M · Maximum operation power 750 V·Aac, 90 Wdc Mechanical working life 2 x 107 operations Electrical working life 2 x 105 operations (at full load) Digital inputs 6 inputs, potential-free

M. 6

Maximum demand control systems

Electrical measurement and control

M. 6Maximum demand control systems

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M.6 - Maximum demand control systems

Introduction · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

Product selection table · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5

DH96 CPP Digital unit used to control the maximum demand · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6

CVM R8 CPP Digital unit used to control the maximum demand · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8

CA-4 / MR-3 Units used to control the maximum demand · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10

Maximum demand control systems .6M

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We can find three items in most corpo-rate electricity bills:

Consumption of active energy }}

(kW ·h)Power factor consumption (kvar·h)}}

Power rating, contracted power or }}

Maximum demand.

Traditionally, utilities companies have focused their energy saving efforts on the following:

Reduction of the quantity of kW·h }}

consumedImprovement the electrical system’s }}

Power Factor

Maximum demand control

M.6

The maximum demand is the power ac-cumulated during a determined period, usually between 8 and 30 minutes.

The most common period in most coun-tries is 15 minutes.The power is calculated by the maxime-ter, which records the greatest value in a month, which is the month billed.

Calculation of the maximum demandThere are different ways of calculating the maximum demand:

Fixed Window The energy supply company provides

Definition

an impulse during each period to syn-chronise the start of the maximum de-mand period.

Sliding windowThere are no synchronisation impulses, so that the last 15 minutes are used (in the case of 15 min periods). The value is updated with the last 15 minutes each second.

Time Synchronisation WindowThis is a variation of the fixed window. The supply company provides the syn-chronisation impulse at the start of the day, which indicates the start of the first

period. During the rest of the day, the synchronisations of each period will be provided by the unit's clock instead of the electrical company. A new impulse will be sent by the company at the end of the day, in order to readjust the unit's clock with the company's clock

Thermal demandThe thermal demand is calculated by a bimetallic analogue maximeter or the electronic simulation of a bimetallic maximeter

However, there is a third factor that can be taken into account to reduce the electricity bill: Adequate management of the power needed by a company.

The optimum management of contrac-ted power can allow us to:

Reduce contracted power }} and ad-just the levels of power required

Prevent Maximum demand penal-}}

ties (when a maximeter is hired)

.6 Maximum demand control systemsM

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Units used to control the maximum demand

How can we control the maximum demand?

The purpose of power control systems is to ensure that the maximum contracted power limit is not exceeded.

Loads that can be disconnected:Packaging machines}}

Grinding machines}}

OtherIn general, all machines that do }}

not affect the main production process or which are not essential.

In addition, an electrical demand con-trol program is highly recommended in the processes with an operation that

CIRCUTOR, SA offers all units re-quired for the optimum management of energy in your company.

The different units measure instantane-ous power and automatically calculate the power used that is exceeding the contracted power. Therefore, any load can be quickly and reliably disconnect-ed with built-in relays.In addition, the CVM-R8 CPP and CA-4 units can con-trol different rates and guarantee a more accurate control of your installation, de-pending on the contracted rate.

Operating methods

There are 2 ways to prevent exceeding the maximum demand:

has large variations in the maximum demand and low load factors, such as smelting, mining, automotive, textile and paper companies, among others.

With power control

Without power control

Preventive

The preventive method is used in com-panies that do not wish to connect or disconnect loads automatically.The system prevents any value above the contracted power with a system of visual or acoustic signals, so that an operator can manually disconnect de-termined loads.

Predictive

The predictive method is the most com-mon and intelligent method.It makes a forecast of the situation at the end of the period and optimises loads, so that the maximum number of loads can be

connected, ensuring that the maximum limit programmed is not exceeded.This system is obviously valid for fixed win-dow requests or windows with synchro-nisation.


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Applications

How does it affect your bill?

This is a real example, with an excess power consumption that affects the monthly electricity bill:

Contracted power: 136 kW

Maximeter reading: 253 kW

Maximum power allowedno additional charges * : 136 kW x 1.05 = 142.80 kW

Excess power consumption * :253 kW - 142.80 kW = 110.2 kW

penalty kW * :110.2 kW x 2 = 220.4 kW

Total kW billed:220.4 kW + 253 kW = 473.4 kW

The adequate management of the power consumption would not have exceeded 136 kW and 205.1 € would have been billed instead of 713.28 € as regards the "Power Bill" (71.25 % less).

