Sola 200-25-730, 200-26-730-00, 200-25-730-00, 200-26-750, 200-25-750 Instruction Manual

Invensys Energy Systems Pty Ltd

SERIES 200

POWER CONDITIONERS

Instruction Manual

(3 to 22.5kVA)

6M4522 Revision 3

Issue Date: 18/10/02

Made in Australia

Series 200 Power Conditioners

Instruction Manual

INDEX

Page No.

SECTION ONE

1.1 Introduction ....................................................................................................... 1

1.2 General Description .......................................................................................... 1

1.3 Principles of Operation...................................................................................... 1

1.4 Applicable Product Range ................................................................................ 2

SECTION TWO

2.1 Service Location ............................................................................................... 6

2.2 Connections ...................................................................................................... 6

2.3 Selection of Input Circuit Breakers.................................................................... 7

2.4 Power Up .......................................................................................................... 7

SECTION THREE

3.1 Performance ..................................................................................................... 8

3.2 Routine Operation............................................................................................. 9

SECTION FOUR

4.1 Servicing ........................................................................................................... 10

4.2 Repair or Return for Service ............................................................................. 10

4.3 Parts List ........................................................................................................... 11

FIGURES

1. Ferroresonant Power Conditioner (Device Schematic)..................................... 1

2. Core and Core Assembly Diagram ................................................................... 2

3. Typical Schematic Diagrams 3 - 18kVA............................................................ 3

4. Typical Schematic Diagram 22.5kVA................................................................ 4

5. Typical Rating Plate .......................................................................................... 5

TABLES

1. Applicable Product Range................................................................................. 2

2. Input Cable Selection Guide ............................................................................. 8

3. Replaceable Spare Parts .................................................................................. 11

Series 200 Power Conditioners

Instruction Manual

SECTION ONE

1.1. INTRODUCTION

This manual is relevant to the SOLA 200 series of power conditioners. These units require no
complicated commissioning or maintenance procedures and will provide many years of trouble­free operation. This manual provides descriptive information and operation and maintenance
instructions.

1.2 GENERAL DESCRIPTION

These power conditioners comprise one or more ferroresonant core/coil/capacitor assemblies.
All functions are performed by these magnetic elements; no electronic components or circuit
boards are required. The magnetics assembly is housed in a sheet metal enclosure. Most
enclosures are fitted with castors (excluding 22.5kVA model) and jacking pads (excluding 3kVA
model).

1.3 PRINCIPLE OF OPERATION

Each ferroresonant core/coil assembly has 3 separate coils on a special lamination which is
punched at the Invensys plant in Dandenong. Connection for each core/coil/capacitor assembly
is shown in Figure 1. (See also Figure 2.)

Current flowing in the B coil leads the voltage due to the capacitor(s) being effectively across
the load. By properly controlling the reluctance of the various flux paths in the core, this leading
load current is used to cause saturation of only that portion of the core under the B coil. Hence
output voltage is virtually constant over a large input voltage range. The C coil causes the
inverse of any harmonic appearing at the output to be magnetically coupled into the B coil, so
limiting the output distortion (with a linear load) to 3% or less, regardless of the input distortion.

Since primary and secondary (A and B coils) are separated by 25mm of earthed core, (see
Figure 2), isolation and hence common mode noise attenuation is excellent. The Resonant
capacitance/inductance circuit and special core design result in the best available transverse
mode noise attenuation.

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Series 200 Power Conditioners

Instruction Manual

Part Number Power

415 - 240V 400 - 230V 380 - 220V kVA Phase

200-26-730 200-25-730 20-44-730 3 1

200-26-730-00 200-25-730-00 N/A 3 1

200-26-750 200-25-750 200-44-750 5 1

200-26-750-HO 200-25-750-HO N/A 5 1

200-26-775 200-25-775 200-44-775 7.5 1 or 3

200-26-790 200-25-790 200-44-790 9 1 or 3

200-26-812M 200-25-812M 200-44-812M 12 1 or 3

200-26-815 200-25-815 200-44-815 15 1 or 3

200-26-818 200-25-818 200-44-818 18 1 or 3

200-46-822 200-35-822 200-24-822 22.5 3

Table 1. Applicable Product Range

1.4 APPLICABLE PRODUCT RANGE

For power conditioners rated greater than 3kVA, 2 or more core/coil assemblies are connected
in parallel. Where 3 or 6 core/coil assemblies are used, a link system is provided to enable easy
site conversion to 3 Phase Y-Y configuration.

