TOSHIBA TE 18-1250A Soft Starter INSTRUCTION MANUAL
Below you will find brief information for TE 18-1250A. The TE 18-1250A is a digitally programmable solid state reduced voltage soft starter. It features a voltage/current ramp with an anti-oscillation circuit for smooth load acceleration. The TE series includes smooth, stepless ramp control, which reduces motor inrush current and excessive wear on the mechanical drive train components.
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INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE
TE SERIES
Low Voltage
Digital Solid State Starter
18 - 1250 A
Issued: 10/09
Manufactured in the USA
SAFETY
NOTE
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.
QUALIFIED OPERATORS ONLY
Only qualifi ed persons are to install, operate, or service this equipment according to all applicable codes and established safety practices.
A qualifi ed person must:
1)
2)
3)
4)
5)
6)
Carefully read the entire instruction manual.
Be skilled in the installation, construction or operation of the equipment and aware of the hazards involved.
Be trained and authorized to safely energize, de-energize, clear, ground, lockout and tag circuits in accordance with established safety practices.
Be trained and authorized to perform the service, maintenance or repair of this equipment.
Be trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses, face shield, fl ash clothing, etc. in accordance with established practices.
Be trained in rendering fi rst 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.
HAZARDOUS VOLTAGE will cause severe injury, death, fi re, explosion and property
• 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.
• Qualifi ed Operators only.
Never attempt to install, operate, maintain or dispose of this equipment until you have fi rst 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 safety standards in effect on the date of manufacture. Unauthorized modifi cations can result in voiding the warranty, severe injury, death and property damage. Do not make any modifi cations 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
(800)
(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
Chapter 1: Introduction
Chapter 2 - Installation
1.1
1.2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Chapter 3 - Motor Overload Protection 3.1
3.2
Chapter 4 – Connections 4.1
4.2
5.1
Chapter 5 – Programming
5.2
5.3
5.4
5.5
5.6
Chapter 6 - Start-up
Chapter 7 - Fault Conditions
6.1
6.2
6.3
6.4
7.1
General Description ……………………
Sizes and Ratings ………………………
Receiving and Unpacking ……………..
Choosing a Location …………………...
Initial Unit Inspection …………………...
SERVICE WARNING! ………………….
Mounting and Cleaning ………………..
Power Terminations ……………………
Remote Keypad Mounting
Dimensions ……………………………...
Solid State Overload Protection ………
NEMA Class Trip Curves ……………...
Power Connections …………………….
Control Connections ……………………
Introduction ……………………………...
Digital Interface …………………………
Display Modes ………………………….
Program Mode ………………………….
5.4.5 Fault Mode …………………………
The TE Function List ………………...
Function Descriptions ………………….
5.6.1 Motor and Overload Functions ….
5.6.2 Starting Mode …………………….
5.6.3/4 Jog Mode / Kick Start Mode …….
5.6.5 Pump-Flex Decel Mode …………
5.6.6 Restart Delay …………………….
43
44
5.6.7 Process Timer Control Mode …… 45
5.6.8 Current and Ground Fault Protection 47
5.6.9 Lockouts, Reset & Internal Protection 49
5.6.10 Output Relays ……………………. 56
36
36
38
42
24
25
28
30
15
16
23
23
5.6.12 System Settings ………………….
5.6.13 Fault History and Statistical Data
Basic Startup ……………………………
Start-up Check List ……………………..
Sequence of Operation ………………..
Testing with a smaller motor …………..
Fault Codes and Numbers …………….
Appendices
Appendix 1 - Ramp Profile Details ………………………………………………………………..
Appendix 2: Pump-Flex
®
Decel Mode Application Considerations ……………………………
Appendix 3: Parameter Lock / User Password Instructions ……………………………………
Appendix 4: Process Control Timer Functions ………………………………………………….
Appendix 5: External Over Load Relay Applications ……………………………….………….
Appendix 6: Soft Starter Settings Record ………………………….…………….………………
Warranty Information ………………………………………………….……………………………
Page
1
4
5
5
5
6
6
7
9
10
11
13
58
60
62
63
63
64
64
66
69
72
74
82
87
92
2
TE Series Digital Solid State Soft Starters 18 – 1250A
Chapter 1 - Introduction
1.1 General Description
The TE Series is a digitally programmable solid-state reduced voltage soft starter. Its six SCR design features a voltage/current ramp with an anti-oscillation circuit for smooth load acceleration. The SCRs are sized to withstand starting currents of 350% for 30 seconds and up to 600% for 10 seconds. 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 features 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.
Acceleration Adjustments
Dual Ramp Settings
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 & 2 = VR,
Ramp 1 = VR, Ramp 2 = CR,
Ramps 1 & 2 = CR;
Ramp 1 = CR, Ramp 2 = VR
Dual Ramp Control:
Ramp #1 = Default,
Ramp = #2 selectable via dry contact input
Deceleration Adjustments
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 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
Kick Voltage: 10 - 100%
Kick Time: 0.1 - 2 seconds
Process Timer
(2 modes)
Minimum Batch Timer: Runs until timer expires
Maximum Batch Timer: Runs unless timer expires
Range: 0 - 9999 minutes
Real Time Clock (RTC)
Controller
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
1
TE Series Digital Solid State Soft Starters 18 – 1250A
Thermal Model Electronic
Overload Protection
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
Overload Curves
Starting: Programmable for Class 5 or 10
Run: Programmable for Class 5 through 30 when "At-Speed" is detected.
Overload Reset
Manual (default) or automatic
Retentive Thermal Memory
Dynamic Reset Capacity
Current Imbalance Trip
PTC Input Trip
Over Current Trip
(Electronic Shear Pin)
Phase Loss
Equipment Ground Fault
Protection
Load Loss Trip
Coast Down (Back Spin)
Lockout Timer
Overload circuit retains thermal condition of the motor regardless of control 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 a successful restart. Starter learns and retains this information by monitoring previous successful starts.
Trip Level: 5 - 30% Imbalance in any two phases
Trip Delay: 1 -20 seconds
Trips on greater than 750 ohms resistance on a dedicated PTC input. Can be used with an Emergency Stop or any other External Lockout.
Trip Level: 50 - 300% of motor FLA
Trip Delay: 1 - 20 seconds
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
Trip Delay: 1 – 60 seconds
Prevents restart when motor may be spinning backwards
Coast Down Time Range: 1 – 60 minutes
1 – 10 successful starts per hour
Starts-per-hour Lockout
Minimum Time between
Starts Lockout
Restart Delay
Auto Reset
Power Device Monitoring
Range: 1 – 60 minutes between start attempts
Sequential Start Feature for restarting delay after a power outage.
1-999 seconds after a power loss
Can be programmed to attempt resetting after selected faults
0 – 10 Attempts, 0 – 999 minutes delay between attempts
Shorted SCR Lockout (1 shorted SCR) and independent Shunt Trip (multiple shorted SCRs). Can be disabled in programming.
2
TE Series Digital Solid State Soft Starters 18 – 1250A
Type of Load:
AC Supply Voltage:
Power Ratings:
Three phase AC induction motors
Universal, 208 - 600VAC ±10%, 50/60 Hz
18 - 1250 Amps, 7.5 - 1000 HP @ 460V
Unit Capacity - Continuous
Max. Amp rating is UL Listed continuous rating
Unit Capacity - Overload Rating
(Percent of motor FLA)
Power Circuit
SCR Firing Angle Detection
SCR PIV Ratings
(Peak Inverse Voltage)
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
Phase Rotation
Operates with any phase sequence, or programmable rotation trip ABC / ACB / Off
Transient Protection
RC snubber dv/dt networks on each phase
Cooling
Fan assisted convection
Bypass Contactor
Standard on all NEMA 12 enclosed units
Units 160A and less: Standard on all open panel units (-BP versions)
Units 210A and over:
Optional on open panel units (-BP versions)
Bypass Contactor Rating
Shunt rated or can be sized for Line start rated contactor (see charts)
Bypass Contactor Control
Integral control is included, but contactor can be externally controlled as well.
Open panel mount units: 0° to 50 °C (32° to 122°F)
Ambient Condition Design
Factory enclosed units: 0° to 40°C (32° to 104°F)
5 - 95% relative humidity
0 - 3300 ft. (1000m) above sea level without derating
Control Power
120VAC (customer supplied), 240VAC optional
Inputs
Programmable Outputs
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.
Output Relay Contact Rating 5 Amps, 240VAC max. (1200VA)
Dedicated Fault Output
Approvals
AC Triac solid state switch
240VAC/DC, 50mA max.
UL Listed, Canadian UL (cUL) Listed, CE Approved
3
TE Series Digital Solid State Soft Starters 18 – 1250A
Model
Number
TE-18-BP
TE-28-BP
TE-39-BP
TE-48-BP
TE-62-BP
TE-78-BP
TE-92-BP
TE-112-BP
TE-150-BP
TE-160-BP
TE-210-BP or -P
TE-275-BP or -P
TE-360-BP or -P
TE-450-BP or -P
TE-550-BP or -P
TE-718-BP or -P
75 - 150
80 - 160
105 - 210
138 - 275
180 - 360
225 - 450
275 - 550
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
9 - 18
14 - 28
19 - 39
24 - 48
36 - 62
39 - 78
46 - 92
56 - 112
Current
Range
Min. - Max.
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 above 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 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.
4
TE Series Digital Solid State Soft Starters 18 – 1250A
Chapter 2 - Installation
2.1 Receiving and Unpacking
Upon receipt of the product, you should immediately do the following:
Carefully unpack the unit from the shipping carton and inspect it for shipping damage (if damaged, notify the freight carrier and file a claim within 15 days of receipt).
Verify that the model number on the unit matches your purchase order.
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 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 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 connections 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.
5
TE Series
WARNING
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 running parallel to the mounting surface. Keep in mind that these are minimums. Wiring may require more clearance, particularly on the bottom.
4" minimum ( 100 mm )
1" minimum (25 mm)
1" minimum (25 mm)
TE Series
Starter
4" minimum ( 100 mm )
Figure 2.5: TE minimum mounting clearances
6
TE Series Digital Solid State Soft Starters 18 – 1250A
TE- 18 ~
TE- 48
WARNING
Load
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 used.
NOTE: All wiring must be sized according to local code standards.
