Transcript Document

OPERATIONS
MANUAL
Capacitor Duty Thyristor Switch
ZCTC-02
TAS Powertek Pvt. Ltd.
Corporate Office:
W-61, MIDC, Ambad, Nasik - 422010, Maharashtra (India)
Tel: +91-(253)-2384038 / 2381090
Email: [email protected]
NOTE
These instructions do not purport to cover all details or
variations in equipment, nor to provide for every possible
contingency to be met in connection with installation,
operation or maintenance.
Should further information be desired or should particular
problems arise which are not covered sufficiently for the
purchasers purposes, the matter should be referred to our
TAS Powertek Pvt. Ltd. office.
The contents of this instruction Manual shall not become
part of or modify any prior or existing agreement or
relationship. The sales contract contains the entire
obligations of TAS Powertek Pvt. Ltd. The warranty
contained in the contract between the parties is the sole
warranty of TAS Powertek Pvt. Ltd. Any statements
contained herein do not create new warranties or modify the
existing warranty.
The reproduction, transmission or use of this
document or its contents is not permitted
without express written authority. Offenders
will be liable for damages. All rights are
reserved.
TAS
PowerTek
Index
Ordering Information
------------------
2
Features
------------------
3
Specifications
------------------
5
Mechanical Dimensions
------------------
7
Main Electrical Parts
------------------
9
--------------
10
------------------
11
------------------------
12
Control Terminals and Reset switch ---------
13
Front Plate Indications
14
Internal construction Photo
Power Connection
Power Configuration
------------------
Typical Connection of control section --------
15
Principle of operation
------------------
18
----------------------
21
Usage of line Reactors
Usage of Discharge Resistors
---------------
22
Recommendations for usage
----------------
23
------------------
25
--------------------
29
Fault finding Guidelines
Contact Information
- 1-
TAS
PowerTek
Ordering Information.
ZCTC – Conf / ###/*/$
:01, 02 or 03 thyristors per switch.
### :Identifies Current rating in Amp.
Conf
•
Ratings are:040,080,110,140 & 210
*
:C – Without ducting.
$
:F – For fast switching mode.
D – With ducting.
B – Contactor bypass hybrid system.
The type no of the units to be ordered should be
mentioned on the Purchase Order.
-2-
TAS
PowerTek
Features:
•Provides following protections.
Spike currents protection.
Over current protection.
Thyristor short circuit monitoring.
Thyristor over-temperature cutoff.
Power down monitoring.(including V harmonic protection)
•Detection of zero voltage across thyristor switches and turn on of
thyristors within maximum  6V…. Typical + 3V.
• Zero voltage sensing thro’ active sensing circuit for giving the
better accuracy and true zero turn ON.
• Suitable for 50Hz mains frequency. Optional model with 60Hz is
available.
• Auxiliary output contact available for enabling/disabling
thyristor bypass contactor. (This is for slower correction
requirements). When disabled as bypass contactor, it is used as
external tripping contact when thyristor fault is detected. This can
be useful to disconnect the switch from mains when thyristors are
short (damaged).
• Provision for inlet air and outlet air ducting. Product is suitable
even for IP-54 enclosures.
-3-
TAS
PowerTek
• Line Chokes for suppressing instantaneous mains supply
spikes currents and / or harmonic currents thro’ capacitors
can be selected by the user, the unit can work with series
reactors ranging from 0.2% to 16.5% voltage drop reactors.
• Fault output (for feedback to controlling relay) of 0V/+12V.
• Fault auto-start for spike, over-current, power down and
over-temperature faults.
• Facility of push button for fault reset.
• Electronic Controlling through high speed RISC processor.
-4-
TAS
PowerTek
Specifications:
•Mains input: 250V to 500V a.c. Line to Line. 50/60Hz.
•Electronics Supply: Built in SMPS capable of handling the
transient supply transients and spikes and giving stable output
to Electronics even with one phase absent.
•Input command to Zero crossing sensing and switch on
response time: 10mS max (cold on condition).
•Zero crossing sensing limits: ±6V… max. (typical ± 3V…).
•Digital I/P & O/P: 0 to 1V for Low & 10V to 12.5V for High.
•Electronics, Power section & Earth isolation level: 2.5kV~.
