auto transformer installation and userʼs manual

Model: 277-240AT

Rev 022113

Please contact Customer Support at 1-800-24VOLTS for further information.

Auto Transformer

Installation and Userʼs Manual

Copyright 2013-2014 all rights reserved by Nextek Power Systems, Inc. in theUnited States and in other countries throughout the world.

ABOUT NEXTEK POWER SYSTEMS 3

1.0 SAFETY 4

2.0 STANDARDS & REQUIREMENTS 5

3.0 PERSONNEL QUALIFICATIONS 5

4.0 INSTALLATION QUALIFICATIONS 5

5.0 PRODUCT SPECIFICATIONS 7

6.0 CAUTIONS AND WARNINGS 8

7.0 INSTALLATION PROCEDURE 97.1 Preparing The Auto-Transformer For Mounting 9

7.2 Mounting The Auto-Transformer 11

7.3 Wiring The Auto-Transformer 11

8.0 TROUBLESHOOTING 13

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For more information: Nextek Power Systems Tel: 313-887-1321 www.nextekpower.com461 Burroughs Street Toll free: 1 (877) 24-VOLTSDetroit, Michigan 48202 Fax: 313-887-9433 [email protected]

2 Copyright 2013-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.

Model 277-240AT

Nextek Auto Transformer Installation Manual

Nextek Power Systems AC/DC integration technology represents a breakthrough in on-site electrical management, combining the availability of AC power with the quality andefficiency of a DC supply.

NEXTEK PRODUCT BENEFITS

• Easy conversion of AC lighting fixtures to DC-powered units

• Easy conversion of AC grid power into DC power for commercial buildingapplications

• Highly efficient management of peak loads

• Future-proof lighting and other systems to be developed

• Nextek Power Systems Direct Coupling® Technology, directly connects cleanpower generated at a building to its electronic loads inside cutting down on over-all power consumption, boosts electricity generated and stored on-site, anddelivers a robust renewable energy ready network.

DISCLAIMER

Nextek Power Systems has made every reasonable effort to ensure the accuracy of theinformation in this catalog. Nextek Power Systems does not guarantee that theinformation is error free, nor do we make any other representation, warranty orguarantee that the information is accurate, correct, reliable or current. Nextek PowerSystems, Inc. reserves the right to make any adjustments to the information containedherein at any time without notice. The specifications in this catalog are for referencepurposes only and are subject to change without notice. Consult Nextek Power Systemsfor the latest design specifications. All trademarks are either the exclusive property ofNextek Power Systems, Inc. or other companies. Copyright © 2013-2014 by NextekPower Systems, Inc. in the United States and other countries throughout the world.

ABOUT NEXTEK POWER SYSTEMS

Copyright 2013-2014 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world. 3

Nextek Auto Transformer Installation ManualModel 277-240AT

1.1 SAVE THESE INSTRUCTIONS– This manual contains important safety andoperating instructions for the Nextek Auto-Transformer, Model 277–240AT.

The following symbols are used throughout this manual to indicate potentiallydangerous conditions or mark important safety instructions:

DANGER:Indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING:Indicates a potentially dangerous condition. Use extreme caution whenperforming this task.

CAUTION:Indicates a critical procedure for safe and proper operation of thecontroller.

NOTE:Indicates a procedure or function that is important for the safe andproper operation of the controller.

1.2 Before using the Model 277–240AT, read all instructions and cautionarymarkings.

1.3 Electrical hazards are probably the most common hazards throughout theindustry. Virtually all workplaces have electrical installations and use electricity.

1.4 It is very important that all industry employees be familiar with electrical hazardsand know how to protect themselves when working on, near, or with electricity.In most cases, industry electrical and electronic equipment is designed for bothmaximum safety and efficiency. However, potentially hazardous conditions suchas inadvertent contact with hazardous voltages may exist while performingservicing and maintenance, handling materials, or cleaning.

1.5 The improper use of electrical extension cords and portable electricalequipment can result in hazardous exposure.

1.6 WARNING - RISK OF ELECTRICAL SHOCK

1.7 DANGER – TO REDUCE THE RISK OF FIRE OR ELECTRICSHOCK, CAREFULLY FOLLOW THESE INSTRUCTIONS

1.7.1 Mount the Model 277–240AT indoors. Prevent exposure to the elementsand do not allow water to enter the unit.

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1.0 SAFETY

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2.0 STANDARDS AND REQUIREMENTS2.1 All AC cable types must meet all local and national codes.

