advanced service repair and troubleshooting instruction

Instruction Booklet IB158001ENEffective May 2016Supersedes May 2013

ContentsDescription Page

Service and maintenance instructions . . . . . . . . . 2Torque chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Advanced service repair and troubleshooting instruction bulletin

This instruction manual is published solely for information purposes and should not be considered all-inclusive . If further information is required, you should consult an authorized Eaton sales representative .

The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties . This literature is not intended to and does not enlarge or add to any such contract . The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Eaton .

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and description contained herein .

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Instruction Booklet IB158001ENEffective May 2016


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Service and maintenance instructions

NOTICEFOR ELECTRICALLY QUALIFIED AND TRAINED PERSONNEL ONLY.

Eaton’s Engineering Services & Systems (EESS) is well trained and qualified to conduct these services . Please contact your nearest Eaton sales office for obtaining this service through Eaton .

Capacitors (switched)

Maintenance testing guidelines

Under normal service conditions, once a capacitor is installed, no further service is required during the life of the capacitor . However, periodic maintenance will maximize equipment life .

The following information is a guide for service and maintenance services . Capacitors should be installed, operated, and maintained by qualified personnel as defined by OSHA 29CFR1910 subpart 5 . These instructions do not cover all details, variations, or combinations of the equipment, its installation, checkout, and safe operation . Care must be exercised to comply with local, state, and national regulations, as well as safety practices for this class of equipment .

For a complete list of Instruction Leaflets (ILs) and Instruction Bulletins (IBs), access the Eaton website at www .eaton .com/pfc . You can also contact Eaton’s Technical Resources Center at 1-800-809-2772 option 4 and then option 2 for any information regarding the capacitor banks .

Prior to testing

• Procure and review all drawings associated with the equipment being tested

• Study all instructional documents (operation and maintenance manuals) applicable to the equipment

• Obtain a copy of the appropriate test form to record test results• Verify suitability and accuracy of equipment to be used for testing• Record all existing equipment settings as well as settings

resulting from any necessary adjustments . The proper settings for testing should be supplied by the customer’s engineer or from a power systems study performed prior to commissioning the equipment

Necessary equipment

• Personal protective equipment (PPE)• RMS multi-meter• Clamp on ammeter (1000 V, Cat IV)• Torque wrench with internal and external hex sockets• Screwdriver bit for tightening—PZ2 / PH1 / 5 .5 x 1• Insulation resistance tester (Megger-1000 volt)• Capacitance meter (BK Precision 878B or equal)• Telescopic magnetic pickup tool if readily available

m WARNINGDO NOT ATTEMPT TO INSTALL OR WORK ON EQUIPMENT WHILE IT IS ENERGIZED. ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT BEFORE PROCEEDING WITH TESTING. ASSUME ALL CIRCUITS ARE ENERGIZED. CONFIRM PRIMARY SOURCES OF POWER ARE DISCONNECTED, TAGGED, AND LOCKED OUT. ALWAYS FOLLOW ALL LOCAL, STATE, AND NATIONAL REGULATIONS INCLUDING OSHA REQUIREMENTS AND GENERALLY ACCEPTED SAFETY PROCEDURES.

Inspection and test procedures

Visual and mechanical inspection

1. Inspect physical and mechanical condition of the unit as installed . Check for correct mounting and required clearances .

2. Inspect all components of the unit including fuses, indicating lights, and conductor landing lugs for any signs of improper termination, overheating, discoloration, or deterioration .

3. Inspect the capacitor cells for any leaks or deposits (sand, dust, dirt, grime, etc .) and/or bulging on top of the capacitors . If present in excess, these contaminants could severely affect the creepage and clearance distances between line to line and line to ground . These contaminants should be cleaned by air suction and care should be taken to prevent such ingress or frequency of preventive maintenance should be improved .

4. If dust is seen, a magnetic pickup tool should be used to verify the conductivity of the dust . Non-magnetic non-conducting dust combined with humidity and moisture also results in reduced creepage distances and care should be taken that the dust filters are regularly replaced and any dust accumulation is cleaned out via suction .

5. Verify that capacitors are electrically connected in their specified configuration .

6. Inspect the discharge resistors fitted integral to the terminals . Check for secured and snug fit, discoloration, cracked or chapped modules .

7. If reactor is present, inspect the reactor for any signs of discoloration and overheating .

8. Inspect and ensure the thermal switch wiring and the switches are securely in place into the hotspot region of the reactor winding .

9. Inspect the electrical connections and perform a pull test on all customer and factory connections by giving a firm tug on all the connections .

10. Inspect the cleanliness of the dust filters and replace if soiled or dirty .

Electrical tests

1. Perform a terminal-to-terminal continuity and resistance measurement using the multi-meter . It should not read open, very high, or unequal resistance between terminals . (Variation of ±0% is acceptable .)

2. Perform insulation-resistance tests from terminal(s) to case for 30 sec on the capacitor cells . Ensure any 300 V rated control components are isolated/disconnected from the test path . Test voltage and minimum resistance shall be as follows:Maximum rating of equipment in volts

Minimum test voltage, DC in volts

Recommended minimum insulation resistance in mega-ohms

250–500 500 25600 1000 100

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3. Inspect all electrical connections for high resistance using both of the following methods:

a. Use of low-resistance ohmmeter .

b. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench . If required, torque the terminals to 2 .3 Nm using the recommended Philips head Ph 1 or Pozidriv Pz 2 bit .

c. Measure resistance of integral discharge resistors . The discharge resistors are three-pronged internally delta connected just like the capacitors and have a printed value of the total resistance on them . The measured resistance between any two prongs should measure approximately two thirds of the printed value .

