IPR-150 INSTALLATION GUIDE
Contents
1. fault condition You can hold down the TEST LED to verify that the off LED illuminates If it does the LED is functional and is indicating a fault condition If it does not illuminate when LED Test is depressed the LED itself may have an issue GRIDCO SYSTEMS Copyright 2014 12 IPR 150 INSTALLATION GUIDE Draft Position Description Status LEDs the following status LEDs are supported Power Blinks during boot solid when the internal software is running System Status Blinks when any alarm is present solid when no alarms are present Controller Solid when there are no Controller hardware issues detected off when Controller HW issue is detected IPR Solid when Controller has a valid connection to the IPR off when the Controller cannot communicate with the IPR Active Solid when IPR is not in bypass off when IPR is in bypass Source Solid when input source power is detected off when no input source power is detected Load Solid when input source power is detected off when no input source power is detected Remote Management Indicates management access to the IPR remains on for 15 minutes after most recent FCT or GMS management access otherwise off RJ 45 Ethernet interface enables direct connection to FCT laptop for local onsite management of the IPR GRIDCO SYSTEMS Copyright 2014 13 IPR 150 INSTALLATION GUIDE Draft INSTALLING THE SYSTEM Installation of the unit sho2. gt gt GRIDCOSYSTEMS oc O lt V LLI Phase 0 co e ed lt g So Hi OU i DE TABLE OF CONTENTS 4 4 ID 4 DO a a PEER AERE SEE E E E S S 4 Specifications C _______ ___ __ ___ __ _ __ _ ___ _ _ 4 9AFETY EEEE C 6 6 6 6 DESCRIPTION oo ee NN WE 7 gt gt _______ _______ _____ _ _ __ ___ ___ __ _ 7 tele 8 Lifting _ _ __ __ _ ____ _ __ gt gt _ ___ _ _ ___ _ 10 0 6 M M 1 gt _ gt _______ gt _ _ _ ___ _ _ _ _ _ _ _ 10 __ _ 77 7 549910 ______ __ ___ __ _ _ _ _ 11 INTEGRATED DOC N Dheeesees i Mgpeseeseceeseeeeee heesccsseesecssosserssessrsesosrcecosassseesees 12 INSTALLING THE SYSTEM mn ee 14 ENERGIZING THEUNIT Le 19 PROVISIONING THE UNIF a nu ERR ERKENNEN KEEN ERR EERR E
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4. Lifting Provisions The following figure shows the location of the four lifting provisions that accept installation of the Gridco supplied hoist rings The hoist rings should be removed and stowed after installation is complete Figure 3 IPR Lifting Provisions HIT 11111 111111 HIT HIT HUTT HIT HUT HOI HIT HANIN TELLER IUD HOTT 111111 Front Physical Dimensions The following illustration shows the physical dimensions of the pad mount IPR Figure 4 Physical Dimensions in millimeters SAGE Ie GRIDCO SYSTEMS Copyright 2014 10 IPR 150 INSTALLATION GUIDE Draft BYPASS SWITCH Each phase specific within the enclosure is equipped with a bypass switch that enables you to force that IPR out of service or power down a specific IPR The bypass switch is located on the front of the phase specific IPR and supports the following settings Note When working with the IPR do not touch the heat sync as it can become extremely hot Doing so may cause injury Off Power to the phase specific IPR is off during which time the system is in passive pass through mode for the specific phase allowing grid power to pass through without regulating e Bypass Phase specific IPR is powered allowing management of the IPR via its corresponding DGC however grid power is detoured around the power electronics during which time the IPR is not regulating On Phase specific IPR is actively regulatin
5. NER EE RRE RN EN 19 MAINTENANCE RN 20 APPENDIX A MECHAMICAL SPECMOD ee 21 GRIDCO SYSTEMS Copyright 2014 IPR 150 INSTALLATION GUIDE Draft INTRODUCTION This document describes how to install the Gridco Systems 150kVA 3 phase In Line Power Regulator IPR The IPR 150 connects in line along a low voltage feeder and provides continuous multi function 3 phase power control including dynamic and precise load voltage regulation reactive power compensation and harmonic cancellation during both forward and reverse power flows Audience This document is intended for trained and qualified personnel responsible for installing transformers and related equipment in underground distribution systems as well as Engineering and utility standards personnel Related Documentation For more information see these documents Table 1 Related Documentation Document Description IPR Operations Guide Describes how to use the Gridco Systems FCT to configure and manage the IPR DNP3 Device Profile for IPR 50 Describes the DNP3 points that you can use to configure and manage the system Release Notes Lists known issues and workarounds where applicable for the In Line Power Regulator Distributed Grid Controller DGC and Field Configuration Tool FCT Support For technical assistance and replacement parts contact Gridco Systems Customer Support at 1 844 4GRIDCO 1 844 447 4326 or email support gridcosystems com Specification
