Circutor OPTIM P&P Series User manual

INSTRUCTION MANUAL
(M063B01-03-19A)
Low voltage capacitor banks switched by
contactors.
OPTIM P&P Series

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OPTIM P&P Series
Instruction Manual

SAFETY PRECAUTIONS
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
CIRCUTOR, recommends using the original cables and accessories that are
supplied with the device.
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.
Follow the warnings described in this manual with the symbols shown below.
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 stan-
dards 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.
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CONTENTS
AFETY 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
3.- INSTALLATION .................................................................................................................................................8
3.1.- PRELIMINARY RECOMMENDATIONS .....................................................................................................8
3.2.- PREPARATION...........................................................................................................................................9
3.3.- INSTALLATION LOCATION..................................................................................................................... 10
3.4.-CONNECTION OF THE CAPACITOR BANK TO THE MAINS................................................................. 10
3.5.-POWER CIRCUIT ...................................................................................................................................... 11
3.6.- EXTERNAL CIRCUIT BREAKER AND PROTECTION ELEMENTS....................................................... 11
3.7.- AUXILIARY CONTROL VOLTAGE........................................................................................................... 11
3.7.1. CAPACITOR BANK WITH AUXILIARY VOLTAGE OBTAINED FROM AN INTERNAL AUTO-
TRANSFORMER ..........................................................................................................................................12
3.7.2. CAPACITOR BANK WITH AUXILIARY VOLTAGE OBTAINED BETWEEN PHASE-NEUTRAL......12
3.8.- EARTH CABLE CONNECTION ............................................................................................................... 13
3.9.- CURRENT TRANSFORMER (CT) CONNECTION ................................................................................. 13
4.- CAPACITOR BANK START-UP ....................................................................................................................15
4.1.- BEFORE START-UP.................................................................................................................................15
4.2.- START-UP.................................................................................................................................................15
4.3.- CHECKS ONCE THE CAPACITOR BANK HAS BEEN CONNECTED AND THE REGULATOR .............
ADJUSTED .......................................................................................................................................................17
5.- MAINTENANCE..............................................................................................................................................18
5.1.- SAFETY REGULATIONS .........................................................................................................................18
5.2.- MAINTENANCE WITH THE CAPACITOR BANK DISCONNECTED ...................................................... 18
5.2.1. BASIC MAINTENANCE PROTOCOL ................................................................................................ 18
5.2.2. TIGHTENING TORQUE OF THE ELECTRICAL CONNECTIONS .................................................... 19
5.2.3. KEY POINTS FOR INSPECTING CONTACTORS............................................................................. 19
5.2.4. KEY POINTS FOR INSPECTING CAPACITORS...............................................................................20
5.2.5. KEY POINTS FOR INSPECTING THE REGULATOR .......................................................................20
5.2.6. CLEANING THE CABINET ................................................................................................................ 21
5.3.- MAINTENANCE WITH THE CAPACITOR BANK CONNECTED ............................................................ 21
5.3.1. REGULATOR CHECKS...................................................................................................................... 22
5.4.- ENVIRONMENTAL CONDITIONS............................................................................................................. 22
6.- TECHNICAL FEATURES ................................................................................................................................23
7.- STANDARD ELECTRICAL DIAGRAMS .........................................................................................................24
8.- MAINTENANCE AND TECHNICAL SERVICE................................................................................................ 35
9.- GUARANTEE...................................................................................................................................................35
10.- CE CERTIFICATE..........................................................................................................................................36
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REVISION LOG
Table 1: Revision log.
Date Revision Description
02/15 M063B01-03-15A Initial Version
04/16 M063B01-03-16A Modication section:
3.9. - 6. - 7.
11/19 M063B01-03-19A Modication section:
3.2. - 4.2. - 10.
Note: The images of the units are solely for the purpose of illustration and may differ from the
original unit.
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1.- VERIFICATION UPON RECEPTION
1.1.- RECEPTION PROTOCOL
Check the following points when you receive the unit:
a) The unit meets the specications 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 installed regulator manual.
