft Starters 18 1250A used to check rotation alignment or slowly move a load into position This is not time limited but should be used cautiousl
113. pply system Another term for this is Sequential Start Delay F028 Restart Delay Time Factory Setting 0 Disabled Range 0 Disabled no delay or 1 999 seconds Sets a delay time before the starter can be restarted after a complete loss of power Use this if multiple motors are connected to a supply system that may have trouble providing adequate power to restart them all at the same time By using different Restart Delay Times on each unit a sequential restart can be achieved NOTE This is similar to the Coast Down Lockout Timer in F048 however it only activates on Power Loss F029 Reserved 44 TE Series 5 6 7 Digital Solid State Soft Starters 18 1250A 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 NOTE These functions may interact with the Coast Down Lockout F048 Starts per Hour Lockout F049 Minimum Time Between Starts F050 Auto Reset F052 and 53 and Restart Delay Time F028 functions if enabled Be sure to review and understand settings for these functions before using the Process Timer F030 F031 Process Control Timer Selection Factory Setting 0 Disabled Range
114. put Figure APP2 2 Pump Flex Decel Graph F024 Deceleration Ramp Factory Setting 0 Disabled Range 0 2 When F024 0 the deceleration feature is disabled When F024 1 the deceleration feature is enabled AND the overload protection feature from F003 F005 remains active When a Stop command is given the starter begins to apply Decel voltage However if an overload trip occurs the starter ceases applying Decel voltage and the motor coasts to a stop to prevent additional motor heating and potential motor damage When F024 2 the deceleration feature is enabled and deceleration will continue even when an overload condition trips This is to be used only when the risk of damage due to an uncontrolled shutdown is considered worse than the potential damage to the motor AMV ARNING Setting F025 2 presents significant risk of over heating the motor beyond its design limits which could result in motor damage and fire hazard Do this only in circumstances where the potential for mechanical damage outweighs the risk of motor damage NOTE The PTC Input will act as an Overload trip disable however it 70 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 F026 F027 Begin Decel Level BDL Factory Setting 60 Range 0 100 of line voltage Use to drop voltage to a level
115. r Settings 23 26 Factory Setting 0 Disabled Range 1 999 seconds or 0 Disabled Use to program the desired On Delay for any Aux Relay that has been programmed for Settings 23 through 26 from the chart below Setting Relay Operation Description Run Stop Changes on Start Command resets on Stop At Speed Stop At Speed End of Decel Start End of Decel hort SCR Trip hase Loss Trip Shunt Trip OL Motor Thermal Overload Trip OT Starter Thermal Over Temperature Trip Short Circuit Trip Current Unbalance Trip Over Current Shear Pin Trip Under Current Trip Ground Fault Trip Phase Rotation Trip Any Trip 5 15 Any Trip 5 15 flashing output oast Down Time Lockout Starts Per Hour Lockout ime Between Starts Lockout Any Lockout 18 20 Run Timer F030 Engaged 3 Run Stop with On delay from F063 At Speed Stop with On delay from F063 At Speed End of Decel with On delay from F063 Start End of Decel with On delay from F063 NOTE Flash rate for Setting 17 is 1 2 second On and Off Table 5 6 10 Output Relay Programming n 2 6s 8 9 10 pe ast at 4 5 16 io F064 Reserved 56 TE Series 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 funct
116. r load protection feature trips F003 NOTE Ramp 2 is often useful as a bump start or as a temporary Across the Line start mode Consult Appendix 1 for details 40 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 This feature can Jog the motor at either a preset Voltage F019 F021 or a preset Current F021 depending upon the settings of the Ramp Type from F010 and can be initiated along with Ramp 1 or Ramp 2 see Dual Ramp Select Section 4 2 5 and 5 6 2 a It is also sometimes useful to use Jog in combination with Ramp 2 see section 4 2 5 c NOTE Jog functions may become disabled by Comm port function F068 setting 3 See section 5 6 11 for details Ramp 1 Dual Ramp Input Ramp 2 Dual Ramp Input Open Closed Setting Ramp amp Initial Jog Ramp amp Initial Jog from Jog Torque Torque Jog Torque Torque Type from from Type from from Voltage Current Voltage Current ACAUTION Table 5 6 3 Jog Settings Although the Thermal Register tracks all motor current use continuous usage of the Jog feature risks thermal Jog Voltage Voltage Ram
