Film capacitors - Power Factor Correction
Contents
1. B25673 B32344E Installation and maintenance instructions for PFC capacitors Vibration resistance The capacitor resistance to vibration corresponds to IEC 68 part 2 6 The following values apply to the capacitor alone Test Conditions Max test conditions Test duration 2h m Frequency range 10 55 Hz max 0 7 g m Displacement amplitude 0 75 mm The connections and the terminals may influence the vibration properties It is necessary to check the stability when an installed capacitor is exposed to vibration Irrespective of this it is not advised to locate capacitors where vibration amplitude could reach maximum levels in strongly vibrating appliances Note For detailed information about PFC capacitors and cautions refer to the latest version of the EPCOS PFC Product Profile Film PC PM PFC April 2010 Please read Cautions and warnings and Page 11 of 12 Important notes at the end of this document EPCOS Important notes The following applies to all products named in this publication 1 Some parts of this publication contain statements about the suitability of our products for certain areas of application These statements are based on our knowledge of typical requirements that are often placed on our products in the areas of application concerned We nevertheless expressly point out that such statements cannot be regarded as binding statements about the suitability of our products for a particular customer applic2. countries Further information will be found on the Internet at www epcos com trademarks Page 12 of 12
3. 44E Installation and maintenance instructions for PFC capacitors Caution Discharge and short circuit the capacitor before handling ae n7 P Push on discharge resistors External discharge resistor Figure 7 Discharge resistor and discharge module Inrush current limitation Switching LV PFC capacitors can cause high inrush currents of more than 200 times the rated current especially when they are connected in parallel to others that are already energized This may cause additional stress to contactors as well as to capacitors and reduce their life cycle Inrush currents have a negative effect on power quality e g transients voltage drop MKK and MKP designs feature high impulse handling capability inrush current limitation is required e g contactors with pre charging resistors for pre loading of capacitors IEC 60831 Standard According to the IEC 60831 standard following maximum switching and Reference operations per year are acceptable PhaseCap Premium PhaseCap HD and PhiCap 5000 switching operations PhaseCap Compact 10000 switching operations Before considering a higher number of switching operations please contact EPCOS Harmonics Harmonics are voltages and currents with frequencies that are different from a 50 Hz or 60 Hz power supply frequency Harmonics result from the operation of electrical loads with non linear voltage current characteristics They are mainly caused by loads operated with moder
4. Film Capacitors PFC Installation and maintenance instructions for PFC capacitors Series Type PhaseCap Premium PhaseCap HD PhaseCap Compact PhiCap Ordering code B25667C B25669 B25673 B32344E Date April 2010 Version 1 EPCOS AG 2010 Reproduction publication and dissemination of this publication enclosures hereto and the information contained therein without EPCOS prior express consent is prohibited B25667C B25669 B25673 B32344E Film Capacitors PFC Installation and maintenance instructions for PFC capacitors Installation and maintenance instructions Read this first Read the following Installation and Maintenance Instructions carefully before installing a capacitor into your application About this manual The information stated in this manual applies to typical approved usage Please refer to our product specifications or request our approval for your own individual specifications before installing capacitors For your safety Disregarding the guidelines in this manual can result in operational failure bursting and fire In case of doubt contact your local EPCOS sales organization or distributor for assistance General safety notes for installation and operation Storage and operation conditions Ambient temperature m Ensure you are using the right capacitor type for your application Please refer to the EPCOS product catalog and application note
5. ance conditions may multiply existing harmonics create power quality problems and damage distribution equipment Occurrences of resonance should by all means be avoided by appropriate application design Total RMS capacitor current incl fundamental and harmonic currents specified in the technical data of the specific series must never be exceeded Electrical components do not have unlimited life expectancies this also applies to self healing capacitors As polypropylene type capacitors seldom produce a pronounced short circuit HRC fuses or circuit breakers alone do not offer sufficient protection All capacitors of the PhaseCap Premium PhaseCap Compact PhaseCap HD and PhiCap series are consequently fitted with a disconnector that responds to overpressure If numerous electric breakdowns occur at the end of life or as the result of thermal or electric overload within IEC 60831 specification the formation of gas causes the pressure inside the capacitor case to rise This causes a change in length because of curvature of the lid or stretching of the expansion bead Expansion beyond a certain degree will separate the internal wires tear off fuses and disconnect the capacitor from the line Caution To ensure full functionality of an overpressure disconnector observe the following requirements 1 The elastic metal top must not be impaired m The connecting lines must be flexible leads cables m There must be suff
