System Controller Capacitors Reactors Switching Module Software & Network Solutions Application Dimension and System Specifications Advantages

System

The Activcomp is a state of the art, electronic switching system designed for Power factor Correction & Harmonic Filter. 

Connection and disconnection of the capacitors to and from the network occurs at zero current crossing. This smooth connection avoids the transient effects typically created by electro mechanically switched PFC systems.
 

The electronic switches do not wear out or deteriorate during the switching process and the capacitors are not adversely affected by transients. These advantages contribute to a much longer life expectancy compared with electro mechanically switched PFC systems.

The power factor is controlled very accurately by means of an advanced closed loop control & measuring unit, that takes into consideration all three phases and the effect of harmonics 
(1 through 63).

The Activcomp system is equipped with a unique scan feature that protects capacitors from "exploding" and contributes to longer life expectancy. This is achieved by reducing over-current and overheating in the capacitors which may result from harmonics on the mains. The switching element can perform an unlimited number of switching operations. The connection of one group of capacitors occurs simultaneously with the disconnection of another group. This operation is performed every few seconds and engages all capacitor group in turn, resulting in a reduction of mean current due to the lower ratio of engagement time to cycle time (duty cycle).

The scan feature, together with the unique reactor design, substantially reduces the temperature rise of the reactors and protects the cabinet from overheating.

Controller

A digital signal processor (DSP) and a VLSI component form the basis of the controller's technology. It features an LCD display, analog and digital circuitry, precise firing algorithms and optional communication capabilities. The controller has 9 input channels; 4 voltages (for Wye networks), 3 main currents and 2 internal system currents. The information obtained from these measurements is used for Fast Fourier Transform (FFT) analysis, performed each network cycle on all channels. Further harmonics are calculated on all phases, allowing the Activcomp to achieve ideal compensation even in the presence of harmonics.

The Activcomp's controller is available with a choice of data gathering levels, from essential power parameter measurements only (V, I, f, kW, kVA, kVAr) to complete power system performance monitoring that takes advantage of the comprehensive measurement system (over 2,000 electrical parameters, including min/max levels and four-quadrant measurement of power and power factor).

The large LCD display is full-graphic, 160x128 pixels, and has long-lasting LED backlighting with FSTN technology. Characters are displayed in varying sizes and methods to enhance visibility. These include a Large Digits display, Harmonic spectrums, real-time Waveform plots and simple Text screens that include menus, easy-to-use setup programs and various measurements.

General Specifications:

Operational Mode

• Manual
  
  
• Automatic
  
  
• Test
  

Scan mode

Display Structure :

• Graphic, high contrast FSTN LCD
  
  
• 4.7", Black/White
  
  
• Long life LED backlight
  
  
• Antiglare coated polycarbonate window
  

Functions :

• Menu driven operation
  
  
• Self explained windows
  
  
• User friendly 
  
  
• Easy installation using wizard
  

Display Modes
(Refer to images on next page):

• Large Digit Screen-displays 9 numerical values
  
  
• Waveform Screen - displays wave shape together with waveform detailed information
  
  

• Harmonics Screen - displays complete harmonic spectrum, including each harmonic details from 1st to 63rd (amplitude, percentage and phase shift).

Built in Power Quality measurement system
Simultaneous measurement of the following sections:

• Mains (total of load and capacitor)
  
  
• Load
  
  

• Capacitor (system)
  
  

• Combination of Mains, Load and Capacitors.
  

For example, if reactive energy parameter is selected, the user can see the KVAr consumption by the Load, the connected KVAr by the Capacitor System and the result on the Mains.

Calculation Method

• True RMS measurements (up to 63rd harmonics).
  
  
• Based on FFT algorithm which is carried out cycle to cycle (128 samples per cycle).
  

Error & Alarms

• Self explained, automatic capacitor group self test procedure
  
  
• Blown fuse error
  
  
• Shorted SCR error
  
  
• Over temperature alarm
  
  
• Parallel resonance detection mechanism

The system identifies the resonance frequency (5th, 7th etc.) and disables the connection of the Capacitors groups as soon as resonance occurs.

• Phase sequence error detection
  
  
• Frequency margins error detection
  
  
• Spikes detection
  
  

• Automatic recording of all troubleshooting related Events including time (year, month, day, hour, minute, second, Cycle number), up to 16,000 events, stored in FIFO Configurations.
  

