INSTALLATION PROCEDURE

OF VOLTAGE STABILIZERS

PEX-XX

DESCRIPTION

This procedure is used for the installation of automatic voltage stabilizers codes PEx-xx. Not
intended for end users. The installation of this type of equipment, like any electrical installation,
must be carried out by licensed electricians.

SCOPE

The following automatic voltage stabilizers will be covered in this document:

- PE4-xx-xx: Special for refrigerators and motors
- PE2-xx-xx: Low power single-phase
- PE3-xx-x: High power single-phase
- PEx-xx-Tx: With isolation transformer
- PET-xx-yy: Three-phase

SURVEY AND PREVIOUS WORK

It is recommended to carry out a survey of the electrical installation prior to installation to ensure
that the equipment is suitable for the conditions in which it will work.
In critical applications (see below), it is advisable to use a network analyzer for one or more time
intervals to evaluate large voltage variations and how these evolve in different periods and load
conditions, harmonics, micro-cuts, wave deformations, transients, frequency variations, etc.
Voltage stabilizers do not modify frequency or compensate for power outages.
The following points should be evaluated and corrected if necessary:
- Input voltage range: While all Mega Red voltage stabilizers support a wide input range,
there is the option to be modified in the factory by running this range for very high or very
low voltage. These values may vary over a given period of time, depending on
consumption, deficiencies in the installation, seasons of the year, etc.
- Significant voltage drops within the electrical installation. The use of inappropriate
conductors, poor splices, losses, etc. must be corrected. Voltage stabilizers will compensate
for voltage drops in conductors prior to the input. This can increase voltage differences in
this part of the network.
- Cosine FI: Appropriate correctors must be used. Failure to do so may result in damage to
the equipment.

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CRITICAL FACILITIES

Critical installations are understood to be those where the equipment, machinery or systems to be
protected are of high cost, have a critical service factor or where the guarantee thereof is
conditioned by the safety of electrical parameters. It should be noted that voltage stabilizers cover
a limited part of power supply failures. There are applications where uninterrupted power is
required and the use of UPSs, generator sets and automatic transfers should be evaluated. In
applications where the possible failure is known to be due to electrical noise, voltage differences
between ground and neutral, harmonics, etc., voltage stabilizers with galvanic isolation
transformers can be chosen. These cover some of these flaws.

USE OF STABILIZERS WITH GENERATOR SETS

Mega Red has versions suitable for use with generator sets in all standard equipment power
ratings. These stabilizers are immune to frequency variations between given parameters, very
common in power supplies with generator sets. They can compensate for voltage differences in
the event of any type of wave deformation since they switch by peak or RMS value (See the data
sheets for each device at [Link]/descargas).
There are typical cases where both voltage stabilizers and generator sets with automatic transfer
are used to supply the same installation. The stabilizer guarantees protection and correction of
voltage values and the generator set compensates for the lack of mains voltage. Whether the
stabilizer is used to stabilize the genset and grid output or just the grid voltage, the transfer board
voltage sensing must be placed at the output of the stabilizer. In this way, the voltage values taken
by the transfer board will be corrected for the installation and this will not reduce the entry into
service of the generator set when it is not necessary.
The use of voltage stabilizers to compensate for malfunctioning or lack of maintenance of generator sets is
strongly discouraged.
Likewise, special care must be taken when calculating the power of the generator set and the load
that will be applied to it. When the generator is overloaded, the motor is stressed and the output
voltage drops. Do not use a voltage stabilizer at the output of the generator to compensate for this
drop in voltage, because although the voltage at the output of the stabilizer will be adequate for
the electrical installation, the generator will be subjected to a greater overload and will be
damaged.

SAFETY ELEMENTS AND PRECAUTIONS

The following safety elements must be present:

- Safety glasses or mask
- Safety shoes
- Appropriate work clothing
- All tools to be used, such as pliers, wrenches, screwdrivers, etc. must be suitable for
electrical use and their electrical insulation must be ensured.

The following precautions should be taken:

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- A suitable installation environment must be ensured, avoiding humidity or any type of

factor with risk of electric shocks.
- It must be grounded and connected to the equipment before enabling voltage from the
panel.
- The equipment to be installed must be positioned in such a way as to ensure its stability; it
can cause serious damage if it falls.
- During operation, terminals, test leads and connections are exposed; accidental direct contact or
contact through tools can cause burns, cardio-respiratory arrest and even death. It must be operated
in a way that avoids the risk of electric shock.
- If load testing is used, resistive test benches must be protected in such a way as to ensure
the safety of the operator; they can cause serious burns in case of direct contact.

