LV PFC Install Instructions 0310

7/30/2019 LV PFC Install Instructions 0310

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March 2010

Caution: The equipment covered by these installation instructionsshould be installed and serviced only by properly trained andqualified personnel. It is not the intent of these instructions toprovide for every possible condition in connection withinstallation, operation or maintenance, nor to cover all detailsor variation in equipment options. Should problems arisewhich are not sufficiently covered herein or should furtherinformation be required, the matter should be directed toMaysteel.

SmartBankLV Power Factor Correction Units

Installation Instructions

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SmartBankLow Voltage Capacitors for Power Factor Correction

Intro

Thank you for purchasing Trinetics Smartbank low voltage power factor correction equipment.

You have purchased the finest power factor correction equipment available! All capacitor cellsare made with state of the art metallized polypropylene film encased in extruded round aluminumenclosures designed for low electrical loss and long life. Each capacitor or group of capacitors isenclosed in a painted steel enclosure fitted with a gasketed cover designed for easy installation.Smartbank low voltage capacitor banks are ETL listed as compliant with UL standard 810.

Notice / Cautionary Notes

Please note that the instructions in this document are intended to guide good practices for thereceiving, inspection, installation, and maintenance of low voltage power factor capacitors.They are not intended to serve as an application guide or as a substitute for safe operatingprocedures. Read the guidelines presented in this document carefully and examine theequipment to become familiar with it prior to installing, operating, or performing maintenance.

Work on your Smartbank unit must be performed by personnel who have been trained in theinstallation, operation, and maintenance of electrical power systems. Individuals who work onthis equipment must have the training and experience with high energy circuits and componentswith an understanding of the hazards involved.

Although care has been taken to provide accurate and authoritative information in this document,no responsibility is assumed by Maysteel LLC for any consequences resulting from the use ofthis material.

Pre-installation (incoming inspection, storage)

When taking delivery:

o Check that all required products have been delivered and that the equipment has not

been damaged in transit. Inspect mounting brackets and enclosure for breakage and/ordents.

o Check internal assemblies for broken fuses (if required), loose wiring, bent or brokenterminals, or dented or bent capacitor cells. DO NOT USE DAMAGED ASSEMBLIESOR CELLS!

o Forward any claims to the carrier immediately by reporting the bill of lading number. TheBill of Lading contains the type of conveyance and the carriers name. Most carriersimpose a 24 hour time limit for reporting lost or damaged goods, so act quickly!

o Notify your Maysteel Sales Representative if you receive a damaged unit. They will beable to assist you in obtaining a replacement unit and/or provide instructions regardingthe disposition of the damaged unit.

Storage of the unit prior to use:

o Store the equipment in a dry, ventilated location, protected from rain, chemicals, orwater spray.

o Do not use or store capacitors in a corrosive atmosphere, especially where chloride gas,sulfide gas, acid, alkali, salt or similar substances are present.

o Stored equipment should be protected by a tarpaulin or other cover providing effectiveprotection against water, dust, dirt, paint, etc.

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o If stored in a dusty environment, cleaning of the terminals is required prior to use toavoid a conductive path between phases and/or phases and ground.

Installation:

Location:

Your Smartbank unit should be located in a cool, well ventilated location in order to maximize theoperating life. Mechanical requirements of mounting the capacitor unit must also be considered.General guidelines for selecting a location include:

o Leave at least 3 inches around all sides of the units and 12 inches above the top of theunit to allow air circulation.

o Avoid placement near hot spots such as transformers, heating ducts, direct sunlight,furnaces, combustible materials, etc.

o Do not install in locations with large harmonic currents or voltages.

o Allow mechanical clearances to allow removal of the cover.

o Leave room as required to provide clear access for cable connections to the unit.

o

The location should be free of excessive dirt and fluids.o The location should be free of human interference.

o The bank can be mounted in locations up to 1800 meters (6000 ft) in altitude without de-rating. Consult Maysteel if you need to mount above this elevation.

