power factor correction cubicles · power factor correction cubicles 2 installation & operating...

Power Factor Correction Cubicles

Operating and Commissioning Instructions - Issue 01/2016


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Installation & Operating Instructions for Powercab Cubicles Description of Part Number PPB ### * ? Q

PB : Power Cab Blue-Line RangeSuperior Plain Design with 480V dielectric rating as standard

PPB : Power Cab PLUS Blue-Line RangeSuperior De-tuned Design with 480V dielectric rating as standard

PG : Power Cab Green-Line RangePlain Design with 440V dielectric rating as standard

PPG : Power Cab PLUS Green-Line RangeDe-tuned Design with 440V dielectric rating as standard

### - Capacitor rating - 050 = 50kVAr; 150 = 150kVAr; 250 = 250kVAr; 300 = 300kVAr.* - Control - M = Master; S = Slave.

? - Incoming device - F = Fuse Switch; J = Isolator; T = Terminals.Q - Special features – see specification sheet for full details

To ensure personal safety and correct operation of the equipment, please ensure that the following instructions and recommendations are followed

Description - The equipment is designed and manufactured to the following requirements;i. BSEN61439 Low Voltage assembliesii. BSEN60831 parts 1 & 2 Capacitorsiii. 72/23/EEC EU Low Voltage directiveiv. 89/336/EEC EU EMC directivev. BSEN61921:2003 Power Capacitors Banks

The control and switching of the capacitors, in Master Cubicles, is achieved via an integral reactive power control relay. Full details of this device is attached to this instruction. For Slave Cubicles, the automatic control will be effected via a remote switching facility.

Installation - Check that the data on the equipment rating plate (i.e. voltage, current, number of phases, frequency) is compatible with the system to which the equipment is to be connected.

Erection - The equipment should be securely fixed to the floor and/or wall as appropriate.

Connection - The equipment should be connected to the supply system via cable rated in accordance with the current edition of the IEE Wiring Regulations (BS7671). The cables should be adequately rated to accommodate the possibility of excess current drawn by the capacitor caused by high voltage and/or harmonic distortion. To comply with BSEN60831 cables must be rate at 1.5 times the nominal capacitor current i.e. for 50Kvar nominal current is 69.5A at 415V; cables must be rated at 100A. The cables must also be sized so that the correct protection is provided by the feeder device. When making the mains connections, care must be taken to ensure that the correct phase rotation is maintained i.e;L1 = Brown (or Red) PhaseL2 = Black (or Yellow) PhaseL3 = Grey (or Blue) Phase

Diagrams & Drawings - The reference of the diagram and drawing follow the same format as the respective part number i.e. PPB150MJ-S Schematic Diagram PPB150MJ-G General arrangement.


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Signal C/T for Master Cubicles - A current signal to the reactive power relay (when fitted) is used to calculate the reactive power on the system, and hence the system power factor. This signal is provided by a current transformer on the red (or brown) phase of the main distribution board. This current transformer must be located at such a point so that it reads the current of the total load including the capacitor. The secondary of the current transformer should be connected to terminals K (S1) & L (S2) on the control strip in the capacitor equipment. The C/T shorting link across these terminals should not be removed until the equipment is commissioned, usually by a Power Capacitors Limited engineer.

Commissioning - The setting up of the control relay (when fitted) is detailed in the Reactive Power Relay Instructions.

Harmonic Distortion - Care must be exercised when installing capacitors onto systems that may be subject to harmonic distortion. Under these conditions it is possible to

a) Overload the capacitors and/orb) Cause system disturbance and amplification of the harmonic

If it is suspected that there may be harmonic distortion (the relay is set up to warn of this eventuality) an appropriate harmonic analysis should be carried out to determine the level of distortion and the possible solutions.

Ventilation - Care must be taken to ensure that the ventilation provided is not obstructed. Where filters are fitted, these MUST be cleaned regularly to maintain the effective cooling of the equipment. The capacitors are designed to withstand the following temperatures within the cubicle, hence it is important that the temperature of the air around the cubicle will allow the ventilation system to cool the capacitors.

