Datakom DKG-108 User manual

DKG-108 User Manual V-1.0(10.08.2011)
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DKG-108 POWER
FACTOR CONTROLLER
8 BANKS, HARMONIC
DISTORTION DISPLAY
Small size
Cost effective and high performance
True RMS AC measurements,high accuracy
4096 samples/sec measurement rate
Easy commissioningthrough automatic setup
Automatic CT reverse polarity correction
Automatic detection of faulty banks
Electronic/mechanical power counter selection
Per-phase regulation capability
Supports both single-phase and triphasebanks
Connection/disconnection of all banks at once
Adjustable delay timers
Dynamic update of capacitor ratings
Equal aging of contactors
Per phase and total V-A-kW-kVAr-cosdisplay
THD display of all V-I parameters (31 harmonic)
Generator phase input
VT ratio for MV applications
kW and kVAr tick output possibility
Front panel programmable
Low panel depth, easy installation
Wide temperature range
Sealed front panel (IP54)
Plug-in connection system for easy replacement
DFC-0108 is a high technology controller
allowing the power factor of the installation to
be stabilized to the requested value by
switching capacitor banks through
contactors. The unit allows also the
visualization of various AC parameters like a
network analyzer.
The unit makes harmonic analysis up to the
31th component. The THD values of all
voltages and currents are available.
Stepping algorithms are selectable between
various types. Thanks to the automatic setup
function, the commissioning and
programming are made easy.
The unit fits into a standard 96x96mm panel
opening.
DESCRIPTION
FEATURES

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Electrical equipment should be installed only by
qualified specialist. No responsibility is assured by the
manufacturer or any of its subsidiaries for any
consequences resulting from the non-compliance to
these instructions.
Check the unit for cracks and damages due to
transportation. Do not install damaged equipment.
Do not open the unit. There is no serviceable parts
inside.
Fuses must be connected to the phase voltage
inputs, in close proximity of the unit.
Fuses must be of fast type (FF) with a maximum
rating of 6A.
Disconnect all power before working on equipment.
When the unit is connected to the network do not
touch terminals.
Short circuit terminals of unused current
transformers.
Any electrical parameter applied to the device must
be in the range specified in the user manual.
Do not try to clean the device with solvent or the like.
Only clean with a dump cloth.
Verify correct terminal connections before applying
power.
Only for front panel mounting.
SAFETY NOTICE
Failure to follow below instructions will result in
death or serious injury

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Section
1. INSTALLATION
1.1. FRONT / REAR PANELS
1.2. MECHANICAL INSTALLATION
1.3. ELECTRICAL INSTALLATION
1.4. CONNECTION DIAGRAM
2. AUTOMATIC SETUP
3. PUSHBUTTON FUNCTIONS
4. DISPLAYS
4.1. DISPLAYS IN AUTO AND MANUAL MODES
4.2. TEST MODE, MANUAL STEP CONTROL
5. STEPPING PROGRAMS
5.1. COMPARAISON OF LEGACY AND OPTIMAL PROGRAMS
6. ALARMS
7. PROGRAMMING
7.1. ENTERING EXITING PROGRAMMING
7.2. LAMP TEST
7.3. MODIFYING PROGRAM PARAMETERS
7.4. PROGRAM PARAMETER LIST
8. TECHNICAL SPECIFICATIONS
TABLE OF CONTENTS
Current Transformers must be used for current
measurement.
No direct connection allowed.

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Before installation:
Read the user manual carefully, determine the correct connection diagram.
Remove all connectors and mounting brackets from the unit, then pass the unit
through the mounting opening.
Put mounting brackets and tighten. Do not tighten too much, this can brake the
enclosure.Self mating brackets do not require tightening.
Make electrical connections with plugs removed from sockets, then place plugs to
their sockets.
Make sure that relay outputs are not overloaded. If necessary use extra contactors.
Below conditions may damage the device:
Incorrect connections.
Incorrect power supply voltage.
Voltage at measuring terminals beyond specified range.
Current at measuring terminals beyond specified range.
Overload or short circuit at relay outputs
Below conditions may cause abnormal operation:
Power supply voltage below minimum acceptable level.
Power supply frequency out of specified limits
Current transformers not matching related phases.
Current transformer polarity incorrect. (if automatic correction is not applied).
Inadequate on-delay setting
Inadequate off-delay setting.
Current Transformers must be used for current
measurement.
No direct connection allowed.
1. INSTALLATION

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Panel Cutout Required Panel Depth
1.2 MECHANICAL INSTALLATION
1.1 FRONT / REAR PANELS

