User’s Guidelines ZCTC-02 Capacitor Duty Thyristor Switch TAS Powertek Pvt. Ltd. Corporate Office: W-61, MIDC, Ambad, Nasik , Maharashtra (India) Tel: +91-(253) /

Specifications: Mains input: 170V to 500V a.c. Line to Line. 50/60Hz. Electronics Supply: Built in SMPS capable of handling the transient supply transients and spikes and giving stable output to Electronics even with one phase absent. Input command to Zero crossing sensing and switch on response time: 20mS max. Zero crossing sensing limits: ±6V… max. (typical ± 3V…). Digital I/P & O/P: 0 to 1V for Low & 10V to 12.5V for High. Electronics, Power section & Earth isolation level: 2.5kV~. (Cooling fan for heat sink cooling isolation level 1.5kV~.) Operating Temperature (Ambient): 0°C to 50°C. Storage Temperature: -10°C to +75°C. Watt Loss: Switch in ON condition with full loading.(Maximum value) Item no.ZCTC-40/2 : 80Watt. Item no.ZCTC-80/2 : 150Watt. Item no.ZCTC-110/2:200Watt. Item no.ZCTC-140/2:300Watt. Item no.ZCTC-210/2:450Watt. Switch in OFF condition. All types: 30Watt maximum. (In case if the switch is to be used for the Auto-Capacitor panel for Voltage control; then discharge resistors will be added which may increase the watt loss per switch extra.) Maximum temperature rise of the casing (Heat Sink) over ambient is 25°C. i.e. 75°C maximum. Line chokes voltage drop at full loading = 0.2% of the phase voltage. (e.g. 0.57V~ at full rated current {40/80Amp}.) Auxiliary Contact for bypass contactor/ Thyristor short tripping: Rating 0.5Amp / 240V~ or 2Amp/48V…. Switch ON time: Maximum 1 cycle of mains. (i.e. time for input control command “High” to thyristor switch-on.: If zero Voltage is sensed.) Switch OFF time: Maximum ½ cycle of mains. (i.e. time for input control command “Low” to thyristor switch-off.) Spike current Detection: 1.8 times the peak of max. rated current. Time: sensing instantaneous. Switch OFF in ½ cycle of mains. Over current Detection: 1.1 times the max. rated current. Over temperature Detection: 80°C - Heat-sink temperature. Maximum permissible dV/dt during Power ON to avoid spurious turn-ON of the switch for ½ cycle: 1000V/mS. Various Timers: Thyristor switch ON/OFF & Bypass Contactor command delay = 5 Sec. Over Temperature Fault tripping to Auto-Resuming time delay = 15 Min. First Occurrence of Spike Current fault tripping to Auto-Resume time delay = 1 Min. Successive 2 nd Occurrence after resuming within 5 sec will go in Permanent tripping. Over Current Detection Time:For 25 sec continuous over-current. Auto Resume time after tripping = 25 sec.

Power Connection Schematic SNUBBER Electronics +12V P.S. & Ext. I/O s. Neutral 0.5mm 2 Wire. N Fan connection Ph (240Vac) GND - -Ve of DC regulated supply. 12P - +ve of DC regulated supply. CMD – Control Command for On/Off. FLT RST – Hardware command for fault reset. FB FLT – Fault indicating Digital output. AO-C – Aux. Output NO one terminal. AO-NO – Aux. Output NO another terminal. Control wiring terminal connections

Typical connections of Control section in PF controller panel. PF relay of TAS: LCPF-02/T or SPF-**/T +12V 0 V Fault Reset Thyristor Switch 1 (ZCTC-***/2) GNDGND CMDCMD RSTRST FLTFLT Thyristor Switch 2 (ZCTC-***/2) GNDGND CMDCMD RSTRST FLTFLT Thyristor Switch 3 (ZCTC-***/2) GNDGND CMDCMD RSTRST FLTFLT LCPF-02/T or SPF(01/03)/T TFB1 TFB2 TFB3 12P C1 C2 C3 12P12P 12P12P 12P12P Power Factor Controller Relay +12V 0 V Fault Reset 1K Thyristor Switch 1 (ZCTC-***/2) COMCOM CMDCMD RSTRST 12V12V FLTFLT Thyristor Switch 2 (ZCTC-***/2) COMCOM CMDCMD RSTRST 12V12V FLTFLT Thyristor Switch 3 (ZCTC-***/2) COMCOM CMDCMD RSTRST 12V12V FLTFLT Fault Indication Typical connections of Control section in PF controller panel. PF relay of Other make than TAS: LCPF-02/T or SPF-**/T - 2 -

