Download S260-16-1

Switches
Service Information
Type SyncCap Power Quality Switch
Installation and Operation Instructions
Figure 1.
Kyle® Type SyncCap Power Quality Switch.
S260-16-1
020097KM
Contents
Safety Information ..................................................... 2
Grounded-Wye Capacitor Rack Application ........... 8
Hazard Statement Definitions ................................ 2
Ungrounded-Wye Capacitor Rack Application .......10
Safety Instructions .................................................. 2
Installation Procedure ..............................................14
Product Information .................................................. 3
Check Nameplate....................................................14
Introduction ............................................................ 3
Cycle the Switch ....................................................14
Acceptance and Initial Inspection .......................... 3
Install the Switch ....................................................14
Handling and Storage ............................................. 3
High-Voltage Connections ......................................14
Description of Operation ........................................ 3
Control Wiring ........................................................15
Dimensions ................................................................. 4
Service Information ...................................................17
Ratings and Specifications ...................................... 5
Service Requirements ............................................17
Check Switch Ratings Prior to Installation ............. 5
Frequency of Inspection .........................................17
Application Configuration ......................................... 6
High-Potential Withstand Testing ...........................17
Set SyncCap for The Appropriate Application......... 6
Inspection of SyncCap Module ..............................17
Synchronizing Voltage ............................................ 7
Testing and Troubleshooting ....................................18
Sample Field Worksheets .........................................19
December 2002 • Supersedes 3/01
Printed in USA
1
Type SyncCap Power Quality Switch Installation and Operation Instructions
!
SAFETY
FOR LIFE
!
SAFETY FOR LIFE
SAFETY
FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high voltage lines and equipment and support our “Safety For Life” mission.
SAFETY INFORMATION
The instructions in this manual are not intended as a substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent technicians who are familiar with this equipment
should install, operate, and service it.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
• Is trained and authorized to energize, de-energize,
clear, and ground power distribution equipment.
• Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield,
hard hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe installation and operation of this equipment, be sure to read
and understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements
that apply to this equipment. Additional statements, related to specific tasks and procedures, are located throughout the manual.
DANGER: Hazardous voltage. Contact with
hazardous voltage will cause death or severe
personal injury. Follow all locally approved safety procedures when working around high and low voltage
lines and equipment.
G103.3
!
WARNING: Before installing, operating, maintaining, or testing this equipment, carefully read
and understand the contents of this manual. Improper
operation, handling or maintenance can result in death,
severe personal injury, and equipment damage. G101.0
!
Hazard Statement Definitions
This manual may contain four types of hazard
statements:
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
!
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
!
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
!
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in equipment damage only.
2
WARNING: This equipment is not intended to
protect human life. Follow all locally approved
procedures and safety practices when installing or
operating this equipment. Failure to comply can result in
death, severe personal injury and equipment damage.
!
G102.1
WARNING: Power distribution equipment must
be properly selected for the intended application.
It must be installed and serviced by competent personnel who have been trained and understand proper safety procedures. These instructions are written for such
personnel and are not a substitute for adequate training
and experience in safety procedures. Failure to properly select, install, or maintain power distribution equipment can result in death, severe personal injury, and
equipment damage.
G122.2
!
!
S260-16-1
SAFETY
FOR LIFE
PRODUCT INFORMATION
Introduction
Electrical Operation
Service Information S260-16-1 provides installation and
operation instructions for the Kyle Type SyncCap Power
Quality Switch.
The SyncCap Power Quality Switch is opened and closed
through electrical operation only. Electrical operation is
achieved by applying rated control voltage to the proper
terminals of the receptacle for a minimum of 300 ms.
Read This Manual First
Read and understand the contents of this manual and follow all locally approved procedures and safety practices
before installing or operating this equipment.
The SyncCap switch has a yellow contact position indicator under the sleet hood as shown in Figure 4.
Note:
The position indicator cannot be used as a manual
operating handle.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described nor provide directions for meeting every possible contingency
during installation or operation. When additional information is desired to satisfy a problem not covered sufficiently for the user's purpose, please contact your Cooper
Power Systems representative.
Acceptance and Initial
Inspection
Each switch is completely assembled, tested, and
inspected at the factory. It is in good condition when
accepted by the carrier for shipment.
Upon receipt, inspect the shipping container for signs of
damage. Unpack the switch and inspect it thoroughly for
damage incurred during shipment. If damage is discovered, file a claim with the carrier immediately.
Handling and Storage
Be careful during handling and storage of the switch to
minimize the possibility of damage. If the switch is to be
stored for any length of time prior to installation, provide a
clean, dry storage area.
WARNING: Hazardous Voltage. Do not rely on
the open position of the contact position indicator;
it does not ensure that the line has been de-energized.
Always establish a visible disconnect. Failure to follow
proper safety practices can result in contact with high
voltage, which will cause death or severe personal
injury.
G123.0
!
Synchronous Operation
SyncCap utilizes a microprocessor-based control and
exclusive closed-loop position feedback system to precisely control vacuum contacts with a voice coil operating
mechanism. The microprocessor-based control continually monitors system voltage to detect voltage zero
crosses. The closed-loop position feedback system constantly measures contact position during the close operation.
With input from the feedback system, the SyncCap control can adjust the velocity of the switch’s operation by
regulating current flow through the voice coil operating
mechanism. The voice coil instantly responds to adjustments from the control for dynamic motion control resulting in repeatable synchronous operation.
Standards
ap Control energ
iz
ncC
Sy voice coil to begin es
e
p
o
r
a
e
t
s
i
o
o
n
cl
The Quality System at the Cooper Power Systems, Kyle
Distribution Switchgear plant is certified to the following
standards:
ISO 9001
CAN/CSA ISO 9001
BS EN ISO 9001
ANSI/ASQC Q9001
Description of Operation
The Kyle Type SyncCap Power Quality Switch is a singlephase, electrically operated vacuum switch with synchronous closing intelligence and mechanism that permits
closing of the switch at voltage zero (synchronous closing). See Figure 2.
