Document: VF010H05
INSTRUCTION MANUAL
__________________________________________________________________________
INSTALLATION - OPERATION - MAINTENANCE
jKSSS Plus Series
Medium Voltage Solid State Starters
Firmware Rev 6.96
Issued: 9/09
Manufactured in the USA
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SAFETy
IMPORTANT MESSAGES
Read this manual and follow its intructions. Signal words such as DANGER, WARNING
and CAUTION will be followed by important safety information that must be carefully reviewed.
Indicates a situation which will result in death, serious injury, and severe property damage if you
do not follow instructions.
DANGER
Means that you might be seriously injured or killed if you do not follow instructions. Severe
property damage might also occur.
CAUTION
Means that you might be injured if you do not follow instructions. Equipment damage might
also occur.
Give you helpful information.
NOTE
Note: The contents of this manual will not become apart 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.
DANGER
QUALIFIED OPERATORS ONLy
Only qualified persons are to install, operate, or service this equipment according to all applicable
codes and established safety practices.
A qualified person must:
1)
2)
Carefully read the entire instruction manual.
Be skilled in the installation, construction or operation of the equipment and aware of
the hazards involved.
3)
4)
5)
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, flash clothing, etc. in accordance with estab-
lished practices.
6)
Be trained in rendering first aid.
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SAFETy
SAFETy CODES
Toshiba motor control is designed and built in accordance with the latest applicable provisions of
NEMA and the National Electrical Code. Installations must comply with all applicable state and
local codes, adhere to all applicable National Electric Code (NFPA 70) standards and instructions
provided in this manual.
HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion and
property damage.
•
•
•
Turn off and lock out Primary and Control Circuit Power before servicing.
Keep all panels and covers securely in place.
Never Defeat, Modify, or Bypass any Safety Interlocks.
Qualified Operators only.
•
Never attempt to install, operate, maintain or dispose of this equipment until
you have first read and understood all of the relevant product warnings and
user directions that are contained in this Instruction Manual.
WARNING
Use only Toshiba-authorized replacement parts.
This equipment is designed and built in accordance with applicable safety
standards in effect on the date of manufacture. Unauthorized modifications
can result in voiding the warranty, severe injury, death and property
damage. Do not make any modifications to this equipment without
the written approval of Toshiba.
For assistance, address correspondence to:
Toshiba International Corporation
Field Service Department
13131 West Little York Road
Houston, Texas 77041 USA
or call:
(713) 466-0277
Fax:
(713) 466-8773
(800) 231-1412
(800) 527-1204 (Canada)
Please complete the following information for your records and retain with this manual:
Model: ___________________________________
Serial Number:
_____________________________
_________________________
Date of Installation:
Inspected by:
______________________________
_________________________
Reference Number:
© TOSHIBA INTERNATIONAL CORPORATION, 2009
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Chapter 1: Introduction ..................................................................................................... 1
JKSSS+ Series
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Overview
Medium Voltage Solid
State Soft Starters
2.3 - 4.2KV
Specifications
Design Features
Structure and Power Bus
Theory of Operation
General Protection
Thermal Overload Protection
Firing Circuit
Installation &
Operation Manual
Electronics
Chapter 2: Installation ..................................................................................................... 12
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Receiving and Unpacking
Initial Unit Inspection
Location
Dimensions
Mounting
Additional Equipment
Before Applying Power
Warnings
Medium Voltage Power Connections
2.10 Control Connections and JKSSS+-TCB
2.11 Reference Section
Chapter 3: Start-Up ........................................................................................................ 29
3.1
3.2
3.3
3.4
3.5
3.6
Preliminary Start-up Check List
Introduction
Acceleration Adjustments
Deceleration Adjustments
Sequence of Normal Operation
Emergency Bypass Operation
Chapter 4: Programming ................................................................................................ 33
4.1
4.2
Keypad/Operator Interface
Menu Navigation
Chapter 5: Setpoint and Programming........................................................................... 36
5 .1
5.2
Setpoints Page List
Setpoint Menu
SP.1 Basic Configuration.................................................................................................46
SP.2 Starter Configuration...............................................................................................47
SP.3 Phase & Ground Settings .......................................................................................50
SP.4 Relay Assignment ...................................................................................................53
SP.5 Relay Configuration ...............................................................................................55
SP.6 I/O Configuration....................................................................................................56
SP.7 Custom Acceleration Curve ...................................................................................59
SP.8 Overload Curve Configuration ...............................................................................62
SP.9 RTD Configuration .................................................................................................63
SP.10 Set Password........................................................................................................65
SP.11 Communications ...................................................................................................66
SP.12 System Setpoints..................................................................................................67
SP.13 Calibration & Service ............................................................................................69
Chapter 6: Metering Pages.............................................................................................. 70
6 .1
Metering Page List
Chapter 7: Maintenance and Troubleshooting/Disposal/Storage ............................... 80
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
Failure Analysis
Typical Block Diagram
Overload Curve Definition
Typical Wiring Diagram for TCB Board
Typical Internal Wiring Diagram
Spare Parts List
Instructions for Stack Replacement
Instructions for Low Voltage Test
Maintenance Program/Servicing Equipment/Disposal/Storage
Warranty and Limitations of Liability ............................................................................. 99
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Reference Chart
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JKSSS+ Series
2.3 - 4.2KV
Chapter 1 - Introduction
This chapter is an introduction to the Toshiba JKSSS+ Series reduced voltage solid
state starter for medium voltage AC motors. It describes the basic configuration,
operation and unit features. It is highly recommended that new users read this
section thoroughly to gain a basic understanding of the starter system before
attempting to start up a unit. If you are already familiar with the JKSSS+ Series
starter, you may begin setup procedures immediately by proceeding to Chapter 2 –
Installation.
1.1 Overview
The standard JKSSS+ Series solid state starter is a complete NEMA Class E-2
motor controller designed for the starting, protection and control of AC medium
voltage motors. It contains the motor disconnect switch, motor circuit fuses,
control power transformer, a line isolation contactor, SCR stack assemblies, a
bypass contactor, low voltage controls and motor terminal blocks in that order.
An optional “soft start only” version is also available which is supplied without
the control power transformer, the disconnect switch and line isolation contactor.
(The soft start only model must be used with a customer supplied, mechanically
interlocked line start panel).
1.2 Specifications
JKSSS+ Series - 1
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JKSSS+ Series
2.3 - 4.2KV
1.2 Specifications (continued)
Advanced Motor Protection
Two Stage Electronic
Overload Curves
Starting: Programmable for Class 5 through 30
Run: Programmable for Class 5 through 30 when "At-Speed" is detected.
Overload Reset
Manual (default) or automatic
Overload circuit retains thermal condition of the motor regardless of control
power status. Unit uses real time clock to adjust for off time.
Retentive Thermal Memory
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.
Dynamic Reset Capacity
Phase Current Imbalance
Protection
Imbalance Trip Level: 5 - 30% current between any two phases
Imbalance Trip Delay: 1 -20 seconds
Over Current Protection
(Electronic Shear Pin)
Trip Level: 100 - 300% of motor FLA
Trip Delay: 1 - 20 seconds
Under Current Trip Level: 10 -90 % of motor FLA
Under Current Trip Delay: 1 - 60 seconds
Load Loss Trip Protection
Coast Down (Back Spin)
Lockout Timer
Coast Down Time Range: 1 - 60 minutes
Range: 1 - 6 successful starts per hour
Time between starts: 1 - 60 minutes between start attempts
Starts-per-hour Lockout Timer
Programmable Outputs
Type / Rating
Form C (DPDT), Rated 5 amps 240 VAC max, (1200 VA)
Run Indication
At Speed Indication
Programmable
Programmable
Programmable Ramp Types: Voltage or Current Ramp (VR or CR)
Starting Torque: 0 - 100% of line voltage (VR) or 0 - 600% of motor FLA (CR)
Ramp Time: 1 to 120 seconds
Acceleration Adjustments
Dual Ramp Settings
Current Limit: 200 - 500% (VR or CR)
4 Options: VR1+VR2; VR1+CR2; CR1+CR2; CR1+VR2
Dual Ramp Control: Ramp 1 = Default
Ramp 2 = selectable via dry contact input
Begin Decel Level: 0 - 100% of line voltage
Stop Level: 0 to 1% less than Begin Decel Level
Decel Time: 1 - 60 seconds
Deceleration Adjustments
Jog Settings
Voltage Jog: 5 - 75%
Kick Voltage: 10 - 100%
Kick Time: 0.1 - 2 seconds
Kick Start Settings
Shorted SCR, Phase Loss, Shunt Trip, Phase Imbalance Trip, Overload,
Overtemp, Overcurrent, Short Circuit, Load Loss, Undervoltage or Any Trip
Fault Display
Lockout Display
Coast Down Time, Starts Per Hour, Time Between Starts, and Any Lockout
Event History
Data includes cause of event, time, date, voltage, power factor and current for
each phase and ground fault current at time of event
Up to 60 Events
JKSSS+ Series - 2
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JKSSS+ Series
2.3 - 4.2KV
1.2 Specifications (continued)
Metering Functions
Percent of FLA
A, B, C Phase Current, Avg Current, Ground Fault (Option)
Remaining thermal register; thermal capacity to start
Motor Load
Current Data
Thermal Data
Avg Start Time, Avg Start Current, Measured Capacity to start, time since last
start
Start Data
RTD Data (Option)
Voltage Metering
Temperature readings from up to 12 RTDs (6 stator RTDs)
kW, kVAR, PF, kWH
Serial Communications
Protocol
Signal
Modbus RTU
RS-485, RS-422 or RS232
Network
Functionality
Up to 247 devices per mode
Full operation, status view, and programming via communications port
Operator Interface
LCD Readout
Keypad
Status Indicators
Alpha numeric LCD display
8 function keys with tactile feedback
12 LEDs include Power, Run, Alarm, Trip, Aux Relays
Up to 1000 circuit-feet from chassis (use twisted, shielded wire & power
source)
Remote Mount Capability
Clock and Memory
Operating Memory
SRAM loaded from EEPROM at initialization
Flash EPROM, field replaceable
Non-volatile EEPROM, no battery backup necessary
Lithium ion battery for clock memory only
Factory Default Storage
Customer Settings and Status
Real Time Clock
JKSSS+ Series - 3
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JKSSS+ Series
2.3 - 4.2KV
1.3 Design Features
The standard JKSSS+ configuration is a complete NEMA Class E-2 motor
controller which includes the following features:
•
Isolation Switch:
An isolation switch is provided in the incoming power section of the starter
assembly. The maximum voltage is 7200V.
Power is switched on and off to the controller by a fixed-mounted, externally-
operated, three-pole isolation switch. When the switch is in the opened
position, incoming power is isolated from the controller compartment interior by
an automatic shutter. For additional safety, the load terminals of the switch are
automatically grounded when the switch is opened. This allows any stored
energy in the controller load circuit to be discharged by closing the contactor
using test power.
A viewing window in the Main Incoming Power Compartment allows visual
inspection of the disconnect blade status with the medium voltage door closed.
The external operating handle for the isolation switch is designed to accept up
to three external padlocks in the OFF position.
For additional information on the isolation switch, see instruction manual
VF010H01, VF010H02 or VF010H03.
•
Power Fuses: As a NEMA Class E2 controller, current limiting primary power
fuses are provided for each incoming phase.
Typically the fuses are ANSI class “R” for units rated up to 4800V. The fuses
are sized according to motor locked rotor current and are coordinated with the
solid state overload relay. The fuse and overload coordination is designed to
allow the controller and contactor to clear low and medium level faults. This
prevents exceeding the contactor interrupt ratings. Fuses interrupt high level
faults that exceed the contactor interrupt ratings. Fuse holders include blown
fuse indicators (wired to the isolation contactor circuit) to disconnect all three
phases if any one of the fuses clears (see section 2.7).
•
SCR Power Modules: For each phase, the SCRs are
matched devices arranged in inverse parallel pairs and in
series strings as indicated in the chart to facilitate sufficient
PIV ratings for the applied voltage.
•
•
RC Snubber Networks: Provide Transient Voltage Protec-
tion for SCR Power Modules in each phase to reduce dv/dt
damage.
Firing Circuit: The SCRs are gated (turned on) using a
Sustained Pulse Firing Circuit. This circuitry is amplified and
isolated from the control voltage by means of fiber optics for
current and ring transformers.
Unit PIV Ratings
JKSSS+ Series - 4
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JKSSS+ Series
2.3 - 4.2KV
•
Contactors: Vacuum contactors are provided for both In-Line Isolation and SCR
Bypass. The contactor voltage ratings are: 7.2kV for 2300 - 6900V units.
A sequencing feature controls the contactors. Under normal operating conditions
this ensures that both contactors make and break under no-load conditions to
maximize contactor life. Vacuum contactors are rated for the maximum starting
requirement of the unit design. The Bypass Contactor is rated to be capable
of emergency start. For further information on the vacuum contactor, see the
instruction manual on the vacuum contactor supplied with the equipment, and
also either VF010H01 (400A Drawout Type) or VF010H03 (Fixed Type).
•
Soft Start Only Option: The JKSSS+ Series is also offered in an optional “Soft
Start Only” package for use in retrofitting behind an existing customer supplied
line start controller. In this configuration, the Disconnect Switch, Fuses and
Line Isolation Vacuum Contactor are NOT included in the JKSSS+ unit, so
proper interlocking of sections containing medium voltage becomes the install-
er’s responsibility.
All retrofit “Soft Start Only” packages must be used with complete line isola-
tion using a contactor or other “air-gap” device. The Optional “Soft Start Only”
includes overload protection in normal operation mode and will sequence the
isolation contactor, so all logic control should be done at the JKSSS+ control
unit. Avoid turning the JKSSS+ on and off using the isolation device.
1.4 Structure and Power Bus
The JKSSS+ Series is a heavy duty design. Special consideration has been given
to the enclosure and unit design to ensure that it is suitable for most applications and
environments.
•
Structure: 11 gauge frame with 16 gauge side, back and top sheets. Doors are
12 gauge steel. The enclosure assembly is NEMA / EEMAC type 1 as standard.
Type 12 and 3R are available as an option.
•
Sections: In a typical arrangement, each enclosure is divided vertically into
three major compartments, each with a separate door. In the JK400, the upper-
most and lowermost compartments contain medium voltage controller compo-
nents (>600V) while the middle compartment contains low voltage components
(<600V). Other variations of this basic arrangement are possible.
The Main Incoming Power Compartment houses the main disconnect switch,
amain power fuses and input isolation contactor. A viewing window provides
clear indication of the switch position without opening the compartment. Main
Bus Compartment contains the horizontal bus bars (if provided). Top, bottom or
side cable entry can be made with minimum bending.
One or more Starter Power Compartments contain the bypass vacuum con-
tactors, SCR power modules, instrument transformers and all other medium
voltage devices. Adequate room is provided for motor lead connections to be
made with minimum conductor bend.
A Low Voltage Control Compartment houses the digital microprocessor
controller and LCD keypad operator interface, along with any other low voltage
devices. This allows the operator to make adjustments without exposure to the
line voltages.
JKSSS+ Series - 5
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JKSSS+ Series
2.3 - 4.2KV
Removable conduit entry plates are provided in the bottom of the enclosure to
facilitate drilling and punching of conduit holes without exposing the equip-
ment to contamination from metal debris.
•
Enclosure Finish: The enclosure is suitable for use in noncorrosive environ-
ments. The paint is ANSI 61 gray polyurethane powder over a zinc phosphate
pretreatment with a minimum thickness of 2 mil. 11 gauge steel is used in all
enclosures. All NEMA 1 & 12 units have bottom entrance plates.
•
Lifting Provisions: Eyes or angles capable of supporting the maximum
weight of each shipping split are provided on the top of the enclosure.
•
Power Bus: Optional main horizontal phase bus bars can be configured to
extend the entire length of the starter lineup. Bus bar material is tin-plated or
silver-plated copper. All bus ratings are per UL Standard 347.
•
•
Bracing: Bus bars are braced with non-tracking fire resistant non-hygroscopic
insulation supports and have a minimum fault current rating of 50,000 Amps.
Connections: All bus connections use 2 bolts minimum, with Belleville spring
washers to ensure tightness. Splice kits for each shipping split are included,
along with specific installation instructions.
•
•
Ground Bus: A continuous ground bus bar with a minimum rating of 400
Amps extends the entire length of the starter near the bottom of each enclo-
sure. A grounding strap connects each vertically adjacent compartment and
also ties the grounding arm of the disconnect switch to the main ground bus
bar (see section 2.11).
Seismic Qualifications: The entire starter assembly, when properly installed,
withstands vertical and horizontal accelerations typical of seismic Zones 1
through 4 as defined in the UBC. The assembly will not overturn or show
significant lateral movement, but cannot be expected to continue operating
during, or after, a seismic event.
1.5 Theory of Operation
The power of the JKSSS+ Series is in the CPU, a microprocessor based
protection and control system for the motor and starter assembly. The CPU
uses Phase Angle Firing of the SCRs to apply a reduced voltage to the motor,
and then slowly and gently increases torque through control of the voltage and
current until the motor accelerates to full speed. This starting method lowers
the starting current of the motor, reducing electrical stresses on the power
system and motor. It also reduces peak starting torque stresses on both the
motor and load mechanical components, promoting longer service life and
less downtime.
Acceleration: The JKSSS+ Series comes standard with several methods of
accelerating the motor so that it can be programmed to match almost any
industrial AC motor application.
The factory default setting applies a Voltage Ramp with Current Limit as this
has been proven the most reliable starting method for the vast majority of
applications. Using this starting method, the Initial Torque setting applies just
enough voltage to the motor to cause the motor shaft to begin to turn. This
voltage is then gradually increased over time (as per the Ramp Time setting)
JKSSS+ Series - 6
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JKSSS+ Series
2.3 - 4.2KV
until one of three things happen: the motor accelerates to full speed, the Ramp
Time expires or a Current Limit setting is reached.
If the motor accelerates to full speed before the ramp time setting has expired,
an automatic Anti-Oscillation feature will override the remaining ramp time and
full voltage will be applied. This will prevent any surging or pulsation in the mo-
tor torque, which might otherwise occur due to the load not being fully coupled
to the motor when operating at reduced voltage and torque levels.
If the motor has not reached full speed at the end of the ramp time setting,
the current limit setting will proportionally control the maximum output torque.
Feedback sensors in the JKSSS+ Series provide protection from a stall condi-
tion, an overload condition or excessive acceleration time.
The Current Limit feature is provided to accommodate installations where there
is limited power available (for example, on-site generator power or utility lines
with limited capacity). The torque is increased until the motor current reaches
the preset Current Limit point and it is then held at that level. Current Limit
overrides the ramp time setting so if the motor has not accelerated to full speed
under the Current Limit setting, the current remains limited for as long as it
takes the motor to accelerate to full speed.
When the motor reaches full speed and the current drops to running levels, the
soft starter detects an At-Speed condition and closes the Bypass Contactor.
The Bypass Contactor serves to shunt power around the SCR stack assemblies
to prevent heat buildup in the starter enclosure due to the slight voltage drop
across the SCRs. At this point, the soft starter has the motor operating at full
voltage, just as any other starter would.
Other starting methods available in the soft starter are:
· Current Ramp: Uses a closed current feedback PID loop to provide a linear
torque increase up to a Maximum Current level.
· Constant Current: Current is immediately increased to the Current Limit
point and held there until the motor reaches full speed.
· Custom Curve: Gives the user the ability to plot torque and time points on a
graph. The soft starter will then accelerate the motor following these points.
· Tachometer Feedback Ramp: Uses a closed loop speed follower method
monitoring a tachometer input signal from the motor or load shaft.
Deceleration: The soft starter provides the user with the option of having
the load coast to a stop or controlling the deceleration by slowly reducing the
voltage to the motor upon initiating a stop command. The Decel feature is the
opposite of DC injection braking in that the motor will actually take longer
to come to a stop than if allowed to coast to a stop. The most common ap-
plication for the Decel feature is pumping applications where a controlled stop
prevents water hammer and mechanical damage to the system.
JKSSS+ Series - 7
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JKSSS+ Series
2.3 - 4.2KV
1.6 General Protection
The soft starter is provided with a built-in motor protection relay that can be
programmed for primary protection of the motor/load system. Operation of the soft
starter can be divided into 4 modes; Ready, Start, Run and Stop.
Ready Mode: In this mode, control and line power are applied and the starter is
ready for a start command. Protection during this mode includes the monitoring
of current for leakage through multiple shorted SCRs or welded contacts on the
Bypass Contactor. Other protection features in effect are:
· Starter Temperature
· Shorted SCR
· Phase Reversal (if enabled)
· Line Frequency Trip Window
· External Input Faults
Note: The “Programming Mode” can only be entered from the Ready Mode.
During programming, all protection features and start command are disabled.
Start Mode: These additional protection functions are enabled when the soft
starter receives a valid Start command:
· Phase Reversal (if enabled)
· Start Curve
· Acceleration Timer
· Phase Imbalance
· Short Circuit / Load Pre-check (Toe-in-the-Water)
· Ground Fault (Optional)
· External Input Faults
· Accumulated Starting FLA Units (I2t Protection)
· Overload Protection
· Thermal Capacity
Note: Shorted SCR and Shunt Trip protection are no longer in effect once the
soft starter goes into the Start Mode.
Run Mode: The soft starter enters the Run Mode when it reaches full output
voltage and the motor current drops below the FLA setting (motor nameplate
FLA plus service factor) for a predetermined period of time. During the Run Mode
these additional protection features are enabled:
· Running Overload Curve
· Phase Loss
· Under Current / Load Loss
· Over Current / Electronic Shear Pin (Jam protection)
· External Input Faults
Stop Mode: Once a Stop command has been given, the protection features
change depending on which Stop Mode is selected.
· Decel Mode: Retains all protection features of the Run Mode. At the end of
Decel, the motor will be stopped and the protection features change as
indicated below.
JKSSS+ Series - 8
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JKSSS+ Series
2.3 - 4.2KV
· Coast-To-Stop Mode: Power is immediately removed from the motor and the
soft starter returns to the Ready Mode.
Additional protection features activated when the stop command is given include:
· Coast-Down / Back Spin Timer
· Starts-per-Hour
· Time Between Starts
· External Input Faults
1.7 Thermal Overload Protection
The JKSSS+ Series plays an important role in the protection of your motor in that it
monitors the motor for excessive thermal conditions due to starting, running or even
ambient conditions. The soft starter has a Dynamic Thermal Register system in the
CPU that provides a mathematical representation of the thermal state of the motor.
This thermal state information is kept in memory and is monitored for excesses in
both value and rate of change. Input is derived from current imbalances and RTD
measurements making it dynamic to all processes involving the motor. The starter
monitors these conditions separately during Start and Run modes to provide proper
thermal overload protection at all times.
Start Mode overload protection is selectable using one of three methods:
· Basic Protection: I2t data is accumulated and plotted based on an Overload
Curve selected in programming. This is programmed per NEMA Class 5-30
standard curves and is based on the Locked Rotor Current (from the motor
nameplate) as programmed into the soft starter.
· Measured Start Capacity: The user enters a measured amount of thermal
capacity from a pre-selected successful start as a setpoint to the Thermal Reg-
ister for the soft starter to follow.
· Learned Curve Protection: The user sets the soft starter to the “LEARN”
mode and starts the motor under normal starting conditions. The CPU then
samples and records 100 data points during the start curve, analyzes them and
creates a graphical representation in memory. The soft starter is then switched
to Curve Follow protection mode and monitors motor performance against this
curve. This feature is especially useful in initial commissioning tests to record a
base line performance sample (in this case, it is not necessarily used for motor
protection).
Run Mode overload protection is initiated when the starter determines that the
motor is At-Speed. Overload Protection is initiated when the motor RMS current
rises above a “pick-up point” (as determined by the motor nameplate FLA and
service factor). Run mode protection is provided by the CPU monitoring the Dy-
namic Thermal Register. Data for the Dynamic Thermal Register is accumulated
from I2t calculations and cooling rates. A trip occurs when the register reaches
100% as determined by the selected Overload Protection Curve (NEMA Class
5-30 standard curves) and is based on the programmed Locked Rotor Current
indicated on the motor nameplate. The Dynamic Thermal Register is altered, or
“biased”, by the following conditions:
· Current Imbalance: Will bias the register higher to add protection from ad-
ditional motor heating during a current imbalance condition.
· Normal Cooling: Provided when the motor current drops below the pick-up
point or the motor is off line. The cooling rate is lower for motors that are off-line
(such as after a trip) since cooling fans are also inoperative.
JKSSS+ Series - 9
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JKSSS+ Series
2.3 - 4.2KV
· RTD Input: Will bias the register in either direction based on real-time input of
the motor, bearing and even ambient temperature conditions.
