AUTOMATIC CAPACITOR BANK WITH CONTACTOR OPERATIONS INSTRUCTION MANUAL (M98125401-03 / 03A) (c) CIRCUTOR S.A.
------Automatic capacitor bank with contactor operations ----- Page 2 TABLE OF CONTENTS 1. Introduction. 2. Operating principle. 3. Technical features. 4. Checks on receipt of the equipment. 5. Installation and start-up. 5.1. Current transformer. 5.2. Location. 5.3. Initial checks (pre-installation, before switching on power). 5.4. Connecting the power circuit. 5.5. Connecting the operating circuit. 5.6. Operating parameters. 5.7. Start-up. 5.8. Safety procedures. 6. Periodical servicing. 7. Locating breakdowns. 8. Safety. 9. Technical service and Guarantee.
------Automatic capacitor bank with contactor operations ----- Page 3 1. INTRODUCTION. CIRCUTOR self regulating banks are automatic capacitor banks that correct the whole of an installation s power factor. The total reactive power that they can supply is divided into steps made up of suitably powered capacitors. The combination of these capacitors allow power generated to be matched to demand over a period of time. Being automatic equipment, once it is installed it does not require any special maintenance nor handling. Only certain safety procedures need to be followed on connecting. 2. OPERATING PRINCIPLE. Each bank step is made up of a capacitor, the contact and the protective fuses. All are governed by a reactive energy regulator. To operate, it is necessary to connect a 5A output current transformer to the outside of the bank. This has to be the correct size for the total maximum current in the installation and has to always read the reactive current required by the installation. The signal from this transformer is interpreted by the reactive energy regulator so that it can select the most suitable number of capacitors to connect in order to correct the power factor according to the preset parameters.
------Automatic capacitor bank with contactor operations ----- Page 4 3. TECHNICAL FEATURES. 3.1. General. Standard voltage (between phases) Capacitor maximum current Regulating programs available Maximum number of regulating steps Cabinet protection Forced air ventilation 230, 400, 460 V according to model: according to type of regulator according to type of regulator IP-21 on request Standards EN 60439, EN 60831 3.2. Operating switchgear. Tripolar contactors Rapid discharge resistance Protection suitable for the connected power supply included NH or NZ fuses according to calibre 3.3. Capacitors. Operating nominal voltage up to 690 V Frequency 50 Hz or 60 Hz Operating temperature -25 / +50 ºC Isolating resistance > 10 6 MΩ µf Dielectric losses tanδ 0.5 W/kvar Maximum over voltage 1.1 Un Maximum overcurrent 1.3 In Dielectric self regenerating polypropylene Dielectric rigidity between terminals 2.15 Un, 10 s, 50 Hz Dielectric rigidity between terminals and casing 3 kv, 10 s, 50 Hz Max resistance of slow discharge included
------Automatic capacitor bank with contactor operations ----- Page 5 4. CHECKS ON RECEIPT OF THE EQUIPMENT. Before installing and handling the equipment check that: 4.1. The equipment has not been damaged during delivery. 4.2. The equipment supplied is suitable for your requirements and is the type you ordered. 4.3. The operating voltage of the equipment supplied is suitable for your requirements. 4.4. Manuals for the equipment and for the regulator are supplied with the capacitor bank. If any problem is noticed, please contact the commercial service department of CIRCUTOR S.A. 5. INSTALLATION AND START-UP. 5.1. Current transformer. The equipment requires a current transformer in order to operate (see section.2). It must be an x/5 type, where x is the nominal current suitable for the maximum total in the installation that is being corrected. The transformer must exclusively supply the reactive regulator. When dealing with an adding transformer and to ensure that the output is in proportion to the current of the different transformers that are connected, check that the ratios of these transformers are the same. 5.2. Location. The equipment must be located indoors, away from heat sources and adequately ventilated. 5.3. Initial checks (pre-installation, before switching on power). 5.3.1. Check that the nominal voltage of the equipment, shown on the technical information label is the same as the nominal voltage between phases for the system to which it will be connected. 5.3.2. Open the cabinet door and take out the (Neozed) fuses from the operating circuit. 5.3.3. Connect the protective conductor: the bank must be earthed through the earthing terminal. 5.3.4. Check and tighten terminals that may have come loose during delivery.