Polemounted
capacitor
control
issues
close
signal
SyncCap control
utilizes closed-loop
position feedback
monitoring, continually
surveying system
voltage and
contact position
SY
NCH
ontrol adjusts current
flow
ap C
ncC
l as necessary to en
Sy gh coi
su
u
p
r
t
r
e
r
e
c
ou
ontac re
m int
ts
thr
cuu
va
esired voltage ze
at d
ro
ite
un
Quality Standards
ontrol process
ap C
e
ncC
system volt s
Sy signal,
age
e
t
p
c
o
,
a
s
s
t
i
n
tion
clo nd co
a
Kyle switches are designed and tested in accordance with
IEC 60265-1 and ANSI C37.66, where applicable.
R e s u lt:
SE
R ONOUS CLO
Figure 2.
Synchronous operation of the SyncCap Power
Quality Switch.
3
Type SyncCap Power Quality Switch Installation and Operation Instructions
DIMENSIONS
Lifting Provision (2)
395
(15.55)
Bushing Terminal
Connector
#10 to 350 MCM
Cable Range
284
(11.18)
76 (2.99)
27 (1.06)
Ground
Terminal
Connector
#8 Solid to
2/0 Stranded
Cable Range
76
(2.99)
27
(1.06)
208
(8.19)
217
(8.54)
A
Bushing
Terminal
Connector
1/0 to 500 MCM
Cable Range
Sleet Hood
Receptacle
11,1 (0.44)
4-HOLES
32 (1.26)
Mounting Hole for
16 (0.625) Bolt
35 (1.38)
70
(2.76)
362
(14.25)
32
(1.26)
153
(6.02 )
174
(6.85)
232
(9.13)
181
(7.13)
244
9.61)
Dim A
SyncCap 15.5 kV, 110 kV BIL
910 (35.83)
SyncCap 15.5 kV, 125 kV BIL
971 (38.23)
Figure 3.
Type SyncCap dimensions.
4
Note:
52
(2.05)
All dimensions are approximate.
Dimensions shown are mm (in).
!
S260-16-1
SAFETY
FOR LIFE
RATINGS AND SPECIFICATIONS
Check Switch Ratings Prior to
Installation
The SyncCap switch must be applied within its specified
ratings. Check nameplate ratings and compare with the
system characteristics at the point of application, prior to
installation. Tables 1 through 6 list the specifications and
ratings of the SyncCap Power Quality Switch.
TABLE 1
General Specifications
15.5 kV, 110 kV BIL
15.5 kV, 125 kV BIL
Creepage Distance, minimum mm (in) . . . . . . . . . . . . . . . . .
610 (24)
790 (31)
Mass kg (Weight lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 (82)
38 (84)
Mechanical Operations without Maintenance (C-O) . . . . . . .
25,000
25,000
Operating Temperature Range, °C . . . . . . . . . . . . . . . . . . . .
-40° to +65°
-40° to +65°
Zero-Volt Closing Tolerance, milliseconds . . . . . . . . . . . . . . .
±0.5
±0.5
TABLE 3
Power Requirement
TABLE 2
Duty Cycle (per ANSI C37.66)
Standard
120 Vac
Operation
200 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Operations
100 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Operations
40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 Operations
Operating Voltage Rating
Accessory
240 Vac
Operation
107 to 127 Vac 214 to 254 Vac
Current (peak, ac) . . . . . .
3A
1.5 A
Current
(continuous, nominal, ac)
20 mA
10 mA
TABLE 4
Voltage Ratings
15.5 kV, 110 kV BIL
15.5 kV, 125 kV BIL
Maximum Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.5 kV
15.5 kV
Rated Basic Impulse Voltage . . . . . . . . . . . . . . . . . . . . . . . .
110 kV
125 kV
Radio Noise Test Voltage (100 µV max noise) . . . . . . . . . . .
9.41 kV
16.4 kV
Dry, 1-minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 kV
60 kV
Wet, 10 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 kV
50 kV
60 Hz Withstand
TABLE 6
Control Wiring Specification
TABLE 5
Current Ratings
Rated Asymmetrical Making Current . . . . . . . . .
9000 A
Rated Continuous Current . . . . . . . . . . . . . . . . .
200 A
Load Interrupting Ability (Inductive)
10% to 100% Power Factor . . . . . . . . . . . . . .
200 A
Capacitive Current (max) . . . . . . . . . . . . . . . . .
200 A
Short-Time Currents
Asymmetrical (10 cycles) . . . . . . . . . . . . . . . .
9000 A
Symmetrical (0.5 second) . . . . . . . . . . . . . . . .
6000 A
Symmetrical (1 second) . . . . . . . . . . . . . . . . .
4500 A
Accessory Plug
Catalog
Number
Number
of Pins
Cable Range
O.D.
Maximum
Wire Size
AWG
KA48NR
5
11–14 mm
(0.437–0.562 in)
12
KA98NR
6
13–16 mm
(0.500–0.625 in)
16
5
Type SyncCap Power Quality Switch Installation and Operation Instructions
APPLICATION CONFIGURATION
Set SyncCap for the Appropriate
Application
IMPORTANT: The Kyle Type SyncCap Power Quality
Switch will not operate until it is correctly configured.
Note:
Refer to the Sample Field Worksheets section of this
manual. The sample worksheets may be copied and
used to set up the SyncCap switch.
The SyncCap switch must be configured for the phase
rotation requirements of the application prior to installation.
All SyncCap switches have two toggle switches (SW1
and SW2) located under the sleet hood and behind the
nameplate. These switches are used to set the appropriate delay and sequence for the closing of each switch
according to the phase rotation and voltage reference
method used in the field installation. See Figure 4.
B. While holding the contact position indicator in the
OPEN position, move toggle switch SW1 to its proper position, depending on application. See Figures 5
and 6.
