CIRCUTOR OPTIM HYB User Manual
Low voltage capacitor bank with static operation.
OPTIM HYB Series
INSTRUCTION MANUAL
(M059B01-03-15A)
OPTIM HYB Series
2
Instruction Manual
OPTIM HYB Series
SAFETY PRECAUTIONS
Follow the warnings described in this manual with the symbols shown below.
DANGER
Warns of a risk, which could result in personal injury or material damage.
ATTENTION
Indicates that special attention should be paid to a speci c point.
If you must handle the unit for its installation, start-up or maintenance, the following
should be taken into consideration:
Incorrect handling or installation of the unit may result in injury to personnel as well as damage
to the unit. In particular, handling with voltages 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 re.
Read the manual carefully prior to connecting the unit. Follow all installation and maintenance
instructions throughout the unit’s working life. Pay special attention to the installation standards of the National Electrical Code.
Refer to the instruction manual before using the unit
In this manual, if the instructions marked with this symbol are not respected or carried out correctly, it can
result in injury or damage to the unit and /or installations.
CIRCUTOR, SA reserves the right to modify features or the product manual without prior noti cation.
DISCLAIMER
CIRCUTOR, SA reserves the right to make modi cations to the device or the unit speci ca-
tions set out in this instruction manual without prior notice.
CIRCUTOR, SA on its web site, supplies its customers with the latest versions of the device
speci cations and the most updated manuals.
www.circutor.com
Instruction Manual
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OPTIM HYB Series
CONTENTS
SAFETY PRECAUTIONS .......................................................................................................................................3
DISCLAIMER ..........................................................................................................................................................3
CONTENTS ............................................................................................................................................................. 4
REVISION LOG .......................................................................................................................................................5
1.- VERIFICATION UPON RECEPTION ................................................................................................................. 6
1.1.- RECEPTION PROTOCOL .......................................................................................................................... 6
1.2.- TRANSPORT AND HANDLING .................................................................................................................6
1.3.- STORAGE...................................................................................................................................................7
2.- PRODUCT DESCRIPTION ................................................................................................................................ 8
2.1.- CAPACITOR BANK COMPONENTS ......................................................................................................... 8
2.1.1. HYBRID REGULATOR .........................................................................................................................8
2.1.2. CPC2 PANEL: ZERO SWITCHING CONNECTION CONTROL BY TWO SINGLE-PHASE
STAGES ........................................................................................................................................................ 13
2.1.3. SINGLE-PHASE POWER BLOCK ..................................................................................................... 14
2.1.4. THREE-PHASE POWER BLOCK ......................................................................................................14
2.1.5. MAINS CONNECTION TERMINALS ..................................................................................................14
3.- INSTALLATION ...............................................................................................................................................15
3.1.- PRELIMINARY RECOMMENDATIONS ...................................................................................................15
3.2.- PREPARATION .........................................................................................................................................16
3.3.- INSTALLATION LOCATION ..................................................................................................................... 17
3.4.-CONNECTION OF THE CAPACITOR BANK TO THE MAINS ................................................................. 17
3.5.-POWER CIRCUIT ...................................................................................................................................... 18
3.6.- EXTERNAL ISOLATION AND PROTECTION ELEMENTS ..................................................................... 19
3.7.- AUXILIARY CONTROL VOLTAGE ...........................................................................................................19
3.8.- EARTH CABLE CONNECTION ...............................................................................................................19
3.9.- CURRENT TRANSFORMER (CT) CONNECTION .................................................................................20
4.- START-UP OF A HYBRID CAPACITOR BANK ..............................................................................................22
4.1.- BEFORE START-UP .................................................................................................................................22
