operating instructions pqm 500 & pqm 300 series general ...operating instructions pqm 500 &...

Operating Instructions PQM 500 & PQM 300 Series General, Technical Construction, Installation Notes, Maintenance & Repair

Power Quality Management Operating Instructions PQM500 & PQM300 Series Page 1 of 12

Maschinenfabrik Reinhausen GmbH 2012. Manual_PQM500_PQM300_Rev05_en.docx

Contents

1 General 21.1 Using the manual ............................................................................................................ 21.2 Safety notes .................................................................................................................... 21.3 Important notes on using the system ................................................................................. 41.4 Standards and responsibilities ........................................................................................... 4

2 General data of the system 52.1 Technical data - nameplate ............................................................................................... 52.2 Ambient conditions .......................................................................................................... 52.1 Intended use ................................................................................................................... 6

3 Installation and Commissioning 63.1 Operation ....................................................................................................................... 73.2 Operational switching off ................................................................................................. 73.3 Protective trip (in the event of a fault) ............................................................................... 83.4 Operational switching on .................................................................................................. 8

3.4.1 Reconnection after operational shutdown ................................................................................ 83.4.2 Reconnection after maintenance and repair measures ............................................................... 8

4 Maintenance 94.1 Preparation ..................................................................................................................... 94.2 Measures to be carried out ................................................................................................ 9

4.2.1 Inspection schedule .............................................................................................................. 104.2.2 Replacement of components ................................................................................................. 114.2.3 Cleaning .............................................................................................................................. 114.2.4 Greasing .............................................................................................................................. 11

5 Dismantling & Waste Disposal 125.1 Lifespan ........................................................................................................................ 125.2 Dismantling .................................................................................................................. 125.3 Waste Disposal .............................................................................................................. 12

Version 1.5 Coverpage changed Version 1.4 Content corrections Version 1.3 Formatting changed Version 1.2 Addition to Maintenance Version 1.1 Addition to Waste Disposal



1 General

1.1 Using the manual These Operating Instructions contain general as well as system-specific information. Technical details on design and open/closed-loop control (if present) can be taken from the relevant sections of the technical documentation. If there is a lack of information or there are further questions, we can be contacted at the address below:

Maschinenfabrik Reinhausen GmbH Wiebestrasse 46

10553 Berlin Tel. +49 30330915-0

Fax: +49 30330915-25 E-mail: [email protected]

1.2 Safety notes

When operating electrical switchgear and control gear, it is inevitable that certain parts of these systems will be carrying dangerous electrical voltage and mechanical parts, even when remotely controlled, can move very quickly. Serious physical injuries and material damage may occur if the safety regulations and warning signs are not observed. Only appropriately qualified staff should work on or in the vicinity of this compensation system. These members of staff must be thoroughly familiar with all warnings in accordance with these Operating Instructions. Trouble-free and safe operation of this compensation system assumes proper transport, professional storage, positioning and installation in addition to careful operation and maintenance.



DANGER as defined by these Operating Instructions and by the warning signs on the products themselves means that death, severe physical injury or substantial material damage will occur if the appropriate precautions are not taken.

Warning as defined by these Operating Instructions and by the warning signs on the products themselves means that death, severe physical injury or substantial material damage will occur if the appropriate precautions are not taken. Caution as defined by these Operating Instructions and by the warning signs on the products themselves means that slight physical injury or material damage may occur if the appropriate precautions are not taken. Qualified staff as defined by these Operating Instructions and by the warning signs on the product itself are people who are familiar with positioning, installation, commissioning and operation of the product and who have the relevant qualifications for their job, such as I. training and instruction or authorization to switch circuits and

equipment/systems on and off, to ground them and to identification mark them in accordance with safety engineering standards.

II. Training or instruction in accordance with safety engineering standards on the care and use of appropriate safety equipment.

III. Training in first aid.



The 5 safety rules

Prior to starting work:

1. Isolate with a safety disconnection function

2. Secure against reconnection

3. Ensure safe isolation from supply (*)

4. Ground and short-circuit

5. Cover/fence off adjacent live parts

DANGER

(*) After isolating the system, the capacitors of the capacitive steps still have

a residual voltage (direct current). Exercise caution regarding the capacitors’

discharge time.

1.3 Important notes on using the system • Trouble-free and safe use of the compensation system assumes:

o Proper transport o Professional installation and commissioning o Careful operation and maintenance by qualified staff o Observance of these Operating Instructions o Compliance with the positioning, operating and safety regulations applicable at the

installation site

1.4 Standards and responsibilities • DIN VDE 0113 • DIN VDE 0100 • All applicable accident prevention regulations of the employer's liability insurance association • Additional country and company-specific requirements may be applied as necessary.



2 General data of the system

2.1 Technical data - nameplate

• You will find the technical data of your system on your system’s nameplate which is located on the inside of the door. Every assembly module also has its own nameplate on the front. Please check before connecting to the low voltage network that the mains data shown on the nameplate, such as nominal voltage, nominal frequency and network configuration, match the conditions on site.

