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frako PQC Operating Manual

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OPERATING MANUAL
PQC
Power Quality Controller
The controller that maximizes reliability
and monitors power quality
FRAKO Kondensatoren- und Anlagenbau GmbH
www.frako.com

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  • Page 1 OPERATING MANUAL Power Quality Controller The controller that maximizes reliability and monitors power quality FRAKO Kondensatoren- und Anlagenbau GmbH www.frako.com...

  • Page 2: Table Of Contents

    5.3.2 PQC initial start-up........
  • Page 3 Decommissioning the PQC ........

  • Page 4: About This Manual

    About this manual The PQC Power Quality Controller is an instrument for controlling the power factor and other power quality parameters. Throughout this manual, it will be referred to simply as the PQC. The current version of this manual can be accessed at our website: www.frako.com.

  • Page 5: Reference Documents

    Damage to property could occur if this sign is not heeded. Notes Notes supplement the general text with additional information on the correct func- tioning and fault-free operation of the PQC. They are marked with the white-on-blue symbol on the left-hand side, as shown below: Note...

  • Page 6: Safety

    – Current transformer circuits must be short-circuited before they are interrupted. – Only approved installation cables must be used. – The PQC must only be employed on duties up to the specified maximum power. Overloading the instrument can result in its destruction, create a fire hazard or cause an electrical accident.

  • Page 7: Management Information

    Social Accident Insurance Institution covering electrical installations. In other countries, the equivalent local regulations must be followed. The safety of the system in which the PQC is incorporated is the responsibility of the persons installing and operating the system.

  • Page 8: Relevant Standards

    Repair Should repair work be necessary, the customer or user must contact the manufacturer of the PQC: FRAKO Kondensatoren und Anlagenbau GmbH, Tscheulinstrasse 21A, D-79331 Teningen, Germany; www.frako.com. 8 | Safety Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 9: Technical Data

    V transformer; measurement inputs In areas where UL / CSA standards apply (versions PQC xxx480x-xx): networks with nominal voltages 115–600 V AC; power failure detection after duration of a half-wave x/5 A AC or x/1 A AC (transformer secondary current ≥ 15 mA), electri-...
  • Page 10 Note: utilization category AC-14/DC-13 as per IEC 60947-5-1; for all PQC types in areas where UL / CSA standards apply: 3 A 250 V AC cos φ = 1 at 85 °C, 3 A 30 V DC L/R = 0 ms at 85 °C 10 | Technical data Power Quality Controller –...
  • Page 11 250 V AC, 70 °C min. 500 V AC, 70 °C Conductor cross section max. 2.5 mm², min. 0.2 mm² Alarm contact Insulation rating: min. 250 V AC, 70 °C Technical data | 11 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 12 (Article No. 20-50015) IP54; rear of instrument Ingress protection and terminals IP20; all as per EN 60529 Pollution degree 2 as per EN 61010-1:2011-07. 12 | Technical data Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 13 (20th harmonic of 50 Hz = 1 kHz). It is therefore to be expected that the measuring circuit clearly respond to the standard test. For this reason, the radio-frequency field test can only be carried out without amplitude modulation. Technical data | 13 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 14 Voltage and current measurement ±1% at 50/60 Hz and 25 °C ambient Accuracy temperature Averaging function Over 1 second, updated every 100 ms Measured via Lx–N Harmonics All even and uneven harmonics up to the 19th 14 | Technical data Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 15: Instrument Description

    Regeneration The PQC has a four-quadrant control function. If active power is fed back into the sup- ply network, for example by combined heat and power systems, the PQC continues to correct for the reactive power drawn from the supply network. When this regeneration occurs, the active power P is displayed with a minus sign before it.