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Although the unit is protected against electromagnetic disturbance, excessive disturbance
can affect the operation, measurement precision and data communication quality.
ALWAYS remove plug connectors when inserting wires with a screwdriver.
Fuses must be connected to phase voltage inputs, in close proximity of the unit.
Fuses must be of fast type (FF) with a maximum rating of 6A.
Use cables of appropriate temperature range.
Use adequate cable section, at least 0.75mm2 (AWG18).
For current transformer inputs, use at least 1.5mm2section (AWG15) cable.
The current transformer cable length should not exceed 1.5 meters. If longer
cable is used, increase the cable section proportionally.
Follow national rules for electrical installation.
Current transformers must have 5A output.
Make sure that relay outputs are not overloaded.
If necessary use extra contactors.
Current Transformers must be used for current
measurement.
No direct connection allowed.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
1.3 ELECTRICAL INSTALLATION

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1.4 CONNECTION DIAGRAM

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In automatic setup mode, the unit :
-automatically detects and corrects reverse connected current transformers.
-automatically measures and memorizes capacitor bank ratings.
It is preferable that there should be no other load on the
capacitor panel. However with constant or slow
changing loads the unit is able to perform auto setup.
If there are fast changing loads, the unit may be unable
to correct CT polarity errors or may read incorrect bank
capacitor ratings. In such cases, auto setup should be
repeated and capacitor ratings should be
checked/corrected through PROGRAMMING menu.
For a successful auto setup, current transformers must
be connected to correct CT inputs.
The connection polarity is not important.
Otherwise the unit will give ALARM_03 and will not
perform automatic setup.
For a successful auto setup, STEP_1 capacitors must be
3 phased.
Otherwise the unit cannot detect connection errors,
gives ALARM_02 and will not perform automatic
setup.
For a successful auto setup, voltage connections must
be 3 phased.
Otherwise the unit will give ALARM_01 and will not
perform automatic setup.
2. AUTOMATIC SETUP

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STEP BY STEP AUTO SETUP
PUSHBUTTON
OPERATION
DISPLAY
In order to enter the auto setup mode, power-
up the unit with MENU button pressed and
hold the button pressed for 10 seconds. The
display will show ctrFand the unit will ask the
current transformer primary rating.
Press again the MENU button. The display will
show the CT primary rating.
Adjust required CT primary rating with arrow
buttons.
For fast increase/decrease please hold the
button pressed.
Press again the MENU button. The display will
show MtErand the unit will ask the power
meter type.
Press again the MENU button. The display will
show the power meter type.
Adjust required power meter type with arrow
buttons.
0 analog power meter
1 digital power meter
Press again the MENU button. The display will
show LErnand the unit will ask to enter the
quick commissioning mode.
Press again the MENU button. The display will
show 0.
Set the parameter to 1 with arrow buttons.
Press again the MENU button. The display will
show the total kVArvalue.
The unit will check CT connections, correct if
necessary, then activate all banks (one by one)
in order to determine capacitor ratings.
When auto setup is finished successfully the
unit will revert to normal operation.

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Access to programming and measurement displays is achieved through 3 pushbuttons on
the front panel.
PUSHBUTTON
FUNCTION
In AUTO mode, acknowledges the displayed alarm.
If the same alarm occurs again, it will not appear on the display.
HELD PRESSED DURING 5 SEC:
Resets all alarms and the alarm led.
Any new coming alarm will appear on the display.
HELD PRESSED DURING 10 SEC AT POWER-ON:
The unit enters automatic setup mode.
Switch to upper display or previous parameter
or increase related value (programming mode)
Switch to lower display or next parameter
or decrease related value (programming mode)
HELD PRESSED DURING 5 SEC:
Switches between AUTO and MANUAL modes.In MANUAL mode
the stepping is disabled. From the MANUAL mode TEST mode
can be selected in order to test each step manually.
HELD PRESSED DURING 5 SEC IN MANUAL MODE:
Switches between MANUAL and TEST modes. In TEST mode, all
steps may be turned on and off manually. For more detailed
information please check chapter 4.2.
HELD PRESSED TOGETHER DURING 5 SEC:
Enters or exits programming mode.
NO PUSHBUTTON PRESSED DURING 15 MINUTES:
Returns to the programmed main display screen.
3. PUSHBUTTON FUNCTIONS

