Clarke PC20, PC40, PC60 Operating & Maintenance Instructions

MODEL NO: PC40 and PC60

PART No: 6012805 and 6012810

0107

MODEL NO: PC20 • PC40 • PC60

PART Nos: 6012800 • 6012805 • 6012810

OPERATING & MAINTENANCE

INSTRUCTIONS

PHASE CONVERTERS

PHASE CONVERTERS

2

When disposing of this product, ensure it is disposed of according to all local
ordinances. DO NOT dispose of with general waste.

Specifications

PC20 PC40 PC60

Part No: 6012785 6012790 6012795

Dimensions: 260x220x335mm 385x255x380mm 385x255x380mm

Weight: 13.8kg 19.5 kg 23 kg

Input Voltage: 230 vac 50hz 230 vac 50hz 230 vac 50hz

MAX Input Current: 10amps 18amps 25amps

Input Current Fuse 10amps 18amps 32amps
(supply)

Output Voltage: 3ph 400VAC 3ph 400VAC 3ph 400VAC

Max Output: 2HP 3.5 HP 5.5 HP

Please note that the details and specifications contained herein are correct at the time of going to

print. However CLARKE International reserve the right to change specifications at any time without

prior notice. Always consult the machines data plate

Copyright CLARKE International. All rights reserved December 2006.

©

3

CLARKE GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period
of 12 months from the date of purchase. Please keep your receipt as proof
of purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product
can be returned to us without prior permission.

This guarantee does not affect your statutory rights.

Please read these instructions carefully before operating the Converter

Thank you for purchasing this CLARKE Single to 3 Phase Converter. i.e. to run 3­phase asynchronous motors ONLY, from a 230V single phase supply.
Please note that this device, because of its characteristics is for use primarily with
constantly running motors. It is not desirable for use with stop start operations.
Before using the device, please read this manual thoroughly and carefully follow
all instructions given. This is for your own safety and that of others around you, and
is also to help you achieve long and trouble free service from your new product.

Contents Page

Specifications ........................................................................ 1

Safety ..................................................................................... 4

Installation ............................................................................. 5

Electrical Connection ......................................................... 6

Operation ............................................................................. 7- 9

Parts List ................................................................................ 10

4

WA RN IN G

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked, or

ignored, personal injury to the operator may result.

FAILURE TO FOLLOW THESE RULES MAY RESULT IN SERIOUS PERSONAL

INJURY

Special care is taken during all stages of manufacture to ensure that your Clarke
Converter reaches you in good condition.

IMPORTANT

Before using this equipment, it is in your own interest and others around you, that
you read and comply with ALL the information given within.

NEVER open or remove any covers on this equipment while it is still connected to

the mains.

NEVER operate this equipment with any panels open or removed.

NEVER attempt to repair this equipment, unless you are a qualified electrician.

If you do experience any problems which you are unable tosafely resolve,
contact your local dealer or Clarke International Service Department on:

020 8998 7400

NEVER use in wet or damp environments.

Whilst this unit has been built and tested in our factory before being dispatched
to comply with current EMC regulations, the user is responsible for installing and
using it according to the manufacturers instructions. If electromagnetic
disturbances are detected then it shall be the responsibility of the user to resolve
the situation. In some cases it could involve constructing an electromagnetic
screen enclosing the power source, and the work complete with associated input
filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

IMPORTANT

HEALTH AND SAFETY, AND IEE REGULATIONS MUST BE OBSERVED AT ALL TIMES.

Safety

PARTS & SERVICE TEL: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

5

Installation

We would recommend that the installation of this equipment is carried out by a
qualified electrician, who has a full understanding of industrial switching
applications.

It is the users responsibility to provide adequate protection for the intended motor
and to ensure that the supply and cabling is of sufficient capacity to enable the
motor to start without causing undue supply disturbances due to a voltage drop.

Before installing this equipment, careful consideration must be given to the location
in which it is to be used, also what machinery it is intended to run, such as drills,
lathes, milling machines, circular saws etc.

Once the location has been established, the installation may be carried out as
follows on page 5.

WAR NIN G

THESE CONVERTERS ARE NOT SUITABLE FOR USE WITH CAR

HOISTS, COMPRESSORS & VACUUM PUMPS DUE TO THEIR

HIGH START UP LOADS.

6

Notes:

• Cable sizes above are the minimum sizes for up to 20 metres. For cables
over this length, refer to the current IEE regulations.

• Models PC40 & PC60 are provided with a 2M (minimum) length of 3-core
cable for connection to the power supply.

• Model PC20 is provided with 2M (minimum) of 3-core cable fitted with a
13amp plug, for use with a standard, domestic 13 amp supply.

IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code:

Green & Yellow .......... Earth

Blue .......... Neutral

Brown .......... Live

As the colours of the flexible cord of this appliance may not correspond with the
coloured markings identifying terminals in your plug, proceed as follows:

• Connect GREEN & YELLOW cord to plug terminal marked with a letter “E” or

Earth symbol “ ”, or coloured GREEN or GREEN & YELLOW.

• Connect BROWN cord to plug terminal marked letter “L” or coloured RED.