1.Provide the Discharge resistors across the capacitors. Faster the switching operation, lower should be the ohm value of these resistors. If fastest switching time is 100mS, then resistor value in ohm multiplied by Capacitor value in Farad should give the time constant < 1Sec. (10 times the fastest switching time from the controller). Please be careful while calculating the wattage of these discharge resistors. 2.Keep the control command and other control wires (+12V) away from any power wiring. It is recommended to route these control wires in separate channels. 3.Earthing in such electronic panels should be of two types. a) Power Earthing. b) Electronic Earthing. The earth-pits used for such earthing should also be separate. The earthing connection provided on SMPS of ZCTC module should be connected to power earth of the system. 4.Every ZCTC should have at least 30mm clearance from all the sides from other ZCTCs or any other electrical item. 5.The panel in which these equipments are mounted should protect them from dust and conductive suspended particles. 6.It is recommended to put the Fuses or MCBs/ MCCBs in line with every ZCTC. 7.It is recommended to put a fixed capacitor bank (without suppression chokes but with fuses ) of 10% rating of the total switched kVAr of the system. This helps in terms of absorbing the line transients and provides additional protection to ZCTCs. This also provides the protection to ZCTCs against dV/dt while mains turn ON. 8.Avoid touching the electronics of the ZCTCs even when they are not energized. 9.Do not use contactor switching capacitor panel or fixed capacitor switching on the same line as where ZCTCs thyristorised capacitor switch ON panel is installed. 10.Provide the proper cooling arrangement to the panel so that panel internal temperature does not exceed 50°C. 11.Regular cleaning with vacuum cleaner helps giving the everlasting performance. Recommendations for Usage In Auto-PF control panel

Fault Finding Guidelines. 1.Unit trips with Spike current indication as soon as input turn ON command is given. : Check the capacitor current by connecting them to mains separately. It should not be more than the rated current of the switch. : Observe the wave-shape of the current through the capacitor by connecting it to the same supply line. (without ZCTC). Check if the harmonic current distortion is causing the peaky natured current wave- shape. Check if this peak is more than 1.6 times the peak of the rated current of the ZCTC. : Check the power wiring connections at input of ZCTC and from ZCTC to capacitor banks for any loose/faulty connection. Tighten all the power wiring connection related to that specific ZCTC. 2.Unit trips with Over current indication during the normal operation. : Check if the capacitor current is more than the rated current of ZCTC by 1.1 times in any one of the three phases. : Check the harmonic currents thro’ the capacitors and check if they are causing the peaky natured currents thro’ the capacitors on continuous basis. 3.Unit trips indicating Thyristor Short Circuit. : Check the thyristor blocks of the unit for any of them to be short. In case they are short, need to replace them. (it is recommended that a person with proper know-how does this job) : Check if the direct phase to capacitor bank is carrying any current. In such case there is possible earth fault near the capacitor connections / terminals. 4.Unit trips indicating Over Temperature fault. : Check if all the cooling fans in ZCTC are working correctly. If not, check if the input supply fuse to them is blown off. Try replacing the fuse if found blown. : Check the temperature switch wiring. The temperature switch(s) is(are) mounted on heat sink and from there the connection is with the electronic module. : Check if really the ambient temperature within which the ZCTCs are working is over the desired limit.(50°C). In that case some arrangement to bring down this temp needs to be done. Either by increasing the cooling fans capacity of the panels or by connecting proper air- conditioning arrangement to the panel

5.Unit does not respond to input command as well as there is no LED indication. : Check if +12 and –12V DC supplies are coming on to main controller module. If not, possible reason is associated with SMPS. Check the input as well as output fuses of the SMPS module under such circumstances. : If +12V DC is OK, then check if permanently there is high command at external reset pin at terminal no.7 of the controller module. 6.Even with input command present, the Phase on indication green LEDs on front are not ON immediately or only 1 or 2 of the three are On and rest turns ON after the delay. : Green indications are for thyristor switches turn on indications and not the input command indications. Thus if zero crossing across switch is not detected in that phase, even with input command present, it will not turn on the thyristor. This is possible if Capacitors are charged to voltage level higher than the mains supply level. Try reducing the capacitor discharge resistors ohm value. : Check for input supply to that phase. It may be absent. Try recovering the same. : Check if electronic controller to thyristor block connections are properly connected. 7.Spike current fault does not reset after the 1 min delay. : Possibility that the unit has gone in permanent block mode. If successive two spike current faults are detected by unit or if after first auto resume after the spike current trip, another occurrence of spike current fault within 5 seconds will cause the unit to go in permanent block mode. Give the external reset and see if unit trips again. If unit trips again, try using the guidelines given in point no.1. 8.Unit randomly turns ON/Off the thyristors and does not respond properly to input command. : Check if the “0” reference at terminal no. 1 of electronic controller is firmly connected. Check the input command high level to be within +10V to +12.5V range. Check that input command low level to be within 0 to +1V range only. : If above point is correct, possibility of electronics going faulty. Try replacing the main electronics module. (Please note that the above checks should be done by the trained personnel and any problems arising out of fault finding, our company will not be responsible.) - 5 -

Corporate Office/Works/Design Centre: W-61, MIDC, Ambad, Nasik , Maharashtra (India) Tel: +91-(253) / Marketing and After-Sales Service: A/58, Kamal Pushpa, K.C. Road, Bandra, Mumbai Tel: Regional Office: Delhi 191-B, Ground Floor, Padam Nagar (Filter Market), New Delhi (India). Tel: