operation manual for static electric power amplifier...
TRANSCRIPT
OPERATION MANUAL FOR
STATIC ELECTRIC POWER AMPLIFIER 1,000 – 2,500 KVAH
Operation Manual Page 2
Table of Contents Introduction .................................................................................................................................................. 3
1. DESCRIPTION AND WORK ..................................................................................................................... 4
1.1. Description and Operation of the Product .................................................................................... 4
1.1.1. Purpose of the Product ......................................................................................................... 4
1.1.2. Specifications......................................................................................................................... 5
1.1.3. Components of the Product .................................................................................................. 6
1.1.4. Device and Operation ............................................................................................................ 7
1.1.5. Measuring Instruments, Tools and Accessories .................................................................... 7
1.1.6. Marking and Sealing .............................................................................................................. 7
1.1.7. Packaging ............................................................................................................................... 8
2. INTENDED USE ....................................................................................................................................... 8
2.1. Operational Limitations ................................................................................................................. 8
2.2. Product Connection Requirements ............................................................................................... 9
2.3. Preparation of the Product for Use ............................................................................................... 9
2.4. Product Operation ....................................................................................................................... 10
3. MAINTENANCE .................................................................................................................................... 11
3.1. Product Maintenance .................................................................................................................. 11
3.1.1. General Instructions ............................................................................................................ 11
3.1.2. Safety Measures .................................................................................................................. 13
3.1.3. Product Maintenance Procedure ........................................................................................ 14
4. ROUTINE REPAIRS................................................................................................................................ 14
5. STORAGE ............................................................................................................................................. 14
6. TRANSPORTATION ............................................................................................................................... 15
7. DISPOSAL ............................................................................................................................................. 15
8. MANUFACTURER'S WARRANTY .......................................................................................................... 16
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Introduction This operating manual is a document containing information on the design, characteristics and instructions for proper and safe operation, maintenance, transportation, storage, and disposal of the Static Electric Power Amplifier (SEPA) with a rated power of 1,000 to 2,500 KVAH (hereinafter referred to as the "Equipment") intended for operation in conditions according to p. 1.1.1.3 of these operating instructions. The operating manual is designed for service personnel who have undergone appropriate training and knowledge testing on the "Rules for the Technical Operation of Power Plants and Networks" and the "Rules for Labor Protection for Operation of Electrical Installations". Attention! In case of any difficulties working with the Equipment, please contact the manufacturer.
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1. DESCRIPTION AND WORK
1.1. Description and Operation of the Product
1.1.1. Purpose of the Product
1.1.1.1. The equipment is designed to let the consumer save the electricity received from the public grid, with a minimum guaranteed ratio of 1.8 times, or 44%, by generating additional power generated at the time of consumption due to the internal circuit of the Equipment, the mechanism of which is described in section 1.1.4. The Equipment is intended for operation in distribution networks of three-phase alternating current with a frequency of 50/60 Hz for a rated voltage of 0.38, 0.4 KV.
1.1.1.2. Reference designation:
SEPA – ХХХХ – Х – ХХ – Х – IPXX
The Equipment of 2,500 KVAH rated power, 0.4 KV rated voltage, 50Hz rated frequency, intended to be installed at non-weather protected locations with 4K2 class of climatic conditions, IP55 enclosure protection class will have a reference designation coding as follows: "SEPA-2500-0.4-4K2-50-IP55".
1.1.1.3. Environmental category and climatic conditions:
The Equipment is designed to be installed at non-weather protected locations with 4K2 class of climatic conditions according to IEC 60721-3-4 standard. The Equipment is intended for operation in areas with a temperate climate with:
non-explosive, non-conductive dust environment;
ambient air temperature: from minus 45°C to plus 40°C;
relative humidity no more than 80% at a temperature of 15°C, an upper value of 98% at 25°C and at lower temperatures without moisture condensation.
Abbreviation of "Static Electric Power Amplifier"
Rated power, KVAH
Rated voltage, KV
Climatic modification and category of placement in accordance with IEC 60721-3-4
Nominal frequency of alternating current, Hz
Enclosure protection class according to IEC 60529
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The equipment is not designed to work in conditions of shaking, vibration, shock, in a chemically active environment.
