UG-1041 eCAP-9040 User's Guide€¦ · UG-1041 eCAP-9040 User's Guide ... The eCAP front panel has...

UG-1041 eCAP-9040

User's Guide

December 2018

UG-1041 eCAP-9040 User's Guide

Copyright © 2017 by QEI UG-1041 eCAP-9040 User's Guide ALL RIGHTS RESERVED

NOTICE

The information in this document has been carefully checked and is believed to be accurate. However, no responsibility is assumed or implied for inaccuracies. Further-more, QEI, reserves the right to make changes to any products herein described to improve reliability, function or design. QEI does not assume liability arising to the application or use of any product or circuit described herein; neither does it convey any license under its patent rights nor the rights of others.

This manual and all data contained constitutes proprietary information of QEI and shall not be reproduced, copied or disclosed to others, or used as the basis for manufacture without written consent of QEI.

45 Fadem Road Springfield, NJ 07081 Phone: (973) 379-7400 Fax: (973) 379-2138 Web Site: www.qeiinc.com

http://www.qeiinc.com/


Copyright © 2017 QEI Revisions i

Revisions

Revision Description Date

A Release to Production January 2003

B Corrected Figure 2.4, added Warnings in section 2.5, Corrected Typographical Errors Sections 3.2, 3.6.4 and 3.5.8

June 2003

C Additional revisions November 2003

D Added information for Radio Interface board and SCADA override capability.

September 2005

E Added information for neutral current detection local automatic functions.

April 2006

F Corrections in Section 5.11 (Neutral Current) for Led Lockout Flash Rate.

March 2007

G Formatting Update September 2012

H

I

Formatting Update

Updated QEI Address

June 2017

December 2018


Copyright © 2017 QEI Contents

Contents

1. Introduction ..............................................................................5 1.1 Definitions .............................................................................. 6 1.2 Specifications ......................................................................... 7

1.2.1 Size ......................................................................... 7 1.2.2 Temperature Sensor ............................................... 7 1.2.3 Operation Counter .................................................. 7 1.2.4 Current Sensor ....................................................... 7 1.2.5 Capacitor Switch Relays ......................................... 7 1.2.6 Supply Voltage ........................................................ 7 1.2.7 Line Frequency ....................................................... 7 1.2.8 Switching Condition (algorithm) Storage ............... 7 1.2.9 RMS Value Measurement ...................................... 7 1.2.10 Power Consumption ............................................... 7 1.2.11 Historical Data Storage ........................................... 7 1.2.12 Environment ............................................................ 8 1.2.13 Case ........................................................................ 8 1.2.14 Switching Algorithms .............................................. 8 1.2.15 Radio/Modem Dimensions ..................................... 8 1.2.16 Radio/Modem Power Supply .................................. 8

2. Installation ................................................................................9 2.1 Making Connections .............................................................. 9 2.2 Grounding .............................................................................. 9 2.3 4-Wire System Installation ................................................... 10 2.4 3-Wire System Installation ................................................... 12 2.5 Line Current Measurement .................................................. 14 2.6 Neutral Current Measurement ............................................. 14 2.7 Meter Socket Mounting ........................................................ 15 2.8 Pole Mounting ...................................................................... 16 2.9 Terminal Strip Mounting ....................................................... 17 2.10 Environmental Considerations ............................................. 17

3. Operation ................................................................................18 3.1 Front Panel Layout ............................................................... 18

3.1.1 Fuses and Fuseholders ........................................ 21 3.1.2 Battery ................................................................... 21 3.1.3 Clock ..................................................................... 21

3.2 Programming an eCAP for Operation .................................. 22 3.3 Menu Summary .................................................................... 23 3.4 eCAP Setup via Front Panel Switches ................................ 24

3.4.1 eCAP Menu Interface Switches ............................ 24 3.4.2 Menu Description .................................................. 26

3.5 eCAP Menu Description ....................................................... 27 3.5.1 Start-up Banner .................................................... 27 3.5.2 Voltage, Current (Condition Status) ..................... 27 3.5.3 KW, kVAr, PF (Condition Status) ......................... 27 3.5.4 Switches Open, Switches Closed (Adjustable) .... 28

eCAP-9040 User's Guide UG-1041

ii Contents Copyright © 2017 QEI

3.5.5 Switch Delay Settings (Adjustable) ...................... 33 3.5.6 Date and Time (Adjustable) .................................. 34 3.5.7 Config Constants (Adjustable) .............................. 35 3.5.8 Operating Mode (Condition Status, Adjustable) ... 36 3.5.9 Unit ID (Adjustable) ............................................... 41 3.5.10 Temperature (Condition Status, Adjustable) ........ 41 3.5.11 Switch Status (Condition Status) .......................... 41 3.5.12 Operations Count .................................................. 42 3.5.13 Switching V-Hyst (Adjustable) .............................. 42

4. Switching Algorithm Reference Guide .................................44 4.1 Introduction .......................................................................... 45

4.1.1 General Considerations ........................................ 45 4.1.2 Operating Parameters .......................................... 45 4.1.3 General Information .............................................. 46

4.2 Common Switching Algorithms ............................................ 50 4.2.1 Temperature Control Switching (Example #1) ..... 50 4.2.2 Temperature Control Switching (Example #2) ..... 50 4.2.3 Time & Date Control ............................................. 51 4.2.4 Time of Day Switching .......................................... 51 4.2.5 Day of Week Switching ......................................... 52 4.2.6 Voltage Control ..................................................... 52 4.2.7 VAR Control .......................................................... 53 4.2.8 VAR Control with Voltage Override ...................... 53 4.2.9 Power Factor Switching ........................................ 54 4.2.10 Current Switching ................................................. 54

4.3 Customized Switching Algorithms ....................................... 55 4.3.1 Switching Algorithm Evaluation Process .............. 55 4.3.2 Switching Algorithm Development Considerations56

5. SmartWare ..............................................................................57 5.1 Running "SmartWare" .......................................................... 58 5.2 Main Menu............................................................................ 60

5.2.1 File Menu .............................................................. 60 5.2.2 Comms Menu ........................................................ 61 5.2.3 Setup Menu........................................................... 61 5.2.4 SmartTrends Menu ............................................... 62 5.2.5 SmartView Menu................................................... 62 5.2.6 SmartSim .............................................................. 62 5.2.7 Help ....................................................................... 62

5.3 Bottom Line Parameters ...................................................... 63 5.4 View Template Window (Configuration Overview Window) 63 5.5 Read from/Send to Cap Control Window ............................ 64 5.6 Setup Fame .......................................................................... 65 5.7 SmartWare Setup Window .................................................. 66

5.7.1 Deleting an Entry .................................................. 67 5.7.2 Modifying an Entry ................................................ 67

5.8 Hardware Configuration Window ......................................... 68 5.8.1 Voltage Constants Frame ..................................... 68 5.8.2 Power Direction Frame ......................................... 69 5.8.3 Switching Delta-V Frame ...................................... 69 5.8.4 Current Sensing Frames ...................................... 70


Copyright © 2017 QEI Contents

5.8.5 Read/Send/Exit Buttons ....................................... 71 5.9 Timing Parameters Window ................................................ 72

5.9.1 Transient Condition Delays Frame ....................... 72 5.9.2 Switch Operation Timing Frame ........................... 72 5.9.3 Capacitor Discharge Inhibit Frame ....................... 72 5.9.4 Anti-Oscillation Inhibit Frame ................................ 73 5.9.5 Inside Temperature Calculation Frame ................ 73

5.10 Holidays Window ................................................................. 74 5.10.1 Holidays List ......................................................... 75

5.11 Neutral (Neutral Current Detection) .................................... 76 5.12 Identification Window ........................................................... 79

5.12.1 Unit Id Number ...................................................... 79 5.13 SmartMemo .......................................................................... 79 5.14 Temperature Units ............................................................... 79 5.15 Calibration ............................................................................ 80 5.16 Reset .................................................................................... 80 5.17 SmartView Window .............................................................. 81

5.17.1 Electrical Conditions Frame .................................. 81 5.17.2 Date-Time Frame .................................................. 82 5.17.3 SmartMemo Frame ............................................... 82 5.17.4 Control Parameters Frame ................................... 83

5.18 Operating Procedures .......................................................... 84 5.19 Additional Help ..................................................................... 84

6. SCADA Communications .......................................................85 6.1 Installing a Radio.................................................................. 85

