How to select and maintain contactors

for capacitor banks?

Energy Efficiency
Technical Guide
Energy Efficiency
A solution to improve
power factor correction
2
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
3
Preamble .................................................................. 4
The advantages of reactive power factor
correction ................................................................ 5
Selection guide to contactors and protection
for stepped capacitor bank
(without a choke) ................................................. 7
Capacitor step control, a specific application .................................................................... 7
LC1DK contactors for capacitors ...................................................................................................................................... 7
Maintenance ........................................................... 8
Capacitor maintenance program ........................................................................................................................................... 8
Visual inspection for contactors .................................................................................................................................................. 8
Specific information about capacitor
operation ................................................................. 9
Example of a single fixed capacitor bank................................................................................................ 9
Equipment selection for a single fixed capacitor bank ......... 11
Example of a stepped capacitor bank .................................................................................................... 12
Equipment selection for a stepped capacitor bank .......................... 13
Whats in the standard? .......................................................................................................................................................................................... 14
Conclusion ........................................................... 15
Contents
Without power factor correction:
Motor
Motor
Active power
Reactive power
Active power
Active power
Reactive power
Active power
Power generation
Power generation
Transmission network
Transmission network
With power factor correction:
Capacitor
Reactive power
0
1
-1
1.5
-1.5
0.5
-0.5
2
-2
0
1
-1
1.5
-1.5
0.5
-0.5
2
-2
0
1
-1
1.5
-1.5
0.5
-0.5
2
-2
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
4
Preamble
Definition of power factor
The active power P (kW) is the real power transmitted to loads
such as motors, lamps, heaters, computers. The electrical active
power is transformed into mechanical power, heat or light.
The apparent power is the basis for electrical
rating. The power factor is the ratio of the active
power P (kW) to the apparent power S (kVA).
=
P (kW)
S (kVA)
S = V
rms

I
rms


In a circuit where the applied r.m.s. voltage
is Vrms and the circulating r.m.s. current is Irms,
the apparent power S (kVA) is:
Power
Factor
is deteriorated by:
Reactive power
(when voltage
and current are
phase-shifted)
Harmonics
(when voltage or
current are distorted)
Compensation of reactive power / energy
Generally, the electricity bill includes components related to active and reactive power absorbed over time
(active and reactive energy). Compensation of reactive energy is typically achieved by producing reactive
energy close to the consuming loads, through connection of capacitor banks to the network.
Then, only the active energy has to be supplied by the energy supplier.
Harmonic mitigation
Operation of active harmonic flter is identical to a noise-cancellation headset:


