Effective May 2016

Instruction Booklet IB158001EN Supersedes May 2013

Advanced service repair and

troubleshooting instruction bulletin
Contents
Description Page
Service and maintenance instructions . . . . . . . . . 2
Torque chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

This instruction manual is published solely

for information purposes and should not be
considered all-inclusive. If further information is
required, you should consult an authorized Eaton
sales representative.
The sale of the product shown in this literature
is subject to the terms and conditions outlined
in appropriate Eaton selling policies or other
contractual agreement between the parties.
This literature is not intended to and does not
enlarge or add to any such contract. The sole
source governing the rights and remedies of
any purchaser of this equipment is the contract
between the purchaser and Eaton.
NO WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR MERCHANTABILITY,
OR WARRANTIES ARISING FROM COURSE
OF DEALING OR USAGE OF TRADE, ARE
MADE REGARDING THE INFORMATION,
RECOMMENDATIONS, AND DESCRIPTIONS
CONTAINED HEREIN. In no event will Eaton be
responsible to the purchaser or user in contract,
in tort (including negligence), strict liability or
otherwise for any special, indirect, incidental
or consequential damage or loss whatsoever,
including but not limited to damage or loss of
use of equipment, plant or power system, cost of
capital, loss of power, additional expenses in the
use of existing power facilities, or claims against
the purchaser or user by its customers resulting
from the use of the information, recommendations
and description contained herein.
Instruction Booklet IB158001EN
Effective May 2016
Service and maintenance instructions
NOTICE
FOR ELECTRICALLY QUALIFIED AND TRAINED PERSONNEL ONLY.
Eaton’s Engineering Services & Systems (EESS) is well trained and
qualified to conduct these services. Please contact your nearest
Eaton sales office for obtaining this service through Eaton.
Capacitors (switched)
Maintenance testing guidelines
Under normal service conditions, once a capacitor is installed, no
further service is required during the life of the capacitor. However,
periodic maintenance will maximize equipment life.
The following information is a guide for service and maintenance
services. Capacitors should be installed, operated, and maintained by
qualified personnel as defined by OSHA 29CFR1910 subpart 5. These
instructions do not cover all details, variations, or combinations of the
equipment, its installation, checkout, and safe operation. Care must be
exercised to comply with local, state, and national regulations, as well
as safety practices for this class of equipment.
For a complete list of Instruction Leaflets (ILs) and Instruction
Bulletins (IBs), access the Eaton website at www.eaton.com/pfc.
You can also contact Eaton’s Technical Resources Center at
1-800-809-2772 option 4 and then option 2 for any information
regarding the capacitor banks.
Prior to testing
• Procure and review all drawings associated with the equipment
being tested
• Study all instructional documents (operation and maintenance
manuals) applicable to the equipment
• Obtain a copy of the appropriate test form to record test results
• Verify suitability and accuracy of equipment to be used for testing
• Record all existing equipment settings as well as settings
resulting from any necessary adjustments. The proper settings
for testing should be supplied by the customer’s engineer or
from a power systems study performed prior to commissioning
the equipment
Necessary equipment
• Personal protective equipment (PPE)
• RMS multi-meter
• Clamp on ammeter (1000 V, Cat IV)
• Torque wrench with internal and external hex sockets
• Screwdriver bit for tightening—PZ2 / PH1 / 5.5 x 1
• Insulation resistance tester (Megger-1000 volt)
• Capacitance meter (BK Precision 878B or equal)
• Telescopic magnetic pickup tool if readily available
m WARNING
DO NOT ATTEMPT TO INSTALL OR WORK ON EQUIPMENT WHILE IT
IS ENERGIZED.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT BEFORE PROCEEDING
WITH TESTING. ASSUME ALL CIRCUITS ARE ENERGIZED. CONFIRM
PRIMARY SOURCES OF POWER ARE DISCONNECTED, TAGGED, AND
LOCKED OUT. ALWAYS FOLLOW ALL LOCAL, STATE, AND NATIONAL
REGULATIONS INCLUDING OSHA REQUIREMENTS AND GENERALLY
ACCEPTED SAFETY PROCEDURES.
2 EATON www.eaton.com
Advanced service repair and
troubleshooting instruction bulletin

