KMB KATKA 80ST 690 User manual

KMB systems, s. r. o.
Dr. M. Hor´akov´e 559, 460 06 Liberec 7, Czech Republic
E-mail: [e-mail], Web: www.kmb.cz
Operating Manual for
THYRISTOR SWITCHING MODULES
KATKA 80ST 690
version 2.0
The complete and most actual version of this manual is available online at http://www.KMB.cz/

Contents
1 Applications 3
2 Connections 4
2.1 Connection of Fan supply voltage to KATKA 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Internal Wiring of KATKA 80ST 690 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Installation of KATKA into cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 ConnectionofLoad............................................ 5
2.4.1 1-phase star connected capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Connection of Control Signal to KATKA 80ST 690 . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Mechanical Dimensions 8
4 Technical Parameters 8
5 Ordering Diagram 9
6 Accessories 10
6.1 Dischargeresistors ............................................ 10
6.2 ZP 24 auxiliary power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Maintenance, Service, Warranty 11
2

1 Applications
KATKA 80ST 690 series of thyristor switching modules have been designed especially for switching power factor
correction capacitors in rapid reactive power compensation (up to 20 control interventions in one second) in
conjunction with fast power factor controllers of the NOVAR series. They can, of course, be also used in other
applications where contact-less load switching is required.
The modules are designed to switch a star- or delta-wired, symmetric or asymmetric, capacitive, resistive or
inductive load in a 690V/400V system. Load is connected under near-zero voltage (typically 5V) across the
switching device and disconnected on zero-cross current.
The benefits of contact-less switching are:
 long life (high number of connections and disconnections)
 reduced current and voltage interference (connection and disconnection at near-zero power)
 fast connection and disconnection
 no switching noise
These benefits are demanded especially at folowing sectors:
 Welding Plants
 Presses, mills
 Windturbines
 Elevators
 Cranes
 places sensitive to harmonic distortions
3

2 Connections
2.1 Connection of Fan supply voltage to KATKA 80
KATKA 80 modules includes thermostat-controlled fan for forced cooling and thermal protection. Auxiliary
voltage for fan on modules with active cooling (KATKA 80) is connected to terminals L and N (fig. 1a). Terminal
LT is output of thermostat. Fan can be permanently turned on by connecting terminal L to LT (fig. 1b). You
can also check its status on LT terminal.
Power
L1
N
LT
L
L
N
230V
(a) Fan will turn on when hot
Power
L1
N
LT
L
L
N
230V
(b) Fan will be on permanently
Figure 1: Connection of fan supply voltage to KATKA 80
2.2 Internal Wiring of KATKA 80ST 690
KATKA T
KATKA ST
L1 C1 L2 C2 L3 C3
L1 L2 L3
Figure 2: Internal wiring
4

2.3 Installation of KATKA into cabinet
During normal operation, modules produce great amount of heat. Therefore it’s necessary to provide sufficient
air flow in the cabinet (holes in bottom and top of the cabinet) and sometimes also use of active cooling (use
of fan) might be necessary. Modules have to be installed vertically to allow air to flow through heatsink from
bottom to top. Ambient temperature (air provided for cooling of the module) should be kept bellow 45 ° C.
When installing multiple rows of modules in one cabinet each row should be staggered or heat deflectors
should be used. Air coming out of the module is very hot and might have negative effect to module directly
above. Modules should be installed to higher levels so hot air can escape cabinet as soon as possible.
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
(a) Staggered placing
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
KATKA
L1 C1 L2 C2 L3 C3
L1 L2 L3
(b) Use of heat deflectors
Figure 3: Installation example
2.4 Connection of Load
When using power factor correction capacitors, implementation of detuned power factor correction is
highly recommended, otherwise an inductance of at least 12 µ H must be wired in series with the switch to
prevent thyristor damage by reducing speed of current rise. A detuning reactor also expands life of power factor
correction capacitors and improves control accuracy. The modules incorporate class C over-voltage protection
varistors. It is further recommended that a class B, 50 kA, lightning current protection device should be installed
in the power lead.
5

2.4.1 1-phase star connected capacitors
Solution for simple single phase power factor correction using 3-phase power factor controlleror for applications
with 690 V/400 V systems.
L1
L2
L3
N
PE
KATKA ST
L1 C1 L2 C2 L3 C3
L1 L2 L3
690V/400V
R
C2
C3
R
C1
R
Figure 4: 1-phase star connected capacitors
System Voltage Max. step output Current/phase
KATKA 80ST 690 690V 3 Ö 26,8 kvar 67 A
Table 1: Maximum allowed power
6