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Display parameter leds at right describe
the measurement on the display.
Phase indicator leds at left describe the
phase related to the display:
2 phase leds are on for Ph-Ph values.
All 3 leds are on for totalcosø, kW,
kVAr.
All leds are off for frequency.
For THD values, THD led,V or A led
and related phase ledsare on
together.
Alarm led turns on if any fault condition
occurs. If the alarm list is displayed, this
led flashes.
Step leds turn on if the related capacitor
bank is activated. If the capacitor bank is
faulty, the led flashes once every 5
seconds. When the step is about to
become active or inactive the led flashes
differently.
C- led shows insufficient regulation.
C+ led shown excessive regulation.
OK led indicates a balanced system.
Current display: If the current
transformer (CT) ratio is lower than
200/5A, currents are displayed with 0.1A
precision. Otherwise they are displayed
with 1A precision.
Voltage display:If the voltage
transformer (VT) ratio is lower than
50.0/1, voltages are displayed in volts.
Otherwise they are displayed with in kV
with 0.01kV precision.
kW, kVA, kVArdisplay: If the
VTxCTproduct is lower than 1000, then
values are shown with 0.1k precision.
Otherwise they are shown with 1k
precision.
Capacitor bank rating display: The
display shows alternatively CAPxand the
rating in kVAr. If the capacitor is single
phase, the related phase led turns on.
Otherwise all phase leds are on.
4. DISPLAYS

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In AUTOmode, the AUTO ledis on. If the generator input is active or if there is any alarm
preventing automatic operation, then the AUTO led is flashing. In MANUAL mode, the
AUTO led is off.
As default the unit displays the total cosø.
With pushbuttons various measured values are scrolled.
If no button is pressed during 15 minutes, the display reverts back to total cosø display
InTESTmode only the total kVAr value is displayed.
WhenTEST mode is selected then the step-1 indicator led will flash. Pressing the
pushbutton will activate this step.Pressing the pushbutton will deactivate this step.
Pressing the MENUpushbutton will select the next step and the related step led will
flash.Using pushbuttons the step may be activated or deactivated. Using the
MENUpushbutton all steps may be scrolled manually.
In TEST mode, if no button is pressed during 1 minute
the unit will automatically return back to
MANUAL mode.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
Holding the pushbutton pressed for 5 seconds
switches betweenTEST and MANUAL modes.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
4.2 TEST MODE, MANUAL STEP CONTROL
If AUTO mode is selected with a step output activated
in MANUAL mode, then the AUTO position starts
with this step activated. The step then may be
deactivated following automatic stepping program.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
Holding the pushbutton pressed for 5 seconds
switches betweenAUTO and MANUAL modes.
Do not install the unit close to high electromagnetic
noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.
4.1 DISPLAYS IN AUTO AND MANUAL MODES

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The unit is able to apply various stepping programs.
The stepping program is selected through “ProG” parameter.
ProG
BANK CONFIGURATION and STEPPING
1
1.1.1.1.1.1.1.1: standardconfiguration, legacy program (a single step is
activated or deactivated at each period).
2
1.2.4.4.4.4.4.4 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
3
1.2.3.3.3.3.3.3 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
4
1.1.2.3.3.3.3.3 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
5
1.1.2.4.4.4.4.4 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
6
1.2.2.4.4.4.4.4 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
7
1.2.3.4.4.4.4.4 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
8
1.2.4.8.8.8.8.8 : standard configuration, legacy program (a single step is
activated or deactivated at each period).
9
Free configuration(programmed or auto-configured),legacy program (a single
step is activated or deactivated at each period).
10
Free configuration (programmed or auto-configured), optimal program (all
necessary steps are activated/deactivated at once).
It is advised to use the OPTIMAL program (10).
Fastest and the most precise regulation is achieved with
this program.
5. STEPPING PROGRAMS

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Step configuration: 1.2.3.4.4.4.4.4
Step type: 3 Phase
Basic step rating: 1kVAr
Target CosØ= 1.000
Inductive reactive load: 20kVar
LEGACY PROGRAM
STEPS
Request
1
2
3
4
5
6
7
8
kVAr
1
↑
1
1
2
↑
1
2
3
3
↑
1
2
3
6
4
↑
1
2
3
4
10
5
↑
1
2
3
4
4
14
6
↑
1
2
3
4
4
4
18
7
↑
1
2
3
4
4
4
4
22
8
↓
2
3
4
4
4
4
21
9
↓
3
4
4
4
4
19
10
↑
1
3
4
4
4
4
20
The unit has reached the target cosø in
10 periods, by operating 1 step at each
period.
During this time the cosøhad been
different from the target and the
reactive power counter has recorded
reactive power.
The unit has made 10
contactoroperations.
The unit has reached the target cosø
with 6 banks in service.
OPTIMAL PROGRAM
STEPS
Request
1
2
3
4
5
6
7
8
kVAR
1
↑
4
4
4
4
4
20
The unit has reached the target cosø in
1 period. As the target cosøis reached
faster, the reactive power counter has
recorded less power.
The unit has made 5
contactoroperations. Thus longer
contactor life is achieved.
The unit has reached the target cosø
with 5 banks in service. Thus capacitor
aging is kept at minimum.
5.1 COMPARAISON OF LEGACY AND OPTIMAL PROGRAMS