4.2.- START-UP .................................................................................................................................................22
4.3.- CHECKS ONCE THE CAPACITOR BANK HAS BEEN CONNECTED TO THE MAINS ........................ 26
5.- MAINTENANCE ............................................................................................................................................... 27
5.1.- SAFETY REGULATIONS .........................................................................................................................27
5.2.- MAINTENANCE WITH THE CAPACITOR BANK DISCONNECTED ...................................................... 27
5.2.1. BASIC MAINTENANCE PROTOCOL ................................................................................................27
5.2.2. TIGHTENING TORQUE OF THE ELECTRICAL CONNECTIONS ....................................................28
5.2.3. KEY POINTS FOR INSPECTING CONTACTORS .............................................................................28
5.2.4. KEY POINTS FOR INSPECTING STATIC SWITCHES ......................................................................29
5.2.5. KEY POINTS FOR INSPECTING CAPACITORS ...............................................................................29
5.2.6. KEY POINTS FOR INSPECTING THE REGULATOR .......................................................................29
5.2.7. CLEANING THE CABINET ................................................................................................................29
5.3.- MAINTENANCE WITH THE CAPACITOR BANK CONNECTED ............................................................30
5.4.- ENVIRONMENTAL CONDITIONS ............................................................................................................ 30
6.- TECHNICAL FEATURES ................................................................................................................................31
7.- OPTIM HYP TYPE DIAGRAM ......................................................................................................................... 32
8.- MAINTENANCE AND TECHNICAL SERVICE ................................................................................................34
9.- GUARANTEE ...................................................................................................................................................34
10.- CE CERTIFICATE .......................................................................................................................................... 35
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Instruction Manual
OPTIM HYB Series
REVISION LOG
Table 1: Revision log.
Date Revision Description
11/14 M059B01-03-14A Initial Version
02/15 M059B01-03-15A
Changes in the following sections:
6
Note: The images of the units are solely for the purpose of illustration and may differ from the
original unit.
Instruction Manual
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OPTIM HYB Series
1.- VERIFICATION UPON RECEPTION
1.1.- RECEPTION PROTOCOL
Check the following points when you receive the unit:
a) The unit meets the specications described in your order.
b) The unit has not suffered any damage during transport.
c) Perform an external visual inspection of the unit prior to switching it on.
d) Check that it has been delivered with the following:
- The unit manual.
- The CVM-MINI-RS485 quick installation guide.
If any problem is noticed upon reception, immediately contact the transport
company and/or CIRCUTOR's after-sales service.
1.2.- TRANSPORT AND HANDLING
The transport, loading and unloading and handling of the unit must be carried
out with proper precautions and using the proper manual and mechanical
tools so as not to damage it.
If the unit is not to be immediately installed, it must be stored at a location
with a rm and level oor, and the storage conditions listed in the technical
features section must be observed. In this case, it is recommended that the
unit be stored with its original protective packaging.
To move the unit a short distance, the unit's oor support proles facilitate handling with a pallet
jack or forklift. (Figure 1)
Figure 1: Transport with pallet jack.
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 unit be
securely fastened and that no abrupt manoeuvres made. The unit should not
be lifted more than 20 cm off the ground
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Instruction Manual
OPTIM HYB Series
When unloading and moving the unit, use a forklift with forks long enough to support the entire
length of the base. Otherwise, the forks should be long enough to support at least ¾ of said
depth. The forks must be at and supported rmly by the base. Raise the cabinet by placing the
forks underneath the prole that supports the unit. (Figure 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 inside the unit. The necessary
precautions must be taken to prevent the unit from tipping over during abrupt
operations.
Figure 2: Unloading with a forklift.
1.3.- STORAGE
The following storage recommendations must be followed for the hybrid capacitor banks:
Avoid placing them on uneven surfaces.
Do not store them in outdoor areas, humid areas or areas exposed to splashing
water.
Avoid hot spots (maximum ambient temperature: 40 ºC)
Avoid salty and corrosive environments.
Avoid storing the units 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 unit cabinets.
Instruction Manual
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OPTIM HYB Series
2.- PRODUCT DESCRIPTION
The purpose of this manual is to assist during the installation, start-up and maintenance of
OPTIM HYB series low voltage (LV) capacitor banks with static operation. Carefully read the
manual to achieve the best performance from those units.
