Phase Technologies HASE PERFECT DPC-A10 User manual
1
PHASE PERFECT
DIGITAL PHASE CONVERTERS
OPERATION & INSTALLATION
MANUAL
PHASE TECHNOLOGIES, LLC
2
DANGER: HIGH VOLTAGE
Electric shock could result in death or injury. Please consult
qualified personnel for installation.
DANGER
–
Risk of Electric Shock
Please wait 30 minutes before servicing
3
OVERVIEW
Congratulations on your purchase of a revolutionary Phase PerfectDigital
Phase Converter. Phase Perfectrepresents the ultimate technology for
converting single-phase electrical power to three-phase electrical power. The
three-phase power produced by Phase Perfect is often superior in power quality
to utility supplied three-phase.
All Phase PerfectDigital Phase Converters provide balanced sinusoidal output
power to any type of load, eliminating the limitations and design considerations
associated with earlier phase conversion technologies. The installation and
operation of Phase Perfectis simple and straightforward compared to alternative
approaches. Phase Perfectcan be operated from almost any 240 VAC power
source with adequate current carrying capacity, and used to power almost any
type of device, without additional external components.
KEY FEATURES AND CONSIDERATIONS
Key points to be considered when selecting a Phase Perfect for your application:
With electronic power factor correction, Phase Perfectoperates at near unity
power factor (.99)
Phase Perfectoutput is three phase, sinusoidal, with virtually no added
harmonic content
Phase Perfectoutput voltages are balanced to +/- 1%
Phase Perfectwill operate in the voltage range from 187 to 260 VAC.
Phase Perfectcan be configured for use as either a Power Supply or a Motor
Starter.
In the Power Supply configuration Phase Perfectcan provide power to
multiple loads and maintain voltage balance. In the Motor Starter
configuration Phase Perfectcan start and protect a single motor load. Phase
Perfectprovides the contactor and solid state motor overload protection
required for a motor starter.
For applications such as pumping, it can be switched ON and OFF
automatically by a remote switch.
Phase Perfectshould be wired by a qualified electrician into a 208 V or 240
V circuit with adequate current carrying capacity and the appropriate sized
breaker.
Phase Perfectincorporates built-in features that protect the load from
brownout, over-voltage, and fault conditions.
The load, such as a submersible pump, can be located a large distance from
Phase Perfectwithout the need for additional filtering equipment.
4
LIMITED WARRANTY
Phase Technologies equipment is warranted against defects in material
and workmanship for a period of one year. This warranty covers both parts
and labor for one year from the date of purchase by the original owner.
Phase Technologies will repair or replace (at our option), at no charge, any
part(s) found to be faulty during the warranty period specified. The
warranty repairs must be performed by/at a Phase Technologies Authorized
Service Center or at Phase Technologies LLC, Rapid City, SD 57702.
Obligations of the Original Owner
1. The original Bill of Sale must be presented in order to obtain “in-
warranty” service.
2. Transportation to Phase Technologies or an Authorized Service Center
is the responsibility of the original purchaser. Return transportation is
provided by Phase Technologies.
Exclusions of the Warranty
This warranty does not cover any of the following: accident, misuse, fire,
flood, and other acts of God, nor any contingencies beyond the control of
Phase Technologies, LLC, including water damage, incorrect line voltage,
improper installation, missing or altered serial numbers, and service
performed by an unauthorized facility. Phase Technologies’ liability for any
damages caused in association with the use of Phase Technologies’
equipment shall be limited to the repair or replacement only of the Phase
Technologies’ equipment. No person, agent, distributor, dealer, or
company is authorized to modify, alter, or change the design of this
merchandise without express written approval of Phase Technologies, LLC.
INSTALLATIONS MUST COMPLY WITH ALL NATIONAL AND LOCAL
ELECTRICAL CODE REQUIREMENTS.
