Power Factor Controller N-6 / N-12

USERS MANUAL

USERS MANUAL

Power Factor Controller N-6 / N-12 USERS MANUAL

Table of Contents
1. General ...................................................................................................3 1.1 Safety...............................................................................................3 1.2 Environmental conditions ................................................................3 1.3 Description.......................................................................................3 2. Installation ..............................................................................................5 3. Display....................................................................................................6 4. Start-up Procedure.................................................................................7 5. Menu Operations....................................................................................7 5.1 General.............................................................................................7 5.2 Main Menu .......................................................................................9 5.3 Bank Pre-Configuration .................................................................11 5.4 Commissioning ..............................................................................13 5.5 Auto Setup of Parameters .............................................................14 5.6 Manual Setup of Parameters .........................................................15 5.7 Measurement Menu .......................................................................17 5.8 Parameter Update..........................................................................18 5.9 Alarms Menu..................................................................................19 5.10 Maintenance Menu ......................................................................20 6. Miscellaneous.......................................................................................23 6.1 Stepping Programs ........................................................................23 6.2 Manual calculation of response value............................................26 6.3 High Voltage use of N-6/N-12 .......................................................27 7. Glossary ...............................................................................................29 8. Technical specifications .......................................................................31

USERS MANUAL

1. General
1.1 Safety
The following precautions must be taken into account when installing and operating the controller The installation of the controller must be performed by a qualified electrician Do not touch the connectors when the controller is energized, make sure that the operating voltage is disconnected before touching any parts located on the rear side of the controller Do not open a live current circuit, this may cause dangerous overvoltages. Always short circuit the current transformer (CT) before replacing or removing the controller installed in a bank. Do not open the controller casing, there are no user serviceable parts inside

For better understanding of the terminology used, please refer to the Glossary (chapter 7) at the end of this manual.

1.2 Environmental conditions:

The controller is designed for the following environmental conditions: Indoor use Altitude up to 2000 m Ambient temperatures within 0+60C Maximum relative humidity 80 percent for temperatures up to 31C decreasing linearly to 50 percent relative humidity at 40C Mains supply voltage fluctuations not to exceed 20/+15 percent of the nominal voltage Transient overvoltage for the Mains supply according to installation categories III Pollution degree 2

1.3 Description
Legend A B C D E F Display Keys Opening of door Door Alarm information Mounting bracket for panel mounting installation

Front view:

USERS MANUAL

Rear view:

Legend G H I J K L M Step output connector Specification label ( Equipment protected by douple or reinforced insulation) Mounting bracket for panel mounting installation Fixing spring for DIN-rail mounting Current/voltage connection inputs ( Fan ( ) and alarm ( ) outputs DIN-rail mounting installation area Alternating current)

Side view:

Legend

Screwdriver guide

See Chapter 8 for technical specifications.

USERS MANUAL

2. Installation
The controller is designed for either panel (cut-out 138 x 138 mm) or DIN-rail installation. It is locked to the rail by a screwdriver-operated fixing spring and to a panel by a side fitting spring. There are two ways of connecting the controller to the network. Voltage LN (Line Neutral) Voltage LL (Line Line) (CT on the same line phase) (CT on the third phase)

Incorrect connections can be automatically corrected by the controller when Auto Setup is selected from the main menu. Caution: For use in HV network, look first at chapter 6.3

Figure 1: Controller connections Control switch switches the power of controller. In ambient temperature of 60C the temperature class of connection wires must be at least 80C. 5

USERS MANUAL

Notes on installation: A switch or circuit breaker shall be included in the building installation. It shall be in close proximity to the equipment and within easy reach of the operator. It shall be marked as the disconnecting device for the equipment. An equipment switch or circuit breaker employed as a disconnecting device shall comply with relevant requirements of IEC 60947-1 and IEC 60947-3. Overcurrent protection devices such as fuse or miniature circuit breaker with a rating of no more than 10 A shall be connected in supply conductors. The overcurrent protection devices need to be certified to national requirements.

