Toshiba JK Series 400A Medium Voltage Controllers Drawout … · 2018-11-14 · Toshiba...

Document: OH01Issued:

TOSHIBA

INSTRUCTIONS

OPERATION MAINTENANCE

JK Medium Voltage Controllers Maximum

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INTRODUCTION Page 1

READ THIS MANUAL carefully for important information about safety, handling, andmaintenance, for general-purpose NEMA Class E magnetic controllers.

This manual and all accompanying drawings should be considered a permanent part of theequipment. 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 theequipment, storage, or installation.

PROBLEMS OR QUESTIONS should be addressed to:

Field Service DepartmentToshiba International Corporation13131 West Little York RoadHouston, Texas 77041 USATelephone: 466 -0277

(800) 231-1412(800) 527-l 204 (Canada)

FAX: (713 ) 466 -8773

Use only Toshiba-authorized replacement parts.

This equipment is designed and built in accordance with applicablesafety standards in effect on the date of manufacture. Unauthorizedmodifications can result in severe injury, death and property damage.Do not make any modifications to this equipment without the writtenapproval of Toshiba.

TOSHIBA INTERNATIONAL CORPORATION, 1994


Page 2 TABLE OF CONTENTS

PageSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Receiving and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Handling and Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Using a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Overhead Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Contactor Carriage Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Indoor Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Outdoor Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Routine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

G E N E R A L D E S C R I P T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Controller Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Isolation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Withdrawable Contactor Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Service Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Load Receptacle and Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . 15Outgoing Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Control Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operating Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Interlocks Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Door Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Handle Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Vacuum Contactor Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Interlocks Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Control Power Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Test Power Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Low Voltage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Main Bus Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Prepared Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Contactor Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Controller Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Horsepower Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rating Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Service Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Installation Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


TABLE OF CONTENTS Page 3

PageGrounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Incoming Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Outgoing Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PRE-ENERGIZATIONCHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34W i r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Devices Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Electrical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Contactor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Initial Energization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Electrical Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Contactor Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Isolation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4Switch Handle Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Load Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Control Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

MAINTENANCE AFTER A FAULT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Isolation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Fuse Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Terminals and Internal Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Vacuum Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

WARRANTY AND LIMITATION OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50


Page 4 SAFETY

IMPORTANT MESSAGES

Read this manual and follow its instructions. Signal words such as DANGER, WARNINGand CAUTION will be followed by important safety information that must be carefullyreviewed.

Indicates a situation which will result in death, serious injury, and severeproperty damage if you do not follow instructions.

means that you might be seriously injured or killed if you do not followinstructions. 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 followall safety signs.

Keep the safety signs visibleand in good shape. Neverremove or cover any safety signs.

D A N G E R NOT REMOVE. DESTROY OR THIS LABEL I

READ THE INSTRUCTION MANUAL CAREFULLY BEFOREI N S T A L L I N G , T H I S

HAZARDOUS VOLTAGE In This Compartment. I I C a u s e I n j u r y , D e a t h , F i r e ,

Exp I And Property Damage.

! Turn Of f And Lock Out Pr mat-y And I C i rcu i t Power S e r v i c i n g

! D o o r U n l e s s I s o l a t i o n

Swi tch OFF And Contac tor I s OPEN.

! Keep A I I Panels And Covers

In P lace .

! Never Defea t , Or Bypass

Safe ty In ter locks

! D u a l i f Opera tors Only .

Safety sign on front cover ofcontroller unit.


SAFETY Page 5

QUALIFIED OPERATORS ONLY

Only qualified persons are to install, operate, or service this equipment according to allapplicable 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 awareof the hazards involved.Be trained and authorized to safely energize, deenergize, clear, ground, lockout andtag circuits in accordance with established safety practice.Be trained and authorized to perform the service, maintenance or repair of thisequipment.Be trained in the proper care and use of protective equipment such as rubbergloves, hard hat, safety glasses, face shield, flash clothing, etc. in accordance withestablished practices.Be trained in rendering first aid.

SAFETY CODES

Toshiba medium voltage controllers are general purpose, Class E, magnetic controllersdesigned and built in accordance with the latest applicable provisions of NEMA ICS 2-324,UL 347 and the National Electrical Code. Installations must comply with all applicablestate and local codes, adhere to all applicable National Electric Code standardsand instructions provided in this manual.


Page 6 SAFETY

HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion andproperty 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, Modify, or Bypass any Safety Interlocks

Qualified Operators only


RECEIVING AND HANDLING Page 7

RECEIVING AND UNPACKING

U p o n r e c e i p t o f t h e e q u i p m e n t , d o t h efollowing:

Make an immediate inspection for anydamage which might have occurredduring shipment (Fig. 1). If damage isfound, it should be noted with thecarrier prior to accepting the shipment,if possible.

C a r e f u l l y u n p a c k t h e e q u i p m e n tsufficiently to check for concealeddamage and to determine that theshipment is complete and correct.

Keep the equipment upright. If thecontroller is not upright upon receipt,notify the carrier of possible damage.Upright the unit as soon as possible.

Do not lay the equipmenton its side or upsidedown.

File a claim with the carrier for anydamaged o r missing item andimmediately notify the nearest ToshibaRepresentative.

Do not install or energizeequipment that has beendamaged.

HANDLING AND MOVING

Medium voltage motor controllers should behandled with care, t o a v o i d d a m a g e t ocomponents and to the frame or its finish(Fig. 2).

The capability of the moving equipment tohandle the weight of the controller shippingsection should be confirmed.

The equipment should remain secured to theshipping skid to prevent distortion of the frameduring m o v i n g a n d t o m i n i m i z e t i p p i n g .Extreme care should be exercised during any

Fig. 1 Inspect The Controller

Fig. 2 Moving The Controller


Page 8 RECEIVING AND HANDLING

m o v e m e n t a n d p l a c e m e n t o p e r a t i o n s t oprevent dropping, or tipping.

Do not place any part ofy o u r b o d y b e n e a t hequipment being lifted.I m p r o p e r l y s e c u r e dequipment can fall or tipover quickly and withoutnotice.

D o n o t a t t e m p tinstallation or removal ofthe contactor carriageusing the lifting methodsdescribed in this section.Always use a Toshiba JKLIFTING DEVICE for theinstallation or removal ofthe contactor carriage.

USING A FORKLIFT

A forklift truck may offer a more convenientmethod of handling the controller. A safetystrap should be used when handling with aforklift. The ends of the forks should not enterthe bottom of an open-bottom enclosure.

OVERHEAD LIFTING

When it is necessary to move the equipmentbetween elevations, overhead hoisting may berequired. Lifting angles (for multiple controllersections) are provided on top of the enclosurefor this purpose.

Spreaders (Fig. 3) should be used to providethe vertical lift on single controllers to preventeye-bolt failure.

Always keep the controller upright while lifting.Some controller sections may contain heavy orspecial equipment that will cause the center ofgravity to be off-center. Rigging lengthsshould be adjusted to maintain the controller inan upright position. The angle between thelifting cables and vertical should not beallowed to exceed 45 degrees (Fig. 4). Ropesor cables should not pass through the holes in

Fig. 3 Use of Spreader Bar-Single Section

L I F T

Fig. 4 Lifting Multiple Sections


RECEIVING AND HANDLING Page 9

lifting angles or eye-bolts. Slings with safetyhooks or shackles of adequateshould be used.

