Toshiba JK Series User manual

Document: OH01
Issued:
TOSHIBA
INSTRUCTIONS
OPERATION MAINTENANCE
JK Medium Voltage Controllers Ma imum
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INTRODUCTION Page 1
READ THIS MANUAL carefully for important information about safety, handling, and
maintenance, for general-purpose NE A Class E magnetic controllers.
This manual and all accompanying drawings should be considered a permanent part of the
equipment. They should be readily available for review and reference at all times.
DIMENSIONS shown in the manual are in metric and/or their English equivalent.
These instructions are not intended to cover all details, combinations, or variations of the
equipment, storage, or installation.
PROBLEMS OR QUESTIONS should be addressed to:
Field Service Department
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041 USA
Telephone: [phone]
[phone]
(800) 527-l 204 (Canada)
FAX: [phone]
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 severe injury, death and property damage.
Do not make any modifications to this equipment without the written
approval of Toshiba.
TOSHIBA INTERNATIONAL CORPORATION, 1994
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Page 2 TABLE OF CONTENTS
Page
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Receiving and Unpacking ............................................
7
Handling and oving ............................................... 7
Using a Forklift ................................................... 8
Overhead Lifting .................................................. 8
Contactor Carriage Handling .......................................... 9
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0
Preparation ..................................................... 10
Indoor Equipment ................................................. 10
Outdoor Equipment ............................................... 10
Routine Inspection ................................................
11
GENERALDESCRIPTION................................................. 12
Construction .................................................... 12
Controller Compartment ............................................
Isolation Switch .............................................
Withdrawable Contactor Carriage ................................. 14
Service Drawer ............................................. 15
Load Receptacle and Current Transformers .......................... 15
Outgoing Load Connections ..................................... 16
Control Power Transformer ..................................... 18
Operating Handle ............................................ 19
Interlocks echanical ........................................ 19
Door Interlock ......................................... 19
Handle Interlock ........................................ 20
Vacuum Contactor Interlock ............................... 20
Interlocks Electrical .........................................
21
Control Power Interlock ............................... 21
Test Power Interlock ................................. 21
Low Voltage Compartment .......................................... 22
ain Bus Compartment ............................................ 22
Prepared Spaces ................................................. 23
Contactor Ratings ................................................ 24
Controller Ratings ................................................ 25
Horsepower Table ................................................ 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rating Verification ................................................ 27
Location ....................................................... 27
Service Conditions ................................................ 27
Installation Site Preparation .......................................... 28
ounting ...................................................... 28
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TABLE OF CONTENTS Page 3
Page
Grounding ...................................................... 29
Connections .................................................... 31
Incoming Line ................................................... 33
Outgoing Load ................................................... 33
PRE-ENERGIZATIONCHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
General ........................................................ 34
Wiring.. ....................................................... 35
Devices echanisms ............................................. 36
Electrical Checks ................................................. 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Contactor Installation .............................................. 38
Initial Energization ................................................ 39
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
aintenance Record ............................................... 41
General Inspection ................................................ 42
Electrical Joints .................................................. 43
Contactor Carriage ................................................ 43
Isolation Switch .................................................. 44
Switch Handle echanism .......................................... 45
Interlocks ...................................................... 46
Load Receptacle .................................................. 46
Control Power Transformer .......................................... 47
MAINTENANCE AFTER A FAULT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Enclosure ...................................................... 48
Isolation Switch .................................................. 48
Fuse Clips ...................................................... 48
Terminals and Internal Conductors ..................................... 48
Overload Relays .................................................. 48
Vacuum Contactor ................................................ 49
Return to Service ................................................. 49
WARRANTY AND LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Page 4 SAFETY
IMPORTANT MESSAGES
Read this manual and follow its instructions. Signal words such as DANGER, WARNING
and CAUTION will be followed by important safety information that must be carefully
reviewed.
Indicates a situation which will result in death, serious injury, and severe
property damage if you do not follow instructions.
means that you might be seriously injured or killed if you do not follow
instructions. Severe property damage might also occur.
means that you might be injured if you do not follow instructions.
Equipment damage might also occur.
NOTE Gives you helpful information
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 signs.
DANGER
NOT RE OVE. DESTROY OR THIS LABEL I
READ THE INSTRUCTION ANUAL CAREFULLY BEFORE
INSTALLING, THIS
HAZARDOUS VOLTAGE In This Compartment.
I I Cause Injury, Death, Fire,
E p I And Property Damage.
! Turn Off And Lock Out Pr mat-y And
I Circuit Power Servicing
! Door Unless Isolation
Switch OFF And Contactor Is OPEN.
! Keep A I I Panels And Covers
In Place.
! Never Defeat, Or Bypass
Safety Inter locks
! Dual if Operators Only.
Safety sign on front cover of
controller unit.
