1 Power Protection and Conditioning MCR Hardwired Series - Power Line Conditioning with Voltage Regulation The MCR Hardwired Series provides excellent noise filtering and surge suppression to protect connected equipment from damage, degradation or misoperation. Combined with the excellent voltage regulation inherent to Sola/Hevi-Duty's patented ferroresonant design, the MCR can increase the actual Mean Time Before Failure (MTBF) of protected equipment. The MCR is a perfect choice where dirty power, caused by impulses, swell, sags, brownouts and waveform distortion can lead to costly downtime because of damaged equipment. Features * 3% output voltage regulation * Noise attenuation - 120 dB common mode - 60 dB transverse mode * Surge suppression tested to ANSI/IEEE C62.41 Class A & B Waveform: - <10 V let through typical * Acts as a step-up or step-down transformer * Harmonic filtering * Hardwired * Galvanic isolation provides exceptional circuit protection. * 25 year typical MTBF * No maintenance required Applications * Industrial automation and control equipment PLCs * Machine tools * Computer loads and electronic equipment * Robotics * Semiconductor fabrication equipment Related Products * On-line UPS (S4K Industrial) * Surge Suppression * Three Phase Power Conditioners Selection Tables: Single Phase Group 2 - MCR Series, 60 Hz Only VA Catalog Number Voltage Input Voltage Output Height (inch) Width (inch) Depth (inch) Ship Weight (lbs) Design Style Elec Conn 120 63-23-112-4 120, 208, 240, 480 120 9 4 5 15 1 D 250 63-23-125-4 120, 208, 240, 480 120 10 6 8 27 1 D 500 63-23-150-8 120, 208, 240, 480 120, 208, 240 13 9 7 37 1 E 750 63-23-175-8 120, 208, 240, 480 120, 208, 240 14 9 7 52 1 E 1000* 63-23-210-8 120, 208, 240, 480 120, 208, 240 17 9 7 62 1 E 1500* 63-23-215-8 120, 208, 240, 480 120, 208, 240 17 13 9 95 1 E 2000* 63-23-220-8 120, 208, 240, 480 120, 208, 240 18 13 9 109 1 E 3000* 63-23-230-8 120, 208, 240, 480 120, 208, 240 19 13 9 142 1 E 5000* 63-23-250-8 120, 208, 240, 480 120, 208, 240 28 13 9 222 1 E 7500** 63-28-275-8 208, 240, 480 120, 208, 240 27 26 9 362 2 F 10000** 63-28-310-8 208, 240, 480 120, 208, 240 28 26 9 446 2 F 15000** 63-28-315-8 208, 240, 480 120, 208, 240 28 38 10 710 3 F * Canadian option: cULus certified units must be ordered by changing "-8" (UL only) to "-C8". ** UL Listed Only. Use Group 3 for cULus. 28 Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 1 Power Protection and Conditioning Selection Tables: Single Phase Group 3 - MCR Series, 60 Hz Only VA Catalog Number Voltage Input Voltage Output Height (inch) Width (inch) Depth (inch) Ship weight (lbs) Design Style Elec Conn 500 63-31-150-8 600 120, 208, 240 13 9 7 38 1 B 1000 63-32-210-8 600 120, 208, 240 17 9 7 62 1 B 2000 63-32-220-8 600 120, 208, 240 18 13 10 109 1 B 3000 63-32-230-8 600 120, 208, 240 19 13 10 142 1 B 5000 63-29-250-8 208, 240, 480, 600 120, 208, 240 28 13 10 221 1 A 7500 63-29-275-8 208, 240, 480, 600 120, 208, 240 27 25 10 360 2 A 10000 63-29-310-8 208, 240, 480, 600 120, 208, 240 28 25 10 441 2 A 15000 63-29-315-8 208, 240, 480, 600 120, 208, 240 28 38 10 706 3 A Group 4 - MCR Series, 50 Hz Only (5% output voltage regulation) VA Catalog Number 120 Voltage Input Voltage Output Height (inch) Width (inch) Depth (inch) Ship weight (lbs) Design Style Elec Conn 63-23-612-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 9 6 8 24 1 C 250 63-23-625-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 11 6 8 27 1 C 500 63-23-650-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 13 9 7 40 1 C 1000 63-23-710-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 18 9 7 64 1 C 2000 63-23-720-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 18 13 10 113 1 C 3000 63-23-730-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 27 13 10 162 1 C 5000 63-23-750-8 110, 120, 220, 240, 380, 415 110, 120, 220, 240 30 13 10 266 1 C 7500 63-28-775-8 220, 240, 380, 415 110, 120, 220, 240 28 26 10 393 2 C1 10000 63-28-810-8 220, 240, 380, 415 110, 120, 220, 240 30 26 10 490 2 C2 15000 63-28-815-8 220, 240, 380, 415 110, 120, 220, 240 30 38 10 776 3 C2 Specifications Parameter Condition Value Input Voltage Current 1 Frequency Continuous at full load (lower input voltage possible at lighter load) +10% to -20% of nominal For temporary surge or sags +20% to -35% of nominal at Full Load & 80% of nominal input voltage Iin (VA/.89)/(Vin x 80%) See Operating Characteristics section for details. 