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The unit constantly monitors abnormal situations occurring in the system.
Every monitored parameter has programmable alarm limits and delay timer. Alarms may be
of latching or unlatching types. The automatic operation may be programmed to be aborted
or continued. For more details please consider the PROGRAMMING section of this
manual.
When any alarm occurs the ALARM led turns on and the alarm code appears on the
display. Following programming, the auxiliary relay output may be activated. The automatic
operation may be aborted or continued, based on programming.
AL-01: NETWORK NOT 3 PHASED
Occurs if automatic setup is attempted
with non 3 phased network.
AL-02:FIRST BANK NOT 3 PHASED
Occurs if automatic setup is attempted
with non 3 phased capacitors at the fist
bank.
AL-03:FAULTY CT ORDER
Occurs if automatic setup is attempted
with CTs not connected to related phases.
AL-04:HIGH VOLTAGE
Occurs if at least 1 phase voltage is
above u-Hi limit during u-dUperiod.
AL-05: LOW VOLTAGE
Occurs if at least 1 phase voltage is below
u-Lo limit during u-dU period.
AL-06: HIGH FREQUENCY
Occurs if the frequency is above F-Hi limit
during F-dU period.
AL-07: LOW FREQUENCY
Occurs if the frequency is belowF-Lo limit
during F-dU period.
AL-08:EXCESS kW
Occurs if the total active power is above
A-Hi limit during A-dU period.
AL-09: LOW kW
Occurs if the total active power is below
A-Lo limit during A-dU period.
AL-10:EXCESS INDUCTIVE kVAr
Occurs if the total reactive power is
inductive and above rInd limit during r-dU
period.
AL-11: EXCESS CAPACITIVE kVAr
Occurs if the total reactive power is
capacitive and above rCAP limit during r-
dU period. (Welded contactors)
AL-12:INDUCTIVE CosØ
Occurs if the total cosø is inductive and
below cInd limit during C-dU period.
AL-13:CAPACITIVE CosØ
Occurs if the total cosø is capacitive and
below cCAP limit during C-dU period.
(Welded contactors)
AL-14: EXCESS CURRENT
Occurs if at least 1 phase current is above
CrHi limit during CrdU period.
AL-15:EXCESS THD(V)
Occurs if at least 1 phase voltage THD is
above thdu limit during uhdU period.
AL-16:EXCESS THD(I)
Occurs if at least 1 phase current THD is
above thdi limit during chdU period.
rAt1...rAt8 CAPACITORVALUE LOSS
Occurs when the measured step rating is
below rtio % compared to its nominal
value. In order to enable this alarm dYnC
parameter must be 1.
AL-18:PHASE ORDER FAULT
Occurs if the voltage phase order is faulty.
Err1...Err8: CAPACITOR DEFECTIVE
Occurs when the measured capacitor
rating is below 20% of its nominal value.
6. ALARMS

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In order to provide the maximum flexibility to the user, the unit features many
programmable parameters.
The parameters are recorded in a non-volatile memory and are not affected by power
supply failures.
The entry to the programming menu is password protected. The factory set password
value is “1” and can be modified with the program parameter “PASS”.
Additionally the password “3282” is always valid and cannot be modified.
PUSHBUTTON
OPERATION
DISPLAY
In order to enter PROGRAM mode please
hold pressed arrow buttons for 5 seconds.
The display will showUser.
When USEr appears please press MENU
pushbutton. The password entry display will
come.
Use the arrow buttons to enter the password.
The factory set password value is “1”
In order to fast increase/decrease please
hold arrow pushbuttons pressed.
Press MENU pushbutton. The first parameter
name(LErn) will come to display.
PUSHBUTTON
OPERATION
DISPLAY
In order to leave the program mode please
hold pressed both arrow buttons during 5
seconds.
If no pushbutton is pressed during 3 minutes, the unit
will automatically terminate the PROGRAM mode.
7.1 ENTERING AND EXITING PROGRAMMING
7. PROGRAMMING