If 3 Phase configurations other than Y-Y are proposed,

you are advised to contact the factory before proceeding.

A typical connection diagram for 1 or 3 Phase (selectable) units is shown in Figure 3. All units
are shipped with an appropriate connection diagram mounted near the terminal panel.

All units are shipped with a 1 Phase configuration, except 22.5kVA with is 3 Phase only as
shown Figure 4.

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Series 200 Power Conditioners

Instruction Manual

Fig 3. Typical Schematic Diagrams 3 - 18kVA

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Series 200 Power Conditioners

Instruction Manual

Fig 4 - Typical Schematic Diagram 22.5kVA

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Series 200 Power Conditioners

Instruction Manual

SERIES 200 POWER CONDITIONER

CATALOGUE NO.

RATING kVA

NO. OF PHASES 1 / 3

NOM. INPUT
VOLTAGE

V / V

MAX. INPUT
CURRENT

A / A

OUTPUT
VOLTAGE

V / V

MAX. OUTPUT
CURRENT

A / A

FREQUENCY 50 Hz

THIS PRODUCT COMPLIES WITH AS3100

FOR SERVICE ON THIS PRODUCT CALL:

1300 303 059

Invensys Energy Systems

Fig 5. Typical Rating Plate for SOLA 200 PC

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Series 200 Power Conditioners

Instruction Manual

SECTION TWO

2.1 SERVICE LOCATION

The power conditioner must be installed in an environment free from conductive dust, water
vapour and corrosive gases. Positioning the unit directly beneath a fire detector, sprinkler or air
conditioning temperature sensor should be avoided.

Sufficient clearance between power conditioner and walls and other objects must be allowed for
unrestricted movement of cooling air, and for installation and service access. The following
clearances should be exceeded where possible.

REAR - 100 mm minimum

Rear access is required for wiring and possible service needs. However with jacking pads up,
the unit can be easily moved so long as the installer allows sufficient cable slack. Additional
space will be required for units with output sockets. Rear mounted input circuit breakers can
normally be operated with 100 mm clearance.

SIDES - 300 mm
FRONT - Provide easy access at all times.
TOP - 700 mm - do not allow material to be stored on top

The surrounding air must dissipate a heat load in kW equal to 10% of the rated kVA of the
power conditioner, without the inlet air (to the power conditioner) exceeding 50

o

C.

e.g. 5kVA Power Conditioner:

Heat Load = 0.1 x 5 = 0.5kW

or Heat Load = 0.1 x 5 x 3413 = 1707 BTU/hour

2.2. CONNECTIONS

Terminals are arranged as in Fig 3 and 4 and are clearly marked.

A connection diagram is displayed inside the unit near the terminals. Select 1 Phase or 3
Phase, where applicable. 22.5kVA units can be configured three phase input/output only.

Since input and output neutrals are isolated by the core/coil assemblies, an MEN link between
earth and output neutral is provided. DO NOT CONNECT INPUT OR SYSTEM NEUTRAL TO
OUTPUT NEUTRAL.

IMPORTANT

Wheel Locks must be engaged before use.

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Series 200 Power Conditioners

Instruction Manual

2.3 SELECTION OF INPUT CIRCUIT BREAKERS

As with all transformer based equipment, ferroresonant transformers are characterised by an
inrush current when switched on. For this reason it is recommended that delayed-trip type
circuit breakers are used when switching power conditioner circuits. In Australia the Heinemann
CF1 and CF3 (for 1 and 3 phase circuits respectively) breakers are appropriate. These are
hydraulic/magnetic type breakers with variable sensitivity. A “Curve 1” type circuit breaker will
provide the correct protection characteristics whilst delaying the trip function during the
transformer in-rush. Select the breaker appropriate to the next current rating above the nominal
rating of the power conditioner.

Table 2 is a guide for cabling between the circuit breaker and power conditioner. The installer
must satisfy himself that the cable size is correct for the installation.

