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STATIC PF AND FILTER CONTROLLER

CPC3i

INSTRUCTIONS MANUAL

M98209401-20-12A

(c) CIRCUTOR S.A.

- Static PF and filter controller CPC3i Ref: M98209401-20-12A Pag 1

OUTLINE

1 GENERAL DESCRIPTION .............................................................................................................................. 3

2 APPLICATIONS ................................................................................................................................................ 4

3 TYPES.................................................................................................................................................................. 5

4 TECHNICAL CHARACTERISTICS............................................................................................................... 5

4.1 SUPPLY AND ENVIRONMENT CHARACTERISTICS............................................................................................. 5 4.2 ENABLE FUNCTION BY MEANS OF VOLTAGE FREE CONTACT OR CONTACTS.................................................... 6 4.3 ENABLE FUNCTION BY MEANS OF CURRENT SENSOR THRESHOLD AND EXTERNAL CT ................................... 6 4.4 ENABLE FUNCTION BY MEANS OF RS-485 COMMUNICATIONS CHANNEL ....................................................... 6 4.5 DIMENSIONS AND WEIGHT............................................................................................................................. 7

5 TERMINALS LAYOUT AND INDICATING LED ........................................................................................ 8

6 SIGNALING AND ADJUSTMENTS................................................................................................................ 9

6.1 CPU LED ..................................................................................................................................................... 9 6.2 PHASE SIGNALING LED ................................................................................................................................. 9 6.3 JP1 JUMPER.................................................................................................................................................... 9

7 RS 485 DRIVER CONTROL........................................................................................................................... 10

7.1 – ADDRESS SELECTION IN RS 485 COMMUNICATIONS CHANNEL ................................................................. 10 7.2 MODBUS FRAME IN CASE OF RS 485 CONTROL........................................................................................ 10

8 SCHEMATICS.................................................................................................................................................. 11


DELIVERY SPOT CHECK

This manual is aimed to be a help for the installation and maintenance of CPC3i. After unpacking the equipment check the following points:

The equipment corresponds to type and size you ordered.

Check that equipment has not suffered any damage during transport

Check that you received the following documents :

Instructions Manual (including schematics)

People installing or maintaining CPC3i equipment must follow the usual safety rules to avoid electric shock and to avoid damaging the equipment and the supply network. Follow the indications in this manual for a safe operation

DANGER! : CPC3i is connected to PF correction equipment or filters containing capacitors which remain charged after switching OFF the equipment. To avoid electric shock, 5 minutes must elapse between voltage switch OFF and equipment service.

Before you connect the equipment check the following items:

Supply voltage and frequency in your site is according to equipment characteristics (see label for type and check in the manual).

Check that connections are made according to schematics given in this manual


1 GENERAL DESCRIPTION

The CPC3i is a driver for three phase static switches (3 bidirectional thyristor blocks). The driver receives the ON - OFF control signals from an external regulator and takes care of the synchronisation of each phase with the respective supply voltage, so that the switch connects at zero voltage (ZVS during ON) and disconnects at zero current (ZCS during OFF). The CPC3i is specially designed to drive the different steps of static var compensation equipment used for fast (real time) PF compensation. Steps may consist of simple capacitors or LC filtering sets.

The basic features of CPC3i driver are as follows:

Possibility of simultaneous ON-OFF control of the three phases of the static switch or individual phase control, both in star or delta configuration.

Intelligent zero crossing detection system, optimized for fast connection of LC filters, either 7% or 14%, despite the overvoltage due to series reactor.

Fast response. Allows one operation every ½ cycle (10ms at 50Hz or 8,33ms at 60Hz)

The driver allows four ON-OFF switching control possibilities:

Potential free contact for simultaneous switching of the three phases.

