AccuSine Power Correction System (PCS) Models: N1, N12, CH, IP30, IP54

Transcription

2 TABLE of CONTENTS 1 Important Information Before You Begin Delivery Delivery Inspection Storage Installation Load Requirements for Optimum Performance Environmental Requirements Physical Installation Physical Description Standard Units Physical Description Integrated Transformer Chassis Systems Environmental Requirements Electrical Connection Circuit Breaker and Manual Disconnect Selection Power Cable Routing Current Transformers (CT) General CT Information Minimum CT Requirements TB1 (Terminal Board 1) CT Installation Single Unit CT Installation Parallel and Transformer Systems Control Wiring Dry Contacts Ethernet Connection Pre-Commissioning General Installation Inspection...2 List of Figures Figure 1: 50 Amp Enclosure Type N1 Dimensional Drawing...28 Figure 2: 50 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...29 Figure 3: 100 Amp Enclosure Type N1 Dimensional Drawing...30 Figure 4: 100 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...31 Figure 5: 300 Amp Enclosure Type N1 Dimensional Drawing...32 Figure 6: 300 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...33 Figure 7 Optional Floor Stand Installation Instructions...34 Figure 8 Floor Stand Mounting Hole Drawing...35 Figure 9: 33 & 39 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...44 Figure 10: 67 & 78 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...45 Figure 11: 200 & 235 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing...46 Figure 12: 50 Amp Chassis Dimensional Drawing...52 Figure 13: 100 Amp Chassis Dimensional Drawing...53 Figure 14: 300 Amp Chassis Dimensional Drawing...54 Figure 15: HMI Panel Cut Dimensions...55 Figure 16: USB Panel Cut Dimensions...56 Figure 17: Typical HMI Cable Connections...57 Figure 18: 50 Amp HMI Cable Route...58 Figure 19: 100 Amp HMI Cable Route...59 Figure 20: 300 Amp HMI Cable Route...60 Figure 21: 50 Amp Enclosure Type N1 Internal Layout Drawing...78 Figure 22: 50 Amp Enclosure Type N12, IP30 IP54 Internal Layout Drawing...79 Figure 23: 100 Amp Enclosure Type N1 Internal Layout Drawing...80 Figure 24: 100 Amp Enclosure Type N12, IP30, IP54 Internal Layout Drawing...81 Figure 25: 300 Amp Enclosure Type N1 Internal Layout Drawing...82 Figure 26: 300 Amp Enclosure Type N12, IP30, IP54 Internal Layout Drawing...83 Figure 27: 33 & 35 Amp Enclosure with Integrated Transformer Layout Drawing...84

3 Figure 28: 67 & 70 Amp Enclosure with Integrated Transformer Layout Drawing...85 Figure 29: 200 & 235 Amp Enclosure with Integrated Transformer Layout Drawing...86 Figure 30: Load Side CT Position Diagram...89 Figure 31: Grid (Source) Side CT Position Diagram...90 Figure 32: Load Side CT Position Parallel Units Diagram...93 Figure 33: Grid (Source) Side CT Position Parallel Units Diagram...94 Figure 34: Load Side CT Position with Transformer Diagram...95 Figure 35: Grid (Source) Side CT Position with Transformer Diagram...96 Figure 36: Ethernet Port Location...1 List of Tables Table 1: Clearance Requirements per Enclosure Type...6 Table 2: Clearance Requirements Integrated Transformer Units...9 Table 3: Qualifications for Enclosure Types...10 Table 4: Physical Specifications Enclosures...20 Table 5: Physical Specifications Enclosures with Integrated Transformers...36 Table 6: Physical Specifications Chassis...48 Table 7: Cable De-rating Factors...62 Table 8: Cable De-rating Factors...62 Table 9: Electrical Specifications 50, 100 and 300 Amp Units...63 Table 10: Electrical Specifications with Integrated Transformer...72 Table 11: CT Wiring for Multiple Unit Operation...91 Table 12: Current-Ratio of Auxiliary CT...92 Table 13: Typical Maximum Distance for CT Wire Length...97 Table 14: CT3000SC & CTFCL Cable Lengths...98 Table 15: Terminals for Dry Contact Layout NEMA1 50, 100 & 300Amp Units...0 Table 16: Terminals for Dry Contact Layout...0

4 1 Important Information Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service, or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists that will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to identify potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.! DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.! WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.! CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. CAUTION CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in property damage. Note: Provides additional information to clarify or simplify a procedure. PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by the manufacturer for any consequences arising out of the use of this manual. This document does not constitute an instruction manual for inexperienced personnel.

5 2 Before You Begin This chapter contains important safety precautions that must be followed before attempting to install, service, or maintain electrical equipment. Carefully read and follow the safety precautions outlined below.! DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH! This equipment must only be installed and serviced by qualified electrical personnel. Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. NEVER work alone. Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of back-feeding. Turn off all power supplying this equipment before working on or inside. Always use a properly rated voltage sensing device to confirm that all power is off. Wait 10 minutes after removing power before opening the door or removing covers to permit the DC bus capacitors to discharge. Replace all devices, doors and covers before turning on power to this equipment. The successful operation of this equipment depends upon proper handling, installation, and operation. Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property. An open circuit current transformer (CT) secondary may develop lethal voltage. Short the CT terminals before and while working on CT circuits. Never open circuit the terminals of a CT connected to a live bus. Never install a CT when power is on. Failure to follow these instructions will result in death or serious injury.