TE - 62 ~
TE - 112
Line
Line
R/ L1 S/L2 T /L3
1.50"
(38.07 mm)
0.45"
(11.42 mm)
Load
V/ T2
U/ T1 W / T3/
1.10"
(27.92 mm)
∅ 0.19"
(4.82 mm)
Figure 2.6.1 Critical clearances for bus tab connections
Line
1.82"
(46.19
0.60"
(15.23 mm)
Load
1.73"
(43.91
∅ 0.38"
(9.64 mm)
1.23"
(31.22 mm)
R/L
S/L2
Line
T/L3
U T
V T
W/ T
Load
1.13"
(28.68
Figure 2.6.2 Critical clearances for bus tab connections
7
TE Series Digital Solid State Soft Starters 18 – 1250A
2.6 Power Connections (cont.)
TE-150
TE-160
Line Load
∅
(9.64 mm)
1.52"
(38.58 mm)
1.54"
(39.09 mm)
2.81"
(71.32 mm)
0.60
(15.23 mm)
0.14"
(3.55 mm)
T/L3
R/L1
U/T1
W/T3
S/L2
V/T2
Line Load
Figure 2.6.3 Critical clearances for bus tab connections
NOTE: Consult factory for bus tab critical dimensions for units
210A and above
8
TE Series Digital Solid State Soft Starters 18 – 1250A
Connection points for units of 160A and below are saddle clamps suitable for stranded wire. Connection points for units of 210A and above are bus tabs with pre-drilled holes (see below). Use appropriate compression or mechanical lugs for termination to these bus tabs.
Suggested wire sizes and tightening torques for factory-supplied connectors when using conductors rated for 75
°C are shown in the chart below. Always consult local codes and industry standard practices for proper wires sizes to accommodate voltage drop and ambient conditions.
Model
Number
TE-18-BP
TE-28-BP
TE-39-BP
TE-48-BP
TE-62-BP
TE-78-BP
TE-92-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
Current
Range
Min.- Max.
9 - 18
14 - 28
19 - 39
24 - 48
Suggested
Wire Size
AWG
12
10
8
6
Tightening
Torque in.-lbs.
35
Screw / Bolt
Size
1 x M5
(included)
Tightening
Torque
Nm
4
Suggested
Wire Size
ISOmm
2
6
10
16
16
36 - 62
39 - 78
46 - 92
56 - 112
4
3
2
2
45
1 x M8
(included)
5
25
35
35
50
75 - 150
80 - 160
0
2/0
80
1 x M8
(included)
9
70
70
105 - 210
138 - 276
180 - 360
225 - 450
4/0
300 kCMIL
500 kCMIL
2 x 250 kCMIL
200
1 x 0.38" hole
(M10) for User supplied
lugs
15
120
150
300
2 x 150
275 - 550 2 x 250 kCMIL
356 – 718
2 x 150
CF CF CF CF CF
450 – 900
50 - 1000
CF CF CF CF CF
CF CF CF CF CF
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
~ ~
~
Figure 2.7
Remote Keypad Mounting Kit
Components
Ribbon Cable,
1, 2 or 3 meters
TE Starter
9
TE Series Digital Solid State Soft Starters 18 – 1250A
Enclosure
Panel (open) with integral bypass contactor
2.8
Dimensions (consult price catalog for enclosed units)
Overall Mounting
Model Number
A B C D E
TE -18-BP thru
TE -48-BP
TE -62-BP thru
TE -112-BP
TE -150-BP and
TE -160-BP
8.75
14.00
19.21
7.95
8.00
8.00
6.66
6.68
6.68
7.56
12.75
18.25
7.00
6.75
6.75
TE -210-BP thru
TE -450-BP
TE-550-BP thru
TE-600-PB
TE-862-BP thru
TE-900-BP
TE-1006-BP thru
TE-1250-BP
28.5
28.50
43.13
46.56
12.5
12.5
25.5
28.2
9.1
9.10
11.86
13.00
Table 2.8: TE Dimensions (subject to change)
27.38
27.38
43.00
42.75
10.75
10.75
23.00
23.25
F
0.22
0.28
0.38
0.40
0.40
0.50
F dia.
A
~ ~
~
D
E
B
Figure 2.8: TE Dimensions
C
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!
Examples:
H 100
100% Thermal Capacity remaining at rest
H 057
57% Thermal Capacity remaining after starting
(43% used)
3.1 Solid State Overload Protection
The TE Series Starter provides true U.L. listed I
2 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 bimetallic 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 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 remaining (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).
11
TE Series Digital Solid State Soft Starters 18 – 1250A
3.1.3 Disabling the Overload Protection
The Overload Protection feature can be disabled if necessary. When using external devices such as Motor Protection Relays or when the TE
Series is wired downstream from an existing starter, this feature can be disabled to prevent conflicts with external overload protection devices.
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.
WARNING
Do NOT disable Overload Protection unless another Thermal Overload Protection
device exists in the circuit for all 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.
WARNING
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 equipment) as required by local code.
WARNING: MOTOR CONNECTED TO THIS EQUIPMENT
MAY START AUTOMATICALLY WITHOUT WARNING
12
TE Series Digital Solid State Soft Starters 18 – 1250A
3.1.3.c
Overload Protection During Bypass
When an integral Bypass Contactor is used to shunt power around the SCRs in the TE Series (as in the TE…-BP version), overload protection is maintained as long as the TE Series is directly controlling the contactor. No additional Overload Relay is
necessary for normal operation.
CAUTION
If a Bypass Contactor is added by the user in the field (i.e. 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 amount 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 starter’s 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.
13
TE Series Digital Solid State Soft Starters 18 – 1250A
3.2.3 Running Overload Curve
During the Run mode, Overload trip curves are selectable from NEMA
Class 5, 10, 15, 20, 25, and 30. Program the appropriate curve according to the characteristics of your motor and load.
3.2.4 Overload Trip Curve Chart
Figure 3.2.4: TE Series Overload Trip Curves
14
TE Series Digital Solid State Soft Starters 18 – 1250A
Chapter 4 – Connections
Disconnect or
Circuit
Breaker
R /
L1
S /
L2
T /
L3
TE Starter
.
Solid State .
Over Load .
4.1 Power Connections
Connect appropriately sized power conductors to the unit input terminals marked L1, L2, L3 (R, S, T for IEC users). Connection points for units of 160A and below are saddle clamps suitable for stranded wire. Connection points for units of 210A and above are bus tabs with pre-drilled holes (see section 2). 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 unit terminals marked T1, T2, T3 (U, V, W for IEC users). Refer to local code standards for wire sizing and length.
If control power is present, but line power is disconnected from L1, L2,
L3, the display will show [n3PH] indicating “no 3 Phase”.
U /
T1
V /
T2
MTR
W
T3
/
Integral
Bypass
Contactor*
Figure 4.1:
TE Power Connections
*Larger units (210A and above) can be ordered with fan cooling instead of
Bypass Contactors, but are intended for use in NEMA 1 ventilated enclosures only. Do not use the TE starter in a sealed enclosure without a bypass contactor.
G
CAUTION
Never interchange input and output connections to the unit. This could cause excessive voltage in the control logic circuit and may damage the unit.
4.1.1 Bypass Contactor
Bypass Contactors are integral (built-in) on all TE…-BP (panel mount), and all TE…–E (NEMA 12 enclosed) versions. See sections 3.2.1.c and
4.2.5 for more details on contactor control and overload protection details.
4.1.2 Power Factor Correction Capacitors
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.
WARNING
Never connect power factor correction capacitors on the load side of the unit. The SCRs will be seriously 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 be 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.
15
TE Series Digital Solid State Soft Starters 18 – 1250A
4.1.4 Testing
The TE Series can be tested with a load smaller than the motor it was originally selected to control, however additional steps must be taken to avoid tripping on Phase Current Loss. See section 5.6.9.a under “Phase
Loss Protection” for additional details on performing this task.
NOTE:
The unit cannot be tested without a motor or other test load connected to the load side of the unit. 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.
Fault code SSd may display if there is no output load connection when control power is applied!
TB1: 12 terminals, #1-12
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
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).
TB2: 10 Terminals, #13-22
N C
RAMP2
JOG PTC OPTO
1
NC NO .
C
2
NC NO .
C
3
NO .
C
1
A1 A2
1 2 3 ............................................... 11 12 13 14 ...........................19 20
24VDC from internal supply
240VAC max. from customer source
= Factory installed jumpers
Opto-Isolated Triac Switch
10-250VAC/DC 50mA max.
120VAC Control Power
(or 240VAC if ordered)
16
TE Series Digital Solid State Soft Starters 18 – 1250A
Figure 4.2: Control Terminal Blocks
4.2.1 AC Control Power Supply Connection
1
NC NO .
C
2
NC NO .
C
3
NO .
C
1
A1 A2
Figure 4.2.1
Control Pow er Supply Connection
TB-2
120VAC
Supply
TE …-BP
Model
TE-18 to 48
TE-62 to 112
TE-150 to 160
TE- 210 to 276*
TE-360 to 450*
Separate AC Control Power supply is required to power the electronics of the TE Series starter. 120VAC is standard, order 240 VAC (optional) if necessary for your line power supply configuration. The control voltage must be connected to terminals marked A1 and A2 of TB-2 as shown in figure 4.2.1 (these are also Terminal #s 21 and 22). This control voltage must be customer supplied, unless an optional control power transformer (see table below) has been supplied with the unit.
AC Control Power VA Requirements
PC
Boards
Fans
-BP: Bypass
Contactor
Inrush
-BP: Bypass
Contactor
Sealed
Recommended minimum
CPT
Rating
48
48
(inc. in PCB)
(inc. in PCB)
95
220
9
17
48 72 298 12.3 500
48 100 380 11.6 500
48 150 571 14
100
250
750
TE-550 to 900*
TE-1006 to 1250*
48 200 600 3.3
48 200 1900 48
750
2000
Table 3: TE Series 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 TB1. This opto-isolated Triac switch is rated for
50mA max., 10-250V AC/DC. Any circuit connected to it must be fused accordingly.
17
TE Series Digital Solid State Soft Starters 18 – 1250A
1 2 3
Connect 3 wire control here as shown
1 2 3
Connect 2 wire control / PLC output here
N C
N C
RAMP2
JOG
RAMP2 JOG
PTC
Figure 4.2.2
3 Wire Control Connection
TB-1
PTC
Figure 4.2.3
2 Wire Control Connection
TB-1
OPTO
OPTO
4.2.2 Three-Wire Control Connection
For standard 3-wire control, connect dry (voltage free) contacts of the
Stop / Start buttons as shown on the diagram directly above the terminal strip. 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 nd
(2 from left) and the NC from the Stop button to Terminal #3 (3 rd
from 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
An alternate connection for automated or unattended operation replaces 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.
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.
4.2.3.a
Automatic Functions and 2 Wire Control
If using the Time Clock functions (F032-F039) or Auto Reset 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.
N C
RAMP2 JOG PTC
4 5
Remove factory jumper and connect external interlock device here
Figure 4.2.
External Interlock Connection
TB-1
OPTO
CAUTION
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
TB1 provides a connection point for an external dry (voltage free) N.C.
(Normally Closed) interlock device between terminals 4 and 5.
Examples where this interlock connection would be used include low oil, high temperature, or excess vibration dropout from user supplied devices. A factory-installed jumper is provided which allows the TE
Series unit to operate if external interlocks are not used. If this jumper is removed and an interlock is not used, the TE Series unit will not function.