Three independent contacts (potential free) for individual control of each phase

Control through RS-485 communications channel (allows both simultaneous three phase control and individual phase control)

ON-OFF switching driven by a current threshold detector. (Direct connection to the secondary of a IN/5A current transformer)

CPC3i is directly compatible with COMPUTER+ (the top range of CIRCUTOR PF regulators, allowing three phase or individual phase control) and with COMPUTER Fast-Com (“Magic series, allowing three phase control with a single regulator or individual phase control with three regulators)

Reinforced insulation version, allowing up to 690V phase to phase, without neutral.

Thyristor switching by means of pulse transformers with high insulation performances.

Microprocessor control core, with intelligent algorithm allowing temperature and firing error surveillance.

Electrically compatible with old CPCb (bigger dimensions, see paragraph 4.5)


2 APPLICATIONS

Figures 1 and 2 show the basic application schematics of CPC3i to drive one step, either in delta or in star configuration. In both cases the CPC3i can control the simultaneous switching of the three phases or the individual phase switching. In case of three phase simultaneous control, the star configuration with only 2 switches, shown in fig. 3, can also be used.

R E G U L A D O RS a lid a E s tá t ica

ϕc o s

L 1 L 2

C P C 3 i

M a n d o

L 3

L

C

U 2 V 2 W 2

U 1 V 1 W 1

U 2 V 2 W 2

U 1 V 1 W 1

Fig.1.- Basic application of CPC3i . One step, delta configuration

R E G U L A D O RS a lid a E s tá t ic a

ϕc o s

L 1 L 2

C P C 3 i

M a n d o

L 3

L

C

U 2 V 2 W 2

U 1 V 1 W 1

U 2 V 2 W 2

U 1 V 1 W 1

Fig.2.- Basic application of CPC3i. One step, 3

R E G U L A D O RS a l id a E s tá t ic a

ϕc o s

L 1 L 2

C P C 3 i

M a n d o

L 3

L

C

U 2 V 2 W 2

U 1 V 1 W 1

U 2 V 2 W 2

U 1 V 1 W 1

Fig.3.- Basic application of CPC3i . One step, 2


switches, star configuration switches, star configuration

3 TYPES

TYPES Applications CPC3i-4MT Three phase control by means of potential free contact (electromechanical or static)

Mains voltage up to 440V CPC3i-4MRS Three phase or individual phase control by means of RS485 communications. Mains

voltage up to 440V CPC3i-4MFF Individual phase control by means of three contacts (electromechanical or static), or

three phase control by means of current threshold detector (Driven by the secondary current of a CT, IN/5A, measuring load current). Mains voltage up to 440V

CPC3i-6MT Three phase control by means of potential free contact (electromechanical or static) Mains voltage up to 690V

CPC3i-6MRS Three phase or individual phase control by means of RS485 communications. Mains voltage up to 690V

CPC3i-6MFF Individual phase control by means of three contacts (electromechanical or static), or three phase control by means of current threshold detector (Driven by the secondary current of a CT, IN/5A, measuring load current). Mains voltage up to 690V

4 TECHNICAL CHARACTERISTICS

4.1 Supply and environment characteristics

Standard supply voltages 230 / 400 Vc.a. (other values on request) Frequency 50 … 60 Hz Working temperature (max.) 40 ºC Relative humidity 95% , without condensation Storage temperature -10ºC to 75ºC


4.2 Enable function by means of voltage free contac t or contacts

The ENABLE function for types CPC3i-xMT is achieved by means of one potential free contact (three phase enable) and for types CPC3i-xMFF by means of three potential free contacts (individual phase enable).

TYPES

ENABLE TERMINALS

CONTACT STATUS

ACTION

OPEN CIRCUIT VOLTAGE

SHORT CIRCUIT CURRENT

CPC3i-xMT ACT - COM Closed Connection of 3 phases Max. 20V Max. 7mA CPC3i-xMFF ACF1 – COM

ACF2 – COM ACF3 - COM

Closed Closed Closed

Connection of phase 1 Connection of phase 2 Connection of phase 3

Max. 20V Max. 7mA

4.3 Enable function by means of current sensor thre shold and external CT

The ENABLE function for types CPC3i-xMFF can also be achieved by means of a current threshold detector associated to an external current transformer (CT) sensing the load current.