The active flter injects currents on the network, eliminating the distortion


Power losses and disturbances are reduced.
Harmonic generators Active flter Result
5
The advantages of reactive
power factor correction
Do you need an easy solution to immediately boost your facilitys
energy efficiency and productivity?
Power factor correction helps lower operating and capital costs and can provide
a very quick return on investments:
Reduce capital expense by up to 30%
Optimise electrical system capacity, avoid oversizing and limit redundant capacity.
Reduce reactive energy billing penalties and lower operating
expenses by up to 10%
Boost the power factor to lower utility bills and reduce losses in transformers
and conductors.
Reduce energy losses by up to 30%
Optimise power consumption, reduce total process energy consumption
and reduce CO
2
emissions.
Improve power system and equipment reliability by up to 18%
Increase power quality to improve business performance and reduce unplanned
outages, as well as enhance the reliability and service life of electrical devices,
while reducing harmonic stress and potential damage to your electrical network.
Power
factor
Cable cross section
multiplying factor
1 1
0.95 1.05
0.9 1.1
0.85 1.17
0.8 1.25
0.7 1.43
Fixed capacitors
This arrangement employs one or more capacitor(s) to form a constant level
of power factor correction. Control may be:
Manual: by circuit-breaker or load-break switch
Semi-automatic: by contactor
Direct connection to an appliance and switched with it.
These capacitors are applied:
At the terminals of inductive devices (motors and transformers)
At busbars supplying numerous small motors and inductive appliance
for which individual power factor correction would be too costly
In cases where the load level is reasonably constant.
Automatic capacitor banks
This kind of equipment provides automatic control of power factor correction,
maintaining the power factor within close limits around a selected level.
Such equipment is applied at points in an installation where the active-power
and/or reactive-power variations are relatively large, for example:
At the busbars of a general power distribution board
At the terminals of a heavily-loaded feeder cable.
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
6
The principles of, and reasons, for using
automatic power factor correction
A capacitor bank is divided into a number of sections, each of which is controlled
by a contactor. Closure of a contactor switches its section into parallel operation
with other sections already in service.
The size of the bank can therefore be increased or decreased in steps,
by the closure and opening of the controlling contactors.
A control relay monitors the power factor of the controlled circuit(s) and is
arranged to close and open appropriate contactors to maintain a reasonably
constant system power factor (within the tolerance imposed by the size of each
capacitor bank step).
By closely matching power factor correction to that required by the load,
the possibility of producing overvoltages at times of low load will be avoided,
thereby preventing an overvoltage condition, and possible damage
to appliances and equipment.
Overvoltages due to excessive reactive power factor correction depend
partly on the value of the source impedance.
The choice between a fixed or automatically
regulated bank of capacitors
Where the kvar rating of the capacitors is less than or equal to 15% of the supply
transformer rating, a fxed value of power factor correction is appropriate.
Above the 15% level, it is advisable to install an automatically-controlled
capacitor bank.
The location of low-voltage capacitors in an installation constitutes the mode
of power factor correction, which may be global (one location for the entire
installation), partial (section-by-section), local (at each individual device),
or some combination of the two. In principle, the ideal power factor correction is
applied at a point of consumption and at the level required at any particular time.
In practice, technical and economic factors govern the choice.
The advantages of reactive
power factor correction
Peak closing
current
Oscillation
frequency
7
Selection guide to contactors
and protection for stepped
capacitor bank (without a choke)
Capacitor step control, a specific application
LC1DK contactors for capacitors
LC1-DK contactors are specifcally designed to control capacitors.
They have a normally open switchover contact block and damping resistors limiting
the current at switch-on. This technology is unique and is the subject of a patent.
See page 8 for the selection guide to contactors and associated fuse protection according to the step power rating.
Such repetitive high-frequency transient overvoltages can damage the reactive power factor correction
capacitor insulation and other devices such as transformers.
Reference LC1DFK LC1DGK LC1DLK LC1DMK LC1DPK LC1DTK LC1DWK12
Pmax @400 V 60C 13 kVAR 16 kVAR 20 kVAR 25 kVAR 30 kVAR 40 kVAR 63 kVAR
Auxiliary contacts 1NO + 2NC 1NO + 2NC 1NO + 2NC 1NO + 2NC 1NO + 2NC 1NO + 2NC 1NO + 2NC
Width 45 mm 45 mm 45 mm 45 mm 55 mm 55 mm 85 mm
Size 1 1 2 2 3 3 4
Capacitor control is accompanied by a transient state, resulting from the
capacitor load. This can result in a massive overcurrent, equivalent to a
short-lasting short-circuit. (See detail page 9)
Line supply voltage Capacitor voltage Capacitor current
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
8
Maintenance
Capacitor maintenance program
To ensure that the fnancial advantages of reduced billing are achieved its necessary to perform periodic maintenance
of the power factor correction capacitors and controlling switchgear. Automatic capacitor bank operating conditions involve
various types of environmental stress: temperature variations, electrical stress (harmonics, transient inrush current).
In order to maintain the equipment performance during the whole installation life cycle, the maintenance program must be carried
out systematically in order to ensure the equipment works properly, preserve its operating life and avoid serious operating faults,
explosion and fre.
Please check the following points annually:
Note: With an automatic battery, one step may have failed and power factor correction is performed by some other steps, so the overall
solution is satisfactory, but each time the faulty step is switched on, transient disturbance may occur. Regular inspection is therefore
the only way to detect failure.
Maintenance program When
Type of checking Capacitor bank part 1 month after energization Once a year
Visual inspection Enclosure
Capacitors
Controller
Chokes if any
Contactors and damping resistors
Cables and connections
Checking switch-on Controller settings/alarms
Protection settings
Capacitor status
Checking switch-off Tightness
Visual inspection for contactors
The contactors are ftted with a block of early-make poles and damping resistors (external resistive wires), limiting the value of the current
on closing to 60 In max. This current limiting increases the life of all the installation components, especially that of the fuses and capacitors.
Visual inspection consists in:
Checking presence of damping resistors
Evaluating whether any overheating has occurred
Examining for the presence of dust, moisture, etc.
Visual checking of electrical connections
If the damping resistors are damaged or missing:
the contactor shall be replaced immediately.
the capacitors operated by the corresponding
contactor shall be checked.
If a capacitor is damaged and replaced, the corresponding contactor shall also be replaced.
Example of damaged damping resistors
When replacing contactors, it is essential
to observe the following rules:
Use suitable connectors
The tightening torque must conform
to that specifed by Schneider Electric
Handle the resistor wires carefully to avoid creating
a fracture starting point on the crimped tags
Retighten the connectors 1 month after
commissioning, then once a year.
U
h
3
C
L
a
L
9
Specific information
about capacitor operation
Example of a single fixed capacitor bank *
The upstream line supply is deemed to be a pure inductance
L
a
such as: We can see that the peak switching current is:
U
n
: rated phase-to-phase voltage
I
sc
: symmetrical three-phase short circuit
current at the capacitor connection point
S
sc
: short-circuit power at the capacitor connection point
Capacitor control is accompanied by a transient state, resulting from
the capacitor load. This can result in a massive overcurrent, equivalent
to a short-lasting short-circuit
L is negligible in the presence of L
a
hence:
L
a
: upstream line supply inductance
L : inductance of the link between the breaking
device and the capacitor bank
The equivalent single phase diagram is as shown
in the fgure below:

