Professional Documents
Culture Documents
www.epcos.com
The Company: EPCOS India Pvt. Ltd.
EPCOS India Private Limited (EIPL) is a EPCOS in India is involved in design, EPCOS India has a strong sales and
Member of TDK-EPC Corporation, manufacturing and marketing of a marketing team spread over the country.
Japan.EPCOS emerged in 1999 as a broad range of top quality products Our strength in market is based on the
successor to the joint venture Siemens such as AC-mfd capacitors, LV Power technical competence and marketing
Matsushita Components and the Factor Correction Capacitors (resin, experience of our sales force. It is
former Siemens passive Components inert gas and oil filled designs), Key backed up by a very efficient and
and Electron Tubes Group. The Components required for PF correction dedicated Channel Partner network to
company has been selling electronic system, PF correction systems (APFC cover entire India and some neighboring
components in India since the early Panels), MV Capacitors, MV Capacitor countries.
60s. Today, all business activities in Switch, MV Reactive Power
India come under the umbrella of Compensation systems, Power About TDK-EPC Corporation:
EPCOS India Private Limited, having Electronic Capacitors, DC Capacitors, TDK-EPC Corporation(TDK-EPC), a TDK
Registered head office at Kalyani Plant MPP film and high performance ferrite group company, is a leading
in West Bengal and regional offices in cores. Nashik factory also houses the manufacturer of electronic components,
Mumbai, Delhi, Bengaluru and Kolkata. Global R&D for Film metallisation, AC modules and systems, headquartered in
In mid-90s EPCOS significantly and PFC Products and Systems while Tokyo, Japan. It was established on
stepped up its commitment to India by Kalyani is Centre of Excellence for soft October 1st 2009. TDK-EPC has
opening new manufacturing facility at ferrites. EPCOS India also services the emerged from combination of passive
Kalyani in West Bengal and Nashik in demands of customers for a wide electronic components business of TDK
Maharashtra. And now, EPCOS again variety of components from global and the EPCOS Group and markets its
reinforced its trust in India by opening factories of TDK-EPC. products under the product brands,
up one more manufacturing facility at TDK and EPCOS.
Bawal in Haryana.
TDK Corporation is the sole shareholder
of TDK-EPC Corporation.
EIPL 2013
Index
Contents Page
Preview 4
Important notes 10
PFC capacitors
PhaseCap Premium 11
PhaseCap Super Heavy Duty 16
PhiCap 21
SquareCap 27
LT-APP 35
Switching devices
Capacitor contactors 54
Thyristor modules for dynamic PFC (TSM-series) 57
Reactors
Reactors - Antiresonance harmonic filter 61
Cautions 82
Contacts 87
EIPL 2013
Preview
U I
I U
Power factor
Power factor improvement Types of PFC
results in Power factor improvement can be (detuned or conventional)
4 EIPL 2013
Preview
EIPL 2013 5
PFC Capacitor Series Overview
6 EIPL 2013
PFC Capacitor Series Overview
SquareCap-EHDLL B32459L . . .
SquareCap-ESHDC B32455L . . .
LT-APP B25160 . . .
EIPL 2013 7
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)
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
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
PQS Key Components Overview
Output range 12.5...100 KVAr for B...J230 TSM-LC: 10...50 KVAr 5...100 KVAr
7...60 KVAr for B...C240 TSM-HV: 50 KVAr
Detuning Suitable for detuned Suitable for detuned Factor: 5.67%, 7%, 14%
and conventional systems and conventional systems
EIPL 2013 9
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 (www.epcos.com/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
www.epcos.com/trademarks.
10 EIPL 2013
PhaseCap Premium PFC Capacitors
Dry type l
Gas-impregnated l Concentric winding l
Wavy cut Triple safety
l system
General
PhaseCap capacitors in cylindrical Improved thermal response and
aluminum cases have been de- simplified installation are advan-
signed for power factor correction tages of the cylindrical aluminum
in low-voltage applications. case.
Loads like motors and transform- PoleCap Capacitors:
ers consume active power as well A modified version of PhaseCap
as reactive power. capacitor with connection cable,
Generators, supply cables and suitable for long-term out door
other electrical distribution equip- applications and for mounting
ment, in turn, should be relieved of on the pole.
reactive power.
The MKK (metalized plastic
compact) AC series is intended to
increase packing density per bank
and cut component costs.
EIPL 2013 11
PhaseCap Premium PFC Capacitors
Dry type l
Gas-impregnated l Concentric winding l
Wavy cut Triple safety
l system
Power-KVAr 5….31KVAr
Frequency 50 Hz
Losses ≤0.5W/KVAr
(without discharge resistors)
Mounting and grounding Threaded stud at bottom of can (max. torque for M12=10Nm)
Enclosure IP 20, indoor mounting (optionally with terminal cap for IP54)
Connection Delta
12 EIPL 2013
PhaseCap Premium PFC Capacitors
Dry type l
Gas-impregnated l Concentric winding l
Wavy cut Triple safety
l system
EIPL 2013 13
PhaseCap Premium PFC Capacitors
Dry type l
Gas-impregnated l Concentric winding l
Wavy cut Triple safety
l system
14 EIPL 2013
PhaseCap Premium PFC Capacitors
Dry type l
Gas-impregnated l Concentric winding l
Wavy cut Triple safety
l system
Dimensional drawings
Capacitor up to 690 V AC Capacitor > 690 V AC
EIPL 2013 15
PhaseCap Super Heavy Duty PFC Capacitors
Wavy cut
Concentric winding l
Semi-dry biodegradable resin l Dual safety
l system
General
The new PhaseCap offers higher inrush current
Super Heavy Duty (SHD) capability (up to 400 IR) and over
l
16 EIPL 2013
PhaseCap Super Heavy Duty PFC Capacitors
Semi-dry biodegradable resin l Wavy cut
Concentric winding l Dual safety
l system
Power-KVAr 5….33KVAr
Frequency 50 Hz
Losses ≤0.45W/KVAr
(without discharge resistors)
Maximum Up to 1.6 l
IR***
permissible current
Mounting and grounding Threaded stud at bottom of can (max. torque for M12=Nm)
Enclosure IP 20, indoor mounting (optionally with terminal cap for IP54)
Connection Delta
EIPL 2013 17
PhaseCap Super Heavy Duty PFC Capacitors
Wavy cut
Concentric winding l
Semi-dry biodegradable resin l Dual safety
l system
PhaseCap Super Heavy Duty - 415 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 440 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 480 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 525 V(AC) 3PH, 50Hz (Series B25673)
18 EIPL 2013
PhaseCap Super Heavy Duty PFC Capacitors
Wavy cut
Concentric winding l
Semi-dry biodegradable resin l Dual safety
l system
PhaseCap Super Heavy Duty - 690 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 800 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 900 V(AC) 3PH, 50Hz (Series B25673)
PhaseCap Super Heavy Duty - 1000 V(AC) 3PH, 50Hz (Series B25673)
EIPL 2013 19
PhaseCap Super Heavy Duty PFC Capacitors
Wavy cut
Concentric winding l
Semi-dry biodegradable resin l Dual safety
l system
Dimensional drawings
Terminal type A, current up to 50 A Terminal type B, current up to 80 A
Terminal cross section 16 mm2 (without cable end lug) Te rminal cross section 25 mm 2 (without cable end lug)
20 EIPL 2013
PhiCap PFC Capacitors
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
General
PhiCap capacitors are a tried and The capacitors are manufactured
tested series of MKP (metalized using metalized polypropylene film
polypropylene) capacitors from as the dielectric and housed in a
EPCOS which have been used cylindrical aluminum case.
