LV CAPACITOR BANKS WITH DETUNED
FILTERS OPERATED BY CONTACTORS
FR SERIES
INSTRUCTION MANUAL
M98121401-20-11A
CIRCUTOR, SA
Instruction Manual 1
SYMBOLS AND WARNINGS
Pay attention to the warnings in this manual, which are shown with the following
symbols.
DANGER: Warns of a risk, which could result in personal injury or material
If you must handle the equipment for its installation, start-up or maintenance, the
following should be taken into consideration:
damage.
WARNING: Indicates that special attention should be paid to a specific point.
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 CENELEC Low
Voltage Directive (
LVD 2006/95/EC)
and the technical instructions of the
Electrical National Code in each country .
The installation, operation and maintenance of LV equipment must only be carried
out by authorised installers. LV local regulations specifically define the
requirements that authorised installers must meet.
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 CENELEC Low Voltage
Directive (
LVD 2006/95/EC)
HV installations in each country.
and to the National Code technical instructions for
Instruction Manual 2
TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................................................. 2
2 SAFETY HAZARDS AND WARNINGS.............................................................................................. 2
2.1 H
2.2 S
2.3 A
3 RECEPTION, TRANSPORT, HANDLING AND STORAGE ............................................................ 3
3.1 R
3.2 T
3.3 S
4 TECHNICAL FEATURES ................................................................................................................... 4
4.1 L
4.2 E
4.3 E
4.4 M
4.5 E
4.6 F
5 INSTALLATION .................................................................................................................................. 6
5.1 P
5.2 I
5.3 C
AZARDS ENCOUNTERED DURING THE INSTALLATION AND START-UP OF ELECTRICAL EQUIPMENT
AFETY WARNINGS
PPLICATION WARNINGS
ECEPTION PROTOCOL
RANSPORT, LOADING AND UNLOADING, HANDLING AND STORAGE
TORAGE
ABEL WITH THE EQUIPMENT'S FEATURES
LECTRICAL FEATURES
NVIRONMENTAL CHARACTERISTICS
ECHANICAL FEATURES
XTERNAL DIMENSIONS AND WEIGHTS
ILTER BANK COMPONENTS
REPARATION
NSTALLATION LOCATION
ONNECTION OF THE FILTER BANK TO THE GRID
5.3.1 Power circuit......................................................................................................................... 7
5.3.2 External insulation and protection elements........................................................................... 7
5.3.3 Auxiliary control voltage........................................................................................................ 7
5.3.4 Earth cable connection.......................................................................................................... 8
5.3.5 Connecting the current transformer (CT) ............................................................................... 8
................................................................................................................................... 4
..................................................................................................................... 2
............................................................................................................ 2
................................................................................................................ 3
.............................................. 3
................................................................................... 4
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............................................................................................................. 5
. ....................................................................................... 5
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.......................................................................... 7
. 2
6 START-UP OF A CAPACITOR BANK WITH DETUNED FILTERS............................................. 10
6.1 B
6.2 S
6.3 C
7 MAINTENANCE ................................................................................................................................ 11
7.1 S
7.2 M
7.3 M
7.4 E
8 GUARANTEE, .................................................................................................................................... 16
9 TECHNICAL ASSISTANCE AND DECLARATION OF CONFORMITY ..................................... 16
9.1 D
10 SCHEMATICS...................................................................... ¡ERROR! MARCADOR NO DEFINIDO.
EFORE START-UP
TART-UP
HECKINGS ONCE THE FILTER BANK IS CONNECTED AND THE REGULATOR HAS BEEN ADJ USTED
AFETY REGULATION
AINTENANCE WITH THE FILTER BANK DISCONNECTED
7.2.1 Basic maintenance protocol ................................................................................................. 11
7.2.2 Tightening the electrical connections. .................................................................................. 12
7.2.3 Key points for inspecting contactors..................................................................................... 13
7.2.4 Key points for inspecting capacitors..................................................................................... 14
7.2.5 Key points for inspecting the regulator................................................................................. 14
7.2.8 Cleaning the cabinet. .......................................................................................................... 14
AINTENANCE WITH THE BATTERY CONNECTED
NVIRONMENTAL CONDITIONS
ECLARATION OF CONFORMITY
................................................................................................................................. 10
.................................................................................................................... 10
... 11
................................................................................................................ 11
............................................................. 11
........................................................................ 14
: ................................................................................................ 15
................................................................................................ 17
Instruction Manual 1
1
INTRODUCTION
The purpose of this manual is to assist during the installation, start-up and maintenance of low
voltage (LV) capacitor banks with FR series detuned filters operated by means of contactors.