Mounting:

o All capacitor assemblies are provided with mounting brackets for mounting to either thefloor or a wall. Brackets have .44 inch diameter holes to accommodate 3/8 screws orbolts for mounting the unit. Make sure that wall anchors and mounting surface aresuitable to support the weight of the bank.

o Assemble the mounting brackets to the side of the enclosure using 6- x20thread forming screws which are provided.

o Your SmartBank unit is designed to be mounted in an upright position with thelabel facing towards the front of the enclosure.

o If mounting space is limited and you require a shorter height profile, yourSmartbank unit can be rotated 90 degrees. The blown fuse indicator lights canbe mounted in 2 different locations. Brackets are required to support thecapacitors if this alternate mounting position is used. Contact the factory toobtain the required capacitor support brackets.

o Hold the unit up to the mounting surface and mark the mounting holes.

o If units are to be ceiling mounted, secure the unit on a platform and secure the platformto the ceiling leaving at least 12 14 inches above the unit for cover removal andaccess to internal wiring.

o Secure enclosure to a flat, hard surface with suitable anchors, washers and bolts usingthe mounting brackets provided.

Electrical operating conditions:

o Smartbank LV units are designed to operate at or below rated voltage. Units can beoperated below rated voltage but the output kVAR will be less than the rated kVAR.Contact Maysteel when derating units for reduced voltages.


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o Capacitors within the Smartbank LV units are rated for operation at 10% above ratednameplate voltage (including harmonics but not transients) for short time intervals.

o Smartbank LV units are designed to operate at 60 Hz. Units can be operated at 50 Hzbut the output kVAR will be less than nameplate kVAR. Contact Maysteel if you intendto operate at 50 Hz.

Connection:

o Remove the enclosure cover. Be careful to retain the screws since they will be used tore-attach the cover.

o Smartbank LV enclosures are designed to allow cable or conduit entry from either thebottom or the back. Possible entry locations are marked with decals on the outside of

the enclosure; one in the bottom and one in the back.

o Feeder cables must be rated a minimum of 135% of the capacitor nameplatecurrent. This figure provides tolerance for potential over-capacitance (0 to 10%),over-voltage (0 to 10%) and nominal harmonic currents. The sum of thesecurrents should not exceed 135% of the capacitance rated current listed on thenameplate. Table RECOMMENDED WIRE SIZES AND FUSING FOR 3PHASE, 60 HZ CAPACITOR BANKS provides recommended wire sizes andfuse values for 3 phase, 60 Hz capacitor banks in accordance with theguidelines provided in the National Electric Code, Article 460.

o Drill or punch a suitably sized hole at the location in either the bottom or back of theenclosure, at the location marked with green circular decals, to facilitate cable or conduitentry. Feeder wiring must be protected as it passes through the entrance opening

through the use of a cable or conduit connector or insulating grommet.o Train cables away from the capacitor discharge resistors or fuses (if provided).

o Connect incoming cables to the terminals provided with the unit. There are 5 holes inthe terminal, one to accommodate #6 AWG to 3/0 wire and four to accommodate #4AWG to #14 AWG wires. The following graphics, located on a decal inside of theenclosure, defines connection points for incoming power leads.

Caution!Connecting capacitors to a voltage greater than nameplate

values will reduce life expectancy and could cause dangerousconditions. Check nameplate values for voltage, frequency,

and phase to ensure system compatibility.

Caution!Never apply fixed capacitor banks to a system that contains an excess ofharmonics. Harmonics are generated by a variety of equipment including

welders, variable frequency drives, motor starters, etc. Power outagesand/or equipment damage may result from improper application of power

factor capacitor banks.