e
=

2
U
n

C
3 L
a
+ L

e
=

2
U
n

C
3 L
a

The link between the breaking device (contactor,
circuit-breaker or switch) and the capacitor bank
is also deemed to be a pure inductance.
S
sc
=
3

U
n

I
sc
L
a
=
U
n

=
U
n
S
sc
3 I
sc
By defnition:
Simplifed diagram of a fxed capacitor bank
* Single fxed capacitor: No big disturbance, no special care
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
10
Its duration is equivalent to the duration of a short
circuit transient cycle, or several dozen ms.
We can compare this current to the capacitor
bank rated current:
The overcurrent is accompanied by an overvoltage
whose maximum value can be almost twice the peak
line supply voltage.
The natural frequency of this current is:
By using:
and
L
a
=
U
n

S
sc
Q
= C
U
n

Example:
Assuming a 250 kvar fxed capacitor bank with phase-to-
phase voltage U
n
= 400 V powered by a maximum short
circuit power supply network S
sc
= 20 MVA, we get:
The maximum peak switching current in this example
is 12.6 times the capacitor bank rated current, its natural
frequency is 447 Hz.
The fgures on the next page represent the switching current
and the line supply voltage, when switching occurs
at the voltage maximum.
Specific information
about capacitor operation

0
=
1
2 L
a
C
I
ncapa
= C
U
n
3
Hence:

e
= 2
1
I
ncapa

L
a
C

0
=

S
sc
= 50

20.10
6
= 447 Hz
2
Q 250.10
3
This gives us:

e
= 2

S
sc
I
ncapa
Q

0
=
1
2 L
a
C

e
= 2

20.10
6
= 12.6
I
ncapa
250.10
3

e
= 2

S
sc
I
ncapa
Q
5000
4000
3000
2000
1000
A 0
-1000
-2000
-3000
-4000
-5000
0 0.01 0.02 0.03 0.04 t(s)
600
500
400
300
200
100
V 0
-100
-200
-300
-400
-500
-600
0 0.01 0.02 0.03 0.04 t(s)
11
Equipment selection for fixed capacitor bank
These transient states do not cause excessive stress to the protection and/or
control device.
Switching current
Line supply voltage on switching
C
L
U
h
3
L
a
1 2 3 n+1
C
L
C
L
C
L
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
12
Example of a stepped capacitor bank *
(or several fixed capacitor banks connected to the same busbar).
The equivalent single-phase diagram for (n+1) capacitor bank steps is as shown in the fgure below:
L
a
: upstream line supply inductance
L : inductance of the link between the breaking device and the capacitor
bank (0.5 H/m)
The peak switching current
e

is at its maximum when n steps are being
used and the n+1
th
step is switched on.
All steps in service discharge into this step. As the inductances (L)
are very low, this switching current is very high (it depends on the line
supply inductance L
a
).
We can see that the peak switching current
is expressed as:
Example:
Assuming a bank with 6 steps, each of which is 50 kvar, with phase-to-phase voltage of 400 V, 1 meter away
from their associated breaking device. This gives us:
The maximum peak switching current in this example equals 168 times the capacitor bank step
nominal current. The capacitors and breaking devices cannot withstand this very high current,
therefore a device must be used to limit the switching current.
Specific information
about capacitor operation

