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Epcos Power Factor Controller Manual

This document discusses power factor correction and capacitor bank sizing. It describes how to calculate the required capacitor bank size to correct the power factor at different load levels from lower to upper thresholds. Equations and examples are provided.

Uploaded by

arunm289
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
227 views40 pages

Epcos Power Factor Controller Manual

This document discusses power factor correction and capacitor bank sizing. It describes how to calculate the required capacitor bank size to correct the power factor at different load levels from lower to upper thresholds. Equations and examples are provided.

Uploaded by

arunm289
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

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5 0 *5. 8 *5B J # 0
PFLOWER. PFLOWER.
KVAR
(Ind)
smallest
Capacitor bank
KVARX 2 width.

PFUPPER. PFUPPER.

- KW. KW.

KVAR
(Cap)

/ $ # &
# &
# &

5,0 *5. 8 *5B J 0

KVAR
(Ind)

smallest
Capacitor bank
PFLOWER. KVAR X 2 width. PFLOWER.

- KW KW

PFUPPER.
PFUPPER.

KVAR
(Cap)

+ & ) $& , -
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530 *5. 8 *5B J # 0


KVAR
(Ind)

smallest
Capacitor bank
KVAR X 2 width.

- KW KW.
PFLOWER. PFLOWER.

PFUPPER. PFUPPER.
KVAR
(Cap)

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$ # & & "


Load CT feedback
L
O
SUPPLY
A
D
Panel
incomer

RS RS YS YS BS BS N
Ph
R
RS YS BS
1 5 1 5 1 5
Ph
Rear side connections Y
for meas. voltage, load
Ph
B

CT sec & cap. CT sec.


L1

RS RS YS YS BS BS
RS YS BS
L2

1 5 1 5 1 5

Capacitor
current CT
feedback

Output commands.
K1 K2
Com C1 C2 C3 C4 C5 C6 C7 C8

N N
K1 K2 K3 K4 K5 K6 K7 K8

Step-1 Step-2
+ & ) $& , -
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% *

Rear side terminals – measurement


voltages, measurement currents, capacitor
current, auxiliary voltage

Voltage feedback connections Auxiliary voltage connections


415V, 3Phase, 3Wire 415V, 1Phase

R Y B
L1 L2
Ph Ph Ph

RS RS YS YS BS BS
RS YS BS
1 5 1 5 1 5

RS RS YS YS BS BS
RS YS BS
1 5 1 5 1 5

Load current CT connection Capacitor current CT


Selectable 1A or 5A Selectable 1A or 5A
Example: For R-phase CT, Example: For R-phase CT,
Select either RS1 (1A) or RS5 Select either RS1 (1A) or RS5
(5A) along with RS (common) (5A) along with RS (common)
Similarly for Y-phase and B- Similarly for Y-phase and B-
phase. phase.

+ & ) $& , -
- 10 -
% *

Bottom side terminals – output


commands, auxiliary input & outputs and
communication
Output commands to capacitor contactors.
8 outputs for BR5008 & 16 outputs for
Auxiliary input BR5016.
AI1C = common, COM = common,
AI1 = 120 - 230Vac C1…C8 (or C16) = potential free
relays, 5A, 230Vac

AI AI
COM C1 C2 C3 C4 C5 C6 C7 C8
1C 1

COM C9 C10 C11 C12 C13 C14 C15 C16

D D AO AO AO AO
G TX RX
– + 2C 2 1C 1

Data communication port. Two


options are possible depending
on configuration of DIP switch Auxiliary outputs – 2nos.
Potential free 5A, 230V
1. RS485 on [D–, D+, G] if
AO1 = 230V ac,
DIP positions 1 & 3 are
AO1C = common,
ON.
AO2 = 230V ac,
2. RS232 on [TX, RX, G] if
AO2C = common
DIP positions 2 & 4 are
ON.

+ & ) $& , -
- 11 -
% *

Terminals available on sides –


DIP switch selector for communication,
temperature sensor terminals

Terminals on left side of


OFF controller – DIP switch for
selection of communication
protocol through port
available on bottom side.
ON 1. Positions 1 & 3 ON =
1 2 3 4 RS485 enabled.
2. Positions 2 & 4 ON =
RS232 enabled.
Selecting both sets of terminals
will not allow any data
download.

Temperature sensor input


TSO TSI G terminals provided on top side.
Use only the sensor type
PT100 (not provided with
controller).

PT100 temperature
sensor.