CONTACTOR CARRIAGE

load rating

NG

( r e f e r t oWithdrawable contactor carriage

found in the OPERATION section, page 38.Two shipping brackets securing the carriage tothe service drawer must be removed beforeattempting to lift the carriage from the drawer.These brackets are used only for transportationand may be discarded.

G E N E R A L D E S C R I P T I O N , p a g e a renormally shipped inside their respectivecontroller compartments. During initialinstallation, the contactor carriages must beremoved from their compartments to allowaccess for anchoring the enclosure to the floor,and for pulling and terminating load cables.

Removal of the contactor carriage is facilitatedby the use of a Toshiba JK carriage liftingattachment (Fig. and a suitable overheadlifting device. The lift ing attachment isf u r n i s h e d w i t h a l l J K m e d i u m v o l t a g econtrollers.

Details on the operation of the service drawerwhich supports the contactor carriage may be

T o a t t a c h t h e l i f t i n g a t t a c h m e n t t o t h ecarriage:

1.

2.

3.4.

Position lift ing attachment on top ofcarriage.Swing side support arms down to meetcarriage base.Securely screw lift bolts into base.Attach overhead lifter to eye bolt ontop of lifting attachment and lift fromdrawer.

M a x i m u m w e i g h t o fcarriage is 1 3 5 I b sequipped with doublebarrel fuses. Verify thatlifter used as adequateload capacity.

LIFTER HERE

Fig. 5 Contactor Carriage Lifting Attachment


Page 10 STORAGE

PREPARATION

If the controller is to be stored for any lengthof time prior to installation, the packing shouldbe restored for protection during that period.Where conditions permit, the packing shouldbe left intact until the controller is at the finalinstallation position. If the packing (Fig. 6) isremoved, t h e t o p a n d o p e n i n g s o f t h ec o n t r o l l e r s h o u l d b e c o v e r e d d u r i n g t h econstruction period to protect it against dustand debris.

INDOOR EQUIPMENT

Controllers designed for indoor installation(NEMA Type 1, 12) which are not to beinstalled and energized immediately, should bestored in a clean, dry space where a uniformt e m p e r a t u r e p reven ts c o n d e n s a t i o n .Preferably, the controller should be stored in aheated building, with adequate air circulationand protected from dirt and water. Equipmentshould be stored where it is not subject tomechanical damage, especially during buildingconstruction.

An indoor controller that is to be storedoutdoors should be securely covered forprotection from weather conditions and dirt.T e m p o r a r y e l e c t r i c a l h e a t i n g s h o u l d b ei n s t a l l e d t o prevent c o n d e n s a t i o n .Approximately 150 watts per enclosure isusually adequate.

NOTE: All loose packing or flammablematerials should be removed before energizingspace heaters.

OUTDOOR EQUIPMENT

An unenergized controller designed for outdoorinstallation (NEMA Type EPIC building,etc.) should be kept dry internally by installingelectrical heating or by energizing self-heaters,if provided.

Fig. 6 Storage

All openings, either used or unused should becovered or sealed to prevent the entry of rain,vermin, insects, etc.


STORAGE Page 11

ROUTINE INSPECTION

Routine scheduled inspection should beestablished if storage for an extended period isanticipated. This is to check for condensation,corrosion, vermin, and adequacy of spaceheating.

Prior to inspection, the equipment should becarefully examined for evidence of physicaldamage, corrosion, or other deterioration.

Do not install equipmentfound to have damage ordeterioration that coulda f f e c t t h e u n i tperformance.


Page 12 GENERAL DESCRIPTION

Toshiba medium voltage controllers are ACgeneral-purpose NEMA Class E controllersdesigned for applications at utilization voltagesranging from 2.3 through 6.6 They arenormally used to control motor loads, althoughother types of loads such as transformers andcapacitors are possible.

CONSTRUCTION

The standard enclosure size is wide by36” deep by 90” high. In a typical two-higharrangement, each enclosure is dividedvertically into three major compartments, eachwith a separate door. The uppermost andlowermost compartments contain mediumvoltage controller components whilethe middle compartment contains low voltagecomponents ( F i g . 7 ) . Othervariations of this basic arrangement arepossible.

Main horizontal bus is provided when requiredto supply power to a line-up of controllers.The main bus is located at the rear of thee n c l o s u r e m i d w a y b e t w e e n t h e t o p a n dbottom. A common ground bus is alsoprovided for multiple sections.

Each controller compartment (Fig. 8) consistsof:

Fixed mounted non-load break isolationswitch.Withdrawable contactor carriage withpower fuses.Built-in service drawer for removingcontactor carriage from compartment.Current transformers for metering.Control power transformer and optionalpotential transformer.Load cable terminations.

Fig. 7 Typical Controller Arrangements

Fig. 8 Controller Compartment


GENERAL DESCRIPTION Page 13

CONTROLLER COMPARTMENT

A . Isolation Switch (Fig. 9)

P o w e r i s s w i t c h e d o n a n d o f f t o e a c hindividual controller compartment by a mounted, externally-operated, three-poleisolation switch. When the switch is in theopen position, incoming power is isolated fromthe compartment interior by an automaticshutter. Also, the load terminals of the switcha r e a u t o m a t i c a l l y g r o u n d e d i n t h e o p e nposition for additional safety.

The isolation switch is designed to accept adirect connection from the line stabs of thewithdrawable contactor carriage. Thisconnection is automatically made when thecontactor carriage is installed in the mediumvoltage compartment. When the switch isclosed by operating the external handle,incoming power is applied to the line side ofthe power fuses. In this position, the motor orother load may be switched on and off byoperating the vacuum contactor.

The isolation switch is mechanicallyinterlocked with the vacuum contactor and thecompartment door. Details of the interlockingare discussed in section H.

The position of the isolation switch blades canbe observed through a window in the mediumvoltage compartment door. Thus, it is possibleto have visual evidence that the power sourceis isolated before entering the medium voltagecompartment. The switch is also providedwith lock-out provisions (Fig. IO).

T h e i s o l a t i o n s w i t c h h a s a m a x i m u minterrupting capacity of 0.4 amperes.

D o n o t c o n n e c tadditional load to theisolation switch.

Fig. 9 Isolation Switch

Fig. 10 Isolation Switch Lockout



Withdrawable Contactor Carriage(Fig. 11)

The withdrawable contactor carriage is aremovable assembly which contains thefollowing components:

Vacuum contactorPower fuse housing assembly.Set of line and load power stabterminals.Auxiliary contacts fo r vacuumcontactor.Control wiring disconnect plug.Set of wheels to facilitate moving thecarriage when it is outside thecontroller.

T h e w i t h d r a w a b l e c o n t a c t o r c a r r i a g e i snormally shipped installed in the controller. Itmay be removed for access to the mediumvoltage compartment during initial installation,connection of motor cables, etc. Periodically,removal of the carriage may also be necessaryfor routine maintenance of the contactor orreplacement of the power fuses.

Always use a Toshiba JKLifting Device (Fig. 12)for removal or installationof the contactor carriage.

When the carriage is installed in the controllercompartment, the following connections areautomatically made:

The line side stabs engage the fixed-mounted isolation switch connectingthe load side of the switch to the lineside of the power fuses.The load side stabs engage the fixed-mounted load receptacle connecting theload side of the vacuum contactor tothe current transformers.The control transformer primary stabsengage fixed-mounted clips connectingthe load side of the power fuses to thep r i m a r y s i d e o f t h e c o n t r o ltransformer(s).