18
TE Series Digital Solid State Soft Starters 18 – 1250A
N C RAMP2
JOG
6 7 8
RAMP 1 RAM P 2
Figure 4.2.5.a:
Dual Ramp Connections
TB-1
N C RAMP2
JOG
6 7 8
Figure 4.2.5.b:
Jog Connections
TB-1
N C RAMP2
JOG
PTC
PTC
RUN JOG
PTC
6 7 8
RAM P 2
RUN JOG
OPTO
OPTO
OPTO
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.
The Dual Ramp feature is useful in instances where the load 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 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.
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
TB-1
19
TE Series Digital Solid State Soft Starters 18 – 1250A
N C RAMP2
JOG
Figure 4.2.6:
PTC Resistor Connection
TB-1
PTC
9 10
**
PTC Resistor in Motor
+
OPTO
** Remove factory jumper
from Te rminals 9 and 10
4.2.6 PTC Thermistor Input
The TE Series starter is provided with input terminals for connecting a
PTC (Positive Temperature Coefficient) Thermistor that may be imbedded in the motor. 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 initiates a PTC trip, and displays it on the readout as
[ PTc ]. This is independent of the Thermal Register overload current protection and provides supplemental protection for high motor ambient temperature applications. Terminals for this input are provided with a factory jumper that must be removed if the PTC input is used. These terminals are located on TB1, Terminals 9 and 10.
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
Ω at 25ºC. If multiple resistors are used in the motor, the sum of all resistors in series must equal or exceed this value.
N C
RAMP2 JOG
Optional
Emergency Stop PB
PTC
9 10
**
External OL Relays
OLR 1 OLR 2
OPTO
Figure 4.2.6.a:
External Overload Relay(s) and/or E-Stop PB Connection
TB-1
** Remove factory jumper
from Terminals 9 and 10
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 multiple OLRs are used, i.e. multiple motors controlled by the same
TE Series starter, simply wire the Aux Contacts in series as shown in Figure 4.2.6.a. See Appendix 5 for additional information.
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 Digital Solid State Soft Starters 18 – 1250A
Control Power or PLC Source
Figure 4.2.7:
Fault Output Opto-Triac Connection
TB-1
Internal Connections
K3
RAMP2 JOG
1
NC NO .
C
2
NC NO .
C
PTC
K5
3
NO .
C
1
A1 A2
13 14 15 16 17 18 19 20
AUX.
RELAY #1
N C
K4
AUX.
RELAY #2
AUX.
RELAY #3
Figure 4.2.8
Auxiliary Relay Connections
TB-2
OPTO
11 12
R
Exte rnal Fault Relay or PLC Input
4.2.7 Fault Signal
An optically isolated Triac output is dedicated as a fault indicator on
TB1, terminals 11 and 12, labeled “Opto”. The output Triac switch is rated for 10 - 250 VAC/DC, 50 mA (maximum). 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.a 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).
AUX 2 – 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) This 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
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!
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.
Reset
Fn
Keys
Up and
Down
Arrows
Right and Left
Arrows
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 decreases the value of the active (flashing) digit and scrolls through the fault history. When entering values, 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 the right or left by one position, allowing you to change higher values of functions without waiting to Auto-step though large numbers.
Power
On
Control power is available at A1 and A2
Green
LEDs
At
Speed
Yellow
LEDs
Display
Shunt
Trip
Shorted
SCR
Over
Current
Phase
Loss
Over
Temp
Over
Load
8888.
The motor is at full power and the Bypass Contactor has been commanded to pull in.
The SCRs are at full conduction and current has dropped.
Two or more SCRs in opposing phases have shorted, and power is flowing to the motor in the Off mode. See section 8 for additional concerns.
There is no voltage drop across at least one 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.
2) During Run, current exceeded either the OC setting in F042 for the delay set in F043. This LED will be accompanied by oCA, oCC or oCd on the display.
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.
One or more of the phase currents dropped below the threshold during starting or running.
Starter has tripped due to excess heat sink temperature. This will automatically reset.
Starter has tripped due to the Thermal Register reaching 0000. The Overload must reset before this fault can be cleared.
4 digit 7 segment display with a decimal point on the right side indicating Phase A.
Table 5.2: TE Series Display Features
23
TE Series Digital Solid State Soft Starters 18 – 1250A
5.3 Display Modes
There are three modes of display: the Status Display Mode, the
Program Mode, and the Fault Mode.
5.3.1 Status Display Mode (Default Display)
The Status Display Mode displays seven “screens” of information. Motor
Currents (3 phases), Remaining Thermal Capacity, Ground Current,
Remaining Time on the Process Timer, and Time Base of the Time
Clock Controller. This is also the entry screen for going into the Program
Mode.
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.
[G000] 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. H070 = 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 digits 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. If flashing, the timer is active.
Press
Key...
Display
Shows...
0120.
0121
0120
G002
H083
0060
M e ans...
Phase A
Current
Phase B
Current
Phase C
Current
Ground Fault
Current
Remaining
The rmal Capacity
Proce ss Timer
Re maining Time
Press the UP arrow
[13.30] Indicates the time base of the Time Clock
Controller is 1:30 PM (24hr time). If flashing, the
time clock is active and pending the next event.
Press the UP arrow
[0120.] Loop back to Phase A current indication
13.. 30
0120.
Time Clock
Time Base
Loop Back to
Phase A Curre nt
Figure 5.3.1: Reading the Status Display
24
TE Series Digital Solid State Soft Starters 18 – 1250A
5.4 Program Mode
The starter must be OFF in order to enter the Program Mode.
Use the Program Mode to view or change Function (Fn) settings. To enter the Program Mode, press the [Fn] key once from the Status
Screen described in 5.3.1 above. The first time you enter the Program
Mode after power has been cycled to the starter, the initial function
[F001] should display with the selected digit flashing. 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:
Motor FLA Setting
[0000.] Indicates that Phase A is drawing no current
(unit is in Off mode).
Press the Fn key
[F001] Indicates that this is Function 001 (Motor FLA).
Press Read / Enter key to view the F001’s value
[0306] Indicates that the programmed motor FLA is
360 Amps.
Press the Fn key to return to the function
[F001] Indicates that you have returned to the Function
Select screen.
Press the Fn key again to return to the Status Display Mode
[0000.] Default screen.
Press
Key...
Fn
READ
ENTER
Fn
Fn
Display
Shows...
0000.
F001
0360
F001
0000.
M eans...
Default Display:
Phase A Current
Selecting
Function #1
Fn 1 Value:
FLA = 360A
Return to Function
# Selection
Return to
Default Display
Without Change
Figure 5.4.1:
View ing 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 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: Figure 5.4.3
Viewing a Function’s Set Value
[0000.] Indicates Phase A is drawing no current
(unit is in Off mode).
Press the [Fn] key
[F001] Indicates this is Function 001 (Motor FLA).
Press [READ/ENTER] key to view the F001 value
[0048] 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
[0049] Indicates you have increased the left digit to a value of 9.
Press the LEFT Arrow key to shift left to the next digit
[0049] The second digit from the left is now flashing, indicating a new cursor position.
Press the UP Arrow key to increase this digit value
[0059] Indicates you have increased the 2 nd
to left digit to a value of 5 (10’s place).
Press [READ/ENTER] key to store the new value
[End]
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.
Example 1: Setting the Motor FLA
Change FLA from 48 to 59A
Press
Key...
Fn
READ
ENTER
READ
ENTER
Display
Shows...
0000.
F001
0048
0049
0049
0059
End
F001
M e ans...
Phase A
Current
Function #1
Se le cte d
Pre v ious Setting of Function #1
New Value of
First Digit
Cursor (flashing)
Position Shift
Ne w Value of
Se cond Digit
Value Acce pte d
(flashe s once)
Re turn to
Function # Display
Figure 5.4.3:
Changing a Function Value
26
TE Series Digital Solid State Soft Starters 18 – 1250A
5.4.3.a
Changing a Value by Increments
Although it may be easier to shift the cursor position, it is also possible to increase or decrease values by pressing the UP or
DOWN arrow keys successively. This will change the Function value by the incremental amount associated with that Function. The
Function List shows increment values for each Function.
Example 2: Figure 5.4.3.a
Changing a Function’s Value by Increments
[0000.] Indicates that Phase A is drawing no current
(unit is in Off mode).
Press the [Fn] key
[F001] Indicates that this is Function 001 (Motor FLA).
The farthest left digit (1) is flashing, indicating this is the digit that you will alter (cursor position)
Press the UP Arrow key twice to increase this digit value to 3
[F003] Indicates that this is Function 003
(OL Class During Start).
Press [READ/ENTER] key to view the F003 value
[0010] Indicates that the programmed OL is Class 10 during the Start Mode. Cursor flashing on leftmost digit.
Example 2: Setting the OL Curve
During Start
Change from Class 10 to Class 20
Press
Key...
Fn x2
Display
Shows...
0000.
F001
F003
M e ans...
Phase A
Current
Function #1
Displaye d
Ne w Value of
First Digit
READ
ENTER
0010
Pre v ious Setting of Function #3
Press the UP Arrow key to increase this digit value
[0015] Indicates that you have increased the Function value by the increment assigned to it, a value of 5 in this case.
Press the UP Arrow key again to increase this digit value
[0020] Indicates that you have again increased the
Function value by the increment assigned to it.
READ
ENTER
0015
0020
End
Value Increased by 1 Incre me nt
Value Incre ase d by 1 Incre me nt
Value Acce pte d
(flashe s once)
Press [READ/ENTER] key to store the new value
[End]
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.
F003
Re turn to
Function # Display
Figure 5.4.3.a:
Changing a Function Value by Increments
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.
CAUTION
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 history. Refer to
Section 7 for details. Fault codes are three-digits in length and are displayed in alpha characters. The first and second characters (reading left to right) are the initials for the applicable English-language fault name. 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
[ PLA.] Indicates that there was a Phase Loss during
Acceleration. The Decimal point on the right signifies that this is the current fault.
Press
Key...
Display
Shows...
M eans...
Fault Display:
PLa.......
on Acceleration
Press the UP Arrow key
[ iBc]
Displays the previous fault, a Phase Imbalance during Constant Speed (running)
Press the UP Arrow key
[ oLc] Displays the oldest fault, an Over Load trip during Constant speed (running).
Press [RESET] key
[rSt ]
Flashes once to indicate a successful Reset of the current fault. If it cannot be reset, the display will read [ inH ] for Inhibited.
RESET
Ibc oLc r st
0000.
Previous Fault:
Phase Imbalance
Oldest Fault:
Over Load at
Constant Speed
Reset Indication
(flashes once)
Return to
Default Display
[0000.] Returns to Default Display, indicating that the unit is ready to re-start.