+ & ) $& , -
- 12 -
% *

Front fascia –
LCD screen, LED indications

PF=1.00 IND A OK

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$ " &
# 4 : 1) = @# 4 $ B :A

+ & ) $& , -
- 13 -
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Front fascia –
LCD screen, RS 232 communication port
( ! " B: " %# %0

PF=0.98 IND A OK

' $ ! 0
& !# 4 &
% * B $ &-9 G /:H &
@G ) H ! A
&
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6
=/: =/: 6 7 8 9

7 )%

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- /
,3, - : "

+ & ) $& , -
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Front fascia –
Keyboard
; "# % ! 4" ! !
! & 4" 0

UP key. Used to scroll up the menu screen;


increment values when entering numbers.
Also used for changing the status of banks.

DOWN key. Used to scroll down the menu


screen; decrement values when entering
numbers. Also use to change status of bank.

RIGHT key. Used to shift the cursor to right;


also used to increase the contrast of LCD in
default display screen mode.

LEFT key. Used to shift the cursor to left;


also used to decrease the contrast of LCD in
default display screen mode.

ENTER key. Used for entering a submenu


or for setting up values.

PROGRAM key. Used for selecting modes


of operation and editing of parameters

MEMORY key. Used to save all changes


made in Edit Parameters menu.

+ & ) $& , -
- 15 -
% *

% $ -
+ ! # % #" $ . <:/
4" 8 $ / 4 "& ( #5 ' : &

PF=0.98 IND A OK !
$
"
$ !
!
*
"

# 48 &

Display !"
$ $
D+
Overall Values 4J 4+) 4+) 54+) & B
* 4+) 4+) 8 ! "&
Display ' ! $
Per-Phase RMS 8
&

Display : " !*
Power ;J ;+) ;+)
;+) &

Display : " $"


4 ;J1 8
Energy ;+) 1 ;+)1 5;+) 1&

Display : " 1: ! +
Harmonics / 8
5 &
%

Display : " 4+)


! &
Step KVAr

Display : " @ # A8
Aux-Function ( &

Time: [Link] : " 8


Date: 23/06/08 4&

EPCOS India : " ! !% &

BR 5008
+ & ) $& , -
- 16 -
% *

. $

continued..

+ & ) $& , -
- 17 -
% *

&&

1 ! 8 $
# % #" $ /
! 1 &* % $ #5
$ $ ! $ 8
! &

continued..
+ & ) $& , -
- 18 -
% *

continued..

+ & ) $& , -
- 19 -
% *

! $. / $ &
* % ! $ !
! 0

Enable If Password Disable


Option is
Enable/Disable.

:!
: " Enter Password:
****

6 $
% #" $
8 4 "&

*
/ M
) J :
N

O ( $

+ & ) $& , -
-20 –
% *

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

:!
: "

Select
1. Edit Parameter

Select
2. Auto Operation

Select
3. Manual Operation

#
( $

+ & ) $& , -
- 21 -
% *

#
Select Select Select
1. Edit Parameter 2. Auto Operation 3. Manual Operation

PF=0.98 IND A OK PF=0.87 IND M OK

) '
' & ' &

Edit Parameters General parameters


General and IO
Edit Parameters Grid / transformer / APFC
System system related parameters

Edit Parameters Fault trip settings


Fault
Edit Parameters Capacitor bank step settings
Step
Edit Parameters Communication related
Communication parameters

Edit Parameters Banks utilization counter


Utilization Cntr

+ & ) $& , -
- 22 -
% *

4 $. /% $
'
% ! @' ) A
! "@ A&
= )' 4 "& % @! # A#" $
4 "& / /% $ 4"
' ! 0

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/ ! &

1
* ! $ &

$ / # % 9
' & %
! " $ % % &
" ! 40
? $ !! "# 4 " &
? 4 $ # 4 #" $ /< **&
?: $ ! # 4< ! "& ' 4 $ ! # 4
! " # 4 %
# ! * &
* : $# 4 ! " $ ! "# 4 0
! / 4 "&
# # 4 % # 4 $& . 4"
! # 4& 4" ! "&
! "# 4 # $ # 4 $ # 4
4" $ # 4 "&
)! " ! / 4"
# 4 $& # @
! % % $ A
' ' M4 "& )! $ $ % P # 4
! & @: ! ) '
A& continued..
+ & ) $& , -
- 23 -
% *
…continued.
* $# 4 % / < ** 0
/ 4" % # 4 $& . 4"
! # 4< " 4"
/ 4" ** # 4&
!' /< ** / 4"
# 4 $&

