| Answers |
| Intelligent Power Factor Controller |
| 1. |
Unpacking & Storage |
|
1.1. |
Contents, Unpacking & Storage - Procedure and Precautions
|
| 1.1.1. |
Packed carton box contains - Operating manual for IPFC/ Computer series Controller, Trouble shooting manual and Limited Warranty Certificate.
|
| 1.1.2. |
First check the carton for signs of damage or liquid spills. If any damage is found, then you must lodge a claim with the transporter. In this case, please contact the transporter before proceeding with the unpacking; he may want his agent to be present. Please also read the Conzerv Limited Warranty certificate received with the Controller.
|
| 1.1.3. |
Do not remove the protective plastic cover of your new Meters until the time of installation. Preserve the packing material. This will be required if the Controller needs to be shipped later for service or calibration. |
| 2. |
Installation/ commissioning |
|
2.1. |
Procedure of installation & commissioning
|
| 2.1.1. |
Please go through the Operating Manual of IPFC, which is supplied along with controller for instructions, installation/ commissioning. Refer wiring Diagram stuck on the case behind the bezel. |
| 3. |
Clarifications |
|
3.1. |
Clarifications on product/product features
|
| 3.1.1. |
Call nearest contact point of Conzerv for assistance
|
| 3.1.2. |
Call our dealers across India, UAE, Thailand, Malaysia, Australia, Indonesia and Singapore. Visit our Products & Services section for more details
|
| 3.1.3. |
Call 1800 425 0555 (Toll Free Phone No. - allover India) for online assistance.
|
| 3.1.4. |
Write to contact@Conzerv.com for details.
|
| 4. |
Problems after installation |
|
4.1. |
Capacitor banks remain "ON" always even though load is reduced and Controller continuously displays lagging PF. Why?
|
| 4.1.1. |
This is due to incorrect connections to the Controller. The correct connections to the Controller should be as per Table - 1.0 below
|
| 4.1.2. |
The current signal to the Controller should be drawn from the maximum loaded phase. |
| |
Table - 1.0 |
Model |
Current signals drawn from phase |
Voltage signals drawn from phase |
Phase mode selection in IPFC |
Computer 6e & 12e |
R |
Y & B |
Not applicable |
Y |
B & R |
B |
R & Y |
Computer 8d & 14d series |
R |
Y & B |
t2 |
R |
B & Y |
t5 |
Y |
Y & B |
t3 |
Y |
B & Y |
t6 |
B |
Y & B |
t1 |
B |
B & Y |
t4 |
|
|
4.2. |
PF is not improving
·
PF is progressively decreasing (instead of increasing) when the capacitor banks are switched "ON" one after the other. Why?
·
PF is not improving despite all capacitors switched "ON". What should I do? |
|
· |
Controller is not showing the correct system PF. Why?
|
| 4.2.1. |
This is due to incorrect connections to the Controller. The correct connections to the Controller should be as per Table - 1.0 above. |
| 4.2.2. |
The current signal to the Controller should be drawn from the maximum loaded phase. |
4.3. |
Controller is showing very low PF (say 0.20), which is not matching with system PF (say 0.70). Why?
|
| 4.3.1. |
Current signal to Controller is drawn from capacitor panel instead of PCC panel. Due to this the Controller senses/gets feedback from the capacitor bank rather than the load current.
|
| 4.3.2. |
It is necessary to connect the current signal from the CT of PCC panel. |
|
4.4. |
IPFC reading does not match with the other 3phase PF Controller connected in the same circuit
|
| 4.4.1. |
Check and ensure that the CT is mounted on the maximum loaded phase.
|
| 4.4.2. |
Check and verify that distance between the CT and capacitor panel is not more than 10 meters. Otherwise CT burden will be more and IPFC may not sense correct PF.
|
| 4.4.3. |
IPFC reads the PF from one phase and compensation is for 3 phases. Whereas PF Controller reads the average of 3 phase PF. There will be difference of PF between the IPFC and Controller if loads are unbalanced. However if load in all the 3 phases are balanced then variation is not likely to occur. |
|
4.5. |
Controller displays alarm and trips all capacitor banks. What action should I take?
|
| 4.5.1. |
Controller has the unique feature of isolating capacitor banks in the event of different alarm conditions as mentioned below
·
The input voltage may be 15% higher than the rated voltage. The Controller displays U.E for over voltage.
·
THD in the circuit may be higher than the set limit. The Controller displays d.E for higher THD in %
·
Set PF is not achievable due to insufficient kVAR rating of capacitors. Controller displays C.E - compensation error. Increase the capacitor bank ratings or reduce the set PF level.