for PFC applications for more than
Available in two designs
15 years.
Normal Duty (ND) for linear
The power range varies from 0.5 to inductive loads.
30.0 kvar and 0.7 to 6.0 kvar per Heavy Duty (HD) for loads having
single capacitor can, depending some amount of non-linearity
on a three-phase or single-phase (with detuning reactor) .
capacitor design.
The PhiCap capacitor is especially
intended for power factor correc-
tion in industrial applications.
EIPL 2013 21
PhiCap PFC Capacitors
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
Frequency 50 Hz 50 Hz
Maximum VR+10%(up to 8 h daily)/ VR +15% (up to 30 min daily)** VR +10%(up to 8 h daily)/ VR +15% (up to 30 min daily)**
permissible voltage VR+20%(up to 5 min daily)/ VR+30% (up to 1 min daily)** VR +20%(up to 5 min daily)/ VR+30% (up to 1 min daily)**
Maximum IR***
1.3 to 1.5 l IR***
1.5 to 1.8 l
permissible current
Case shape/finish Extruded round aluminium can with stud Extruded round aluminium can with stud
Mounting and grounding Threaded stud at bottom of can (max. Threaded stud at bottom of can (max.
torque 4 Nm for M8 and 10Nm for M12) torque 4 Nm for M8 and 10Nm for M12)
Enclosure IP 00, indoor mounting (optionally with IP 00, indoor mounting (optionally with
terminal cap for IP54) terminal cap for IP54)
Discharge resistor Provided with discharge resistor Provided with discharge resistor
Casing of capacitor cell Extruded round aluminium can with stud Extruded round aluminium can with stud
22 EIPL 2013
PhiCap PFC Capacitors
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
PhiCap Normal Duty - 415 V(AC) 3PH, 50Hz (Series B32343 and B32344)
PhiCap Normal Duty - 440 V(AC) 3PH, 50Hz (Series B32343 & B32344)
EIPL 2013 23
PhiCap PFC Capacitors
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
24 EIPL 2013
PhiCap PFC Capacitors
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
PhiCap Heavy Duty - 415 V(AC) 3PH, 50Hz (Series B32447 & B32448)
PhiCap Heavy Duty - 440 V(AC) 3PH, 50Hz (Series B32447 & B32448)
EIPL 2013 25
Stacked winding l
Semi-dry biodegradable resin l Dual safety system
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
General
The SquareCap box type capacitor SquareCap series is available in three
is self standing in nature and is designs:
having modular construction (above
6KVAr) in a sheet metal enclosure. ENDC: EPCOS Normal Duty Capacitor
for normal inductive loads.
It is a very popular capacitor design
in India for many decades. EHDLL: EPCOS Heavy Duty Long life
Capacitor for loads exhibiting some
The SquareCap series is especially amount of non-linearity.(Preferably with
intended for use in industrial detuning reactor).
applications and locations such as
commercial complexes, malls etc. ESHDC: EPCOS Super Heavy Duty
The internal construction comprises Capacitor for non linear arduous and
of single phase basic capacitors fluctuating loads and systems containing
cells connected to form delta higher degree of harmonics.(Preferably
construction externally within the with detuning reactor).
enclosure. The terminal arrangement
is of stud type.
Electrical Safety
High pulse current withstand Self-healing
capability Overpressure disconnector
Very high life expectancy Sheet metal enclosure
EIPL 2013 27
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
Frequency 50 Hz 50 Hz 50 Hz
Maximum IR***
1.3 l IR***
1.5 l IR***
1.6 l
permissible current
Life expectancy Up to 100 000 hours Up to 125 000 hours Up to 150 000 hours
Terminal Threaded stud terminals Threaded stud terminals Threaded stud terminals
with ceramic bushing with ceramic bushing with ceramic bushing
Mounting and Self standing with mounting Self standing with mounting Self standing with mounting
grounding plates and screws for plates and screws for plates and screws for
grounding grounding grounding
Enclosure IP 20 IP 20 IP 20
Discharge resistor PCB mounted -included PCB mounted -Included PCB mounted -included
Casing of capacitor cell Extruded aluminium can Extruded aluminium can Extruded aluminium can
(hermetically sealed) (hermetically sealed) (hermetically sealed)
No. of switching Max. 5000 switching Max. 6000 switching Max. 7500 switching
per annum
28 EIPL 2013
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
EIPL 2013 29
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
30 EIPL 2013
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
EIPL 2013 31
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
32 EIPL 2013
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
EIPL 2013 33
SquareCap PFC Capacitors
Modular construction l
Semi-dry biodegradable resin l Triple safety system
Container cover
Bushing
PCB resistor
Top plate
Basic cell
Container
34 EIPL 2013
LT-APP Capacitors
Biodegradable NPCB Oil impregnated l
PP + Foil technology l
Internal fuse protection
General
EIPL 2013 35
LT-APP Capacitors
Biodegradable NPCB Oil impregnated l
PP + Foil technology l
Internal fuse protection
Frequency 50 Hz /60Hz
Transient peak IR
(400 to 500) l
current maximum permissible
Reference standard IS: 13585 (part - 1/2012) ISI mark applicable for 415 and 440 V up to 25 KVAr.
