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












C-135, Hos. Complex, Phase-II Extn., Noida-201305 (UP) INDIATel.: 0120-4221631 to 33 Fax: 0120-4221635Email : [email protected] Web : www.naacenergy.com

realcomp system catalogue - neptune-ducati

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