· Dynamic Reset is another feature that adds reliability and consistency to the
performance of the soft starter. If a motor overload condition occurs and the soft
starter trips, it cannot be reset until sufficient cool down time has elapsed. This
cool down time is determined by the thermal state of the motor when it tripped
(i.e. hot motors cool more quickly due to additional convection). The cool down
time is also biased by RTD measurements when used.
·
Retentive Memory provides continuous overload protection and real time
reset even if power is lost. Upon restoration of power, the soft starter will
read the Real Time Clock and restore the thermal register to what it should be
given the elapsed time.
· Learned Reset Capacity is a feature that is unique to the JKSSS+ Series. By
sampling the amount of thermal capacity used in the previous three successful
starts, the soft starter will not allow a reset until a sufficient amount of thermal
capacity has been regained in the motor. This prevents nuisance tripping and
insures that unsuccessful start attempts (which would otherwise use up the
starts-per-hour capacity of the motor) are not counted.
1.8 Firing Circuit
The SCR gate firing circuit is critical to performance and stability of the system.
The firing circuit includes several unique features which enhance the ruggedness,
noise immunity and flexibility for maximized performance. In most applications, this
performance is attained without the need for reactors or field installed devices. These
features include:
Auto Synchronizing of the gate timing pulses match each phase firing angle
to their respective phases. The starter actively tracks minor shifts in the line fre-
quency, avoiding nuisance tripping that may happen with conventional gate firing
systems. This is especially useful on portable or backup generator supplies,
allowing the starter to be used confidently in applications that have unstable
power.
Sustained Pulse firing keeps the firing signal active for 270 electrical degrees,
ensuring that the DC gate pulse causes the SCR to fire even if line noise is
present at a critical moment. This provides the soft starter with superior noise
immunity and protects against misfiring, enhancing the system reliability.
Closed Loop Firing Control is a method of balancing the SCR firing pattern
based on the desired output. The CPU uses feedback signals from both the
output current and voltage providing smooth output and preventing imbalances
during ramping which prevents unnecessary motor heating.
Transformer Isolation of the firing signals prevents interference from line noise
and EMI/RFI signals that may be present. Specially designed 120V 3 phase iso-
lation transformers provide potential measurement, firing board power and gate
power systems while being isolated from the line voltage. High isolation Ring
Transformers are used to step this down to 28Vac for the Sustained Pulse firing
circuit, providing further isolation for the SCR gates.
Fiber Optic Isolation is provided for all signal interfaces between the Medium
Voltage and Low Voltage systems. Even the current signals from CTs are con-
verted to fiber optic signals for maximum isolation and safety.
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1.9 Electronics
The JKSSS+ Series electronics systems are divided into two categories, Low Voltage
and Medium Voltage, based solely on where they are located in the starter structure.
Low Voltage electronics include the Keypad Operator Interface, CPU and Main
Power PC boards are located in an isolated Low Voltage Compartment of the
enclosure.
· Keypad Operator Interface: a 2 line x 20 character LCD display with backlight-
ing for low ambient conditions. The display reads out in truncated English and
can show multiple data points in each screen. Also included are 12 LED indica-
tors, which include Power, Run, Alarm, Trip and the status of the 8 Aux. Relays.
It communicates to the CPU via a serial link and, if necessary, can be remotely
mounted up to 1000’ from the soft starter.
· CPU Board: where the microprocessor and communications coprocessor
reside. It is attached to the main power board, and communicates to it and
the Keypad Operator Interface via serial links. The CPU determines operating
functions, stores user programming and acts upon feedback signals for faults,
metering and historical data. This board also contains the flash EPROM and
SRAM memory, as well as the Analog I/O and terminations.
Keypad Operator Interface
· Main Power Board: is also referred to as the Firing Board. It contains the
Digital I/O relays and interfaces to the TCB board (see below) for user inter-
face. It also controls the sequencing of the Isolation and Bypass contactors with
the SCR firing. This board generates all firing signals for the SCR stacks and
receives feedback signals from fiber optic transmitters. It converts analog levels
to digital signals for the CPU. These firing pulses are via fiber optic signals to
isolate them from the Medium Voltage environment.
Control Electronics are located in the medium voltage and low voltage sections of
the soft starter. The main line power must be disconnected before these electronics
can be accessed. They include the TCB, Gate Drive and Temp/CT boards.
· TCB (Terminal and Control Board): is the user connection interface board. It
is located in the Low Voltage section in order to satisfy UL termination require-
ments, and does not connect directly to the medium voltage components other
than the contactor coils. This board contains the user terminal blocks, output
relays (duplicated), inputs and control power connections. It also contains ad-
ditional timed relays for interfacing with Power Factor Correction contactors (if
used) and other external devices. Please note Power Factor Capacitor warn-
ings in Section 2.8.
· Gate Drive Boards: located directly on the SCR stacks. These boards com-
municate to the Main Power board via fiber optic cables. They amplify the gate
pulse signals with power from the Ring Transformers to create the Sustained
Pulse Firing of the SCRs. There is one Gate Drive board for each pair of SCRs
in each stack.
· Temp / CT Boards: are attached to the Gate Drive boards on the SCR stacks
and provide the heat sink temperature and current signals back to the Main
Power Board via fiber optic cables.
· MOV Boards: are attached to standoffs mounted on the SCR heat sinks and
are mounted directly below the Gate Drive boards. The MOV boards are used
to protect the gate/cathode section of the SCRs.
· DV/DT Boards: are also attached to standoffs mounted on the SCR heat sinks
and are mounted below the MOV boards. The DV/DT boards are used to re-
duce voltage transients across the stack assemblies.
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Chapter 2 - Installation
For additional information on the equipment, refer to the following additional
instruction manuals:
For fixed type input isolation contactor - “JK Series Medium Voltage Controllers
- Fixed Type”, manual number VF010H03 or “JK Series 720 Ampere Medium
Voltage Controllers”, manual number VF010H02.
For drawout type input isolation contactor - “JK Series Medium Voltage
Controllers”, manual number VF010H01.
2.1 - Receiving, Handling/Moving and Unpacking
Upon receipt of the equipment, do the following:
•
•
•
•
All JKSSS+ Series units are shipped in the vertical (upright) position and should be
handled accordingly when received. If the controller is not upright upon receipt, notify
the carrier of possible damage. Upright the unit as soon as possible. Immediately
notify the nearest Toshiba representative.
Carefully unpack the unit and make an immediate inspection for any damage which
might have occurred during shipment. If damage is found, it should be noted with the
carrier prior to accepting the shipment, if possible. Report any damage immediately
and file a claim with the freight carrier within 15 days of receipt.
Carefully unpack the equipment sufficiently to check for concealed damage and
to verify that the starter description on your unit matches your purchase order.
The starter information is located on stickers in the medium voltage, incoming
compartment.
Keep the equipment upright. If is located on stickers in the medium voltage, incoming
compartment.
Do not install or energize equipment that has been damaged.
Do not lay the equipment on its side or upside down.
WARNING
CAUTION
Handling and Moving
Medium voltage motor controllers should be handled with care, to avoid damage to
components and to the frame or its finish.
The capability of the moving equipment to handle the weight of the controller shipping
section should be confirmed. The equipment should remain secured to the shipping skid
to prevent distortion of the frame during moving and to minimize tipping. Extreme care
should be exercised during any movement and placement operations to prevent dropping
or tipping.
Do not place any part of your body beneath equipment
WARNING
being lifted. Improperly secured equipment
can fall or tip over quickly and without notice.
Using a Forklift
A forklift truck may offer a more convenient method of handling the controller. A safety
strap should be used when handling with a forklift. The ends of the forks should not enter
the bottom of an open-bottom enclosure.
Overhead Lifting
When it is necessary to move the equipment between elevations, overhead hoisting may
be required. Lifting angles (for multiple controller sections) are provided on top of the
enclosure for this purpose. Spreaders (Fig. 1) should be used to provide the vertical lift
on single controllers to prevent eye-bolt failure.
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Always keep the controller upright while lifting. Some controller sections may contain
heavy or special equipment that will cause the center of gravity to be off-center. Rigging
lengths should be adjusted to maintain the controller in an upright position. The angle
between the lifting cables and vertical should not be allowed to exceed 45 degrees
(Fig. 2). Ropes or cables should not pass through the holes in lifting angles or eye-
bolts. Slings with safety hooks or shackles of adequate load rating should be used.
2.2 - Initial Inspection
•
•
•
Make a complete visual check of the unit for damage which
may have occurred during shipping and handling. Do not
attempt to continue installation or start up the unit if it is
damaged.
Check for loose mechanical assemblies or broken wires
which may have occurred during transportation or handling.
Loose electrical connections will increase resistance and
cause the unit to function improperly.
Prior to beginning the installation, verify that the motor and
JKSSS unit are rated for the proper amperage and voltage.
2.3 - Location
Storage
If the controller is to be stored for any length of time prior to
installation, the packing should be restored for protection
during that period. Where conditions permit, the packing
should be left intact until the controller is at the final installation
position. If the packing is removed, the top and openings
of the controller should be covered during the construction
period to protect it against dust and debris.
Fig. 1 Use of Spreader Bar - Single Section
Indoor Equipment
Controllers designed for indoor installation (NEMA Type 1, 12)
which are not to be installed and energized immediately, should
be stored in a clean, dry space where a uniform temperature
prevents condensation. Preferably, the controller should be
stored in a heated building, with adequate air circulation and
protected from dirt and water. Equipment should be stored
where it is not subject to mechanical damage, especially during
building construction. An indoor controller that is to be stored
outdoors should be securely covered for protection from weather
conditions and dirt. Temporary electrical heating should be
installed to prevent condensation. Approximately 150 watts per
enclosure is usually adequate.
NOTE: All loose packing or flammable materials should be
removed before energizing space heaters.
Fig. 2 Lifting Multiple Sections
Outdoor Equipment
An unenergized controller designed for outdoor installation (NEMA Type 3R, EPIC
building, etc.) should be kept dry internally by installing electrical heating or by energiz-
ing self-heaters, if provided. All openings, either used or unused should be covered or
sealed to prevent the entry of rain, vermin, insects, etc.
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Routine Inspection
Routine scheduled inspection should be established if storage for an extended period is
anticipated. This is to check for condensation, corrosion, vermin, and adequacy of space
heating. Prior to inspection, the equipment should be carefully examined for evidence of
physical damage, corrosion, or other deterioration.
Do not install equipment found to have damage or
deterioration that could affect the unit performance.
WARNING
Overhead should be checked for plumbing condensation, sprinklers or similar possible
sources of trouble.Aclearance of 1/2 inch should be provided between a wall and the rear
of the controller for indoor equipment, when rear access is not required. If rear access is
required in either environment, a minimum of 30 inches should be provided. A minimum
of 48 inches working space should be allowed in front of the controller. This minimum
should be increased if necessary to accommodate movement around open enclosure
doors to comply with applicable codes.
SERVICE CONDITIONS
Toshiba medium voltage controllers are intended for usual service conditions as defined
by NEMA. The equipment should not be exposed to corrosive or explosive fumes, dusts,
vapors, dripping or standing water, abnormal vibration, shock, tilting, or other abnormal
operation conditions. The temperature of the ambient air surrounding the controller should
be between the limits of 0°C(32°F) and +40°C(104°F). The altitude of the equipment
installed should not exceed 3300 ft (1000m).
NOTE: Temperature or altitude conditions outside of the usual limits may require derating
or other special equipment, such as heating, cooling or ventilation. Contact Toshiba for
further information.
If the location for installation is damp, space heaters may be required. If space heaters
are furnished inside the controller, they should be connected in accordance with the wir-
ing diagram furnished.
Do not install this equipment in areas where unusual service
conditions exist, unless the equipment has been specially
designed for the particular environment.
Installation Site Preparation
It is recommended that site preparation be completed before the controller is unpacked,
so that possible problems such as headroom, conduit location, cable tray locations, ven-
tilation, etc. can be solved, assuring a proper installation in compliance with the building
plans and codes. The floor on which the controller will be placed must be level so that the
enclosure is not distorted when bolted in place. Ensure the equipment adequately clears
any underground raceways or cables.
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2.4 - Dimensions
Note: Dimensions are for reference only and subject to change.
Contact factory for exact dimensions.
2.5 - Mounting
Each shipping section must be leveled and firmly secured to its supporting
foundation. Steel shims may be used for final leveling (Fig. 3), if necessary.
When three or more shipping sections are to be arranged in one continuous
line-up, the center shipping section should normally be the first located.
Follow the equipment outline drawings to determine the location of the
mounting bolt holes and any conduit locations.
Sill channels may or may not be furnished, depending on order specifica-
tions. Refer to outline drawings furnished for location
of sill channels, if furnished.
Various methods may be used to anchor the enclosure to the foundation,
including expandable inserts or “J” bolts embedded
in concrete. The recommended size for anchor bolts is 1/2" (Fig. 4).
Fig. 3 Leveling Using Shims
Heavy Equipment. Enclosure must be securely
anchored to prevent tipping over.
2.6 - Additional Cabinet Entries
If conduit entry locations are required in areas other than the
removable plates, cover the electrical assemblies to prevent
metal filings from becoming lodged in areas which may cause
a reduction in the high voltage clearances or a short circuit.
After the work is completed, thoroughly clean the area and
reinspect the unit for foreign material.
2.7 - Pre-energization Check
AFTER INSTALLATION, BUT BEFORE ENERGIZING THE CONTROLLER
for the first time, follow the procedure below to
verify that the equipment is properly installed and functional.
Fig. 4 Securely Anchor the Controller
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There is a rating data label on the inside of each medium voltage compartment door.
Verify that the controller ratings properly match the system data by checking the follow-
ing:
1.
2.
3.
Verify agreement of full load current, locked rotor current and acceleration time
with motor nameplate.
Verify that system voltage, number of phases and frequency matches controller
rating.
Verify that available short circuit current of power system is less than rated
short circuit capacity of controller.
Check connections - Although the equipment and devices have been completely tested
at the factory, a final field check should be made that all electrical wiring and bus bar
connections are correct and have not become loose in transportation. Refer to MAINTE-
NANCE Section for electrical joint specification.
All blocks or other temporary braces used for shipment must be removed.
Before closing the enclosure, all metal chips, scrap wire and other debris left over from
installation must be cleaned out.
If there is an appreciable accumulation of dust or dirt, the enclosure should be cleaned
by using a brush, vacuum cleaner or clean, lint free brush.
The integrity of all bus bar supports must be checked for secureness and damage.
Care should be exercised that when covers are installed and doors closed, no wires are
pinched and that all enclosure parts are properly aligned and tightened.
A supply of spare parts, fuses, etc. should be established.
Instruction manuals and diagrams should be collected and filed.
WIRING CHECK
Field wiring should be checked for clearance to live busses where necessary, physically
secured to withstand the effects of fault current.
All grounding connections should be checked.
Each motor should be connected to its intended controller, and phase rotation should be
correct prior to startup.
Changes made to circuit diagrams during installation should be recorded.
DEVICE/MECHANISM CHECKS
All devices should be checked for damage. All necessary repairs or replacements should
be made.
Do not energize damaged equipment that has not been repaired
and verified.
WARNING
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Ensure that safety signs are not covered or obscured by paint.
Do not remove, cover or destroy any safety signs.
WARNING
The setting of any adjustable current and voltage trip mechanisms should be verified to
the proper values.
NOTE: Damage from faults can be reduced if devices used for short circuit and ground
fault protection are chosen and set to operate at values as close to minimum as feasible,
while allowing normal transients.
All switches, relays and other operating mechanisms should be manually exercised to
make certain that they are properly aligned and operate freely.
Operating mechanisms such as interlocks, key switches, etc. should be checked for func-
tion as intended for protection of personnel and equipment.
Overload relay settings should be checked to be sure they are selected and adjusted to
the proper settings per the load nameplate data.
Power circuit fuses were selected and installed in accordance with the application re-
quirements. Fuses must be completely inserted in their holders. Instruction on removing
and installing the fuses can be found in one of the following manuals: VF010H03 (Fixed
Type) or VF010H01 (Drawout Type).
Electrical Checks
With incoming power isolated and all loads disconnected electrically, the control cir-
cuit and other mechanisms should be exercised to determine that the devices operate
properly. An auxiliary source of control power will be necessary to provide power to the
electrical operators.
Electrical shock hazard. Do not touch energized components
during a test using auxiliary power.
The ground fault protection system (if furnished) should be tested in accordance with the
instructions furnished with the device.
An electrical insulation test should be performed to ensure that the controller and asso-
ciated field wiring are free from short circuits and grounds. The preferred method is to
perform a dielectric test at 2.25 times the nominal system voltage plus 2000 volts. This
should be done phase-to-ground, phase-to-phase and phase-to-neutral (if applicable),
with all switches and circuit breakers opened. Disconnect any devices which may have
limited dielectric strength and that are not intended for this test.
The light or buzzer, or both, used to indicate breakdown should be calibrated to indicate
failure with an output current between 1.5 and 2.0 milliamperes per 1000 volts applied.
Hazardous voltages are present during dielectric testing
which can result in serious injury or death. High potential
tests should be performed only by qualified personnel.
Refer to safety instructions provided with the test equipment.
All devices must be set to their normal or OFF position before energizing incoming power.
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2.8 - Warnings & Cautions
This section involves working with potentially lethal voltage
levels! Use extreme caution to prevent injury. Pressing “Stop”
WARNING
push button does not remove AC mains potential.
Do not service this equipment with voltage applied! The unit
can be the source of fatal electric 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.
WARNING
Do not connect the capacitors to the load side (motor side)
of the solid state starter. This will cause di/dt damage to the
SCRs when they are turned on.
CAUTION
CAUTION
!
CAUTION
SCR DAMAGE
Do not connect (PFC) capacitors to the load side of
the unit.
Do not connect the capacitors to the input side of the unit.
If you cannot avoid using capacitors across the power lines, they
must be located as far upstream as possible of the input line
contactor. In this situation, optional power factor correction (PFC)
caps contactor should be specified. For additional information and
specifications, please contact the factory.
Doing so will cause DI/DT damage to the SCRs when
energized.
Never interchange the input and output power connections
on the unit. This will cause excessive voltage to the control circuit
logic.
CAUTION
CAUTION
For bus protection, it is strongly recommended to use non-gap
lightning arrestors in areas where lightning is a significant
problem. The arrestors should be mounted on the nearest utility pole.
2.9 - Medium Voltage Power Connections
Use a properly calibrated torque wrench to tighten all MV connections
according to the chart.
Torque at Full
Bolt
Engagement
Size
(ft - lbs)
Connections
1/4 - 20
3/16 - 18
3/8 - 16
7/16 - 14
1/2 - 13
9/16 - 12
5/8 - 11
3/4 - 10
7/8 - 9
6
Cable and wire bundles that enter the controller enclosure should be routed to
avoid interference with moving parts. Minimum bending radius for the type of
cable used should be observed.
12
18
30
45
Power cables should be braced and/or laced to withstand short circuit forces
wherever such cables are unsupported. Power cables should be adequately sized
to carry the motor full load current in accordance with NEC requirements, and
have an adequate voltage rating. Cables should be dressed and terminated as
appropriate to the voltage class and cable manufacturer’s recommendations.
68
90
150
240
245
1.0 - 8
Torque Specs for MV Power
Connections
Main power bus (when provided) and horizontal ground bus are supplied with links
to join shipping sections together. These should be installed in accordance with Fig.
5 through Fig. 7.
All access covers, barriers, partitions, etc. that are temporarily removed during installation
must be replaced.
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NOTE: Covers and braces supplied only for protection during shipment should not be
replaced. All debris and tools should be removed from each compartment as cabling is
completed.
Fig. 5 Main Bus Splice Connections - 1200A Main Bus
Fig. 6 Main Bus Splice Connections - 2000A Main Bus
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2.9.1 - Incoming Line
On the Standard JKSSS, incoming power cable connections should be made at the
points shown on the wiring diagram furnished with the equipment.
Note: Proper phase sequence must be observed when connecting the input power.
For example, phase A must lead phase B, which in turn must lead phase C by 120°
respectively. If the phase rotation is not correct, a fault light and the LCD display will
indicate the problem. The SCR output will be clamped.
2.9.2- Load Connections
The load cables should be routed through the wireways furnished within the enclosure.
Load cable termination arrangements, refer to the drawings furnished with the equip-
ment.
2.9.3- Ground Connections
The controller line-up must be grounded in accordance with the requirements of the Na-
tional Electrical Code. Proper equipment grounding must be established before making
any incoming power connection. If a main ground bus is furnished, make the ground con-
nection to this bus. If there is no ground bus, the sections which are shipped separately
should be connected in such a way as to ensure a continuous grounding path.
Each section contains a vertical ground bus extending from the main ground bus or ground
pad to each controller compartment.
Special attention should be paid to protection for operating personnel, to protection of
equipment itself, (i.e. such as ground fault relays, if used) and protection of sensitive
transducers or control devices that are electronic in nature.
The following may be used as a general guide with regard to equipment grounding.
Controller used as service equipment for a grounded system or as a main section for a
seperately derived system:
a. The grounding electrode conductor (ground wire) sized in accordance with NEC 250
should be run from the grounding electrode to the controller ground bus or ground
terminal.
b. Unless already done at the factory, a main bonding jumper should be installed from
the incoming grounded connector bus (neutral) to the ground bus or designated
grounding point. If a jumper is not furnished, one having a size in accordance with
NEC 250 should be selected.
c. Steps (a) and (b) should effectively connect together the grounding electrode, the
controller frame, all outgoing equipment grounding conductors and the grounded
neutral bus of the system.
d. No connection should be made to ground on the load side of any neutral disconnecting
line or any sensor used for ground fault protection. No connections should be made
between outgoing grounding connectors and the neutral.
e. Where the controller or system is dual-fed (double-ended) and has ground fault
protection, special precautions are necessary to accomplish proper grounding and
bonding.
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Controller used as service equipment for an ungrounded system or as a main section for a separately derived
system.
a. A grounding electrode conductor (ground wire) sized in accordance with NEC 250 should be run from the
grounding electrode to the controller ground bus or ground terminal.
b. If the system is grounded at any point ahead of the controller, the grounded conductor should be run to the
controller in accordance with NEC 250 and connected to the ground bus or ground terminal.
c. Steps (a) and (b) should effectively connect together the grounding electrode, the controller frame, all outgoing
equipment grounding connectors and any grounded conductor which runs to the controller.
Controller not used as service equipment or as a main section for a separately derived system, and used on either
a grounded or ungrounded system:
a. The controller frame and any ground bus should be grounded by means of equipment grounding conductors
having a size in accordance with NEC 250 and run with the main supply conductors or by bonding to the
raceway enclosing the main supply conductors in accordance with NEC 250.
b. Ground leads should be connected to cable potheads/shields as specified by the manufacturer of these de-
vices.
Fig. 7 Ground Bus Splice
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2.10 Control Connections - TCB (Terminal and Control Board)
THIS SECTION INVOLVES
POTENTIALLy LETHAL VOLTAGE
LEVELS! USE ExTREME
C us tomer P rovided
WARNING
Momentary or Maintained
S ta rt / S top S witching
CAUTION TO PREVENT INjURy.
Maintained
S TOP
Do not bypass the electrical or mechanical
interlocks. This will cause severe equipment
damage and possible fatal injury.
S TAR T
Fus es
Momentary
F1: Control Fus es for TB 1
1
-
9
Part #ACG 1A250 VAC or equivalent
F2: Contactor and relay output fus es
Part #ACG 4A250 VAC or equivalent
F3: TB 2 Pin #6
2.10.1 JKSSS Plus-TCB Board
Part #ACG 4A250 VAC or equivalent
The JKSSS Plus-TCB board provides
interconnections between the main power and
CPU boards and the customer’s control logic
connections. It is a 120Vac control board with
several auxiliary dry control contacts, built-in
time delay circuits and emergency bypass func-
tions. It also controls the sequence of the inline
isolation and bypass contactor and provides
provisions for shutdown interlocks. (see section
2.10.2)
12
Aux S tart
Output
11
10
9
E 1
E 3
E 2
E 4
120 VAC
Neutral
A C
R ed
L E D
Neut
8
S tart
S top
FUS E
7
T B 1
R ed
L E D
6
T 1
5
Inter
Loc k
Optional
Interloc ks
FAULT
4
3
Inter
Loc k
2
A C
120 VAC
S ource
1
S ourc e
10
9
F1
8
F2
F3
HE AT S INK
FAC TOR Y WIR E D
DO NOT US E
7
G reen
L E D
6
Line
1
2
3
4
5
6
7
8
9
120VAC
{
5
Neutral
-12V
T B 2
4
E mergency B ypas s
AUX C ontac ts
G reen
L E D
Start/Stop Control
Figure 2-1
G reen
Delayed S tart
3
L E D
2
E mergency B ypas s
Full Voltage S tart
+12V
S TAR T
F us e B lown/
1
T B 6
ON
Disconnect Open
2.10.2 Description of Terminal Connections
12
Dual R amp
OFF
S W1
J P 1
11
10
9
Start/Stop Control - Terminal Block 1 (TB1) :
R emove J P 1 for electronic
motor overload protection
during emergency
B ypas s S tatus
R un
DUA L ADJ
•
•
Positions 1 and 9 are the 120 Vac control power.