Cross

Sectional Area Current Rating

(sq. mm.) 3 Phase 1 Phase

4 25 25

6 32 32

10 40 50

16 50 63

25 80 80

35 92 105

50 110 125

70 140 155

Table 2. Cable Selection Guide

2.4 POWER UP

When the installation has been approved by the local power authority, the power conditioner
may be energised with load equipment switches in the OFF position. A few seconds after
energisation, load equipment may be switched on. Whilst no special commissioning procedure
is required, the following may prove useful for future reference:

Using a good quality (preferably True-RMS) voltmeter and current tongs, measure and record
all input and output voltages and currents. Also record details of load equipment and running
time of the power conditioner from cold. Output voltage will be 1 or 2% higher than normal until
the unit has operated for 2 hours or more. Check output voltage against nameplate and
performance data - Section 3.1. If output voltage is incorrect, call Invensys Service on 1300 303
059

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Series 200 Power Conditioners

Instruction Manual

SECTION THREE

3.1 PERFORMANCE

A detailed performance specification is available from Invensys Customer Service Centres.
Details given here are those easily measured on site and useful for assessment of proper
operation or otherwise.

Output Voltage

is factory set to the value stated on the rating plate and cannot easily be

changed on site. Setting conditions are:

1. Nominal input voltage and frequency.

2. 85% of Full Load - Resistive.

3. Precision, True-RMS voltmeters used.

4. Operation temperature compensated.

So long as input voltage is within rated range, output voltage will be within +/-3% of nominal
with normal service variations of the other parameters. Even with input considerably outside
rated input range, output is generally maintained within +3%, -8%. This range is maintained for
loads in the approximate range of 20% to 120% of rating. With very light loads, output voltage
may be as high as +5% under some conditions. The above regulation description when applied
to 3 Phase units refers to phase to neutral output voltage and will generally be true for phase to
phase voltages if currents are balanced within 15%. WITH GROSSLY UNBALANCED LOADS,

PHASE TO PHASE VOLTAGES MAY BE UNACCEPTABLE FOR SOME LOAD EQUIPMENT
DUE TO UNBALANCED PHASE SHIFTS. HOWEVER PHASE TO NEUTRAL VOLTAGES
ARE UNAFFECTED BY LOAD UNBALANCE. THE POWER CONDITIONER DOES NOT
REGULATE PHASE TO PHASE VOLTAGE.

Rated Input Range of 200-26-XXX series is 190V to 260V Phase to Neutral (-21%, +8% for
240V). For the 200-25-XXX series, the range is 190V to 260V Phase to Neutral (-17%, +13%
for 230V). For the 200-44-XXX series, the range is 180V to 240V Phase to Neutral (-18%, +9%
for 220V). The range for the 200-46-822 unit, which CAN ONLY be configured for a three phase
input, is 329V to 450V phase to phase, i.e. -21%, +8% for 415/240V and for the 200-35-822 is ­17%, +13% for 400/230V. For the 200-24-XXX the range is -18%, +9% for 380/220V. Useable
output voltage is available for limited periods on all units for input deviations as high as +/-40%.

Operating Temperature

- during normal operation, the internal core(s) and windings of the

power conditioner will operate at around 120

o

C. This is normal, and well within the allowable
temperature rating of the insulation system. Operating temperature of the core/coil
assembly(ies) when energised, but not loaded, is only slightly less than when fully loaded.

Overload Protection

- these power conditioners have inbuilt protection against overloads or
short circuits on the output. Under normal service conditions, the power conditioner will supply
up to 200% of full load for 10 seconds or more without damage or excessive voltage drop. This
allows for startup requirements of some computer equipment (up to 500% is possible for very
short duration for flash inrush, e.g. capacitor charging currents). If more severe overloads are
applied the power conditioner will virtually shut down, preventing damage. Even under direct
short circuit, load current is restricted to around 200% of rated full load, which will not damage
the unit even if it is in this condition indefinitely.

When the overload is removed the unit will continue to operate in a normal fashion.

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Series 200 Power Conditioners

Instruction Manual

3.2 ROUTINE OPERATION

No complicated procedures are required - the following simple steps will optimise performance:

POWER 1. All load equipment switches in OFF position
UP: 2. Power conditioner input circuit breaker to ON position.

3. Switch ON load equipment in correct sequence - if possible do not power
up more than one item of equipment simultaneously.