2.2 Shut off all AC breakers before installing any unit into the field.

2.3 Torque all the Auto-Transformer ground terminals to 35 inch-pounds (4NM).

2.4 AC Wiring to Auto-Transformer:

2.4.1 Use a minimum of 12 AWG, 3 conductor cables to reduce losses andensure high performance.

2.4.2 Copper wiring must be rated at 60°C or higher.

2.4.3 The Auto-Transformer must be protected by a circuit breaker.

3.0 PERSONNEL QUALIFICATIONS3.1 Installation work and electrical wiring of permanently-connected power units

must be performed only by qualified service personnel in accordance with allapplicable codes and standards, including fire-rated construction.

4.0 INSTALLATION QUALIFICATIONS4.1 Every work environment should provide a safe place for every employee, which

includes protecting the employee from electrical hazards such as fault currentsto ground.

4.2 When an electrical ground fault occurs, the current flows through the pathhaving minimum impedance to ground. It is imperative that an employee doesnot inadvertently become the conductor of the current.

4.3 Two approved methods of protecting the worker from a ground fault, in additionto other requirements for equipment-grounding conductors, are:

4.3.1 Use of ground fault circuit interrupters (GFCI)

4.3.2 An assured equipment grounding conductor program

4.4 Installers should be advised:

4.4.1 These installation instructions are for use by qualified personnel only.

4.4.2 The equipment contains AC voltages.

NOTE: Installers must reference the National Electric Code to ensure propersystem wiring and grounding compliance. In addition, all state and federalOccupational Safety and Health Administration (OSHA) guidelines andregulations must be followed.

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2.0 STANDARDS AND REQUIREMENTS


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NOTE: INSTALLERS MUST REFERENCE THE SPECIFIC SITE SCOPE ANDPROJECT DRAWINGS FOR ADDITIONAL INFORMATION ANDCONSIDERATIONS, INCLUDING THE SYSTEM LAYOUT AND ANY RELATEDELECTRICAL DRAWINGS.

4.5 Tools

4.5.1 Standard construction and electrical tools along with basic electricalsafety and testing instruments are required for the installation of thecombiner box. In addition to this, installation requires the following:

4.5.1.1 Phillips Screwdriver

4.5.1.2 Torque Wrench

4.5.1.3 Wire Strippers

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4.0 GENERAL REQUIREMENTS



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COMPLIANCE• UL1012 – Power Units Other Than Class 2

• RoHS – Compliant (Pending)

• Transformer meets UL 506 and CSA C22.2 No. 66

ELECTRICALInput Power

277 VACRated Primary Current: 7.3 ARated Frequency: 60 Hz

Output240 VAC2 KVA

EfficiencyQuiescent Power = .78W99.2% @ 277 VAC input; 1600W output

MECHANICALWeight

5.0 pounds

Mounting OrientationFlat vertical surface using 4 screws

Thermal SwitchShuts off operation at 120°C at transformer

Operational Environmental LimitsTemperature Range 0°C – 50°CTemperature Rise at Rated Current: 54°CHumidity: 90% RH non-condensing

Storage Environmental LimitsTemperature Range -40°C – 120°CHumidity: 90% RH non-condensing (transport and storage in protectivecontainer)

ConstructionMade of 16 gauge steelMeets NEMA/EEMAC Type 1 requirements

5.0 PRODUCT SPECIFICATIONSModel 277-240AT

8 Copyright 2012 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.


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6.1 The Nextek Auto-Transformer connection should only be performed by trainedservice personnel.

6.2 Follow installation procedure to install and to power up the system.

6.3 The Nextek Auto-Transformer is designed to keep the temperature of its surfacefrom rising to more than 120°C.

6.4 Treat any conductors and parts of electric equipment as energized that havebeen de-energized, but have not been properly locked or tagged out and testedto a zero energy state.

LOCKOUT/TAGOUT SHOULD ALWAYS BE USED.6.5 AC connections are made inside the Nextek Auto-Transformer using wire

connectors.