6. caused by an uneven mounting surface GRIDCO SYSTEMS Copyright 2014 16 IPR 150 INSTALLATION GUIDE Draft Jack Screws x4 2 on each side some components removed for clarity Ka 14 Install an eyebolt grounding terminal on the unit s grounding lug 1 27cm x 2 54cm 50 x 1 00 and 2 connect the system to earth ground using 10mm 70mm ground wire Note that the ground wire should enter the unit from below some components removed for clarity 17 Copyright 2014 GRIDCO SYSTEMS IPR 150 INSTALLATION GUIDE Draft 15 Locate the conductor rack me mg H mme E we 1 m T e e DM G 1 Li Le ke Bi L gt 1 ale 18 he LEE 2 Warning Be sure the source and load wires and unit are de energized before connecting the IPR 150 Failure to do so may result in personal injury death or equipment damage Conductor Rack SE nn 16 The power terminals insulated set screw terminals on the conductor rack are covered by rubber boots to help protect the connection Remove the rubber boots from all terminals except the prewired connections refer to wiring figure in next step then cut the bottom end of the rubber boots that you have removed to match the wire size that you are connecting Rubber Boot On Rubber Boot Off Insulated Set Screw Terminal Cut to a
7. g grid power flows Figure 4 Bypass Switches for Phase Specific IPRs IPR Phase 1 IPR Phase 2 IPR Phase 3 Front Heat Sink Bypass Switch Warning The terminal side of the unit is always live unless the cables are removed from both source and load bushings GRIDCO SYSTEMS Copyright 2014 11 IPR 150 INSTALLATION GUIDE Draft INTEGRATED DGC An integrated DGC is connected to each phase specific IPR to enable management and data acquisition on a specific phase The DGCs are connected to an integrated wireless radio to allow for remote monitoring and management of the system An Ethernet port located on the front panel of the DGC enables you to connect an FCT laptop directly to the unit for on site configuration and management of the system The following figure shows the key components on the DGC faceplate GRIDCOSYSTEMS DISPLAY PANEL Power Alarm Status Controller Power Regulator Active Source load Remote Management COMMUNICATIONS PORT ETHERNET i ter MET ce v rege 8 Remote Communmcetions Position Description LCD panel that displays the phase assigned to this DGC LED test button used to verify LEDs are functional from a hardware perspective Hold down the button to illuminate all LEDs Under normal conditions i e when everything is functioning correctly all LEDs should be illuminated red no issues An LED that is off indicates a
8. losure can get extremely hot Be sure to take appropriate precautions when handling or servicing the unit RECEIVING Each unit ships fully assembled ready to install and anchored onto the pallet by four shipping brackets The unit is wrapped with an environmental bag and encapsulated within a crate for shipping The fully assembled unit weighs approximately 771 kg 1700Ibs and must be moved with equipment of appropriately rated capacity 2000Ibs capacity rating recommended utilizing the lifting provisions located on each corner of the enclosure Carefully inspect the unit prior to installation to ensure that no damage has occurred during shipment If damage is apparent do not install the unit and contact Gridco Systems GRIDCO SYSTEMS Copyright 2014 6 IPR 150 INSTALLATION GUIDE Draft DESCRIPTION The IPR 150 is an IP 65 enclosure constructed of 12 gauge steel and aluminum finished in weather resistant light tan RAL 7035 powder coat a stainless steel option is available for harsh environments Doors on the front of the unit are secured with padlock provision and provide access to internal components including e Conductor Rack Enables connection to source and load for each phase Primary and secondary cables connect to the unit from below through openings in the pad e Phase specific IPRs IPRs that provide multi function power control per phase There are 3 integrated IPRs 1 IPR per phase e Digital Grid Controller
9. mpartment cover providing access to the conductor rack used to connect load and source power Also provides access to the IPR assigned to Phase 1 located above the conductor rack Note that you need to open door 3 to open door 2 Main compartment cover providing access to the IPRs assigned to Phase 2 and Phase 3 Also provides access to Phase 1 through 3 DGCs DGC compartment door providing convenient access to Phase 1 through 3 DGCs eliminating the need to open the main compartment door to access the DGCs You can use this door when you need to connect an FCT laptop directly to a DGC or visually inspect the LED status of the DGCs GRIDCO SYSTEMS Copyright 2014 8 IPR 150 INSTALLATION GUIDE Draft Figure 2 IPR Front View Door Open Position Description Integrated single phase IPR providing multi function power control on phase 1 Integrated single phase IPR providing multi function power control on phase 2 Integrated single phase IPR providing multi function power control on phase 3 Surge suppressors installation of up to 2 is supported however a minimum of 1 surge suppressor is required Integrated DGC for management and data collection for IPR 1 on phase 1 Integrated DGC for management and data collection for IPR 2 on phase 2 Integrated DGC for management and data collection for IPR 3 on phase 3 GRIDCO SYSTEMS Copyright 2014 9 IPR 150 INSTALLATION GUIDE Draft