(Cooling fan for heat sink cooling isolation level 1.5kV~.)
•Operating Temperature (Ambient): 0°C to 55°C.
•Storage Temperature: -10°C to +75°C.
•Watt Loss:
Switch in ON condition with full loading.(Maximum value)
Item no.ZCTC-40/2 : 80Watt. Item no.ZCTC-80/2 : 150Watt.
Item no.ZCTC-110/2:200Watt. Item no.ZCTC-140/2:300Watt.
Item no.ZCTC-210/2:450Watt.
Switch in OFF condition.
All types: 30Watt maximum.
(In case if the switch is to be used for the Auto-Capacitor panel
for Voltage control; then discharge resistors will be added
which may increase the watt loss per switch extra.)
•Maximum temperature rise of the casing (Heat Sink) over
ambient is 25°C. i.e. 80°C maximum.
-5-
TAS
PowerTek
•Auxiliary Contact for bypass contactor/ Thyristor short
tripping: Rating 0.5Amp / 240V~ or 2Amp/48V… .
•Switch ON time: Maximum 1 cycle of mains. (i.e. time for
input control command “High” to thyristor switch-on.: If zero
Voltage is sensed.)
•Switch OFF time: Maximum ½ cycle of mains. (i.e. time for
input control command “Low” to thyristor switch-off.)
•Spike current Detection: 2.2 times the peak of max. rated
current.
Time: sensing instantaneous. Switch OFF in ½ cycle of mains.
•Over current Detection: 1.15 times the max. rated current.
•Over temperature Detection: 90°C - Heat-sink temperature.
•Maximum permissible dV/dt during Power ON to avoid
spurious turn-ON of the switch for ½ cycle: 2000V/mS.
•Various Timers:
Thyristor switch ON/OFF & Bypass Contactor command
delay = 3 Sec.
Over Temperature Fault tripping to Auto-Resuming time
delay = 15 Min.
First Occurrence of Spike Current fault tripping to AutoResume time delay = 25sec. Successive 2nd Occurrence after
resuming within 5 sec will go in Permanent tripping.
Over Current Detection Time:For 25 sec continuous overcurrent. Auto Resume time after tripping = 25 sec.
•Power Down Fault with:
1. Presence of V harmonics above 10th harmonic with more
than 5% amplitude.
2. No current detection when ON command is given.
3. No Voltage detected across thyristors in OFF condition.
-6-
TAS
PowerTek
Mechanical Dimensions.
ZCTC-02/040 & 080
-7-
TAS
PowerTek
Mechanical Dimensions.
ZCTC-02/110, 140, 210.
-8-
TAS
PowerTek
Main Electrical Parts
Exhaust
Cooling fan.
Power
Terminals1
Control
Terminals
Fault Reset
Push Button.
Status Indication
LED display
Power
Terminals2
Power
Control
Terminal
s
-9-
TAS
PowerTek
Internal Construction Photograph:
After Opening the top cover.
ZCTC-02/140/C/F
- 10 -
TAS
PowerTek
Power Connection Schematic
ZCTC-02.
Power Terminals 1
SNUBBER
SNUBBER
Electronics
Power Terminals 2
Note: Any set of power terminal set can be used as either
input supply and output towards capacitors. Its for user to
define which set of Power terminals are input and which set
of Power terminals are output.
- 11 -
TAS
PowerTek
Power Configurations.
(Wired by User)
3 Phase Line configuration
Only with ZCTC-**/2.
The Scheme shown:
The most commonly used scheme.
Normally, when the Delta connected Capacitor
banks are available, this scheme becomes the
most cost efficient as well as electrically efficient.
ZCTC-02 version is only designed for such
schemes.
Here Only two phases (I & II) are controlled. This
reduces the watt losses.
- 12 -
TAS
PowerTek
Control Terminals and Reset switch.
Auxiliary
NO contacts
CMD: This is the control command Input terminal. High 8
to 14Vdc at this terminal will turn on the switch and 0 to
1Vdc at this terminal would turn off the switch.
Maximum current sinked by this terminal is 10mA dc.
RST: Reset command for resetting the switch from any
fault. Normally this terminal is already wired up with the
reset switch provided on the thyristor switch module. This
reset switch is seen on the photo shown above.