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o Torque settings for connection terminals are as follows:

o Slotted screw in #14 - #4 holes:

#10 to #14 wires 35 in-lbs. #8 wire 40 in-lbs. #4 to #6 wires 45 in-lbs.

o hex screw in #6 3/0 hole:

#4 to #6 wires 110 in-lbs. #1 to #3 wires 150 in-lbs. 1/0 to 2/0 wires 180 in-lbs. 3/0 wires 250 in-lbs.

o Connectors on capacitor: 10.6 in-lbs


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o Ground the bank with the supplied grounding lug and torque the connection to 100 in-lbs.

o Ensure that all contaminants are removed from within the enclosure and all cables aresecured. Improper or loose connections will cause terminal overheating and possibleearly failure of the capacitors.

o Replace the enclosure cover prior to connecting power to the unit. Hand tighten the 8-32 x 5/16 thread forming screws to secure the cover. The unit is now ready to energize.

Protection:

o The national Electrical Code, Article 460, guides the installation of capacitors.Capacitors used in Smartbank LV units meet all of the requirements of the code relativeto discharge resistors and over current protection.

o Capacitors are provided with self-healing technology and overpressure disconnectors.These devices are not intended to fulfill the NEC requirements for over currentprotection in each ungrounded conductor.

o Smartbank LV units are available with optional current limiting fusing with faultinterruption ratings up to 200 kA. Fused units are provided with neon type blown fuse

indicators.o Fuses can be installed at the factory or in the field. A complete kit, consisting of fuses,

indicator lights, all required mounting hardware and installation instructions is available.As shown below, fusing can be added without removing the wiring to the capacitors.

Incoming power connectedto one of these posts

Power tocapacitors

connected to oneof these posts

Single fuse connected tothese posts

Second fuse in parallel fusingconnected to these posts


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RECOMMENDED WIRE SIZES AND FUSING FOR 3 PHASE,60 HZ CAPACITOR BANKS

(Wire sizes based on 135% of rated current in accordance with the National Electric Code, Article460)

240 Volt AC 480 Volt AC

kVAR

RatedCurrent(amps)

WireSize 90C-TypeTHHN,XHHW

orequiv.*

Fuse(amps)

RatedCurrent(amps)

WireSize 90C-TypeTHHN,XHHW

orequiv.*

Fuse(amps)

2.5 6 14 10 3 14 6

5.0 12 12 20 6 14 10

7.5 18 10 30 9 14 15

10.0 24 8 40 12 12 2012.5 30 8 50 15 10 25

15.0 36 6 60 18 10 30

20.0 48 4 80 24 8 40

25.0 30 8 50

30.0 72 2 125 36 6 60

37.5 90 1/0 150

40.0 48 4 80

45.0 108 3/0 200 54 4 90

50.0 120 3/0 200 60 2 100

60.0 144 3/0 250 72 2 125

75.0 90 1/0 150

80.0 96 2/0 17590.0 108 3/0 200

100.0 120 3/0 200

120.0 144 3/0 250

Rated current based on operation at rated voltage, frequency and kVAR.

* Consult National Electrical Code for other wire types. Above sizes based on 35 C AmbientOperation. (Refer to NEC table 310-16)

Note: Fuses furnished within the capacitor bank may be rated at higher value than shown in thistable. The table is correct for field installations and reflects the manufacturer's suggested ratingfor over current protection and disconnect means in compliance with the National Electric Code.

o A properly rated disconnect switch or circuit breaker must be provided to safely isolatethe capacitor bank from the circuit if service is required. For units connected to the loadside of the motor starter (locations B and C), the NEC allows the motor starter to provideisolation and overcurrent protection for the capacitor and cables. For units connected tothe line side of a motor starter (location A), a suitably sized fused disconnect switch orcircuit breaker must be supplied to provide isolation and protection for the conductors.


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o If the Smartbank unit is connected between the motor starter and the overload relay(position B), the motor overloads do not need to be resized.

o If the Smartbank unit is connected between the motor overload relay and the motor(position C), the motor overload relay size or setting must be reduced to reflect the lowercurrent draw by the motor. Measure the current drawn by the motor with and without thecapacitor energized and reduce the overload relay by the difference between theamounts measured.

o Caution: If the capacitor bank is applied to motors which are subject to jogging,reversing, plugging, or open transition compound starting, it is recommended that youconnect the bank between the motor starter and the disconnect at location A. In thisposition the capacitor bank is energized even when the motor is not operating. Thebreaker or fused safety switch provides the appropriate means for the required removalcapacity per Code.

