Three-Phase Power Conditioner - Emerson Electric...Page: 3 Solatron : Three-Phase Voltage Regulator — 20, 30, 50, 75 kVA Installation! WARNING Failure to follow all instructions

Three-Phase Power Conditioner

Solatron™: Three-Phase Voltage Regulator — 20, 30, 50, 75 kVA


CONTENTSImportant Safety Instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1

Receiving and Unpacking � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2

Moving and Lifting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2

Storage � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2

Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Mechanical Considerations � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Electrical Considerations � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4

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

Maintenance Log � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 11

Troubleshooting Table � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13

Technical Support � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14

Warranty � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14

FIGURES Figure 1: Component Layout � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3

Figure 2: Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4

Figure 3: Status Indicators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4

Page: 1


Important Safety InstructionsThe 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�

! WARNING

Failure to follow all instructions herein will cause death, severe injury, or significant equipment damage, and void the unit warranty�

• 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�


Page: 2

Receiving and UnpackingPrior 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 LiftingThe Solatron™ unit must be lifted by the base only using a pallet jack or forklift�

! WARNING


• 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

! WARNING


• 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�

Page: 3


Installation

! WARNING


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

Output Distribution Blocks

Control Board

Front View

Input Circuit Breaker

Auxiliary Circuit Breakers

(CB2, CB3)

Figure 1: Component Layout


Page: 4

Status Indicator Lights

See Detail A

Mounting Holes (4X)

3/8" Clearance

36"

36"

6"

12"

25�25"25�5"

Figure 2: Overview

Bypass

Over-tempNormal

Detail A: Status Display Lights(Front Panel)

Figure 3: Status Indicators

Page: 5


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�

! WARNING


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

TorqueCable Range

TorqueCable Range

TorqueCable 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

TorqueCable Range

TorqueCable Range

TorqueCable Range

Torque

20kVA #14-2/0#14-8: 5.6Nm or 50in-lb.#6-2/0: 13.56Nm or 120in-lb.

#14-2/0#14-8: 5.6Nm or 50in-lb.#6-2/0: 13.56Nm or 120in-lb.











75kVA #4-500mcm 56.49Nm or 500in-lb. #4-500mcm 56.49Nm or 500in-lb. #14-2/0#14-8: 5.6Nm or 50in-lb.#6-2/0: 13.56Nm or 120in-lb.



Page: 6

To Install the Solatron™ Unit

! WARNING


• 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�

! WARNING


• 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�

! WARNING


• Ensure that all retaining bolts are reinstalled�

Page: 7


StartupWhen 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�

! WARNING


• 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 OperationThe 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.


Page: 8

Automatic Internal BypassThe 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

! WARNING


• 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:

! WARNING


• 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)�

Page: 9


Circuit Breaker OperationThe 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).

! WARNING


• Do not operate the input breaker by any operating mechanisms other than those on the front panel of the Solatron™�

Surge SuppressionThe Solatron™ contains a transient voltage surge suppression device (SPD) unit which is wired to the input circuit breaker load terminals�

AlarmsRemote 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

Contact Ratings

Max� Switching Voltage 220VDC, 250VAC

Rated Current 2A

Switching Power 60W, 62.5VA

Min� Switching Voltage 100uV

UL Contact Ratings

30VDC, 2A, 60W (N.O. Only)110VDC, 0�3A, 33W220VDC, 0.27A, 60W125VAC, 0.5A, 62.5W250VAC, 0.25A, 62.5W


Page: 10

Status Indicator LightsThe 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�

MaintenanceThe 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

! WARNING


• 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�

Page: 11


Maintenance LogInstallation Date: ________________ Model #: _______________________ Serial #: ______________

Inspection/ Maintenance Date

PersonnelInspections Performed/

Actions Taken

Troubleshooting! WARNING


• 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�


Page: 12

Troubleshooting Table

Condition Possible Causes Troubleshooting Action

The “Overtemp” indicator light is illuminated

The external ambient temperature exceeds the temperature rating of the unit

Take measures to reduce the ambient temperature or prevent excessive heating

The unit may have been overloadedConfirm that the load does not exceed the nameplate rating of the unit

The “Bypass” indicator light is illuminated

An auxiliary circuit breaker may have TRIPPED 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�

One or more semiconductor devices may have failed

The control board may have failed

The unit may have been overloadedConfirm 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 closedThe 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�

Page: 13


SpecificationsApplication

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)


Page: 14

The information in this manual is provided as a guide for installation, operation, and maintenance� It does not affect or exceed our obligations under the Terms and Conditions of Sale�

Note that unit specifications are subject to change without notice.

Technical SupportWebsite: www�solahd�com

Technical Support E-Mail: solahd�technicalservices@emerson�com

Toll-Free: (800) 377-4384

USA: (847) 268-6651

WarrantyPlease see the “Terms & Conditions of Sale” document within the product packaging.

While every precaution has been taken to ensure accuracy and completeness in this manual, Appleton Grp LLC d/b/a Appleton Group assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors or omissions�

Solatron™: Three-Phase Voltage Regulator — 20, 30, 50, 75 kVA A272-094 Rev. 7 06/2019

The Emerson logo is a trademark and service mark of Emerson Electric Co� Appleton Grp LLC d/b/a Appleton Group� SolaHD is a registered trademark of Appleton Grp LLC� All other marks are the property of their respective owners� © 2019 Emerson Electric Co� All rights reserved�

United States (Headquarters) Appleton Grp LLC9377 W� Higgins RoadRosemont, IL 60018United StatesT +1 800 621 1506

Australia Sales OfficeBayswater, VictoriaT +61 3 9721 0348

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Three-Phase Power Conditioner - Emerson Electric...Page: 3 Solatron : Three-Phase Voltage Regulator — 20, 30, 50, 75 kVA Installation! WARNING Failure to follow all instructions