NECESSARY EQUIPMENT AND ELEMENTS

- Tester with RMS (True Effective Value) measurement Fluke or similar. Testers without a
calibration certificate from the manufacturer or without verification by measurement
entities are not suitable for taking measurements. The use of “economic” type instruments
will lead to erroneous measurements.
- Fluke amperometric clamp or similar. Clamp meters without a calibration certificate from
the manufacturer or verification by measuring entities are not suitable for taking
measurements. The use of “economical” type instruments will lead to erroneous
measurements.

OPTIONAL EQUIPMENT AND ELEMENTS

- Fluke Amperocofimetric clamp or similar.

- Schneider or similar network analyzer
- Tektronix, Trio or similar oscilloscope
- Load bank: This is an optional element, mostly used in subsequent surveys and not usual
for the installation of equipment. It is of the resistive type with elements for simulating
consumption at the output of a fixed load. Wire resistors, halogen lamps, etc. can be used.

LOCATION OF EQUIPMENT

Place the equipment on a flat and suitable surface, in a ventilated place that is not exposed to
moisture and possible liquid spills. Placing voltage stabilizers outdoors, exposed to moisture or in
unventilated environments, not only voids the warranty but can cause fires and explosions, electric
shock, power grid failures and damage to any devices connected to the network.
If the equipment will be placed on platforms, brackets, shelves, etc., take into account the
dimensions and weights. See the data sheets for each device at [Link]/descargas
Some models, such as the PE2-5.5-0, have slots in the base that allow for fixing to the wall with
anchors.

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GENERAL PROCEDURE

1. Check the current with the current clamp at full load to ensure that the equipment to be
installed meets the required power. Please note that if the stabilizer is to be used with
motors or refrigeration equipment, the power must be oversized to compensate for the
current that will circulate during the start-up of the motors. In refrigeration equipment,
power values can exceed up to 5 to 7 times the nominal values.
2. Place the equipment in the place where it will be placed.
3. Ensure power cut at the input panel.
4. In stabilizers with terminal covers, remove it and identify the input(s) and output(s)
5. Turn off the stabilizer with the thermal or ignition key (depending on the model).
6. Connect the equipment ground. It is highly recommended, in critical or complex
installations or when a reliable ground cannot be secured, to use a dedicated stabilizer rod.
7. Connect the input cables making sure there is no tension. Ensure that the section of the
conductors used is suitable for the maximum current that will circulate. In equipment with
divisible (screw) terminals, verify the correct adjustment and fixing of the conductors. On
any equipment with nutted terminal blocks, NEVER place the cables directly on the
terminal block. ALWAYS use appropriate terminals. If the cables are used directly on the
terminal block, it has been proven that they are damaged. Even if this does not occur,
significant voltage drops and failures are observed in the electrical installation.

Chart 1 – Example of terminal usage

8. Enable board voltage.
9. Turn on the equipment with the output cables disconnected.
10. Wait for the stabilizer network analysis. In equipment with high or low voltage cut-off, the
output will not be enabled until the conditions generated by the stabilizer are adequate.
This can be verified by the “line” indicator flashing from power-up until the output is
enabled.
11. Measure the input and output voltage. Note that the output RMS voltage values must
correspond to the input range. These may differ for 2 reasons: The mains sine wave is
distorted and the stabilizer corrects by peak value and not by RMS (see equipment data
sheet) or because the input voltage range is outside the highest regulation values of the
equipment. In this case, if the output voltage does not reach critical values, one of the high
or low voltage indicators will flash. If the output voltage value exceeds the critical values,
one of the high or low voltage indicators will remain on. On equipment with cut-off, it
will cancel the output.
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12. Turn off the stabilizer
13. Interrupt the voltage from the board

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14. Connect the output cables. Observe the same recommendations as in point 6. In critical
installations or when there are doubts about the electrical installation, suitable loads can
be used to simulate consumption before using the stabilizer with real loads.
15. Enable board voltage.
16. Turn on the stabilizer.
17. Perform input and output voltage and current measurements again.
18. Turn off the stabilizer
19. Interrupt the voltage from the board
20. Install the terminal cover if applicable.

