TEAL Electronics

Model MCT 100/480 Isotran Plus

TEAL Part Number 4450028-04

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TABLE OF CONTENTS

SPECIFICATIONS ...........................................................................................................ii
1- SAFETY ......................................................................................................................1
2 - PRODUCT DESCRIPTION.........................................................................................2
2-1 Product ................................................................................................................................................... 2
2-2 Grounding .............................................................................................................................................. 2
2-3 Additional Features ................................................................................................................................ 3
3- PHYSICAL INSTALLATION .......................................................................................3
3-1 Unpacking .............................................................................................................................................. 3
3-2 Shipping Brackets .................................................................................................................................. 3
3-3 Mounting ................................................................................................................................................ 4
4- CONNECTIONS ..........................................................................................................4
4-1 Line ........................................................................................................................................................ 4
4-2 Load ....................................................................................................................................................... 5
4-3 Voltage Adjustment................................................................................................................................ 5
4-4 ABB Option ............................................................................................................................................ 6
5- MAINTENANCE ..........................................................................................................7
5-1 Surge Suppression ................................................................................................................................ 7
6- REVISION HISTORY ...................................................................................................7
7- DRAWINGS
Dimension Diagram
Component Location
Schematic
Appendix A
Appendix B
Appendix C
Appendix D

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SPECIFICATIONS
COMMON ALL MODEL NUMBERS
SPECIFICATIONS
Input Voltage 200/208/240/380/400/416/440/480/500 VAC DELTA

Frequency 50/60 Hertz

Output Voltage 277/480 VAC WYE , 120 VAC

Surge Withstand Will withstand and protect against worst case power line surges as defined by
ANSI/IEEE C62.41 Categories A and B up to 6000V, 3000A capability ringwave and
impulse waveform.

Spike Protection With Category A ringwave applied to input either normal mode or common mode,
output transient will be less than 50V H-N and 0.5V N-G.

Construction Materials All transformer wires are insulated with Haptz Class H materials. Windings are
insulated with a Nomex paper insulation system before vacuum varnishing. Internal
wiring is minimum 200 degree C rated and sleeved with Class H material. A grain-
oriented silicon iron core with 14-mil laminations interleaved 1-1 is used to minimize
eddy currents and to keep external magnetic fields below 0.1 oersted (measured at 12
inches from unit in any direction).

INDIVIDUAL MODEL NUMBERS

SPECIFICATIONS
Model Number MCT 100/480 MCT 100/480
Isotran Plus Isotran Plus

(TEAL) Part Number 4450028-03 4450028-04

Power Rating 115 KVA(I) 115 KVA(I)

Overload Protection Refer to Table Refer to Table

on Schematic on Schematic
Load Current @ 277V 42 Amps 42 Amps
@ 120V 20 Amps 20 Amps

Weight Pounds (Kg.) 697 (316) 697 (316)

Transfer Impedance

60 Hz (L-N) <0.06 Ω <0.06 Ω

60 Hz (L-L) .1 Ω .1 Ω

Efficiency Percent > 98.3% > 98.3%

Load Regulation
(0-Peak% Load) < 3.026% < 3.026%

Operating Temperature 0 - +40 C 0 - +40 C

Humidity 0-90 Non- 0-90 Non-

Condensing Condensing

Heat Loss (BTU/Hr.) < 2350 < 2350

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1- SAFETY

Even when an EPO/EMO switch is present, this does not guarantee that the power has
been cut off coming into the unit. Units are heavy, ensure adequate lifting capacity is
used. To avoid tipping over, do not tip beyond 10° from vertical and avoid abrupt
movements.

High voltage. Turn power off before servicing.

Electrical shock hazard. Lock out power at main panel. Failure to

do so could result in serious injury or death.

Failure to set transformer input taps to match nominal input voltage

may result in improper output voltages which may damage
equipment, cause load equipment to malfunction or cause injury.

Failure to set control transformer to match nominal input voltage

may result in equipment damage or malfunction of equipment.

Isotran Plus must be properly grounded for safety per National

Electric Code, State or Local code.
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2 - PRODUCT DESCRIPTION

2-1 Product

The Isotran Plus consists of four basic components:

• A very well insulated, well shielded, low impedance isolation transformer. This
provides protection against “common mode” noise and spikes (neutral-ground
potentials). The system can withstand and protect against impulses up to 6000
volts. It can also provide the inrush and peak currents required by disk drives and
modern switch mode power supplies in today’s computer systems.
• A low pass power filter with an exceptional ability to suppress “normal mode” noise
(fast line-neutral voltage spikes and dips).
• A surge suppressor, which shunts large impulses to ground. While the isolation
transformer and low pass filter handle virtually all disturbances, this surge
suppressor’s function is to reduce unusually large voltage spikes to levels that are
harmless to electronic equipment.
• An output contactor that can be controlled by a remote ON/OFF switch.