5
TABLE OF CONTENTS
1. INTRODUCTION
2. INSTALLATION
2.1 PHYSICAL INSTALLATION
2.2 ELECTRICAL INSTALLATION
2.2.1 WIRING TO TERMINALS
2.2.1.1 GENERAL WIRING CONSIDERATIONS
2.2.1.2 INPUT WIRING CONSIDERATIONS
2.2.2 TYPICAL SYSTEM CONFIGURATIONS
2.2.2.1 MOTOR STARTER CONFIGURATION
2.2.2.2 MOTOR STARTER WITH REMOTE ON/OFF
CONTROL
2.2.2.3 POWER SUPPLY CONFIGURATION
3. OPERATION
3.1 ON/OFF FUNCTION
3.2 STATUS LIGHTS
4. OVERLOAD RELAY INFORMATION
5. TROUBLESHOOTING
5.1 GENERAL TROUBLESHOOTING TIPS
5.2 TROUBLESHOOTING WITH STATUS LIGHTS
6. FEATURES AND SPECIFICATIONS
6.1 FEATURES
6.2 SPECIFICATIONS
6
1. INTRODUCTION
Phase Perfectconverts single-phase electrical power to three-phase power.
The diagram below illustrates the basic design of Phase Perfect
:
L1 and L2 of the single-phase input pass directly through the phase converter to
provide two legs of the three-phase output. A manufactured phase is combined
with the two input legs to produce three-phase output power. Hence, the three-
phase output voltage of Phase Perfect will be equal to the single-phase
input voltage (e.g. a 240 VAC single-phase input will produce 240 VAC three-
phase output).
The three-phase output is delta configured. While the phase-to-phase voltages
are equal, the phase-to-ground voltages are not equal. When T1 and T2 to
ground voltage is 120V, T3 to ground voltage will be approximately 208V. For
three-phase loads that are designed for delta connection, the load derives its
voltage phase-to-phase, so the phase-to-ground voltage should not affect the
operation of the equipment. If the connected load has a neutral connection and
requires wye configured power, the output of the phase converter must be
passed through a delta-to-wye isolation transformer before connection to the
load.
Unlike other converter technologies, Phase Perfectactively monitors input and
output currents and voltages to maintain power balance under all load conditions,
near unity power factor, and sinusoidal output with virtually no harmonic
distortion.
Phase Perfectcan be configured as a three-phase power supply or as a motor
starter depending on the application, and is designed to eliminate the need for
most additional external electrical components and controls. Phase Perfectcan
also be configured to accept inputs from remote control switches, thereby
automatically controlling power to a pump motor, or other load.
CONTROLLER
AC to DC
Regulated
Switching
Converter
DC to AC
Regulated
Switching
Converter
-
Power Input
Sinusoidal
Three-Phase
Output
Power
Signal Input
L1
L2
Built-in
Contactor
Optional
Built-in
Overload
Relay
PHASE PERFECT
BLOCK DIAGRAM
Single-Phase
Input Power
7
2. INSTALLATION
Models are available in Type 1 indoor or Type 3R rain proof enclosures. The unit
should be securely mounted to a level surface and care taken to minimize the
introduction of dust and other contaminants into ventilation openings.
2.1 PHYSICAL INSTALLATION
Properly locating Phase Perfectis important to the performance and normal
operating life of the unit. The unit should be installed in a location free from:
Excessive dirt and dust
Corrosive gases or liquids
Excessive vibration
Airborne metallic particles
It is important that the unit be located away from excessive dirt and dust. Phase
Perfectshould be set on a clean, flat horizontal surface. Elevating the unit
above the ground will help to reduce the introduction of dust and contaminants
into the enclosure.
Models DPC-20 and DPC-30 are provided with lifting brackets inside the
enclosure. CABLES, STRAPS OR CHAINS USED FOR LIFTING THESE UNITS
MUST BE ATTACHED ONLY TO THE PROVIDED BRACKETS. Access the
brackets by removing the top cover of the enclosure. Brackets with a hole for
attaching lifting equipment are located on each side-wall of the enclosure.
In order to provide proper ventilation, do not obstruct the open space under and
around the enclosure. Make sure air intake and exhaust openings are not
obstructed. If the unit is mounted in a cabinet or shed, make certain there is
adequate ventilation to provide cooling for the unit.
2.2 ELECTRICAL INSTALLATION
Electrical connections to the Phase Perfectare made behind the front panel of
the enclosure, as described in section 2.2.1. Phase Perfectis available
configured for use as a motor starter with single motor loads, or configured as a
power supply for multiple loads. These configurations are described in section
2.2.2.
Status lights provide information about the status of the Phase Perfectunit, and
about the entire system into which the unit is wired. The status lights are very
useful in troubleshooting system problems. Detailed information on the use of
the status lights for troubleshooting purposes is found in section 5.2.
