Download - Realcomp System Catalogue - Neptune-Ducati
REALCOMPMost Advanced and
Intelligent Real Time Power
Factor and Harmonic
Filtration Solution
NFC connectivity for programming via smart devices and AppŸfrontal optical port for connection to a PC via USB or Wi-FiŸ
Switching to zero crossing guarantees very short switching times and allows to reduce to a
minimum the current peaks generated on the capacitors during the insertion phase and allows
a switching off of the capacitors without voltage peaks, with consequent extension of the life of
the capacitors themselves.
Thyristor control through RS485 bus upto 31 stepsŸ
The Realcomp Dynamic Real Time Power Factor Correction System is characterized by a high
switching speed that ensures the switching on and off of the capacitors in one cycle.
Integrated current transformer with specific function for current monitoring and Ÿprotections of switching modules.
Very low losss single layer wound harmonic block reactorsŸ
Ready to use without programming if used with standard features.Ÿ
Super Heavy Duty Cylindrical Capacitor Banks from Ducati Energia, Italy monitoring and Ÿsetting through mobile App.
Advanced communication functionsŸ
IOT enabledŸ
This makes them particularly suitable for applications requiring dynamic power factor
correction, where the power factor varies very rapidly as a result of sudden and frequency
changes in the load, such as welding machines, presses, cranes, mixers, automation robots,
etc... which could not be compensated by a traditional power factor correction system with
switching on by electro-mechanical contactors.
REALCOMP
REALCOMP
REALCOMP
REALCOMP
Ÿ Programming from front keyboard, PC or smartphone or
tablet with App.
Ÿ Can command upto 31 steps with RS485 bus
Example welding machines, presses, moulding machines, etc.
Ÿ Graphic backlit LCD with texts in 10 languages
The REALCOMP Controller automatic power factor correction
controller is designed to meet the requirement of a dynamic
power factor correction for applications where the reactive load
varies rapid over time and a quick correction must be applied.
Easy to read 128x80 pixes, with adjustable
brightness, texts and graphs
LCD Graphic Display with backlighting
Ÿ electrical safety (no risk of accessing
dangerous live parts)
IR Front optical port
Ÿ no needs to switch off the power supply
The optical port on the front allows you to
communicate with your PC, smartphone to
tablet via USB device or Wi-Fi to perform
programming, monitoring and diagnostic
functions.
Ÿ convenience of operating directly from the
front
GSM / GPRS MODEM
With the GSM expansion module, the
controller is equipped with a GSM /
G P R S m o d e m , a u t o m a t i c a l l y
configured by the control unit. This
simplifies installation and wiring.
- digital inputs
- static outputs for increasing steps
Expandability with Expansion Modules
- relay outputs (for controll ing electo-
mechanical contactors)
Four slots for expansion modules, choose
between:
- communication ports: USB, Rs232, Rs485,
Ethernet, Profibus-DP, Modem GPRS-GSM
- PT100, 0/4...20mA, 0...10V, 0...±5 analogue
inputs
- analogue outputs type 0/4...20mA, 0...10V,
0...±5V
- data memory, calender-clock with backup
reserve energy for data logging.
Ÿ Mobile application for Android and iOS
smart device
Ÿ Software for remote control & configuration
from PC.
Software Compatibility
Ÿ Data view for supervision and energy
management
Once a data traffic enabled SIM card is inserted,
the controller can send alarm or event SMSs
and e-mails and data files can be transmitted
to FTP servers.