Fig. 11 Withdrawable Contactor Carriage

Fig. 12 Lifting Device



In addition, when the withdrawable contactorcarriage is inserted i n t o t h e c o n t r o l l e rcompartment, it becomes interlocked with theisolation switch so that the switch may not beopened or closed unless the contacts of thevacuum contactor are opened.

C. Service Drawer (Fig. 13)

The withdrawable contactor carriage is movedin and out of the controller compartment on abuilt-in sliding service drawer. The drawer hasfour locating pins on top of it. When thecontactor carriage is placed on the drawer,these pins engage four holes in the bottom ofthe carriage which serve to align it properly.

The drawer moves in and out of the controllercompartment on sliding ball bearing typerails. There is a handle on the front of thedrawer to provide a gripping point.

D. Load Receptacle and CurrentTransformers (Fig. 14)

The load receptacle is a fixed three-phasedisconnecting block. The vacuum contactorload stabs on the withdrawable carriageengage the load receptacle when the carriageis installed in the controller compartment.

The load receptacle uses bolted pressure typestab contacts similar to those used in theisolation switch.

The operation of the bolted pressure contactmechanism in the load receptacle is controlledby a release lever located at the front of thecompartment be low t he se r v i ce d rawe r .Further details on the operation of the releaselever can be found in the OPERATION sectionof this manual.

Power from the load receptacle is fed throughthree current transformers located just behindit. Current transformers furnished may beeither wound primary (bar) type, or window

Fig. 13 Service Drawer

Fig. 14 Load Receptacle



E. Outgoing Load Connections

Connections for outgoing load cable arel o c a t e d a t t h e r e a r o f e a c h c o n t r o l l e rcompartment just above the currenttransformers. Cables may enter the controllerfrom either the top or bottom of the enclosurethrough the provided.

If no specific information is provided when theequipment is ordered regarding the type of loadcables to be used and the direction of entry,the standard termination assembly shown inFig. 15 and Fig. 16 is supplied. Non-shieldedcables sized up one 350MCM per phase can beaccommodated entering either from the top orbottom of the enclosure (Fig. 15). Thisarrangement can also accept shielded cablesentering from the top sized up to one350MCM per phase (Fig. 16). Space isprovided for installation of termination kits(stress cones) and user-supplied one- or hole compression type connectors.

When the installation requires termination ofshielded load cables entering from the bottomof the enclosure, this should be specified whenthe equipment is ordered and the terminationassembly shown in Fig. 17 is then provided.This arrangement can accept shielded or non-shielded cables up to one 350MCM per phaseentering from the bottom. A field conversionkit is available to convert from the standardtermination assembly (Fig. 15 and Fig. 16) tothe arrangement shown in Fig. 17. Consultyour local sales representative for informationregarding this kit.

When routing and terminating load cables,observe the following:

If a ground current sensor (optional)is supplied with the equipment, routeall of the load cables through thesensor. Ground wires from shieldedcable terminators must be routed backthrough ground sensor window beforeattaching to ground bus.

E X I T C A B L E SMAX S IZE 350MCM NON-SHI

1 CABLE PER PHASE

BOTTOM EXIT CABLESMAX 350MCM NON-SHIELDED1 C A B L E P E R P H A S E

Fig. 15 Non-Shielded Cable Termination

TOP EXIT CABLESM A X S H I E L D E D

1 C A B L E P E R P H A S E

S W I T C H

Fig. 16 Shielded Cable Termination TopEntry



Use Listed compression connectorssuitable for the cable being used.

Use the hardware provided witht h e c o n t r o l l e r t o a t t a c h c a b l econnectors to bus pads. Afterinstallation, torque hardware to 45 ft.

After installation, check to see that atleast three inches clearance ismaintained between live parts ofopposite polarity and between liveparts and ground.

Fig. 17 Shielded Cable Termination BottomEntry



F . Control Power Transformer

A control power transformer (Fig. 18) is mounted on the left-hand side wall of thecontroller compartment. Power is supplied tot h e f u s e d p r i m a r y o f t h e c o n t r o l p o w e rtransformer from stabs on the withdrawablecontactor carriage. These stabs engage clipson the transformer when the carriage isinserted into the compartment.

Optionally, a second transformer (Fig. normally used as an instrument transformer,can be mounted in the compartment. Whenthis option is supplied, a third set of stabs isfurnished on the withdrawable carriage. Thetwo transformers are then connected in anopen-delta arrangement.

Another option sometimes supplied is a secondcontrol power transformer connected in parallelwith the first to increase the available KVAcapacity.

B o t h t h e c o n t r o l a n d o p t i o n a l p o t e n t i a ltransformer are used to supply power to thelow voltage circuits of the controller. Thisincludes power for the vacuum contactoroperating coil and for various instrumentation.

An electrical interlock is provided to ensurethat all load is disconnected from the controlpower transformer secondary winding beforethe power isolation switch can be opened orclosed.

Fig. 18 Control Power Transformer

Fig. 19 Optional Transformer



G. Operating Handle

The external operating handle shown in Fig. 20is used to control the operation of the isolationswitch. Moving the handle upward turns theswitch on, thus applying incoming power tothe current-limiting fuses on the withdrawablecarriage. The withdrawable contactor carriagecan neither be inserted nor removed when theoperating handle is in the “on” position.

Moving the handle down opens the isolationswitch, de-energizing all medium voltageincoming power to the controller compartment.At the same time an automatic shutter withinthe switch closes providing an effective barrierbetween the controller compartment and theincoming supply. The opening of the switchalso causes the line side of the power fuses tobe grounded.

Fig. Operating HandleH. Interlocks Mechanical

a. Door Interlock

A mechanical interlock is provided to preventopening or closing t h e m e d i u m v o l t a g ecompartment door unless the switch operatinghandle is off (Fig. 21).

Fig. 21 Door Interlock



b . Handle Interlock

Two mechanical interlocks are provided toprevent operating the switch handleimproperly.

The first interlock prevents moving the handlefrom OFF to ON unless the compartment dooris closed (Fig. 22).

The second interlock prevents the switchhandle from being moved in either directionunless the contacts of the vacuum contactoro n t h e w i t h d r a w a b l e c a r r i a g e a r e o p e n(Fig. 23).

C. Vacuum Contactor Interlock

T h e v a c u u m c o n t a c t o r i s m e c h a n i c a l l yinterlocked to prevent it from closing unlessthe switch handle is in the fully ON or fullyOFF position. The interlock shown in Fig. 23provides this function.

If the switch handle is in the intermediateposition, and a closing signal is given to thecontactor, it is mechanically prevented fromoperating.

Fig. Handle Interlock to Door

Fig. 23 Handle Interlock to Vacuum Contactor



I. Interlocks Electrical

a. Control Power Interlock

T h e c o n t r o l p o w e r i n t e r l o c k i s amicroswitch which is directly driven by theoperation of the switch handle (Fig. 24). Thisnormally open switch is closed only when thehandle is fully ON. It ensures that all load isdisconnected from the control powertransformer secondary winding before theisolation switch can be operated.

As the switch handle is moved from ON toOFF, the CPI opens before the main contactsof the power isolation switch. Conversely,during closing of the switch, the CPI contactsdo not close until the switch contacts havefully closed. The isolation switch is thereforeonly subjected to making and breaking currentsequal to the no-load magnetizing current of thetransformer.