THREE-PHASE INSTALLATIONS WITH MODULAR OR MONOPHASE EQUIPMENT

Mega Red has three-phase equipment (PET-XX-YY) up to 165KVA total. But in a single cabinet
in powers up to 45KVA. For higher power, 3 single-phase modules are used.
All Mega Red single-phase stabilizers can be used in three-phase configuration with this same
criterion.
For this type of applications the following must be taken into account:
- The output of the stabilizers can be configured in star, delta or both combined.
- The entrance must always be star type. Both three-phase stabilizers in a single cabinet and
modular or single-phase ones require using neutral at the input.
- When 3 single-phase stabilizers are used, the standard output high or low voltage cut-off
type will be per phase (e.g. 3 x PE2-4.0-0) or no cut-off (e.g. 3 x PE3-33-8). See below
how total cuts (all 3 phases will cut output in the event of extreme high or low voltage or
failure of any of the phases) can be achieved with modular stabilizers.

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Below are the 3 possible types of three-phase installations using modular or single-phase
stabilizers:

Chart 2 – Three-phase installations with single-phase stabilizers

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IMPLEMENTATION OF TOTAL CUT-OFF IN MODULAR THREE-PHASE

INSTALLATIONS – OPTION 1: CUT-OFF SIGNAL

When using three-phase or single-phase modular stabilizers of the PEx-xx-SC type equipped with
a cut-off signal, the following connection will be used.
Modular stabilizers prepared for total cutting through a loop should not be confused. See next
section

Chart 3 – Use of cut-off signal in three-phase installations

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IMPLEMENTATION OF TOTAL CUT-OFF IN THREE-PHASE MODULAR

INSTALLATIONS – OPTION 2: INTERNAL CUT-OFF WITH EXTERNAL LOOP

Mega Red has modular voltage stabilizers with total cut-off that DO NOT require the use of
external contactors. Each module contains an internal contactor and special terminals independent
of the voltage input and output terminals, which allow a loop to be created between the
equipment. If the output is cut off in any of the modules, the output of the other two is
automatically interrupted.
Each module will be identified with the legend “MODULE 1”, “MODULE 2” and “MODULE 3”.
They are the most commonly used in CT scanner installations, for example.
They should not be confused with PEx-x-SC type stabilizers which do not have internal contactors
but dry contacts.
A loop must be made between the 3 modules as follows. Low section cables can be used.

Chart 4 – Loop connection on modular stabilizers for full cut.

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POSSIBLE PROBLEMS AND SOLUTIONS

The stabilizer does not turn on immediately This is normal operation. The equipment analyzes the network
before delivering voltage to the output. This period can last from
seconds to 1 minute.
The stabilizer has no output voltage

Check if the output was cut off due to high or low voltage. In three-
phase equipment in a single cabinet, since they do not have high or
low voltage indicators, a suitable tester must be used (see
“REQUIRED EQUIPMENT AND ELEMENTS”) to verify the
input and output ranges. If the problem is repetitive, contact Mega
Red technical service to modify the input range of the stabilizer.
The stabilizer cuts off the output but when you
turn it off and on, it restores. The input voltage ranges are outside the equipment regulation
ranges. Contact Mega Red technical service to modify the stabilizer
input range.
The stabilizer cuts the output due to high or low
voltage but even when the voltage normalizes, it
does not restore the output. The high or low output voltage cut-off values are calculated to
protect the electrical installation. But the range in which the
stabilizer automatically resets is limited to the highest regulation
values. For example, if a standard stabilizer type PE2-xx-0 cut off
due to high voltage with a 250VAC input, until the voltage is below
approx. 234VAC. the team will NOT replace the output.
The output voltage values do not correspond to
the assumed input voltage values.
Voltage stabilizers measure and correct according to the output
voltage only, either by RMS or peak values. The relative input voltage
values are indicative and theoretical. There are several factors that
can cause slight differences between the input and output voltage.
The output voltage falls outside the specified
values.
The instrument being measured is inadequate (see “REQUIRED
EQUIPMENT AND ELEMENTS”) or the stabilizer is correcting by
RMS or peak measurements against a distorted sinusoidal wave. If
there are doubts or discrepancies between the behavior of the
stabilizer in the installation and the Mega Red technical service test
bench, a Tektronix type oscilloscope or similar should be used to
analyze the electrical network. Testers (of any type) and
amperometric clamps (of any type) are not suitable for this type of
analysis. Values obtained by a network analyzer may be useful but
are insufficient. They can be used as a complement to the analysis
performed with the oscilloscope.
The stabilizer does not light any LED and there Check if there is voltage at the input or if the value is close to or
is no voltage at the output below 120VAC.
When the stabilizer is turned on, the circuit In three-phase installations, verify the correct installation of the
breaker on the dashboard trips. neutral. In single-phase equipment, disconnect the output and turn
on the stabilizer. If the problem persists, send the equipment to
Mega Red for repair.

