CIRCUTOR FRE User Manual

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LV CAPACITOR BANKS WITH DETUNED

FILTERS AND STATIC SWITCHING

FRE / FRES

INSTRUCTION MANUAL

(M98247101-03-12A)

FRE / FRES

SYMBOLS AND WARNINGS

Pay attention to the danger and warning indications in this manual, which are shown with the following symbols.

DANGER: Warns of a risk, which could result in personal injury or material

damage.

WARNING: Indicates that special attention should be paid to a specific point.

If you must handle the equipment for its installation, start-up or maintenance, the following points should be taken into consideration:

Incorrect handling or installation of the unit may result in injury to personnel as well as damage to equipment. In particular, handling with power applied may result in electric shock, which may cause death or serious injury to personnel. Defective installation or maintenance may also lead to the risk of fire.

Carefully read the manual prior to connecting the equipment. Follow all the installation and maintenance instructions for the equipment throughout its working life. In particular, follow the installation standards indicated in the Low Voltage regulations and additional technical instructions.

The installation, operation and maintenance of LV equipment must only be carried out by authorised installers. See the National Code Instructions specifically defining the requirements that authorised installers must meet in each country.

If in order to install the equipment, you must work in areas that have high-voltage (HV) equipment installed, then the personnel handling equipment in this area must be authorised to work in HV installations. Refer to the National Code Instructions, in each country, which specifically regulate the requirements for personnel and maintenance companies autorised to handle high-voltage installations.

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TABLE OF CONTENTS

1 INTRODUCTION .................................................................................................................................................. 4

2 SAFETY HAZARDS AND WARNINGS................................................................................................................ 4

2.1 H

2.2 S

2.3 A

3 RECEPTION, TRANSPORT, HANDLING AND STORAGE ................................................................................ 5

3.1 RECEPTION PROTOCOL .................................................................................................................................... 5

3.2 T

3.3 S

4 TECHNICAL CHARACTERISTICS ...................................................................................................................... 6

4.1 LABEL WITH THE EQUIPMENT'S CHARACTERISTICS ............................................................................................... 6

4.2 E

4.3 E

4.4 M

4.5 EXTERNAL DIMENSIONS AND WEIGHTS ............................................................................................................... 8

4.6 C

5 INSTALLATION ................................................................................................................................................. 10

5.1 PREPARATION .............................................................................................................................................. 10

5.2 I

5.3 C

6 START-UP OF A STATIC CAPACITOR BANK WITH DETUNED FILTER (FRE OR FRES) ........................... 13

6.1 B

6.2 S

6.3 TESTS ONCE THE CAPACITOR BANK IS CONNECTED AND THE PF REGULATOR HAS BEEN ADJUSTED ......................... 14

7 MAINTENANCE ................................................................................................................................................. 15

7.1 S

7.2 M

7.3 M

7.4 E

8 WARRANTY ....................................................................................................................................................... 18

9 TECHNICAL ASSISTANCE AND DECLARATION OF CONFORMITY ............................................................ 18

9.1 C

SCHEMES

AZARDS ENCOUNTERED DURING THE INSTALLATION AND START-UP OF ELECTRICAL EQUIPMENT. ............................ 4

AFETY WARNINGS.......................................................................................................................................... 4

PPLICATION WARNINGS .................................................................................................................................. 5

RANSPORT, LOADING AND UNLOADING, HANDLING AND STORAGE ........................................................................ 5

TORAGE ....................................................................................................................................................... 6

LECTRICAL CHARACTERISTICS ........................................................................................................................ 7

NVIRONMENTAL CHARACTERISTICS ................................................................................................................. 7

ECHANICAL CHARACTERIST ICS: ...................................................................................................................... 7

APACITOR BANK COMPONENTS ....................................................................................................................... 8

4.6.1 Fast regulator........................................................................................................................................... 9

4.6.2 CPC, zero switching controller ................................................................................................................. 9

4.6.3 Power block: .......................................................................................................................................... 10

NSTALLATION LOCATION ................................................................................................................................ 10

ONNECTION OF THE CAPACITOR BANK WITH FILTERS TO THE GRID ..................................................................... 10

5.3.1 Power circuit. ......................................................................................................................................... 11

5.3.2 External isolation and protection elements ............................................................................................ 11

5.3.3 Auxiliary control voltage. ........................................................................................................................ 11

5.3.4 Earth cable connection .......................................................................................................................... 11

5.3.5 Connecting the current transformer (CT) ............................................................................................... 12

EFORE START-UP ........................................................................................................................................ 13

TART-UP .................................................................................................................................................... 13