3. Display
The controller is equipped with a backlighted LCD-display.

Figure 2 : Display layout and symbols

USERS MANUAL

4. Start-up Procedure
Before connecting power, check the wiring of all controller terminals. Check carefully for correct operating voltage. Selection of wrong voltage input can permanently damage the controller. After the first power switch-on, the controller will automatically ask for the language setting of the menu.

Figure 3: Language setting dialog

5. Menu Operations
5.1 General
Navigation between different menu levels As a precaution against accidental use, the access of certain menus has been protected by a keylock, which is a special sequence of keystrokes enabling the use the particular menu item. 7

USERS MANUAL

Figure 4: General way of entering the menu with a keylock

Adjusting a value

Figure 5: Adjusting a value

Special case: The wiring editor

Figure 6: The wiring editor

USERS MANUAL

5.2 Main Menu

The main menu contains all basic submenus required to set up and operate the controller. Which menu to choose?

Figure 7: Required skills and menu selection

If bank preconfiguration is properly done, commissioning does not require any special skill.

USERS MANUAL

(1) Bank pre-configuration When factory settings have not been changed, this menu provides the bank builder the means of preconfiguring the bank at the workshop. After preconfiguration, this menu topic is replaced by (2) Commissioning, by which the controller is taken into service. (3) Automatic setup of parameters In the event that the controller has not been preconfigured, an inexperienced user can automatically set up all the characteristics of the bank and bring it into service. (4) Manual setup of parameters In the event that the controller has not been preconfigured, an experienced user can manually set up all the characteristics of the bank and bring it into service. (5) Measurement The measurement menu contains the most common measurements taken from the network and provides some information about the bank. This is a read-only menu. (6) Parameter update At any time, an experienced user can access the most common operating parameters from this menu. Unlike the configuration and setup sequences, this is a menu allowing a free and unrestricted entry into all its items and should be used when an occasional parameter access is needed. (7) Alarm settings To adjust status and parameters of alarms. (8) Maintenance The maintenance menu provides some useful information about the usage of the bank, capacitors and contactors. Some auxiliary settings and action have also been provided. This menu is basically intended for use by the manufacturers maintenance team.

Figure 8: Main menu

10

USERS MANUAL

5.3 Bank Pre-Configuration

This menu item is a forced sequence, meaning that all items must be accessed before the preconfiguration takes place.

NOTE:

Do not use of the Bank Pre-Configuration menu for HV network applications

key.

The sequence can be interrupted by pressing

See Glossary (chapter 7) for parameters definitions.

11

USERS MANUAL

Figure 9: Bank pre-configuration

12

USERS MANUAL

5.4 Commissioning
A pre-configured controller is put into service by this menu. The sequence contains an automatic parameter verification to check that the manually entered parameters agree with the network used. See Glossary (chapter 7) for parameter definitions. NOTE: Do not use of the Commissioning menu for HV network applications

Figure 10: Commissioning What to do in case of error ? Error codes can help you to identify a problem and make corrections. 13

USERS MANUAL

Code

Meaning
Unstable network: The controller is unable to operate due to excessive load variations on the network. CT oversized.

Action to do
Enter the parameter settings manually using Parameter Update menu. Rerun the commissioning sequence Check wiring, CT, condition of st capacitor steps (1 step) Check the condition and sizes of steps and contactors Check the condition and sizes of steps and contactors Use manual setup to confirm or correct the information obtained by autosetup

Step size too small: The effect of the 1 step cannot be measured. CT oversized, wrong wiring, inoperative steps. Sequence not found: Step ratio does not match available step sequences. Step size too large: The ratio of measured step st compared with the 1 step is too large. Step sequence cannot be resolved. Non-relevant autosetup process with this bank configuration

st

to

Reserved

Wiring verify error: Controller wiring not correct.

Check the wiring of voltageand current inputs Check the Wiring setting from Parameter Update menu Check the Number of Steps setting Check the number of steps in the bank and the condition of steps Check Step Sequence setting Check step sizes used in the bank Check the response value used st Check the size of 1 step in the bank

Step count error: The Number of Steps setting is incorrect.

Step sequence error: The step size ratios differ from the selected step sequence.

C/K value error.