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SAFETY Page 5
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:
Carefully read the entire instruction manual.
Be skilled in the installation, construction or operation of the equipment and aware
of the hazards involved.
Be trained and authorized to safely energize, deenergize, clear, ground, lockout and
tag circuits in accordance with established safety practice.
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
established practices.
Be trained in rendering first aid.
SAFETY CODES
Toshiba medium voltage controllers are general purpose, Class E, magnetic controllers
designed and built in accordance with the latest applicable provisions of NE A ICS 2-324,
UL 347 and the National Electrical Code. Installations must comply with all applicable
state and local codes, adhere to all applicable National Electric Code standards
and instructions provided in this manual.
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Page 6 SAFETY
HAZARDOUS VOLTAGE will cause severe injury, death, fire, e plosion and
property damage.
Turn off and lock out Primary and Control Circuit Power before servicing.
Do not open door unless Isolation Switch is OFF and Contactor is OPEN.
Keep all panels and covers securely in place.
Never Defeat, odify, or Bypass any Safety Interlocks
Qualified Operators only
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RECEIVING AND HANDLING Page 7
RECEIVING AND UNPACKING
Upon receipt of the equipment, do the
following:
ake an immediate inspection for any
damage which might have occurred
during shipment (Fig. 1). If damage is
found, it should be noted with the
carrier prior to accepting the shipment,
if possible.
Carefully unpack the equipment
sufficiently to check for concealed
damage and to determine that the
shipment is complete and correct.
Keep the equipment upright. If the
controller is not upright upon receipt,
notify the carrier of possible damage.
Upright the unit as soon as possible.
Do not lay the equipment
on its side or upside
down.
File a claim with the carrier for any
damaged or missing item and
immediately notify the nearest Toshiba
Representative.
Do not install or energize
equipment that has been
damaged.
HANDLING AND MOVING
edium voltage motor controllers should be
handled with care, to avoid damage to
components and to the frame or its finish
(Fig. 2).
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
Fig. 1 Inspect The Controller
Fig. 2 Moving The Controller
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Page 8 RECEIVING AND HANDLING
movement and placement operations to
prevent dropping, or tipping.
Do not place any part of
your body beneath
equipment being lifted.
Improperly secured
equipment can fall or tip
over quickly and without
notice.
Do not attempt
installation or removal of
the contactor carriage
using the lifting methods
described in this section.
Always use a Toshiba JK
LIFTING DEVICE for the
installation or removal of
the contactor carriage.
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. 3) should be used to provide
the vertical lift on single controllers to prevent
eye-bolt failure.
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. 4). Ropes
or cables should not pass through the holes in
Fig. 3 Use of Spreader Bar-Single Section
LIFT
Fig. 4 Lifting Multiple Sections
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RECEIVING AND HANDLING Page 9
lifting angles or eye-bolts. Slings with safety
hooks or shackles of adequate
should be used.
CONTACTOR CARRIAGE
load rating
NG
(refer toWithdrawable contactor carriage
found in the OPERATION section, page 38.
Two shipping brackets securing the carriage to
the service drawer must be removed before
attempting to lift the carriage from the drawer.
These brackets are used only for transportation
and may be discarded.
GENERAL DESCRIPTION, page are
normally shipped inside their respective
controller compartments. During initial
installation, the contactor carriages must be
removed from their compartments to allow
access for anchoring the enclosure to the floor,
and for pulling and terminating load cables.
Removal of the contactor carriage is facilitated
by the use of a Toshiba JK carriage lifting
attachment (Fig. and a suitable overhead
lifting device. The lifting attachment is
furnished with all JK medium voltage
controllers.
Details on the operation of the service drawer
which supports the contactor carriage may be
To attach the lifting attachment to the
carriage:
1.
2.
3.
4.
Position lifting attachment on top of
carriage.
Swing side support arms down to meet
carriage base.
Securely screw lift bolts into base.
Attach overhead lifter to eye bolt on
top of lifting attachment and lift from
drawer.
Ma imum weight of
carriage
is 135 Ibs
equipped with double
barrel fuses. Verify that
lifter used as adequate
load capacity.
LIFTER HERE
Fig. 5 Contactor Carriage Lifting Attachment
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Page 10 STORAGE
PREPARATION
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 (Fig. 6) is
removed, the top and openings of the
controller should be covered during the
construction period to protect it against dust
and debris.
INDOOR EQUIPMENT
Controllers designed for indoor installation
(NE A 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.
OUTDOOR EQUIPMENT
An unenergized controller designed for outdoor
installation (NE A Type EPIC building,
etc.) should be kept dry internally by installing
electrical heating or by energizing self-heaters,
if provided.
Fig. 6 Storage
All openings, either used or unused should be
covered or sealed to prevent the entry of rain,
vermin, insects, etc.
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STORAGE Page 11
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.
