frako STR Series Guide

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Power Factor Correction
Power Factor Correction Systems
Commissioning and Maintenance

2
Dear Customer,
We would like to thank you for choosing a power factor correction system from FRAKO Kondensatoren- und Anlagenbau GmbH. It is
a pleasure to welcome you into the ever-expanding circle of satised users of FRAKO products worldwide. We hope that the following
information will help you to install and operate the power factor correction system without encountering any problems. If you have any
questions or need help, we are always at your disposal.
Best regards from FRAKO Kondensatoren- und Anlagenbau GmbH
Power Factor Correction Systems
Commissioning and Maintenance
General
FRAKO power factor correction systems are prewired and receive
a thorough individual inspection to verify the good working order of
all components before leaving the factory.
Before commissioning the system it is only necessary to connect
the power supply and the cabling to the current transformer. The
current transformer itself, however, is not included in the scope of
supply for power factor correction systems.
The reactive power control relay must be adjusted according to the
separate operating manual supplied with the instrument.
Any questions that may arise concerning the wiring and commissi-
oning of the system are treated in detail in these instructions.
Safety instructions
Caution: Dangerous voltages are exposed inside the cabinet.
Every operation that involves opening the door may therefore only
be made by a qualied electrician.
The installation of the power factor correction system, the verica-
tion of its good working order and any actions taken to rectify faults
may only be carried out by appropriately qualied specialists who
have received instruction on the electrical hazards involved.
All other actions can be carried out by persons who have familia-
rized themselves with these instructions and the operating manual
for the reactive power control relay and follow them at all times.
nThese instructions and the operating manual for the reactive
power control relay must be read through carefully before the
system is installed, connected up and commissioned.
nThe power factor correction system must always be earthed.
nDo not install the system near to any liquids, and do not expo-
se it to an excessively humid atmosphere.
nIf the power factor correction system is visibly damaged, it
must not be installed, connected up or commissioned.
nDo not cover the ventilation grille.
nDo not expose the system to direct sunlight or install it near to
a source of heat.
nIf the system is not put into service immediately, it must be
stored in a dry location at a temperature between -20°C and
+60°C.
nPlease observe all current statutory regulations governing the
recycling of the packaging materials.
Contents:
Commissioning and Maintenance
System location – correct installation, ingress protection and room temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuses and cables – supply cable cross section and rated current of main fuse......................................................... 3
Cable connections – conneting the main supply cable ........................................................................... 3
Current transformer – selection, correct arrangement and connections .............................................................. 3
Reactive power control relays: RM 9606, RM 2106, RM 2112, EMR 1100 S and EMR 1100
– automatic detection of connection, switching sequence and response current, No-volt release, etc… ...................................... 4
Commissioning – switching power on and checking system functions ............................................................... 5
Operation and maintenance – monitoring of fuses, contactors screwed connections, etc ................................................ 5
Troubleshooting – a tabular guide to troubleshooting any problems arising during commissioning ......................................... 6
Check list - a particar help when consulting FRAKO ............................................................................. 7
EC Declaration of Conformitiy – LSFC, LSK .................................................................................. 8
Assembly instruction
Switch board cabinets .................................................................................................... 9
Power loss.............................................................................................................. 9
Set up of a power factor correction system with C -modules .................................................................... 9
Complete power factor control relay packages (STR- …)....................................................................... 10
Capacitor modules, capacitor /reactor modules .............................................................................. 10
Set up of power factor correction systems for main voltages > 400V ............................................................ 10
Circuit diagram ..........................................................................................................11

3
Power Factor Correction Systems
Commissioning and Maintenance
System location
Standard versions of FRAKO power factor correction systems are
constructed with IP30 ingress protection to EN60529 (in some ca-
ses IP20 and IP54 for small Series LSK systems) and are desig-
ned for operation in dry rooms. The ambient temperature must not
exceed 40°C. Openings are provided in the enclosures for ventila-
tion, and these must not be covered, as this would inhibit the free
circulation of air.
Special versions, such as those constructed for IP54 ingress pro-
tection or for room temperatures over 40°C, or choked systems,
are tted with fan/lter units. If there is any tendency for hot air to
accumulate in the room where the system is installed, it must be
ensured that the room is adequately ventilated.
Fuses and cables
When the installation work is carried out in Germany, the VDE (Ger-
man Association of Electrical Engineers) regulations VDE 0100
and VDE 0105, the general guidelines of the VDEW (German
Electricity Association) and the conditions of supply of the utility
company concerned must be complied with. In other countries the
relevant local regulations must be observed.
VDE 0560 Part 46 states that capacitor units must be suitable for
a continuous r.m.s. current of 1.3 times the current that is drawn
at the sinusoidal nominal voltage and nominal frequency. If the
capacitance tolerance of 1.1×CNis also taken into account, the
maximum allowable current can reach values of up to 1.38×IN.
This overload capability together with the high inrush current to the
capacitors must be taken into account when dimensioning fusess
and cable cross sections.
Note: FRAKO power capacitors offer a current load capacity of 1.5-2.2 × IN
at 400V.
Table 1: Fuses and supply cable cross sections according to VDE 0298
Part 4, installation category C
Cable connections
Each cabinet or wall-mounted enclosure must always be provided
with its own supply cable, with terminals for the L1, L2, L3, N and
PE conductors. If a four-core cable is used, a connection must be
made between the PE and N conductors in order to supply power
to the reactive power control relay and contactor coils.
