Instruction Manual: JK Series 720 Ampere Medium Voltage Controllers
Instruction Manual: JK Series 720 Ampere Medium Voltage Controllers
Instruction Manual: JK Series 720 Ampere Medium Voltage Controllers
INSTRUCTION MANUAL
Issued: 9/19
Basic Installation and Operation Guide JK Series 720 Series Controllers
Basic Installation and Operation Guide JK Series 720 Controllers
Important Notice
The instructions contained in this manual are not intended to cover all details or variations in equipment
types nor may it provide for every possible contingency concerning the installation, operation, or
maintenance of this equipment. Should additional information be required, contact your Toshiba
Customer Support Center.
The contents of this manual shall not become a part of or modify any prior or existing agreement,
commitment, or relationship. The sales contract contains the entire obligation of Toshiba International
Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba
International Corporation and any statements contained herein do not create new warranties or modify
the existing warranty.
Any electrical or mechanical modifications to this equipment without the prior written consent of
Toshiba International Corporation may void all warranties or other safety certifications.
Unauthorized modifications may also result in safety hazard or equipment damage.
Misuse of this equipment could result in injury and equipment damage. In no event will Toshiba
International Corporation be responsible or liable for direct, indirect, special, or consequential
damage or injury that may result from the misuse of this equipment.
At Toshiba International Corporation we are continuously striving for better ways to meet the constantly
changing needs of our customers. E-mail your comments, questions, or concerns about this publication
to [email protected].
Basic Installation and Operation Guide JK Series 720 Controllers
This manual provides information on the various features and functions of this device, including:
• Installation
• Operation
Included is a section on general safety instructions that describe the warning labels and symbols that
are used on the device and throughout the manual. Read the manual completely before installing,
operating, performing maintenance, or disposing of this equipment.
This manual and the accompanying drawings should be considered a permanent part of the equipment
and should be readily available for reference and review. Dimensions shown in the manual are in
imperial units and/or the metric equivalent. Connection drawings within this document convey the typical
topology of the JK 720 controller.
Because of our commitment to continuous improvement, Toshiba International Corporation reserves the
right, without prior notice, to update information, make product changes, or to discontinue any product or
service identified in this publication.
Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or
consequential damages resulting from the use of the information contained within this manual.
This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form
without the prior written consent of Toshiba International Corporation.
TOSHIBA® is a registered trademark of Toshiba Corporation. All other product or trade references
appearing in this manual are registered trademarks of their respective owners.
The Support Center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Center’s toll free
number is US (800) 231-1412/Fax (713) 937-9349 CAN (800) 872-2192 MEX 01 (800) 527-1204.
For after-hours support follow the directions of the outgoing message when calling.
You may also contact Toshiba International Corporation by writing to:
For further information on Toshiba International Corporation’s products and services, please visit our
website at www.toshiba.com/tic.
JK Series Controller
DO NOT attempt to install, operate, maintain, or dispose of this equipment until you have read and understood
all of the product safety information and directions that are contained in this manual.
The Safety Alert Symbol is comprised of an equilateral triangle enclosing an exclamation mark. This indicates
that a potential personal injury hazard exists.
Signal Words
Listed below are the signal words that are used throughout this manual followed by their descriptions and
associated symbols. When the words DANGER, WARNING, and CAUTION are used in this manual, they will be
followed by important safety information that must be carefully followed.
The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous situation exists
that, if not avoided or if instructions are not followed precisely, will result in serious injury to personnel or loss of
life.
DANGER
The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous situation exists
that, if not avoided or if instructions are not followed precisely, could result in serious injury to personnel or loss
of life.
WARNING
The word CAUTION proceeded by the safety alert symbol indicates that a potentially hazardous situation exists
that, if not avoided or if instructions are not followed precisely, may result in minor or moderate injury.
CAUTION
The word NOTE provides helpful information.
NOTE
TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
DO NOT attempt to install, operate, perform maintenance, or dispose of this equipment, until you have read and
understood all of the product labels and user directions that are contained in this manual.
Warning labels that are attached to the equipment will include the exclamation mark within a triangle.