IEC 60931 - 1
36 EIPL 2013
LT-APP Capacitors
Biodegradable NPCB Oil impregnated l
PP + Foil technology l
Internal fuse protection
EIPL 2013 37
PF Controllers BR6000 Series
Intelligent l
User-friendly l
Cost-effective l
Version 5.0
General
Controllers for PFC are of major Different versions of the BR6000
importance in the PFC system. series provide solutions to various
They measure the actual power applications:
factor and connect or disconnect
capacitor stages to achieve a BR6000-R6 and BR6000-R12
specific desired value (cos j ). for conventional applications with
slowly changing loads (optionally
The PF controller series with RS485 interface)
and BR6000 (six and twelve
stages) offer highly intelligent BR6000-T6 and BR6000-T12
control behavior and are very for dynamic PFC in applications
user-friendly thanks to menu-driven with fast-changing loads
handling (plain language). Their
multifunctional display greatly
simplifies installation, handling and
maintenance.
38 EIPL 2013
PF Controllers BR6000 Series
Intelligent l
User-friendly l
Cost-effective l
Version 5.0
EIPL 2013 39
PF Controllers BR6000 Series
Intelligent l
User-friendly l
Cost-effective
*RS 232-B44066R6312R230N1
*RS 485-B44066R6412R230N1
40 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%
EIPL 2013 41
PF Controller BR5000 Relay Output
Intelligent l
User-friendly l
Cost-effective
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 sec.and 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
42 EIPL 2013
PF Controller BR5000 Transistor Output
Intelligent l
User-friendly l
Cost-effective
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
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
EIPL 2013 43
PF Controllers BR5000 Series
Intelligent l
User-friendly l
Cost-effective
44 EIPL 2013
PF Controllers BR4000 Series
Intelligent l
User-friendly l
Cost-effective
General
The BR4000 controller series is BR4000 Controller series is
the most economical series and available in 4 stages and 8 stages.
intended to serve the basic Best suited with conventional
purpose of power factor APFC applications.
corrections... The simplest menu
driven version controller with
navigational keys. The
microcontroller based logic,
multifunctional display of
electrical parameters, compact
size 96 x 96 mm and protections
makes this controller extremely
user friendly.
EIPL 2013 45
PF Controllers BR4000 Series
Intelligent l
User-friendly l
Cost-effective
2A 6A
L1 N S S1/S5 COM K1
BR 4008 Controller
C1 C2 C3 C4 C8
Rear side terminals - measurement voltage, measurement current and auxiliary supply
S1
S5
N
S
COM
C8
C7
C6
C5
C4
C3
C2
C1
46 EIPL 2013
PF Controllers BR4000 Series
Intelligent l
User-friendly l
Cost-effective
EIPL 2013 47
PF Controller BR7000
15 relay outputs l
Three-phase measuring and controlling
General
The PF controller BR7000* is a a single-phase capacitor to N
folllow-up development of the PF (usually 5 per phase, balancing of
controller BR6000-series, featuring grid is possible)
two devices in one: it can be used Mixed
l operation: 6 single-phase
as a controller as well as a grid capacitors (2 per phase) for
measuring tool. balancing plus 9 steps for
The BR7000 offers 15 relay outputs conventional compensation
for the steps and three message/ (three-phase capacitors)
alarm relays. Due to the possibility of The controller can be connected
programming, the 15 outputs can be to a PC via an RS485 interface.
used for a broad range of applica- The Windows-based software
tions, for example: BR7000-SOFT allows the readout
15 conventional
l steps, each for of acquired data. The possibility
one three-phase capacitor of graphical display of all values
15 steps
l for single-phase capaci- offers a comfortable visualization.
tors, where each output will switch
Features
LCD full
l graphic display 15 switching
l outputs
128 x 64 dots, 8 lines 3 additional alarm/message
Self explanatory menu navigation
l relays
in five languages 2 isolated interfaces
l
Three-phase measuring and
l Detailed error messages with time
l
controlling; display of following stamp
grid parameters: Automatic initialization/test run
l
– Voltage Automatic and manual operation,
l
– Current service operation, expert mode
– Frequency Three-phase and single-phase
– Real power controlling; mixed mode possible
– Reactive power Display and storage of maximum
l
– Apparent power values, switching operations and
– Power factor operating time
– Missing reactive power Display of date and time
l
– Harmonic of voltage and current Time-controlled functions possible
(up to 31st) by internal timer
– THD-V Oscilloscope mode for graphical
l
– THD-I display
– Temperature Quick programming
l
HELP-button for interactive
l
help text
48 EIPL 2013
PF Controller BR7000
15 relay outputs l
Three-phase measuring and controlling
BR7000
Supply voltage 110 … 230 V AC 50/60 Hz
Measurement voltage range 3 · 30 … 440 V AC (L-N); 50 … 760 V AC (L-L)
Power consumption < 3 VA
Operating ambient temperature –20 … 60 °C
Display illuminated graphic display, 128 x 64 dots, 8 lines
Large display of 3 grid parameters selection in display editor
Plain language E / ES / GER / RU / TR
In- and outputs
Number of relay outputs 15 switching outputs, freely programmable for switching of 1- or 3-phase capacitors
Number of transistor outputs –
Alarm/message relay 1/1
Additional separate fan relay yes
Interface 2 independent isolated RS485-interfaces
Input 2nd parameter-set switchover
target PF yes
Special functions
Measuring three-phase
Controlling single-phase, three-phase, mixed mode
Automatic initialization yes
Test-run of complete PFC-system yes
Quick-program yes
Internal timers yes
Oscilloscope (graphical display) mode yes
Display editor yes
Backwards navigation ESCAPE button yes
HELP button for interactive help text yes
Number of control series 20 series pre-set
Control series editor for free programming yes
EIPL 2013 49
PF Controller BR7000
15 relay outputs l
Three-phase measuring and controlling
50 EIPL 2013
PF Controller BR7000
15 relay outputs l
Three-phase measuring and controlling
EIPL 2013 51
Grid Analysis Tool MC7000-3
Three-phase measuring l 1GB memory card included
Easy evaluation of data l
General
The measuring device MC7000-3* SD memory card slot. A memory
has been developed for three- card (1 GB) for data storage and
phase measuring, display and easy passing on to a PC is already
storage of electric parameters in included in the delivery.