6.1.1 Universal Radio Mounting Plate ........................... 86 6.2 Radio Power Supply ............................................................. 86 6.3 RS-232 Port Connections .................................................... 87 6.4 RS-232 Cables ..................................................................... 88 6.5 Communications Board........................................................ 90

6.5.1 Jumpers - Factory Configuration .......................... 90 6.5.2 TX / RX LEDs ...................................................... 91 6.5.3 Setting the Baud Rate .......................................... 92

6.6 Radio Interface Board .......................................................... 92 6.6.1 DB9 RS-232 Cable: .............................................. 94 6.6.2 DB25 RS-232 Cable: ............................................ 95

6.7 Antenna ................................................................................ 95 6.8 Local/Remote Front Panel Switch ....................................... 96

7. SCADA Override (optional) ....................................................96 7.1 Introduction .......................................................................... 96 7.2 Relevant DNP Points ........................................................... 98 7.3 Algorithm Programming Considerations .............................. 98

7.3.1 “VCor” and “Learn Mode” ...................................... 98 7.4 Algorithms .......................................................................... 100

7.4.1 Example #1 ......................................................... 100 7.4.2 Example #2 : ....................................................... 101

8. DNP3 Device Profile w/Point List ........................................103

9. CAP-9040 Communications Upgrade Kit ...........................115 9.1 Preparation ......................................................................... 115


iv Contents Copyright © 2017 QEI

9.2 Power Supply Installation ................................................... 116 9.3 SCADA Comm. & Radio Interface Board Installation ........ 118


Copyright © 2017 QEI Introduction 5

1. Introduction

The eCAP-9040 is part of QEI’s family of Capacitor Bank Controllers. Although it still performs the same functions as the QEI “MiniCap” and “MicroCap”, the eCAP adds a SCADA communications port, and can support a variety of communications hardware (data radios, modems, etc.). Communications equipment may be mounted inside the eCAP enclosure, which saves on installation costs. All analog, status, and control points are remotely accessible via DNP3 communications protocol. Other protocols are available.

Like the MCAP family, the eCAP is designed to monitor any combination of AC voltage, current, watts, vars, power factor, time, date, day-of-week, holiday, or temperature. eCAP will automatically switch a capacitor bank in to or out of the circuit depending on the conditions observed. (Note: current, watts, vars, phase angle, and power factor monitoring require a customer-supplied Line Post Current Sensor or Current Transformer. The sensor is not required for voltage, time/date/day-of-week/holiday, or temperature monitoring.) There is no need to buy or inventory separate units based on monitoring requirements. One eCAP unit does it all.

eCAP makes switching decisions by measuring or calculating values such as voltage, current, watts, vars, power factor, time-of-day, day-of-week, date, holiday, temperature, etc. (eCAP contains a battery-backed time of day clock/calendar and a temperature sensor as standard equipment.) Monitored (or calculated) values are then compared against a list of user configured switching conditions (algorithms) that are set in the controller. A list of up to 10 switching conditions for each Cap Bank switch position (OPEN or CLOSED) can be created.

The eCAP keeps historical information in non-volatile memory. It maintains an operations log and a history of the measurements taken of the monitored circuit. The measurement history is optionally saved as 1, 2, 5, or 15 minute averages. Enough information is saved so that a complete operating history is available.

eCAP can be set up and operated via a serial link to a typical laptop computer (or other PC), running QEI=s ASmartWare@ program This program is also used to

retrieve and examine the historical data stored by the controls. The program allows the data from multiple controls to be saved and viewed.

The eCAP front panel has an AAuto/Manual@ switch and an AOpen/Close@ switch.

Three LED indicators are included. A yellow LED indicates Auto Mode (LED is on or blinking) or Manual Mode (LED is off). A red LED indicates that the Cap Bank is CLOSED (red LED is on), or a CLOSE operation is pending (red LED is blinking). A green LED indicates that the Cap Bank is OPEN (green LED is on), or an OPEN operation is pending (green LED is blinking).

A panel mounted 9 pin female RS232 connector allows the eCAP to be connected to a laptop (or any PC with a standard 9-pin serial port) using a standard one-to-one 9-pin serial port cable. A switch labeled “Remote/Local” is used to place the eCAP under control of a laptop PC (Local) or under SCADA control via DNP3 through communications hardware (Remote). Two red LEDs indicate data transmit/receive (Tx/Rx) when the switch is in the “Remote” state.


6 Introduction Copyright © 2017 QEI

Special QEI SmartWare software, installed on a laptop (or other) computer, is used for editing all of the configuration settings, as well as for historical data retrieval. eCAP configuration settings are also accessible remotely via SCADA communications, or locally via front panel switches and LCD display.

Internal timers and logic in the eCAP protect user and equipment from undesired and non-secure operations. Using timers and logic, the controls can prevent unsafe operations. Internal timers also allow the user to initiate local operations and leave the vicinity of the control before the switching operation occurs.

Latest new features in the QEI eCAP-9040 include local voltage override capability for SCADA, and expanded neutral current detection features that provide local automatic functions.

1.1 Definitions

Below is a list of special terms that are used throughout this user=s guide:

Switching Algorithms. The internal control schemes that the controller uses to determine whether to switch the cap bank opened or closed. These control schemes are programmed into the controller by the user, through the eCAP

front panel switches or using QEI’s SmartWare software to enter them into the controller via its front panel RS-232 port.

SmartWare. This is a PC based program that is used to setup, operate, and interrogate the eCAP.

Window. A window is the display element that is used to transmit information to the operator / user. It is a rectangular area of the screen with border around it. It has a top line with a title and may have a bottom line separated into individual communication areas called Panels.

Frame. A frame is a subsection of a window. Frames normally contain groups of information that are logically related.

Panel. A panel is an optional area at the bottom of a window that is contains information relating to the entire window. The bottom line may contain several panels.

Data Entry Box. When a box like the one shown appears, the user can enter a value into the box. The number entered becomes the value of the parameter.

Selection Window. When a data entry box like the one shown is present, this indicates that there are a number of fixed selections that the user can make using the box. By selecting the arrow, the list of available selections is shown. If the user clicks on one of the selections, it becomes the value of the box.


Copyright © 2017 QEI Introduction 7

1.2 Specifications

1.2.1 Size

Height 12", Width 10", Depth 7.5"

1.2.2 Temperature Sensor

0 to 140F (-15 to 60C)

1.2.3 Operation Counter

Internal software counter and optional electro-mechanical counter

1.2.4 Current Sensor

Line Post Sensor or a Current Transformer (neither are included with the control)

1.2.5 Capacitor Switch Relays

Electro-mechanical relays rated at 20 amps continuous duty at 240 VAC.

1.2.6 Supply Voltage

120 VAC or 240VAC. The supply voltage is also used to sense the line voltage.

1.2.7 Line Frequency

50 Hz or 60 Hz

1.2.8 Switching Condition (algorithm) Storage

10 Close steps and 10 Open steps

1.2.9 RMS Value Measurement

True RMS values are calculated through rapid and simultaneous voltage and current sampling.

1.2.10 Power Consumption

2 VA, not including communications transceivers (data radio, modem etc.).

1.2.11 Historical Data Storage

The average of all electrical parameters is saved on a 1-minute interval (13 days), 2-minute interval (26 days), 5-minute interval (65 days), or 15-minute interval (196 days).


8 Introduction Copyright © 2017 QEI

1.2.12 Environment

-40F to 149F (-40C to 65C) Temperature; 95% Humidity (non-condensing)

1.2.13 Case

NEMA 4 rated, weatherproof outdoor type.

1.2.14 Switching Algorithms

Capacitor bank is switched on any combination of the following parameters: Voltage, Current, VARs, Watts, Power Factor, Temperature, Time, Date, Day-of-Week, Holiday.

1.2.15 Radio/Modem Dimensions

Height 7” max. X Width 6” max. X Depth 1.5” max. Radio and antenna are not supplied by QEI. The customer can choose.

1.2.16 Radio/Modem Power Supply

A power supply is included in the eCAP, and can be used to provide power for a radio or a modem.

Input: 90-264VAC 50/60Hz.

Output: +12Vdc @ 2.5 Amps.


Copyright © 2017 QEI 9

2. Installation

2.1 Making Connections

The diagram below shows how to connect the eCAP to the capacitor bank switches, the 120VAC transformer, the line post current sensor, and Neutral Current CT. The 120VAC transformer furnishes the power to the eCAP and also serves as the voltage sensor for the control.