AFETY REGULATION ..................................................................................................................................... 15

AINTENANCE WITH THE FILTER BANK DISCONNECTED ...................................................................................... 15

7.2.1 Basic maintenance protocol ................................................................................................................... 15

7.2.2 Tightening the electrical connections. .................................................................................................... 15

7.2.3 Key points for inspecting static switches. ............................................................................................... 15

7.2.4 Key points for inspecting capacitors. ..................................................................................................... 16

7.2.5 Key points for testing the PF regulator .................................................................................................. 16

7.2.6 Cleaning the cabinet .............................................................................................................................. 16

AINTENANCE WITH THE CAPACITOR BANK CONNECTED .................................................................................... 16

NVIRONMENTAL CONDITIONS: ....................................................................................................................... 17

ONFORMITY DECLARATION ........................................................................................................................... 19

FRE / FRES

Code Instructions specifically

It is recommended that several personnel are present when handling the

1 INTRODUCTION

The purpose of this manual is to assist during the installation, start-up and maintenance of FRE and FRES series equipment. FRE and FRES are PF correction equipment with detuned filters and static

switching. Carefully read the manual to achieve the best equipment performance.

2 SAFETY HAZARDS AND WARNINGS

2.1 Hazards encountered during the installation and start-up of electrical equipment.

The installation, operation and maintenance of LV equipment must only be carried out by authorised installers. See the National defining the requirements that authorised installers must meet in each country.

Do not access the active elements of a detuned filter with static switching that has been previously powered, since it might have residual voltages at the capacitors. Wait at least 5 minutes after the power supply has been disconnected.

Do not touch the terminals or active parts of the unit until you have verified that there is no residual voltage at the capacitors. If you have to handle or touch the terminals or other control panel components while the equipment is connected to the supply, use adequately insulated personal protection equipment and tools.

After maintenance and before re-applying the power supply to the unit, check that its enclosure is properly closed and that no items or tools were left inside that could cause a short-circuit.

Do not open the secondary circuit of current transformer without short-circuiting it first. The operation of a current transformer with an open secondary will cause an overvoltage that can damage it and electrocute the person handling it.

2.2 Safety warnings

Apart from the general standards listed above, the standards and applicable laws of the country where the capacitor bank is installed or operated should be strictly followed.

Installation or maintenance personnel should read and understand this manual before operating the equipment.

A copy of this manual should always be available to maintenance personnel for reference purposes.

Connecting the equipment to the public grid will be carried out in compliance with standard EN-IEC60204-1, on the safety of LV electrical installations.

equipment for either installation or maintenance. If damage or faults are detected during equipment operation, or in circumstances

that compromise safety, immediately stop work in that area and disconnect the equipment in order to check it once it is de-energized.

Modifying, upgrading or rebuilding the equipment without written authorization from the manufacturer is strictly prohibited.

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FRE / FRES

2.3 Application warnings

Capacitor banks with detuned filters can attenuate the remote control signals transmitted through the network which are used in some countries to connect or disconnect certain loads or lines. When remote control frequencies close to the tuning frequency of FRE or FRES filters are used, blocking filters must be placed in the supply line, or the tuning frequency of the FRE /or FRES filters must be changed.

3 RECEPTION, TRANSPORT, HANDLING AND STORAGE

3.1 Reception protocol

 Make sure that the equipment has not been damaged during transport.  Check that the equipment received matches with the order and that its electrical characteristics

are suitable for the grid where it is to be connected.

 Check the shipping documentation. The dispatch note number must coincide with the number

marked on the outer part of the unit package.

 Unload and transport the equipment in accordance with the instructions in section 3.2  Perform an external and internal visual inspection of the equipment prior to connecting it.  Check that all items on the packing list are present and match with the delivered documentation.

If any discrepancy is detected upon reception, immediately contact the transport company or CIRCUTOR's after-sales services.

3.2 Transport, loading and unloading, handling and storage

The transport, loading and unloading and handling of the equipment must be carried out with proper precautions and using the proper manual or mechanical tools to prevent damaging the equipment.

If the equipment is not to be immediately installed, it must be stored at a location with a firm and level floor and satifying the storage conditions listed in the technical characteristics section. It is recommended that the equipment be stored with its original protective packaging.

To move the equipment a short distance, the unit's floor support profiles facilitate handling with a pallet jack or forklift.

The centre of gravity of some units may be at a considerable height. Therefore, when handling with a forklift, it is recommended that the equipment be securely fastened and that no abrupt operations are made. The equipment should not be lifted more than 20 cm over the ground.

