Emerson CVS Hardwired Constant Voltage Service Manual

Constant Voltage Sinusoidal Transformers
Operating and Service Manual
Introduction
This operating and service manual has been prepared to ensure that your Sola/Hevi-Duty Constant Voltage Transformer can be operated and serviced with minimal effort and involvement. This manual covers Sola/Hevi-Duty Constant Voltage Sinusoidal (CVS) Transformers.
Installation - Mechanical Position
All stock sizes with end housings are intended to be mounted with the silk-screened this side up legend facing upwards. This will place the ventilated capacitor compartment downward, thus providing cooler operation of the capacitor(s). However, all units will give satisfactory performance if mounted in a horizontal position. In either case, the unit should be mounted in an area where it is unlikely that anyone will come into contact with the core surface of the unit.
Mounting Considerations
If a unit is to be wall mounted, the mounting hardware should be sized as in Table 1 below. All mounting holes provided must be used
Table 1: Mounting Screw/Bolt Sizing
Rated VA of Regulator Min. Diameter of Steel Mounting Screw
30-120 #10 Machine Screws
250 1/4” bolts
500 to 1000 5/16” bolts
1500 to 10000 3/8” bolts
15000 1/2” bolts
.
Table 2: CVS Weights and Physical Dimensions, 60 Hz Single Phase
(in)
D
Dimensions
E
(in)
(in)
F
(in)
G
(in)
H
VA
30 23-13-030-2 A 6.12 5.19 3.47 4.00 3.50 3.00 1.75 .22 x .59 7
60 23-13-060-2 A 6.94 5.19 3.47 4.00 3.50 3.00 1.75 .22 x .59 9
120 23-22-112-2 A 8.12 5.19 3.47 4.00 3.50 3.00 2.44 .22 x .59 13
250 23-23-125-8 A 10.50 7.56 4.75 5.63 4.75 4.12 3.03 .39 x .69 28
500 23-23-150-8 A 13.00 6.50 8.12 9.00 8.12 5.62 3.06 .38 x .81 37
1000 23-23-210-8 A 17.25 6.81 8.12 9.00 8.12 5.62 5.25 .38 x .81 63
2000 23-23-220-8 B 17.58 9.44 10.56 12.75 11.75 3.88 5.19 .44 x .69 109
3000 23-23-230-8 B 18.96 9.44 10.56 12.75 11.75 5.25 5.19 .44 x .69 142
5000 23-23-250-8 B 28.53 9.44 10.56 12.75 11.75 8.25 8.88 .44 x .69 222
7500 23-28-275-6 C 26.91 9.27 23.55 25.81 24.81 6.62 8.88 .44 x .69 365
Catalog
Number
Outline
Drawing
(in)
A
(in)
B
(in)
C
Figure 1: Mounting Holes and Dimensions
Approx.
Shipping
Weight (lbs)
All ratings depend on natural draft air circulation for cooling. They should not be mounted in conned or enclosed spaces unless special provisions have been made for ventilation. Technical Services is available for assistance in doubtful situations (see note on Operating Temperature). Table 2 and Figure 1 show model number with their weight and physical dimensions
.
Installation – Electrical
On 60VA or smaller units, screw-type lugs in the outlet box are marked “input” and “output”, and no connection diagram is necessary. Units rated 120 to 15000 VA are provided with multiple inputs for any one, two, three, or four different line voltages, and some have provision for three-wire output. With all units, a connection diagram is attached to the inside lid of the box cover, or inserted in the outlet box. Figure 2 shows typical connections for –8 models, and Figure 3 shows multiple input connections for all other models. Figure 4 shows the output connections for all models.
Figure 2: Electrical Connections for -8 models
All Except 250 VA250 VA only
Figure 3: Electrical Connections for Non-8 models
Note: Secondaries are not grounded. Ground X2 per Code.