"
" " $ &
" $ # &
4" " ! #
& " ! # 0

* 5 0* $ $ &
$ 0* <
$ " $ &
0* $ &
0 # 4 $ &
6 0 &
2 7 0 4 > &

)! $ " / #5 !
! " &
! #5 ! "" $ ! &
M #5 $ #" $ /
4"
! #5 = )' 4 " &
" )+ %
" " #5 &
! % $ $
= )' 4 " $ &

/ 0 ! 4" !
! "
$ &

+ & ) $& , -
- 24 -
% *
* 5
PASSWORD % 0 # # % &
Enable :1 + 0 I: # I # &
CHANGE PASSWORD $ % 0 % ! % @6
: 0001 $ A
&* " ! % K L
LOAD DEFAULT B :! 0B ! " ! &
No :0 I/ IM &
THD TO DISPLAY R/F 1: : "0 " ! 1: # " ! +
F-THD :1 & I 5 1: @ ' A I*5 1: @! A
&
RESET ENERGY CNTR $" 0 $"
No :0 > & I/ IM &
AUX IP1 FUNCTION
) ( * 0 $ ( "
None :0
& I/ I < # < #
,I' <= 3I ! &
AUX OP1 FUNCTION
) ( * 0 $ ( "
None :0
# / " ! ! % $0 I/
AUX OP2 FUNCTION
$
None :0
I ! ,I " ! 3I ! &
) ( ,* 0 # &

$
Meas. Voltage ' + $ 0* "
: 415 % &* % $ "&
EXT-PT Ratio (5 0 " ! & 0 #
0001.0:1 ( # &B 0
CUR CT Primary B% 0 & . 0 &
Mains : 1000 "0 @' A8=
0* # 4
CUR CT Primary ! = @! %
Genr : 0500 A&B
0 B% 0 . 0 ----&
CAP CUR CT Prim "0 * &
: 1000 B 0 B% 0 . 0 ----&
PF Up Lim : Mains % * B 0 9 , &
[Ind :1] 0.980 ! ' 8 ! = &* #
PF Up Lim: Mains
8 % # ! .
Ind : 1 [0.980] * B% *& * #
PF Low Lim: Mains
&
[Ind :1] 0.970
' <= 0:! %
5 ! ! ' @ A ! = @ A
PF Low Lim: Mains
) " 0) "
Ind :1 [0.970]
! # # & I: # I # &
PF Up Lim: Gen
) " * 0. ! 5
[Cap : 0] 0.820
" %
PF Up Lim: Gen
4& ! ( !
Cap:0 [0.820]
" ! &
PF Low Lim: Gen ) " > 0 #
[Cap:0] 0.800 ! ! # &

continued..
+ & ) $& , -
- 25 -
% *

PF Low Lim: Gen !


…continued.
Cap:0 [0.800] ! & ! (
Mains Generator ! !) 5 " &
Mains :0 $ * &
Phase Auto Sync ) " 0 ! 5
No :0 " ! #" D M
Auto Sync Fault * &
Tol (%) :15 (& &' 0 # # !
Reset Auto Sync ( &
No :0
EXT. Temp. Meas
Disable :0

* ! " !! !
Over voltage flt # 0
Disable :0 I: #
Over voltage
I @: " * ' $ 8 * A
Limit :115%
+I !! @ % !
!/ *( #" A
,I !!*( ) @ % !
!) #" A
Over voltage
8I* !
! @ % !
! A
Resume :110%
Under voltage flt * ! "% ! &
Disable :0 : B B &:
Under voltage B !( #" %
Limit :085% ! #" " !! @ $ 5
Under voltage # A& B ! # %
Resume :090% % ! &
Over load flt
Disable :0 ? + $ 0) $$ ! 5+ $
Over load &
Limit :130% ?. + $ 0* . 5+ $ &
Over load ? B 0 ! CC " "
Resume :125%
Under load flt
! !
Disable :0
&. &
) " # &
Under load
?. B ! 0 F !
Limit :020%
' ( ;J& ! !# 4
Under load
4 ! &+
Resume :025%
! . 5B ;J # % &

continued..
+ & ) $& , -
- 26 -
% *

KVAR
(Ind)

Under Load settings:


PFLOWER.

1.25 X smallest PFUPPER.


Capacitor bank

KW.

KW
Under-
Load.

No change band.

KVAR Capacitor Addition band.


(Cap)
Capacitor Removal band.