* In other countries, the penalty formula is different and it can be even stricter

Product selection tableNo. of

controlled loads

Company impulse input

Operating systems Operating method Software

used Communications Page

DH

96 C

PP

4 Yes Any Preventive or predictive Easy Comm RS-232 or

RS-485 (1) 6

CVM

-R8

CPP 17 (2) Yes Fixed window Predictive - - 8

CPP

-BT

/ C

PP-C

T

128 YesWindow sliding or

fixed

Preventive or predictive Power C RS-232 10

(1) Type DH96 CPP-RS(2) With expansion module CVM-R10


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Digital unit used to control the maximum demand

DH96 CPP

Power supply circuit 230 Vac (-15...+10%)

Consumption 4 V·A (without card), 7 V·A (with card)

Frequency 45..0.65 Hz

Measurement circuit

Reading accuracy 0.5 % (±1 dig)

Resolution 10 bits

Overvoltage (permanent / during 10 s) 1.2 Un / 2 Un

Overload (permanent / during 10 s) 1.2 In / 5 In

Measurement margin 2 ...120 %

No. of conversions per cycle 32

Display Seven 14 mm segments, red

Digits 4

Display refresh < 1s

Decimal place Programmable

Scale excess indicator " - - - - "

Insulation Between the input, measurement and optional card output

Test voltage 3 kV, 50 Hz, 1 min

Impulse test 4 kV (1.2 / 50 ms)

Output relays 1 simple contact

Isolation voltage 750 V contact-contact / 2 000 V Contact-Coil

Thermal current (lth) 5 A

Maximum operation power 750 V·A

Mechanical working life 2 x 107 operations

Electrical working life 30 000 operations at 5 A and 250 V

Digital inputs 2 inputs, potential-free contacts (20 mA-24 Vdc)

Ambient conditions

Storage temperature - 40 ... +70 ºC

Operating temperature -10 ... +65 ºC

Build features

Box material ABS V0, grey anthracite

Degree of protection Box and terminals: IP 20 / Front panel: IP 54

Weight 550 g

Standards

IEC 1010, IEC 348, IEC 664, VDE 0110, VDE 0435

FeaturesDescription


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ConnectionsDimensions

Software


DH96 CPP

Communications Type Code

- DH96 CPP M60201

RS-485 DH96 CPP-RS M60211

References

M 6 X X X X 0 0 X X

CodeInternal Code

Auxiliary power supply

Standard (230 V) 0 100 ... 120 V ac 1380 ... 400 V ac 3 480 ... 500 V ac 4

18 ... 36 V dc 736 ... 72 V dc 840 ... 170 V dc 9

Current inputStandard (.../ 5 A) 0

... / 1 A 1

Coding table


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CVM R8 CPP

Power supply circuit

Voltage Single-phase 220 Vac ( -15 ... +10 %)

Frequency 50 ... 60 Hz

Consumption 7 V·A

Output relay characteristics

Number of relays 8

Isolation voltage (Ui) 270 V ac / 125 V dc


AC 11 Ie / Ue 2 A / 250 V ac

DC 11 Ie / Ue 2 A / 30 V dc

Maximum operation power 750 V·Aac, 90 W dc


Electrical working life 2 x 105 operations (at full load)

Digital inputs 6 inputs, potential-free contacts(20 mA - 24 Vdc)

Analogue inputs 2 inputs 0 ... 2 Vdc

Display

1 x 8 Character alphanumerical display (50 x 15 mm)

Ambient conditions


Build features

Type of box Self-extinguishing plastic module

Connection Metallic terminals with "posidriv" screws

Fixing Adjustable to DIN rails 46277 (EN 50022)(Optional fixing with screws)

Cover Lexan Front

Degree of protection Embedded relay : IP 41 / Terminals : IP 20

Dimensions 140 x 70 x 110 mm (8 modules)

Safety Category II (EN 61010)

Standards

IEC 255, IEC 348, UNE 21 136, IEC 664, VDE 0110, UL 94

FeaturesDescription


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Connections

Type Code

CVM R8 CPP M60311

References

DimensionsOperation


CVM R8 CPP

Fixed window

The unit is synchronised with the company's maximeter during its op-eration. To do so, it requires the maximeter's synchronism impulses. When it receives the impulse, it ends the period and starts a new one.

Measurement by impulses

The measurement of energy consumed during each integration period is calculated with the impulses emitted by a meter with an issuer con-tact or a different measurement unit with an energy impulse output.


