Three-Phase Power Conditioner. Solatron Series. Instruction Manual

Three-Phase Power Conditioner Solatron Series Instruction Manual

ii Contents CONTENTS Important Safety Instructions 1 Receiving and Unpacking 2 Moving and Lifting 2 Storage 2 Installation 3 Mechanical Considerations.......................................... 3 Electrical Considerations........................................... 5 To Maintain UL1012 Listing........................................... 5 Lug Size Tables................................................ 5 To Install the Solatron Unit 6 Startup 7 Normal Operation 7 Automatic Internal Bypass 8 Circuit Breaker Operation 9 Surge Suppression 9 Alarms 9 Remote Alarm Relay Dry Contacts....................................... 9 Status Indicator Lights 10 Maintenance 10 General Condition............................................... 10

SOLATRON SERIES iii CONTENTS Maintenance Log 11 Troubleshooting 11 Troubleshooting Table............................................. 12 Specifications 13 Contact Information 14 Warranty 14 FIGURES Figure 1: Component Layout.......................................... 3 Figure 2: Overview.............................................. 4 Figure 3: Status Indicators........................................... 4

1 Important Safety Instructions Important Safety Instructions The Solatron unit and related equipment must be installed, operated, and maintained in accordance with this manual. After complying with all of the information in this manual, it should be saved for future reference. Failure to follow all instructions herein will cause death, severe injury, or significant equipment damage, and Only properly qualified and trained personnel should be permitted to install, service, and operate this equipment. Follow all safe electrical work practices. Use all applicable personal protective equipment (PPE). The unit is intended to be installed where it is not accessible to the general public. Access to this equipment must be limited to properly qualified and trained personnel. Dangerous and potentially lethal voltages are present inside the enclosure of the unit; the hazard of electric shock, arc flash, and explosion are present. Under no circumstances should anyone be permitted to operate or energize the unit without all covers in place, doors closed, and all safeguards in place. Under no circumstances should anyone be permitted to reach into or perform any action within the enclosure for maintenance, decommissioning, or other purposes without properly de-energizing and grounding the unit. The transformer coils must be discharged of any potential static charge. The unit must be installed in accordance with all applicable federal, state, and local codes. The unit enclosure must be properly grounded using the provided ground connections. The unit must be installed a safe distance from any combustible material unless separated and shielded by appropriate fire resistance and heat dissipative barriers in accordance with the National Electrical Code (NEC) and all applicable local codes. The unit must only be installed in locations suitable for the level of protection afforded by the enclosure type. No claim is made that these instructions cover all possible details or variations in unit manufacture or address all possible contingencies that might be encountered during the installation, operation, or maintenance of the unit. All questions, concerns, informational needs, or problems that arise regarding receiving, unpacking, moving, lifting, storing, installing, operating, or maintaining the unit which are not sufficiently addressed herein should be referred to SolaHD.

SOLATRON SERIES 2 Receiving and Unpacking Prior to removing any shipping or packing material, the unit must be immediately inspected upon receipt for any indication of damage sustained during shipping. During unpacking, inspect the inside and outside of the unit for any dents, scrapes, bent or loose parts, water entry, moisture, or any other signs of damage. If there is any reason to believe that the unit has been damaged: Note the damage on the shipping documentation and notify the carrier. Document and photograph any damage found. Contact the shipping company to file a claim if necessary or SolaHD Customer Service. Moving and Lifting The Solatron unit must be lifted by the base only using a pallet jack or forklift. The center of gravity may not be in the center of the unit. Use appropriate procedures for handling unbalanced loads. Do not lift the Solatron from the top. Ensure that the capacity of the lifting equipment is appropriately sized for lifting and moving the Solatron. Contact SolaHD Technical Support if there are any questions or concerns regarding moving or lifting the unit. Storage Prior to installation, the Solatron must be stored in a location which prohibits the entry of liquid or moisture into the enclosure. Condensation must not be allowed to form on the internal components. Contact SolaHD Technical Support if there are any questions or concerns regarding storage.