With wall-mounted systems, either a PG cable gland or a rubber
grommet with a strain relief clip, depending on the power rating
concerned, is provided for cable entry. With freestanding cabinets
the cables enter through the oor of the enclosure.
In the case of systems with a built-in fan / lter unit, care must be
taken that the opening in the oor is closed again after the cables
have been connected, in order to achieve an efcient cooling ef-
fect within the cabinet.
Current transformer
A current transformer is necessary to operate power factor correc-
tion systems. This is not included in FRAKO’s standard scope of
supply, but can be supplied with the system if the requirements in
the customer’s installation have been claried.
The primary current in the current transformer is dictated by the
user’s current consumption, the device being selected on the basis
of the maximum current load or the load connected to the transfor-
mer. The circuit to the reactive power control relay is designed for
a ... / 1 to ... / 5 A current transformer with a rating of 5 VA, Class 3.
If additional instruments are to be operated from the same current
transformer, this must be taken into account when specifying its
rating.
If ammeters are installed in series with the control relay, the rating
of the current transformer must be increased to suit. The internal
power consumption in the control relay circuit amounts to some
1.8VA for a current transformer with 5A nominal current.
Losses also occur in the current transformer wiring, and these
must also be taken into account if there are long lengths of cable
between the current transformer and the reactive power control
relay.
Table 2: Power losses in copper conductors from a current transformer
with a secondary current of 5A.
Note: The current transformer must be installed in any one of the
three phases so that the entire current to the loads requiring po-
wer factor correction and the capacitor current ow through it (as
shown in Figs. 1-3). Terminal P1 (K) is connected to the supply
side, terminal P2 (L) to the load side.
Caution: When the circuit is broken, voltage surges occur which
could destroy the current transformer. The terminals S1 (k) and
S2 (l) must therefore be short-circuited before the current transfor-
mer circuit is broken.
When selecting the current transformer, the step-down ratio must
be considered as well as the installed load, in order to ensure opti-
mum functioning of the reactive power control relay.
Please look up the smallest and largest capacitor stages that can
be switched in as stated in the technical documentation supplied
with the power factor correction system. The minimum and maxi-
mum possible current transformer step-down ratios can then be
obtained from Table 3 below.
230V/50Hz 400V/50Hz 525V/50Hz
Power Current Fuse Cross section Current Fuse Cross section Current Fuse Cross section
in kVAr en A in A en mm2in A in A in mm2in A in A in mm2
2.50 6.3 10 4×1.5 3.6 10 4×1.5 2.7 10 4×1.5
5.00 12.6 20 4×2.5 7.2 10 4×1.5 5.5 10 4×1.5
6.25 15.7 25 4 × 4 9.0 16 4×2.5 6.9 10 4×1.5
7.50 18.8 35 4 × 6 10.8 16 4×2.5 8.2 16 4×2.5
10.00 25.1 35 4 × 6 14.4 20 4×2.5 11.0 16 4 × 2.5
12.50 31.4 50 4×10 18.0 25 4 × 4 13.7 20 4×2.5
15.00 37.7 63 4×16 21.7 35 4 × 6 16.5 25 4 × 4
17.50 43.9 63 4×16 25.3 35 4 × 6 19.2 35 4 × 6
20.00 50.2 80 3 × 25 / 16 28.9 50 4×10 22.0 35 4 × 6
25.00 62.8 100 3 × 35 / 16 36.1 50 4×10 27.5 50 4×10
27.50 69.0 100 3 × 35 / 16 39.7 63 4×16 30.2 50 4×10
30.00 75.3 125 3 × 50 / 25 43.3 63 4×16 33.0 50 4×10
31.25 78.4 125 3 × 50 / 25 45.1 63 4×16 34.4 50 4×10
37.50 94.1 160 3 × 70 / 35 54.1 80 3 × 25 / 16 41.2 63 4×16
40.00 100.4 160 3 × 70 / 35 57.7 80 3 × 25 / 16 44.0 63 4×16
43.75 109.8 160 3 × 70 / 35 63.1 100 3 × 35 / 16 48.1 80 3 × 25 / 16
45.00 113.0 160 3 × 70 / 35 65.0 100 3 × 35 / 16 49.5 80 3 × 25 / 16
50.00 125.5 200 3 × 95 / 50 72.2 100 3 × 35 / 16 55.0 80 3 × 25 / 16
52.50 131.8 200 3 × 95 / 50 75.8 125 3 × 50 / 25 57.7 80 3 × 25 / 16
60.00 150.6 250 3 × 120 / 70 86.6 125 3 × 50 / 25 66.0 100 3 × 35 / 16
62.50 156.9 250 3 × 120 / 70 90.2 125 3 × 50 / 25 68.7 100 3 × 35 / 16
67.50 169.4 250 3 × 120 / 70 97.4 160 3 × 70 / 35 74.2 125 3 × 50 / 25
68.75 172.6 250 3 × 120 / 70 99.2 160 3 × 70 / 35 75.6 125 3 × 50 / 25
75.00 188.3 315 3 × 185 / 95 108.3 160 3 × 70 / 35 82.5 125 3 × 50 / 25
87.50 219.6 315 3 × 185 / 95 126.3 200 3 × 95 / 50 96.2 160 3 × 70 / 35