Outline A Outline B Outline C
Input & Output Connections – All except 250 VA
Volts Input Jumper Volts Output
95-130 H1-H2
175-235 H1-H4
190-260 H1-H5
380-520 H1-H10 (H2 + H3) (H5 + H6) (H7 + H8)
*Note: The entire load up to the rated capacity of the unit can be drawn from either half of
the 240 volt winding. It is not necessary to divide or balance the load.
(H1 + H3 + H6 + H8) (H2 + H5 +
H7 + H10)
(H2 + H3) (H7 + H8) (H1 + H6)
(H4 + H9)
(H2 + H3) (H7 + H8) (H1 + H6)
(H5 + H10)
X1 – X2 or
120
240 X1 – X3
X2 – X3
Input Connections - 250 VA Only
Volts Input Jumper Volts Output
95-130 H1-H2
190-260 H1-H4
380-520 H1-H8
Primary Voltage
30 & 60 VA 120 VA 7500 VA
120 N/A N/A
N/A 120 240
N/A 240 480 H2 to H3 H1 & H4
Secondary Voltage
30 & 60 VA 120 VA 7500 VA
120 120 N/A X1 & X2
N/A N/A 120
N/A N/A 240 X1 & X3
(H1 + H3 + H5 + H7) (H2 + H4 + H6 + H8)
(H2 + H3) (H6 + H7) (H1 + H5) (H4 + H8)
(H2 + H3) (H4 + H5)
(H6 + H7)
Interconnect
Note: H3 & H4
are not used
Interconnect
H1 to H3 H2 to H4
120 X1 – X2
Connect
Lines To
H1 & H2
H1 & H4
Connect
Lines To
X1 & X2 or
H3 & X2
Table 3: Recommended Wire Sizes and Fusing
CVS Input Output
VA Rating
30
60 2
120
250
500
1000
2000
3000
5000
7500
* Leads in the wiring department must be sleeved with 105oC sleeving.
Rated
Volts
95-130
95-130
190-260
95-130 6
380-520 1
95-130 10
175-235 6
190-260 6
380-520 3
95-130 15
175-235 10
190-260 10
380-520 6
95-130 30 10
175-235 20 12
190-260 15 14
380-520 10 14
95-130 45 8
175-235 25 10
190-260 25 10
380-520 15 14
95-130 80 4
175-235 40 8
190-260 40 8
380-520 20 12
190-260 60 6
380-520 30 10 8
Req. Circuit
Protection (In Amps,)
1
3 14 120 14
Min. Gauge
90°C Wire
14 120 14
14 120 14190-260 3
14
14
Rated
Volts
120 208 240
120 208 240
120 208 240
120 208 240
120 208 240
120 208 240
321
Min. Gauge
90°C Wire
14
14
10 14 14
8 12 12
8* 10 10
4
654
Three-Phase Power Wiring
If operation from a three-phase source is required, three hardwired regulators may be wired in delta as shown in Figure 4.
Other Considerations
It is desirable to have a switch in the input circuitry for turning off power to the unit when it is not in use. While all CVS transformers are designed for continuous duty, they draw appreciable current regardless of output loading.
The outputs of all Sola/Hevi-Duty standard CVS transformers are isolated from the input lines. Voltage generated by internal leakage currents will occur with respect to ground. This can have undesirable effects in many pieces of electronic equipment. Therefore, if Figure 4 circuit “B” is used, it is suggested that the installer remove X2 grounding on –8 units, then connect all X2 from each phase to one location and ground at that location only. This is not required for circuit “A”. This will not affect regulation or the ability to reject power line noise or transients.
Any three stock units having a tap for 190-260 input connections may be connected in delta to a 240-volt, three-phase power supply. Those units equipped with primary tap for 175-235 volts may also be connected in delta to a 208-volt supply. (Terminals to be used are identied on the connection diagram located on the inside face of the outlet box cover.)
All stock production, harmonic-free units now have uniform terminal polarity. This eliminates the need for “phasing out” either input or output connections.