This Isotran Plus removes noise and spikes from the AC power line. It is installed
between the source of power (such as a wall outlet) and the equipment that needs
protection from power lines disturbances.

Clean power enhances the reliability and mean time between failure of computers and
other sensitive electronic equipment. Depending upon the type of system being
protected, cleaner power can for example, enhance testing sensitivity, testing yields, or
image quality.

2-2 Grounding

Good grounding and ground bonding are critical to the reliable operation of electronic
systems as well as personnel safety. The following directions should be followed only in
as far as they are consistent with all local and national electrical codes. Grounding can
often be confusing and difficult. Contact TEAL Electronics at 858-558-9000 if you wish
more specific advice.

This Isotran Plus includes an isolation transformer that can significantly improve the
quality of system grounding. By re-referencing the phase conductors to ground, it
eliminates incoming line-side "common mode" noise (and complies with Article 250-5 of
the NEC). The output neutral (if present) is bonded to ground.

Input service ground requirements: If all communicating system components are

powered from this single point ground with isolated ground-type distribution, the system
is then completely isolated from external ground quality issues. Non-isolated code

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minimum input grounds can then be used. Verify input grounding meets codes prior to
installation.

If the system has non-isolated communications lines from other devices not
powered by the Isotran Plus, the system is then less isolated and incoming ground
quality becomes more important. The communications line becomes a "back door"
through which power and grounding problems can disrupt or damage the system. Good
grounding of devices on both ends of the line helps minimize potential problems, as
would surge suppressors on the communications line or an Isotran Plus on the device
on the other end. Surge suppressors on the device, however, hurt much more than they
help. Isolation of the communications line (optical or magnetic) eliminates this problem
altogether.

If a "good" input ground is required, it should be a continuous, insulated, isolated,

oversized wire back to the service entrance. This wire for the TEAL Isotran Plus refers to
the ground wire in a 4-wire DELTA installation, installed with the 3 phase wires.

Local Grounding Bond: Article 250-30 of the National Electric Code (NEC) requires
that hard wired power conditioners (including the Isotran Plus) be bonded to nearest
available local building grounding electrode as well as the equipment ground. The
required local ground bond points are:

a. Building Steel, or
b. Grounded metal water pipe if building steel is not available, or
c. Other types of electrodes per NEC 250-50 and 250-52 if building steel or
grounded metal water pipe is not available.

This also helps reduce electrical noise issues by referencing the system to local ground
potential in case parts of the system might be touching grounded parts.

Isolated output grounding: Except at the single local ground point at the Isotran Plus,
it is important that the output ground from the Isotran Plus be kept isolated from building
ground in any output wiring. If receptacles are hard wired to the Isotran Plus in the field,
isolated ground receptacles must be used. These special receptacles avoid re-
connecting the output ground to the conduit, and because they look different they
reduce the chance of non-critical loads being inadvertently plugged into the Isotran Plus
power.

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2-3 Additional Features

A customer supplied momentary ON switch with a normally closed OFF switch must be
installed at TB7, if not installed at the factory, for proper operation of the system.

A customer supplied, normally open external EPO switch may be installed at the EPO
terminal block (TB5) at terminals 1 and 2. (Refer to Schematic).

3- PHYSICAL INSTALLATION

3-1 Unpacking

• Ensure levelers are raised to avoid damage when moving off pallet.
• Protect finish, light, extended handles and buttons from damage while uncrating and
placement.
• If forklift is used, lift only by frame, avoiding damage to sheet metal covers. Avoid
casters with forks. If there is a removable door remove it while uncrating and during
placement to avoid damage to hinges and latches.

If there is external damage or if internal components “rattle”, do not apply voltage.

Check for any loose components or connections, call TEAL Tech Support for
assistance.

Please retain packing materials until the unit is satisfactorily install and accepted.

Damage in transit is always possible. Visible external damage should be noted on the
bill of lading upon receipt and a claim filed with the shipper. Concealed damage can
also be claimed with the shipper within 15 days. Contact TEAL if you wish assistance in
filing your claim.

Each unit is inspected and tested before it leaves the factory. An individual check-out
sheet is maintained on file by TEAL and retrievable by power size and serial number.
Items tested include voltages input/output, current, and spike attenuation both normal
and common mode.