5.5 Auto Setup of Parameters

The auto setup sequence is intended for inexperienced users so they can commission the bank with minimal prior knowledge. The user need only input three of the most common parameters and then launch an automatic search for the other parameters. NOTE: The use of Auto Setup of Parameters menu is forbidden on HV network applications

In the event of error, see the Commissioning Menu (chapter 5.4).

14

USERS MANUAL

Figure 11: Auto setup of parameters

5.6 Manual Setup of Parameters

The manual setup sequence is intended for experienced users. There are nine important parameters to input before the controller can be taken into service. This sequence is completed by an automatic verification of the parameters entered earlier in this sequence. This menu item is a forced sequence, meaning that all items must be accessed before the validation of the setup takes place. The sequence can be interrupted by pressing key.

See Glossary (chapter 7), for parameter definitions. In case of error, refer to the Commissioning Menu, chapter 5.4. 15

USERS MANUAL

Figure 12: Manual setup of parameters

16

USERS MANUAL

5.7 Measurement Menu

The measurement menu contains the most common measurements taken from the network. This is a read-only menu sequence.

Figure 13: Measurement menu

17

USERS MANUAL

5.8 Parameter Update

The most common operating parameters can be accessed from this menu. Unlike the configuration and setup sequences presented earlier in this text, this is a menu allowing a free and unrestricted entry into all of its items and should be used when occasional parameter access is needed. See Glossary (chapter 7), for parameter definitions. In case of error, refer to the Commissioning Menu, chapter 5.4.

Figure 14: Parameter update 18

USERS MANUAL

5.9 Alarms Menu

In Alarms menu, each individual alarm can be enabled or disabled. Once an alarm condition is detected, the corresponding alarm number is shown at the upper part of the display, and the alarm symbol is on. The alarm relay is also activated. An alarm can be reset by an extended pressure of key, this clears all passive alarms. If alarm condition is still active, the alarm cannot be reset. List of alarms:
Alarm No.
1 2

Alarm
Low power factor Hunting

Possible cause
Wiring or LL/LN definition error Undersized bank Too small C/K value Wrong program choice Defective capacitors (optimal program) Wiring mistake overcapacitive network (welded contactors) Too low current

Controller action

Pauses regulation for 10 minutes

Abnormal Cos Phi

4 5

Low voltage Overcapacitive Wiring or LL/LN definition error Improper use of fixed steps Wrong or unstable network frequency detected at startup Undersized CT

Disconnection till voltage returns

6 7 8 9 10

Wrong frequency Overcurrent Overvoltage Overtemperature Voltage distortion

Stop regulation. No automatic restart

Temporary disconnection of steps Ambient temperature too high Defective coolingsystem Harmonic pollution Resonance Temporary disconnection of steps Temporary disconnection of steps

Alarm contacts are closed when the controller is not energized opened when the controller is energized without alarm closed when the controller is energized with alarm ALRM.SET informs on the status of each alarm : enabled or disabled allows enabling or disabling of each individual alarm by setting it ON or OFF. If an alarm is set to OFF, it cannot cause an alarm under any condition. To allow a normal alarm response, the appropriate alarm must be enabled, i.e. set ON. Some alarm triggering levels can be adjusted Alarm No 9 (overtemperature ), with temperature limit setting Alarm No 10 (voltage distortion ), with THD(U) limit setting

19

USERS MANUAL

Figure 15: Alarms menu

5.10 Maintenance menu

The maintenance menu provides useful information about the usage of the bank, capacitors and contactors. Also, some auxiliary settings have been provided. CAUTION: CAUTION: This menu access is dedicated to specialists. In case of installation in a HV bank (with VT), you must adjust the default factory settings. The reconnection delay must be changed to a larger value (e.g. 600 secs) to prevent destruction of capacitors.

