frako RM 9606 User manual

1
Operating Instructions
Reactive Power Control Relay RM 9606

2
.
Ind
Cap
Made in Germany
Fig. 1: View of Front Panel
Digital display
LED´s for
inductive or
capacitive mode
LED´s for
stages switched on
LED for alarm
LED for
power feedback
LED for
manual mode
or set-mode
+
_
RM 9606
Blindleistungsregler / Reactive Power Control Relay
cos phi / Power Factor
Harmonische / Harmonics
Ampere / Ampere
1 2 3 4 5 6
Rückspeisung / Regeneration
manuell / Manual
Alarm / Alarm I
P
+ -
I
Q
Set
Man
Harm
I
S
LED for power
factor display and
alarm marker
LED for
harmonic display
and alarm marker
LED for
IQ , IP and ISand
alarm marker
Selection for IQ
display
Selection for IP display
display
(Selection for IS
display
press IQand IP simul.)
Buttons to switch
capacitor stages off
and on manually (also
to alter preset values
during programming
operation)
Selection button for
automatic or manual
operation
Button to confirm
programme
Selection for harmonic
display
• IP= active current
• IQ= reactive current
• IS= apparent current
Figure 1: View of Front Panal

3
View from below
S1 S2
max 5A
N/L
230V~
400V~
a b
250V~ /3A
Alarm
1 2 3 4 5 6 P
Relay 380V~ /5A
50/60Hz
Figure 2: View from below

4
Contents Page Page
1. Summary of Instructions............7
2. Functions....................................8
2.1 Automatic Identification of
Voltage and Current Source..........8
2.2 Automatic Identification of the
Connected Capacitor Stages.........8
2.3 Automatic Setting of
Switching Time Delay ...................9
2.4 Power Feedback...........................9
3. Installation and Connection...... 10
3.1 Installation..................................10
3.2 Voltage Connection.....................10
3.3 Current Transformer Connection.11
3.4 Alarm Contacts...........................11
3.5 Control Contacts.........................12
3.6 Additional Instructions.................12
4. Commissioning.........................13
4.1 First Commissioning...................13
4.2 Renewed Commissioning............13
5. Programming (Set)...................14
5.1 Setting of Target Power Factor....19
5.2 Parallel Shift (PS).......................20
5.3 Limitation (L) ..............................20
5.4 Switching Time Delay .................22
5.5 Automatic Stage Current (c/k)
Identification "ON/OFF"...............22
5.6 Response Current (c/k) ..............23
5.7 Switching Sequence...................25
5.8 Number of Contactors used.........25
5.9 Specifying fixed Stages ...............25
5.10 ON/OFF Connection Identification26
5.11 Connection Mode........................26
5.12 Setting Capacitor Discharge Time26
5.13 Setting Cyclic/
Non-Cyclic Switching Rotation.....26
5.14 Setting Threshold for
Number of Switchings Alarm .......26
5.15 Reseting Switching Counter.........27
5.16 Current Transformer (CT) Ratio...27
5.17 Voltage Transformer Ratio...........27
5.18 Setting 5th Harmonic Threshold....27
5.19 Setting 7th Harmonic Threshold....27
5.20 Setting 11th Harmonic Threshold..28
5.21 Setting 13th Harmonic Threshold..28
5.22 Harmonic Over-Current
Alarm Signal................................28
5.23 Suppressing the
Power Factor Alarm.....................28
5.24 Total kvar Display........................28
6. Operation...................................29
6.1 Modes of Display.........................29
6.2 Manual Operation........................30
6.3 Alarms........................................31
7. Technical Data...........................33
8. Trouble-Shooting ......................35

5
Safety and Warning Instructions!!
!!! Important, read before commissioning !!!
• The user must make sure that every person handling this unit
must know these operating instructions and handle the unit
accordingly.
• These operating instructions must be read thoroughly before
the unit is installed and commissioned.
• Proceed only according to these operating instructions.
• Only trained personnel should install and commission this
unit. Specific rules and regulations must be observed.
• The unit is under power and must not be opened.
• If the unit is visibly damaged it must not be installed, con-
nected and commissioned.
• Disconnect the unit immediately if it does not operate after
commissioning.
• Do observe all laws and regulations concerning this product.
Additionally all safety and commissioning instructions of the
Reactive Power Control System are to be observed.