Do not connect anyadditional load to theisolation switch.

b. Test Power Interlock

The test power interlock is a schemeprovided to allow simulated operation of thecontroller from a separate control power (test)source with power removed from the mediumvoltage circuit. During normal controlleroperation with the isolation switch closed,c o n t r o l p o w e r is fed from the controltransformer secondary to a receptacle mountedon the low voltage (Fig. 25). A plug,inserted into this receptacle, supplies power tothe controller’s low voltage compartment.

For testing purposes, the isolation switch mustbe turned off and the controller door must beopened. The plug is then removed andinserted into an ordinary extension cord.Plugging the extension cord into a conventionaloutlet provides power for performingcontrol circuit operational tests while themedium voltage circuit is de-energized.

Fig. 24 Control Power Interlock

Fig. 25 Test Power Receptacle



LOW VOLTAGE COMPARTMENT

T h e l o w v o l t a g e c o m p a r t m e n t c o n t a i n scontroller components r a t e d 6 0 0 v o l t smaximum. These may include such items asoverload relays, pilot devices, control relays,

Hazardous Voltage. Turnoff and lock out controlcircuit power beforeservicing.

The location and size of the low voltagecompartment will vary depending on theparticular controller arrangement. In a typicaltwo-high controller, the l o w voltagecompartment is located in the center of theenclosure.

A is located behind the low voltagedoor which is used to mount various relays andother devices. The is hinged in sucha way it can be swung open if necessary togain access to the main horizontal bus whichis located directly behind (Fig. 26).

Hazardous Voltage. Turnoff and lock out allcontrol a n d primarypower before openingthis panel.

Low voltage vertical feed directlyinto the upper and lower left hand corners ofthe low voltage compartment. A horizontallow voltage is provided at the lowerfront of each low voltage compartment. Ateach end of the horizontal there is anopening for inter-cubicle control wiring.

MAIN BUS COMPARTMENT

Main bus bars extending horizontallythroughout a line-up are located in an isolatedcompartment located in the rear center of theenclosure (Fig. 27). From the main bus, riserbars supply power to each individual controller.Standard main bus bars are copper with tinplating. A copper ground bus is also located in

Fig. 26 Low Voltage Opened toExpose Main Bus

Fig. 27 Main Bus Compartment



the main bus compartment and is used toprovide a common ground point betweencubicles. Vertical ground riser bars extendf r o m t h e c o m m o n g r o u n d b u s i n t o e a c hmedium voltage controller compartment.

Access to the main bus compartment can beobtained either by removing the enclosure backsheet or by swinging open the hinged lowvoltage bpanel.

Hazardous Voltage. Turnoff and lock out allcontrol and primarypower before accessingthis compartment.

Bus splice links (Fig. 28) are furnished forjoining the main bus and ground bus betweenshipping sections. With the low voltage

swung open, all splice links can beinstalled from the front of the unit. Refer toInstallation Section for details.

PREPARED SPACES

Prepared spaces are compartments equippedfor future addition of controllers. Prepareds p a c e s a r e s u p p l i e d w i t h t h e f o l l o w i n gcomponents:

Isolation SwitchService DrawerLoad Receptacle

In order to convert a prepared space to afunctional controller, the following must beadded:

Fig. 28 Bus Splice Links

contactor carriageHandle mechanism for switchCurrent transformersControl power transformer



CONTACTOR RATINGS

TABLE 1. CONTACTOR TYPE HCV-5HAM (Magnetically Held)

Coil drive board setting required (120 VAC standard).

CONTACTOR TYPE HCV-5HAML (Latched Type)

Permissible Switching Frequency

Mechanical Life

Tripping Voltage

Tripping Current

250,000 Operations

Rated DC

4.8 A DC Max

Other characteristics of latched contactor same as magnetically held type except number ofauxiliary contacts is reduced to 2 N.O.-3 N.C. Standard operating voltage is Close/l 25VDC Trip.



CONTROLLER RATINGS

TABLE 2. SHORT-CIRCUIT & WITHSTAND CAPABILITY

InterruptingCapacity

Amperes)

50,000 RMS

InterruptingCapacity

MVA)

Short TimeCapability30 Seconds

2400 A

TABLE 3. CONTINUOUS CURRENT

Short TimeCapability1 Second

6000 A

DielectricWithstand1 Minute

AC 19 DC 26

ImpulseVoltageWithstand

BIL60

Enclosure Type Max. Continuous Amperes Max. Continuous Amperes

One-High Controller or Upper Controller in a Lower Controller in a High StackingHigh Stacking ArrangementArrangement

NEMA-1 Ventilated I 360 I 320

NEMA-1 Non-Ventilated I 360 I 280

NEMA-12, 3R 310 280



TABLE 4. APPROXIMATE* MAXIMUM HORSEPOWER BASED ON CONTINUOUS CURRENT

Enc losedMax imum

Cont inuousCurrent

(Amperes)

360

320 1250 I 1500 I 1250 I 2250 I 2500 2250 3500 4500 3500

310 1250 I 1500 I 1250 I 2000 I 2500 2000 I 3500 I 4000 I 3500

280 1000 1250 1000 1750 2250 1750 3000 3500 3000

Maximum Horsepower at Utilization Voltages

2300 Volts, 3-Phase I 4000 Volts, -Phase I 6600 Volts, 3-Phase

Syn.Motors

0.8 1 .oPF PF

1500 1750

Ind.Motors

1500

Motors

0.8 1 .oPF PF

2500 3000

Ind.Motors

Syn.Motors

Ind.Motors

2500 4000 5000 4000

Motor FLA depends on mfgr, speed, other factors which must be considered.


INSTALLATION Page 27

RATING VERIFICATION PRIOR TOINSTALLATION

The maximum fault capability of the powersystem at the point of installation should beverified and must not exceed the short-circuitrating of the controller (See RATINGS section).A l l s y s t e m a c c e s s o r i e s s u c h a s s u r g esuppressors, lightning arrestors, etc. should bechecked to verify their ratings capacity.

Do not exceed theratings specified on thecontroller nameplate orsystem accessories.

LOCATION

Overhead should be checked for plumbingcondensation, sprinklers or similar possiblesources of trouble. A clearance of inchshould be provided between a wall and therear of the controller for indoor equipment,when rear access is not required. If rearaccess is required in either environment, aminimum of 30 inches should be provided.

A minimum of 48 inches working space shouldbe allowed in front of the controller. Thisminimum should be increased if necessary toaccommodate movement around openenclosure doors to comply with applicablecodes.

SERVICE CONDITIONS

T o s h i b a m e d i u m v o l t a g e c o n t r o l l e r s a r eintended for usual service conditions asdefined by NEMA. The equipment should notbe exposed to corrosive or explosive fumes,dusts, vapors, dripping or standing water,abnormal vibration, shock, ti lt ing, or otherabnormal operation conditions. Thetemperature of the ambient air surrounding thecontroller should be between the limits of

and The altitudeof the equipment installed should not exceed3300 ft

outside of the usual limits may require deratingor other special equipment, such as heating,cooling or ventilation. Contact Toshiba forfurther information.

If the location for installation is damp, spaceheaters may be required. If space heaters(Fig. 29) are furnished inside the controller,they should be connected in accordance withthe wiring diagram furnished.

Do not install thisequipment i n areaswhere unusual serviceconditions exist, unlessthe equipment has beenspecially designed for theparticular environment.