Maximum ambient 50ᵒCHighest Mean over 24 Hours 40ᵒC

Highest Mean over 1 Year 30ᵒC

Maintenance - Power Factor Correction Equipment should be regularly inspected (at least annually) to verify its effective operation. These checks should include

a) Check on the operation of the isolatorb) Check on all fusesc) Check on the operation of the contactorsd) Check on the operation of the ventilation systeme) Check the running current of each capacitor section

Power Capacitors Limited offers an on-site service for all makes of Power Factor Correction Equipment. Requests for this service should be addressed to [email protected] and 0121 708 2811


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InstallationObserve all relevant local and international standards and safety regulations during installation!

1. Compare voltage and current ratings of the PFR-X-R with the data of your mains and installation

2. Fix the controller in a 138 x 138mm window within your control panel using the 2 mounting clips

3. Connect the PE terminal of the controller with a protective earth conductor

4. Install the PFR-X-R according to the connection diagram

5. Remove the bridge-link from the CT terminal

CommissioningIf the PFR-X-R has already been presetUpon powering-up the PFR-X-R, a 90 sec countdown starts after which the capacitor discharge time lock (default 75s unless set otherwise) is activated. During these two delays, the PFR-X-R does not activate any control outputs. The countdown can be interrupted by pushing the ◀ (esc) button. After the countdown, normal control starts with the preset parameters.

If the PFR-X-R has not been setDuring the initial countdown, automatic initialisation of the PFR-X-R can be started by pushing ▶ (↵). After the discharge blocking time (default 75s), the controller starts detecting and locking idle switching outputs. It will also detect and correct faulty connections of voltage and and current polarity. After automatic initialisation the PFR-X-R starts its controlling functions. During normal operation, it will identify the size of each connected capacitor branch. Manual settings of c/k values and switching programs are not required.

Note: If mains conditions are not suitable for automatic setup,the PFR-X-R will abort automatic initialisation and display the error code: “Ai Abrt”. Consult the reference manual of the controller for manual setup instructions if several attempts at automatic initialisation have showed no results (not included as standard).


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Display and OperationDisplay Functions

“Auto”The message “Auto” is displayed during regular control function.If this message does not show, check for the following reasons: controller in manual operation mode, control function switched off, temperature too high, current less than 15mA, voltage out of range, harmonic level (voltage) too high.

“U Alarm”The PFR-X-R is equipped with over and under voltage monitoring. The permitted voltage range is related to the rated mains voltage (ph-ph). The alarm message shows when the voltage is out of range. In such case, adjust the setting of nominal voltage to local ratings.

Values and Information

In default mode, the controller displays voltage-based values only. Enable display of the full range of available measurement values by entering the ratio of the current transformer (CT) in the “setup” menu.

The PFR-X-R is operated by means of four keys on the front panel.Navigation though menu levels:• Select main menus by pressing ▲ and ▼.• Open submenus of a selected main menu by pressing ▶ (↵).• Return to next higher level by pushing ◀ (esc).

AUTO, MANUAL: cosphiSETUP, INFO: Nummer Untermenü


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Measured Values

Select the following values to be displayed by pushing ▲ and ▼:voltage UPh-Ph, voltage Uph-N, current I, active power P, reactive power Q, reactive power short to reach target ΔQ, apparent power S, THD (U), 3.-15. Harmonic of voltage displacement power factor cos(ϕ), power factor PF (Λ), average power factor APF, frequency F, temperature t, max. temperature thi, operating hours OPh

INFO (database of capacitor branches)Attention: The status of the outputs is not displayed in this menu!

Use ▲ and ▼ to select a capacitor branch. The branches are indicated in the display. Press ▶ (↵) to show information for the selected branch.

It is possible to connect branches with capacitive as well as inductive power. The power rating is always referring to the selected nominal voltage.