e
=

n
U
n

C
3 n+1 L
We can compare this current to the nominal current
of a step I
ncapa
I
ncapa
= C
U
n
3
Where: Q = step reactive power
This gives us:

e
=

n
U
n

1
I
ncapa
3 n+1 QL
=

5

400

1
=168
3 6 50 10
3
314 0.5 10
6

e
=

n


U
n

1
I
ncapa
3 n+1 QL
Simplifed diagram of a stepped capacitor bank
* Stepped capacitor: Big disturbance = Special contactor and special care
800
600
400
200
A 0
-200
-400
-600
-800
0 0.11 0.12 0.13 0.14 t(s)
400
300
200
100
V 0
-100
-200
-300
-400
0 0.11 0.12 0.13 0.14 t(s)
13
Note: If it is not possible to use contactors specifically designed to control
capacitors, chokes which limit the current at switch-on must be used.
Current in the switched-on capacitor
Voltage at the switched-on capacitor terminals and line supply voltage
Energy Efficiency-Technical Guide - How to select and maintain contactors for capacitor banks?
14
International standard IEC 60831-1 "Shunt power capacitors of the self-healing type for a.c.
systems with a rated voltage up to and including 1000 V" recommend the use of such contactor.
Equipment selection for a stepped capacitor bank
What's in the standard?
Specific information
about capacitor operation
The switching currents are limited by pre-insertion resistors; how these work is illustrated in the fgure below:
Schematic diagram of pre-insertion resistors LC1 DPK
Step power
at 400 V kVAR
400 V
step current Amps
Fuse protection
rating (curve gG)
Contactor for
capacitor application
Qmax 400 V
60C
2.5 3.6 6.3 A LC1 DFK -
5 7.2 16 A LC1 DFK -
6.25 9.0 16 A LC1 DFK -
7.5 10.8 20 A LC1 DFK -
10 14.4 25 A LC1 DFK -
12.5 18.0 32 A LC1 DFK 13 kVAR
15 21.7 40 A LC1 DGK 16 kVAR
20 28.9 50 A LC1 DLK 20 kVAR
25 36.1 63 A LC1 DMK 25 kVAR
30 43.3 80 A LC1 DPK 30 kVAR
40 57.7 100 A LC1 DTK 40 kVAR
45 65.0 125 A LC1 DWK12 -
50 72.2 125 A LC1 DWK12 -
60 86.6 160 A LC1 DWK12 63 kVAR
The power values given in the selection table above are for the following operating conditions:
Prospective peak current at switch-on
LC1 DK .................................................................................................................................................. 200 In
Maximum operating rate
LC1 DFK, DGK, DLK, DMK ......................................................................................... 240 operating cycles/hour
LC1 DPK, DTK, DWK .......................................................................................................... 100 operating cycles/hour
Electrical durability at nominal load 400 V
All contactor ratings................................................................................................................. 300,000 operating cycles
Each capacitor bank step must be controlled
by a contactor equipped with auxiliary contacts.
Resistors are connected in series with
the auxiliary contacts.
On contactor closing, the auxiliary contacts
are closed instantaneously, allowing precharging
by means of the resistors.
After approximately 3 ms, the main contacts close,
short-circuiting the resistors, then the auxiliary
contacts open.
With such contactors there is no need to use
choke inductors for either single or multiple-
step capacitor banks.
15
The installations global energy performance depends on
the performance of the reactive power capacitor banks.
Failures in this type of equipment are difficult to detect as they do not have a direct effect on the electrical
distribution network. Often customers only realise that reactive power correction is not working when they see
their electrical bills from the energy company increasing. However any malfunctions can cause problems in the
installation, and regular inspection of this equipment is therefore vital.
Conclusion
06-2013 EDCED313001EN
35, rue Joseph Monier
CS 30323
F- 92506 Rueil Malmaison Cedex
France
RCS Nanterre 954 503 439
Capital social 896 313 776
www.schneider-electric.com
Printed on ecological paper.
As standards, specifcations and designs change
from time to time, please ask for confrmation of
the information given in this publication.

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