Note:
The toggle switch must lock into the proper position upon release.
C. While holding the contact position indicator in the
OPEN position, move toggle switch SW2 to its
proper position, depending on application. See
Figures 5 and 6.
Note:
The toggle switch must lock into the proper position upon release.
D. Slowly release the contact position indicator to the
CLOSED position.
SyncCap
Sleet Hood
POS1
POS1
POS2
POS2
POS3
POS3
SW1 SW2
O
P
E
N
020098KM
Kyle ®
SyncCap
Nameplate
POW Type S
ER QU
yn
ALIT cCapY SW
ITCH
OPEN/CLOSED
Contact Position Indicator
(shown in OPEN position)
15
Toggle Switches
Figure 4.
SyncCap sleet hood with nameplate partially
removed to expose toggle switches.
Figure 5.
Hold the yellow position indicator down in the
OPEN position while setting toggle switches.
The toggle switches on every SyncCap switch are factoryset in the OFF (SW1 and SW2 in POS2) position. The
SyncCap switch will not operate until the toggle switches
are set per the following procedure:
1. Completely remove one screw and loosen the other
screw so the nameplate swings freely to expose the
toggle switches. See Figure 4.
2. Position the toggle switches as described below:
A. With one hand, grab the yellow contact position
indicator flag and apply light downward pressure to
move the indicator flag into the OPEN position as
shown in Figure 5.
Note:
All SyncCap switches are shipped in the
CLOSED position.
Manually rotating the indicator will not open the
switch contacts.
IMPORTANT: The yellow contact position indicator flag
serves as an indicator of contact position only, it is not
intended to trip or close the switch.
6
Figure 6.
To operate the toggle switches located under the
SyncCap sleet hood, pull the switch out and move
upward or downward per application need.
3. After the appropriate application has been set,
reposition the nameplate and reattach and tighten
the screws.
!
S260-16-1
SAFETY
FOR LIFE
Synchronizing Voltage
An input voltage must be provided to the SyncCap Power
Quality Switch for use as a synchronizing voltage via the
standard five-pin (or accessory six-pin) control cable
receptacle. Refer to Figure 19 or 20.
When applying SyncCap switches in a three-phase installation, the synchronizing voltage may be provided from
each phase independently or from just one reference
phase. If the synchronizing voltage is provided independently from each phase, then each SyncCap switch is configured to close on its respective reference voltage zero
point. If just one reference phase voltage will be used for
the installation, then each SyncCap must be appropriately
configured to close relative to the one common reference
voltage zero point. The range of settings for the SyncCap
switch is shown in Table 7 (refer to Figure 7).
Note:
Unless there is a specific reason to supply the reference voltage from each phase independently (three
potential transformers), it is recommended that only
one reference voltage be used. This manual does not
cover the case of three independent phase reference
voltages.
There are three application considerations leading to the
proper configuration of the SyncCap switch:
• Connection of the capacitor rack, grounded or
ungrounded.
• Primary connection of the transformer supplying the
reference voltage, phase-to-ground or phase-tophase.
• System phase rotation.
POS1
POS1
POS2
POS2
POS3
POS3
SW1 SW2
Figure 7.
Switch settings.
TABLE 7
SyncCap Close Phase Switch Settings
Degree Lag
From Voltage Zero
SW1 Switch
Position
SW2 Switch
Position
0°
POS 1
POS 3
30°
POS 2
POS 1
60°
POS1
POS 1
90°
POS 1
POS 2
120°
POS 3
POS 3
150°
POS 2
POS 3
180°
POS 3
POS 1
OFF
POS 2
POS 2
*
POS 3
POS 2
* Reserved for future use.
Switch is OFF.
7
Type SyncCap Power Quality Switch Installation and Operation Instructions
Grounded-Wye Capacitor Rack
Application
Transformer Secondary;
Synchronizing Voltage
A
A typical grounded-wye capacitor rack installation
includes the capacitors, mounting rack, controller, switches,
overcurrent protection, and a single-phase distribution
transformer connected phase-to-ground to power the
capacitor controller, switches, and other ancillary equipment.
See Figure 8. The secondary from this transformer is
also used to provide the synchronizing voltage for the
SyncCap switches.
SyncCap
Switch
Distribution
Transformer
Each SyncCap switch will close independently at its
respective phase’s voltage zero point. The SyncCap
switch connected to the leading phase will lag the reference phase zero crossing by 60 electrical degrees to
close at its phase’s voltage zero. Next, the SyncCap
switch connected to the lagging phase will lag the reference phase zero crossing by 120 electrical degrees to
close at its phase’s voltage zero. Finally, the SyncCap
switch connected to the reference phase itself will lag the
reference phase zero crossing by 180 electrical degrees
to close at its phase’s voltage zero. Refer to Figure 9.
Note:
The SyncCap switch that is connected to the reference
phase CAN be set for either a zero degree lag or a 180
degree lag. The preferred setting is 180 degree lag for
the following reason: It is desirable to assure that the
reference voltage signal is free of any disturbances during
the complete closing sequence. If the switch connected
to the reference phase closes first, the reference voltage will increase due the switched-in capacitance in
that phase. Since this same reference voltage is being
fed to the two switches in the other phases, the disturbance may upset the control feedback loop.
Grounded-Wye
Capacitor Bank
SyncCap
Switch
B
SyncCap
Switch
C
Figure 8.
Circuit diagram for grounded-wye capacitor racks
(ABC rotation).
Knowledge of the system’s phase rotation is critical to the
proper installation and operation of the SyncCap switch.
There are two phase rotations in three-phase electrical
power distribution. Labeling the three phases ABC, the
two phase rotations are A-B-C and C-B-A (B-C-A and CA-B rotations are equivalent to A-B-C; A-C-B and B-A-C
rotations are equivalent to C-B-A).
