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Capacitor compensation, also known as power factor correction, is a widely used method to improve the efficiency of electrical systems. In industrial and commercial power networks, inductive loads such as motors, transformers, and HVAC equipment often lower the power factor, leading to higher line losses, voltage drops, and increased operating costs.
Capacitor compensation cabinets are designed to solve this issue by automatically switching capacitor banks into the circuit. These capacitors inject reactive power to offset inductive loads, thereby improving power factor, stabilizing voltage, and enhancing overall energy efficiency. As a result, facilities such as manufacturing plants, data centers, substations, and renewable-energy farms can achieve lower energy waste and more stable operation.
To meet the technical and safety requirements of power factor correction systems, GRL has developed customized component solutions specifically for capacitor compensation cabinets. This article introduces some of the key elements, including flexible busbars, fuse holders, DNH1 fuse disconnect switches, surge protection devices, and busbar system clamps. These components work together to provide high-performance assurance, compact design, reliable protection, and long-term durability for capacitor bank applications.
GRL’s enclosed busbar systems form the electrical backbone of a compensation cabinet, distributing high currents between components. Busbar systems replace bulky cable harnesses with flat copper bars in a compact enclosure. This modular approach “drastically reduces the space required inside the cabinet” and “saves roughly 50–60%” of wiring, enabling much more compact panels. By mounting multi-pole switchgear and modules directly onto the busbars, GRL systems also speed up assembly and simplify maintenance.
Notably, modern busbar enclosures can be built to meet high safety standards, ensuring an “electrically safe installation” with minimal exposed conductors.
In capacitor cabinets, this means safer operation and easier troubleshooting during capacitor replacement or fault detection.
These are GRL-style copper busbar segments. GRL uses flat copper busbars (often in 30–185 mm widths) whose excellent conductivity and low inductance minimize losses.
These rigid bars efficiently carry the capacitor bank currents with minimal heat generation. By contrast, traditional cabling would be larger and more lossy. Copper busbars also provide a stable, pre-engineered mounting structure for switches and capacitors, reducing assembly time and space.
Specifically, copper busbars from GRL are chosen for their superior electrical properties. Copper’s low series resistance and low inductance ensure that “more electrical energy is used for its intended purpose rather than wasted”.
In practical terms, high-current copper bars avoid voltage drop and heat buildup, improving system reliability. GRL can supply custom busbars (solid copper, laminated copper) to suit any amperage. In a multi-pulse capacitor bank, these bars carry balanced phase currents directly between the capacitors and the incoming switchgear with minimal energy loss.
GRL PVC busbar insulation cover for a 12×5 to 30×5 mm flat copper bus. These busbar covers insulate and protect bare busbars in the cabinet.
They are made of flame-retardant PVC and clip on easily, preventing dust accumulation and accidental contact. Keeping busbars covered “avoids potential problems” from exposed conductors and helps the system run smoothly.
To complete the busbar system, GRL provides busbar accessories. Snap-on space covers electrically insulate the live bars, so that maintenance personnel can work safely and the panels meet touch-safety ratings.
These covers are lightweight, flame-resistant, and can be cut to length. GRL also offers clamps, spacers, and supports to mount the busbars securely in any cabinet layout. Together, the enclosed busbar (copper bar + PVC cover) forms a rugged, bus-mounted distribution bus that is ideal for high-current capacitor banks.
Click to view the GRL busbar system product catalog>>
GRL’s RT18 fuse holder series is widely used in power distribution panels and can serve capacitor circuits or auxiliary feeds. These holders mount on standard DIN rails and accept cylindrical fuses up to 22×58 mm. The GRL RT18-32-3P model shown below is a 3-pole holder with blown-fuse indicator LEDs and a robust PA66 housing.
This DIN-rail module holds three 10×38 mm ceramic fuses and accommodates up to 32 A (500 VAC) or 25 A (690 VAC) per pole. Rated to 800 V and 100 kA breaking capacity, it provides high-speed short-circuit protection for each phase of the capacitor bank. Optional LEDs on top indicate a blown fuse, simplifying troubleshooting.