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 proles 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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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 prole 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.
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2.- PRODUCT DESCRIPTION
The purpose of this manual is to assist during the installation, start-up and maintenance of
OPTIM P&P series low voltage (LV) capacitor banks switched by contactors. Carefully read the
manual to achieve the best performance from those units.
3.- INSTALLATION
3.1.- PRELIMINARY RECOMMENDATIONS
In order to use the unit safely, it is critical that individuals who handle it follow the
safety measures set out in the standards of the country where it is being used,
use the personal protective equipment necessary, and pay attention to the vari-
ous warnings indicated in this instruction manual.
Installation or maintenance personnel should read and understand this manual
before operating the unit.
A copy of this manual should always be available to maintenance personnel for
reference purposes
Connecting the unit to the public mains must be carried out in compliance with
the EN-IEC60204-1 standard, regarding the safety of LV electrical installations.
It is recommended that several personnel are present when handling the unit for
installation or maintenance.
If damage or faults are detected during unit operation, or in circumstances that
compromise safety, immediately stop work in that area and disconnect the unit in
order to check it without voltage.
The manufacturer of the unit is not responsible for any damage resulting from failure by the
user or installer to heed the warnings and/or recommendations set out in this manual, nor for
damage resulting from the use of products or accessories that did not come with the unit or that
were made by other manufacturers.
If an anomaly or malfunction is detected in the unit, do not use it to perform any operation.
Modifying, upgrading or rebuilding the unit without written authorisation from the
manufacturer is prohibited.
The installation, operation and maintenance of low voltage (LV) units must only
be carried out by authorised installers. LV regulations (Art. 22) specically dene
the requirements that authorised installers must meet.
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Do not access the active elements of a capacitor bank with static operation that
has been powered and might have voltages present. Wait at least 5 minutes af-
ter the power supply has been disconnected.
Do not touch the terminals or active parts of the unit until you have veried that
voltage is not present. If you have to handle or touch the terminals or other control
panel components, use adequately insulated personal protection equipment and
tools.
After any maintenance and before re-connecting the power supply to the unit,
check that its enclosure is properly closed and that no items or tools were left
inside that could cause a short-circuit.
Do not disconnect the current transformer secondary without short-circuiting it
rst. The operation of a current transformer with an open secondary will cause an
overvoltage that could damage it and electrocute the person handling it.
3.2.- PREPARATION
The CIRCUTOR OPTIM P&P static capacitor banks come ready for easy installation and start-
up.
Remove the packaging of the unit and verify that its electrical features are suitable for connec-
tion to the available mains. To do so, check the features label located inside the cabinet next to
the FP regulator, see Figure 3.
Key data to be checked:
 Mains frequency and voltage, Un / fn.
 Nominal power of the capacitor bank, Qn (kvar) and composition
 Current consumption, In . This current must be considered to select the proper size
of the power supply cable of the unit and ultimately the circuit breakers and protection
elements to be connected in front of it.
 Auxiliary control voltage, Uaux.( See “3.7.- AUXILIARY CONTROL VOLTAGE”)
 Environmental conditions. (See “6.- TECHNICAL FEATURES”)
Figure 3: Features label.
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3.3.- INSTALLATION LOCATION
It is important to maintain a minimum distance around the unit to facilitate cooling.
In self-supporting cabinets, the back and front sides of the cabinet must be kept at least 50 cm
away from walls of other units and other infrastructure to allow for ventilation.
In terms of the side walls, it is recommended that a separation of 10 cm be maintained between
adjacent cabinets.
On wall-mounted cabinets, it is recommended that at least 20 cm of separation be maintained
between the sides of adjacent cabinets.
Make sure the unit can be accessed easily.
The environmental conditions of the location where the unit is installed must not exceed the
limits set forth in the technical features (See “6.- TECHNICAL FEATURES”)
To ensure proper ventilation, the unit must be installed in a vertical position.