Fig. 29 Typical Space Heater

NOTE: Temperature or altitude conditions


Page 28 INSTALLATION

INSTALLATION SITE PREPARATION

It is recommended that site preparation becompleted before the controller is unpacked,so that possible problems such as headroom,conduit location, cable tray locations,ventilation, etc. can be solved, assuring aproper installation in compliance with thebuilding plans and codes.

The floor on which the controller will be placedmust be level so that the enclosure is notdistorted when bolted in place. Ensure theequipment adequately clears any undergroundraceways or cables.

MOUNTING

Each shipping section must be leveled andfirmly secured to its supporting foundation.Steel shims may be used for final leveling(Fig. if necessary. When three or moreshipping sections are to be arranged in onecontinuous line-up, the center shipping sectionshould normally be the first located.

Follow the equipment outline drawings todetermine the location of the mounting boltholes and any conduit locations.

Sill channels may or may not be furnished,depending on order specifications. Refer tooutline drawings furnished for location ofsill channels, if furnished.

Various methods may be used to anchor theenclosure t o t h e f o u n d a t i o n , includingexpandable inserts or bolts embedded inconcrete. The recommended size for anchorbolts is (Fig. 31).

Heavy Equipment.Enclosure m u s t b esecurely t oprevent tipping over.

Fig. 30 Leveling Using Shims

FLOOR

CONTROLLER BOTTOM PLATE

BOLT

FOR ANCHOR LOCATIONS SEEFLOOR PLAN DRAWINGS FURNISHEDWITH EQUIPMENT.

Fig. 31 Securely Anchor the Controller



GROUNDING

The controller line-up must be grounded inaccordance with the requirements of theNational Electrical Code. Proper equipmentgrounding must be established before makingany incoming power connection. If a mainground bus (Fig. 32) is furnished, make theground connection to this bus. If there is noground bus, the sections which are shippedseparately should be connected in such a wayas to ensure a continuous grounding path.

Each section contains a vertical ground bus(Fig. 33) extending from the main ground busor ground pad to each controller compartment.

Special attention should be paid to protectionfor operating personnel, to protection ofequipment itself, (i.e. such as ground faultrelays, if used) and protection of sensitivet r a n s d u c e r s o r c o n t r o l d e v i c e s t h a t a r eelectronic in nature.

The following may be used as a general guidewith regard to equipment grounding.

Controller used as service eauioment for aqrounded svstem or as a main section for aseparately derived system:

a. The grounding electrode conductor(ground wire) sized in accordance withNEC 250-94 should be run from thegrounding electrode to the controllerground bus or ground terminal. Seealso NEC 250-91 and 250-92 (a).

b. Unless already done at the factory, amain bonding jumper should be installedfrom the incoming grounded connectorbus (neutral) to the ground bus ordesignated grounding point. If a jumperis not furnished, one having a size inaccordance with NEC 250-79 shouldbe selected.

C. Steps (a) and should effectivelyconnect her t h e g r o u n d i n gelectrode, the controller frame, all

Fig. 32 Main Ground Bus

Fig. 33 Vertical Ground Bus



outgoing equipment groundingconductors and the grounded neutralbus of the system.

d . No connection should be made toground on the load side of any neutraldisconnecting line or any sensor usedfor ground f a u l t p r o t e c t i o n . N oconnections should be made betweenoutgoing grounding connectors and theneutral.

e . Where the controller or system is fed (double-ended) and has ground faultprotection, special precautions arenecessary to accomplish propergrounding and bonding.

Controller used as service equipment for anunqrounded system or as a main section for aseparately derived system.

a . A grounding electrode conductor(ground wire) sized in accordance withNEC 250-94 should be run from thegrounding electrode to the controllerground bus or ground terminal. Seealso NEC 250-91 (a) and 250-92(a).

b . If the system is grounded at any pointahead of the controller, the groundedconductor should be run to thecontroller in accordance with NEC 250-23 and connected to the ground busor ground terminal.

C. Steps (a) and should effectivelyconnect together the groundingelectrode, the controller frame, alloutgoing equipment groundingconnectors and groundedconductor which runs to the controller.

Controller not used as service equipment or asa main section for a derived svstem,and used on either a or unaroundedsystem:

equipment grounding conductors havinga size in accordance with NEC 250-95a n d run with the mainconductors or by bonding to theraceway enclosing the main supplyconductors in accordance with NEC

1

b . Ground leads should be connected tocable as specified bythe manufacture of these devices.

a . The controller frame and any groundbus should be grounded by means of



CONNECTIONS

C a b l e a n d w i r e b u n d l e s t h a t e n t e r t h econtroller enclosure should be routed to avoidinterference with moving parts. Minimumbending radius for the type of cable usedshould be observed.

Power cables should be braced and/or laced towithstand short circuit forces wherever suchcables are unsupported. Power cables shouldbe adequately sized to carry the motor full loadcurrent in accordance with NEC requirements,and have an adequate voltage rating. Cabless h o u l d b e d r e s s e d a n d t e r m i n a t e d a sappropriate to the voltage class and cablemanufacturer’s recommendations.

Main power bus and horizontal ground bus aresupplied with links to join shipping sectionstogether. These should be installed inaccordance with Fig. 34 through Fig. 36.

All access covers, barriers, partitions, etc. thatare temporarily removed during installationmust be replaced.

NOTE: Covers and braces supplied only forprotection during shipment should not bereplaced. All debris and tools should beremoved from each compartment as cabling iscompleted.

I, I E L I T

Fig. 34 Ground Bus Splice Connections



x 1 4

C L E S P L I T

X 1 G R A D E 5 C A R R I A G E B O L T

F L A T W

w F L A T W A S H E R

5 H E X

I H E X N U T

TOP VIEWM A I N S P L I C E E A R

x 4

P A R T N O .

FRONT VIEW

Fig. 35 Main Bus Splice Connections 1200A Main Bus

x

CLE IT

X 1 G R A D E

F L A T

W A S H E R

5 H E X B O L T

V I E W

F L A T W A S H E R

L O C K

H E X NUT

M A I N S P L I C E BAR

X 4 C O P P E R

P A R T N O .

T W O P E R P H A S E

FRONT VIEW

5 CARRIAGE BOLT

Fig. Main Bus Splice Connections 2000A Main Bus



INCOMING LINE

Incoming power cable connections should bemade at the points shown on the wiringdiagram furnished with the equipment. Theseconnections will normally be made in aseparate incoming compartment to bus lugs orto an incoming load interrupter switch orvacuum circuit breaker.

OUTGOING LOAD

Outgoing load connections are made in eachcontroller compartment at the points shown inFig. 15 through Fig. 17.

The load cables should be routed through the furnished within the enclosure.

Typical routing of load cables for a two-highcontroller arrangement is depicted in Fig. 37and Fig. 38 for both top and bottom entry ofcables.

Load cable termination arrangments for certaincontrollers s u c h a s reduced voltageautotransformer types may differ from thoseshown in this manual. In these cases refer tothe drawings furnished with the equipment.

Fig. 37 Controller Load Wiring Top Entry

Fig. 38 Controller Load Wiring Bottom Entry


Page 34 CHECK

GENERAL

AFTER INSTALLAT ION, BUT BEFOREENERGIZING THE CONTROLLER for the firsttime, follow the procedure below to verify thatthe equipment is properly installed andfunctional.