TYPES ENABLE TERMINALS

STATUS ACTION THRESHOLD ADJUSTMENT

ADJUSTMENT MARGIN

CPC3i-xMFF S1 – S2 I > %Threshold Connection of 3 phases

16 steps rotary switch

3% to 48% of IN in steps of 3%

4.4 Enable function by means of RS-485 communicatio ns channel

The ENABLE function for types CPC3i-xMRS is achieved by means of a MODBUS message sent by means of an RS485 communications channel

TYPES ENABLE TERMINALS

STATUS ACTION Address selection

Frame

CPC3i-xMRS RS+, RS-, SH Modbus command

Connection of 3 phases or individual phase

16 steps rotary switch

See paragraph 7.2


4.5 Dimensions and weight

230

4φ

80

4φ

80

4φ

17020

4φ

40

Old CPCb , 200 x 100 mm

Weight: 710 g


5 TERMINALS LAYOUT AND INDICATING LED

SH

RS

+R

S-

AL1

CO

M

CPC3i-xMFFIndividual phase control 3contacts

Current threshold control (CT)

S1

S2

0V 230V

400V

2G2

2K2

2G1

2K1

TR1

AL1

CO

MA

CT

CO

M

3G2

3K2

3G1

3K1

1K2

1G2

1G1

1K1

TP3 TP2 TP1

LEDPH3

LEDPH2

LEDPH1

JP1

LEDCPU

TEST

0

7

15

311

1

2

45

6 8 910

121

314

ADJ

JP1

LEDCPU

TEST

JP1

LEDCPU

TEST

0

7

15

311

1

2

45

6 8 910

121

314

ADJ

A B C D E F G

A B C D E F G

AC

F3

CO

MA

CF

2C

OM

AC

F1

CO

MA B C D E F G

CPC3i-xMRS Three orindividual phase control by

RS485 channel

CPC3i-xMTThree phase control

Fig.4.- Terminals layout and indication LED in the CPC3i driver


6 SIGNALING AND ADJUSTMENTS

The CPC3i board has several LED for signaling of the driver status and to show different error situations (see fig.4).

6.1 CPU LED

The CPU LED (see fig.4 for location) is a red LED showing the CPU status. When CPU is operating normally it blinks at a frequency of 1s. In case that some error is detected the LED is flashing at a frequency of 40ms.

6.2 Phase signaling LED

Each phase has a signaling red LED (see fig. 4 for location) , which shows three possible status summarized in the following table.

LED STATUS INDICATION

ON Indicates that the phase connection is enabled and the phase switch is ON

BLINKING Indicates that the synchronism signal is detected but the phase switch is OFF

OFF Indicates that synchronism is not detected and the phase switch is OFF

6.3 JP1 jumper

When jumper JP1 is ON , the thermal alarm is disabled. In normal conditions , if thermal alarm is desired, an external NC thermal contact (potential free) is connected to terminals AL1-COM (see fig.4). Usually the thermal contact consists of a klixon sensing the reactors temperature in a LC filter step. In case that overheating is detected, the firing of the faulty step is inhibited. If JP1 is short-circuited (ON) , this function is inhibited. Usually the jumper is ON in capacitor banks without filtering reactors.


7 RS 485 DRIVER CONTROL

7.1 – Address selection in RS 485 communications ch annel

When the connection of several steps is controlled by the RS485 channel, a step address has to be assigned to each CPC3i driver. This is done by means of the16 positions rotary switch ADJ (see fig. 4 for location). This allows the selection of 16 different addresses , i.e. up to 16 different steps in the capacitor or filter bank. Notice that in the same bank all the CPC3i should have different addresses. Two CPC3i having the same address will switch ON and OFF simultaneously.

7.2 MODBUS frame in case of RS 485 control

The control of CPC3i by means of RS485 channel is achieved by sending a MODBUS message using function 15 (N bits write function). The message is sent in broadcast mode , i.e. is addressed to all the drivers in the bus. The frame format is as shown in fig. 5.