93.75 235.3 400 2 × 3 × 95 / 50 135.3 200 3 × 95 / 50 103.1 160 3 × 70 / 35
100.00 251.0 400 2 × 3 × 95 / 50 144.3 200 3 × 95 / 50 110.0 160 3 × 70 / 35
112.50 282.4 400 2 × 3 × 95 / 50 162.4 250 3 × 120 / 70 123.7 200 3 × 95 / 50
120.00 301.2 500 2 × 3 × 120 / 70 173.2 250 3 × 120 / 70 132.0 200 3 × 95 / 50
125.00 313.8 500 2 × 3 × 120 / 70 180.4 250 3 × 120 / 70 137.5 200 3 × 95 / 50
150.00 376.5 630 2 × 3 × 185 / 95 216.5 315 3 × 185 / 95 165.0 250 3 × 120 / 70
175.00 439.3 630 2 × 3 × 185 / 95 252.6 400 2x 3 × 95 / 50 192.5 315 3 × 185 / 95
200.00 502.0 800 2 × 3 × 240 / 120 288.7 400 2 × 3 × 95 / 50 219.9 315 3 × 185 / 95
225.00 – – – 324.8 500 2 × 3 × 120 / 70 247.4 400 2 × 3 × 95 / 50
250.00 – – – 360.8 500 2 × 3 × 120 / 70 274.9 400 2 × 3 × 95 / 50
275.00 – – – 396.9 630 2 × 3 × 185 / 95 302.4 500 2 × 3 × 120 / 70
300.00 – – – 433.0 630 2 × 3 × 185 / 95 329.9 500 2 × 3 × 120 / 70
350.00 – – – 505.2 800 2 × 3 × 240 / 120 384.9 630 2 × 3 × 185 / 95
375.00 – – – 541.3 800 2 × 3 × 240 / 120 412.4 630 2 × 3 × 185 / 95
400.00 – – – 577.4 800 2 × 3 × 240 / 120 439.9 630 2 × 3 × 185 / 95
Cross section Losses per metre of
in mm2two-core cable in VA
2.5 0.36
4.0 0.22
6.0 0.15
10.0 0.09

4
reactive power
control relay
Table 3: Minimum and maximum current transfomer step-down ratios
Power Factor Correction Systems
Commissioning and Maintenance
Smallest
stage
(in kVAr)
Largest
stage
(in kVAr)
Min. and
max. current
transformer
ratios
Min. and max.
nominal pri-
mary currents
for ... / 5 A
transformers
Min. and max.
nominal pri-
mary currents
for ... / 2.5 A
transformers
Min. and max.
nominal pri-
mary currents
for ... / 1 A
transformers
2.50 2.50 1.5...80 10... 400 5...200 5...80
2.50 5.00 3...80 15... 400 10... 200 10...80
2.50 7.50 4.5...80 25...400 15...200 15...80
2.50 10.00 6...80 30 ... 400 20... 200 20...80
2.50 15.00 9...80 50 ... 400 25 ... 200 25 ... 80
2.50 20.00 12...80 60...400 30...200 30...80
5.00 5.00 3...160 15...800 10...400 10 ... 160
5.00 10.00 6...160 30...800 20...400 20 ... 160
5.00 15.00 9...160 50...800 25...400 25 ... 160
5.00 20.00 12...160 60...800 30...400 30 ... 160
5.00 30.00 18...160 100...800 50...400 50 ... 160
5.00 40.00 24...160 120...800 60...400 60 ... 160
6.25 6.25 3.75...160 20...1000 10...500 10 ... 160
6.25 12.50 7.5...160 40...1000 20...500 20 ... 160
6.25 18.75 11.3... 160 60 ... 1000 30... 500 30...160
6.25 25.00 15...160 75...1000 40...500 40 ... 160
6.25 37.50 22.5...160 120 ... 1000 60 ... 500 60 ... 160
6.25 50.00 30...160 150... 1000 75... 500 75...160
7.50 7.50 4.5...240 25...1200 15...600 15 ... 240
7.50 15.00 9 ... 240 50 ... 1200 25 ... 600 25 ... 240
7.50 22.50 13.5...240 75...1200 40...600 40 ... 240
7.50 30.00 18...240 100... 1200 50... 600 50...240
7.50 45.00 27...240 150... 1200 75... 600 75...240
7.50 60.00 36...240 200... 1200 100...600 100...240
10.00 10.00 6 ... 320 30 ... 1600 20 ... 800 20 ... 320
10.00 20.00 12...320 60...1600 30...800 30 ... 320
10.00 30.00 18...320 100... 1600 50... 800 50...320
10.00 40.00 24...320 120... 1600 60... 800 60...320
10.00 60.00 36...320 200... 1600 100...800 100...320
10.00 80.00 48...320 250... 1600 120...800 120...320
12.50 12.50 7.5...400 40...2000 20...1000 20 ... 400
12.50 25.00 15...400 75...2000 40...1000 40 ... 400
12.50 37.50 22.5...400 120 ... 2000 60 ... 1000 60 ... 400
12.50 50.00 30...400 150... 2000 75...1000 75 ... 400
12.50 75.00 45...400 250... 2000 120...1000 120...400
12.50 100.00 60... 400 300 ... 2000 150...1000 150... 400
15.00 15.00 9 ... 480 50 ... 2400 25 ... 1200 25 ... 480
15.00 30.00 18...480 100... 2400 50...1200 50 ... 480
15.00 45.00 27...480 150... 2400 75...1200 75 ... 480
15.00 60.00 36...480 200... 2400 100 ... 1200 100 ... 480
15.00 90.00 54...480 300... 2400 150 ... 1200 150 ... 480
25.00 25.00 15...800 75...4000 40...2000 40 ... 800
25.00 50.00 30...800 150... 4000 75...2000 75 ... 800
25.00 75.00 45...800 250... 4000 120 ... 2000 120 ... 800
25.00 100.00 60... 800 300 ... 4000 150...2000 150... 800
50.00 50.00 30...1600 150 ... 8000 75 ... 4000 75 ... 1600
50.00 100.00 60... 1600 300 ... 8000 150 ... 4000 150...1600
Fig. 1: Correctly installed current transformer registers load current and
capacitor current
reactive power
control relay
Fig. 2: Incorrect! The current transformer only registers the load current:
the capacitor bank is switched in but not out again. Automatic calibration of
the reactive power control relay is not possible!