IR
REALCOMP Controller
rated current: 5A or 1A (programmable)Ÿ
Operational Characteristics
Voltage Measurement Circuit :
Aux. supply voltage : 100...415V AC / 110...250V DCŸSeparate, single-phase or three-phase Ÿmeasurement input: 50...720V AC
rated frequency: 50/60Hz (±10%)Ÿ
C.T. Circuit :
Single and three-phase inputŸ
Static Outputs :
8 integrated capacity 120mA max.Ÿ16 optional, capacity 55mA max.Ÿ
Measurement and Control :
power factor adjustment : 0.5 ind....0.5 cap.Ÿvoltage measurement range : 50...720V ACŸcurrent measurement range: 0.025...6AŸ
OOperating Temperature : -20...+70 CŸHousing : flush mounting 144x144 mmŸ
type of voltage and current measurement: true Ÿroot mean square (TRMS)
Degree of protection : IP65 front; IP20 on terminalsŸ
Certifications: cULus, EAC, RCM
REALCOMP
RS 485
Steps Statistics
Alarm Diagnosis
Dedicated to the Dynamic Power Factor
Correction through the control of
Perfect coupling with the Thyristor Modules,
which are controlled via RS485 bus as per
figure below. There is option of controlling the
switching modules through static outputs on
the Controller
thyristor modules
Through the RS485 serial command it is also
possible to monitor the status of each single
thyristor module from the Realcomp Controller
display and read measurements such as residual
power, voltages, currents, THD-I, temperature and
working hours.
Through RS485 serial command and connection to
the Thyristor Modules, the display can show the
description of the possible alarms of each single
step.
Panel over-temperature protection via
3 Current inputs for current transformer with
secondary 5A or 1A
A parameter can enable the controller for use with Ÿa 5A or 1A secondary current transformer;
Measurements in TRMS (True Root Mean
Square)
Voltage and Current harmonic content
analysis up to 31st order
Wide range of rated voltage measurements
Automatic recognition of current flow directionŸ
Balanced use of step with same power rating
(Measurement of reactive power installed for each
step)
internal sensor
Aux. power supply (100...415V AC / 110...250V DC)
separate from the three phase voltage measuring
circuit (50...720V AC)
REALCOMP REALCOMP REALCOMP REALCOMP
REALCOMP
Switching to zero crossing guarantees very
short switching times and allows to reduce to a
minimum the current peaks generated on the
capacitors during the insertion phase and
allows a switching off of the capacitors without
voltage peaks, with consequent extension of
the life of the capacitors themselves.
Integrated current transformer with specific
function for current monitoring and protection
power and harmonics of the capacitor bank.
Ready to use without programming if used
with standard features.
Advanced communication functions :
NFC connectivity for programming via Ÿsmart devices and App
RS485 port for switching commandsŸ
frontal optical port for connection to a PC Ÿvia USB or Wi-Fi
REALCOMP Thyristor Switching Module Dedicated to the Dynamic Power Factor
Correction (Fast)
The Realcomp Thyristor Modules is characterized
by a high switching speed that ensures the
switching on and off of the capacitors in one
cycle.
This makes them particularly suitable for
applications requiring dynamic power factor
correction, where the power factor varies very
rapidly as a result of sudden and frequency
changes in the load, such as welding machines,
presses, cranes, mixers, automation robots, etc...
which could not be compensated by a traditional
power factor correction system with switching on
by electro-mechanical contactors.
Noise Reduction
Switching on and off of capacitors are
electronically managed and due to the absence
of moving mechanical components the thyristor
modules can work silently. This makes them
part icu lar ly su i table for insta l lat ion in
environments that require minimum noise, such
as shops, offices, hotels, hospitals, cinemas etc.
Switching on at Zero-Crossing
Capacitors are switched exactly when the
potential difference between the mains voltage
and the residual voltage on the capacitor is zero,
allowing the current peak on the capacitors to be
reduced to a minimum during switch-on and
switch-off transients. This feature makes the
thyristor modules suitable for systems that
require a very high number of manoeuvres or in
which devices particularly sensitive to transient
over-current or over-voltages are installed.
The thyristor module incorporate an 8A 250V
AC relay output with changeover contact,
which can be programmed for one of the
following functions :
Programmable relay output
Ÿ Alarm signalling : the output switches in
case of global alarm, the type of active
alarm can be identified from the number of
flashes of the FAULT LED on the front of the
device
Monitoring and protection of current, power
and current harmonic in the capacitor bank
Fan control: possibility of programming the Ÿoutput to control an external fan in case of
over temperature.