Prior to operating the controller, be surethat the proper withdrawable contactorcarriage is installed in the mediumvoltage compartment.

There is a data label (Fig. on thes i d e o f each contactor carriageindicating the configuration of thatparticular unit. A corresponding label islocated on the inside of each mediumvoltage controller compartment door.Before installing a contactor carriage ina n y c o m p a r t m e n t , v e r i f y t h a t t h einformation on the two labels agreescompletely.

In particular, the following informationmust agree:

1.

2.

3.4.

5.6.

Part n u m b e r o f contactorcarriage.Power fuse type, voltage andcurrent ratingControl voltage and frequencyContactor type, magneticallyheld or latchedSingle or dual CPTAny optional features

Check connections Although theequipment and devices have beencompletely tested at the factory, a finalfield check should be made that allelectrical w i r i n g and bus barconnections are correct and have notbecome loose in transportation(Fig. 40). Refer to MAINTENANCESection for electrical joint specification.

Fig. 39 Data Label on Contactor Carriage

Fig. 40 Check Connections

All blocks or other temporary bracesused for shipment must be removed.


PRE-ENERGIZATION CHECK Page 35

Before closing the enclosure, all metalchips, scrap wire and other debris leftover from installation must be cleanedout.

If there is an appreciable accumulationof dust or dirt, the enclosure should becleaned by using a brush, vacuumcleaner or clean, lint free brush.

The integrity of all bus bar supportsmust be checked for secureness anddamage.

Care should be exercised that whencovers are installed and doors closed,no wires are pinched and that allenclosure parts are properly aligned andtightened.

A supply of spare parts, fuses, etc.should be established.

Instruction m a n u a l s a n d d i a g r a m sshould be collected and filed.

WIRING CHECK (Fig. 41)

Field wiring should be checked forc l e a r a n c e t o live b u s s e s w h e r enecessary, physically s e c u r e d t owithstand the effects of fault current.

All grounding connections should bechecked.

Each motor should be connected to itsintended controller, and phase rotationshould be correct prior to startup.

Shorting jumpers (Fig. 42) for currenttransformer secondary windings mustbe removed once the secondary circuitis completed. A circuit transformermust not be operated with itssecondary windings open.

Changes made to circuit diagramsduring installation should be recorded.

Fig. 41 Wiring Check

Fig. 42 Removing Current TransformerShorting Jumpers


Page 36 CHECK

DEVICEIMECHANISM CHECKS

All devices should be checked fordamage (Fig. 43). All necessary repairsor replacements should be made.

Do not energize damagedequipment that has notbeen repaired andverified.

E n s u r e t h a t s a f e t y s i g n s a r e n o tcovered or obscured by paint.

Do not remove, cover ordestroy any safety signs.

The setting of any adjustable currentand voltage trip mechanisms should beverified to the proper values.

NOTE: Damage from faults can bereduced if devices used for short circuitand ground fault protection are chosenand set to operate at values as close tominimum as feasible, while allowingnormal transients.

All switches, relays and other operatingmechanisms s h o u l d b e manuallyexercised to make certain that they areproperly aligned and operate freely.

Operating mechanisms s u c h a sinterlocks, key switches, etc. should bechecked for function as intended forprotection of personnel and equipment.

Overload relays should be checked tobe sure they are selected and adjustedto the proper settings per the loadnameplate data (Fig. 44).

Power circuit fuses should be selectedand installed in accordance with theapplication requirements. Fuses mustbe completely inserted in their holders.

Fig. 43 Device/Mechanism Check

Fig. 44 Overload Setting Check


PRE-ENERGIZATION CHECK Page 37

ELECTRICAL CHECKS

With incoming power isolated and allloads disconnected electrically, thecontrol circuit and other mechanismsshould be exercised to determine thatt h e d e v i c e s o p e r a t e p r o p e r l y . A nauxiliary source of control power will benecessary to provide power to theelectrical operators (Fig. 45).

Electrical shock hazard.Do not touch energizedcomponents during a testusing auxiliary power.

The ground fault protection system (iffurnished) should b e t e s t e d inaccordance with the instructionsfurnished with the device.

An electrical insulation test should beperformed to ensure that the controllerand associated field wiring are freefrom short circuits and grounds. Thep r e f e r r e d m e t h o d i s t o p e r f o r m adielectric test at 2.25 times the nominalsystem voltage plus 2000 volts. Thisshould be done phase-to-ground, to-phase and phase-to-neutral (ifapplicable), with all switches and circuitbreakers opened. Disconnect anyd e v i c e s w h i c h m a y h a v e l i m i t e ddielectric strength and that are notintended for this test.

The light or buzzer, or both, used toindicate breakdown should be calibratedt o i n d i c a t e f a i l u r e w i t h a n o u t p u tcurrent between 1.5 and 2.0milliamperes per 1000 volts applied.

Hazardous voltages arepresent during dielectrictesting which can resultin serious injury or death.

High potential testsshould be performed onlyby qualified personnel.

R e f e r t o s a f e t yinstructions providedwith the test equipment.

All devices must be set to their normalor OFF position before energizingincoming power.

Fig. 45 Using Test Power Source


Page 38 OPERATION

CONTACTOR INSTALLATION

T o i n s t a l l t h e c o n t a c t o r c a r r i a g e i n t h econtroller:

Lift and pull the release lever out all theway, then pull out the service drawer(Fig. 46).

To avoid tipping over,the controller enclosuremust be securely boltedto the floor.

Lift and place the contactor carriage onthe service drawer (Fig. 47). The frontof the carriage should line up with thef r on t o f t he d rawe r , and t he f ou rlocator pins on top of the drawershould engage the holes in the bottomo f t h e c a r r i a g e . Installation ofcontactor carriages in the uppercompartments of two- and three-highstacking arrangements require the useof a Toshiba JK lifting device.

Manually lifting heavyequipment c a n causeserious injury. Use aToshiba JK lifting device.

With the carriage properly in place onthe service drawer, push the drawerf i r m l y all t h e into t h ecompartment. Then push the releaselever in until it drops slightly andlatches. This operation causes the loadreceptacle to apply bolted pressure tothe load stabs of the carriage.

Fig. 46 Release Lever Disengaged

Fig. 47 Placing The Contactor On The Service Drawer


OPERATION Page 39

The release lever must be pushed in (Fig. 48)before the isolation switch is closed or thecontroller is operated under load. The mediumvoltage compartment door cannot be closedunless the release lever is pushed in. Amechanical interlock prevents the isolationswitch from being closed unless the mediumvoltage door is closed.

Release lever must bepushed in and latchedbefore operating thecontroller.

INITIAL

Energizing a medium voltage controller or line-up of controllers for the first time is potentiallydangerous. Therefore only qualified personnelas defined in the SAFETY section of thismanual, should energize the equipment(Fig. 49). If faults caused by damage or poorinstallation practices have not been detected inthe PRE-ENERGIZATION CHECK section, majordamage including personal injury can resultwhen the power is applied. Extra precaution isrecommended on initial energization of theequipment.

Hazardous Voltage.Improperly installed, ordamaged equipment willresult in severe injury,death, and property loss.Correct all problems priort o energizing t h i sequipment.

Only qualified personnelshould energize thisequipment.