2.2 Ambient conditions

• The permitted ambient conditions depend on the system’s degree of protection. You will find this

on the nameplate. The standard degree of protection is IP20. The following table provides information about the significance of the IP code:

Protection against solid bodies Protection against water 1st numeral

Description 2nd numeral

Description

0 no protection 0 no protection 1 Solid bodies > 50 mm 1 Dripping water falling vertically 2 Solid bodies > 12.5 mm 2 Dripping water falling at an angle of 15° 3 Solid bodies > 2.5 mm 3 Spray water falling at an angle of 60° 4 Solid bodies > 1 mm 4 All-round protection against spray

water

• Climatic conditions: Relative humidity: max 95%, non-condensing Do not use the systems in corrosive environments; environments containing chlorine, sulphur, acid or salt may damage the system. PQM 500: maximum ambient temperature: 40 °C We recommend an ambient temperature of 25 °C for an extended lifetime of the capacitors. PQM 300: maximum ambient temperature: 40 °C We recommend an ambient temperature of 25 °C for an extended lifetime of the capacitors.



2.1 Intended use

• Compensation systems of type PQM 300 & PQM 500 are used for the incoming supply of capacitive reactive power. The power discharged can either be controlled by a reactive power controller or can be set to a fixed value. Subsequent technical modifications to the systems, in particular the use of capacitors, fuses or contactors with different technical parameters or third-party components, without consulting MR is prohibited for reasons of safety. It is also prohibited to carry out modifications to protective covers, safety equipment and safety settings without consulting MR.

3 Installation and Commissioning

• Remove the packaging and transport materials at the installation site. Check the system for transport damage prior to installation. Set up the system on a firm foundation in a stable position; its weight is shown in the circuit manual. Caution, the system may be top-heavy when being transported on the pallet truck. Take care during installation that none of the system’s ventilation openings are covered up, the rear air inlet vent of the PQM 300 in particular must remain open (maintain distance from wall, see circuit manual).

• Connect the system to the grid. Dimension your leads according to the rated current of the fuse protection, the type of lead and the type of installation, if necessary allowing for additional derating factors depending on local conditions. Select the compensation system’s fuse protection according to EN DIN IEC 60269-5. Test the connection according to the applicable standards.

• Connect the control wires according to the circuit manual. Pay attention to the polarity of the current transformer and open all existing short-circuiting jumpers after installation. The measurement must be situated upstream of the connection point between system and grid in the direction of the incoming supply.

• Energize the system and then parameterize the controller. There are dedicated operating

instructions for operating the controller. First of all, use the controller’s automated initialization; in this case, the controller adjusts automatically to the connections and compensation steps provided.

• Test the controller’s measurement because efficient control can only take place if measuring is

correct: o The measured current must match the measuring instruments of its incoming supply

otherwise the current transformer’s ratio must be adjusted in the controller o The voltage should correspond to the rated voltage o If the current and voltage measurement are correct but the power or the power factor is

not feasible, correct the phase difference between current and voltage measurement in the controller’s settings.

• Test the controller’s setting:

o The target power factor should be set to 0.98i o Test the alarm output to the outside and remote control from outside if present o Your system is now ready for operation; the controller should now switch the steps on

and off according to the reactive power demand when load changes occur. o The roof fans, if present, should switch on in a controlled manner



3.1 Operation

3.2 Operational switching off

• Operational switching off of the compensation steps is carried out by the system-internal switchgear, e.g. capacitor contactor.

• The corresponding upstream circuit breaker or fuse circuit is used to isolate the system or if there is no internal switchgear present.

• Notes: With compensation systems connected parallel to equipment without internal switchgear, switching off of the upstream circuit breaker leads to shutdown of the drive!

Warning

For capacitive compensation steps, it is imperative to adhere to the discharge time of 3 min specified by the manufacturer.

The system’s busbar is energized in the switched off state.

Danger

The contactor-switched capacitor steps are loaded with a dangerous residual voltage during the discharge time!

In thyristor systems, the capacitors are charged to the grid’s peak voltage even when the thyristors are switched off!

Warning/note

It is imperative to observe the 5 safety rules prior to working on the system (see Section 1.2)



3.3 Protective trip (in the event of a fault)

• After a protective trip of individual steps or the whole system by the controller, the system must not be reconnected unless the following points are observed!

o A systematic fault analysis is necessary prior to connection

Check the thermal conditions (cooling vents, roof panels, fans)

Check the set values in the controller

Check the capacitors

Check the overcurrent protection equipment

o Replace any defective components with components of identical design after remedying the cause of the defect

o Please contact the service department if the cause of the defect is not clearly identifiable:

Maschinenfabrik Reinhausen GmbH Wiebestr. 46 10553 Berlin

Tel. +49 30 330915-0 Fax: +49 30 330915-25

E-mail: [email protected]

3.4 Operational switching on

3.4.1 Reconnection after operational shutdown

• Capacitive compensation systems may not be reconnected until the capacitors’ discharge time has elapsed. If the system has a controller, it will take over monitoring of the discharge time when it switches on

• Reconnection takes place via the controller in the door or by acknowledging pending error messages on the controller

• Check that the system is in proper working order

3.4.2 Reconnection after maintenance and repair measures

• The system must be returned to its original state after the completion of maintenance and repair measures, that means all disconnected mechanical and electrical connections must be re-established with the relevant torque,

• Ensure before locking the system that all tools that have been brought in are outside the system again.

