Installation & User Manual
Contents
1. The units are self commissioning and are fully automated to ensure optimum savings are achieved as well as ensuring continuity of supply even during bypass operation The Apex Voltage Optimisation VO units are supplied Rating in 2 frame sizes Each device in the range of Apex Voltage Optimisation VO units is supplied complete with a 3 pole mains isolator and LCD display An optional Moulded Case Table 1 Circuit Breaker in place of the isolator is available as an extra cost option All Apex Voltage Optimisation VO units feature an LED indicator status to identify the following conditions Main Unit in Save Mode amp Unit in Bypass Mode The LCD display on the front of the unit shows incoming voltage outgoing voltage and current drawn per phase The incoming voltage to a site will vary around the country but by law it can be between 216V and 253V current European Legislation ESQCR 2002 However sudden voltage surges can damage electronic equipment and cause premature failure due to the stresses a high voltage applies All electrical equipment is designed to work within a range of 207V and 253V if it complies with European Conformity CE But critically the optimum and most efficient supply voltage for these appliances is 220V When the supply voltage exceeds 220V wasted power can be generated as both heat and vibration This could significantly reduce the life span and ef2. rallation amp User Manual Commercial Voltage Optimisation Unit 563 200 3 Phase y y 7 j j j j e SSS i ii i Ht j i f f Energy UK Commercial Voltage Optimisation Unit Table of Contents TOC O 3 POSS 5 PON S 5 WARNINGSAND CAUTIONS 6 PS EAN CHO een 7 DT TAO 12 ae ee eee 12 O92 ge G10 a creer 12 Fe 9 gee ee ene ee ee ee 13 TU UNOS 14 14 OCP ES CCI Ca O aeons 15 Document Revision Revision No Date Reason for revision September 2012 Page 2 of 15 Energy UK Commercial Voltage Optimisation Unit Introduction This Installation amp User Manual covers the installation and use of the Apex Commercial Voltage Optimisation VO units Apex Energy have a range of 3 phase voltage optimisation products ranging from 63A 100A 160A and 200A They have been specifically designed to suit a wide range of applications and can be installed on main incoming supplies or on sub circuits to reduce energy costs on specific loads
3. 245 ae AC solator Generation Meter 245V Integration of Apex VO With a PV installation 240V gt Grid Power 245V gt PV Power 222V gt Optimised Power Hale Grid Power and Pi Power are exame values and will Tluciuate PV Array 222W tit Distribution Board tit 222v eas Consumer isolator suppliers Fuse _ ere 1 gt 240V Suppliers Meter Figure 2 Typical installation with PV solar power system September 2012 Page 8 of 15 Energy UK Commercial Voltage Optimisation Unit 1 The 63A and 100A three phase commercial units can be wall mounted The 160A and 200A three phase commercial units are recommended for floor mounting only 2 Cable entries are supplied on either side of the top of the units via the gland plate 3 Remove the front cover to allow access to the mounting plate fixing and the terminations for the supply and feed cables a Secure the base to the wall as follows 63A and 100A units only b Choose a location for the base unit of the Apex VO unit either horizontally or vertically on a solid surface in a convenient position for access and in a well ventilated and dry location Ensure the unit has a minimum 100mm clearance all around for ventilation CAUTION If the unit is to be installed vertically the transformer must be positioned uppermost c Measure and mark positions of the six 6 securing screws accor
4. Impedance check it is within limits max Zs for the protective devices installed within the Apex VO unit refer to BS7671 17 edition chapter 4 Prospective fault current if not obtained by enquiry make sure this does not exceed the breaking current of the unit Input Voltage Output Voltage e Record results obtained in steps c and d on an installation certificate and include a copy for the consumer refer to Appendix 7 BS7671 OSG f Replace the cover and secure with the four screws g Re instate the supply and turn on the Apex VO unit and leave it to go through its self setting procedure Figure 5a 63A 100A Unit September 2012 Page 11 of 15 Energy UK Commercial Voltage Optimisation Unit Operation The Apex VO unit constantly monitors the input supply voltage and current and will automatically control the supply within the parameters of the product The incoming supply will fluctuate constantly the Apex VO unit will react as follows A click noise may be heard from the unit as it changes state this is normal Under Voltage The incoming supply will fluctuate constantly where a risk of under voltage exists the Apex VO unit will automatically revert back to mains voltage Over Current The Apex VO unit must NOT be subjected to a current on any phase that is above its name plate rating Suitable thermal protection MUST be installed downstream of the Apex VO unit to protect the un