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 low voltage (LV) equipment must
only be carried out by authorised installers. See CENELEC Low Voltage Directive
(LVD 2006/95/EC) and the technical instructions of the Electrical National Code in
each country to find the requirements that authorised installers must meet.
Do not access the active elements of a filter bank that has been powered, since
residual voltages might be present because of capacitors charge. 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
voltage is not present. If you have to handle or touch the terminals or other control
panel components, use adequately insulated personal protection gloves,
equipment and tools.
After maintenance and before re-applying power 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 disconnect the current transformer secondary 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
regulations of the country where the filter 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 must be carried out in compliance with
standard EN-IEC60204-1, on the safety of LV electrical installations.
It is recommended that several personnel are present when handling the
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 while it is de-energized.
Modifying, upgrading or rebuilding the equipment without written authorization from
the manufacturer is prohibited.
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. When remote
control frequencies close to the tuning frequency of FR filters are used, blocking
filters must be placed in front or the tuning frequency of the FR filters must be
changed.
Instruction Manual 2
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 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 packaging.
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.
If any discrepancy is noticed 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 the storage conditions listed in the technical features
section must be observed. In this case, 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 found 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. Otherwise, the forks should be long enough to support the total depth.
The 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).
There might be an offset in the centre of gravity from the centre of the cabinet, as a
result of the uneven distribution of loads in equipment. The necessary precautions
must be taken to prevent the equipment from tipping over during abrupt operations.
Instruction Manual 3
Fig. 3-2 .-Unloading with a Forklift
3.3 Storage
The following storage recommendations should be followed for capacitor banks with detuned
filters:
- Avoid placing it on uneven surfaces.
- Do not store in outdoor areas, humid areas or areas exposed to the splashing of water.
- Avoid hot spots (maximum environmental temperature: 45 ºC)
- Avoid saline and corrosive environments.
- Avoid storing the equipment in areas where a lot of dust is generated or where the risk of
chemical or other types of contamination is present.
- Do not place any weight on top of the equipment cabinets.
4
TECHNICAL FEATURES
4.1 Label with the equipment's features
The label with the equipment's features is located inside it, generally next to the PF regulator (refer
to Fig. 4-1). The filter bank includes the p% information, which states the filter's tuning factor. This
information is important to establish the filter's resonance frequency.
Ref.
Cod.
Nr Serie
QN(U
max
p% filtro
100 mm
Norma/Prot
UN/U
max/fN
I
max
U
/ f
aux
N
Temp
I
cc
FR8-600-440
R36625
3094701005
)
600 kvar
50 + 50 + 5x100 kvar
7%
EN-61921, EN-61642 / IP21
3x400 V/440 V/50 Hz
750 A
230 V/50Hz
-25 / +45 ºC
35 kA
Made in UE / Spain
80 mm
Type
Code
Serial Nr
Reactive Power at Umax
Nr of Steps
p% overvoltage factor, UL/UC in %
Standards / Protection degree
Rated & Maximun voltage / Rated frequency
Maximum current
Auxiliary control voltage (1)
Range of allowable temperature inside the cabinet
Default value. See particular values in the label
Fig. 4-1.- Label showing the main characteristics
4.2 Electrical features
- Operating voltage and nominal frequency: Un / f , listed on the label
- Design voltage: Un+ 10% (440 V for 400V equipment)
- Nominal power and distribution of steps: Qn and composition, (see label)
- Overvoltage factor, p% Standard 7% ,
Others 14%, 8.2% and 5.67% (see label)
- Total loss: Standard 3.5 to 4 W/kvar
- Residual discharge voltage: 75 V after 3 minutes
- Overload capacity: 1,3 . In in all items
- Auxiliary control voltage: U
NOTE: In general, use a 1.5 mm2 cable to supply external power.