A panel with terminal blocks for connecting wires is found behind the front panel.
Section 2.2.1 below illustrates the wiring connections and controls found on the
panel. Section 2.2.1.1 provides a description of general wiring considerations.
Section 2.2.1.2 provides diagrams of typical input power wiring configurations,
and discusses important considerations involved in input wiring from various
sources.
8
2.2.1 WIRING TO Phase PerfectTERMINALS
Remove the front panel of the enclosure to gain access to the wiring panel. The
wiring panel and key components of Model DPC-20 are illustrated below:
INPUT POWER
GROUNDING LUG
INPUT POWER
TERMINAL BLOCK
CONTROL
TERMINALS
OUTPUT POWER
GROUNDING LUG
OUTPUT WIRING
TERMINAL BLOCK
FACTORY INSTALLED
JUMPER
9
CONNECTION FUNCTION COMMENTS
GND EARTH GROUND FOR SINGLE-
PHASE INPUT POWER
L1, L2 SINGLE-PHASE INPUT POWER
TERMINALS
JUMPER FROM
A TOB ENABLES THE OPTIONAL MOTOR
OVERLOAD RELAY (WHEN
INCLUDED)*
SHIPPED FROM FACTORY WITH JUMPER
FROM A TO B
MOTOR OVERLOAD RELAY IS DE-
ACTIVATED IF CONTROL JUMPER IS
CONNECTED FROM B TO C.
JUMPER FROM
B TOC CONFIGURES UNIT AS POWER
SUPPLY REPLACE JUMPER WITH THE LEADS OF
AN APPROPRIATE RATED SWITCH
CIRCUIT FOR REMOTE ON/OFF CONTROL
UNIT WILL NOT OPERATE WITH-OUT
JUMPER OR REMOTE SWITCH CIRCUIT
CONNECTED
GND EARTH GROUND FOR THREE-
PHASE OUTPUT POWER
T1, T2,T3 THREE-PHASE OUTPUT POWER
TERMINALS T3 IS THE MANUFACTURED PHASE
*The solid state overload relay is present only when the optional Motor Starter
feature is ordered. The Motor Starter option allows Phase Perfect® to start and
protect single motor loads. Models DPC-A10, DPC-20 and DPC-30 are
equipped with a remote reset button on the front of the enclosure so that the
overload relay can be reset without opening the enclosure.
2.2.1.1 GENERAL WIRING CONSIDERATIONS
Installations must comply with all national and local electrical code requirements.
General Wiring Considerations Include:
1. This Unit Is Suitable For Use In A Circuit Capable Of Delivering
Not More Than 5 kA RMS Symmetrical Amperes, 240 V Maximum.
2. Use 600 V vinyl-sheathed wire or equivalent. The voltage drop of the
leads needs to be considered in determining wire size. Voltage drop is
dependent on wire length and gauge.
3. Wire used within the motor circuit and all field wiring terminals must be
rated for 60 C
4. Wires fastened to the terminal blocks shall be secured by tightening
the terminal screws to a torque value listed in Table 1.
5. Use wire size suitable for Class 1 circuits.
10
6. The input wire gauge must be sized to accommodate the single-
phase input current, which will be approximately 1.8 times the
total three-phase output current to the load(s). For example, if the
output load is 20 Hp, the three-phase output current will be
approximately 54 amps, and the single-phase input current will be 88
amps.
7. The maximum wire gauge for the input terminals is listed in Table 1.
8. Never allow bare wire to contact the metal surfaces.
9. Never connect AC main power to the output terminals T1, T2, and T3.
10.Input power to Phase Perfectshould be wired by a qualified electrician
into a 208V or 240 V circuit with adequate current carrying capacity
and the appropriate sized breaker. Branch circuit protection to the
phase converter should be provided by either an appropriate size 2
pole, linked circuit breaker. Circuit breaker size for each model Phase
Perfectis listed in Table 1.
Table 1
Model: DPC-A10 DPC-20 DPC-30
Input Terminals
Tightening torque 16 in.-lb. 50 in.-lb. 275 in.-lb.
Max. wire size 14- 6 AWG 6- 1/0 AWG 6 AWG –250 MCM
Output Terminals
Tightening torque 16 in.-lb. 45 in.-lb (4-6 AWG)
40 in.-lb. (8AWG)
35 in.-lb. (10-16 AWG) 50 in.-lb.