1. Modular pole count – available 1P to 3P+N, so you can fuse individual phases or phase+neutral.
2. High ratings – up to 125 A (depending on model) and insulation up to 800 V.
Safety – “T2 copper” contacts and high-strength insulating material for durability.
3. Security – An external lockout can prevent accidental fuse removal, and optional indicator lamps show when a fuse has blown. The dual-lamp design ensures indication even if one LED fails.
4. Standards – Compliant with IEC 60269 fuse standards, providing reliable performance under fault conditions.
In capacitor cabinets, RT18 holders can be used to fuse individual capacitor branches or auxiliary circuits. By mounting them on DIN rails, engineers can quickly insert or swap fuses during commissioning and maintenance. The visual LED indicators also help technicians identify blown fuses without opening the circuit. In short, GRL RT18 holders integrate fuse protection in a compact, user-friendly form factor, enhancing safety and serviceability.
For main isolation and protection, GRL offers the DNH1 series fuse-switch disconnectors. These heavy-duty units combine an on/off knife switch with standard NH fuse links to protect up to 630 A. A DNH1 module can be mounted directly onto the GRL busbar system or onto a backplate.
The DNH1 series is “applied to rated current 40A–630A” with NH fuse links. It features a fully enclosed arc-quenching chamber and test/test-switch holes on the cover, allowing safe under-voltage checking without removing fuses. Each pole is electrically isolated when the switch is open, enabling safe maintenance. DNH1 units meet IEC 60947-3 and GB 14048.3 standards for low-voltage switchgear, and can optionally include mechanical or electronic blown-fuse indicators.
In a capacitor cabinet, DNH1 disconnectors are typically placed upstream of each capacitor bank or bank section. They serve two roles: manually connecting/disconnecting the capacitors and providing short-circuit protection via the NH fuses. If a capacitor or feeder shorts, the fuse-link in the DNH1 blows and the switch interrupts the current, preventing damage to the rest of the system. GRL offers NH fuse links (NT/NH series) for all common ratings, designed to “interrupt any current surge” as needed.
Key attributes of GRL DNH1/NH: Load-break switching under full rated current, built-in arc flash suppression, optional fuse monitoring, and compliance with IEC/GB standards. These ensure safe, reliable isolation of capacitor banks.
GRL components bring several clear benefits to capacitor compensation cabinets:
1. Safety and Compliance: All GRL parts are CE/CCC/TUV certified and designed to IEC standards. Enclosed busbars and covered fuse gear achieve high IP and touch-safety ratings.
2. Efficiency: Copper busbars and high-grade contacts minimize resistive and inductive losses, maximizing how much reactive power actually reaches the capacitors. Less loss means cooler, more efficient operation.
3. Space and Time Savings: Modular busbar systems and DIN-rail fuse holders reduce wiring complexity. Cabinets can be 50–60% smaller than with discrete cabling, saving materials and installation time.
4. Flexibility: GRL’s platform is fully configurable – engineers can mix and match single/double bus sections, pole counts, fuse holders, and switches to suit any design. Components can be quickly interchanged or expanded.
5. Global Support: GRL is a seasoned manufacturer (founded in 2003) with global reach. Its products have been exported to over 30 countries and are used worldwide in industries from construction and petrochemical to photovoltaics and railways.
Typical application scenarios include industrial power factor correction panels, automatic PFC switchgear for commercial buildings, reactive power banks in utility substations, and renewable-energy inverter centers. Anywhere a capacitor bank is installed (e.g., 400–690 V distribution networks), GRL’s busbars, switches, and fuses ensure it is efficient, safe, and easy to maintain.
By integrating GRL’s specialized components—closed busbar systems, insulated covers, RT18 fuse holders, DNH1 fuse-switches, and NH fuses—capacitor compensation cabinets achieve high performance and reliability. These products are engineered for the exact requirements of reactive-power systems, providing compact power distribution, secure protection, and clear indication of faults. In sum, GRL’s solutions enhance power quality equipment globally, helping customers build low-voltage capacitor banks that save energy and meet rigorous safety standards.
In addition, GRL also has the following products that can be applied to capacitor compensation cabinets, such as copper busbars, surge protection devices, etc. If you want to get a customized solution, please contact us.
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