If “Internal” , is marked, the equipment does not require external power.
, listed on the label.
aux
Instruction Manual 4
-
Current Transformer Input: 5 A ,
NOTE: Minimum cable section 2.5mm2.
(Transformer In/5A)
- Compliance with Standards UNE EN 61921 and EN-61642
- Protection elements:
Power Fuses Type gL, NH gauge (minimum 1,5×I
nominal
Reactor thermostat: 90ºC ±5ºC
Insulation 3 kV /50 Hz
Breaking capacity 10A / 250 V CA, resistive load
- Capacitor characteristics:
Capacity tolerance: ± 5%
Insulation level to earth: 3 kV /50 Hz
Impulse test: 15 kV , 1,2/50 µs standard wave
Protection elements: Internal fuses and over-pressure system
Compliance with Standards UNE EN 60831
- Reactor characteristics:
Inductor tolerance: ± 5%
Nominal working voltage standard 500 V (RMS value)
Saturation current standard at 1.4 In, ∆L=5%
(Others in RBX)
Level of insulation between: 3kV /50Hz; 15kV ; 1,2/50 µs standard wave
phases and to earth
Max. overload Σ(n.In)2 20% permanent; Transient (1 min.) 2 In
4.3 Environmental Characteristics
- Capacitor max. temperature Category C in accordance with EN 60831-1
Maximum for 1h 50ºC
24h average 40ºC
Annual average 30ºC
- Max. temperature of reactors In accordance with IEC 60076-6
Maximum environmental temperature 60ºC
Indoor temperature at In <110ºC
- Cabinet ventilation For outdoor t
Protection thermostat 90 ºC
> 30ºC, forced ventilation
amb
must be used for the cabinet
- Maximum relative humidity: 80%
-
Altitude: 1000 m
maintain forced ventilation)
(For higher altitudes, always
4.4 Mechanical features
- Protection degree: Marked on the label:
- Paint Oven dried epoxy type
- Standard colours RAL 7035 Grey ; RAL 3005 Maroon
)
4.5 External dimensions and weights.
Model
FRS 700 1000 380 215
FR4 800 1900 650 460
Fig. 4-2.- Dimensions
FR6 1100 1900 650 685
FR8 1500 1900 650 1000
FR12 2200 1900 650 1389
Dimensions (mm)
Width Height
(*)
Depth
Max weight
(kg)
(*)
Maximum dimensions
Instruction Manual 5
4.6 Filter bank components
Fig. 4-3 shows the different models of filter banks and their essential components. Some
protection elements are optional.
Fig. 4-3 .- FR Filter bank components
5
INSTALLATION
5.1 Preparation
CIRCUTOR's FR filter banks 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 at the 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 frequency, UN / f.
- Nominal power of the filter bank, QN (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
max
proper size of the supply cable circuit breakers and other protection devices to be
connected upstream the supply terminals.
- Auxiliary control voltage, U
(See section 4.2)
aux
- Environmental conditions. (See section 4.3)
Instruction Manual 6
5.2 Installation location
It is important to maintain a minimum distance around the equipment to facilitate cooling. In selfsupporting cabinets, the back and front sides of the cabinet must be placed at least 50 cm away
from other walls and equipment. Regarding the side faces of the cabinet, it is recommended to
keep a gap of 10 cm with adjacent equipment. On wall mounted cabinets, it is recommended to
keep a gap of at least 20 cm between the side faces of adjacent equipment.
Make sure that 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 4.3)
To ensure proper ventilation, the unit must be installed in a vertical position.
In accordance with the EEC LV Directive, once the unit is installed, it must be protected against
direct and indirect contacts. Therefore, an earth leakage or insulation surveillance device must
be installed for the protection of the power supply line and the filter bank.
5.3 Connection of the filter bank to the grid
Check that the nominal voltage of the FR filter bank matches the phase to phase
voltage of the grid where it is being connected. Also check the auxiliary control voltage
(contactors supply). For this, refer to section 5.3.3
For the feeding cables of the filter bank cabinet, use always the entry windows
available for this purpose.
Do not drill holes into the cabinet for feeding cables through them or for installing
support brackets. Drilling produces metal shavings that may enter the contactors or
other switching or protection devices and cause short-circuits.
