APS REG-6S-100 Manuale utente

Power factor regulators

REG-6S-100 / REG-12S-100

Instructions Manual

(M982282AP-03-13A)

M982282AP-03-13A REG-6S-100 / REG-12S-100

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Index______________________________________________________________

1INTRODUCTION AND SAFETY RECOMMENDATIONS ........................................................................3

1.1 DELIVERY SPOT CHECK....................................................................................................................................3

1.2 STARTING SCREEN...........................................................................................................................................4

1.3 DEFINITIONS....................................................................................................................................................4

1.3.1 Four quadrant regulators......................................................................................................................4

1.3.2 FCP program (FAST Computerized Program).....................................................................................4

1.3.3 Stages and steps ....................................................................................................................................4

1.3.4 Stages ratio program.............................................................................................................................4

2GENERAL CHARACTERISTICS..................................................................................................................5

3FRONT PANEL: SCREEN AND KEYBOARD.............................................................................................6

3.1 DISPLAY SCREEN.............................................................................................................................................7

3.2 MEASURED PARAMETERS ................................................................................................................................7

3.3 ERRORS AND ERROR MESSAGES ....................................................................................................................7

3.4 ALARM RELAY.................................................................................................................................................7

3.5 REGULATOR STATUS AND KEY FUNCTIONS......................................................................................................8

3.5.1 Key functions in normal RUN status.....................................................................................................8

3.5.2 Key functions in SET-UP status. ...........................................................................................................8

4INSTALLATION AND START UP ................................................................................................................9

4.1 TECHNICAL CHARACTERISTICS .......................................................................................................................9

4.2 DEVICE INSTALLATION..........................................................................................................................10

4.2.1 Mechanical Installation.......................................................................................................................10

4.2.2 Connections.........................................................................................................................................10

4.2.3 Cabling cross sections and protections...............................................................................................11

4.2.4 Schematics...........................................................................................................................................11

5CONFIGURABLE PARAMETERS..............................................................................................................12

5.1 TARGET COSΦ................................................................................................................................................12

5.2 SMALLER AVAILABLE CAPACITOR STEP.........................................................................................................12

5.3 C/K PARAMETER CALCULATION ....................................................................................................................13

5.4 STAGE’S CONFIGURATION OF PF CORRECTION EQUIPMENT (CONFIGURATION PROGRAM)............................13

5.5 CONNECTION AND RE-CONNECTION TIME SETTINGS:.....................................................................................13

5.6 SELECTION OF THE NUMBER OF STAGES.........................................................................................................14

5.7 U,I PHASE ANGLE SETTING.............................................................................................................................14

5.8 PROGRAMMING THE CT RATED CURRENT (PRIMARY)...................................................................................14

6SET-UP MENU AND PROCEDURE............................................................................................................14

6.1 HOW TO ACCESS THE SET-UP MENU...............................................................................................................14

6.2 NAVIGATION SCHEMATIC. .............................................................................................................................15

7RUN STATUS..................................................................................................................................................16

7.1 FUNCTIONS OF THE DEVICE IN NORMAL RUN MODE......................................................................................16

7.2 REG-6S-100/ REG-12S-100 BEHAVIOUR IN ALARM MODE........................................................................17

8MAINTENANCE ............................................................................................................................................17

9TECHNICAL SERVICE................................................................................................................................17

M982282AP-03-13A REG-6S-100 / REG-12S-100

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1 INTRODUCTION AND SAFETY RECOMMENDATIONS

APS would like to thank you for showing your trust by choosing one of our REG-6S-100 and REG-12S-

100 series regulators. These units are constructed with the latest state-of-the-art technology, including a

powerful processor to calculate the optimum algorithms for achieving the best compensation of cosφ.

The units comply with the Electrical Safety Standard EN 61010, in accordance with the requirements of

the Low Voltage Directive (LVD) 73/23/EC and EMC Directive (2004/108/EC) and, therefore, they are

certified to carry the CE mark.

This user manual describes the operation of the REG-6S-100 and REG-12S-100 series regulators and

shows the user the procedures required to install, commission and operate the units.

SAFETY

CAUTION!

The installation and maintenance of the unit must be performed by duly trained and

authorised staff and in accordance with the national and international standards. Any

inappropriate manipulation or use of this equipment out of the conditions specified by the

manufacturer may involve serious dangers to the user.

DANGER!

Before performing any maintenance operation on the computer and associated PF

compensation equipment, be sure to disconnect the main switch. After disconnecting the

switch, wait at least 5 minutes to ensure that the capacitors are totally discharged.