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Page 12 GENERAL DESCRIPTION
Toshiba medium voltage controllers are AC
general-purpose NE A Class E controllers
designed for applications at utilization voltages
ranging from 2.3 through 6.6 They are
normally used to control motor loads, although
other types of loads such as transformers and
capacitors are possible.
CONSTRUCTION
The standard enclosure size is wide by
36” deep by 90” high. In a typical two-high
arrangement, each enclosure is divided
vertically into three major compartments, each
with a separate door. The uppermost and
lowermost compartments contain medium
voltage controller components while
the middle compartment contains low voltage
components (Fig. 7). Other
variations of this basic arrangement are
possible.
ain horizontal bus is provided when required
to supply power to a line-up of controllers.
The main bus is located at the rear of the
enclosure midway between the top and
bottom. A common ground bus is also
provided for multiple sections.
Each controller compartment (Fig. 8) consists
of:
Fixed mounted non-load break isolation
switch.
Withdrawable contactor carriage with
power fuses.
Built-in service drawer for removing
contactor carriage from compartment.
Current transformers for metering.
Control power transformer and optional
potential transformer.
Load cable terminations.
Fig. 7 Typical Controller Arrangements
Fig. 8 Controller Compartment
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GENERAL DESCRIPTION Page 13
CONTROLLER COMPARTMENT
A. Isolation Switch (Fig. 9)
Power is switched on and off to each
individual controller compartment by a
mounted, externally-operated, three-pole
isolation switch. When the switch is in the
open position, incoming power is isolated from
the compartment interior by an automatic
shutter. Also, the load terminals of the switch
are automatically grounded in the open
position for additional safety.
The isolation switch is designed to accept a
direct connection from the line stabs of the
withdrawable contactor carriage. This
connection is automatically made when the
contactor carriage is installed in the medium
voltage compartment. When the switch is
closed by operating the external handle,
incoming power is applied to the line side of
the power fuses. In this position, the motor or
other load may be switched on and off by
operating the vacuum contactor.
The isolation switch
is mechanically
interlocked with the vacuum contactor and the
compartment door. Details of the interlocking
are discussed in section H.
The position of the isolation switch blades can
be observed through a window in the medium
voltage compartment door. Thus, it is possible
to have visual evidence that the power source
is isolated before entering the medium voltage
compartment. The switch is also provided
with lock-out provisions (Fig. IO).
The isolation switch has a maximum
interrupting capacity of 0.4 amperes.
Do n o t connect
additional load to the
isolation switch.
Fig. 9 Isolation Switch
Fig. 10 Isolation Switch Lockout
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Page 14 GENERAL DESCRIPTION
Withdrawable Contactor Carriage
(Fig. 11)
The withdrawable contactor carriage is a
removable assembly which contains the
following components:
Vacuum contactor
Power fuse housing assembly.
Set of line and load power stab
terminals.
Auxiliary contacts for vacuum
contactor.
Control wiring disconnect plug.
Set of wheels to facilitate moving the
carriage when it
is outside the
controller.
The withdrawable contactor carriage is
normally shipped installed in the controller. It
may be removed for access to the medium
voltage compartment during initial installation,
connection of motor cables, etc. Periodically,
removal of the carriage may also be necessary
for routine maintenance of the contactor or
replacement of the power fuses.
Always use a Toshiba JK
Lifting Device (Fig. 12)
for removal or installation
of the contactor carriage.
When the carriage is installed in the controller
compartment, the following connections are
automatically made:
The line side stabs engage the fixed-
mounted isolation switch connecting
the load side of the switch to the line
side of the power fuses.
The load side stabs engage the fixed-
mounted load receptacle connecting the
load side of the vacuum contactor to
the current transformers.
The control transformer primary stabs
engage fixed-mounted clips connecting
the load side of the power fuses to the
primary side of the control
transformer(s).
Fig. 11 Withdrawable Contactor Carriage
Fig. 12 Lifting Device
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GENERAL DESCRIPTION Page 15
In addition, when the withdrawable contactor
carriage
is inserted into the controller
compartment, it becomes interlocked with the
isolation switch so that the switch may not be
opened or closed unless the contacts of the
vacuum contactor are opened.
C. Service Drawer (Fig. 13)
The withdrawable contactor carriage is moved
in and out of the controller compartment on a
built-in sliding service drawer. The drawer has
four locating pins on top of it. When the
contactor carriage is placed on the drawer,
these pins engage four holes in the bottom of
the carriage which serve to align it properly.
The drawer moves in and out of the controller
compartment on sliding ball bearing type
rails. There is a handle on the front of the
drawer to provide a gripping point.
D. Load Receptacle and Current
Transformers (Fig. 14)
The load receptacle is a fixed three-phase
disconnecting block. The vacuum contactor
load stabs on the withdrawable carriage
engage the load receptacle when the carriage
is installed in the controller compartment.