• Connect BLUE cord to plug terminal marked letter “N” or coloured BLACK.

Under no circumstances must the PC40 & PC60 convertors be
connected to the mains using a standard 13amp plug. All models
must be connected via a separate isolator, and must be protected
by a fuse or circuit breaker, (see fuse rating details below).

Check details on converter rating plate are compatible with the electric supply
and the machine to be driven. (machine details should be found on the motor
data plate).

Note:
The converter will only supply a 3 phase, 3 line load as standard, if a neutral is
required. Contact your nearest dealer or Clarke Service for advice.

Electrical Connection

Supply - 230 Volts

Model MAX HP kW Fuse (A) Cable (mm)

PC20 2 1.5 13 amp 1.5mm

PC40 3.5HP 2.6kW 20 amp 1.5mm

PC60 5.5HP 4.0kW 32 amp 2.5mm

IMPORTANT

7

1. Before inserting the output plug, switch all three switches (G) to OFF. Then
switch the converter ON, using the ON/OFF switch (A) on the front panel.

In this condition the lamp (B) will illuminate. In the case of the PC20, the rocker
switch A will illuminate.

Check to ensure the ammeter(C) is set to zero. If necessary adjust using the
small adjustment screw located at the bottom centre of the ammeter so that
it reads zero.

CONNECTING THE OUTPUT

The output is plugged into the socket (E, Fig. 2), using a 4-pin -plug (not provided
but which can be purchased from your Clarke dealer).
The illustration below shows the socket configuration. The plug should be wired
ensuring pins L1 and L3 are used for the connections across the motors windings,
i.e. these are the ‘hot phases’.

Operation

Fig. 1

Fig. 2

If you are unsure as to how to
wire the plug, you should
consult a qualified technician

8

3. Switch OFF the converter and connect the plug from the motor to the output
socket (E).

4. Using the three switches (G), set the output so that it is equivalent to the HP of
the motor to be driven. This value should be found on the motors’ data plate.

The charts below show the switch settings for the required outputs.

3. With the switches set, and the output plugged in, switch ON the converter
and proceed to start the motor/machine. Note that indicator lamp (F) will
illuminate when the switches (G) are set.

Model PC20

Motor SW 1 SW 2 SW 3

HP 0.5 HP 0.5 HP 1HP

0.5 ON OFF OFF

0.5 OFF ON OFF

1ONONOFF

1 OFF OFF ON

1.5 ON OFF ON

1.5 OFF ON ON

2ONONON

Model PC40 Model PC60

Motor SW 1 SW 2 SW 3 Motor SW 1 SW 2 SW 3

HP 0.5 HP 1 HP 2 HP HP 1 HP 1.5 HP 3 HP

0.5 ON OFF OFF 1ONOFF OFF

1 OFF ON OFF 1.5 OFF ON OFF

1.5 ON ON OFF 2.5 ON ON OFF

2 OFF OFF ON 4 ON OFF ON

2.5 ON OFF ON 4.5 OFF ON ON

3 OFF ON ON 5.5 ON ON ON

3.5 ON ON ON

THERMAL OVERLOAD

Should the unit overheat for any reason, the thermal overload will trip, shutting off
supply to the motor/machine. In this event, switch OFF the converter and wait for at
least 5 minutes to allow it to cool, before pressing the Reset Button (D, Fig.2), and
restarting.

You should also investigate the reason for overheating and take the necessary steps
to avoid this reoccuring. If necessary, consult a qualified engineer.

NOTES:

• Please take into account the various losses which are incurred in the
conversion from single to three phase supply. It will be necessary to select an
output from the Converter which is greater than the rated power of the motor
being driven. Ensure also the wiring to the motor is of sufficient size so as not to
incur losses.

• If the machine, which is to be fed from the converter, has a contactor starter,
it should be noted that the control circuit should be fed from the two live
phases (pins ‘L1’ and ‘L3 in the socket). Should the contactor chatter or not
operate at all, this indicates that the control circuit is not fed from lines ‘L1’
and ‘L3’.

• If the control circuit is designed for 230 volts AC, a separate feed for the control
circuit must be provided. Consult a qualified technician if in doubt.

• When using the converter with multispeed machines, care must be taken
to allow the machine to slow down before switching from high to low speeds,
if this procedure is not followed, the excess motor, back E.M.F. could damage
both the converter and motor.

• When reversing motors, ensure that the motor has stopped fully before doing
so.

• For some applications of small motors, or motors of unusual magnetic
characteristics, it may be necessary to provide a pilot motor to obtain a
balance of phases. Generally the pilot motor should be a 2 pole (2800 rpm)
motor and as a general guide should be at least twice as big as the motor to
be driven.

If necessary, consult a qualified technician

9

Typical Wiring Diagram for 230V to 400V Phase Converter

Standard on-line starting.

