EPCOS Product Profile (India) 2013

Power Factor Correction

Power Quality Solutions

[Link]
Preview

U I

I U

Linear loads: Non linear load produce

voltage was followed non sinusoidal currents when
by current. connected to sinusoidal voltage.

General How reactive power is generated

The increasing demand of electrical Every electric load that works with reactive power compensation systems
power and the awareness of the magnetic fields (motors, chokes, (detuned /conventional) are installed
necessity of energy saving is very up transformers, inductive heating, arc for larger loads like industrial machinery.
to date these days. Also the aware- welding, generators) produces a vary- Such systems consist of a group
ness of power quality is increasing, ing degree of electrical lag, which is of capacitor units that can be cut in
and power factor correction (PFC) and called inductance. This lag of inductive and cut out and which are driven and
harmonic filtering will be implemented loads maintains the current sense (e.g. switched by a power factor controller.
on a growing scale. Enhancing power positive) for a time even though the
quality – improvement of power factor negative-going voltage tries to reverse
*
– saves costs and ensures a fast it. This phase shift between current * sin
return on investment. In power distrib- and voltage is maintained, current and
With power factor correction the apparent power
ution, in low- and medium-voltage voltage having opposite signs. During S can be decreased by reducing the reactive
networks, PFC focuses on the power this time, negative power or energy power Q.
flow (cos Ø ) and the optimization of is produced and fed back into the
voltage stability by generating reactive network. When current and voltage Reactive Power [KVAr]
power – to improve voltage quality and have the same sign again, the same Q2 = S2 — P 2
reliability at distribution level. amount of energy is again needed to Q2 QC
build up the magnetic fields in induc-
tive loads. This magnetic reversal Q1

energy is called reactive power. S2

P j
1
In AC networks (50 /60 Hz) such a S1
process is repeated 50 or 60 times a j
2
second. So an obvious solution is to Apparent Power [kVA]
briefly store the magnetic reversal S2 = P 2 + Q2
energy in capacitors and relieve the Active Power [kW]
network (supply line) of this reactive P 2 = S 2 — Q2
energy. For this reason, automatic

Power factor
Power factor improvement Types of PFC
results in Power factor improvement can be (detuned or conventional)

Higher energy consumption and achieved by individual or fixed compensation

costs, Compensation of reactive power (each reactive power producer is
Less power distributed via the with capacitors, individually compensated),
network, Active compensation – using group compensation (reactive power
Power loss in the network, semiconductors, producers connected as a group
Higher transformer losses, Overexcited synchronous machine and compensated as a whole),
Increased voltage drop in power (motor /generator). central or automatic compensation
distribution networks. (by a PFC system at a central point),
mixed compensation.

4 EIPL 2013
Preview

Power Quality Solution strategy

Along with the emerging demand for tests under laboratory conditions that Application know-how
power quality and a growing aware- may differ significantly from the reality Technical skills
ness of the need for environmental in the field. In addition, load structures Extensive experience in the field of
protection, the complexity in the ener- have changed from being mainly linear power quality improvement
energy market is increasing: users and in the past to non-linear today. All this A worldwide network of partners
decision-makers are consequently produces a clear trend: the market Continuous development
finding it increasingly difficult to locate is calling increasingly for customized Sharing of information
the best product on the market and to solutions rather than off-the-shelf These are the cornerstones on which
make objective decisions. It is in most products. This is where Power Quality Power Quality Solutions are built. On
cases not fruitful to compare catalogs Solutions come into the picture. It the basis of this strategy, EPCOS is
and data sheets, as many of their offers all key components for an not only the leading manufacturer of
parameters are identical in line with effective PFC system from a single power capacitors for PFC applications
the relevant standards. Thus operating source, together with: but also a PQS supplier with a century
times are specified on the basis of of field experience, reputation and
reliability.