• Furthermore, the steps outlined above are applicable (switching on after operational shutdown)



4 Maintenance 4.1 Preparation

• Necessary spare parts such as capacitors or fuses and auxiliary materials must be obtained in advance

• The points outlined in Section 3.1 Operational Switching Off must be observed prior to starting work.

• The system must be isolated in accordance with the 5 safety rules,

• in addition to this, all further provisions of the generally recognized codes of practice and of the employer's liability insurance associations and in-house regulations shall be applied.

Note: When working on the system, care must be taken to ensure the correct scope and condition of the personal protective equipment.

4.2 Measures to be carried out

DANGER High Voltage

Touching the live parts will result in death or severe physical injuries. Only qualified staff who are familiar with the Operating Instructions and particularly who observe the warning signs may operate the system.



4.2.1 Inspection schedule Annually Every two years

• General visual inspection,

• Check spare parts and accessories to ensure they are complete and in good condition.

• Isolate the system (see Section 3.1),

• Clean the system inside and out of heavy soiling, check connections, check screws for tightness, tighten screws at contact points,

• Examine capacitors for tripping of the internal overpressure disconnectors, defective discharge resistors or reactors

• Examine the switchgear for burn marks and soiling • Examine filter and shunt reactors (if present) for burn marks and tracking, • Determine capacitor capacities and compare with nominal data, • Calculate the tuning frequency of the compensation step using the following

formula: tuning frequency = 2 ∗ π / √(L ∗ C) and compare with the nominal data (inductor-type compensation field only), • Check the overcurrent protection equipment for tripping and firm fit, • Check and clean thermostats and fans (if present), test switching points of

thermostats, Replace fan after 5 years at the latest • Clean vents of compensation cabinet, Check filter mats (if present) and replace

if necessary • Test controller setting/number of switching operations of the steps • Test functions and start up the system in accordance with Section 3.4.

Maintain and care for the installed equipment such as contactor, current transformer, auxiliary relay, fan, isolator, circuit breaker, control and protection devices, etc. according to the information in the associated datasheets. Examine insulating parts for mechanical damage and any tracking.

Tools customary in the trade are adequate for maintenance. Measuring bridges or digital LCR measuring equipment customary in the trade are used to determine a capacitor’s capacitance value.

The two-pole measured capacitance of a three-phase capacitor corresponds to 1.5 times the rated capacitance shown on the nameplate due to the internal

series/parallel connection. Alternatively, the power of the capacitor steps can also be determined via the service current of the stage in the switched on state. The rated current is shown on the nameplate or can be determined according to the

following equation: I=Q/(U*1.732)

The step must be considered defective in the case of asymmetrical stage currents of more than 10%.

Note: Carry out maintenance and care work at shorter intervals if there is a lot of dust, or if the air is very humid and polluted!



4.2.2 Replacement of components

• Individual parts such as capacitors, filter reactors or discharge reactors, reactive power controllers, measuring instruments, current transformers, etc. can be replaced.

• Information required for ordering spares of single parts and equipment:

o Type and factory number of the compensation system (see rating plate),

o Exact description of equipment or parts with reference, if necessary, to the information and images in the associated operating instructions or other documentation.

• Notes: Waste management of the replaced components must be environmentally compatible and comply with statutory regulations.

4.2.3 Cleaning Tools/materials:

• Cold degreasing and cold cleaning agent, e.g. HAKU 1025-900, brushes, cleaning rags, vacuum cleaner.

Caution Cleaning agents containing hydrocarbons must not be used for electrically stressed insulating parts (e.g. cast resin).

• Water with the addition of a household detergent is suitable for cast resin.

4.2.4 Greasing • Grease the hinges and locks of the doors immediately after cleaning.



5 Dismantling & Waste Disposal 5.1 Lifespan

The systems have an average lifespan of 10 years. Mechanical equipment such as contactors and fans are subject to different loads depending on the environmental and grid conditions and may need to be replaced earlier if necessary. The contactors are designed for 200,000 switching operations in choked systems and 120,000 in unchoked systems. In continuous operation, the fans must be replaced after 5 years.

5.2 Dismantling

Reverse the order of the installation process to dismantle the plant.

5.3 Waste Disposal

Separate the existing raw materials of the system according to type of disposal and material. Components containing copper, e.g. busbar and leads, can be recycled. Equipment such as contactors, fuses, capacitors, controllers and terminals shall be disposed of as electrical waste; these components must not be disposed of in domestic waste as they may contain small amounts of heavy metals due to solder containing lead or halogenated compounds and PVC. The system’s housing and mounting plates can be recycled as scrap metal.

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