------Automatic capacitor bank with contactor operations ----- Page 6 5.4. Connecting the power circuit. Connect the three power terminals (L1, L2 and L3) using a cable thick enough for the power of the bank (see maximum current on the equipment s technical information label). WARNING! If holes need to be drilled in the casing to feed cables through, take care to avoid shavings falling onto the contactors. 5.5. Connecting the operating circuit. 5.5.1. Install the current transformer at a point in the connection where all the installation s current is flowing. The capacitor current has to be able to be read (see connection diagram in fig.1). 5.5.2. Connect the secondary current transformer (terminals S1 and S2) to terminals marked S1 and S2, located on the bank. If, once connected, the capacitor connection/disconnection operation does not work correctly, swap the S1 and S2 terminals on the current transformer (physically or by program, according to regulator). Fig. 1 - Connection diagram for the current transformer CORRECT INCORRECT The current transformer has to be in front of the bank and the receptors (motors, etc). No capacitor is to be connected so that the current transformer does not give any type of signal. All capacitors are connected, but are not disconnected when the load decreases. There is a risk of overcorrecting without a load.
------Automatic capacitor bank with contactor operations ----- Page 7 5.6. Operating parameters. Before starting the bank the operating parameters indicated below must be set in the reactive energy regulator. How to change each parameter according to the regulator model is shown in the regulator manual supplied with the bank. 5.6.1. cosϕ. cosϕ of the command to be corrected. 5.6.2. C/K (according to regulator model). Value given by the following formula: Ic C/K = --------- where Ic = First capacitor current (It / 5) It = TC primary current It is advisable that C/K is adjusted to the value set by the above formula. A C/K below the calculation makes the regulator connect and disconnect capacitors at a higher than normal rate. This will shorten the working life of the capacitors and contactors. A C/K above the calculation makes the regulator perform fewer operations than is usual. This may mean that it never corrects to the preset value. Appendix 2 shows tables to calculate C/K at 400V and at 230V. 5.6.3. Number of capacitors. Number of steps or capacitors in a bank. 5.6.4. Connecting program. Power ratio between capacitors: 1:1:1, 1:2:2, 1:2:4, etc. e. g.: the 1:2:4 program tells the regulator that the 2 nd capacitor is ½ that of the 3 rd, and that the 1 st is ½ that of the 2 nd and ¼ of the 3 rd. 5.6.5. Connecting phase. Locating the TC with respect to voltage reading. Check the regulator manual on how to change this parameter. 5.6.6. Connecting time. Time during which the conditions have to be maintained so that the regulator performs the preset operation (connecting or disconnecting the capacitor). 10 seconds will ensure the proper functioning of the bank.
------Automatic capacitor bank with contactor operations ----- Page 8 5.6.7. Reconnecting - safety time. The minimum waiting time between disconnection and a new connection of the same capacitor. 50 seconds will ensure the discharge of a capacitor below the necessary limit to protect the equipment from excessive connection points. 5.7. Start up. 5.7.1 Check again the control and power circuit connections. 5.7.2 Relocate the protective fuses in the operating circuit. 5.7.3. Connect the bank to the power supply. If there is a need for reactive energy at this time, then the bank will start correcting cosϕ (after the assigned connecting time) to the preset value. 5.7.4. Check the manual operation of the bank. Disconnect some of the capacitors by pressing the relevant button for a few seconds. After pressing and after the connecting time, connect them again. NOTE. During periods of low charge, it is not advisable to manually connect all of the bank, because at certain times resonance may occur with the power supply transformer.