5. MUST ONLY BE PERFORMED BY A QUALIFIED ELECTRICIAN CAUTION Removing the cover of the Apex Voltage Optimisation VO unit without contacting Apex Energy may invalidate your warranty Both LEDs not lit on Loss of Power Consult supplier to check if supply power has Optimiser been cut Loss of Power Check visually cable from meter to optimiser only qualified electricians should carry out further checks or attempt to reconnect cables Red LED continuously Optimiser Unit Contact your Apex supplier flashing Failure Warranty The Commercial Voltage Optimisation Unit is guaranteed for one year from the date of purchase The installer will record the serial numbers of the Apex VO unit and the circuit board on the warranty card This warranty card must be sent to Apex Energy to increase the warranty to three years September 2012 Page 14 of 15 Commercial Voltage Optimisation Unit Technical Specification Cooling Case is naturally ventilated Voltage Surge Able to withstand 3 3kv for 60 seconds Breaking Current 10kA Temperature rise Full load above 63A 10 degrees ambient 100A 10 degrees 160A 10 degrees 200A 10 degrees Operating Current Continuous Maximum current dependant on model 63A 100A 160A 200A Dimensions 63A 480mm W 702mm 230mm 100A 480mm W 702mm 230mm 160A H 600mm W 700mm D 300mm 200A H 600mm W 700mm D 300mm 63A 42kg 100A 42kg 160A 90kg 200
6. A 90kg INSTALLATION amp USER MANUAL COMMERCIAL VOLTAGE OPTIMISATION UNIT Designed developed and manufactured in the UK by Apex Energy UK St Johns Road Meadowfield Ind Est Durham DH7 8R S September 2012 Page 15 of 15
7. ding to whether the unit is to be mounted horizontally or vertically The dimensions of the hole centres are given in Figure 3 d Drill appropriate size hole for either direct fixing into wood or the correct type of wall plugs for plasterboard brick etc Use M12 screws with wall plugs if lt appropriate Leave the heads of the screws protruding sufficiently to locate in their relative location holes in the base unit Ott f Locate the base unit on the M12 screws if necessary tighten the screws to prevent any movement of the base unit but do not tighten fully as it should be made possible for the unit to slide in and out of R6 position 300 702 300 R6 77 86 300 R6 6 Figure 3 Dimensions of mounting hole centres 63A and 100A Wall Mounted Unit Only 4 Isolate the supply to the premises at the isolation switch meter or by removing the supply fuses as applicable If the supply fuses are removed make sure that the fuse holder is covered with insulation material to prevent any possible contact with live terminals September 2012 Page 9 of 15 Energy UK Commercial Voltage Optimisation Unit 5 Remove the tails and connect directly to the Apex VO unit or Mould Case Circuit Breaker MCCB or if not possible due to inconvenient lengths cut or use new longer tails If it is necessary to connect longer tails get permission before you remove any
8. e parameters such as incoming voltage outgoing voltage load current temperature even its own performance ensuring the unit always delivers the optimum performance to the premises The Apex VO unit will automatically select the correct level of voltage reduction or even to bypass depending on the algorithm of conditions Incorporating the latest sine wave sampling SWS and active sine wave mapping ASWM technology enables the unit to monitor and control three critical performance and safety functions 1 Low Voltage Threshold LVT eliminates the risk of the optimised voltage falling below a minimum target voltage When it detects the voltage has recovered and stabilised it automatically switches back to save mode 2 High Current Threshold HCT 63A unit and 160A unit only protects against over current The unit will automatically detect this and remains a temporary bypass mode until the over current reduces 3 Optimum Switching Threshold OST by constantly mapping the sine wave the Apex VO unit will only switch at the optimum point which eliminates any interruption to the supply voltage It also eliminates spikes and transients September 2012 Page 4 of 15 Energy UK Commercial Voltage Optimisation Unit Purpose The purpose of the Apex VO unit is as follows e Reduce energy waste and carbon footprint by reducing the power consumed by appliances e Contribute to Government funded targets on carbon reduc