Positions 2-3 and 4-5 are factory jumpers
installed and can be removed for customer’s
normally closed, dry, shutdown contacts (See
Fig. 2-1 above).
10
bypas s operation
8
1
2
3
4
5
6
7
7
T B 3
TC B
BOAR D
6
5
C P U (AUX1) F ault
At S peed
T B 7
4
•
•
Positions 6-7-8 are for either two wire or three-
wire start/stop logic. Two wire is connected to
positions 6 and 8 with a N.O. dry, maintained
start/stop contact. Three wire control connects
to 6 with 7 as the stop push-button, and the start
push-button is connected to 7 and 8.
3
2
1
F us e B lown/
Disconnect
Interlock Input
12
1
2
G reen
L E D
11
10
9
3
T B 8
E xternal O verload
P F C
T IME D
OUT
4
Positions 10-11-12 is a dry FORM C contact.
The contact is an immediate start/stop contact.
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
8
5
B ypas s Aux C ontact
7
6
T B 4
P F C
AUX
S TAR T
A1
6
7
B ypas s
{
C oil
A2
5
8
4
9
A1
G reen
L E D
Main
{
C oil
3
10
A2
2
DE L AY
T IME D
OUT
1
TCB (Terminal and Control Board)
Figure 2-2
(See page 85 for larger version)
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Emergency Bypass Control - Terminal Block 2 (TB2):
TB2
•
Positions 1 and 2 are for an emergency bypass contact. If a dry contact
closes position 1 and 2, this causes the CPU to be shut off
so there is no display. Then when a start is initiated, it pulls in the inline
isolation contactor which starts the motor across the line.
#1 #2 #3 #4
NO O
#6 #7
N
#10
NC
#5
NC
#8 #9
NO
C
NO
S
C
EMER BYP
SWITCH
CUST. POWER DELAYED
OUTPUT START
INTER
LOCK
See section 3.6 for more details.
•
Positions 3-4-5 are a FORM C contact. This is a dry contact that is
initiated by the emergency contact being closed. It provides indication
of the emergency bypass mode.
Emergency Bypass Control
Figure 2-3
•
•
Positions 6 and 7 is a customer connection for control power. Position
6 is the 120 Vac supply at (400 VA) and position 7 is the return.
Positions 8-9-10 are a FORM C contact. The dry contact is a delayed start/
stop contact. The amount of delay is determined by X1, X2 and SW3. See
“Switch Positions” and “Jumper Selection” on the next page. Note: Additional
Time Delay to SP2 of the CPU programming.
CAUTION
OVERLOAD PROTECTION LOSS
When operating the unit in Emergency Bypass Mode,
there is no electronic overload protection.
External overload protection must be provided for
continued safe operation.
•
JP1 - Motor Protection Jumper. Removing jumper JP1 on the TCB Board will
allow the soft starter CPU to continue providing electronic motor protection while operating in the Emer-
gency Bypass Mode. If necessary to disable the CPU system during operation in Emergency Bypass, be
sure JP1 is placed over both pins and an external means of overload protection is used.
Fault - Terminal Block 3 (TB3):
TB3
•
Positions 1-2-3 and 4-5-6 are sets of FORM C contacts. These are dry
contacts that operate when a blown fuse indication is given or discon-
nect is open.
#1 #2 #3 #4
NC C
#6 #7
C
#10 #11 #12
NO NC
C
#5
NO
#8 #9
NO NC
C
NC
NO
•
Positions 7-8-9 and 10-11-12 are sets of FORM C contacts. These are
fault contacts that change state if any fault condition occurs.
Lockout/Fault Contacts
Figure 2-4
Optional Relay - Terminal 4 (TB4):
•
Positions 1-2-3 and 4-5-6 are sets of FORM C contacts. These are aux-
iliary time delay contacts that will change state (after a delay) when the
Start contact is initiated. X3, X4 and SW4 determine the amount of delay.
(Switch Position and Jumper Selection on following page)
•
Positions 7-8-9 and 10-11-12 are sets of FORM C contacts. These are
power factor correction capacitor (PFC) contacts to pull in an isolation con-
tactor for the capacitors (if required by the application). These will change
state when the At Speed contact is initiated. X5, X6 and SW5 determine the
amount of delay. See “Switch Positions” and “Jumper Selection” on
Time
Delay/PFC Cap Contacts
Figure 2-5
the following page. Note: This delay is in addition to SP2 of the CPU programming.
Terminal Block 6 (TB6):
•
•
•
•
•
Positions 1 and 2 are 120 VAC power supply to the Main and CPU circuit boards.
Positions 3 and 4 are the start input connections to the Main and CPU circuit boards.
Positions 5 and 6 are the fuse blown input connections to the Main and CPU circuit boards.
Positions 7 and 8 are the Dual Ramp input connections to the Main and CPU circuit boards.
Positions 9 and 10 are the Bypass Status input connections to the Main and CPU circuit boards.
Terminal Block 7 (TB7):
•
•
•
•
Positions 1 and 2 are the Run contacts (AUX 3) from the Main and CPU circuit boards to the TCB board.
This signal is used to hold the Main Contactor closed during deceleration.
Positions 3 and 4 are the Main and CPU circuit board output connections to the TCB that signal the AUX1
Fault Status.
Positions 5 and 6 are the At Speed contacts (AUX 4) from the Main and CPU circuit boards that signal the
Bypass Contactor to close.
Position 7 has no connection..
Terminal Block 8 (TB8):
•
Positions 1 and 2 accept dry, normally closed contacts from blown fuse indicators and/or disconnect inter-
lock contact.
•
Positions 3 and 4 accept dry, normally closed contacts from an external overload protection device (re-
quired if emergency bypass is used).
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•
•
•
Positions 5 and 6 accept dry, normally closed contact from the bypass contac-
tor for an At Speed indication. (Factory wired)
Positions 7 and 8 are wired to the coil of the bypass contactor and energizes
and de-energizes the contactor. (Factory wired)
Positions 9 and 10 are wired to the coil of the inline isolation contactor and
energizes and de-energizes the contactor.
Note: All customer contacts are 960VA, 120VAC (Max) rated dry contacts.
LEDs provided on the TCB board (for low voltage testing only):
•
•
•
•
•
•
•
-12 VDC power supply
+12 VDC power supply
Start = start is initiated to TCB board
Fault = any fault has occurred
Fuse Blown = disconnect open or blown fuse has activated
PFC On = Power Factor Correction Capacitor contacts have energized
Timed Out = Auxiliary time delay contacts have energized
jumper Selection
For the following, please refer to Figure 2-6.
Start Delay
This is a selectable delay period between the intiation of the start command and
when the CPU actually receives the start signal. Selecting Jumper X1 or X2 deter-
mines the method by which this delay (in cycles or seconds) is calculated. See SW3
below for instructions on setting the actual delay time.
jumper Selection on TCB Board
Figure 2-6
•
•
X1 = (DLY-C) Start time delay in cycles
X2 = (DLY-S) Start time delay in seconds (Factory setting)
Auxiliary (Start) Delay (from the time the start input is given). Selecting jumper X3 or
X4 determines the method by which this delay is calculated (cycles or seconds). See
SW4 below for instructions on setting delay time.
•
•
X3 = (AUX-C) Auxiliary time delay in cycles
X4 = (AUX-S) Auxiliary time delay in seconds (Factory setting)
Power Factor Correction (PFC) Capacitor Contactor Delay (From the time the
bypass closes to when contacts change state). Jumper selection determines the
method by which this delay is calculated. See SW5 for instructions.
•
•
X5 = (PFC-C) Time delay in cycles
X6 = (PFC-S) Time delay in seconds (Factory setting)
Switch Positions
Please refer to Figure 2-7.
•
•
SW1 = ON = Dual Adjustment
OFF = Disabled
SW2* = Not used - Switches SW3, SW4 and SW5 are 7 position dip switches
that use binary code to count up to 127 seconds/cycles (see “Jumper Selec-
tion” above).
Figure 2-7
Example:
•
•
•
SW3 = Start Delay; 7 position dip switch uses binary count up to 127 seconds/
cycles (see jumper selection above). Factory setting: 1 second.
SW4** = Auxiliary (Start) Delay 7 position dip switch uses binary count up to
127 seconds/cycles (see jumper selection above). Factory setting: 1 second.
SW5** = PFC time delay; 7 position dip switch uses binary count up to 127
seconds/cycles (see jumper selection above). Factory setting: 1 second.
Switch settings are cumulative.
Setting dip switch positions 1, 2,
and 3 to “on” = 1+2+4 = 7 seconds
total time. Note: This example ap-
plies to SW3, SW4 & SW5.
* Note: This switch interacts with the CPU programming when the Decel function is
enabled.
** Note: These times are in addition to SP2 in the CPU setpoints.
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2.11 Reference Section
2.11a RTD Board
RTD2
RTD5
RTD8
RTD11
RTD1
RTD3
RTD4
RTD6
RTD7
RTD9
RTD10
RTD12
RTD
Typical RTD
Installation
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2.11b Communications Board
REAR
VIEW
(RS422)
(RS485)
Note: Remove for last unit in modbus string
2.11c Communications Board Connections
RS485 Connections
(Customer Connections)
RS422 Connections
(Factory Only)
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2.11d Power Board
Board
Ground
Test Points
7
1
19
20
19
20
1
2
7
1
1
2
J3
J6
J5
J4
AI
AT
BI
BT
CI
CT
GF
J1
C1
B1
C2
B2
7, A - Phase
4, B - Phase
A1
A2
1, C - Phase
J2
J8
J7
J2
F1
TB2
TB1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
TB3
2.11e Power Board Connections
TB2
TB1
Factory use only. Do not reprogram.
Refer to Setpoint Page 5 for programming information
12 13 14 15 16 17 18 19 20 21 22 23
N.O.
1
2
3
4
5
6
7
8
9
10 11
N.O.
24
N.O.
N.O.
N.O.
N.O.
N.O.
N.O.
C
N.C.
C
N.C.
C
N.C.
C
N.C.
C
N.C.
C
N.C.
C
N.C.
C
N.C.
AUX2
AUX3
(RUN)
Relay
AUX4
(AT SPEED)
Relay
AUX6
Relay
AUX7
Relay
AUX8
Relay
AUX1
(TRIP)
Relay
AUX5
Relay
(ALARM)
Relay
(Max Relay Contact Rating is 240 VAC, 4A, 960VA)
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2.11f CPU Board Connections
2
1
20
19
2
1
20
19
Contact factory for remote
reset connections
Factory wired. Do not change
TB1
TB2
TB3
1
2
3
+
4
-
5
6
7
8
1
2
-
3
4
+
5
-
6
7
+
8
-
9
1
+
2
-
3
+
4
-
5
+
6
-
7
+
8
-
+
Note: Install program jumper to enable
setpoint programming. Jumper must be
removed after programming or for
prolonged storage to preserve settings.
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Chapter 3 - Start-up
THE JKSSS+ UNIT DEALS WITH POTENTIALLy LETHAL VOLTAGE
LEVELS. yOU MUST BE CERTAIN THAT PERSONNEL ARE
THOROUGHLy TRAINED IN THE APPLICABLE SAFETy
PRECAUTIONS BEFORE PROCEEDING WITH THIS SECTION!
3.1
Preliminary Start-Up Check List
Please make the following checks before applying power to the unit:
•
Qualified personnel have hi-potted the line and load wiring before connecting to the soft
start. (Typically 1.5 x Rated Voltage)
•
•
Verify that all wiring is completed and all connections are tightened.
Check the motor nameplate and confirm the unit is programmed with the correct motor
FLA.
Note: It is necessary to connect the line power to L1, L2 and L3, or the “Phase
Rotation Protection” will be activated.
•
Verify control logic via 120V test switcher (available on standard JKSSS+ NEMA Class
E2 Starters only). A separate 120Vac test receptacle can be supplied to the control logic
without powering up the medium voltage section for control logic testing. It also allows
isolation of the 120Vac from back-feeding the control power transformer.
Connect control supply (Optional “Soft Start Only” Package only). The “On” and “Stop”
LEDs will light up.
•
•
Review all parameters and readjust as required. See Chapter 5 - Programming for de-
tailed instructions. Try factory settings first.
•
•
•
•
•
•
•
Verify that the interlocks for the system are installed and working properly.
Verify that the feed transformer is correctly sized for the motor(s).
Check for any loose mechanical parts or metal debris in the enclosure.
Check the motor strapping and connections.
Verify that the unit is properly grounded.
Remove tie straps from Blown Fuse Indicator.
Connect line voltage to line terminals.
3.2 Introduction
It is best to operate the motor at its full load starting condition to achieve the proper time,
torque and ramp settings. Initial settings are set to accommodate most motor conditions.
TRy INITIAL SETTINGS FIRST. See Setpoint 5.1.2 Starter Confiuration (Setpoint Page
2) to make any adjustments.
3.3 Acceleration Adjustments
The unit is set at the factory with typical starting characteristics that perform well in most
applications. When the system is ready to start, try the initial unit settings. If the motor
does not come up to speed, increase the current limit setting. If the motor does not start
to turn as soon as desired, raise the starting voltage adjustment. Adjustment description
and procedures are described as follows. See Setpoint 5.1.2 Starter Configuration (Set-
point Page 2) for additional Accel settings.
3.3.1 Starting Voltage
Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage
Starting voltage adjustment changes the initial starting voltage level to the motor.
3.3.2 Ramp Time
Factory Setting = 10 sec.
Range = 0 - 120 sec.
Ramp time adjustment changes the amount of time it takes to reach the current limit
point or full voltage if the current limit point was not reached.
Note: Refer to your motor manual for the maximum number of starts per hour allowed by
the manufacturer and do not exceed the recommended number.
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3.3.3 Current Limit
Factory Setting = 350% of unit FLA
Range = 200% - 500% of unit FLA
The current limit adjustment is factory set for 350% of the unit’s rating.
The range of adjustment is 200% to 500%. The main function of cur-
rent limit is to cap the peak current. It may also be used to extend the
ramping time if required. The interaction between the voltage ramp
and the current limit will allow the soft start to ramp the motor until the
maximum current is reached and the current limit will hold the current
at that level. The current limit must be set high enough to allow the
motor to reach full speed. The factory setting of 350% is a good start-
ing point. Do not set the current limit too low on variable starting
loads. This could cause the motor to stall and eventually cause
the overload protection to trip.
Note: If the motor does stall, refer to the motor manufacturer’s motor data
for the proper cooling time.
3.4 Deceleration Adjustments (Pump Control)
Decel extends the stopping time on loads that would otherwise stop too
quickly if allowed to coast to stop. Decel control provides smooth deceler-
ation until the load comes to a stop. Three adjustments optimize the deceleration
curve to meet the most demanding requirements. The unit is shipped from the
factory with the decel feature disabled.
Deceleration Applications
The unit is shipped from the factory with the decel feature disabled.
Apply power and adjust the soft start before enabling or modifying the
deceleration adjustments. Both acceleration and deceleration adjust-
ments should be made under normal load conditions.
The deceleration feature provides a slow decrease in the output voltage,
accomplishing a gentle decrease in motor torque during the stopping
mode. This is the OPPOSITE OF BRAKING in that it will take longer to
come to a stop than if the starter were just turned off. The primary use
of this function is to reduce the sudden changes in pressure that are
associated with “Water Hammer” and slamming of check valves with
centrifugal pumps. 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. The
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 it dissipates. 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.
By using the Soft Stop/Deceleration feature of the soft starter, the pump
output torque is gradually and gently reduced, which slowly reduces the
pressure in the pipe. When the Output Pressure is just slightly lower than
the 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
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Shock Wave is avoided. When the output voltage to the motor is low enough to no longer
be needed, the soft starter will end the Decel cycle and turn itself off.
Another common application for decel control is on material handling conveyors as a
means to prevent sudden stops that may cause products to 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.
3.4.1 Start Deceleration Voltage
Factory Setting = 60% of line voltage
Range = 0% - 100% of line voltage
The step down voltage adjustment eliminates the dead band in the deceleration mode
that is experienced while the voltage drops to a level where the motor deceleration is
responsive to decreased voltage. This feature allows for an instantaneous drop in volt-
age when deceleration is initiated.
3.4.2 Stop Deceleration Voltage
Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage
The stop voltage level setpoint is where the deceleration voltage drops to zero.
3.4.3 Deceleration Time
Factory Setting = 5 sec.
Range = 0 - 60 sec.
The deceleration ramp time adjusts the time it takes to reach the stop voltage level set
point. The unit should be restarted and stopped to verify that the desired deceleration
time has been achieved.
DO NOT ExCEED THE MOTOR MANUFACTURER’S RECOMMENDED
NUMBER OF STARTS PER HOUR. WHEN CALCULATING THE
NUMBER OF STARTS PER HOUR, A DECEL CURVE SHOULD BE
COUNTED AS A START CURVE. FOR ExAMPLE: RECOMMENDED
NUMBER OF STARTS PER HOUR = 6, ALLOWABLE STARTS WITH
DECEL CyCLE PER HOUR = 3.
3.5 Sequence of Normal Operation
•
•
Apply control power and check that the “Power” LED comes on. (Display 1)
Apply three phase power to the unit. The motor should run only when the
start command is applied.
•
Apply the start command. (Display 2). The RUN LED will be lit. (Display 3)
The AUX3 LED will be lit. If the motor does not enter run mode in the
set time (Acceleration time limit, see SP8.2), a trip will occur.
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•
•
When the motor reaches full speed, the “AUX4” LED (At Speed) will be lit.
MOTOR STOPPED
READY TO START
Display 1
Display 2
Display 3
Display 4
The POWER, RUN, AUX3 LEDs will be lit, indicating that the contact has
energized. IA, IB, IC will display the current setting for Phase A, Phase B,
and Phase C and the G/F indicates ground fault. (Display 4)
If the motor decelerates, or stops, during the acceleration period, hit the
stop button immediately and open the disconnect line. If the unit does not
follow this operational sequence, please refer to the Troubleshooting Chapter.
MOTOR STARTING
00 X FLA
•
OVERLOAD ALARM
TIME TO TRIP: XXX SECS.
IA: _ _ _ IB: _ _ _
IC: _ _ _ G/F: _ _ _
It is best to operate the motor at its full load starting condition to achieve the proper
time, torque and ramp settings. Initial settings are set to accommodate most motor
conditions. TRy INITIAL SETTINGS FIRST. See Section 5.1.1 (Setpoint Page 2) to
make any adjustments.
•
•
•
•
Initial Voltage
Soft Start Curve
Current Limit
Acceleration Time
If decel is enabled, the following parameters for Deceleration Time, Start Decel Volt-
age (see SP2) and Stop Decel Voltage (see SP2) must also be programmed.
3.6 Emergency Bypass Operation
•
!
HAZARDOUS OPERATION
DANGER
Do not operate the Bypass Contactor with medium
voltage power applied to the unit.
Failure to follow this instruction will cause the motor
to start unexpectedly.
Remove input power (using line start section and lock out disconnect).
•
•
•
Close the emergency bypass contact.
Re-close the disconnect on line start panel.
If integral overload protection is not to be used (see JP-1 Motor Protection
Jumper), then bimetallic or solid state overload protection is required
(customer supplied if factory emergency overload protection option has not
been included.)
IN THE EMERGENCy ByPASS MODE, THERE IS NO
OVERLOAD PROTECTION UNLESS A SEPARATE
(OPTIONAL OR CUSTOMER SUPPLIED) THERMAL OR SOLID
STATE OVERLOAD RELAy IS INSTALLED, OR jP-1 (MOTOR
PROTECTION jUMPER) IS REMOVED FROM THE TCB BOARD.
WARNING
The line start panel is operable as a normal across-the-line starter. When
power is applied, the bypass contactor is energized, tying the input terminals
directly to its output terminals. When the “ON/OFF” contact is closed, the
main contactor is energized and the motor line starts. When the “ON/OFF”
contact is opened, the motor is disconnected from the line via the main in-line
vacuum contactor.
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Chapter 4 - User Interface & Menu Navigation
This chapter explains the keypad operator interface, the LCD descriptions and the
programming features
4.1
Keypad/Operator Interface
The user keypad/ keypad operator interface consists of:
• 2 row by 20 characters Liquid Crystal Display (LCD)
• 12 LEDs
• 8 pushbuttons
Note: The soft start is menu driven and there are three levels of programming. The
programming for two of these levels is password protected. Level two requires a
three digit password and level three requires a four digit password.
Toggle between the menu selection for metering and
MENU
setpoint pages.
RESET
Will clear the trip indicator and release the trip relay.
Keypad Operator Interface
In the edit mode, press the ENTER pushbutton so the
unit will accept the new programming information.
When not in the edit mode, the ENTER pushbutton
will toggle through the event indicator list (such as
alarms or trips)
ENTER
HELP
Provides general help information about a specific
setpoint or action.
Will scroll up through the setpoint and metering menu
page. It will scroll to the top of the setpoint page or a
UP ARROW section. In edit mode it will increase a setpoint in an
incremental step or toggle through the available
options in the setpoint.
Button
In the main menu the RIGHT ARROW button provides
access to the setpoint page. For setpoint pages with
RIGHT ARROW multiple columns, the RIGHT ARROW will scroll the
setpoint page to the right. When in edit mode it will
shift one character to the right.
Will scroll down through the setpoint pages and down
through the setpoints. In edit mode, it will decrement
DOWN ARROW
through values and toggle available options in the
setpoint.
Will move to the left through setpoint pages with
multiple columns. When in edit mode it will become
LEFT ARROW
the backspace key and will shift one character to the
left.
Power
Run
Indicates control power is present
Indicates unit/motor is running
Lights in conjunction with AUX 2 to indicate event or
warn of possible critical condition.
Alarm
LED
Lights in conjunction with AUX 1 to indicate a critical
condition has occurred.
Trip
AUX 1-8
Auxilary relays
Note: The directional arrow buttons are sensitive. In edit mode, if the buttons
are held for a long period, the scrolling speed will increase.
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4.2 Menu Navigation
Notes:
1. The MENU keys allow you to toggle the screens between the Setpoint Menu and
the Metering Menu. Simply use the arrow keys to get to the different screens
within each menu.
MENU
(1)
Example: To access Setpoint Page 3: PHASE & GROUND SETTINGS, press the
MENU key once and the DOWN ARROW two times.
PAGE 1 BASIC
CONFIGURATION
2. Levels 1, 2 and 3 indicate password protection levels for these setpoint pages.
LEVEL 1
PAGE 2 STARTER
CONFIGURATION
PAGE 3 PHASE &
GROUND SETTINGS
PAGE 4 RELAY
ASSIGNMENT
LEVEL 2
PAGE 5 RELAY
CONFIGURATION
PAGE 6 USER I/O
CONFIGURATION
PAGE 7 CUSTOM
ACCELERATION CURVE
PAGE 8 OVERLOAD
CURVE CONFIGURATION
PAGE 9 RTD
CONFIGURATION
LEVEL 3
PAGE 10 SECURITY
SET PASSWORD
PAGE 11
COMMUNICATIONS
PAGE 12
SETPOINTS
SYSTEM
FACTORY
LEVEL
PAGE 13 CALIBRATION
& SERVICE
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4.2.1 Password Access
Screens in Level 1 of the setpoint menu can be changed without password
access because they list basic motor information. Screens in Levels 2 and
3 require passwords because they provide more in-depth protection and
control of the unit. The password in Levels 2 and 3 can be changed by the
user.
NOTE: Setpoints can only be changed when the motor is in Stop/
Ready Mode! The soft starter will not allow a start if it is still
in the Edit Mode. When the unit is in the Edit Mode, an
asterisk is in the top right corner of the display.
4.2.2 Changing Setpoints
Example 1: Changing Motor FLA
A. Press MENU button to display Setpoint Page 1, Basic Configuration
B. Press the RIGHT ARROW you will view the screen Motor Full Load
Amps.
C. Press the ENTER button for edit mode. Note the asterisk (*) in the top
right corner of the LCD screen that indicates Edit Mode.
D. To change the value, select the UP ARROW or DOWN ARROW.
E. To accept the new value, press the ENTER button. The unit will accept
the changes and will leave the edit mode. Note the * is no longer in the
top right corner of the LCD Display.