VA Reference phase zero crossing: set for 180° lag
VB Lagging phase zero crossing: set for 120° lag
VC Leading phase zero crossing: set for 60° lag
VA Reference phase zero crossing
A
A
C
VLG
B
60°
120°
180°
0
60
120
180
240
300
360
420
480
Electrical Degrees
Note: Choice of reference phase is arbitrary.
Figure 9.
Closing characteristics for grounded-wye capacitor racks (ABC rotation).
8
!
S260-16-1
SAFETY
FOR LIFE
TABLE 8
Phase designations for systems with A-B-C phase rotation, phase-to-ground connected reference voltage
transformer, and grounded-wye capacitor racks.
Phase Energizing
Reference Voltage
Transformer
Reference
Voltage
Phase Leading
Reference
Phase Lagging
Reference
Reference
Phase
60°
Switch setting for:
120°
180°
VAN
C
B
A
B
VBN
A
C
B
C
VCN
B
A
C
A
TABLE 9
Phase designations for systems with A-C-B phase rotation, phase-to-ground connected reference voltage
transformer, and grounded-wye capacitor racks.
Phase Energizing
Reference Voltage
Transformer
Reference
Voltage
Phase Leading
Reference
Phase Lagging
Reference
Reference
Phase
60°
Switch setting for:
120°
180°
VAN
B
C
A
B
VBN
C
A
B
C
VCN
A
B
C
A
Reference Phase
Preferred: 180° Lag
(Lags Reference Zero by 180°)
Leading Phase
60° Lag:
(Lags Reference closing by 60°)
Lagging Phase
120° Lag:
(Lags Reference closing by 120°)
POS1
POS1
POS1
POS1
POS1
POS1
POS2
POS2
POS2
POS2
POS2
POS2
POS3
POS3
POS3
POS3
POS3
SW1 SW2
SW1 SW2
For SyncCap use on the reference phase,
SW1 in POS 3 and SW2 in POS 1.
For SyncCap use on the leading phase,
both SW1 and SW2 in POS 1.
POS3
SW1 SW2
For SyncCap use on the lagging phase,
both SW1 and SW2 in POS 3.
Reference Phase
Alternate: 0° Lag
(Closes at Reference Zero)
POS1
POS1
POS2
POS2
POS3
POS3
SW1 SW2
For SyncCap use on the reference phase,
SW1 in POS 1 and SW2 in POS 3.
Figure 10.
Toggle switch positions for reference, leading, and lagging phases in a grounded-wye capacitor rack.
Use Tables 8 and 9 to determine each phase’s characteristic (reference, leading, or lagging) based on the
phase energizing the rack’s distribution transformer.
Refer to the Set SyncCap for the Appropriate
Application section of this manual for procedures to
operate the toggle switches.
The two toggle switches located under the sleet hood are
used to configure SyncCap switches to the appropriate
phase of the phase rotation of the given application. See
Figure 10.
9
Type SyncCap Power Quality Switch Installation and Operation Instructions
Ungrounded-Wye Capacitor
Rack Application
A typical ungrounded-wye capacitor rack installation
includes the capacitors, mounting rack, controller, switches, overcurrent protection, and a single-phase distribution
transformer connected to the system to power the capacitor controller, switches, and other ancillary equipment. The
secondary from this transformer is also used to provide the
synchronizing voltage for the SyncCap switches.
reference LL voltage. This switch is set to 60° lag which
places it at the point where the voltage difference
between the first two switches to close is zero, or where
the VCA is at a zero crossing. Finally, the last switch to
close (B phase in this example) is set to 150° lag where
it crosses its natural zero (VBN).
Note:
The primary connection of the single-phase distribution
transformer is an important consideration in the
ungrounded-wye capacitor rack installation. Connecting
the transformer phase-to-phase or phase-to-ground will
affect each switch’s setting.
Phase-to-Phase Connected
Distribution Transformer
In this installation, synchronous closing occurs when the
second of two switches closes at the point when the voltage difference between their two phases is zero followed
by the closing of the third pole at that phase’s voltage
zero (90 electrical degrees after the operation of the
other two).
Note:
The SyncCap will operate on the first available zero
crossing of the reference voltage regardless of the
slope of the wave. Figure 12 illustrates the zero crossing on a negative slope. It will operate just as well on
the positive slope, in which case everything is shifted
by 180 electrical degees. One outcome of this characteristic is that the polarity of the distribution transformer
as it is connected to the primary phases will not affect
the settings of the switches. However, it is important to
have a common ground on the switch and transformer
secondary.
Transformer Secondary;
Synchronizing Voltage
A
B
Figures 11 and 13 illustrate the case of an ABC phase
sequence with the phase-to-phase transformer connected to A and B phases giving a reference voltage VAB. The
two phases that energize the distribution transformer are
used as the synchronizing reference voltage in switching
the ungrounded-wye capacitor rack. This is a line-to-line
voltage. Refer to Figures 11 and 13.
C
The first switch to close is chosen to be the first phase
that lags the reference LL voltage (VA in Figure 13). This
switch is set to 30° lag. Lag is referenced to VAB. The
second switch to close is the third phase that lags the
30° Lag
(Lags Voltage Zero by 30°)
Ungrounded-Wye
Capacitor Bank
Distribution
Transformer
The timing of the first switch closing is not important
since no current can flow, and no disturbance can
occur, until a second switch closes.
Referring to Figure 13, VAB is the reference line-to-line
voltage and each phase line-to-neutral voltage is referenced to VAB. VAN lags the reference by 30°, VBN lags by
150°, and VCN lags by 60°. The reference zero crossing
is the point where the voltage difference between phase A
and phase B is zero; this is the point where VAB crosses
zero as noted in the figure.
SyncCap
Switch
SyncCap
Switch
SyncCap
Switch
Figure 11.
Circuit diagram for ungrounded-wye capacitor racks.
(ABC phase rotation, phase-to-phase connected
distribution transformer.)