DO NOT remove or cover any of these labels. If the labels are damaged or if additional labels are required, contact
the Toshiba Customer Support Center.
Labels attached to the equipment are there to provide useful information or to indicate an imminently hazardous
situation that may result in serious injury, severe property and equipment damage, or loss of life if safe procedures
or methods are not followed as outlined in this manual.
Qualified Personnel
Installation, operation, and maintenance shall be performed by Qualified Personnel ONLY. A Qualified Person
is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of
the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of
NFPA 70E for additional safety requirements).
• Become familiar with the construction and function of the starter, the equipment being driven, and the hazards
involved.
• Be able to recognize and properly address hazards associated with the application of motor-driven equipment.
• Be trained and authorized to safely energize, de-energize, ground, lock-out/tag-out circuits and equipment, and
clear faults in accordance with established safety practices.
• Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats,
safety glasses, face shields, flash clothing, etc., in accordance with established safety practices.
TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
Equipment Inspection
• Upon receipt of the equipment, inspect the packaging and equipment for shipping damage.
• Carefully unpack the equipment and check for parts that may have been damaged during shipping, missing
parts, or concealed damage. If any discrepancies are discovered, it should be noted with the carrier prior to
accepting the shipment, if possible. File a claim with the carrier if necessary and immediately notify your Toshiba
Customer Support Center.
• Ensure that the rated capacity and the model number specified on the nameplate conform to the order
specifications.
• Modification of this equipment is dangerous and is to be performed by factory trained personnel ONLY. When
modifications are required, contact your Toshiba Customer Support Center.
• Contact your Toshiba Customer Support Center to report discrepancies or for assistance, if required.
• Use proper lifting techniques when moving the equipment, including properly sizing up the load, getting
assistance, and using a forklift, if required.
• Store in a well-ventilated location, preferably in the original packaging, if the equipment will not be used upon
receipt.
• Store in a cool, clean, and dry location. Avoid storage locations with extreme temperatures, rapid temperature
changes, high humidity, moisture, dust, corrosive gases, or metal particles.
• The storage temperature range of the contactor is 23° to 104° F (-5° to 40° C). If stored at a lower temperature
or where high humidity exists, a cubicle space heater is required, powered from an external 120Vac source.
• DO NOT store the unit in places that are exposed to outside weather conditions (e.g. wind, rain, snow).
Disposal
Never dispose of electrical components via incineration. Contact your state environmental agency for details on
disposal of electrical components and packaging in your area.
TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
Table of Contents
PAGE
RECEIVING, HANDLING/MOVING, AND UNPACKING ........................................................................1
Receiving and Unpacking ...........................................................................................................1
Handling and Moving ..................................................................................................................1
Using a Forklift ............................................................................................................................1
Overhead Lifting..........................................................................................................................2
Initial Inspection ..........................................................................................................................2
LOCATION.............................................................................................................................................2
Storage .......................................................................................................................................2
Indoor Equipment........................................................................................................................2
Outdoor Equipment .....................................................................................................................3
Routine Inspection ......................................................................................................................3
INSTALLATION .....................................................................................................................................3
Rating Verification .......................................................................................................................3
Location ......................................................................................................................................3
Service Conditions ......................................................................................................................4
Installation Site Preparation ........................................................................................................4
Mounting .....................................................................................................................................5
Additional Cabinet Entries ...........................................................................................................5
Ground Connections ...................................................................................................................5
Medium Voltage Power Connections ..........................................................................................7
Incoming Line .............................................................................................................................9
Load Connections .......................................................................................................................9
GENERAL DESCRIPTION...................................................................................................................14
Construction ..............................................................................................................................14
Controller Compartment ............................................................................................................15
Isolation Switch .............................................................................................................15
Vacuum Contactor .........................................................................................................16
Outgoing Load Connections ..........................................................................................16
Control Power/Potential Transformers ...........................................................................17
Operating Handle ..........................................................................................................18
Interlocks - Mechanical ..................................................................................................18
Door Interlock ....................................................................................................18
Handle Interlock .................................................................................................19
Vacuum Contactor Interlock ...............................................................................19
Interlocks - Electrical .....................................................................................................20
Control Power Interlock (CPI).............................................................................20
Test Power Interlock (TPI) .................................................................................20
Low Voltage Compartment ........................................................................................................21
Main Bus Compartment ............................................................................................................22
Contactor Ratings .....................................................................................................................23
Controller Ratings .....................................................................................................................24
Horsepower Table.....................................................................................................................25
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Basic Installation and Operation Guide JK Series 720 Controllers
OPERATION .....................................................................................................................................26
Initial Energization .....................................................................................................................26
MAINTENANCE ................................................................................................................................27
Maintenance Record .................................................................................................................27
General Inspection ....................................................................................................................28
Electrical Joints .........................................................................................................................28
Power Fuses .............................................................................................................................29
Vacuum Contactor ....................................................................................................................29
Isolation Switch .........................................................................................................................30
Switch Handle Mechanism ........................................................................................................31
Interlocks ..................................................................................................................................32
Control Power/Potential Transformers ......................................................................................32
TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
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.