6 3 Delivery Inspect the active filter for any damage as soon as it is received. Transfer of the equipment to a carrier at any manufacturing plant or other shipping point constitutes delivery to the purchaser. Title and all risk of loss or damage in transit shall pass to the purchaser at that time, regardless of freight payment. 3.1 Delivery Inspection Check that all packages and/or crates have been delivered and that the equipment has not been damaged in transit. On the outside packaging and inside the unit, Tip N Tell and Drop N Tell monitoring devices are installed. If these have been activated indicate this to the carrier immediately. Forward any claims to the carrier immediately (most carriers impose a 24-hour time limit for reporting of loss or damage). In the event of damage or missing items, provide the Bill of Lading number when making your claim to the carrier. Goods, whether sent freight pre-paid or not, are shipped at the consignee's risk. Damaged or missing items are the responsibility of the carrier and must be reported. Check that the information shown on the equipment nameplates corresponds with the order specifications. The packaging material should be replaced to protect the unit until installation has begun. 3.2 Storage If the active filter is not to be installed when unpacked, it should be stored indoors in a clean, dry place. The storage temperature must be between -40 C (-40 F) and 65 C (149 F) with a maximum humidity of 95%, non-condensing. It is preferable to store the unit in its original shipping container to protect the unit from potential damage.

7 4 Installation This chapter provides the information required to properly install the active filter and associated equipment for proper operation and performance. Frequently commissioning difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. Read and understand all instructions in this Manual prior to installation. To meet the requirements for Seismic Certification also see Appendix A. The following information is a guide for proper installation. The manufacturer does not assume responsibility for compliance with any code, national, local or otherwise, or for the proper installation of this equipment. Personal injury and/or equipment damage may result if codes and instructions are ignored during installation CAUTION HAZARD OF IMPROPER INSTALLATION Install active filter according to national, state, and local codes. Install active filter according to specific product related requirements provided in this manual. Failure to follow these instructions may result in damage to the active filter or other equipment on same electrical system. 4.1 Load Requirements for Optimum Performance For optimum performance in harmonic mitigation mode the following recommendations must be implemented: 1. All harmonic generating loads should have a minimum 3% line reactor or 3% DC choke installed. 2. No capacitors downstream of the Main CTs Failure to follow these recommendations can result in one or more harmonic orders not being compensated for by the active filter system. This can result in the target harmonic current level not being met. 4.2 Environmental Requirements Active filters require unrestricted exchange of environmental air to the inside of the enclosure for proper cooling. Insure that the environment meets Pollution Degree 2, i.e. does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. If this is not followed, malfunction and possible destruction of the active filter may occur. The active filter generates significant heat during operation. Consult the product specifications in Table 9 for the watt losses for each active filter model. Insure that the room where the active filter is mounted has adequate ventilation. Maintain ambient temperature between 0 C (32 F) and 40 C (104 F) and with a humidity level not greater than 95%, non-condensing. The operating temperatures are maximum and minimum levels the unit is designed to operate within. Above or below these levels will result in the unit either shutting down or reduced performance. The upper or lower limit should not be used as objective room temperature levels. System reliability and performance will improve if temperature levels are maintained between 20 C and 30 C. N1 style enclosures require 12 inches (300 mm) of clearance on top and 6 inches (150 mm) of clearance on both sides for adequate air flow for cooling. Wall mount enclosures require 6 inches (150 mm) of bottom clearance. N12, IP30 and IP54 enclosures do not require any side or back clearances. Cooling is provided through the door of the enclosure. See Table 1 Table 1: Clearance Requirements per Enclosure Type

8

9

10 Table 2: Clearance Requirements Integrated Transformer Units

11 4.3 Physical Installation The active filter is available as a chassis or enclosed. The chassis units are referred to as CH units. Active filters can be enclosed in 4 kinds of enclosures and are referred to as N1, N12, IP30 or IP54. Table 3 provides in detail the qualifications for each of these units. These enclosures are suitable for an indoor installation only. Table 3: Qualifications for Enclosure Types

12

13

14

15

16

17

18

19 Note: 1. This list indicates minimal qualifications. Complete descriptions of the requirements are provided in the standards referenced in this list.

20 volt rated units are not UL listed. The wall mounted units must be mounted in a vertical position on a smooth, non-flammable surface using the mounting holes provided. Select a mounting location with adequate strength to hold the weight of the unit. Select mounting bolts of appropriate size for the weight of the unit. (See Table 3 for weights) Dimensional drawings are provided in Figure 1 through Figure Amp and 100 Amp N1 cabinet cable routing is bottom entry only. 300 Amp N1 cable routing is top entry only. All N12, IP30, IP54 cabinets power cabling can be either top or bottom entry. See Table 4. Lifting lugs are provided for hoisting. An optional Floor stand is available for 50 amp and 100 amp N1 models. Installation instructions and drawings are available in Figure 7 Active filter 50, 100 and 300 amp models (units without an integrated transformer) are seismically certified for site-specific seismic requirements of the model building codes and/or standards. Optional construction features may be required, depending on the location of the installation and the particular code and/or standard of interest. Seismic certifications of compliance and equipment labels can be provided upon request. See Error! Reference source not found.