20

USERS MANUAL

Figure 16/1: Maintenance menu

21

USERS MANUAL

Figure 16/2: Maintenance menu

22

USERS MANUAL

6. Miscellaneous
6.1 Stepping programs
The controller's algorithm will try to reach the target cos inside a tolerance area dependant upon the C/K value. It reaches the value by switching on or off available relevant steps. The regulation step program choice is as follows: a) Stack Program (linear) : All capacitor steps are of equal size (ex :1.1.1.1). The operation sequence obeys to a last-infirst-out (LIFO) principle. The first step connected will be the last one to be disconnected and vice versa. See Fig. 17 b) Normal program (2+ linear) Normal program can be used on bank whose step ratio is 1.2.4.4.. The linear sequence starts with the 3rd step. The two first steps are used as fine-tuning. The controller always start by switching the first step then the second. Other steps are used successively See Fig. 18. c) Circular A program All capacitor steps are of equal size (ex :1.1.1.1). The operation sequence obeys the first-in-firstout (FIFO) principle. The first step connected will be the first one to be disconnected and vice versa. Then a circular sequence is followed. In order to operate correctly, the number of steps programmed into the controller must strictly comply with the number of physical steps See Fig. 19. d) Circular B program (1+Circular) Circular B program can be used on a bank whose step ratio is 1.2.2.2 The first step is used as tuning after the activating limit is exceeded. The circular sequence starts with the 2nd step.
Step demand + + + + + + + + + 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Step number 2 3 4 5 6
Step demand + + + + + + + X X X X X X 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 2 Step number 3 4 5 6

Figure 18: Normal program - Operation sequence 1:2:4:4

Figure 17: Stack program - Operation sequence 1:1:1:1 23

USERS MANUAL

Step demand + + + + + + + + -

1 X X X X

Step number 2 3 4

Step demand +

1 X X X

Step number 2 3 4

X X X X X X X X X X X X X X X X X X X X X X X X X X

+ + + + + + + + -

X X X X X X X X X X X X X

X X

X X X

X X X X X X X X

X X X X X X X X X X X X X X X

X X X X X

X X

Figure 19: Circular A program - Operation sequence 1:1:1

Figure 20: Circular B program Operation sequence 1:2:2

e) Optimal Program : The optimal program operates with many step configurations: 1.1.1.1.1 1.1.2.3.3 1.2.2.2.2 1.1.2.4.4 1.2.4.4.4 1.2.3.3.3 1.2.4.8.8 1.2.3.4.4 1.1.2.2.2 1.2.3.6.6

The target cos power is reached using the fewest number of steps in minimal time. Like the circular program, this algorithm equalises the usage of steps. This program uses optimally selected steps sizes when approaching the target power and at the same time the response delays are shortened, particularly if there is a large requirement for kvar or if the network suddenly becomes capacitive. Comparison between normal and optimal program: Normal program will reach the cos target value by successive connection/disconnection of kvar corresponding to the smallest step value. Optimal program will reach the target cos value by successive connection/disconnection of kvar corresponding to the highest relevant and available step value

24

USERS MANUAL

Optimal Stepping Program

Uncompensated reactive power

Compensated reactive power

+4
Connection of steps

Step sizes : 1:2:4:4

+4 +4 Ind Cap
Steps on : 4

+1
Steps on : 4+4+4+1

t
Steps on : 4+1

-4 -4
Disconnection of steps

-4

Normal Stepping Program

+1 +2 +4 +4 Ind Cap
Steps on : 4

Step sizes : 1:2:4:4

+4 -1 -2 -4
Steps on : 4+4+4+4

t
Steps on : 4

-4 -4

Figure 21: Regulation example - Optimal vs. Normal

25

USERS MANUAL

6.2 Manual calculation of response value

Normally the response value, more generally known as the C/K value, is set automatically as a part of the Auto Setup sequence, but there are cases when these values must be entered manually. The correct value can be calculated using an equation requiring the 1st step size (in vars), line-to-line voltage of the network used (in volts) and the CT ratio as follows

C/K =

Q1st I1 5 A U LL 3
size of 1st step in vars line-to-line voltage in volts CT ratio

where

Q1st ULL I1/5A

= = =

Alternatively, the C/K value can be taken from the table below (valid for 400 V networks)

n1/n2 100/5 150/5 200/5 250/5 300/5 400/5 500/5 600/5 800/5 1000/5 1500/5 2000/5 2500/5 3000/5 6000/5 12,5 0,91 0,60 0,45 0,36 0,30 0,23 0,18 0,15 0,11 0,09 0,06 0,05 0,04 0,03 0,02 20 1,44 0,96 0,72 0,58 0,48 0,36 0,29 0,24 0,18 0,14 0,10 0,07 0,06 0,05 0,02 25 1,80 1,20 0,90 0,72 0,60 0,45 0,36 0,30 0,23 0,18 0,12 0,09 0,07 0,06 0,03