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 the EEC LV Directive. Generally, the cables of the phases follow the
following colour code: L1 (black), L2 (brown), L3 (grey). If auxiliary voltage is required, the
neutral cable will be connected to N (blue colour)
• 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
The neutral cable must be at least 1.5 mm2.
5.3.2 External insulation and protection elements
• In case the filter bank 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, insulation switches and/or switches that are added
externally to the filter 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 relay for the filter bank is installed, its sensitivity and
trip delay must be adjustable.
• For filter banks with equipped with a standard regulator measuring the current in a single
phase, we advise installing the current transformer (TC) in the phase connected to L1 (black
cable). The CT terminals S1 and S2 must be connected to the terminals with the same name
at the filter bank. For more details about the connection of the CT, see 5.3.5
5.3.3 Auxiliary control voltage.
• Control circuits are defined as those related with the regulator's output relays and contactors
switching the filter's LC steps. These circuits are usually powered with an auxiliary voltage of
230VAC (the most common case) or in special cases can be powered with 110VAC (the later
is frequently used for 500V or 690V filter banks). There are two possible ways of feeding the
control circuitry.
Instruction Manual 7
• FR filter bank with an auxiliary voltage obtained from an internal
AUTOTRANSFORMER
This configuration does not require the connection of the external neutral. The label box
/f in such equipment indicates "interna"
U
aux
• FR filter bank with auxiliary voltage obtained between PHASE and NEUTRAL
Requires the connection of the external neutral to terminal N (see Fig. 5-2 and Fig. 5-4.
The label box U
/f in such equipment indicates the value of control voltage (usually
aux
230V)
Fig. 5-1 .- Auxiliary power supply with
autotransformer
Fig. 5-2 .- Auxiliary power supply with neutral
5.3.4 Earth cable connection
• Connect the earth terminal of the filter bank located inside the equipment control 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 REBT ( ITC-BT-19 – Indoor or
receiver installations).
5.3.5 Connecting the current transformer (CT)
A current transformer (TC) that is external to the filter bank must be installed to
measure the total load current plus that of the filter bank (see Fig. 5-3).
The standard transformer must have a nominal output of 5A at the secondary.
We recommend connecting the TC to phase L1 in the direction of the current flow
from P1 to P2 (see Fig. 5-3) and connecting the secondary (terminals S1, S2) to the
terminals with the same name on the filter bank (see Fig. 5-3).
Avoid the flow of current through the TC's primary before connecting the secondary
to the filter bank's S1 and S2 terminals. If the TC must be installed while the
installation is under load, short-circuit S1 and S2 while they are not connected to the
filter bank.
• The current value of the TC primary winding must be equal to or slightly greater than the size
of the installation's mains switch. Therefore, the TC must be able to measure the maximum
forecast current consumption that will be consumed by all the loads being compensated.
Instruction Manual 8
Fig. 5-3 .- Installation of the current transformer (TC) (external)
• The connection point of the TC for a filter bank that compensates an entire installation is after
the installation's mains switch.
• To prevent excessive attenuation of the signal, the minimum secondary cable section
(terminals S1, S2) should be at least 2.5 mm2.
Fig. 5-4 .- TC and neutral connection terminals if required
• Once the cables are installed, disconnect the jumper connecting terminals S1 and S2 on the
filter bank (see Fig. 5-5)
Fig. 5-5 .- Jumper for short-circuiting the secondary winding of the current transformer (TC).
Any time you wish to change or disconnect a current transformer that is already
installed, it is important to install the jumper connecting S1 and S2.
Instruction Manual 9
cted to the grid,
6
START-UP OF A CAPACITOR BANK WITH DETUNED FILTERS
6.1 Before start-up
Automatic capacitor banks with FR filters have a built-in power factor regulator. Prior to start-up,
the operation of said regulator must be known; for this reason, all filter banks come with the
specific manual of the regulator used. Ensure you have this manual available for the startup process.
The adjustment of the built-in regulator of filter banks with and its optimum start-up
requires the installation to have at least a 30 to 40% nominal load for which the
filter bank was dimensioned. If all the stages are not included, they can be
manually connected to check them all.