21 4.3.1 Physical Description Standard Units Table 4: Physical Specifications Enclosures

22

23

24

25

26

27 Notes: 1. Mount in a clean, dry location. 2. Insure that the room where the active filter is mounted has adequate ventilation. Maintain ambient temperature between 0 C (32 ) and 40 (104 F). 3. Lifting lugs are provided for hoisting. 4. For wall mounted units select a mounting location with adequate strength to hold the weight of the unit. Select mounting bolts of appropriate size for the weight of the unit.

28 5. Enclosed units require unrestricted exchange of environmental air to the inside of the enclosure for proper cooling. Insure that the environment meets Pollution Degree 2, i.e. does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. If this is not followed, malfunction and possible destruction of the active filter may occur.

29 Figure 1: 50 Amp Enclosure Type N1 Dimensional Drawing Note: See Figure 7 and Figure 8 for installation instructions for Optional Floor Stand.

30 Figure 2: 50 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing

31 Figure 3: 100 Amp Enclosure Type N1 Dimensional Drawing Note: See Figure 7 and Figure 8 for installation instructions of Optional Floor Stand.

33 Figure 5: 300 Amp Enclosure Type N1 Dimensional Drawing

35 Figure 7 Optional Floor Stand Installation Instructions. Assembly Instructions: 1. Remove the bottom wall mounting brackets from the unit and save the hardware for step Remove four white plugs from the mounting holes at the bottom of the unit. 3. Cut hole in Floor Stand as necessary for conduit pass through. 4. Attach the floor stand to the bottom of the unit. Secure in place using one 5/16 18 screw, one 5/16 lock washer and one 5/16 flat washer per mounting hole. Torque screws to 100 in-lbs.

36 Figure 8 Floor Stand Mounting Hole Drawing

37 4.3.2 Physical Description Integrated Transformer Table 5: Physical Specifications Enclosures with Integrated Transformers

38

39

40

41

42

43 Notes: 1. Mount in a clean, dry location. 2. Insure that the room where the active filter is mounted has adequate ventilation. Maintain ambient temperature between 0 C (32 ) and 40 (104 F). 3. Lifting lugs are provided for hoisting. 4. For wall mounted units select a mounting location with adequate strength to hold the weight of the unit. Select mounting bolts of appropriate size for the weight of the unit.

44 5. Enclosed units require unrestricted exchange of environmental air to the inside of the enclosure for proper cooling. Insure that the environment meets Pollution Degree 2, i.e. does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. If this is not followed, malfunction and possible destruction of the active filter may occur.

45 Figure 9: 33 & 39 Amp Enclosure Type N12, IP30, IP54 Dimensional Drawing 44

48 4.3.3 Chassis Systems Environmental Requirements Active filters require unrestricted exchange of environmental air to the inside of the enclosure for proper cooling. Insure that the environment meets Pollution Degree 2, i.e. does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. If this is not followed, malfunction and possible destruction of the active filter may occur. The active filter generates significant heat during operation. Consult the product specifications in Table 9 for the watt losses for each active filter model. Insure that the room where the active filter is mounted has adequate ventilation. Maintain ambient temperature between 0 C (32 F) and 40 C (104 F) and with a humidity level not greater than 95%, non-condensing. The operating temperatures are maximum and minimum levels the unit is designed to operate within. Above or below these levels will result in the unit either shutting down or reduced performance. The upper or lower limit should not be used as objective room temperature levels. System reliability and performance will improve if temperature levels are maintained between 20 C and 30 C. Chassis-type units must be installed in an adequate enclosure according to UL codes. Chassis-mount units are unprotected from accidental physical contact. Lethal voltages are accessible Physical Installation! WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Install chassis type units in an adequate enclosure. Failure to follow this instruction may result in death or serious injury. Three warning labels to be attached on the front and sides of user supplied enclosures are provided with shipment of all chassis units from the manufacturing plant. These warning labels pertain to personnel safety and operational safety issues. For optimal cooling the chassis must be mounted in a vertical position using the mounting holes provided. See Figure 12, Figure 13, and Figure 14 for mounting dimensions and position of mounting holes. Chassis-mount units may be mounted side-to-side without any clearance. Chassis units require a remote Human Machine Interface (HMI). The remote HMI including its connecting cable is a separately purchased item. HMI is designed for mounting in an enclosure door. HMI should not be installed in close proximity to a heat-source, power-wiring, or high-power switching elements. The cable-assembly connecting the RJ45 labeled RS232 of the HMI to J4 or J10 of the Control PCB must not be routed in parallel with or attached to power-wiring. Consult installation instructions provided with remote HMI. HMI is rated for UL Type 4 (aka NM4) and IP65 enclosures. HMI does not have UV protection and is suitable for indoor use only. 47

49 Table 6: Physical Specifications Chassis 48

50 49

51 50

52 Notes: 1. Insure that the enclosure where the active filter is mounted has adequate ventilation. (See Table 3 for CFM requirements) Maintain intake air temperature between 0 C (32 ) and 40 (104 F). 2. Insure that the air intake meets Pollution Degree 2, i.e. does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. If this is not followed, malfunction and possible destruction of the active filter may occur. 3. Insure that the enclosure does not allow the exhaust air to be re-circulated to the air intake. 51

