Commissioning Instructions

Novar 300 Capacitor Controller forPower Factor Correction

HANDLING OF ELECTRONIC EQUIPMENT

A person's normal movements can easily generate electrostatic potentials of several thousand volts.Discharge of these voltages into semiconductor devices when handling electronic circuits can cause seriousdamage, which often may not be immediately apparent but the reliability of the circuit will have beenreduced.

The electronic circuits of ALSTOM T&D Protection & Control Ltd products are immune to the relevant levels ofelectrostatic discharge when housed in their cases. Do not expose them to the risk of damage bywithdrawing modules unnecessarily.

Each module incorporates the highest practicable protection for its semiconductor devices. However, if itbecomes necessary to withdraw a module, the following precautions should be taken to preserve the highreliability and long life for which the equipment has been designed and manufactured.

1. Before removing a module, ensure that you are at the same electrostatic potential as the equipment bytouching the case.

2. Handle the module by its front-plate, frame, or edges of the printed circuit board.Avoid touching the electronic components, printed circuit track or connectors.

3. Do not pass the module to any person without first ensuring that you are both at the same electrostaticpotential. Shaking hands achieves equipotential.

4. Place the module on an antistatic surface, or on a conducting surface which is at the samepotential as yourself.

5. Store or transport the module in a conductive bag.

More information on safe working procedures for all electronic equipment can be found in BS5783 andIEC 60147-0F.

If you are making measurements on the internal electronic circuitry of an equipment in service, it ispreferable that you are earthed to the case with a conductive wrist strap.Wrist straps should have a resistance to ground between 500k – 10M ohms. If a wrist strap is not available,you should maintain regular contact with the case to prevent the build up of static. Instrumentation whichmay be used for making measurements should be earthed to the case whenever possible.

ALSTOM T&D Protection & Control Ltd strongly recommends that detailed investigations on the electroniccircuitry, or modification work, should be carried out in a Special Handling Area such as described inBS5783 or IEC 60147-0F.

Commissioning Instructions

Novar 300 Capacitor Controller forPower Factor Correction

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SAFETY SECTION

This Safety Section should be read before commencing any work on the equipment.

Health and safetyThe information in the Safety Section of the product documentation is intended toensure that products are properly installed and handled in order to maintainthem in a safe condition. It is assumed that everyone who will be associated withthe equipment will be familiar with the contents of the Safety Section.

Explanation of symbols and labelsThe meaning of symbols and labels which may be used on the equipment or inthe product documentation, is given below.

Caution: refer to product documentation Caution: risk of electric shock

Protective/safety *earth terminal

Functional *earth terminal.Note: this symbol may also be used for a protective/safety earth terminal if that terminal is part of aterminal block or sub-assembly eg. power supply.

*Note: The term earth used throughout this manual is the direct equivalent ofthe North American term ground.

Installing, Commissioning and Servicing

Equipment connectionsPersonnel undertaking installation, commissioning or servicing work on thisequipment should be aware of the correct working procedures to ensure safety.The product documentation should be consulted before installing, commissioningor servicing the equipment.

Terminals exposed during installation, commissioning and maintenance maypresent a hazardous voltage unless the equipment is electrically isolated.

If there is unlocked access to the rear of the equipment, care should be taken byall personnel to avoid electric shock or energy hazards.

Voltage and current connections should be made using insulated crimpterminations to ensure that terminal block insulation requirements are maintainedfor safety. To ensure that wires are correctly terminated, the correct crimpterminal and tool for the wire size should be used.

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Before energising the equipment it must be earthed using the protective earthterminal, or the appropriate termination of the supply plug in the case of plugconnected equipment. Omitting or disconnecting the equipment earth may causea safety hazard.

The recommended minimum earth wire size is 2.5 mm2, unless otherwise statedin the technical data section of the Service Manual.