Follow-up inspection and maintenance:

Fused

SafetySwitch orBreaker

Motor

Starter(contactors)

Overload

Relay

Breaker orFusedSafetySwitch

SmartbankCapacitor

Bank

SmartbankCapacitor

Bank

SmartbankCapacitor

Bank

Mo

Main Feed

MotorFeed

A B C

Warning!Capacitors store potentially lethal voltage even when disconnected. The use of improper

maintenance procedures can result in serious injury or even death. All SmartBank capacitor unitsinclude integral discharge resistors to reduce terminal voltage to less than 50V within 1 minute.

Before handling equipment or removing terminal cover, wait at least 1 minute after disconnectingfrom service, remove terminal cover, then short and ground each capacitor terminal with an

insulated tool.

Warning!

A properly rated disconnect switch or circuit breaker must be provided to safely isolate thecapacitor bank from the circuit if service is required. Always disconnect power from the

Smartbank unit prior to removing the cover


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o Recommended practice is to measure and record current at time of installation to: 1) becertain that fuses are not blown and 2) serve as reference against future readings.

o Routine inspection should be conducted 24 hours after installation, then yearlythereafter.

o Check all cable connections for proper torque settings. The torque settingsdefined in the following table apply:

#4 to #14 port #6 to 3/0 portCapacitorconnector Ground lug

#10 to #14 wire 35 in-lbs 100 in-lbs

#8 wire 40 in-lbs 10.6 in-lbs 100 in-lbs

#4 to #6 wire 45 in-lbs 10.6 in-lbs 100 in-lbs



1/0 to 2/0 wire 180 in-lbs 100 in-lbs

3/0 wire 250 in-lbs 100 in-lbs

o Confirm that no dust, dirt, or debris has accumulated within the terminalchamber.

o Measure voltage and current on all phases to make sure that readings arebalanced. Check readings against initial values to determine if there have beensignificant changes.

o Confirm that terminal voltage is less than 110% of nameplate rated voltage.

o Confirm that operating current is less than 135% of nameplate rated current forthe assembly. If current is in excess of 135% of the nameplate rating, check thefollowing:

1. Voltage at the terminals is less than 110% of the rated nameplatevoltage

2. Ambient temperature is within the allowable range. See locationambient temperature above.

3. The unit has sufficient space to allow air flow around the enclosure.

4. The unit is not connected in a circuit with variable frequency drives,motor starters, or other devices that generate harmonics.

5. Using proper equipment, measure the harmonic current and voltage ofthe unit. Contact Maysteel if the voltage harmonic distortion is in excessof 3% or harmonic current distortion is in excess of 5%.

o Disconnect the capacitor unit if current is in excess of 135% of the nameplate

rating. Capacitor current in excess of 135% of the nameplate rating mayindicate excessive harmonics on the network.

o To determine if a capacitor is operating effectively, measure each phase with a clamp-onammeter and compare the measured current with the rated current listed in the tableRECOMMENDED WIRE SIZES AND FUSING FOR 3 PHASE, 60 HZ CAPACITORBANKS. Phase currents should be balanced. If any abnormal reading (or zero) isshown, turn off the power to the capacitor, wait at least one minute for the charge tobleed off, then short between all terminals to be certain that the capacitor hasdischarged completely. Use an ohmmeter to check the capacitor cells. Zero theohmmeter by touching the probes together. Measure ohms between all phases on the


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capacitor terminals. If the ohmmeter reads zero, the capacitor is shorted and must bediscarded. If the meter goes to zero quickly and then moves back toward mid-scale, thecapacitor is probably good.

o The most common cause of capacitor unit outage is a blown fuse caused bymisapplication resulting in excessive current. If your unit is equipped with blown fuselights, the light will glow when the fuse blows. Before replacing the fuse, make sure that

the capacitor(s) are not shorted.