POWER 1. Power down load equipment in proper sequence.
DOWN: 2. Switch input circuit breaker to OFF position.

NOTE - The steps above should be followed because:

1. Output voltage of the power conditioner is allowed to stabilise before being applied to load
equipment.

2. Possible problems due to overload should be avoided.

3. The power conditioner is switched off when not required. Because the resonant circuit is
energised whenever the power conditioner is energised (whether loaded or not) the
standing, or no-load losses are significant. Additionally, since MTBF refers to operational
hours (whether loaded or not), the already excellent total life expectancy will be increased.

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Series 200 Power Conditioners

Instruction Manual

SECTION FOUR

4.1 SERVICING

Since SOLA 200 Power Conditioners are simple, rugged devices without moving parts or
printed circuit boards no adjustments, servicing or maintenance is required in the normal sense.
If poor performance is suspected, the following should be carried out by a competent electrician
or technician:

Measure and record voltages and currents as described in Section 2.3 of this manual. Compare
with records of earlier tests if available.

If output voltage is high, probable causes are - very light load, very high input voltage or supply
frequency, or a combination of these. Excessive output voltage under rated conditions is most
unlikely. Re-test under rated conditions if possible.

If output voltage is low, probable causes are - overload, very low input voltage or frequency, or
a combination. Re-test under rated conditions if possible.

4.2 REPAIR OR RETURN FOR SERVICE

If the power conditioner performance is unsatisfactory and outside of specification, contact the
Service Centre (details listed on the back page of this Manual) and advise all the results of tests
and observations. Servicing arrangements can then be made. If a power conditioner is to be
returned to Invensys for any reason, please obtain a Return Authorisation Number first, and
after ensuring appropriate packaging, mark the “RA” number on it so that it is clearly visible.
Packages without this “RA” number may not be accepted by our Inwards Goods Department.

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Series 200 Power Conditioners

Instruction Manual

4.3 PARTS LIST

The following replaceable parts are available (if your model is not listed below, contact Invensys):

Power SOLA PART NUMBERS

Conditioner QUANTITY OF CORE/COIL/CAP

SETS PER UNIT

INDICATOR CIRCUIT

BREAKER

OUTPUT

SOCKETS

MAINS

LEAD
Part Number (for
240V/240V)

6C3635

(2.0kVA)

6C3640

(2.5kVA)

6C3645

(3.0kVA)

6E1208 6E2524 6E2028 &

6E0842

6E1612

200-26-730 - - 1 1 1 - -

200-26-730-00 - - 1 1 1 4 1

200-26-750 - 2 - 1 1 - -

200-26-750-HO - 2 - 1 1 4 1

6E2575

200-26-775 - 3 - 1 1 - -

200-26-790 - - 3 1 1 - -

200-26-812M 6 - - 1 1 - -

200-26-815 - 6 - 1 1 - -

200-26-818 - - 6 1 1 - -

200-46-822 - 9 - 1 1 - -

Power SOLA PART NUMBERS

Conditioner QUANTITY OF CORE/COIL/CAP

SETS PER UNIT

INDICATOR CIRCUIT

BREAKER

OUTPUT

SOCKETS

MAINS

LEAD
Part Number (for
230V/230V)

6C3634

(2.0kVA)

6C3639

(2.5kVA)

6C3644

(3.0kVA)

6E1208 6E2524 6E2028 &

6E0842

6E1612

200-25-730 - - 1 1 1 - -

200-25-730-00 - - 1 1 1 4 1

200-25-750 - 2 - 1 1 - -

200-25-750-HO - 2 - 1 1 4 1

6E2575

200-25-775 - 3 - 1 1 - -

200-25-790 - - 3 1 1 - -

200-25-812M 6 - - 1 1 - -

200-25-815 - 6 - 1 1 - -

200-25-818 - - 6 1 1 - -

200-35-822 - 9 - 1 1 - -

Power SOLA PART NUMBERS

Conditioner QUANTITY OF CORE/COIL/CAP

SETS PER UNIT

INDICATOR CIRCUIT

BREAKER

OUTPUT

SOCKETS

MAINS

LEAD
Part Number (for
220V/220V)

6C3711

(2.0kVA)

6C3715

(2.5kVA)

6C3720

(3.0kVA)