Fig. 3-1 .-Transport with pallet jack

When unloading and moving the equipment, use a forklift with forks long enough to support the entire length of the base. In the limit, the forks should be long enough to support at least ¾ of the depth. The

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FRE / FRES

There might be an offset in the centre of gravity from the centre of the cabinet, as a

must be taken to prevent the equipment from tipping over during abrupt operations.

forks must be flat and laid firmly on the base. The cabinet must be raised by placing the forks underneath the profile that supports the equipment. (Fig. 3-2).

result of the uneven distribution of loads in equipment. The necessary precautions

Fig. 3-2 .-Unloading with a Forklift

3.3 Storage

The following storage recommendations should be followed for static capacitor banks with detuned filters:

- Avoid placing it on uneven surfaces.

- Do not store in outdoor or humid areas or areas exposed to the splashing of water.

- Avoid hot zones for storage (maximum environmental temperature: 45 ºC)

- Avoid saline and corrosive environments.

- Avoid storing the equipment in areas where dust is generated or where the risk of chemical or other types of contamination is present.

- Do not place heavy parcels or other equipment on top of the FRE or FRES cabinets.

4 TECHNICAL CHARACTERISTICS

4.1 Label with the equipment's characteristics

The label with the equipment's characteristics is located inside it, generally next to the PF regulator (refer to Fig. 4-1). A capacitor bank with filters includes always the p% information, which states the filter's tuning factor. This information is important to establish the filter's resonance frequency.

Fig. 4-1.- Label of characteristics

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FRE / FRES

4.2 Electrical characteristics

- Operating voltage and nominal frequency: U

- Design voltage: U

- Nominal power and distribution of steps: Q

/ f , listed on the label

+ 10% (440 V for 400 V equipment)

and composition, (see label)

- Overvoltage factor, p% Standard 7% ,

Others 14%, 8.2% and 5.67% (see label)

- Total loss: Standard 3.5 at 4 W/kvar

- Residual discharge voltage: 75 V after 3 minutes

- Overload capacity: 1.3 . I

- Contact operating voltage: U

NOTE: In general, use a 1.5 mm2 cable to supply external power. If the label indicates “Internal” , means that this the auxiliary circuit does not require external power.

in all items

, listed on the label.

aux

- Current Transformer Input: 5 A , (Transformer In /5 A)

NOTE: Minimum cable section 2.5mm2.

- Compliance with Standards EN-61642 and UNE EN 61921

- Protection elements:  Fuses Type gL, NH gauge (minimum 1.5 x I

 Reactor thermostat: 90 ºC ±5 ºC

Insulation 3 kV /50 Hz Breaking capacity 10 A / 250 V

, resistive load

- Capacitor characteristics:

 Capacity tolerance: ± 5%  Insulation level from earth: 3 kV /50 Hz  Impulse test: 15 kV , ray type wave 1.2/50 µs  Protection elements: Internal fuses and over-pressure system  Compliance with Standards EN 60831

- Reactor characteristics:

 Inductor tolerance: ± 5%  Rated voltage standard 500 V (RMS value)

 Saturation current Standard at 1.4 I

, L=5% (Others for RBX)

 Level of insulation phases to earth 3 kV /50 Hz; 15kV shockwave 1.2/50 µs  Max. overload Σ(n.I

)2 Permanent 20% ; Transient (1 min) 2 In

)

4.3 Environmental Characteristics

- Capacitor max. temperature Category C in accordance with EN 60831-1

 Maximum for 1h 50 ºC  24h average 40 ºC

 Annual average 30 ºC

- Max. temperature of reactors In accordance with IEC 60076-6

 Maximum environmental temperature 60 ºC  Indoor temperature at In <110 ºC

 Protection thermostat 90 ºC  Cabinet ventilation For Tout > 30 ºC, forced ventilation must

be used for the cabinet

- Maximum relative humidity: 80%

- Altitude: 1000 m (For higher altitudes, always

maintain forced ventilation)

4.4 Mechanical characteristics:

- Protection degree: Marked on the label:

- Paint Oven dried epoxy type

- Standard colours RAL 7035 Grey ; RAL 3005 Maroon

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4.5 External dimensions and weights

Type Length (mm) Height(mm) Width (mm) Weight (kg)

FRES

FRE4

FRE6

FRE8

FRE12

700 1000 380 215

930 1900 650 460

1360 1900 650 685

1760 1900 650 1000

2720 1900 650 1389

Fig. 4-2. - Dimensions (*)

Maximum dimensions

4.6 Capacitor bank components

Fig. 4-3 shows the different models of capacitor banks with filters and their essential components. Some protection elements are optional.

