COMAR QSR 6 Power Factor Regulator User Manual
The QSR 6 is an automatic microprocessor regulator that controls the switching on and off of capacitor banks to maintain the desired power factor. It operates using an RMS measure for accurate operation and display, even in the presence of harmonics. The microprocessor controls all settings and parameters.
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ATTENZIONE
La COMAR declina ogni responsabilità per eventuali danni a persone o cose originati da uso improprio o da errato impiego dei propri prodotti.
Soggetto a modifiche senza preavviso.
WARNING
COMAR declines all liability for any damage to people or property caused by unsuitable or incorrect use of its products.
Comar reserves
The right to change product specifications wiThout prior notice.
ATTENTION
COMAR décline toute responsabilité pour éventuels dommages à personnes et matériels causés par une utilisation impropre ou par un emploi des produits incorrect. Comar se reserve le droit de modifier sans preavis les caracteristiques tecniques des materiels.
ACHTUNG
COMAR lehntjede
Verantwortung für eventuelle
Schäden an
Personen oder
Sachen infolge von unsachgemäßem
Gebrauch der
Control ab.
Änderungen vorbehalten.
ATENCION
La COMAR declina toda responsabilidad por eventuales danos a personas o cosas producidos por el uso inadecuado o equivocado de sus productos.
Puede ser modificado sin preaviso.
COMAR CONDENSATORI S.p.A.
Via del Lavoro, 80 - CRESPELLANO (Bologna)
Tel. + 39 51 733.383 - Fax + 39 51 733.620
P.O. Box 134 - 40011 ANZOLA EMILIA (Bologna)
USER MANUAL
QSR6 User manual page 21
1.4
1.5
2
2.1
2.2
2.3
2.4
1
1.1
1.2
1.3
2.5
3
3.1
3.2
3.3
3.4
3.5
4
4.1
Index
Instruction
Introduction p.22
p.22
Operator safety p.23
Instructions for proper p.23
installation
Cleaning
Warranty
General
Unit description
Mechanical fixing
Working situation
Power of controlled banks
Number of steps p.23
p.24
p.24
p.24
p.24
p.25
p.25
p.25
Technical features
General features
Reference standard p.26
p.26
p.27
Mechanical dimensions p.28
Pinout diagram p.29
How to choose the C.T. p.30
Functions p.32
Powering on p.32
21
4.2
4.3
4.4
4.5
4.6
4.7
5
5.1
5.2
6
Key functions
Automatic
Manual
Manual insertion of the banks
Alarms
Alarm memory
Set-up
C/K setting
P.F. setting
Working troubles and solution p.32
p.33
p.34
p.35
p.36
p.37
p.38
p.38
p.39
p.40
1 Instruction
1.1 Introduction
Before connecting the regulator to the mains, read the instructions in this handbook, they provide important indications about the safety, use and maintenance. Take carefully this handbook for any information.
This regulator has been manufactured and tested in accordance with international standard, it leaves the factory in perfect safety conditions. In order to mantain these condition and to ensure safe operation, the user must comply with the instructions and remarks given in this manual. After removing the packaging check that the regulator has not been damaged during transport.
In case of doubt, do not attempt to fix or use the regulator. If the equipment has falled down or has been violently shaken during transport, it could suffer internal damages which may be dangerous.
After checking that regulator cannot be safely used, it must be placed out of order and not used before checking of experienced personnel. Causes that bring to put the regulator out of order are the presence of external damages, missed functioning, unproper stocking or transport conditions. Technical
Assistance on the regulator must be performed exclusively by COMAR personnel.
22
1.2
Operator safety
Before to perform any maintenance, the regulator must be disconnected from any power supply source, wait 5 minutes before start any action. During maintenance it is necessary to follow standard safety procedures. Do not touch any printed circuit board for any reason.
This regulator will be assigned only to the use for which it has been specifically made. Each other use has to be considered improper and therefore dangerous.
1.3 Instruction for proper installation
Before connect the equipment, check the data plate: this has to be in conformity with the electrical network (the plate is located on the back of the P.F. Regulator). The regulator is not provided with protection fuse on the power supply, it has to be protected externally by the user. Being the regulator designed for permanent operation (CEI EN 61010-1), the supply have to be interrupted by automatic switch, which has to be placed close the regulator for easy intervention.