2.2 Grounding

Proper grounding is critical when wiring a QEI eCAP. The neutral of all elements (the capacitor switches, the 120VAC transformer, the Line Post Sensor and Neutral Current CT) should be connected to a common point in a junction box on the pole near the top of the pole. A separate ground wire should run down the pole to a

ground rod driven into the soil at the base of the pole. The earth ground must not be

connected at or through the eCAP. The diagram on the next page illustrates the correct method of connecting the eCAP and grounding.


10 Installation Copyright © 2017 QEI

2.3 4-Wire System Installation

The installation block diagram for a 4-Wire system is shown below. Please note the following installation guidelines for proper installation of the eCAP units on a 4-Wire system.

The placement of the LPCS (Line Post Current Sensor) must be located in between the Source and Capacitor Bank for proper electrical VAR sensing.

All components must be star grounded at the Neutral Support Point shown in the 4-Wire System Installation Pictorial Diagram below.

Voltage and Current signals should come from the same phase on a 4-Wire System in order for the eCAP to indicate correct electrical value readings. If this is an inconvenience, please consult the factory for recommendations.

4-Wire System Block Diagram


Copyright © 2017 QEI Installation 11

4-Wire Installation Pictorial



2.4 3-Wire System Installation

The installation block diagram for a 3-Wire system is shown below. Please note the following installation guidelines for the eCAP units on a 3-Wire system.

The placement of the LPCS (Line Post Current Sensor) should be located in between the Source and Capacitor Bank for proper electrical VAR sensing.

It is recommended that the customer place the LPCS on the untapped phase. This LPCS setup allows the customer to use a known phase shift (90o) of the current and voltage signals without knowledge of the rotation of the system. The customer may use either of the tapped phases if the rotation of the

system is known. This will only apply to customers using current

sensors. For example, if supply voltage on the control were applied from A Phase and B Phase, the customer would place the LPCS on the C Phase.

3-Wire System Block Diagram



3-Wire Installation Pictorial



2.5 Line Current Measurement

A Fisher-Pierce Series 1301 LPCS, 1701 LPCS or Lindsey 9600 Series LPCS with a 600 amp: 10-volt output, or a 5-amp CT secondary are used to sense line current. The output from this device is monitored directly by the eCAP control unit.

NOTE: Please indicate whether the sensor is a true CT or a current-to-voltage type sensor when ordering. Some manufacturers manufacture both true CT sensors and current-to-voltage sensors. It is absolutely necessary that the customer indicate which one will be used. Using a different sensor than what is specified for our controls may cause damage to the unit.

WARNING: Do not connect a CT to a unit labeled with a LPCS (Line Post Current Sensor) Only Sticker. Also, a LPCS cannot be connected to a unit with a CT only sticker. Failure to follow the unit’s markings may result in unit damage.

WARNING: When disconnecting CT’s, make certain that all shorting procedures are followed prior to disconnection. Failure to follow this may result in damage to the unit and/or personal injury or death.

2.6 Neutral Current Measurement

A Current Transformer is used to sense neutral current. Maximum input to the eCAP for neutral current is 6 Amps from the current transformer. Please note that a line

post current sensor cannot be used for neutral current sensing.

WARNING !!!

CURRENT TRANSFORMER (CT) OUTPUT LEVELS CAN BE DANGEROUSLY

HIGH WHEN DISCONNECTED FROM THE eCAP. EXERCISE EXTREME CARE

WHEN HANDLING CURRENT TRANSFORMER CONNECTIONS.



2.7 Meter Socket Mounting

Meter Socket mounted units are available in 5 socket configurations as shown in the figure below. Inspect the eCAP unit and verify that the unit matches the available socket. Consulting the sticker on the inside of the unit cover does this. (The views below are looking into the meter socket.)

Units are secured in place with a lock collar to prevent the eCAP from being removed from its socket by unauthorized personnel.

WARNING !!!






2.8 Pole Mounting

Pole mount units are fastened to a flat surface using four corner bolts or to a pole using a standard mounting plate. These units are shipped with an optional cable terminated at one or both ends with seven pin circular AMPHENOLJ connectors. For

cables terminated at one end, the other end of the cable is 6 un-terminated wires. The functions and color code of the un-terminated wires are listed below:

WARNING !!!



WHEN HANDLING THE P CONNECTIONS TO A CURRENT TRANSFORMER.

WARNING !!!






2.9 Terminal Strip Mounting

A barrier-type .375 spacing terminal strip is provided, with #5-40 x 3/16" L screws which will accommodate fork or ring-type wire crimp lugs. Drilling an access hole at the bottom of the enclosure, and bringing wiring in through the hole makes attachment. The two knurled screws, which secure the hinged front panel of the eCAP, must be turned counter-clockwise to gain access to the terminal strip for attachment of the wiring. A cord-grip connector (not supplied) is typically used to provide a strain relief and watertight connection for wiring entering at the bottom of the enclosure.

2.10 Environmental Considerations

To maintain the environmental integrity of the control enclosure, it is important that the control be mounted right side up so that any openings for connectors and temperature sensors are underneath the control. Opening the control and looking at the control itself can easily determine the top of the control.

WARNING !!!



WHEN HANDLING THE P CONNECTIONS TO A CURRENT TRANSFORMER.


18 Operation Copyright © 2017 QEI

3. Operation

3.1 Front Panel Layout

The following two pages show the location of all front panel switches, indicators, and controls. A description of each item appears on the following pages.

Front Panel Layout Pictorial


Copyright © 2017 QEI Operation 19

# ITEM DESCRIPTION

1 Display Contrast This control is used to adjust the contrast on the LCD Display. Turning the control clockwise makes the display contrast darker.

2 Two Line LCD

Display

This 2 line x 16-character display is used for a number of functions. It is used to enter switching algorithms, review and set configuration items and parameters, and to view actual operating conditions. The function of the display depends on the menu item selected. For more detailed information, consult the description of menu item functions.

3 Modify Up/Down

Switch

This switch has several uses: When on a non-numeric item, it is used to select the desired value. When on a numeric item, it increments or decrements the underlined digit.

4

Switch

This switch is used to multiply or divide a numeric value by 10 thereby shifting the value one digit to the left or right. This switch in conjunction with the Modify Up/Down switch is used to enter numeric values.

5 Select Right/Left

Switch

This switch has two uses: When the main menu is displayed, this switch moves forward and backward to the main menu items. When a submenu item is displayed, this switch moves forward and backward through the submenu elements.

6 Select Menu/Item

Switch

This switch is used to navigate around the eCAP menu. SELECT MENU always returns to the current main menu item. SELECT ITEM displays the data from the submenu of the current main menu item. If there are multiple sub items, successive operation of the SELECT ITEM key displays the additional items. In the case of the “Switches Open” and “Switches Closed” submenus, additional operation of the SELECT ITEM key, displays the next step in the switching algorithm.

7 Operations Counter (Optional) A non-resetting front panel mounted electromechanical counter keeps track of the number of OPEN operations of the capacitor bank switch. The eCAP also has a firmware based operations counter.

8 Operating Mode

LED

A yellow LED to the left of the AUTO switch indicates if the control is in auto or manual mode as follows:

ON (Continuous): Auto - Auto mode ON (blinking): Auto - Remote mode OFF: Manual mode

9 Auto/Manual Switch This switch in combination with an attached computer sets the operating mode of the control. There is additional information about the operating modes later in this user guide.



# ITEM DESCRIPTION

10 Close/Open Switch This switch is used in Manual mode to switch the capacitor bank onto or out of the line. There are a number of delays that govern the actual switching of the capacitor bank. See the Manual Operation and Automatic operation sections for a more detailed description of these delays.

11 Capacitor Bank

Switch State LEDs

These Red and Green LEDs adjacent to the Close/Open switch indicate the state of the capacitor bank switch:

Red LED On - The capacitor bank is CLOSED (connected to the power line).

Red LED Blinking – A CLOSE operation is pending. The capacitor bank will be CLOSED after any delay timers have expired.

Green LED On - The capacitor bank is OPEN (disconnected from the power line).

Green LED Blinking – An OPEN operation is pending. The capacitor bank will be OPENED after any delay timers have expired.

12 RS232 Connector This 9-pin female D-sub connector is used to connect the eCAP to a laptop computer. The computer uses QEI’s “SmartWare” program to communicate with the eCAP. The SMARTWARE program is described in a later section of this manual.