• Voltage free contact (N.O./N.C.) Alarm relay
  

Communication.

• Isolated RS485
  
  
• Up to 115k Baud Rate 
  
  
• Protocols options: ELCOM-( High-Speed Communication protocol) ModBus/RTU (IEEE 754 Floating Point)
  
  
• Full remote control
  

Controller Specifications

Measured Parameters in Activcomp Controller

Capacitors

Neptune-Ducati ranges of Capacitor Banks are using Capacitor modules from M/s Ducati energia s.p.a, Italy. Ducati energia is a leading company in production of power factor correction capacitors. Following this tradition, continuous investments in research and development of new products have represented the policy of the company.

The result of this philosophy is the new range of Long Life Capacitors MONO16 and MODULO50. Thanks to the technological innovation of self-healing metallized polypropylene; the rated power of 50 KVAR is achieved in just one 3-phase element with very compact dimensions & a much higher life expectancy in comparison with other models.

These new Long Life capacitors Mono16 & Modulo50 reach an expected life of more than 150,000 hours and a size reduction up to 40% against the technologies so far applied with low loss of 0.2W/KVAR. With 4In capabilities and oil impregnation, the performance of these capacitors are much better in comparison to other technologies available in market like gas filled and dry type.    

Reactors

Harmonic Block Reactor

Design Features

Neptune Filter Circuits are designed as three-phase reactors with an iron core and air gap. Harmonic Filter Reactors are made out of high quality material and very stringent quality control. It has been designed with properties like low temperature rise and lower flux density so that it can operate in worst conditions of ambient and harmonic overloads. They offer very good degree of linearity and low losses. Cheaper and non-linear reactors may trigger

undesirable chain phenomena during periods of operation with high harmonic values, such as reducing in the inductance with consequent increase in the resonance frequency of the LC group, which would drain off more harmonic 


Capacitor Specifications

current, further reducing its inductance and overload the reactor more and more. Reactors are available with filtering factor of 5.6%, 7% and 14% as per standard ratings. Any other filtering factor and rating can be developed on request.

Losses

The 50 Hz losses are comparatively low but when the filter circuit reactors are installed into the cabinets, they are charged with additional currents, predominately those of the 5th, 7th & 11th harmonics. Then the total heat losses are dissipated by the means of Centrifugal Fans on the ceiling of cabinets.

Series Combination

Reactors are designed to be used in series with capacitor banks to make Tuned or
De-Tuned Filter Circuit as per Activcomp design requirement.

Switching Module

The switching module is comprised of solid state switching elements, which provide reliable, high speed, transient free operation. Each switching module switches up to three capacitor groups.

Software & Network Solutions

Power IQ - Software

• Provides complete System Remote Control
  
  

• Real Time measurements
  
  

• Time-Of-Use
   
• Harmonic & Waveform graphic and tabular Display
   
• Comprehensive Data Logging, including Triggers and set points

General

This easy - to - use software displays the system's status, as well as the measurement results on numerous screens running under Windows (95, 98, me, NT, 2000 & XP). PowerIQ integrates all Activcomp systems, allowing power quality analysis, cycle to cycle demand & power factor monitoring. PowerIQ includes real - time measurements, as well as comprehensive data logging and power quality analysis features. All screens allow customization, printing and exporting of data. The network version enables complete and Internet operation, as well intra-net as modem access.

Power IQ - Power Quality Management System

PowerIQ displays the harmonics spectrum, both as a graph and table, in addition to harmonic analysis parameters (THD, K-Factor and Crest-Factor). Compliance monitoring of international power quality standards, such as IEEE-519, allows easy network analysis.

Scope Displays waves and their phase shifting, and enables detection of existing or potential power quality problems.

Real Time Measurement

Provides clearly visible real time values, with min. and max..

Application

Application of Activcomp

Industries with Non-Linear Loads

Industries employing large nos. of Variable speed DC drives or Non- Linear Loads generating harmonics. Activcomp is the most viable solution as it not only offers accurate P.F correction in presence of Harmonics but at the same time brings down the THD level in Voltage and currents. 