Use Tables 10 and 11 to determine each phase’s characteristics (1st, 2nd, or 3rd phase lagging) with respect to
the reference voltage. The two toggle switches under the
sleet hood are used to select appropriate application on
each phase of the phase rotation. Refer to Figure 12.
Refer to the Set SyncCap for the Appropriate
Application section of this manual for procedures to
operate the toggle switches.
60° Lag
(Lags Voltage Zero by 60°)
150° Lag
(Lags Voltage Zero by 150°)
POS1
POS1
POS1
POS1
POS1
POS1
POS2
POS2
POS2
POS2
POS2
POS2
POS3
POS3
POS3
POS3
POS3
POS3
SW1 SW2
SW1 SW2
SW1 SW2
For SyncCap use on 30° Lag,
SW1 in POS2 and SW2 in POS1.
For SyncCap use on 60° Lag,
SW1 in POS1 and SW2 in POS1.
For SyncCap use on 150° Lag,
SW1 in POS2 and SW2 in POS3.
Figure 12.
Toggle switch positions for use in an ungrounded-wye capacitor rack with a phase-to-phase connected distribution transformer.
10
!
S260-16-1
SAFETY
FOR LIFE
VAB
VB Second lagging phase: set for 150° lag*
VC Third lagging phase: set for 60° lag*
VA First lagging phase: set for 30° lag*
Reference phase zero crossing
VCA
VAB
C
* with respect to the reference L-L voltage, VAB
VCA
VBC
C
B
VLN and VLL
A
30°
60°
150°
0
60
120
180
240
300
Electrical Degrees
360
420
480
Figure 13.
Closing characteristics for ungrounded-wye capacitor racks (ABC phase rotation, phase-to-phase connected
distribution transformer).
TABLE 10
Phase designations for systems with A-B-C phase rotation, phase-to-phase connected reference voltage
transformer, and ungrounded-wye capacitor racks.
Phase Energizing
Reference Voltage
Transformer
Reference
Voltage
1st Phase Lagging
Reference
3rd Phase Lagging
Reference
2nd Phase Lagging
Reference
30°
Switch setting for:
60°
150°
A to B
VAB
A
C
B
B to C
VBC
B
A
C
C to A
VCA
C
B
A
TABLE 11
Phase designations for systems with A-C-B phase rotation, phase-to-ground connected reference voltage
transformer, and grounded-wye capacitor racks.
Phase Energizing
Reference Voltage
Transformer
Reference
Voltage
1st Phase Lagging
Reference
3rd Phase Lagging
Reference
2nd Phase Lagging
Phase
30°
Switch setting for:
60°
150°
B
C
A to C
VAC
A
C to B
VCB
C
A
B
B to A
VBA
B
C
A
11
Type SyncCap Power Quality Switch Installation and Operation Instructions
Phase-to-Ground Connected
Distribution Transformer
A
In the ungrounded-wye capacitor rack installation that
includes a phase-to-ground connected transformer, the
phase that energizes the transformer is the last to close.
Figures 14 and 15 illustrate the case of an ABC phase
sequence with the phase-to-ground transformer connected to C phase giving a reference voltage VC.The distribution transformer is connected from phase C to ground
making VC the reference voltage, see Figures 14 and 15.
The first switch to close is connected to the phase that
leads the reference phase, VB in this example. Its voltage
zero lags the voltage zero of the reference phase by 60
electrical degrees and is set for 60° lag. Next, the switch
connected to the phase lagging the reference phase, VA
in this example, is set to close 90° after the reference
phase which is the point where the voltage difference
between the first two phases to close is zero. Finally, the
third switch lags the reference voltage point by 180° (the
next voltage zero point for the reference phase).
SyncCap
Switch
Ungrounded-Wye
Capacitor Bank
SyncCap
Switch
B
Transformer Secondary;
Synchronizing Voltage
SyncCap
Switch
C
Distribution
Transformer
Figure 14.
Closing characteristics for ungrounded-wye capacitor racks. (ABC phase rotation, phase-to-ground
connected distribution transformer.)
Use Tables 12 and 13 to determine each phase’s characteristics (1st, 2nd, or 3rd phase lagging) with respect to
the reference voltage. See Figure 16 for the configuration
of toggle switches SW1 and SW2 for proper application.
Refer to the Set SyncCap for the Appropriate
Application section of this manual for procedures to
operate the toggle switches.
VC Reference phase: set for 180° lag
VA Lagging phase zero crossing: set for 90° lag
VB Leading phase zero crossing:set for 60° lag
VC Reference phase zero crossing
A
Choice of reference
phase is arbitrary.
B
C
VLN
C
Note:
60°
90°
180°
0
60
120
180
240
300
360
420
480
Electrical Degrees
Figure 15.
Closing characteristics for ungrounded-wye capacitor racks with phase-to-ground connected transformer.
12
!
S260-16-1
SAFETY
FOR LIFE
Leading Phase
60° Lag
(Lags Reference Voltage
Point by 60°)
Lagging Phase
90° Lag
(Lags Reference Voltage
Point by 90°)
Reference Phase
180° Lag
(Lags Reference Voltage
Point by 180°)
POS1
POS1
POS1
POS1
POS1
POS1
POS2
POS2
POS2
POS2
POS2
POS2
POS3
POS3
POS3
POS3
POS3
SW1 SW2
For SyncCap use on 60° Lag,
both SW1 and SW2 in POS1.
For SyncCap use on 90° Lag,
SW1 in POS1 and SW2 in POS2.
POS3
SW1 SW2
SW1 SW2
For SyncCap use on 180° Lag,
SW1 in POS3 and SW2 in POS1.
Figure 16.
Toggle switch positions for use in an ungrounded-wye capacitor rack with a phase-to-ground connected distribution transformer.
TABLE 12
Phase designations for systems with A-B-C phase rotation, phase-to-ground connected reference voltage
transformer, and ungrounded-wye capacitor racks.