Wire size 14- 6 AWG 16 – 4 AWG 6- 1/0 AWG
Optional overload relay
Tightening torque 14 in.-lb. 35 in.-lb. 150 in.-lb.
Max. wire size 14- 6 AWG 2 AWG 8-1/0 AWG
Circuit Breaker
Amps 60 -70 110 - 125 175 - 200
11
2.2.1.2 INPUT WIRING CONSIDERATIONS
Phase Perfectcan be operated from most typical input power sources ranging
from 187 VAC to 260 VAC, including 120/240 VAC single-phase sources with a
grounded center tap, or single-phase power derived from two legs of a three-
phase source. However, specific input wiring issues must be considered when
wiring to three-phase input sources. Incorrect L1 and L2 wiring from some
three-phase sources can damage the unit. These considerations are outlined
below:
Some buildings and offices derive single-phase power from two legs of a three-
phase source. TO AVOID POSSIBLE DAMAGE TO THE UNIT, ALWAYS
VERIFY THAT THE INPUT LINE VOLTAGES L1-TO-GROUND AND L2-TO
GROUND ARE APPROXIMATELY 120 VOLTS PRIOR TO CONNECTING
INPUT POWER TO PHASE PERFECT.
Three-phase, 208/120 V, Grounded-Wye
Single-phase 208 V input power can be taken from
two legs of a three-phase grounded-wye source.
There are two possible ways to connect L1 and L2 to
the unit from any two legs. If the unit is connected
incorrectly the generated phase-to-ground voltage
will be 240 V, causing the unit to shutdown and the
yellow status light to flash. In this event reverse the
L1 and L2 input connections.
PHASE
PERFECT
120 V
120 V
120 V
208
V
GND
L1
L2
POWER OUTLET OR
BREAKER PANEL
Three-phase, 240/120 V, Delta--
CAUTION!!!
In rare situations single-phase 240 V input power
is taken from a three-phase source wired as
illustrated to the left. EXTREME CAUTION
must be exercised if using such a source for power
input to the unit. Power can only be taken across
points 1 and 2, with a center ground, as illustrated.
Power taken across points 2 and 3, or 3 and 1, will
DAMAGE the unit. To avoid possible damage,
always verify the voltage to ground for the L1
and L2 inputs to be approximately 120 V
PHASE
PERFECT
240 V
120
V
120
V
208
1
23
L1
L2
GND
POWER OUTLET OR
BREAKER PANEL
Single-phase, 120/240 V, 3 Wire
In most installations, single-phase 240 V input
power will be taken from a 120/240 V center tap
source. This approach is straight forward, with no
additional considerations.
PHASE
PERFECT
120 V
120 V
240 V
L1
L2
GND
POWER OUTLET OR
BREAKER PANEL
12
2.2.2 TYPICAL SYSTEM CONFIGURATIONS
Phase Perfectis designed to simplify installations, to provide maximum
versatility, and to eliminate or minimize the need for external electrical
components and related costs. The output of Phase Perfectis sinusoidal with
virtually no harmonic components, eliminating the need for output filtering that
would often be required for a variable frequency drive (VFD). With virtually no
harmonics on the input, Phase Perfectdoes not require input filtering. With the
Motor Starter option, Phase Perfectcan start and protect a single-motor load,
eliminating the need for a three-phase starter panel in many single-motor
applications. A motor starter is not required at the input to Phase Perfect
, as
would be required for a rotary phase converter. All types of equipment, including
inductive, resistive, and capacitive loads can be safely powered by Phase
Perfect
.
Three typical Phase Perfectinstallations are diagrammed and explained below:
(1) a motor starter configuration for use with a single-motor load, (2) a pump
configuration in which a pressure or level switch automatically controls power to
the pump, and (3) a power supply configuration for use in powering multiple
three-phase loads.