50 Hz or 60 Hz depending on model Output Line Regulation Overload Protection Output Harmonic Distortion Noise Attenuation Vin >80% and <110% of nominal 5% for 50 Hz units, 3% for 60 Hz units At Nominal Input Voltage Current limited at 1.65 times rated current At full load within input range 3% total RMS content -Common Mode -Transverse Mode 120 dB 60 dB General At Full Load Up to 92% Storage Temperature Humidity <95% non-condensing -20 to +85C Operating Temperature Humidity <95% non-condensing -20 to 50C Full Resistive Noise 35 dBA to 65 dBA 60 Hz Models UL1012, CSA evaluated by UL 50 Hz Models CE (EMC & LVD) See General Information section for details 10 + 2 Years Efficiency Audible Noise Approvals Warranty Notes: 1 - Consult user manual for fuse sizing. Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 29 1 Power Protection and Conditioning Electrical Connections A Primary Voltage Interconnect B Connect Lines To 208 H1 to H4 H2 to H5 H1 & H5 240 H1 to H4 H3 to H6 H1 & H6 Primary Voltage 480 H3 to H4 H1 & H6 600 600 H3 to H4 H1 & H7 Secondary Voltage Interconnect Connect Lines To Secondary Voltage 120 X1 & X2 or X3 & X2 208 X4 & X5 240 X1 & X3 Interconnect H1 & H2 Interconnect X1 & X2 or X3 & X2 208 X4 & X5 240 220-240 H1 to H3 H2 to H5 380-415 Connect Lines To H1 & H5 H2 to H3 Secondary Voltage Interconnect Connect Lines To 110-120 H1 to H3 H2 to H4 H1 & H4 220-240 H2 to H3 H1 & H4 380-415 H2 to H3 H1 & H5 Secondary Voltage Interconnect Connect Lines To 110 X1 & X2 or X3 & X2 120 X4 & X2 or X5 & X2 220 X1 & X3 240 X4 & X5 MCR 60 Hz 500-3000 VA MCR 50 Hz 120-5000 VA C2 D Primary Voltage Interconnect Connect Lines To Primary Voltage 220-240 H2 to H3 H1 & H4 120 H1 & H2 380-415 H2 to H3 H1 & H5 208 H1 & H3 Secondary Voltage Interconnect Connect Lines To 240 H1 & H4 110 X1 & X2 or X3 & X2 480 H1 & H5 120 X4 & X2 or X5 & X2 Secondary Voltage 220 X1 & X3 120 240 X4 & X5 Interconnect Connect Lines To H1 & H4 Interconnect Connect Lines To 110 X1 & X2 or X2 & X3 120 X4 & X2 or X5 & X2 220 Interconnect Connect Lines To X1 & X2 X1 & X3 240 X4 & X5 MCR 50 Hz 7500 VA 30 Primary Voltage X1 & X3 C1 Interconnect Connect Lines To 120 MCR 60 Hz 5000-15000 VA Primary Voltage Connect Lines To C MCR 60 Hz 120-250 VA MCR 50 Hz 10000-15000 VA Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 1 Power Protection and Conditioning Electrical Connections E Primary Voltage Interconnect Connect Lines To H1 & H2 Primary Voltage 208 H1 & H3 208 240 H1 & H4 240 480 H1 & H5 480 120 G F Interconnect Connect Lines To Primary Voltage Interconnect Connect Lines To 120 H1 to H3 H5 to H7 H2 to H4 H6 to H8 H1 & H2 240 H2 to H3 H6 to H7 H1 to H5 H4 to H8 H1 & H4 480 H2 to H3 H4 to H5 H6 to H7 H1 & H8 Interconnect Connect Lines To H2 & H3 H2 & H4 H1 & H4 Connect Lines To Secondary Voltage 120 X1 & X2 or X3 & X2 120 X1 & X2 or X3 & X2 208 X4 & X5 208 X4 & X5 Secondary Voltage X1 & X3 120 Secondary Voltage Interconnect 240 X1 & X3 Interconnect Connect Lines To 240 X1 & X2 MCR 60 Hz 500-5000 VA MCR 60 Hz 7500, 10000 and 15000 VA H Series-Multiple Primary with Tap for two input voltages CVS 60 Hz 250 VA only J Open MCR/CVS terminal Primary Voltage Interconnect Connect Lines To 120 H1 to H3 to H6 to H8 H2 to H5 to H7 to H10 H1 & H2 30 & 60 VA Primary Voltage 120 VA Primary Voltage 7500 VA Primary Voltage Interconnect Connect Lines To 120 N/A N/A Note: H3 & H4 are not used H1 & H2 240 H1 to H3 H2 to H4 H1 & H4 208 H2 to H3 H1 to H6 H7 to H8 H4 to H9 H1 & H4 240 H2 to H3 H7 to H8 H1 to H6 H5 to H10 H1 & H5 N/A 240 480 H2 to H3 H1 & H4 480 H2 to H3 H5 to H6 H7 to H8 H1 & H10 30 & 60 VA Secondary Voltage 120 VA Secondary Voltage 7500 VA Secondary Voltage Interconnect Connect Lines To Secondary Voltage Interconnect N/A 120 Connect Lines To 120 120 N/A X1 & X2 120 X1 & X2 or X3 & X2 N/A N/A 120 X1 & X2 or H3 & X2 240 X1 & X3 N/A N/A 240 X1 & X3 CVS 60 Hz 500-5000 VA Note: Secondaries are not grounded. Ground X2 per Code. CVS 60 Hz 30-120 VA & 7500 VA Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 31 1 Power Protection and Conditioning Model Comparison Description VA Ratings Hardwired CVS Hardwired MCR Portable MCR 30 to 7500 VA 120 to 15000 VA 70 to 3000 VA +10/-20% of nominal Input Voltage Range Voltage Regulation 1% for an input line variation of +10/-20%. No loss of output for line loss of 3 msec. 3% for an input line variation of +10/-20% (50 Hz hardwired units 5%.) No loss of output for complete line loss of 3 msec. Limits output current to 1.65 x rated current at nominal input. Overload Output Harmonic Distortion 3% total RMS content at full load. 40 dB common and normal code. 120 dB common mode and 60 dB normal mode. Up to 6000 Volt surges are suppressed to a let through of less than 1% per ANSI/IEEE C62.41 Class A & B waveforms. ANSI/IEEE C62.41 Class A & B 6000 waveforms are suppressed to a let-through of less than 0.2%. Noise