1.1.2. Specifications
1.1.2.1. Main technical characteristics of the Equipment:
Parameter Name Parameter Value
Rated power, KVAH 1,000 1,500 2,000 2,500
Nominal frequency of alternating current, Hz 50/60
Short circuit voltage (%) 6
Enclosure protection according to IEC 60529 IP 55
Overall dimensions (WxDxH), mm 2176x1160x1820
Weight, kg 1000
Sanitary zone around the perimeter of the installation, m
1.5
1.1.2.2. Key technical characteristics that must be maintained when operating the Equipment:
Parameter Name Parameter Value
Grounding requirement 2-3 Ohms, IEC 60364-5-54:2011
Grounding impedance rate Minimum 1.5 kAh
Reactive power Must be compensated
Resistance of the internal circuit of the installation 0.3 – 0.6 Ohms
Periodically tighten the mounting bolts of transformers, inductors, capacitors
-
Input voltage 380V / 50Hz
Output voltage 380V / 50Hz
Phase A voltage 220V / 50Hz
Phase B voltage 220V / 50Hz
Phase C voltage 220V / 50Hz
The sum of the phases AB (input/output) 380V / 50Hz
The sum of the phases BC (input/output) 380V / 50Hz
The sum of the phases AC (input/output) 380V / 50Hz
The sum of the phases ABC (input/output) 380V / 50Hz
1.1.2.3. The average lifetime of the equipment is 20 years.
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1.1.3. Components of the Product
1.1.3.1. The Equipment consists of the following components:
1. Control block 2. Pulse block:
2.1. Cascade pulse generator 2.2. Spark gap control unit 2.3. Induction block
3. Three-phase meter for recording output 4. Three-phase meter for recording input 5. Input voltage bus 6. Output voltage bus
Spare parts, tools, fixtures and measuring instruments:
automatic reserve switch according to customer specification (optional);
circuit breaker according to customer specification – 2 pieces (optional);
electric contactor;
Equipment toolbox.
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1.1.4. Device and Operation
1.1.4.1. Cascade-pulse generator consists of three-phase cosine-type power factor correction capacitors having a rated voltage of 0.38KV and 0.4KV produced in accordance with the manufacturer’s specifications under the requirements of IEC 60871-1:2014. Capacitor fuses meet the requirements of IEC 60871-4:2014.
1.1.4.2. The spark gap monitoring unit consists of BH-0.66 KV current transformers, which meet the requirements of IEC 61869-2:2012.
1.1.4.3. The induction unit consists of inductors produced in accordance to the manufacturer’s specifications under the requirements of IEC 61869-2:2012.
1.1.4.4. When a voltage is input on the 0.4 side, the current enters the distributor of the pulse unit, where the additional power is generated by means of a cascade-pulse generator by charging a cascade of capacitors, the spark gaps of which are developed using the developed technology through a balance block with a frequency of 50/60 Hertz and a power of over 1.8 times exceeding the incoming one, are transmitted to the consumer.
1.1.5. Measuring Instruments, Tools and Accessories
1. Dielectric mat 2. Dielectric gloves 3. Three-phase electric meter (2 pieces) for measuring the electricity consumption at
the input and at the output 4. Multimeter to check the resistance of the circuit of the main circuits and secondary
switching circuits, to check the absence of breaks in the circuit 5. Antistatic wrist 6. Tool with current-insulated handles for work on the connection to the tested
circuits 7. Locksmith tools:
(a) flat-headed and cross-headed screwdrivers; (b) spanner; (c) pliers; (d) terminal clamp.
1.1.6. Marking and Sealing
1.1.6.1. Equipment marking must comply with the requirements listed below.
1.1.6.2. Each unit must have a label indicating the factory number.
1.1.6.3. A plate containing the following data is fixed on each installation:
symbol;
rated power in kVA;
type of performance;
factory number;
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date of manufacture;
Equipment dimensions;
total weight of the unit in kilograms.
1.1.6.4. Transportation marking in accordance to ISO 7000. At the same time handling signs must be applied in addition to the main and additional inscriptions: "Slinging location", "Center of gravity".
1.1.6.5. Marking method - according to the technology of the manufacturer.
1.1.6.6. There are warning signs on the Equipment: "Caution! Electrical voltage", "Caution! Strictly forbidden to open!", "Do not open without special permission". There is an instruction with key technical parameters of the Equipment and the rules of connection and maintenance, as well as informing signs: "Input Accounting", "Output Accounting", "380V / 50Hz Input", "380V / 50Hz Output". Equipment grounding points are marked with signs "Grounding".
1.1.6.7. The Equipment has factory seals installed on PIC microcontrollers, in a cascade-pulse
generator, on buses of a balance block, the numbering and list of which is indicated in the Equipment Installation Act and completion of commissioning.
1.1.7. Packaging
1.1.7.1. The equipment is packed by the manufacturer in the way that ensures the integrity of the Equipment during transportation.