13 Line, Neutral,

Current, +12VDC,

Common

Test Jacks

These terminals are used connect the control to a meter that is used in checking the control. A multimeter set to 200VAC scale between the NEUTRAL and VOLTAGE test points measures the actual AC line voltage. A multimeter set to 20 VAC scale between NEUTRAL and CURRENT measures the actual output of the line post sensor (current) input to the controller.

14 Temperature Sensor An optional external temperature sensor is mounted near the bottom of the eCAP. The sensor allows for the unit to switch the Cap Bank OPEN or CLOSED based on environmental temperature.

15 Local/Remote

Switch LOCAL - When the switch is in this position, a laptop

PC can be connected to the front panel RS232 port to configure, monitor, or control the eCAP (Using QEI’s “SmartWare” software.)

REMOTE – When the switch is in this position, the eCAP is monitored and controlled via SCADA communications (through a data radio, modem, fiber etc.) The front panel RS232 port is disabled when the switch is in this position.

16 TX/RX LEDs These LEDS indicated SCADA communication status. TX= data transmitted from the eCAP. RX= data received by the eCAP.



3.1.1 Fuses and Fuseholders

There are three fuses associated with the eCAP. A 10 Amp AGC type 1-1/4 inch cylinder fuse (QEI No. 10-003669-039) is located in the front panel fuseholder (item 17 in the front panel pictorial). Another fuse is a ¼ Amp 5 x 20mm slo-blo type fuse (QEI No. 10-003669-044, Littlefuse 218.250) on the lower (larger) printed circuit board located underneath the front panel. If the control were inoperative, one of the first steps would be to verify that either of these fuses is not blown. A third fuse is a 2 Amp 5 x 20mm located on AC input of the internal +12VDC radio power supply. Both of the 5 x 20mm fuses are accessed by opening the hinged front panel of the eCAP.

3.1.2 Battery

Each of the two eCAP circuit boards has a +3 VDC lithium battery installed. The batteries maintain the clock, and trending (historical data) memory, when power is removed from the eCAP. The circuit boards are accessed by opening the hinged front panel of the eCAP, so that the rear of the front panel is viewed. On the lower (larger) circuit board , there is one battery labeled B1, and it is installed in the upper left corner of the board. The second battery is located on the upper (smaller) printed circuit board. This battery is labeled BH1 and is located in the upper right corner. The maximum life expectancy of the lithiums in-circuit is 4 years. Customer may request

for replacement from the factory. Do not substitute with different model number. The manufacturer and model of the batteries is indicated below.

Manufacturer: Renata

Model Number: CR1225

3.1.3 Clock

The eCAP has an internal clock for time keeping when switching is based on Date,

Time, or DOW (day of the week). Another function of the clock is as a reference to keep track of trending (historical) data.

The eCAP’s internal clock has been tested and passed for Year 2000 compliance

and will adjust for Leap Years. The internal clock will not adjust for Daylight

Savings time. The clock is kept running at all times by the lower internal 3 VDC lithium battery.



3.2 Programming an eCAP for Operation

Before being placed into service, the eCAP must be configured.

The eCAP has a front panel RS-232 port, which can be connected to a laptop PC (with QEI’s “SmartWare” software installed and running on the PC) for configuration

of all operating parameters (see the “SmartWare” software section of this user guide.)

Additionally, the eCAP has a Hardware Interface, which is a set of four toggle switches and an LCD Display. The Hardware Interface can be used to set up many of the operating parameters directly from the front panel, without the use of a computer. This may allow for easier set up in the field.

The following MENU SUMMARY table contains a listing of all eCAP Hardware Interface Menus and sub-Menus. Information about each item can be found in the OPERATION section of this guide, under “eCAP MENU DESCRIPTION”.



3.3 Menu Summary

Menu Item Submenu Item Format Comments

eCAP vXXX-XX

LLPS 0 - 270 Amps

Startup Banner, appears at power up.

Switches Open Open[0] T F VCor < 120.5 O C

Successive steps selected by operating the “SELECT ITEM”

switch.

Switches Close Close[0] T F Volt < 120.5 O C

Successive steps selected by operating the “SELECT ITEM”

switch.

Switch Delays Delay Close Open Sec 10 10

Used to view and alter these parameters

Date Date Yr Mo Da is 01 01 12

Used to view and set the date

Time Time Hr Mn Wk is 22 45 3

Used to view and set the time

Config Constants Volts Amps Deg 7200 60 0

Displays configuration constants that are set through “Smartware”

Operating Mode Comm Local Auto Manual

Status only

Unit ID Unit ID Number 1342

Used to view and set this parameter

Temperature Amb Indoor Lag 77 73 30

See the text for a complete description

Switch Status Status Pending Close Open

Status only

Operations Count Operations Count 321

Used to view and set this parameter

Switching V-Hyst Learn ClsV OpnV Yes 2.6 2.0

Used to view and set these parameters

Voltage, Current Volts VCor Amps 122.4 120.4 73

Status only

kW, kVAr, PF kWatt kVAr PF 3156 -327 93

Status only



3.4 eCAP Setup via Front Panel Switches

The eCAP front panel menu interface consists of 4 control toggle switches, 2 operating mode-related switches and an LCD display. The control toggle switches are shown below. Each control switch is divided in one of two groups: Select and Modify.

3.4.1 eCAP Menu Interface Switches

Selecting

The Select group includes the controls used to traverse the menus on the LCD display. The MENU/ITEM and RIGHT/LEFT toggle switches are classified under this group. A Flow Diagram of all the possible menu options is shown on the next page.

Selecting the MENU of the MENU/ITEM switch returns the display to the present menu option.

Selecting the ITEM of the MENU/ITEM switch enters the menu item field display of the LCD.

RIGHT rotates through all the menu options in one direction. It will also move a cursor when available to the right by one.

LEFT rotates through all the menu options in the opposite direction of RIGHT toggle switch. It will also move the cursor when available to the left by one.



Modifying

The MODIFY group includes the controls used to alter the field conditions of

the menu items indicated on the LCD display. The UP/DOWN and 10/10 toggle switches are under this group.

Selecting UP of the UP/DOWN switch increments the adjustable field conditions up by one.

Selecting DOWN of the UP/DOWN switch increments the adjustable field conditions down by one.

10 (Multiplier 10) multiplies the numeric value indicated above the cursor by 10 or 1 decimal place to the right.

10 (Divider 10) divides the numeric value above the cursor by 10 or 1 decimal place to the left.

NOTES

*Both the UP/DOWN and 10/10 only affect adjustable field conditions.

*The 10/10 only affects numeric field conditions.

Along with the 4 control toggle switches listed on the previous page, the eCAP also includes 2 more mode-related switches located at the bottom left side of the front panel. The first, labeled Auto/Manual, sets the capacitor to the switching mode desired by the user. The second switch, labeled Open/Close, opens or closes the capacitors under only Manual Mode.



3.4.2 Menu Description

The Menu Flow Diagram (shown below) lists all menu options available to the user. The listings in the 2 central columns are titled menu options. The two outer column listings are titled menu items. The top row headings in the menu items are titled fields. The bottom row listings in the menu items are titled field conditions. All of the above terms will be used for the remainder of this operating manual.



3.5 eCAP Menu Description

What follows is a description of all menus and sub-menu items that can be accessed via the eCAP Menu. For the following sections, the menu options and their associated items require the user to be familiar with a few terms. Menu options are categorized as either a Condition Status or Adjustable.

Condition Status. The LCD Display conveys information from the controller.

Adjustable. The LCD Display indicates the present settings of the controller and will also allow the user to change the settings manually through the

hardware interface switches.

3.5.1 Start-up Banner

This starting menu item is displayed when the unit first starts and whenever the switches have been idle for some time. It identifies the unit as an eCAP, firmware version, the current sensor (LLPS - Lindsey Line Post Sensor, FLPS - Fischer-Pierce Line Post Sensor, CT - Current Transformer), and the range of the current sensor.

eCAP vXXX-XX LLPS 0 - 270 Amps

3.5.2 Voltage, Current (Condition Status)

Selecting this item allows the user to monitor the following real-time electrical parameters:

Voltage. PT level:120VAC Nominal

VCor (Voltage w/ Correction). Details in section titled Switch V-Hyst

Current. Single Phase

Shown below is an example of the LCD display under this item:

Volt VCor Cur 119.3 120.3 119

3.5.3 KW, kVAr, PF (Condition Status)

This menu option lets the user monitor the following real-time electrical parameters:

Kilowatts. Single Phase kWatt 3

KiloVARs. Single Phase kVAr 3. Negative value (-) equals leading, otherwise lagging

Power Factor. In percent units.