6

7
1. Summary of Instructions
On delivery, the control relay is set to pre-
programmed standard values.
(see Table 1, pages 15 to 17)
The Reactive Power Control Relay RM
9606 is self-regulating (i.e. it detects and
adjusts to the voltage phase connection,
frequency and the response curent (c/k
ratio) automatically).
Before a reactive power control system
can be put into operation, the target power
factor has to be programmed.
How to programme the Control Relay:
a) The control relay should be connected
as shown in (see page 11).
b) ) Apply voltage to the control relay: "---"
appears on the digital display. The con-
trol relay now identifies the location of
the current and voltage source. This
process takes at least 2 minutes and a
maximum of 15 minutes. The power
factor is displayed. (If this is not the
case, see section 8. page 35).
c) Press the "Set" button for 8 seconds.
"-01-" will appear on the digital display
and the "manual" LED flashes.
d) By repressing the "Set" button the tar-
get power factor is displayed. If neces-
sary, reprogramme to the nearest
higher or lower value by pressing either
the "+" or "-" button until the required
target power factor is displayed.
If no numbers appear on the display
then the control relay must be briefly
disconnected from the voltage
source and the "Set" button has to
be pressed again according to c).
e) To confirm the value press the "Set"
button again. "-02-" will appear on the
display.
f) Now press the "-" button twice until
"END" appears on the display. Store
this value by pressing the "Set" button.
The target power factor is now stored
permanently.
To display the correct values for power
and current, enter the current and voltage
transformer ratios
(see sections 5.16 and 5.17).
To prevent unintentional reprogramming,
the set mode can only be activated within
the first 5 minutes after the operating volt-
age has been applied. If the set mode has
been activated within the first 5 minutes,
you have one hour to complete the pro-
gramming. In order to obtain the set mode
again after this period of time the control
relay must be briefly disconnected from
the voltage source.
On pages 15 - 17 all other preprogrammed
standard values and their programme
ranges are listed. The function of the pre-
programmed standard values is described
under section 5.

8
2. Functions
The reactive power and active power por-
tions of the power source are continuously
calculated in the control relay from the
measured voltage and the signals of the
current transformer. If the reactive power
portion exceeds certain threshold values,
which the control relay has measured at
the time of auto-adaption or are set as per
section 5, a switching action will take
place at the switching outputs.
In the case of inductive reactive current
(inductive reactive power) one or more
control contacts of the reactive power con-
trol relay are closed after the prepro-
grammed time delay.
This causes the RM 9606 to switch ca-
pacitor stages onto the power source sup-
ply, as and when required, in order to
achieve the programmed target power
factor. If the inductive reactive current por-
tion of the load is reduced, the excess of
reactive current causes the capacitor
stages to be switched off line.
The Control Relay RM 9606 allows a
variety of possible settings to meet the
conditions on site. The relay's cyclic op-
erations prolong the life of all connected
devices by averaging the length of time
the capacitor stages are switched on. An
effective supervision of the reactive power
control system (capacitor bank) is secured
by the power factor display.
2.1 Automatic Identification of
Voltage and Current Source
When voltage is initially applied to the con-
trol relay, it determines the location of the
current and voltage sources (automatic
phase rotation), i.e. it identifies in which
phase and at which phase angle the cur-
rent path and the voltage path are con-
nected. Should the control relay fail to
identify the current and voltage source due
to power instabilities, repeat the procedure
when the power has stabilized. It is also
possible to programme the phasing
manually (see sections 5.10 and 5.11).
Resetting of the control relay and re-
identification of voltage and current
sources is initiated by pressing but-
tons "+" and "Set" simultaneously for
at least 8 seconds.
2.2 Automatic Identification of the
Connected Capacitor Stages
Having determined the voltage and current
source identification, the RM 9606 auto-
matically calculates the c/k identification.
During the identification process all the
control contacts of the relay are individu-
ally switched on and off again. The stage
currents ascertained are then stored.
These values determine the stage se-
quence. In this way it can also be deter-
mined which switching outputs are in use.