low-voltage grids. The Windows- Featuring an illuminated 128 x 64
based software (included in the graphic display and a large number
delivery) allows a fast and comfort- of configuration options for data
able evaluation of the measured collection, display and storage the
data. Based on the findings of this new standard measuring tool is
evaluation the optimum design for flexible and easy to use in the field.
a tailormade PFC solution or the Additionally its compact design
inspection of an existing one is and the light weight suitcase make
easily performed. The collected it easy to transport. A further benefit
data is available in Excel-format for very user is the availability of
giving the user further processing not only English, but also German,
options. As an additional feature Spanish, Russian and Turkish as
the MC7000-3 is equipped with an menu languages.
52 EIPL 2013
Grid Analysis Tool MC7000-3
Three-phase measuring l 1GB memory card included
Easy evaluation of data l
EIPL 2013 53
Switching Devices - Capacitor Duty Contactors
Soft Switching of Capacitor l
Excellent Damping of Inrush l
Improved Power Quality l
UL Certified
General
54 EIPL 2013
Switching Devices - Capacitor Duty Contactors
Soft Switching of Capacitor l
Excellent Damping of Inrush l
Improved Power Quality l
UL Certified
Connection diagram
L1 L2 L3
All types B44066S****J230 (with preload resistors),
B44066S1811J230 with wires on the bottom,
B44066S9911J230 with resistors inside housing.
A1 1 2 3
AUX
A2 2 4 6
EIPL 2013
55
Switching Devices - Capacitor Duty Contactors
Soft Switching of Capacitor l
Excellent Damping of Inrush l
Improved Power Quality l
UL Certified
Connection diagrams
Types B44066S...1C240 Types B44066S...2C240
L1 L2 L3
A1 1 2 3 13 31
A2 2 4 6 14 32
AUX AUX
56 EIPL 2013
Switching Devices - Thyristor Modules
for Dynamic PFC TSM Series
Ultrafast Smooth Switching l
Natural Cooled l
Compact Design l
Enhanced Life of System
Applications Features
Main supply networks with high Easy installation: it can be used
load fluctuations for dynamic similar to a contactor
PFC systems All the intelligence needed is
Presses offered within the thyristor module
Welding machines itself
Elevators Reaction time: 5 milliseconds only
Cranes Permanent self-controlling of:
Wind turbines – voltage parameter
– phase sequence
– capacitor output
Display of
– operation
– faults
– activation
Voltage range: 440 V and 690 V
Output range:
440 V: 10, 25 and 50 KVAr
690 V: 50 KVAr
EIPL 2013 57
Switching Devices - Thyristor Modules
for Dynamic PFC TSM Series
Ultrafast Smooth Switching l
Natural Cooled l
Compact Design l
Enhanced Life of System
2A
2A
58 EIPL 2013
Switching Devices - Thyristor Modules
for Dynamic PFC TSM Series
Ultrafast Smooth Switching l
Natural Cooled l
Compact Design l
Enhanced Life of System
EW-22:
Dimensions (w x d x h) : 90 x 50 x 100 mm
Weight (approx.) : 0.3 kg
Design panel : for mounting on heat sink/fitting
Connection : wago terminal, ready for three-phase
connection to the capacitor
Note :
Three phase current limitation reactor for thyristor modules
TSM-series in conventional dynamic PFC-systems without reactor is a must
Used for limitation of the pace of current increase di/dT in the thyristors
to the maximum permissible value
EIPL 2013 59
Buffer Card
Current amplifier for TSM application l
Short circuit protected
- VE +24V From
9 10 11 12 13 14 15 16 From
SMPS
BUFFER CARD 16 STEPS
SMPS - VE +24V
I/P16 O/P16
125
From
APFC To TSM
Controller Module
1 2 3 4 5 6 7 8
72 I/P1 O/P1
Front View
44
125
115
125
37
44
72 125
Top View Side View
60 EIPL 2013
Reactors - Antiresonance Harmonic Filter
Type tested at CPRI l
’H’ Class insulation l
Thermal Micro Switch l
Linearity ≥173%
General
The increasing use of modern Such a resonance although can lead frequency is below the lowest line
power electronic apparatus (drives, to the following undesirable effects: harmonic. The detuned PFC system
uninterruptible power supplies, etc.) – overloading of capacitors, is purely inductive seen by
produces nonlinear current and – overloading of transformers and harmonics above this frequency. For
thus influences and loads the transmission equipment, the base line frequency (50 or 60 Hz
network with harmonics – interference with metering and usually), the detuned system on the
(line pollution). control systems, computers and other hand acts purely capacitive,
electrical gear, thus correcting the reactive power.