Uninterruptible Power supply Power Factor Correction (PFC)

and Harmonic Filtering
EMC filter
C

DC link Tuned Linear load Dynamic Passive Active

(Aluminum electrolytic harmonic with fixed PFC harmonic harmonic
or film capacitors) filters PFC systems filters filters
Frequency converter
Overvoltage Overvoltage Overvoltage Overvoltage Overvoltage
protection protection protection protection protection
Charging
resistor
M
3~ C
(de-tuned
250/350/ M PFC
Output filter EMC filter
550 Hz 3~ systems)

EIPL 2013 5
PQS Key Components Overview

PF controllers
BR6000
BR6000-R06 BR6000-R12 BR6000-T06 BR6000-T12
Supply voltage 245 V AC ( 20%; L-N) 245 V AC ( 20%; L-N) 245 V AC ( 20%; L-N) 245V AC ( 20%; L-N)

Measurement 30-525 V AC (L-N) 30-525 V AC (L-N) 30-300 V AC (L-N) 30-300 V AC (L-N)

voltage range or (L-L) or (L-L) - -

Measurement X/5 or X1/A X/5 or X1/A X/5 or X1/A X/5 or X1/A

current selectable selectable selectable selectable

Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz

BR5000
BR5000-R08 BR5000-R16 BR5000-T16
Supply voltage 415V AC 415V AC 415V AC
(-40% to +20%; L-L) (-40% to +20%; L-L) (-40% to +20%; L-L)
Measurement 3Ph 3wire 415V AC 3Ph 3wire 415V AC 3Ph 3wire 415V AC
voltage range (-40% to +20%) (-40% to +20%) (-40% to +20%)
Measurement current X/5 or X1/A selectable X/5 or X1/A selectable Only 5Amp CT secondary
Frequency 45Hz to 62.5Hz 45Hz to 62.5Hz 45 Hz to 55 Hz

BR4000
BR4904 BR4008
Supply voltage 230V AC (-25% to +20%; L-N) 230V AC (-25% to +20%; L-N)
Measurement voltage range 230V AC (-25% to +20%; L-N) 230V AC (-25% to +20%; L-N)
Measurement current X/5 or X1/A externally selectable X/5 or X1/A externally selectable
Frequency 47Hz to 53 Hz 47Hz to 53 Hz

BR Series and Ordering Details

Output stages Relay outputs Transistor outputs Interface Ordering code
BR6000-R06 6 - B44066R6006R230N 1
BR6000-R12 12 - B44066R6012R230N 1
BR6000-R12 12 - RS232 B44066R6312R230N 1
BR6000-R12 12 - RS485 B44066R6412R230N 1
BR6000-T06 - 6 - B44066R6106R230N 1
BR6000-T12 - 12 - B44066R6112R230N 1
BR5000-R08 8 - RS232 and RS485 B44066R5908A415N 1
BR5000-R16 16 - RS232 and RS485 B44066R5916A415N 1
BR5000-T16 - 16 RS232 and RS485 B44066R5716A415N 1
BR4904 4 - - B44066R4904A230N 1
BR4008 8 - - B44066R4808A230N 1

BR7000 15 relay outputs PF controller for 3 phase measuring and controlling B44066R7415E230

MC7000-3 Grid analysis tool for 3 phase measuring, display and storage B44066M1301E230
of electric parameters

8 EIPL 2013
Important Notes

The following applies to all products named in this 4. In order to satisfy certain technical requirements,some of
publication: the products described in this publication may contain
1. Some parts of this publication contain statements about substances subject to restrictions in certain jurisdictions
the suitability of our products for certain areas of appli- (e.g. because they are classed as hazardous).
cation. These statements are based on our knowledge Useful information on this will be found in our Material
of typical requirements that are often placed on our prod- Data Sheets on the Internet ([Link]/material).
ucts in the areas of application concerned. We neverthe- Should you have any more detailed questions, please
less expressly point out that such statements cannot be contact our sales offices.
regarded as binding statements about the suitability 5. We constantly strive to improve our products. Conse-
of our products for a particular customer application. quently, the products described in this publication
As a rule, EPCOS is either unfamiliar with individual may change from time to time. The same is true of the
customer applications or less familiar with them than corresponding product specifications. Please check
the customers themselves. For these reasons, it is always therefore to what extent product descriptions and speci-
ultimately incumbent on the customer to check and decide fications contained in this publication are still applicable
whether an EPCOS product with the properties described before or when you place an order.
in the product specification is suitable for use in a partic- We also reserve the right to discontinue production
ular customer application. and delivery of products. Consequently, we cannot
2. We also point out that in individual cases, a malfunc- guarantee that all products named in this publication will
tion of electronic components or failure before the always be available.
end of their usual service life cannot be completely The aforementioned does not apply in the case of
ruled out in the current state of the art, even if they are individual agreements deviating from the foregoing for
operated as specified. In customer applications requiring customer-specific products.
a very high level of operational safety and especially in
customer applications in which the malfunction or failure 6. Unless otherwise agreed in individual contracts, all
of an electronic component could endanger human life or orders are subject to the current version of the “General
health (e.g. in accident prevention or life-saving systems), Terms of Delivery for Products and Services in
it must therefore be ensured by means of suitable design the Electrical Industry” published by the German
of the customer application or other action taken by the Electrical and Electronics Industry Association (ZVEI).
customer (e.g. installation of protective circuitry or 7. The trade names EPCOS, BAOKE, Alu-X, CeraDiode,
redundancy) that no injury or damage is sustained by third CSMP, CSSP, CTVS, DeltaCap, DigiSiMic, DSSP,
parties in the event of malfunction or failure of an electronic FormFit, MiniBlue, MiniCell, MKD,MKK, SquareCap,
component. AgriCap, PoleCap, MLSC, MotorCap, PCC, PhaseCap,
3. The warnings, cautions and product-specific notes PhaseCube, PhaseMod, PhiCap, SIFERRIT, SIFI,
must be observed. SIKOREL, SilverCap, SIMDAD, SiMic,SIMID, SineFormer,
SIOV, SIP5D, SIP5K, ThermoFuse, WindCap are
trademarks registered or pending
in Europe and in other countries. Further information
will be found on the Internet at
[Link]/trademarks.