10

Parts Lists and Diagrams

PC20

1 Frame For Starter

2 Green Pilot Light Switch 16A-250V

3 Circuit Breaker 10A

4 Ammeter 8A F516

5 Front Panel For Small Converter

6 Handle

7 Contactor 220V 10A

8 Cover Panel

9 Relay LY2 24VDC

10 Socket For LY2 Relay PTF 80A

11 Orange Pilot Lamp 220V+Rules L=500

12 Cable Clamp For Cable Diam.6+ Screw

13 Input Cable 3x1,5 M2,5 W/UK Plug +Fuse 13A

14 Red Toggle Switch

15 CEE 16A 380V 3PH Socket + Panel Earth

16 Capacitor 4.7mf-63V 5x11 P-2

16 W10 Rectifier

17 6k8 Ohm 50W Armoured Resistance

18 Auto transformer For Converter PC 20

19 Capacitors Support For Converter PC20

20 Lower Panel For Converter PC20

21 Capacitor 20mf 450V M8 35x95

21 Capacitor 5mf 450V M8 28x56 Shank

21 Capacitor 8mf 450V M8 32x56 Shank

21 Capacitor 16mf 450V M8 36x68 Shank

1 EM21690441

1 EM22200039

1 EM22210005

1 EM 22600045

1 EM 33710372

1 EM 21600045

1 EM 22225006

1 EM 33705460

1 EM 22225318

1 EM 22225319

1 EM 22610013

1 EM 04600233

1 EM 20220068

3 EM 22200042

1 EM22105067

1 EM26000005

1 EM 26014005

1 EM26031001

1 EM 44145002

1 EM 33640256

1 EM 33700265

1 EM 22315006

1 EM 22315017

2 EM22315018

2 EM22315019

No: Description Qty Part No:

PC20

11

PC40

12

PC40

1 Front Frame

2 D.38 Knob For Red Switch + Indicator

3 Green Pilot-lamp 220V+Rules L=230

4 Circuit Breaker 20A

5 Ammeter 20A F540

6 Capacitor 10mf 450A M8 35x71

6 Capacitor 40mf 450A

6 Capacitor 5mf 450A M8 28x56 Shank

6 Capacitor 8mf 450A M8 32x56 Shank

6 Capacitor 16mf 450A M8 36x68 Shank

7 Relay LY2 24VDC

8 Capacitor 4.7mf-63V SX11 P-2

8 W10 Rectifier

9 Plastic Handle

10 Cover Panel For Big Converter

11 Switch 12A ON/OFF

12 Orange Pilot Lamp 220V

13 Red Toggle Switch

14 input Cable 3x1,5 M2,5

15 Cable Clamp D.10+ Screw

16 CEE 16A 380V 3pH Socket + Panel Earth

17 Front Panel For Big Converter

18 Back Panel For Big Converter

19 Capacitors Support

20 Socket For LY2 Relay PTF 80A

21 6k 8Ohm 50W Armoured Resistance

22 Auto Transformer

23 Lower Panel

24 Contactor 220V 10A

2 EM21690425

1 EM04600268

1 EM22610006

1 EM22210018

1 EM22600046

1 EM22315005

1 EM22315008

1 EM22315017

1 EM22315018

2 EM22315019

1 EM22225318

1 EM26000005

1 EM26014005

1 EM21600030

1 EM33705461

1 EM22205009

1 EM22610013

3 EM22200042

1 EM20220014

1 EM04600234

1 EM22105067

1 EM33710373

1 EM33715123

1 EM33640257

1 EM22225319

1 EM26031001

1 EM44145003

1 EM33700252

1 EM22225006

No: Description Qty Part No:

13

PC60

14

PC60

1 Front Frame

2 D.38 Knob For Red Switch + Indicator

3 Green Pilot-Lamp 220V

4 Circuit Breaker 32A

5 Ammeter 30S FS60

6 Capacitor 8mf 450V Mb 32x56 Shank

6 Capacitor 16mf 450V M8 36x68 Shank

6 Capacitor 25mf 450V M8 40x93 Shank

6 Capacitor 50mf 450V Mb 50x93 Shank

7 Relay LY2 24VDC

8 Capacitor 4.7mf-63V 5x11 P-2

8 W10 Rectifier

9 Plastic Handle

10 Cover Panel

11 Switch I6A Sch 1602

12 Orange Pilot Lamp

13 Red Toggle Switch

14 PVC Input Cable 3x2,5 M.2,5

15 Cable Clamp D.10 + Screw

16 CEE 16A 380V 3pH Socket + Panel Earth

17 Front Panel

18 Back Panel

19 Capacitor Support

20 Socket For LY2 Relay PTF 80A

21 6kb ohm 50W Armoured Resistance

22 Auto transformer

23 Lower Panel

24 Contactor 220V I0A

2 EM21690425

1 EM04600268

1 EM22610006

1 EM22210012

1 EM22600051

1 EM22315018

2 EM22315019

2 EM22315020

1 EM22315021

1 EM22225318

1 EM26000005

1 EM26014005

1 EM21600030

1 EM33705461

1 EM22205021

1 EM22610013

3 EM22200042

1 EM20220020

1 EM04600234

1 EM22105067

1 EM33710373

1 EM33715123

1 EM33640257

1 EM22225319

1 EM26031001

1 EM44145004

1 EM33700252

1 EM22225006

No: Description Qty Part No:

15

Wiring Diagrams

PC20

16

PC40

17

PC60

18

19