53 Figure 12: 50 Amp Chassis Dimensional Drawing 52

56 Figure 15: HMI Panel Cut Dimensions 55

57 Figure 16: USB Panel Cut Dimensions 56

58 Figure 17: Typical HMI Cable Connections 57

59 Figure 18: 50 Amp HMI Cable Route 58

62 4.4 Electrical Connection Circuit Breaker and Manual Disconnect Selection An external circuit breaker or fuse disconnect is required as an isolation device. This circuit breaker must be rated for at least 125% of the rated load current. See Table 9 or Table 10 Note: National and local codes and regulations must be checked to ensure compliance Power Cable Routing Power cables connected to the active filter must be placed in metal conduit or be shielded encapsulated cables to reduce noise coupling. Entry for all power cables has to be made through the removable entry plates on the bottom or top of the active filter enclosure (see Figures 6-12). For all power systems the following points must be observed: Active filters have regulatory approval for use with copper wire only rated 75 o C or higher. The phase sequence of the 3-phase power wires feeding the active filter must be positive sequence, i.e. a phase rotation meter should indicate clockwise. For best performance all nonlinear loads should have a 3-phase AC line reactor of minimally 3% impedance, a 3% DC choke or isolation transformer inserted at the nonlinear load input. Metal conduit or the encapsulated cable shield has to be grounded to the active filter ground-terminal located adjacent to the power terminals. All panels must be installed to ensure proper system cooling. CAUTION HAZARD OF DRILLING ENTRY HOLES Remove conduit entry plates or top panels to drill cable entry holes. Failure to follow this instruction can result in equipment damage. The active filter warranty is void if operational difficulties are found to be caused by metal particles from the installation process Power and Ground Cable Selection All power wiring has to be routed directly from the conduit entry plate to the terminations on power terminals (and the earth grounding terminal) without loops. Instrumentation and CT wiring has to be routed in a separate grounded metal conduit or shielded encapsulated cable. Note: National, state and local codes and regulations must be checked to ensure compliance. 61

63 Cable Selection Used as a harmonic current compensation device, the active filter produces currents at frequencies that are multiples of the AC line fundamental frequency. Power cables, as well as input disconnect devices, should be rated at 125% of the active filter rated current in order to avoid excessive heating due to any skin effect resistance increase of these higher frequencies. For purposes of selecting the size of the power cable, it is reasonable to assume that full load current occurs at 400 Hz. No de-rating is needed for wire sizes smaller than 3AWG (25 mm 2 ) when using copper wire. Table 7 and Table 8 list de-rating factors for copper wire sizes larger than 3AWG. Paralleling of conductors is an option to avoid a de-rating penalty. For general guidelines on employing conductors in parallel, refer to NEC or other applicable code. The active filter 300 Amp model has been designed for parallel power cables. A dedicated ground conductor must be used. Per NEC, its size depends on the selected power cable. Codes define the size and it is dependent on the selected power cable. An 8 AWG (10 mm 2 ) THHN copper ground wire is recommended for the 50 Amp unit, whereas a 4 AWG (25 mm 2 ) THHN copper ground wire should be used for the 100 Amp unit. 1 AWG (50 mm 2 ) THHN copper ground wire is recommended for the 300 Amp rated unit. Table 7: Cable De-rating Factors Cable Size (AWG mm 2 ) Diameter (DIA) in inches (mm) /0 50 2/ (5.8) (6.5) (7.4) (8.2) (9.3) Wire De-rating Factor Further De-rating Factors can be calculated using the formula: De-rating Factor = (2/Dc) * Sqrt (Dc * ), where Dc = Conductor Diameter in inches Table 8: Cable De-rating Factors Copper Cable Size 4/0 AWG (107 mm 2 ) 250 MCM (126 mm 2 ) 300 MCM (152 mm 2 ) 350 MCM (185 mm 2 ) 400 MCM 500 MCM mm 2 (253 mm 2 ) Diameter (DIA) in inches (mm) (11.7) (18.1) (16.0) (17.3) (18.5) (25.3) Wire De-rating Factor Further De-rating Factors can be calculated using the formula: De-rating Factor = (2/Dc) * Sqrt (Dc * ), where Dc = Conductor Diameter in inches. 62

64 Table 9: Electrical Specifications 50, 100 and 300 Amp Units

65

66

67

68

69

70

71

72 Notes: 1. National, state and local codes and regulations must be checked to ensure compliance. 2. Active filter has regulatory approval for use with copper wire only rated 75 C or higher. 3. Active filter generates significant heat during operation. Insure that the room where the active filter has adequate ventilation to maintain ambient temperature between 0 C (32 F) and 40 C (104 F).

73 Table 10: Electrical Specifications with Integrated Transformer

74

75

76

77

78 Notes: 1. National, state and local codes and regulations must be checked to ensure compliance. 2. Active filter has regulatory approval for use with copper wire only rated 75 C or higher. 3. Active filter generates significant heat during operation. Insure that the room where the active filter has adequate ventilation to maintain ambient temperature between 0 C (32 F) and 40 C (104 F).