In accordance with the LVR, once the unit is installed, it must be protected against direct and in-
direct contacts; therefore, a circuit breaker and earth leakage protection for the capacitor bank
power supply line should be installed.
3.4.-CONNECTION OF THE CAPACITOR BANK TO THE MAINS
Check that the rated voltage of the capacitor bank matches the voltage between
phases of the network to which it is being connected.
Also check the operating circuit voltage (contactors).
( See “3.7.- AUXILIARY CONTROL VOLTAGE”)
For feeding cables into the capacitor bank cabinet, always and only use the cable
entry points available for this purpose.
There is a cable entry point on the bottom (base of the cabinet) in all the models
and also an entry point on the side in some models.
If another part of the cabinet is cut out to be used for cable entry, the CIR-
CUTOR manufacturer's guarantee shall be rendered void.
Do not cut holes in other parts of the cabinet for feeding cables through or for
installing support brackets.
It may produce trimmings that can cause short-circuits.
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3.5.-POWER CIRCUIT
Connect input terminals L1, L2 and L3 (power circuit) to the mains using proper sized cable in
accordance with the LVR, ITC-BT-19.
Generally, the cables of the phases adhere to 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)
In order to determine the size of the phase cables, the nominal current In must be taken into
account, indicated on the unit label, and it should be able to withstand an overload in transients
of 1.5 times In. The neutral cable will be a minimum of 1.5 mm2.
3.6.- EXTERNAL CIRCUIT BREAKER AND PROTECTION ELEMENTS
If the capacitor bank does not have an internal switch or isolation switch, it must be connected
to a line that has an external switch or isolation switch.
The protection elements, isolation switches and/or switches that are added exter-
nally to the capacitor bank must be of a minimum size to withstand a current 1.5
times greater than what is indicated on the label (LVR, ICT-BT-48)
If an earth leakage protection for the capacitor bank is installed, its sensitivity and
trip delay must be adjustable.
When the capacitor bank is connected to the mains, it is recommended that the current
transformer (CT) is placed on the phase going to L1 (black cable).
Outputs S1 and S2 of the CT must be connected to the terminals with the same name.
3.7.- AUXILIARY CONTROL VOLTAGE
Control circuits are dened as those related with regulator output relays and the capacitor's
operating contactors. These circuits are usually powered with an auxiliary voltage of 230 V
~ (the most common case) or other voltages such as 110 V ~ (frequently for 500 V or 690 V
capacitor banks).
There are two possible ways of powering the circuit:
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3.7.1. CAPACITOR BANK WITH AUXILIARY VOLTAGE OBTAINED FROM AN INTERNAL
AUTOTRANSFORMER
Does not require connection of the external neutral. The label indicates Uaux/f … internal
Figure 4: Auxiliary power supply with autotransformer.
3.7.2. CAPACITOR BANK WITH AUXILIARY VOLTAGE OBTAINED BETWEEN
PHASE-NEUTRAL
Requires the connection of the external neutral to terminal N (see Figure 5 and Figure 7 )
The label indicates Uaux/f … (control voltage)
Figure 5: Auxiliary power supply with neutral.
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3.8.- EARTH CABLE CONNECTION
Connect the earth cable to the capacitor bank's earth terminal located on the operating panel
of the unit.
The earth cable cross-section will be selected in accordance with the admissible current limits
established in the LVR (ITC-BT-19 – Internal or receiver installations) for each type of cable and
their location.
3.9.- CURRENT TRANSFORMER (CT) CONNECTION
A current transformer (CT) that is external to the capacitor bank must be
installed to measure the total load current plus that of the capacitor bank
(Figure 6).
The standard transformer must have a nominal output of 5 A at the secondary.
We recommend connecting the CT to phase L1 in the direction of the current ow
from P1 to P2 (see Figure 6) and connecting the secondary (terminals S1, S2) to
the terminals with the same name on the capacitor bank (see Figure 6)
Avoid current ow through the CT primary winding prior to connecting it to termi-
nals S1 S2 of the bank.