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Basic Installation and Operation Guide JK Series 720 Controllers
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. 2) 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. 3). Ropes or cables should
not pass through the holes in lifting angles or eye-bolts. Slings
with safety hooks or shackles of adequate load rating should be
used.
Storage
If the controller is to be stored for any length of time prior to installation, the packing
should be restored for protection during that period. Where conditions permit, the
packing should be left intact until the controller is at the final installation position. If the
packing (Fig. 4) 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 (e.g. Type 1, 12) that 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
Fig. 4 Storage
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Basic Installation and Operation Guide JK Series 720 Controllers
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 un-energized controller designed for outdoor installation (e.g. Type 3R) should be kept dry internally by installing
electrical heating or by energizing provided space heaters. All openings, either used or unused, should be covered
or sealed to prevent the entry of rain, vermin, insects, etc.
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
WARNING
the unit performance.
INSTALLATION
DANGER Do not exceed the ratings specified on the controller nameplate or system accessories.
Location
Overhead should be checked for plumbing condensation, sprinklers, or similar possible sources of trouble. A clearance
of 1/2 inch should be provided between a wall and the rear of the controller for indoor equipment, when rear access
is not required. If rear access is required in either environment, a minimum of 30 inches should be provided. Consult
local codes in case more space is required.
A minimum of 48 inches working space should be allowed in front of the controller. This minimum should be increased
if necessary to accommodate movement around open enclosure doors to comply with applicable codes.
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Basic Installation and Operation Guide JK Series 720 Controllers
Service Conditions
Toshiba medium voltage controllers are intended for usual service conditions as defined by NEMA. The equipment
should not be exposed to corrosive or explosive fumes, dusts, vapors, dripping or standing water, abnormal
vibration, shock, tilting, or other abnormal operation conditions. The temperature of the ambient air surrounding the
controller should be between the limits of 0°C (32°F) and +40°C (104°F). The altitude of the equipment installed
should not exceed 3300 ft. (1000m).
NOTE: Temperature or altitude conditions outside of the usual limits may require derating or other special
equipment, such as heating, cooling, or ventilation. Contact Toshiba for further information.
Do not install this equipment in areas where unusual service conditions exist,
WARNING
unless the equipment has been specially designed for the particular environment.
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Basic Installation and Operation Guide JK Series 720 Controllers
Mounting
Each shipping section must be leveled and firmly secured to its supporting
foundation. Steel shims may be used for final leveling (Fig. 6), if necessary.
When three or more shipping sections are to be arranged in one
continuous line-up, the center shipping section should normally be located
first.
Ground Connections
The controller line-up must be grounded in accordance with
the requirements of the National Electrical Code. Proper
equipment grounding must be established before making any
incoming power connection. If a main ground bus (Fig. 8) is
furnished, make the ground connection to this bus. If there is
no ground bus, the sections which are shipped separately
should be connected to ensure a continuous grounding path.