The message consists of a frame sent to slave address 00H (broadcast message) . The 1st bit address of CPC3i board is 00H – 64H and the frame consists of 64 bits (00H – 40H) , grouped in 8 octets.

Slave Nr1 byte

Funct1 byte

1st bit addr.2 bytes

Nr of bits2 bytes

Nr Oct1 byte

DataCRC

2 bytes

00 0F 00 - 64 00 - 40 08 DD0 A DD7 XX - XX

Broad,to all

Funct15

64 bits 8octetos

Data8 bytes

CRC2 bytes

address

Fig. 5.- Control frame in the CPC3i driver (MODBUS, function 15)

The meaning of the 8 bytes DD0 a DD7 is detailed in table 1.


TABLE 1.- Meaning of data in the control frame

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

DD0 - thy3_np2 thy2_np2 thy1_np2 - thy3_np1 thy2_np1 thy1_np1








where :

thyn_npx means thyristor n in slave x (The slave address , x , is different for each CPC3i board and is set by means of a rotary switch in the PCB).

Notice that up to 16 CPC3i drivers can be addressed allowing individual phase by phase control

8 SCHEMATICS

See application schematics in the following pages


Fig. 6.- Three phase control of a CPC3i by means of potential free contact (One step detail)


Fig. 7.- Three phase or independent phase control of a CPC3i by means of RS485 communications channel (One step detail)


L1

L2

L3

COM

AL1

L

C

1G1

1K1

1G2

1K2

2G1

2K1

2G2

2K2

3G1

3K1

3G2

3K2

Bloque de Potencia

COM

AL1

L

C

1G1

1K1

1G2

1K2

2G1

2K1

2G2

2K2

3G1

3K1

3G2

3K2

Bloque de Potencia

COM

AL1

L

C

1G1

1K1

1G2

1K2

2G1

2K1

2G2

2K2

3G1

3K1

3G2

3K2

Bloque de Potencia

400V AC SUPPLY

F ast Com p 12r t

CO

M

C1

C1

C1

Fast Com p 1 2r t

COM

C1

C1

C1

Fast Com p 12r t

CO

M

C1

C1

C1

FASE L1 FASE L2 FASE L3

2G2

2K2

2G1

2K1

3G2

3K2

3G1

3K1

1K2

1G2

1G1

1K1

CPC3i-xMTMando

Trifásico

0V

230V

400V

TE

ST

ACF1COMACF2COMACF3COM

BCDEFG

2G2

2K2

2G1

2K1

3G2

3K2

3G1

3K1

1K2

1G2

1G1

1K1

CPC3i-xMTMando

Trifásico

0V

230V

400V

TE

ST


2G2

2K2

2G1

2K1

3G2

3K2

3G1

3K1

1K2

1G2

1G1

1K1

CPC3i-xMTMando

Trifásico

0V

230V

400V

TE

ST


BCDEFG

BCDEFG

Fig. 8.- Individual phase control of a CPC3i by means of 3 potential free contacts (3 FastCom regulators)


L1

L2

L3

400V AC SUPPLY

Fas t Com p 12r t

CO

M

C1

C1

C1

Fast Comp 1 2r t

CO

M

C1

C1

C1

Fast Com p 12 r t

CO

M

C1

C1

C1

FASE L1 FASE L2 FASE L3

COM

AL1

L

C

1G1

1K1

1G2

1K2

2G1

2K1

2G2

2K2

3G1

3K1

3G2

3K2

Bloque de Potencia

2G2

2K2

2G1

2K1

3G2

3K2

3G1

3K1

1K2

1G2

1G1

1K1

CPC3i-xMTMando Trifásico

0V

230V

400V

TEST


BCDEFG

Fig. 9.- Individual phase control of a CPC3i by means of 3 potential free contacts , 3 FastCom regulators (One step detail)

static pf and filter controller cpc3i ...docs.circutor.com/docs/m98209401-03.pdf- static pf and...

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