The load receptacle uses bolted pressure type
stab contacts similar to those used in the
isolation switch.
The operation of the bolted pressure contact
mechanism in the load receptacle is controlled
by a release lever located at the front of the
compartment below the service drawer.
Further details on the operation of the release
lever can be found in the OPERATION section
of this manual.
Power from the load receptacle is fed through
three current transformers located just behind
it. Current transformers furnished may be
either wound primary (bar) type, or window
Fig. 13 Service Drawer
Fig. 14 Load Receptacle
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Page 16 GENERAL DESCRIPTION
E. Outgoing Load Connections
Connections for outgoing load cable are
located at the rear of each controller
compartment just above the current
transformers. Cables may enter the controller
from either the top or bottom of the enclosure
through the provided.
If no specific information is provided when the
equipment is ordered regarding the type of load
cables to be used and the direction of entry,
the standard termination assembly shown in
Fig. 15 and Fig. 16 is supplied. Non-shielded
cables sized up one 350 C per phase can be
accommodated entering either from the top or
bottom of the enclosure (Fig. 15). This
arrangement can also accept shielded cables
entering from the top sized up to one
350 C per phase (Fig. 16). Space is
provided for installation of termination kits
(stress cones) and user-supplied one- or
hole compression type connectors.
When the installation requires termination of
shielded load cables entering from the bottom
of the enclosure, this should be specified when
the equipment is ordered and the termination
assembly shown in Fig. 17 is then provided.
This arrangement can accept shielded or non-
shielded cables up to one 350 C per phase
entering from the bottom. A field conversion
kit is available to convert from the standard
termination assembly (Fig. 15 and Fig. 16) to
the arrangement shown in Fig. 17. Consult
your local sales representative for information
regarding this kit.
When routing and terminating load cables,
observe the following:
If a ground current sensor (optional)
is supplied with the equipment, route
all of the load cables through the
sensor. Ground wires from shielded
cable terminators must be routed back
through ground sensor window before
attaching to ground bus.
EXIT CABLES
MAX SIZE 350 C NON-SHI
1 CABLE PER PHASE
BOTTO EXIT CABLES
AX 350 C NON-SHIELDED
1 CABLE PER PHASE
Fig. 15 Non-Shielded Cable Termination
TOP EXIT CABLES
MAX SHIELDED
1 CABLE PER PHASE
SWITCH
Fig. 16 Shielded Cable Termination Top
Entry
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GENERAL DESCRIPTION Page 17
Use Listed compression connectors
suitable for the cable being used.
Use the hardware provided with
the controller to attach cable
connectors to bus pads. After
installation, torque hardware to 45
ft.
After installation, check to see that at
least three inches clearance is
maintained between live parts of
opposite polarity and between live
parts and ground.
Fig. 17 Shielded Cable Termination Bottom
Entry
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Page 18 GENERAL DESCRIPTION
F. Control Power Transformer
A control power transformer (Fig. 18) is
mounted on the left-hand side wall of the
controller compartment. Power is supplied to
the fused primary of the control power
transformer from stabs on the withdrawable
contactor carriage. These stabs engage clips
on the transformer when the carriage is
inserted into the compartment.
Optionally, a second transformer (Fig.
normally used as an instrument transformer,
can be mounted in the compartment. When
this option is supplied, a third set of stabs is
furnished on the withdrawable carriage. The
two transformers are then connected in an
open-delta arrangement.
Another option sometimes supplied is a second
control power transformer connected in parallel
with the first to increase the available KVA
capacity.
Both the control and optional potential
transformer are used to supply power to the
low voltage circuits of the controller. This
includes power for the vacuum contactor
operating coil and for various instrumentation.
An electrical interlock is provided to ensure
that all load is disconnected from the control
power transformer secondary winding before
the power isolation switch can be opened or
closed.
Fig. 18 Control Power Transformer
Fig. 19 Optional Transformer
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GENERAL DESCRIPTION Page 19
G. Operating Handle
The external operating handle shown in Fig. 20
is used to control the operation of the isolation
switch. oving the handle upward turns the
switch on, thus applying incoming power to
the current-limiting fuses on the withdrawable
carriage. The withdrawable contactor carriage
can neither be inserted nor removed when the
operating handle is in the “on” position.
oving the handle down opens the isolation
switch, de-energizing all medium voltage
incoming power to the controller compartment.
At the same time an automatic shutter within
the switch closes providing an effective barrier
between the controller compartment and the
incoming supply. The opening of the switch
also causes the line side of the power fuses to
be grounded.
Fig. Operating Handle
H. Interlocks Mechanical
a. Door Interlock
A mechanical interlock is provided to prevent
opening or closing the medium voltage
compartment door unless the switch operating
handle is off (Fig. 21).
Fig. 21 Door Interlock
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