reactive power
control relay
Fig. 3: Incorrect! The current transformer only registers the capacitor cur-
rent: the capacitor bank is not switched in. The reactive power control relay
gives the message “I= 0” (no current in transformer circuit)!
Reactive power control relays: RM 9606, RM
2106, RM 2112, EMR 1100 S and EMR 1100
To avoid reactive power penalty charges, the reactive power cont-
rol relay must be set, as a minimum requirement, at the target va-
lue of cos ϕrequired by the local utility company. The basic factory
settings represent the most frequently specied cos ϕrequirement.
A detailed description of the possible control characteristics is gi-
ven in the operating manual for the reactive power control relay.
Automatic detection of connection, switching sequence and
response current.
The reactive power control relays automatically detect the connec-
tion (phase position), the switching sequence and the response
current (c / k). These instruments have a factory setting of 0.92 for
the target power factor. If it is desired to operate at this power fac-
tor, no further setting is necessary when commissioning the reac-
tive power control relay.
When the AC supply voltage is applied to the instrument for the
rst time, the reactive power control relay carries out the connec-
tion and response current detection process, and is then ready to
operate.

5
Power Factor Correction Systems
Commissioning and Maintenance
Note: As the control relays always adapt to the installed supply
system conguration, it can be necessary in individual cases to
enter the required parameters manually.
When the low voltage supply system is fed by several transformers
arranged in parallel, the capacitor current is distributed between all
the transformers. If this current is not measured via totalizing cur-
rent transformers, the change in current measurable by the cont-
rol relay when the capacitor stages are switched in is too small,
which would result in too low response current for automatic C / k
detection. In cases of this type and also in networks with continu-
al load changes (e.g. saw mills, automatic presses, welding lines
and drop forges with switching periods < 2 seconds), the c / k value
has to be entered manually.
No-volt release
The reactive power control relays are provided with a no-volt re-
lease function. This prevents all the capacitor stages being swit-
ched in simultaneously following an outage of the supply voltage
when the latter is restored. The contactors are released on power
failure, and are then energized again to suit requirements.
Standard systems are wired so that the control voltage for the con-
tactors is tapped from the voltage supply to the control relay. It is
strongly advised not to use an external control voltage, since with
this the no-volt release would no longer function, with the possi-
bility that damage might be caused not only to the power factor
correction system but also to other components in the electrical
installation.
Overcurrent trip
The RM 9606, RM 9612 and EMR 1100 control relays have the
capability of determining the ratio between the r.m.s. current and
the fundamental current in the capacitor. If this ratio exceeds a
value set at the control relay for at least one minute, on account of
system harmonics and the consequent amplication they produce
due to resonance, all the capacitor stages are switched out. An
alarm signal is also given when this happens.
With unchoked systems we recommend setting this ratio or factor
at a value of 1.3 (factory setting), whereas with choked systems
it must be set at its maximum value of 3.0 (and therefore not ac-
tive)!
Commissioning
Before the AC supply voltage is applied to the system, a visual
check should be carried out by a qualied technician to verify that
no equipment or connections have worked loose during transport.
If this has happened, however, the components and connections
concerned must be correctly tightened again. Please verify that
the connections to the current transformer are made at terminals
S1 and S 2 (current transformers are not included in the standard
scope of supply).
Powering up
When the AC supply voltage is applied to the control relay, it auto-
matically carries out the connection detection procedure. Horizon-
tal lines appear in the digital display. After switching in all capacitor
stages several times, the measured power factor appears in the
display. This is preceded by a + sign to indicate inductive condi-
tions (the procedure takes some 5-10 minutes).
The capacitor stages required are switched in within a few se-
conds, and their corresponding LEDs light up on the control relay.
When inductive loads are switched off, the control relay within a
few seconds switches out a sufcient number of stages until the
set power factor has been reached again.
The operating manual supplied with the control relay describe in
detail how to reprogram the set power factor or other parameters
if required.
If the control relay does not react as described here, please sys-
tematically check through the individual points given in Troubles-
hooting.
Switching in capacitor stages manually
Press the Man/Set key for about three seconds. The Manual
LED then begins to ash, indicating that the instrument has been
switched over to manual operation. A capacitor stage can then be
selected by means of the +or -keys. After a delay of about ten
seconds the selected stage is switched in, or if that stage was al-
ready switched in, it is switched out. Defective or unidentied ca-
pacitor stages are signalled as follows in manual mode:
The number of the selected stage ashes.