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Basic Installation and Operation Guide JK Series 720 Controllers
Special attention should be paid to protection for operating personnel, to protection of equipment itself (e.g. ground
fault relays), and protection of sensitive transducers or control devices that are electronic in nature.
The following may be used as a general guide with regard to equipment grounding.
Controller used as service equipment for a grounded system or as a main section for a separately derived system:
a. The grounding electrode conductor (ground wire) sized in accordance with NEC 250 should be run from the
grounding electrode to the controller ground bus or ground terminal.
b. Unless already done at the factory, a main bonding jumper should be installed from the incoming grounded
connector bus (neutral) to the ground bus or designated grounding point. If a jumper is not furnished, one having
a size in accordance with NEC 250 should be selected.
c. Steps (a) and (b) should effectively connect together the grounding electrode, the controller frame, all outgoing
equipment grounding conductors, and the grounded neutral bus of the system.
d. No connection should be made to ground on the load side of any neutral disconnecting line or any sensor used
for ground fault protection. No connections should be made between outgoing grounding connectors and the
neutral.
e. Where the controller or system is dual-fed (double-ended) and has ground fault protection, special
precautions are necessary to accomplish proper grounding and bonding.
Controller used as service equipment for an ungrounded system or as a main section for a separately derived
system:
a. A grounding electrode conductor (ground wire) sized in accordance with NEC 250 should be run from the
grounding electrode to the controller ground bus or ground terminal.
b. If the system is grounded at any point ahead of the controller, the grounded conductor should be run to the
controller in accordance with NEC 250 and connected to the ground bus or ground terminal.
c. Steps (a) and (b) should effectively connect together the grounding electrode, the controller frame, all outgoing
equipment grounding connectors, and any grounded conductor which runs to the controller.
Controller not used as service equipment or as a main section for a separately derived system, and used on either
a grounded or ungrounded system:
a. The controller frame and any ground bus should be grounded by means of equipment grounding conductors
having a size in accordance with NEC 250 and run with the main supply conductors or by bonding to the
raceway enclosing the main supply conductors in accordance with NEC 250.
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Basic Installation and Operation Guide JK Series 720 Controllers
Main power bus (when provided) and horizontal ground Torque at Full
bus are supplied with links to join shipping sections Bolt Size Engagement Type of Connection
together. These should be installed in accordance with (ft – lbs)
Fig. 9 through Fig. 12. All access covers, barriers, 1/2 - 13 45 Bus - Bus
partitions, etc., that are temporarily removed during 28 Bus - Bus
installation must be replaced. 3/8 - 16 25 Bus - Glastic Ins.
18 Bus - Porcelain Ins.
5/16 - 18 15
M 12 35
Fig. 10b Torque Specs for Bus Connections
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Basic Installation and Operation Guide JK Series 720 Controllers
NOTE: Covers and braces supplied only for protection during shipment should not be replaced. All debris
and tools should be removed from each compartment as cabling is completed.
Remove part number identification or any label on the splice bus before installation.
Tighten and torque the bolts for all bus splice connections and other bus if loosened
during installation of the bus splice.
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Basic Installation and Operation Guide JK Series 720 Controllers
Incoming Line
On the standard JK, incoming power cable connections should
be made at the points shown on the wiring diagram furnished
with the equipment. These connections will normally be made in
a separate incoming compartment to bus lugs, an incoming load
interrupter switch, or a vacuum circuit breaker.
Load Connections
Outgoing load connections are made in the controller
compartment to the three copper pads located on the left hand
side wall.
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Basic Installation and Operation Guide JK Series 720 Controllers
PRE-ENERGIZATION CHECK
General
AFTER INSTALLATION, BUT BEFORE ENERGIZING THE CONTROLLER for the first time, follow the procedure
below to verify that the equipment is properly installed and functional.
There is a rating data label (Fig. 15) on the inside of each medium
voltage compartment door. Verify that the controller ratings properly
match the system data by checking the following:
Before closing the enclosure, all metal chips, scrap wire, and
other debris left over from installation must be cleaned out. If
there is an appreciable accumulation of dust or dirt, the
enclosure should be cleaned by using a brush, vacuum
cleaner, or clean, lint free brush.