Isolation Surge Suppression Efficiency Operating Temperature Up to 92% at full load Up to 90% at full load -20oC to 50oC -20oC to 40oC Audible Noise 32 dB to 65 dB 35 dB to 65 dB 34 dB to 49 dB Conformance Listed to UL 1012. CSA Certified UL Listed and CSA Certified.50 Hz models in compliance with Low Voltage Directive Specification EN60950. Listed to UL 1012. CSA Certified on all models except 3000 VA. Warranty 10 + 2 years Note: All values are typical and may vary based on VA ratings of actual units. BTU Output Chart for CVS and MCR Series VA Ratings 120 250 500 750 1000 1500 2000 3000 5000 7500 10000 15000 Total BTU's 136 225 280 444 519 686 1229 1331 2117 2407 3209 4813 Note: Ratings are for a 40oC ambient temperature. 34 Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 1 Power Protection and Conditioning Operating Characteristics of the CVS & MCR Series Regulation Sola/Hevi-Duty's CVS power conditioners will hold output voltages to 1.0% or less with input variations as great as 15% (115V 15% or 120 V +10%/-20%). Units operated at less than rated load will maintain approximately 1% regulation over a wider input line voltage variation. Output meets NEMA voltage specifications even when input voltage drops to 65% of nominal. The output versus input voltage relationship for a typical CVS is show in Figure A. CVS Conditioner Rating - VA Increase in Output Voltage due to Load Removal 30 3% 60 & 120 2% 250 & over 1% Input Characteristics Sola/Hevi-Duty power conditioners include a resonant circuit that is energized whether or not it is serving load. The input current at no load or light load may run 50% or more of the full primary current. As a result, the temperature of the unit may rise to substantially full-load level, even at light or no load. Input power factor will average 90-100% at full load, but may drop to about 75% at half load and 25% at no load. In any case, the current is always leading. The input no load watts are about 12.5% of the VA rating. Figure A: Load Variation Note: MCR line regulations: 3% for 60 Hz; 5% for 50 Hz. The typical performances shown in Figure B indicate that most of the residual changes take place near the lower (95 V) and upper (130 V) ends of the input range. It is possible to improve output regulation if line variations remain within a restricted range near the center of the nameplate range (for example, 100-120 V). Frequency Output voltage varies linearly with a change of frequency of the input voltage. This change is about 1.5% of the output voltage for each 1% change in input frequency and in the same direction as the frequency change. Power Factor Sola/Hevi-Duty power conditioners regulate any power factor load. Output voltage is a function of load current and load power factor (see Figure C). If lower voltage under lagging power factor is objectionable, correction may be made with capacitors at the load. "Median" value of output voltage will vary from the nameplate rating if the load has a power factor other than that for which the transformer was designed. Load regulation will also be relatively greater as the inductive load power factor is decreased (see Figure C). However, the resulting median values of output voltage will be regulated against supply line changes at any reasonable load or load power factor. Figure B: Line Regulation Normally, the output voltage will rise as the load is decreased. Typical percentages for changes in resistive load from full to zero load as shown below. Except as noted, all characteristics of Sola/Hevi-Duty's CVS products also apply to the MCR series. Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 35 1 Power Protection and Conditioning Operating Characteristics of the CVS & MCR Series Figure C: Power Factor Efficiency The copper magnet wire and lamination material used in Sola/Hevi-Duty ferroresonant products are selected to achieve efficiencies of 90% or higher. Whether or not an external load is being served, current will be drawn from the line whenever the primary is energized, since the capacitor remains connected in the circuit. Overload and Short Circuits When the load is increased beyond the regulator's rated value, a point is reached where the output voltage suddenly collapses and will not regain its normal value until the load is partially released. Under direct short circuit, the load current is limited to approximately 150-200% of the rated full load value and the input watts to less than 10% of normal. A constant voltage regulator will protect both itself and its load against damage from excessive fault currents. Fusing of load currents may not be necessary. The actual value of short-circuit