FLT F/B: This is the output terminal from the thyristor
switch. This gives 10 to 12.5Vdc output when switch is
tripped due to any fault. Maximum sourcing current from
this terminal is 10mA. With no fault trip, this terminal is at
zero volt dc.
GND: This is the ground reference terminal. The CMD or
FLT F/B voltage levels are with respect to this terminal.
Aux NO: for ZCTC-02----/F it turns on for thyristor fault.
For ZCTC-02----/B it is used for actuating bypass
contactor.
- 13 -
TAS
PowerTek
Front Plate Indications:
Red color LED indications are for faults. As the
indications suggest it means that unit has tripped due
to
•Unit tripped due to spike current detected.
•Unit tripped due to capacitor over Current condition.
•Detected that Thyristors in the units are short.
•Over Temperature at the heat sink
•Shows that no Power is present for at least one of the
Power terminals or V Harmonics high level.
Step ON indicates that the switch has turned On the
connected capacitor bank.
Power ON indicates that Control electronics for the
switch is Powered up. (Supply at Power Control
terminals)
- 14 -
TAS
PowerTek
Typical connections of Control section
in PF controller panel. PF relay of
TAS: LCPF-02/T
R
Y
B
AO
AO
INPUT
C1
C2
C3
C4
C5
C6
GND _
FLT F/B
FLT RST
RESET
Thyristor
Switch
ZCTC-02
CMD
12P
Switch number:
GND
DC
Rph control
TFB1
TFB2
TFB3
TFB4
TFB5
TFB6
COM
Yph control
OUTPUT
R
Y
Bph control
B
+ 12V
Neutral
LCPF-02/T
- 15 -
TAS
PowerTek
Typical connections of Control section
in PF controller panel. PF relay of
TAS: SPF-03/T
RLY-08/S
R
Y
B
C1
C2
C3
C4
C5
C6
C7
C8
12P
AO
AO
INPUT
FLT F/B
FLT RST
RESET
Thyristor
Switch
ZCTC-02
CMD
12P
Switch number:
GND
12V
DC
Rph control
TFB1
TFB2
TFB3
TFB4
TFB5
TFB6
COM
Yph control
OUTPUT
R
Y
Bph control
B
Neutral
SPF-03/T
- 16 -
TAS
PowerTek
Typical connections of Control section
in PF controller panel. PF relay of
Other makes. (Other than TAS)
R
Y
B
AO
C1
C2
C3
C4
C5
C6
C7
C8
AO
INPUT
FLT F/B
FLT RST
RESET
Thyristor
Switch
ZCTC-02
CMD
12P
Switch number:
GND
CX
Rph control
Yph control
OUTPUT
R
Y
Bph control
B
Neutral
-
+
12Vdc
Regulated
Power
Supply
(200mA)
- 17 -
PF correction relay
TAS
PowerTek
Principle Of Operation
This equipment is a three phase capacitor, ON/
OFF control.
Two out of three phases are controlled in
ZCTC-02.
It’s a known fact that any step voltage given to
the capacitor theoretically causes infinite surge
current through the capacitors. This gives rise
to reduction in life of capacitors as well as
switching devices. Also causes undesirable line
transients.
Here the difference in line voltage and the
capacitor voltage (across every thyristor switch)
is sensed and whenever it is zero, the
capacitors are made to turn ON if input
command to turn ON is present.
Following Diagram will clarify this point.
This diagram even reveals the point that even
with capacitor in charged condition, it can be
turned ON without spike current.
- 18 -
TAS
PowerTek
VSW
R-Phase Block
+
Ic
_
R
Vc
Y
B
B-Phase Block
V
Control Command
Ic
VSW
VC
VSW = 0.
- 19 -
TAS
PowerTek
In ZCTC the voltage across every thyristor
switch is sensed and when found zero (+3V),
checks if input command for that phase is
present. If present turns ON the thyristor switch
instantaneously(Max response time from zero
cross sensing to thyristor turn ON command =
6μSec.)
Apart from this, the circuit has been
programmed to give the protection to the unit
against Capacitor spike current occurrence,
capacitor overload, over temperature and false
zero crossing detection in presence of Voltage
harmonics etc. It has also self monitoring
mechanism. In case of thyristor/s is/are short, is
indicated thro’ faults and tripping command
relay can be configured to turn ON.