Shown below is an example of the LCD display in this item:



kWatt kVAr PF 2555 -105 100

3.5.4 Switches Open, Switches Closed (Adjustable)

The Switches Open and Switches Closed is the core of the eCAP control logic determining the course of action in regards to switching the capacitor bank ON or

OFF the line. The Switches Open item is used by the eCAP to decide its course of

action while the status of the Cap Bank switch is OPEN. The Switches Closed item is used by the eCAP control to decide its course of action while the status of the Cap

Bank switch is CLOSED. Up to 10 steps each can be programmed into both the

Switches Open and Switches Close items. There are five fields per step that

include Parm, Function, Value, True, and False.



Parm This sub-field indicates what parameter status condition to base its decision on for the present step. The parameters include:

Voltage

Current

kWatts

kVAr

PF (Power Factor)

Temperature

Date

DOW (Day of week)

Time

VCor (Voltage with Correction)

Function. This sub-field indicates the equality condition against which the control must base the present step decision. This is used in conjunction with

the Value sub-field status condition and the Parm sub-field to form the switching logic condition for each step. Three functions are allowed in the

eCAP algorithms. These are LESS THAN (), GREATER THAN (), and

EQUAL TO (). Only the Date, Time, and DOW parameters are allowed

access to the EQUAL TO (=) equality.

Value. This sub-field is the value against which the Parm is measured and will be termed the cutoff. All values are to be integer values with exception to the VCor and Voltage. Both VCor and Voltage are allowed one decimal place. For example, the customer may user a cutoff value of 124.6 for Voltage or VCor. Below is a description for the correct value entry for each of the parameters.

Voltage. Secondary voltage value (110.0 to 150.0 volts)

Current. (+) current value up to the Max Current Limit of the unit (amps)

VCor. Secondary voltage w/ correction (110.0 to 150.0 volts)

kWatts. integer value, (+) forward, (-) reverse in kWatt units



kVArs. integer value, (+) lagging, (-) leading in kVAr units

PF. % integer value (0 to 100), (+) lagging, (-) leading

Temperature. (+) integer value (0 to 130) in Fahrenheit degree units

Date. MMDD format (integer value). Example: July 4 = 0704

Time. HHMM format (integer military time). Example: 12:23 AM = 0023, 1:23 PM = 1323

DOW. (0 to 9) 1 = Monday 2 = Tuesday 3 = Wednesday 4 = Thursday 5 = Friday 6 = Saturday 7 = Sunday 0, 8, and 9 regarded as special and used in the holiday feature. See “SmartWare” software section.

True, False. This field indicates the action to take for the present step for the

either the True or False switching logic condition. For example, if a logic step

evaluates true then action indicated under True will be initiated. The 4

actions are Open, Close, Next, and Skip:

Open indicates a pending OPEN operation.

Close indicates a pending CLOSE operation.

Next indicates the next step condition will be evaluated following the present step.

Skip indicates the next step following the present step will be skipped.



3.5.4.1 Entering the Switching Algorithms

Assume the user would like to enter the following switching algorithm.

Switches Open Switches Close

Step# T F T F

0 Volt < 124.0 N O Volt > 128.0 O N

1. Begin with the Switches Open switching set.

2. Toggle through the Menu Options with the LEFT/RIGHT switch until the

LCD displays Switches Open option.

3. Toggle ITEM and you are taken to the Switches Open item. Below is an example of the Switches Open item.

Open[0] T F Volt < 120.0 C 0

Notice the cursor under the Volt field condition. This cursor indicates where change will be made with the Modify group switches.

4. Place the cursor where change is desired, and use the Modify group switches to alter the field condition.

5. Place the cursor under the desired Field Condition with the LEFT/RIGHT switch.

6. Use the UP/DOWN key to toggle through the possible choices, and stop at the selection desired. Repeat until all field conditions are set.

7. To add another step, toggle the MENU/ITEM switch in the ITEM direction.

The bracketed field next to the Open field advances by 1. Repeat for the following step.

8. Once editing the steps under the Switches Open item is complete.

Toggle the MENU/ITEM switch in the MENU direction to get back to the option display.

9. Repeat the steps above to enter the Switches Closed set.

Additional information about switching algorithms is provided on the next page, and in Switching Algorithm Reference Guide.



The following example is a set of switching logic that forms an algorithm upon which

all actions will be decided. This is a typical algorithm known as VAR Switching with

Voltage Override.

Switches Open Switches Closed

Step# T F T F

0 Volt < 124.0 N O Volt > 128.0 O N

1 kVAr > 600 C O kVAr < - 300 O C

Suppose the following conditions: Capacitor bank is Open. Voltage is 122.9 and

kVAr is 839.

Then only the switching logic under the Switches Open heading will be evaluated.

Switches Open - Step 0 The eCAP will begin evaluation at Step 0. Observing Step 0, we find that the present voltage of 122.9 is less than the stated cutoff condition voltage of 124.0 shown in Step 0. Therefore the logic evaluates True. The step taken under True is Next, indicating that Step 1 will be evaluated. (Note: Now go to Step 1 under Switches Open) If the voltage were higher than 124.0, then Step 0 would have evaluated False. The action under False would have been to stay Open, and evaluation repeats from Step 0 under the Switches Open heading until an action is taken which would change the status of the capacitor bank.

Switches Open - Step 1 The eCAP has now advanced from Step 0 by the Next action. We see that the present kVAr of 839 is greater than 600, which evaluates True. The action taken would then be to Close the capacitor bank. Once the bank is Closed, the steps under the Switches Close heading are evaluated. If the present kVAr were less than 600, the logic would have evaluated False. The

step taken under False for Step 1 would have been to stay Open, and

evaluation repeats from Step 0 under the Switches Open heading until an action is taken.

Suppose the following conditions: Capacitor bank is Closed. Voltage is 122.9 and

kVAr is -600.

Switches Closed - Step 0 The eCAP now begins evaluation at Step 0. Observing Step 0, we find the present voltage of 122.9 is less than 128.0, which evaluates False. The action taken under Step 0 for False is to go to the Next step (Step 1 under Switches Close heading). If the voltage had been greater than 128.0 volts, the logic for Step 0 would have evaluated True. In which case, the action taken under True would be to Open the capacitor bank.



Switches Closed - Step 1 The eCAP unit having taken a Next action based on the Step 0 now begins evaluation of Step 1. Notice logic states the kVAr must be less than cutoff point of -300 to be evaluated True. It is known that the present kVAr is -600, which is definitely less than -300. The step is evaluated True, and the step taken is Open. If the kVAr had not been less than -300, Step 1 would have evaluated False. The action taken under False would have been to stay Closed. The evaluation under Switches Closed would then have repeated at Step 0 until an action is taken.

NOTES (1) It is necessary that the actions in the final step of both the Switches Close and Switches Open must either be Open or Close for both the True and False sub-fields. Under no circumstances is there to be a Next action in the last step. Doing so will cause unpredictable switching behaviors in the controls. (2) There is a safety feature in the eCAP which, if enabled, will only allow one Open or Close operation per hour (time interval is programmable). Upon 10 consecutive switching operations (number is programmable) in 10 hours (1 operation per hour, for example), the safety feature will switch the eCAP to Remote Mode. See Section 3.5.8 (Operating Mode) for more detail.

3.5.5 Switch Delay Settings (Adjustable)

The eCAP uses the Delay Settings to avoid switching caused by surges, spikes or other electrical transients. This parameter can also be used to coordinate switching

with other capacitor banks controlled by other units. The Close delay setting indicates the amount of time a switching condition must be maintained before actual

Close action. The Open delay setting indicates the amount of time an Open

switching condition must be maintained before actual Open action.

If the switching condition passes before the countdown time to switching ends, the

Delay timer will reset for the next occurrence of switching condition.

For example, suppose the following conditions and switching algorithms.

Voltage: 125.3 volts

Capacitor Status: Closed

Switches Open Switches Close

Step# T F T F

0 Volt < 118.0 C O Volt > 128.0 O C



Under the conditions and the switching algorithm shown above, no action should occur as long as the conditions hold steady at their value. Suppose a high voltage transients cause the voltage to be raised above 128.0 volt for a period of 2 seconds. This would allow enough time for the control to register a change and attempt to

Open even after the condition had passed. If the Open Delay setting were set to 10 seconds, this would require the control to wait 10 seconds and then observe the

condition for steady state. If the condition remains steady, the Open action would be

initiated. This also holds true for the Close Delay.