------Automatic capacitor bank with contactor operations ----- Page 9 5.8. Safety procedures. For optimum operation of the bank, the following points must be considered: 5.8.1. Voltage. The operating voltage must not exceed the nominal voltage; Operating in overload conditions considerably reduces the life of the capacitors. 5.8.2. Current. The absorbed current for each capacitor, measured at the contactor output, must not exceed 1.3 times its nominal current. Whenever the current absorbed by the capacitors is higher than the nominal current may be due to the presence of harmonics in the system or a voltage higher than the nominal voltage. Both situations are harmful to the capacitors. In this event, the bank must be disconnected and CIRCUTOR s technical department must be contacted to ascertain the best way to resolve the problem. 6. PERIODICAL SERVICING. Maintenance should be carried out in accordance to the safety procedures detailed in section 8. The banks require minimal maintenance, but it is recommended that the following procedures be undertaken: 6.1. During the first month of operation. 6.1.1. Visually inspect the capacitors. 6.1.2. Examine the protective fuses. 6.1.3. Control the temperature. 6.1.4. Control the service voltage (especially under low charging conditions). 6.1.5. Retighten terminals and connections. 6.2. Annually. 6.2.1. Check the capacitor's nominal current. 6.2.2. Clean the terminals and isolators on the capacitors. 6.2.3. Check that the terminal connections are tightened. 6.2.4. Check the condition of the contacts on the contactors.
------Automatic capacitor bank with contactor operations ----- Page 10 7. LOCATING BREAKDOWNS. Possible problems, causes and possible solutions. The display does not illuminate or has a very faint light Check that the voltage of the power supply is correct. Check the control fuses are in good condition. El display shows "- -" or "00" according to regulator model Indicates that the regulator is not receiving current. Check: Current transformer connection. Preset C/K or It value. The display shows a numerical value and the LED is lit showing capacitive cosϕ The regulator is finding capacitive load in the system. If what is expected is an inductive charge, check the connections on the current transformer. Swap the cables to the S1 and S2 terminals (on the operating board of the bank). Not all steps enter despite the fact that the regulator does not show the required cosϕ Check parameter setting on the regulator. The bank keeps all capacitors entered, but the cosϕ remains very low and unchanged Check that the current transformer is actually connected upstream from the battery shunt (see TC connection diagram in section 5.5.1). The regulator does not work but the display is lit Check that the TC is connected in phase L1 for regulators of different series to the 8dcomputer or 14dcomputer. The display shows "01" on regulators prior to 8d and 14d series The transformer is not correctly installed. Check the connection point. The regulator works correctly but the contactors do not operate Connect neutral and operate at 230 V (only in 400 V nominal voltage banks). Check protective fuses in the control circuit. Swap the S1 and S2 connections on the current transformer secondary. The regulator repeatedly connects and disconnects a step C/K poorly adjusted. The value is less than what is needed. The regulator does not connect all steps because it does not reach the assigned cosϕ C/K poorly adjusted. The preset value is less than what is needed. For other faults, please consult the regulator manual.
------Automatic capacitor bank with contactor operations ----- Page 11 8. SAFETY. Before handling any device in the bank all power fuses must be removed and check that the capacitors are discharged. Even when the bank is disconnected, there still may be voltage in the capacitors. Therefore, after having removed the fuses, wait for 3 minutes and then short circuit them and earth the terminals or output cables on each capacitor. 9. TECHNICAL SERVICE AND GUARANTEE. CIRCUTOR guarantees its products against manufacturing faults for one year from the date of delivery. The guarantee does not cover protective devices (fuses) nor operating devices subject to natural wear and tear. This guarantee becomes void in the event of improper handling or disregard of the handling conditions. CIRCUTOR has its CONSULTANCY AND TECHNICAL ASSISTANCE service at your disposal throughout Spain. CIRCUTOR, S.A. Vial Sant Jordi, s/n - 08232 Viladecavalls - (08007 Barcelona) Spain Tel.: +34 93 745 29 00 Fax: +34 93 745 29 14 E-mail: central@circutor.es http:// www.circutor.com
------Automatic capacitor bank with contactor operations ----- Page 12 Appendix 1 - a) Single line diagram of the 400 V bank Nez 6A FAN Thermostat (The number of outputs depends on the REGULATOR model mounted on the bank) Connected to the rest of the steps. Only on equipment with ventilation units.