Example: 120 kohms for a 180 kohm resistor .Example: 180 kohms for a 270 kohm resistor .

4. Measure the capacitance of all terminal combinations and verify it with the following table . +10% and –5% variation would be considered an acceptable value for a good capacitor .Rated voltage 240 480 600

Nameplate kvar (three-phase) uF uF uF

1.00 23.0 5.8 3.71.50 34.5 8.6 5.52.00 46.1 11.5 7.42.50 57.6 14.4 9.23.00 69.1 17.3 11.14.00 92.1 23.0 14.75.00 115.1 28.8 18.46.00 138.2 34.5 22.16.25 143.9 36.0 23.07.50 172.7 43.2 27.68.00 184.2 46.1 29.58.33 191.8 48.0 30.710.00 230.3 57.6 36.812.50 287.8 72.0 46.115.00 345.4 86.3 55.316.66 383.6 95.9 61.417.50 403.0 100.7 64.520.00 460.5 115.1 73.725.00 575.6 143.9 92.130.00 690.8 172.7 110.535.00 805.9 201.5 128.940.00 921.0 230.3 147.445.00 1036.2 259.0 165.850.00 1151.3 287.8 184.255.00 1266.4 316.6 202.660.00 1381.6 345.4 221.0

5. Low-voltage testsWhere practical, a control power only low-voltage test can be used to verify the electrical operation of the bank .

a. Remove the three fuses on the primary side of the control power transformer (CPT) located on the control panel .

b. Tie/tape the door interlock limit switch shut to allow the control circuit interlock to be defeated temporarily .

c. Use an available 120 V power source, suitably fused, and connect the phase to the fuse and neutral to the grounded terminal .

d. While taking appropriate electrical precautions, energize the 120 V supply and turn the ON/OFF switch on the front of the door to ON position .

e. The controller should power on and the ventilation fans should immediately power up . Ensure the fans are rotating in the correct direction by feeling the draft of the air from the enclosure is in “exhaust” mode .

f. Engage the controller in the manual mode and step through the various stages, one step at a time, and hear for the contactor to pull in .

g. Once all contactors have been verified to energize, disconnect the 120 V power supply, remove the defeat mechanism of the door interlock, and replace the primary control fuses at the CPT .

6. Post testing full voltage test

a. Remove all test equipment and tools used during testing .

b. Replace all barriers and covers, close all doors, and secure all latches .

c. Review all test results . If the results are satisfactory, the equipment is qualified for service and proceed with commissioning/re-commissioning the unit in accordance with the Operations and Maintenance Manual .

d. If the results are in question, contact the Technical Resource Center to report results .

e. If the unit is found to be satisfactory, defeat the door interlock switch, place a clamp-on meter on one of the line conductors, ensuring the range is within the rated nameplate current of the unit and while maintaining proper PPE gear, energize the unit and record the current reading .

f. The current should be within -–5% to +10% of the rated nameplate current at rated voltage .

g. Ensure that the door interlock defeat is removed before returning the unit to normal operation .

Reactors

1. Perform a terminal-to-terminal continuity and resistance measurement using the multi-meter of each coil of the reactor . It should not read open, very high, or unequal resistance between the three windings (a variation of ±15% is acceptable) .

2. Perform insulation-resistance tests from terminal(s) to case for 30 sec on the reactor . Ensure the 1 A control fuses and any other 300 V rated control components are isolated/disconnected from the test path . Test voltage and minimum resistance shall be as follows:

Maximum rating of equipment in volts

Minimum test voltage, DC in volts

Recommended minimum insulation resistance in mega-ohms

250–500 500 25600 1000 100

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© 2016 EatonAll Rights ReservedPrinted in USAPublication No . IB158001EN / Z18245May 2016

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All other trademarks are property of their respective owners .



Torque chart

Location identifier

Torque table

Torque value Remarks

1 Customer incoming conductor to mechanical lug (customer wiring) 275 in-lb For lug size suitable to accommodate conductors maximum up to 350 kcmil375 in-lb For lug suitable to accept conductors greater than 350 kcmil up to 750 kcmil

2 Mechanical lug to bus bar (factory wiring) 20 ft-lb3 4 AWG wire terminated onto bus (factory wiring) 60 in-lb4 4 AWG wire terminated onto reactor (if applicable) (factory wiring) 60 in-lb5 4 AWG wire terminated onto fuse (factory wiring) 60 in-lb Bottom terminals6 4 AWG (pigtail) wire terminated onto contactor (factory wiring) 45 in-lb Bottom terminals7 Capacitor mounting M8/M10 stud (factory wiring) � 14.8 ft-lb Stud on bottom of capacitor8 8 AWG wires to capactors contactors (factory wiring) � 22 in-lb Top terminals9 8 AWG wires to contactors (factory wiring) � 45 in-lb Top terminals10 Nest assembly mounting bolt (not a factory torqued live part) 20 ft-lb Rear of nest

11 Reactor mounting bolt (not a factory torqued live part) 20 ft-lb

� Customer wiring if expanding unit in field.

For technical support and application engineeringassistance, please contact Eaton’s TRC at1-800-809-2772 option 4, option 2or email [email protected]

advanced service repair and troubleshooting instruction

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