Emerson CVS Hardwired Constant Voltage Transformers Operating and Service Manual
Contents
1. Figure 1 Mounting Holes and Dimensions Outline A Input amp Output Connections All except 250 VA eee eee H1 H3 H6 H8 H2 H5 X1 X2 or 95 130 H1 H2 ET va H2 H3 H7 H8 H1 H6 175 235 H1 H4 H4 H9 H2 H3 H7 H8 H1 H6 190 260 H1 H5 A 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 Itis not necessary to divide or balance the load X1 X3 Input Connections 250 VA Only GORMO pew we aeg e e Lines To 30 amp 60 VA 120 VA 7500 VA are niet used H1 to H3 Connect H2 to H2t0H3 O H1 HTB HS Secondary Voltage Canna 30 amp 60 VA 120 VA 7500 VA Lines To lt x18 x2 X1 amp X2 or E S 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 Thr2. 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 field 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 Effect of Frequency Changes in the frequency of the supply voltage will be directly reflected
3. 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 ire nii compartment downward thus providing cooler y neses operation of the capacitor s However all units will id e 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 vette ses sagte sesietes 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 All ratings depend on natural draft air circulation for cooling They should not be mounted in confined or enclosed spaces unless special provisions have been made for ventilation Technical Services is available for assistance in doubtful situations see note on Op
4. e 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 aD 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 subs
5. ee Phase Connections OA OB OC oq D p A Isolated Single Phase Loads A B OC Regulator Regulator Regulator lood Le Load i Load o B Separate Single Phase Loads in Grounded Wye Outline B Outline C Table 3 Recommended Wire Sizes and Fusing Req Circuit VA Rating Paea Protection Volts In Amps 95 130 14 120 14 E E 130 190 260 260 95 130 250 190 260 14 120 14 500 208 Min Gauge 90 C Wire Min Gauge 90 C Wire 1000 2000 208 3000 5000 208 10 7500 208 Leads in the wiring department must be sleeved with 105 C sleeving 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 durin
6. erating 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 Ground O 250 VA only All Except 250 VA Figure 3 Electrical Connections for Non 8 models Lower Input Voltage Higher Input Voltage Three Wire Output Single Output Note Secondaries are not grounded Ground X2 per Code 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
7. g 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 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
8. 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 subs
9. inals G Transformer Operating Temperature 1 These transformers are designed to operate at high flux 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 EMERSON Industrial Automation Sola Hevi Duty 800 377 4384 www solahd com P N 299 35206 01 Rev 05 Nov 2014
10. 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 itis 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 0 fo SANnnnNNEN WED CPR REET T eC e 4 a PINE Tt Treed Pt NET TT i P 50 FULL LOAD PET Nt et tt jE PANE EE a_t_ tT tT IONS LE LT too rut von EHRRTATNTARMA 1 100 95 90 85 80 75 70 65 60 55 50 45 40 LOAD POWER FACTOR LAGGING PERCENT i on OUTPUT VOLTAGE DEVIATION FROM NOMINAL N Change in Median Output Voltage vs Load Power Factor at various loads 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 term
11. s 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 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 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 mor
12. 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 identified 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 Table 2 CVS Weights and Physical Dimensions 60 Hz Single Phase Outline Drawing Catalog Number Approx Shipping Weight Ibs 10 50 es ee ona a 39x 69 lt 17 25 1000 23 23 210 8 foa oe Fee oa a8 10 56
13. tantial 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 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 Sola catalog number and or model number Serial number Company name address phone number and contact person Proof of purchase from Distributor Description of problem a ah 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 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
14. tantially the same temperature as room ambient temperature 25 C E Factory Test and Inspection If the field 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 Hevi Duty Distributor may then suggest further helpful field 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 ha
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