MENU
MOTOR FULL LOAD AMPS
: 140 AMPS
PAGE 1 BASIC
CONFIGURATION
ENTER
MOTOR FULL LOAD AMP*
: 142 AMPS
2x
ENTER
MOTOR FULL LOAD AMP
: 142 AMPS
JKSSS+ Series - 35
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JKSSS+ Series
2.3 - 4.2KV
Chapter 5 - Setpoint Programming
The JKSSS+ Series has thirteen programmable setpoint pages which define the
motor data, ramp curves, protection, I/O configuration and communications. In Section
5.1, the setpoint pages are outlined in chart form. In Section 5.2 the setpoint pages
are illustrated and defined for easy navigation and programming. Note: Setpoints can
only be changed when the starter is in the Ready Mode. Also the soft start will not start
when it is in programming mode.
5.1
Setpoints Page List
These charts list the Setpoint Page, the programmable functions and the section.
5.1.1 Basic Configuration (Setpoint Page1)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
50 - 100% of Unit Max Current Rating
(Model and Service Factor dependent)
Motor Full Load Amps (FLA)
Model dependent
SP1.1
Service Factor
Overload Class
NEMA Design
Insulation Class
Line Voltage
1.15
1.00 – 1.3
SP1.2
SP1.3
SP1.4
SP1.5
SP1.6
SP1.7
10
O/L Class 5-30
A-F
B
B
A, B, C, E, F, H, K, N, S
1000 to 7200V
50 or 60 HZ
Model dependent
60
Line Frequency
5.1.2 Starter Configuration (Setpoint Page 2)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Jog, Start Ramp 1, Start Ramp 2, Custom
Accel Curve, Start Disabled, Dual Ramp,
Tach Ramp
SP2.1
SP2.2
Start Control Mode
Start Ramp 1
Jog Voltage
50%
5-75%, Off
Current, Voltage
0-100%
Start Ramp #1 Type
Initial Voltage #1
Ramp Time #1
Voltage
20%
10 sec
350% FLA
200% FLA
10 sec
350% FLA
Disabled
60%
0-120 sec
SP2.3
Current Limit #1
Initial Current #1
Ramp Time #1
200-500 %
0-300%
0-120 sec
Maximum Current #1
Start Ramp #2 Type
Initial Voltage #2
Ramp Time #2
200-500 %
Current, Voltage, Disabled
0-100 %
10 sec
350 % FLA
200% FLA
10 sec
350% FLA
Disabled
65%
0-120 sec
SP2.4
Current Limit #2
Initial Current #2
Ramp Time #2
200-500 %
0-600 %
0-120 sec
Maximum Current #2
Kick Start Type
200-500 %
Voltage or Disabled
10-100 %
SP2.5
SP2.6
Kick Start Voltage
Kick Start Time
0.50 sec
Disabled
60%
0.10-2.00
Deceleration
Enabled or Disabled
0-100 %
Start Deceleration Voltage
Stop Deceleration Voltage
Deceleration Time
Timed Output Time
Run Delay Time
At Speed Delay Time
30%
0-59 %
5 sec
1-60 sec
Off
1-1000 sec, Off
1-30 sec, Off
1-30 sec, Off
SP2.7
SP2.8
SP2.9
1 Sec
1 Sec
JKSSS+ Series - 36
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2.3 - 4.2KV
5.1.3 Phase and Ground Settings (Setpoint Page 3)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Imbalance Alarm Level
Imbalance Alarm Delay
Imbalance Trip Level
15% FLA
1.5 sec
20%
5-30 %, Off
SP3.1
1.0-20.0 sec
5-30 %, Off
SP3.2
SP3.3
Imbalance Trip Delay
2.0 sec
Off
1.0-20.0 sec
10-90 %, Off
1.0-60.0 sec
100-300 %, Off
1.0-20.0 sec
100-300 %, Off
1.0-20.0 sec
Undercurrent Alarm Level
Undercurrent Alarm Delay
Overcurrent Alarm Level
Overcurrent Alarm Delay
Overcurrent Trip Level
Overcurrent Trip Delay
Phase Loss Trip
2.0 sec
Off
SP3.4
2.0 sec
Off
SP3.5
2.0 sec
Enabled
0.1 sec
ABC
Enabled or Disabled
0-20.0 sec
SP3.6
Phase Loss Trip Delay
Phase Rotation Detection
Phase Rotation Trip Delay
*Ground Fault Alarm Level
*Ground Fault Alarm Delay
*Ground Fault Loset Trip Level
*Ground Fault Loset Trip Delay
*Ground Fault Hiset Trip Level
*Ground Fault Hiset Trip Delay
Overvoltage Alarm Level
Overvoltage Alarm Delay
Overvoltage Trip Level
Overvoltage Trip Delay
Undervoltage Alarm Level
Undervoltage Alarm Delay
Undervoltage Trip Level
Undervoltage Trip Delay
Line Frequency Trip Window
Line Frequency Trip Delay
P/F Lead P/F Alarm
ABC, ACB or Disabled
1.0 - 20.0 sec
5-90 %, Off
SP3.7
1.0 sec
Off
SP3.8
0.1 sec
Off
0.1-20.0 sec
5-90 %, Off
SP3.9
0.5 sec
Off
0.1-20 sec
5-90 %, Off
SP3.10
SP3.11
SP3.12
SP3.13
SP3.14
SP3.15
SP3.16
SP3.17
SP3.18
SP3.19
0.008 sec
Off
0.008-0.250 sec
5 -30%, Off
1.0 sec
10%
1.0-30.0 sec
5-30%, Off
2.0 sec
Off
1.0-30.0 sec
5-30%, Off
1.0 sec
15%
1.0-30.0 sec
5-30%, Off
2.0 sec
Disabled
1.0 sec
Off
1.0-30.0 sec
0-6 Hz, Disabled
1.0-20.0 sec
0.1-1.00, Off
1-120 sec
P/F Lead Alarm Delay
P/F Lead P/F Trip
1.0 sec
Off
.01-1.00, Off
1-120 sec
P/F Lead Trip Delay
1.0 sec
Off
P/F Lag P/F Alarm
.01-1.00, Off
1-120 sec
P/F Lag Alarm Delay
1.0 sec
Off
P/F Lag P/F Trip
.01-1.00, Off
1-120 sec
P/F Lag Trip Delay
1.0 sec
10 min
Off KW
Off KVA
Off KVAR
Off Amps
Power Demand Period
KW Demand Alarm Pickup
KVA Demand Alarm Pickup
KVAR Demand Alarm Pickup
Amps Demand Alarm Pickup
1 - 60 min
Off, 1-100000
Off, 1-100000
Off, 1-100000
Off, 1-100000
SP3.20
* Ground fault option must be installed.
JKSSS+ Series - 37
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5.1.4 Relay Assignments (Setpoint Page 4)
Factory Setting
2nd
Setpoint
Page
Security
Level
Description
Range
Section
1st
Trip Only
Trip
3rd
O/L Trip
I/B Trip
S/C Trip
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
Trip Only
Trip
Overcurrent Trip
Stator RTD Trip
Non Stator RTD Trip
*G/F Hi Set Trip
*G/F Lo Set Trip
Phase Loss Trip
Accel. Time Trip
Start Curve Trip
Over Frequency Trip
Under Frequency Trip
I*I*T Start Curve
Learned Start Curve
Phase Reversal
Overvoltage Trip
Undervoltage Trip
Power Factor Trip
Tach Accel Trip
Inhibits Trip
None
None
Trip
Trip
Trip
Trip Only
Trip Only
None
Trip
Trip
Trip
Trip
Trip
Trip
None
None
None
Trip
Trip(AUX1)
Alarm(AUX2)
AUX3
AUX4
Shunt Trip
None
None
None
None
None
None
AUX5-8
Bypass Discrepancy
Only Available in 8 Relay
System
TCB Fault
Trip
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
External Input #2
Dual Ramp
None
None
Trip
Notes:
AUX1 to AUX4 are for Factory
Use only. Do not change!
SP4.1
Thermostat
O/L Warning
Alarm
Alarm
None
Alarm
None
AUX3
Alarm
None
None
None
Trip
Only AUX 5 - 8 are used in the
2nd & 3rd relay assignments.
Overcurrent Alarm
SCR Fail Shunt Alarm
*Ground Fault Alarm
Under Current Alarm
Motor Running
I/B Alarm
Stator RTD Alarm
Non-Stator RTD Alarm
RTD Failure Alarm
Self Test Fail
Thermal Register
U/V Alarm
Alarm
Alarm
Alarm
None
None
None
None
None
None
None
AUX4
O/V Alarm
Power Factor Alarm
KW Demand Alarm
KVA Demand Alarm
KVAR Demand Alarm
Amps Demand Alarm
Timed Output
Run Delay Time
At Speed
JKSSS+ Series - 38
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2.3 - 4.2KV
5.1.5 Relay Configuration (Setpoint Page 5)
JKSSS+ Series - 39
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2.3 - 4.2KV
5.1.6 User I/O Configuration (Setpoint Page 6)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Enabled or Disabled
Section
Tachometer Scale Selection
Manual Tach Scale 4.0 mA:
Manual Tach Scale 20.0 mA:
Tach Accel Trip Mode Select
Tach Ramp Time
Disabled
0 RPM
SP6.1
0 - 3600
2000 RPM
Disabled
20 sec
0 - 3600
Underspeed, Overspeed or Disabled
1 - 120
0-3600
0 - 3600
1 - 60
SP6.2
Tach Underspeed Trip PT
Tach Overspeed Trip PT
Tach Accel Trip Delay
1650 RPM
1850 RPM
1 sec
Off, RPM 0-3600, Hottest Non-Stator RTD
0-200°C, Hottest Stator RTD
Analog Output #1
RMS Current
0 - 200°C, RMS Current 0 - 7500 A, %
Motor Load 0 - 600% Kw
SP6.3
SP6.4
Analog Output #1 4mA:
Analog Output #1 20mA:
Analog Output #2
0
0-65535
250
0-65535
% Motor Load
Same As Analog Input #1
0-65535
Analog Output #2 4mA:
Analog Output #2 20mA:
0
1000
0-65535
User Programmable External
Inputs
TCB Fault
Enabled
TCB Fault
NO
Enabled or Disabled
Name Ext. Input #1
TCB Fault Type
User Defined, up to 15 Characters
Normally Open or Closed
0-60 sec
TCB Fault Time Delay
External Input #2
Name Ext. Input #2
External Input #2 Type
External Input #2 Time Delay
Dual Ramp
1 sec
Disabled
Enabled or Disabled
User Defined, up to 15 Characters
Normally Open or Closed
0-60 sec
NO
SP6.5
0 sec
Dual Ramp
Dual Ramp
NO
Enabled or Disabled or Dual Ramp
User Defined, up to 15 Characters
Normally Open or Closed
0-60 sec
Name Ext. Input #3
Dual Ramp Type
Dual Ramp Time Delay
Thermostat
0 sec
Enabled
Thermostat
NC
Enabled or Disabled
Name Ext. Input #4
Thermostat Type
Thermostat Time Delay
User Defined, up to 15 Characters
Normally Open or Closed
0-60 sec
1 sec
JKSSS+ Series - 40
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5.1.7 Custom Acceleration Curve (Setpoint Page 7)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Custom Accel Curve
Disabled
Disabled, Curve A, B, or C
Custom Curve A
Curve A Voltage Level 1
Curve A Ramp Time 1
Curve A Voltage Level 2
Curve A Ramp Time 2
Curve A Voltage Level 3
Curve A Ramp Time 3
Curve A Voltage Level 4
Curve A Ramp Time 4
Curve A Voltage Level 5
Curve A Ramp Time 5
Curve A Voltage Level 6
Curve A Ramp Time 6
Curve A Voltage Level 7
Curve A Ramp Time 7
Curve A Voltage Level 8
Curve A Ramp Time 8
Curve A Current Limit
25%
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
0-100%
1-60 sec
200-500%
2 sec
30%
2 sec
37%
2 sec
45%
2 sec
55%
SP7.1
2 sec
67%
2 sec
82%
2 sec
100%
2 sec
350% FLA
Same Programmable Data Points and Ranges
as Custom Curve A
Custom Curve B
Custom Curve C
Same Programmable Data Points and Ranges
as Custom Curve A
5.1.8 Overload Curve Configuration (Setpoint Page 8)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Basic Run Overload Curve
Run Curve Locked Rotor Time
Run Locked Rotor Current
Coast Down Timer
O/L Class
1-30 sec, O/L Class
400-800%
SP8.1
600% FLA
Disabled
1-60 Min, Disabled
Basic Start Overload Curve
Start Curve Locked Rotor Time
Start Locked Rotor Current
Acceleration Time Limit
Number of Starts Per Hour
Time Between Starts Time
Area Under Curve Protection
Max I*I*T Start
O/L Class
600% FLA
30 sec
1-30 sec, O/L Class
400-800%
SP8.2
1-300 sec, Disabled
1-6, Disabled
Disabled
5 min
1-60 Min, Disabled
Enabled or Disabled
1-2500 FLA*FLA*sec
Disabled, Learn, Enabled
5-40%
Disabled
368 FLA
Disabled
10%
SP8.3
SP8.4
Current Over Curve
Learned Start Curve Bias
Time for Sampling
30 sec
1-300 sec
JKSSS+ Series - 41
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2.3 - 4.2KV
5.1.9 RTD Configuration (Setpoint Page 9)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Use NEMA Temp for RTD Values Disabled
Enabled or Disabled
SP9.1
# of RTD Used for Stator
RTD Voting
4
0-6
SP9.2
SP9.3
Disabled
Enabled or Disabled
120 OHM NI, 100 OHM NI, 100 OHM PT, 10
OHM CU
Stator Phase A1 Type
Off
RTD #1 Description
Stator A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
Stator Phase A1 Alarm Level
Stator Phase A1 Trip Level
Stator Phase A2 Type
RTD #2 Description
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
Stator A2
Stator Phase A2 Alarm
Stator Phase A2 Trip Level
Stator Phase B1 Type
RTD #3 Description
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
Stator B1
Stator Phase B1 Alarm Level
Stator Phase B1 Trip Level
Stator Phase B2 Type
RTD #4 Description
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
Stator B2
Stator Phase B2 Alarm Level
Stator Phase B2 Trip Level
Stator Phase C1 Type
RTD #5 Description
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
SP9.4
Stator C1
Stator Phase C1 Alarm Level
Stator Phase C1 Trip Level
Stator Phase C2 Type
RTD #6 Description
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
Stator C2
Stator Phase C2 Alarm Level
Stator Phase C2 Trip Level
End Bearing Type
Off
Off
0-240C (32-464F), Off
Off
Same as Stator A1
RTD #7 Description
End Bearing
User defined, Up to 15 Characters
0-240C (32-464F), Off
End Bearing Alarm Level
End Bearing Trip Level
Shaft Bearing Type
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
RTD #8 Description
Shaft Bearing
Shaft Bearing Alarm Level
Shaft Bearing Trip Level
RTD #9 Type
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
RTD #9 Description
User defined
RTD #9 Alarm Level
Off
Off
RTD #9 Trip Level
0-240C (32-464F), Off
JKSSS+ Series - 42
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2.3 - 4.2KV
5.1.9 RTD Configuration Page 9 Cont’d
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
RTD #10 Type
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
RTD #10 Description
RTD #10 Alarm Level
RTD #10 Trip Level
RTD #11 Type
User defined
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
RTD #11 Description
RTD #11 Alarm Level
RTD #11 Trip Level
RTD #12 Type
User defined
SP9.4
Off
Off
0-240C (32-464F), Off
Off
Same as Stator Phase A1
User defined, Up to 15 Characters
0-240C (32-464F), Off
RTD #12 Description
RTD #12 Alarm Level
RTD #12 Trip Level
User defined
Off
Off
0-240C (32-464F), Off
5.1.10 Security Set Password Page 10
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Set Level 2 Password
Set Level 3 Password
100
000 – 999 Three Digits
0000 – 9999 Four Digits
SP10.1
SP10.2
1000
5.1.11 Communications Page 11
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Set Front Baud Rate
9.6 KB/sec
2.4, 4.8, 9.6, 19.2, 38.4 KB/sec
2.4, 4.8, 9.6, 19.2, 38.4 KB/sec
1 – 247
SP11.1
SP11.2
SP11.3
SP11.4
SP11.5
Set Modbus Baud Rate
Modbus Address Number
Set Access Code
9.6 KB/sec
247
1
1 – 999
Set Link Baud Rate
38.4 KB/sec
2.4, 4.8, 9.6, 19.2, 38.4 KB/sec
Remote Start/Stop
Disabled
Enabled or Disabled
SP11.6
JKSSS+ Series - 43
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2.3 - 4.2KV
5.1.12 System (Setpoint Page 12)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Default Display Screen
Metering Data Page #
1
1
Enter Metering Page (1-4)
Enter Metering Screen
Page 1(1-10)
SP12.1
Metering Data Screen #
Page 2 (1-11)
Page 3 (1 - 29)
Page 4 (1 - 6)
Alarms
RTD Failure Alarm
Disabled
90%
Enabled or Disabled
Off, 40-95%
SP12.2
Thermal Register Alarm
Thermal Alarm Delay
Thermal Register Setup Info
Cold Stall Time
10 sec
1-20 sec
O/L Class
½ O/L Class
30 Min
O/L Class (5-30) or 4-40 second time delay
Hot Stall Time
½ O/L Class, 4-40 sec
10-300 Min
Stopped Cool Down Time
Runing Cool Down Time
Relay Measured Cool Rates
Thermal Register Minimum
Motor Design Ambient Temp
15 Min
10-300 Min
Disabled
15%
Enabled or Disabled
10-50%
SP12.3
40C
10-90C
Motor Design Run Temperature
80% Max
50-100% of Motor Stator Max Temp
Motor Stator Max Temp
INS CLS
Enabled
7
INS CLS, 10-240 C
Enabled or Disabled
1-50, On
I/B Input to Thermal Register
Use Calculated K or Assign
Press Enter to Clr Thermal Register
SP12.4
5.1.13 Calibration and Service (Setpoint Page 13)
Setpoint
Page
Security
Level
Factory Setting
Default
Description
Range
Section
Set Date and Time
FACTORY SET;
##/##/## ##:##
(DDMMYY:HHMM)
FACTORY SET;
##/##/####
SP13.1
Enter Date (DDMMYYYY)
D=1-31, M=1-12, Y=1970-2069
H=00-23, M=0-59
FACTORY SET;
##:##
Enter Time (HH:MM)
Model #
FACTORY SET;
Display Only, Cannot be changed
Available to Qualified Factory Personnel
SP13.2
SP13.3
Firmware REV. #
######
######
Press Enter to Access Factory
Settings
JKSSS+ Series - 44
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2.3 - 4.2KV
5.2 Setpoint Menu
Note:
1. Push MENU key to toggle the screens between Setpoint Menu and Metering
Menu.
2. Follow the arrow keys to get to different screens.
Example: For Page 3 PHASE & GROUND SETTINGS, press the MENU key and
the DOWN ARROW two times.
MENU
(1)
PAGE 1 BASIC
CONFIGURATION
LEVEL 1
PAGE 2 STARTER
CONFIGURATION
PAGE 3 PHASE &
GROUND SETTINGS
PAGE 4 RELAY
ASSIGNMENT
LEVEL 2
PAGE 5 RELAY
CONFIGURATION
PAGE 6 USER I/O
CONFIGURATION
PAGE 7 CUSTOM
ACCELERATION CURVE
PAGE 8 OVERLOAD
CURVE CONFIGURATION
PAGE 9 RTD
CONFIGURATION
LEVEL 3
PAGE 10 SECURITY
SET PASSWORD
PAGE 11
COMMUNICATIONS
PAGE 12
SETPOINTS
SYSTEM
FACTORY
LEVEL
PAGE 13 CALIBRATION
& SERVICE
JKSSS+ Series - 45
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2.3 - 4.2KV
SP.1 Basic Configuration (Setpoint Page 1)
In Setpoint Page 1, the starter is looking for the following basic
nameplate data of the motor.
MENU
PAGE 1 BASIC
CONFIGURATION
MOTOR FULL LOAD AMPS
: 200 AMPS
SP1.1Motor Full Load Amps: Allows the user to enter the motor’s
FLA rating. Range of adjustment is 50 - 100% (less
programmed service factor).
Range: 50 - 100% of Unit
MAX CURRENT AMPS
Increments of 1
SERVICE FACTOR
: 1.15 X FLA
SP1.2Service Factor: Sets the pickup point on the overload curve
as defined by the programmed motor full load current. Ex:
If the motor FLA is 100 and the service factor is 1.15, the
overload pickup point will be 115 Amps.
Range: 1.00 - 1.3
Increments of 0.01
OVERLOAD
CLASS: 10
SP1.3Overload Class: Choose the motor protection overload class,
Range: 5 - 30
Increments of 5
range from 5-30.
Ex: Overload Class 10 will trip in 10 seconds at six times
FLA.
NEMA
DESIGN: B
Range: A - F
INSULATION
CLASS: B
Range: A - S
LINE VOLTAGE
INPUT: 4160 VOLTS
Range: 100 - 7200
LINE FREQUENCY
HZ: 60
Range: 50 or 60
SP1.4
SP1.5
NEMA design: The motor design maximum allowed slip
(Select from Class A through F).
Insulation Class: The motor insulation temperature class
(Select A, B, C, E, F, H, K, N or S).
SP1.6
SP1.7
Line Voltage Input: Applied Voltage
Line Frequency: The user may choose either 50 Hz or 60
Hz.
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SP.2 Starter Configuration (Setpoint Page 2)
MENU
(Hit DOWN ARROW one time)
PAGE 2 STARTER
CONFIGURATION
START CONTROL MODE
: START RAMP 1
JOG, START RAMP 1,
START RAMP 2, DUAL
RAMP, CUSTOM ACCEL
CURVE,START DISABLED
If
If
CURRENT
selected
these
screens
will appear.
VOLTAGE
selected
these
screens
will appear.
JOG VOLTAGE
: 50%
Range: 5 - 75% or Off
Increments 5
INITIAL CURRENT
#1: 200% FLA
INITIAL VOLTAGE
#1: 20%
START RAMP #1 TYPE
: VOLTAGE
Options:Voltage, Current
or Off
Range: 0 - 300%
Increments of 1
Range: 0 - 100%
Increments of 1
RAMP TIME
#1: 10 SEC.
RAMP TIME
#1: 10 SEC.
Range: 0 - 120 SEC
Increments of 1
Range: 0 - 120 SEC.
Increments of 1
MAXIMUM CURRENT
#1: 350% FLA
CURRENT LIMIT
#1: 350% FLA
Range: 200-500%
Increments of 10
Range: 200 - 500%
Increments of 10
If
If
VOLTAGE
selected
these
screens
will appear.
CURRENT
selected
these
screens
will appear.
START RAMP #2 TYPE
: DISABLED
INITIAL CURRENT
#2: 200% FLA
INITIAL VOLTAGE
#2: 60%
Options: Voltage, Current
or Off
Range: 0 - 300%
Increments of 1
Range: 0 - 100%
Increments of 1
RAMP TIME
#2: 10 SEC.
RAMP TIME
#2: 10 SEC.
Range: 0 - 120 SEC
Increments of 1
Range: 0 - 120 SEC.
Increments of 1
MAXIMUM CURRENT
#2: 350% FLA
CURRENT LIMIT
#2: 350% FLA
Range: 200-500%
Increments of 10
Range: 200 - 500%
Increments of 10
KICK START
TYPE: DISABLED
KICK START VOLTAGE
: 65%
Range: Voltage or Disabled
Range: 10 - 100%
Increments of 5
KICK START TIME
: 0.50 SEC.
DECELERATION
: DISABLED
Range: 0.10 - 2.00
Increments of 0.10
Range: Enabled or Disabled
START DECELERATION
VOLTAGE: 60%
TIMED OUTPUT
TIME: OFF
Range: 0 - 100%
Increments of 1
Range: 1 - 1000 sec, OFF
Increments of 1
STOP DECELERATION
VOLTAGE: 30%
RUN DELAY
TIME: 1 SEC.
Range: 0 - 59%
Increments of 1
Range: 0 - 30 sec, OFF
Increments of 1
DECELERATION
TIME: 5 SEC.
AT SPEED DELAY
TIME: 1 SEC.
Range: 1 - 60
Increments of 1
Range: 0 - 30 sec, OFF
Increments of 1
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SP.2 Starter Configuration (Setpoint Page 2)
Provides multiple choices for starting ramps that can be
selected for particular loads and applications.
• Voltage Ramping with Current Limit is the most
used curve and is similar to voltage ramping.