In order to minimize the risk of injury ordamage, there should be no load on thecontroller or group o f c o n t r o l l e r s w h e nincoming power is first turned on. Alldownstream loads, including those such asdistribution equipment and other remotedevices, should be turned off. The isolationswitch ahead of each controller should be in

Fig. 48 Release Lever Engaged

Fig. 49 Preparing For Initial Energization


Page 40 OPERATION

the off position.

The equipment should be energized insequence by starting at the source end of thesystem and working towards the load end.First the main devices, then the feeder devicesand then the branch circuit devices should beclosed.

With all removable barriers in place and alldoors closed and latched, the devices shouldbe turned on with a firm, positive motion.Protective devices and switches that are notquick-acting should not be “teased” into theclosed (or open) positions. The isolationswitch handle should be moved between OFFand ON positions in a single continuoussmooth movement. (Fig.

After all disconnect devices have been closed, may be operated to turn on loads

such as motors, transformers, heaters, etc.

Fig. 50 Closing Isolation Switch


MAINTENANCE Page 41

In order to ensure continued reliable and safeoperation of the equipment, a program ofperiodic maintenance must be established.Operating and environmental conditions willdictate the frequency of inspection required.NFPA Publication 70B “Electrical EquipmentMaintenance” (Fig. 5 may be used as a guidefor setting up the maintenance program.

MAINTENANCE RECORD

A permanent record of all maintenance workshould be kept (Fig. 52). At a minimum, thisrecord should include information on:

Items inspectedTest reportsEquipment conditionCorrective actions or adjustmentsDate of workComments

The degree of detail will depend on theoperating conditions.

Contact with energizedcomponents can causesevere injury or death.Turn-off and lock outPrimary and ControlCircuit Power beforeservicing.

Improper maintenancecan cause severe injury,death, and extensiveproperty damage. Onlyqualified and authorizedpersons are to install,operate, or service theequipment.

This equipment utilizesb o t h l o w a n d h i g hvoltage for operation.Verify that all testequipment is suitable fort h e v o l t a g e beingchecked.

Fig. 51 NFPA Electrical EquipmentMaintenance

Fig. 52 Maintenance Record


Page 42 MAINTENANCE

NOTE: Refer to the SAFETY section of thismanual for important information.

After disconnecting and locking out incomingpower and before performing any maintenance,it is recommended that a safety ground beconnected to the main power bus (Fig. 53).After maintenance is complete, perform thechecks in the CHECKsection of this manual before restoring power.

T h e f o l l o w i n g p a g e s d e t a i l m a i n t e n a n c eprocedures recommended for Toshiba JKmedium voltage controllers. In general, thefollowing items should be included on themaintenance checklist:

CleaningChecking and tightening of electricalconnectionsChecking of fuses and fuse clipsProper installation of any removablebarriersVacuum contactor maintenance

The information presented here is intended tocover preventive maintenance only. It doesnot cover major rework or repair. Thefollowing M A I N T E N A N C E S H O U L D B EPERFORMED AT LEAST ANNUALLY or morefrequently depending on operating conditions.

GENERAL INSPECTION (Fig. 54)

Thoroughly clean the equipment,r e m o v i n g a l l d u s t , d i r t a n d o t h e raccumulations. Wipe insulators cleanusing a clean, dry cloth. Do not usepetroleum-based solvents or cleaners.

Check for any signs of moisture insidethe enclosure. If there are signs ofdripping water entering the enclosure,eliminate the source. Thoroughly dryany insulation which shows signs ofwetness and repeat the dielectric testp r o c e d u r e g iven in t h eENERGIZATION CHECK. Replaceinsulators, if necessary.

Fig. 53 Attaching Safety Ground

Fig. 54 General Inspection


MAINTENANCE Page 43

C h e c k f o r a n y s i g n s o f r u s t e d o rcorroded parts.

Check for free movement of all movingparts and mechanisms. Lubricate ifnecessary with Toshiba grease.

Grease is conductive.Do not apply grease toelectrical insulation.

ELECTRICAL JOINTS

Examine all visible terminals and jointsfor signs of overheating (Fig. 55). Anoverheated connection will appeardiscolored. Be suspicious of anyconducting joint which has a darkercolor than other similar joints.

C h e c k a l l b o l t e d c o n n e c t i o n s f o rtightness. T h e p r o p e r t o r q u e i sdependent on the size of the hardwareand the materials used. As a generalguide, use the following table:

HardwareSize

4 -6 6-l 8 IO-15

6 20-3040 -50

The above values apply to metal-to-metaljoints, e.g., copper-to-copper, etc. Whentorquing a bolt threaded into an insert moldedinto a plastic part, use approximately thetorque shown.

WITHDRAWABLE CONTACTOR CARRIAGE

C h e c k t h e c o n d i t i o n o f t h e s t a bt e r m i n a l s o n the w i t h d r a w a b l econtactor carriage for any signs ofdamage or discoloration (Fig. 56). Ifthere is any excessive build-up of dirt orother foreign material, wipe clean andrelubricate with a light coat of Toshiba

grease, making sure that no grease

Fig. 55 Check Electrical Joints

Fig. 56 Checking Stabs On WithdrawableContactor Carriage


Page 44 MAINTENANCE

gets on the insulated fuse housing.

Wipe off any dust or dirt which mayhave accumulated on the inside oroutside of the insulated power fusehousing or on the vacuum contactorhousing.

Check the power fuses for any signs ofdiscoloration. A fuse barrel whichappears darker than others indicatesoverheating. Possible causes of fuseoverheating, other than load problems,are misapplication (fuse current ratingtoo small), loose fuse clips, or damagedfuse.

Check the torque on the bolts whichc l a m p t h e f u s e c l i p s t o t h e f u s eferrules. The proper torque is 4-6 lb-ft.

Fig. 57 Checking Isolation SwitchMaintenance instructions for the 5HAM vacuum contactor are providedin a separate publication, number

Radiation ExposureHazard. X-Radiation maycause illness or injury.Stay at least 1 meter(3.3 feet) away from thecontactor during potential tests.

ISOLATION SWITCH

The isolation switch (Fig. 57) provided in eachcontroller is a bolted pressure type device. Itis designed to maintain proper adjustment andcontact pressure over its mechanical life of10,000 close-open cycles. Under normaloperating conditions, no maintenance isrequired other than periodic inspection andcleaning.

Wipe off any dust or dirt which mayh a v e a c c u m u l a t e d o n t h e s w i t c hhousing, the insulating blade drive linksand the shutter.


MAINTENANCE Page 45

Open and close the switch and verifythat no excessive force is required.Observe that the line terminal shutteropens and closes properly. Lubricatet h e m o v i n g p a r t s o f t h e h a n d l emechanism and, if necessary, apply alight coat of Toshiba B8 grease to theinside contact surfaces of the switchblades.

Grease is conductive.Do not allow grease tocontact t h e s w i t c hhousing or the insulatedshutter.

Examine the current-carrying switchblades for any sign of discoloration dueto overheating.

Each bolted pressure switch blade assembly ispre-torqued and adjusted to the proper settingsat the factory. Do not attempt to change thetorque settings or replace individual parts ofthis assembly in the field. Should it ever

become necessary to replace the bladeassemblies, contact the nearest Toshibarepresentative.

SWITCH HANDLE MECHANISM

The handle mechanism which operates theisolation switch is adjusted at the factory andunder normal operation requires no furtheradjustment. Adjustment can be checked,however, as follows (Fig. 58):

Move handle to full OFF position.

Observe that isolation switch blades arein contact with the ground pads.