117. rammed OL is Class 10 t F003 First Digit during the Start Mode Cursor flashing on leftmost ae FP Previous Setting digit 0010 of Function 3 Press the UP Arrow key to increase this digit value 0015 Value Increased 0015 Indicates that you have increased the Function 7 by 1 Increment value by the increment assigned to it a value of 5 dauci in this case 0020 Beri Press the UP Arrow key again to increase this digit value B ind Value Accepted 0020 Indicates that you have again increased the w flashes once Function value by the increment assigned to it e turn t Press READ ENTER key F003 Function Display to store the new value End The word End will flash briefly to indicate that the new value has been entered and accepted cenaro ero sion Vai OYIGE Menis After flashing once the display will revert to showing the Function number 5 4 4 Storing the Altered Value of a Function Once the desired value is displayed press the READ ENTER key This stores the value in memory The readout momentarily displays End and then returns to the function code ACAUTION If the Fn key is pressed or power is lost before the READ ENTER key is pressed the TE Series Starter will not store the selected value in memory 27 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 histo
118. ration based on the Process Timer settings in F030 above If F030 0 Disabled the TCC will be ignored So if F032 1 8 and F030 0 the starter will not operate Make sure that if F030 0 F032 0 as well 78 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 F034 Event 2 Start Time Same as above except for event 2 F035 Event 3 Start Time Same as above except for event 3 F036 Event 4 Start Time Same as above except for event 4 F037 Event 5 Start Time Same as above except for event 5 F038 Event 6 Start Time Same as above except for event 6 F039 Event 7 Start Time Same as above except for event 7 NOTE Start Events are completely independent of one another and can be programmed in any order For instance the Start Time in F037 can be earlier than the Start Time in F033 This allows easier alterations or additions of new Start Times after a unit is already installed 79 TE Series Function Type Setting Digital Solid State Soft Starters 18 1250A Function Description Range Timer Initiated By Motor Starts When Timer Reset When
119. rements Setting t 0 Disabled or 0 Current Imbalance Trip 5 30 imbalance 1 Disabled 2 Current Imbalance Trip Delay 1 20 seconds 1 second 0 Disabled or 1 0 Disabled Fn Group Function Description Adjustment Display Range Setting Setting Over G rrent iip 100 300 of motor FLA Over Current Trip Delay 1 20 seconds 1 second 1 second i 0 Disabled or 0 Under Current Trip 10 90 of motor FLA f Disabled Under Current Trip Delay 1 60 seconds 1 second 0 2 Current and Ground Fault Protection o o o HEl f fled pelted e pe i lel lt li Ground Fault Trip 1 Ground Fault Trip Delay 1 second towne i Maximum Starts per Hour 1 R Time Between 1 minute Internal Protection Settings oe a 1 Fault Preferences 1 12 4 See 5 6 9 b Fault Reset Selection Phase Table Loss only Auto Reset Attempts Soe de ae Timer Value ae Hour Timer Value ii Time Value Between Starts for F050 1 3600 Seconds Auto Reset on Selected Faults Lockouts Reset and Internal Protection 1 1 1 1 1 1 Thermal Capacity to Start for F005 0 100 Thermal Capacity 1 Operation 1 26 see Aux Relay 1 setting Aux Relay Settings Chart Operation 1 26 see Aux Relay 2 setting Aux Relay Settings Chart A A Operation 1 26 see A Aux Relay 3 setting Aux Relay Settings Chart 1 2 16 0 Output Relays Aux Relay Delay Timer for Operations 22 26 0 Disabled or 1 999 seconds