Fig. 4-3 .- FRE Capacitor bank components

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NOTES:

• Some elements of protection shown in Fig. 4-3 are optional and may not be present in your equipment

• In FRES equipment, capacitors are cylindrical type and static switches cut only two phases

Static switching equipment have a series of characteristic elements, which are very different from those in equipment using contactors. Namely the main blocs are:

4.6.1 Fast regulator

Static capacitor banks are equipped with computer Max f, computer Smart f or computer Plus TF fast regulators. The outputs of these regulators are static; that is to say, instead of an output via relay contact they have a semiconductor-based switch which allows them to perform operations in rapid succession, practically every network cycle. This type of output is prepared to drive COM and ACT inputs on CPCxx zero switching controller

Fast regulators enable regulation with minimum delay, generally between 20 and 100 ms (see manual for the specific regulator being used)

4.6.2 CPC, zero switching controller

Static capacitor banks are equipped with CPCxx controllers (xx means that there are different types according to the network voltage, control voltage and control type).

The role of the CPCxx is to control the switching of the thyristors at zero voltage during the turn ON operation, thus avoiding current transients. The typical connection diagram of a single step is shown in Fig. 4-4 and in more detail in the simplified wire diagram in section 10.

CPC controllers are powered with an auxiliary voltage U networks with U

= 440 V, nevertheless they have a dual-voltage supply circuit able to be supplied at a

max

. The standard CPCs are mainly used for

aux

rated voltage of 230 V or 400 V (±10%) . There are special controllers, type CPC3i, which are designed to operate on networks up to 690 V. Notice that even for the latter case, the auxiliary control voltage, U

aux

must be 400 V or 230 V. The CPC3i controllers allow three-phase or individual phase-phase control, thanks to an RS-485 bus. However, the standard control is through a voltage-free static contact (semiconductor-based), which opens or closes the circuit between the controller's COM and ACT terminals.

Fig. 4-4 .- Basic connection diagram of the CPCxx to the power block

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Check that the nominal voltage of the capacitor bank with filters matches the voltage between phases of the grid where it is being connected. Also check the circuit voltage (

For feeding cables into the capacitor bank cabinet, always use the entry points available for this purpose.

Do not drill holes into the cabinet for feeding cables through them o support brackets. Drilling produces metal shavings that may enter the contacts or other devices and cause short

4.6.3 Power block:

The power block of FRE or FRES units is made up of 3 to 12 thyristors + capacitor groups, depending on the type. Each group consists of a 6-terminal capacitor (three single-phase capacitors), three (*) thyristor modules attached to a cooling heatsink, one RBE reactor for each step and the suitable protection elements addapted to the module's rated power.

(*) On some models the three thyristor modules are integrated into a single encapsulated package

5 INSTALLATION

5.1 Preparation

FRE and FRES CIRCUTOR's static filters are prepared for an easy installation and start-up.

Remove the equipment's packaging and verify that the unit's electrical characteristics are suitable for connection to the available grid. For this, check the characteristics label located inside the cabinet, next to the regulator, refer to Fig. 4-1 as an example. Key data to be checked:

- Grid voltage and mains frequency, U

- Nominal power of the capacitor bank, Q

/ f.

(kvar) and composition

- Type of filter, identified by the p% factor (7%, 14%, ..., etc.)

- Current consumption, I

(See label). This current must be considered to select the proper size

max

of the equipment's power supply cable and ultimately the main switch or the external circuit breaker to protect the equipment.

- Auxiliary control voltage, U

(See section 5.3.3)

aux

- Environmental conditions. (See section 4.3)

5.2 Installation location

For static switching equipment it is specially important to maintain a minimum distance around the equipment to facilitate cooling. In self-supporting cabinets, the back and front sides of the cabinet must be kept at least 50 cm away from walls and other equipment. Regarding the sides, it is recommended that a separation of 10 cm to be maintained between adjacent equipment. On wall mounted cabinets, it is recommended that at least 20 cm of separation be maintained between the sides of adjacent equipment.

NOTE: Static units have one or more aluminium heatsinks for cooling the thyristors. Periodically clean these heatsinks with a brush or with compressed air and ensure that they have maximum ventilation.

Make sure the equipment can be accessed easily. The environmental conditions of the location where the equipment is installed must not surpass the

limits established in the technical characteristics (See section -) To ensure proper ventilation, the unit must be installed in a vertical position. In accordance with most National Electric Codes and LVD, once the unit is installed, it must be

protected against electric shock hazard due to direct or indirect contacts; therefore, a circuit breaker and an earth leakage protection relay should be provided for the capacitor bank's supply line.