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PUSHBUTTON
OPERATION
DISPLAY
When parameter names are displayed, select
required parameter with arrow buttons.
When the required parameter is found press
MENU pushbutton. The parameter value will
be displayed.
Adjust required value with arrow buttons.
In order to fast increase/decrease please
hold arrow pushbuttons pressed.
Press MENU pushbutton. The parameter
value will be recorded and the parameter
name will be displayed again.
7.3 MODIFYING PROGRAM PARAMETERS
If no pushbutton is pressed for 3 minutes the unit will
automatically terminate the PROGRAM mode
without lamp test.
The unit makes a LAMP TEST when exiting the
PROGRAM mode. During lamp test all lights turn on.
By pressing the MENU pushbutton, normal
operation is resumed.
7.2 LAMP TEST

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DISPLAY
DESCRIPTION
MIN
STD
MAX
PASSWORD ENTRY
The user password is required. The
password is determined by the program
parameter “PASS”. The factory set value
is “1”.
The password “3282” is always valid.
0
1
9999
AUTOMATIC SETUP
When this parameter is set to 1, and if
the unit is in MANUAL mode, steps are
activated consecutively and bank ratings
are measured.
0
0
1
RESETTING DYNAMIC STEP VALUES
AND FAULT COUNTERS
When this parameter is set to 1, fault
counters and dynamic bank values are
reset.
0
0
1
RESETTING STEP COUNTERS
When this parameter is set to 1, step
activation and operation counters are
reset.
0
0
1
RETURN TO FACTORY SETTINGS
When this parameter is set to 1, all
program parameters return back to
factory set values.
0
0
1
TARGETcosø
This is the target cosøvalue that the unit
is trying to reach in AUTO mode. The
value can be adjusted between 0.800
capacitive and 0.800 inductive.
Capacitive values are shown in c.999
format. Inductive values are shown in
0.999 format.
0.800
cap.
0.999
ind.
0.800
ind.
ADJUSTING THE NUMBER OF STEPS
The number of used steps can be
adjusted between 1 and 8. Unused steps
are not taken into account in the
stepping program.
1
8
8
7.4 PROGRAM PARAMETER LIST

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DISPLAY
DESCRIPTION
MIN
STD
MAX
STEPPING PROGRAM SELECTION
This parameter selects
betweenLEGACY and OPTIMAL
stepping programs.
The unit is advised to be operated under
OPTIMAL program.
Program details are emphasized in
chapter 5.
1
10
10
STEP TURN-ON DELAY
When a new capacitor combination is
required, the unit continues
measurements during this timer and the
new combination found at the end of this
timer is directed to step outputs.
1 sec
20 sec
2000
sec
STEP TURN-OFF DELAY
When a new capacitor combination is
set to step outputs, stepping is disabled
during this period.
1 sec
30 sec
2000
sec
DISCHARGE TIMER
Common discharge timer for all steps. A
deactivated bank cannot be reactivated
before this timer has expired.
3 sec
60 sec
2000
sec
CAPACITOR TYPE (CON1...CON8)
Selects capacitor connection type.
If “Prog” parameter is selected between
1and 8, these parameters have no
effect and all banks are supposed to be
3 phased.
0 3 phase capacitor
1 single phase capacitor at phase L1
2 single phase capacitor at phase L2
3 single phase capacitor at phase L3
0
0
3

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DISPLAY
DESCRIPTION
MIN
STD
MAX
CAPACITOR RATING (CAP1...CAP8)
This is thecapacitor bank rating,
adjusted between 0.1 and 999.9 kVAr.
If the parameter“Prog” is set to a value
between 1and 8, then only CAP1
parameter is used. Other CAPx
parameters are don’t care.
0.0
kVAr
1.0
kVAR
999.9
kVAr
CURRENT TRANSFORMER RATIO
The CT ratio is the primary rating of both
phase CTs, adjusted in 5A steps.
The CT secondary rating must be 5A.
5 Amp
500
Amp
5000
Amp
VOLTAGE TRANSFORMER RATIO
The voltage transformer ratio is adjusted
between 0.1 and 200.0 in 0.1 steps.
0.1
1.0
200.0
SELECTION OF POWER METER TYPE
For the correct operation of the
controller, this parameter must be set
properly.
0 analog power meter (the sum of all
phases are regulated)
1 digital power meter (each phase is
individually regulated)
0
1
1
DYNAMIC MEASUREMENT OF
CAPACITOR kVArRATINGS
When this parameter is set to 1,
capacitor kVAr ratings are continuously
measured and modified in small
amounts.
0
0
1
DEFAULT DISPLAY SCREEN
If no pushbutton is pressed during 15
minutes, the display switches
automatically to this selection. The
factory set value is the total cosø
display.
0 L1 voltage
1 L2 voltage
2 L3 voltage
3 Frequency display
The order is the same as the
measurements display.
0
14
32