A good general setting for the Open and Close Delays is 30 seconds. This setting would rule out a majority of the transients and temporary conditions that would cause premature switching and ensure switching under proper conditions.

3.5.6 Date and Time (Adjustable)

These options from the main menu allow the user to read and set the capacitor

internal clock. Below is an example of the Date and Time fields.

3.5.6.1 Date

Date Yr MO Da is 02 / 06 / 22

3.5.6.2 Time

Time Hr Mn Wk is 15 : 45 3

A blinking cursor beneath the Date and Time fields indicates the current condition mode. There are three available condition modes:

Is. Indicates the present set time running in memory (Condition status)

Enter. Indicates eCAP Date or Time is ready for correction by the user (Adjustable)

Set. Writes the Date or Time to memory and begins running the clock from

correction point previously entered in the Enter mode. Once change has

been attained, the Set mode will then revert itself back to the Is condition mode.

NOTE For the “Time” Display: “Wk” = day of the week, where 1=Monday, 2=Tuesday, … 7=Sunday.



3.5.7 Config Constants (Adjustable)

Three electrical constants affect the electrical data read, displayed, and stored in trending memory. These are:

Voltage. Primary voltage

Amps. Equals the maximum measurable current divided by 3. See explanation below

Phase. Current sensor phase shift in degrees.

Example display:

Volts Amps Deg 7200 60 90

3.5.7.1 Voltage (Volts)

The Voltage constant indicates to the eCAP the primary line voltage. This value is

used in the calculation of kWatts and kVArs. This value can be defined to be any line voltage the customer wishes. Observe the example display shown above. The

7200 value under Volts indicates that the primary line nominal voltage is 7200 with respect to secondary nominal voltage of 120. This is a 60:1 ratio. If the secondary voltage displayed by the controller is 121.1 Volts, then:

Primary voltage = 121.1 60 = 7266 volts

NOTE

The Primary voltage is only used for deriving kWatts and kVAr. The Voltage

constant must be set correctly or the resulting kWatt and kVAr values will be incorrect.

3.5.7.2 Current (Amps)

The Current constant is used by the eCAP to read correct current. This value is

dependent on the maximum current set by the external SmartWare software.

NOTE The user should not change this value through the hardware interface. Allow the QEI “SmartWare software to change this value automatically based on the selected current sensor. Consult the “SmartWare” software section in this user’s guide for more information concerning this subject.

On the MCAP front panel display (see example above), this value is represented as the maximum measurable current level ( I MAX ) divided by 3. For the example display above:

I MAX / 3 = 60, and 180 / 3 = 60 ; Therefore, I MAX = 180 Amps



It can be seen from this calculation that the maximum measurable current level in the example display above is 180 Amps.

Based on the industry standard ratio of 1 Volt = 60 Amps, a current sensor for the example above, must have an output of 3 Volts @ 180 Amps.

As another example, say that the Config constants are as follows:

Volts Amps Deg 7200 120 90

For the example display above:

I MAX / 3 = 120, and 360 / 3 = 120 ; Therefore, I MAX = 360 Amps

It can be seen from this calculation that the maximum measurable current level in the example display above is 360 Amps.

Based on the industry standard ratio of 1 Volt = 60 Amps, a current sensor for the example above, must have an output of 6 Volts @ 360 Amps.

3.5.7.3 Phase (Deg)

The Phase constant is used by the eCAP to compensate for the phase shift of different manufacturer’s current sensors. The phase shift unit associated with this value is in degrees.

The following list includes several manufacturers, their associated current sensor

model, and the Phase shift (in degrees) necessary for that particular sensor.

Manufacturer Sensor Model Degrees Phase Shift System

Standard CT X amps: 5 amps 0 4-Wire

Fisher-Pierce Series1301 LPCS 104 4-Wire

Fisher-Pierce Series1701 LPCS 90 4-Wire

Lindsey 9600 Series LPCS 0 4-Wire

NOTE The Phase shift must be set correctly or the resulting kWatt, kVAr and PF trending data and eCAP display will be incorrect.

3.5.8 Operating Mode (Condition Status, Adjustable)

The Operations Mode item indicates the point of control of the unit. The term point of control refers to where the commands to initiate the OPEN and CLOSE actions originate: software or hardware? Two fields are used to refer to the point of control.



The first field titled Comm is used to indicate the point of control from the software side whether it be from the firmware or the external “SmartWare”. This field is only relevant when the AUTO/MANUAL switch is set on AUTO. Otherwise it is disregarded until at some point in time the AUTO/MANUAL is set on AUTO.

The second field titled Local is used to indicate the point of control from the hardware side. This field is only relevant when the AUTO/MANUAL switch is set on MANUAL. Otherwise it is disregarded until the AUTO/MANUAL switch is set on MANAUL.

From the two fields, four points of control (modes) are available to user.

MANUAL

AUTO-AUTO

AUTO-TEST

AUTO-REMOTE

3.5.8.1 Manual Mode

The MANUAL mode indicates the eCAP is NOT using its internal logic to evaluate

and initiate action (OPEN and CLOSE) of any sort. All actions to be initiated must be

done through the manual OPEN/CLOSE toggle switch by the user. This mode

corresponds to the AUTO/MANUAL switch in the MANUAL position, and it is the only

mode that can be access directly through the hardware AUTO/MANUAL switch. Shown below is an example of the eCAP display under this mode. Note that the

Comm field is to be ignored under this mode. Only the Local field condition is of relevance.

Comm Local Auto Manual

Manual Mode Tutorial This section describes the operation of the eCAP using the OPEN/CLOSE switch on the front panel, when the AUTO/MANUAL switch is set to MANUAL. There are a number of inherent delays built into the controller firmware that govern the operation of the control. These delays are explained in the section below.

1. Place the control in its MANUAL mode by placing the AUTO / MANUAL switch in the MANUAL position. When this is done the yellow LED will turn off.

2. The Red and Green LEDs next to the CLOSE / OPEN switch show the current position of the capacitor bank switch.

3. If the capacitor bank is connected to the line, the Red (Close) LED is on. In this case, the capacitor bank can be removed from the line by operating the CLOSE / OPEN switch to its OPEN position.

4. When this is done, the Green (Open) LED will begin flashing. This



5. Indicates that an OPEN operation is pending. There is a delay built into manual operations to allow the operator to move away from the capacitor bank if desired. The delay is 20 seconds for an OPEN operation and 4 seconds for a CLOSE operation.

6. When the delay expires, the eCAP will cause the capacitor bank switches to OPEN, disconnecting the capacitor bank from the line.

7. When the eCAP senses that the capacitor switches are open, the Green LED will stop flashing and turn on continuously, and the Red LED will turn off.

8. At this point if the operator wishes to reconnect the capacitor bank to the line, the CLOSE / OPEN switch must be operated to the CLOSE position.

9. When this is done, the Red LED will begin flashing. This indicates a pending Close operation. In this case, the Close operation will not happen for 5 minutes. There is a 5-minute delay built into the controller for all Close operations occurring immediately after an Open operation. The reason for the delay is that when the capacitor bank was removed from the line it retained an electrical charge. The capacitor bank must be allowed to discharge before it is reconnected to the line. If this does not happen, equipment damage and/or injury to the operator may result.

10. If the capacitor bank has been disconnected for 5 minutes or longer before the Close is requested, the 5-minute delay is not necessary and does not happen, however, there is still a 4 second delay to allow the operator to move away from the control and capacitor bank. The eCAP remembers when the capacitor bank was last disconnected from the line (regardless of the operating mode when it was disconnected) and always allows a minimum of 5 minutes to elapse before allowing reconnection of the capacitors to the line.

11. When the delay expires, the capacitor bank is reconnected to the line. The Red LED will stop flashing and turn on continuously, and the Green LED will turn off.

The Capacitor Discharge delays operate in addition to above delays. This means that if the bank was recently switched out of the circuit, the eCAP will wait 5 minutes instead of 4 seconds to reclose the capacitor bank switches

3.5.8.2 Auto-Auto Mode

The AUTO-AUTO mode indicates the eCAP is using its internal logic to evaluate and initiate action (OPEN and CLOSE) based on the switching algorithms entered by the user. This mode is only relevant when the AUTO/MANUAL switch is in the AUTO position and is one of three Auto modes that can only be initiated with the AUTO/MANUAL switch in the AUTO position. While under this mode, the user will not be able to manually initiate any actions with the OPEN/CLOSE switch. Shown below is an example of the eCAP display under the AUTO-AUTO mode. Note that



the Local mode field is to be ignored, as it is not of relevance as long as the Local condition indicates AUTO.

Comm Local Auto Auto

In addition to the Transient Delay Timer, switching actions initiated by the

control under the AUTO-AUTO mode are governed by the following set of inherent safety features:

5-Minute Open-to-Close Delay Timer. Prevents transients caused by switching in a charged capacitor bank. This feature prevents the capacitor from closing until five minutes after the last OPEN operation. (The time is programmable for 5 or 10-minutes through “SmartWare”).

1-Hour Anti-Oscillation Timer. This feature prevents switching from occurring more than once per hour (time interval is programmable through “SmartWare”).

Decade AUTO-REMOTE Mode Switchover Counter. Used in conjunction with the anti-oscillation timer above, the eCAP switches itself automatically to

the AUTO-REMOTE mode after counting (for example )10 consecutive switching operations within 10 hours (number of times/hours is programmable through “SmartWare”). This feature prevents “hunting” caused by improper

logic in the switching algorithm. Proceed to AUTO-REMOTE mode description for further information.

NOTE

Under this mode the user will not be able to use the manual OPEN and

CLOSE toggle switches located on the center portion of the eCAP front panel.

3.5.8.3 Auto-Test Mode

The AUTO-TEST mode indicates the eCAP is using its internal logic to evaluate and initiate action (OPEN and CLOSE) based on evaluation of the switching algorithms entered. This is one of three Auto modes that is relevant and can be initiated only with the AUTO/MANUAL switch in the AUTO position. Once in the AUTO position, the control unit can only be in one of the three modes. While under this mode, the user will not be able to manually initiate any actions with the OPEN/CLOSE switch. With exception to the 1-Hour Anti-Oscillation Timer, which is disabled, the AUTO-TEST mode acts the same as the AUTO-AUTO mode. All other inherent times and safety features are observed. Shown below is an example of the eCAP display under this mode. Note that the Local mode field is to be ignored, as it is not of relevance as long as the Local condition indicates AUTO. Enabling this mode requires the use of SmartWare through the SmartView menu. See SmartWare section of this manual.

Comm Local Test Auto



The AUTO-REMOTE mode indicates the eCAP is under the control of another intelligent device or system.

Essentially, the eCAP itself becomes a dumb-switch.

With the control set to AUTO-REMOTE, the eCAP will NOT use its internal logic to evaluate and initiate action (OPEN and CLOSE) based on switching algorithms entered by the user.

With the control set to AUTO-REMOTE, the user will NOT be able to initiate any actions using the OPEN/CLOSE switch.

This mode is one of three Auto modes that can only be initiated with the

AUTO/MANUAL switch in the AUTO position. Only one of the three can be the point

of access at any one time with the AUTO/MANUAL switch in the AUTO position.

This eCAP uses the AUTO-REMOTE mode in one of two possible functions.

The first is a residual effect of the 1-Hour Anti-Oscillation Delay Timer

safety feature. The AUTO-REMOTE mode is enabled by the eCAP after 10 consecutive switching operations in 10 hours (1 operation per hour) under the

AUTO-AUTO mode. This means the AUTO-AUTO mode is disabled. In this

way the REMOTE mode then acts as a safety feature to prevent ”hunting” or

oscillation of the capacitor banks caused by a logically faulty switching algorithm.

The second function is to act as a switch point for an intelligent device or

system such as SCADA to be controlled remotely, hence the term REMOTE. All actions are then initiated through the controlling system. The controlling system also has the ability to retrieve any information stored in the eCAP unit.

Such information would include the real-time based electrical (voltage,

current, kW, etc…) and non-electrical parameters (temperature) and trending data.

Once AUTO-REMOTE mode is enabled, the eCAP can only be switched manually under 1 of the following 2 conditions: The first condition is that the user toggles the AUTO/MANUAL switch back to MANAUL at the location of the eCAP. The second condition is that the customer uses the SmartWare interfacing software via a communications link such as a serial cable or a modem to initiate a switching operation. (See SmartWare section of this manual.) Either of these two conditions will then allow the customer to manually switch the capacitor bank.



Shown below is the Operating Mode item on the LCD under the AUTO-REMOTE mode.

Comm Local Remote Auto

3.5.9 Unit ID (Adjustable)

The user is allowed to enter any value from 0 to 9999 as an identification number in this item. The SmartWare interfacing software uses this value when downloading data for each specific unit. All units must have a distinct number. It is recommended

that the customer use the Serial Number located inside the lid of the control unit.

3.5.10 Temperature (Condition Status, Adjustable)

This item displays three fields and their associated field condition shown below.

Ambient : numeric : Condition status

Indoor : numeric : Condition status

Lag : numeric : Adjustable

Ambient. This is the temperature as recorded by the optional temperature sensor located on the bottom of the eCAP.

Indoor. This is a calculated temperature as would be found inside an unheated (or uncooled) building. This value is calculated using the ambient

temperature and the lag time constant. The Indoor temperature will trail the

Ambient temperature by the Lag time constant.

Lag. This adjustable value is the number of minutes it will take the temperature inside an unheated (or uncooled) building to reach the ambient

temperature. The Indoor temperature is used in all switching algorithms. If switching on the ambient temperature is desired, set the lag constant to zero.

Shown below is a sample LCD display.

Amb Indoor Lag 89 90 2

3.5.11 Switch Status (Condition Status)

Two title headings are shown in this item indicating the condition status of the capacitor switch.

Status. Indicates the present status of the capacitor bank. Open or Close

Pending. Indicates a pending operation to occur. Open indicates open

operation pending when the status of the bank is Close. Close indicates

close operation pending when the status of the capacitor bank is Open. A

blank field condition indicates NO pending operation is about to occur.

Status Pending Open



3.5.12 Operations Count

This counter tracks the number of times that the controller executes an OPEN operation. Each time an OPEN operation is issued, the counter increments by one.

NOTE An optional electromechanical counter is available for the eCAP.

Operations Count 20

3.5.13 Switching V-Hyst (Adjustable)

Switching Voltage Hysteresis: A product of switching a capacitor bank on-line is a voltage rise, which occurs due to resonance. A possible complication that may arise

for some customers is over-voltage. Suppose a capacitor is off-line (OPEN), and the voltage is fairly high. Let us suppose also from experience that we know there will be

a rise of roughly 2 volts once the capacitor bank is CLOSED. If an algorithm intended to switch on VARs were used, the algorithm would not be able to foresee this unless the customer specifically devises a voltage scheme with the VAR switching which requires some amount of thought.

The VCor (Voltage with Correction) parameter is a feature in the eCAP intended to

solve this problem. Essentially, VCor is a prediction of the voltage for the pending operation based on the present voltage value, the status of the capacitor bank and

the correction values listed under the Switching V-Hist item.

Shown below are the following fields and their associated field conditions:

ClsV. Post-CLOSE correction value. Value (in volt units plus 1 decimal

place) added to the present voltage while status is OPEN to predict the

voltage after a CLOSE operation. Prediction is placed in the VCor field in the

Voltage, Current item (see Section 3.5.2). This value is only utilized when

the status of the capacitor bank is OPEN.

OpnV. Post-OPEN correction value. Value (in volt units plus 1 decimal

place) subtracted from the present voltage while status is CLOSED to predict

the voltage after an OPEN operation. Prediction is placed in the VCor field in

the Voltage, Current item (see Section 3.5.2). This value is only utilized

when the status of the capacitor bank is CLOSE.



Learn. Allows the customer to set the eCAP in learning mode. Essentially, the control will log the last few operations and learn the voltage rise and drops

from those operations. The control will then set the ClsV and OpnV accordingly. After 4 or more operations the unit will have predicted a fair

approximation of the VCor voltage with the banks under the OPEN and

CLOSE status. In this way, the user is free from guessing a value, which may

be imprecise. It is recommended the customer pre-set the ClsV and OpnV

values to 2.0 volts when setting using this feature. This will give the Learn

feature a good starting point. The value set under this field is textual and has

only two conditions: Yes or No

A sample of the display is shown below:

Learn ClsV OpnV Yes 2.0 2.0


44 Switching Algorithm Reference Guide Copyright © 2017 QEI

4. Switching Algorithm Reference Guide

Setting up the eCAP consists of entering the parameters that govern the automatic operation of the control. These parameters, termed “Switching Algorithms,” are evaluated by the controller to determine when to switch the capacitor bank into and out of operation. The eCAP switching algorithms can be set up via a computer interface using the QEI “SmartWare” program (described later in this guide). Additionally, the Algorithms can be configured through the front panel switches.

The QEI eCAPs are very flexible and allow a wide variety of capacitor bank switching algorithms. This section describes how to set up the controller to implement an automatic switching algorithm.

INTRODUCTION This section describes how the controller evaluates switching algorithms. Some general information about this subject is necessary to allow switching algorithms to be described and entered into the controller.

COMMON ALGORITHMS This section contains the most common switching algorithms. If any of these switching algorithms fit the users needs, the user only has to enter the selected schemes into the control.

CUSTOM ALGORITHMS The eCAP also allows the user to design a custom switching algorithm and enter it into the control. The next section describes how the eCAP evaluates a switching algorithm and the complete range of options available in designing custom switching algorithms.

FRONT PANEL ENTRY This section describes how to enter a switching algorithm using the front panel switches.


Copyright © 2017 QEI Switching Algorithm Reference Guide 45

4.1 Introduction

4.1.1 General Considerations

There are a number of items that must be set up for the eCAP to function properly. There are specific parameters that must be entered that describe the electrical environment to the eCAP. This is necessary for the control to properly measure the voltage, current, and power factor and to properly calculate the kWatts and kVArs. The user must also enter a switching algorithm that the eCAP uses to determine when to switch the capacitor bank into and out of the line.

4.1.2 Operating Parameters

The following parameters must be determined for the intended installation and entered into the eCAP. The parameters can be entered using the ASmartWare@

program in a computer attached to the control with a serial RS232 cable. In the case of an eCAP control, the parameters may be optionally entered via the front panel.

Open Switch Delay

Close Switch Delay

Date and Time

Primary Voltage

Amp Conversion Constant

Sensor Phase Shift

Unit Identity

Temperature Lag Value

For a detailed description of each of these parameters consult the OPERATION section of the user’s guide, under ECAP MENU DESCRIPTION.



4.1.3 General Information

There are two branches in a switching algorithm: one branch is evaluated when the capacitor bank switch is open and the other branch is evaluated when the capacitor bank switch is closed. The first branch tells the eCAP when to connect the capacitor bank onto the line; the second branch tells the eCAP when to disconnect the capacitor bank from the line. These two branches are identified by the phrases:

Switches Open and Switches Closed. When the switching algorithms are described, a table containing these two phrases as a header indicates them.

Switching algorithms consist of one or more steps in each branch. The example above illustrates a sample algorithm for the first step in the SWITCHES OPEN branch, as might be seen on the LCD Display of a eCAP, as an item in the “Switches Open” Menu when configuring a eCAP using the front panel switches. A similar display is also shown when using QEI “SmartWare” software’s “Algorithm Builder” to configure an eCAP.

Each step contains the following information:

BRANCH & STEP IDENTIFIER. Indicates the SWITCHES OPEN branch, or SWITCHES CLOSED branch, and step number. There are ten available steps for each branch, numbered 0 through 9.

PARAMETER. The physical parameter to evaluate (i.e., Temperature, Time, Voltage, VARs, etc.).

FUNCTION. How to evaluate the value of the parameter (i.e., , or =).

VALUE. The value used to evaluate the measured parameter.

IF TRUE. What action to take if the evaluation is true (i.e., Close - switch the bank on, Open - switch the bank off, Next go to the next step).

IF FALSE. What action to take if the evaluation is false.



In the above example, if the evaluation is TRUE (when the cap bank is OPEN, and the measured voltage is LESS THAN 120.0 Volts), the controller will CLOSE the cap bank (after any timers have expired). If the evaluation is FALSE (when the cap bank is OPEN, and the measured voltage is GREATER than 120.0 Volts, the controller will advance to the next step in the SWITCHES OPEN branch, and begin evaluating that step.

The options for each field above are discussed in detail in the tables on the following pages.



4.1.3.1 Switching Algorithm PARAMETER Descriptions

Parameter Abbreviation Comments / Limitations

Secondary Voltage w/correction (volts)

VCor This is the anticipated secondary voltage after the capacitor bank is switched into or out of the circuit. The voltage difference caused by switching the capacitors in and out of the line is measured each time that the capacitors are actually switched into or out of the circuit. This difference is used to calculate this value. Voltage is based on a nominal 120VAC secondary voltage.

Secondary Voltage (volts)

Volt Voltage on the measured phase. A current sensor is not needed for this measurement. Voltage is based on a nominal 120VAC secondary voltage.

Current (amps) Current Current on the measured phase when a current sensor is present (line amperage).

Power (kilowatts) Power kW is calculated from voltage and current sensors on the measured phase multiplied by three.

Reactive Power (kiloVARs)

kVAr kVAr is calculated from voltage and current sensors on the measured phase multiplied by three. Positive values = Lagging, Negative values = Leading

Power Factor PF Power Factor is calculated from voltage and current sensors on the measured phase. Positive values = Lagging, Negative values = Leading

Temperature Temp This parameter is measured from the optional temperature sensor on the control. It is presented in Farenheight or Celsius depending on the units selected for the control.

Date Date Format: mmdd where mm = month (01 to 12) & dd = day (01 to 31)

Time Time Format: hhmm where hh = hour (00 - 23) & mm = minute (00 to 59)

Day of the Week DOW 1 - 7 = Monday to Sunday. (0,8,9 are holiday day types as defined in the holiday list)

DOW < 6 = Weekdays (this includes the 0 holiday day type)

DOW > 5 = Weekends and Holidays (holiday day types 8 & 9)



4.1.3.2 Switching Algorithm FUNCTION Descriptions

Operator Abbreviation Comments / Limitations

Is more lagging > Applies to kVAr and Power Factor

Is more leading < Applies to kVAr and Power Factor

Is greater than > Applies to corrected voltage, voltage, current, watts, and temperature

Is less than < Applies to corrected voltage, voltage, current, watts, and temperature

Is after > Applies to date, time, and day of the week

Is before < Applies to date, time, and day of the week

Is exactly = Applies to date, time, and day of the week

4.1.3.3 Switching Algorithm ACTION Descriptions

Action Abbreviation Action Description

Open switches O Opens the capacitor bank switches placing the capacitor bank off line. If the switches are already open, this action does nothing.

Close switches C Closes the capacitor bank switches placing the capacitor bank on line. If the switches are already closed, this action does nothing.

Next Step N Causes the next step to be evaluated.

Skip step S Skips the next step



4.2 Common Switching Algorithms

This section contains a number of common switching algorithms that a user can simply copy. The numeric values in each of the switching algorithms listed below may not be appropriate for any specific installation and must be determined by the user for the intended installation.

4.2.1 Temperature Control Switching (Example #1)

This switching algorithm uses the temperature sensor on the eCAP to decide when the switch the capacitors into and out of the line. It is one of the simplest switching algorithms and does not require a current sensor.

Switches OPEN

Parameter Function Value True False

Temp > 80* Close Open

Switches CLOSED


Temp < 70* Open Close

*The temperatures used to switch the capacitor bank on and off should be determined by the user. Using the above values the capacitor bank would be switched on when the Indoor temperature exceeds 80F and off when the Indoor temperature dropped below 70F. The temperatures selected should not be very close together (i.e. on at 75 off at 73). This could cause undesired switching operations.

NOTE The Indoor temperature is used all switching algorithms. If the ambient temperature is desired, set the temperature lag constant to zero.

4.2.2 Temperature Control Switching (Example #2)

Switches Open Status Switches Close Status T F T F 0) Temp < 50 C N 0) Temp < 50 C N 1) Temp > 90 C O 1) Temp > 90 C O

The algorithm indicated above will close the banks for temperatures above 90 degrees and below 50 degrees Fahrenheit. For temperatures in the “mild zone” the banks remain open. The purpose of the broad range in-between 50 and 90 is due to the lag times involved in temperature changes. This also allows fewer switching operations thereby avoiding hunting where sudden changes in climates might occur. Temperature switching is more suited to seasonal loads.



4.2.3 Time & Date Control

This switching algorithm uses the internal clock and calendar in the control to determine when to switch the capacitor bank in and out of the line. It does not need a current sensor.

Switches OPEN


DOW < 6* Next Open

Time > 0800* Next Open

Time < 1800* Close Open

Switches CLOSED


DOW < 6* Next

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