5.3 Connection of the capacitor bank with filters to the grid

auxiliary

CPC controllers). For this, refer to section 5.3.3

-circuits.

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r for installing

FRE / FRES

5.3.1 Power circuit.

• Connect input terminals L1, L2 and L3 (power circuit) to the grid using proper sized cable in accordance with the LVR. Generally, the cables of the phases follow the following colour code: L1 (black), L2 (brown), L3 (grey). If an auxiliary voltage is required to supply some auxiliary elements, the supply is obtained from a suitable transformer or auto-transformer.

• To determine the size of the phase cables, the maximum nominal current I equipment's label and a transient overload of up to 1.5 times I

must be taken into account.

max

shown on the

max

5.3.2 External isolation and protection elements

• In case the capacitor bank with filters does not have an internal switch or circuit breaker, it must be connected to a line with an external switch or circuit breaker.

The protection elements, isolation switches and/or switches that are added externally to the capacitor bank must be of a minimum size to withstand a current

1.5 times greater than what is indicated on the label If an earth leakage protection for the capacitor bank is installed, its sensitivity and

trip delay must be adjustable.

• For static capacitor banks with filters equipped with a standard regulator that measures the current in one single phase, we advise installing the current transformer (CT) in the phase connected to L1 (black cable). The CT secondary outputs, S1 and S2, must be connected to the terminals with the same name on the main cabinet. For more details about the connection of the CT, see 5.3.5

5.3.3 Auxiliary control voltage.

• The auxiliary control circuits include those related to the power supply of the CPCxx controllers and other control or protection devices and ventilation units. The CPC controllers, up to 400 V are supplied at 400 V

and up to 690 Vac, the CPC must be supplied from an auxiliary source, usually obtained from a

suitable transformer or auto-transformer. In such case the label will indicate U

from phase to phase voltage. In other applications using a voltage above 440

/f … internal.

aux

, usually

•

Fig. 5-1.- Auxiliary supply by means of autotransformer

5.3.4 Earth cable connection

Connect the earth terminal of the FRE or FRES equipment, located inside the equipment cabinet(see Fig. 4-3) to the exterior earth connection. The earth cable section will be selected in accordance with the admissible current limits established in the Low Voltage Directive or in the National code of the country where the filter is installed.

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FRE / FRES

An external current transformer (CT) must be installed to measure the total

capacitor bank terminals.

5.3.5 Connecting the current transformer (CT)

• The current rating of the CT primary winding must be equal to or slightly greater than the size of the installation's mains switch. Therefore, the CT must be able to measure the maximum expected current of the loads being compensated.

load current plus that of the filter (see Fig. 5-2).

The standard transformer must have a nominal secondary output of 5A. We recommend connecting the CT to phase L1. The primary indications P1 - P2 must be placed in the direction grid to load (see Fig. 5-2). Terminals S1-S2, must be connected to terminals with the same name on cabinet terminal strip (see Fig. 5-2). Avoid the flow of current through the CT primary before closing the secondary to terminals S1 and S2 in the cabinet. If the CT must be installed while the installation is working, make a short-circuit between S1 and S2 while they are not connected to the

Fig. 5-2 .- Installation of the current transformer (CT) (external)

• The connection point of the CT for a capacitor bank that compensates an entire installation is after the installation's mains switch.

• To prevent excessive attenuation of the signal, the minimum cross section of secondary cables (terminals S1, S2) should be 2.5 mm2.

Fig. 5-3 .- CT connection terminals

• Once the cables are installed, disconnect the jumper connecting terminals S1 and S2 inside the capacitor bank (see Fig. 5-4)

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FRE / FRES

recommended, as in some cases resonance with the installation power transformer could occur.

SAFETY

bank is installed or operated should be strictly followed.

Fig. 5-4 .- Jumper for short-circuiting the secondary winding of the current transformer (CT).

Any time you wish to change or disconnect a current transformer from the filter cabinet. it is important to install a jumper connecting S1 and S2.

6 START-UP OF A ST ATIC CAPACITOR BANK WITH DETUNED FILTER (FRE or FRES)

6.1 Before start-up

FRE and FRES filters have a built-in power factor regulator. Prior to start-up, the operation of such regulator device must be known. For this reason, all capacitor banks and filters come with the specific instructions manual of the PF regulator used. Ensure you have this manual available before the start-up process. In case of static banks the PF regulator must be MOS static output type (computer Max f, computer Smart f , computer PlusTF or equivalent)

The set-up of the PF regulator controlling the filter and its optimum adjustment during start-up requires the installation to have at least a 30 to 40% of rated load. If the load during the start-up process is low , only a few steps will connect. In such case, manually force the connection of all the steps in order to check them all.