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Basic Installation and Operation Guide JK Series 720 Controllers
Wiring Check
Field wiring (Fig. 17) should be checked for clearance to live busses
where necessary, physically secured to withstand the effects of fault
current.
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Basic Installation and Operation Guide JK Series 720 Controllers
Device/Mechanism Checks
All devices should be checked for damage (Fig. 19). All necessary
repairs or replacements should be made.
The setting of any adjustable current (e.g. motor overload protection relay) and voltage trip mechanisms should
be verified to the proper values.
NOTE: Damage from faults can be reduced if devices used for short circuit and ground fault protection are
chosen and set to operate at values as close to minimum as feasible, while allowing normal
transients.
All switches, relays, and other operating mechanisms should be manually exercised to make certain that they are
properly aligned and operate freely.
Operating mechanisms such as interlocks, key switches, etc. should be checked for function as intended for
protection of personnel and equipment.
Power circuit fuses were selected and installed in accordance with the application requirements. Confirm the proper
fuses were provided. The fuses must be completely inserted in their holders. Instructions on removing and installing
the fuses can be found in this manual on page 29.
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Basic Installation and Operation Guide JK Series 720 Controllers
Electrical Checks
With incoming power isolated and all loads disconnected electrically, the control circuit and other mechanisms
should be exercised to determine that the devices operate properly. An auxiliary source of control power will be
necessary to provide power to the electrical operators.
The ground fault protection system (if furnished) should be tested in accordance with the instructions furnished with
the device.
An electrical insulation test should be performed to ensure that the controller and associated field wiring are free
from short circuits and grounds. The preferred method is to perform a dielectric test at 2.25 times the nominal
system voltage plus 2000 volts. This should be done phase-to-ground, phase-to-phase, and phase-to-neutral (if
applicable), with all switches, contactors and circuit breakers opened. Disconnect any devices which may have
limited dielectric strength and that are not intended for this test.
The light or buzzer, or both, used to indicate breakdown should be calibrated to indicate failure with an output
current between 1.5 and 2.0 milliamperes per 1000 volts applied.
Hazardous voltages are present during dielectric testing that can result in
WARNING serious injury or death. High potential test should be performed only by
qualified personnel. Refer to safety instructions provided with the test
equipment.
All devices must be set to their normal or OFF position before energizing incoming power.
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Basic Installation and Operation Guide JK Series 720 Controllers
GENERAL DESCRIPTION
Toshiba JK 720 ampere medium voltage controllers are AC
general-purpose NEMA Class E2 controllers designed for
applications at utilization voltages ranging from 2.3 through 6.6
kV. They are normally used to control motor loads, although other
types of loads such as variable frequency drives (VFDs),
transformers and capacitors are possible.
Construction
The standard enclosure size for the 720 ampere controller is 36"
wide by 36" deep by 90" high. One controller is supplied per
vertical section. Each section is divided into two isolated
compartments, each with a separate door. The lower
compartment contains medium voltage controller components
(>600V) while the upper compartment contains low voltage
components (<600V) (Fig. 21).
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Basic Installation and Operation Guide JK Series 720 Controllers
Controller Compartment
A. Isolation Switch
Power is switched on and off to the controller by a fix-mounted,
externally-operated, three-pole, non-load break, isolation
switch (Fig. 23). When the switch is in the off position, incoming
power is isolated from the controller compartment interior by
an automatic shutter. For additional safety, the load terminals
of the switch are automatically grounded when the switch is off.
The isolation switch is mechanically interlocked with the vacuum contactor and the compartment door. Details of the
interlocking are discussed in Section F.
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Basic Installation and Operation Guide JK Series 720 Controllers
B. Vacuum Contactor
The Type HCV-6KAU vacuum contactor (Fig. 25) used in Toshiba
JK 720 ampere controllers is a compact, fix-mounted device. It is
mounted to the floor of the controller compartment, beneath the
isolation switch.