3-2 Shipping Brackets

The shipping brackets used with this unit were designed to be utilized when mounting
the unit to the floor. Refer to Seismic Calculation section (Section 4) for more
information.

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3-3 Mounting

Refer to the attached mechanical drawing for dimensional information. The unit should
be mounted in a dry location. Conduit entrance may be through the rear of the unit.

HIGH VOLTAGE. Turn power off before removing cover.

If the unit is mounted on a raised floor (such as a computer room floor) provisions must
be made to support the weight of the unit

Because the TEAL Isotran Plus is designed to operate at a high efficiency, a minimum
amount of ventilation is required for proper operation. However, one should not block
the vents at the top of the unit and always allow at least one inch around the unit for
natural convection to take place.

4- CONNECTIONS

It is generally desirable to have all communicating system components (e.g. CPU,

printer, terminal, modem) powered from the same “clean” source and the same ground
point. That means they should all be connected to the same Isotran Plus (which should
have been correctly sized to handle the total load). Call TEAL Tech Support (800-888-
TEAL) if you need advice on these connections.

Check the labels on the Isotran Plus to make sure that the input and output voltages and
currents match the system’s requirements. If there are any questions, please call TEAL
or your local representative.

4-1 Line

The Isotran Plus is connected through terminal blocks and receptacles. Input
connections are made to the Input terminal blocks and the Output connections are
made to terminal blocks and 5-20R receptacles. The terminal blocks are compression
type, so no special hardware is required. Check to make sure that all leads and
connections are well insulated. Recheck the tightness of all lugs, as a loose connection
may damage the unit and/or the load.

This unit has multiple input voltages that can be changed in the field. There will be a
tag attached to the input circuit breaker specifying which input voltage tap has been
selected at the factory. Check the voltage present to determine if it is correctly set. If

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not, refer to the “Voltage Adjustment “ Section 4-3 and drawing “Voltage Selection” for
instructions.

4-2 Load

Once voltage has been applied to the Isotran Plus, without a load connected, turn on the
main input circuit breaker switch. There should be a soft hum and the switch should
stay on. Energize the 277/480V output by pushing the customer supplied momentary-
ON start switch (Refer to Schematic). Using a voltmeter, check the output for proper
voltage. With no load, these voltages will often be a few percent higher than the input
voltage (e.g. 123V for nominal 120V circuit). This is to compensate for circuit losses
when the load is connected.

4-3 Voltage Adjustment

This unit is equipped with voltage adjustment taps to compensate for different voltages in
different areas. Only qualified personnel may do this adjustment as it involves a high
voltage electrical connection. Failure to make this adjustment will result in the wrong
output voltage from the Isotran Plus that could potentially harm the load.

High voltage. Turn power off before servicing.

Ensure all electrical connections are tight. Loose connections are

the most common failure point in this and all wiring systems.

NOTICE! Wiring Configuration vs. TEAL serial Number

Case PDU p/n PDU rev S/N Photo Drawing
Case I 4450028-03 B5 and 122314 and Appendix A Appendix B
below below file name
0810649 A0
Case II 4450028-03 B6 and 122315 Appendix A Appendix B
above through file name
4450028-04 A3 and 124521 0810649 A0
below
Case III 4450028-04 A4 and 124523 and Appendix C Appendix D
above above file name
0810560 A0

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In April 2010 TEAL attempted to change the tap change wiring in the PDU.
Unfortunately, the actual wiring was not changed, but the wiring diagram in the manual
was. As the above table shows, Case II PDUs shipped between April 1010 and
October 2010, s/n range 122315 through 124521, have a mismatch with their manuals.
Trying to change taps on a PDU wired up per the photo in appendix A with the wiring
diagrams in appendix D will result in the PDU tripping its input breaker. There is no
hazard involved, just the PDU will not work.

The serial number data is thought to be 99% accurate. As there may be a serial
number or two outside the above range, inspection is needed.

Units shipped from the factory

For serial #’s 124521 and below
should correspond to Appendix A photo, and Appendix B wiring diagram. In any case,
rewire as necessary to meet your input voltage requirements according to Appendix B
wiring diagram.

Units shipped from the factory

For serial #’s 124522 and above
should correspond to Appendix C photo, and Appendix D wiring diagram. In any case,
rewire as necessary to meet your input voltage requirements according to Appendix D
wiring diagram.