Inspection and test procedures
Visual and mechanical inspection
1. Inspect physical and mechanical condition of the unit as installed.
Check for correct mounting and required clearances.
2. Inspect all components of the unit including fuses, indicating
lights, and conductor landing lugs for any signs of improper
termination, overheating, discoloration, or deterioration.
3. Inspect the capacitor cells for any leaks or deposits (sand, dust,
dirt, grime, etc.) and/or bulging on top of the capacitors. If
present in excess, these contaminants could severely affect the
creepage and clearance distances between line to line and line
to ground. These contaminants should be cleaned by air suction
and care should be taken to prevent such ingress or frequency of
preventive maintenance should be improved.
4. If dust is seen, a magnetic pickup tool should be used to verify
the conductivity of the dust. Non-magnetic non-conducting dust
combined with humidity and moisture also results in reduced
creepage distances and care should be taken that the dust filters
are regularly replaced and any dust accumulation is cleaned out
via suction.
5. Verify that capacitors are electrically connected in their
specified configuration.
6. Inspect the discharge resistors fitted integral to the terminals.
Check for secured and snug fit, discoloration, cracked or
chapped modules.
7. If reactor is present, inspect the reactor for any signs of
discoloration and overheating.
8. Inspect and ensure the thermal switch wiring and the
switches are securely in place into the hotspot region of
the reactor winding.
9. Inspect the electrical connections and perform a pull test on
all customer and factory connections by giving a firm tug on all
the connections.
10. Inspect the cleanliness of the dust filters and replace if soiled
or dirty.
Electrical tests
1. Perform a terminal-to-terminal continuity and resistance
measurement using the multi-meter. It should not read open,
very high, or unequal resistance between terminals. (Variation
of ±0% is acceptable.)
2. Perform insulation-resistance tests from terminal(s) to case for
30 sec on the capacitor cells. Ensure any 300 V rated control
components are isolated/disconnected from the test path.
Test voltage and minimum resistance shall be as follows:
Maximum rating Minimum Recommended minimum
of equipment test voltage, insulation resistance
in volts DC in volts in mega-ohms
250–500 500 25
600 1000 100
Advanced service repair and Instruction Booklet IB158001EN
troubleshooting instruction bulletin Effective May 2016

3. Inspect all electrical connections for high resistance using both 5. Low-voltage tests
of the following methods: Where practical, a control power only low-voltage test can be
a. Use of low-resistance ohmmeter. used to verify the electrical operation of the bank.