Output must serve three, independent, single-phase loads of the same total volt-ampere rating. Connections should be made in one of two ways shown in Figure 4.
Use With Switchmode Power Supplies
If a CVS transformer is used as a source for a switchmode power supply, a slight amount of ringing may be noticed on the sinewave output of the CVS at half cycle intervals for a short duration. This ringing occurs at the point when the switchmode power supply current demand drops to zero. The ringing should not be a cause for concern since it is of relatively low magnitude and frequency. The CVS has been tested with a variety of switchmode power supplies and it has been determined that the ringing never affects the D outputs, nor has it been found to degrade the components of any switchmode power supply.
Figure 4. Three Phase Connections
A: Isolated, Single Phase Loads
Multiple Operation
Two CVS transformers with the same rating may be connected with their inputs and outputs in parallel. The regulating action will usually be excellent although the standard ±1% cannot be guaranteed. Series connection of either input or output is not recommended.
Use With Rectifier Loads
The ratio of crest to rms values is approximately 1.3 at rated load, and slightly lower at fractional loads. This factor must be considered when all or a portion of the voltage is rectified. The rectified voltage will now be 10 – 15% lower than if connected directly to a sinewave source.
Operation With Motor Loads
Because of the current limiting effect described later, special attention should be given to motor applications. In general, the CVS must have a load rating nearly equal to the maximum power drawn during the starting cycle. This may run from two to eight times the normal running rating of the motor. In doubtful cases, it is advisable to measure the actual starting current.
Cascade Operation
For applications requiring close regulation, two CVS transformers may be operated in “cascade”. The output of the combination will show little or no detectable change arising from supply line variations of up to ±15%. However, the combined units will still be frequency sensitive (as discussed under Effect of Frequency, page 15). Since even good power systems may vary in frequency by 0.1% or more, the output of a Sola/Hevi-Duty cascade combination may vary by up to 0.25% from this cause alone. In actual practice, then, a cascade combination is highly recommended for special applications requiring regulation in the general region of ±0.25%. If the tandem setup is to be operated at near full rating, then the Type CVS “driver” unit should be one standard size larger than the driven unit, in order to overcome the losses in the latter.
B: Separate, Single Phase Loads in Grounded Wye
7 98
Constant Voltage Sinusoidal Transformers
Operating and Service Manual
Physical Characteristics of Operation
Operating Temperature
Standard units are designed to operate in ambient temperatures of minus 20°C to plus 50°C. In operation, a temperature rise will occur whether or not the transformer is serving load. Normally, this rise may fall anywhere in the range of 45°C to 110°C, depending on the type and rating. In any case, the maximum operating temperature at an ambient of 50°C is always within safe operating limits for the class of insulating material used. (Special units can be designed for lower heat rise or wider ambient temperature range.)
External Magnetic Fields
In almost all applications, this effect may be disregarded. On critical applications, care should be exercised in the orientation of the core with respect to critical circuits, in order to minimize the effect of the eld.
In certain rare cases in which the transformer is connected to, or mounted near, high gain audio frequency circuits, special attention may need to be given to adequate physical spacing and/or orientation of the CVS transformer to avoid interaction with the audio circuits. Sola/Hevi-Duty’s Technical Service Department (800-377-4384) may be able to offer suggestions for such problems.
Electrical Characteristics of Operation
Checking With Voltmeters
All checks on output voltages should be made with a true RMS voltmeter such as a Fluke model 8020 A. Rectifier-type voltmeters will not give accurate readings due to the small amount of harmonics present in CVS output.
Load Regulation
Changes in output voltage resulting from changes in resistive loads are usually small - running one percent or less in the larger units. Table 4 shows average values for output voltages.
Table 4: Output Voltage Changes – 20% Load to Full Load (100% Power Factor – Nominal Input Voltage)
Transformer VA %Change - Output Voltage
31-120 approximately 3%
121-150 approximately 2%
151-over approximately 1%
Phase Shift
The phase difference that exists between input voltage and output voltage is in the range of about 120° to 140° at full load. This phase difference varies with the magnitude of the load and, to a lesser extent, with changes in line voltage.
