NAPCES Online Rotary Installation Manual

NAPCES Online Rotary Installation Manual
North America
Phase Converters
&
Electrical Supply
OPERATION AND
INSTALLATION
MANUAL
ROTARY
PHASE CONVERTERS
(Models PL, UL & CP)
240 VOLTS
WARNING: To reduce the risk of injury, the user must read and understand the operator’s manual before using
this product.
Table of Contents
Section 1: Introduction and Installation Notes
Section 2: Installation
2.1 Typical Line Diagram
2.2 Branch Circuit (Circuit Breaker & Fuse) and Wire Sizing
2.3 Control Panel Connection
2.4 Idler Generator Connection
2.5 Switch Assembly
Section 3: Checking the Converter
3.1 Checking single phase power
Section 4: Operation & Maintenance
4.1 Operation
4.2 Maintenance
Section 5: Trouble Shooting
Section 6: Warranty
Section 1: Introduction and Installation Notes
HIGH VOLTAGE – Risk of Electrical Shock. This equipment is connected to line voltage that can
create a potentially hazardous situation.
Your rotary phase converter has been engineered and manufactured to our standards for dependability,
ease of operation, and operator safety. When properly cared for, it will give you years of rugged, troublefree performance.
•
Installation of this equipment must comply with all national, state and local electrical codes.
•
Installation must be performed by qualified personnel and should have experience working with
this line voltage.
•
Always make certain power is off before servicing this equipment.
•
The input wire gauge must be sized to furnish the single-phase input current (amperage); this
wire is larger than the three phase output current to the load.
•
Make sure the input voltage is 208-240 before connecting.
•
Do not connect control circuits to T3.
•
Do not connect a ground or neutral to T3.
•
All loads (including transformers) must be turned off before starting phase converter.
•
Do not bolt idler generator down solid. This can cause diminished generator life.
•
Make sure phase converter control panel, generator and equipment are properly grounded.
•
Wire recommendations are minimums. Voltage drop is dependent on wire length and gauge.
Increase wire one (1) additional size for every fifty (50) feet of wire run.
•
Wire recommendation is based on the use of copper wire. If using aluminum wire, use the
copper equivalent for current amount.
•
Single phase loads must always be energized by lines T1 and T2.
SAVE THIS MANUAL FOR FUTURE REFERENCE
Section 2: Installation
2.1 Typical Line Diagram
Single Phase
Single Phase
Power
Disconnect
*See Chart 2.2 for
Switch
Fuse and Circuit
Or
*See Chart 2.2 for
Breaker
Load Center
Ranges/Sizes
(Columns A & B)
Minimum Single
Phase Wire Sizes
(Column C)
Rotary
Phase
Converter
Control
Panel
*See Chart 2.2 for
Minimum Three Phase
Output Wire Sizes
(Column D)
Three Phase
Disconnect
Switch
Three Phase
Or
Loads
Load Center
(If Required)
1.
2.
3.
4.
5.
6.
Installation must comply with all National, State and Local Electrical Codes.
Installation must be performed by a licensed electrician.
Rotary phase converter must start first before loads are started.
T3 is the generated leg, do not use for single phase loads or control circuits.
Do not bolt generator down solid.
Rotary phase converter should reach full speed within 2 to 3 seconds.
2.2 Branch Circuit and Wire Sizing
Column
Horse
A
Minimum
B
Maximum
Circuit Breaker Circuit Breaker
C
Minimum
D
Minimum
Single Phase
Three Phase
Power
& Fuse Size
& Fuse Size
Wire Sizes
Wire Sizes
3
10 amps
20 amps
12
12
5
15 amps
30 amps
10
12
7.5
15 amps
40 amps
8
10
10
20 amps
50 amps
6
10
15
20 amps
80 amps
4
8
20
30 amps
100 amps
2
6
25
40 amps
125 amps
1/0
4
30
50 amps
150 amps
2/0
2
40
60 amps
200 amps
4/0
1
50
75 amps
250 amps
300 MCM
2/0
60
100 amps
300 amps
400 MCM
3/0
Branch Circuit (Circuit breaker and Fuse) Sizing: Your NAPCES rotary phase converter has a
minimum and maximum circuit range/size. Your circuit protection can be sized at the minimum, maximum
or anywhere between the two amounts.
To determine your single phase branch circuit required to feed your converter and load:
• Add your total 3 phase loads together and multiply by 1.73. This is the amount of single phase
current you will draw at full load. This is the minimum single phase service needed to run your
phase converter and loads. However, the National Electric Code (N.E.C.) Article 455
recommends multiplying your total phase loads by 2.5.
Examples:
Total 3 phase load(s) amperage X 1.73 = Single Phase Current Draw
Total 3 phase load(s) amperage X 2.5 = Minimum Circuit Protection Size
Wire / Conductor Sizing: Wire sizing is extremely important in order that proper voltage may be
maintained during motor start-up. The N.E.C. Article 455.6 governs the wire size of phase converters.
Article 455.6 states that the input wire size shall not be less than 125% of the phase converter nameplate
input full-load amperes (for variable loads) and/or not less than 250% of the sum of the full-load 3-phase
current rating (for variable and fixed loads).
Minimum wire size recommendations are listed in the chart above. These wire recommendations are for
wire runs of fifty (50) feet or less. Increase the wire size one (1) size for ever additional fifty (50) foot run.