120. res on the TE Series as well as the integrated Batch Process Timer and Time Clock Controller used for automated applications By simply adjusting the unit s starting torque ramp time and current limit functions the starting electrical characteristics of the motor can be matched to the mechanical characteristics of the drive train for controlled acceleration of the load The TE Series includes solid state electronic overload protection in addition to numerous other protective features It requires 120VAC 240VAC optional control power and uses dry contact inputs for Start Stop control Programmable auxiliary contacts and provisions for interlocking are also included 1 1 1 Control Features Programmable Ramp Types Voltage Ramp VR or closed loop Current Ramp CR Starting Torque 0 100 of line voltage VR or 0 600 of motor FLA CR Ramp Time 1 to 120 seconds Current Limit 200 600 VR or CR 4 Options Ramps 1 amp 2 VR Ramp 1 VR Ramp 2 CR Ramps 1 amp 2 CR Ramp 1 CR Ramp 2 VR Dual Ramp Control Ramp 1 Default Ramp 2 selectable via dry contact input Begin Decel Level 0 100 of line voltage Stop Level 0 to 1 less than Begin Decel Level Decel Time 1 60 seconds Programmable to Decel or coast to stop upon overload trip Jog function selected via dry contact closure input Voltage Jog 5 100 Time of Voltage Jog 1 20 seconds Current Jog 100 500 A Kick Voltage 10 100
121. rs 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 If the TE Series starter has been programmed and power to the unit has not been cycled the readout will display the last function viewed or changed To change to a different function use the arrow keys 5 4 1 Viewing Function Programming and Values The programming of each individual Function can be viewed without making changes values can also be viewed in the Run Mode however no changes can be made Each Function is signified by the letter F in the beginning of the data the 4 digit value of the function follows after hitting the READ ENTER key F001 The F indicates the programmable Function 0000 This is the present setting of the applicable function This display may include decimals between digits depending on the function setting s range and incremental steps Example Figure 5 4 1 Viewing a Function s Set Value i Means Motor FLA Setting 0000 Indicates that Phase A is drawing no current Default Display unit is in Off mode gt Phase A Current Press the Fn key Sisal F001 Indica
122. ry 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 The third or right most character can be either A c or d to denote when the fault occurred A denotes Acceleration c denotes Constant speed d denotes Decel Example Figure 5 4 5 Viewing a Fault and History Means PLA Indicates that there was a Phase Loss during Fault Display Acceleration The Decimal point on the right Phase Loss signifies that this is the current fault 2 on Acceleration Press the UP Arrow key Previous Fault iBc Displays the previous fault a Phase Imbalance Phase Impalance during Constant Speed running Oldest Fault Press the UP Arrow key Over Load at oLc Displays the oldest fault an Over Load trip Constant Speed during Constant speed running Reset Indication Press RESET key flashes once rSt Flashes once to indicate a successful Reset of the current fault If it cannot be reset the Return to Default Display display will read inH for Inhibited 0000 Returns to Default Display indicating that the Figure 5 4 5 unit is ready to re start Viewing Faults This Fault History can only be accessed during a fault condition While the active fault number is being displayed use the Up and Down Arrow keys to scroll through the Fault History A
123. s a PTC trip and displays it on the readout as PTc This is independent of the Thermal Register overload current Figure 42 6 protection and provides supplemental protection for high motor ambient PTC Resistor Connection t temperature applications Terminals for this input are provided with a OAE AE NETA factory jumper that must be removed if the PTC input is used These fromTerminals9and10 terminals are located on TB1 Terminals 9 and 10 PTC Resistor in Motor PTC resistors are also found in other devices such as bearings air receivers oil or coolant reservoirs and air discharge systems that may require shutdown of the motor PTC Resistor Values Resistance must be greater than or equal to 750 Q at 25 C If multiple resistors are used in the motor the sum of all resistors in series must equal or exceed this value 4 2 6 a External Over Load Relay Connection If an external Over Load Relay OLR is used see Section 3 1 3 c and Appendix 5 connect the NC aux contact of the OLR to the PTC input after removing the jumper When the external OLR trips the contact will open opening the resistance input to the PTC circuit the resistance goes to infinity This indicates an immediate Over Load to the starter which trips and displays it on the readout as PTc to differentiate from the internal Thermal Over Load trip If Eterna Oe steal nial multiple OLRs are used i e multiple motors controlled by the same an