Phase Energizing
Reference Voltage
Transformer
1st Phase Lagging
Reference
3rd Phase Lagging
Reference
2nd Phase Lagging
Reference
60°
Switch setting for:
90°
180°
VAN
C
B
A
B
VBN
A
C
B
C
VCN
B
A
C
A
Reference
Voltage
TABLE 13
Phase designations for systems with A-C-B phase rotation,phase-to-ground connected reference voltage
transformer, and ungrounded wye-capacitor racks.
Phase Energizing
Reference Voltage
Transformer
1st Phase Lagging
Reference
3rd Phase Lagging
Reference
2nd Phase Lagging
Reference
60°
Switch setting for:
90°
180°
VAN
B
C
A
B
VBN
C
A
B
C
VCN
A
B
C
A
Reference
Voltage
13
Type SyncCap Power Quality Switch Installation and Operation Instructions
INSTALLATION PROCEDURE
WARNING: This equipment is not intended to
protect human life. Follow all locally approved procedures and safety practices when installing or operating this equipment. Failure to comply can result in
death, severe personal injury and equipment damage.
!
G102.1
CAUTION: Follow all locally approved safety
practices when lifting and mounting the equipment. Use the lifting lugs provided (see Figure 3). Lift
the unit smoothly and do not allow the unit to shift.
Improper lifting can result in equipment damage. G106.2
!
WARNING: Hazardous voltage. Solidly ground all
equipment. Failure to comply can result in death,
severe personal injury, and equipment damage.
T223.2
!
CAUTION: Personal injury. Bushings have sharp
edges. Wear protective gloves when handling the
unit. Failure to do so can result in cuts and abrasions. T258.0
!
Check Nameplate
Make sure that ratings on the nameplate are correct for
the planned installation. See Figure 17.
IMPORTANT: The Kyle Type SyncCap Power Quality
Switch will not operate until it is properly configured.
See Set SyncCap for the Appropriate Application
section of this manual.
Cycle the Switch
The SyncCap switch must be energized and cycled
through an open-close-open cycle before installing. The
purpose of these operations is to establish the precise
closing stroke to contact make. The control will store
(remember) this parameter for the next operation. The
procedure is as follows. Refer to Figure 18.
1. Apply 120 Vac to receptacle pins A and B.
the switch, immediately retorque the head-to-tank
mounting bolts in an alternating pattern to 19–34 N•m
(14–25 ft•lbs).
IMPORTANT: Verify that the tank is properly centered
on and seated to the head casting. Misalignment will
cause interference with the magnetic circuit causing
misoperation. Misalignment may also lead to entry of
moisture.
2. Bushing terminal adjustment. Bushing terminals may
also be rotated about their axis for optimum alignment to high-voltage conductors. If terminal rotation is
required, use the following procedure:
A. Loosen the terminal clamp.
B. Rotate terminal to desired location.
C. Retighten the terminal clamp. Torque to 20–23 N•m
(15–17 ft•lbs).
3. Install the switch. Follow all locally approved installation procedures. The SyncCap switch includes a
mounting bracket welded to the tank with a keyway
opening for simple mounting and installation. See
Figure 3.
High-Voltage Connections
CAUTION : Equipment Damage. Ground connection
to the SyncCap switch must be made only at the ground
terminal located upon the switch head casting. Failure
to comply can result in equipment damage and misoperation of the switch.
T279.0
1. Ground the switch. Make the ground connection to the
ground terminal. The ground terminal is located on the
switch head casting as shown in Figures 3 and 17.
2. Make line connections. Connect the primary leads to
the switch terminals. The universal clamp-type terminals accommodate #10 solid through 350 MCM conductor. See Figure 3.
2. Open the SyncCap switch by connecting a jumper
lead across receptacle pins A and D.
3. Close the SyncCap switch by connecting a jumper
lead across receptacle pins A and C.
4. Open the SyncCap switch by connecting a jumper
lead across receptacle pins A and D.
5. Disconnect the power to the SyncCap switch while in
the open position.
Install the Switch
1. Reorient switch position if required for installation.
Loosen the head-to-tank mounting bolts only if it is
necessary to reorient the position of the switch to
make high-voltage line connections. After reorienting
14
Nameplate
Ground Terminal
Figure 17.
SyncCap switch ground terminal.
020099KM
!
S260-16-1
SAFETY
FOR LIFE
Control Wiring
SyncCap
Connections to the SyncCap switch are made through the
standard five-pin (or optional six-pin) receptacle on the
head casting. The six-pin receptacle is provided when the
auxiliary switch accessory is ordered with the SyncCap.
Refer to Figures 19-22.
Voice Coil Operator
Microprocessor Logic
Input Circuitry
The polarity of the transformer connections providing the
reference voltage to pins A and B is not important to the
operation of the SyncCap switch. However, the secondary connection to receptacle pin B must be connected to a common ground with the head casting of the
switch. Refer to Figure 17.
5-Pin
Receptacle
IMPORTANT: Be sure that the reference voltage connection to receptacle B is grounded.
A
Mating plugs for the receptacle must be ordered separately. Maximum cable and wire sizes accommodated by
the plugs are listed in Table 6.
B
Pin orientation diagrams for the receptacles are shown in
Figure 18.
C
D
E
OPEN
CLOSE
KEY
Synchronizing
Voltage
F
E
A
D
C
B
5-pin
Receptacle
E
A
D
B
Control
Voltage
Neutral
Figure 19.
Connection diagram for three-wire control.
SyncCap
C
Auxiliary
Switch
Voice Coil Operator
6-pin
Receptacle
Microprocessor Logic
Figure 18.
Receptacle pin orientation.
"A"
Contact
Input Circuitry
Three Wire Control
The basic device for remote control of the Type SyncCap
switch is a single-pole, double-throw switch (three-wire
control) supplied by the customer. Any manual switch,
time switch, voltage-, current-, or photoelectric-controlled
switch, or similar device can be used, provided the control circuit is energized for a minimum of 300 ms for each
operation.