Figure 5.4.5:
View ing 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. An additional Fault History complete with Time and Date stamps is also available for viewing at any time in F085 through F093.
Figure 5.4.5.b
Rem ote Reset Connection
TB-2
1
NC NO .
C
2
NC NO .
C
3
NO .
C
1
A1 A2
Control Pow er
Supply
Rem ote Reset
Once a fault condition has been corrected, pressing the Reset key will return the readout to the Status Display mode. To reset faults, press the [RESET] key on the keypad. Alternatively, most faults will reset upon removal and return of control power. Over Load trips will
NOT be reset in this way unless sufficient time has passed for the
Thermal Register to regain sufficient capacity for a successful restart (see section 3.1).
Because most trips can be reset by removing control power, remote reset can be accomplished this way. A NC remote contact (or pushbutton) 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.
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 noncritical faults and Over Load. For non-critical fault resets, see section 5.6.9 for program details of F052 and F053. For automatic
Over Load reset, see section 3.1 and 5.6.1 for programming details.
5.4.5.d
Lockout Functions
Lockout functions such as Minimum Time Between Starts and
Starts per Hour are not true fault conditions. 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
F071.
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
Fn # Group
F001
F002
F003
F004
5.5 The TE Function List
5.5.1 Motor FLA, Service Factor and Overload Protection
Functions
Function Description Adjustment / Display Range
Setting
Increments
Factory
Setting
Section
Motor Nameplate FLA
FLA must be programmed for starter to function.
Motor Nameplate
Service Factor
Overload Class During Start
Overload Class During Run
50-100% of Max Amp Rating.
Upper limit of range automatically adjusts downward as Service factor is increased.
1.00 - 1.30 SF
NEMA / UL Class 5 - 20
NEMA / UL Class 5 - 30
1 amp
0.05
5
5
0
1.0 SF
Class 10
Class 10
5.6.1 and
3.2
0 = Manual
1 = Auto
2 = Disabled Overload
1
0
(Manual)
F006
-
F009
Reserved for factory use
Table 5.5.1: Motor and Overload Function Group
Fn # Group
F010
F011
5.5.2 Starting Mode Functions
Function Description Adjustment / Display Range
Ramp Type Selection:
VR = Voltage Ramp
CR = Current PID Ramp
1 = Ramp 1, 2 = Ramp 2
Initial Torque (VR) of Ramp 1
Setting 1 = VR1 + VR2
Setting 2 = CR1 + CR2
Setting 3 = VR1 + CR2
Setting 4 = CR1 + VR2
0-100% Line Voltage
F012
F013
F014
Initial Torque (CR) of Ramp 1 0-600% Motor Current
Accel Ramp Time of Ramp 1
Max Current Limit of Ramp 1
1-120 seconds
200 - 600% Motor Current
Setting
Increments
Factory
Setting
Section
1
1
VR1+VR2
5.6.2 and
1% 60%
Append.
1% 200%
1
1 second
10 seconds
1% 350%
F015
F016
Initial Torque (VR) of Ramp 2 0-100% Line Voltage
Initial Torque (CR) of Ramp 2 0-600% Motor Current
1-120 seconds F017 Accel Ramp Time of Ramp 2
F018 Max Current Limit of Ramp 2
Table 5.5.2: Starting Mode Function Group
200 - 600% Motor Current
1% 60%
5.6.2,
1 second
10 seconds
1 and
4.2.5.b
1% 350%
30
TE Series Digital Solid State Soft Starters 18 – 1250A
5.5.3 Jog Mode Functions
Fn # Group
F019
Function Description
Voltage Jog
Adjustment / Display Range
5 – 100% Line Voltage
F020 Time of Voltage Jog
F021 Current Jog
Table 5.5.3: Jog Mode Function Group
Setting
Increments
Factory
Setting
1% 50%
1 – 20 Seconds 1 second
10 seconds
100 – 500% Motor Current 1%
5.5.4 Kick Start Mode Functions
Fn # Group
F022
Function Description
Kick Start Voltage
F023 Kick Start Time
Table 5.5.4: Kick Start Mode Function Group
Adjustment / Display Range
0 = Disabled, or
10 - 100% Line Voltage
0.1 - 2 Seconds
Setting
Increments
1%
0.1second
Factory
Setting
0
Disabled
0.8 seconds
Fn # Group
F024
5.5.5 Decel Mode Functions
Function Description Adjustment / Display Range
Deceleration Ramp
Pump Flex Control /
0 = Disabled (coast to stop)
1 = Enabled, except after OL trip
2 = Enabled, continued Decel even if there is an OL trip
F025
Begin Decel Level (BDL),
Immediate Drop Down Torque
0 - 100 % of Output Voltage
F026 Decel Shut Off Voltage 0 to (BDL minus 1)% Voltage
F027 Decel Ramp Time
Table 5.5.5: Pump Flex Decel Mode Function Group
1 – 60 Seconds
5.5.6 Restart Function
Fn # Group
F028
Function Description
Restart Delay Time
(Sequential Start Delay)
Adjustment / Display Range
0 = Disabled, or
1-999 seconds after a Power Loss
(Status can be read in F054)
F029
Reserved for Factory Use
Table 5.5.6: Restart Function Group
Setting
Increments
1
1%
1%
1 second
Setting
Increments
1 second
Factory
Setting
0
Disabled
60%
30%
10 seconds
Factory
Setting
0
Disabled
Section
5.6.3 and
4.2.5.b
Section
5.6.4
Section
5.6.5 and
Append.
2
Section
5.6.6
31
TE Series Digital Solid State Soft Starters 18 – 1250A
5.5.7 Process Timer Features
Fn # Group
F030
Function Description
Run Timer Selection
Adjustment / Display Range
0 = Disabled (No timer operation)
1 = Minimum (Batch) Run Timer
2 = Permissive Run Timer
F031
F032
F033
Run Timer Time for use in F030 above
24hr
Time Clock Controller (TCC)
Start Event Mode.
Chose “One Shot” or 1 to 7 “Start Events” from F033 – F039
Run time for this mode comes from F030 above.
Start Event #1 Start Time
1-9999 minutes after a Start
Command or Start Event from TCC
Start Event Cycle (SEC) Settings.
1 = Loop SEC every day
2 = Loop SEC every 2 nd
day
3 = Loop SEC every 3
4 = Loop SEC every 4 rd th
day
5 = Loop SEC every 5 th
day
6 = Loop SEC every 6 th
day
day
7 = Loop SEC one day per week
8 = Single 24hr SEC
(until programmed again)
0 = One Shot: Start Event comes from Start command only
00:00-23:59 (hh:mm) or OFF
Setting
Increments
1
1 1
1
1
Factory
Setting
0
Disabled
0
One Shot
OFF
Section
5.6.7 and
Append.
4
F034
F035
F036
Start Event #2 Start Time
Start Event #3 Start Time
Start Event #4 Start Time
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
1
1
1
OFF
OFF
OFF
F037
F038
F039
Start Event #5 Start Time
Start Event #6 Start Time
Start Event #7 Start Time
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
1
1
1
OFF
OFF
OFF
Table 5.5.7: Run Timer and Time Clock Controller Function Group
5.5.8 Current and Ground Fault Protection Features
Fn # Group
F040
F041
Function Description Adjustment / Display Range
Current Imbalance Trip
0 = Disabled, or
5 - 30% imbalance
Current Imbalance Trip Delay 1 - 20 seconds
Setting
Increments
1%
1 second
Factory
Setting
0
Disabled
2 seconds
F042 Over Current Trip
0 = Disabled, or
100 - 300% of motor FLA
1%
0
Disabled
1 second 1 second F043
F044
F045
Over Current Trip Delay
Under Current Trip
Under Current Trip Delay
Ground Fault Trip Delay
1 - 20 seconds
0 = Disabled, or
10 - 90% of motor FLA
1 - 60 seconds
0 = Disabled, or
5 - 90% of CT ratio from Fn 74
F047 1 - 60 seconds
Table 5.5.8: Current and Ground Protection Features Group
1%
1 second
1%
1 second
0
Disabled
2 seconds
0
Disabled
2 seconds
Section
5.6.8
32
TE Series Digital Solid State Soft Starters 18 – 1250A
5.5.9 Lockouts, Reset and Internal Protection Functions
Fn # Group
F048
F049
Function Description
Coast Down (Back Spin)
Lockout Timer
Maximum Starts per Hour
Adjustment / Display Range
0 = Disabled, or 1 - 60 minutes
0 = Disabled, or 1 – 10 starts
Setting
Increments
1 minute
1
Factory
Setting
0
Disabled
0
Disabled
F050
F051
Minimum Time Between
Starts
0 = Disabled, or 1 - 60 minutes
1 – 127
See“ F051 Definition Table”
1 minute
1
0
Disabled
127
Enable all
F052
F053
F054
F055
Internal Protection Settings
Auto Reset on Selected Faults
Auto Reset Attempts
Restart Delay Time Value
Readout (for F028)
Coast Down Timer Value for F048
Fault Preferences 1 – 12
See Table 5.6.8:
”Auto-Reset Selected Faults”
0 = Disabled, or 1-10 attempts
0-999 Minutes
1-3600 Seconds
1
1
1
1
4,
Phase
Loss only
1
0
0
F056
F057
F058
F059
Starts Per Hour Timer Value for F049
Starts Per Hour
For F049 for F050
Time Value Between Starts
Thermal Capacity to Start for F005
1-3600 Seconds
1-10 Starts
1-3600 Seconds
0-100 % Thermal Capacity
1
1
1
1
0
0
0
0
Section
5.6.9
5.6.9.a
5.6.9.b
5.6.9.c
Table 5.5.9: Lockouts, Reset and Internal Protection Group
Fn # Group
F060
F061
F062
F063
F064
5.5.10 Output Relay Programming Features
Function Description Adjustment / Display Range
Setting
Increments
Aux Relay 1 setting
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
Factory
Setting
Section
1 1
Aux Relay 2 setting
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
1 2
5.6.10
Aux Relay 3 setting
Aux. Relay Delay Timer
(for Operations 23-26)
Reserved for factory use
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
0 (Disabled), or 1-999 seconds
1 16
1 second
0
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
Fn # Group
F065
Function Description
Communications
Adjustment / Display Range
0 = Disabled
1 = Enabled (11Bit)
2 = Enabled (10Bit)
F066
F067
Baud Rate
Modbus Address
4.8, 9.6 and 19.2 KB
1 - 247
F068 Remote Starter Control
0 = Disabled
1 = Enabled w/ Start button
2 = Enabled w/o Start button
3 = Enabled via Jog-Remote Input
F069 Reserved for factory use
Table 5.5.11: Serial Communications Function Group
Fn # Group
F070
F071
F072
F073
5.5.12 System Settings
Function Description Adjustment / Display Range
Parameter Lock
Customer Password
System Clear / Reset
Reserved for Factory Use
Frame Rating
0 – 999
0 = Disabled
Any Other Numbers = Password
0 = Disabled
1 = Clear THR and Lockout Timers
2 = Reset to Factory Default Settings
18 - 550
40-1200
F075
F076
Year
Month
F077
F078
Day
Hour
F079 Minute
F080 Second
F082 –
F084
Reserved for factory use
Table 5.5.12: System Settings Function Group
2000 - 2047
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
-
Setting
Increments
Factory
Setting
0
(displays encrypted code)
Section
1 0
3 rates
1
1 0
Setting
Increments
1
1
1 year
1 Month
1 Day
1 Hour
1 Minute
1 Second
Factory
Setting
9.6 KB
1
By Model
(defaults to 48)
By Model to 40)
2000
1
1
0
0
0
5.6.11
Section
5.6.12 and
Append.