For PFUPPER Inductive and PFLOWER Inductive :


1.25 X Smallest bank KVAR.
Under-Load KW value setting =
[tan{cos -1(PFLOWER)} – tan{cos-1(PFUPPER)}]

For PFUPPER Capacitive and PFLOWER Inductive :


1.25 X Smallest bank KVAR.
Under-Load KW value setting =
[tan{cos -1(PFUPPER)} + tan{cos-1(PFLOWER)}]

For PFUPPER Capacitive and PFLOWER Capacitive:


1.25 X Smallest bank KVAR.
Under-Load KW value setting =
[tan{cos -1(PFUPPER)} – tan{cos-1(PFLOWER)}]

+ & ) $& , -
- 27 -
% *
…continued.
Load Unbalance Flt B # ! 0B ! F !
Disable :0 ( !
Load Unbalance % ! &
Limit :020% ? * 0 !
Over CC Flt % 4 B & !
Disable :0 " $ ! &
Over CC . ! ) 5 K # L
Limit : 130% # $% ) 5 &/ %
Over CC
) 5 ! # 8 4 $ 5
Resume :125%
! " " $
&
Over CC Auto Restart
?. * 0 ! # "
Disable :0
% & 5 : # D & !
Auto Restart Time
! $ # 4&
Seconds : 0060
! ) 5 % 4% / B
Under CC Flt
8 $ &
Disable :0
? * 0.
Under CC 9 $&
Limit :095% $ # ) *
Under CC $ #" !
Resume : 097% ! 9 % !&. !
Int Temperature Flt $ % ! @ A
&
Disable :0 ? 1:0 #
Int Temperature & 1: !
Lower Limit : 50 Deg C ! 1: ( $ $
Int Temperature ! &
Upper Limit : 50 Deg C ? 1 40 9
CC THD FLT $ ! 4+) ! " & %
Disable :0 &
CC THD ! ( ! # 4
Limit :010% ! "&
CC THD ? ! 4 * 0 "% D: # D
Resume :080% & ! % !
Step Health Chk
! 0K % " *
Disable : 0
B% * "
# 4 / &
Step CC Flt Tolerance
?/+5 "* 0 * /+5 )' 8
% :10
# " 9& 1 !# "
Out of banks Flt
4 $ # & ! ! 5 "8!
Disable :0
# % $$ $ 8 $
NV RAM Battery Fault
@ "% A&
Disable :0

+ & ) $& , -
- 28 -
% *

Steps connected 0:! # !


: 08 &: $ * " # 4
Default mode &
Auto :0 ?:! ' 0 0) 0' &
Compensation kVAr ! $ % & @: ! 0) A
Mean :1 ? ;+) 0 0 8 0' &
Cap Bank Voltage :! ! ;+) & !
0415 V # %
Correction Time !;+) !
Seconds :00010 &
Discharge Time
? 4+ $ 0 # 4 $
Seconds :00060
! & & & ! + $
! ;+) &
Step Response Time
? 0:! &
Cycles : 00045
# % % ;+) &
Fix-Bank Setting
?: $ 0 ! !
________
$ ! " #
Correction Type
/ $ &
C Series :2
? 0:! ! %
C – Series : 00 ;+) ! " # %
11111111111111 &
E - Series ? *(5 4 $0 : ! # 4 #
1488888888888888 !( & # 4 !
C / E Series Bank kVAr # **& # 4
: 200 "# ** ! &@! $
Unequal Bank KVAr ! ! A &
[1] = 050 ? " 0 9 # 4 !$
Unequal Bank KVAr ! #"! & I "
[2] = 050 I. ,I 3I &
Unequal Bank KVAr " ! 0,06090 555&
[3] = 050 .5 % # 4 $ ! &
Unequal Bank KVAr ! &
[4] = 050 9 # &
Unequal Bank KVAr . ! & # 4
[5] = 050 ! # ! &
Unequal Bank KVAr
:$ # , 55 - ) : *& & & #
[6] = 050
( 0* & & 0 &
Unequal Bank KVAr
[7] = 050
Unequal Bank KVAr
[8] = 050