  • Page 16: Instrument Versions

    Instrument versions The PQC is available in various versions, identifiable by their type designation: – Type designation – Example – Measurement inputs: 1 = Temperature (I/O extension) Interface: 2 = Modbus RTU 3 = Ethernet 4 = FRAKO Starkstrombus (Frakobus)

  • Page 17: Password Protection

    Protected menu items: – Main menu > Configuration Security level 1, Password: last four digits of the serial number (see label on PQC or Section 6.4 “About PQC”. – Main menu > Configuration > Service > Reset Switch. Count –...

  • Page 18: Installation

    (see also Section 2.1 “Intended use” and Section 3 “Technical data”): – Only install the PQC in areas where there is no danger of gas or dust explosions. – Do not expose the PQC to direct sunlight or high temperatures, and do not install the instrument near to devices that generate heat.

  • Page 19: Mounting The Instrument

    Mounting the instrument The PQC is designed for mounting in a 138 mm x 138 mm cutout to IEC 61554 in the front of a control cabinet. It is held in place by four retaining lugs in the corners of the instrument.

  • Page 20: Electrical Installation

    – All live components in the vicinity must be covered to prevent inadvertent contact. 1. Turn the four retaining screws at the front of the PQC anticlockwise so that the four retaining lugs in the corners of the instrument are swivelled to lie flat behind its front panel.

  • Page 21: Completing The Electrical Installation

    WARNING! Danger from electricity! If there is a fault in the wiring adjacent to the PQC, there is a danger that its four retaining screws could become live and therefore a safety haz- ard. Touching live components at the instrument terminals and connecting cables can cause serious injury or may even be life-threatening.

  • Page 22: Specifications For The Electrical Connections

    An external disconnecting device, such as an isolator or circuit breaker, must be fitted in the power supply line to the PQC. This must be located in the vicinity of the instrument and must be able to isolate all cables connected to the AUX terminals of the PQC.

  • Page 23: Voltage Measurement

    5.2.6 Voltage measurement Depending on the instrument type, the PQC can measure one, two or three AC volt- ages. The voltage measurement inputs are electrically interconnected via high resist- ances. See Section 3 “Technical data” for the measurement ranges. DC voltages cannot be measured.

  • Page 24: Current Measurement

    The PQC is designed for connection to x/1 A and x/5 A external current transform- ers electrically isolated from the power supply. Depending on the instrument type, the PQC can measure one, two or three AC currents. Attention must be paid to the allowable measurement range. See Section 3 “Technical data” for further information.

  • Page 25: Output Relays (Control Outputs)

    5.2.8 Output relays (control outputs) Depending on instrument type, the PQC is equipped with 6 or 12 output relays (con- trol outputs). Relays or contactors are usually connected to these to switch the capac- itor stages in and out. The output relays Q1–Q12 (Q1–Q6 in the case of PQC versions with 6 output relays) receive their control voltage from a common feed P.
  • Page 26 Messspannung Versorgungsspannung voltage measurement supply voltage 100V–690VAC~ VDE 100V-15% – 240V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relays output relays φ φ 250VAC~ 3A cos 250VAC~ 3A cos Alarm 26 | Installation Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 27 φ φ φ φ 250VAC~ 3A cos 250 VAC~ 3A cos 250VAC~ 3 A cos 250VAC~ 3A cos Alarm Alarm Installation | 27 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 28 Part of connection diagram for 400/415 V networks with no neutral conductor 2 A T 2A T Instrument type: PQC 1204803-xx 400 V AC / 415 V AC – Networks with no neutral N 28 | Installation Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 29 100V–690VAC~ VDE 100V-15% – 240V+10% AC~5VA 100V-15% – 240V+10% AC~5VA Alarmrelais Ausgangsrelais alarm relay output relays φ φ 250VAC~ 3A cos 250VAC~ 3A cos Alarm Installation | 29 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 30: Commissioning (Initial Start-Up)

    Touching live components at the instrument terminals and connecting cables can cause serious injury or may even be life-threatening. – It must be verified that the PQC is installed and connected in accordance with its intended use before power is switched on.
  • Page 31 When the power is switched on, the PQC Start screen is displayed, showing infor- mation about the installed firmware. The initial start-up dialogue then starts automati- cally, in which the essential parameters for operation can then be set and the start-up mode selected.