Thanks to the presence of integrated current
transformers, it is possible to monitor and
protect the bank of capacitors against
overcurrent phenomena generated, for
example by the distortion of the voltage
waveform. It is also possible to continuously
monitor electrical measurements such as the
residual power of the capacitor bank, three-
phase voltages and currents, heat sink and
capacitor temperatures, THD-I, working hours
and maximum voltage, current and temp.
values, to signal faults on fuses, on the
capacitor bank or on the thyristor module
itself.
This feature is very useful for remote Ÿdiagnostics & reporting of a fault condition,
eg. problems with the system (eg.
excessively high voltages or currents), or if
the thyristor module is not working
properly (e.g short-circuited module), or
for checking whether the integrated fan is
not working or is blocked.
Programmable protection thresholds
capacitor maximum temperature threshold Ÿ(measured with optional external probe
NEC01)
If required, the thyristor modules allows complete
monitoring and protection of the capacitor bank.
The following protection thresholds can be
programmed using the NFC App, mobile App or
the PC software
maximum voltage thresholdŸ
Monitoring and diagnosis of the integrated fan
operation
The switching module cooling fans as standard
to ensure proper ventilation. The operation of the
fan is monitored by means of an analogue
measurement of the supply current of the fan
and the temperature by means of an integrated
probe, which allows the status of the fan to be
checked and any faults (eg. fan not connected or
blocked to be detected automatically)
heatsink maximum temperature thresholdŸ
current asymmetry thresholdŸ
capacitor residual power min. thresholdŸ
Overtemperature protection
Overtemperature protection via integrated
probe or probe input external NEC01 for
temperature measurement directly in the area of
installation of the capacitors (useful for example
when the capacitors are installed away from the
thyristor modules) protection against over
temperature is guaranteed.
THD-I thresholdŸ
maximum current thresholdŸ
POWER : signals the presence of the auxiliary Ÿpower supply
ON : indicates that the module is activatedŸ
FAULT : global alarm (with identification of Ÿthe active alarm by number of flashes)
3 Front Indication LEDs
Software Compatibility
Ÿ Mobile application for Android and iOS
smart device
Ÿ Software for remote control & configuration
from PC.
Ÿ Data view for supervision and energy
management
The absence of moving mechanical parts allows
a considerable reduction in maintenance times
compared to a traditional power factor
correction system controlled by electro-
mechanical contactors.
High sturdiness and little maintenance
electrical safety (no risk of accessing Ÿdangerous live parts)
The front optical port, in combination with the
USB and W-Fi connection devices, allows a
secure connection from the front with a PC,
smartphone or tablet
convenience of operating on the front.Ÿ
no need to remove power from the panel to Ÿconnect to the thyristor module
Front Optical Port
POWER ON FAULT
IR
Power connections with double, screw-type
terminal
Thyristor Switching Module are created with a
basic programming that allows to use them
without the need of any programming in most
cases. When necessary, however, you can
adapt them to each application via apps or
software.
The power terminals of the switching module
(excluding sizes 100 and 120 KVAR) are made
with double screw-type terminals, which
greatly simplify the wiring for connecting
thyristor modules in parallel without the need
for external parallel bridges.
Ready to work
Thyristor Switching Module can be installed
either vertically or horizontally without any
performance derating.
The 690V AC (IEC), 600V AC (cULus) version
Thyristor Switching Module have a very high
peak inverse voltage (PIV) of 3600V AC; this
makes them particularly resistant to mains
transients
This makes them extremely flexible &
adaptable for various layouts of power factor
correction panels, where often there is not
enough space for tradit ional vert ical
mounting and it is necessary to mount the
thyristor module on the horizontal plane (eg.
rack installation)
Possibiligy of installing invertical or horizontal
position
High PIV
Reference Standard : EN 60831-1/2
Standard Voltage (Un) : 525V / 690V
Rated Frequency : 50Hz
AC Test Volt. between term. : 3kV x 10”
Discharge Resistor : 10% of Un in 20 Sec.