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CA- 4 / MR-3

CA-4

Power supply circuit 24 V dc (± 25 %)

Consumption 500 mA

Output relays 4 relays

Isolation voltage 1,000 V contact-contact 4 000 V Contact-Coil


Maximum operation power 1,500 V·A


Electrical working life 350 operations / hour (at full load)

Digital inputs 4 inputs, potential-free contacts (10 mA - 24 V dc)

Ambient conditions


Build features

Fixing Can be coupled to DIN 46277 rail(EN 50022)

Cover Lexan Front

Safety Category I (EN 61010)

Standards

EN 50082-1, EN 50082-2, EN 61000-3-2, EN 61000-3-3, EN 61010-1

MR-3

Power supply circuit 24 V dc

Consumption 65 mA

Output relays 3 relays 10 A / 250 Vac

Digital inputs 3 polarised inputs

Communications RS-485

Ambient conditions


Quickness of}} of load connection / dis-connection response

Impulse input}} to measure the maximum demand being measured by the company's meter (when the supply company allows for its installation). If the supply company does not allow its installation, we can install our own meter with the impulse output for such purposes

Work with the }} most common maximum demand systems (sliding window and fixed window)

With auxiliary power supply }} PS-24, DCSafety times to enter medium voltage }}

lines in the systemSimulation system}} , to carry out a test

before starting the system and prevent un-wanted operations

Top }} performance / price, with incredible short-term investment returns

FeaturesDescription


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Software

Control of up to 128 loads or groups of loads.

System of priorities, to distinguish the loads with a lower priority and which can be com-monly disconnected and the loads with the highest priority that must only be disconnect-ed when needed, in order to avoid exceeding the contracted power.

Optional creation of load groups with the same priority and FIFO or LIFO connection / disconnection sequences.

Definition of up to 4 load states: Active, Inac-tive, Forced active and Forced inactive (for example, in the case of forced inactive, we can carry out the repair of a load with no need to worry about the fact that the said load can be reconnected)It detects when the load is connected or stopped.

Modular system adapted to the number of loads in any installation. It only acquires what is needed.

It has a modular system that can connect / disconnect loads near the loads them selves to simplify the cabling structure, reduce ca-bling distances and improve the response time.

Communications and software included to display the information in a PC and store the connections and disconnections of our power control unit.

Optional programming of a contracted power calendar for the next 2 years. Optional pro-gramming of contracted power calendars in accordance with the hours of the day, type of day, etc.

Individual calendars available for loads, not only to start and stop them automatically, but also to guarantee the perfect control of power, knowing the loads in operation prior to said tasks.

Firstly, the user defines the basic power con-trol parameters, such as the type of window, period of integration, etc.

Likewise, the type of calendar of contracted power or the power ratings we wish to attain will be assigned, as well as the types of dates when the rates used by the electricity com-pany will be applied. The software supports up to 8 types of rate on 8 different dates.

Assignment of basic parameters

Assignment of the calendar Assignment of the rate

Control of loads Modular system


CA- 4 / MR-3


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Creation of load groups

Lists of loads New load

Calendar of loads

Real-time monitoring

Secondly, the groups of loads are defined, the disconnection system of the loads of this group is assigned (FIFO or LIFO) and the disconnection order of the group in relation to others is also assigned (if it is the first one or the last one, etc.)

These groups are created in accordance with the installation (for ex.: groups of compres-sors or lights, etc.). Next, the loads corre-sponding to any MR3 or the same CA4 are assigned to each group. The loads in each group are unlimited.

We can see that the power disconnection or-der consumed by each load is displayed at all times, including the total power per group, informing the user whether this is a FIFO or LIFO sequence.

After creating the groups, the user must sim-ply program the loads with their correspond-ing power, the relay that controls them and if a specific calendar can be created for each one.

For example, we can force the disconnec-tion of the machine during a determined time, with no option to connect it again during said period.This period can even be defined over a two year long period, thanks to the memory capacity of the CA-4.

When all parameters have been defined, we can create a simulation to check the correct operation and complete the system's con-figuration.

When the system has been started, the Power Control Software can be used to check the status of loads in real time, stop them manually or even maintain them per-manently stopped, by simply selecting the corresponding software.

The load status is clearly defined and the in-formation displayed will vary, depending on the status:


CA-4 / MR-3


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Description Type Code

Load controller + software CA-4 M60411

3-line expansion MR-3 M60412

Basic power control kit (3 Loads):1 CA-4 controller1 PS-24 Power Supply 24V dc1 power control software installed in the box (280 x 280 x 150)

CPP-B M60421

References Dimensions

MR-3

CA-4

Connections


CA-4 / MR-3


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Documents

M · Maximum operation power 750 V·Aac, 90 Wdc Mechanical working life 2 x 107 operations Electrical working life 2 x 105 operations (at full load) Digital inputs 6 inputs, potential-free