6. ation As a rule EPCOS is either unfamiliar with individual customer applications or less familiar with them than the customers themselves For these reasons it is always ultimately incumbent on the customer to check and decide whether an EPCOS product with the properties described in the product specification is suitable for use in a particular customer application We also point out that in individual cases a malfunction of electronic components or failure before the end of their usual service life cannot be completely ruled out in the current state of the art even if they are operated as specified In customer applications requiring a very high level of operational safety and especially in customer applications in which the malfunction or failure of an electronic component could endanger human life or health e g in accident prevention or life saving systems it must therefore be ensured by means of suitable design of the customer application or other action taken by the customer e g installation of protective circuitry or redundancy that no injury or damage is sustained by third parties in the event of malfunction or failure of an electronic component 3 The warnings cautions and product specific notes must be observed In order to satisfy certain technical requirements some of the products described in this publication may contain substances subject to restrictions in certain jurisdictions e g because they are classed as hazardous U
7. h the supply cable only with the maximum permissible torque values m PhaseCap Premium 2 0 Nm m PhaseCap Compact Capacitor diameter lt 85 mm 1 2 Nm Capacitor diameter gt 85 mm 2 0 Nm m PhaseCap HD 2 5 Nm m PhiCap 1 2 Nm Use an appropriate screw driver PhaseCap Premium PhiCap and PhaseCap Compact 5 5 x 1 Ph2 Pz2 type PhaseCap HD DIN 5264 B 1 2 x 6 5 Figure 6 Fixing the supply cable Discharge resistors are included in the delivery package pre mounted by the factory for PhaseCap PhaseCap Compact and PhiCap E series Capacitors with voltage from 765 V onwards and all PhaseCap HD types are provided with external discharge module see figure 7 on the next page Discharge resistors are required for discharging of capacitors to protect operating personal risk of electric shock hazard and for re switching capacitors in automatic PFC equipment phase opposition EPCOS discharge resistors are designed to discharge capacitors down to 75 V or less within 60 seconds some types within 90 seconds please refer to the specific data sheet Make sure that the correct resistor is used for replacement e g ohmic value and push on connector diameter Before re switching capacitors must be discharged to 10 of the rated voltage or below A discharge resistor can be easily replaced by pushing it onto the exposed top on the terminal April 2010 Page 6 of 12 Film Capacitors PFC B25667C B25669 B25673 B323
8. icient space for expansion above the connections stated for the different models m The folding groove must not be retained by clamps 2 The maximum allowed fault current of 10000 A to the UL 810 standard must not be exceeded 3 Stress parameters of the capacitor must be within the IEC 60831specification Film PC PM PFC Please read Cautions and warnings and Important notes at the end of this document April 2010 Page 8 of 12 Film Capacitors PFC B25667C B25669 B25673 B32344E Installation and maintenance instructions for PFC capacitors Overcurrent short circuit HRC fuses or moulded case circuit breakers for short circuit protection protection have to be used Short circuit protection equipment and connection cable should be dimensioned to handle the 1 5 times rated current of the capacitor permanently m HRC fuses do not protect the capacitor against overload They are only a short circuit protection m HRC fuse rating has to be 1 6 1 8 times nominal capacitor current E Do not use HRC fuses for switching capacitors lightning arc m Use thermal magnetic overcurrent relays for overload protection Maintenance Caution Disregarding the following measures may result in severe operation failures bursting and fire m Check tightness of the connections terminals periodically two weeks after installation at the latest and then once every month m Clean the terminals bushings peri
9. ific series Parallel connection of capacitors via the terminal is not recommended Connecting the supply cable Cable specification The connection cable must be of flexible type material should preferably be copper Note Do not use solid core cables Maximum cable cross section is for E PhaseCap Premium 25 mm m PhiCap 16 mm m PhaseCap Compact Capacitor diameter lt 85 mm 16 mm Capacitor diameter gt 85 mm 25 mm m PhaseCap HD 35 mm Further information can be found in the Appendix The connection cables to the capacitor should be dimensioned for a current of at least 1 5 times the rated current so that no heat is conducted into the capacitor Film PC PM PFC April 2010 Please read Cautions and warnings and Page 5 of 12 Important notes at the end of this document B25667C B25669 B25673 B32344E Film Capacitors PFC Installation and maintenance instructions for PFC capacitors Maximum terminal currents Attaching the supply cable Screw driver Using discharge resistors Discharge the capacitor Film PC PM PFC Please read Cautions and warnings and Important notes at the end of this document Do not exceed the maximum allowable current E PhaseCap Premium Max 80 A total RMS current m PhaseCap Compact Capacitor diameter lt 85 mm Max 50 A Capacitor diameter gt 85 mm Max 80 A m PhaseCap HD Max 130 A total RMS current m PhiCap Max 50 A total RMS current Attac