For the correct functioning of the equipment, the limit of voltage, current and temperature, imposed by the CEI and IEC standard must never be exceeded. The equipment has to be protected from athmospheric conditions.
1.4 Cleaning
After disconnecting the instrument from the power supply, clean the external surface of the plastic box using a soft cloth dipped in water only.
Never use abrasive or solvent. Never wet the connection terminals.
23
1.5 Warranty
Comar Condensatori S.p.A. guarantees its own products for twelve months from purchase date.
The warranty covers the faults of materials and manufacture and it has to be understand for goods ex-works. Before the equipment works, all instructions, present on this handbook, have to be meticulously followed. Breakdowns caused from improper use and/or not conformity to enclosed instructions and faults caused from tampering by unqualified technicians aren’t covered.
The misuse of any of the previous points will erode the right of warranty.
2 General
2.1 Unit description
QSR is an automatic microprocessor regulator which operates the switching on and off of the capacitors steps which are necessary to reach and to maintain the required power factor value. The QSR operate an RMS measure which allows correct operation and display even in presence of harmonics.
The central microprocessor unit controls all settings and parameters.
2.2 Mechanical fixing
The regulator should be mounted in a cutout (drilling template 92x92mm.) using the special fixings supplied.
24
2.3 Worning situation
The regulator works according to binary logic sequence; the switching on and off of capacitors banks always start from the first bank.
2.4 Power of controlled banks
For correct operation of the automatic bank, the power ratio per bank should be: a.
b.
c.
equal to each other double of the previous bank equal or double of the previous bank
(1-1-1-1-1-1-1-1)
(1-2-4-8-16-32)
(1-1-2-2-4-4)
2.5 Number of steps
Is determined by the power combination which has been used on single capacitors bank:
Examples: 6 banks in the sequence 1-1-1-1-1-1
6 banks in the sequence 1-1-2-4-4-4 make 6 steps make 16 steps
6 banks in the sequence 1-2-4-8-16-32 make 63 steps
Note. A too high number of steps as a too high power of first step , produce an high number of switching operation that reduce the life of the equipment.
When the first step is too high in power hunting may occur which again would produce excessive wear and reduced life of the components.
Normally 8-16 regulating steps is the best solution to adopt
25
3 Technical features
3.1 General features
Rated supply voltage
Rated consumption
Rated supply current
Multivoltage 380
÷
415V a.c.
±
10%
400V -10% / +5% continuous operation
3 VA
By means of CT secondary side
5A max., 1st class - 5VA (Imin. = 500mA)
Current circuit consumption 2VA
Rated frequency
Controlled banks
50Hz or 60Hz autoset
6
Output relays 5A 250 Va.c. resistive load
Max current relays common 5A at 40
°
C resistive load
Switching steps delay
Alarm delay
P.F. setting
Operating range
25" (5" on request)
10"
÷
1"
0,90 lag
÷
0,90 lead
Power Factor 0,20
÷
1,00 lag / lead
Digital monitoring Alphanumeric 2x16 characters
Measurement monitoring
Accuracy
LCD display
P.F. 0,20
÷
1,00 lag / lead
On the P.F. regulation range
±
2 f.s.
at +25
°
C and 2,5A.
26
Temperature accuracy
Connection
Mechanical dimensions
Cut out dimension
Mechanical fixing
Plastic case
Weight
Protection degree
Working temperature
Storage temperature
Relative humidity
Type of service
+/- 10%
With terminal fixing screws, cable of 2,5 mm
2
c.s.a.
96x96 mm FRONT (according to DIN43700)
60mm DEPTH
92x92 mm (tolerance -0mm /+ 1mm).
With the special accessories supplied included
Insulating self-extinguishing material
0,5 Kg
IP 54 front panel - IP20 terminal board
0
°
C to + 50
°
C
-20
°
C to +60
°
C
Max. 90% at 20
°
C noncondensing
Indoor service, no dusty condition. Do not place directly under sun light.