3
5.6.12
5.6.12.a
34
TE Series Digital Solid State Soft Starters 18 – 1250A
Fn # Group
F085
F086
5.5.13 Fault History and Run Time
Function Description Adjustment / Display Range
Fault History #1, Latest Fault
Based on F078-80
Time Stamp, Fault #1
0 = No fault history, or
Fault # 1 - 27: see Fault code list
00.00-23.59 (hh.mm)
[hh = 00-23; mm = 00-59]
F087
F088
F089
F090
F091
F092
F093
Date Stamp, Fault #1
Based on F076-77
Fault History #2, Previous
Fault
Time Stamp, Fault #2
Date Stamp, Fault #2
Fault History #3, Oldest Fault
Time Stamp, Fault #3
Date Stamp, Fault #3
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 – 12.31 (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]
F094 Run Time, Hours 000.0 – 999.9 hours
F095
F096
F097
Run Time,
1000 Hour Overflow
Run Cycle Counter
Run Cycle Counter
10K overflow
0000 – 9999 thousand hours
0000 – 9999 times
0000 – 9999 10 thousand times
Table 5.5.13: Fault History and Run Data Group
Setting
Increments
Factory
Setting
1 0
Section
00.01 00.00
00.01 01.01
1 0
00.01 00.00 5.6.13
00.01 01.01
1 0
00.01 00.00
00.01 01.01
0.1 hours 0
1 k-hour
1 times
0
0
10k times 0
5.6.13.
a
35
TE Series
MOTOR FLA (F001) must be programmed for unit to operate!
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.
Set the value of this function to the motor nameplate Full Load
Amps (FLA). Adjustments for service factor are not necessary 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 the 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 Digital Solid State Soft Starters 18 – 1250A
F004 = Overload Class During Run
Factory Setting = 10 (Class 10)
Range = 5 - 30 NEMA / UL Class
Set value according to the instructions provided by your motor / equipment manufacturer. This trip curve will not be enabled until the motor has reached full speed.
F005 = Overload Reset
Factory Setting = 0 (Manual)
Range = 0 – 2
Set value to determine starter behavior after an overload condition has cleared.
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.
WARNING
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 Overload 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 nd
ramp, the TE Series will ignore all settings in reference to Ramp 2.
Ramp 1
(Dual Ramp Input Open)
F010
Setting
Ramp Profile
1 Voltage
2 Current
3 Voltage
4 Current
Ramp 2
(Dual Ramp Input Closed)
Ramp Profile
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 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 & 6 (see section 4.2.5). If this input is left open, the TE
Series will respond only to Ramp 1 settings as listed above. Since ramp 2 is always used as an alternate to the default Ramp 1, different combinations of ramp profiles can be selected in F010.
Refer to Appendix 1 for additional information on ramp profiles.
F015 = 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.
F016 = 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.
F017 = 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.
F018 = 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 over load protection feature trips (F003).
NOTE:
Ramp 2 is often useful as a “bump start” or as a temporary Acrossthe-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.
Setting from
F010
Ramp 1 (Dual Ramp Input
Open)
Ramp &
Jog
Type
Initial
Torque from…
Jog
Torque from…
Ramp 2 (Dual Ramp Input
Closed)
Ramp &
Jog
Type
Initial
Torque from…
Jog
Torque from…
Table 5.6.3: Jog Settings
Jog
Command
M ax.
Jog
Time
Jog
Command
CAUTION
Although the Thermal Register tracks all motor current use, continuous usage of the Jog feature risks thermal motor damage or nuisance tripping.
Jog Voltage
Setting
Time
Jog Current
Setting
Voltage Ramp
New Start
Command
Figure 5.6.3.1:
Voltage Jog and Jog Time
Current Ramp
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
New Start
Command
Time
Figure 5.6.3.2:
Curre nt Jog
41
TE Series Digital Solid State Soft Starters 18 – 1250A
Kick Start
Voltage Setting
Kick
Time
Time
Start
Command
Kick Start
Voltage Setting
=
Ramp Initial
Voltage Setting
Normal Ramp
Figure 5.6.4:
Kick Start
Normal
Voltage Ramp
Kick
Time
Time
Figure 5.6.4.a:
Dwe ll Start Using Kick Start
used to check rotation, alignment, or slowly move a load into position. This is not time-limited but should be used cautiously.
5.6.4 Kick Start Mode
Kick Start applies a pulse of voltage to the motor producing a momentary “kick” of high torque to break the motor load free from high friction or frozen components. This pulse is limited to 2 seconds.
F022 = 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.
F023 = 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 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.
Stop Command
(Bypass Contactor Opens)
Full Speed
Time
WARNING
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.
F025: Begin Decel Level
(Immediate step down)
F026: Stop Level
(VMX Output Off)
F027: Decel Ramp Time
(Determines slope)
Figure 5.6.5:
Pump-Flex De cel 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 Digital Solid State Soft Starters 18 – 1250A
CAUTION
Decel is THE OPPOSITE of braking. Enabling the Decel feature will make the motor take
LONGER to stop than if it were simply turned off.
5.6.6 Restart Delay
The TE Series can be programmed to delay restarting upon restoration of line power after an outage. This allows multiple units to be programmed to restart at staggered times in an effort to avoid causing additional problems with the power supply system. 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 Digital Solid State Soft Starters 18 – 1250A
5.6.7 Process Timer Control Mode (F030 through F039):
The following special functions allow the TE Series starter to operate automatically from a Process Control Timer using an internal Real Time
Clock.
Only brief descriptions of the functions are provided here.
REFER TO APPENDIX 4 at the end of this manual for detailed
operations and instructions.
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 = Process Control Timer Selection
Factory Setting = 0 (Disabled)
Range = 0, 1, 2
This function enables a Process Control Timer, which may be used alone or in conjunction with the Time Clock Controller feature (F032-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.
F031 = 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 Digital Solid State Soft Starters 18 – 1250A
F032 = Real Time Clock Controller
Factory Setting = 0 (One Shot)
Range = 0 - 8 settings
This function is used to select the operating mode of the 24hr /
7 Day Time Clock Controller (TCC). F032 sets the number of days in which the TCC will repeat the Start Event Cycle of up to seven discrete Start Events selected in F033 through F039.
After each Start Event, the TE Series will run per the time value set in F030 above. 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).
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
RTCC above. Once started by this event, the TE will run the motor according to the selections entered into F030 and F031.
F034 = 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.
F035 = 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.
F036 = 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.
F037 = 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.
F038 = Event #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.
F039 = 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
F042: O. C.
Trip Setting
Over Current Trip
Running
Current
Time
F043: O.C.
Trip Delay
Figure 5.6.8.a:
Ov e r Curre nt Trip
Normal
Running
Current
Time
F044: U.C.
Trip Setting
Under Current
Trip
F045: U.C.
Trip Delay
Figure 5.6.8.b:
Unde r Curre nt Trip
Digital Solid State Soft Starters 18 – 1250A
5.6.8 Current and Ground Fault Protection Features
F040 – F050 set extended protection features that may be used in the
TE Series starter. Percentages shown are all based automatically upon the Motor FLA setting from F001 (except Ground Fault, F046). No additional calculations are necessary.
NOTE:
All of these features are disabled at the factory and must be
enabled via user programming as follows:
F040 = 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.
F041 = Current Imbalance Trip Delay
Factory Setting = 2 seconds
Range = 1 - 20 seconds
Provides a time delay to prevent nuisance trips from shortduration 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.
F042 = 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.
F043 = Over Current Trip Delay
Factory Setting = 1 second
Range = 1 - 20 seconds
Provides a time delay to prevent nuisance trips from shortduration transients. For example using default settings, if the output current of any phase exceeds F042 for more than 1 second, the starter will trip.
F044 = 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.
F045 = Under Current Trip Delay
Factory Setting = 2 seconds
Range = 1 - 60 seconds
Provides a time delay to prevent nuisance trips from shortduration 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 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).
WARNING
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 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 shortduration transients. Using default setting, if the Ground Fault current exceeds the level set in F046 for more than 2 seconds, the starter will trip.
CAUTION
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 Digital Solid State Soft Starters 18 – 1250A
5.6.9 Lockouts, Reset and Internal Protection Features
F048 – F050 provide lockout protection for motors and equipment that may have potentially damaging consequences from premature restart or with limited duty cycles. Time and count values for these lockouts can be viewed in F055 – F058. Time values are based on the Real Time
Clock and DONOT reset when power is lost or disconnected.
Emergency clearing of lockouts can be accomplished in F071.
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.
WARNING
When F048 through 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.
Figure 5.6.9:
Coast Down Lockout Timer
F048 = 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 (antiplugging timer).
F049 = 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 “Starting
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 nonstandard applications. Factory default settings are as follows:
Phase Rotation: Protection is ON, expected rotation sequence is set for A-B-C
Phase Current Loss (Running): Protection is ON, trips at <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 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 that 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 F060-63), wired to a Shunt Trip coil in an upstream circuit breaker or an in-line contactor. This is so that power flow to the motor windings can be interrupted to prevent damage. 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 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.
CAUTION
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
Bit
#
Fault
Display
Code
Protection
Function
Description
0 rtd
*
Phase
Rotation
Trip
Phase Rotation protection.
Phase rotation must match selection in Bit #2 below. Setting to Off (0) will make the TE insensitive for use behind a reversing contactor
Expected
2 = A-B-C Phase Rotation Sequence Only
0 = A-C-B Phase Rotation Sequence Only
Sequence
2
PLa or
PLc*
Phase
Current
Loss
Phase Current Loss, any phase current reading is less than 20% of unit max amp rating after 3 seconds from Start command.
At least one SCR has shorted; there is no voltage drop across the SCR phase assembly.
Shunt Trip of the main Circuit Breaker or Isolation
Contactor (if provided and wired to an Aux. relay in F060-F061)). 2 or more SCRs have shorted in opposing phases so current was flowing to the motor while the TE was in the Off state.
PTC Trip function. This can be disabled so that a jumper is not required across the PTC inputs.