Please do not forget to press the Man/Set key again to revert to
automatic control!
Switching off the voltage
If the voltage is to be removed from the power factor correction
system, switch the control relay over to manual mode and then
switch out all the capacitor stages. This enables the main fuses
to be removed or the fuse switch-disconnecter to be switched off
under no-load conditions.
Operation and maintenance
Power factor correction systems operate automatically and for a
long time without any maintenance. Carrying out a regular ins-
pection at least once a year can, however, prevent reactive power
penalty charges suddenly being incurred or the correction system
being damaged by an undetected fault.
Alarm signal
All FRAKO reactive power control relays are provided with a built-
in alarm contact (terminals a and b), which can be connected to
an alarm system. If the set power factor is not achieved, a signal
is given and the Alarm LED on the instrument itself lights up conti-
nuously. The operating manual for the control relay contains more
information on the types of alarm and the programming of their set
points.
Fuses
Low voltage, high breaking capacity fuses undergo an ageing pro-
cess when carrying the high switched currents associated with
capacitors. They should therefore be inspected at least once per
year. We recommend replacing the fuse links after ten years at
the latest.
Contactors
Contactors specially designed to switch capacitors in and out are
always used in FRAKO systems. Please therefore ensure when
replacing contactors that only the capacitor-switching type is t-
ted.
The contacts of capacitor switching contactors have a particular-
ly demanding duty. They are tested for 80,000 switching cycles
and must be completely replaced once this number has been re-
ached. If the power factor correction system has a control relay
with a switching cycle counter (such as the RM 9606, EMR 1100S
or EMR 1100), a separate message is given for each stage after
80,000 switching cycles (factory setting which can, however, be
reprogrammed) to inform the operator that contactor replacement
is due.

6
Power Factor Correction Systems
Commissioning and Maintenance
The current counter readings can be accessed via the control re-
lay: when capacitor stages are switched in manually, the number
of switching cycles appears briey in the display (multiply reading
by 1000).
Wear and tear of the switching contacts has an adverse effect on
the service life of the capacitors!
Temperature monitoring
Power factor control relays have a built-in temperature switch in-
terlocked with the control system. If a build-up of heat causes the
interior temperature of the enclosure to rise above 60 °C +/- 3 K,
the system shuts down.
Note: The evaluation of the alarm contact from the control relay
will inform the user. The temperature switch has to be reset ma-
nually.
If the system comprises several cabinets, the temperature inter-
lock is looped through all of them.
Discharge resistors
The discharge resistors are tted to the capacitor terminals for
safety reasons in compliance with VDE (German Association of
Electrical Engineers) regulations. In addition to their safety func-
tion, they are also indispensable for problem-free operation of the
system and must on no account be removed. Attention must be
paid to this point particularly when capacitors are replaced!
Choked systems
Choked systems have been specially designed for operation in
networks that are highly distorted by harmonics.
The lter circuit chokes have a strong self-heating tendency and
can reach temperatures in excess of 100°C. They are, however,
designed for these temperatures and have a built-in temperature
switch. This switches off the contactor associated with the choke
for a long enough time until the latter has cooled down again.
Ventilation / heat dissipation
For correct ventilation ensure that there is no handicap at the air
input and also at the air output. Also ensure that the switch board
cabinet at the bottom is closed especially the area around the in-
coming cables for clean air and dened air directions. Depending
on the air pollution at the installation location, the air input and the
air output system has to be cleaned frequently.
Fan
Power factor correction systems with high power losses are equip-
ped with fans. The fan motor is interlocked in the control circuit
with a fuse and a thermostat, adjusted to 30°C.
Capacitors
The capacitors must be checked visually during the annual ins-
pection for any mechanical changes. Any variation in capacitance
or distortion by harmonics can be inferred from the operating
currents measured. If any irregularities are detected, please con-
tact your local FRAKO representative or call us directly (Tel. +49
7641/453-0).
General
Please ensure that the system is kept clean at all times, if neces-
sary having it cleaned by skilled personnel. During the annual ins-
pection the system must be given a visual check by an electrician
to verify its good working order (sound electrical contacts, no evi-
dence of overheating, etc.).
Troubleshooting
If the power factor correction system does not operate as expected, please
investigate the following points systematically:
No reaction, no display at all on control relay.
Cause: No voltage at control relay
Action: Check voltage at terminals L1, L2, L3 and N,
check control circuit fuse,
check temperature switch.
Contactors do not close even though the capacitor stage display on
the control relay indicates switched-in stages.
Cause: No control voltage or N at contactor If four-wire supply,
no jumper installed between N and PE
Action: Check control fuses and cabling.
Contactors do not close. Cap is indicated in the display, even though
the load is inductive.
Cause: Current transformer installed in spur to capacitors
Action: Install current transformer in the main supply line,
as shown at page 4, Fig. 1.
The message “U = 0” ashes in the control relay display.
Cause: No voltage or wrong voltage connected to control relay
for measurement
Action: Check whether the voltage being measured at
the control relay is at the correct level.
The message “I = 0” ashes in the control relay display.
Cause: No current or too little current in
the current transformer circuit
Action: Check current transformer (Imin ≥ 0.02 A) and cabling.
The message “C = 0” ashes in the control relay display.
Cause: The control relay has not detected any capacitances despite
carrying out the calibration procedure. No capacitor current is
registered by the current transformer. See page 4, Fig. 2.