  • Page 32: Automatic Connection And Stage Identification

    Regardless of the initial start-up mode, all the configuration data are saved in a non-volatile memory. In the event of power loss (intended or not) these data are not lost. When the power supply returns, the PQC starts up automatically and begins the control process after booting up.

  • Page 33: Manual Connection And Stage Identification

    The following settings can be selected here: Stat (Status): auto Ò The stage is available to the PQC as capacitance for automatic power factor correction purposes. fix Ò The stage is permanently switched in, e. g. for transformer power factor correction.
  • Page 34 PFC – Overview screen. If at this moment there is a concrete need for reactive power control, the PQC commences to switch stages in or out as necessary. Note Manual start-up mode deactivates the capacitive power identification function when the PQC is operating.
  • Page 35 96 128 160 192 257 321 385 642 96 120 144 192 241 289 481 1000/5 96 128 160 192 321 1500/5 2000/5 96 120 144 241 2500/5 96 115 192 96 160 3000/5 Installation | 35 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 36 The smallest value of c/k that can be set is 20 mA. If a smaller value is determined in the calculation, either a smaller current transformer ratio or a larger stage corrective power (capacitance of the smallest stage) must be selected. In these cases FRAKO Service + Support is available to offer a customized instrument solution.

  • Page 37: Description Of The Menu

    About PQC System parameters PFC Equip. System & PQ parameter Control Service parameters Alarms & Alarms Sys time notific. Communica- tion Temp. I/O Service Description of the menu | 37 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 38: Display

    Service Cap. stage kvar Switching Configuration Temperatures I/O status status diagram diagram Alarms & notific. Alarms & Min/Max Alarm history notific. Data 38 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 39: Pfc

    Power feed-in to supply Switched capacitor stages Available stage (switched out) Available stage (switched in) Stages not available Error Communication Alarm message if present Description of the menu | 39 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 40 This parameter is the sum of all the connected 3-phase Total power (Q) capacitor stage corrective powers. Available power (Q) This parameter is the 3-phase capacitor corrective power still available for switching in. 40 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 41: System & Pq

    Display of the momentary current Display of the momentary apparent power ∑ Sum of all the phases (L1 to L3); if a single-phase PQC, theoretical calculation of the sum assuming a balanced load 6.2.2.2 THD Main menu > Display > System & PQ > THD...
  • Page 42 I (f = 50/60 Hz) Angle φ Angle between V and I in degrees Angle γ Angle between V (fundamental) and I in degrees 42 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 43: Service

    Type of connection for L1, L2 and L3 current transformers. Connection type See Table in Section 5.3.4 “Manual connection and stage identification” Description of the menu | 43 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 44 6.2.3.5 Temperatures (optional temperature I/O extension) Main menu > Display > Service > Temperatures Displays the temperature from the activated PT-100 / 1000, NTC1 and NTC2 probes. 44 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 45: Alarms & Notifications

    (sorted by time). Selecting one of the lines shown and pressing the key causes the alarm condition to be displayed in plain language. Description of the menu | 45 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 46 • NTC1 • NTC2 Note Pressing the key shows the times elapsed since the minimum and max- imum values displayed on the screen occurred. 46 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...