1.1.7.2. For the period of transportation, the terminal wires, which are installed when connected, are removed from the capacitors.
1.1.7.3. The toolbox for the maintenance of the Equipment is wrapped in air-pimply and plastic films and fixed inside the Equipment case.
1.1.7.4. The accompanying technical documentation, wrapped in a moisture-proof package, is enclosed in a packing place or sent to the customer by mail. The set of accompanying technical documentation includes: passport and instruction manual.
1.1.7.5. The case of the equipment has 3 doors with locks. In order to avoid unauthorized access to the Equipment upon shipment prior to its installation the Equipment is sealed with 3 seals, the numbers of which are indicated in the consignment note of the carrier and in the certificate of equipment sealing.
2. INTENDED USE
2.1. Operational Limitations
2.1.1. It is forbidden to drop the Equipment or subject it to the strong mechanical stress.
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2.1.2. Attention: it is forbidden to install the Equipment in an area where there is a risk of flooding.
2.2. Product Connection Requirements
2.2.1. The consumer is obliged to provide the following requirements for connecting the Equipment to its network:
three-phase connection with specifications according to the rated power of the Equipment;
automatic reserve switch corresponding to the rated power of the Equipment;
emergency input of a reserve of the corresponding rated power of the Equipment;
connection of the Equipment to the ground loop;
attention: grounding no more than 3 Ohms according to IEC 60364-5-54:2011 and impedance rate of no less than 1.5 kAh, reactive power must be compensated;
sanitary zone no less than 1.5 meters along the perimeter of the Equipment;
a cable corresponding to the rated power of Equipment must be laid at both ends from the place of input-output of the network to the place of installation of the Equipment. Each end must be at least 3 meters from the ground.
2.2.2. The recommended connection diagram of the Equipment is presented as follows:
The recommended connection diagram of the Equipment (isolated neutral)
2.3. Preparation of the Product for Use
2.3.1. Attention: it is strictly necessary to have a tolerance of up to 1000 volts to work with the Equipment.
2.3.2. The equipment must be installed on a flat platform in an open area or in a ventilated area in compliance with the sanitary zone specified in section 1.1.2.1 and the requirements for installing high-voltage electrical equipment in an enclosed area.
2.3.3. Connect the input to the terminal bus through crimped tinned terminals without contact of the wire with the housing.
2.3.4. Attention: check that the phase sequence on the input and output is the same: ABC → ABC.
2.3.5. After connecting the Equipment, check the values in the measurement table specified in section 1.1.2.2.
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2.3.6. Attention: to provide grounding no more than 3 Ohms according to IEC 60364-5-54:2011 and impedance rate of not less than 1.5 KAH, reactive power must be compensated.
2.3.7. After connecting to grounding, check the values for compliance with the table of sizes specified in section 1.1.2.2.
2.3.8. Attention: in case of deviation of values from the data of the table DO NOT switch on the Equipment until they are eliminated.
2.3.9. Check for damage to the cable insulation.
2.3.10. Make sure that there are no foreign objects inside the case.
2.4. Product Operation
2.4.1. Security measures:
2.4.1.1. Security measures comply with the regulations for the operation of transformer substations 10 / 0.4.
2.4.1.2. Attention: The Equipment should be serviced by specialists who are qualified and permitted to work with voltage up to 1000 volts.
2.4.1.3. Lay a dielectric mat and wear dielectric gloves before opening the Equipment.
2.4.2. It is strictly forbidden:
2.4.2.1. To perform work and switch on the equipment connected to the network from at least one side.
2.4.2.2. To switch the Equipment on without connection to ground. 2.4.3. Periodic measurements of Equipment operation:
2.4.3.1. Read technical parameters of the Equipment specified in section 1.1.2.2 and record in a
technical journal at least once a month.
2.4.3.2. In case of deviations of technical parameters of the Equipment operation, refer to the table of possible malfunctions, causes and ways to eliminate them, presented in clause 2.4.4, or contact the manufacturer’s service department.
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2.4.4. Possible malfunctions, causes and remedies:
Class of Malfunction
Malfunction Location
Possible Causes and Remedies
Equipment does not work
Automatic reserve operation is triggered.
Incorrect Equipment connection or unbalanced phase connection. Check the connection according to paragraphs. 2.3.4 and 2.3.5
Equipment turns off spontaneously
Automatic reserve transfer is activated or fuses blow
Ground is not connected or grounding capacity exceeds 3 Ohms and / or does not meet the requirements of IEC 60364-5-54:2011 specified in clause 1.1.2.2. Adjust grounding capacity to specified requirements.