The power factor correction or – resonance elevation, i.e.
capacitance of the power capacitor amplification of harmonics,
forms a resonant circuit in – voltage distortion.
conjunction with the feeding
transformer. Experience These resonance phenomena can
shows that the self-resonant be avoided by connecting capacitors
frequency of this circuit is typically in series with filter reactors in
between 250 and 500 Hz, i.e. in the the PFC system. These so called
region of the 5th and 7th “detuned” PFC systems are scaled
harmonics. in a way that the self-resonant
Applications Features
Avoidance of resonance High harmonic loading capability
conditions Very low losses
Tuned and detuned harmonic High linearity to avoid choke tilt
filters Low noise
Reduction of harmonic distortion Convenient mounting
(network clearing) Long expected life time
Reduction of power losses Temperature protection (NC contact)
Irms = √
2 2 2
Effective current (I 1 +I 3 ... I 13 )
Fundamental current I1 = 1.06 · IR (50 Hz or 60 Hz current of capacitor)
Temperature protection microswitch (NC)
Dimensional drawings and terminals see page 62 and 63
Frequency 50 Hz or 60 Hz
Voltage 230, 380, 400, 415, 440, 690, 750, 800, 1000
Output 5 … 100 KVAr
Detuning 5.67%, 7%, 14%
Cooling natural
Ambient temperature 40 °C
Class of insulation H
Enclosure IP00
EIPL 2013 61
Reactors - Antiresonance Harmonic Filter
Type tested at CPRI l
’H’ Class insulation l
Thermal Micro Switch l
Linearity ≥173%
L W
1 e
WAGO TERMINAL
L TYPE
2.5 mm sq/500 V.
H
open slot
d1 x d2 - 4 Nos.
d1 n1 n2 d2
A 7
l2 b
62 EIPL 2013
Type tested at CPRI l
’H’ Class insulation l
Thermal Micro Switch l
Linearity ≥173%
Fundamentals of Power Factor Correction
PFC controller
Fuses
Capacitor
contactors
Thyristor
M M
modules
3– 3–
Reactors
The rational use of electrical energy reduce the lagging reactive power that an electrical installation operates
calls for economical generation, trans- component transmitted over the net- more economically (higher effective
mission and distribution with little work. If grid conditions change, the power for the same apparent power).
losses. That means restricting all fac- required leading reactive power can Improved
l voltage quality
tors in electrical networks that cause be matched in steps by adding or
losses. One of these factors is lagging taking out single power capacitors Reduced
l voltage drops
reactive power. Loads in industrial and (automatic PFC) to compensate the Optimum
l cable design
public power grids are primarily of an lagging reactive power. – Cable cross-sections can be
ohmic-inductive nature. The purpose reduced with improvement of power
of systems for power factor correction Benefits of power factor factor (less current). In existing
in networks is to compensate the gen- correction installations for instance, extra or
erated lagging reactive power by lead- higher power can be transmitted.
ing reactive power at defined nodes. Fast return
l on investment through
lower power costs Reduced
l transmission losses
This also serves to avoid impermissibly
– Power factor correction reduces The transmission and switching
high voltage drops and additional
the reactive power in a system. devices carry less current, i.e. only
ohmic losses. The necessary leading
– Power consumption and thus the effective power, meaning that
power is produced by capacitors par-
power costs drop in proportion. the ohmic losses in the leads are
allel to the supply network, as close as
reduced.
possible to the inductive load. Static Effective
l use of installation
capacitive compensation devices An improved power factor means
64 EIPL 2013
Components of Power Factor Correction
kWh meter
Apparent
power
P
Grid S
Q
kvarh meter
Capacitors for
compensation
1. Capacitor Series
l PhaseCap and PhaseCap metalized paper as the electrode
HD dry technology – carrier and an unmetalized
Power factor correction (PFC) capacitors impregnation with an inert gas polypropylene film as the dielectric.
produce the necessary leading reactive This combination is especially well
(nitrogen N2).
power to compensate the lagging
Series PhaseCap Compact –
l suited for high power dissipations.
reactive power. They should be capable
semi-dry biodegradable resin. The film- paper arrangement that
of withstanding high inrush currents
Series PhiCap –
l impregnation forms the winding is wound in a
caused by switching operations
(>100 l IR). If they are connected in with semi-dry biodegradable soft slightly staggered alignment:one
parallel, i.e. as banks, the inrush current resin. edge of each double- sided metalized
will increase (≥150 l IR) because the paper projects from the winding.
charging current comes from the power MKV technology
line as well as from other capacitors Based on oil-impregnated The edges are electrically contacted
connected in parallel. polypropylene - paper capacitor with vaporized zinc.The Schooping
winding.The winding element or metal-spray process uses zinc of
Design of capacitors consists of double sided the highest purity.
MKK/MKP technology
Metalized plastic compact capacitors
with self-healing properties and a Wavy cut design
polypropylene dielectric. Film
metallization with zinc/aluminum alloy Section A Section A
Metal spray
results in high performance and a low film Metalization
EIPL 2013 65
Components of Power Factor Correction
1 Dielectric
2 Metalized electrodes
3 Material displacing shock wave
4 Ai r gap with metal vapor
5,6 Plasma zone
7 Boundary layer between gas phase dielectric and plasma
8 Breakdown channel
9 G as phase dielectric
10 Zone of displaced metalization and dielectric
(isolating region)
Safety
Self-healing properties Overpressure disconnector Dry technology/vacuum impregnation
In the event of thermal or electrical At the end of the capacitor’s service The active winding elements are
overload,an electric breakdown life or when a high pressure forms heated and then dried for a defined
occurs. The dielectric in the breakdown inside the can, the overpressure period. Impregnation is performed
channel is broken down into highly disconnector is activated. under vacuum. In this way, air and
compressed plasma that explodes out The specially designed cover with moisture are extracted from the inner
of the breakdown channel and pushes an expansion bead (or bellow as capacitor, and oxidation of the
the dielectric layers apart. The dis- shown in lower fig.) moves upwards electrodes as well as partial discharges
charge continues within the spreading will separate the wires and disconnect are avoided. Afterwards, the capacitor
plasma via the metal layers so that the the capacitor safely from the line. The elements are hermetically sealed in
metal surrounding the faulty area is disconnector is separated at its break cases (e.g. aluminum). This elaborate
completely burnt out. This produces point (small notch) and the flow of process ensures excellent capacitance
perfect isolation of the faulty area current to the capacitor windings is stability and long useful life.
within microseconds. The self-healing interrupted.
process results in negligible capaci-
tance loss – less than 100 pF per 2. Power factor controller
event. The capacitor remains fully Caution: Modern PF controllers are micropro-
functional during the entire process. To ensure full functionality of an over- cessor based.The microprocessor
pressure disconnector, the following is analyzes the signal from a current
30 µm 10 µm
required: transformer and produces switching
commands to control the contactors
1. The elastic elements must not be
hindered, i.e. that add or remove capacitor stages.