  • Page 47: Configuration

    Alarms Communica- tion Alarms Relay settings Temp. I/O Service Factory Reset Reset alarm Manual Reset switch. Commissioning Service control settings count Min/Max history Description of the menu | 47 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 48: System Parameters

    If the system is not detuned, 0% must be entered.) 6.3.3 Control parameters Main menu > Configuration > Control parameters 48 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 49 (profile switching) (from V 4.2 onwards)” 6.3.3.2 Settable control profiles Main menu > Configuration > Control parameters > Control profiles > Profile Description of the menu | 49 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 50 Note Further information is given in the “PQC Application Note“. 50 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 51 Switching delay OFF 5 to 500 seconds (in increments of 1 s) Active Activate control profile (only one profile can be active) Phase L1, L2 or L3: select controlled phase (only with 3-phase versions) Description of the menu | 51 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 52 The switching delays, i.e. the times between one switching action and the next, can be set between the values of 5 and 500 seconds in 1-second increments. ‘Delay ON’ specifies the time during which the PQC integrates the calculated control deviation before switching the appropriate capacitance in. ‘Delay OFF’ is similar, except that here the time to elapse before the appropriate capacitance is switched out is specified directly.
  • Page 53 The Control profiles menu also includes the Phase setting. This is used to select the phase used by the PQC for control purposes (can only be edited on 3-phase PQCs). Any one of the three phases L1, L2 and L3 may be selected.

  • Page 54: Alarms

    (Q(V1) etc.) The automatic profile switching function enables the PQC control profiles to be changed automatically. With this, a Q(V) or Q(P) control curve with 5 points on it can be set up (see “PQC Application Note”). The following parameters can be used to prompt switching: –...
  • Page 55 – Alarm signal via Temp-I/O output If the PQC has the Temperature I/O option, the alarms can also be connected to separate outputs. The assigned output remains switched on for the duration of the alarm concerned (NO mode only).
  • Page 56 1. The measured cos φ is more inductive than the control band and all the capaci- tance is already switched in. The PQC cannot therefore switch in any more capaci- tance to make cos φ more capacitive (see area A in the diagram below).
  • Page 57 – or, in the case of a negative value, needing to be switched out – that would enable the PQC to adjust cos φ to the middle of the specified control band. 6.3.4.3 Switching cycle counter...
  • Page 58 Setting range: OFF to 95% (OFF: In the power factor correction process, there is no monitoring of stage corrective power.) Note If the PQC is calibrated manually, this alarm is automatically deactivated and the alarm limit set at OFF. The alarm can, however, be reactivated manually.
  • Page 59 50% to 93% (in increments of 1%) Sensitivity (voltage sag value) as % (100% corresponds to V 50% = not sensitive, 93% = highly sensitive Description of the menu | 59 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 60: Communication (Optional)

    6.3.4.14 Inputs I/O 1–I/O 5 (optional temperature I/O extension) An activated input of the temperature and I/O extension can allow the PQC to process logic signals. Example: Interruption of the control function when a logic 1 is received. The possibil- ities here are extremely diverse.
  • Page 61 Data bits 5 to 8 Stop bits 1 or 2 Parity even, odd or none Note Further details are described in the Modbus Specification. Description of the menu | 61 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 62 When these settings have been made, the available services (Modbus TCP, web server) can be accessed in the network. The PQC is accessible via the Modbus TCP/IP protocol and port 502 at the set IP address. The data that can be retrieved are listed in the FRAKO Modbus Specification.

  • Page 63: Temperature I/O (Optional)

    250VAC~ 3 A cos 250 VAC~ 3 A cos Alarm Frakobus The PQC bus address can only be changed at the instru- ment itself. 6.3.6 Temperature I/O (optional) Typical circuits for the passive digital inputs and outputs, plus the temperature meas-...
  • Page 64 If a defined alarm limit is to be monitored with each temperature measurement input, these can be set in the PQC Alarms menu (see Section 6.3.4 “Alarms”). A fixed hysteresis of 1.5 K is programmed. Connections for a PT-100 / 1000 temperature measurement input are provided:...