3 Installation Installation The Solatron unit must be installed in an area appropriate for industrial electrical equipment, which includes but is not limited to the following characteristics: Concrete or other non-combustible, non-flammable floor adequate to support the weight of the unit. Adequate ventilation. Free from combustible or flammable materials, liquids, gases, or dust. Secure from unauthorized access by the general public. Consistent with the NEMA duty rating of the enclosure (NEMA 1). Contact SolaHD Technical Support if there are questions or concerns regarding installation. Mechanical Considerations Cable entry and exit must be made through the sides or top of the enclosure. Cable entry and exit penetrations must be made by the end user. Debris from creating cable penetrations must not be allowed on any component within the enclosure. The input and output connection locations and phase sequence are shown in Figure 1. The unit must be installed with the clearances shown in Figure 2. Only the top, front, and rear enclosure panels are removable. The front panel can only be removed with the input circuit breaker handle in the OFF (OPEN) position. Remote Alarm Contacts Input Circuit Breaker Output Distribution Blocks Auxiliary Circuit Breakers (CB2, CB3) Control Board Figure 1: Component Layout Front View

SOLATRON SERIES 6 36 12 36 Status Indicator Lights See Detail A Mounting Holes (4X) 3/8 Clearance 25.5 25.25 Figure 2: Overview Over-temp Normal Bypass Detail A: Status Display Lights (Front Panel Figure 3: Status Indicators 4

5 Installation Electrical Considerations The nominal input voltage applied to the Solatron unit shall be as listed on the unit nameplate. The nominal operating frequency must match the nameplate frequency. The maximum continuous load must not exceed the kva nameplate rating. The unit must be grounded using the provided ground lugs. The unit must be installed in a location appropriate for industrial electrical equipment, which includes but is not limited to the following characteristics: Compliance with IEEE 519. The input voltage waveform shall maintain 5% or less THD. If the THD percentage exceeds this value, the unit s performance may be adversely affected. To Maintain UL1012 Listing: Each AC output power circuit shall be provided with overcurrent protection for all ungrounded conductors. The voltage rating of the overcurrent protection shall not be less than the rating of the circuit which with which it is used. The overcurrent protection device shall be a circuit breaker or a fuse evaluated for use as branch circuit protection. The rating of the overcurrent protection device must meet NEC Article 240 requirements. The output overcurrent protection devices are not included with the unit and must be provided by the end user or purchaser. Failure to install the output overcurrent protection devices voids the UL1012 listing for the unit. Lug Size Tables Input Circuit Breaker Lug Sizes (Copper wire only) 208V 240V 480V 600V Cable Range Torque Cable Range Torque Cable Range Torque Cable Range Torque 20kVA #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. 30kVA #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. 50kVA #10-250mcm 14Nm or 123.91in-lb. #10-250mcm 14Nm or 123.91in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. 75kVA (2) 3/0-250mcm 18Nm or 159.31in-lb. #10-250mcm 14Nm or 123.91in-lb. #14-1/0 7Nm or 61.95in-lb. #14-1/0 7Nm or 61.95in-lb. Output Distribution Block Sizes (Copper wire only) 208V 240V 480V 600V Cable Range Torque Cable Range Torque Cable Range Torque Cable Range Torque 20kVA #14-2/0 #14-2/0 #14-2/0 #14-2/0 30kVA #14-2/0 #14-2/0 #14-2/0 #14-2/0 50kVA #14-2/0 #14-2/0 #14-2/0 #14-2/0 75kVA #4-500mcm 56.49Nm or 500in-lb. #4-500mcm 56.49Nm or 500in-lb. #14-2/0 #14-2/0