Available branch types are: Auto, Fon (Fix on), Foff (Fix off), Defective, AL (Alarm, e.g. for fan control)

MANUAL operation To avoid accidental stop of control, this menu function can only be entered by pushing ▶ (↵) for 3 sec.

When entering manual mode, the controller freezes the actual position of all outputs, and automatic control is deactivated. Individual steps can now be selected by pressing ▲ and ▼. The state of an output is altered by pushing ▶ (↵) and indicated in the display.

Note: Switching time delay is disabled in manual mode. For safety reasons, however, the discharge lock time of the capacitor can not be deactivated.

When exiting the manual mode, PFR-X-R will resume controlling with our switching-off all steps before.

SETUP

Setup/Expert menu is sub-divided into 6 sub-menus (100 - 600). Select setup and press ▶ (↵) shortly to enter sub-menu 100 only. For access to the Expert-menu, select setup ad push ▶ (↵) for 3 seconds. use ▲ and ▼ to navigate between the parameters and sub-menus. Press ▶ (↵) to open sub-menus or to switch parameters into edit mode.

Return to next higher menu level with ◀ (esc).

In edit mode, press ◀ and ▶ to move the blinking cursor in left or right direction. use and to alter the highlighted value.

To save settings, move cursor to outer right position and press ▶ (↵).To discard changes, move cursor to outer left position and press ◀ (esc).

actual power of branch

actual branch output related to rated power

number of switching operations

type of branch


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ANNEX: Menu settings

The following chart contains an overview of the PFR-X-R parameters. Settings in menus 200…600 should be made only be using our detailed reference manual.

Quick Start Menu 100:Un nominal voltage (is necessary for over- and under-voltage monitoring and serves as reference for the database of capacitor branches)Ct current transformer ratio (required for display of full range of measured values)Pt voltage transformer ratioAi start of automatic initialisation (this function is running only in “Auto” mode)PFC PF-control ON/OFF (all branches are switched off) / HOLD (all branches are locked in current position)CP1 target power factor 1St switching time delayOUt type of branch: 1…(depending on controller type up to 14 branches)

Detailed Menu structure


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Alarms

PFR-X-R has an extended alarm system. For available alarm settings see menu structure. When an alarm is active, the sign “ALARM” blinks in the display and an error code is displayed in the LCD. Possible error codes are:

Technical Data


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Site Services and supportPower Capacitors is power quality and we have forty years of experience behind us. Our trained engineers can help you get to the bottom of any power quality problem. If you are unsure about whether power factor correction can benefit you then we can provide you with a survey and some accurate calculations free of charge - just give us a call. We are also able to provide you with load profiling and harmonic surveys along with interpretation and recommendations. Our service also includes mathematical modelling of load & supply systems, predicting levels of Power Factor & Harmonic Distortion. If you need specification support to incorporate any kind of power quality equipment into your existing product or service then we can provide expert unbiased advice.

Why use Power Capacitors?

Delivery - Once the decision is made to install power factor correction equipment then the sooner the equipment is installed the quicker it starts to pay for itself. Our fast, efficient ISO 9001 approved manufacturing facility is able to do just that.

Cost v Performance - The PowerCab & PowerCabPlus have a proven pedigree in outstanding, reliable performance coupled with impressive payback periods of between one and two years.

It’s ALL we do - Power quality is ALL we do at power capacitors. For over forty years we have led the way in technology and reliability and are acknowledged specialists in the field.

Service & Support - Our customer relationship is ongoing and we not only supply your product but offer servicing, maintenance and a reliable source of information.

Quality standards - We are a BS EN ISO9001:2008 quality assured manufacturer. When on your premises, we work to safe contractor procedures and BSI approvals. Power Capacitors are NICEIC registered and are members of BEAMA, so you can always be assured that whether we are building your equipment in house or working on your site we set the same high standards you do.

ISO 9001Registered

QualityManagement

Power Capacitors Ltd30 Redfern Road, Tyseley

Birmingham. B11 2BH

Telephone: 0121-708-4511 | Fax: [email protected] | powercapacitors.co.uk

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