User’s Handbook for

The MLC-42WCIX500

301 Gaddis Boulevard • Dayton, Ohio 45403

U.S. Toll Free 866-261-1191
(937) 253-1191 • Fax: (937) 253-1723
Web site: www.stacoenergy.com

Form No.003-2262 06/28/06

Auto. Voltage Regulator MLC-42WCIX500

CONTENTS

LIMITED WARRANTY.............................. ERROR! BOOKMARK NOT DEFINED.

DESCRIPTION ............................................................................................2
INSTALLATION ..........................................................................................2
RATINGS AND SPECIFICATIONS ..................................................................3
CONTROLS ................................................................................................4
Microterminal .........................................................................................4
Controller On/Off Switch ..........................................................................4
Motor On/Off Switch ................................................................................4
Internal Raise/Lower Switch .....................................................................4
Transient Suppression .............................................................................4
Isolation Transformer ..............................................................................4
OPERATION ...............................................................................................5
MAINTENANCE ...........................................................................................6
PARTS LIST ...............................................................................................8

DRAWINGS ............................................................................................ 11

Form No. 003-2262

Auto. Voltage Regulator MLC-42WCIX500

C:\Documents and Settings\engineering\My Documents\Manuals\standard warranty.doc

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DESCRIPTION

The conditioner comprises a shielded isolation transformer and a transient suppressor.

Each phase of the conditioner comprises a motor-driven variable autotransformer, a
buck-boost fixed ratio transformer, and a manual raise/lower switch. The
microprocessor controller automatically positions each of the autotransformers to hold
the output voltage of each phase constant. A RS-232 interface is provided for remote
operation and monitoring.

INSTALLATION

On receipt inspect the unit for any evidence of shipping damage. If damage is indicated,
it should be reported to the carrier. Installation consists only of placing the unit in
position and making the necessary electrical connections in accordance with local
codes and requirements. The input and output terminal blocks are located in the front of
the cabinet and are accessible through the removable front panels. A ground lug is
located inside the cabinet adjacent to the terminal blocks for cabinet grounding.

NOTE
There is no internal fusing for the supply or
input to the unit. This must be provided by the
user. The variable transformers are protected
by the fuses, accessible through the removable
front panel.

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RATINGS AND SPECIFICATIONS

Nominal Output Voltage 208Y/120 Volts

Input Voltage Range 1 384-528
Maximum Output, Amperes 1388
Rated Output, KVA 500
Frequency Range 57-63 Hz
Accuracy ±1%
Operating Temperature 0°C (32°F) to +40°C (104°F)
Control Band (User Selectable)2 ±0.5V, ±1.0V, ±2.0V, ±4.0V
Correction Rate 28 Volts/Second
Common Mode Noise Rejection 120 db

1 At nominal output voltage. Input voltage range shifts proportionally with output voltage settings.
2 Factory set at ±0.5V.

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CONTROLS

The Following front panel controls are provided:

Microterminal
The terminal is provided for local control of the unit. See the MP user’s handbook (form
003-1622) for detailed information.

Controller On/Off Switch

This switch turns off power to the microprocessor controller only.

Motor On/Off Switch

This switch turns off power from the microprocessor to each of the autotransformer
motors.

Internal Raise/Lower Switch

These switches, one for each phase, allow for each phase of the unit to be manually
controlled individually. When released they will return to the center position. These
switches are located on each motor plate of the variable transformer, and are front
accessible.

Transient Suppression
The transient suppressor unit is mounted inside the cabinet with indicator lamps located
on the suppressor. When functioning properly all three lamps will be lit. If any one or
more of the indicator lamps go out, the suppressor unit is defective and will require
replacement. The transient suppressor has a peak surge current of 40,000 amps/phase

CAUTION
Damage will result to the transient suppressor if the
conditioner output exceeds 150 Vrms (L-N) / 300
Vrms (L-L) when controlling manually.

