Installation and Service Manual 4.cdr
Contents
1. 216 VOLTS l 222 VOLTS 230 VOLTS All the wire connections including the unused wires should be well insulated with approved connectors then double insulated with electrical tape Page 6 Installation Secondary Connections Two identical secondary windings are provided on each transformer These can be connected in series or in parallel or used as individual windings Each of the two secondary windings is designed to carry half the rated KVAoutput of the transformer The secondary windings may be connected in parallel for 115 volt output or wired in series for use in 230 volt applications The diagrams below illustrate the possible combinations of output connections The output voltage and configuration will be determined by the requirements of the tower lighting system Refer to the lighting manual and specifications before connecting the output of the A E01D1 tothe tower lighting 115V bd 115V 115v 230 V bd x S al 3 i rs al a x als z x u 4 W lt w 3 W X wm Er uw au oo a mM fav W a al fa a pe m a gt 0 m w oO VVVVY VVVY COO COO 115 VOLT 115 0 115 VOLT DUAL 115 VOLT 230 VOLT TWO 2 WIRE THREE 3 WIRE TWO 2 WIRE TWO 2 WIRE Secondary Wiring Configurations for2. Installation Instructions for A E01D1 Austin E Cap Series Isolation Transformer Dual Winding Multi Voltage Austin Insulators Inc 7510 Airport Road Mississauga Ontario L4T 2H5 CANADA Tel 905 405 1144 Fax 905 405 1150 email support austin insulators com Revised Nov 17 2004 website www austin insulators com AUSTIN ISOLATION TRANSFORMER E CAP A E01D1 PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLING ANY LIGHTING TRANSFORMER WHETHER ON A NEW INSTALLATION ORAS A REPLACEMENT UNIT The Austin E Cap Isolation Transformer is intended for use on LF to HF radio masts antennas and towers with low to moderate RF potential When installed in an open environment the permissible RF potential between primary and secondary sides must be less than the wet flashover figures given below For operation under wet dusty or insect infested conditions the maximum permissible voltage will depend on the amount of rain etc the frequency of occurrence and the acceptability of occasional arc overs and level of drip corona Under heavy rain conditions excessive drip corona may occur before arc over It is unlikely that satisfactory operation in an exposed location will be achieved above the following levels CAPACITY NOMINAL OUTPUT AC VOLTAGE RF FLASHOVER RATING VA VOLTAGE FREQUENCY WET SEALEVEL 170 115 230 50 60 Hz 14 KV Peak CAUTION Before beginning any installation repai
3. 115 and 230 volt output All the wire connections should be well insulated with approved connectors then double insulated with electrical tape Page 7 APPENDIX Troubleshooting Guide PROBLEM POSSIBLE CAUSE RESOLUTION High amperage draw Possible short circuit in the Check all wires and connections for shorts with no load present secondary junction box and exposed conductors Test supply Windings are connected voltage level and consult wiring diagrams incorrectly for input voltage on page 6 for proper connections Output voltage is very Secondary connection does _ Test the supply voltage to the transformer not match the primary primary Consult wiring diagrams on page 6 connection and 7 to be sure output matches the input connections No load on the secondary or Test the voltage and amperage load on the the load exceeds the secondary and compare it to the primary lower than expected transformer ratings input Incorrect Primary taps have Use the following chart to ensure the output been used falls within the guidelines for transformer use Primary input voltage Possible connection Consult wiring diagrams on page 6 and 7 is present No output problems Windings are out for proper connections of the Primary and on secondary of phase Secondary windings The wire colors must be hooked up correctly for the transformer to operate Charts for Output Voltages at Various VA Loads In order for the E Cap series o
4. Aset screw is provided to lock the transformer in position Page 3 Installation Mounting cont The E Cap should be situated so that the bottom of the transformer is approximately level with the base of the mast or tower it services In any event Austin recommends the E Cap module be high enough above grade or the surrounding ground level to avert any possibility of contact with water The transformer must be mounted at a sufficient distance from the tower or mast to prevent any arc over or corona especially during inclement weather The spark gap spacing on the A E01D1 has been set at the factory No further adjustment should be necessary The spark gap balls should be approximately 2 or 5 cm from the body of the transformer and approximately 1 1 2 or 3 5 cm apart If the transformer has been subjected to extremely rough handling during transport the spark gap may require adjustment Refer to Appendix II for instructions on Transformer Adjustments Installation Bonding The Primary or Input side of the transformer should be grounded by three different means 1 Powersupply conduit ground The transformer has been designed to be connected to the main electrical supply and the tower lighting by means of a metal electrical conduit This may take the form of a rigid pipe or flexible metallic conduit with a watertight covering In either case the installer should ensure the conduit is installed in accordance with the manufactur