current varies with the specific design and rating. Units may be operated indefinitely at short-circuit. This characteristic protects the unit itself as well as the load and load circuit being served. Typical overload performance is shown in Figure D. 36 Figure D: Overload Performance Motor Loads Because of the fast response time of the Sola circuit, any current-limiting characteristic must be taken into account for transient overloads such as motor starting and solenoid operation. In general, the Sola constant voltage regulator must have a capacity nearly equal to the maximum demand made on it, even for an instant. To determine the power rating of the regulator, peak motor-starting current or solenoid inrush current should be measured or power factor correcting capacitors should be used to reduce the starting VA of the load. Response Time An important advantage of Sola's ferroresonant transformer is its fast response time compared with other types of AC regulators. Transient changes in supply voltage are usually corrected within 1-1/2 cycles or less; the output voltage will not fluctuate more than a few percent, even during this interval. Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Power Protection and Conditioning 1 Operating Characteristics of the CVS & MCR Series Temperature Sola's ferroresonant power conditioners are very stable with respect to temperature. The change in output voltage is only 0.025%/C. Units are factory adjusted to +2%/-0% of nominal, with full load and nominal input voltage. This adjustment to the high side of nominal is to compensate for the natural temperature drift of about 1% that takes place during initial turn-on or warm-up. When the unit warms up to operating temperature, the voltage typically falls about 1%. At a stable operating temperature, the output voltage will change slightly with varying ambient temperatures. This shift is equal to approximately 1% for each 40C of temperature change. The normal maximum temperature rise of a Sola power conditioner may fall anywhere in the range of 40C to 110C depending on the type and rating. The nominal design ambient range is between -20C and +50C (-20C to +40C for 70 - 1000 VA, 60 Hz portable models). External Magnetic Field In almost all applications, this effect may be disregarded. The exclusive Sola/Hevi-Duty "wide outside leg" construction (U.S. Patent 2,806,199) reduces stray magnetic fields to a practical minimum. On critical applications, care should be taken in orientation of the core with respect to critical circuits to minimize the effect of the field. Phase Shift The phase difference which exists between input and output voltages is in the range of 120 degrees to 140 degrees at full load. This phase difference varies with the magnitude and power factor of the load, and to a lesser extent, with changes in line voltage and load power factor. Transient Protection Ferroresonant power conditioners protect input transients (caused by lightning and load switching) from damaging the sensitive electronic load. A typical surge protective device (SPD) tries to `clamp' a transient by diverting it to ground. A ferroresonant power conditioner "blocks" the transient. This `blocking' action is achieved by total physical separation from input (primary) to output (secondary). Because of this difference in operation, it is difficult to apply the same specifications to a ferroresonant power conditioner. Some parallels can be made however. One, is that under load, the let-through voltage of a ferroresonant power conditioner (SPD refer to "clamping voltage") is less than 10 V above the point where the sine wave would normally be at any given time. The ferroresonant power conditioner is an `active tracking' suppressor with several advantages. The Ferro power conditioner will not shunt the transient to the ground line as SPD devices typically do. Shunting the transient to ground can cause the disturbance to be transmitted to other sensitive loads within a facility. This can pose serious problems with electronic or microprocessor-based equipment, especially if there is poor grounding within a facility. Other advantages provided by ferroresonant power conditioners include noise filtering, filtering of harmonic distortion and protection against voltage fluctuations such as sags or swells. These features are not provided by standard surge suppression devices but are often misrepresented or misused by SPD manufacturers trying to market their product as a "Do All" power quality device. Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com Gross Automation (877) 268-3700 * www.solahevidutysales.com * sales@grossautomation.com 37