The wiring difference between Appendix A and Appendix C is easily determined with
one observation. Look at the left most transformer coil. Find wire 0013 coming down
from the input circuit breaker. If wire 0013 terminates at the second tap from the left at
the top of the coil, the wiring matches Appendix A. This is the proper configuration for
units below serial number 124521 and below.

The proper termination tap for Appendix C (serial numbers 124522 and above) is to the
right most tap at the top of the left most coil.

Step-By-Step Checklist
• Retap the main transformer to the required voltage.
• Re-configure the input circuit breaker (if necessary).
• Retap the control transformer to the correct voltage.

4-4 Input Circuit Breaker

When changing input voltage it may also be necessary to change the circuit breaker
current rating switches (refer to Schematic). To change the circuit breaker switches,
remove the circuit breaker panel. Open the plastic cover located at the bottom of the
circuit breaker to access switches. Reverse the preceding steps replacing circuit
breaker panel.

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Fram e
Current rating Instantaneous threshold
Tripping threshold value control switches (I3),
control switches (S/I)
(I1)

t2 switches

Tim e-current
curve control
switch (t1) Tm ax

CIRCUIT BREAKER IMAGE SHOWN IS FOR REFERENCE ONLY.

Three dip-switches on the circuit breaker panel control the input voltage overload
setting, the overload delay, and the short-circuit trip adjustment. Factory settings for the
three switches are:

• I1 - set based on the input voltage. Refer to the Schematic for a table of the other I1
settings.
• t1 - longest delay (set to 12s)
• I/S – longest delay (set to I position)
• t2 – All three dip switches in down position
• I3 – All four dip switches in up position

Use a small blade screwdriver to move the dip switch toggles to the appropriate
settings.

5- MAINTENANCE

5-1 Surge Suppression

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The surge suppressors are equipped with indicator flag on the front of the unit to
indicate that the suppressor modules are operational for the 277/480V output. If the red
indicator flag is visible, the surge suppressor is not operational.

To replace any of the (3) surge suppressor modules on the front of unit, proceed as
follows:
1. Turn off the input circuit breaker.
2. Remove suppressor module.
3. Replace module with module of the same type, size, and rating.
4. Turn on the input circuit breaker. All circuits should operate properly.

No other maintenance is required other than periodically (i.e. every 6 months) all
electrical connections should be checked for tightness. Any accumulations of dust or
debris should be removed to keep ventilation working for convection cooling.

6- REVISION HISTORY

Revision A0 New Release, similar to 1050217.

Checked By: T. Donaldson Date: 6-23-06
Approved By: V. Soto Date: 6-29-06
Revision A1 Updated CB t2 switches in the schematics.
Approved By: EBG Date: 1-3-07
Revision A2 Customer request for new seismic
calculation, refer to ECR 09077.
Approved By: DEG Date: 4-16-09
Revision A3 Customer request that the voltage selection
page in the manual be identical for three
units (4450028-03, 3550015-01, 3550018)
Approved By: D. Truong Date: 04-09-10
Revision A4 Replace F3, 5A fuse with 2A fuse per
ECO 5860.

Approved By: D. Truong Date: 5-19-10

Revision A5 Updated 4450028-03 to 4450028-04 (ECO
5874)

Approved By: D. Truong Date: 06-01-10

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Revision A6 Added more voltage selection information to
help field installers choose the right voltage
selection page
Approved By: D. Bilak Date: 10-26-10

Revision A7 Modest changes to rev A6 in 4-3 voltage

adjustment section.

Approved By: D. Bilak Date: 11-02-10

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 Wire number 0013

Appendix A Earlier configuration, applies to s/n 124521 and below.

Not to be touched during voltage changes.

 Wire 0013

Appendix C new configuration s/n 124522 and above

Not to be touched during voltage changes.

 TEAL TWO YEAR
WARRANTY
TEAL Electronics Corporation warrants its Power Conditioners to
be free from defects in the materials and workmanship for a period
of two (2) years from the date of shipment. TEAL'S obligation for
breach of warranty is limited to the repair or replacement at
TEAL'S option, at the factory without charge to the customer when
returned prepaid within the warranty period. Warranty is void on
units that have been subject to misuse, neglect, accident, or that
have been subject to repair or modification by persons not
authorized by TEAL.

The forgoing constitutes the sole and exclusive remedy of the

purchaser and liability of TEAL, and is in lieu of all other
warranties expressed or implied, TEAL makes no other warranty
except as expressly stated above, including without limitation any
warranty of merchantability or fitness for a particular purpose. In no
event shall TEAL be liable for direct, incidental, special or
consequential damages.

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