AC Test Volt. between term. : 2.15Un x 10”
and Case
Service : Continuous
Capacitors installed are having Un of 525V or
690V as per network voltage or application.
OOver Heating : <60 C
OTemperature class : -40 + 55 C
Max. permissible current : 4 In
Connection : Delta
Installation : Internal
Capacitor Specification :
Capacitance Tolerance : -0+5%
Terminals : 1 x M12 (upto 50 KVAR)
Expected life : 150,000h
Inrush Current withstand Capability : 200 In
Dielectric losses : <0.2W / KVAR
Capacitor Banks
Neptune-Ducati ranges of Super Heavy
Cylindrical type Duca Power series Capacitor
Banks from M/s Ducati energia s.p.a, Italy. are
installed in Realcomp System
The Capacitor Banks are characterised by
high temperature withstand capacity and
high peak current of 4xIn capacity. Thereby
make it suitable for to operate in worst
condition of ambient and harmonic overload.
This lead to long operational life of capacitor
bank.
OTemp. Sensor(normally closed) : 155 C
Rated Voltage : 3x415/440V
Linearity : 200%
Winding Material : Cu. / AL.
Filtering factors / Tuning Freq. : 5.6% (210Hz),
Harmonic Block Reactors
Neptune Filter Circuits are designed as three-
phase reactors with an iron core and air gap.
Harmonic Filter Reactors are made out of high
quality material and very stringent quality
control. It has been designed with properties like
low temperature rise and lower flux density so
that it can operate in worst conditions of ambient
and harmonic overloads. All the reactors are
designed with single layer strip winding with
proper air channels for low temperature rise.
All the reactors are designed with 200% linearity
(L> 0.95 x Ln) and constructed with the core and
winding material ensuring very low operational
losses. This ensures that Realcomp System
operated with very low running cost thereby
saving consumer thousands of units every year.
The reactors in Realcomp System are available in
option of 5.67% (210 Hz), 7% (189 hz), 12.5% (141 Hz)
and 14% (133 Hz). The final rating and design is
r e c o m m e n d e d a s p e r n e t w o r k l o a d
characteristics and other related parameters like
fault level and harmonic distortion in the network.
Harmonic Block Reactors Specification :
Construction Max. Voltage : 1000V
Test Voltage : 2500V
Frequency : 50 Hz
7% (189Hz), 14% (133Hz)
Cooling method : Forced air cooling in enclosure
Tolerance of Inductance : + 3%
OAmbient Temperature : + 55 C
Installation : Indoor
Reference Standard :
IEC 61558-2-20
Insulation Class : H
REALCOMP
Programming the parameters via tablet and
smartphone is now possible also through NFC
wireless technology. Bringing a smartphone or tablet
with NFC connection enabled near the thyristor
module activates the APP and the connected
thyristor module is automaticlly recognized. It will
then be possible to modify the parameters and
program the thyristor module
read the list of eventsŸ
sent commandsŸdisplay active alarmsŸ
The communication device is the access point Ÿto the controller and the thyristor module via
the mobile app.
set the parameters, save a copy in a file and Ÿrecover them if necessary; the file can also be
sent via email
Mobile app can be downloaded from Google ŸPlay Store or Apple store
view the measurement on your smartphone or Ÿtablet
It is a software that allows you to:Ÿ
read the measuresŸ
set the parameters from PC to Controller or Ÿvice versa
send commandsŸ
view events and alarmsŸ
The Controller is compatible with softwareŸ
The Ethernet port is suitable for both static IP Ÿand dynamic IP address operation and the
network configuration of the controller is
similar to that normally performed on a PC.