9. ficiency of the equipment The commercial range of Apex Voltage Optimisation VO units feature a Dual Tap function This enables the unit to automatically select the correct tap setting according to the incoming voltage This offers 2 major benefits 1 Prevents the site voltage going below the recommended lower voltage 2 Ensures that even when the incoming voltage drops the Apex VO unit can automatically adjust to a lower tap setting ensuring that savings are still being achieved September 2012 Page 3 of 15 Energy UK Commercial Voltage Optimisation Unit Electric loads that will deliver energy savings are those that are known as voltage dependent loads Appliances that will benefit from voltage optimisation are typically e Refrigeration loads e Air conditioning without invertors e Electric motors without speed drives e Heating pump motors e Metal Halide SON Lamps e Incandescent lamps e Compact fluorescent lamps e Fluorescent tubes 8 T12 e Halogen lighting indoor and outdoor e LED lighting e Process loads Savings may vary between different manufacturers In addition to energy saving the Apex VO unit can also protect your appliances from harmful over voltages and spikes that can significantly reduce the electrical life of sensitive electronic equipment The Apex VO units have a dedicated electronic control unit ECU which intelligently and constantly monitors all th
10. it from irreparable damage that will be caused should this happen The operating status of the Apex VO unit is indicated by two LED s in the small circular indicator window Refer to Figure 7 Energy UK Figure 7 63A 100A Apex VO unit Figure 7b 160A 200A Apex VO unit The Apex VO unit will instantly switch to save mode when it is powered up and switched on Should the Apex VO unit detect a low voltage on any one of the three phases it will automatically revert to a bypass condition until the voltage is high enough to allow save mode to be selected There may be a delay between these states as the Apex VO unit is establishing that the supply voltage has stabilised September 2012 Page 12 of 15 Energy UK Commercial Voltage Optimisation Unit Status Indications The status indicated by the LEDs is described in the following table A graphical representation of this is given in Figure 6 Save The unit is working normally and in Save mode mode Flashing Single Internal The unit is conducting internal tests this will typically Flashing Testing occur following a power outage The unit will revert to Save mode once completed Flashing Single The unit has reverted to Bypass mode due to a Flashing temporary under voltage Once the voltage increases to specification levels the unit will automatically revert back to Save mode Flashing Double The unit has reverted to B
11. never be covered September 2012 Page 6 of 15 Energy UK Commercial Voltage Optimisation Unit Installation The configuration of a typical commercial installation is illustrated in Figure 1 The configuration when integrated with a typical PV installation is illustrated in Figure 2 222V Integration of Apex VO 240V E gt Grid Power 222V mi gt Optimised Power Note Grid Power values are example values and will Suctuale Distribution Board m 240V Consumer Isolator t 240V Suppliers Meter i Suppliers Fuse t 240V t 240V Figure 1 Typical Commercial Installation Note Before commencing with the installation e Make sure that you have the correct CSA and length of tails Add together the total maximum design current of the circuits to be supplied by the Apex VO unit to calculate the conductor size of the cable required refer to Appendix 6 of the BS7671 On Site Guide e Establish how isolation is to be achieved If an isolation switch is not installed check if there is an isolation facility on the meter As a last resort remove the supply fuse this is usually a BS88 or BS371 cartridge type If seals are fitted notify the supplier and ask permission before you remove them e Make sure the unit is clean and undamaged prior to installation September 2012 Page 7 of 15 Commercial Voltage Optimisation Unit DC Isolator Inverter lA a