During low load periods, manually connecting the full power of the filter bank is not

6.2 Start-up

Apply the safety regulations listed in section 2 of this manual before operating the equipment. The standards and applicable national laws of the country where the static filter

• Ensure that the inner circuit breaker that starts the regulator, shown as the control circuit protection in Fig. 4-3 is connected

• Connect the FRE or FRES equipment to power supply and check that the PF regulator display illuminates immediately. If not, stop and check the previous step.

• Check the cosϕ indication of PF regulator display. If the indication is out of range 0.5 to 1, the current transformer and / or the power supply to the regulator may be improperly connected. Most of the regulators use only one current transformer. In this case, connect as per Fig. 6-2 (place the current transformer in phase L1 and take the power voltage from phases L2 and L3)

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FRE / FRES

%)p100(

%p.100

RED

−

∆

%)p100(

%p.100

.VV

MAINSL

−

Check the working temperature of the capacitors and reactors after they have been

can reach temperatures of about 60 ºC

Fig. 6-1 .- Computer Max f Regulator

(Picture provided as an example. It may not coincide

with the model used on your unit).

• Once ensured that the regulator is properly connected, set-up the regulator parameters according to the installation you are attempting to compensate. For this, follow the regulator's instructions manual included in the static filter documentation.

6.3 Tests once the capacitor bank is connected and the PF regulator has been adjusted

• After start-up, make sure that the equipment is operating correctly. A sign of proper operation after the regulator's reaction time has passed is a cosϕ indication close to 1. In addition, the reactive energy meter must stop.

• Check that the power supply voltage does not exceed the nominal value +10% (IEC 60831-1)

• Check the current absorbed by each LC group of the filter. Under normal working conditions, it must

be close to the nominal values (see Table7-4) and never more than 1.3 times this value continuously. Continuous consumption over the nominal value may be caused by the presence of harmonics in the grid or an excessively high power supply voltage. Both circumstances are harmful for capacitors and the filter reactors.

• In accordance with the IEC 60831-1 Standard, the capacitor is prepared to operate at the permanent voltage assigned and with an overvoltage of up to 10% during 8 hours every 24 hours.

Fig. 6-2 .- Standard connection of a regulator with a

single CT

(3 current transformers will be used when Computer + is

used. See the specific manual of the Computer + regulator)

• NOTE: For capacitor banks with filters, the capacitor's voltage exceeds the grid voltage by a % that is approximately equal to the filter's overvoltage factor (p%). In fact, the capacitor's real overvoltage is

• To check the filter's correct tuning, make sure that the voltage on the terminals of each winding of the

reactor is

operating for 24 hours. The capacitor case must be under 40 ºC. The housing of reactors

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FRE / FRES

SAFETY

FRE filters is installed or operated should be strictly followed.

Device

TORQUE (Nm)

NH-00 fUSES

15,2

Power circuit of thyristors

3,25

Thyristor to heatsink clamping

7 MAINTENANCE

7.1 Safety regulation

Apply the safety regulations listed in section 2 of this manual before operating the equipment. The standards and applicable national laws of the country where the capacitor bank with

7.2 Maintenance with the filter bank disconnected

7.2.1 Basic maintenance protocol

Monthly

• Visually inspect the capacitors

• Check the protection fuses

• Control the environment temperature (average must be about 30 ºC. in accordance with IEC 60831 ).

• Control the supply voltage (especially during moments of low load, it must not exceed the nominal

value +10%).

• Check the temperature of thyristor's heat sinks. It must be less than 80ºC

Every six-month

• Keep the capacitor terminals and reactors clean.

• Force all steps off (push down key at PF regulator front plate). Once all disconnected, check that the

current drawn by the three phases is practically zero. If significative current is detected in any phase indicates that there is a shorted thyristor.

• Check that the current at each step and each phase is not less than 25% neither greater than 120% of the nominal value. Unbalance between phases must be less than 15%.

Annually

• Perform isolation tests on the different elements of the power circuit, applying 2.5 kV during 1s between passive components (basically L and C) and ground terminal.

NOTE: To carry out isolation tests, thyristors must be short-cutted.

• Check the capacity of the different steps. An indirect verification can be performed by checking that the consumption matches the value stated in Table7-4, with a maximum deviation of ± 10%.

• Check the tightness of all terminal connections on the different power elements.

• Inspection of the fuses.