Note – Wire recommendations are for copper wire. If using aluminum wire, use the copper equivalent for
current amount.
2.3 Wire Connection
All NAPCES rotary phase converters are equipped with power distribution blocks for wire terminations.
Single phase input power connections are labeled L1 and L2.
Output idler generator and load power connections are labeled T1, T2 and T3.
T3 is the manufactured leg of power.
Here is an illustration of the wiring connections:
T1
T2
T3
L1
L2
*Front view of power distribution blocks
Recommend Tightening
Torque
10 - 14 AWG
35 Lb.-in
8 AWG
40 Lb.-in
6 - 2/0 AWG
120 Lb.-in
1/0 - 400 MCM
275 Lb.-in
2.4 Idler Generator Connection
For 9 Lead Wire Idler Generators (Motors) - ODP – All Sizes and TECF – 3HP, 5HP, 7.5HP and 10HP
Connect the idler generator according to the nameplate wiring diagram. Your 9 wire lead connection is
most commonly referred to as a wye connection.
Connect wire leads 4, 5 and 6 together. Insulate this connection with electrical tape of heat shrink tubing.
These 3 leads are connected to each other and NOT to any other wires.
Now, connect wire leads 1 & 7 to T1 in the control panel, wire leads 2 & 8 to T2 in the control panel and
wire leads 3 & 9 to T3 in the control panel.
For 12 Lead Wire Idler Generators (Motors) – TEFC - 15HP, 20HP, 25HP, 30HP, 40HP and 50HP
Connect the idler generator according to the nameplate wiring diagram. This 12 wire lead connection is
most commonly referred to as a delta connection run.
Connect wire leads 1, 6, 7 & 12 to T1 in the control panel, wire leads 2, 4, 8 & 10 to T2 in the control
panel and wire leads 3, 5, 9 & 11 to T3 in the control panel.
Here is a line diagram for reference:
9 Lead Wire Idler Generators
4
T1
2
T2
10
11
7
8
9
6
4
5
1
2
3
9
8 1
12
6
5
7
12 Lead Wire Idler Generators
3
T1
T3
T2
T3
Finally, properly ground idler generator to earth ground.
*Note – this is low voltage. Low voltage is 208 – 240 volts.
2.5 Switch Assembly
On the front cover of the control panel, press the “red” stop button. While doing this, look at the back side
of the panel cover and note on which side the “red” tab pushes forward.
Securely push the terminal blocks into the back of switch. The “red” terminal block matches the “red” tab.
Lastly, slide the tab on top of the terminal blocks to the right (when looking at the back of the switch) to
lock the switch terminal blocks into place.
Section 3: Checking the Converter
3.1 Checking Single Phase Line Voltage
Measure the single phase utility input supply voltage between L1 and L2 with a voltmeter and record. It
should measure between 220 and 245 on a standard single phase system. Note – If your input voltage is
too high, you may need to install a buck-boost transformer to decrease the voltage. Please contact
NAPCES; we carry a complete line of buck-boost transformers.
Input Voltage L1-L2 _____________
3.2 Checking Three Phase Output Voltage
Start the rotary phase converter. Press the “Green” Start push button. A light between the start and stop
buttons will illuminate. The phase converter should reach full speed within 2 – 3 seconds. Note – If the
phase converter does not start in 5 seconds, turn it off.
Measure the output line-to-line voltages at the phase converter and record. This is done by measuring
between the three (3) combinations of output terminals. (T1-T2, T1-T3 and T2-T3).
Output Voltages T1-T2____________, T1-T3____________, T2-T3____________
T1-T2’s voltage should be the same or within 1-2 volts of L1-L2. T1-T3 and T2-T3 should measure 5 – 15
volts higher than T1-T2 without a load running. Once a load is applied, these voltages will drop down
closer together.
Note – If voltage is too high, capacitors can be removed. If voltage is too low, capacitors can be added.
Note – Line–to-ground voltage are not relevant. However, T1 and T2 should measure @120 to
ground and T3 should measure between 190 and 250 when measuring to ground.
You can now start your loads. Note – If a load motor rotates backwards, switch any two (2) connections
at the load.
Section 4: Operation & Maintenance
1.1 Operation
1.
2.
3.
4.
5.
A NAPCES rotary phase converter may operate continuously with or without a load.
DO NOT start the phase converter under load.
Wait until phase converter reaches full speed before starting loads.
If possible, avoid starting more than one load at the same time.
Turn rotary converter off if excessive noise or vibration occurs.
1.2 Maintenance
Your NAPCES converter requires very little maintenance. We recommend periodic lubrication,
cleaning and inspection.
Lubrication
All NAPCES rotary phase converters generator bearings are pre-greased by the factory. This
initial greasing generally will last the lifetime of the generator; however, a squirt of grease may be
needed from time to time.
Recommended grease – Exxon Polyrex EM Bearing Grease
Cleaning and Inspection
1. Inspect the rotary converter from time to time.
2. Make sure all vents are clear and clean.
3. Clean off dust, dirt and any debris buildup on the generator. This can insulate the generator
and cause overheating.
4. Open control panel and inspect power and control components.
5. Check all wires for loose connections, cuts/nicks or damage. Clean, tighten or replace if
necessary.
INTENTIONALLY LEFT BLANK
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