Smallest step (kvar) 30 40 50 60 1,44 1,08 0,87 0,72 0,54 0,43 0,36 0,27 0,22 0,14 0,11 0,09 0,07 0,04 1,92 1,44 1,16 0,96 0,72 0,58 0,48 0,36 0,29 0,19 0,14 0,12 0,10 0,05

75

100

1,80 1,44 1,20 0,90 0,72 0,60 0,45 0,36 0,24 0,18 0,14 0,12 0,06

1,73 1,44 1,08 0,87 0,72 0,54 0,43 0,29 0,22 0,17 0,14 0,07

1,80 1,35 1,08 0,90 0,68 0,54 0,36 0,27 0,21 0,18 0,09

1,80 1,44 1,20 0,90 0,72 0,48 0,36 0,29 0,24 0,12

Table 1: C/K-values for 400 V network By successive connections (or disconnections) of steps we adjust the reactive power between two symmetrical limits corresponding to response value

26

USERS MANUAL

Figure 22: Compensation example and consequences

6.3 High Voltage use of N-6/N-12

This controller is primarily intended for LV network, but may be used in HV networks under the commissioners full responsibility, if the following points are taken into account. Connections must employ VT and CT with respect to the following figure. In HV applications the power values displayed in Measurement Menu represent only the secondary side values of the VT. To avoid potential misunderstandings, set the CT ratio to percentage scale. Safety (or reconnection) delay must be adapted to the value of the discharge resistors of the capacitors, the most usual value is 10 minutes (600 seconds). The controllers default response delay is adapted for LV use. Using too short a response delay may damage the capacitors. Important: the whole commissioning process must be performed using the Manual setup menu and Parameter menu the commissioner should not use Bank Pre-Configuration and Commissioning menus the use of Auto Setup menu is strictly forbidden to prevent capacitor destruction

27

USERS MANUAL

HV connection of N-6/N-12
L1 L2 L3 PE

Example 20 kV 50/60 Hz

20 kV 110 V

Auxiliary voltage 230 VAC

Alarm circuit

400V 230V 110V 0V

S1 S2

Power Factor Controller N-12

Steps 2...6

Capacitor Step 1

Figure 23: HV use of the controller

C 7 8 9 10 11 12

1 2 3 4 5 6 C

Steps 7...11

28

F1 F2

A B

Capacitor Step 12

LOAD

USERS MANUAL

7. Glossary
Display information ALARMS ALRM.SET AUTO AUTO.SET BANK.PRE BANK.TST Long form text Alarms Menu Alarm Setup (Enable/Disable) Automatic search of C/K response value Automatic Setup Sequence Bank Pre-configuration Sequence Menu Bank Test: each step is automatically connected and disconnected in turn. This facilitates testing of the operation of each capacitor step contactor. See also Step Test. Circular A stepping program Circular B stepping program Response value, normally set up automatically by the controller Clear Statistics Commissioning Sequence Menu Target cos value 0,8ind 25/5 10s 1.00 % 50s 0,9cap 6000/5 600s Current Transformer primary setting, xxx/5 A Safety Delay or reconnection delay. Response delay is fixed 20% of reconnection delay. The default value corresponds to capacitors with internal discharge resistors 50V 1 min Language names: English, for instance Error in parameter search or verify. NN= error number Restore Factory Settings The controller does not require the information about step sequence for any program outside Optimal. The controller defines it automatically. Current too high Current too low Language Selection for menus Line to Line connection Line to Neutral connection Low Voltage Maintenance Menu Manual Setup Sequence Menu Manual setting of C/K response value. See further Measurements Menu 0,01 0,50 1,99 <2,5% IN Min value Default value Max value