If the CT must be installed while the installation is under load, short-circuit S1 and
S2 while they are not connected to the capacitor bank.
The current value of the CT primary winding must be equal to or slightly greater than the size of
the mains switch of the installation. Therefore, the CT must be able to measure the maximum
current expected to be consumed by all the loads being compensated.
Figure 6: Installation of the external current transformer (CT).
The connection point of the CT for a capacitor bank that compensates an entire installation is
after the mains switch of the installation.
To prevent excessive attenuation of the signal, it is recommended that the minimum cross-sec-
tion of the secondary section winding cable (terminals S1, S2) is at least 2.5 mm2.
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Figure 7: Current transformer (CT) and neutral connection terminals (if required).
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.
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4.- CAPACITOR BANK START-UP
4.1.- BEFORE START-UP
The automatic capacitor banks include a power factor regulator.
The operation of said regulator must be known prior to start-up; for this reason, all
the capacitor banks include a specic manual for the regulator used.
Ensure you have this manual available for the start-up process.
In order to adjust the regulator incorporated to the capacitor bank and for opti-
mum start-up, the installation load must be at least 30% or 40% of the nominal
load for which the capacitor bank has been dimensioned. If all the stages are not
included, they can be manually connected to check them all.
During low load periods, the entire capacitor bank should not be connected man-
ually, as in some cases resonance with the power transformer of the installation
could occur.
The capacitors are connected in manual mode, rst allow enough time for the ca-
pacitors to discharge (as indicated in the capacitor bank's features label) before
reconnecting them to the network.
Otherwise, they could start-up out of phase with a voltage of up to 2xUn causing
the destruction of the capacitor.
4.2.- START-UP
Apply the safety regulations listed in section “3.- INSTALLATION” of this manual
before operating the units.
The National Electric Code of the country where the capacitor bank is in-
stalled or operated should be strictly followed.
1.- Ensure that the inner circuit breaker that starts the regulator (Figure 10) is connected.
2.- Connect the power supply to the panel and check that the regulator display illuminates im-
mediately. Otherwise, stop and check the previous step.
3.- Check the regulator's cos φ indication.
If the indication is out of range 0.5 to 1, it may be possible that the current transformer and/or
the power supply to the regulator are not properly connected.
Most of the regulators use only one current transformer. In this case, connect according to
Figure 9 (place the current transformer on phase L1 and take the power supply voltage from
phases L2 and L3).
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Figure 8: Plug&Play Computer Max Regulator. (Photo as an example, it may not coincide with the model used on
your unit).
- + C1 ... C6
-
L1
L2
L3
N
POWER
SUPPLY
0
1 2 3456
400 V ac
A B
P1 P2
S1 S2
C D
Figure 9: Connection of a regulator with only one CT. (If using Computer SMART III or Computer Plus, 3 CT are
used. Check the specic manual. )
Figure 10: Two-pole circuit breaker for the auxiliary power circuit.
4.- Once ensured that the regulator is properly connected, adjust the regulator parameters for
the installation you are attempting to compensate. For this, follow the instructions on the man-
ual of the regulator, included with the capacitor bank.
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4.3.- CHECKS ONCE THE CAPACITOR BANK HAS BEEN CONNECTED AND THE
REGULATOR
1.- After start-up, make sure that the unit is operating correctly. A sign of proper operation is the
display indicating a cos φ close to 1 and the reactive energy meter should stop (if it is electro-
mechanical) or the blinking light of the indicator LED of the kvar.h/pulse ratio should reduce its
rate.
2.- Check that the power supply voltage does not exceed the nominal value +10%
(IEC 60831-1).
3.- Check the current absorbed by each capacitor.
Under normal conditions, it must be close to the nominal value indicated on its dataplate and
never exceed 1.3 times this value constantly.
Continuous consumption over the nominal value may be caused by the presence of harmonics
in the network or an excessively high power supply voltage. Both circumstances are harmful
for capacitors.