9
The processes of automatic identification
of voltage and current source and/or the
automatic identification of capacitor stages
are only carried out when switching on or
pressing the combination of buttons "+",
"-" and "Set" for min. 8 seconds.
(see section 2.1)
Precondition: The automatic identification
mode or the automatic identification of
connected capacitor stages mode are
switched to "ON".
The RM 9606 checks stored stage cur-
rents at specific time intervals during nor-
mal operation. If it recognises that a
capacitor stage has failed, this stage
(stage without capacitance) will be ignored
in future normal operations.
All failed stages are switched on from time
to time in order to re-check their capaci-
tance. If a capacitor stage is added later
on, or defective fuses are exchanged, the
RM 9606 itself identifies this after some
time and the stage is then reintegrated into
the normal operation. However, we
recommend that if capacitor stages are
added at a later date, the set-up procedure
be repeated (see section 2.1).
Note:
In case of low voltage networks being fed
by several transformers switched in
parallel, the capacitor current is distributed
to all the transformers. If measurements
are not carried out via a summation trans-
former, the current change,
measured by the control relay, is too low
when switching on the capacitor stages,
which can lead to errors during the auto-
matic stage identification process. In such
situations we recommend that the stage
identification be switched off and the rele-
vant values be programmed manually.
(see sections 5.5 to 5.8)
2.3 Automatic Setting of Switching
Time Delay
In order to keep the wear of the capaci-
tor's contactors down to a minimum the
response time of the control relay is
lengthened or shortened automatically
according to the frequency of the change
of the load.
2.4 Power Feedback
The RM 9606 is equipped with a four
quadrant control. This means that even
when active power is fed back into the
mains, the control relay ensures compen-
sation for the reactive power which has
been drawn from the mains. In this case
the LED "Regeneration" lights up.

10
3. Installation and Connection
The Reactive Power Control RM 9606
automatically determines the location of
the current and voltage sources (auto-
matic phase rotation). It may be connected
either to two phases (phase / phase) or to
one phase and neutral (phase/neutral).
The current transformer can be installed in
any phase. It has to be passed by both
capacitor and consumer current.
IMPORTANT NOTICE:
During installation and service work
the control relay must be kept free of
voltage.
3.1 Installation
Individually supplied control relays are
provided with insulated fixing screws.
These can be used to install the control
relay into switchgear cabinets of cubicles
of protective class II. Furthermore a seal-
ing ring is supplied, which must be used
when installing the control relay in switch-
gear cabinets and cubicles of protection
class IP 54.
The pre-mounted terminal connections
allow a quick and easy installation. The
control relay is electrically connected
through a multiple connecting terminal
supplied with the relay.
3.2 Voltage Connection
The control relay should preferably be
connected to the three-phase system as
shown in (page 11). To keep the function
"Zero Voltage Alarm" operational the sup-
ply voltage of the control relay should be
connected in the same phase as the con-
tactor voltage.
Supply voltage of 230 V should be con-
nected between the terminals "N/L" and
"230V". Supply voltage of 400V should be
connected at the terminals "N/L" and
"400V".
IMPORTANT NOTICE:
The control relay is designed for a
mains voltage of 230 VAC or 400 VAC
(phase/neutral or phase/phase).
For voltages greater or equal to 400 V,
a control transformer for the supply of
the controller must be used.
It is not allowed to use both connecting
terminals "230V" and "400V" simulta-
neously.
The connection of the supply voltage
must be fused externally
with max 4A.

11
Figure 3: Circuit Diagram
3.3 Current Transformer Connection
The outputs S1 and S2 of the current
transformer are connected to the terminals
S1 and S2 of the control relay. In order to
keep the load on the current transformer
as low as possible the supply lines should
have a cross-section area of 2.5 mm².
ATTENTION:
The rated current in the current trans-
former path should not exceed 5 Amps.
Notice:
After connection the short-circuiting bridge
might have to be removed from the cur-
rent transformer.
3.4 Alarm Contacts
A potenial-free alarm signal contact is ac-
cessible on the terminals "a" and "b". The
contact closes when either there is no
mains voltage applied to the control relay
or when an alarm is signalled.(section 6.3)