Action: Install current transformer in main supply line
as shown at page 4, Fig.1.
Control relay switches all stages in, but does not switch them out
when the load reduces.
Cause: Current transformer registers only the load current without
the capacitor current.
Action: Install current transformer in main supply line
as shown at page 4, Fig.1.
The reactive power control relay does not terminate the automatic
calibration procedure.
Cause 1: Fault in control circuit (contactors not closing)
Action: Check control circuit fuse and cabling.
Cause 2: Very unstable network (wide cos ϕ uctuations).
Action: Wait for stable network conditions or enter C / k and type of
connection manually (see control relay operating manual).
Cause 3: No current in current transformer circuit
Action: Check current transformer and cabling.
Reactive current consumption too high even though all capacitors are
switched in
Cause 1: Capacitor power rating inadequate
Action: Check whether all contactors have closed.
Check fuses and capacitor currents.
Review the calculation of the required capacitor rating.
Cause 2: Spur to capacitors is connected before the instrument
transformer for the utility company’s meter.
Action: Relocate the connection.

7
Please keep the completed list available in case you need to consult FRAKO because of technical problems.
Contact person (department for power factor correction projects): Tel.: [phone] Fax.: [phone]
Power factor correction system type designation:
Current transformer step-down ratio:
Supply line to power factor correction system Cross section: mm2
Overcurrent protection: A
Length of cable between current transformer and PFC system: metres
Core cross section of current transformer cable: 2× mm2
Is an additional measuring device connected to the current
transformer in addition to the power factor correction system?
no Yes
(Please state type of instrument)
If yes, how is it connected? in series with the reactive power control relay
in parallel with the reactive power control relay
Types of load? – normal inductive loads approx. kW
– high-speed switching loads approx. kW (load cycles ≤ 5 seconds)
Is “low-load“ operation ever required? no yes approx. kW
Does the facility have its own transformer? no yes Rating: kVA,uK. %
Is a xed PFC system connected to transformer? no yes Rating: kVAr
Where do the utility company’s meters measure consumption? low voltage side
high voltage side (before transformer)
Further information or sketch of network
FRAKO Kondensatoren- und Anlagenbau GmbH
Tscheulinstrasse 21a · 79331 Teningen · Germany · Telephone [phone] · Telefax +49 7641/453-545 · E-mail: [email protected] · http://www.frako.de
Check list
We recommend that you complete the following check list, so that if it ever becomes necessary at a later date to trace faults and possibly
consult FRAKO, all the relevant data is available on one sheet. This will greatly speed up the troubleshooting process.
Power Factor Correction Systems
Commissioning and Maintenance

8
Blindleistungs-Regelanlagen
Inbetriebnahme und Wartung
EG-Konformitätserklärung
Declaration of Conformity
Dokument-Nr. EG-LSFC-201A / 07.2009
Document-No. EC-LSFC-201A / 07.2009
Wir/We FRAKO Kondensatoren- und Anlagenbau GmbH
Tscheulinstraße 21 a 79331 Teningen GERMANY
erklären in alleiniger Verantwortung, dass das Produkt
Declare under our sole responsibility that the product
Produktbezeichnung: Blindleistungs – Regelanlagen, eingebaut in Stahlblechgehäuse name of product Power Factor Control System
Typenreihe: LSFC ab Fert.-Nr. G200930001
.oN.reSmorfylimaf
auf das sich diese Erklärung bezieht, mit der/den folgenden Norm(en) oder normativen Dokument(en) übereinstimmt:
to which this declaration relates is in conformity with the following standard(s) or other normative document(s):
1. EN 61000-6-3 2007-09 EMV, Fachgrundnorm Störaussendung - Wohnbereich, Geschäfts- und Gewerbebereiche
EMC, Emission standard for residential, commercial and light-industrial environments EN 61000-6-4 2007-09 EMV, Fachgrundnorm Störungsaussendung Industriebereich
EMC, Emission standard for industrial environments
EN 61000-6-1 2007-10 EMV, Fachgrundnorm Störfestigkeit - Wohnbereich, Geschäfts- und Gewerbebereiche
EMC, Immunity for residential, commercial and light-industrial environments
EN 61000-6-2 2006-03 EMV, Fachgrundnorm Störfestigkeit Industriebereich EMC, Immunity for industrial environments
gemäß den Bestimmungen der Richtlinien / following the provisions of Directive
2004/108/EG Elektromagnetische Verträglichkeit / Electromagnetic Compatibility Directive
2. EN 60439-1 2005-01 Niederspannungs-Schaltgerätekombination
Low-voltage switchgear and control gear assemblies
EN 61921 2004-02 Leistungskondensatoren – Kondensatorbatt. zur Korrektur des Niederspg.- Leistungsfaktors
Power Capacitors – Low voltage power factor correction banks
EN 60 831-1 2003-08 Selbstheilende Leistungs-Parallelkondensatoren mit Nennspannung bis 1000 V
Teil 1 Allgemeines und Sicherheitsanforderungen EN 60 831-2 1997-09 Teil 2 Alterungsprüfung, Selbstheilprüfung und Zerstörprüfung
Shunt power capacitors of the self-healing type for AC systems having a rated voltage up to
and including 1 kV Part 1: General; Performance, testing and rating; Safety requirements;
Part 2: Ageing test, self-healing test and destruction test
gemäß den Bestimmungen der Richtlinien / following the provisions of Directive
2006/95/EG Niederspannungsrichtlinie / Low Voltage Directive
Teningen, 20. July 2009
tsbreH.P
Diese Erklärung bescheinigt die Übereinstimmung mit den genannten Richtlinien, beinhaltet jedoch keine Zusicherung von
Eigenschaften. Die Sicherheitshinweise der mitgelieferten Produktdokumentation sind zu beachten. This declaration certifies conformity with the above-mentioned Directives, but does not contain any assurance of properties. Please observe the safety instructions of the attached product documentation.