2.2.2.1 MOTOR STARTER CONFIGURATION
With the Motor Starter option, Phase Perfectcan be used to start and protect
single-motor loads, eliminating the need for a three-phase starter panel. An
appropriate sized fusible disconnect must be installed on the input side of Phase
Perfect
. The optional overload relay can be adjusted for motor ratings up to the
rated HP capacity of the converter. The motor starter configuration used to
power a single motor is illustrated below:
SINGLE-PHASE
PANEL
C T
O E
N R
T M
R I
O N
L A
L
L1
L2
GND
T1
T2
T3
GND
A
B
C
PHASE
PERFECT
CONTROL JUMPER A TO B
FOR MOTOR STARTER
CONFIGURATION
SINGLE
MOTOR
FUSIBLE
DISCONNECT
13
The following points should be considered when wiring Phase Perfectas a motor
starter to power a single motor:
1. Verify that no power is provided to Phase Perfect
.
2. Remove the front panel to gain access to the wiring terminals. See
section 2.2.1, “Wiring to Phase PerfectTerminals,” for an illustration.
3. Verify that control terminals A and B are shorted together. Phase
Perfectis shipped from the factory in this configuration. When
contacts A and B are shorted together the optional motor protection
unit is enabled, and Phase Perfect is configured as a motor starter.
4. Wire Phase Perfectto the motor as illustrated above. Three-phase
output power wire connections are made to the T1, T2, and T3 output
terminals, and secured with the terminal block screws.
5. Set the motor protection unit to the desired settings:
a. Adjust the trip current to the appropriate current for the motor load
being powered. The trip rating is 120% of the dial setting.
b. Set the overload relay to auto or manual reset as desired. For auto
reset, push and turn the reset button clockwise to the Auto
position. The button will remain depressed. DANGER: In this
position the relay will reset automatically approximately two
minutes after tripping, providing power to the load without
warning. For manual reset, push and turn the reset button to the
manual position. In this position pushing the button in resets the
overload relay. Additional information on the motor protection unit
is provided in Section 4., “Motor Protection Unit.”
6. Wire power into Phase Perfectfrom an appropriate 208 V or 240 V
circuit. See section 2.2.1.2, “Input Wiring Considerations,” for
additional information.
7. Re-attach the front panel.
8. Provide power to Phase Perfectfrom the fusible disconnect. Power
will be provided to the motor after a delay of approximately five to
eight seconds. Check the motor for correct rotation. If the motor
rotation is incorrect, reverse any two of the three output power leads
T1, T2, and T3.
9. Note: A low power remote switch can be wired into Phase Perfectto
control the motor as described in the following section, “Control Circuit
Configuration.”
2.2.2.2 MOTOR STARTER WITH REMOTE ON/OFF CONTROL
Phase Perfectcan be used to power individual pumps or single-motor loads
which are automatically switched ON and OFF by a remote switch such as a
pressure switch or level switch with at least a 240 VAC, 0.5 amp rating. This
feature can eliminate the need for an external three-phase starter panel to control
the load. Phase Perfectincorporates a contactor and adjustable overload relay,
and when combined with a field installed fusible disconnect provides the
necessary components of a motor starter. The built-in overload relay can be
adjusted for a wide range of motor HP ratings. The installation is similar to the
14
motor starter configuration, with the addition of an ON/OFF control switching
mechanism. The configuration used to power an individual motor with control
circuit is illustrated below:
The following points should be considered when wiring Phase Perfectto power
a motor controlled by a remote switch such as a level or pressure switch:
1. Verify that no power is provided to Phase Perfect
.
2. Remove the front panel to gain access to the wiring terminals. See
section 2.2.1, “Wiring to Phase PerfectTerminals,” for a drawing
illustrating the components found under the access panel.
3. Remove the factory installed jumper between the control terminal
contacts A and B. Wire the remote pressure switch, level switch, or
other control switch to control terminals A and B. When the remote
switch is closed the overload relay will be enabled and power will
be provided to the motor or load after an approximately five to
eight second delay. The control switch should have a minimum
rating of 240 VAC, 0.5 amp. A 3 amp fuse located just below the
printed circuit board protects the remote switch circuit.
4. Wire Phase Perfectto the motor as illustrated above. Three-phase
output power wire connections are made to the T1, T2, and T3 output
terminals, and secured with the terminal block screws.