6
PLd or n3Ph
Line Phase
Loss Trip
Protection against loss of input line voltage.
Disable when using an In-Line Isolation Contactor or any other system that normally removes line power from the starter. Resets automatically when line voltage returns.
7 --- Reserved Reserved for factory use
* = Operating Mode designation. See Fault Code List for description.
Table 5.6.9.a: Function 51 table of Hardware Protection Features
Default
Bit
Setting
1 (On)
1
(A-B-C
Rotation)
1 (On)
1 (On)
1 (On)
1 (On)
1 (On)
0 (Off)
Decimal
Value
1
2
4
8
16
32
64
128
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 now, 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 safety 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
Setting
Fault Condition Description
Display Readout
Reference
0
1
2
3
Auto Reset Disabled
Over Temperature Trip
Over Current (Shear Pin) Trip
Under Current Trip
---
OT
OC
UC
4
5
6
Phase Loss Trip
Current Unbalance Trip
Ground Fault Trip
Faults 1, 2 or 3 above
Faults 4, 5 or 6 above
Any Fault except 7
Any Fault except 6 & 7
PLa or PLc
UB
GF
SC
OT, OC or UC
PL, UB or GF
8
9
10
11
No SC
No GF and no SC
12 Any Fault above, 1 - 7
OT, OC, UC, PL, UB or GF
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)
Range = 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 = Restart Delay Time Readout
Factory Setting = Not Applicable
Range = 1 - 999 Seconds
Remaining time value readout of F028, the Auto-Restart Delay
Timer.
F055 = Coast Down (Backspin) Timer Value
Factory Setting = Not Applicable
Range = 1 - 3600 Seconds
Remaining time value readout of F048, the Coast Down
Lockout Timer.
F056 = 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.
F057 = Starts per Hour Counter Readout
Factory Setting = Not Applicable
Range = 1 - 10 Starts
Incremental counter value readout of F050, the Starts-per-Hour
Lockout.
F058 = 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.
F059 = Thermal Capacity to Start Readout
Factory Setting = 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.
F060 = Aux Relay 1: Form C (SPDT)
Factory Setting = 1 (Run / Stop)
Range = 1 - 26 (See list)
Use to program the desired operation for Relay # 1.
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 for 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
1
2
3
4
Relay Operation Description
Run / Stop (Changes on Start Command, resets on Stop)
At Speed / Stop
At Speed / End of Decel
Start / End of Decel
6 Phase Loss Trip
8
9
10
11
OL (Motor Thermal Overload) Trip
OT (Starter Thermal Over Temperature) Trip
Short Circuit Trip
Current Unbalance Trip
12
13
Over Current (Shear-Pin) Trip
Under Current Trip
14 Ground Trip
16
17
18
19
20
21
22
23
24
25
26
Any Trip (#5 - #15)
Any Trip, (#5-#15) flashing output*
Coast Down Time Lockout
Starts Per Hour Lockout
Time Between Starts Lockout
Any Lockout (#18-#20)
Run Timer (F030) Engaged
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 ½ second On and Off
Table 5.6.10: Output Relay Programming
F064 = Reserved
56
TE Series Digital Solid State Soft Starters 18 – 1250A
Special Note when using Serial Comm:
When F068 = 3, the function of the Jog /
Remote Input on TB-1 terminals 7 and 8 will change. Closing the Input will cause the
Comm. port control to function as per setting
1. Leaving the input open will cause the
Comm. port to function as per setting 0.
When F068 = 1, 2 or 3, the Jog function will cease to operate. Since Jogging is a local function, set F068 to 0 when using it.
N C
RAMP2 JOG
6 7 8
PTC
OPTO
Local Remote
Figure 5.6.11:
Local - Remote Control Connections to TB-1
Only when F068 = 3
5.6.11
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 = 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.
F066 = Baud Rate
Factory Setting = 9.6 KB
Range = 4.8 to 19.2 KB
Set value to either 4.8 KB, 9.6 KB or 19.2 KB and match the setting of the host device.
F067 = 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.
F068 = 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 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 Digital Solid State Soft Starters 18 – 1250A
F069= Reserved
5.6.12
System Settings
The following functions set operator interface controls and unit programming. Also contained here are the Clock settings used for history functions. Change the Clock settings if accurate time values are important.
F070 = Parameter Lock / User Password
Factory Setting = 0 (disabled)
Range = 0 – 999
Use only when necessary to prevent unauthorized access.
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 state.
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.
WARNING
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
– 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 rd would display [09.03]
Fault #1
(Latest Fault)
Fault #2
(Previous Fault)
Fault #3
(Oldest Fault)
Fault code:
(See Chapter 7)
Time Stamp
(HH.mm)
Date Stamp
(MM.DD)
F085 F088 F091
F086 F089 F092
F087 F090 F093
Table 5.6.13.a: Fault 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 = 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.
Examples:
Run Time
23,047 Hours
Overflow
Value
Basic
Value
F095 F094
0002 3047
F097 F096
Run Counts
18,702 Starts
0001 8702
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 #
F001
F002
F003
F004
F005
Function
Name
Motor Nameplate
FLA.
Motor Nameplate
Service Factor
Overload Class
During Start
Overload Class
During Run
Overload Reset
0
Factory
Setting
1.0 SF
Class 10
Class 10
0 (Manual)
1
Description / Factory Setting
FLA must be programmed for starter to function.
Change only if necessary AND motor is rated over 1.0SF
NEMA / UL Class 10
NEMA / UL Class 10
0 = Manual
Ramp 1 and Ramp 2 =
Voltage Ramp with Current Limit
F011
F013
F014
F015 –
F018
F019 –
F052
F053
Initial Torque
Ramp Time
Current Limit
Ramp 2 settings
Software protection and control features
Internal hardware protection features
60
10
350
---
---
60% Initial Voltage
10 Second Ramp (Ramp 1)
350% of programmed FLA
Inactive unless Ramp 2 Input is closed
Inactive unless selected
F054 –
F059
F060
F061
F062
F063
Timer and counter value readouts
Aux Relay #1
Aux Relay #2
Aux Relay #3
Aux Relay Delay
1
2
16
0
Run / Stop
At-Speed / Stop
Any Trip
No Delay
F065 –
F068
Communications ----
Not Used unless without optional
Comm Adaptor
F070
F071
Parameter Lock
Reset Function
0
0
User password disabled
Use to reset to default values
F073 –
F080
System settings and time clock
--- User choice to adjust clock
F085 –
F093
Fault History --- Read only
Table 6.1.2: Factory Presets
62
TE Series Digital Solid State Soft Starters 18 – 1250A
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 motor’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.
6.3 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 display 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 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
Fault Condition Description
No Full Load Amps entered into F001
Over Current during Acceleration
Over Current during Constant speed
Over Current during Deceleration
Phase Loss during Acceleration
Phase Loss during Constant speed
Phase Loss during Deceleration
Line Voltage Loss (no 3 phase prior to start)
Over Temperature during Acceleration
Over Temperature during Constant speed
Over Temperature during Deceleration
Over Load during Acceleration
Over Load during Constant speed
Over Load during Deceleration
Shorted SCR during Acceleration
Shorted SCR during Constant speed
Shorted SCR during Deceleration or Stop
Shunt Trip during Acceleration
Shunt Trip during Constant speed
Shunt Trip during Deceleration
Current Imbalance during Acceleration
Current Imbalance during Constant speed
Current Imbalance during Deceleration
Under Current during Acceleration
Under Current during Constant speed
Under Current during Deceleration
Short Circuit during Acceleration
Short Circuit during Constant speed
Short Circuit during Deceleration
Ground Fault during Acceleration
Ground Fault during Constant speed
Ground Fault during Deceleration
Bypass Discrepancy during Acceleration
Bypass Discrepancy during Constant speed
Bypass Discrepancy during Deceleration
PTC Trip during Acceleration
PTC Trip during Constant speed
PTC Trip during Deceleration
Rotation Trip during Acceleration
Rotation Trip during Constant speed
Rotation Trip during Deceleration
Table 7.1: Fault code List
Ucc
Ucd
ScA
Scc
Scd
GFA
GFc
SSd st st st
IBA
IBc
IBd
UcA
GFd
BPA
BPc
BPd
PtA
Ptc
Ptd rtA rtc rtd otc otd oLA oLc oLd
SSA
SSc nFLA ocA occ ocd
PLA
PLc
PLd n3Ph oTA
Fault Display
Code
Readout
Fault Number
Code used in
History,
F085, F088 and F091
LED
Indicator
30
31
32
33
26
27
28
29
21
22
23
24
25
17
18
19
20
12
13
14
15
16
8
9
10
11
4
5
6
6
7
1
2
3
Over
Current
Phase
Loss
Over
Temp
Over Load
Shorted
SCR or no load
Shunt Trip
---
---
Over
Current
---
---
34
35
36
Over Load
37
38 ---
39
65
TE Series Digital Solid State Soft Starters 18 – 1250A
Appendix 1 - Ramp Profile Details
The TE Series offers four different types of starting ramp profiles.
Simply select the one that best matches your motor / load requirements.
In addition, two separate ramps are available that can be selected via contact closure (see section 4.2.5.a), and each one can be set up for any ramp type as shown in the table below.
R a m p
T y p e
R a m p 1 S e t t t i n g s
I
I n i i t t i i a l l
T o r r q u e f f r o m
… f f
R r
T a o i m m m p e
…
C u r r e n t t
L i i m i t f f r o m
…
“Ramp Type
Selection” from F010
Ramp
Type
Ramp 2 Settings
Initial Ramp
Torque from…
Time from…
Current
Limit from…
1 Voltage
2 Current
3 Current
4 Voltage
Table APP 1.1: Ramp Selection Choices and Settings
Initial Torque
Time
Initial Torque
Time
Ramp Time
Full Speed
Figure APP 1.1:
Voltage Ramp w/o Current Limit
Ramp Time
Full Speed
Current
Limit Setting
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 maximize 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
Initial Torque
Current Limit
Ramp Time
Time
Figure APP 1.3:
Curre nt / Torque Ramp
At
Speed
Initial Torque
Current Limit
Time
Figure APP 1.4:
Curre nt Ste p Starting
At
Speed
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 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 to 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 (WK
2
) 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 determined 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 reached before the Ramp Time has expired.
In the 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%.
CAUTION
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-M ech. starter)
Pump On
Pump-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.
Pump Flow
Pump Off
Check Valve
Open
Back Flow
Check Valve
Slams
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.
Pump Off
Pump-Flex
®
Soft Stop
(using VMX Series starter)
Pump
Soft Stop
Pump Off
((( SHOCK WAVE )))
Check Valve
Closed
Neutralized Flow
Check Valve
Closes Slowly
NO SHOCK WAVE
Check Valve
Closed
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”. 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.
CAUTION
Decel is THE OPPOSITE of braking. Enabling the Decel feature will make the motor take LONGER to stop than if it were simply turned off.