Heated output cable
The temperature of the output cable is significantly higher than the temperature of the input cable.
Cable specifications do not meet the requirements specified in section 2.2.1. Adjust the cable to the specified requirements.
3. MAINTENANCE
3.1. Product Maintenance
3.1.1. General Instructions
3.1.1.1. The list and frequency of maintenance work under normal operating conditions are listed in the Table «The List and Frequency of Maintenance Work».
3.1.1.2. The frequency of cleaning depends on conditions of the environment in which the
Equipment is operated.
3.1.1.3. In case of a rapid accumulation of dust, increase the frequency of cleaning.
3.1.1.4. For any information when contacting the service department, you should indicate the information from the nameplate and, especially, the serial number of the Equipment.
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The List and Frequency of Maintenance Work
The List of Works
Periodicity
Once a year
Once in 8
years
1. EXTERNAL INSPECTION OF EQUIPMENT
a) Check for absence of mechanical damage to the cable on the input and output
●
2. EQUIPMENT OPERATION MONITORING UNIT
a) Measure key technical parameters and compare with target values in clause 1.1.2.2
●
b) Remove dust and dirt ●
c) Check that the connections on the input and output bus are tight ●
d) Check the connections of grounding switches with grounded elements: measure the contact resistances in accordance with the standards set by IEC 60384
●
e) Check the phase-zero circuits (grounding circuits) in electrical installations up to 1 kV with a neutral grounding in accordance with the standards set by IEC 60384
●
f) Carry out an external inspection of the clamp on the cables for cracks, corrosion, mechanical damage
●
g) Check the operation of the input and output metering of electricity consumption
●
h) Check the operation of the alarm system in case of unauthorized access
●
i) Measure the insulation resistance of the input and output buses in accordance with the standards set by IEC 60384
●
j) Test isolation of input and output buses with increased voltage in accordance with the standards set by IEC 60384
●
k) Measure the insulation resistance of the load switches in accordance with the standards set by IEC 60384
●
l) Test the isolation of overvoltage circuit breakers in accordance with the standards set by IEC 60384
●
3. CASCADE-PULSE GENERATOR
a) Remove dust and dirt ●
b) Conduct an external inspection of capacitors for tightness and the absence of deformation and damage to the body: swelling, sagging, etc. Measurements should be carried out with an accuracy of ±2 mm
●
c) Check the condition of paint coatings of enclosures and metal coatings of contact surfaces
●
d) Conduct an external inspection for leak detection (drip or other) of a liquid dielectric
●
e) Conduct an external inspection for the integrity of the capacitor insulators
●
f) Wipe off insulators and capacitor housings ●
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The List of Works
Periodicity
Once a year
Once in 8
years
g) Conduct an external inspection for no damage to the capacitor terminals
●
h) Check the reliability of mounting terminals on capacitors ●
i) Check the reliability of the contact connections (check the tightness of the bolts)
●
j) Carry out an external inspection of the clamp on the cables for cracks, corrosion, mechanical damage
●
k) Check the connection cable for flashing ●
l) Measure the capacitance of each capacitor and compare with the target values of the technical documentation for the Equipment
●
m) Measure the resistance of the capacitor discharge resistor ●
n) Assess the need for cable replacement ●
o) Conduct a high voltage capacitor test in accordance with the standards set by IEC 60384
●
p) Conduct a capacitor battery test in accordance with the standards set by IEC 60384
●
4. SPARK GAP CONTROL UNIT
a) Remove dust and dirt ●
b) Conduct an external inspection of transformers to verify the absence of insulation on the surface of cracks and chips
●
c) Check transformers mounting ●
d) Check the reliability of the contact connections ●
e) Measure the insulation resistance of transformers in accordance with the standards set by IEC 61558
●
f) Test transformer isolation with increased voltage in accordance with the standards set by IEC 61558
●
g) Conduct tests the volume and standards of which are set by IEC 61558
●
5. THE INDUCTION BLOCK
a) Remove dust and dirt ●
b) Conduct an external inspection of inductors to verify the absence of insulation on the surface of cracks and chips
●
c) Check inductors mounting ●
d) Check the reliability of the contact connections ●
e) Conduct tests the volume and standards of which are set by IEC 61558
●
3.1.2. Safety Measures
3.1.2.1. When carrying out maintenance work on the Equipment you should be guided by the requirements of the current "Rules for the Installation of Electrical Installations", "Rules for the Technical Operation of Electrical Installations of Customers", and the "Rules for
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Labor Protection for Operation of Electrical Installations", these operating instructions, as well as other applicable local codes and regulations.