5. Set the motor protection unit to the desired settings:
c. Adjust the trip current to the appropriate current for the motor load
being powered. The trip rating is 120% of the dial setting.
d. Set the overload relay to auto or manual reset as desired. For auto
reset push and turn the reset button clockwise to the Auto
position. The button will remain depressed. DANGER: In this
position the relay will reset automatically approximately two
minutes after tripping, providing power to the load without
warning. For manual reset push and turn the reset button to the
POWER OUTLET OR
BREAKER PANEL
PHASE
PERFECT
240 VAC
0.5 AMP
C T
O E
N R
T M
R I
O N
L A
L
CLOSED
FOR ON
CONTROL SWITCH
MOTOR
T1
T2
T3
GND
A
B
C
L1
L2
GND
FUSIBLE
DISCO
NNECT
15
manual position. In this position pushing the button in resets the
motor protection unit. Additional information on the motor
protection unit is provided in Section 4., “Motor Protection Unit”.
6. Wire power into Phase Perfectfrom an appropriate 208 V or 240 V
circuit. See section 2.2.1.2, “Input Wiring Considerations,” for
additional information.
7. Re-attach the front panel.
8. Provide power to Phase Perfectfrom the fusible disconnect. When
the remote switch is closed power will be provided to the motor after an
approximately five second delay. Check the motor for correct rotation.
If the rotation is incorrect reverse any two of the three output power
leads T1, T2, and T3.
2.2.2.3 POWER SUPPLY CONFIGURATION
Phase Perfectcan be configured as a power supply to provide three-phase
power to multiple loads of any type, including inductive, resistive, and capacitive
loads. If the Phase Perfect® unit includes the optional Motor Starter feature, the
jumper on the control terminals should be moved to connect B and C terminals.
This will disable the motor overload relay. Separate, properly sized motor starters
should be provided for each motor load to be powered. The power supply
configuration used to power multiple loads is illustrated below:
SINGLE-PHASE
PANEL
PHASE
PERFECT
T1
T2
T3
GND
T1
T2
T3
GND
L1
L2
GND
MOTOR 1
MOTOR 2
LOAD WITH
INTEGRATED
CONTROLS
MOTOR
STARTER
MOTOR
STARTER
T1
T2
T3
GND
A
B
C
CONTROL JUMPER B TO C
FOR POWER SUPPLY
CONFIGURATION
L1
L2
L3
GND
L1
L2
L3
GND
C T
O E
N R
T M
R I
O N
L A
L
DISTRIBUTION
PANEL
FUSIBLE
DISCONNECT
16
The following points should be considered when wiring Phase Perfectas a
power supply to provide three-phase power to multiple loads:
1. Verify that no power is provided to Phase Perfect
.
2. Remove the front panel to gain access to the wiring terminals. See
section 2.2.1, “Wiring to Phase PerfectTerminals,” for a drawing
illustrating the components found under the access panel.
3. Phase Perfectis shipped from the factory with control terminals A and
B shorted together. Remove the control jumper between terminals A
and B, then install the control jumper between terminals B and C.
4. With the control terminal jumper between terminals B and C
Phase Perfectis configured as a three-phase power supply with
the optional motor protection unit disabled.
5. Wire Phase Perfectto the motor and non-motor loads as illustrated
above. Three-phase output power wire connections are made to the
T1, T2, and T3 output terminals, and secured with the terminal block
screws. Make certain that the total power requirement of all the loads
does not exceed the rated capacity of the Model.
6. Wire power into Phase Perfectfrom an appropriate 208 V or 240 V
circuit. See section 2.2.1.2, “Input Wiring Considerations,” for
additional information.
7. Re-attach the front panel.
8. Provide power to Phase Perfectfrom the fusible disconnect. Power
will be available to the load circuits after an approximately five to
eight second delay. Check each motor for correct rotation. If the
motor rotation is incorrect reverse any two of the three output power
leads T1, T2, and T3 at the output of the motor starter.
9. Note: A low power remote switch can be wired into Phase Perfectto
provide remote ON/OFF switching of the Phase Perfectunit (see
“Control Circuit Configuration” in the previous section).
3. OPERATION
Operation of the Phase Perfectunit is straightforward after completion of
installation and wiring.
3.1 ON/OFF FUNCTION
When Phase Perfectis configured as a motor starter (see section 2.2.1) or a
power supply (see section 2.2.3), power to the Phase Perfectunit is controlled
by a properly installed fusible disconnect. When switched on, power is provided
to the load after a delay of approximately five to eight seconds.