continued..
+ & ) $& , -
- 29 -
% *
…continued.
? 0+ @ A #
0 & 0 , ,, 6 6 66 6 6 6 6 66 6&
0 ,,,, , , , , , ,
,& , , , , 0 , ,6 6 6 66 6 6 6 6 66 6&
,0 , 3 3 3 3 3 3 3 3 3
3& 3 3 3 3 ,0 ,, , , ,, , , , , ,, ,&
30 , 3 6 6 6 6 6 6 6 6
6& 6 6 6 6 30 , 33 3 3 33 3 3 3 3 33 3&
60 , 6 6 6 6 6 6 6 6 6
6& 6 6 6 6 60 , 66 6 6 66 6 6 6 6 66 6&
0 ,3 & 0 , 69 9 9 99 9 9 9 9 99 9&
0 ,699 9 9 9 9 9 9 9 9 9 9 9& 0 , , 33 3 3 33 3 3 3 3 33 3&
70 , , , , , , , , , , , ,& 70 , 3 66 9 9 99 9 9 9 9 99 9&
90 & 90 , , 66 6 6 66 6 6 6 6 66 6&
-0 ,,, , , , , , , , , , , ,& -0 , , ,6 6 6 66 6 6 6 6 66 6&
? 5 0) ( ! &
:$ # P ! *& & &
? << 4;+) 0 ;+) ! # 4
;+) ! # 4& & ! #" $ G H
"&
?. 4;+) Q R& S 0 ! ;+) # 4 !$
# ! ! "# 4;+) @
! 4+ $ A & 9 # $
$ # # # ( ;+)
! &

6 . :0 + 0 ----& : !
&:! 6 $ : !
5,3, :
&
? # & 0
D 69 # D- # , D -, # 3D
396 # 6D 7 # &
? 0:! $&
?: 0:! $&
? > 0 D/ DM &
:! $M > @ 4A
# ! &@ !
$ )+ A
&
? /+ )'0 D / DM &
:! $M /+ )' @ 4A
9& % $"
$ "
/+ )' 4 ! @ ! $
)+ A&
?= ' 0= '
# # $ & "
$ # &
? ' /0:! # % '
# &/ " ' / # &
+ & ) $& , -
- 30 -
% *

2 7

. > 0 4 0 $
# ! /< ** !
K L # 4&
? . > 0 4 0
KM L K/ L&
: $ ! # 4 % M
$ %
! # 4 >
> & "
! # 4
% % &

+ & ) $& , -
- 31 -
% *

6 &
#

" 9 &6 !
$ "
&)
% $ % $ $ &

+ " # 9 &6 !
% # "!
< ! < ! # $ &
# ! B * # 4 4 $!
! &
< B$ ! !
: ( $
& ! #
! $ ( &
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Important notes

The following applies to all products named in this publication:

1. Some parts of this publication contain statements about the suitability of our products for
certain areas of application. These statements are based on our knowledge of typical
requirements that are often placed on our products in the areas of application concerned. We
nevertheless expressly point out that such statements cannot be regarded as binding
statements about the suitability of our products for a particular customer application. As
a rule, EPCOS is either unfamiliar with individual customer applications or less familiar with
them than the customers themselves. For these reasons, it is always ultimately incumbent on
the customer to check and decide whether an EPCOS product with the properties described in
the product specification is suitable for use in a particular customer application.

2. We also point out that in individual cases, a malfunction of electronic components or


failure before the end of their usual service life cannot be completely ruled out in the
current state of the art, even if they are operated as specified. In customer applications
requiring a very high level of operational safety and especially in customer applications in which
the malfunction or failure of an electronic component could endanger human life or health (e.g.
in accident prevention or life-saving systems), it must therefore be ensured by means of
suitable design of the customer application or other action taken by the customer (e.g.
installation of protective circuitry or redundancy) that no injury or damage is sustained by third
parties in the event of malfunction or failure of an electronic component.

3. The warnings, cautions and product-specific notes must be observed.

4. In order to satisfy certain technical requirements, some of the products described in this
publication may contain substances subject to restrictions in certain jurisdictions (e.g.
because they are classed as hazardous). Useful information on this will be found in our
Material Data Sheets on the Internet ([Link]/material). Should you have any more
detailed questions, please contact our sales offices.

5. We constantly strive to improve our products. Consequently, the products described in this
publication may change from time to time. The same is true of the corresponding product
specifications. Please check therefore to what extent product descriptions and specifications
contained in this publication are still applicable before or when you place an order.
We also reserve the right to discontinue production and delivery of products.
Consequently, we cannot guarantee that all products named in this publication will always be
available.
The aforementioned does not apply in the case of individual agreements deviating from the
foregoing for customer-specific products.

6. Unless otherwise agreed in individual contracts, all orders are subject to the current version
of the “General Terms of Delivery for Products and Services in the Electrical Industry”
published by the German Electrical and Electronics Industry Association (ZVEI).

7. The trade names EPCOS, BAOKE, Alu-X, CeraDiode, CSMP, CSSP, CTVS, DSSP, MiniBlue,
MiniCell, MKK, MLSC, MotorCap, PCC, PhaseCap, PhaseCube, PhaseMod, PhiCap,
SIFERRIT, SIFI, SIKOREL, SilverCap, SIMDAD, 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.

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