EG-Konformitätserklärung
Declaration of Conformity
Dokument-Nr. EG-LSK-201A / 07.2009
Document-No. EC-LSK-201A / 07.2009
Wir/We FRAKO Kondensatoren- und Anlagenbau GmbH
Tscheulinstraße 21 a 79331 Teningen GERMANY
erklären in alleiniger Verantwortung, dass das Produkt
Declare under our sole responsibility that the product
Produktbezeichnung: Blindleistungs – Regelanlagen, eingebaut in Stahlblechgehäuse name of product Power Factor Control System
Typenreihe: LSK ab Fert.-Nr. G200930001
.oN.reSmorfylimaf
auf das sich diese Erklärung bezieht, mit der/den folgenden Norm(en) oder normativen Dokument(en) übereinstimmt:
to which this declaration relates is in conformity with the following standard(s) or other normative document(s):
1. EN 61000-6-3 2007-09 EMV, Fachgrundnorm Störaussendung - Wohnbereich, Geschäfts- und Gewerbebereiche
EMC, Emission standard for residential, commercial and light-industrial environments EN 61000-6-4 2007-09 EMV, Fachgrundnorm Störungsaussendung Industriebereich
EMC, Emission standard for industrial environments
EN 61000-6-1 2007-10 EMV, Fachgrundnorm Störfestigkeit - Wohnbereich, Geschäfts- und Gewerbebereiche
EMC, Immunity for residential, commercial and light-industrial environments EN 61000-6-2 2006-03 EMV, Fachgrundnorm Störfestigkeit Industriebereich EMC, Immunity for industrial environments
gemäß den Bestimmungen der Richtlinien / following the provisions of Directive
2004/108/EG Elektromagnetische Verträglichkeit / Electromagnetic Compatibility Directive
2. EN 60439-1 2005-01 Niederspannungs-Schaltgerätekombination
Low-voltage switchgear and control gear assemblies
EN 61921 2004-02 Leistungskondensatoren – Kondensatorbatt. zur Korrektur des Niederspg.- Leistungsfaktors
Power Capacitors – Low voltage power factor correction banks
EN 60 831-1 2003-08 Selbstheilende Leistungs-Parallelkondensatoren mit Nennspannung bis 1000 V
Teil 1 Allgemeines und Sicherheitsanforderungen EN 60 831-2 1997-09 Teil 2 Alterungsprüfung, Selbstheilprüfung und Zerstörprüfung
Shunt power capacitors of the self-healing type for AC systems having a rated voltage up to
and including 1 kV Part 1: General; Performance, testing and rating; Safety requirements;
Part 2: Ageing test, self-healing test and destruction test
gemäß den Bestimmungen der Richtlinien / following the provisions of Directive
2006/95/EG Niederspannungsrichtlinie / Low Voltage Directive
Teningen, 20. July 2009
tsbreH.P
Diese Erklärung bescheinigt die Übereinstimmung mit den genannten Richtlinien, beinhaltet jedoch keine Zusicherung von
Eigenschaften. Die Sicherheitshinweise der mitgelieferten Produktdokumentation sind zu beachten. This declaration certifies conformity with the above-mentioned Directives, but does not contain any assurance of properties. Please observe the safety instructions of the attached product documentation.

9
Power Factor Correction Systems
Assembly instruction
Switch board cabinets
The maximum ambient temperature of power factor correction
systems must not exceed 40°C (EN 60439-1, VDE 0660 T500).
The switch boards must have sufcient air bleeds in the door as
well as in the roof of the cabinet in order to carry off dissipation
heat.
In most cases choked power factor correction systems require a
forced ventilation with a motor fan.
Cabinets built in protection class IP54 have to be equipped, in
most cases, with lter fans, even if they are unchoked.
Capacitors and combined capacitor / reactor modules of the type C
have been constructed for different widths and depths of cabinets:
The C- modules are inserted in the cabinet on module rails and
xed on them with the screws that have been supplied along with.
Cabinets with a larger depth than the minimum depth, have se-
veral xing positions on the module rails. When using one of the
xing positions at the back, the xing straps at the front have to be
bent to the outside. At the mounting rails there are also xing pos-
sibilities for cable channels for the control circuit. The xing straps
needed can for this purpose be bent out.
The module rails for the different types of cabinets have to be or-
dered separately.
When choosing the type of switch board the weights of the modu-
les have to be taken into consideration, in order to make sure that
a cabinet with a sufcient stability is chosen.
Power loss
The loss power of the modules consisting of the loss power of the
capacitors, resp. choke coils, fuses, contactors and wiring is esti-
mated as follows:
Unchoked modules
or power factor correction systems max. 2.5 W / kVAr
Choked modules
or power factor correction systems max. 8.5 W / kAVr
The switch board cabinet has to be designed in a way that the
loss power can be eliminated and the temperature of the housing
does not exceed 60°C.