During the installation, maintenance or commissioning of equipment regulated by a REG-6S-100 and

REG-12S-100 unit, the following safety precautions must be observed:

Before connecting the equipment make sure that the earth terminals have been properly connected.

A defective earth connection may cause a wrong operation of equipment and involves a danger of

electric shock to the user or system operator.

Maintenance must be performed taking the necessary precautions to avoid electrocution and electric

shock. Ensure that the unit has been disconnected and wait the necessary time to ensure that the

capacitors are totally discharged before any maintenance action. We recommend the use of safety

goggles and gloves when cabinet doors are open and protection covers removed.

If a PF compensation unit is connected to mains and capacitors are accidentally connected without

load, a resonance may occur. In such condition voltage harmonics may be amplified, cause

overvoltage and damage the compensation unit and other equipment connected to the mains.

The start-up and interruption procedures indicated in the manual must be followed to avoid

damaging the PF equipment and/or other equipment connected to mains.

The adjustment or replacement of components or parts of the unit must be made with original

replacement parts and in accordance with the procedures described in the corresponding instruction

manual.

1.1 Delivery spot check

After unpacking the equipment check the following points:

Check that equipment has not suffered any damage during transport.

The equipment corresponds to type you ordered. (See label at the rear face, fig. 1.1)

Check that the characteristics in the label are suitable for the site where the regulator has to be

installed. (Supply voltage and frequency, measuring range, etc.)

Follow the instructions in section 3 for installation and set-up.

If you may observe any anomaly during the installation or set-up, contact with APS, technical

service.

M982282AP-03-13A REG-6S-100 / REG-12S-100

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Fig. 1.1.- Rear face label

1.2 Starting screen

When the REG-6S-100 and REG-12S-100 is started (just after supply

connection) the screen shows a code indicating the device version. It’s important

to indicate this code in case of reporting any device fault or error.

1.3 Definitions

In this section we shall give several definitions which will be useful to understand several sections of this

manual

1.3.1 Four quadrant regulators

This term is used to describe the regulators which are able to perform measure and control, either if the

active power flows from the utility to the customer network (the common case of a consuming facility) or if

it flows in the reverse sense. The later is the case of facilities containing power generation equipment

which export some amount of generated power to the utility.

1.3.2 FCP program (FAST computerized Program).

The units having FCP program, control the switching of capacitor stages in order to minimize the number

of switching operations to reach the required PF compensation. Moreover, the program assigns the

capacitor stages to be connected or disconnected using a FIFO criterion (FIFO= First IN, first OUT), that

way the times of use of all stages are equalized.

1.3.3 Stages and steps

We must distinguish between these two terms. In this manual we call STAGE to each of the capacitor

groups that constitute the PF correction unit. The capacitor stages in PF correction equipment may have

all the same power or not, as explained in the following paragraphs.

The term STEP is used to describe the minimum fraction of reactive power in which the PF correction

equipment is divided. Usually this is the power of the lower stage.

1.3.4 Stages ratio program

Powers of successive capacitor stages in PF correction equipment generally follow certain patterns called

stages ratio program or simply “Program”. The stages program indicates the relationship between the

different capacitor stage powers. Most common stages ratio programs are the as follows:

M982282AP-03-13A REG-6S-100 / REG-12S-100

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Program 1:1:1. All capacitor stages have the same rated power (kvar). For instance, a 5-stage unit of

100 kvar would be formed by 5 equal stages of 20 kvar and would be described as a unit of (5 x 20) kvar.

Program 1:2:2. All capacitor stages from the second and up have a rated power (kvar) which is twice the

rated power of first stage. For instance, a 5-stage unit of 180 kvar would be formed by a first stage of 20

kvar and 4 equal stages of 40 kvar, and would be described as a unit of (20 + 4 x 40) kvar.

Program 1:2:4. The rated power of the second stage is twice the rated power of the first stage and the

rated power of third stage and up is 4 times the power of the first stage. For instance, a 5-stage unit of

300 kvar would be formed by a first stage of 20 kvar, a second stage of 40 kvar and 3 equal stages of 80

kvar, and would be described as a unit of (20 + 40 + 3 x 80) kvar.