3.2 Reference standard
Safety
EMC
Protection degree
IEC 1010 440V CAT III
EN50082-1, EN50082-2, EN50011,
EN55022
CEI-EN 605.29
27
3.3 Mechanical dimensions
96mm
91mm
4" Setup
Power Factor Regulator
3,5mm
60mm
38,2mm
18,3mm
28
3.4
Carichi
Loads
Charges
Verbraucher
Cargas
Pinout diagram
C1....6
220V
T1 T2 T3 T4 T5 T6
0V
Max 4A
1A
CT../5
L K
A A
X1X2 1 2 3 4 5 6 C
Allarme
Alarm
Alarme
Störung
Alarma
V V
29
3.5 How to choose the CURRENT TRANSFORMER (C.T.)
Use a Current Transformer (C.T.) with 5A at secondary circuit and primary equal or slightly higher than the maximum absorbed by the loads. The C.T. must be chosen in such a way to obtain a good current signal in the secondary circuit. Current values between 0.5 and 5Amps are suitable to obtain good working conditions of the regulator.
The C.T. must be good quality (first class) and with power equal or higher to 5VA. If the C.T. has been mounted far from the equipment, it needs to add the normal demanded the power consumed from the cables of connection
(normaly 0.2VA per meter of bifilar lines with 2.5mm
2
section) and the power dissipated by others possible tools connected in the circuit.
The equations, used to calculate the real losses, are the sequents:
R = 2 x x L/S
P=(R+0.08) x I
2
(VA)
(
Ω
) Total resistance of amperometric circuit
L o s s e s o f a m p e r o m e t r i c a l c i r c u i t
‘ ’ is the electrical resistivity ( 0.018 for the copper )
‘L’ is the length of amperometric circuit (mt)
‘S’ is the across section of cables at the secondary of TA
‘I’’ is Imax. at the secondary of C.T.
‘0.08’ are the internal resistance of P.F. regulator
When single-phase inductive loads are connected (unbalanced three-phase system), place C.T. on the phase where Power Factor is lower and/or where higher current value is absorbed.
The cables at the secondary of C.T. have to be of 2,5mm
2
section.
The C.T. connection must not to be protected with fuses or interruped by switch.
30
The C.T. has to be connected to the line, upstream the load and the P.F.
Regulator: the C.T., can then measure the current demanded by the load, inductive and capacitive. Possible capacitors for fixed P.F.Regulation will be mounted downstream of the C.T., as they aren’t used and dimensioned for the P.F. Regulation of transformers that feed the load.
It’s important to check that the phase, where the C.T. is connected, is the same that will be connected to terminals of the main switch, inside the equipment, signed with the letter “L1”.
Before doing any work on the C.T. circuit, be sure that the C.T. is shortcircuited, otherwise dangerous voltages can rise, add bringing to breakdown the C.T.
P.F. correcting two or more lines (transformers in parallel), you need to use two or more C.T (.../5) of which the secondary circuits will be supplied a add transformer with 5Amps at secondary: connect the current transformers at the same phase.
If two or more C.T. ‘s are used with an additional transformer, the value of the primary current is the sum of each C.T. Example: n
°
3 C.T. ‘s 500/5 = n
°
1 C.T. 1500/5.
Connecting two or more cables (for load and P.F.Regulator) on the same terminal - phase “L1” - from the general main switch, It needs to pass through the hole of the C.T. all the derived cables.
Note. QSR regulators are able to detect automatically the current phasing of the CT. It is not necessary to ensure correct polarity connections as with other Power Factor Regulators.
31
4 Functions
P.F. Value
“+” P.F. Lag
“-” P.F. Lead
Banks
4.1 Powering on
When power is switched on, an internal disconnection self test routine has been performed.
The display shows the installed s/w release.
Spinning when working
+0,93 PF/
CAP 123 --- IND
Output
ON
Output
OFF
Banks connenction
Power Factor Regulator
SELF TEST - v1.9
4.2 Key function
The key enable change from
“Automatic” to “Manual” (light is on).
When pressed for 4 seconds it enable to enter the set-up page and confirm setting
4" Setup
After start-up process, the regulator is working in ”Automatic” operation.
Keys used in “Manual” enable switch-on and off the output.
Used in “SET-UP” enable setting of the value.
U s e d i n “ A u t o m a t i c ” e n a b l e visualization and reset of “Alarm memory”.