12
When there is an alarm signal, the LED
"alarm" lights up and the relevant LED
begins to flash on the control relay.
IMPORTANT NOTICE:
It must not be possible to touch the
applied voltage at the alarm contact. If
this cannot be achieved the voltage
must be earthed, even if it is only small
protective voltage.
The maximum load for the alarm
contact is 250 VAC and 3 Amps.
3.5 Control Contacts
The control voltage of the contactors
should be connected to the terminals "PI"
and "PII". These circuits are potential free.
IMPORTANT NOTICE:
In order not to overload the control
contacts the sum of the holding cur-
rents of all contactor coils connected
may not exceed a value of 5 Amps.
The max. load of the switching con-
tacts is 380 VAC.
In order to maintain the function of the
undervoltage monitoring it is absolutely
necessary to make sure that the control
voltage of the contactors is in the same
phase as the control relay supply.
3.6 Additional Instructions
The installation and connection of the RM
9606 is only finished, once it has been
installed and wired according to these in-
structions.
IMPORTANT NOTICE:
Before commissioning of the control
relay it has to be ascertained that it is
not possible to touch the connecting
terminals (e.g. by means of a locked
door or covering).
The control relay must be kept voltage
free during wiring and installation
works.

13
4. Commissioning
After the control relay has been installed
as described in section 3, the relay can be
put into operation.
4.1 First Commissioning
When the control relay is put into operation
for the first time it tries to determine the
mode of connection and the size of the
stages. The display shows "---" and after a
discharge time for the capacitors the
stages are switched on and off again one
after the other. This process can take up
to 15 minutes.
ATTENTION:
If the RM 9606 does not act as de-
scribed above, remove voltage source
and check installation.
If the identification process is not
concluded within 15 minutes there is
probably a fault. (See section 8, page 35)
Notice:
In order for the relay to be able to
determine the mode of connection at
least one capacitor stage must be
operational.
Possibly the control relay has already
been used before and acts as described in
section 4.2.
It is also possible to discontinue the identi-
fication process by switching off the auto-
matic connection and stage current identi-
fications. This takes place in set mode and
at the same time it is necessary to
programme the connection and stage
parameters manually (see section 5).
After the identification process the actual
power factor appears on the display and
the control relay begins to function.
If the power factor shown does not
coincide with the real power factor, the
identification process must be repeated.
This can be done by pressing the buttons
"+", "-" and "Set" simultaneously for at
least 8 seconds.
4.2 Renewed Commissioning
After a mains failure the control relay
immediately starts the normal control
programme again. The data which were
determined whilst being put into operation
for the first time are stored in a non-volatile
memory.
By pressing the buttons "+", "-" and "Set"
simultaneously for a least 8 seconds these
data are erased from the memory and the
control relay again begins to determine the
mode of connection and the size of
stages.
It is assumed that the automatic connec-
tion and stage current identification are
switched on (see section 5).

14
5. Programming (Set)
In order to permit the widest possible use
of the control relay, multiple settings are
available. To simplify matters, the control
relay is set to standard values in our
factory before delivery.
(see Table 1, pages 15 to 17)
The user only needs to change the target
power factor or a few values to suit his
special requirements. As a protection
against unintentional reprogramming, the
set mode (programming mode) can be
invoked only within 5 minutes after operat-
ing voltage is applied. After this period the
values can only be read (read-only mode).
If the set mode has been activated within
these 5 minutes, it remains available for
one hour. In order to reach the set mode
again after this period, it is necessary to
disconnect the control relay from its sour-
ce for a short period of time.
The procedure for checking or repro-
gramming the set values is as follows:
• Press the "man/set" button for at least
eight seconds to switch to the set mode.
The display then shows "-01-". This
number corresponds to the first variable
which is displayed or can be changed in
the following sequence (see Table 1).
• The actual value appears on the display
when the "man/set" is pressed again.
• By pressing the "+" or "-" button the next
higher or lower setting can be attained.
The control relay is in the read-only
mode if above is not possible. To reach
the set mode again, the control relay
must be disconnected from its source
for a short period of time.
• Press the "man/set" button repeatedly;
the mode numbers appear followed by
the programmed value (see Table 1).
• If the "+" is pressed again after mode
number "-24-" appears on the display, or
if the "-" is pressed again after mode
number "-01-" appears on the display,
then the display will show "End".
• By confirming the display "End" by
pressing the "man/Set" button the con-
trol relay assumes normal operation; the
preset values are then permanently
stored in a non-volatile memory.
Notice:
During the "set mode" none of the
capacitor stages is changed and there is
no switching of the alarm contact.