Output Wave Shape
The CVS transformers all include harmonic-neutralizing circuitry. These units typically have less than 3% total harmonic distortion at full load and less than
4.5% at no load.
Response Time
An important advantage of the Sola/Hevi-Duty principle of static magnetic regulation is its exceedingly fast response time compared with other types of AC regulators. Transient changes in supply voltage are usually corrected with a Sola/Hevi-Duty CVS with 1 1/2 cycles or less, the output voltage will not fluctuate more than a few percent during this interval.
Isolation
Since the input and output are separated not only electrically, but also physically, by a magnetic shunt, the Sola/Hevi-Duty CVS has a stronger isolating effect than a conventional transformer. This may often eliminate the need for static shields.
Factors Affecting Operation
Input Characteristics
As the Sola/Hevi-Duty CVS transformer includes a resonant circuit that is fully energized whether or not a load is present, the input current at no load or light loads may run 50% or more of the full-load primary current. As a result, the temperature of the unit may rise to near full-load levels, even at light or nonexistent loads. Input power factor will average 90-100% at full load, but may drop to approximately 75% at half load and 25% at no load. In any case, it is always leading.
Effect of Load Power Factor
The median value of output voltage will vary from the nameplate rating of the load if a power factor other than that for which the unit was designed is used. Load regulation will also be relatively greater as the inductive load power factor is decreased (see Figure 5). However, the resulting median values of the output voltage will be regulated against supply line changes at any reasonable load or power factor.
Figure 5: Median Output Voltage vs. Load Power Factor
Effect of Frequency
Changes in the frequency of the supply voltage will be directly reflected in the output voltage. A change of approximately 1.8% in the output voltage will occur for every 1% change in input frequency in the same direction as the frequency change.
Effect of Temperature
The output voltage will show a small change as the unit warms up to stable operating temperatures at a constant ambient temperature. This change may be about 1 or 2% depending on the unit’s VA rating. At a stable operating temperature, the output voltage will change slightly with varying ambient temperature. This shift is approximately 1% for each 40°C of temperature change.
Current Limitation
When the load is increased beyond the transformer’s rated value, a point is reached where the output voltage suddenly collapses and will not regain its normal value until the load is at least partially released. Under a direct short circuit, the load current is limited to approximately 150-200% of the rated full load value and the input wattage to less than 10% of normal. A CVS will protect both itself and its load against damage from excessive fault currents. Fusing of load circuits is not necessary.
Manufacturing Tolerance
The nominal output voltage of each stock Constant Voltage Transformer is adjusted at the factory to within plus 2%, minus 0% of rated (nameplate) value with rated, nominal voltage at rated frequency applied to the input, and with full rated load at 100% power factor applied to the output. This adjustment is made with the unit at substantially the same temperature as room ambient temperature (25°C).
Servicing
Routine Maintenance
As the Sola/Hevi-Duty CV Transformer is a simple rugged device without moving parts or manual adjustments, no servicing or maintenance is needed in the ordinary sense. The percentage of possible poor performance or failure is exceedingly low. In any case of apparent poor performance, the user is urged to check the following points immediately:
Checklist on Factors Affecting Performance
A. Nominal Voltage Too High
1. The load may be considerable less than full rating. (See “Load Regulation”).
2. The load may have a leading power factor.
B. Nominal Voltage Too Low
1. Load power factor may be lagging. (See Load Regulation).
2. Unit may be slightly overloaded. (See Current Limitation).
C. Does Not Regulate Closely
1. Unit may be slightly overloaded. (See Current Limitation).
2. Actual line voltage swings may be outside the rated coverage of unit, particularly on the low side.
3. On varying loads, a certain amount of load regulation may be mixed with the line voltage regulating action. (See Load Regulation).