4.- In accordance with the IEC 60831-1 Standard, the capacitor is prepared to operate at the
permanent voltage assigned to it and with an overvoltage of up to 10% for 8 out of every 24
hours.
Check the working temperature of the capacitors after they have been operating
for 24 hours.
The housing must be below 40 ºC.
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5.- MAINTENANCE
5.1.- SAFETY REGULATIONS
Take the safety regulations listed in section of this manual into account before
operating the units “3.1.- PRELIMINARY RECOMMENDATIONS”
The National Electric Code of the country where the capacitor bank is installed or
operated should be strictly followed.
5.2.- MAINTENANCE WITH THE CAPACITOR BANK DISCONNECTED
5.2.1. BASIC MAINTENANCE PROTOCOL
Monthly:
 Visually inspect the capacitors.
 Check the protection fuse.
 Control the ambient temperature (average of 35 ºC. In accordance with IEC 60831 ).
 Control the service voltage (especially during moments of low load, it must not exceed
the nominal +10%).
Bi-annually:
 Keep the capacitor terminals clean.
 Verify the state of the contacts of operating elements.
 Check that the capacitor current is not lower than 25% nor greater than 120% of the
nominal value by phase and that there is no phase unbalance greater than 15%.
Annually:
Carry out a dielectric rigidity test by applying 2.5 kV for 1 second between the terminals
of the capacitor and earth.
Check the capacity of the capacitors at the different steps.
One indirect check may be to check that the consumption is manual.
Check the tightness of all terminal connections.
Inspect the fuses.
- Power Circuit: NH fuses. Check continuity and temperature.
- Power Circuit: Check the continuity and temperature of the three-pole or four-pole
circuit breaker.
- Control Circuit: Check the continuity and temperature of the two-pole circuit breaker.
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5.2.2. TIGHTENING TORQUE OF THE ELECTRICAL CONNECTIONS
The connections must be tight.
The tightening torques for the fuse bases, circuit breakers and the contactors are indicated in
Table 3 ,Table 4 and Table 4.
Table 2:Tightening torques of the cables to the fuse bases.
Fuse base Torque (Nm)
NH-00 15.2
Table 3:Torques of power cables to two-pole and three-pole circuit breakers.
Circuit breaker Torque (Nm)
In ≤ 3 x 63 A 2
In ≤ 2 x 6 A 2
Table 4:Torques of cables to connector terminals
Model Auxiliary (Nm) Power (Nm)
CMC-12 1.3 1.6
CMC-18 1.3 2.2
CMC-32 1.3 2.9
CMC-40 1.3 2.9
CMC-50 1.3 4.5
CMC-65 1.3 4.5
CMC-75 1.3 4.5
CMC-85 1.3 5.1
CMC-150 1.3 9
5.2.3. 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 4.
 The terminals must be clean.
If the capacitor bank includes RD discharge resistors, check they are in good condition (that
they are not open or show signs of burning). (Figure 11)
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RD K1
Figure 11: Connection of the discharge resistors.
Cleaning the contactors: In dirty environments (dust, sawdust, rust particles, etc.) vacuum
the contactor periodically.
There is no estimated time frame for cleaning, it depends on the amount of dirt that is inside the
capacitor bank.
5.2.4. KEY POINTS FOR INSPECTING CAPACITORS
Inspect the cables and terminals. They should not be overheated or blackened.
 The terminals must be clean.
 The slow discharge resistors must be in good condition. They must not be open or show
signs of burning.
 Check the tightness of the capacitor terminals, as shown in Table 5.
Table 5:Torques of the cables to the capacitor terminals.
Cylindrical capacitor Power terminal torque (Nm)
CLZ FP 2
Prismatic capacitor Torque
Power terminal (Nm)
Torque
Earth terminal (Nm)
CV 4.49 6.2
CSB 21 6.2
5.2.5. 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 should be clean and should not be hardened or over-
heated.
 Inspect the connections and the insertion of removable power strips:
- The power strips must be well fastened on removable regulators.
- Check that the terminals are tightened properly. The recommended torque is 0.6 Nm.
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