10. ove the 4 mounting brackets that secure the unit to the crate Shipping Brackets x2 on each side of the unit Note The mounting brackets can be used as an alternative method of mounting the unit to a pad if desired 7 Re install the eight bolts 2 per bracket that were used to secure the brackets to the sides of the unit Be sure to store the shipping brackets in a safe place for possible later use in transporting the unit 8 Confirm that the lifting capacity of the crane and rigging equipment are rated for 907kg 2000Ibs 9 Utilize 4 equal length straps that are a minimum of 1 524m 5 long and rated for lifting to move the unit into place onto the pedestal Use padding to ensure slings do not scratch the unit during lifting 10 Open the main compartment and terminal compartment front doors of the unit GRIDCO SYSTEMS Copyright 2014 15 IPR 150 INSTALLATION GUIDE Draft 11 Locate the 4 mounting holes located along the edge of the base The following figures show the underside of the unit calling out the location of the 4 mounting holes 7 EX 19 THRU 2x 53 98 2x 1962 15 2X 129 2X 298 12 Install penta head bolts into each of the 19mm mounting holes from inside the unit to secure the unit to the pedestal 13 If needed use a 19mm socket or wrench to adjust the Jack screws 2 on each side of the base to stabilize the unit and minimize racking that may be
11. ppropriate size of wire 17 Slide the rubber boots onto the wires that you are connecting cone side first 18 Connect the source and load LV lines for each phase labeled as Line 1 through 3 in the below figure and neutral to the conductor rack as described in the following wiring diagram Wires connecting the loads to the phase specific IPRs are pre wired Wires connect to the conductor rack using insulated set screw terminals that accept 8mm Allen wrench and a wire size range from 4mm to 185mm aluminum or copper GRIDCO SYSTEMS Copyright 2014 18 IPR 150 INSTALLATION GUIDE Draft Note Prewired connections use wire size of 120mm for phases and 10mm for neutral jj ees Di mmm Line 1 source load Line 1 IPR prewired mmm line source load mm line 2 IPR prewired Line 3 source load Line 3 IPR prewired mmm Neutral source load Neutral IPR prewired 19 Slide the rubber boots up onto each of the terminals 20 Close the doors and secure with padlock provision ENERGIZING THE UNIT Before energizing the unit perform a final inspection to ensure there is no damage to the unit all connections are securely attached and all tools are removed from around the IPR To energize the unit apply line voltage to the IPR 150 After approximately 60 seconds the power electronics become fully operational and start regulating power as per configured IPR settings After approxima
12. s The following table describes key IPR 150 specifications Additional information is described on the IPR nameplate Table 2 Specifications Parameters Description Type Three phase 50 Hz Power Rating 150kVA GRIDCO SYSTEMS Copyright 2014 4 IPR 150 INSTALLATION GUIDE Draft Parameters Description Mounting Standalone pad or pedestal mount Input amp Output Voltage 400 230 VAC Source Voltage 400 230 VAC Nominal Source Voltage Range 27 to 30 of Nominal Load Voltage Regulation Boost Buck up to 8 4 of Nominal 0 5 accuracy Programmable set point or dead band VAr Compensation Range 10 of rating expandable leading lagging Programmable VAr or PF set point Harmonic Correction 3 to 15 odd order Programmable source current amp load voltage enable disable Harmonic Distortion Voltage THD lt 3 Current TDD lt 5 Efficiency gt 99 Communication via DGC DNP 3 0 Secure Web Services IEC 60870 101 104 future IEC 61850 future GRIDCO SYSTEMS Copyright 2014 5 IPR 150 INSTALLATION GUIDE Draft SAFETY The following guidelines help ensure your safety and protect the system from damage However the list is not all inclusive so please take appropriate precautions Refer to your utility safety standards for power equipment The units should be installed operated and serviced only by qualified and competent personnel The unit weighs appropriately 771 kg 1700Ibs