5. econdary power output wires Ifa junction box is used on the output side of the transformer this ground braid should be connected to the interior of the box by means of the supplied grounding screw In either case a separate electrical conductor wire must pass through the conduit and be connected to the approved ground point in the tower lighting junction box Installation Wiring In order to ensure that no substantial radio frequency potential exists between the secondary winding and its outer shield special noise squelching circuits have been built into the E Cap transformer series These circuits provide a path to dissipate any static charge or RF interference that might be induced in the secondary power circuit These EMI and capacitance devices will provide a cleaner power output without affecting the electrical or performance characteristics of the transformer The tower lighting circuit should be run through a continuous metallic conduit that is well bonded to the mast This will greatly assist in reducing electro magnetic interference The primary power should also be brought to the transformer from the main power supply through conduit or metallic covered cable which is bonded to the antenna ground system The grounding braid and electrical conductors mentioned previously are critical to the safe and reliable operation of the E Cap transformer If all installation procedures are adhered to the bonding and filtering will provide adeq
6. ers instructions and local electrical codes 2 Powersupply ground conductor A separate electrical conductor must be included in the power supply conduit for the purposes of grounding It should be connected to the interior of the transformer junction box by means of the supplied grounding screw The other end should be connected toa ground point in the main electrical supply box in accordance with local regulations 3 Exterior Grounding Stud A threaded stud with accompanying hardware has been supplied for bonding the primary side of the transformer with a good mechanical and electrical connection to the antenna ground system This stud is located on the lower spark gap arm mounting collar and points downward near the base of the unit It is designed to accommodate a ground strap terminal with a 3 8 or 1 cm hole All bonding connections should be made as short and direct as possible Page 4 Installation Bonding cont The Secondary or Output side of the transformer relies on two methods to remain bonded to the mast or tower 1 Austin Insulators recommends using a rigid metal or flexible metallic conduit with a watertight covering to connect the output of the secondary transformer windings to the lighting junction box on the mast or tower The installer must be sure the conduit is installed in accordance with the conduit manufacturers instructions and local electrical codes 2 Aseparate ground braid wire is included with the s
7. f transformers to achieve maximum isolation some magnetic de coupling is inevitable The following charts show the voltage shift as the lighting load increases 115 Volts Input 230 Volts Input Volts Out VA Out Volts Out VA Out 121 0 240 0 120 36 235 50 119 63 232 92 117 99 226 135 112 160 220 155 NOTE When using any sort of meter to test the E Cap windings please remember the built in filter system may affect the readings to some slight degree Page 8 APPENDIX Il Spark GapAlignment The spark gap on the E Cap A E01D1 is preset at the factory and should not require adjustment If the transformer has suffered damage in shipment and the gap ball support arms have been bent it will be necessary to re align the spark gap ATTENTION Under no circumstances should you attempt to bend the support arms while they are attached to the transformer body 1 2 gt Disconnect any wires in the junction boxes Remove the junction boxes from the pipe fittings in the transformer body Do NOT apply excessive force to the pipe fittings or attempt to remove them from the transformer They are permanently molded into the casing Locate and loosen the set screw in the arm mounting collar Slide the arm assembly off the pipe fitting Consult the diagram to check the proper angles for the support arm If the angle from the collar to the arm is not cor
8. rect place the collar in a vice and carefully bend the rod to the proper angle If the bend in the arm is not correct place one side of the rod in the vice and carefully bend the other side to the proper angle Check the arm angles and shape to see if it matches the diagram Reinstall the arm assembly NOTE There is a notch in the corner of the transformer body that allows the rod to lock into place as it passes the corner Be sure the rod is fit into this notch to prevent misalignment of the spark gap Tighten the set screw to keep the arm in position Reinstall the junction boxes being careful not to cut or damage the transformer wiring NOTE Do not apply excessive force to the junction boxes or any other fittings you may connect to the transformer Use Teflon tape on the pipe threads to maintain a watertight seal without using undue force Page 9 Maintenance The surface of the transformer should be kept reasonably free of dirt build up to help prevent premature arc overs and corona The surface of the transformer is not affected by arcing flashovers or other electrical phenomenon and will not burn or track If the transformer body is scratched during installation there is no need to touch up the surface The E Cap casings will not rust chip or absorb water After several years in full sunlight and extremes of weather a slight chalking of the surface may occur Please observe standard safety procedure for tran