2.1.- CAPACITOR BANK COMPONENTS
From the electrical standpoint, the unit is made up of the following blocks:
2.1.1. HYBRID REGULATOR
The hybrid capacitor banks are equipped with Computer HYB hybrid regulators (Figure 3).
Figure 3: Computer HYB Hybrid Regulator.
This regulator has two types of outputs (see the inputs and outputs identied in Figure 4.:
6 relay outputs with operating voltage of 250 V ~. and operating current of 4 A (AC1) for
the auxiliary control voltage of the electromechanical contactors that operate the three-phase
capacitors (three-phase steps of the OPTIM HYB capacitor bank).
24 static outputs to provide a 12 Vdc activation signal to the + and - inputs of the CPC2
connection controller boards at zero voltage difference. These boards control the semiconductor modules (thyristor-diode) and operate the single-phase capacitors (single-phase steps of
the OPTIM HYB capacitor bank).
The Computer HYB also has the following notable features:
The necessary information to calculate compensation demand by phase is provided by a
CVM-MINI-RS485-model power analyzer via RS-485 communications with the Modbus/RTU
protocol.
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Instruction Manual
OPTIM HYB Series
The communication parameters installed in the unit are:
Speed: 9600 bps, parity: No, data bits: 8, stop bits : 1
The standard OPTIM HYB models come with the CVM-MINI-RS485 analyzer built into the door
panel and programmed with the above values.
Note: If the OPTIM HYB capacitor bank does not include the CVM-MINI-RS485 analyzer and
you intend to use the existing unit in the installation to be compensated, with an RS-485 output
that is not being used to communicate with any data display system, the RS-485 communications must be programmed as indicated above.
(For more information, see the CVM-MINI-RS485 instruction manual at www.circutor.com).
The connection terminals for the external RS-485 signal are indicated in Figure 4.
Unit auxiliary power supply: 230 V ~ ± 10 % / 50-60 Hz.
Setpoint value of target cos phi set at 1, individually for each phase.
Regulation with a delay between connections/disconnections (response to compensation de-
mands) differentiated between the single-phase steps operated by semiconductors by default
of 1 s; and the three-phase steps by default of 20 s.
Reactive power compensation algorithm consisting of prioritising the connection of single-phase steps to compensate more quickly, and of substituting these connected single-phase
steps for a three-phase step when the compensation needs allow it.
Thus, the connected single-phase steps are replaced with a three-phase power step with an
equivalent phase if 20 s after the last single-phase stage is connected there is an available
three-phase step in the capacitor bank with the same three-phase value for the 3 connected
single-phase stages. In this situation, the single-phase steps would be disconnected and the
three-phase equivalent would be connected at the same time. In this way, the single-phase
stages are again enabled for fast connection if new three-phase or single-phase compensation
demands arise.
LEDs on the front panel indicating the connected stages, CPU operation, communication
status with the CVM-MINI-RS485 and alarm signals. See Figure 5 for a detailed description of
the LEDs on the Computer HYB front panel.
Additional input for RS-485 communications, for programming and control of internal regulator functions
Note: only for use by CIRCUTOR personnel or by those properly trained in its use.
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OPTIM HYB Series
The available combinations for standard models are selected through internal mini-dips.
The programming is done in-factory and should not be modied, except by
CIRCUTOR personnel or by those properly trained in its use.
Note: If you need to nd out the conguration of the mini-dips for each combination, please
contact CIRCUTOR technical assistance.
The available staging combinations as of the date of publication of this manual are exclusively
those indicated in Table 2:
Table 2:Available stage combinations.