– connecting lines must be flexible Intelligent control by microprocessor
leads (cables), based PF controllers ensures even
– there must be sufficient space (at utilization of capacitor stages,a
Terminal
least 20 mm) for expansion above minimized number of switching
the connections (specified for the operations and an optimized life
Snapped
different models),
connection Bellow cycle of the capacitor bank.
– folding beads must not be
retained by clamps. After the required capacitor output
Aluminium A B 2. The maximum permissible fault has been determined,the number of
Can
current of 10 000 A to the UL 810 steps should be defined.The broad
standard must not be exceeded. product range of controllers from
3. Stress parameters of the capacitor EPCOS allows customized solutions:
A Safety device
must be within the IEC 60831 the BR4904 is suited to small PFC
specification. systems with four steps.
66 EIPL 2013
Components of Power Factor Correction
Selection table
Power Current Cross section Fuse rating
KVAr A mm2 A
Rated voltage 230 V, 50 Hz
2.5 6.3 1.5 10
5.0 12.6 4.0 25
7.5 18.8 6.0 35
10.0 25.1 10.0 50
12.5 31.4 16.0 50
15.0 37.7 16.0 63
20.0 50.2 25.0 80
25.0 62.8 35.0 100
30.0 75.8 50.0 125
40.0 100.4 70.0 160
50.0 125.5 95.0 200
75.0 188.3 185.0 315
100.0 251.0 2 x 120.0 400
125.0 - - -
150.0 - - -
175.0 - - -
200.0 - - -
Rated voltage 400 V, 50 Hz
The above mentioned values are guidelines for operation in normal conditions at ambient temperatures up to 35 °C.
Upgrade accordingly if conditions differ, e.g. temperature or harmonics differ. The internal wiring of a capacitor bank is sometimes possible with a smaller
cross section. Various parameters such as temperature inside the cabinet, cable quality, maximum cable insulation temperature, single or multi core
cable, cable length and laying system have to be considered for a proper selection. The local panelbuilder/installer is responsible for a proper selection
of the cable sizes and fuses according to the valid regulations and standards in the specific country where the PFC panels are installed.
68 EIPL 2013
Standard Values: Selection Tables for Cables,
Cable Cross Sections and Fuses
Selection table
Power Current Cross section Fuse rating
KVAr A mm2 A
Rated voltage 480 V, 50 Hz
2.5 3.0 1.5 10
5.0 6.0 2.5 16
7.5 9.0 2.5 16
10.0 12.0 4.0 25
12.5 18.0 6.0 35
15.0 21.0 6.0 35
20.0 24.0 10.0 50
25.0 30.0 10.0 50
30.0 36.0 16.0 63
40.0 48.0 25.0 80
50.0 60.0 35.0 100
75.0 90.0 70.0 160
100.0 120.0 95.0 200
125.0 150.0 120.0 250
150.0 180.0 185.0 315
175.0 210.0 2 x 95.0 350
200.0 240.0 2 x 95.0 400
Rated voltage 525 V, 50 Hz
EIPL 2013 69
<_1
Cos j
Qc=Pmot x F(0.96)=...(KVAr)
100 x 1.01=101.0 KVAr
70 EIPL 2013
Individual PFC for Motors
Approximate values (specified by the German Electricity Association VDEW) for fixed PFC of motors
Motor nominal rating Capacitor power rating Capacitor power rating Capacitor power rating
(1500 r.p.m.*) (1000 r.p.m.*) (750 r.p.m.*)
KVAr KVAr KVAr
EIPL 2013 71
Individual PFC for Transformers
10 1.0 1.5
20 2.0 1.7
50 4.0 2.0
75 5.0 2.5
100 5.0 2.5
160 7.0 4.0
200 7.5 5.0
250 8.0 7.5
315 10.0 8.0
400 12.5 8.5
500 15.0 10.0
630 17.5 12.5
800 20.0 15.0
1000 25.0 16.7
1250 30.0 20.0
1600 35.0 22.0
2000 40.0 25.0
2500 50.0 35.0
3150 60.0 50.0
For an exact calculation of the right There are regional differences in the before installation of a compensation
capacitor value, following formula guidelines of power suppliers bank. Modern transformers have
can be used: concerning the admissible size of laminations which only need low
capacitors directly connected with capacity to reverse the magnetism.
a transformer. Therefore a In case the capacitor output is too
consultation with the respective high, stress increase may occur
power supplier is recommended during idling.
Qc = needed capacitor (KVAr)
I0%= magnetising current of
the transformer
AN = apparent rated power of
the transformer in KVA
72 EIPL 2013
Detuned PFC in General
When installing capacitors for PFC This is achieved by modifying the The reactors must be selected in line
purpose, the problem of dealing with basic LC circuit formed by the trans- with the inductance value to obtain the
harmonics has to be faced. They have former and the capacitor bank, intro- desired tuning frequency and current
to be taken into account when design- ducing a filter reactor in series with the capability high enough for the harmonic
ing the PFC system in order to prevent capacitors, making this way a more current absorption that can be expected.
parallel and /or series resonance con- complex resonant circuit but with the The tuning frequency is usually
ditions that would damage the whole desired feature of having a resonance indirectly referred to as the detuning
electrical system. frequency below the first existing har- factor p and expressed as percentage.