79 Figure 21: 50 Amp Enclosure Type N1 Internal Layout Drawing See Table 9 for wire size range and torque value. 78

80 Figure 22: 50 Amp Enclosure Type N12, IP30 IP54 Internal Layout Drawing See Table 9 for wire size range and torque value. 79

81 Figure 23: 100 Amp Enclosure Type N1 Internal Layout Drawing See Table 9 for wire size range and torque value. 80

82 Figure 24: 100 Amp Enclosure Type N12, IP30, IP54 Internal Layout Drawing See Table 9 for wire size range and torque value. 81

83 Figure 25: 300 Amp Enclosure Type N1 Internal Layout Drawing See Table 9 for torque value. 82

84 Figure 26: 300 Amp Enclosure Type N12, IP30, IP54 Internal Layout Drawing See Table 9 for wire size range and torque value. 83

85 Figure 27: 33 & 35 Amp Enclosure with Integrated Transformer Layout Drawing 84

88 4.5 Current Transformers (CT)! DANGER HAZARD OF ELECTRIC SHOCK FROM CURRENT TRANSFORMERS Never install CT when power is on. Never allow CT secondary circuit to be open while power is on. Lethal voltages will occur. Failure to follow this instruction will result in death or serious injury. CAUTION HAZARD OF IMPROPER INSTALLTION OF CURRENT TRANSFORMERS Failure to follow the CT selection, installation, and wiring instructions will cause Active filter malfunction and may result in damage to Active filter or other equipment installed in the electrical system. Failure to follow this instruction can result in equipment damage General CT Information CT must be orientated properly during installation. The orientation is specified in the drawings with an arrow indicating the direction or polarity of the CT. Most CT manufactures will indicate orientation with a label indicating H1 on one side of the CT, or a dot. There can also be a label indicating H2 and/or an arrow on the CT. The H1 side of the CT should always be closest to the power source. If the CT has an orientation arrow it should point from the source towards the load. See the installation instructions for the specific CTs being installed. A good practice, but not required, is the insertion of an interposing terminal board with shorting jumpers placed in a separate enclosure from the active filter. This provides the ability to short the CT without entering the active filter enclosure (which otherwise would require a power shutdown). If more than one CT wire is to be terminated at the same terminal on TB1, an interposing terminal board is required. CT location is defined in relationship to the active filter system. CT location on the Grid Side indicates that the CTs are physically located upstream of the active filter. The CTs will measure the improvement to the current as a result of the active filter operating. A CT location on the Load Side indicates that the CTs are downstream of the active filter. The CTs will monitor the Load current provided by both the source and active filter currents. Two CTs are required to be installed, one on A (L1) phase and one on B (L2) phase of the conductors powering the loads to be compensated for by the active filter system. If there are any line-to-neutral connected loads downstream of the active filter system s main CTs a third CT is required on C (L3) phase. 87

89 4.5.2 Minimum CT Requirements The active filter uses a minimum of two (2) external current transformers (CT) to measure load current waveforms. Standard CT rated for 400 Hz with Type 1 accuracy rating, with a 5 amp secondary are required. The largest primary rating for the CT is 10,000 amps. Any splicing to the CT leads needs to be done with crimp style connectors or soldered. The CT should be mounted on phases A and B with the orientation arrow pointing toward the load. Systems that are using two CTs can have the CTs installed on A and C or B and C if necessary. If A and C or, B and C CT configurations are used this information must be provided to the qualified person commissioning the unit. CT may be installed on the source (grid) side or on the load side of the active filter power connection. Three (3) external CT are required if line-to-neutral connected loads are present. CT wiring must be routed separately from power cables. Shield or conduit must be grounded to the active filter ground terminal only. CT wiring must be routed directly from the conduit entry-plate to TB1. CT must be selected for: 1) 5 amp secondary 2) 250:5 to 10,000:5 ratio range 3) 400 Hz Rated 4) Type 1 accuracy 5) The maximum load current where they are installed; 6) The maximum burden (in VA) on the CT formed by the CT wiring and total active filter burden (Note: Each active filter burden is 2.5 VA or 0.1 Ohms). 7) Wire size of the CT must be 12 AWG (4 mm2) or larger. This is critical to assure proper performance. See Table 13 and Table 14 for adding wire length to CT secondary wiring. 8) CT secondary wiring must be either twisted and/or shielded pairs 9) Do not connect the active filter CT to any other loads. Use a separate current transformer if additional uses are required. 10) Any splicing to the CT leads needs to be done with crimp style connectors or soldered TB1 (Terminal Board 1) Each unit is equipped with a terminal board named TB1 for connection of the CT secondary wiring. Three shorting bars are provided adjacent to TB1. Once the CTs have been installed and have current flowing through the conductor on which they are attached, the shorting bars must be installed before interacting with the wiring downstream of TB1 or unplugging J1 on the Control Boards. CT secondary wiring should not be removed or left open when power is flowing through the cable or bus bar which they are monitoring. TB1 can accept wire sizes of up to 10AWG (6mm 2 ) wire and has a torque specification of 9in lbs. See Figure 18 through Figure 23 for TB1 physical location CT Installation Single Unit Terminal X1 of the A Phase CT is connected to TB1-1. Terminal X2 of the A Phase CT is connected to TB1-2. Terminal X1 of the B Phase CT is connected to TB1-3. Terminal X2 of the B Phase CT is connected to TB1-4. Terminal X1 of the C Phase CT is connected to TB1-5. (see Note below) Terminal X2 of the C Phase CT is connected to TB1-6. (see Note below) Terminate shields on one of the terminals marked earth ground on TB1. The shield can be grounded in only one location. Grounding at both ends will cause circulating currents. Do not allow the conductor on which the CT is mounted to be lodged in the joint-area of a splitcore CT because inaccurate operation of the filter will result. For Load side CT position see Figure 30, for Grid side CT position see Figure 31 Note: C Phase CTs are only required if there are Line-to-Neutral loads downstream of the Main CTs. See 4.5.1General CT Information for details. 88