Other switching programs. Other switching programs are also commonly available, like 1:2:2:4 or

1:1:2:2, etc. Abbreviated designation form, as can be deduced from previous cases, consists of a

sequence of numbers giving the relationship between the different stage powers (kvar), and the first

stage power, which value is taken as unit (1 ). The successive stages will be designated by 1, or 2 or 4,

etc. meaning that the kvar ratio of such stages with regard to first stage are equal, twice, four times, etc.

2 GENERAL CHARACTERISTICS

The power factor regulators, of types REG-6S-100

and 2S-100 measure the cos φ

(sometimes called Displacement Power Factor,

DPF) in a supply network and control the

connection and disconnection of power capacitors

in order to regulate such parameter.

The difference between the two types is the

number of output relays, which determines the

number of stages that they can control.

Type

Maximum Nr of

output relays

REG-6S-100

6 relay outputs

REG-12S-100

12 relay outputs

Among the most important features of this PF regulator series we can stand out the following:

- FCP regulation system, which minimizes the number of switching operations.

- Wide choice of switching programs: 1:1:1, 1:2:2, 1:2:4 , 1:1:2:2, etc. which allows the split up of

the total power into up to 31 steps in or up to 79 steps in .

- Four quadrants control (see fig.2.1) , display of the connected stages, of cos φand active and

reactive power signs (inductive or capacitive )

- LCD display screen with three seven segments characters plus 20 icons to sign up the different

possible working conditions.

- Regulator set-up with only three keys and without disconnecting the device from the supply.

- Multiple supply frequency range, either 50 or 60 Hz

- Main electrical parameters displayed during RUN mode

- Easy panel mounting, without the need of tools.

- Front frame size (144 x 144 mm) according to DIN 43 700 (panel hole 138+1 x 138+1 mm)

- Measurement and power supply in one single input.

- Four quadrant regulation (suitable for installations importing or exporting energy)

M982282AP-03-13A REG-6S-100 / REG-12S-100

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0º

90º

180º

-90º

Imported Power

Exported Power

KW +

kVAr +

Leading/Capacitive

KW -

kVAr - KW +

kVAr -

Lagging / Inductive

KW -

kVAr +

Cos-

Lagging / Inductive

Cos-

Cos+

Leading/Capacitive

Fig. 2.1.- Power signs in four quadrants measurements

3 FRONT PANEL: SCREEN AND KEYBOARD

The PF regulator’s front panel shows the following items:

Fig. 3.1.- Front cover and screen

NOTE: The set-up procedure, the description of different

parameters and the different control modes are described in detail in

the SET-UP section (section 6)

Front Screen

Configurable Parameters

Measured Parameters

Navigation keys

M982282AP-03-13A REG-6S-100 / REG-12S-100

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3.1 Display screen

REG-6S-100 and REG-12S-100 devices are equipped with a 3 digits x 7 segments LCD screen. The

screen has also a set of icons, which provide information about the regulator status. The main indications

are: cosφ value, reactive power sign ( for lagging or inductive PF and for leading or capacitive

PF), connected stages and measurement of different parameters (see section 3.2)

Icons

Screen and LED

Icons Indications

: Lagging or inductive

power indication

: Leading or capacitive

power indication

The LED (red) is ON

in normal working conditions

The LED shows

that the reading of current or

max. current has to be

multiplied by 10

In normal working conditions, RUN

LED (red) is ON and cursor

points to the parameter being

displayed (Left column list)

In SET-UP mode, the RUN LED is

OFF, the cursor is blinking and

pointing to the parameter being

configured (Right column list).

Symbols indicating the stages

which are connected (only in RUN

mode)

3.2 Measured parameters

When the instrument is in normal RUN mode, the following parameters can be displayed: cos, mains

current, THD of both mains current and mains voltage. The instrument can also display the maximum

values of mains current and voltage since the last parameters clear. The parameter being displayed can

be selected with the navigation keys and is indicated by the cursor.

3.3 Errors and ERROR messages

In case that the regulator detects a possible error, the front screen shows an error code. The possible

error codes are listed and explained in table 3-1.

Table 3-1: Possible errors and messages displayed on the screen

ERROR

message

Description

Load current below the threshold current, or current transformer (CT) not

connected. The threshold is 0,1 A at the secondary side of CT

Overcompensation. The regulator detects that some stages should be

disconnected but all the stages are already disconnected.

Under-compensation. The regulator detects that some stages should be

connected and all the stages are already connected.

Overcurrent. The measured current exceeds the rated current by a + 20%.

(Rated current is considered to be the CT primary rated current)

Overvoltage. The measured voltage exceeds the rated voltage by a +15%.