Note:
6-Pin
Receptacle
A
B
C
D
E
F
OPEN
CLOSE
Pin A provides the synchronizing voltage and control
power to the SyncCap and must be continually energized for proper operation.
Connection diagrams for a standard three-wire control,
with and without auxiliary switch accessory, are shown in
Figures 19 and 20.
Neutral
Synchronizing
Voltage
Control
Voltage
Ratings for Auxiliary Switch
Maximum Voltage
220 Vdc, 250 Vac
Maximum Switching Power
125 VA
Maximum Switching Current
2A
Figure 20.
Connection diagram for three-wire control with auxiliary switch accessory.
15
Type SyncCap Power Quality Switch Installation and Operation Instructions
Two-Wire Control
The control can also be operated by an SPST device
(two-wire control). A factory-installed accessory is
required for two-wire control operation.
SyncCap
Voice Coil Operator
Auxiliary
Switch
Microprocessor Logic
The control circuit (pin D) must be closed for a minimum
of 300 ms and maintained closed for a close operation.
The SyncCap switch will open as soon as the control
voltage is removed from pin D. Both the synchronizing
voltage signal and the control power are provided
through pin A and must be maintained at all times for
proper operation.
Input Circuitry
"A"
Contact
"B"
Contact
Connection diagrams for the two-wire control, with and
without auxiliary switch accessory, are shown in Figures
21 and 22.
6-Pin
Receptacle
A
B
D
E
C
F
SyncCap
Voice Coil Operator
Microprocessor Logic
Input Circuitry
Control
Voltage
Neutral
Synchronizing
Voltage
5-Pin
Receptacle
A
B
Neutral
Synchronizing
Voltage
C
D
Control
Voltage
Figure 21.
Connection diagram for two-wire control.
16
E
Ratings for Auxiliary Switch
Maximum Voltage
220 Vdc, 250 Vac
Maximum Switching Power
125 VA
Maximum Switching Current
2A
Figure 22.
Connection diagram for two-wire control with auxiliary switch accessory.
!
S260-16-1
SAFETY
FOR LIFE
SERVICE INFORMATION
Service Requirements
4. Apply proper test voltage to the ungrounded bushing. The
switch should withstand the test voltage for 60 seconds.
IMPORTANT: The SyncCap switch must be in the
closed position prior to transporting the switch. Failure to
do so can result in misoperation of the SyncCap Switch.
5. Reverse the test and ground connections to the bushings.
The Kyle Type SyncCap Power Quality switch is calibrated at the factory for proper operation. There are no userserviceable components on the SyncCap.
The switch has been designed with a minimum mechanical life of 25,000 operations. It requires routine inspection to check for physical damage and to verify operation.
Frequency of Inspection
WARNING: Hazardous voltage. The switchgear
and high voltage transformer must be in a test
cage or similar protective device to prevent accidental
contact with high voltage parts. Solidly ground all
equipment. Failure to comply can result in death,
severe personal injury, and equipment damage. T221.3
!
CAUTION: Radiation. At voltages up to the
specified test voltages, the radiation emitted by
the vacuum interrupter is negligible. However, above
these voltages, radiation injurious to personnel can be
emitted. See Service Information S280-90-1, Vacuum
Interrupter Withstand Test Voltage Ratings Information
for further information.
G109.2
!
Because these switches are applied under widely varying
operation and climatic conditions, service intervals are
best determined by the user based upon actual operating
experience.
High-Potential Withstand
Testing
Use the following procedures to perform high-potential
withstand tests at 75% of the rated low-frequency withstand voltage for one minute. See Table 14.
To prevent damage to the SyncCap circuitry during testing, ground the control receptacle by wiring the pins
together and connecting to ground.
Closed Contacts Test
1. Close the switch contacts.
2. Ground the switch.
3. Apply proper test voltage to the bushing terminal. The
switch should withstand the test voltage for 60 seconds.
Open Contacts Test
1. Open the switch contacts.
2. Ground the switch.
3. Ground the bushing on one side of the switch.
6. Apply proper test voltage to the ungrounded bushing.
The switch should withstand the voltage for 60 seconds.
Withstand Test Results
The high-potential withstand tests provide information on
the dielectric condition of the switch.
If the switch passes the closed-contacts test and fails the
open-contacts test, the cause is likely to be in the interrupter assembly.
If the switch fails the closed contacts test, the cause is
likely to be diminished electrical clearance or failed
insulation.
TABLE 14
Type SyncCap Vacuum Interrupter Withstand
Test Voltage Ratings Information
Description
75% of Rated
Low-Frequency
Withstand Voltage
(1 minute dry) (kV rms)
SyncCap, 15.5 kV, 110 kV BIL
37.5
SyncCap, 15.5 kV, 125 kV BIL
45
Inspection of SyncCap Module
If the SyncCap module was exposed to an external
flashover, an inspection process is recommended to
assure proper operation of the switch. Should the
SyncCap exhibit external flashover attributes (carbon
tracking or discoloration), the following procedure is recommended to restore the encapsulation back to its original condition:
1. Remove device from service.
2. Inspect module for damage to the terminals. Remove
any damaged terminals and replace.
3. Inspect module for damage to the module rods. If
there is damage to the module rods, the module must
be replaced.
4. Verify through careful inspection that there is no damage to the housing or head casting that could inhibit
proper operation.
5. Clean the damaged module with isopropyl alcohol
and a scratch-free, nylon scouring pad to remove any
carbon deposit.
6. With a clean rag, apply a thin coat of dielectric silicone grease to the cleaned areas.
7. Confirm the dielectric strength of the module by performing high-potential withstand testing. Confirm both
phase-to-ground and phase-to-phase conditions. See the
High-Potential Withstand Testing section of this
manual.