During low charge periods, manually connecting the entire filter bank is not
recommended, as in some cases resonance with the installation power
transformer could occur.
For manual connections of the LC steps, remember that you must wait until the
capacitors have been discharged before they can be conne
otherwise, the system could start up having a transient voltage of up to 2xUn,
causing current peaks in the capacitors.
6.2 Start-up
SAFETY
Apply the safety regulations listed in section 2 of this manual before operating the
equipment.
The standards and applicable national regulations of the country where the filter
bank is installed or operated should be strictly followed.
• Ensure that the inner circuit breaker supplying the regulator (shown as the operating protection
in fig. 4.3) is connected
• Apply power to the panel and check that the regulator display illuminates immediately. If not,
stop and check the previous step.
• Check the regulator's cosϕ indication. 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)
Fig. 6-1 .- Computer Max Regulator
(Picture provided as an example. It may not
coincide with the model used on your unit).
Instruction Manual 10
Fig. 6-2 .- Standard connection of a regulator with a
single TC
is used. See the specific manual of the Computer + regulator)
(3 current transformers will be used when Computer +
∆
• Once ensured that the regulator is properly connected, adjust the regulator parameters for the
installation you are attempting to compensate. For this, follow the regulator's instructions
manual included with the battery.
6.3 Checkings once the filter bank is connected and the 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 near to 1. In addition, the reactive
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 Table 7.5) 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's 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.
• NOTE: For filter banks, 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
V
overvoltage is
• To check the filter's correct tuning, make sure that the voltage on the terminals of each winding
of the reactor is
Check the working temperature of the capacitors and reactors after they
have been operating for 24 hours. The capacitor capsule must be under
40ºC. The housing of reactors can reach temperatures of about 60ºC
7
MAINTENANCE
7.1 Safety regulation
SAFETY
Apply the safety regulations listed in section 2 of this manual before operating the
equipment.
The standards and applicable national regulations of the country where the filter
bank is installed or operated should be strictly followed.
7.2 Maintenance with the filter bank disconnected
C
%
RED
=
=
.VV
REDL
V
%p.100
%)p100(
−
%p.100
%)p100(
−
7.2.1 Basic maintenance protocol
Monthly
• Visually inspect the capacitors
• Check the protection fuses
• Control the environmental temperature (average of 30 ºC. In accordance with IEC 60831 ).
• Control the service voltage (especially during moments of low charge, it must not exceed the
nominal +10%).
Six-monthly
Instruction Manual 11
• Keep the capacitor terminals and reactors clean.
• Verify the state of the contactors of operating elements.
• Check that the capacitor current is not less than 25% or greater than 120% of the nominal
value by phase and that there is no phase unbalance greater than 15%.
Annually
• Perform dielectric rigidity tests on the different elements of the power circuit, applying 2.5 kV
during 1s between the capacitor and earth terminals.
• Check the capacity of the different steps. An indirect verification can be performed by checking
that the consumption matches the value stated in Table 7.5, 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 protection: Neozed fuses or circuit breaker. Check continuity and
temperature.
7.2.2 Tightening the electrical connections.
• The connections must be tight. The following tightening torques for the fuse bases and
contactors are listed in tables 7-1 and 7-2
Table 7-1.- Tightening torques of the cables to the fuse bases
FUSE BASE TORQUE (Nm)
NEOZED 63 A 3.6
NH-00 15.2
Instruction Manual 12
Table 7-2.- Tightening torques of the cables to contact terminals
MODEL
GMC-12 1.3 1.6
GMC-18 1.3 2.2
GMC-32 1.3 2.9
GMC-40 1.3 2.9
GMC-50 1.3 4.5
GMC-65 1.3 4.5
GMC-75 1.3 4.5
GMC-85 1.3 4.5
GMC-150 1.3 9
Table 7-3.- Tightening torques of the cables to reactor terminals.