Isolation Transformer
The double shielded isolation transformer protects the load from common mode noise
by shunting noise to ground via the shielding in lieu of transferring it to the load.

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OPERATION

On completion of installation and wiring, assure that connections are correct and tight,
and in accordance with local codes and requirements.

CAUTION
Damage will result to the transient suppressor
network if the output voltage of the conditioner
exceeds 150 Vrms (L-N) / 300 Vrms (L-L) via the
manual control switch in the raise position.

Turn on the supply power to the unit, and then place the controller and motor switches
in the “On” position. The switches should both now be illuminated and the system
regulating with the microterminal display indicating the A(1) or B (2) conditioned output
voltage. See the MP user’s handbook (form #003-1622) for more information on local
and remote operation (via the RS-232 interface).

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MAINTENANCE

WARNING
DO NOT USE ROTORS AS MEANS FOR ROTATING SHAFT ON GANGED
UNITS.

DO NOT APPLY OPPOSING PRESSURE TO ROTORS ON GANGED

UNITS.

FAILURE TO COMPLY WITH THE ABOVE STATEMENTS WILL RESULT IN

DAMAGE TO THE VARIABLE TRANSFORMER AND VOID THE
WARRANTY.

The unit should be inspected on a regular basis for accumulation of dust or shop dirt
and for brush wear and brush track condition. Disconnect power to the unit, and
remove the front panel. Accumulation of dust may be blown out using low pressure
compressed air.

Inspect the brushes for wear and indications of arcing. The brushes should be replaced
if the “A” dimension is less than .090 or if the brush is cracked or chipped. Inspect the
brush track for indications of overheating or arcing. The track should be uniform in
appearance with no discolored bars. The brush track may be cleaned using isopropyl
alcohol and a lint free cloth. Do not use any abrasive material to clean the track, as this
will remove the gold plating.

New brushes installed will require seating before placing the unit back in service.
Disconnect all power to the unit and proceed as follows for the motor driven assembly
as required.

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Disconnect the three external motor control wires at the R-C-L terminal block located on
the motor plate of the variable transformer near the limit switches.

NOTE

Mark these wires before removing, as they

must be replaced in the same order. Prepare
a single pole, double throw center off toggle
switch with leads and a line cord per the
following sketch.

Connect the switch to the R-C-L terminals as shown in the sketch and plug the
assembly into a 120 volt AC source. This will provide a means of driving the rotors for
the brush seating operation.

Remove the existing brush assembly by removing the four 6-32 screws that attach it to
the brush block. Place a piece of 400 grit “wet or dry” type sandpaper approximately 2-
1/2" wide by 6" long against the brush track (grit side towards the brushes), and install
the new assembly. Hold the sandpaper flat against the track, and drive the rotor back
and forth over approximately a two inch distance four or five times, or until a full width
carbon track for each brush is visible on the sandpaper. Remove the sandpaper by
running the brushes off one end. On completion of installation and seating of brushes
blow out the accumulated carbon dust. Restore the original wiring connections to the
motor drive and replace access panels before placing the unit back in service.

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PARTS LIST

Item Part Number Quantity

Microprocessor Control Panel 924-0269-S 3 1
Microprocessor Board-2/T 4 825-0276 1
Three Phase Option C Board4 825-0279 1
Microterminal4 460-0265 1
Power Supply Board4 825-0270 1
Sense Transformer Assy4 980-0157 3
Switch-Lighted Rocker4 664-0406 2
Connector 3 Pin4 243-0410 3

Variable Transformer 034-8823 1

Brushes for 034-8823 812-0470-S3 21
Transformer-Buck Boost 712-1105 3
Fuse-1 Ampere 307-0041 1
Raise/Lower Switch 664-0417 3
Transformer-Isolation 712-1497 1
Transient Suppression 712-1162 1
Fuse-40 Amp, 600V 307-0195 21

3 Available as spare parts.

4 Included on Front Panel Assembly

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