32
4.3
Automatic
Power Factor Regulator
+0,93 PF/
12345 - IND
4" Setup
Fig. 1
Power Factor Regulator
-0,99 PF/
CAP -345 -
4" Setup
Fig. 2
Power Factor Regulator
+0,97 PF/
--45 -
4" Setup
33
Fig. 3
Fig.1: inductive loads connected
(motors, transformers, decharge lamps, etc.).
“IND” indication on and regulator that inserts the required outputs.
Fig. 2: capacitive loads connected.
“CAP” indication on and regulator that disconnects the exceeding outputs.
Fig. 3: P.F. value setted is achieved when Cap and IND indications are off. Output are not changing.
4.4
Manual
Power Factor Regulator
+0,93 PF/ MANUAL
123 ---
Power Factor Regulator
-0,99 PF/ MANUAL
CAP -3456
4" Setup
Fig.1 The key is lit (on)
Power Factor Regulator
+0,99 PF/ MANUAL
123456 IND
4" Setup
Fig.2 Output insertion (switch on)
34
4" Setup
Fig.3 Output switch off
Manual working visualize balanced load (IND and CAP indication off).
Switch on/off are made only after the proper response time (25 seconds standard).
4.5
Manual insertion of the banks
Power Factor Regulator
+0,93 PF/ MANUAL
1 -----
Power Factor Regulator
+0,93 PF/ MANUAL
------
4" Setup
Fig.1 Bank insertion
Power Factor Regulator
+0,93 PF/ MANUAL
1 -----
Blinking
4" Setup
Fig.2 Entering memory
4" Setup
Fig.3 Reset memory
In Automatic operation the “stored” output are always on.
The remaining output are working in Automatic, the stored output can be disconnected exclusively when operation shows in fig.3 occurs (key on, key pressed) or switching off the power supply
35
4.6
Alarms
The QSR has a normally closed NC alarm contact (rated 5 A 250 V resistive load). It will be possible to give an external alarm signal. This contact is signed with X1 and X2 in the base of the regulator.
When alarm condition disappears, the regulator will reset itself automatically.
Reference
No supply voltage
Low P.F. value
in the network
Low voltage
High voltage
Zero Current
Condition Display indications Alarm relay
X1 X2
V = 0
PF = IND for 15 minuts
V < 340Vac RMS for 10 seconds
V > 450Vac RMS for 10 seconds
A<50mA RMS for 10 seconds
Blinking
0,35 PF/ ALARM
123456
Blinking ALARM
0,95 PF/ MIN V
123 ---
Blinking ALARM
0,95 PF/ MAX V
------
X1
X1
X1
X2
X2
X2
Blinking ALARM
-,-- PF/ A = 0
------
X1 X2
Quick switch off for all outputs
Quick switch off for all outputs
Quick switch off for all outputs
36
Reference
Low current
Hight current
Leading P.F. value
Hight temperature
No alarm
Condition
A<350mA RMS for 10 seconds
A>5,5A RMS for 10 seconds
PF<
±
0,20 for 10 seconds
T
°
>50
°
C for 10 seconds
Hysteresis level 5
°
C
Standard operation
Display indication
Bliking ALARM
0,35 PF/ MIN A
123 ---
Bliking ALARM
0,95 PF/ MAX A
123 ---
Bliking ALARM
-,-- PF/ CAP
------
Bliking ALARM
0,95 PF/ TEMP
------
Alarm relay
X1 X2
X1 X2
Inhibit output insertion
X1 X2
Quick switch off for all outputs
X1 X2
Quick switch off for all outputs
X1 X2
0,95 PF/
123 ---
4.7
Alarm memory
To visualize last alarm press
MEMORY = MAX V
123 ---
To erase memory press at the same time
MEMORY = VOID
123 ---
A dot indicates an alarm message stored in memory
37
5 Set-up
5.1
C/K setting
Power Factor Regulator
+0,93 PF/ MANUAL
123 ---
4" Setup
Puss 4 seconds for aut. functioning
Power Factor Regulator
SETUP
3 C/K +0,97 PF
Blinking
4" Setup
38
The suggested value to set is given on the table.
Use the or buttons to change the selection.
C/K
T.A. - C.T.