However, it adds an adjustable maximum current
output. Voltage is increased gradually until the
setting of the Maximum Current Limit setpoint
is reached. The voltage is held at this level until
the motor accelerates to full speed. This may be
necessary in applications where the electrical
power is limited. Typical applications include
portable or emergency generator supplies, utility
power near the end of a transmission line and
utility starting power demand restrictions. Note:
Using Current Limit will override the Ramp Time
setting if necessary, so use this feature when
acceleration time is not critical. To achieve Voltage
Ramping with Current Limit, select VOLTAGE for
the START RAMP #1 setpoint and set CURRENT
LIMIT #1 setpoint to a desired lower setting, as
determined by your application requirements.
SP2.1Start Control Mode: Start Ramp 1, Jog, Start
Disabled, Tach Ramp, Custom Accel Curve, Dual
Ramp, Start Ramp 2.
• Dual Ramp: The dual ramp mode works in
conjunction with External Input #3. This allows
the user to switch between the two start ramps
without having to reconfigure the start mode. (For
details on configuring External Input #3 for DUAL
RAMP see Setpoint Page 6.)
• Custom Accel Curve: Allows the user to
custom design the acceleration start curve to the
application. (See setpoint page 7 for configuration
setup.) Note: If Custom Accel Curve has not
been enabled in setpoint page 7, the soft starter
will ignore the start control mode and read this
setpoint as disabled.
Start Ramp 1 Type: Current
Current Ramping (Closed Loop Torque Ramping)
is used for smooth linear acceleration of output
torque. This ramp is only used on some conveyor
systems (long haul or down hill). Output voltage
is constantly updated to provide the linear
current ramp, and therefore the available torque
is maximized at any given speed. This is for
applications where rapid changes in torque may
result in load damage or equipment changes.
Typical applications include overland conveyors
if belt stretching occurs; fans and mixers if blade
warping is a problem; and material handling
systems if stacked products fall over or break.
This feature can be used with or without the
Maximum Current Limit setting. To achieve
Current Ramping select CURRENT for START
RAMP #1 TYPE setpoint and the MAXIMUM
CURRENT #1 setpoint to the desired level.
• Tach Ramp: See setpoint page 6 for configuration
setup of tachometer input.
SP2.2jog Voltage: The voltage level necessary to cause
the motor to slowly rotate.
SP2.3Start Ramp 1 Type: The ramp type can be setup for
either Voltage or Current. If Voltage is selected,
initial voltage, ramp time and current limit are
adjustable. If Current is selected, initial current,
ramp time and maximum current are adjustable.
Start Ramp 1 Type: Voltage
• Voltage Ramping is the most reliable starting
method, because the starter will eventually
reach an output
voltage high enough to
draw full current and
develop full torque.
This method is useful
for applications where
the load conditions
change frequently and
where different levels
of torque are required.
Typical applications
include material handling
Current Limit Only: (Current Step) start uses the
Current Limit feature exclusively. This method of
starting eliminates the soft start voltage/current
ramp and instead, maximizes the effective
application of motor torque within the limits of the
motor. In this mode, setpoint RAMP TIME #1 is
set to zero (0), so the output current jumps to the
current limit setting immediately. Typically used
in with a limited power supply, when starting a
difficult load such as a centrifuge or deep well
pump, when the motor capacity is barely adequate
(stall condition or overloading occurs) or if other
starting modes fail. Since ramp times are set to
zero (0). START RAMP #1 TYPE is set to either
VOLTAGE or CURRENT.
conveyors, positive
displacement pumps and drum mixers.
Voltage is increased from a starting point (Initial
Torque) to full voltage over an adjustable period of
time (Ramp Time). To achieve Voltage Ramping,
select VOLTAGE for the START RAMP #1 TYPE
setpoint and set CURRENT LIMIT #1 setpoint
to 500% (the maximum setting). Since this is
essentially Locked Rotor Current on most motors,
there is little or no Current Limit effect on the
• Initial Torque (Initial Voltage #1 or Initial
Current #1): Sets the initial start point of either
Ramp profile.
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the Voltage Ramp or the Current Ramp. Every
SP2.5Kick Start: Used as an initial energy burst in
load requires some amount of torque to start from
a standstill. It is inefficient to begin ramping the
motor from zero every time, since between zero
and the WK2 break-away torque level, no work is
being performed. The initial torque level should be
set to provide enough torque to start rotating the
motor shaft, enabling a soft start and preventing
torque shock damage. Setting this start point too
high will not damage the starter, but may reduce
or eliminate the soft start effect.
applications with high friction loads.
• Kick Start Voltage: The initial voltage (as a
percent of full voltage value) that is needed to
start the motor (i.e. Breakaway or Initial Torque).
• Kick Start Time: The time the initial torque boost
is applied.
SP2.6Deceleration: Allows the motor to gradually come to
a soft stop.
• Ramp Time #1: Sets the maximum allowable time
for ramping the initial voltage or current (torque)
setting to either of the following:
1) the Current Limit setting when the motor is still
accelerating, or
• Start Deceleration Voltage: The first part of
the deceleration ramp. The soft starter initially
drops to this voltage level upon receiving a STOP
command. (Represented as a percent of voltage
value.)
2) full output voltage if the Current Limit is set to
maximum.
Increasing the ramp time softens the start process
by gradually increasing the voltage or current.
Ideally, the ramp time should be set for the longest
amount of time the application will allow (without
stalling the motor). Some applications require
a short ramp time due to the mechanics of the
system (i.e. centrifugal pumps, because pump
problems can occur due to insufficient torque).
• Stop Deceleration Voltage: The drop-off point of
the deceleration ramp. (Percent of voltage value.)
• Deceleration Time: Decel ramp time.
SP2.7Timed Output: Used with an AUX 5-8 relay. When
enabled, and upon a start command, it waits until
the programmed time plus the run delayed time
has expired. The relay energizes and remains so
until a stop command is received. It de-energizes
upon receiving a stop command.
• Current Limit: Sets the maximum motor current
the starter will allow during Ramping. As the motor
begins to ramp, the Current Limit feature sets a
ceiling at which the current draw is held. Current
Limit remains in effect until the following occurs:
1) the motor reaches full speed (detected by the
At-Speed detection circuit) or
2) the Overload Protection trips on Motor Thermal
Overload.
Once the motor reaches full speed, the Current
Limit feature becomes inactive.
SP2.8Run Delay Time: Can be used with an AUX 5-8
relay. The delay timer begins upon receipt of the
start command. The relay will then drop out when
the time has expired.
SP2.9At Speed Delay Time: Used with an AUX 4 relay, it
waits until after the motor reaches the end of ramp
and the programmed delay time has expired. The
relay energizes until a stop command has been
received.
In the Voltage Ramp Profile, the voltage output is
increased until it reaches the Current Limit. Ramp
time is the maximum amount of time it takes for
the voltage to increase until the Current Limit
setting takes over. With some load conditions, the
Current Limit is reached before the Ramp Time
expires.
The Current Ramp profile varies the output
voltage to provide a linear increase in current up
to the Maximum Current setpoint value. A closed
loop feedback of motor current maintains the
Current Ramp profile.
SP2.4Start Ramp 2: The same options and screen setups
as Start Ramp 1. Note: CUSTOM ACCEL CURVE
overrides the voltage or current start in Ramps 1
and 2 when selected to be the start control mode.
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SP.3 Phase & Ground Settings
(Setpoint Page 3)
(Security Level: 2)
MENU
(Hit DOWN ARROW two times)
IMBALANCE ALARM
LEVEL: 15% FLA
IMBALANCE ALARM
DELAY: 1.5 SEC.
PAGE 3 PHASE &
GROUND SETTINGS
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 20.0 SEC.
Increments of 0.1
IMBALANCE TRIP
LEVEL: 20%FLA
IMBALANCE TRIP
DELAY: 2.0 SEC.
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 20.0 SEC.
Increments of 0.1
UNDERCURRENT ALARM
LEVEL:
UNDERCURRENT ALARM
DELAY: 2.0 SEC.
OFF
Note: Proper phase sequence must be observed when
connecting the input power. For example, phase A
must lead phase B, which in turn must lead phase
C by 120° respectively. If the phase rotation is
not correct, a fault light and the LCD display will
indicate the problem.
Range: 10 - 90%, OFF
Increments of 1
Range: 1.0 - 60.0 SEC.
Increments of 0.1
OVERCURRENT ALARM
LEVEL: OFF
OVERCURRENT ALARM
DELAY: 2.0 SEC.
Range: 100 - 300%, OFF
Increments of 1
Range: 1.0 - 20.0 SEC., OFF
Increments of 0.1
OVERCURRENT TRIP
LEVEL: OFF
OVERCURRENT TRIP
DELAY: 2.0 SEC.
SP3.1Imbalance Alarm Level: This is an advance warning
of a phase imbalance problem. The problem may
not be a fault in the motor, but merely caused by
imbalanced voltages.
Range: 100 - 300%, OFF
Increments of 1
Range: 1.0 - 20.0 SEC.
Increments of 0.1
PHASE LOSS TRIP
:
PHASE LOSS TRIP
DELAY:
ENABLED
0.1 SEC.
Options: Enabled or Disabled
Range: 0 - 20.0 SEC.
Increments of 0.1
• Imbalance Alarm Delay: The amount of time the
imbalance condition must exist before an alarm
occurs.
PHASE ROTATION
DETECTION: ABC
PHASE ROTATION TRIP
DELAY: 1.0 SEC
Options: ABC, ACB or
Disabled
Range: 1.0 - 20.0 SEC.
SP3.2Imbalance Trip Level: This will trip the motor on
excessive phase imbalance. The trip level should
be programmed to a higher value than the alarm
level.
GROUND FAULT ALARM
LEVEL: OFF
GROUND FAULT ALARM
DELAY: 0.1 SEC.
*
*
Range: 5 - 90%, OFF
Increments of 1
Range: 0.1 - 20.0 SEC.
Increments of 0.1
• Imbalance Trip Delay: The amount of time the
imbalance condition must exist before a trip will
occur.
GROUND FAULT LOSET
TRIP LEVEL: OFF
GROUND FAULT LOSET
TRIP DELAY: 0.5 SEC
Range: 5 - 90%, OFF
Increments of 1
Range: 0.1 - 20.0 SEC.
Increments of 0.1
SP3.3Undercurrent Alarm Level: Typically used to warn
of possible load loss, a coupling breaking or other
mechanical problems.
GROUND FAULT HISET
TRIP LEVEL: OFF
GROUND FAULT HISET
TRIP DELAY: 0.008 SEC.
*
Range: 5 - 90%, OFF
Increments of 1
Range: 0.008 - 0.250 SEC.
Increments of 0.002
• Undercurrent Alarm Delay: The amount of time
the undercurrent condition must exist before an
alarm will occur.
OVERVOLTAGE ALARM
LEVEL: OFF
OVERVOLTAGE ALARM
DELAY: 1.0 SEC.
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 30.0 SEC.
Increments of 0.1
SP3.4Overcurrent Alarm Level: Typically used to indicate
when the motor is overloaded. This feature can be
used to either stop the feed to the equipment or
warn operators of an overload condition.
OVERVOLTAGE TRIP
LEVEL: 10%
OVERVOLTAGE TRIP
DELAY: 2.0 SEC.
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 30.0 SEC.
Increments of 0.1
UNDERVOLTAGE ALARM
LEVEL: OFF
UNDERVOLTAGE ALARM
DELAY: 1.0 SEC.
• Overcurrent Alarm Delay: The amount of time the
overcurrent condition must exist before an alarm
will occur.
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 30.0 SEC.
Increments of 0.1
UNDERVOLTAGE TRIP
LEVEL: 15%
UNDERVOLTAGE TRIP
DELAY: 2.0 SEC.
Range: 5 - 30%, OFF
Increments of 1
Range: 1.0 - 30.0 SEC.
Increments of 0.1
LINE FREQUENCY TRIP
WINDOW: DISABLED
LINE FREQUENCY TRIP
DELAY: 1.0 SEC.
Range: 0 - 6, Disabled
Increments of 1
Range: 1.0 - 20.0 SEC.
Increments of 0.1
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SP.3 Phase & Ground Settings (Setpoint Page 3)
MENU
(Hit DOWN ARROW two times)
POWER FACTOR LEAD
P/F ALARM: OFF
P/F LEAD ALARM
DELAY: 1 SEC.
PAGE 3 PHASE &
GROUND SETTINGS
Range: .01 - 1.00, OFF
Increments of .01
Range: 1 - 120 SEC
Increments of 1
POWER FACTOR LEAD
P/F TRIP: OFF
P/F LEAD TRIP
DELAY: 1.0 SEC.
SP3.5Overcurrent Trip Level: Typically used to indicate
the motor is severely overloaded and at which
point a trip occurs.
Range: .01 - 1.00, OFF
Increments of .01
Range: 1 - 120 SEC.
Increments of 1
POWER FACTOR LAG
P/F ALARM:
P/F LAG ALARM
DELAY: 1.0 SEC.
OFF
• Overcurrent Trip Delay: The amount of time the
overcurrent condition must exist before a trip will
occur.
Range: .01 - 1.00, OFF
Increments of .01
Range: 1 - 120 SEC.
Increments of 1
POWER FACTOR LAG
P/F TRIP:
P/F LAG TRIP
DELAY: 1.0 SEC.
OFF
Range: .01 - 1.00, OFF
Increments of .01
Range: 1 - 120 SEC.
Increments of 1
SP3.6Phase Loss
Trip: When
POWER DEMAND
PERIOD: 10 MINUTES
enabled, the
soft starter will
trip the motor
off-line upon a
loss of
Range: 1 - 60 Minutes
Increments of 1
KW DEMAND ALARM
PICKUP: OFF KW
phase power.
Range: OFF, 1 - 100000
Increments of 1
• Phase Loss Trip Delay: The amount of time the
phase loss condition must exist before a trip will
occur.
KVA DEMAND ALARM
PICKUP: OFF KVA
Range: OFF, 1 - 100000
Increments of 1
SP3.7Phase Rotation Detection: The soft starter is
continuously monitoring the phase rotation. Upon
a start command, a trip will occur if it detects a
change in the phase rotation.
KVAR DEMAND ALARM
PICKUP: OFF KVAR
Range: OFF, 1 - 100000
Increments of 1
AMPS DEMAND ALARM
PICKUP: OFF AMPS
• Phase Rotation: There are two possible phase
rotation options: ABC or ACB. This setpoint
monitors the wiring to ensure that the phase
rotation is correct. To view the present phase
rotation, go to Metering Page1, screen number 4.
Range: OFF, 1 - 100000
Increments of 1
SP3.10 * Ground Fault Hiset Trip Level: Used to trip the
motor (within milliseconds) upon detecting a high
level of ground current leakage. This setpoint is
intended to detect low impedance faults.
SP3.8* Ground Fault Alarm: Typically used to warn of low
level ground current leakage.
• * Ground Fault Alarm Delay: The amount of time
that the ground fault condition must exist before an
alarm will occur.
• *Ground Fault Hiset Trip Delay: The amount
of time that the ground fault condition must exist
before a trip will occur.
SP3.9* Ground Fault Loset Trip Level: Typically used
to trip the motor on a low level of ground current
leakage. This setpoint is intended to detect high
impedance faults.
SP3.11 Overvoltage Alarm Level: Typically used to
indicate when the line voltage is too high. This is
an alarm level.
• Overvoltage Alarm Delay: The amount of time
that the overvoltage condition must exist before a
trip will occur.
• * Ground Fault Loset Trip Delay: The amount
of time that the ground fault condition must exist
before a trip will occur.
*Ground Fault Option must be installed
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SP3.12 Overvoltage Trip Level: Typically used to indicate
that the line voltage is too high and at which point a
trip occurs
SP3.18 Power Factor Lag Alarm: Typically used to
indicate a lagging power factor.
• Power Factor Lag Alarm Delay: The amount of
time that the power factor lagging condition must
exist beyond the window before a trip will occur.
• Overvoltage Trip Delay: The amount of time that
the overvoltage condition must exist before a trip
will occur.
SP3.19 Power Factor Lag Trip: The acceptable amount
SP3.13 Undervoltage Alarm Level: Typically used to
indicate when the line voltage is too low. This is an
alarm level.
of power factor lag before a trip is generated.
• Power Factor Lag Delay: The amount of time
that the power factor lag condition must exist
beyond the window before a trip will occur.
• Undervoltage Alarm Delay: The amount of time
that the overvoltage condition must exist before a
trip will occur.
SP3.20 Power Demand Period: The soft starter
measures the demand of the motor for several
parameters (current, kW, kvar, kVA). The demand
values of motors assists in energy management
programs where processes may be altered or
scheduled to reduce overall demand. Demand
is calculated by a programmed amount of time
where current, kW, kvar and kva samples are
taken and then averaged and stored to assess
demand.
SP3.14 Undervoltage Trip Level: Typically used to
indicate that the line voltage is too low and at which
point a trip occurs
• Undervoltage Trip Delay: The amount of time that
the undervoltage condition must exist before a trip
will occur.
SP3.15 Line Frequency Trip Window: The acceptable
amount of drift above or below the line frequency
(Hz) before a trip is generated.
• Line Frequency Trip Delay: The amount of time
that the frequency drift condition must exist beyond
the window before a trip will occur.
SP3.16 Power Factor Lead Alarm: Typically used to
indicate a leading power factor.
• Power Factor Lead Alarm Delay: The amount of
time that the power factor lead condition must exist
beyond the window before a trip will occur.
SP3.17 Power Factor Lead Trip: The acceptable amount
of power factor lead before a trip is generated.
• Power Factor Lead Delay: The amount of time
that the power factor lead condition must exist
beyond the window before a trip will occur.
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SP.4 Relay Assignment (Setpoint Page 4)
PHASE REVERSAL
1ST: TRIP
I/B ALARM
1ST: ALARM
MENU
(Hit DOWN ARROW three times)
OVERVOLTAGE TRIP
1ST: TRIP
STATOR RTD ALARM
1ST: NONE
O/L TRIP
1ST: TRIP ONLY
PAGE 4 RELAY
ASSIGNMENT
Range: TRIP (AUX1),
ALARM (AUX2), AUX3,
AUX4
UNDERVOLTAGE TRIP
1ST: TRIP
NON-STATOR RTD ALARM
1ST: NONE
I/B TRIP
1ST: TRIP
POWER FACTOR TRIP
1ST: NONE
RTD FAILURE ALARM
1ST: NONE
S/C TRIP
1ST: TRIP ONLY
TACH ACCEL TRIP
1ST: NONE
SELF-TEST FAIL
1ST: TRIP
OVERCURRENT TRIP
1ST: TRIP
INHIBITS TRIP
1ST: TRIP
THERMAL REGISTER
1ST: ALARM
STATOR RTD TRIP
1ST: NONE
SHUNT TRIP
1ST: NONE
U/V ALARM
1ST: ALARM
NON-STATOR RTD TRIP
1ST: NONE
BYPASS DISCREPANCY
1ST: NONE
O/V ALARM
1ST: ALARM
G/F HI SET TRIP
1ST: TRIP
TCB FAULT
1ST: TRIP
POWER FACTOR ALARM
1ST: NONE
EXTERNAL INPUT #2
1ST: NONE
G/F LO SET TRIP
1ST: TRIP
DUAL RAMP
1ST: NONE
KW DEMAND ALARM
1ST: NONE
PHASE LOSS TRIP
1ST: TRIP
THERMOSTAT
1ST: TRIP
KVA DEMAND ALARM
1ST: NONE
ACCEL. TIME TRIP
1ST: TRIP ONLY
O/L WARNING
1ST: ALARM
KVAR DEMAND ALARM
1ST: NONE
START CURVE TRIP
1ST: TRIP ONLY
OVERCURRENT ALARM
1ST: ALARM
AMPS DEMAND ALARM
1ST: NONE
OVER FREQUENCY TRIP
1ST: NONE
SCR FAIL SHUNT ALARM
1ST: NONE
TIMED OUTPUT
1ST: NONE
UNDER FREQUENCY TRIP
1ST: TRIP
GROUND FAULT ALARM
1ST: ALARM
UNDERCURRENT ALARM
1ST: NONE
RUN DELAY TIME
1ST: NONE
I*I*T START CURVE
1ST: TRIP
LEARNED START CURVE
1ST: TRIP
MOTOR RUNNING
1ST: AUX3
AT SPEED
1ST: AUX4
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SP.4 Relay Assignment (Setpoint Page 4)
(Security Level: 2)
The protection functions are user programmable to an output relay. Factory setting for the trip functions assigned to TRIP
(AUX1) relay and alarm functions to ALARM (AUX2) relay. AUX1 - 4 are Factory Set and should not be changed.
SP4.1 The following is a list of the user programmable functions.
FUNCTIONS
RELAy ASSIGNMENTS
1st
2nd
3rd
OVERLOAD TRIP
IMBALANCE TRIP
SHORT CIRCUIT TRIP
OVERCURRENT TRIP
STATOR RTD TRIP
NON-STATOR RTD TRIP
GROUND FAULT HI SET TRIP*
GROUND FAULT LO SET TRIP*
PHASE LOSS TRIP
TRIP ONLY
TRIP (AUX1)
TRIP ONLY
TRIP (AUX1)
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
TRIP (AUX1)
TRIP (AUX1)
TRIP (AUX1)
TRIP ONLY
TRIP ONLY
NONE
TRIP (AUX1)
TRIP (AUX1)
TRIP (AUX1)
TRIP (AUX1)
TRIP (AUX1)
TRIP (AUX1)
NONE
NONE
TRIP (AUX1)
NONE
NONE
TRIP (AUX1)
NONE
ACCEL TIME TRIP
START CURVE TRIP
OVER FREQUENCY TRIP
UNDER FREQUENCY TRIP
I*I*T START CURVE
LEARNED START CURVE
PHASE REVERSAL
OVERVOLTAGE TRIP
UNDERVOLTAGE TRIP
POWER FACTOR TRIP
TACH ACCEL TRIP
INHIBITS TRIP
SHNT TRIP
BYPASS DISCREPANCY
TCB FAULT
EXTERNAL INPUT 2
DUAL RAMP
NONE
THERMOSTAT
TRIP (AUX1)
ALARM (AUX2)
ALARM (AUX2)
ALARM (AUX2)
ALARM (AUX2)
NONE
AUX3
ALARM (AUX2)
NONE
OVERLOAD WARNING
OVERCURRENT ALARM
SCR FAIL SHUNT ALARM
GROUND FAULT ALARM*
UNDERCURRENT ALARM
MOTOR RUNNING
IMBALANCE ALARM
STATOR RTD ALARM
NON-STATOR RTD ALARM
RTD FAILURE ALARM
SELF TEST FAIL
THERMAL REGISTER
U/V ALARM
O/V ALARM
POWER FACTOR ALARM
KW DEMAND ALARM
KVA DEMAND ALARM
KVAR DEMAND ALARM
AMPS DEMAND ALARM
TIMED OUTPUT
NONE
NONE
TRIP (AUX1)
ALARM (AUX2)
ALARM (AUX2)
ALARM (AUX2)
NONE
NONE
NONE
NONE
NONE
NONE
NONE
AUX4
RUN DELAY TIME
AT SPEED
*Ground fault option must be installed.
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SP.5 Relay Configuration (Setpoint Page 5)
(Security Level: 2)
MENU
In Setpoint Page 5 the user
(Hit DOWN ARROW four times)
can configure the four output
relays as either fail-safe or
non fail-safe and latching or
non-latching.
PAGE 5 RELAY
CONFIGURATION
TRIP (AUX1) RELAY
FAIL-SAFE: NO
TRIP (AUX1) RELAY
LATCHED: YES
Options: Yes or No
SP5.1When a relay has been configured
as fail-safe and power is applied,
the relay will be energized. The
relay will then de-energize when
an event occurs or if the power
fails. Note: The relays in the
ALARM (AUX2) RELAY
FAIL-SAFE:
ALARM (AUX2) RELAY
LATCHED: NO
NO
AUX 3 RELAY
FAIL-SAFE: NO
AUX3 RELAY
LATCHED:
NO
soft starter will not prevent a start
sequence unless they are wired in
as interlocks. If power is lost, the
motor power is also lost. Do not
change the programming for AUX
1-4. These are for factory use only.
AUX 5-8 are user defined outputs.
AUX4 RELAY
FAIL-SAFE: NO
AUX4 RELAY
LATCHED: NO
AUX5 RELAY
FAIL-SAFE: NO
AUX5 RELAY
LATCHED: NO
SP5.2A relay configured as non-latching
will reset itself when the cause of
the trip event is not continuous.
The TRIP (AUX1) relay should
always be programmed for latching,
because this trip should require a
visual inspection of the motor and
starter before issuing a manual
reset to release the relay after a trip
has been stored.