Reactor Connection Terminal (Nm)
R-5-400 Terminal 1.83
R-10-400 Terminal 1.83
R-15-400 Terminal 1.83
RB-20-400 Flat strip 6.2
RB-25-400 Flat strip 6.2
RB-30-400 Flat strip 15.2
RB-40-400 Flat strip 15.2
RB-50-400 Flat strip 30
RB-60-400 Flat strip 30
RB-80-400 Flat strip 30
Auxiliary (Nm)
POWER (Nm)
7.2.3 Key points for inspecting contactors.
• Check that the plastic parts are not blackened and do not show signs of burning or hardening.
• Check that the head is properly inserted
• Check the tightness of cables and terminals, as shown in table 7-2
• The terminals must be clean.
• If the filter bank includes RD discharge resistances, check they are in good condition (that they
are not open or show signs of burning).
Fig. 7-1 .-
• Cleaning the contactors: In dirty environments (dust, sawdust, metal trimmings, etc).
Periodically vacuum the dust and solid remains. There is no estimated time frame for cleaning,
it depends on the amount of dirt that penetrates the filter bank's cabinet.
Connection of the discharge resistances
Instruction Manual 13
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 resistances 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 7-4
Table 7-4.- Tightening torques of the cables on the filter bank terminals
Capacitor
CV
CF, CS
Power terminal
Earth terminal
(Nm)
(Nm)
4.49 6.2
21 6.2
CLZ CAPACITORS
Diameter (mm)
Power terminal
(Nm)
Earth terminal
(Nm)
2.5 0.33 0.463
3 0.57 0.8
4 1.3 1.83
5 2.59 3.62
6 4.49 6.2
8 10.9 15.2
10 21 30
12 37 50
7.2.5 Key points for inspecting the 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.
7.2.8 Cleaning the cabinet.
• Remove possible metallic and non-metallic particles.
• Clean the inside of the cabinet
• Clean ventilation grilles
7.3 Maintenance with the battery connected.
• Check that the mains switch connects and disconnects, without having to force the mechanism
• If there is an individual earth leakage protection for the filter bank, check its proper operation
by pressing the test button.
• Check that the auxiliary control voltage is within the tolerance limits. If the filter bank has an
autotransformer, check it is in good condition and does not show signs of deterioration.
• Force the connection and disconnection of the capacitors in manual mode. (refer to the
regulator's manual before carrying out these actions) and perform the following checkings:
- Check that the contactors connect and disconnect properly.
- Check that the contact, once connected, does not rattle or vibrate.
- Check the consumption of the different LC steps, in each phase. The normal values are
shown in Table 7-5, in accordance with the power of each step.
Instruction Manual 14
Table 7-5.- Nominal consumption of the LC steps of an FR filter, depending on its power
POWER
2.5 kvar
5 kvar
7.5 kvar 18.85 A 10.8 A
10 kvar
12.5 kvar
15 kvar 37.7 A 21.6 A
20 kvar
25 kvar
30 kvar
40 kvar 100.48 A 57.6 A
50 kvar
60 kvar
70 kvar
80 kvar
- Check the voltage on all of the reactor's windings (input to output of the same winding, not
between phases). The voltage depends on the filter's p% factor (see label on the
equipment). The voltage must be in accordance with the following formula:
VV
=
For example, in the case of the 400V grid and p%=7, VL=17.38V. For the 400V grid and
p%=14, VL=37.57V. The value is proportional to the voltage for other voltages.
NOTES:
• When the consumption of the steps is 25% less than that stated in Table 7-5 and the voltage
is within the tolerance limits, this is a sign of degradation of 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 Table 7-5, 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.
)phase_to_phase(MainsL
6.28 A 3.6 A
12.56 A 7.2 A
25.12 A 14.4 A
31.41 A 18 A
50.24 A 28.8 A
62.82 A 36 A
75.4 A 43.2 A
125.64 A 72 A
150.8 A 86.4 A
175.92 A 101.1 A
200.96 A 115 A
%p.577,0
%)p100(
−
CURRENT
230V 400V
In In
Refer to the manual of the specific PF regulator used in the filter bank. This
manual is always supplied with the filter 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.
7.4 Environmental Conditions:
• Check that the maximum environmental conditions listed in section 4.3 are observed
Instruction Manual 15
8
GUARANTEE,
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 features 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
Web: www.circutor.es – email: sat@circutor.es
Instruction Manual 16
9.1 Declaration of conformity
Instruction Manual 17
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