3.4 Alarm relay

In case that the number of stages configured in a REG-6S-100 or REG-12S-100, is less than 6 or 12

respectively, the relay number 6 or 12 is automatically configured as alarm relay. The relay remains

connected in absence of alarm (positive safety) and disconnects in case that one or more of the errors

listed in section 3.2 occur. Notice that the absence of supply voltage will always be detected as an alarm

condition. The alarm relay has a delay of 10 s in case of Over-compensation and Under-compensation,

but the operation is instantaneous (delay < 1 s) in case of Over-voltage and Over-current.

M982282AP-03-13A REG-6S-100 / REG-12S-100

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3.5 Regulator status and key functions

REG-6S-100 and REG-12S-100 regulators have two possible status.

Normal or RUN Status: This is the normal working status of the regulator. In such status the device

measures and displays the cosof the loads and automatically regulates the connection and

disconnection of capacitors in order to compensate according to programmed target value. The regulation

depends on several parameters configured during the starting set-up process.

Set-up or adjustment status: This status allows the configuration of the device. Push the key for a

time >1 s to enter the set-up status mode. This will stop the automatic PF regulation, will cause the

progressive disconnection of connected stages and once disconnected will allow the set-up of the

regulator.

The navigation keys have different functions depending on the regulator status.

3.5.1 Key functions in normal RUN status.

Key to enter set-up mode: After a long push (> 1 s) of this key, the device will enter

the set-up mode, and will accept configuration changes.

Manual connection of capacitor stages: If this key is pushed for more than 1s, the

regulator starts connecting new steps in a sequential mode, respecting the adjusted

connection times, ton

Manual disconnection of capacitor stages: If this key is pushed for more than 1s,

the regulator starts disconnecting steps in a sequential mode, respecting the adjusted

disconnection times, toff

3.5.2 Key functions in SET-UP status.

Long Push (>1 s): This is to initiate or exit the set-up mode. Exiting the set-up mode

with a long push (>1 s) will automatically save the changed parameters. Exiting with a

short push will not save the changes.

Long Push (<1 s): This is used to initiate or exit the different set-up sub-menu options

(different configurable parameters). Warning! The new programmed values are not

saved unless a long push of this key (>1 s) is used to exit the set-up menu.

Upwards navigation in the menu options available in the set-up menu.

Increment of numerical values inside the set-up sub-menus.

Downwards navigation in the menu options available in the set-up menu.

Decrement of numerical values inside the set-up sub-menus.

Change the digit to be edited in case of numerical values with more than one digit.

long push

Alarm Enable / Disable: keep pushing these keys at the same time for more than 1s

to disable or enable Measured current below threshold, Over-

compensation and Sub-compensation alarms (paragraph 3.3). When these alarms

were disabled, the regulator doesn’t show its error messages.

M982282AP-03-13A REG-6S-100 / REG-12S-100

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4 INSTALLATION AND START UP

This section contains information instructions and warnings that the user must follow by its own security

and to ensure safe operation of the device.

WARNING! REG-6S-100 and REG-12S-100 regulators are usually connected to

equipment containing capacitors, which remain charged after removing supply voltage. To

avoid risk of electric shock, you must wait at least 5 minutes between the disconnection

of the equipment and handling of the internal components thereof.

Any handling or use of equipment in different way or conditions to that specified by

the manufacturer, may compromise the user safety.

In case that some damage or deterioration signs are detected in the device or a wrong operation is

observed, disconnect the supply voltage and contact APS authorized technical service.

To safely use the REG-6S-100 and REG-12S-100 it is important that people installing it or handling it

follow the usual safety precautions stated in the LV or MV Electrical Code Rules of each Country as well

as the different warnings stated in this instruction manual.

4.1 Technical Characteristics

The main technical characteristics of every particular REG-6S-100 and REG-12S-100 device are printed

in the rear label (see fig. 1.2) and are also summarized in the following table.

Supply and measuring circuit

voltage (Terminals C-D)

480, 400, 230 or 110 Vac ; +15% -10% (depending on model);

45…65 Hz. Connect preferably to phases L2-L3.

Supply Cables

Cross Section 1,5 mm2

Supply circuit protection

By means of a 0,5 to 2 A fuse (gl type)

Current measurement circuit.

(Terminals A-B)

External Current Transformer (CT). Current ratio In/5. To be placed

preferably in phase L1.