AUX6 RELAY
FAIL-SAFE: NO
AUX6 RELAY
LATCHED: NO
AUX7 RELAY
FAIL-SAFE: NO
AUX7 RELAY
LATCHED: NO
AUX8 RELAY
FAIL-SAFE: NO
AUX8 RELAY
LATCHED: NO
JKSSS+ Series - 55
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SP.6 User I/O Configuration (Setpoint Page 6)
(Security Level: 2)
MENU
(Hit DOWN ARROW five times)
ENABLED
PAGE 6 USER I/O
CONFIGURATION
TACHOMETER SCALE
SELECTION: DISABLED
MANUAL TACH SCALE
4.0 mA: 0 RPM
Options: ENABLED or
DISABLED
Range: 0-3600
Increments of 5
MANUAL TACH SCALE
20.0 mA: 2000 RPM
Range: 0-3600
Increments of 5
TACH ACCEL TRIP MODE
SELECT: DISABLED
TACH RAMP TIME
: 20 SEC
Range: 1 - 120 SEC.,
Disabled
Increments of 1
TACH UNDERSPEED TRIP
PT: 1650 RPM
Range: 0 - 3600
Increments of 5
TACH OVERSPEED TRIP
PT: 1850 RPM
Range: 0 - 3600
Increments of 5
TACH ACCEL TRIP
DELAY: 1 SEC
Options: UNDERSPEED,
OVERSPEED or DISABLED
Range: 1 - 60
Increments of 1
ANALOG OUTPUT #1
:RMS CURRENT
ANALOG OUTPUT #1
4ma: 0
ANALOG OUTPUT #1
20mA: 250
Range:
Range: 0-65535
Increments of 1
Range: 0-65535
Increments of 1
Analog Output
RPM
Hottest Bearing
Range
0 - 3600
0 - 200°C
Hottest Stator RTD 0 - 200°C
RMS Current
% Motor Load
KW
0 - 6500A
0 - 1000%
0-30000 KW
OFF
Increments of 1
ANALOG OUTPUT #2
:% MOTOR LOAD
ANALOG OUTPUT #2
4mA: 0
ANALOG OUTPUT #2
20mA: 1000
Range: See Analog Output #1
Increments of 1
Range: 0-65535
Increments of 1
Range: 0-65535
Increments of 1
USER PROGRAMMABLE
EXTERNAL INPUTS
Continued...
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SP.6 User I/O Configuration (Setpoint Page 6)
(Security Level: 2)
The controller can be configured to accept a tachometer
feedback signal through the 4-20mA input.
SP6.1The first screen of setpoint page 6 is TACHOMETER
SCALE SELECTION. When this is set to
SP6.3The controller provides two 4-20mA analog outputs.
Each analog output is independent of the
ENABLED, the user will need to input the
tachometer scale of the 4-20mA input range.
other and can be assigned to monitor different
functions. The available output ranges are RPM,
Hottest Non-Stator (Bearing) RTD, Hottest Stator
RTD, RMS current, % Motor Load, or kW.
• Manual Tach Scale 4.0 mA: The unit is looking
for an RPM value to assign to the lowest point on
the scale. This value should represent the motor
at zero speed.
• Analog Output #1 – Select a function from
the available options to be transmitted from
the 4-20mA output. Note: If selecting RPM,
the Tachometer feedback input signal must be
present in order for the controller to give proper
output. If selecting RTD, the RTD option must
be installed and an RTD input signal must be
present for a proper output to be given from the
analog output.
• Analog Output #1 (4 mA): Enter a value that the
4mA level will represent for the selected function;
typically this value should be 0.
• Analog Output #1 (20 mA): Enter a value that
the 20mA level will represent for the selected
function.
• Manual Tach Scale 20.0 mA: The unit is looking
for an RPM value to assign to the highest point on
the scale. This value should represent the motor
at full speed.
SP6.2Tach Accel Trip Mode Select: When enabled, the
underspeed or overspeed must be selected for the
Tach Accel Trip. If underspeed is selected, only
the Tach Underspeed Trip Point will be used. If
overspeed is selected only the Tach Overspeed
Trip Point will be used.
• Tach Ramp Time: This is the duration of time
before the tachometer begins to sample.
SP6.4Analog Output #2 – All of the setpoints and setup
screens for Analog Output #2 are the same as
those for Analog Output #1.
• Tach Underspeed Trip: The minimum value of
motor RPM which must be achieved before the
Tach Ramp Time sample is taken.
• Tach Overspeed Trip: The maximum motor RPM
allowed when the Tach Ramp Time sample is
taken.
• Tach Accel Trip Delay: The duration of time that
the Tach Accel trip condition must persist before a
trip is generated.
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SP.6 User I/O Configuration (Setpoint Page 6)
(Security Level: 2)
USER
TCB FAULT
SELECT: ENABLED
NAME EXT. INPUT #1
TCB FAULT
TCB FAULT
TYPE: NORMALLY OPEN
TCB FAULT
TIME DELAY: 1 SEC.
PROGRAMMABLE
EXTERNAL
INPUTS
Options: Enabled or Disabled
See text for directions
Options: Normally Open or
Normally Closed
Range: 0 - 60 SEC
Increments of 1
(Continued)
EXTERNAL INPUT #2
SELECT: DISABLED
NAME EXT INPUT #2
EXTERNAL INPUT #2
TYPE: NORMALLY OPEN
EXTERNAL INPUT #2
TIME DELAY: 0 SEC.
Options: Enabled or Disabled
See text for directions
Options: Normally Open or
Normally Closed
Range: 0 - 60 SEC.
Increments of 1
DUAL RAMP
SELECT: DUAL RAMP
NAME EXT INPUT #3
SECOND RAMP
DUAL RAMP
TYPE: NORMALLY OPEN
DUAL RAMP
TIME DELAY: 0 SEC.
Options: Enabled, Disabled or
Dual Ramp
See text for directions
Options: Normally Open or
Normally Closed
Range: 0 - 60 SEC
Increments of 1
THERMOSTAT
SELECT: ENABLED
NAME EXT INPUT #4
THERMOSTAT
THERMOSTAT
TYPE: NORMALLY CLOSED
THERMOSTAT
TIME DELAY: 1 SEC.
Options: Enabled or Disabled
See text for directions
Options: Normally Open or
Normally Closed
Range: 0 - 60 SEC.
Increments of 1
SP6.5User Programmable External Inputs: The
controller provides up to 4 digital external inputs
which are individually programmable. A description
name can be assigned to each individual input for
easy identification.
• External Input #3: The setup screens and
setpoints for External Input #3 includes the option
of being configured for Dual Ramp. In Dual Ramp
mode, the initial contact setting is the same as the
START RAMP #1. Upon a change in input contact
state, the controller will switch over to START
RAMP #2 and use that setting for start control
mode. Note: The start RAMP types should only be
switched while the motor is stopped. In Setpoint
Page 4 Relay Assignments, do not assign any
output relay to this function. The controller will
ship with External input #3 programmed for dual
ramp. If it is not needed, disable the dual ramp.
• External Input #1: Factory programmed for TCB
Trip.
• External Input #2: If used, this setpoint must be
enabled.
• Name Ext. Input #2: The user can assign a
description name to the input to easily identify
the cause of external trip or alarm. Up to 15
characters including spaces can be used to assign
the name.
• External Input #2 Type: The external input can
be set as either a normally open or normally
closed contact.
• External Input #4: This input screens are for the
thermostat input and can be enabled or disabled.
Note: It is recommended that this function remain
enabled. If the thermostat indicates an over
temperature condition, the controller will trip the
motor.
• External Input #2 Time Delay: Upon a change in
contact setting, the unit will wait the programmed
amount of time before generating an output. If
no delay is needed, then input 0 seconds. The
controller will post an event upon seeing a change
in state.
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SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)
MENU
(Hit DOWN ARROW six times)
PAGE 7 CUSTOM
ACCELERATION CURVE
CUSTOM ACCEL CURVE
: DISABLED
Range: DISABLED,
CURVE A, B or C
CURVE A VOLTAGE
LEVEL 1: 25%
SP7.1Setpoint Page 7 allows the user to custom design
the acceleration curve (start curve) to the specific
application. The user can custom design up to
three different curves in the soft starter. Only one
curve can be active (enabled) at a time. Each of
the three curves allow for eight voltage plotting
points, with corresponding ramp times and a
current limit setting.
CUSTOM CURVE A
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 1: 2 SEC
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 2: 30%
Note: Each successive voltage level must be
programmed to a voltage level equal to or greater
than the previous level. All eight levels of voltages
must be programmed and the eighth level has
been preset at 100%.
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 2: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 3: 37%
• If Custom Accel Curve has been set to curve A,
B or C on this page, the soft starter will override
the Start Control Mode selected in Setpoint Page
2, (even if Start Control Mode in Setpoint Page 2
has not been set to Custom Accel Curve).
Note: Setpoint Page 7 has a security level 3
requirement.
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 3: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 4: 45%
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 4: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 5: 55%
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 5: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 6: 67%
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 6: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE A VOLTAGE
LEVEL 7: 82%
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 7: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
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SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)
CURVE A VOLTAGE
LEVEL 8: 100%
CURVE B VOLTAGE
LEVEL 7: 82%
CUSTOM CURVE A
CUSTOM CURVE B
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE A RAMP
TIME 8: 2 SEC
CURVE B RAMP
TIME 7: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE A CURRENT
LIMIT: 350% FLA
CURVE B VOLTAGE
LEVEL 8: 100%
Range: 200 - 500%
Increments of 10
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 8: 2 SEC
CURVE B VOLTAGE
LEVEL 1: 25%
CUSTOM CURVE B
Range: 1 - 60 SEC
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B CURRENT
LIMIT: 350% FLA
CURVE B RAMP
TIME 1: 2 SEC.
Range: 200 - 500%
Increments of 10
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 2: 30%
CURVE C VOLTAGE
LEVEL 1: 25%
CUSTOM CURVE C
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 2: 2 SEC.
CURVE C RAMP
TIME 1: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 3: 37%
CURVE C VOLTAGE
LEVEL 2: 30%
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 3: 2 SEC.
CURVE C RAMP
TIME 2: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 4: 45%
CURVE C VOLTAGE
LEVEL 3: 37%
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 4: 2 SEC.
CURVE C RAMP
TIME 3: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 5: 55%
CURVE C VOLTAGE
LEVEL 4: 45%
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 5: 2 SEC.
CURVE C RAMP
TIME 4: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range:1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 6: 67%
CURVE C VOLTAGE
LEVEL 5: 55%
Range: 0 - 100%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 6: 2 SEC.
CURVE C RAMP
TIME 5: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Range: 1 - 60 SEC
Increments of 1
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SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)
SP7.1Setpoint Page 7 allows the user to custom design
the acceleration curve (start curve) to the specific
application. The user can custom design up to
three different curves in the soft starter. Only one
curve can be active (enabled) at a time. Each of
the three curves has eight voltage levels, with
corresponding ramp times and a current limit
setting.
CURVE C VOLTAGE
LEVEL 6: 67%
CUSTOM CURVE C
Range: 0 - 100%
Increments of 1
CURVE C RAMP
TIME 6: 2 SEC.
Note: Each successive voltage level must be
programmed to a voltage level equal to or greater
than the previous level. All eight levels of voltages
must be programmed and the eighth level has
been preset at 100%.
Range: 1 - 60 SEC
Increments of 1
CURVE C VOLTAGE
LEVEL 7: 82%
Range: 0 - 100%
Increments of 1
• If Custom Accel Curve has been set to curve A, B
or C on this page, the soft starter will override the
Start Control Mode selected in Setpoint Page 2,
(even if Start Control Mode in Setpoint Page 2 has
not been set to Custom Accel Curve).
CURVE C RAMP
TIME 7: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
Note: Setpoint Page 7 has a security level 3
requirement.
CURVE C VOLTAGE
LEVEL 8: 100%
Range: 0 - 100%
Increments of 1
CURVE C RAMP
TIME 8: 2 SEC.
Range: 1 - 60 SEC
Increments of 1
CURVE C CURRENT
LIMIT: 350% FLA
Range: 200 - 600%
Increments of 10
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SP.8 Overload Curve Configuration (Setpoint Page 8)
(Security Level: 3)
MENU
(Hit DOWN ARROW seven times)
PAGE 8 OVERLOAD
CURVE CONFIGURATION
BASIC RUN
OVERLOAD CURVE
RUN CURVE LOCKED
ROTOR TIME: O/L CLASS
RUN LOCKED ROTOR
CURRENT: 600% FLA
Range: 1 - 30 SEC, O/L CLASS
Range: 400 - 800%
Increments of 1
Configures the unit’s start and
run protection mode. The unit has
independent start and run curve
protection and the settings can be
based on the OL Class or set by the
motor’s locked rotor current and time.
COAST DOWN TIMER
TIME: DISABLED
Range:1 - 60 MIN, DISABLED
Increments of 1
START LOCKED ROTOR
CURRENT: 600% FLA
BASIC START
OVERLOAD CURVE
START CURVE LOCKED
ROTOR TIME: O/L CLASS
Range: 400 - 800%
Increments of 10
Range:1 - 30 SEC, O/L CLASS
Increments of 1
SP8.1Basic Run Overload Curve
• Run Curve Locked Rotor
Time: Set the locked rotor time
to the OL Class default chosen
in Setpoint Page 1 or set the
time in seconds. This is the
time the locked rotor condition
exists before a trip occurs.
ACCELERATION TIME
LIMIT: 30 SEC
Range:1 - 300 SEC, DISABLED
Increments of 1
NUMBER OF STARTS PER
HOUR: DISABLED
Range: 1 - 6, DISABLED
Increments of 1
• Run Locked Rotor Current:
The current the motor draws
with full voltage on the windings
and no rotor movement (as a
percent of motor FLA). Refer to
the nameplate data or contact
the motor manufacturer.
TIME BETWEEN STARTS
TIME: 5 MIN
Range:1 - 60 MIN, DISABLED
Increments of 1
AREA UNDER CURVE
PROTECTION: DISABLED
MAX I*I*T START
: 368 FLA*FLA*SEC
• Coast Down Timer: If enabled,
this prevents the motor from
restarting for the programmed
amount of time, after a stop
command is given.
Range: ENABLED or DISABLED
Range:1 - 2500, FLA*Time (Sec)
Increments of 1
CURRENT OVER
CURVE: DISABLED
LEARNED START CURVE
BIAS: 10%
TIME FOR SAMPLING
: 30 SEC
Options: DISABLED, LEARN
or ENABLED
Range: 5 - 40%
Increments of 1
Range: 1 - 300 SEC
Increments of 1
SP8.2Basic Start Overload Curve
• Start Curve Locked Rotor Time: The locked
rotor time can be set to the OL Class default
chosen in Setpoint Page 1 or to a specific
time. The overload condition must exist for the
programmed amount of time before a trip occurs.
• Start Locked Rotor Current: The current the
motor draws with full voltage on the windings and
no motor movement (as a percent of motor FLA).
Refer to the motor nameplate data or contact the
motor manufacturer.
• Acceleration Time Limit: If the motor does not
enter run mode (reach at speed) within the preset
time, the unit trips on acceleration time limit.
• Number of Starts per hour: If enabled, this
limits the maximum number of starts permitted per
hour. This setpoint allows a maximum of 6 starts
per hour. Contact motor manufacturer.
SP8.3Area Under Curve Protection: If enabled, this
secondary start protection uses both the basic start
protection and the area under the curve protection.
• Max I*I*T Start: The maximum I2T allowed during
start. If the I2T to start exceeds this number then the
soft starter will generate a trip.
SP8.4Current Over Curve: Learns the motor’s starting
characteristics and protects the motor based upon
the learned curve. It is useful when commissioning a
new motor.
• Learn: The unit reads the motor’s starting
characteristics. Start the motor and allow it to come
to full speed. The start feedback enables the motor
protection based on the learned start curve.
• Learned Start Curve Basis: The maximum allowed
deviation above or below the start curve before a trip
is generated.
• Time for Sampling: The time the soft starter
continues to sample the start curve characteristic
during learn the mode.
• Time Between Starts: If enabled, the soft
starter prevents another start attempt until the
programmed time has expired.
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SP.9 RTD Optional Configuration (Setpoint Page 9)
(Security Level: 3)
MENU
(Hit DOWN ARROW eight times)
Ranges:
*
120 OHM NICKEL (NI)
100 OHM NICKEL (NI)
10 OHM COPPER (CU)
100 OHM PLATINUM (PT)
OFF
PAGE 9 RTD
CONFIGURATION
USE NEMA TEMP FOR
RTD VALUES: DISABLED
Options: ENABLED OR
DISABLED
** OFF or 0 - 240C (32-464F) Example: ### C = ### F
Increments of 1
# OF RTD’S USED FOR
STATOR:
4
*** STATOR A1, STATOR A2, STATOR B1, STATOR B2, STATOR C1, STATOR C2,
FRONT BEARING, BACK BEARING, BEARING BOX, AMBIENT, NONE
Range: 0 - 6
Increments of 1
RTD VOTING
: DISABLED
Options: ENABLED or
DISABLED
STATOR PHASE A1 TYPE
: OFF
RTD # 1 DESCRIPTION
STATOR PHASE A1
STATOR PHASE A1 ALARM
LEVEL: OFF
STATOR PHASE A1 TRIP
LEVEL: OFF
Range: *
Range: ***
Range: **
Range: **
STATOR PHASE A2 TYPE
: OFF
RTD # 2 DESCRIPTION
STATOR PHASE A2
Range: ***
STATOR PHASE A2 ALARM
LEVEL: OFF
STATOR PHASE A2 TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
STATOR PHASE B1 TYPE
: OFF
RTD # 3 DESCRIPTION
STATOR PHASE B1
Range: ***
STATOR PHASE B1 ALARM
LEVEL: OFF
STATOR PHASE B1 TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
STATOR PHASE B2 TYPE
: OFF
RTD # 4 DESCRIPTION
STATOR PHASE B2
STATOR PHASE B2 ALARM
LEVEL: OFF
STATOR PHASE B2 TRIP
LEVEL: OFF
Range: *
Range: ***
Range: **
Range: **
STATOR PHASE C1 TYPE
: OFF
RTD # 5 DESCRIPTION
STATOR PHASE C1
Range: ***
STATOR PHASE C1 ALARM
LEVEL: OFF
STATOR PHASE C1 TRIP
LEVEL: OFF
Range: *
Range: ***
Range: ***
STATOR PHASE C2 TYPE
: OFF
RTD # 6 DESCRIPTION
STATOR PHASE C2
Range: ***
STATOR PHASE C2 ALARM
LEVEL: OFF
STATOR PHASE C2 TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
END BEARING TYPE
: OFF
RTD #7 DESCRIPTION
END BEARING
Range: ***
END BEARING ALARM
LEVEL: OFF
END BEARING TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
SHAFT BEARING TYPE
: OFF
RTD # 8 DESCRIPTION
SHAFT BEARING
Range: ***
SHAFT BEARING ALARM
LEVEL: OFF
SHAFT BEARING TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
RTD # 9 TYPE
: OFF
RTD # 9 DESCRIPTION
RTD # 9
RTD # 9 ALARM
LEVEL: OFF
RTD # 9 TRIP
LEVEL: OFF
Range:*
Range: ***
Range: **
Range: **
RTD # 10 TYPE
: OFF
RTD # 10 DESCRIPTION
RTD # 10
RTD # 10 ALARM
LEVEL: OFF
RTD # 10 TRIP
LEVEL: OFF
Range: *
Range: ***
Range: **
Range: **
RTD # 11 TYPE
: OFF
RTD # 11 DESCRIPTION
RTD #11
Range: ***
RTD # 11 ALARM
LEVEL: OFF
RTD # 11 TRIP
LEVEL: OFF
Range: *
Range: **
Range: **
RTD # 12 TYPE
: OFF
RTD # 12 DESCRIPTION
RTD # 12
RTD # 12 ALARM
LEVEL: OFF
RTD # 12 TRIP
LEVEL: OFF
Range: *
Range: ***
Range: **
Range: **
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SP.9 RTD Configuration (Setpoint Page 9)
(Security Level: 3)
The soft starter comes with an RTD card that provides 12
programmable RTDs which are individually programmable
for type. The available types are 100 ohm platinum, 100 ohm
nickel, 120 ohm nickel and 10 ohm copper. Each RTD can
be identified with a description name of up to 15 characters
(including spacing). Also, each individual RTD has it own alarm
and trip level.
SP9.1Use NEMA Temp for RTD Value: When this setpoint
is enabled, the soft starter will use the NEMA design
insulation class to limit the maximum allowed range
of the alarm and trip level. The maximum allowed
temperature range is 240° C or (464°F).
SP9.2# Of RTD’S Used for Stator: Up to six RTDs can be
assigned to monitor the stator of the motor.
SP9.3RTD Voting: When this is enabled, the soft starter will not
post a trip until 2 RTD’s have exceeded the trip level.
This prevents nuisance RTD tripping.
SP9.4All 12 RTDs are configured in the following manner. The
first column is the RTD type, the second column is the
RTD description, the third column is the alarm level,
and the fourth column is the trip level.
The first six RTDs have been pre-programmed with
a description name for the STATOR, with two RTDs
per phase. RTDs #1 & #2 have been named STATOR
PHASE A1 and A2 respectively. RTDs #3 & 4 are
named STATOR PHASE B1 and B2, RTDs #5 & 6
are named STATOR PHASE C1 and C2. If other
description names are required, press the right arrow
button from the RTD Type screen to go the RTD
description screen. If no alarm or trip level is required
these setpoints can be turned off.
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SP.10 Set Password (Setpoint Page 10)
(Security Level: 3)
MENU
(Hit DOWN ARROW nine times)
The soft starter has three levels of user programmable
setpoint screens. Level one setpoints do not require a
password because the data contained in level one is basic
nameplate data and starter control. Level two setpoint
screens require a three-digit password to configure the
protection schemes. Level three setpoint screens require
a four-digit password to access the full range of protection
and starter schemes.
PAGE 10 SECURITY
SET PASSWORD
SET LEVEL 2
PASSWORD: 100
Range: 000 - 999
SET LEVEL 3
PASSWORD: 1000
Range: 0000 - 9999
SP10.1 Set Level 2 Password: This level uses a 3-digit
password. The default level 2 password is 100.
SP10.2 Set Level 3 Password: Level three uses a 4-digit
password. The default level 3 password is 1000.
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SP.11 Communications (Setpoint Page 11)
(Security Level: 3)
MENU
SP11.1 Set Front Baud Rate: Configures the RS232
(Hit DOWN ARROW ten times)
communications baud rate.
PAGE 11
SET FRONT BAUD
COMMUNICATIONS
RATE: 9.6 KB/SEC
SP11.2 Set Modbus Baud Rate: Configures the
Modbus communications baud rate.
Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC
SP11.3 Modbus Address Number: Assigns a Modbus
SET MODBUS BAUD
RATE: 9.6 KB/SEC
address to the soft starter relay.
Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC
SP11.4 Set Access Code: Assigns an access code to
the Modbus addressing. This is typically not
used.
MODBUS ADDRESS
NUMBER: 247
Range: 1 - 247
Increments of 1
SP11.5 Set Link Baud Rate: Configures the RS422
communications baud rate between the keypad
operator and the CPU board. (For applications
with remote keypad only.)
SET ACCESS CODE
CODE: 1
Range: 1 - 999
Increments of 1
SET LINK BAUD
SP11.6 Remote Start/Stop: Allows the RS485 Modbus
communications to start and stop the motor.
Contact factory for details.
RATE: 38.4 KB/SEC
Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC
REMOTE START/STOP:
DISABLED
Option: Enabled or Disabled
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SP.12 System Setpoints (Setpoint Page 12)
(Security Level: 3)
MENU
(Hit DOWN ARROW eleven times)
PAGE 12 SYSTEM
SETPOINTS
DEFAULT DISPLAY
SCREEN
METERING DATA
PAGE #: 1
METERING DATA
SCREEN #: 1
Enter Metering Page (1 - 4)
Number for display
Enter Metering
Screen Number for display
RTD FAILURE ALARM
ALARM: DISABLED
ALARMS
Enabled or Disabled
THERMAL REGISTER
ALARM: 90%
THERMAL ALARM
DELAY: 10 SEC.
Range: Off, 40 - 95%
Increments of 1
Range: 1 - 20 SEC.
Increments of 1
COLD STALL TIME
: O/L CLASS
THERMAL REGISTER
SETUP INFORMATION
Range: O/L CLASS,
4 - 40 SEC
Increments of 1
HOT STALL TIME
: 1/2 O/L CLASS
Range: 1/2 O/L CLASS,
4 - 40 SEC
Increments of 1
STOPPED COOL DOWN
TIME: 30 MIN
Range: 10 - 300 MIN
Increments of 1
RUNNING COOL DOWN
TIME: 15 MIN
Range: 10 - 300 MIN
Increments of 1
RELAY MEASURED COOL
RATES: DISABLED
Range: ENABLED or
DISABLED
THERMAL REGISTER
MINIMUM: 15%
Range: 10 - 50%, OFF
Increments of 1
MOTOR DESIGN AMBIENT
TEMPERATURE: 40 C
Range: 10 - 90 C
Increments of 1
MOTOR DESIGN RUN
TEMPERATURE: 80% MAX
Range: 50 - 100% of Motor
Stator Max Temp.