D. Output Voltage Very Low (20-60V)
1. Unsuspected or unplanned overloads of substantial size may occur intermittently (motor-starting currents, solenoid inrush currents, etc.). (See Current Limitation).
2. One or more capacitor units in the CVS transformer may be defective. (See Field Replacement of Capacitors)
Change in “Median” Output Voltage vs. Load Power Factor at various loads
121110
Checklist on Factors Affecting Performance - continued
E. No Output Voltage At All
1. Check power source breakers or fuses.
2. Check continuity between input terminals, and also between output terminals.
G. Transformer Operating Temperature
1. These transformers are designed to operate at high ux density, and hence, relatively high temperatures (see Operating Temperature). After connection to line for a half hour or so, the exposed core structure may be too hot to touch with bare hand, but this is normal and need give no concern. However, if there is any indication of oil or compound leakage, unit should be returned to factory (see below).
Note
In case the transformer is operating but does not appear to have the correct output, it is very helpful to apply the following test:
1. Disconnect the working load.
2. Connect a dummy load of lamps, heaters, or other resistive load substantially equal to the full load rating of transformers, directly across its output terminals.
3. Measure the output voltage of the CVS using a true RMS type voltmeter directly across its output terminals.
This test will usually establish whether the apparent poor performance is due to a fault in the CVS transformer or to some peculiarity of the working load. Sola/Hevi-Duty’s Technical Service Department will then be in far better position to give helpful service advice or suggest factory test or service as indicated.
Factory Test and Inspection
If the eld test suggested earlier indicated that the CVS transformer itself may be faulty, a full report of the difficulty should be communicated to the place of purchase, with a request for permission for return. The Authorized Sola/Hevi­Duty Distributor may then suggest further helpful eld tests, or authorize return for inspection at once. A Return Authorization Number will be issued. This number must appear on the outside of the shipping container. Otherwise the shipment will not be accepted.
Field Replacement of Capacitors
Capacitors used in all CVS transformers are of the highest commercial grade available. Nevertheless, there is a certain small percentage of failure. Sola/Hevi-Duty’s guarantee includes free replacement at the factory of any capacitor unit that fails within one year from date of purchase. Older units can be replaced at moderate charge.
It may be possible to test and identify defective capacitors in the field, and to make field replacement with new units shipped from the factory. In all such
cases, factory advice and cooperation should be requested in advance.
Warranties
Sola/Hevi-Duty warrants its standard catalog products to be free from defects in materials and workmanship and agrees to correct by repair or replacement, at the option of Sola/Hevi-Duty, products that may fail in service provided the product has been installed, operated and maintained in accordance with accepted industry practice.
Warranty begins at the date of manufacture and is according to the following schedule:
1. Standard catalog transformer and single phase power conditioning products – 10 years plus an additional 2 years if online registration (www.solahd.com) is completed within 14 days after installation.
2. Products manufactured to a purchaser’s specifications – 1 year.
151413
Return Policy
Most instances of initial failure to operate properly can be remedied through a telephone conversation between the user and Technical Service. If it is determined that a product must be returned, contact your local Sola/Hevi-Duty distributor for a Return Authorization. If the distributor is unknown, contact Customer Service by e-mail at ReturnGoods.AppletonGroup@emerson.com or by phone at (877) 999-7652 for instructions.
All returns to the Sola/Hevi-Duty factory must have a Return Authorization (R.A.#). The following information required for a Return Authorization (R.A.#):
1. Sola catalog number and/or model number.
2. Serial number.
3. Company name, address, phone number and contact person.
4. Proof of purchase from Distributor.
5. Description of problem.
For proper handling upon receipt at Sola/Hevi-Duty, the R.A.# must be clearly placed in several locations on the outside of the package. Sola/ Hevi-Duty is not responsible for damage on returned goods not packaged properly or customer-abused units.
Sola/Hevi-Duty
(800) 377-4384
www.solahd.com
16 17
P/N 299-35206-01
Rev. 05 (Nov 2014)
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