15
Table 1: Programming of Values
Programme
Mode No. Description Pre-programmed standard Value Programme Range
-01- Target Power
Factor Ind. 0.92 from cap. 0.90 to ind. 0.8 in increments of 0.01 steps
-02-
Parallel Shift PS
-
1.0 (Target Power
Factor is lower
than limit value)
from –2 to +4 in increments
of 0.5 steps
-03- Limitation L +1.0
(Overcompensation
is avoided)
from –2 to +2 in increments of
0.5 steps
-04- Switching time
delay in
seconds
45 5 to 500 seconds in 1 sec. steps
or at a high speed
in 5 sec.steps.*)
-05- Automatic c/k
Identification ON ON=automatic mode OFF=manual mode
When “ON“, the programme
switches directly to programme
mode no. -09-
-06- Manual c/k
Value setting 2.0 From 0.02 to 2.0 in 0.01 steps or At high speed in 0.05 steps.*)
-07- Switching se-
quence 1:1:1:1:1
1:1:1:1:1:1
1:1:2:2:2:2
1:1:2:2:4:4
1:1:2:3:3:3
1:1:2:4:4:4
1:1:2:4:8:8
1:2:2:2:2:2
1:2:3:3:3:3
1:2:3:4:4:4
1:2:3:6:6:6
1:2:4:4:4:4
1:2:4:8:8:8
-08- Number of con-
tactors used 6 From 1 to 6
-09- Determination of
Fixed stages 0 0= no fixed stage 1= output fixed
2= outputs 1 and 2 fixed
3= outputs 1 to 3 fixed
*) by pressing the buttons "+" or "-" for some time, the high speed mode will be activated.

16
Table 1 Programming of Values
Programme
Mode No. Description Pre-programmed standard Value Programme Range
-10- Automatic
identification of
voltage and
current source
ON ON= automatic
OFF= manual
When “ON“, mode -11- can only
be read but not changed.
-11- Enter or read
mode of
connection
Automatic
identification See Table 2
-12- Switching-off
time 60 From 5 to 900 seconds. *)
-13- Setting cyclic /
non-cyclic
switching
rotation
ON ON= cyclic switching
OFF= non-cyclic switching
-14- Threshold for
number of
switching
alarm
OFF From OFF to 1000 the value must
be entered in x1000 switches
-15- Cancelling
individual
switching
counters
0 Enter a number of 1-6. When
leaving this menu point the counter
of the corresponding capacitor
stage will be set to 0. Point “ALL“
will reset all counters to 0.
-16- Current trans-
former Ratio 1 From 1 to 7000 in steps of 1 or at high speed in steps of 5.*)
-17- voltage trans-
former ratio 1 From 1 to 300 in steps of 1 or at high speed in steps of 5.*)
*) by pressing the buttons "+" or "-" for some time, the high speed mode will be activated.

17
Table 1 Programming of Values
Programme
Mode No. Description Pre-programmed standard Value Programme Range
-18- 5th harmonic
threshold in % 5 From 1 to 20 % in 0.1 % steps or 0.5 % steps at high speed.*)
-19- 7th harmonic
threshold in % 4 From 1 to 20 % in 0.1 % steps or 0.5 % steps at high speed.*)
-20- 11th harmonic
threshold in % 3 From 1 to 20 % in 0.1 % steps or 0.5 % steps at high speed.*)
-21- 13th harmonic
threshold in % 2.1 From 1 to 20 % in 0.1 % steps or 0.5 % steps at high speed.*)
-22- Harmonic
over-current 1.3 From 1.05 to 3.0 times the nominal value in 0.05 steps or 0.1
increments at high speed
-23- Power factor
alarm tripping
signal
ON ON or OFF
By setting “OFF“ a power factor
alarm can be suppressed.
-24- Total kvar dis-
play Will only be displayed when in
operation
By pressing “set“ button the total
power in kvar will be displayed.
*) by pressing the buttons "+" or "-" for some time, the high speed mode will be activated.