  • Page 65: Service

    When this option is active, profile switching takes place exclusively via this input (no profile switching is then possible from the PQC menu or optional Modbus RTU interface) and only between the stored control profiles 1 (input 1: low level) and 2 (input 1: high level).
  • Page 66 P and Q. 6.3.7.3 Factory default settings Main menu > Configuration > Service > Factory settings Resets the PQC at its factory default settings (without affecting the switching cycle counter). 6.3.7.4 Clear switching cycles counters Main menu > Configuration > Service > Reset Switch. Count Reset switching cycle counters for all stages to zero (singly or individually, service password necessary);...

  • Page 67: About Pqc

    400 V Nominal frequency 50 Hz System parameters Transformer ratio (I) Transformer ratio (V) PFC parameters (Section 6.3.2 “PFC Equip. parameters”) Tuning factor PFC parameters Description of the menu | 67 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 68 0.920 ind cos φ 4 0.980 cap Settings for Low load control profile 3 Switching delay ON 45 s Switching delay OFF 45 s Active Phase 68 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 69 80 k Alarm relay Switching cycle counters Display Emergency trip Alarm limit Alarm relay Undervoltage Display Emergency trip Alarm relay Undercurrent Display Emergency trip Description of the menu | 69 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 70 Alarm limit 110% Alarm relay Overvoltage Display Emergency trip Harmonic Alarm limit % Alarm limit V Harmonics 0.43 0.41 1.76 Alarm relay Display Emergency trip 70 | Description of the menu Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 71 Temp. I/O (Section 6.3.6 “Temperature I/O (optional)”) Temperature units °C NTC1 NTC2 I/O 1 Input Temp. I/O I/O 2 Input I/O 3 Input I/O 4 Input I/O 5 Input Description of the menu | 71 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 72: Service Interface

    Service interface The PQC has a service interface in the form of a Micro USB port. This is used for servicing tasks such as firmware updates. Note This interface is solely for the use of trained FRAKO Service + Support personnel.

  • Page 73: Cleaning And Maintenance

    – All connections must be checked to verify that they are no longer live. – All live components in the immediate vicinity must be covered. Cleaning The PQC may only be cleaned with a dry cloth. Do not use aggressive or abrasive cleaning agents or solvents. Maintenance The PQC does not contain any components that need maintenance.

  • Page 74: Troubleshooting

    Troubleshooting If alarms occur during operation of the PQC, the following table provides assistance in identifying and remedying the faults. Alarm Fault Possible cause Remedial action message PQC not working; No power – or the wrong Check that the correct no display voltage –...
  • Page 75 Severe reactive power Wait for power supply to fluctuations stabilize; set c/k value and connection type manually. Troubleshooting | 75 FRAKO | Operating Manual | Power Quality Controller – PQC...
  • Page 76 Severe reactive power Read off the corrective fluctuations power still lacking from the menus. Faulty calibration Repeat the calibration procedure. 76 | Troubleshooting Power Quality Controller – PQC | Operating Manual | FRAKO...
  • Page 77 Neutral not connected to activated. contactors. Note Additional error messages are described in the “PQC Application Note”. Troubleshooting | 77 FRAKO | Operating Manual | Power Quality Controller – PQC...

  • Page 78: Decommissioning And Removal, Storage And Disposal

    The instrument terminals can become hot during operation and could cause burns. – After the PQC has been operating, sufficient time must be allowed for the instrument and its terminals to cool down before work is carried out on the connections.

  • Page 79: Pqc Removal

    10.2 PQC removal The PQC is held in place against the rear of the cabinet front wall by four retaining lugs in the corners of the instrument. These can be released by undoing the retaining screws. 1. Turn all four screws anticlockwise with a screwdriver. This slackens the four retaining lugs and swivels them to lie flush behind the PQC front panel.
  • Page 80 Reactive power controllers Power factor correction systems Modules EMS components Measuring instruments and network analysers Power quality EMS ISO 50001 FRAKO Kondensatoren- und Anlagenbau GmbH Tscheulinstrasse 21a D-79331 Teningen, Germany Phone: +49 7641 453-0 Fax: +49 7641 453-535 sales@frako.de www.frako.com...

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