SOLATRON SERIES 6 To Install the Solatron Unit: The following instructions must be followed. Contact SolaHD Technical Support with any questions or concerns. 1. Ensure that all electrical circuits are properly de-energized and locked out. 2. Locate and access the input and output terminal blocks or lugs. 3. Ensure that cable entry points comply with the appropriate NEMA rating of the enclosure (NEMA 1). Cable entry points should not be made through removable or panels. 4. Ensure that the enclosure and internal components are not damaged when installing source and load cabling. 5. Route and restrain the source and load cabling within the enclosure such that it is not in contact with any components, surface, or sharp corners. Note that all source and load wiring must be installed in accordance with all applicable federal, state, and local codes. 6. If required, install appropriately rated remote alarm cabling. Refer to the Alarms section for details and contact ratings. 7. After installation of the source and load wiring, inspect all wiring and internal components for any sign of damage. Ensure that all connections are tight and wires are secure. Report any signs of damage to components, connectors, or wiring insulation to SolaHD Technical Support prior to energizing the unit. 8. Ensure that the internal auxiliary circuit breakers (CB2 and CB3) are ON (CLOSED). 9. Replace all removable panels which were opened during installation. Ensure that all retaining bolts are reinstalled.

7 Startup Startup When powering the Solatron unit for the first time, please follow these instructions to ensure normal operation. Note that the unit has been fully tested and calibrated and requires no user adjustments during startup or during normal operation. If there are any questions or concerns, please contact SolaHD Technical Support immediately. If any of the checks during startup are not satisfactory, do not continue to the next step, and refer to the Troubleshooting section or contact SolaHD Technical Support. Ensure that all installation requirements have been met. All field installed wiring must be complete and secure and the unit enclosure must be fully closed and secured. 1. Ensure that the input breaker is OFF (OPEN). 2. Turn ON the upstream source to apply voltage to the Solatron. 3. Turn the input circuit breaker handle to the ON (CLOSED) position. This energizes the control circuits and the transformers. After several seconds, the Normal light is illuminated indicating normal operation. The Bypass and Overtemp lights are not illuminated indicating that there are no alarm conditions. The Solatron is now in normal operation mode and is supplying regulated voltage to the load. Normal Operation The Solatron is considered to be in normal operation mode when the load is supplied with regulated voltage. The unit is in normal operation mode when the following conditions are met: The input circuit breaker is ON (CLOSED). The Normal status indicator light is illuminated. If one or more of the normal conditions are not met, the load may not be supplied with power, or the power supplied to the load may be unregulated. While in normal operation, the Solatron automatically regulates the output voltage to within the output voltage regulation range. The unit selects discrete transformer taps to regulate the output voltage. Each phase of the Solatron is regulated independently to achieve optimum phase balance within the regulation range. When the unit changes taps, it is not unusual to see a change in output voltage equal to approximately the total output regulation range. The output regulation range is +/-3%, so the output voltage may change up to 6% during a tap change. The resulting output voltage remains within the output regulation range.

SOLATRON SERIES 8 Automatic Internal Bypass The unit has an automatic internal bypass mode included with the objective of protecting the switching semiconductors in the event of failure modes which include but are not limited to: Semiconductor malfunction Severe over-currents Control board malfunction Power supply malfunction The unit is in automatic internal bypass mode if either or both of the internal auxiliary circuit breakers (CB2 or CB3) are tripped. In most cases, the power to the load is maintained, but the output voltage is not regulated. The unit is in automatic internal bypass mode if all of the following conditions are met: The input circuit breaker is ON (CLOSED) The Bypass status indicator light is illuminated Note that while the automatic internal bypass mode protects the Solatron unit and maintains power to the load, it does not cover all possible contingencies or failure modes. The output terminals of the unit remain energized when in automatic internal bypass mode. To return the Solatron unit from automatic internal bypass mode to normal operation mode: The unit must be de-energized with the input breaker OFF (OPEN) before proceeding. Step 1 Verify that there are no exposed voltages in the electronics compartment. Step 2 Determine which auxiliary circuit breaker(s) have tripped. Step 3 Reset each tripped breaker. Step 4 Once all auxiliary circuit breakers are ON (CLOSED), replace all access panels and close all access doors, and follow the instructions for returning the unit to normal operation (See Startup Section).