18
If the current transformer is installed in correct direction and the connections S1(k) and
S2(l) are correctly connected with the control relay, the following kinds of Connection
modes are valid:
Connection at the voltage path
Connection mode L/N – L L/N – L L/N – L
0 L1 – N L2 – N L3 – N
1 L1 – L3 L2 – L1 L3 – L2
2 N – L3 N – L1 N – L2
3 L2 – L3 L3 – L1 L1 – L2
4 L2 – N L3 – N L1 – N
5 L2 – L1 L3 – L2 L1 – L3
6 N – L1 N – L2 N – L3
7 L3 – L1 L1 – L2 L2 – L3
8 L3 – N L1 – N L2 – N
9 L3 – L2 L1 – L3 L2 – L1
10 N – L2 N – L3 N – L1
11 L1 – L2 L2 – L3 L3 – L1
CT Location in phase:
↑
L1
↑
L2
↑
L3
Table 2: Connection mode
Note:
If S1(k) and S2(l) are connected the wrong way around or the CT is installed in wrong
direction, connection mode number must be added by 6. If the result is higher than 11,
12 must be subtracted. The result corresponds to the connection mode number which
have to be entered.

19
5.1 Setting of Target Power Factor
The desired target power factor can be set
from cap. 0.9 to ind. 0.8 in 0.01 steps.
The mode of operation of this adjustment
can be seen in Figure 4 and Figure 5.
If the control relay operates within the
band range shown no switching opera-
tions will be activated.
However, if the control relay operates out-
side the band range, the RM 9606 will try
to come within the band range with the
minimum of switchings.
Figure 4: Control response after setting
target power factor = 1; L = OFF; PS =0
Active current
current
Reactive current
2
3
-2
-3
ind
cap
Regeneration
Switched on
Switched off
One scale division
corresponds to 0.65 *
smallest capacitor stage
Figure 5: Control response after setting
target power factor = 0.92 ind; L = OFF;
PS = 0
Active current
Reactive current
2
3
-2
-3
ind
cap
Regeneration
Switched
on
Switched
off
One scale division
corresponds to 0.65 *
smallest capacitor stage
In Figure 5 the behaviour of the control
relay during feedback operation can also
be seen. The "kink" in the band
(characteristic line) is not reflected in the
feedback operation but is extended at the
point of intersection of the reactive power
centre line (axis) with the feed-back
operation line.
By shifting the band into the capacitive
range (see Figure 7 in section 5.2) the
occurrence of an inductive reactive power
during the feedback operation can be
virtually avoided.
When a capacitive target power factor
mode is set, the control band is reflected
from the supply side to the feedback side.
(see Figure 10).

20
5.2 Parallel Shift (PS)
This setting causes a parallel shift of the
band range as shown in Figure 4 by the
set value.
It will shift to the inductive direction if the
plus sign is used and to the capacitive
direction if the minus sign is used.
The values -2 to +4 can be set in 0.5
steps. The effects are illustrated by the
two examples in Figure 6 and Figure 7.
Figure 6: Control response after setting
target power factor = 1; L = OFF;
PS = +1.0
Active current
Reactive current
3
-1
-2
ind
cap
Regeneration
Switched
on
Switched off
One scale division
corresponds to 0.65 *
smallest capacitor stage
1
-3
The set target power factor is therefore
the upper limit of the control band.
Figure 7: Control response after setting
target power factor = 0.92 ind; L = OFF;
PS = -1.0
1
Reactive current
2
-2-3
ind
cap
Regeneration
Switched
on
Switched
off
One scale division
corresponds to 0.65 *
smallest capacitor stage
Active current
The set target power factor is the lower
limit of the control band range.
(This is the recommended setting
when using asynchronic generators in
parallel.)
5.3 Limitation (L)
This setting gives new possibilities that
could not be attained before due to
opposing requirements.
The range of values for L are -2 to +2 in
steps of 0.5 and the setting "OFF". Setting
the limitation value of 1 and a target power
factor of 1.0 has the same effect as the
parallel shift. For a target power factor
other than 1.0 there is a "kinked"
characteristic as shown in Figure 8.