1. General information and purpose
This manual is dedicated to maintaining a power factor correction system using a capacitor bank, reactor and controller. These systems are used in industrial installations to reduce the load on the power grid, reduce energy losses and increase the efficiency of electrical equipment. The minimum term for performing support is every 6 months or when changes are detected in the system parameters, such as the deviation of the power factor from the specified level.
2. Safety warning
Disconnecting the power supply: Before starting any work on the power factor correction system, perform the lockout and tagout procedure according to EN 50114 and DSTU 2021:2017 standards.Protective clothing: Use protective gloves, goggles, protective equipment against electric shock and safety shoes according to ISO 11611. standards
Turning off electrical components: Before accessing system components, turn off the power and perform a no-voltage test according to EN 50114. standards
Working with electrolytes: Capacitors may contain electrolytes that are harmful to health. In the event of an electrolyte leak, use appropriate protective equipment and clean up in accordance with DSTU 2021:2017 standards.
3. Necessary tools and materials
| Tool | Specification | Quantity |
|---|---|---|
| Torque wrench | 10–50 Nm | 1 |
| Multimeter | 0–600 V, 0–2000 Ohm | 1 |
| Laser for measurement | 0.01 mm / 10 m | 1 |
| Thermometer | -20 to +150 °C | 1 |
| Stands for cables | Acceptance of 100 A | 2 |
| Wire tool | 0.5–2.0 mm in diameter | 1 |
4. Before support: Check
| Point | Verification | Acceptance/rejection criteria | Notes |
|---|---|---|---|
| Turning off the power supply | done | Power supply is disconnected | The blocking and marking procedure has been performed |
| Protective clothing | done | Protective clothing is used | Includes gloves, goggles, safety shoes |
| Electrolyte on capacitors | Absence | There is no electrolyte | Leak test performed |
| Cleanliness of the system | Acceptable | The surface is free of dust and moisture | Use a dry cloth to clean |
| Ambient temperature | Corresponding | The temperature is in the range of 20–40 °C | Thermometer measurement was performed |
5. Step by step: Procedure
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Condenser battery inspection
Perform a visual inspection for electrolyte leakage, shell damage, or cracks. Measure the temperature of the capacitors with a thermometer.
Temperature: The maximum temperature of capacitors should not exceed 40 °C.
Deviation: If the temperature exceeds 40 °C, perform an additional check for loss of capacitance.
Error: Using non-protective equipment during inspection.
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Measurement of electric capacity
Use the multimeter in capacitance mode to check the value on each capacitor.
Electric capacity: The value should be within 95–105% of the nominal value.
Indicators: If the value is below 95%, the capacitor does not meet the requirements.
Error: Measurement without power off.
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Checking the reactor
Perform a visual inspection for chipping, shell damage, or electrolyte leakage.
Resistance: Measure the resistance of the reactor in the resistance mode of the multimeter. The value should be within 0.1–0.5 Ohm.
Indicators: If the resistance is higher than 0.5 Ohm, the reactor does not meet the requirements.
Error: Measurement without power off.
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Controller calibration
Calibrate the controller using a test signal that matches the nominal value.
Voltage: The controller must be rated between 220-240V.
Indicators: If the value is out of range, perform calibration or replace the controller.
Error: Using an inappropriate test signal.
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Checking measuring devices
Use a laser to measure the distances between system elements and check for deviations.
Deviation: The maximum deviation should be no more than 0.1 mm.
Indicators: If the deviation exceeds 0.1 mm, perform a countdown or replace the element.
Error: Using an incorrect laser.
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Voltage and power measurement
Use a multimeter to measure voltage and power in the system.
Voltage: Nominal voltage should be 220-240V.
Power: Nominal power should be between 95-105%.
Error: Measurement without power off.
6. After support: Verification
| Test | Expected result | Actual result | Pass/Fail |
|---|---|---|---|
| Measurement of electric capacity | 95–105% of nominal | Measured | Pass/Fail |
| Resistance measurement | 0.1–0.5 Ohm | Measured | Pass/Fail |
| Calibration of the controller | 220–240 V | Measured | Pass/Fail |
| Voltage measurement | 220–240 V | Measured | Pass/Fail |
| Power measurement | 95-105% | Measured | Pass/Fail |
7. Concerns and solutions
| Symptom | A possible reason | Recovery |
|---|---|---|
| Power factor deviation | Changes in capacitors or reactor | Checking and replacing elements |
| Temperature change | System malfunction | Controller calibration check |
| Power outage | Inappropriate electrical capacity | Inspection and restoration of capacitors |
| Voltage change | Calibration errors | Checking and calibrating the controller |
| Measurement error | Errors in electrical capacity | Inspection and restoration of capacitors |
8. Recommended support schedule
| The task | Frequency | Estimated time | Skill level |
|---|---|---|---|
| Inspection of the capacitor bank | Every 6 months | 1–2 hours | Average |
| Checking the reactor | Every 12 months | 1–2 hours | Average |
| Calibration of the controller | Every 6 months | 1–2 hours | Average |
| Full system check | Every 24 months | 2–4 hours | Tall |
9. Referral for spare parts
| Description of spare parts | Typical specification | UNITEC-D category |
|---|---|---|
| Capacitor | 10–50 kVar | CAP-10 |
| Reactor | 1–5 kHz | REACTOR-1 |
| Controller | 220–240 V | CONTROLLER-1 |
| Thermometer | -20 to 150 °C | TEMP-1 |
| Multimeter | 0–600 V | MULTI-1 |
10. Referral
This manual complies with EN 50114, DSTU 2021:2017 and ISO 50001. Additional references: Manufacturer's technical documentation.