Hospitals and Other Medical Centers

Medical equipment includes some of the most sensitive apparatus available. Electro-mechanical switching transients can cause equipment failure, which may result in serious consequences. Plus modern medical equipment can cause Harmonics. The Activcomp's transient-free switching together with its Harmonic Filter capabilities, is the only solution for power factor correction at hospitals and other medical centers.

Data Centers

High availability is the requirement of data centers. Due to the large volume of computers, UPS systems and other communications equipment, data centers have very high

Harmonic pollution and are extremely sensitive to transients. In order to meet the high availability requirements, data centers use the Activcomp transient-free compensation systems with Harmonic Filter.

Extrusion

Extruders create a tremendous amount of harmonics. The harmonics cause energy losses, overheating and may sometimes lead to fire. Using tuned or de-tuned Activcomp systems, customers can reduce the harmonic pollution (THD - Total Harmonic Distortion) apart from maintaining high Power Factor. Decreasing THD both saves energy and prevents potentially dangerous resonance conditions.

Office Buildings

Office buildings incorporate a significant amount of high harmonic polluting apparatus, including computers, fluorescent lighting and modern elevators. Filtering harmonics saves energy and reduces electrical bills. Using an Activcomp system with Harmonic Filter assures long life and high performance.

Dimension and System Specifications

Standard Activcomp balanced systems for 415V- 440V / 50Hz with 7% Detuned Reactors.

Standard Systems with Circuit Breaker 
Breaker section depth can be upto 1200 mm

Advantages

Advantages Over Electro-mechanical Compensation System

Fast and Accurate Compensation

The Activcomp is a Transient Free Fast Compensation System. It is used for Power Factor Correction & Harmonic Filter. The compensation is based on averaging the FFT analysis of each cycle, resulting in more accurate compensation, even in the presence of harmonics.

Simultaneous Group Connection

When load changes require connection or disconnection of more than one step, the Activcomp controls the switching of as many steps as required at precisely the same time. Simultaneous connection or disconnection provides the following benefits :

• Fast full compensation.
  
  

• For Eg., with 1:2:2 system configuration and groups 1 & 2 are connected. 
  When 1 more step is required, group 3 will be connected simultaneously while 
  group 1 is disconnected.
  
  

• Real binary sizing - 1:2:2 is exactly the same as 1:1:1:1:1.

Transient-free Switching

Electronic switching technology prevents any transients typically associated with conventional capacitor switching. This is extremely important in sites with sensitive electronic equipment, such as hospitals, data centers and facilities.

Fixed Capacity & Filter Characteristics

The capacity of the Activcomp capacitors is virtually permanent over the years, which prevents the need to replace capacitors. Moreover the tuning frequency remains constant over time, which allows system performance to remain at the highest possible level.

There is an ongoing cumulative reduction of capacity in electro mechanically switched PFC systems due to the effect of transients during connections and disconnection. This can be detrimental to detuned electro mechanically switched systems where the changes in ratio between the capacitors/reactors shift the resonance frequency, which may result in resonance. The Activcomp prevents these conditions.

Long Life and Reduced Maintenance Costs

Neptune Activcomp reduces site maintenance costs by increasing the lifetime of:

• Switching elements
  
  

• Capacitors
  
  

• Sensitive electronic equipment

Capacitor Duty Cycle-SCAN Mode

The unique SCAN feature protects the Activcomp's capacitors & reactors, increases their lifespan. Simultaneous connection and disconnection of steps in FIFO (First In First Out) manner is shown in diagram on the previous page.

The scan feature reduces the average current in the capacitors and the reactors and therefore providing the following advantages:

• Reduces substantially the increase of temperature in these elements resulting in longer life expectancy of the inductors and capacitors.
  
  

• Reduces the effect of over-current and over voltage caused by the harmonics on the capacitors and inductors.
  
  

• The tuning frequency of the de-tuned filter or tuned filter is stable due to the fact that the capacitor value (micro farad) doesn't change due to the low temperature achieved by the scan mode.

Easy to Use and Maintain

The advanced DSP and microprocessor-based controller, with its large full graphic LCD display, provides easy-to-use operation. The controller includes a complete electrical measurement system, which can replace a facilities main monitoring meter. The controller operates the BIT (Built In Test), which reports system or network conditions. The optional PowerlQ software can remotely control all Activcomp operation and display additional system power information.