124. s separated by a point This indicates the time base of the Time Clock Controller described in section 5 6 7 If the display shows 00 00 the TCC is not enabled This follows the time settings in F075 F080 Example Figure 5 3 1 Reading the Status Display 0120 Indicates Phase A is drawing 120 amps Press the UP arrow 0121 Indicates Phase B is drawing 121 amps NOTE Decimal points are not present in the readouts for Phases B and C Press the UP arrow 0120 Indicates Phase C is drawing 120 amps Press the UP arrow G002 Indicates that there are 2 amps of current flowing to ground in the motor leads or motor Press the UP arrow H083 Indicates the motor has 83 of its thermal capacity remaining H Heat Press the UP arrow 0060 Indicates there is 60 minutes remaining on the Process Timer f flashing the timer is active Press the UP arrow 13 30 Indicates the time base of the Time Clock Controller is 1 30 PM 24hr time _ f flashing the time clock is active and pending the next event Press the UP arrow 0120 Loop back to Phase A current indication Key 24 0120 0121 0120 02 H083 13 30 0120 Means Phase A Current Phase B Current Phase C Current Ground Fault Current Remaining Thermal Capacity Process Timer Remaining Time Time Clock Time Base Loop Back to Phase A Current Figure 5 3 1 Reading the Status Display TE Series Digital Solid State Soft Starte
125. special considerations regarding Overload Protection NOTE The TE BP Series starters include the ability to connect a dry contact directly to the Bypass Contactor coil control circuit These terminals shipped are covered and should be used ONLY when necessary for Emergency Bypass operation and with an external Overload Relay See Appendix 5 for additional information No field wiring is necessary to these terminals if this feature is not used TE Series Chapter 2 Installation Digital Solid State Soft Starters 18 1250A 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 Confirm that the ratings sticker on the unit matches or is greater than the motor s HP and current rating 2 2 Choosing a Location Proper location of the TE Series is necessary to achieve specified performance and normal operation lifetime The TE Series should always be installed in an area where the following conditions exist Ambient operating temperature Panel open chassis unit 0 to 50 C 32 to 122 F Enclosed unit 0 to 40 C 32 to 104 F Protected from rain moisture and direct sun Humidity 5 to 95 non condensing Free from meta
126. speed contactors to select Ramp 2 so that separate ramp profiles can be used 4 2 5 b Jog Remote Command Connecting a dry voltage free contact between TB1 Terminals 7 and 8 will enable the Jog feature A Start command Run Command or Start button is required to activate the Jog feature See Section 5 6 3 for setup of the Jog Function The Jog feature can be used for tasks such as lining up machines for blade or bit changes or inching belts along to check tracking Figure 4 2 5 b l spore This input is also used to change the function of the Serial Communications port control through F068 For additional information see instructions of that function in section 5 6 11 4 2 5 c Using Both Commands It may be useful to initialize the Ramp 2 and Jog command simultaneously when jogging If this is the case terminals 6 and 8 can be jumped together and controlled with one contact closure to Terminal 7 the common 24VDC Figure 4 2 5 c Dual Ramp Jog Connections TE Series Digital Solid State Soft Starters 18 1250A 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 These are specialized resistors imbedded in some motor windings that increase resistance as the temperature increases When the TE Series detects that the PTC input resistance is too high it initiate
127. st Over Load Over Load peara J 252W MTR oN y a In this example The TE Series is used ahead of an existing 2S2W starter which already has separate OLRs for each speed Dry Aux contacts of the 2S2W starter are used to provide a Run command to the TE Series so that all existing controls can be used In addition another dry Aux of the Fast contactor is used to select Ramp 2 When started in Slow Ramp 1 default is used If started in Fast different ramp settings are necessary so Ramp 2 is used See section 4 2 5 a for Dual Ramp info Either OLR will trip the TE Series which will display Ptc and light the Overload LED 86 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 Setting Factory Increments Setting Setting Setting Motor Nameplate FLA 50 100 of Max Amp Rating Upper limit of range automatically 1 amp FLA must be programmed for adjusts downward as Service factor starter to function is increased Motor Nameplate Overload Class During Start NEMA NEMA ULClass5 20 UL NEMA ULClass5 20 5 20 Class 10 FT Overload Class During Run NEMA UL Class 5 30 Class 10 o o 0 Manual 0 Overload Reset 1 Auto 1 2 Disabled Overload Manual inte a H OOO a ae Ramp Type Selection Setting 1 VR1 VR2 7 Setting 2 CR1 CR2 VR Voltage Ramp S