Before energising the equipment, the following should be checked:

Voltage rating and polarity;

CT circuit rating and integrity of connections;

Protective fuse rating;

Integrity of earth connection (where applicable)

Equipment operating conditionsThe equipment should be operated within the specified electrical andenvironmental limits.

Current transformer circuitsDo not open the secondary circuit of a live CT since the high voltage producedmay be lethal to personnel and could damage insulation.

External resistorsWhere external resistors are fitted to relays, these may present a risk of electricshock or burns, if touched.

Battery replacementWhere internal batteries are fitted they should be replaced with therecommended type and be installed with the correct polarity, to avoid possibledamage to the equipment.

Insulation and dielectric strength testingInsulation testing may leave capacitors charged up to a hazardous voltage.At the end of each part of the test, the voltage should be gradually reduced tozero, to discharge capacitors, before the test leads are disconnected.

Insertion of modules and pcb cardsThese must not be inserted into or withdrawn from equipment whilst it isenergised, since this may result in damage.

Fibre optic communicationWhere fibre optic communication devices are fitted, these should not be vieweddirectly. Optical power meters should be used to determine the operation orsignal level of the device.

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Older productsElectrical adjustmentsEquipments which require direct physical adjustments to their operatingmechanism to change current or voltage settings, should have the electricalpower removed before making the change, to avoid any risk of electric shock.

Mechanical adjustmentsThe electrical power to the relay contacts should be removed before checkingany mechanical settings, to avoid any risk of electric shock.

Draw out case relaysRemoval of the cover on equipment incorporating electromechanical operatingelements, may expose hazardous live parts such as relay contacts.

Insertion and withdrawal of extender cardsWhen using an extender card, this should not be inserted or withdrawn from theequipment whilst it is energised. This is to avoid possible shock or damagehazards. Hazardous live voltages may be accessible on the extender card.

Insertion and withdrawal of heavy current test plugsWhen using a heavy current test plug, CT shorting links must be in place beforeinsertion or removal, to avoid potentially lethal voltages.

Decommissioning and Disposal

Decommissioning: The auxiliary supply circuit in the relay may includecapacitors across the supply or to earth. To avoid electricshock or energy hazards, after completely isolating thesupplies to the relay (both poles of any dc supply), thecapacitors should be safely discharged via the externalterminals prior to decommissioning.

Disposal: It is recommended that incineration and disposal to watercourses is avoided. The product should be disposed of ina safe manner. Any products containing batteries shouldhave them removed before disposal, taking precautions toavoid short circuits. Particular regulations within thecountry of operation, may apply to the disposal of lithiumbatteries.

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Technical Specifications

Protective fuse ratingThe recommended maximum rating of the external protective fuse for thisequipment is 6A, unless otherwise stated in the technical data section of theproduct documentation.

Insulation class: IEC 601010-1: 1990/A2: 1995 This equipment requires aClass I protective (safety) earthEN 61010-1: 1993/A2: 1995 connection to ensure userClass I safety.

Installation IEC 601010-1: 1990/A2: 1995 Distribution level, fixedCategory Category III installation. Equipment in(Overvoltage): EN 61010-1: 1993/A2: 1995 this category is qualification

Category III tested at 5kV peak,1.2/50µs, 500Ω, 0.5J,between all supply circuitsand earth and also betweenindependent circuits.

Environment: IEC 601010-1: 1990/A2: 1995 Compliance isPollution degree 2 demonstrated by referenceEN 61010-1: 1993/A2: 1995 to generic safety standards.Pollution degree 2

Product safety: 73/23/EEC Compliance with theEuropean Commission LowVoltage Directive.

EN 61010-1: 1993/A2: 1995 Compliance isEN 60950: 1992/A11: 1997 demonstrated by reference

to generic safety standards.

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Section 1. INTRODUCTION

There is a warning symbol on the equipment, an exclamation mark within atriangle. This alerts the user to refer to these Commissioning Instructions (I9-083)or the Operation and Maintenance Manual (I9-092) before installing,commissioning or operating the equipment.