17
Type SyncCap Power Quality Switch Installation and Operation Instructions
TESTING AND TROUBLESHOOTING
Testing Guidelines
The recommended method to test a SyncCap switch is to
use a dc testing voltage higher than the nominal 20 V arc
voltage of the switch. This assures that a normal arc is
established at contact make and break. Lower voltages
will give inconsistent results. SyncCap switches are tested in production with a low-impedance 24 Vdc supply.
Certain precautions should be observed to ensure valid
test results.
1. Do not use the auxiliary contacts for timing purposes.
The contacts are not guaranteed to have a consistent
timing with switch opening and closing.
2. Do not use low-voltage, high-impedance circuits to
detect switch closure. The vacuum switch contacts
will make or break the low-signal circuit under very
slight movement or vibration, giving a false interruption and closure indication.
3. Passing ac signals through the switch to detect close
is not recommended. The switch is designed to close
at or near voltage zero. Trying to verify zero-closing
with low-magnitude, near-zero signal can be, at best,
difficult.
4. The SyncCap can never be more accurate than the
reference signal it is monitoring. It uses the powering
voltage to maintain its phase lock. If the powering
voltage is not in exact phase with the switch voltage,
the SyncCap will not operate at maximum accuracy.
5. Vacuum contacts become less effective with repeated no-load mechanical operations. That is, if they do
not interrupt current their performance degrades. This
is due to the forming and breaking of cold welds on
the contact surfaces. The SyncCap is intentionally set
to interrupt at a current peak to clean the contact surfaces without causing undue wear on the contacts.
After many no-load operations, it may be necessary
to operate the switches under normal switching load
several times before accurate closing is re-established.
18
Unit Will Not Respond to Control
Signals
• Check all cables for proper connection.
• Verify that the switch has power.
• Verify that the toggle switches under the sleet hood
are locked in the proper position for the required
application.
If the three steps above do not resolve the problem, contact your Cooper Power Systems representative. There
are no user-serviceable components on the SyncCap.
!
S260-16-1
SAFETY
FOR LIFE
Field Worksheet
Installation Variables: Grounded Cap Bank; Positive Phase Rotation
As Planned (assumed)
Field Condition
Basis of Determination
System
Phase Rotation
A-B-C
Bank Grounding
Solidly Grounded
Reference Voltage
phase connection
A ph
LG
SyncCap Toggle Switch
A phase: S1/S2
Zero (ref): 1/3
B phase: S1/S2
120° lag: 3/3
C phase: S1/S2
60° lag: 1/1
VA Reference phase zero crossing: set for 180° lag
VB Lagging phase zero crossing: set for 120° lag
VC Leading phase zero crossing: set for 60° lag
VA Reference phase zero crossing
A
A
C
VLG
B
60°
120°
180°
0
60
120
180
240
300
360
420
480
Electrical Degrees
Note: Choice of reference phase is arbitrary.
19
Type SyncCap Power Quality Switch Installation and Operation Instructions
Field Worksheet
Installation Variables: Grounded Cap Bank; Negative Phase Rotation
As Planned (assumed)
Field Condition
Basis of Determination
System
Phase Rotation
A-C-B
Bank Grounding
Solidly Grounded
Reference Voltage
phase connection
A ph
LG
SyncCap Toggle Switch
A phase: S1/S2
Zero (ref): 1/3
B phase: S1/S2
60° lag: 1/1
C phase: S1/S2
120° lag: 3/3
VA Reference phase zero crossing: set for 180° lag
VC Lagging phase zero crossing: set for 120° lag
VB Leading phase zero crossing: set for 60° lag
VA Reference phase zero crossing
A
A
B
VLG
C
60°
120°
180°
0
60
120
180
240
300
Electrical Degrees
20
360
420
480
!
S260-16-1
SAFETY
FOR LIFE
Field Worksheet
Installation Variables: Ungrounded Cap Bank; Positive Phase Rotation
As Planned (assumed)
Field Condition
Basis of Determination
System
Phase Rotation
A-B-C
Bank Grounding
Ungrounded
Reference Voltage
phase connection
A and B phases LL
SyncCap Toggle Switch
30° lag: 2/1
B phase: S1/S2
150° lag: 2/3
C phase: S1/S2
60° lag: 1/1
VB Second lagging phase: set for 150° lag*
VC Third lagging phase: set for 60° lag*
VA First lagging phase: set for 30° lag*
Reference phase zero crossing
VCA
VAB
C
* with respect to the reference L-L voltage, VAB
VCA
VBC
C
B
A
VLN and VLL
VAB
A phase: S1/S2
30°
60°
150°
0
60
120
180
240
300
360
420
480
Electrical Degrees
21
Type SyncCap Power Quality Switch Installation and Operation Instructions
Field Worksheet
Installation Variables: Ungrounded Cap Bank; Negative Phase Rotation
As Planned (assumed)
Field Condition
Basis of Determination
System
Phase Rotation
A-C-B
Bank Grounding
Ungrounded
Reference Voltage
phase connection
A and B phases LL
SyncCap Toggle Switch
A phase: S1/S2
150° lag: 2/3
B phase: S1/S2
30° lag: 2/1
C phase: S1/S2
60° lag: 1/1
VA Second lagging phase: set for 150° lag*
VC Third lagging phase: set for 60° lag*
VB First lagging phase: set for 30° lag*
VBA Reference phase zero crossing
VCB
VBA
C
* with respect to the reference LL voltage, VBA
VCB
VAC
C
A
VLN and VLL
B
30°
60°
150°
0
60
120
180
240
300
Electrical Degrees
22
360
420
480
!
SAFETY
FOR LIFE
S260-16-1
23
Type SyncCap Power Quality Switch Installation and Operation Instructions
!
SAFETY
FOR LIFE
©2002 Cooper Power Systems, Inc.
Kyle® is a registered trademark of Cooper Industries, Inc.
KA2048-493 Rev: 01
P.O. Box 1640
Waukesha, WI 53187
www.cooperpower.com
KMG
12/02