This thyristor is designed to work almost with
any type of Automatic PF control relay unit and
provides the reliable operation of switch ON and
OFF of the capacitors with zero switching surge
current.
Entire operation of this is governed by the high
speed RISC Microcontroller which ensures the
precision accuracy of the unit’s functions.
- 20 -
TAS
PowerTek
Usage of Line Reactors:
It is mandatory to use the series line reactors along with all the
thyristor switches. The usage of appropriate rating of reactors
is mandatory.
The reactors can be selected on the basis of the mains supply
conditions.
Product warranty is valid only if the proper type of
reactors are used along with the ZCTC thyristor switches.
TAS Powertek recommends to use the following type of
reactors depending on the mains supply conditions.
Mains Supply Condition
Type of
Reactors
(TAS make)
Clean supply with no
harmonics and no spike
currents (no fixed
capacitors on supply)
RECT-002
No harmonics but
possibility of certain
glitches.
RECT-010
% Voltage
drop across
reactors.
0.2% of phase
value
0.96% of
phase value
Harmonics with no triplet
harmonics.
RECT-075
7.5% of phase
value
All type of harmonics
presence.
RECT-165
16.5% of
phase value
- 21 -
TAS
PowerTek
Usage of Discharge Resistors for
Faster response:
The capacitors after switch off command, can get charged to
the DC level which is higher than the Mains voltage peak level.
Therefore for the Operations where faster on-off sequences
are required, its important to discharge the capacitors by some
amount to get the appropriate response time out of the system.
For ZCTC-02 type of thyristor switches, following graph gives
some typical values of resistors to be used against the
response time.
Its recommended to use excel program provided by TAS for
getting the exact values of the resistors.
25kVAr
415V.
60k
10kVAr
415V.
50k
50kVAr
415V.
40k
30k
100kVAr
415V.
20k
Values with RECT-010 reactors.
10k
0
0.5
1.0
1.5
2.0
2.5
3.0
0k
- 22 -
3.5
4.0
4.5
5.0
5.5
6.0 Sec
TAS
PowerTek
Recommendations for Usage
In Auto-PF control panel.
1.
Provide the Discharge resistors across the
capacitors. Faster the switching operation,
lower should be the ohm value of these
resistors. Please be careful while calculating
the wattage of these discharge resistors.
2.
Keep the control command and other control
wires (+12V) away from any power wiring. It
is recommended to route these control wires
in separate channels.
3.
Earthing in such electronic panels should be
of two types.
a) Power Earthing.
b) Electronic Earthing.
The earth-pits used for such earthing should
also be separate.
The earthing connection provided on SMPS of
ZCTC module should be connected to power
earth of the system.
4.
Every ZCTC should have at least 30mm
clearance from all the sides from other ZCTCs
or any other electrical item.
- 23 -
TAS
PowerTek
5.
The panel in which these equipments are
mounted should protect them from dust
and conductive suspended particles.
6.
It is recommended to put the Fuses or
MCBs/ MCCBs in line with every ZCTC.
7.
It is recommended to put a fixed capacitor
bank (without suppression chokes but with
fuses ) of @10% rating of the total
switched kVAr of the system. This helps in
terms of absorbing the line transients and
provides additional protection to ZCTCs.
This also provides the protection to ZCTCs
against dV/dt while mains turn ON.
8.
Avoid touching the electronics of the ZCTCs
even when they are not energized.
9.
Do not use contactor switching capacitor
panel or fixed capacitor switching on the
same line as where ZCTCs thyristorised
capacitor switch ON panel is installed.
10.
Provide the proper cooling arrangement to
the panel so that panel internal
temperature does not exceed 50°C.
11.
Regular cleaning with vacuum cleaner helps
giving the everlasting performance.
- 24 -
TAS
PowerTek
Fault Finding Guidelines.
1.
Unit trips with Spike current indication as
soon as input turn ON command is given.
: Check the capacitor current by
connecting them to mains separately.
It should not be more than the rated
current of the switch.
: Check if the jumpers on PCB J1 & J5 are
inserted if used along with the detuned
reactors of 7% or 14% rating.