WARNINGS

1. Installation, commissioning and maintenance should only be carried out bysuitably qualified personnel.

2. Terminations exposed during installation, commissioning and maintenancemay present a hazard unless the equipment is electrically isolated.

3. The equipment should only be operated as intended eg. with the covers inplace, and within the specified electrical and environmental limits.

4. Susceptibility to Electrostatic Discharge: 8kV air discharge/4kV contact.

This specification applies for direct contact with the terminals and via airdischarge when the front cover is fitted. When setting the DIL switches, usingthe front buttons or making adjustments, appropriate ESD protection must betaken.

Section 2. COMMISSIONING

The Novar 300 should be connected to the system as per the wiring diagram onthe side of the case. Ensure that the current and voltage connections are madeup to the correct terminals and have the required phase relationship.Capacitors must be connected on the load side of the CT. Fuses (0.5A rated)should be connected as shown on the wiring diagram. Full details are given inthe catalogue (I6-010).

The following settings need to be made:Sequence, Time and Limit DIL selector switches plus c/k and cosϕ potentiometersettings.

Models 301 and 303The sequence, time and limit selector switches are mounted internally for security.If these switches have been factory pre-set to the user’s requirements then only thec/k and cosϕ potentiometers will require setting. If setting of the selector switchesis required, disconnection from the system is necessary.

DANGER

OPEN CIRCUIT CURRENT TRANSFORMERS ARE DANGEROUS.THE CURRENT TRANSFORMER SECONDARY SHOULD BE SHORT-CIRCUITED BEFORE THE CONTROLLER INPUTS ARE DISCONNECTED.

Care must be taken to earth oneself effectively before removing the Novar fromits housing. Use of a wrist strap connected to earth through a 1MΩ resistor isrecommended.

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Models 302, 304 and 305All the necessary adjustments are accessible on the controller fascia(see Figure 1).

1. Selector switch settingsUse a small tool to set the DIL selector switches BEFORE power is applied.

Set switch numbers 1 to 10 inclusive according to the desired sequence, timedelay and stage limit required. Table 1 provides all the details. Further detailsand explanations of the switch functions are provided in the catalogue (I6-010).

2. Setting c/k potentiometerSetting range = 0.03 to 1.0

c/k =smallest capacitor step size in vars

3 V I x 5

where V = nominal primary system voltage.

I = primary rating of the current transformer

Adjust using a small screwdriver.

Example

Smallest capacitor step size = 50 kvar

CT primary rating = 600 A

Primary system voltage = 415 V

c/k = 50000 3 x 541 x 600

x 5 = 0.58

3. Setting target power factor (cosϕ) potentiometerSetting range 0.80 lagging to 0.95 leading.

Adjust using a small screwdriver.

4. Power may now be applied to the NovarNote: If a sequence or limit selector switch is adjusted whilst the Novar is

energised, all capacitor stages will be switched out automatically.

A safety lockout time will be imposed to allow for capacitor dischargebefore any further switching.

5. Self-testAt switch-on the Novar will automatically undertake a self-test procedure.The model type is indicated for a few seconds on units equipped with a displayand is repeated every 10 minutes. Any malfunction detected will result in adisplay of the model type number and the CAP and IND LEDs on the front fasciaflashing alternately. Under normal operation, models with display will show thesystem power factor.

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Figure 1: Novar indication and user adjustments

1 2 3 4 5 6 7 8 9 10 11 12

POWER

H

CAP

J

IND

K

C/K

C

E

F

AUTO

MANUAL

+

0

–

% Vn

% In

COS ϕ

COS ϕ

D

0 1

Sequence

Time

Limit

G

Model 305A

% Vn

% In

COS ϕ

B

Fascia key

A – Secret-until-lit display of energised stages

B – High definition liquid crystal display

C – C/K setting

D – COS ϕ setting

E – Dual mode button: auto/manual

F – Dual mode button: capacitor switching (man) and display selection (auto)

G – DIL switch (sequence, time and limit setting)

H – Power on indication LED

J – Switching in progress, circuit is capacitive

K – Switching in progress, circuit is inductive

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6. Connection errorIf the voltage or current connections have been made to the wrong phase, theNovar will indicate this by flashing the CAP and IND LEDs on the front fascia.Models 303, 304 and 305 will also display the phase angle by which thecurrent leads the voltage to assist with connection fault diagnosis.