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 Spe e d
F025: Begin Decel Level
(Immediate step down)
Check Valve
Closes
F026: Decel Shut Off
(VMX Output Off)
F027: Decel Ramp Time
Time
Figure APP2.2: Pump-Flex Decel Graph
= Motor Torque
= Pump Output
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.
WARNING
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 = Begin Decel Level (BDL)
Factory Setting = 60%
Range = 0 - 100% of line voltage
Use to drop voltage to a level where there is a noticeable effect on motor torque during Decel mode. Generally, systems with high head pressure need to start Decel near the top of the ramp
(85-95%). Low head systems can drop to lower settings (50-
60%). System conditions vary greatly by pump type, pipe size and system head. Some experimentation with settings may be necessary.
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, 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.
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). 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.
NOTE:
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. The 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.
CAUTION
DO NOT LOSE YOUR PASSWORD.
If the password has been lost or forgotten, contact Toshiba for assistance.
72
TE Series Digital Solid State Soft Starters 18 – 1250A
Example: Figure App 3
Enabling Password Protection / Parameter Lock
Starting from the Status Display Mode, no previous function number entered, no existing password...
Press the Fn key.
Displays F001 to indicate the beginning of the function list.
Press the LEFT arrow key
Selects the second digit (from the right). NOTE: do it in this 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 key
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] signifies that a password 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 key
Pre ss
Ke y...
Fn
READ
ENTER
READ
ENTER
Example: Setting a Password x 3 x 2
Using Password 123
Display
Shows...
0000.
F070
3552
0003
0003
0023
0023
0123
End
M e ans...
Phase A
Current
Se le ct
Function #70
Default Se tting of Function #70
New Value of
First Digit
Cursor (flashing)
Position Shift
Ne w Value of
Se cond Digit
Cursor (flashing)
Position Shift
Ne w Value of
Se cond Digit
Value Acce pte d
(flashe s once)
The display will flash [End] to confirm you have entered a password. Then it will return to displaying thee Function #.
Changing passwords:
F070
Re turn to
Function # Display
Figure App 3:
Entering a Passw ord
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].
2
73
TE Series Digital Solid State Soft Starters 18 – 1250A
Ramp 0mofile
Appendix 4: Process Control Timer Functions
F030 through F039; Overview of Process Timer Control and Time Clock Controller Features:
The following special functions allow your TE Series starter to operate automatically from an internal Process
Control Timer and Time Clock Controller (TCC) using a real time clock. The Process Control Timer (F030 and
F031) can be used independently or together with the TCC feature (F032-39). 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.
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 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 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.
NOTE:
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.b (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 Digital Solid State Soft Starters 18 – 1250A
Example: Figure App 4.1
Minimum Run (Batch) Timer
An irrigation pump needs to come on when called for by a soil moisture control system, and run for ½ hour. If during that ½ hour the well level drops and shuts the pump down, the pump needs to restart when the well recovers and finish the ½ hour pump time.
Set F030 to [0001] for Minimum Run Timer.
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)
Example: Process Timer for Well Pump
Pre ss
Ke y...
READ
ENTER
READ
ENTER
READ
ENTER
READ
ENTER x 3
Display
Shows...
F030
0000
0001
End
F031
0000
0030
End
F031
M eans...
Starting at
Function #30
Default Se tting of Function #30
Set F030 = 1
M inimum Run Time r
Value Accepte d
(flashes once)
Change to
F031
Default Se tting of Function #31
Change Se tting to 30 minute s
Value Accepte d
(flashes once)
Re turn to
Function # Display
Cycle Control Powe r to Acce pt Change s
Figure App 4.1:
Program m ing the Minim um Run Tim er Functions
NOTE on interaction with other functions:
When 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, 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 changes 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.
Example: Process Timer for Compressor
Pre ss
Ke y...
READ
ENTER
Display
Shows...
F030
0000
M eans...
Starting at
Function #30
De fault Se tting of Function #30 x 2
0002
Set F030 = 2
Permissiv e
Run Time r
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 allow 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.
READ
ENTER
READ
ENTER x 2
READ
ENTER x 6
End
F031
0000
0600
End
F031
Value Accepte d
(flashes once )
Change to
F031
Default Se tting of Function #31
Change Se tting to 600 minutes
Value Accepte d
(flashes once )
Re turn to
Function # Display
Cycle Control Power to Accept Change s
Figure App 4.2:
Program m ing Perm issive Run Tim er Functions
NOTE:
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 the new one.
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 counting 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 Digital Solid State Soft Starters 18 – 1250A
IMPORTANT NOTE: When F030 or F031 is changed in program mode, the timer
will not respond to the new settings until after control power has been cycled (off
and back on again).
F032 = Time Clock Controller (TCC)
Factory Setting = 0 (One Shot)
Range = 1 - 8 settings
This function is used to select the operating mode of the 24hr /
7 Day Time Clock Controller (TCC).
F032 = 0 operates the SEC in a “One-Shot” mode (factory default setting). 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 ignore 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 rd
day.
F032 = 4 operates the SEC every 4 th
F032 = 5 operates the SEC every 5 th
day.
F032 = 6 operates the SEC every 6 th
day.
day
F032 = 7 operates the SEC 1 day per week.
F032 = 8 operates the SEC for a single 24HR event, nonrepeating. 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 2wire 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 operation based on the Process
Timer settings in F030 above.
CAUTION
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 Digital Solid State Soft Starters 18 – 1250A
Fn#
Function
Type
Setting
0
Function Description / Range
Timer
Initiated
By…
Motor
Starts
When…
No Process Control Timer operation (default setting from factory)
Motor
Stops
When…
Timer
Reset
When…
F030
Process
Control
Timer
Mode
1
2
Minimum (Batch) Run Timer
(works the same with or without TCC control)
Permissive Run Timer, without TCC
(F032 =0, “One Shot”)
Permissive Run Timer, with TCC
(F032 = 2 thru 8)
Start command and/or
TCC
Start command
Start command
TCC Start
Event only
Start command
Time
Expires,
Trip, or
Stop
Command
Time
Expires +
Stop command only
Time
Expires
Next SEC only
F031
Process
Timer
Value
Run
Time
Value
Timer value setting used by F030
Range: 1 – 9999 minutes (166.65 hours)
--- ---
Per F030 setting
0 One-Shot, follows Start command only
Start command
Start command
Per F030 setting
Per F030 setting
F032
24 hr /
7 day
Time Clock
Controller
Chart APP 4.1
1
2
3
4
5
6
Loop the Start Even Cycle (SEC) daily
Loop the 24hr SEC every other day
Loop the 24hr SEC every 3 rd
day
Loop the 24hr SEC every 4
Loop the 24hr SEC every 5
Loop the 24hr SEC every 6 th th th
day
day
day
7
8
Loop the 24hr SEC one day per week
Single 24hr SEC, without repeating
(until programmed again)
Start time
Start time
Start time
Start time
Start time
Start time
Start time
24hr TCC Start Time for Event #1
24hr TCC Start Time for Event #2
24hr TCC Start Time for Event #3
24hr TCC Start Time for Event #4
24hr TCC Start Time for Event #5
24hr TCC Start Time for Event #6
24hr TCC Start Time for Event #7
Process Timer and TCC Operations Logic Chart
24hr Real
Time
Clock on day of program change
F032 =1-8
Per F030 setting
Per F030 setting
Continuous unless program is changed
Change of
Program
Continuous unless program is changed
NOTE:
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 Digital Solid State Soft Starters 18 – 1250A
Example: Figure App 4.3
Time Clock Controller with Minimum Run Timer
An irrigation pump fed from a well with a single float level control needs to come on every other day at 5:30 PM, and run for ½ hour.
If during that ½ hour the well level drops and shuts the pump down, the pump needs to restart when the well recovers and finish the ½ hour pump time.
Set F030 to [0001] for Minimum Run Timer.
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 nd
Day
This will begin the Start Even Cycle on the day of programming and every other day from then on.
Set 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].
Example: Process Timer and TCC for Irrigation Pump
Pre ss
Ke y...
READ
ENTER
READ
ENTER
READ
ENTER
READ
ENTER
READ
ENTER
READ
ENTER
READ
ENTER x 3 x 2
Display
Shows...
F030
0000
0001
End
F031
0000
0030
End
F032
0000
0002
End
F033
17..30
End
F033
M eans...
Starting at
Function #30
Default Se tting of Function #30
Se t F030 = 1
M in. Batch Timer
Value Acce pte d
(flashe s once)
Change to
F031
Default Se tting of Function #31
Change Se tting to 30 minute s
Value Acce pte d
(flashe s once)
Change to
F032
Default Se tting of Function #32
Se t to 2:
Ev e ry 2nd Day
Value Acce pte d
(flashe s once)
Change to
F033
Se t to 17.30
(5:30 PM military)
Value Acce pte d
(flashe s once)
Re turn to
Function # Display
Cycle Control Powe r to Acce pt Change s
Figure App 4.3: Program m ing Tim er Functions
NOTE:
If programming is entered AFTER the set time value, the TCC will 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).
81
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.
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 Series 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 connection 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
NOTE:
Use these terminals only when separate control of the Bypass Contactor is necessary
Bypass Control
Terminals
62 - 160A Units
Bypass Control
Terminals:
210 – 550A with or without integral bypass
83
TE Series Digital Solid State Soft Starters 18 – 1250A
Appendix 5 (cont.) External OL Relay Applications
Across-the-Line (Direct-on-Line) Bypass
A suggested control schematic is shown below for using the TE …-BP
Series rated for Across-the-Line Bypass with an External Overload:
AC CONTROL POWER
Start / Run
Command
Disconnect or
Circuit
Breaker
(2-wire or 3-wire)
CR
R /
L1
S /
L2
T /
L3
TE Starter
.
Over Load .
CR
Off
S S AT-L
97 98
External
OL
CR
U /
T1
V /
T2
MTR
W /
T3
Bypass
Contactor
"BP"
External
Over Load
G
1 2
TE-TB-1
(24VDC)
3
TE-
TB-4
B1 B2
AC
Control Power
Potential
A1 A2
TE-
TB-2
Internal Bypass
Pilot Relay
BP
Bypass
Contactor
Coil
TE...-BP Series
Internal Wiring
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 nd
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 coil 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.
CAUTION
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.
120VAC CONTROL POWER
A1 A2
VMX-TB-2
Disconnect or
Circuit
Breaker
External
OL 1
External
OL 2
R /
L1
S /
L2
T /
L3
TE Starter
.
Solid State
.
Over Load
.