Model Composition
OPTIM HYB1-90-440 (3 x 2 x 5) kvar / 230 V + (3 x 15) kvar / 400 V / 50 Hz
OPTIM HYB1-110-440 (3 x 2 x 5) kvar / 230 V + (4 x 15) kvar / 400 V / 50 Hz
OPTIM HYB2-165-440 (3 x 3 x 5) kvar / 230 V + (3 x 30) kvar / 400 V / 50 Hz
OPTIM HYB2-200-440 (3 x 3 x 5) kvar / 230 V + (4 x 30) kvar / 400 V / 50 Hz
OPTIM HYB2-270-440 (3 x 3 x 5) kvar / 230 V + (6 x 30) kvar / 400 V / 50 Hz
OPTIM HYB2-325-440 (3 x 3 x 10) kvar / 230 V + (3 x 60) kvar / 400 V / 50 Hz
OPTIM HYB3-400-440 (3 x 3 x 10) kvar / 230 V + (4 x 60) kvar / 400 V / 50 Hz
OPTIM HYB3-470-440 (3 x 3 x 10) kvar / 230 V + (5 x 60) kvar / 400 V / 50 Hz
OPTIM HYB3-540-440 (3 x 3 x 10) kvar / 230 V + (6 x 60) kvar / 400 V / 50 Hz
Digital input for external temperature relay signal (Figure 4) installed at the top of the heatsink
to dissipate the semiconductors. ( Normally in closed position )
In the event of an alarm, the connected steps would disconnect until the thermal relay returns
to its NC position and the condition triggering the alarm disappears.
The alarm situation is indicated by a combination of lit LEDs on the front panel of the Computer
HYB (See Figure 5).
Lack of compensation alarm, installed in the Computer HYB.
The alarm goes off when the non-compensated three-phase power is greater than 30% of the
total three-phase power available in the capacitor bank, or in other words, is greater than 30%
of its nominal power of 400 V~.
The alarm situation is indicated by the cos φ LED being lit on the front panel of the Computer
HYB. (See Figure 5).
2.1.1.1. Computer HYB Regulator Connections.
Note : See the general connection diagram in “7.- OPTIM HYP type diagram”
The regulator comes fully connected, expect in the case of units that do not have the CVM-MINI-RS485 analyzer.
In this case, you must connect the CVM-MINI-RS485 communications output to the ASB COM2
terminal of the Computer HYB, using a shielded communication cable with at least 3 wires and
with a section of at least 0.25 mm2.
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Instruction Manual
NC THERMAL RELAY
OPTIM HYB Series
Any modication to the regulator connections must be performed exclusively
by CIRCUTOR personnel or by those properly trained in its use
The regulator's input and output terminals are shown in Figure 4.
OUTPUTS 5 AND 8
PANEL CONTROL CPC4
SINGLE-PHASE STAGES L2
OUTPUTS 1 AND 8 PANEL CONTROL CPC4
SINGLE-PHASE STAGES L3
OUTPUTS 1 AND 3
CONTACTORS
CONTROL
AUXILIAR SIGNAL
INPUT RS485
SIGNAL INPUT RS485
FROM CVM-MINI-RS485
5 C 6 7 8 1 2C C C C C 3 C 4 5 6 7 8C C C C C
L2
L1
1 C 2 3 4 5 6C C C C C 7 C 8 1 2 3 4C C C C C
OUTPUTS 1 AND 8 PANEL CONTROL CPC4
SINGLE-PHASE STAGES L1
L3
L2
OUTPUTS 1 AND 4
PANEL CONTROL CPC4
SINGLE-PHASE STAGES L2
Figure 4: Terminals on the Computer HYB Hybrid Regulator.
K4 k5 k6 SC1 A B SA B
COM1 COM2
K1 k2 k3 C1
OUTPUTS 1 AND 3
CONTACTORS
CONTROL
POWER
SUPPLY
INPUT SIGNAL
LN
2.1.1.2. Indicator LEDs on the Computer HYB regulator.
The Computer HYB regulator has a series of LEDs on its front panel to indicate the connected
stages, CPU operation, communication status with the CVM-MINI-RS485 and alarm signalling.
The different LEDs on the Computer HYB front panel are shown in Figure 5.
Instruction Manual
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