128. t 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 If F030 0 the TCC settings are ignored See Appendix 4 for additional details 1 1 day per week 2 2 days per week 7 7 days per week 8 A single 24HR event non repeating 0 One Shot When set to 0 the TE Series responds only to each Start input command Use this setting to allow the Process Timer to operate without the TCC see Appendix 4 if F030 2 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 RTCC above Once started by this event the TE will run the motor according to the selections entered into F030 and F031 Event 2 Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 2 in the TCC above Event 3 Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 3 in the TCC above Event 4 Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 4 in the TCC above Event 5Start Time Factory Setting OFF Range 00 00 through 23 59 or OFF This function is used to select the start time for Event 5 in the TCC above Event
129. t F033 to 17 30 This is the 24HR time value representing 5 30 PM At this time every other day the TE Series starter will automatically start provided the Stop float in the well is closed and run for 30 minutes as programmed in F030 If the pump needs to come on again at 7 00 PM program F034 to 19 00 If later on it is needed to come on at 6 00 AM as well simply change any other unused start time i e F038 to 06 00 Even though this is Event 6 and the lower numbered events had later start times in the program the starter will execute 6 on time in the next available cycle If the pump needs to come on every day program F032 to 0001 NOTE 0 N MA READ ENTER Digital Solid State Soft Starters 18 1250A Example Process Timer and TCC for Irrigation Pump vg og so Ye O7 eN g o ol a Q may may ma zA Y zm Zm Zm o EES bnd qc Ld FER O 29 ao A o Ke ti E RE Rey KEN P x lt oo m Q N J W I 7 SN EA i 2h Q gt ye N Ke oO Ey 2 Hi Means Starting at Function 30 Default Setting of Function 30 Set F030 1 Min Batch Timer Value Accepted flashes once Change to F031 Default Setting of Function 31 Change Setting to 30 minutes Value Accepted flashes once Change to F032 Default Setting of Function 32 Set to 2 Every 2nd Day Value Accep
130. t this is based on the Max Amp rating and not the programmed FLA Turn it to OFF if the motor no load current is exceptionally low such as in high inertia machines or if you are testing a large starter with a small motor Phase Loss Running Protection Numeric Value 4 If this feature is On default setting and you want to turn it Off Subtract 4 from F051 If this feature is Off and you want to turn it On add 4 to F051 Shorted SCR Lockout protection This feature will cause a Lockout if at least one SCR is shorted based on the expected voltage drop across the SCR assembly when the unit is OFF a shorted SCR cannot be detected while the unit is running or in Bypass mode If someone who understands the ramifications of having a shorted SCR issue requires an emergency restart this feature can be turned to OFF This is not the same as a Shunt Trip circuit see below This is a lockout of the NEXT start command Shorted SCR Lockout Numeric Value 8 If this feature is On default setting and you want to turn it Off Subtract 8 from F051 If this feature is Off and you want to turn it On add 8 to F051 51 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 FO60 63 wired to a Shu