10. il 2010 Please read Cautions and warnings and Page 9 of 12 Important notes at the end of this document Film Capacitors PFC B25667C B25669 B25673 B32344E Installation and maintenance instructions for PFC capacitors Appendix Connection cable cross section Listed below are recommendations to VDE 0100 for fusing and cable HRC fuse rating cross sections for three phase power capacitors VDE 0100 recommendations Cross section values mentioned below are guideline values valid for operation under normal conditions and at an ambient temperature of 40 C Higher values should be selected if conditions differ from the norm such as higher temperatures or harmonic distortion kvar rating at Nominal HRC fuse Cross section 400 V current rating of supply cable For other voltage ratings 230 V table figure 1 74 440 V table figure 0 91 480 V table figure 0 83 525V table figure 0 76 690 V table figure 0 58 800 V table figure 0 50 The internal wiring of a capacitor bank can be normally done with a lower cross section Various parameters such as temperature inside cabinet quality of cable maximum cable isolation temperature single or multi core cable and length of cable have to be taken into consideration when selecting the appropriate value Film PC PM PFC April 2010 Please read Cautions and warnings and Page 10 of 12 Important notes at the end of this document Film Capacitors PFC B25667C B25669
11. n electronic devices such as converters electrical drives welding machines and uninterruptible power supplies UPS Ensure that the current through the capacitor doesn t exceed 1 5 2 0 Ik for PhaseCap Premium PhaseCap HD and PhiCap For PhaseCap Compact the maximum limit is 1 6 2 0 lr This may indicate heavy presence of harmonics Check the voltage and current using a true RMS multi meter Ensure that the voltage doesn t exceed 1 1 Vp and the peak voltage doesn t exceed 1 6 Vr Use a true rms and peak voltmeter or oscilloscope to check it Film PC PM PFC April 2010 Please read Cautions and warnings and Page 7 of 12 Important notes at the end of this document B25667C B25669 B25673 B32344E Film Capacitors PFC Installation and maintenance instructions for PFC capacitors Attention Only power capacitors with reactors namely de tuned capacitor banks should be used in applications with harmonic distortion Depending on the chosen series resonance frequency a part of the harmonic current will be absorbed by the power capacitor The rest of the harmonic current will flow into the grid The use of power capacitors with reactors reduces harmonic distortion and minimizes the disturbing effects on operation of other loads Avoid resonance conditions Overpressure Disconnector The most important reason for installing de tuned capacitor banks is to avoid resonance conditions Reson
12. nted only in the vertical position Figure 3 PhaseCap HD and PhiCap in vertical mounting position April 2010 Page 3 of 12 Film Capacitors PFC B25667C B25669 B25673 B32344E Installation and maintenance instructions for PFC capacitors Mounting conditions Cooling space for capacitors Using reactors cooling space for cables Fixing threaded bottom stud Film PC PM PFC Please read Cautions and warnings and Important notes at the end of this document PFC capacitors must be installed in a cool and well ventilated place and not close to objects that radiate heat such as filter circuit reactors and furnaces or in the direct sunlight Make sure that sufficient cooling space is provided see Figure 4 A minimum distance of 20 mm between the capacitors is necessary to maintain sufficient cooling m Keep at least 20 mm space above the capacitor and do not attach any mounting components at the crimp or on top This gap will allow a longitudinal extension of the can in order to ensure that the over pressure disconnector can fully extend 20mm 220mm 20 mm Figure 4 Minimum space over and between the capacitors If reactors are used in an application note that they operate at a much higher temperature The distance between the reactor and capacitor must be large enough so that no reactor heat is conducted via the connection cable to the capacitor or that heat radiation from the reac
13. odically to avoid short circuits due dust or other contamination Mm Check the short circuit protection fuses m Take current reading twice a year and compare with nominal current Use a harmonic analyzer or true effective RMS meter E Incase of a current above the nominal current check your application for modifications m If a significant increase in the amount of non linear loads is detected a consultant has to be called in for a harmonic study m In cases of the presence of harmonics the installation of a de tuned capacitor bank reactors must be considered m Check the discharge resistors reactors and in case of doubt check their function 1 Power the capacitor up and down 2 After 60 seconds the voltage between the terminals must decline to less than 75 V Please note that for specific types discharge time is 90 seconds m Check the temperature of energized capacitors In case of excessive temperature of individual capacitors it is recommended to replace this capacitor as this could be an indication for loss factor increase which is a sign for reaching end of life Note For detailed information about PFC capacitors and cautions refer to the latest version of EPCOS PFC Product Profile Please note again that these Installation and Maintenance Instructions apply to typical specifications Refer to our product specifications or request our approval for your specification before installing a capacitor Film PC PM PFC Apr
