Toshiba Dvr 35 Instruction Manual

							INSTRUCTION MANUAL
TD SERIES
Low Voltage
Digital Solid State Starter
48 - 1250 A
Issued: 9/03
Manufactured in the USA
INSTALLATION - OPERATION - MAINTENANCE
DOCUMENT: NBZ0001 
						

							SAFETY
    WARNING
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 a\
ll applicable state and local
codes, adhere to all applicable National Electric Code (NFPA 70) standards and instructions provided
in this manual.
HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion andproperty damage.
•       Turn off and lock out Primary and Control Circuit Power before ser\
vicing.
• Keep all panels and covers securely in place.
• Never Defeat, Modify, or Bypass any Safety Interlocks.
            •       Qualified Operators only. Never attempt to install, operate, maintain or dispose of this equipment\
 until
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 designed and built in accordance with applicable safet\
y
standards in effect on the date of manufacture.  Unauthorized modificati\
ons
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 wi\
th this manual:
Model: ___________________________________
Serial Number: _____________________________
Date of Installation: _________________________
Inspected by: ______________________________
Reference Number: _________________________
   © TOSHIBA INTERNATIONAL CORPORATION, 2003 
						

							SAFETY
    DANGER
    WARNING
    CAUTION
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 b\
e 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.  Equi\
pment damage might
also occur.
Give you helpful information.
NOTE
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.
    
DANGER
QUALIFIED OPERATORS ONLY
Only qualified persons are to install, operate, or service this equipmen\
t 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\
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 equip- ment.
5) Be trained in the proper care and use of protective equipment such as ru\
bber gloves, hard hat, safety glasses, face shield, flash clothing, etc. in accordanc\
e with estab-
lished practices.
6) Be trained in rendering first aid.
Note:  The contents of this manual will not become a part of or modify t\
he warranty
policy, the terms of which are set forth at the end of this manual. 
						

							TD Series
Digital Solid State Soft Starter
48 - 1250A
Chapter 1: Introduction ..................................................... 1
1.1 General
1.2 Specifications and Performance Features
Chapter 2: Installation ....................................................... 4
2.1 Receiving and Unpacking
2.2 Location
2.3 Initial Unit Inspection
2.4 Warning
2.5 Mounting and Cleaning
2.6 Power Terminal Wire Range and Tightening Torque
2.7 Dimensions
Chapter 3:  Motor  Overload Protection ........................... 7
3.1 Solid State Overload Protection
3.2 NEMA Class Trip Curves
Chapter 4: Connections .................................................. 10
4.1 Power Connections
4.2 Control Connections
4.3 Interlock Connection
Chapter 5: Programming ................................................ 13
5.1 Introduction
5.2 Digital Interface
5.3 Display Modes
5.4 Function List
5.5 Function Descriptions
Chapter 6: Start-Up .......................................................... 32
6.1 Quick Start
6.2 Start-up Check List
6.3 Sequence of Operation
Chapter 7: Fault Conditions ........................................... 35
7.1 Fault Codes and Numbers (In History)
Chapter 8: Troubleshooting ........................................... 36
8.1 Failure Analysis
8.2 SCR Testing Procedure
8.3 Replacing SCR Devices
8.4 Replacing Printed Circuit Board Assembly
Chapter 9: Printed Circuit  Board Layout ....................... 41
9.1 Power Board and CPU Board (PC Board Assembly)
9.2 Typical Wiriing Diagram
Chapter 10: Maintenance/Disposal/Storage ................. 43
Appendix 1: Ramp Profile Details
Appendix 2: Decel Mode Application Considerations
Appendix 3: Parameter Lock / User Password Instructions
Appendix 4: Soft Starter Settings
Warranty Policy
Table of Contents 
						

							TD - Series- 1 -
TD SeriesDigital Solid State Soft Starter 48 - 1250A
1.1    General
The TD 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 500% for 60 seconds (compared to
350% for 30 seconds from other manufacturers). The TD Series features
smooth, stepless ramp control which reduces motor inrush current and
excessive wear on the mechanical drive train components. In addition to
having easy to understand diagnostic LEDs, the TD Series includes a
programmable keypad for setting operating parameters for the ideal
starting cycle. Starting torque, ramp time, current limit, dual ramp, and
decel control are standard features on the TD Series. 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 TD Series includes solid state electronic overload protection in
addition to numerous other protective features. It is factory wired for 120
VAC control voltage and two or three-wire start/stop control (Units can
also be ordered with 240 VAC control voltage if required). Programmable
auxiliary contacts and provisions for interlocking are also included.
Chapter 1 - Introduction
1.2    Specifications and Performance Features
Type of LoadThree phase AC induction motor
AC Supply Voltage208 - 600VAC ±10%, 50/60 Hz
HP Ratings48 - 1250 Amps, 10 - 1125 HP
Unit Overload Capacity
(Percent of motor FLA)125% - Continuous
500% - 60 seconds
600% - 30 seconds
Power Circuit6 SCRs
SCR Diode Ratings
(Peak Inverse Voltage)1600V
Phase InsensitivityUnit operates with any phase sequence
Transient Voltage ProtectionRC snubber dv/dt networks on each phase.
CoolingConvection up to 180A, fan assisted 62 - 120A,
Fan ventilated 220 - 1250A
Bypass ContactorFull horsepower rated contactor included as standard in all
Type 12, 3R, 4 & 4X enclosed units 120A and above.
Ambient Condition DesignChassis units: 0° to 50 °C (32° to 122°F)
Enclosed units: 0° to 40°C (32° to 104°F)
5 - 95% relative humidity
0 - 3300 ft. (1000m) above sea level without derating
Control2 or 3 wire 120VAC (customer supplied)
Optional 240VAC control voltage and CPTs are available.
Type / Rating: Form C (SPDT), rated 5 Amps,
240VAC max. (1200VA)
3 Programmable Relays
Fault Indicator: AC triac solid state switch
240VAC, 50mA max.
ApprovalsUL Listed, Canadian UL (cUL) Listed Auxiliary Contacts 
						