Increments of 1%
MOTOR STATOR MAX
TEMPERATURE: INS CLS
Range: Insulation Class
10 - 240 C
Increments of 1
I/B INPUT TO THERMAL
REGISTER: ENABLED
Options: ENABLED or
DISABLED
USE CALCULATED K OR
ASSIGN: 7
Range: 1 - 50, ON
PRESS ENTER TO CLR
THERMAL REGISTER
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SP.12 System Setpoints (Setpoint Page 12)
(Security Level: 3)
SP12.1 Default Display Screen: This setpoint group
allows the user to choose the default screen the
soft starter displays while the motor is running.
Select the metering page number (1-3), then
select the metering screen number. The range
varies depending on the selected page. To display
a default screen, program the following two
setpoints:
• Thermal Register Minimum: Sets the value
in the thermal register which represents a
motor running at the nameplate current (with
no overheating or negative sequence currents
present).
• Motor Design Ambient Temperature: Use the
data from the motor manufacturer’s specifications.
When RTDs are used, this setpoint will be the
base point for the RTD biasing of the Thermal
Register.
• Motor Design Run Temperature: Use the data
from the motor manufacturer’s specifications. This
setpoint defines the operating temperature rise of
the motor at full load amps or 100% load.
• Motor Stator Max Temperature: This represents
the maximum temperature the stator insulation
will withstand. The user may choose to use
the temperature setting of the insulation class
(selected in Setpoint Page 1) or enter a specific
maximum temperature. This value should not
exceed the stator’s insulation temperature. This
maximum temperature represents 100% thermal
capacity.
• Metering Data Page#: Range is Page 1 - 3.
• Metering Data Screen#: If Page 1 is selected
as the default page, then Screens 1- 10 are
available. If Page 2, Screens 1-29 are available.
If Page 3 is selected, then Screens 1-6 are
available. (See Metering Menu, MP.1, for screen
number assignment.)
SP12.2 Alarms: Configures the RTD failure alarm and the
thermal register alarm.
• RTD Failure Alarm: If enabled, and an RTD
shorts or open, an alarm occurs.
• Thermal Register Alarm: Sets a level in the
thermal register to generate an alarm when the
Thermal Register Capacity Used has exceeded
this level.
• U/B Input to Thermal Register: Always enabled.
It allows the soft starter to use the line current
imbalance information to bias the Thermal
Register.
• User Calculated K or Assign: When the setpoint
is set to ON the controller will calculate the k
constant factor for biasing the thermal register, or
the user may choose to assign the k value.
• Thermal Alarm Delay: The amount of time that
the Thermal Register Used must exceed the
setpoint before an alarm condition will occur.
SP12.3 Thermal Register Setup Information: This
setpoint group will configure the thermal register
and indicate to the soft starter which inputs to use
when thermal modeling.
• Cold Stall Time: Enter the time from the motor
manufacturer’s specification sheet or use the time
defined by the OL Class. This setpoint is used to
define the thermal capacity of the motor.
• Hot Stall Time: Enter the amount of time
specified by the motor manufacturer or use half of
the time defined by the OL Class.
SP12.4 Press Enter to CLR Thermal Register: Allows
the level three password user to clear the thermal
register for emergency restarts.
• Stopped Cool Down Time: The time the motor
requires to cool down after it has stopped. Use
only the data provided by the motor manufacturer.
This setpoint is used to configure the cooling rate
of the thermal register.
• Running Cool Down Time: The amount of
time the motor requires for cooling down while
running. Use only the data provided by the motor
manufacturer.
• Relay Measured Cool Rates: When RTDs are
used, the soft starter can be configured to use the
measured cool rates from the RTDs instead of the
programmed settings. This setpoint should only be
enabled when RTDs are present.
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SP.13 Calibration & Service (Setpoint Page 13)
(Security Level: Factory Use Only)
MENU
(Hit DOWN ARROW twelve times)
PAGE 13 CALIBRATION
& SERVICE
SET DATE AND TIME
##/##/## ##:##
ENTER DATE (DDMMYYYY)
:##/##/####
ENTER TIME (hh:mm)
:##:##
Range: D = 1 - 31, M = 1-12,
Y = 1970 - 2069
Increments of 1
Range: H = 00 - 23, M = 0 - 59
Increments of 1
MODEL #: ######
FIRMWARE REV. #: ######
PRESS ENTER TO ACCESS
FACTORY SETTINGS
SP.13 Calibration & Service (Setpoint Page 13)
Certain screens are displayed for user information only, such
as: Current date and time, Model number and Firmware
revision number. Setpoint changes in this page will only be
accessible to factory personnel.
SP13.1 Set Date and Time: Displays the date and time.
• Enter Date (DDMMyyyy): Allows the factory
personnel to program the date for the soft starter in
the format shown.
• Enter Time (hh:mm): Allows the factory personnel to
program the time for the soft starter.
SP13.2 Model & Firmware #: Displays the model number
and firmware revision in the soft starter.
SP13.3 Press Enter to Access Factory Settings: Available
to qualified personnel.
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Chapter 6 - Metering Pages
The soft starter offers performance metering which gives the user the ability to view
information about the motor and the JKSSS+ unit.
6.1
Metering Page List
The following charts list each Metering Page and the functions within that page. The
applicable section of the manual is also referenced.
6.1.1 Metering Menu & Data (Metering Page 1)
Metering
Description of Display
Page
Screen
Phase A, B, C and Ground Fault (Option)
Average current of the % of imbalance and the motor's RPM
Motor load as a percentage of motor FLA
Line frequency and present phase sequence
Percentage of remaining Thermal Register
Thermal capacity required to start the motor
Average time required to start
1
2
3
4
5
6
7
Average current during start
8
Measured I2T required to start the motor
9
Amount of time required to start the motor during the last successful start
10
6.1.2 Metering (Metering Page 2)
Metering
Description of Display
Page
Screen
Phase A, B, C currents and Power Factor
Phase A, B, C currents and Ground Fault (Option)
Displays kW and kVA
1
2
3
Displays kVAR and Power Factor
Displays Peak ON and kW Demand
Displays Peak ON and kVA Demand
Displays Peak ON and kVAR Demand
Displays Peak ON and Amps Demand
Clears Demand values
4
5
6
7
8
9
Displays Megawatt hours used
10
11
Press enter to clear statistics on MWH values
6.1.3 RTD Values (Metering Page 3)
Metering
Description of Display
Page
Screen
Hottest stator RTD (#1 - 6)
1
Hottest non-stator RTD (#7 - 12)
2
3
Temperature of start phase A1 in °C and °F
Maximum temperature for RTD #1
4
Same as Screens 3 - 4 for RTDs #2 - 12
5 - 26
27
Clear the maximum temperature register (Level 3 password required)
Measured running thermal stabilization time of motor (in minutes)
Measured stopped cooling time (to ambient) of motor (in minutes)
28
29
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6.1.4 Status (Metering Page 4)
Metering
Page
Description of Display
Screen
Current status
1
2
3
4
5
6
Amount of time remaining before an overload trip occurs
Amount of time remaining from a thermal inhibit signal
Coast down time remaining
Amount of time remaining before a start command can be given
Excessive number of starts per hour
6.1.5 Event Recorder (Metering Page 5)
Metering
Page
Description of Display
Screen
Displays the event with date and time (Up to 60 events)
1
Displays Phase A, B, C current values, Ground Fault (Option) at time of trip
Displays Vab, Vbc, Vca and Power Factor at time of trip
1A
1B
6.1.6 Last Trip (Metering Page 6)
6.1.7 Statistics (Metering Page 7)
Metering
Page
Description of Display
Screen
Total megawatt hours
1
2
3
4
Accumulated total running hours
Clear the total running hour count
Total number of trips
Number of start and run overload trips since the last statistical data
clearing
5
Number of frequency trips and imbalance trips
Overcurrent trips
6
7
Stator and non-stator RTD trips
Ground fault hiset and loset trips
Acceleration time trips
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Start under curve trips
Start over curve trips
I2T start curve trips
Learned start curve trips
Fail shunt trip trips
Phase loss trip trips
Tach accel trip trips
Undervoltage and Overvoltage trips
Power Factor trips
Phase reversal trips
Ext Inp #1
Ext Inp #2
Ext Inp #3
Ext Inp #4
Press enter to clear statistics
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6.2
Metering Menu
Push MENU key to toggle the screens between Setpoint Menu and Metering Menu
and follow the arrow keys to get to different screens.
MENU
METERING PAGE 1
CURRENT METERED DATA
METERING PAGE 2
VOLTAGE & POWER DATA
METERING PAGE 3
RTD VALUES
METERING PAGE 4
STATUS
METERING PAGE 5
EVENT RECORDER
METERING PAGE 6
LAST TRIP
METERING PAGE 7
STATISTICS
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MP.1 Metering Data (Metering Page 1)
MENU
Displays the basic current metering data:
Screen 1: Phase A, B, C and ground fault (option)
current.
IA: ######
IB: ######
METERING PAGE 1
CURRENT METERED DATA
Screen 1
Screen 2
Screen 3
Screen 4
IC: ###### G/F: #####
Screen 2: Displays the average current, percent of
imbalance and the motor’s RPM (available
with tachometer input)
I (AVG): ####
Screen 3: Displays the motor load in percent of motor
I/B: ## %
RPM: ####
FLA.
Screen 4: Displays the line frequency and the present
MOTOR LOAD % OF FLA
FLA: ### %
Phase Order.
Screen 5: Displays the percent of the remaining thermal
register. In order for the motor to successfully
start, the percentage must be greater than
the thermal capacity required for a successful
start.
LINE FREQUENCY:: ##.##
PHASE ORDER: ###
THERMAL REGISTER
REMAINING: ### %
Screen 6: Displays the thermal capacity required to
Screen 5
Screen 6
Screen 7
Screen 8
Screen 9
Screen 10
successfully start the motor.
Screen 7: Displays the average time required to start.
THERMAL CAPACITY
TO START: ### %
Screen 8: Displays the average current during start.
Screen 9: Displays the measured I2T required to start
the motor.
AVERAGE START TIME
TIME: ##.# SECS
Screen 10: Displays the amount of time required to start
the motor during the last successful start.
AVG START CURENT
: ###### AMPS
I*I*T TO START
I*I*T: #######
LAST START
TIME: ##.# SEC
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MP.2 Metering (Metering Page 2)
MENU
Displays the statistical voltage metering informa-
tion.
Screen 1
METERING PAGE 2
VOLTAGE & POWER DATA
Vab: ### Vbc: ###
Vca: ### P/F: ## #.##
Screen 1: Displays Phase A, B, C and Power Factor.
Note: P/F: N/A Motor stopped
P/F: LG #.## (Lagging)
Screen 2
IA: ##### IB: #####
IC: ##### G/F:###.#
P/F: LD #.## (Leading)
Screen 2: Displays Phase A, B, C and Ground Fault
Screen 3
Current.
kW: #####
kVA: #####
Screen 3: Displays KW and KVA.
Screen 4
kVAR: #####
P/F: ## #.##
Screen 4: Displays KVAR and Power Factor.
Screen 5: Displays Peak On and KW demand.
Screen 6: Displays Peak On and KVA demand.
Screen 5
PEAK ON: ##/## ##:##
kW: #####
Screen 6
Screen 7: Displays Peak On and KVAR demand.
Note: P/F: N/A Motor stopped
P/F: LG #.## (Lagging)
PEAK ON: ##/## ##:##
kVA: #####
Screen 7
P/F: LD #.## (Leading)
PEAK ON: ##/## ##:##
kVAR: #####
Screen 8: Displays Peak On and Amps demand.
Screen 9: Clears Demand Values.
Screen 8
PEAK ON: ##/## ##:##
AMPS: #####
Screen 10: Displays the Megawatts used per hour.
Screen 11: Press Enter to clear statistics on MWH values.
Screen 9
PRESS ENTER TO CLEAR
DEMAND VALUES
Screen 10
MWH USED
: #####
Screen 11
PRESS ENTER TO CLEAR
MWH VALUES
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MENU
Screen 1
HOTTEST STATOR
RTD#: # @ ### C
METERING PAGE 3
RTD VALUES
MP.3 RTD Values (Metering Page 3)
Displays the RTD information.
Screen 2
HOTTEST NON-STATOR
RTD#: # @ ### C
Screen 1: Displays the hottest stator RTD (#1 - 6
depending upon number of RTDs used for
stator).
Screen 4
Screen 3
STATOR PHASE A1
RTD #1: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #1: ### C
Screen 6
Screen 5
Screen 2: Displays the hottest non-stator RTD (#7-12 if
STATOR PHASE A2
RTD #2: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #2: ### C
#1-6 is used for stator).
Screen 3: Displays the temperature of stator phase A1
Screen 8
Screen 7
in °C and °F.
MAX TEMP SINCE
CLEAR RTD #3: ### C
STATOR PHASE B1
RTD #3: ### C = ### F
Screen 4: Displays the maximum temperature for
RTD #1 since the last command to clear the
thermal register.
Screen 10
Screen 9
STATOR PHASE B2
RTD #4: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #4: ### C
Screen 5 - 26: Same as Screens 3 - 4 for RTDs #2-12.
Screen 12
Screen 11
STATOR PHASE C1
RTD #5: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #5: ### C
Screen 27: Allows the user to clear the maximum
temperature register upon entering the
setpoint level 3 password.
Screen 14
Screen 13
STATOR PHASE C2
RTD #6: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #6: ### C
Screen 28: Displays the measured run cool time in
Screen 16
Screen 15
minutes.
END BEARING
RTD #7: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #7: ### C
Screen 29: Displays the measured stopped cool time in
minutes.
Screen 18
Screen 17
SHAFT BEARING
RTD #8: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #8: ### C
Screen 20
Screen 19
RTD #9
RTD #9: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #9: ### C
Screen 22
Screen 21
RTD #10
RTD #10: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #10: ### C
Screen 24
Screen 23
MAX TEMP SINCE
CLEAR RTD #11: ### C
RTD #11
RTD #11: ### C = ### F
Screen 26
Screen 25
MAX TEMP SINCE
CLEAR RTD #12: ### C
RTD #12
RTD #12: ### C = ### F
Screen 27
PRESS ENTER TO
CLEAR MAX TEMP REGS
Screen 28
MEASURED RUN COOL
TIME: ### MIN
Screen 29
MEASURED STOPPED
COOL TIME: ### MIN
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MP.4 Status (Metering Page 4)
MENU
Displays the present status of the soft start.
Screen 1 (See note at left)
Screen 1: Displays the present state of the unit as
METERING PAGE 4
STATUS
(CURRENT STATUS)
follows:
Screen 2
Screen 1 Note:
O/L TRIP LEFT TO
TRIP: ###### SEC
CURRENT STATUS Screens include:
1. MOTOR STOPPED
READy TO START
Screen 3
2. MOTOR STARTING
THERM INH TIME LEFT
: #### MIN
MULT. OF FLA
3. MOTOR RUNNING
AT ###.## x FLA
Screen 4
COAST DOWN TIMER
TIME LEFT: #:## MIN
4. LAST TRIP CAUSE
NONE (or trip cause)
Screen 5
5. PROGRAMMING
SETPOINTS
TIME BETWEEN STARTS
TIME: #:## MIN
6. MOTOR STATUS
Screen 6
STARTS PER HOUR TIME
## ## ## ## ## ## ##
UNKNOWN STATE ### (displays relay state upon error)
Screen 2: Displays the amount of time remaining before
an overload trip will occur.
Screen 3: Displays the amount of time remaining from
a thermal inhibit. The inhibit time comes from
the amount of thermal register remaining
versus the amount of thermal capacity
required to start.
Screen 4: Displays the coast down time remaining
(Backspin time). The time remaining depends
upon the user setting in Setpoint Page 8,
Coast Down Time.
Screen 5: Displays the amount of time remaining before
a start command can be given.
Screen 6: If the number of starts per hour has exceeded
the setting.
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MP.5 Event Recorder - 60 Events (Metering Page 5)
MENU
Screen 1b
Screen 1
Screen 1a
:<cause of event>
:##/##/## ##:##
Vab: ###### Vbc: ######
Vca: ###### P/F: ####
METERING PAGE 5
Event Recorder (60 event)
IA: ###### IB: ######
IC: ###### G/F: ####
1st
Event
:<cause of event>
:##/##/## ##:##
Vab: ###### Vbc: ######
Vca: ###### P/F: ####
IA: ###### IB: ######
IC: ###### G/F: ####
2nd
Event
:<cause of event>
:##/##/## ##:##
IA: ###### IB: ######
IC: ###### G/F: ####
Vab: ###### Vbc: ######
Vca: ###### P/F: ####
59th
Event
:<cause of event>
:##/##/## ##:##
IA: ###### IB: ######
IC: ###### G/F: ####
Vab: ###### Vbc: ######
Vca: ###### P/F: ####
60th
Event
All events will be viewed from oldest event in buffer to most recent event.
The events are listed from oldest to most recent.
Screen 1: Displays the event (i.e. Imbalance Trip) with the
date and time it occurred.
Screen 1a: Displays the current of Phase A, B, C and the
ground fault at the time of the trip.
Screen 1b: Displays the Vab, Vbc, Vca and power factor at the
time of trip.
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MP.6 Last Trip (Metering Page 6)
MENU
Displays the information regarding the last trip.
Screen 1
Screen 1: Displays the cause of the last trip.
(cause of trip)
(value at time of trip)
METERING PAGE 6
LAST TRIP
Screen 2: Displays the measured phase current at the
time of the trip.
Screen 2
Ia: ####
Ic: ####
Ib: ####
G/F: ####.#
Screen 3: Displays the Vab, Vbc, Vca and power factor
at the time of trip.
Screen 3
Vab: ###### Vbc: ######
Vca: ###### P/F: ######
Screen 4: Displays the imbalance percentage, the
frequency and the kW at the time of the trip.
Screen 4
Screen 5: Displays the hottest stator RTD temperature
I/B: ## % Hz: ##.#
KW: ########
at time of the trip.
Screen 5
Screen 6: Displays the hottest non-stator RTD
HOTTEST STATOR
RTD# # @ ### C
temperature at the time of the trip.
Screen 6
HOTTEST NON-STATOR
RTD# # @ ### C
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MENU
Screen 1
METERING PAGE 7
STATISTICS
MWH TOTAL
: ###
Screen 3
Screen 2
RUNNING HOURS TOTAL
TIME: ## ## HOURS
PRESS ENTER TO
CLEAR RUN HOURS
MP.7 Statistics (Metering Page 7)
Displays the statistical trip information.
Screen 1: Displays the total of megawatt hours.
Screen 2: Displays the accumulated total running hours.
Screen 4
TOTAL TRIPS: ###
S/C TRIPS: ###
Screen 3: Clears the total running hour count.
Screen 5
Screen 18
Screen 4: Displays the total number of trips since the
last clearing the statistical data and the total
number of short circuit trips.
START O/L TRIPS: ###
RUN O/L TRIPS: ###
U/V TRIPS: ###
O/V TRIPS: ###
Screen 5: Displays the numbers of start overload and
run overload trips since the last clearing of the
statistical data.
Screen 6
Screen 19
FREQUENCY TRIPS: ###
I/B TRIPS: ###
POWER FACTOR
TRIPS: ###
Screen 6: Displays the number of frequency trips and
Screen 7
Imbalance trips.
Screen 20
OVERCURRENT
TRIPS: ###
PHASE REVERSAL
TRIPS: ###
Screen 7: Displays the number of overcurrent trips.
Screen 8: Displays the number of Stator and non-Stator
Screen 8
RTD Trips.
Screen 21
STATOR TRIPS: ###
Screen 9: Displays the number of Ground Fault Hi and
NON-STATOR TRIPS: ###
EXT INP #1: ###
Lo Set trips.
Screen 9
Screen 10: Displays the number of acceleration time trips.
Screen 11: Displays the number of start under curve trips.
Screen 12: Displays the number start over curve trips.
Screen 13: Displays the number of I2T start curve trips.
G/F HISET TRIPS: ###
G/F LOSET TRIPS: ###
Screen 22
EXT INP #2: ###
Screen 10
ACCELERATION TIME
TRIPS: ###
Screen 14: Displays the number of learned start curve
Screen 23
trips.
EXT INP #3: ###
Screen 11
Screen 15: Displays the number of fail shunt trips.
START UNDER CURVE
TRIPS: ###
Screen 16: Displays the number of phase loss trips.
Screen 24
Screen 17: Displays the number of tachometer
EXT INP #4: ###
acceleration trips.
Screen 12
START OVER CURVE
TRIPS: ###
Screen 18: Displays the number of undervoltage and
Screen 25
overvoltage trips.
PRESS ENTER TO
CLEAR STATISTICS
Screen 19: Displays the number of power factor trips.
Screen 20: Displays the number of phase reversal trips.
Screen 21: Displays the number of external input #1 trips.
Screen 22: Displays the number of external input #2 trips.
Screen 23: Displays the number of external input #3 trips.
Screen 24: Displays the number of external input #4 trips.
Screen 13
LEVEL 2 Password required
I*I*T START CURVE
TRIPS: ###
Screen 14
LEARNED START CURVE
TRIPS: ###
Screen 25: Requires a Security Level 2 password to clear
Screen 15
the statistics.
FAIL SHUNT TRIP
TRIPS: ###
Screen 16
PHASE LOSS TRIP
TRIPS: ###
Screen 17
TACH ACCEL TRIP
TRIPS: ###
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Chapter 7 - Maintenance and Troubleshooting
The soft starter is designed to be a maintenance-free product. However, as with all electronic equipment, the
unit should be checked periodically for dirt, moisture or industrial contaminants. These can cause high voltage
arc-over, carbon tracking or prevent proper cooling of the SCR heat sinks. All bolts should be checked annu-
ally for proper tightness using an accurate torque wrench. According to the manufacturer’s manual, check the
contactor for air gap spacing of the vacuum bottles.
Note: If the unit is installed in a contaminated environment and forced air cooling is used, blower
filters must be checked and cleaned regularly to insure proper air flow and cooling of the enclosure.
7.1 - Failure Analysis
When a fault occurs, the LCD will display the fault error and the listed LED and AUX Relay will be lit.
Please clear all faults before attempting to restart the unit. Note: If the problem persists after the
required programming changes have been made, and all corrective action has been taken, please
contact the factory for assistance.
Aux
Problem
CPU LCD Display
LED
Possible Cause
Solutions
Relay
One of the main
fuses blows or
circuit breaker
opens when the
power is applied
or disconnect is
open
Short circuit between the
inputs
Locate and remove short
TCB FAULT TRIP
Trip
AUX1
Remove power and test SCR(s). Refer to
Section 7.1.1 for the SCR testing
procedure
Faulty SCRs
Short circuit or ground fault
in motor/cabling
Locate and remove short or ground
Repair cause of phase loss
Phase Loss
Branch circuit protection Verify correct sizing of branch circuit
not correctly sized
protection
Short Circuit Trip
SHORT CIRCUIT TRIP
Trip
AUX1
Remove power and replace main circuit
board.
Faulty main circuit board
Remove power and test SCR(s). Refer to
Section 7.1.1 for the SCR testing
procedure
Faulty SCRs
Single phase incoming
power
Correct problem with incoming power
SINGLE PHASE TRIP
(Check LCD display for
possible fault indicators)
Single Phase Trip
Trip
AUX1
Remove power and test SCR(s). Refer to
Section 7.1.1 for the SCR testing
procedure
Faulty SCRs
If fans have power, remove power and
replace fan(s). If fans do not have power,
find cause of power loss and repair.
Fan(s) not functioning
(If supplied)
Remove power and clean heatsink with
Heatsink coated with dirt high pressure air (80 - 100 psi max clean
and dry air)
Verify that running current does not
Overcurrent on unit
EXTERNAL TRIP ON
THERMOSTAT
Thermostat trips
during run
Trip
AUX1
exceed unit rating
Environment temperature
over 122° F (ambient
Place unit in environment temperature
temperature for chassis
less than 122°F for panel version or less
units) or over 104°F
than 104°F for enclosed version.