: Check if excessive presence of Capacitor
current harmonics. This can be checked
by putting a fixed capacitor on same line
with other electromechanical device and
then checking its current harmonics.
: Check the power wiring connections at
input of ZCTC and from ZCTC to capacitor
banks for any loose/faulty connection.
Tighten all the power wiring connection
related to that specific ZCTC.
2.
Unit trips with Over current indication
during the normal operation.
: Check if the capacitor current is more
than the rated current of ZCTC by 1.15
times in any one of the three phases.
: Check the harmonic currents thro’ the
capacitors and check if they are causing
the peaky natured currents thro’ the
capacitors on continuous basis.
- 25 -
TAS
PowerTek
3.
Unit trips indicating Thyristor Short Circuit.
: Check the thyristor blocks of the unit for
any of them to be short. In case they are
short, need to replace them. (it is
recommended that a person with proper
know-how does this job)
: Check if the direct phase to capacitor
bank is carrying any current. In such case
there is possible earth fault near the
capacitor connections / terminals.
4.
Unit trips indicating Over Temperature
fault.
: Check if all the cooling fans in ZCTC are
working correctly. If not, check if the input
supply fuse to them is blown off. Try
replacing the fuse if found blown.
: Check the temperature switch wiring.
The temperature switch(s) is(are)
mounted on heat sink and from there the
connection is with the electronic module.
: Check if really the ambient temperature
within which the ZCTCs are working is over
the desired limit.(50°C). In that case some
arrangement to bring down this temp
needs to be done. Either by increasing the
cooling fans capacity of the panels or by
connecting proper air-conditioning
arrangement to the panel.
- 26 -
TAS
PowerTek
5.
Unit indicates Power Down Fault:
: This can happen with input supply is not
present to any one of the three phase of
power terminals. In such case check the
input fuses and/or MCBs power connections.
: This can even happen if any one or more
terminals on Capacitor side are in open
condition. Check these power connections
for possible loose connection or open circuit.
Also check the capacitors for any internal
dis-connector open circuit.
: In presence of excessive Voltage
harmonics, this fault blocks the units from
turning ON. Under such case important to
use fixed capacitor on same line without any
series reactors. This can improve the
situation.
6.
After the input command and the steps are
on, the unit trips due to Power down
indication fault:
: This can happen if any one of the phases
shows zero current even is spite of thyristor
switch is turned on. This can happen if after
the capacitor turn on, one of the input
mains fuses blows off or power input MCB
trips off. Check for these conditions and
correct the same.
: Check for any possible fault with the
capacitors and one of the phases do not
conduct.
- 27 -
TAS
PowerTek
7.
Spike current fault does not reset after the 1/2
min delay.
: Possibility that the unit has gone in permanent
block mode. If successive two spike current
faults are detected by unit or if after first auto
resume after the spike current trip, another
occurrence of spike current fault within 5
seconds will cause the unit to go in permanent
block mode. Give the external reset and see if
unit trips again. If unit trips again, try using the
guidelines given in point no.1.
Note: It is not recommended to regularly
reset the unit if it trips due to spike current
fault frequently. In such case try to find the
root cause for such event and eliminate the
same before resetting the units.
8.
Unit Does not show Power On indication:
Check that the Power control terminals are given
the supply. Possibility of one of the phases not
present there.
: In case all the phase and Neutral connections
are correct, check on control terminals for +12V
supply present. In case it is absent, internal
SMPS might have failed.
(Please note that the above checks should be done by
the trained personnel and any problems arising
out of fault finding, our company will not be
responsible.)
- 28 -
TAS
PowerTek
Corporate Office/Works/Design Centre:
W-61, MIDC, Ambad, Nasik - 422010, Maharashtra (India)
Tel: +91-(253)-2384038 / 2381090
Email: [email protected]
Marketing and After-Sales Service:
A/58, Kamal Pushpa, K.C. Road, Bandra, Mumbai-400050.
Tel: +91-9930513923
Email: [email protected]
Regional Office: Delhi
191-B, Ground Floor, Padam Nagar (Filter Market),
New Delhi - 110007 (India).
Tel: +91-9911615701
Email: [email protected]
- 29 -
TAS
PowerTek