							TD - Series- 2 -
TD  Series    Digital Solid State Soft Starter 48 - 1250A
1.2    Specifications and Performance Features Cont’d
Note 1: Enabled via programming
Two Stage Electronic
Overload CurvesStarting: Programmable for Class 5 through 30
Run: Programmable for Class 5 through 30 when At-Speed 
is detected.
Overload Reset (Note 1)Manual (default) or automatic
Retentive Thermal MemoryOverload circuit retains thermal condition of the motor 
regardless of control power status. Unit uses real time clock 
to adjust for off time.
Dynamic Reset CapacityOverload will not reset until thermal capacity available in the 
motor is enough for a successful restart. Starter learns and 
retains this information by monitoring previous successful 
starts.
Phase Current Imbalance
Protection (Note1)Imbalance Trip Level: 5 - 30% current
between any two phases
Imbalance Trip Delay: 1 -20 seconds
OverCurrent
(Electronic Shear Pin)
Protection (Note 1)Trip Level: 50 - 300% of motor FLA
Trip Delay: 1 - 20 seconds
Load Loss Trip Protection
(Note 1)Under Current Trip Level: 10 -90 % of motor FLA
Under Current Trip Delay: 1 - 60 seconds
Coast Down (Back Spin)
Lockout Timer (Note 1)Coast Down Time Range: 1 - 60 minutes
Starts-per-hour Lockout Timer
(Note 1)Range: 1 - 10 successful starts per hour
Time between starts: 1 - 60 minutes between start attempts
Type / RatingForm C (SPST), Rated 5 amps
240 VAC max, (1200 VA)
Run IndicationStart/Stop or Start/End of Decel
At Speed IndicationAt Speed/Stop or At Speed/End of Decel
Acceleration AdjustmentsProgrammable Ramp Types: Voltage or Current Ramp
(VR or CR)
Starting Torque: 0 - 100% of line voltage (VR)
or 0 - 600% of motor FLA (CR)
Ramp Time: 1 to 120 seconds
Current Limit: 200 - 600% (VR or CR)
Dual Ramp Settings4 Options: VR1+VR2; VR1+CR2; CR1+CR2; CR1+VR2
Dual Ramp Control: Ramp #1 = Default, 
Ramp = #2 selectable via dry contact input
Deceleration AdjustmentsBegin 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 Settings
Jog function selected via
dry contact closure input)Voltage Jog: 5 - 100%
Time of Voltage Jog: 1 - 20 seconds
Current Jog: 100 - 500%
Kick Start Settings
(Note 1)Kick Voltage: 10 - 100%
Kick Time: 0.1 - 2 seconds
Fault IndicationsShorted SCR, Phase Loss, Shunt Trip, Phase Imbalance 
Trip, Overload, Overtemp, Overcurrent, Short Circuit, Load 
Loss, or Any Trip
Lockout IndicatorCoast Down Time, Starts Per Hour,
Time Between Starts, and Any Lockout Programmable Outputs Advanced Motor Protection 
						

							TD - Series- 3 -
TD SeriesDigital Solid State Soft Starter 48 - 1250A
1.2    Specifications and Performance Features Cont’d
Phase Currents0 - 9999 Amps, Phase A, B, or C
Remaining Thermal Capacity0 - 100% of available motor thermal capacity
Elapsed Time0 - 1,000,000.0 hours, non resetable
Run Cycle Counter0 - 10,000,000 run commands non resetable
Lockout Time ValuesRemaining time of any enabled lockout timer
Fault CodesAbbreviated fault codes, indicating trip and operating mode
Fault HistoryLast 3 faults with Time and Date Stamps
ProtocolModbus RTU
SignalRS-485
NetworkUp to 247 devices per mode
FunctionalityFull operation, status view, and programming
via communications port
LED Readout4 digit alpha numeric, high brightness, 7 segment display
Keypad8 functions keys with tactile feedback
Status Indicators8 LEDs
Remote Mount CapabilityUp to 10 feet (3 meters) from chassis
Operating MemoryDRAM loaded from EPROM and EEPROM at initialization
Factory Default StorageFlash EPROM, field replaceable
Customer Settings and StatusNon-volatile EEPROM, no battery backup necessary
Real Time ClockLithium ion battery for clock memory only, 
10+ years life spanOperator Interface
Clock and Memory Metering Functions
Serial Communications 
						

							TD - Series- 4 -
TD  Series    Digital Solid State Soft Starter 48 - 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    Location
Proper location of the  TD Series is necessary to achieve specified
performance and normal operation lifetime. The  TD Series should
always be installed in an area where the following conditions exist:
•Ambient operating temperature:
Chassis unit: 0 to 50°C (32 to 122°F)
Enclosed unit: 0 to 40°C (32 to 104°F)
•Protected from rain and moisture
•Humidity: 5 to 95% non-condensing
•Free from metallic 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. Contact factory for assistance in
sizing enclosures.
2.3    Initial Unit Inspection
• Make a complete visual check of the unit for damage which 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
connections will increase resistance and cause the unit to function
improperly.
• Prior to beginning the installation, verify that the motor and  TD unit
are rated for the proper amperage and voltage.
2.4    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.
Chapter 2 - Installation
    WARNING