90 Figure 30: Load Side CT Position Diagram (CT s installed on the Load Side or downstream of the active filter) A (L1) Grid (Source) Load B (L2) X1 X2 C (L3) X1 X2 3-phase Protection Device Provided by others. Phase Rotation Clockwise phase rotation required. A (L1) B (L2) C (L3) Active Filter TB1 X1 X2 X1 X2 X1 X X1 X2 Optional 3 rd CT Required if there are Line-to- Neutral connected Loads downstream of the CTs. Notes: CT wiring is required to be located outside the power conduit or shielding. Minimum 12AWG twisted or shielded pair CT shielding is to be grounded at the available ground points on TB1. AccuSine CT burden is 2.5VA or 0.1 Ω. CT output current can not be shared with other equipment (metering, automatic capacitor bank ). 89

91 Figure 31: Grid (Source) Side CT Position Diagram (CT s installed on the Grid Side or upstream of the active filter) A (L1) Grid (Source) Load B (L2) X1 X2 C (L3) X1 X2 X1 X2 3-phase Protection Device Provided by others. X1 X2 X1 X2 A (L1) B (L2) C (L3) Active Filter Phase Rotation Clockwise phase rotation required Optional 3 rd CT Required if there are Line-to- Neutral connected Loads downstream of the CTs. Notes: CT wiring is required to be located outside the power conduit or shielding. Minimum 12AWG twisted or shielded pair. See Notes. CT shielding is to be grounded at the available ground points on TB1. AccuSine CT burden is 2.5VA or 0.1 Ω. CT output current can not be shared with other equipment (metering, automatic capacitor bank ). 90

92 4.5.5 CT Installation Parallel and Transformer Systems Multiple active filters may be connected in parallel to operate from a common set of external CTs. This common set of external CTs may be either mounted on the load or the grid side of the multiple parallel active filters. A transformer can be used to apply the active filter to systems operating above 480 volts. The CTs monitoring the load current may be either mounted on the load or grid side of the active filter system CT Installation Parallel Units For parallel systems, if the external CTs are mounted on the grid side, then auxiliary CTs are required. Auxiliary CTs are mounted on the input power cables of each active filter that is operating in parallel. These auxiliary CTs are to be connected in parallel to the external CTs with the same phase and orientation. See Figure 32 for Load sensing and Figure 33 for Grid Sensing CT wiring diagrams. The primary unit is the unit receiving the external CT wiring on TB1 terminals 1 through 6. From this unit, TB1 terminals 7 through 12 are connected to TB1 terminals 1 through 6 of the next unit. Each additional unit is connected in the same manner. Refer to wiring diagram Figure 32 and Figure 33. See Table 13 and Table 14 for allowable cable-length and wire gauge. The interconnection requires two (three if C phase requires a CT) shielded or twisted-pair cables. Each wire pair carries up to 5 amperes at not more than 10 volts. Table 11: CT Wiring for Multiple Unit Operation Primary Unit Secondary Unit Connect First Pair (A phase) Connect Second Pair (B phase) Connect Third Pair (C phase) (If required for 4-wire system) Pin 7 Pin 1 Pin 8 Pin 2 Pin 9 Pin 3 Pin 10 Pin 4 Pin 11 Pin 5 Pin 12 Pin 6 Note: Terminals 7-13 of TB1 come with shorting jumpers installed. These jumpers are to remain in place unless parallel operation of the active filter is employed. Remove these jumpers from all but the last unit in the parallel sequence CT Installation Transformer Systems A transformer can be used to apply the active filter to systems operating above 480 volts. The CTs monitoring the load current may be either mounted on the load or grid side of the active filter system. When Grid position CTs are utilized auxiliary CTs are required. The auxiliary CTs will be installed on the high voltage side of the transformer. See Figure 34 Load side CT position and Figure 35 Grid side CT position for a diagram of an active filter connected to a system greater than 480 volts. 91