131. ted flashes once Change to F033 Set to 17 30 5 30 PM military Value Accepted flashes once Return to Function Display Cycle Control Power to Accept Changes Figure App 4 3 Programming Timer Functions If programming is entered AFTER the set time value the TCC will Vi E9 ISA 81 wait until the next valid time before executing i e if you entered the above example program changes at 5 35 PM the pump would not come on automatically until 5 30 PM 2 days from now 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 NOTE If the Decel Function is activated F024 additional consideration must be put into determining how the starter is to operate in the event of an Over Load Trip See Section 5 6 5 for issues regarding this application Vi a INA HIGHER LEVEL PROTECTION SYSTEMS Because of a desire for uniformity and or operator familiarity in some facilities Motor Protection Relays or other coordinated OEM protection systems may be used in lieu of the TE S
132. termined that your application has other considerations Applications where this setting should be shorter include Centrifugal Pumps because pump problems may occur as a result of insufficient torque during acceleration through the pump curve NOTE Ramp Time is affected by the following conditions 1 Current Limit will automatically override the Ramp Time if set to Voltage Ramp F010 1 and if the motor does not reach full speed while in current limit mode 2 An Anti Oscillation circuit built in to the TE Series will shorten the Ramp Time if the motor reaches full speed before end of ramp Current Limit This Function sets the maximum motor current that the starter allows during Ramping It is active in both the Voltage Ramp and Current Ramp modes As the motor begins to ramp this feature will set a ceiling at which the current draw will be held Current Limit will remain in effect until one of the following two events occur 1 The motor reaches full speed as detected by the At Speed detection circuit 2 The Overload Protection trips on Motor Thermal Overload see Ch 3 Once the motor has reached full speed the Current Limit feature becomes inactive In the Voltage Ramp Profile the Voltage output is increased until the Current Limit is reached The Ramp Time is the maximum time it will take for the voltage to increase until the Current Limit setting takes over Under some load conditions Current Limit may be rea
133. tes that this is Function 001 Motor FLA Pancian i Press Read Enter key to view the F001 s value Fn 1 Value 0306 Indicates that the programmed motor FLA is FLA 360A 360 Amps Press the Fn key Return to Function to return to the function Selection F001 Indicates that you have returned to the Function Benito Select screen Default Display Press the Fn key again Without Change to return to the Status Display Mode 0000 Default screen Figure 5 4 1 Viewing a Function s Set Value NOTE If password protection has been enabled operator will need to obtain password access before function settings can be changed See Section 5 6 12 and Appendix 3 25 TE Series 0000 F001 0048 0049 0049 0059 End Example 1 Figure 5 4 3 Viewing a Function s Set Value Indicates Phase A is drawing no current unit is in Off mode Press the Fn key Indicates this is Function 001 Motor FLA Press READ ENTER key to view the F001 value Indicates the programmed motor FLA is 48 Amps The farthest left digit 8 is flashing indicating that this is the digit that you will alter cursor position Press the UP Arrow key to increase this digit value Indicates you have increased the left digit to a value of 9 Press the LEFT Arrow key to shift left to the next digit The second digit from the left is now flashing indicating a new cursor position Press the UP Arrow key to increas
134. tions will increase resistance and cause the unit to function improperly Prior to beginning the installation verify that the motor and TE Series unit are rated for the proper amperage and voltage TE Series AMVARNING Digital Solid State Soft Starters 18 1250A 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 5 Mounting and Cleaning When drilling or punching holes in the enclosure cover the electrical assembly to prevent metal filings from becoming lodged in areas which can cause clearance reduction or actually short out electronics After work is complete thoroughly clean vacuum the area and re inspect the unit for foreign material 2 5 1 Clearances Make sure there is sufficient clearance all around the unit for cooling wiring and maintenance purposes To conserve panel space the TE Series BP models were designed for close horizontal clearances of only 1 inch 25mm on either side A minimum vertical clearance of 4 100 mm on the top and bottom is necessary to maximize effective airflow and cooling and the unit must be installed with its heat sink ribs oriented vertically and