When PFC capacitors are connected, monic. This way it’s not possible to
the inductance of the transformer to- have a real resonance condition.
gether with the capacitors forms a reso- Besides this main objective, the react
nant circuit that could be excited by a tor connected in series with capacitors f : fundamental frequency
harmonic current generated by the load. form a series resonant circuit with a fRES : tuning frequency
This resonant circuit has a resonance certain tuning frequency at which the
frequency, and if a harmonic current of branch will offfer a low impedance PFC detuned filtering is an engineering
this frequency (or close to it) exists, it will path. Filtering of harmonic currents speciality that takes experienced
lead the circuit into a resonance condi- and “cleaning” of the grid will be know-how to implement it in a satisfy-
tion where high current will flow through achieved. ing and safe way.
the branches (L: the transformer, and Components for PFC detuned filters The design instructions for detuned
C: the capacitor bank), overloading them must be carefully selected according PFC systems on page 74 to 77 have
and raising the voltage across them and to the desired PFC purpose, to the to be followed to ensure an optimum
across the whole electrical system that is harmonics present in the system, to performance of the PFC system.
connected in parallel. some features of the system like short Note: The recommendations given in
PFC detuned filtering is a technique to circuit power and impedances, to the selection tables are meant as a
correct the power factor avoiding the the desired filtering effect and to the support tool. EPCOS does not take
risk of resonance condition performed characteristics of the resonant circuit over any responsibility for the design,
by shifting the resonance frequency configured. as apart from the theoretical conditions
to lower values where no harmonic For example, the voltage across the the prevailing circumstances in the
currents are present. capacitors will be higher than the application have to be taken into
nominal grid voltage when they have a account.
reactor connected in series.
EIPL 2013 73
Detuned PFC:
Important Facts and Instructions
74 EIPL 2013
Capacitor Voltage Rating selection guideline for
a Detuned Capacitor Bank
General
It is necessary to understand the Hence, when you apply a basic _ j XC
importance of choosing the right voltage divider formula to these Vcap = _ x 1pu
voltage rating while using capacitors impedances, it's obvious that there j X C + j XL
in a 'Detuned' system. In commonly exists a steady state voltage 'rise'
accepted technical parlance, we say across the capacitor in the circuit. Where X L = p. X C
'voltage drop across the reactor', Now the steady state voltage
however, notice that a capacitor and across the capacitor shall be p = Detuning percentage
reactor are electrical components as follows:
with opposite signs,
i.e., =jX L and -jX c
7% detuning reactor
System
voltage
Consider an additional overvoltage
440V
factor of 10% towards system voltage
Voltage variation and harmonic loading. Then
across capacitor the design requirement would be
=1.075X440 520.43V. Hence it is recommended
=473.12V that the capacitor voltage rating be
chosen at the closest standard
voltage rating of 525V.
7% detuning reactor
System
voltage Consider an additional overvoltage
415V factor of 10% towards system voltage
variation and harmonic loading. Then
Voltage the design requirement would be
across capacitor 490.86V. Hence it is recommended
=1.075X415 that the capacitor voltage rating be
=446.24V chosen at the closest standard
voltage rating of 500V, or atleast
480V.
EIPL 2013 75
Capacitor Voltage Rating selection guideline for
a Detuned Capacitor Bank
_ j 100
Vcap = _ x 1pu = 1.63 pu
j 100 + j 14
System
voltage
Consider an additional overvoltage
440V
factor of 10% towards system voltage
Voltage variation and harmonic loading. Then
across capacitor the design requirement would be
=1.163X440 562.79V. Hence it is recommended
=511.63V that the capacitor voltage rating be
chosen at the closest standard
voltage rating of 600V.
System
voltage
415V Consider an additional overvoltage
factor of 10% towards system voltage
Voltage variation and harmonic loading. Then
across capacitor the design requirement would be
=1.163X415 530.81V. Hence it is recommended
=482.56 that the capacitor voltage rating be
chosen at the closest standard voltage
rating of 525V.
76 EIPL 2013
Capacitor Voltage Rating selection guideline for
a Detuned Capacitor Bank
_ j 100
Vcap = _ x 1pu = 1.06 pu
j 100 + 5.67
EIPL 2013 77
Dynamic PFC:
Important Facts and Instructions
General
Conventional PFC systems quickly shortens the life expectancy of the charge times up to 50 sec as necessary
reach their limits when they have to capacitor, but also increases the risk for conventional PFC is not required
deal with fast changing loads. Applica- of premature failure and in the worst here.
tions like rolling mills, steel presses, case represents a potential safety risk. In summary dynamic PFC does not
wind turbines, container cranes and But furthermore the capacitor itself is only prevent wear-off of the capacitors
large buildings include a huge amount specified for a limited number of and the switches and increases thus
of electric consumers that require a switching operations per year. The the lifetime of a PFC system and its
reactive power adjustment on the ms standard IEC 60831 gives an accept- safety. It also increases the power
scale. Production equipment, eleva- able value of 5 000 switching opera- quality in the grid essentially as it can
tors, chillers, and other electric de- tions per year, a value far below almost react in real time to reactive
vices not only require such dynamic switching numbers up to 100 000 that power demands. Fast enough for ex-
reactions of the power factor compen- may be required per year in dynamic ample, to take care of motor start up
sation equipment, they also lead very applications. Such large switching effects or spot welding requirements.
soon to a total number of switchings numbers and the respective overvolt-
that exceeds the specifications of EPCOS offers all necessary key com-
ages and overcurrents during each ponents to set up a dynamic PFC sys-
standard electromechanical contac- switching operation are likely to dam-
tors by far. tems as the thyristor modules (TSM,
age the capacitor and may lead to a see page 57), the required fast transis-
In conventional PFC systems, stan- very early capacitor failure. tor output controllers (BR6000-T, page
dard capacitor contactors are used to In dynamic PFC systems, the capaci- 38), and the EPCOS standard reactor
switch capacitor steps on and off. tor contactors are replaced by thyris- (page 60) and of course capacitor
These electromechanical devices offer tor modules that are suitable for a series (page 12).