o Wait at least one minute so the charge can bleed off.

o Use an ohmmeter to check the capacitor cells. Zero the ohmmeter by touchingthe probes together. Measure ohms between all phases on the capacitorterminals. If the ohmmeter reads zero, the capacitor is shorted and must bediscarded. If the meter goes to zero quickly and then moves back toward mid-scale, the capacitor is probably good and blown fuses should be replaced withthe same value fuse.

o If fuses continue to blow, take steps to determine the cause. If the ohmmeterneedle does not move, the capacitor element is open circuited. If this is theresult of interrupter action inside the capacitor case, the cell cover will be bulgedoutward on the end with the connections and discharge resistors. Replace the

cells, retest and operate.

o Fuses (if supplied) must be replaced with the same type and rating as thoseoriginally shipped in the unit. Contact Maysteel if a replacement fuse isrequired.

Location Ambient Temperature:

There are 2 important ambient temperatures that must be evaluated for proper operation of yourSmartbank LV unit. Location ambient temperature is the temperature of the air in the areawhere the capacitor will be operating. It is the ambient temperature in the area before thecapacitors are installed or when the capacitors are installed but not energized. Operatingambient temperature is the temperature of the surrounding air when the unit(s) are energized.

Your Smartbank capacitor unit is designed for use in a maximum operating ambient temperaturerange of -40 C (-40 F) to +50 C (+122 F) but the amount of time in operation at elevatedtemperatures should be limited to the following:

1. 24 hour mean: +40 C (104 F)

2. 1 year mean: +30 C (86 F)

Care must be exercised in selecting an installation location. If there is a question as to theoperating ambient temperature in location of choice, it is suggested that temperaturemeasurements should be taken in accordance with the following NEMA instructions:

1. Let units operate for at least 24 hours before taking temperaturemeasurements.

2. The operating ambient temperature should be measured by taking the

average readings of 3 thermometers located as follows:

a. One thermometer level with the top of unit(s).

b. One thermometer 12 inches above the bottom of the unit(s)

c. One thermometer midway between a and b positions above.

All 3 thermometers should be located 12 inches (horizontally) from the unit(s).

If the maximum operating ambient temperature limit is exceeded, units should bedisconnected from the AC line. Contact your sales representative at once for advice onrequired corrective actions.


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Service parts:

o Under normal operating conditions, a capacitor will have a nominal life of 15 to 20 years.Premature decline in capacitor performance is usually a result of a problem with theapplication or environment. Capacitors in the Smartbank LV units can easily bereplaced if necessary. Contact Maysteel if a replacement capacitor is required.

o Fuses (if supplied) must be replaced with the same type and rating as those originallyshipped in the unit. Contact Maysteel if a replacement fuse is required.

Disposal:

Smartbank LV capacitor elements are constructed with metalized polypropylene all-dry dielectricand contain no fluids. None of the materials used in the construction of the Smartbank LVcapacitors are listed as hazardous materials however incineration or disposal should be inaccordance with Federal, State, Provincial and Local regulations.

Warranty:

Smartbank LV units are warranted to be free of defects and workmanship in accordance withstandard Maysteel LLC terms and conditions unless otherwise agreed upon in writing byauthorized Maysteel personnel. Contact Maysteel or any authorized Maysteel representative fordetails of standard warranty terms and conditions.

Notes:

Connection to voltages and frequencies above the rated values will reduce life expectancy ofyour Smartbank LV device and could be dangerous. Consult Maysteel for advice if youencounter unusual operating conditions. Operation at voltages and frequencies below ratedvalues will result in kVAR values that vary from nameplate ratings. The kVAR ratings can becalculated with the following formulas:

o For operation at reduced voltage:

Actual kVAR = Rated kVAR (Actual Voltage/Rated Voltage)2

o For operation at reduced frequency:

Actual kVAR = Rated kVAR (Actual Frequency / Rated Frequency)

Documents

LV PFC Install Instructions 0310