If adjustment is required, loosen locknut securing yoke on handle end ofconnecting rod. Remove pin whichattaches yoke to handle drive lever.Turn yoke in required direction toachieve adjustment defined in step 2.Re-attach yoke and pin to drive leverand tighten yoke lock nut.

EE

H

Fig. 58 Switch Mechanism Adjustment


Page 46 MAINTENANCE

The moving joints should be occasionallylubricated with a light coat of Toshiba grease.

INTERLOCKS

Circumvent the handle interlock bypushing a screwdriver through the slotand operate the handle several times.

Check that the CPI electrical interlock(microswitch) operates each time thehandle is moved. The CPI (controlpower interlock) should closeapproximately before the handlereaches the full ON position. As thehandle is moved from ON to OFF, theCPI switch should open by the time thehandle has moved approximately 1 or one inch (Fig. 59).

Check that the handle interlock to thevacuum contactor operates freely.Lubricate with Toshiba B8 grease ifnecessary. Refer to the GENERALDESCRIPTION section for the locationof the handle mechanical interlocks andthe CPI electrical interlock.

LOAD RECEPTACLE

The load receptacle requires little maintenanceother than periodic cleaning and inspection.

Using a clean, dry cloth, wipe off thesurfaces of the load receptacle insulatorand the insulating drive links.

Operate the release lever to check forfree movement of the bolted pressuremechanism. Do not attempt to changet h e t o r q u e s e t t i n g s o f t h e b o l t e dpressure clip assembly.

I S W I T C H A C T U A T I O N

S W I T C H

ENGAGE,’ I

O F F

O P E N ]

Fig. 59 Interlock Sequence Check


MAINTENANCE Page 47

CONTROL POWER TRANSFORMER

Wipe off the surface of the controlpower transformer. (Fig. 60)

Check the condition of the primaryfuses and fuse clips. Check all screwsfor tightness.

Check that the primary stab clips whichmate with the withdrawable contactorcarriage are tight and properly alignedwith the carriage stabs.

Fig. 60 Inspect Control Power Transformer


Page 48 MAINTENANCE AFTER A FAULT CONDITION

The following covers procedures to return toservice a medium voltage controller which hasbeen required to interrupt a load side circuit or ground fault. These procedures arenot intended to cover devices such as wiringand motors, which may also require attention.

In an installation which has been properlycoordinated and in service prior to a fault, theopening of the current-limiting power fuses inthe controller indicates a fault condition inexcess of operating overload. This faultcondition must be corrected and necessaryrepairs made to the load circuit before energizing the controller.

The following inspection and repair proceduresshould be carried out by qualified personnel.

Hazardous Voltage. Turnoff and lock out Primaryand Control CircuitPower beforeinspection or testing.

ENCLOSURE

Check the condition of the enclosure for anysigns of bowing or deformation. Check thecondition of the doors and latches for damage.

If substantial damage has occurred to theenclosure, such as deformation, displacementof parts or burning, this indicates a problemwithin the controller which requires majorreconditioning or complete replacement of thecontroller. In this event, contact the nearestToshiba representative.

ISOLATION SWITCH

The external operating handle must be capableof opening the switch. If the handle fails toopen the switch or if visual inspection afteropening indicates deterioration beyond normalwear and tear such as overheating or pitting ofblades, insulation breakage or charring, contactyour Toshiba representative.

FUSE CLIPS

Check the condition of the power fuse clips(Fig. 61) and the insulated housing. Anydeterioration of these components requiresreplacement of the damaged parts.

TERMINALS AND INTERNAL CONDUCTORS

Indication of arcing damage or overheating, orboth, such as discoloration and melting ofinsulation, requires replacement of thedamaged parts.

OVERLOAD RELAYS

The overload relay must be checked to verifythat it will still trip properly. Follow the testinstructions provided with the overload devicefor verifying trip characteristics.

Fig. 61 Examine Fuse Clips


MAINTENANCE AFTER A FAULT CONDITION Page 49

VACUUM CONTACTOR

Operate the vacuum contactor (Fig. 62)electrically from test power and observe that itopens and closes freely. If the vacuum bottlesshow any signs of binding, they should ber e p l a c e d . C o n t a c t y o u r T o s h i b arepresentative. Check for any signs of arcingdamage to the insulated housing.

RETURN TO SERVICE

Before returning the controller to service,repeat the procedure outlined in the ENERGIZATION CHECK section of this manual.

Fig. 62 Check Vacuum Contactor


Page 50 WARRANTY AND LIMITATION OF LIABILITY

Toshiba International Corporation (“Company”) warrants that all equipment and parts described herein will befree from defects in materials and workmanship. THIS WARRANTY WILL EXPIRE EIGHTEEN (18) MONTHSAFTER THE DATE ON WHICH SUCH EQUIPMENT AND PARTS (EXCLUDING REPAIRED OR REPLACEMENTEQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY) ARE SHIPPED BY THE COMPANYTO THE INITIAL PURCHASER OR TWELVE (12) MONTHS AFTER SUCH EQUIPMENT AND PARTS (EXCLUDINGREPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY) AREFIRST PLACED IN OPERATION, WHICHEVER PERIOD FIRST EXPIRES.

The Company will, at its option, repair or replace such equipment or part which is defective under the termsof the foregoing warranty, free of charge; provided the purchaser (1) promptly notifies the Company in writingof such defect, and (2) furnishes the Company satisfactory proof thereof, and (3) establishes that theequipment or part has been properly installed, maintained and operated within the limits of rated capacity andnormal usage and in accordance with this manual, and (4) if requested by the Company, returns the defectiveequipment or part to the Company and pays all expenses incurred in connection with such return. The repairedor replacement equipment or part will be delivered, free of charge, to the purchaser F.O.B. the Company’swarehouse or, at the Company’s option, F.O.B. a Company authorized service shop, not loaded on truck orother 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 ANDEXCLUSIVE REMEDY OF THE PURCHASER, ITS CUSTOMERS AND USERS OF THE EQUIPMENT AND PARTSFOR BREACH OF THE FOREGOING WARRANTY. THE COMPANY WILL HAVE NO OBLIGATIONS TODISASSEMBLE ANY EQUIPMENT OR PART WHICH IS DEFECTIVE WITHIN THE TERMS OF THE ABOVEWARRANTY OR TO INSTALL ANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAY ANYCOSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION. THE COMPANY,TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL OTHEREXPRESS, STATUTORY AND IMPLIED WARRANTIES. INCLUDING, WITHOUT LIMITATION, ALL EQUIPMENTAND PARTS FURNISHED PURSUANT TO THE FOREGOING WARRANTY AND ALL IMPLIED WARRANTIES OFMERCHANTABILITY.

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, arisingout of, connected with or resulting from the equipment and parts described in this manual or the performanceor 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 theretofurnished by the Company shall not in any event exceed the price allocable to the equipment, part or servicewhich gives claim, loss or damage. In no event, whether as a breach of contract or warranty, allegednegligence, liability without fault, or otherwise, shall the Company, Toshiba Corporation or their suppliers orsubcontractors be liable for special or consequential damages, including, without limitation, loss or profits orrevenue, loss of equipment described herein or any associated equipment, cost of capital, cost of substituteequipment or parts, facilities or services, down-time costs, labor costs or claims of customers of the purchaserfor such damages.

The Company will not assume liability for any such damages resulting from unauthorized modifications to theequipment.


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