9 Circuit Breaker Operation Circuit Breaker Operation The input circuit breaker is mechanically operated by a handle on the front panel. To reset the input circuit breaker, it must be turned OFF (OPEN) before it may be turned ON (CLOSED). Do not operate the input breaker by any operating mechanisms other than those on the front panel of the Solatron. Surge Suppression The Solatron contains a transient voltage surge suppression device (SPD) unit which is wired to the input circuit breaker load terminals. Alarms Remote Alarm Relay Dry Contacts The Solatron unit provides dry relay contacts for remotely monitoring the operating condition. Note that the dry relay contacts must be field-wired, and no wire or cable is provided to make such connections. The remote alarm contacts are one set of dry normally closed Form B contacts from a pilot relay available at DIN terminal blocks labeled Remote Alarm. During normal operation, the relay is energized. The relay is de-energized for conditions where the unit may require attention which includes: Automatic Internal Bypass mode ( Bypass light is illuminated). High temperate ( Overtemp light is illuminated). Input circuit breaker is OFF (OPEN). Loss of utility power. The unit is NOT in normal operation Max. Switching Voltage Rated Current Switching Power Min. Switching Voltage UL Contact Ratings Contact Ratings 220VDC, 250VAC 2A 60W, 62.5VA 100uV 30VDC, 2A, 60W (N.O. Only) 110VDC, 0.3A, 33W 220VDC, 0.27A, 60W 125VAC, 0.5A, 62.5W 250VAC, 0.25A, 62.5W

SOLATRON SERIES 10 Status Indicator Lights The Solatron unit is equipped with three status indicator lights: Normal, Overtemp, and Bypass. The function of the Normal light is to indicate that the unit is in normal operation mode. The Overtemp light is an indication that the transformer coils may be overheating. If the Overtemp light is illuminated, the unit requires immediate attention. The unit may require cleaning, may have been overloaded, or may be in an environment with a high ambient temperature. Refer to the troubleshooting section for more information. The Bypass light is an indication that the unit is in automatic internal bypass mode. If the Bypass light is illuminated, one or both of the internal auxiliary circuit breakers (CB2 and CB3) may need to be reset. Refer to the troubleshooting section for more information. Note that both the Overtemp and Bypass indicator lights activate the remote alarm contacts. If either of the Overtemp or Bypass lights are illuminated, the unit is not in normal operation, and the Normal light is not illuminated. Maintenance The following items should be addressed at least annually as part of a responsible maintenance routine. If there are any questions regarding the functionality of the unit during any maintenance procedures, please contact SolaHD Technical Support. The included log should be used to log and record maintenance activities. General Condition The Solatron unit must be completely de-energized, including power on the line side of the input circuit breaker and any remote alarm contact power. Failure to observe maintenance may degrade unit performance or cause load power interruption. The entirety of the enclosure should be thoroughly examined for any signs of damage, moisture, or liquids. All wires and cables should be inspected for signs of damaged insulation or overheating. SolaHD Technical Support should be contacted if any of these signs are present. The enclosure should be free from dust and debris. The unit should be cleaned in accordance with good cleaning practices for industrial electronic equipment.

11 Maintenance Log Maintenance Log Installation Date: Model #: Serial #: Inspection/ Maintenance Date Personnel Inspections Performed/Actions Taken Troubleshooting Refer to the Important Safety Information section prior to troubleshooting. The Solatron unit must be completely de-energized and locked out prior to troubleshooting. In the event of alarm conditions or unexpected operation, please refer to the Troubleshooting Table on the next page as a guide to return Solatron unit to normal operation. Note that while many conditions are described, no claim is made that all possible contingencies are covered. If the Troubleshooting Table is unclear, the condition is not listed, or the troubleshooting action does not remedy the condition, please contact SolaHD Technical Support: 1-800-377-4384 Option #2 or email: solahd.technicalservices@emerson.com.