10 EIPL 2013
PF Controllers BR5000 Series
Intelligent l
User-friendly l
Cost-effective

General
The BR5000 controller series is The three versions of BR5000 Controller
intended to be used with are
unbalanced three phase loading BR5000 – 16 for contactor switching
conditions and to correct the logic for slow varying loads
power factor. The controller needs BR5000 – 16TX for rapidly changing
3 Load CT inputs and loading conditions
corresponding voltages. The (Option for GSM communication
overall compensation is done on available)
averaging basis. The controller is BR5000 – HT for High tension upto
having ultra intelligent processor 33kV sensing of power factors and
in built. It covers almost all the correction. Version available in
electrical parameters to be 8/16 steps.
displayed and monitored .

Features
Microcontroller logic for Unique external temperature Important display parameters
measurements Voltage
Control mode: Binary, unequal, Settable alarm facility - Current
Preset and user defined undervoltage, overvoltage and Active power
Multifunctional LCD display so on Reactive power
Three CT sensing for unbalanced Settable auxiliary outputs - 2 Nos Apparent power
loads for Alarm, etc. Capacitor current
Dual target Power Factor setting- Auxilary input -1 No Per phase values of V, I and
useful for utility and DG mode EMI/EMC type tested neutral current
operation Individual Harmonic measurement Power factor
Automatic synchronization Upto 15th Frequency
possible VTHD
Separate 3 CT monitoring of Protection Warning ITHD
healthiness of capacitor within Over / under voltage
panel Capacitor over / under current Technical Data
Data logging Over / under frequency Auxiliary supply voltage -1Ph,
RS 232 in front and RS 232/485 Load unbalance 415V (-40% to + 20%)
switchable connection at rear Over temperature Measurement voltage: 3PH 3 wire
Step operation indication on LCD Out of steps (Indication) 415 VAC (-40% to + 20%)
display plus LED which facilitates NV-Ram battery down Current Input - 1A or 5A
viewing from a distance Steps - 8 and16 relay outputs
Unique facility of including ‘Fixed Supply frequency - 45 Hz to 62 Hz
Capacitor Bank’ for purpose of
Transformer compensation. This Mechanical and Maintenance
can be set such that the Operating temperature - 0O to 70OC
controller doesn’t ‘see’ this Storage temperature -
capacitor -10OC to +75OC
Humidity -0 to 98%

Dynamic Power Factor Controller (Transistorised) available in 16 steps

Special 8/16 step Controller for Medium Voltage application available

EIPL 2013 41
PF Controller BR5000 Relay Output
Intelligent l
User-friendly l
Cost-effective

Typical wiring diagram for PF correction : Contactor switching

Load CT feedback
R
L
Y O
SUPPLY
B A
N D

Panel
incomer

2A
RS RS RS YS YS YS BS BS BS
Ph
R

Note: 1 5 1 5 1 5 2A
Ph
Y

CT connection
Rear side connections 2A
selectable 1A
for meas. voltage, load
Ph
B

or 5A Example:
Select either CT [Link] Capacitor 2A
CT sec.
L1

S1 (1A) or
S5 (5A) RS RS 2A
RS YS YS YS BS BS BS
L2

along with 1 5 1 5 1 5
S (common)

Capacitor
current CT
feedback

6A Output commands.