between 100 000 and 200000 nearby unlimited number of switching
switching operations in total during operations as there is no mechanical
their life time which means that in such wear-off. Thyristor modules feature
an application they reach their life ex- electronic semiconductor switches
pectancy after 1 to 2 years already. It that are able to react to a changing re-
has to be mentioned that capacitors active power demand on the ms scale
are much stricter limited with regard and that can switch capacitors without
to the permitted annual number of additional stress. The EPCOS TSM-
switching operations (IEC 60831). This thyristor switches keep the capacitors
typically results in destruction of their at the peak value of the grid voltage
inrush current damping capability and and connect them only when the grid
may also damage the contacts in the reaches this peak voltage value. Thus
main power circuit. Burnt main con- the capacitors are switched current
tacts may produce oscillation or “un- free and inrush currents that can reach
clean” (re-bouncing) switching opera- values of 200 times the nominal cur-
tions. This massive overload not only rent for conventional contactors are
avoided. Additionally capacitor dis-
78 EIPL 2013
PFC Basic Formulae
QC = (VC)2· · C = (VC)2· 2 · f· C
Formula 9
EIPL 2013 79
PFC Basic Formulae
Three-phase PFC applications have two types of capacitor connections: star and delta.
STAR connection
QTOT = 3 · QC
Formula 10
VC = VL / 3
VL
Formula 11
DELTA connection
VC = VL
Formula 13
Example 1:
The relationship between active, Real power = 100 kW
reactive and real power and cos j After PFC = Reactive power
105 KVA After: 33 KVAr
80 EIPL 2013
PFC Basic Formulae
Example 2:
Calculation of capacitor rating for
industrial installation
Given parameters: Target to correct the power factor to 0.9:
Induction motor 220 kW cos 1 = 0.7 tan 1 = 1.02
Network 440 V AC, cos 2 = 0.9 tan 2 = 0.48
(line delta) 3-phase QC = P (tan 1 – tan 2) 440 V/50Hz
Example 3:
Calculating capacitor ratings for
DELTA and STAR connections in
example 2
STAR connection: DELTA connection:
VL 440
VC = –––– = –––– = 254 V VC = VL = 440 V
3 3
QTOT QTOT QTOT QTOT
CSTAR = ––––––– –– = ––––––––––––– CDELTA = –––––––––– =––––––––––––––
(VL)2 · (VL)2 · 2 · f 3·(VL)2 3·(VL)2 2 ·f
118.8 · 1000 118.8 · 1 000
CSTAR = ––––––––––––––––– CDELTA = ––––––––––––––––––––
–
(440)2 · 2 ·50 3· (440) 2 ·2 ·50
= 1 954 µF / Line (phase)
CTOT
Example 4:
Calculating apparent power
reduction (S1–S2) in example 2 Cable cross section calculation
EIPL 2013 81
Cautions
Line frequency 1.00 · VR Continuous duty Highest mean during entire operating time
of capacitor; exceptions (see below) are
admissible for times of < 24 h
Line frequency 1.10 · VR 8 h daily Line voltage fluctuations
Line frequency 1.15 · VR 30 min daily Line voltage fluctuations
Line frequency 1.20 · VR 5 min daily Line voltage fluctuations
Line frequency 1.30 · VR 1 min daily Line voltage fluctuations
Line frequency Such that current does not exceed maximum admissible figure (I max. =1.3.IR)
with harmonics
Temperature class of capacitors to The useful life of a capacitor depends adjacent components (reactors, bus
standard IEC 60831-1 very much on temperature. Proper bars, etc). Forced cooling is preferable
Capacitors are divided into tempera- cooling of a capacitor must ensure for compact designs. And it is highly
ture classes. Each class is represented that the maximum temperature is not inadvisable to arrange capacitors
by a number followed by a letter, e.g. exceeded, otherwise useful life is directly above reactors. Exceeding
–40/D. The number is the lowest am- degraded. When configuring a circuit, specified temperature limits may set in
bient temperature at which a capacitor one should make sure that capacitors worst case the safety device out of
may operate. The upper limit tempera- are not subjected to heat from operation.
ture is indicated by the letter (see table
above).
82 EIPL 2013
Cautions
EIPL 2013 83
Cautions
84 EIPL 2013
Cautions
Installation Keep at least 20 mm space above Please read the Installation and Main-
Specifications like IEC 61921, the capacitor and do not attach any tenance Instructionson the internet at
VDE 0100, VDE 0101, VDE 0560 part component on the top. This gap will www.epcos.com/pfc.
4 and 46, EN 60831 and IEC60831 allow a longitudinal extension of can
apply to the installation and operation in order to ensure that over-pressure Note
of power capacitors. Capacitors disconnector can fully extend. Products shown in this catalog reflect
should be sited in cool and well venti- typical specifications. You are kindly
Useful life of capacitors strongly
lated locations away from other heat- requested to approve our product
depends on the operating temperature
radiating elements. Natural heat dissi- specifications or request our approval
(refer to page 44, temperature classes
pation is generally sufficient for cooling for your specification before ordering.
of capacitors).
purposes if enough air is able to flow
to and away from them and the Exceeding maximum allowed temper-
capacitors are spaced at least 20 mm ature may set the safety device out of
apart. Otherwise, in a less well venti- operation.
lated environment, forced cooling
(fans) will be necessary, scaled so that
the maximum admissible ambient
temperature is not exceeded.
EIPL 2013 85
Other PFC products in the basket
AC (mfd) Capacitors
86 EIPL 2013
Contacts:
EIPL 2013
EPCOS India Pvt. Ltd. “Product development is a continuous
process. Consequently the data indicated
A Member of TDK-EPC Corporation
in this catalogue is subject to change without
Sales Head Office:
prior notice. For the latest information,
14/2, Rajesh Chambers, Brunton Road, Bengaluru 560001.
contact your local partners.”
Tel: +91-80-4039 0640. Fax :+91-80-4039 0603.
Email: sales.in@epcos.com.
EIPL- PFC Product Profile 2013 Prudent 012013 01