When Phase Perfect is configured to power a motor (see section 2.2.2) or other
load via a control circuit, the fusible disconnect is left on. When a control switch
such as a pressure or level switch is closed, then power is applied to the load
after a delay of approximately five to eight seconds. When the fusible disconnect
17
is on, and the control switch is open, Phase Perfectwill not draw any power and
power will not be provided to the load. When either the fusible disconnect is off,
or the control switch is open, the front panel green status light will be OFF.
3.2 STATUS LIGHTS
The GREEN, YELLOW, and RED status lights are found on the front panel of
Phase Perfect
. The status lights cannot be viewed in direct sunlight, but should
be shaded for clear viewing. The status lights provide information about the
status of the Phase Perfectunit, and provide useful troubleshooting information
about the entire system into which Phase Perfectis wired.
Three basic status light indications are:
GREEN STATUS LIGHT ON Steady: Power ON, Control Switch Closed (if
present)
YELLOW STATUS LIGHT ON Steady: Internal Unit Temperature Too High
RED STATUS LIGHT Flashing: Internal Short in Unit, Consult Factory
Note: The red and yellow status lights may flash briefly when starting heavy
loads. This is normal and can be ignored.
In addition to the basic status light functions indicated above, flashing status
lights and combinations of status lights are designed to indicate and help
troubleshoot a wide range of potential problems. A complete listing of status
light indications is provided in Section 5.2, “Troubleshooting with Status Lights.”
4. SOLID STATE OVERLOAD RELAY INFORMATION
Phase Perfectis available with an optional solid overload relay for single-motor
applications. The solid state solid overload relay replaces earlier style thermal
relays in motor starter applications, and provides significant advantages over
older thermal relay technologies. For example, the solid overload relay provides
an expanded current adjustment range suitable for a wide motor horsepower
range up to the capacity of the converter. The overload relay unit is enabled
when Phase Perfectis used in the motor starter configuration by shorting control
terminals A and B together in the wiring cavity. The overload relay is disabled
when Phase Perfectis used in the power supply configuration by shorting
terminals B and C together in the wiring cavity. This section provides detailed
information on the overload relay, as illustrated below:
18
The following points describe adjustment and features of the motor protection
unit. Remember, the motor protection unit is bypassed in the power supply
mode by shorting control terminals B and C together in the wiring cavity.
1. TRIP CURRENT ADJUSTMENT BUTTON—Used to adjust the current trip
limit when Phase Perfectis used as a motor starter in the motor starter
configuration. To adjust the trip current, turn the dial until the desired current
is aligned with the pointer. The trip rating is 120% of the dial setting.
2. MANUAL/AUTO RESET BUTTON—Used to control automatic and manual
reset features of the overload relay, and to reset the motor protection unit if it
trips out. The unit is shipped from the factory in the manual mode. Automatic
reset of the overload relay is often desirable when Phase Perfect is located at
remote locations such as a pumping shed. Manual reset is typically used
when the Phase Perfect unit is readily accessible, such as in a machine shop.
a. For auto reset, push and turn the reset button clockwise to the Auto
position. The button will remain in the IN position. The unit will reset
automatically approximately two minutes after tripping. ATTENTION: Do
not use the automatic reset mode in applications where unexpected
automatic restart of the motor can cause injury to persons or
damage to equipment.
b. For manual reset push and turn the reset button to the Manual position. In
this position pushing the button in resets the overload relay.
c. To manually trip the overload relay, push and turn the button
counterclockwise to the trip position. Releasing the button reverts the unit
to the manual position.
d. To reset the overload relay push the button.
OVERLOAD REL
AY
OVERLOAD RELAY
INPUT POWER SECURE
SCREWS
PUSH TO TEST
BUTTON
TRIP CURRENT
ADJUSTMENT KNOB
MANUAL/AUTO
RESET BUTTON
TRIP WINDOW
CONTACT MODE
SCREWS
OVERLOAD RELAY
OUTPUT POWER
SECURE SCREWS
19
3. TEST BUTTON—Will shut OFF Phase Perfect and power to the load when
pushed.
4. TRIP INDICATOR WINDOW—A yellow indicator will be visible on the relay if
it has tripped due to an overload condition. The overload relay can be reset
by pushing the manual/auto reset button IN when the button is in the manual
position.
5. OUTPUT POWER SECURE SCREWS—Used to secure power wires in place
between the motor protection unit and the load.