2.5 Connection of Control Signal to KATKA 80ST 690
The control voltage is galvanically isolated from the other circuits. The modules have a Power indicator, to
indicate voltage presence, and a Control indicator to indicate closed circuit condition of the module when
control voltage is applied.
L3
=
+-
24VDC
+
C1 C2 C3
1A
Figure 5: Connection of control signal
NOTE:
When C1, C2, C3 terminals are connected to same signal (fig. 6), all three switches of KATKA will be switched
at same time. Behavior of KATKA will be then similar to KATKA T models.
L3
+
C1 C2 C3
Figure 6: Linking of C1, C2 and C3
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3 Mechanical Dimensions
KATKA 80 T 400
Power Control
L1 C1 L2 C2 L3 C3
N
LT
L24VDC
L1 L2 L3
90
122
245 231
157
4x ø 6,5
4 Technical Parameters
Parameter KATKA 20D 400 KATKA 20T 400
KATKA 20ST 400
KATKA 20T 690
KATKA 20ST 690 KATKA 80D 400 KATKA 80T 400 KATKA 80ST 400
KATKA 80T 690
KATKA 80ST 690
nom. operating volt. 400V/230V±10% 400V/230±10%
440V/250V±10% 690V/400V±10% 400V/230V±10% 400/230±10% 440/250±10% 690V/400V±10%
max. block. voltage 1600V
max. oper. current 29A 22A 87A 67A
max. rate o I rise 50A/us
conductor x-section 10mm225mm2
number o switches 2 3 2 3
load character C/R/L
an aux. voltage - 230±10%
an power - 32 VA
aux. cond. x-section - 2.5mm2
an threshold temp. -°C 60°C±5°C
ctrl. volt. / current 24 VDC/ 10mA (30mA for KA KA S )
ctrl. cond. x-section 2.5mm2
thermal protection - 100°C±5°C
overvolt. protection C
IP rating IP20
operating temp. -20 ÷ 45°C
oper. humidity 5 ÷ 95% non-condensing
dimensions 122W×192H×117Dmm 122W×245H×157Dmm
mass 2.05kg 2.15kg 3.35kg 3.45kg
8

5 Ordering Diagram
KATKA 8OT 4OO
Instrument Class
Construction and power
KATKA = Thyristor switching module
2O = passive cooling, up to 22A (T, ST)/up to 29A(D)
8O = active cooling, up to 67A (T, ST)/up to 87A(D)
Switching method
D = two-phase, two thyristors
T = three-phase, three thyristors
ST = individual switching of each phase, three thyristors
System Voltage
4OO = 4OO/23OV up to 44O/25OV
69O = 69O/4OOV (available only for option T and ST)
9

6 Accessories
6.1 Discharge resistors
3pcs of Auxiliary discharge resistors 33kΩ / 13W are delivered with thyristor modules. Resistors are designed
to be used with connection on fig. ??. Its possible to connect resistors directly to terminals of capacitors.
6.2 ZP 24 auxiliary power supply
Auxiliary supply 24 VDC is necessary for thyristor switches modules or auxiliary relays excitation. Maximum
load of the supply is 100 mA, that means up to 10 thyristor modules (Model T or D) can be connected to a
single supply. In case of higher load appropriate number of supplies is required. The supply is without case (IP
20) and is equipped withholders for installation on DIN 35 mm.
230V
L N
24V
- +
58
54
Figure 7: ZP24 dimensions
L
N
230V
230V
L N
24V
- +
Control
L3
24VDC
Control
L3
24VDC
PFC common pole
1A
Figure 8: Possible connection of ZP24
10

7 Maintenance, Service, Warranty
Maintenance: the KATKA 80ST 690 modules does not require any special maintenance during its operation
but following should be respected. For reliable operation heat sink should be cleaned regularly from any debris
and dust as cooling performance can be reduced otherwise. Also regular inspection of fan operation (when
equipped) should be performed. It is also necessary to meet the operating conditions specified and not expose
the instrument to violent handling and contact with water or chemicals which could cause mechanical damage.
Service: in the case of failure or a breakdown of the product, you should contact the supplier at their address:
KMB systems, s. r. o.
Tˇr. dr. M. Hor´akov´e 559
460 05 Liberec 7
Czech Republic
Tel. [phone], Fax [phone]
E-mail: [e-mail], Web: www.kmb.cz
The product must be in proper packaging to prevent damage during transit. A description of the problem
or its symptoms must be delivered together with the product.
If a warranty repair is claimed, the warranty certificate must be sent in. In case of an out-of-warranty repair
you have to enclose an order for the repair.
Warranty certificate: warranty period of 24 months from the date of purchase is provided for the instrument,
however, no longer than 30 months from the day of dispatch from the manufacturer. Problems in the warranty
period, provably because of faulty workmanship, design or inconvenient material, will be repaired free of charge
by the manufacturer or an authorized servicing organization.
The warranty ceases even within the warranty period if the user makes unauthorized modifications or changes
to the instrument, connects it to out-of-range quantities, if the instrument is damaged due to ineligible or
improper handling by the user, or when it is operated in contradiction with the technical specifications presented.
Type of product: KATKA 80ST 690 Serial number: . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date of dispatch: . . . . . . . . . . . . . . . . . . . . . . . . . . . Final quality
inspection:
...........................
Manufacturer’s seal: . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date of purchase: . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplier’s seal: . . . . . . . . . . . . . . . . . . . . . . . . . . .
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