For example: At unity power factor with a reversed CT, the display will indicate270 °.

7. Current beyond operational limitsIf the current is below 10% of nominal rating, model types 303, 304 and 305will display ‘- - - -’ ; the Novar will, however, be functioning correctly. If thecurrent is higher than 120 % of nominal rating ‘A – HI’ will be displayed andrelay switching will stop. Switching will recommence once the current has fallenbelow 120% of nominal rating.

8. Expanded display modeOn display models, a more accurate setting of c/k and cosϕ can be made aswell as showing selected sequence, time and limit settings:

Press the lower push button for approximately five seconds to enter expandeddisplay mode.

Repeatedly press and release lower button to loop through functions:

• Sequence displayed as : * *

• Time displayed as : * * * (seconds)

• Limit displayed as : * *

• c/k setting displayed as : * *

Then adjust c/k potentiometer to desired setting.

• Target cosϕ setting displayed as : * *

Then adjust cosϕ potentiometer to desired setting.

• System power factor indication (followed by % Vn and % In for model 305only).

Press lower button for approximately five seconds to exit expanded displaymode. Power Factor Indication will be shown. The Novar will exit expandeddisplay mode after 15 minutes if left unattended.

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9. Manual capacitor switchingPressing the upper button will enter the manual mode as indicated by the LED onthe Novar fascia. The ‘0’ LED will also light.

A depression of the lower button will instruct the Novar to switch in all capacitorsat intervals of one-fifth of the safety lockout time as indicated by the ‘+’ LED andthe Stage LEDs (providing that the safety lockout time has elapsed).

Once all stages have been switched in, a further two depressions of the lowerbutton will instruct the Novar to switch out all stages at intervals of one-fifth of thesafety lockout time as indicated by the ‘–’ LED and the Stage LEDs.

Pressing the upper button returns the Novar to automatic mode. If the Novar isleft in manual mode it will return to automatic mode after the safety lockout timeplus five minutes.

Any setting changes or keypad activity within this time will inhibit the return toauto.

WARNING

THE MANUAL FACILITY SHOULD NOT BE USED TO DISABLECAPACITORS FOR MAINTENANCE PURPOSES.

10. Novar 305 measurement displayWith the Novar 305 in AUTO mode, repeatedly pressing the lower button allowsthe display to read % Vn and then % In before returning to cosϕ. The nominal Vnand In values are printed on the rating label.

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Electromagnetic Compatibility Directive 89/336/EEC

Emissions standard EN50081-2 1994 Industrial environment

Immunity standard EN50082-2 1995 Industrial environment

(IEC 60801 parts 2, 3 and 4)

Susceptibility toElectrostatic Discharge 8kV air discharge/4kV contact.

WARNING: This specification applies for direct contact with the terminalsand via air discharge when the front cover is fitted. When setting the DILswitches, using the front buttons and making adjustments, appropriate ESDprotection must be taken.

Low Voltage Directive 72/23/EEC

Designed to EN61010-1 1993 safety requirements.

ALSTOM T&D Protection & Control Ltd St Leonards Works, Stafford, ST17 4LX EnglandTel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232

Email: enquiries@pcs.alstom.co.uk Internet: www.gecalsthomgpc.co.uk

Our policy is one of continuous product development and the right is reservedto supply equipment which may vary from that described.

©1998 ALSTOM T&D Protection & Control Ltd

Publication I9-083G Printed in England.