12. seals at the meter If applicable connect the tails to the meter make sure that the connection is in accordance with BS7671 Chapter 13 of the Wiring Regulations 17 Edition e That all the terminal screw is in contact with the conductive part of the cable e There is no excess conductor exposed Connect the cable tails from the meter to the Apex VO unit and the output cables as follows a Connect the cables to the terminals of the triple pole isolator or moulded case circuit breaker at the Apex VO unit Connect the output cables from the Apex VO unit at the din rail connectors Refer to Figure 4 for cable installation OUT Neutral OUT Live IN Neutral yen Live we 180 Figure 4 Cable installation x 3 for 3 Phase connections b Connect the correct size earth bonding cable refer to Chapter 4 of the BS7671 On Site Guide between the main earth terminal and the chassis of the Apex Voltage Optimisation VO unit using a terminal lug crimped to the earth cable Note Leave the main earth conductor usually 16mm CSA connected between the main earth terminal and the distribution board September 2012 Page 10 of 15 Energy UK Commercial Voltage Optimisation Unit c Carry out the following dead checks Continuity of all cables Polarity of the live and neutral Insulation between phase and earth d Carry out the following live checks Earth Loop
13. tion e Generate end user savings which start immediately after installation e Substantially extend the life of appliances and lighting e Protect sensitive electrical devices from damage Important Points e Familiarise yourself with this manual and the Apex VO unit before installing and or operating the unit e In particular ensure that you have read the WARNINGS AND CAUTIONS section e Contact your electrical supplier before breaking any main fuse seals during the installation of this product Apex Energy recommends if necessary that you ask the supplier to install an isolator switch September 2012 Page 5 of 15 Energy UK Commercial Voltage Optimisation Unit WARNINGS AND CAUTIONS These warnings and cautions must be observed when installing and or operating the Commercial Voltage Optimisation Unit WARNING 1 ELECTRICITY CAN KILL INSTALLING THIS EQUIPMENT WITHOUT ISOLATING THE SUPPLY IS NOT ONLY DANGEROUS BUT CONTRAVENES THE ELECTRICITY AT WORK REGULATIONS 1989 WARNING 2 MAKE SURE THAT MAXIMUM CONDUCTIVE CABLE SURFACE IS IN CONTACT WITH TERMINALS AND THAT THEY ARE SECURE LOOSE CONNECTIONS CAN CAUSE ARCING THAT MAY RESULTS IN HEAT DAMAGE TO COMPONENTS AND ULTIMATELY FIRE WARNING 3 THIS WORK MUST BE CARRIED OUT BY A REGISTERED ELECTRICIAN CAUTIONS e Install the VO unit in free air ventilation e Make sure the installation location is clean and dry to prevent any current leakage e The unit must
14. ypass mode due to a Flashing temporary over current Once the current drops the voltage optimisation device will automatically revert back to Save mode Flashing Triple The unit has reverted to Bypass mode due to a Flashing temporary over temperature Once the unit temperature drops to specification levels the voltage optimisation device will automatically revert back to Save mode Off Continuous Unit The unit has shutdown either because the incoming Flashing Shutdown voltage has exceeded 290V OR the unit has become too hot OR the unit has exceeded its maximum load Switching the main Isolator off then on again should reset the unit Please note that there may need to be a time delay before the unit will reset if it tripped due to over temperature Table 2 Fault Status RED indicates a fault condition VO Mode GREEN indicates voltage selection mode Number of flashes indicates fault type Solid for VO Mode Flashing for Bypass Mode Power up Self test Start up Bypass mode Figure 6 Graphical presentation of status indicators September 2012 Page 13 of 15 Energy UK Commercial Voltage Optimisation Unit Troubleshooting WARNING 4 ELECTRICITY CAN KILL TROUBLESHOOTING THIS EQUIPMENT WITHOUT ISOLATING THE SUPPLY IS NOT ONLY DANGEROUS BUT CONTRAVENES THE ELECTRICITY AT WORK REGULATIONS 1989 WARNING 5 TROUBLESHOOTING THAT REQUIRES THE REMOVING OF INSULATING COVERS
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