SOLATRON SERIES 12 Troubleshooting Table Condition Possible Causes Troubleshooting Action The external ambient temperature exceeds the temperature rating of the unit Take measures to reduce the ambient temperature or prevent excessive heating The Overtemp indicator light is illuminated The unit may have been overloaded Confirm that the load does not exceed the nameplate rating of the unit An auxiliary circuit breaker may have TRIPPED The Bypass indicator light is illuminated One or more semiconductor devices may have failed The control board may have failed Follow the steps in the automatic internal bypass section to return the unit to normal operation. If the unit continually enters internal automatic bypass mode, please contact SolaHD Technical Support. The unit may have been overloaded Confirm that the load does not exceed the nameplate rating of the unit The input circuit breaker is TRIPPED The unit may have been overloaded Confirm that the load does not exceed the nameplate rating of the unit. Refer to the Circuit Breaker Operation section for resetting the circuit breaker. The remote alarm contacts are closed The unit may be in an alarm condition or de-energized Re-energize the unit or refer to the status indicator lights on the front of the unit.

13 Specifications Specifications Application Model Number 63TXY3ZZ: Nominal Input Voltage X = A (208V), B (240V), C (480V), D (600V) Nominal Output Voltage Y = A (208V), B (240V), C (480V), D (600V) Power Rating / Size ZZ = 20, 30, 50, or 75kVA Phases - Frequency 3 phase, 60Hz nominal Input Voltage Range +10% to -25% of nominal input voltage Output Voltage Regulation +/-3% of nominal output voltage Connections 3 Wire plus ground (Delta) input, 4 Wire plus ground (Wye) output Operating Characteristics Regulation Variation None - regulation constant for 0 to 100% load Overload Capacity 1000% for 1 second, 500% for 5 seconds, 200% for 1 minute - 1000% fault clearing Minimum Load No minimum load or part load limitations Load Power Factor No limitations, compatible with all load types Tap Switching No load current interruption on switching regardless of load or power factor Zero Crossing Sensitivity Tap switching not dependent on determining load current zero crossing Harmonic Distortion No distortion added regardless of load or power factor Response Time 1 cycle typical regardless of load or load power factor Efficiency 96% Typical EMI <0.2 gauss at a distance of 3 feet Insulation Resistance 100 megohms from winding to core measured at 500VDC Operating Frequency ±3% of nominal frequency Noise/Surge Suppression & Short Circuit Protection Noise Attenuation 150 db at 100kHz common mode; 65 db at 100 khz normal mode Surge Suppression Included, complies with ANSI/IEEE C26.41 Input Circuit Breaker Included, standard Automatic Bypass Internal auxiliary circuit breakers; No load interruption on activation Construction Technology Electronically-controlled tap switching with series transformer Switching Semiconductors Non-full power semiconductors - individual SCRs do not carry full unit current Controls Microprocessor-based control, RMS based measurements Cooling Natural Convection Transformer Isolation: Delta-Wye Enclosure NEMA 1 Environmental Requirements & Conditions Audible Sound Level Meets or exceeds NEMA standards Temperature - Humidity Ambient 32 to 104 F (0 to 40 C) - Relative humidity 0-95% non-condensing Operating Altitude 0 to 10,000 ft. (3000m)

SOLATRON SERIES 14 The information in this manual is provided as a guide for installation, operation, and maintenance and does not affect or exceed SolaHD s obligations under its terms and conditions. Contact Information Website: www.solahd.com Technical Services E-Mail: solahd.technicalservices@emerson.com Note that unit specifications are subject to change without notice. Warranty Please see the Terms & Conditions of Sale.

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