6.6 The Nextek Auto-Transformer does not come with the AC power cord. The ACpower cord must be a three 12 AWG conductor cable.

Refer to Table 6.1 for list of acceptable equivalent cords

6.7 There are no operator adjustable voltage selectors in this system.

6.0 CAUTIONS AND WARNINGS

Basic Cord Type Other Suitable Types

TS TST

SP-2 SPE-2, SPT-2

SP-3 SPE-3, SPT-3

SV SVE, SVO, SVOO, SVT, SVTO, SVTOO

SJ SJE, SJO, SJOO, SJT, SJTO, SJTOO

SE SE, SO, SOO, ST, STO, STOOTable 6.1 Suitable Cord Types

7.0 INSTALLATION PROCEDURE

7.1 Preparing The Auto-Transformer For Mounting

7.1.1 Be sure to turn off all main power before starting this project, using theLock Out/Tag Out method. Refer to the facility electrical drawings toidentify the mounting locations and any specific electrical locationrequirements or special instructions.You must mount the autotransformerin a position/ location where it is easily accessible.

7.1.2 Enclosed in the shipping container are:

7.1.2.1 Transformer housing

7.1.2.2 Ground kit & wire connectors (right)

7.1.3 Additional material required for mounting (notincluded)

7.1.3.1 Four Hex Flange Head (Lag Screws)1/4”x 1-1/2” long.

7.1.3.2 The input power cord must be a three12 AWG conductor cable.

7.1.3.3 The output power cord must be a three12 AWG conductor cable.

7.1.4 Removing the front panel.

7.1.4.1 Loosen the four front screws of the enclosure.

7.1.4.2 Remove the front panel.



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7.1.5 Grounding kit installation instructions:

7.1.5.1 Drill a 7/32” hole in the enclosure atthe top of the enclosure.

7.1.5.2 Remove paint where the groundingconnector will contact the enclosureto insure electrical continuity.

7.1.5.3 Install the grounding connector withthe bolt, star washer and hex nutprovided.


7.2 Mounting The Auto-Transformer

7.2.1 The auto-transformer is designed to be mounted to plywood.

7.2.2 Use four hex flange head (Lag Screws) 1/4”x 1-1/2” long to secure the auto-transformer usingall four holes inside back side of the enclosure,making sure the unit is straight and level.

7.3 Wiring The Auto-Transformer

7.3.1 Turn off power before installing or removing any connectors

7.3.2 Strip wires 5/16”

7.3.3 Cable Insertion into enclosure

7.3.3.1 Using the side punch-outs, insert theinput and output cables through theholes using the appropriate sizedconduit.

7.3.4 Connection

7.3.4.1 Hold stripped wires together with endseven and align any frayed strands

7.3.4.2 Push wires into connector and screwon until two twists are visible in wires

7.3.4.3 Input voltage (277 VAC)

7.3.4.3.1 L-1 Common tied to red wireon the auto-transformer

7.3.4.3.2 L-2 Feed tied to black wireon the auto-transformer

7.3.4.3.3 N Ground tied to chassis utilizing the grounding kit

7.3.4.4 Output voltage (240 VAC)

7.3.4.4.1 L-3 Common tied to red wire on the auto-transformer

7.3.4.4.2 L-4 Feed tied to brown wire on the auto-transformer

7.3.4.4.3 N Ground tied to chassis utilizing the grounding kit


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7.3.5 Installing the front panel

7.3.5.1 Place the panel over thefour screws

7.3.5.2 Tighten the screws down.

12 Copyright 2012 all rights reserved by Nextek Power Systems, Inc. in the United States and in other countries throughout the world.


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8.0 TROUBLESHOOTING

FAULT PROCEDURENo Power at the OuputDevice

• Make sure the power circuit feeding the device is turned on.

• Make sure the circuit is wired properly

• Safely and cautiously check to make sure the device has notoverheated from an excessive current draw.

• If it has, you will need to turn off the output to allow the device tocool.

• The output power draw will need to be reduced to preventoverheating



For more information: Nextek Power Systems Tel: 313-887-1321461 Burroughs Street Toll free: 1 (877) 24-VOLTSDetroit, Michigan 48202 Fax: 313-887-9433www.nextekpower.com [email protected]

auto transformer installation and userʼs manual

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