Start / Run
Command
1 2
TE-TB-1
(24VDC)
3 9 10
TE-TB-1
(PTC Input)
TE...-BP Series
Control Wiring
U /
T1
V /
T2
W /
T3
Bypass
Contactor
"BP"
G
MTR
1
External
Over Load 1
85
MTR
2
External
Over Load 2
TE Series Digital Solid State Soft Starters 18 – 1250A
Appendix 5 (cont.) External OL Relay Applications
SPECIAL MOTOR APPLICATIONS
2S2W Motors
2 speed / 2 winding motor applications require a separate OLR sized for each set of windings. These would need to be external OLRs.
120VAC CONTROL POWER
A1 A2
VMX-TB-2
Disconnect or
Circuit
Breaker
2S2W Starter
(Logic not shown for clarity)
MS
MF
R /
L1
S /
L2
T /
L3
TE Starter
.
Solid State
.
Over Load
.
1
MF
MS
2
TE-TB1
(24VDC)
3
MF
6 7
TETB1
( Ramp 2 )
Slow
OL
Fast
OL
9
10
TE-TB1
(PTC Input)
Bypass
Contactor
"BP"
U /
T1
V /
T2
W /
T3 G
TE...-BP Series
Control Wiring
External 2-Speed 2-Winding (2S2W ) Starter
MS
Slow
Over Load
2S2W
MTR
MF
Fast
Over Load
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
F011
F012
F013
F014
F015
F016
F017
F018
F019
F020
F021
Appendix 6 - Soft Starter Settings Record
The following chart may be used to record the changes made to the factory settings.
Fn # Group Function Description Adjustment / Display Range
Setting
Increments
Factory
Setting
Setting Setting
F001
Motor Nameplate FLA
FLA must be programmed for starter to function.
50-100% of Max Amp Rating.
Upper limit of range automatically adjusts downward as Service factor is increased.
1 amp 0
F002
Motor Nameplate
Service Factor
1.00 - 1.30 SF 0.05 1.0 SF
F003 Overload Class During Start NEMA / UL Class 5 - 20 5 Class 10
F004 Overload Class During Run NEMA / UL Class 5 - 30
0 = Manual
1 = Auto
2 = Disabled Overload
5
1
Class 10
0
(Manual)
F006-9
Reserved for factory use
F010
F022
F023
Ramp Type Selection
VR = Voltage Ramp
CR = Current PID Ramp
1 = Ramp 1, 2 = Ramp 2
Setting 1 = VR1 + VR2
Setting 2 = CR1 + CR2
Setting 3 = VR1 + CR2
Setting 4 = CR1 + VR2
Initial Torque (VR) of Ramp 1 0-100% Line Voltage
Initial Torque (CR) of Ramp 1 0-600% Motor Current
Accel Ramp Time of Ramp 1
Max Current Limit of Ramp 2
1-120 seconds
200 - 600% Motor Current Max Current Limit of Ramp 1
Initial Torque (VR) of Ramp 2 0-100% Line Voltage
Initial Torque (CR) of Ramp 2 0-600% Motor Current
Accel Ramp Time of Ramp 2 1-120 seconds
200 - 600% Motor Current
Voltage Jog
Time of Voltage Jog
Current Jog
Kick Start Voltage
Kick Start Time
5 – 100% Line Voltage
1 – 20 Seconds
100 – 500% Motor
0 = Disabled, or
10 - 100% Line Voltage
0.1 - 2 Seconds
1
1
VR1+VR2
1% 60%
1% 200%
1 second
10 seconds
1% 350%
1% 60%
1% 200%
1 second
10 seconds
1% 350%
1%
1 second
50%
10 seconds
1%
0.1second
0
Disabled
0.8 sec
87
TE Series Digital Solid State Soft Starters 18 – 1250A
F033
F034
F035
F036
F037
F038
F039
Appendix 6 (cont.) Soft Starter Settings Record
Fn # Group
F024
F025
F026
F027
F028
F029
F030
F031
Function Description
Pump Flex Control /
Deceleration Ramp
0 = Disabled (coast to stop)
1 = Enabled, except after OL trip
2 = Enabled, continued Decel even if there is an OL trip
Begin Decel Level (BDL),
Immediate Drop Down Torque
0 - 100 % of Output Voltage
Decel Shut Off Voltage
Decel Ramp Time
Restart Delay Time
(Sequential Start Delay)
Reserved for Factory Use
Process Control Timer
Selection
Run Timer Time for use in F030 above
Adjustment / Display Range
0 to (BDL minus 1)% Voltage
1 – 60 Seconds
0 = Disabled, or
1-999 seconds after a Power Loss
(Status can be read in F054)
0 = Disabled (No timer operation)
1 = Minimum Batch Run Timer
2 = Permissive Run Timer
1-9999 minutes after a Start
Command or Start Event from TCC
Setting
Increments
1
Factory
Setting
0
Disabled
Setting Setting
1% 60%
1% 30%
1 second
10 seconds
1 second
0
Disabled
1
0
Disabled
1 1
F032
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 Cycle (SEC) Settings
0 = One Shot: Start Event comes from Start command only
1 = Loop SEC every day
2 = Loop SEC every 2 nd
day
3 = Loop SEC every 3 rd
4 = Loop SEC. every 4 th
day
day
5 = Loop SEC. every 5 th
6 = Loop SEC. every 6 th
day
day
7 = Loop SEC one day per week
8 = Single 24hr SEC
(until programmed again)
1
0
One Shot
Start Event #1 Start Time
Start Event #2 Start Time
Start Event #3 Start Time
Start Event #4 Start Time
Start Event #5 Start Time
Start Event #6 Start Time
Start Event #7 Start Time
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
00:00-23:59 (hh:mm) or OFF
1
1
1
1
1
1
1
OFF
OFF
OFF
OFF
OFF
OFF
OFF
88
TE Series Digital Solid State Soft Starters 18 – 1250A
Fn # Group
F040
F041
F042
F043
Function Description
Current Imbalance Trip
Adjustment / Display Range
0 = Disabled, or
5 - 30% imbalance
Current Imbalance Trip Delay 1 - 20 seconds
Over Current Trip
Over Current Trip Delay
0 = Disabled, or
100 - 300% of motor FLA
1 - 20 seconds
F044
F045
F047
Under Current Trip
Under Current Trip Delay
Ground Fault Trip Delay
0 = Disabled, or
10 - 90% of motor FLA
1 - 60 seconds
0 = Disabled, or
5 - 90% of CT ratio from Fn 74
1 - 60 seconds
F048
F049
F050
F051
F052
F053
Coast Down (Back Spin)
Lockout Timer
Maximum Starts per Hour
Minimum Time Between
Starts
Internal Protection Settings
Auto Reset on Selected Faults
0 = Disabled, or 1 - 60 minutes
0 = Disabled, or 1 – 10 starts
0 = Disabled, or 1 - 60 minutes
1 – 127
See 5.6.9.a
Fault Preferences 1 – 12
See 5.6.9.b Fault Reset Selection
Table
0 = Disabled, or 1-10 attempts
F054
F055
F056
F057
F058
F059
F060
Auto Reset Attempts
Restart Delay Time Value
Readout (for F028)
Coast Down Timer Value for F048
Starts Per Hour Timer Value for F049
Starts Per Hour
For F049
Time Value Between Starts for F050
Thermal Capacity to Start for F005
Aux Relay 1 setting
0-999 Minutes
1-3600 Seconds
1-3600 Seconds
1-10 Starts
1-3600 Seconds
F061
F062
F063
F064
Aux Relay 2 setting
Aux Relay 3 setting
Aux. Relay Delay Timer
(for Operations 22-26)
Reserved for factory use
0-100 % Thermal Capacity
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
Operation # 1 – 26: see
”Aux. Relay Settings Chart”
0 (Disabled), or 1-999 seconds
Setting
Increments
1%
1 second
1%
1 second
1%
1 second
1%
1 second
1 minute
1
1 minute
1
1
Factory
Setting
0
Disabled
2 seconds
0
Disabled
1 second
0
Disabled
2 seconds
0
Disabled
2 seconds
0
Disabled
0
Disabled
0
Disabled
127
Enable all
4:
Phase
Loss only
Setting Setting
1 1
1 0
1 0
1 0
1 0
1 0
1 0
1 1
1 2
1 16
1 second
0
No Delay
89
TE Series Digital Solid State Soft Starters 18 – 1250A
Appendix 6 (cont.) Soft Starter Settings Record
Fn # Group
F065
F066
F067
F068
F069
F070
F071
F072
F073
F075
F076
F077
F078
F079
F080
Function Description
Communications
Baud Rate
Modbus Address
Remote Starter Control
Reserved for factory use
Parameter Lock
Customer Password
System Clear / Reset
Reserved for Factory Use
Frame Rating
Year
Month
Day
Hour
Minute
Second
Adjustment / Display Range
0 = Disabled
1 = Enabled (11Bit)
2 = Enabled (10Bit)
4.8, 9.6 and 19.2 KB
1 - 247
0 = Disabled
1 = Enabled w/ Start button
2 = Enabled w/o Start button
3 = Enabled by Jog / Remote Input
0 – 999
0 = Disabled
Any Other Numbers = Password
0 = Disabled
1 = Clear THR and Lockout Timers
2 = Reset to Factory Default Settings
18 - 550
40-1200
2000 - 2047
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
Setting
Increments
Factory
Setting
Setting
1 0
Setting
3 rates
1
9.6 KB
1
1 0
1
0
(displays encrypted code)
1 0
1
1 year
1 Month
1 Day
1 Hour
1 Minute
1 Second
By Model
(defaults to 48)
By Model to 40)
2000
1
1
0
0
0
-
F082 –
F084
Reserved for factory use
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TE Series Digital Solid State Soft Starters 18 – 1250A
Appendix 6 (cont.) Soft Starter Settings Record
Fn # Group
F085
F086
F087
F088
F089
F090
F091
F092
F093
F094
F095
F096
F097
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
Time Stamp, Fault #2
Date Stamp, Fault #2
Fault History #3, Oldest Fault
Time Stamp, Fault #3
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 – 12.31 (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
Date Stamp, Fault #3
Run Time, Hours
Run Time,
1000 Hour Overflow
Run Cycle Counter
Run Cycle Counter
10K overflow
0000 – 9999 thousand hours
0000 – 9999 times
0000 – 9999 10 thousand times
Setting
Increments
Factory
Setting
1 0
Setting Setting
00.01 00.00
00.01 01.01
1 0
00.01 00.00
00.01 01.01
1 0
00.01 00.00
00.01 01.01
0.1 hours 0
1 k-hour 0
0 1 times
1 10k times
0
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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 WARRANTIES 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 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 shall 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
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Key features
- Programmable overload protection
- Voltage/current ramp for smooth acceleration
- Dual ramp settings for different starting conditions
- Deceleration control with optional coast to stop
- Process timer for automated applications
- Real-time clock for scheduling operations
- Integrated bypass contactor for across-the-line starting
- Multiple protection features including thermal model overload, phase loss, and ground fault
- Programmable keypad for easy configuration and diagnostics
- Remote mounting option for the keypad