135. tor s FLA has been programmed in function F001 The thermal overload is properly set Use F003 and F004 to set OL Class The motor area and equipment are clear of people and parts before start up Sequence of Operation Apply three phase power to the unit The motor should not run until the start command is applied Apply control power and check that the Power On LED comes on Status Display should read 0000 showing no current in Phase A minor flickering of the first digit is common Apply the Run Start command The motor should begin to accelerate Status display will read Phase A Amps at an increasing rate When the motor reaches full speed the At Speed LED comes on Status display should show a sharp decrease in Phase A amps If a Bypass Contactor is present TE BP model the Bypass Contactor should pull in If the motor does not fully accelerate decelerates or stops during the acceleration period hit the Stop button immediately and open the disconnect line If Pump Flex Decel is programmed in F025 Remove the Run Command or hit the Stop button At Speed LED will go out If a Bypass Contactor is present TE BP model the Bypass Contactor should drop out Status display should read Phase A amps increasing as motor begins to decelerate Motor should begin to slow down Status display should begin to show decreasing motor amps When motor reaches Stop Level starter should turn off Status displa
136. ts Per Hour Time Value Between Starts for F050 1 3600 Seconds Thermal Capacity to Start for F005 0 100 Thermal Capacity Table 5 5 9 Lockouts Reset and Internal Protection Group Lockouts Reset and Internal Protection 5 5 10 Output Relay Programming Features Setting Factory Fn Group Function Description Adjustment Display Range Increments Setting Operation 1 26 see Aux Relay Settings Chart i S i d Operation 1 26 see Aux Relay 2 setting Aux Relay Settings Chart 5 6 10 Aux Relay 3 setting Aux Relay Settings Chart Output Relays Aux Relay Delay Timer i for Operations 23 26 0 Disabled or 1 999 seconds No Delay Table 5 5 10 Output Relay Function Group NOTE Check wiring to each relay before changing programming to ensure there are no unintended consequences Relays programmed to some protection features will not operate if function is disabled elsewhere 33 TE Series Digital Solid State Soft Starters 18 1250A 5 5 11 Serial Communications Setting Factory Increments _ Setting _ Section Fn Group Function Description Adjustment Display Range 0 Disabled Communications 1 Enabled 11Bit 2 Enabled 10Bit 0 Disabled 1 Enabled w Start button 2 Enabled w o Start button 3 Enabled via Jog Remote Input Communications Table 5 5 11 Serial Communications Function Group 5 5 12 System Settings Setting Factory
137. uto Reset utput here functions F052 F053 special consideration must be given to using 2 wire control Refer to Appendix 3 for additional details and information on time clock functions and section 5 6 9 for details on using Auto Reset functions NOTE When a maintained contact is used for start stop it is advisable to set the overload relay to the manual reset position This will prevent the motor from restarting if the thermal overload trips and then cools off ACAUTION Control Terminals 1 10 of TB1 are a 24VDC circuit from an internal power supply of the TE Series Use dry unpowered contact closures only Applying any voltage to these terminals will result in damage to the TE Series control board If existing 120VAC or other powered control circuit must be interfaced use interposing relays or control the TE Series with 2 wire control as shown above 4 2 4 Interlock Connection L TEES oro TB1 provides a connection point for an external dry voltage free N C al Normally Closed interlock device between terminals 4 and 5 EEPE Examples where this interlock connection would be used include low oil high temperature or excess vibration dropout from user supplied i ye pareve way jumper devices A factory installed jumper is provided which allows the TE l interlock device here Series unit to operate if external interlocks are not used If this jumper is areaz removed and an interlock is not used the