------Automatic capacitor bank with contactor operations ----- Page 13 Appendix 1 - b) Single line diagram of the 230 V bank Nez 6A FAN Thermostat (The number of outputs depends on the REGULATOR model mounted on the bank) Connected to the rest of the steps. Only on equipment with ventilation units.
------Automatic capacitor bank with contactor operations ----- Page 14 Appendix 1 - c) Single line diagram of the 400 V bank - Without neutral connection Nez 6A FAN Thermostat (The number of outputs depends on the REGULATOR model mounted on the bank) Connected to the rest of the steps. Only on equipment with ventilation units.
------Automatic capacitor bank with contactor operations ----- Page 15 Appendix 2 - Tables for C/K calculation Voltage: 400V Ratio Transformer Current Power of the first capacitor in kvar 2.5 5 7.5 10 15 20 25 30 37.5 40 50 60 75 80 150/5 0.12 0.24 0.36 0.48 0.72 0.96 200/5 0.09 0.18 0.27 0.36 0.54 0.72 0.90 250/5 0.07 0.14 0.22 0.29 0.43 0.58 0.72 0.87 300/5 0.06 0.12 0.18 0.24 0.36 0.48 0.60 0.72 0.90 0.96 400/5 0.05 0.09 0.14 0.18 0.24 0.36 0.48 0.58 0.67 0.72 0.87 500/5 0.07 0.11 0.14 0.22 0.29 0.36 0.45 0.54 0.54 0.72 0.87 600/5 0.06 0.09 0.12 0.18 0.24 0.30 0.36 0.45 0.48 0.60 0.72 0.90 0.96 800/5 0.07 0.09 0.14 0.18 0.23 0.27 0.33 0.36 0.45 0.54 0.68 0.72 1000/5 0.05 0.07 0.11 0.14 0.18 0.22 0.27 0.29 0.36 0.43 0.54 0.57 1500/5 0.05 0.07 0.10 0.12 0.14 0.18 0.19 0.24 0.29 0.36 0.38 2000/5 0.05 0.07 0.09 0.11 0.13 0.14 0.18 0.22 0.27 0.28 2500/5 0.06 0.07 0.09 0.10 0.12 0.14 0.17 0.22 0.23 3000/5 0.05 0.06 0.07 0.09 0.10 0.12 0.14 0.18 0.19 4000/5 0.05 0.06 0.07 0.09 0.11 0.14 0.14 Voltage: 230 V Ratio Power of the first capacitor in kvar Transformer Current 2.5 5 7.5 10 15 20 25 30 37.5 40 150/5 0.21 0.42 0.63 0.84 200/5 0.16 0.31 0.47 0.63 0.94 250/5 0.13 0.25 0.38 0.50 0.75 1.00 300/5 0.10 0.21 0.31 0.42 0.63 0.84 400/5 0.08 0.16 0.24 0.31 0.47 0.63 0.78 0.94 500/5 0.06 0.13 0.19 0.25 0.38 0.50 0.63 0.75 1.00 600/5 0.05 0.10 0.16 0.21 0.31 0.42 0.52 0.63 0.84 800/5 0.08 0.12 0.16 0.24 0.31 0.39 0.47 0.63 1000/5 0.06 0.09 0.13 0.19 0.25 0.31 0.38 0.50 1500/5 0.06 0.08 0.13 0.17 0.21 0.25 0.33 2000/5 0.05 0.06 0.09 0.13 0.16 0.19 0.25 2500/5 0.05 0.08 0.10 0.13 0.15 0.20 3000/5 0.06 0.08 0.10 0.13 0.17 4000/5 0.06 0.08 0.09 0.13 For other voltages, calculate the C/K using the formula in Section 5.6.2.