Install a module ME or MT.5.202 Build a converter with a Booster module. ME modules deliver unbalanced three-phase voltages, sufficient for machines with threephase motors. MT produces balanced three-phase voltages for VFDs, welders, plasma cutters, inverter based machines (CC, air conditioning, heat pumps) and for motors running under extreme loads. To build such a converter based on a Booster module, a standard three-phase motor is required. For locations where two-phase is not available, a single -phase auto transformer is needed to convert 240V or 480V into single -phase. Simple connections will combine these three items into one converter. Let an electrician make the connections if you are not the electrical expert yourself. Position these items: Smaller versions: Mount the enclosed transformer and the module side by side on a wall, the motor in a safe box. Larger versions: Install the module on a wall, transformer and idler motor inside a safe box. Or all items in one box. The transformer's kva rating should be 0-5% above the converter's kw rating. Transformer manufacturers may put labels on transformer terminals which are often wrong for three-phase converters. This common labeling is shown in brackets. For a step-up transformer in a converter, must to be connected to the center tap and L to the common tap. Test: Measure about 75V between the third connector and eutral. Measure across Common and the opposite connector. Any voltage between a transformer output and eutral must not be higher than the input voltage. for standard 240V single phase supply: (45) 75V to (L) eutral 240V L () 240V to (0) eutral Labeling shown above in brackets is often found with standard transformers. They are wrong for use in converters. Change labels. Test voltages first before you connect a transformer to a module. Make sure phase of a converter is always 240V to eutral. Rural 480V split phase supply: La 480V 75V to eutral Lb 240V to eutral
Use 240V 75V to to eutral step-up transformer for a standard 240V single 240V to phase eutral supply L 240V Single phase input Module ME MT 2 2 three-phase output to machines Use 480V to step-down transformer for a standard 480V split-phase supply La 75V to eutral La Lb 480V Single phase input The correct supply voltage to a module M is + - 0%. o transformer is required when the supply is (two phases from a three-phase supply). The output of a module M must be connected to a 2-pole three-phase idler motor (large soft-start modules require two identical motors). This motor must be in configuration (almost all motors for 50Hz above kw are when set to ), the kw rating must be as specified for a module. Make sure the motor is connected for. ever use a motor other than specified here. A module ME can be used without an idler motor but only if the load motor is exactly as the idler motor. Such a motor will only produce about 75% maximum torque and power. We recommend to always use an idler motor. A module MT always requires an idler motor to work. The idler motor supports phase voltage balancing and correct phase angle separation. Direction of the rotation can be left or right. Three-phase voltages are only present when a motor is running. Control transformers and single-phase loads: A eutral wire is only required if a control transformer or a single-phase load inside a machine is connected between one of the phases and eutral (240V). Find out by measuring the resistance of a control transformer on a disconnected machine's plug (when the main switch is in On position). If eutral is needed, feed a eutral wire through a converter to the output. For single-phase loads or control transformers inside a machine, only use L to eutral. The voltages between phase or 2 to eutral are not 240V. If a motor in a machine rotates in the wrong direction: swap phases and 2. A control transformer or a single-phase load inside a machine is : identify the two phases where the control transformer or load is connected to by measuring the coil resistance on a machine's plug (main switch in On position). Connect the two phases for such a single-phase load to converter output and only. If a motor in a machine rotates in the wrong direction: swap phases and only. Start installation: Drill holes for glands into the bottom side of the module. See the drill guides in box.
Install: - the module onto a wall. Use the wall brackets supplied. Protect from water and heat. - a slow motor-rated or D-curved circuit breaker in the house's fuse box, see values below. - a dual circuit breaker for disconnecting both phases if supply is two- phase or 480V. - an industrial single phase (240V) or two-phase (480V) wall switch. - three-phase wall outlets or a distribution panel near the machines. - the idler motor on soft rubber mounts (Embleton, Mackay, Skellerup or others). Connect the three output phases of a module to the idler motor connector: > left, 2 > centre, > right or, if vertical, - 2 - from top to bottom. This is for easier service should phone support be needed. Connect: - Protective Earth () to the transformer, to the module (T), to the pilot motor, to the power outlets and to the machines. - Single-phase supply to a protective circuit breaker inside the house fuse box, then to a wall switch, then to the transformer and to the module. - Module output 2 to the idler motor and to the machines. Large modules require a second motor. Supply Fuse Transformer ME4 MT4 240V 20A 4.5kVA 240 to.7kw (5hp) ME8 MT8 240V 40A 9kVA 240 to 7.5kW (0hp) MT8 480V 2x 20A - MT2 480V 2x 0A 4kVA 480 to kw (5hp) MT2 240V 60A 4kVA 240 to kw (5hp) MT6 480V 2x 40A 9kVA 480V to 5kW (20hp) MT6 240V 80A 9kVA 240V to 5kW (20hp) MT24 480V 2x 60A 27kVA 480V to 2x kw (5hp) MT24 240V 20A 27kVA 240V to 2x kw (5hp) Test: Test transformer first for correct output voltages. Connect to module. Connect to idler motor(s). Apply power. motor starts fast and runs quietly. Test voltage phase to eutral = 240V. Test voltages between phases for +- 0% when the idler motor is running. Connect machines after voltages found to be correct and connections of machine's control transformers are correct. Should a motor rotation be wrong: swap two phases to the machine, see under control transformers. Welders: Transformer-type welders often require only two of the three phases. Connect these phases to converter output L and L. Inverter type welders: find any control transformer connection (if present) as with machines (measure control transformer resistance on welder's plug). If resistance is found to be symmetrical. Connect as you like. Some machines have a phase sequence relay and only work if the phase sequence is correct. Danger: Do not run a module when open. Capacitors are charged with high voltages. Voltages are slowly discharged and remain dangerous for some minutes. Open a module: Disconnect from power. Wait for at least ten minutes until internal capacitors are fully discharged. Measure first if all capacitors and connectors have a safe voltage before doing any work.
In Out Left: Transformer, module, motor installed seperately Right: Transformer and motor in a box. Module on a wall. Below: Transformer, motor and module in one box.
A special application: The three-phase load is not one or several three-phase motors but an inverter (VFD, CC, welder, plasma cutter, air conditioning). Add a second idler motor, same specification as the first one. This can be done by a manual switch. Start converter, then start motor 2, then start load. Or use a contactor and a delay circuit. Set delay to two seconds. 2 will start two seconds after motor. Start load when both motors are running. Module ME MT Manual 2 In 2 Out Manual switch Module ME MT Automatic 2 In 2 Out 2A contactor A2 A 240V coil 8 5 A A2 Merlin Gerlin Multi 9 RTA timer set to 2 sec on-delay