Cables for the current

measurement circuit (CT

secondary side)

Minimum cross section : 2,5 mm2. If cable length between regulator

and CT must exceed 25 m, increase the cross section by 1mm2every

10 m or use a CT with a higher primary rated current.

Current margin

0,05 to 5 A (maximum overload +20%)

Measurements precision

Voltage and Current: 1%; cos: 2% 1 digit

cossetting margin

0,85 ind. A 0,85 cap. Default setting: 1

Power Consumption

(depending on model)

110 V: 7 VA (no load); 8,8 VA (6 relays); 10 VA (12 relays)

230 V: 7,4 VA (no load); 8,2 VA (6 relays); 9,9 VA (12 relays)

400 V: 5 VA (no load); 6,6 VA (6 relays); 8,8 VA (12 relays)

480 V: 8,7 VA (no load); 9,5 VA (6 relays); 10,7 VA (12 relays)

Screen

1 line x 3 digits x 7segments + 20 icons

Output: Relay contacts

Working voltage: 250 Vac, Admissible current: 4 A, AC1.

Cabling and protection of

relays output.

Minimum cables cross section: 1,5 mm2, Protect by means of a circuit

breaker 6 A, curve C or fuse 6 A, gl type

Alarm relay

In case that not all the relay outputs are used to drive the capacitors,

the highest number relay is by default configured as alarm relay.

Reference standards

EN 61010, EN 61000-3-2, EN 61000-3-3, EN 50081-2, EN 50082-1, EN

50082-2, EN 61000-4-2, EN 61000-4-4, EN 61000-4-8,

EN 61000-4-5, EN 61000-4-11 , UL 94

Safety and Insulation class

Installation Category III. Protection against electrical shock with

double insulation (class II ), according to EN 61010-1

Protection degree

IP 40 (device mounted in panel front)

IP 30 (device case) according to EN-60529

Environment admissible

conditions

Temperature: -20 … +60 ºC; Relative humidity: max. 95% (without

condensation). Max. altitude: 2000 m

Control system

FCP (Program which minimizes the number of operations)

M982282AP-03-13A REG-6S-100 / REG-12S-100

- 10 -

4.2 DEVICE INSTALLATION

4.2.1 Mechanical Installation

Mechanically, the device is intended to be mounted attached to the front door of the cabinet. The fitting

hole must be according to DIN 43 700, (dimensions 138+1x138+1mm).

4.2.2 Connections

Before connecting the supply to the device check the following items:

The installation and maintenance of the device must be carried out by specialised and dully

trained staff, according to National Electric Codes and Rules and International Standards

All the connections must be at the inner part of a protection cabinet.

Notice that when the device is connected to supply, the voltage at certain terminals can be

hazardous and cause electric shock in case of contact. Opening the electrical cabinet or

removing certain covers can compromise the user safety and should only be done by

qualified and authorized staff.

The REG-6S-100 and REG-12S-100 devices are used together with capacitor banks, which

can remain charged after supply disconnection. In order to avoid shock hazard, wait during 5

minutes after supply disconnection before any manipulation inside the equipment cabinet.

REG-6S-100 and REG-12S-100 devices require current sensing of the installation. A current transformer

(CT) must be installed externally to perform this function. Usually the current ratio of the CT is In/ 5 A,

where In must be at least 1,5 times the maximum expected load current.

The CT must be installed at the incoming supply line (point of coupling of the user), so that it measures

the total current of all the loads, including also the compensation capacitor bank (see fig. 4.1)

The CT should be installed preferably in phase L1, while the voltage measuring terminals of REG-6S-100

and REG-12S-100 should be connected to phases L2 and L3 (see schematics in figs. 4.2 and 4.3). It’s

important to respect the connection senses of P1-P2 and S1-S2 shown in the above mentioned figs,

otherwise the phase difference will have to be corrected by adjusting the device according to set-up

procedure indicated in paragraph 5.17.

RIGHT CONNECTION

WRONG CONNECTIONS

LOAD CAPACITORS

TC S1

The CT measures the whole

current of loads + capacitor bank.

In case of malfunction check that

the CT is not shortcircuited

TC S1

LOAD CAPACITORS

If CT is placed in this position,

NONE of the CAPACITOR

STAGES WILL CONNECT.

The equipment does not regulate

properly.

TC S1

LOAD CAPACITORS

If CT is placed in this position

ALL THE CAPACITOR STAGES

WILL CONNECT.

WARNING! This situation may

cause overcompensation,

resonance and overcurrent

Fig. 4.1.- Placement of current transformer (CT)

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