9. rs or adjustments Make sure the following conditions are met Ensure the RF Transmitter is off Ensure the tower or mast is grounded Ensure that the supply power wires are not live Check that the tower lighting circuit is not faulty Ensure the lighting load does not exceed the transformer capacity rating Ensure that the primary protective circuit meets following specifications Ooh WN Page 2 Primary Protective Circuit Where incandescent lighting is used a circuit breaker is not recommended unless it has been chosen to have the required delayed action to withstand the inrush current to the tower lighting equipment A fuse will provide ideal protection and has the inherent thermal delay to deal with the inrush current when activated Towers that employ LED neon or xenon lighting will not be affected by inrush currents to the same degree Whether a fuse or circuit breaker is chosen its operating current should be approximately 35 per cent above the normal operating current for the lamp load in use The maximum recommended fuse rating for the A E01D1 is 4 amps Transformers are sometimes damaged due to choosing the incorrect protective circuit Though there is some flux leakage resulting from the isolated nature of the primary and secondary windings the self regulation design of the transformer makes the windings susceptible to over heating and damage if the full load rating is exceeded The safest operation i
10. s assured if the primary current is measured under normal load conditions and a fuse chosen with a rating approximately 35 percent above this operating current Installation Mounting WARNING DO NOT ATTEMPT TO TURN ORADJUST THE PIPE NIPPLES THAT ARE MOLDED INTO THE TRANSFORMER BODY APPLYING EXCESSIVE FORCE TO THE FITTINGS WILL BREAKTHE SEALS ANDALLOW WATER TO ENTER The E Cap transformers are shipped in tri wall cartons When removing the transformer from its carton do not attempt to lift it out by grasping the spark gap arms or the wiring harnesses Carefully lift the transformer by supporting the body of the unit Do not lay the transformer body on its sides which would pinch the wiring against the ends of the pipe fittings Do not lay the transformer body on its front surface with the spark gap downward as this could bend the spark gap support arms The transformer body may be positioned on its back or upside down and resting on it s top while fittings and wiring are installed The E Cap transformers are designed to be mounted vertically using a single steel post This mounting post may be one of the following types A steel post having an outside diameter of 1 3 8 1 375 A steel pipe having an inside diameter of 1 A standard steel pipe having an outside diameter of 30 to 35 mm The mounting flange in the base of the A E01D1 will fit over any of these mounting posts without the need for threads or other preparation
11. sformer repair and maintenance Using a fine steel wool or other mild abrasive gently rub down surface of the transformer to remove the chalk build up Wash the casing with a mild detergent and treat with any commercially available exterior wax product This procedure will help to maintain the RF withstand rating of the transformer and ensure that the E Cap A E01D1 will operate reliably for many more years to come No other maintenance procedures should be necessary The E Cap transformers are designed to provide many years of trouble free service If they are installed and used in accordance with these instructions you may expect faithful and reliable operation Page 10 Physical Diagrams amp Dimensions for the E Cap A E01D1 11 31 Total Depth Transformer Footprint viewed from the bottom Spark gap dimensions shown are approximate and may vary by 0 25 or 6mm Mounting flange will IN accommodate pipe size from 30 har to 35mm or 1 31 to 1 4 625 i i 16mm i 18 3 8 cm oe 8 25 i 21 cm i i i 11 25 i 28 6cm i PEE Transformer Profile om viewed from front spark gap IN side ia 13 33 cm IN wes l i as 8 25 i 3 8 om avian Page 11
12. uate protection against stray RF pick up and electrical noise Page 5 Installation Primary Connections Two sets of primary windings are provided on the transformer Portions of these windings can be connected in series for use with a nominal 230 volt source or in parallel for use with a nominal 115 volt power source Due to the arrangement of voltage adjustment taps caution must be used in making the parallel connections The section of the primary windings connected to the Red and Yellow wires and the Green and Blue wires are balanced and can be connected in parallel as shown below The outer portions of the primary windings connected to the Black and White wires are not identical and have been designed to give greater flexibility when voltage adjustments are required The diagrams below illustrate the various combinations that may be used with either voltage range The output on the secondary side of the transformer has been designed to be either 115 volts or 230 volts However if a slightly higher output voltage is necessary the primary voltage taps may be used to increase the output of the transformer For example if 120 volts output is required a 115 volt supply may be connected to the 108 volt taps on the primary side Use caution when making these adjustments PRIMARY INPUT CONNECTIONS FOR VARIOUS SUPPLY VOLTAGES 108 voLTs 115 voLTs l 122 vots i 130 VOLTS
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