(ambient temperature for
enclosed version
Bypass failed to close
Check bypass contactor and wiring
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Aux
Relay
Problem
CPU LCD Display
LED
Possible Cause
Solutions
Loss of 1 or more
phases of power from Check power source
utility or generated power
Phase Loss
Trip
AUX1
PHASE LOSS
Blown power fuses
Check for short circuits
Check motor nameplate versus
programmed parameters
Improper programming
Overload
Trip
Trip
AUX1
AUX1
OVERLOAD TRIP
ACCEL TIME TRIP
Possible load damage or
jammed load
Check motor currents
Improper setting for
motor load condition
Verify current limit setting
Check for load failure
Stall prevention
Damaged load
Improper programming Check setpoint settings
Wrong position of
Check disconnect or open breaker
disconnected breaker
Under Voltage
Trip
Trip
AUX1
UNDER VOLTAGE TRIP
Main contactor failed to
close
Check internal connections
Reduce current limit setting, saturation
or sagging power supply transformer
Transformer too small
Improper programming Check setpoint settings
Under Current
Trip
UNDER CURRENT TRIP
SELF-TEST FAILURE
Trip
Trip
AUX1
AUX1
Unloaded motor
Check load
Failed CPU or Main Firing
Board
Contact factory
Self-test Failure
Vibration
Check internal wiring connections
Troubleshoot and repair generator
Contact utilities company
Line Frequency
Trip
Generator Power
Problem or grid change
OVER OR UNDER
FREQUENCY TRIP
Trip
Trip
AUX1
AUX1
Main board failure
Three phase power removed from
Main Board
Improper programming Check program setpoints
Any wire going to ground
(I.e. stator ground, motor
ground, soft start ground)
Check with megger or Hi-pot motor
leads and motor
GROUND FAULT
HI-SET OR LO-SET
Any Ground
Fault Trip
High vibration or loose
connections
Check internal connections
This is a serious fault condition. Ensure that the fault
Warning:
condition is cleared on the load before attempting to restart the
motor.
Motor stopped
during run
Check for fault indication
Trip
AUX1
None
Load shorted/ grounded/
Remove power and repair.
faulted
Faulty main circuit board Replace the main circuit board
Remove power, locate and remove
Control circuit
fuses blow after
control power is
applied.
Short in control circuit
this short
None
None
Apply the correct voltage to the control
Wrong control voltage
circuit
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Aux
Problem
CPU LCD Display
LED
Possible Cause
Solutions
Relay
No control voltage applied Apply control voltage to TB1 pins 1 and 6
to control board on the power board
Control power transformer Remove power and replace the power
failure or CPT fuse failure transformer or the CPT fuse
Start circuit wired
incorrectly
Remove power and correct the start
circuit wiring
No start command
Apply the start command
Any fault indication
message
Motor will not start
Trip
AUX1
No 3 phase line voltage Apply 3 phase line voltage to the unit
Remove power and test SCR(s). Refer to
Shorted SCR in starter Section 7.1.1 for the SCR testing
procedure
Remove power and repair the control
Faulty control logic
logic.
Failure of main circuit
Replace the main circuit board
board
Check the motor and the motor
Faulty motor
connections
Remove power and perform the SCR
Faulty SCRs
Motor vibrates/
Motor growls
while starting or
extremely
unbalanced motor
currents run mode
device checks
Trip
AUX1
IMBALANCE TRIP
Remove power and test SCR(s). Refer to
Faulty gate/cathode on
Section 7.1.1 for the SCR testing
SCRs
IMBALANCE ALARM
procedure
Faulty main circuit board Replace the main circuit board
Faulty motor/wiring
Troubleshoot and repair/replace wiring
Alarm
AUX2
Faulty main circuit board Replace the main circuit board
7.1.1 - SCR Testing Procedure
Perform the SCR Heat Sink Ohm test on each Stack Assembly.
Test To Perform
Ohm Meter Reading
Greater than 10K Ohm
Less than 10K Ohm
Greater than 10K Ohm
Less than 10K Ohm
Test Result
Pass
From Position A to
Position B
Fail
From Position B to
Pass
C
Position C
Fail
Pass (Typical 8 to 20
Ohms)
Gate (G) to Cathode
8 to 100 Ohms
(K) for each SCR
Less than 10 or greater than 100 Ohms
Fail
B
Note: Allow 15 minutes after shutdown for DV/DT network to discharge DC
voltage.
A
Gate Drive
Board
K = Cathode = Red Wire
G = Gate = White Wire
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7.2 - Typical Block Diagram
L1
L2
L3
Voltage
Transformer
Ring
Transformer
3
CT
4
Fiber Optics
3
CT
4
3
CT
4
A
B
C
CPU
Digital
Fiber Optics
Main
Firing Board
Controller
SCR Assembly
Control Board
Customer Connections
T1
T2
T3
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7.3 - Overload Curve Definition
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Customer Provided
7.4 - TCB Diagram
Momentary or Maintained
Start / Stop Switching
Maintained
STOP
START
Fuses
Momentary
F1: Control Fuses for TB1 1 - 9
Part #ACG1A250VAC or equivalent
F2:Contactor and relay output fuses
Part #ACG4A250VAC or equivalent
F3: TB2 Pin #6
Part #ACG4A250VAC or equivalent
12
Aux Start
Output
11
10
9
E1
E3
E4
E2
120 VAC
Neutral
AC
Red
LED
Neut
8
Start
Stop
FUSE
7
TB1
Red
LED
6
T1
5
Inter
Lock
Optional
Interlocks
FAULT
4
3
Inter
Lock
2
AC
120 VAC
Source
1
Source
10
9
F1
8
F2
F3
HEATSINK
FACTORY WIRED
DO NOT USE
7
Green
LED
6
Line
1
2
120VAC
{
5
Neutral
-12V
TB2
4
Emergency Bypass
AUX Contacts
3
Green
LED
Green
LED
Delayed Start
3
4
2
Emergency Bypass
Full Voltage Start
5
+12V
START
Fuse Blown/
Disconnect Open
Dual Ramp
1
TB6
ON
6
7
12
OFF
SW1
JP1
8
11
10
9
9
Remove JP1 for electronic
motor overload protection
during emergency
Bypass Status
DUAL ADJ
10
bypass operation
8
1
2
3
4
5
6
7
7
Run
CPU (AUX1) Fault
At Speed
TB3
TCB
6
5
BOARD
TB7
4
3
2
1
Fuse Blown/
Disconnect
12
1
2
Green
LED
11
10
9
Interlock Input
3
TB8
External Overload
PFC
4
TIMED
7
6
5
4
3
2
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
OUT
8
5
Bypass Aux Contact
7
6
TB4
PFC
AUX
START
A1
6
7
Bypass
{
Coil
A2
5
8
4
9
A1
Green
LED
Main
Coil
{
3
10
A2
2
DELAY
TIMED
OUT
1
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7.5 - Typical Wiring Diagram
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7.6 - Spare Parts List
Unit Voltage
Quantity
Req./Unit
Description
Current
Part Number
and Amp Rating
Contact Factory
Specify model number
3
Transformer
MVC3-STK23200
MVC3-STK23400
MVC3-STK23600
MVC3-STK41200
MVC3-STK41400
MVC3-STK41600
MVC3-STK72200
MVC3-STK72400
MVC3-STK72600
25-0200-6500-23
25-0400-6500-23
25-0600-3500-23
25-0200-6500-41
25-0400-6500-41
25-0600-3500-41
25-0200-6500-72
25-0400-6500-72
25-0600-3500-72
10-0090
2300V, 200A
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
6
12
9
9
2300V, 400A
2300V, 600A
Heatsink
3300/4160V, 200A
3300/4160V, 400A
3300/4160V, 600A
6000 - 7200V, 200A
6000 - 7200V, 400A
6000 - 7200V, 600A
2300V, 200A
Assembly with
Boards
(1 Phase)*
2300V, 400A
2300V, 600A
SCR(s) Clamped
in Heat Sink
Alone
3300/4160V, 200A
3300/4160V, 400A
3300/4160V, 600A
6000 - 7200V, 200A
6000 - 7200V, 400A
6000 - 7200V, 600A
2300V, 200A & 400A
2300V, 600A
10-0090
Gate Drive
10-0090
3300/4160V, 200A & 400A
3300/4160V, 600A
6000 - 7200V, 200A & 400A
6000 - 7200V, 600A
Transfomer
10-0090
10-0090
10-0090
Temperature &
Current Board
MVC3-Temp/CT-PS
All models
3
PCB Mounting Order
Gate Drive
Board
MOV
Board
DVDT
Board
Temp CT
Board
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7.7 - Instructions for Stack Replacement
For Reference Only
TEMP / CT Board
Gate Drive Board
MOV Board
DV/DT Board
PCB Mounting Order
Gate Drive
MOV
DVDT
Board
Board
Board
Temp CT
Board
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7.7 - Instructions for Stack Replacement
DANGER
HAZARDOUS VOLTAGE
Disconnect all power supplying this equipment prior
to working on it.
Failure to follow this instruction will result in death
or serious injury.
Note: All power sources must be removed and a waiting period of at
least 15 minutes must be observed before initiating any repairs to
the unit(s) because DC voltage may still be present immediately after
turning off power to the unit.
Note: It is good practice to disassemble and reassemble one stack at a
time so you can have an assembled and wired stack in the unit as a
reference.
Note: Toshiba recommends that the order include the SCR with the heat-
sink assembly at a minimum. Only an experienced technician should
attempt to replace the SCRs.
Tools:
• Phillips screwdriver
• 3/8” 12 point socket set
• 2 9/16” wrenches
• ½” wrench
• AC/DC Multimeter
• JKSSS+ manual (refer to drawings in this section)
Procedure:
1. Verify that no DC or AC voltage is present on any of the power compo-
nents.
2. Disconnect all four wires connected to TB1 positions 1-3 on the tempera-
ture CT board.
3. Disconnect the 4 red transformer wires on each of the gate drive boards.
These would be TB1, positions 3 and 5 for each gate drive board. Typically,
the 2300V unit will have only 4 wires per phase to disconnect, a 4160V unit
will have 8 wires per phase, and a 6000 - 7200V unit will have 12 wires per
phase. (Note: the 7200V/600A unit will also have 24 wires.)
4. Use the 9/16 wrench and carefully unbolt all of the line and load power con-
nections attached to the heat sinks. Note: If the unit is a 6000 - 7200V, re-
move the power strap connecting one side of the stack to the stack directly
below it.
5. Before removing the fiber optic wiring, make a note of the label on the
fiber cable to ensure they are placed exactly in the same socket they were
removed from. Now remove all fiber optic connectors on the stack. Gently
push on the connector tab and pull with a gentle left-to-right motion on the
connector in the direction away from the fiber optic device. Two connectors
will be found per gate drive board and one duplex connector will be found
on the small Temp/CT board on top. Caution: Do not touch the tip of the
connectors or contaminate the connection sockets with any dust or foreign
material.
6. Remove the wires from the Temp/CT board terminal block (3 screws).
7. Use a 9/16” socket with a 6” extension to remove the lower bolt that
routes through the front face of the heat sink and into the isolation standoff
mounted to the white panel. Then carefully hold the heat sink in place with
one hand and remove the top bolt from the heat sink.
8. Ensure the fiber optic connectors and all wires are positioned out of the
way, and then the heat sink can be gently removed from the unit.
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SCR Replacement:
FAILURE TO PERFORM THIS PROCEDURE
CORRECTLy WILL DAMAGE THE SCR AND
WILL NOT BE COVERED UNDER WARRANTy.
1. Remove white jumper wires on the gate drive board and make a note
of their placement.
2. Remove both 7/16 bolts and the singular 10 - 32 screw at the top of
gate drive board and lift off the board.
3. To remove the MOV board, remove the SCR gate/cathode leads (thin
red and white wires) and the white jumper wires attached to them.
Make a note as to how they were connected. Unbolt the ½” fasteners
as well.
4. At this point, all boards should now be removed from the aluminum
heat sink assembly.
5. Make a note (or drawing) of how each of the SCRs are oriented within
the heat sink. If factory supplied replacement SCRs and heatsinks are
used, the following steps are not required.
6. Loosen and carefully remove the ½” feed-through bolt and two black
springs that hold the assembly together and turn it on its side.
7. Remove the two (2) SCRs in the top layer, making certain to note that
the SCRs are not facing the same direction.
8. Remove the two (2) SCRs in the bottom layer, also making certain to
note that the SCRs are not facing the same direction.
9. Clean the heat sink surface area thoroughly and reapply some thermal
heat sink grease sparingly to the SCRs mating surfaces.
10. Please note that replacement SCRs are in matched sets of four and as
such, please try to keep the matched sets within the same phase.
11. Now, take any two SCRs from a set and place them on the heat sink in
the same direction as the old SCRs were, ensuring that the dimple in
the center of the SCR is properly placed onto the center pin of the heat
sink assembly. Place the next level of heat sink bar on the mounted
SCRs. Note: There is a difference in the heat sink bars. The center bar
has more holes drilled in it for mounting the circuit boards on it.
12. Now replace the other two (2) SCRs by repeating steps 10 and 11.
13. Next, carefully sandwich the SCRs and turn the stack over so the heat
sink bars are vertical and run the center bolt through the springs and
hand tighten the nut on the center bolt assembly.
14. Then make approximately 3 and ½ full revolutions on the nut to create
the appropriate amount of compression force. You can tell if there is
enough compression force applied to the heat sink by the fact that the
force needed to turn the nut will suddenly increase.
15. Finally, reinstall all boards in the same manner in which they were
removed.
16 Refer to drawing PCB for disassembling and reassembling the stack
assembly.
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Reinstallation:
1. Hold the rebuilt or new stack assembly in the vertical position with
the Temp/CT board on top (only the top stack assembly will have this
board in a multi-stack phase) and place the stack on the positioning
studs that protrude from the isolation standoffs.
2. While pressing on the stack to hold it on the positioning studs, place
the feed-through bolt through the heat sink and finger-tighten the top
bolt. Then repeat the process with the bottom feed-through bolt to
ensure the stack is held against the isolation standoffs.
3. After verifying no wires or fibers have been pinched between the stack
assembly and isolation standoffs, tighten the top bolt completely, then
repeat the process for the bottom bolt. Now the stack assembly should
be held firmly in place.
4. Using the 9/16” wrench reinstall the line and load power cables and
tighten.
5. If needed, refer to the appropriate drawing to reconnect red transformer
wires on each gate drive board. As an example, for the 4160V stack,
reattach TB4-1 to X3, TB4-3 to X4, TB1-3 to X2 and TB1-1 to X1. Verify
all X(#) wires are reconnected to their original position on the gate drive
boards. Otherwise the SCRs will misfire.
6. Reconnect thermostat wires on TB1 positions 2 and 3 of the Temp/CT
board.
7. Reconnect the main CT black wire to TB1-1. Then feed the white wire
through the board mounted CT and connect to TB1-1 on the Temp/
CT board. Please note that one each of the thick white wires from the
encapsulated CT must be connected with the Main CTs wiring.
8. Ensure the same fiber optic routing is used as before. If the fiber optic
wiring is positioned close to a heat source, (such as the 25-watt resis-
tors on the gate drive board) melting or distortion of the plastic fiber
may occur. Minimum distance is a ½ inch with a minimum bend radius
of 2 inches. All gate drive boards require 2 single connectors per board
and the Temp/CT connector is a duplex piece with a mating tab that
faces away from the stack. If the tab is broken off, refer to an adjacent
stack’s labels to see how the labels should be positioned when install-
ing a duplex connector with a broken tab. Again, caution should be
taken not to touch the fiber connector end or force it in with the tab
facing down.
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7.8 - Instructions for Low Voltage Test
DANGER
HAZARDOUS VOLTAGE
Disconnect all power supplying this equipment prior
to working on it.
Failure to follow this instruction will result in death
or serious injury.
Tools:
• Phillips screwdriver
• Medium voltage fuse pullers if available
• Two control power transformer (Test PT) 500 VA minimum
• 120Vac control power (Test plug)
• Low voltage motor strapped for the proper voltage (typically 5 HP or
less)
• Oscilloscope if available
• Wire jumper
• Test switch (single pole i.e. - light switch)
480 or 240 VAC 3 Phase Supply
Construct an open delta low
voltage source for powering
the MVC for low voltage testing
(Minimum of 500VA each)
B
C
A
DANGER
Ensure proper
HAZARDOUS VOLTAGE
phase sequence
H2
H1
X2
H2
H1
Remove all medium voltage fuses to prevent back-
feeding transformers.
PTs
X1
Failure to follow this instruction will result in death
or serious injury.
X1
A
X2
B
C
Low Voltage Panel
• Manual (reference drawing above)
TB1 Terminal 3
TB1 Terminal 1
TB1 Terminal 5
Procedure:
120 VAC 3 Phase Output
1. Verify that no DC or AC voltage
is present on any of the power
components.
Connect to MVC3-MB (Main Firing Board)
Caution: Remove the three phase transformer PT fuses and CPT fuses
on panel to prevent backfeed to the Medium Voltage
2. Verify setup of control power
transformers for the proper
voltage. If using 480Vac or 240Vac 3 phase verify transformers are
strapped for that voltage. See above drawing. Configure as an open
delta for 3 phase as shown in drawing.
3. Verify medium voltage disconnect is open and pull medium voltage
fuses including PT and CPT fuses.
4. Connect 3 phase power 480 or 240Vac to the down stream side of
the fuses. Do not connect to disconnect side of fuses. Depending on
the small test motor used will depend on what size cable or current
that is required. Also, connect the Primaries of the TEST PT in the
proper phase sequence of A-B-C.
5. Disconnect medium voltage motor.
6. Connect low voltage motor. (Typically 5 HP or less)
7. Connect a wire jumper between TB8 pins 1 and 2 on the TCB (con-
trol board) to bypass fuse blown and open disconnect fault. The
TCB is located in the low voltage compartment.
8. Install a switch on TB1 pins 1 and 8 on the TCB (control board) to
bypass all interlocks (TEST Switch).
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9. Verify or wire a 120Vac plug to the TEST plug supplied by the factory.
10. Remove all both power fuses on the medium voltage CPT (single
phase control power transformer), if present..
11. Remove 3 fuses from the medium voltage potential transformer (PT).
12. Verify the 120-volt test switch is in the “NORMAL” position.
13. Connect test power to test plug connector and place the 120-volt test
switch to the “TEST” position.
14. The keypad should be energized with the “Power LED,” Stop LED.
15. Close the temporary Start switch, which is connected to the control
board.
16. The Main Vacuum contactor should close and the keypad should
trip on “Under Voltage” Open temporary TEST switch and reset CPU
fault.
17. Connect the Secondary of the TEST PT to Panel TB1 positions 1 -
phase A, position 3- phase B, and position 5 - phase C on the main
firing board (JKSSS+-MB). It is physically located behind the low
voltage compartment door. (Screw terminal block)
18. Verify all connections are good and then energize the low voltage of
either 480 or 240 volt, three phases.
19. Use the multimeter on the AC scale and verify 3 phase 120Vac
(phase to phase) at TB1 pins 1, 3 and 5 of the main firing board.
20. If all 120Vac 3 phase is present then de-energize low voltage of 480
or 240Vac.
21. Re-energize the low voltage of 480 or 240Vac.
22. Now all test voltages should be present 480 or 240Vac and three
phase 120Vac (TEST PT) and 120Vac single phase for control
power.
23. Close the temporary Start switch and the test motor should spin up
smoothly.
24. Use the Multimeter on the AC scale and check (phase to phase)
voltages on T1, T2 and T3 motor leads. The voltages should be bal-
anced.
25. If the motor doesn’t spin up smoothly the soft starter is malfunction-
ing. Proceed to step 27 for troubleshooting.
26. If the motor starts and runs smoothly then repeat this procedure in
reverse to remove all test connect and reinstall all fuses.
Low Voltage Troubleshooting:
Tools: Ungrounded Oscilloscope
27. Open test switch and stop motor.
28. Change Setpoint Page 5 AUX4 is set at non-fail safe. Change it to fail
safe.
29. Observe bypass contactor closes immediately.
30. Place the Oscilloscope on the 2msec time scale and 1 Volt per
division.
31. Connect the Oscilloscope probe to the Gate and Cathode of the
SCRs.
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32. The gate and cathode leads are the white wires on the gate drive
board in the medium voltage cabinet. See drawing below.
33. If waveform is inverted, swap Oscilloscope connections for proper
polarity. Close the temporary Start switch and allow the test motor to
reach full speed.
34. Then verify all gating signals to each SCR (two gating signals on
every gate drive board). See drawing below for correct waveform.
35. Once the bad signal(s) are found; write down the location and call
the factory for further guidance.
Waveform is
the gating signal as
measured with an
ungrounded oscilloscope
at the gate to cathode
of the SCR. The
waveform should be 1.7
to 2msec off time and
approximately 1.5 to
3 Vdc. This signal is only
present at full conduction
or the motor is at speed.
Each SCR gating signal
should be checked
in accordance with the
low voltage test procedure.
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7.9 - Maintenance Program/Servicing Equipment/Disposal/Storage
MAINTENANCE PROGRAM
In order to ensure continued reliable and safe operation of the equipment, a
program of periodic maintenance must be established. Operating and environmental
conditions will usually dictate the frequency of inspection required. NFPAPublication
70B “Electrical Equipment Maintenance” may be used as a guide for setting up the
maintenance program.
Contact with energized components can cause severe injury, death and
property damage. Turn off and lock-out primary and control circuit power
before servicing.
Improper maintenance can cause severe injury, death and property
damage. Only qualified and authorized persons are to install, operate or
service this equipment.
Grease is conductive. Do not allow grease or any other substances to
contaminate insulating materials. Contaminated insulators can allow a
short-circuit or ground fault to occur.
NOTE:
Refer to the SAFETY section of this manual for important
information.
MAINTENANCE RECORD
Keep a permanent record of all maintenance work. At a minimum, this record should
include information on:
1) Items inspected
2) Reports of any testing
3) Equipment condition
4) Corrective actions or adjustments
5) Date of work
6) Comments
The degree of detail of the record will depend somewhat on the operating
conditions.
SERVICING EQUIPMENT
For your safety, turn off and lock out main and control circuit power before servicing
the starter. Certain minimum safety procedures must be followed:
1) Only qualified personnel should attempt this service.
2) Never perform service on or next to exposed components energized with line
voltage.
Failure to adhere to these safety procedures can result in severe injury,
death and property damage.
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DISPOSAL
Contact your state environmental agency for details on disposal of electrical
components and packaging in your particular area.
STORAGE
If the starter is to be stored for any length of time prior to installation, the
following precautions should be taken:
1) The original packing should be restored, if possible.
2) Do not subject the equipment to moisture or sun rays. Store in cool, clean,
and dry location.
3) Place a dust cover over the starter packaging to protect against dirt and
moisture.
4) Store in an upright position.
INSPECTION DURING STORAGE
Routine scheduled inspection is necessary if storage is for an extended
period. The unit should be checked for condensation, moisture, corrosion,
and vermin.
Prior to installation, the starter should be carefully examined for evidence of
physical damage, corrosion, or other deterioration.
The MAINTENANCE section of this manual describes various types of
inspections recommended for this starter during the operation period.
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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 WILLEXPIRE TWENTY-FOUR (24) MONTHSAFTER SUCH
EQUIPMENT AND PARTS (EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED
PURSUANT TO THIS WARRANTY)ARE PLACED IN OPERATION OR THIRTY (30) MONTHSAFTER THE DATE ON
WHICH SUCH EQUIPMENTAND PARTS (EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENTAND PARTS
FURNISHED PURSUANTTOTHISWARRANTY)ARESHIPPEDTOTHEINITIALPURCHASER, WHICHEVERPERIOD
FIRST EXPIRES. THEREARE NO OTHER WARRANTIES WHETHER EXPRESS, IMPLIED, STATUTORY OR OTHER-
WISE,INCLUDINGTHEIMPLIEDWARRANTIESORMERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE.
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 INSTALLANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAYANY COSTS
INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION. THE COMPANY, TOSHIBA
CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHER EXPRESS,
STATUTORYAND IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION,ALLEXPRESS, STATUTORYAND
IMPLIEDWARRANTIES,SUCHASMERCHANTIBILITYANDFITNESSFORAPARTICULARPURPOSEAPPLICABLETO
ALLREPAIREDORREPLACEDEQUIPMENTANDPARTSFURNISHEDPURSUANTTOTHEFOREGOINGWARRANTY.
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,
propertydamage,lossofprofitsorrevenue,lossofinformationordata,lossofequipmentdescribedhereinoranyassociated
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.
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TOSHIBA
TOSHIBA INTERNATIONAL CORPORATION
INDUSTRIAL DIVISION
13131 West Little York Rd., Houston, Texas 77041
Tel 713-466-0277 Fax 713-466-8773
US 800-231-1412 Can 800-872-2192
Mex 95-800-527-1204
World Wide Web http://www.toshiba.com/ind
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