Thanks to the communication expansion Ÿmodules controller can immediately
connected to a network without the need for
additional external accessories
Serial and Ethernet communication is Ÿsupported
NFC App
Mobile App
Configuration and remote control software
Supervision and Energy Management software
REALCOMP
Some of the major Applications of REALCOMP SYSTEM
Automobile / Welding Machines
Office Buildings / Hospitals / Commercial Buildings
Port Cranes / Mixing Machines
Metro / Railways
Presses / Lifts / Elevators
Data Center / IT Industry / Injection Moulding Machines
Robots / Wind Energy production
Airport / Stadium
All types of non-linear load industries likeSteel, Textile, Cement, Rubbers etc.
All types of non-linear load industries likePaper, Plastic etc.
Capacitors : DUCA POWER Super Heavy Duty series used are rated at 525V, 690V and
800V, 50/60Hz as per network voltage
Modular Controller : 3 Phase, 3 CT Input, CT Input 1A / 5A with inbuilt Power Quality and Load
Manager
O 35 C annual average O -10 C low limit
Other output ratings, switching combination or design voltages are
available upon request
OAmbient Temperature : 50 C max. short time
*Specifications are subject to change without notifications
Enclosure Finish : Epoxy Powder Coated, in grey (RAL 7035) structure finish
Reactors : H-Class, Single layer Wound (Cu. / AL. )
Rated Design Voltage : 415V-440V, 50Hz, 3 Phase 3 Wire (Design available for 380V, 400V, 480V,
690V, 750V - 50/60Hz)
Duty : Continuous
Switching : Heavy Duty Thyristor Switched, 2200 PIV
Output Rating : Refer to the table
Incoming / Outgoing : MCCB / ACB as incomer and HRC Fuses for backup protection (other
combinations on request)
Enclosure Design : Standardized bolted Modular Sheet Steel Enclosure-Non
compartmentalized. Compartmentalized on request
O 40 C average in 24 hours
Protection Class : IP 40
Realcomp System for 415V- 440V/50Hz
Technical Specification :
Part No. OutputkVAR
SwitchingSequence
DimensionsW x D x H (mm)
REAL1377-415-50-P7 1377 KVAR 1x27 KVAR, 1x54 KVAR, 12x108 KVAR 3250 x 1150 x 2100
REAL1269-415-50-P7 1269 KVAR 1x27 KVAR, 1x54 KVAR, 11x108 KVAR 2450 x 1150 x 2100
REAL1053-415-50-P7 1053 KVAR 1x27 KVAR, 1x54 KVAR, 9x108 KVAR 2250 x 1150 x 2100
REAL1485-415-50-P7 1485 KVAR 1x27 KVAR, 1x54 KVAR, 13x108 KVAR 3250 x 1150 x 2100
REAL837-415-50-P7 837 KVAR 1x27 KVAR, 1x54 KVAR, 7x108 KVAR 2250 x 1150 x 2100
REAL1161-415-50-P7 1161 KVAR 1x27 KVAR, 1x54 KVAR, 10x108 KVAR 2450 x 1150 x 2100
REAL945-415-50-P7 945 KVAR 1x27 KVAR, 1x54 KVAR, 8x108 KVAR 2250 x 1150 x 2100
REAL297-415-50-P7 297 KVAR 1x27 KVAR, 1x54 KVAR, 2x108 KVAR 850 x 1150 x 2100
REAL729-415-50-P7 729 KVAR 1x27 KVAR, 1x54 KVAR, 6x108 KVAR 1650 x 1150 x 2100
REAL513-415-50-P7 513 KVAR 1x27 KVAR, 1x54 KVAR, 4x108 KVAR 1650 x 1150 x 2100
REAL405-415-50-P7 405 KVAR 1x27 KVAR, 1x54 KVAR, 3x108 KVAR 850 x 1150 x 2100
REAL621-415-50-P7 621 KVAR 1x27 KVAR, 1x54 KVAR, 5x108 KVAR 1650 x 1150 x 2100
C-135, Hos. Complex, Phase-II Extn., Noida-201305 (UP) INDIATel.: 0120-4221631 to 33 Fax: 0120-4221635Email : [email protected] Web : www.naacenergy.com