K1 K2 K8
Com C1 C2 C3 C4 C5 C6 C7 C8 330 ohms/3W
0.1 MFD/1kV
(recommended)
N N N
K1 K2 K3 K4 K5 K6 K7 K8

Step-1 Step-2 Step-8

42 EIPL 2013
PF Controller BR5000 Transistor Output
Intelligent l
User-friendly l
Cost-effective

Typical wiring diagram for PF correction : TSM switching

Load CT feedback
R L
SUPPLY Y O
B A
N D

Panel
-ve

incomer
2A

Ph
24V

R
RS RS 5 YS YS 5 BS BS 5
2A
Note:

Ph
T O/P T O/P T O/P

Y
1

Load CT and Rear side connections

2A
Ph
Cap CT connection, for meas. voltage, load
B
2

Secondary CT [Link] Capacitor

should be 5A 2A
CT sec.
L1
3

for all 3 phase

Example: Select RS RS 5 YS YS 5 BS BS 5 2A
L2

RS5 (5A) with

RS common
T O/P
16
AIC

Capacitor
current CT
AI

feedback

Command
Outputs

LEGEND:
LC Load CT secondary
CC Capacitor CT
secondary

RY B Measurement voltage
L1, L2 Auxiliary voltage High
Speed
24V 24V for command Fuses
T O/P 1,2,..16 Output commands
T O/P1 T O/P2 T O/P16
-ve Common ground for
-ve -ve -ve
command

EW 22

Step-1 Step-2 Step-16

EIPL 2013 43
PF Controllers BR5000 Series
Intelligent l
User-friendly l
Cost-effective

Selection table for controllers

BR5000 relay output BR5000 transistor output

Steps 8 STEP 16 STEP 16 STEP

Switching Contactor Contactor Thyristor
Ordering code B44066R5908A415N1 B44066R5916A415N1 B44066R5716A415N1
Auxiliary supply 1Ph 415V (-40% to +20%) 1Ph 415V (-40% to +20%) 1Ph 415V (-40% to +20%)
Measurement voltage 3Ph 3wire 415V (-40% to +20%) 3Ph 3wire 415V (-40% to +20%) 3Ph 3wire 415V (-40% to +20%)
Load CT Input current 1/5 A-separate connectors 1 / 5 A-separate connectors only 5Amp CT secondary
for either of the CT connections for either of the CT connections
No. of outputs 8 Nos. relay o/p of burden 16 Nos. relay o/p of burden 16 digital outputs
1000VA by contactor coils 1000VA by contactor coils maximum 20 mA loading
Alarm outputs 2 Nos. 2 Nos. 1 No.
-Insufficient Yes Yes Yes (only display)
Compensation
-Overcompensation Yes Yes Yes
-Over / under voltage Yes Yes Yes
-Overcurrent Yes Yes Yes
Automatic initialisation No NoNo
Communication RSXXX RS232 and RS485 RS232 and RS485 RS232 and RS485
interface
Parameters displayed --
System voltage Yes Yes Yes
Load current Yes Yes Yes
Capacitor current No No No
Active power Yes Yes Yes
Reactive power Yes Yes Yes
Apparent power Yes Yes Yes
Frequency Yes Yes Yes
Individual harmonics 15 15 15
measurement upto
THD - V Yes Yes Yes
THD - I Yes Yes Yes
Monitoring of Yes - Health check Yes - Health check Yes - total panel capacitor
individual capacitor current monitored
current
Apparent current Yes Yes Yes
Overtemperature Yes Yes (only INT temp.)
Real time cos j Yes Yes Yes
Target cos j Yes (upper and lower target Yes (upper and lower target Yes- (upper and lower target
PF- programmable) PF- programmable) PF- programmable)
KVAr value to target Yes - displayed as Yes - displayed as Yes - displayed as
cos j System reactive power System reactive power System reactive power
Switching and
discharge time range
-Correction time 1 - 240 sec 1 - 240 sec 20-5000 m sec
-Discharge time 1 - 240 sec 1 - 240 sec NA
Number of control series Unequal, Unequal, Binary, unequal
C-series (1-15), E-series C-series (1-15), E-series C-series (1-15), E-series
Weight (in kG) 2.5 kG 2.5 kG 2.5 kG
Dimensions 144 x 155 x 144 mm 144 x 155 x 144 mm 144 x 155 x 144 mm
(L x D x H in mm)

44 EIPL 2013