Type min. width of the cabinet min. depth of the cabinet
C64 600mm 400mm
C65 600mm 500mm
C66 600mm 600mm
C84 800mm 400mm
C85 800mm 500mm
C86 800mm 600mm
Set up of power factor correction systems
with C - modules
A modular power factor correction system consists of the following
components:
ncabinet
ncomplete power factor control relay package (STR-...)
nmounting plate for the control unit
n capacitor module(s) or capacitor / reactor module(s) including
control-connecting wires (part of the modules)
nmodule rail(s) for modules, also needed for the mounting plate
of the control unit
nfan package
Power Factor Correction systems with several modules are equip-
ped from bottom up. This sequence also applies for the wiring of
the contactor control.
From the control terminal strip a cable, or the corresponding num-
ber of single conductors, has to be laid to the relay (already pre-
mounted in case the complete power factor control relay package
has been ordered). From the control terminal strip he control
wires (supplied with the modules) must be laid to the capacitor
module(s). In case several contactors should be switched parallel,
it will be done by using clamp bridges on the module plugs or with
single conductors from the control terminal strip to the capacitor
module(s).
With this kind of set up an extension at a later time is easy to hand-
le. The set up is shown below. Slot 0 is left empty and serves as
the cable terminal compartment. If required, audio frequency re-
jectors will be installed here.
The rst module has to be put in slot 1. Slot 4 remains empty in
case systems are only equipped with, for example, 3 modules. An
extension at a later time is possible with low effort. Provided that
the cross sections have been sufciently dimensioned for the ex-
tension, the cables for the feeder remain unchanged.
control unit
slot 4
slot 3
slot 2
slot 1
slot 0

10
Power Factor Correction Systems
Assembly instruction
Complete packages of power factor control
relays (STR-...)
STR- modules are available as follows: with 6- and with 12 - step
power factor control relay. The module contains the power factor
control relay (RM 9606, EMR 1100 S or EMR 1100), the accom-
panying control terminal strip with control fuse and temperature
limiter as well as the pre-mounted relay cable.
The temperature limiter switches off the contactors at max. 70°C
over the no-voltage release of the relay (note: the temperature li-
miter has to be set back manually after it has triggered).
The control terminal strip as well as the temperature limiter have to
be mounted on the predetermined position on the mounting plate
with the enclosed mounting material. The xing ange of the tem-
perature limiter has to be included in the safety precaution (this is
fullled when mounting has been done as recommended).
For extension units we have 12-step control terminal strips
(without control fuse) with temperature limiter.
Important! When connecting extension units to a basic unit the
jumper of T1 to T2 of the control clamp (basic unit) has to be re-
moved. In case there is already an extension unit connected to the
basic unit, the jumper T 2 to T 3 of the control clamp (rst extensi-
on unit) has to be removed. Otherwise the temperature monitoring
function of the extension unit is not activated.
Choked power factor correction systems are additionally equipped
with a fan and a temperature controller. The temperature controller
should be mounted in the upper part of the switch board cabinet
and set to 30°C.
Capacitor modules,
capacitor / reactor modules
The capacitor modules are equipped with low-loss power factor
correction capacitors (encased-single capacitors, switched as
batteries with discharge resistors, discharge on min. 75V in 60s),
contactors and a bus bar system with NH00-fuses. The capaci-
tor / reactor modules do additionally have a reactor connected in
series. The feeder is connected to the bus bar system, which is
bent rectangularly.
In case the feeder should be connected vertically, a bus con-
nection bracket set is needed. This set is available as accessory
equipment and has to be ordered separately (=CUAW-1).
The cables of the contactor coil are led on one (1-3 steps) resp.
two (4- 7 steps) 4 - pole plugs (pins).
The connection of the capacitor module with the control terminal
strip is made through a cable with the prefabricated plug (socket),
which is enclosed to the accessories of the modules.
By these connections or by parallel connection of the contactors
with jumpers at the plugs of the capacitor module, several contac-
tors can be switched at the same time. Therefore more capacitor
batteries can be interconnected. This is necessary in case of lar-
ger step power.
At the same step power the stepping is equivalent to the switching
sequence: 1:1:1... . In case further steps are twice as large as the
rst, the switching sequence would be: 1:2:2... .
The switching sequence 1:1:2... states, that the rst two steps
have , for example 25kVAr and all further steps have 50 kVAr.
Power factor control relays detect these switching sequences au-
tomatically (can also be entered manually).
In case of manual set-up of the minimum operating current (c / k -
value) the minimum step power (=valance1) and the transforma-
tion ratio of the transformer have to be taken into consideration.
When using a sum current transformer the sum of all currents of
the main transformers during the set-up of the c / k - value has to be
taken into consideration.
Set up of power factor correction systems
for main voltages > 400V
In case it is planned to use modules resp. power factor correction
systems for a mains voltage of >400V, a control transformer with
the adequate power has to be xed for the control unit (contactors,
fans and possibly a power factor control relay).
The coils of the contactors are designed for a mains voltage of
230 V / 50 Hz and 240 V / 60 Hz!
As a back-up fuse for the control transformer a motor circuit brea-
ker instead of the neozed-fuses has to be used on the control
clamp (fuses are only approved up to 400V!). Control transfor-
mers with a power of 800VA and an input voltage up to 690V are
available as accessory equipment.