13. s DGC Provides management access and data acquisition for each phase specific IPR There are 3 integrated DGCs 1 DGC per phase specific IPR The following figure shows the location of the integrated phase specific IPRs DGCs and conductor rack Figure 1 IPR 150 Integrated Components IPR IPR IPR Phase 1 Phase 2 Phase 3 es Bee eee I mm mp wm we Sp ge WE en KT enne E Lee ay zt LA 2 L 2 Conductor DGC Rack Phase 2 DGC DGC Phase 1 Phase 3 Cooling The IPR implements a passive cooling design utilizing natural convection to enable longer device lifespan and minimal to no maintenance Heat sinks mounted to the front and rear panel of each phase specific IPR facilitate heat dissipation and cooling Air vents on all sides of the enclosure help ensure adequate air flow over internal components To ensure proper cooling a 61cm 24 clearance is required on all sides GRIDCO SYSTEMS Copyright 2014 7 IPR 150 INSTALLATION GUIDE Draft Front View The following figures describe the key components of the IPR 150 Figure 1 IPR Front View Door Closed Position Description Lifting provisions two are shown and there are two situated on the rear of the unit not shown for a total of 4 lifting provisions These lifting provisions accept installation of hoist rings provided by Gridco Systems Terminal co
14. so appropriate equipment and number of personnel must be used to install the unit Cranes must utilize the unit s lifting boss provisions The unit must be installed with adequate venting and clearance on all sides Failure to provide 61cm 24 of clearance on all sides of the unit may result in equipment damage or personal injury The unit must be properly grounded before energizing the system Failure to properly ground the unit may result in equipment damage personal injury or death The front compartments are protected from unauthorized access Doors with provision for securing with padlock accept up to 9 525mm 3 8 shackle or other equivalent locking mechanism Failure to secure the doors may result in access by unauthorized personnel and can cause severe injury death or equipment damage Ensure the unit is de energized prior to servicing Failure to do so may result in equipment damage property damage personal injury or death Should damage to the unit be observed de energize and remove the unit from service until repairs are completed by qualified personnel and the unit is verified as operational Before proceeding with connecting power or working on the system check your work area for possible hazards Do not work alone whenever potentially hazardous conditions exist Ensure that you have nameplate information handy when communicating with Gridco Systems regarding the unit The surfaces of IPR heat sinks inside the main enc
15. tely 2 3 minutes the DGC completes its boot process and the unit is fully operational Note Each DGC completes its boot process after approximately 3 minutes All LEDS on the DGC front panel should illuminate solid red to indicate that the unit is operating without issue PROVISIONING THE UNIT After the DGCs have completed their boot process you can use the FCT application to configure the unit To do so connect the FCT laptop to the Ethernet interface on the faceplate of any DGC then launch the FCT application FCT then automatically discovers the IPRs assigned to each phase labelled as Phase 1 Phase 2 and Phase 3 You can now use the FCT to manage each phase specific IPR Note For more information on how to use the FCT to manage IPRs see the IPR Operations Guide GRIDCO SYSTEMS Copyright 2014 19 IPR 150 INSTALLATION GUIDE Draft MAINTENANCE Warning The IPR must be de energized prior to replacing parts or performing maintenance Failure to do so may result in personal injury death or equipment damage The unit contains no moving parts and needs little to no maintenance However you should periodically inspect the unit for damage Repairs and or maintenance should only be performed by qualified trained personnel using Gridco Systems recommended components GRIDCO SYSTEMS Copyright 2014 20 IPR 150 INSTALLATION GUIDE Draft APPENDIX A MECHANICAL SPECIFICATIONS 2x 53 98 gt GRIDCO
16. uld only be performed by trained and qualified personnel Warning The unit must be grounded prior to energizing Failure to do so can result in personal injury death or equipment damage Warning Ensure the pad or pedestal is clean and free from foreign matter The unit must sit flush on the mounting surface allowing no gaps 1 Inspect the shipping crate for damage Note If damage is apparent you must take extra precautions to verify that the unit within the crate is not affected If damage is apparent do not install the unit and contact Gridco Systems 2 Remove the top and sides of the shipping crate by removing the wood screws 3 Cut to remove the environmental seal bag that covers the unit Be sure to dispose of the desiccant 4 Locate the lifting boss provisions located on each corner of the unit There are two lifting provisions on the front of the unit and two on the rear of the unit as shown in the following figure Front Lifting Provisions 2 Rear Lifting Provisions 2 l TEE 1 i MINU THLE Tithe HHNH THLE TLL FILER Front 5 The system ships with 4 hoist rings rated for the full weight of the unit approximately 771 kg Secure the Gridco supplied hoist rings onto the lifting provisions located at each corner of the unit using an 8mm Allen wrench GRIDCO SYSTEMS Copyright O 2014 14 IPR 150 INSTALLATION GUIDE Draft 6 Use a 19mm socket or wrench to rem
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