- Power circuit: NH fuses. Check continuity and temperature.

- Control Circuit: Neozed fuses or circuit breaker. Check continuity and temperature.

7.2.2 Tightening the electrical connections.

• The connections must be tight. The tightening torques for different elements of the filter banc are listed in Table 7-1, Table 7-2 and Table 7-3

Table 7-1.- Tightening torques of cables fuses and to thyristors

7.2.3 Key points for inspecting static switches.

• Check that the plastic parts are not blackened and do not show signs of burning or hardening.

• Check the tightness of cables and terminals, as shown in Table 7-1

• The terminals must be clean.

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FRE / FRES

Reactor

Connection

Terminal (Nm)

RE-5-400

Terminal

1.83

RE-10-400

Terminal

1.83

RE-15-400

Terminal

1.83

RE-20-400

Terminal

6.2

RE-25-400

Terminal

6.2

RE-30-400

Terminal

15.2

RE-40-400

Terminal

15.2

RBE-50-400

Flat strip

RBE-60-400

Flat strip

RBE-80-400

Flat strip

(Nm)

CFB, CSB

6.2

Tubular

• In dirty environments (dust, sawdust, metal trimmings, etc.). Vacuum the dust and solid remains regularly. There is no estimated time frame for cleaning, it depends on the amount of dirt that penetrates the capacitor bank cabinet.

Table 7-2.- Tightening torques of the cables to reactor terminals.

7.2.4 Key points for inspecting capacitors.

• Inspect the cables and terminals. They should not be overheated or blackened.

• The terminals must be clean

• The slow discharge resistors must be in good condition (they should not be open or show signs of

burns)

• Check the tightness of capacitor terminals, as shown in Table 7-3

Table 7-3 .- Tightening torques of the cables on the capacitor bank terminals

Capacitor

7.2.5 Key points for testing the PF regulator

• Check that the regulator does not show signs of deterioration and the display is lit as normal.

• Inspect the cables and terminals. They must be clean, not hardened or overheated.

• Check the connections and the insertion of removable terminal strips, if used:

- The terminal strips must be well fastened on removable regulators.

- Check that the terminals are tightened properly. The recommended torque is 0.6 Nm.

7.2.6 Cleaning the cabinet

• Remove possible metallic and other debris.

• Clean the inside of the cabinet

• Clean ventilation grills

7.3 Maintenance with the capacitor bank connected

• Check that the main switch turns on and off, without having to force the mechanism

• If there is an individual earth leakage protection for the capacitor bank, check its proper operation by

pressing the test button

• Check that the auxiliary control voltage is within the tolerance limits. If the capacitor bank has an autotransformer, check that it is in good condition and does not show signs of deterioration

• Force the connection and disconnection of the different steps in manual mode. (refer to the regulator manual before carrying out this operation) and perform the following tests:

Power terminal

Earth terminal

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FRE / FRES

CURRENT

230V

400V

2.5 kvar

6.28 A

3.6 A

5 kvar

12.56 A

7.2 A

7.5 kvar

18.85 A

10.8 A

10 kvar

25.12 A

14.4 A

12.5 kvar

31.41 A

18 A

15 kvar

37.7 A

21.6 A

20 kvar

50.24 A

28.8 A

25 kvar

62.82 A

36 A

30 kvar

75.4 A

43.2 A

40 kvar

100.48 A

57.6 A

50 kvar

125.64 A

72 A

60 kvar

150.8 A

86.4 A

70 kvar

175.92 A

101.1 A

80 kvar

200.96 A

115 A

%)p100(

%p.577,0

)phasephase(MAINSL

−

- Check that the steps connect and disconnect properly

- Check that there is no consumption in any phase with the step disconnected. If there is consumption this means that some of the thyristors are defective.

- Check the consumption of the different steps, in each phase. The normal values are shown in Table7-4

Table 7-4.- Nominal consumption of the LC steps of an FRE or FRES filter

POWER

- Check the voltage on all of the reactor's windings (input - output of the same winding, not between phases). The voltage depends on the filter's p% factor (see label on the equipment), in

accordance with the following formula:

For example, in the case of the 400V grid and p%=7, V

=37.57V. For other line voltages, the VL value is proportional to the line voltage.

NOTES:

• When the consumption of the steps is 25% less than that stated in Table7-4 and the voltage is within the tolerance limits, this is a sign of degradation in the capacitors. These must be replaced with a suitable spare part if these symptoms are detected in a step.

• When the consumption of the steps is 10% more than the values stated in Table7-4, this can be caused by the presence of resonances. If this is detected, measure the grid's voltage THD (it must be under 5%) or check the filter's tuning frequency.