3.1.2.2. Personnel performing maintenance of the Equipment should clearly understand the
purpose of the individual parts, their interaction and state during operation.
3.1.3. Product Maintenance Procedure
3.1.3.1. When carrying out maintenance work on the Equipment you should be guided by the requirements of the current "Rules for the Installation of Electrical Installations", "Rules for the Technical Operation of Electrical Installations of Customers", and the "Rules for Labor Protection for Operation of Electrical Installations", this operating manual, as well as other applicable local norms and rules that take into account the specifics of a particular object, climatic zone, nature of consumers and other factors. Local regulations must comply with the requirements of the current Electrical Installation Rules.
3.1.3.2. The operation mode of the Equipment should be monitored by reading the values of the
technical parameters of the Equipment operation specified in section 1.1.2.2, at least once a month. Under normal operating conditions, the parameters should match the specified values.
3.1.3.3. Equipment in operation should be subject to periodic inspections. During the inspection,
attention should be paid to the condition of the inputs, outputs, buses, cables, and equipment grounding.
4. ROUTINE REPAIRS
4.1. Current transformers, inductors, as well as capacitors, which are the key components of the Equipment, do not require repair over the entire service life.
4.2. Current transformers should be inspected in accordance with IEC 60044-8. The recommended calibration interval is 8 years.
5. STORAGE
5.1. Storage conditions in terms of the impact of environmental climatic factors:
the upper and lower air temperature values are respectively equal to plus 50°С and minus 50°С;
average monthly relative humidity is 80% at 20°С;
the upper value of relative humidity is 98% at 25°C.
5.2. The allowable storage period for the Equipment in the original packaging prior to commissioning is two years.
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6. TRANSPORTATION
6.1. The Equipment is transported and stored in the factory packaging in an upright position.
6.2. When loading, transporting and unloading Equipment, it is necessary to comply with the requirements set forth in these operating instructions.
6.3. The equipment is sent to the customer by any means of transport: by rail, road, sea (river),
air.
Road transportation
6.4. Immediately after arriving at the place of destination, before unloading the Equipment, together with a representative of the transport organization, it is necessary to inspect the package and ensure that there are no mechanical damages. Upon detection of a mechanical damage, it is necessary to draw up a statement on the results of the inspection.
6.5. When loading, transporting and unloading Equipment, the following requirements must be observed:
Equipment can only be moved in an upright position;
avoid strong vibrations of the Equipment during transportation;
transportation of the Equipment is carried out in accordance with the requirements of the relevant regulatory documents. The weight of the Equipment is indicated in the transport documentation and on the Equipment plate;
it is necessary to ensure reliable fastening of the Equipment in order to exclude movements of the Equipment on the platform;
unloading of the Equipment should be carried out by mechanisms and devices whose carrying capacity corresponds to the mass of the product;
angle of the lines from the vertical should not exceed 60 degrees.
6.6. Moving the Equipment with a forklift: when using a forklift, it is necessary to lift the Equipment by inserting a forklift under the equipment's lower supporting channels.
6.7. Moving the Equipment with a crane: lifting the Equipment is carried out using four tie-down brackets. The angle made by the two cutting chains must not exceed 60 degrees.
7. DISPOSAL
7.1. Parts and components of the product do not emit harmful substances during operation and storage.
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7.2. The case and the terminals of capacitors that have served their life, damaged during installation and operation, with irreparable faults must be disposed of, and the impregnating liquid and the removable part must be incinerated in special installations.
7.3. Current transformers do not pose a danger to the environment and human health and, after the end of their service life, must be disposed of on generally accepted basis.
7.4. No other special measures are required when disposing the Equipment.
8. MANUFACTURER'S WARRANTY
8.1. The warranty period is 3 years from the date of commissioning.
8.2. The warranty is valid on condition that the customer observes the rules and requirements specified in these operating instructions.
8.3. Warranty does not cover damage to equipment due to and in the case of:
improper operation and/or violation of the requirements of the Equipment manual;
violation of the integrity of seals installed on microcontrollers, in the cascade-pulse generator, on the buses of the balance unit of the impulse block of the Equipment;
violations of the norms of storage and storage equipment;
accidental, negligent or intentional (vandalism, theft, etc.) actions of the end user or third parties;
unauthorized changes and modifications to the Equipment and/or its components;
force majeure circumstances: natural disasters, fires, earthquakes, military actions, etc.