93 Auxiliary CTs Parallel units and unit that use a transformer to correct system with voltages above the nameplate volt rating with Grid side CT position require Auxiliary CTs. Auxiliary CT minimum requirements. 1 The Main CTs and Auxiliary CTs must be provided by the same manufacturer. 2 When active filters are connected in parallel, ensure the burden rating of the CT is appropriate for the number of units installed. 3 The CT wire size must never be less than 12 AWG (4 mm 2 ). 4 The CT has limited output VA capacity. Therefore, it is imperative to observe the wire length limits (maximum total wire length between the CT and all active filters in line). Table 13 and Table 14 define the formula to calculate the wire length limits. Observe that the wire length limits depend upon the chosen CT (which have different output VA for different transformer ratios), the chosen wire size, and the number of active filters in parallel. 5 Any splicing to the CT leads needs to be done with crimp style connectors or soldered. 6 CT wiring termination must be based on the X1 and X2 markings rather than relying on wire colors as color conventions used by CT vendors are not consistent. 7 Observe the orientation of these Auxiliary CT. The arrow must point towards the load (H1 at the side of the active filter power terminals and H2 closest to the load). For parallel installations the Auxiliary CTs can be physically installed inside the associated active filter. 8 When using shielded pairs ground the shield at one end only to prevent circulating current. The primary current rating of the Auxiliary CTs can be reduced due to the reduced current levels monitored. It is important that the ratio of Main CT and the Auxiliary CTs are the same. Table 12 indicates the proper Auxiliary CT rating based to the Main CT rating. Installing Auxiliary CTs with the same primary and secondary values as the Main CTs is also acceptable. Table 12: Current-Ratio of Auxiliary CT Main-CT Current-Ratio Auxiliary CT Current-Ratio 3,000:5 600:1 5,000:5 1,000:1 The outputs of the Auxiliary CTs of all units are connected to TB1 of active filter #1 (in parallel with the already installed source-ct) as follows: X1 of A-phase Auxiliary CT to TB1-1 X2 of A-phase Auxiliary CT to TB1-2 X1 of B-phase Auxiliary CT to TB1-3 X2 of B-phase Auxiliary CT to TB1-4 X1 of C-phase Auxiliary CT to TB1-5. (see Note below) X1 of C-phase Auxiliary CT to TB1-6. (see Note below) Terminate shields on one of the terminals marked earth ground on TB1. The shield can be grounded in only one location. Grounding at both ends will cause circulating currents.. Do not allow the conductor on which the CT is mounted to be lodged in the joint-area of a split-core CT because inaccurate operation of the filter will result. For parallel Grid side CT position see Figure 33. For transformer with grid side CT configuration see Figure 35. Note: C Phase CTs are only required if there are Line-to-Neutral loads downstream of the Main CTs. See 4.5.1General CT Information for details. 92

94 Figure 32: Load Side CT Position Parallel Units Diagram

95 Figure 33: Grid (Source) Side CT Position Parallel Units Diagram A (L1) Grid (Source) Load B (L2) X1 X2 C (L3) X1 X2 X1 X2 X2 X2 X1 3-phase Protection Devices Provided by others. Phase Rotation Clockwise phase rotation required. Optional 3 rd CT Required if there are Line-to- Neutral connected Loads downstream of the CTs. X2 X1 X1 X2 X2 X1 CTs located in dotted line can be installed in the associated AccuSine enclosure. X2 X1 X1 X2 X2 X1 X1 X2 X2 X1 X1 X2 X2 X1 X1 External Terminal Block A (L1) B (L2) C (L3) Active Filter 1 TB1 TB1 A (L1) B (L2) C (L3) Active Filter TB1 2 TB1 TB come with shorting jumpers installed. Remove these jumpers from all but the last unit in the parallel sequence. X1 X2 X1 X2 X1 X Notes: CT wiring is required to be located outside the power conduit or shielding. Main CTs and Auxiliary CTs must be provided by the same manufacturer. Minimum 12AWG Twisted or shielded pair CT shielding is to be grounded at the available ground points on TB1. AccuSine CT burden is 2.5VA or 0.1 Ω. CT output current can not be shared with other equipment (metering, automatic capacitor bank ).

96 Figure 34: Load Side CT Position with Transformer Diagram A (L1) B (L2) Grid (Source) Greater than 480 volt Load C (L3) 3-phase Protection Device Provided by others. X1 X2 Phase Rotation Clockwise phase rotation required. A (L1) B (L2) C (L3) Active Filter X1 X2 X1 Auto Transformer or Isolation Transformer. Isolation transformer must be wired delta/delta or wye/ wye. TB1 X Optional 3 rd CT Required if there are Line-to- Neutral connected Loads downstream of the CTs. Notes: CT wiring is required to be located outside the power conduit or shielding. Minimum 12AWG twisted or shielded pair CT shielding is to be grounded at the available ground points on TB1. AccuSine CT burden is 2.5VA or 0.1 Ω. CT output current can not be shared with other equipment (metering, automatic capacitor bank ).