6. INPUT POWER SECURE SCREWS—Used to secure input power wires from
Phase Perfectelectronics to the overload relay in place. Factory pre-installed
wires at this location should not be removed or altered.
7. CONTACT MODE SCREWS—Used to secure wires to configure the contact
mode of the overload relays. Wires connected to the NC contacts are pre-
wired at the factory, and should not be removed.
Note: If problems develop with the overload relay, contact the Field Support
Manager at Phase Technologies, (605) 343-7934.
5. TROUBLESHOOTING
This section provides troubleshooting information for potential system problems.
5.1 GENERAL TROUBLESHOOTING TIPS
After the system is fully wired, turn the Phase Perfectunit ON with the fusible
disconnect.
If the unit fails to turn ON, and all status lights are OFF, check the following:
1. Verify that the appropriate circuit breaker in the building’s electrical
distribution box is set ON and is properly sized.
2. Check the control circuit fuse located on the panel just below the
printed circuit board. If necessary, replace with appropriate 3 A fuse.
3. Verify that the jumper on the control terminal is connected either A to
B for motor starter configuration, or B to C for power supply
configuration. The unit will not operate unless the jumper wire or
control circuit wires are connected to the appropriate control terminals.
For single-motor applications, if the unit turns ON but power is not provided to the
load: 1. Check the TRIP INDICATOR WINDOW on the motor protection unit to
see if it has tripped. If tripped, push the AUTO/MANUAL RESET
button on the motor protection unit.
2. Verify that the overload relay current limit is appropriately set for the
load.
After turning the motor ON always check for correct rotation. If the motor rotation is
incorrect, reverseanytwoofthethreeoutputpowerleads T1,T2,andT3.
20
Refer to the following status light information for additional troubleshooting tips.
5.2 STATUS LIGHTS
The status lights provide a very useful tool for detecting and diagnosing system
problems. The table on the following page provides a list of status light modes,
the indicated problem, and potential causes of the problem.
STATUS LIGHT TROUBLESHOOTING TABLE
STATUS LIGHT MODE INDICATED PROBLEM POTENTIAL CAUSES SUGGESTED FIXES NOTES
Steady Green System normal
Steady Yellow Phase Perfect
overheated Blockage of air intake and
exhaust
Ambient temperature too high.
(ambient temp. should not
exceed 40 C)
Internal dirt buildup
Failed internal fan
Make certain vents are clear.
Verify adequate clearance
between unit and surroundings.
Ensure that building is adequately
vented.
Avoid direct sunlight.
Contact factory.
Note: fan is temp. controlled, and
does not operate continuously.
1
Flashing Red Fault Internal short in unit Contact manufacturer 2
Steady Red and Steady
Green Input voltage too low Low utility line voltage Ensure the input line voltage
between L1 and L2 is above 187
VAC
3
Steady Red and Steady
Yellow PLL not in sync Noisy line voltage Contact utility 3
Flashing Green and
Flashing Yellow Output current too high Short between T3 & T1 or T2
Excessive load Eliminate short
Ensure steady state current is
within ratings. Higher current is
OK for momentary load startup
2
Steady Green and Yellow
Or Steady Red High DC bus voltage High utility line voltage
Short between T1 & T2 or T3
Ensure input line voltage between
L1 and L2 is below 255 VAC
Eliminate short
3
Flashing Yellow Output GND voltage (T3
to GND) too high Grounded-wye three-phase input
used with L1 and L2 reversed Reverse L1 and L2 2
Flashing Red, Green and
Yellow Abnormal DC bus
voltage T3 to ground fault Eliminate short
Ensure steady state current is
within ratings. Higher current is
OK for momentary load startup
2
Steady Red and Steady
Yellow Input voltage too high High utility line voltage Ensure input line voltage between
L1 and L2 is below 255 VAC 3
Notes:1. WARNING: The unit will automatically turn back ON after internal
temperature reaches acceptable levels.
2. The output will remain de-energized until the fusible disconnect is
cycled OFF/ON, or the control signal is cycled OFF/ON.
3. The unit will automatically turn back ON 15 seconds after the problem
is corrected.
If problems cannot be corrected, contact the Field Support Manager at
Phase Technologies, (605) 343-7934.
6. FEATURES AND SPECIFICATIONS
This manual suits for next models
5
Table of contents
Other Phase Technologies Media Converter manuals