6E1208 6E2524 6E2028 &

6E0842

6E1612

200-44-730 - - 1 1 1 - -

200-44-750 - 2 - 1 1 - -

200-44-760 - - 2 1 1 - -

6E2575

200-44-775 - 3 - 1 1 - -

200-44-790 - - 3 1 1 - -

200-44-812M 6 - - 1 1 - -

200-44-815 - 6 - 1 1 - -

200-44-818 - - 6 1 1 - -

200-24-822 - 9 - 1 1 - -

Table 3. Replaceable Spare Parts

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Series 200 Power Conditioners

Instruction Manual

Invensys Energy Systems Pty Ltd

ABN 82 054 056 709

This Warranty is subject to Invensys Energy Systems Pty Ltd (IES) standard Conditions of Sale which govern all
sales of products by Invensys Energy Systems Pty Ltd.

1. IES products, in general, are warranted against failure due to faulty materials and/or workmanship for a

period of two years from despatch date (ex IES store) as per invoice. The Ferroresonant and 95 Series
Power Conditioners and Dry Type Transformers have an extended warranty - 5 years from date of
despatch.

2. If, within the applicable Warranty period, any IES product does not meet the warranty specified above,

and the product was installed and operated in accordance with Australian standards and IES standard
installation procedures, IES shall thereupon correct any defects due to faulty materials and/or
workmanship.

3. Any modification made to the product other than those made by IES or its authorised representative may

cause the Warranty to be void.

4. For units up to 3kVA that are installed as a portable device, the Warranty covers repair or replacement of

defective parts at the factory, or other service locations as nominated by IES, provided the unit has been
returned by the user packed adequately to prevent shipping damage, and approval has been obtained from
IES before shipment. All costs associated with the return of the product to IES are at the customer's
expense.

For hardwired products 3kVA and above, the Warranty covers on site repair (Metropolitan area, Capital
Cities only), during normal working hours, by IES technicians or appointed agents. For units installed in
remote locations, IES may, at its discretion, request the equipment to be recovered and returned to the
factory or other nominated service locations. In this case, it is the customer's responsibility to pack the
equipment adequately to prevent shipping damages and pay freight charges to the location nominated by
IES. Approval to return goods must be obtained from IES before the goods are despatched.

5. Units returned for in-warranty repairs, which are found not to be defective, will be subject to an

inspection and handling charge, plus transportation charges.

6. High grade batteries, designed for Uninterruptible Power Supply (UPS) applications, are supplied by IES

for use with IES UPS equipment. These batteries have a finite life expectancy depending on a number of
variables, including rate of discharge, depth of discharge, operating temperature, etc.

7. Providing that the batteries are used within the limits as set out in the battery manufacturer’s warranty

statement and are provided as an integral part of new equipment, they are guaranteed for two years, from
despatch date as per invoice. A copy of this warranty statement is available on request. Batteries provided
as spare parts or replacements have a one year warranty. Other optional warranty terms for batteries are
available on request.

8. IES reserves the right to charge for replacement batteries if within the one year guarantee period

replacement batteries are necessary as a result of misuse or misapplication by the purchaser or end user.

REF: WARRANTY.DOC Rev 7 Effective Date: March 13, 2001

Series 200 Power Conditioners

Instruction Manual

REPAIR

If poor performance is confirmed (refer SERVICING information on Page 10 of this Manual) you
should contact Invensys National Service operation. If the unit is to be returned to Invensys for
any reason, please obtain a “Return Authorisation” (RA) number first, and mark it clearly on the
packaging.

Delivery of packages not marked with an “RA” number may not be accepted by our Inwards
Goods Department.

Invensys Energy Systems NATIONAL SERVICE

Phone [phone]

Prepaid Fastfix and SOLACARE Service Contracts are available for this product.

When ordering replacement parts, always specify:

1. Part Number and Rating.

2. Serial Number of the unit.

3. Part Number, Description and Quantity required.

4. Original Date of Purchase of the Power Conditioner.

5. Any Special Shipping Instructions.

Parts, orders and all correspondence regarding repairs under the warranty should be
addressed to Invensys Service Department in Melbourne.

Invensys Energy Systems Pty Ltd

ABN 82 054 056 709

13 Healey Road, Dandenong, Victoria 3175

Phone:[phone] Fax: [phone]

6M4522 Revision 3 18/10/02