97 Figure 35: Grid (Source) Side CT Position with Transformer Diagram

98 Table 13: Typical Maximum Distance for CT Wire Length General formula for CT wire length: from mains CT to all Active filters: L = (VA - 2.5*X)/(25*R)/2 L is length in feet or meters from CT to all active filters VA is the VA rating of the secondary of the CT X is the of quantity of active filters operating on the same mains CT R is the resistance in ohms/feet of the cable (or ohms/meter) CT1000SC Cable Lengths CT1000SC # (Suitable for one unit only) VA = 5 Feet VA = 5 Meters Wire Gauge (AWG mm 2 ) Resistance (Ohms/ft) 1 Wire Gauge (AWG mm 2 ) Resistance (Ohms/meter) 1 # # # # # # # # # CT1000SC is provided with 12 feet (3.65 m) of twisted pair cable attached. This distance extends the tables by 12 feet (3.65 m). It is not recommended to use less than #12 AWG (4 mm 2 ) for the extension cable. 97

99 Table 14: CT3000SC & CTFCL Cable Lengths P/N CT3000SC & CTFCL ^ (Total cable length from CT to all active filter units) Feet VA = 45 Quantity of Active filters operating on same mains CT Wire Gauge (AWG mm) Resistance (Ohms/ft) # # # # # #3 AWG # P/N CT3000SC & CTFCL500058^ (Total cable length from CT to all active filter units) Meters VA = 45 Number of Active filter operating on same mains CT Wire Gauge (AWG mm) Resistance (Ohms/meter) # # # # # #3 AWG # ^ CT3000SC and CTFCL50058 are provided with 12 feet (3.65 m) of twisted pair cable attached. These cables extend the table distances 12 feet (3.65 m). Never use CT wires with a cross section of less than 12 AWG (4 mm 2 ).

100 AccuSine Power Correction System (PCS) Models: N1, N12, CH, IP30, IP54 Sizes: 50A, 100A, 300A 4.6 Control Wiring The active filter is provided with both dry contacts for remote indicator lights as well as an Ethernet connection for communication. The following sections provide instruction for control wiring connections Dry Contacts The active filter has dry contacts and Ethernet connections for customer use. The dry contacts can provide indications of the systems operating condition. The Ethernet connection can provide remote detailed system monitoring and/or control Dry Contacts N1 50 Amp, 100 Amp and 300 Amp There are four relays with form C type contacts to indicate the various operational states of the active filter. The connection to these contacts is located at the bottom of the Control PCB labeled J2. See Figure 21, Figure 23, or Figure 25 for physical location. They may be used to power indicating lights or other low power control circuits. Each contact is an isolated, dry contact rated at 120/240 VAC and 1 Amp. Table 15 shows the pin layout (1 12) of the user output contacts located on J2 of the active filter Control. Maximum wire size for J2 is 12AWG (4mm 2 ) set a tightening torque of 7 lb-in. Table 15: Terminals for Dry Contact Layout NEMA1 50, 100 & 300Amp Units Power On Run Fault At Max. Capacity NC C NO NC C NO NC C NO NC C NO Note: C means common terminal, NO means normally open, NC means normally closed Dry Contacts N12, IP30 and IP54 and Integrated Transformer Units There are four relays with form C type contacts to indicate the various operational states of the active filter. Three relays are accessible at J2 of the Control PCB, the fourth is located on K11. See Figure 22, Figure 24, and Figure 26, for physical locations. They may be used to power indicating lights or other low power control circuits. Each contact is an isolated, dry contact rated at 120/240 VAC and 1 Amp. Wiring connected to J2 and K11 must be routed directly from the conduit entry-plate to J2 on the Control PCB or to the auxiliary contactor, K11. Power On Control PCB J2 Table 16: Terminals for Dry Contact Layout Run K11 Fault Control PCB J2 At Max. Capacity Control PCB J NC C NO NC NO NC C NO NC C NO Note: C means common terminal, NO means normally open, NC means normally closed Schneider Electric. All rights reserved.

101 4.6.2 Ethernet Connection The active filter is equipped with embedded Ethernet capability to allow remote operations. The unit can be controlled and monitored on Ethernet TCP/IP via a Web Gate server. Modbus communication protocol is also supported. The Ethernet Interface transmits and receives data at 10 Mbps or 100 Mbps. Figure 36 shows the location of the Ethernet connector port on the HMI Figure 36: Ethernet Port Location CAUTION HAZARD OF IMPROPER INSTALLATION! o o o o IMPROPER CONNECTIONS CAN DAMAGE COMMUNICATION PORTS Do not confuse the RJ45 Ethernet connector with the RJ45 COM1/COM2 serial port. (RS485/RS232) Do not connect the serial cable to the Ethernet port. Do not connect the Ethernet cable to the serial port. Carefully observe the product markings distinguishing between the Ethernet and serial ports. Failure to follow these instructions can result in equipment damage to the HMI that will stop the active filter from operating. RJ45 Ethernet cable connector location Note: Ethernet networks should be installed by a trained and qualified person.1:1 connections should be made with a hub or a switch. It is possible to use the 1:1 connection with a cross cable depending on the connected PC and network cards.

102 5 Pre-Commissioning This chapter provides the sequence of steps required to permit commissioning of the active filter. Before applying power, read and understand this information thoroughly. 5.1 General! DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. This equipment must only be installed and serviced by qualified electrical personnel. Turn off all power supplying this equipment before working on or inside equipment. Wait 10 minutes after removing power before opening the door or removing covers to permit the DC bus capacitors to discharge. Always use a properly rated voltage sensing device to confirm power is off. Replace all devices, doors and covers before turning on power to this equipment. Failure to follow these instructions will result in death or serious injury. 5.2 Installation Inspection Be sure the input voltage matches the voltage rating of the unit installed. Inspect all connections for both power and control wiring. Insure that the correct termination points have been made for each wire. Insure that all connections are firmly tight prior to permit start-up.