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The stabilizer cuts off on high but not on low
voltage. output This is the typical behaviour of PEx-x-E3 automatic voltage
boosters or special equipment without low voltage cut-off.
The stabilizer makes a “click” noise every so
often. This is normal operation due to the switching of the relays.
The stabilizer makes a constant “click” noise
with a very high frequency. Check that there is no overload on the stabilizer or incorrect
installation of the equipment. In many cases it is necessary to repair
it and/or replace it with one of greater power.
The stabilizer switches when any engine starts.
This is common due to the voltage drop caused by the motor
starting current and the stabilizer compensates. In any case, care
must be taken both in the calculation of the stabilizer being used
with motors and in the correct sizing of the conductors in the entire
electrical installation.
In the stabilizer, it cuts off the output due to low
voltage when a motor starts.
The case is similar to the previous one but at the moment of starting
the motor, the input voltage falls below the equipment cut-off
values. Contact Mega Red technical service to modify the input
range of the stabilizer or replace it with a booster if necessary.
The stabilizer makes a constant loud and low
noise Check that there is no overload. If this occurs, it is necessary to
repair it and/or replace it with one of greater power. There are also
cases where, due to impacts during transport or a fall, the supports
of some equipment component are damaged.
The temperature of the equipment is excessive
Although stabilizers can raise temperatures, excessive values will
be due to an overload. In some cases, damage to equipment
subjected to overload can cause it to continue to raise its
temperature even after the overload is removed. It will be necessary
to repair it and/or replace it with one of greater power.
There was a possible overload but the thermal
switch did not trip.

Thermal switches are NOT primarily intended to protect stabilizers

against overloads but rather against short circuits, various faults or
for maintenance.
The behavior of thermal switches varies according to the current
values and duration times and may differ widely from the nominal
values.
The power of each equipment must be calculated and ensured over
time through appropriate measurements and not by trial and error.

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The UPS connected after the stabilizer goes into
“battery” mode constantly
There are very few cases where it is necessary to use voltage
stabilizers with UPSs. Double conversion online UPSs typically
support very wide input ranges. Consult the UPS manufacturer for
proper installation. In mixed installations with voltage stabilizers in
general panels and UPSs distributed after the stabilizers, the
conditions and survey of the electrical installation coincide with any
other listed.

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The stabilizer behaves erratically when used
with the generator set or the generator set is
constantly and unnecessarily put into service.

The model you are using is not suitable for use with generator sets.
See “USE OF STABILIZERS WITH GENERATOR SETS”. Even
if a stabilizer prepared for this use is used, verify the correct
operation and maintenance of the generator set. If the problem
persists but the stabilizer works correctly with mains voltage, place
it outside the generator set circuit and the generator transfer panel
(if present) should sense the voltage of the panel and not the
stabilizer output. In any case, this indicates a problem in the transfer
board or the generator set and not in the stabilizer. Consult the
technical service of the group manufacturer.
The voltage between ground and neutral at the
output of a stabilizer with isolation transformer The measurement criteria is incorrect. There is no directly measured
is greater than “0”. value that is in any way relevant even if the highest quality instrument
on the market is used.
If it is necessary to determine the voltage between ground and
neutral, the impedance of the instrument must be compensated. For
this, a very high value resistor can be used between neutral and
ground and the potential difference between the two can be
measured.

SCOPE OF RESPONSIBILITIES
This document is property of Mega Red electronic devices SRL
Mega Red electronic devices SRL is not responsible for any direct or indirect damage caused by
the total or partial use of this document.

MEGARED Electronic Devices SRL reserves the right to make changes to the detailed specifications without prior
notice.

Questions and queries: serviciotecnico@[Link]

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