b. Verify tightness of accessible bolted electrical connections a. Remove the three fuses on the primary side of the control
by calibrated torque-wrench. If required, torque the terminals power transformer (CPT) located on the control panel.
to 2.3 Nm using the recommended Philips head Ph 1 or b. Tie/tape the door interlock limit switch shut to allow the
Pozidriv Pz 2 bit. control circuit interlock to be defeated temporarily.
c. Measure resistance of integral discharge resistors. The c. Use an available 120 V power source, suitably fused,
discharge resistors are three-pronged internally delta and connect the phase to the fuse and neutral to the
connected just like the capacitors and have a printed value grounded terminal.
of the total resistance on them. The measured resistance d. While taking appropriate electrical precautions, energize the
between any two prongs should measure approximately two 120 V supply and turn the ON/OFF switch on the front of the
thirds of the printed value. door to ON position.
Example: 120 kohms for a 180 kohm resistor.
e. The controller should power on and the ventilation fans
Example: 180 kohms for a 270 kohm resistor. should immediately power up. Ensure the fans are rotating
4. Measure the capacitance of all terminal combinations and verify in the correct direction by feeling the draft of the air from the
it with the following table. +10% and –5% variation would be enclosure is in “exhaust” mode.
considered an acceptable value for a good capacitor. f. Engage the controller in the manual mode and step through
Rated voltage 240 480 600 the various stages, one step at a time, and hear for the
Nameplate kvar contactor to pull in.
(three-phase) uF uF uF
g. Once all contactors have been verified to energize,
1.00 23.0 5.8 3.7 disconnect the 120 V power supply, remove the defeat
1.50 34.5 8.6 5.5 mechanism of the door interlock, and replace the primary
2.00 46.1 11.5 7.4 control fuses at the CPT.
2.50 57.6 14.4 9.2
3.00 69.1 17.3 11.1 6. Post testing full voltage test
4.00 92.1 23.0 14.7 a. Remove all test equipment and tools used during testing.
5.00 115.1 28.8 18.4 b. Replace all barriers and covers, close all doors, and secure
6.00 138.2 34.5 22.1 all latches.
6.25 143.9 36.0 23.0 c. Review all test results. If the results are satisfactory,
7.50 172.7 43.2 27.6 the equipment is qualified for service and proceed with
commissioning/re-commissioning the unit in accordance
8.00 184.2 46.1 29.5
with the Operations and Maintenance Manual.
8.33 191.8 48.0 30.7
d. If the results are in question, contact the Technical Resource
10.00 230.3 57.6 36.8 Center to report results.
12.50 287.8 72.0 46.1
e. If the unit is found to be satisfactory, defeat the door
15.00 345.4 86.3 55.3 interlock switch, place a clamp-on meter on one of the line
16.66 383.6 95.9 61.4 conductors, ensuring the range is within the rated nameplate
17.50 403.0 100.7 64.5 current of the unit and while maintaining proper PPE gear,
20.00 460.5 115.1 73.7 energize the unit and record the current reading.
25.00 575.6 143.9 92.1 f. The current should be within -–5% to +10% of the rated
30.00 690.8 172.7 110.5
nameplate current at rated voltage.
35.00 805.9 201.5 128.9 g. Ensure that the door interlock defeat is removed before
returning the unit to normal operation.
40.00 921.0 230.3 147.4
45.00 1036.2 259.0 165.8 Reactors
50.00 1151.3 287.8 184.2
55.00 1266.4 316.6 202.6 1. Perform a terminal-to-terminal continuity and resistance
measurement using the multi-meter of each coil of the reactor.
60.00 1381.6 345.4 221.0 It should not read open, very high, or unequal resistance
between the three windings (a variation of ±15% is acceptable).
2. Perform insulation-resistance tests from terminal(s) to case for
30 sec on the reactor. Ensure the 1 A control fuses and any
other 300 V rated control components are isolated/disconnected
from the test path. Test voltage and minimum resistance shall be
as follows:
Maximum rating Minimum Recommended minimum
of equipment test voltage, insulation resistance
in volts DC in volts in mega-ohms
250–500 500 25
600 1000 100

EATON www.eaton.com 3
Instruction Booklet IB158001EN Advanced service repair and
Effective May 2016 troubleshooting instruction bulletin

Torque chart

Location Torque Torque

identifier table value Remarks
1 Customer incoming conductor to mechanical lug (customer wiring) 275 in-lb For lug size suitable to accommodate conductors maximum up to 350 kcmil
375 in-lb For lug suitable to accept conductors greater than 350 kcmil up to 750 kcmil
2 Mechanical lug to bus bar (factory wiring) 20 ft-lb
3 4 AWG wire terminated onto bus (factory wiring) 60 in-lb
4 4 AWG wire terminated onto reactor (if applicable) (factory wiring) 60 in-lb
5 4 AWG wire terminated onto fuse (factory wiring) 60 in-lb Bottom terminals
6 4 AWG (pigtail) wire terminated onto contactor (factory wiring) 45 in-lb Bottom terminals
7 Capacitor mounting M8/M10 stud (factory wiring)  14.8 ft-lb Stud on bottom of capacitor
8 8 AWG wires to capactors contactors (factory wiring)  22 in-lb Top terminals
9 8 AWG wires to contactors (factory wiring)  45 in-lb Top terminals
10 Nest assembly mounting bolt (not a factory torqued live part) 20 ft-lb Rear of nest
11 Reactor mounting bolt (not a factory torqued live part) 20 ft-lb
 Customer wiring if expanding unit in field.

For technical support and application engineering

assistance, please contact Eaton’s TRC at
1-800-809-2772 option 4, option 2
Eaton
1000 Eaton Boulevard

or email pfc@eaton.com
Cleveland, OH 44122
United States
Eaton .com

© 2016 Eaton
All Rights Reserved Eaton is a registered trademark .
Printed in USA
Publication No . IB158001EN / Z18245 All other trademarks are property
May 2016 of their respective owners .