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Basic Installation and Operation Guide JK Series 720 Controllers
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Basic Installation and Operation Guide JK Series 720 Controllers
E. Operating Handle
The external operating handle shown in Fig. 29 is used to control the operation
of the isolation switch. Moving the handle upward turns the switch on, thus
applying incoming power to the main current-limiting fuses.
Moving 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.
Further details on the isolation switch and external operating handle can be
found in the Maintenance section.
F. 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. 30).
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Basic Installation and Operation Guide JK Series 720 Controllers
b. Handle Interlock
Two mechanical interlocks are provided to prevent operating the switch
handle improperly.
The first interlock prevents moving the handle from OFF to ON unless the
compartment door is closed (Fig. 31).
The second interlock prevents the switch handle from being moved in
either direction unless the contacts of the vacuum contactor are open
(Fig. 32).
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Basic Installation and Operation Guide JK Series 720 Controllers
G. Interlocks - Electrical
a. Control Power Interlock (CPI)
The control power interlock (CPI) is a microswitch which is directly driven
by the operation of the switch handle (Fig. 33). This normally open switch
is closed only when the handle is fully ON. It ensures that all load is
disconnected from the control power transformer secondary winding
before the isolation switch can be operated.
As the switch handle is moved from ON to OFF, the CPI opens before
the main contacts of the power isolation switch. Conversely, during
closing of the switch, the CPI contacts do not close until the switch
contacts have fully closed. The isolation switch is therefore only
subjected to making and breaking currents equal to the no-load
magnetizing current of the transformer. More than one CPI may be
present. Reference the equipment’s schematic drawings to confirm
number of CPIs in the equipment.
For testing purposes, the isolation switch must be turned off and the
controller door must be opened. The plug is then removed and inserted
into an ordinary extension cord. Plugging the extension cord into a
conventional outlet provides 120VAC power for performing control
circuit operational tests while the medium voltage circuit is de-energized.
The CPI(s) prevent the high voltage back feeding on the CPT (PT)
primary.
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Basic Installation and Operation Guide JK Series 720 Controllers
A low voltage vertical wireway feeds directly into the lower left hand corner of the low voltage compartment. This
wireway provides isolation for control wires entering the bottom of the enclosure. Control wires entering the top of the
enclosure feed directly into the low voltage compartment. A horizontal low voltage wireway is provided at the lower
front of the low voltage compartment. At each end of the horizontal wireway there is an opening for inter-cubicle control
wiring.
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Basic Installation and Operation Guide JK Series 720 Controllers
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Basic Installation and Operation Guide JK Series 720 Controllers
CONTACTOR RATINGS
Interrupting Capacity (NEMA Class E1) 7200 Amps RMS Sym. @ 7.2 kV Max
A latched contactor is the same as magnetically-held type, except number of auxiliary contacts is reduced
to 2 N.O. - 2 N.C. Standard operating voltage is 120Vac Close/125Vdc Trip.
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Basic Installation and Operation Guide JK Series 720 Controllers
CONTROLLER RATINGS
Interrupting
Interrupting Short Time Short Time Dielectric Impulse
Capacity
Capacity Capability Capability Withstand Voltage
(Sym.
(Sym. MVA) 30 Seconds 1 Second 1 Minute Withstand
Amperes)
[email protected]
50,000 RMS [email protected]
@2.3-6.6kV 4320 A 10,800 A 22 kVac 60 kV BIL
400A4.6kV
(7.2kV Max)
[email protected]
NEMA-12, 3R 600
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Basic Installation and Operation Guide JK Series 720 Controllers
Maximum Kilowatt
Maximum Horsepower Rating
Rating
Enclosed
Maximum 2300V, 3-Phase 4200V, 3-Phase 6600V, 3-Phase
Continuous
Current Synchronous Induction Synchronous Induction Synchronous Induction
(Amperes)* Motors Motors Motors Motors Motors Motors
* - Motor FLA depends on manufacturer, speed, and other factors which must be considered.
C.F. – Consult factory with your application requirements.
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Basic Installation and Operation Guide JK Series 720 Controllers
OPERATION
Initial Energization
Energizing a medium voltage controller or line-up of controllers
for the first time is potentially dangerous. Therefore only qualified
personnel, as defined in the SAFETY section of this manual,
should energize the equipment (Fig. 38). If equipment damage or
poor installation practices have escaped detection in the PRE-
ENERGIZATION CHECK, major damage, including personal
injury, can result when the power is applied. Extra precaution is
recommended on initial energization of the equipment.
With all removable barriers in place and all doors closed and
latched, the devices should be turned on with a firm, positive
motion. Protective devices and switches that are not quick-acting
should not be "teased" into the closed (or open) positions. The
isolation switch handle should be moved between the OFF and
ON positions in a single continuous smooth movement (Fig. 39).
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Basic Installation and Operation Guide JK Series 720 Controllers
MAINTENANCE
In order to ensure continued reliable and safe operation of the equipment, a
program of periodic maintenance must be established. Operating and
environmental conditions will dictate the frequency of inspections required.
NFPA Publication 70B "Electrical Equipment Maintenance" (Fig. 40) may be
used as a guide for setting up the maintenance program.
Maintenance Record
A permanent record of all maintenance work should be kept. At a
minimum, this record should include information on:
1) Items inspected
2) Test reports
3) Equipment condition Fig. 40 NFPA 70B
4) Corrective actions or adjustments Electrical Equipment
5) Date of work Maintenance
6) Comments
Improper maintenance can cause severe injury, death, and extensive property
WARNING damage. Only qualified and authorized persons are to install, operate, or
service the equipment.
This equipment utilizes both low and high voltage for operation. Verify that
WARNING
all test equipment is suitable for the voltage being checked.
NOTE: Refer to the SAFETY section of this manual for important information.
After disconnecting and locking out incoming power and before performing
any maintenance, it is recommended that a safety ground be connected to
the main power bus (Fig. 41). After maintenance is complete, perform the
checks in the PRE-ENERGIZATION CHECK section of this manual before
restoring power.
- Cleaning
- Checking and tightening of electrical connections
- Checking of fuses and fuse connections
- Proper installation of any removable barriers
- Vacuum contactor maintenance
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
The information presented here is intended to cover preventive maintenance only. It does not cover major
rework or repair. The following MAINTENANCE SHOULD BE PERFORMED AT LEAST ANNUALLY or more
frequently depending on operating conditions.
General Inspection
Thoroughly clean the equipment, removing all dust, dirt, and other accumulations. Wipe insulators clean using
a clean, dry cloth. Do not use petroleum-based solvents or cleaners.
Check for any signs of moisture inside the enclosure. If there are signs of dripping water entering the
enclosure, eliminate the source. Thoroughly dry any insulation which shows signs of wetness and repeat the
dielectric test procedure given in the PRE-ENERGIZATION CHECK. Replace insulators, if necessary.
Check for free movement of all moving parts and mechanisms. Lubricate, if necessary, with Toshiba B9
grease.
Electrical Joints
Examine all visible terminals and joints for signs of overheating
(Fig. 41). An overheated connection will appear discolored. Be
suspicious of any conducting joint which has a darker color than
other similar joints.
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
Power Fuses
The power fuses supplied in Toshiba JK 720 ampere controllers
are of the bolt-in or clamp-in type, therefore overheating due to
loss of fuse clip pressure is not a problem. The tightness of the
fuse clamping bolts (Fig. 44) should, however, be periodically
checked and maintained within a range of 20-30 ft-lbs.
Vacuum Contactor
Maintenance instructions for the HCV-6KAU vacuum contactor
are provided in a separate publication, number VF010H08A.
Contact the equipment supplier or the factory if this publication
is needed and was not provided with the equipment.
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
Isolation Switch
The isolation switch provided in each controller is a bolted pressure type device. It is designed to maintain
proper adjustment and contact pressure over its mechanical life of 10,000 close-open cycles. Under normal
operating conditions, no maintenance is required other than periodic inspection and cleaning.
Wipe off any dust or dirt which may have accumulated on the switch housing, the insulating blade drive links,
and the shutter.
Open and close the switch and verify that no excessive force is required. Observe that the line terminal shutter
opens and closes properly. Lubricate the moving parts of the handle mechanism and, if necessary, apply a light
coat of Toshiba B9 grease to the inside contact surfaces of the switch blades. Contact the equipment supplier
or the factory to obtain B9, grease if required.
WARNING Grease is conductive. Do not allow grease to contact the switch housing or the
insulated shutter.
Examine the current-carrying switch blades for any sign of discoloration due to overheating.
Each bolted pressure switch blade assembly is pre-torqued and adjusted to the proper settings at the factory.
DO NOT attempt to change the torque settings or replace any individual parts of this assembly in the field.
If it is necessary to replace the blade assemblies, contact the nearest Toshiba representative.
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
2) Observe that the isolation switch blades are in contact with the ground pads.
3) If adjustment is required, loosen lock nut securing yoke on handle end of connecting rod. Remove pin
which attaches yoke to handle drive lever. Turn yoke in required direction to achieve adjustment
defined in step 2. Attach yoke and pin to drive lever and tighten yoke lock nut.
4) Check the position of the handle interlock with the vacuum contactor in the OFF position. The tab
extending from the interlock should clear the notch in the handle, allowing the handle to be moved freely
between OFF and ON. Operate the contactor on test power and check that there is no binding and that the
contactor is able to reach its full travel in both directions.
The moving joints of all linkages should be occasionally lubricated with a light coat of Toshiba B9 grease.
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
Interlocks
Circumvent the handle interlock by pushing a screwdriver through the slot and operate the handle several times.
Turn off and lock out Primary and Control Circuit Power.
Check that the CPI electrical interlock (microswitch) operates each time the handle is moved. The CPI (control
power interlock) should close approximately 10° before the handle reaches the full ON position. As the handle
is moved from ON to OFF, the CPI switch should open by the time the handle has moved approximately 10° or
one inch (Fig. 48).
Refer to the GENERAL DESCRIPTION section for the location of the handle mechanical interlocks and the CPI
electrical interlock.
Check the condition of the primary fuses and fuse clips. Check all screws
for tightness.
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TOSHIBA
Basic Installation and Operation Guide JK Series 720 Controllers
In an installation which has been properly coordinated and in service prior to a fault, the opening of the current-
limiting power fuses in the controller indicates a fault condition in excess of operating overload. This fault condition
must be corrected and necessary repairs made to the load circuit before re-energizing the controller.
The following inspection and repair procedures should be carried out by qualified personnel.
WARNING Hazardous Voltage. Turn off and lock out Primary and Control Circuit Power
before any inspection or testing.
Enclosure
Check the condition of the enclosure for any signs of bowing or deformation. Check the condition of the doors and
latches for damage.
If substantial damage has occurred to the enclosure, such as deformation, displacement of parts, or burning, this
indicates a problem within the controller that requires major reconditioning or complete replacement of the controller.
In this event, contact the nearest Toshiba representative.
Isolation Switch
The external operating handle must be capable of opening the switch. If the handle fails to open the switch or if
visual inspection after opening indicates deterioration beyond normal wear and tear such as overheating or pitting
of blades, insulation breakage, or charring, contact your Toshiba representative.
Fuse Mounting
Check the condition of the power fuse mounting hardware, clamps, and insulating bases. Any deterioration of these
components requires replacement of the damaged parts.
Overload Relay
The overload relay must be checked to verify that it will still trip properly. Follow the test instructions provided with
the overload device for verifying trip characteristics.
Vacuum Contactor
Operate the vacuum contactor electrically from test power and observe that it opens and closes freely. If the vacuum
bottles show any sign of binding, they should be replaced. Contact your Toshiba representative. Check for any
sign of arcing damage to the insulated housing.
Return to Service
Before returning the controller to service, repeat the procedure outlined in the PRE-ENERGIZATION CHECK
section of this manual.
33
TOSHIBA
Motors and Drives Division
Power Apparatus & Components
13131 West Little York Road | Houston, TX 77041
Tel: 713-466-0277 | US: 800-231-1412 | CAN: 800-872-2192
www.toshiba.com/tic
Printed in USA