• If the voltage drop in a reactor deviates from the values stated in this section, check the reactor. This phenomenon can be caused by the presence of a resonance.

7.3.3 PF regulator checkings.

Refer to the manual of the specific regulator used in the capacitor bank. This manual is always supplied with the capacitor bank.

• Make sure that there are no damaged segments on the display (abnormal brightness).

• Make sure that regulator's keyboard is working properly:

- Enter Setup and check the adjusted values

- Force the manual connection and disconnection of a step.

=17.38V. For the 400V grid and p%=14,

7.4 Environmental Conditions:

• Check that the maximum environmental conditions listed in section 4.3 are observed

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FRE / FRES

8 WARRANTY

CIRCUTOR guarantees its products against any manufacturing defect for two years after equipment delivery. CIRCUTOR will repair or replace any defective factory product returned during the guarantee period.

No returns will be accepted and no unit will be repaired or replaced if it is not accompanied by a report indicating the defect detected or the reason for the return.

The guarantee will be void if the equipment has been improperly used or the storage, installation and maintenance instructions listed in this manual have not been followed. "Improper usage" is defined as any operating or storage condition contrary to LV Regulations or that surpasses the limits indicated in the technical and environmental characteristics of this manual.

In particular, capacitor units are very sensitive to adverse environmental conditions, to temperatures above the established limits and overloads produced by the absorption of harmonic currents. Therefore, special care must be taken to not surpass these usage conditions.

CIRCUTOR accepts no liability for possible damage to equipment or other parts of the installation, nor will it cover any possible penalties resulting from possible failure, improper installation or "improper usage" of the equipment.

Consequently, this guarantee does not apply to failures occurring in the following cases:

1. Overvoltages and/or electrical disturbances in the supply;

2. Water, if the product does not have the appropriate IP classification;

3. Poor ventilation and/or excessive temperatures;

4. Improper installation and/or lack of maintenance;

5. Buyer repairs or modifications without the manufacturer's authorisation.

9 TECHNICAL ASSISTANCE AND DECLARATION OF CONFORMITY

CIRCUTOR provides advice and technical assistance services throughout Spain for the planning and installation of capacitors, automatic power factor correction equipment and harmonics filters.

CIRCUTOR, SA

Vial Sant Jordi, s/n – 08232 – Viladecavalls (Barcelona) Tel. +34 93 745 29 00 – Fax: +34 93 745 29 14

www.circutor.es – email: sat@circutor.es

Web:

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FRE / FRES

9.1 Conformity declaration

19 / 20

FRE / FRES

CIRCUTOR FRE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 INTRODUCTION

2 SAFETY HAZARDS AND WARNINGS

2.1 Hazards encountered during the installation and start-up of electrical equipment.

2.2 Safety warnings

2.3 Application warnings

3 RECEPTION, TRANSPORT, HANDLING AND STORAGE

3.1 Reception protocol

3.2 Transport, loading and unloading, handling and storage

3.3 Storage

4 TECHNICAL CHARACTERISTICS

4.1 Label with the equipment's characteristics

4.2 Electrical characteristics

4.3 Environmental Characteristics

4.4 Mechanical characteristics:

4.5 External dimensions and weights

4.6 Capacitor bank components

4.6.1 Fast regulator

4.6.2 CPC, zero switching controller

4.6.3 Power block:

5 INSTALLATION

5.1 Preparation

5.2 Installation location

5.3 Connection of the capacitor bank with filters to the grid

5.3.1 Power circuit.

5.3.2 External isolation and protection elements

5.3.3 Auxiliary control voltage.

5.3.4 Earth cable connection

5.3.5 Connecting the current transformer (CT)

6 START-UP OF A ST ATIC CAPACITOR BANK WITH DETUNED FILTER (FRE or FRES)

6.1 Before start-up

6.2 Start-up

6.3 Tests once the capacitor bank is connected and the PF regulator has been adjusted

7 MAINTENANCE

7.1 Safety regulation

7.2 Maintenance with the filter bank disconnected

7.2.1 Basic maintenance protocol

7.2.2 Tightening the electrical connections.

7.2.3 Key points for inspecting static switches.

7.2.4 Key points for inspecting capacitors.

7.2.5 Key points for testing the PF regulator

7.2.6 Cleaning the cabinet

7.3 Maintenance with the capacitor bank connected

7.4 Environmental Conditions:

8 WARRANTY

9 TECHNICAL ASSISTANCE AND DECLARATION OF CONFORMITY

9.1 Conformity declaration