14. or higher temperature requirements EPCOS offers MKV type capacitors for ambient temperatures of up to 70 C with natural cooling Caution Exceeding the maximum allowed temperature may set the safety device out of operation Capacitors should not be used any longer in case of dents mechanical or any other kind of damage Check the integrity of discharge resistors before installation Film PC PM PFC Please read Cautions and warnings and Important notes at the end of this document April 2010 Page 2 of 12 B25667C B25669 B25673 B32344E Film Capacitors PFC Installation and maintenance instructions for PFC capacitors Installation Mounting the capacitors Mounting positions Phase Cap Premium PhaseCap Compact PhiCap PhaseCap HD Figure 1 Capacitor overview Capacitors installed in a cabinet should be placed on the bottom to ensure the lowest stress temperature possible Warning PhaseCap Premium PhaseCap Compact PhaseCap HD PhiCap Film PC PM PFC Please read Cautions and warnings and Important notes at the end of this document Do not install the capacitor in case of dents deeper than 0 5 mm The PhaseCap Premium and PhaseCap Compact capacitor series may be mounted in the vertical or horizontal position Figure 2 PhaseCap Premium and PhaseCap Compact in vertical or horizontal mounting position The PhaseCap HD and PhiCap capacitors series may be mou
15. s for proper selection of capacitors Please contact EPCOS for any assistance required in selection Maintain good effective grounding of capacitor enclosures Provide the means to isolate any faulty units banks in the system Handle capacitor units carefully as they may be charged even after disconnection due to faulty discharging devices E Follow proper engineering practices E Do not use the HRC fuses to power up and down the capacitor otherwise this could lead to the risk of electrical arcing m Also consider terminals of capacitors connected bus bars and cables and any other devices which are connected with them as being energized The device is electrically charged Do not use or store capacitors in a corrosive atmosphere especially where chloride gas sulfide gas acid alkali salt or similar substances are present In a dusty environment regular maintenance and cleaning especially of the terminals is required to avoid a conductive path between phases and or phases and ground The ambient temperature category for most standard types is 40 D This means a max temperature of 55 C an average temperature over 24 hours of 45 C and the average temperature in one year should not exceed 35 C The maximum casing temperature of 60 C must not be exceeded Temperature is one of the main stress factors for polypropylene type capacitors Temperature has a major influence on the useful life expectancy of the capacitor F
16. seful information on this will be found in our Material Data Sheets on the Internet www epcos com material Should you have any more detailed questions please contact our sales offices We constantly strive to improve our products Consequently the products described in this publication may change from time to time The same is true of the corresponding product specifications Please check therefore to what extent product descriptions and specifications contained in this publication are still applicable before or when you place an order We also reserve the right to discontinue production and delivery of products Consequently we cannot guarantee that all products named in this publication will always be available The aforementioned does not apply in the case of individual agreements deviating from the foregoing for customer specific products Unless otherwise agreed in individual contracts all orders are subject to the current version of the General Terms of Delivery for Products and Services in the Electrical Industry published by the German Electrical and Electronics Industry Association ZVEI The trade names EPCOS BAOKE Alu X CeraDiode CSMP CSSP CTVS DeltaCap DigiSiMic DSSP MiniBlue MiniCell MKK MLSC MotorCap PCC PhaseCap PhaseCube PhaseMod PhiCap SIFERRIT SIFI SIKOREL SilverCap SIMDAD SiMic SIMID SineFormer SIOV SIP5D SIP5K ThermoFuse WindCap are trademarks registered or pending in Europe and in other
17. tor to the capacitor causes overheating The threaded mounting stud is at the bottom of the capacitor S Figure 5 Mounting stud April 2010 Page 4 of 12 Film Capacitors PFC B25667C B25669 B25673 B32344E Installation and maintenance instructions for PFC capacitors Fixing The threaded bottom stud must be fastened with certain specified torques m PhaseCap Premium PhaseCap Compact PhaseCap HD M12 bottom stud torque 10 Nm m PhiCap M12 bottom stud for diameters gt 53 mm torque 10 Nm M 8 bottom stud for diameters lt 53 mm torque 4 Nm Grounding The M12 M8 bottom stud is used for grounding Connect it to the ground by cable or connect the capacitor to any other conductive item which is connected to the ground Note Suitable connectors have to penetrate existing layers of lacquer to ensure good constant conductivity and sufficient current carrying capabilities If grounding is done via the metal chassis the capacitor is mounted to then the layer of varnish beneath the washer and nut should be removed Connecting When connecting avoid bending cable lugs or cables or the use of other forms of mechanical force on the terminals Otherwise leakage could disable the safety device Ensure firm fixing of terminals fixing torque to be applied as per individual specification In any case the maximum specified terminal current may not be exceeded Please refer to the technical data of the spec
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