5
30/5 5
50/5
60/5
80/5
100/5
150/5
3
2
3
3
3
200/5
250/5
300/5
400/5
500/5
600/5
800/5
2
1
1
1
2
2
2
1000/5
1200/5
1500/
2000/5
2500/5
3000/5
4000/5
1
1
1
1
1
1
1
Power 1 st
bank (kvar)
2
2
1
1
2
2
2
4
4
3
6
5
3
3
1
1
1
1
1
1
1
2
2
2
2
3
3
3
12,5
-
-
5
5
4
3
1
1
1
2
1
1
1
3
3
2
2
3
3
3
-
-
-
20
-
5
5
1
1
1
2
2
2
1
2
2
2
2
3
3
2
10
-
5
5
5
3
3
1
1
1
1
1
1
1
3
3
3
2
4
3
3
-
-
-
25
-
-
5
1
1
1
2
2
2
1
4
3
3
3
-
5
5
-
-
-
-
-
50
-
2
2
2
3
3
2
2
3
3
3
3
5
5
4
-
-
-
-
-
40
-
2
2
1
3
2
2
2
When the CT secondary current signal is lower than 2 amps, the C/K value should be increased by 0,1.
When using the regulator on 220Vac networks the C/K values should be doubled.
“-” means installation of C.T. with primary value too small.
5.2
P.F. setting
After setting the C/K value
Power Factor Regulator
SETUP
3 C/K +0,97 PF
Blinking
4" Setup
Press the “Manual” key
Power Factor Regulator
SETUP
3 C/K +0,97 PF
Blinking
4" Setup
Use the or buttons to change the selection. A P.F. of 0,95 is recommended.
By pressing the button, the C/K and P.F. values which have been selected will be saved and the regulator works in “Automatic” condition.
39
6 Working tuonbles and solution.
TROUBLE Soluzione
All banks on with a low inductive load on the network
Continous switching on and off of first bank (hunting phenomena)
The CT is connected upstream the load but not of capacitors.
Connect the CT as shown in the connection diagram ( § 3.4).
a) The C/K value is not correct.
Check in the table "C/K VALUES" for the right value ( § 5.1).
b) The power of the first bank is too high for the selected PF requirements.
Reduce the first bank power according to paragraphs 2.4 and 2.5.
Increase the selected PF value ( § 5.2).
Displayed PF values not correct
CT installed in the wrong phase: connect to phase L1 ( § 3.4).
IND and CAP leds off a) Possible stand-by condition: at least one capacitor bank on.
Check the PF value of the network on the display.
b) Possible MANUAL working condition: choose the AUTOMATIC operation.
IND led ON and no insertion of capacitor banks
Minimun current alarm. Current lower than 500mA (see § 4.6).
CAP led is ON without capacitor banks working
CT installed in the wrong phase: connect to phase L1 (see § 3.4).
Blinking display
Display off, regulator not working
Display on, banks inserted signalling, but capacitors not working a) Alarm condition of least one value: see chapter (§ 4.6). b) Check supply voltage is correct.
a) Check if supply voltage is present.
b) Check if supply voltage is equal to the rated voltage of the regulator.
a) Check if supply voltage is equal to the rated voltage of the regulator.
b) Check the “0Vac” connection on contactors. c) Check if “220Vac” has been connected on "C" terminal.
d) Check contactor functioning.
Displayed “ ALARM CAP” on display a) Possible capacitive load condition.
b) CT installed in the wrong phase: connect to phase L1 (§ 4.6).
c) P.F. lower than 0,20 IND or CAP.
Displayed “-.--” on display a) Zero current signal: check the C.T. and its connection and ensure the minimum secondary current level is least 10mAmps (§ 3.4).
b) C.T. connected on the supply cable of the PFC equipment.
Connect according the connection diagram ( § 3.4).
IF PROBLEMS PERSIST AFTER ALL ABOVE MENTIONED SOLUTIONS SWITCH OFF THE REGULATOR FOR AT LEAST 20
SECS AND THEN SWITCH ON AGAIN. IF THE PROBLEM IS STILL PRESENT PLEASE CALL OUR TECHNICAL DEPARTMENT.
40
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Key Features
- Microprocessor control
- RMS measurement
- Automatic and manual operation
- 6 capacitor banks
- Alarm functions
- Adjustable C/K setting
- Preset P.F. setting
- Digital display