138. w and subtract from 127 then enter that number to accomplish it Example F051 reads a numeric value of 109 meaning that something has been changed but you don t know what By subtracting 109 from 127 you have a value of 18 remaining and since 18 does not represent a single bit it means that some combination has been used Subtract the largest represented bit i e bit 4 value of 16 which leaves a value of 2 representing bit 1 So in this example the Shunt Trip feature had been turned off and the Expected Phase Sequence had been changed to A C B If you do not wish to bother with what the previous settings were simply decide which features you now want to be turned on and come up with a new numeric value to enter For instance if you want all features on but you need phase rotation to be A C B bit 1 then simple subtract a value of 2 from 127 and enter 125 into F051 53 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 NOTE When using 3 wire control For safet
139. y 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 F022 F023 Kick Start Voltage Factory Setting 0 Disabled Range 10 100 When F022 anything but 0 a voltage pulse is applied before the initial torque setting of F011 or F012 if Current Ramp This sets the voltage level and the duration of the pulse is set by F023 This setting should be higher than F011 except for Dwell Starting see below and high enough to provide a benefit in the worst starting condition Kick Time Factory Setting 0 8 seconds Range 0 1 2 seconds Sets the duration of time the Kick Start voltage is applied 5 6 4 a Dwell operation using Kick Start In some applications such as chain drive machinery the Kick Start feature can be used to slowly take up slack in the drive chain before applying full torque This is referred to as Dwell Starting because the torque output stays low for a short time To take advantage of this feature simply set the Kick Start to the same level as the Initial Torque setting This will only work in Voltage Ramp mode NOTE Do not use the Kick Start feature unless you determine that you need it Using this feature may eliminate many of the mechanical and electrical benefits of using a Soft Starter 42 TE Series
140. y reasons the TE Series will not attempt restarting unless the Start Command is reinitiated and maintained during a restart attempt F052 Auto Reset Selected Faults Factory Setting 0 Disabled Range 1 12 or 0 Disabled If F053 1 through 12 the TE Series will attempt to restart after the fault s coded in the following table Only one selection can be entered F053 Tp T Display Readout Setting Fault Condition Description Butcronce Auto Reset Disabled Over Temperature Trip T Over Current Shear Pin Trip Under Current Trip Phase Loss Trip PLa or PLc Current Unbalance Trip Ground Fault Trip 7 Short Circuit Trip Faults 1 2 or 3 above Faults 4 5 or 6 above 10 Any Fault except 7 11 Any Fault except 6 amp 7 12 Any Fault above 1 7 1 NOTE 1 UC OC or UB require operation to resume before the fault can be detected 2 NOTE 2 Cycling and or restoration of control power will reset all of the above faults 3 NOTE 3 Overload Trip reset function is programmed only in F005 See Section 3 for details 4 NOTE 4 Reset attempts that occur when the fault condition is still present will cause a new fault This will be logged into the fault history F085 F093 and may overwrite previous fault records 5 Line Loss Trip see F051 will automatically reset and so is not included in this list Table 5 6 9 b Faults Selected for Auto Restart F053 Auto Restart Attempts Factory Setting 0 Disabled Rang
141. y will again show 0000 If the unit does not follow this operational sequence please refer to the Service and Troubleshooting Guide 63 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 Chapter 7 Fault Conditions Additional information on Fault Codes and possible causes can be found in the Service and Troubleshooting Guide 7 1 Fault Codes and Numbers in History A three character fault code is displayed in the LED display at the time of the trip event The first two digits indicate the trip condition see Table 7 1 The third digit is a suffix showing the TE Series operating mode when the trip occurred Operating modes are as follows Code suffix A Acceleration meaning that the TE Series was ramping up but had not yet achieved At Speed status see section 4 2 9 b for a brief description of At Speed indication Code suffix c Constant Speed running meaning that the TE Series has reached the At Speed condition and the motor was running when the trip occurred Code suffix d Decel or Stop meaning that TE Series was either stopped off but

Toshiba 18 - 1250 A Remote Starter User Manual

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