CIRC.A CIRC.B C/K CLR.STAT COMMISS COS PHI CT DELAY

ENGLISH ERR NN FACTOR.S IGNORED I HIGH I LOW LANGUAG LL LN LV MAINTEN MAN.SET MANUAL MEASURE

>115% IN

29

USERS MANUAL

Display information N.CONNEC N.STEPS NORMAL OPTIM PARAMET PROGRAM

Long form text Number of Connections Number of used steps Normal, Standard stepping program Optimal program Parameters Menu Selection of suitable stepping program between (see 6.1 Stepping programs) The controlers algorithm will try to reach the target cos inside a tolerance area dependant upon the C/K value. It reaches the value by switching on or off available relevant steps. Stack Normal Circular A Circular B Optimal Search (response value, step sizes, wiring...) Serial Number of the product (for internal manufacturer use) Linear stepping program Setting of Step Size Sequence 1.1.1.1.1 - 1.1.2.2.2 - 1.1.2.3.3 - 1.1.2.4.4 - 1.2.2.2.2 1.2.4.4.4 - 1.2.4.8.8 -1.2.3.3.3 - 1.2.3.4.4 - 1.2.3.6.6 This concerns the Optimal program. Step sequence are predefined with other programs and modification request are not then taken into account Step Test: each step can be manually connected and disconnected. This facilitates testing of the operation of each capacitor step contactor. See also Bank Test.

Min value

Default value

Max value

6/12

12

SEARCH SERIAL.N STACK STEP.SEQ

STEP.TST

TEMP.LIM THD.U THD.U.LIM U LOW UPTIME VERIFY VERSION VOLTAGE WIRING

Temperature Limit (adjustable) 20C Fan switch-on limit is 15C lower than temperature limit. Total Harmonic Distortion of Voltage Maximum Harmonic Distortion of Voltage (adjustable) 5%

50C

60C

7%

20%

Voltage too low <85%UN Uptime (Power On Hours) Automatic verification of parameters Software version number (for internal manufacturer use) Input Voltage reference value for voltage alarms 80V Connections of voltage and current inputs. Example: U.L2-L3 (Voltage connected between phase 2 and 3) Example: I.1.AUTO (Current connected to phase 1 with automatic polarity selection) Current polarity selections: DIR = direct connection INV = inverted connection AUTO = automatic polarity (defined by controller)

400V

460V

30

USERS MANUAL

8. Technical specifications
Number of steps Dimensions Frequency Measuring current Measuring and supply voltages 6 or 12 155 x 155 x 70 mm 50 Hz nominal (range 48...52 Hz) 60 Hz nominal (range 58...62 Hz) 0...5 A 110 V nominal (range 88...130 V) 230 V nominal (range 185...265 V) 400 V nominal (range 320...460 V) 13 VA 120 Vac/5A, 250 Vac/2A, 110 Vdc/0,3A, 60 Vdc/0,6A, 24 Vdc/2A LCD glass with 160 symbols, backlighted IP41 front panel, IP20 rear part 0,85 ind...1,00...0,90 cap 0,01...1,99 symmetrical 10...600 s 20 % of reconnection delay, min. 10 s cos , P, Q, S, THD(U), temperature Panel installation, DIN-rail installation Impact resistant PC/ABS, UL94V-0 0...60C List of 5 last alarms Yes Yes Is: 5% Iq: 5% U/I-samples: 5% Phase: 5 Distortion: 3 dB (up to 11th) Temperature: 3C 25/5...6000/5 Reaction time > 15 ms IEC 61010-1 IEC 61000-6-2 IEC 61000-6-4 IEC 61326 UL 61010B-1/CSA-C22.2 NO. 1010.1

Rated power Relay inputs/outputs Display Protection class Target cos -range Response limits, C/K Reconnection delay Response delay Displayed measurements Installation method Casing Operating temperature range Alarm log Step counters Fan control with dedicated relay Accuracy (of FS)

CT setting range Power outage detection Approvals

31

Nokian Capacitors Ltd Kaapelikatu 3, P.O.Box 4 FIN-33331Tampere, Finland Tel. +358 3 3883 11, fax +358 3 3883 360 www.nokiancapacitors.fi
KOSS90051/200804