·
If the current across CT secondary is more than 5A, Controller displays A.E indicating over current.
·
Contactor(s) coil may be short circuited or grounded. Controller displays CO3. Replace the contactor coil or isolate the faulty contactor from the circuit temporarily. |
|
4.6.
|
Voltage input fuse is burning out frequently, why?
|
| 4.6.1. |
Malfunction in internal circuitry of the Controller does not cause these problems. This could be due to panel Contactor coil short-circuited.
|
|
4.7.
|
Capacitor bank LED is glowing but capacitor / contactor is not getting ON |
| 4.7.1. |
Auxiliary supply to the IPFC relays (terminal C - common point) in Comp series is not given. |
| 4.7.2. |
Connectors are not inserted properly. |
| 4.7.3. |
No continuity between the relay and contactor coils. |
|
5. |
Key factors for success - IPFC installation
|
Sl. No |
Parameters |
Recommended |
Causes if not followed |
| 1. |
C.T. mounting position |
a) C.T. to be always mounted in the incoming of PCC panel where it can sense load current & capacitors current
b) C.T. should be mounted on the phase which has maximum load current.
|
a) The controller will sense wrong system PF.
b) Unnecessary switching-ON & OFF of capacitors banks
c) Possibility of increase of system voltage, demand.
d) Failure of contactors coil, auxiliary contactors, Capacitors IPFC P.T. |
| 2. |
Voltage Sag/Swell - E.g., Flickering of lamps, chattering of contactors etc. |
Where there is a continuous voltage Sags/ Swells, it is necessary to use -
a) Voltage regulator for IPFC inputs & power contactors coil.
b) Auxiliary contactors at auto & manual path along with control fuse of 2A. |
Contactors starts chattering which in turn create spikes resulting in failure of - contactors coil or auxiliary contactors or failure of IPFC Relay contact points or failure of IPFC PT or IPFC relay card. |
| 3. |
Using of poor quality of Capacitors or old capacitors or selection of wrong type of capacitors in the panel |
a) Always use reputed make of Capacitors
b) Periodic inspection of old Capacitors is required to be done. It is recommended not to use old Capacitors along with any IPFC
c) Poor quality of Capacitors: -It is very difficult to say which capacitors are poor hence it is necessary to check periodically that the output current of each capacitors maintained as per IS 13340 levels |
Due to poor quality of capacitors heavy inrush current may flow into the contactors which will result in -
a)
Failure of contactors, contactor coil winding
b)
IPFC Relay card burning or IPFC P.T. failure
c)
IPFC relay points failure. |
| 4. |
Contactors rating/ bus bar rating & cable rating |
These contactors should be always: -
·
Capacitors heavy-duty contactors.
·
Of reputed and suitable rating, main MCCB/MCB to be used
·
Of appropriate rating of cable & fuse to be used.
For exact details please contact CONZERV for consultancy |
1) Failure of contactors, burning of capacitors
2) Contactor coil welding or short-circuiting.
3) Frequent tripping of capacitors
4) Failure of IPFC PT/IPFC Relay card or gradual failure of IPFC Relay contacts one by one.
5) Wrong selection of cable will produce more heat and cable will burn and there is possibility of short circuit. |
| 5. |
Phase sequence |
Normally the voltage input to IPFC should be as per the phase sequence given in the manual of IPFC.
|
IF not done as per the instructions, then: -
a) IPFC will not measure and maintain the accurate system Power Factor
b) Unnecessary switches ON & OFF all capacitors banks
c) There is possibility of occurring all above stated problems |
| 6. |
Periodic inspection |
It is necessary to do periodic inspection of the panel & IPFC to check for any loose connection. |
If not, the loose connection may lead to burning of cables and short circuit which in turn results in the failure of contactors and IPFC |
| 7. |
Electric panel temperature |
The Electric Room temperature should be maintained within 50º C |
If not, there is possibility of Capacitors failures |
| 8. |
Electric Panel should be dust free |
It is necessary that all the electrical equipment are protected against dust & if possible to clean the same periodically |
If not, dust will create humming sound and will lead to failure of contactors coil. |
| 9. |
Switching time |
Default switching time
·
Switching ON & OFF time: 40 seconds
·
Reconnection time 30 seconds.
Any change in the timings should be done |
Wrong selection of switching time lead to following problems.
a)
Frequent failure of contactors & contactors coils.
b)
Frequent failure of control fuses.
c)
Frequent tripping of MCCB/MCB.
d)
Sudden increase in the system voltage.
e)
Increase of KVA demand.
f)
Failure of IPFC PTs & Relay contact points. |
|
Support 
