ESTAmat® PFC
Mounting Instructions
MV1161
VISHAY ELECTRONIC GMBH - Geschäftsbereich ROEDERSTEIN, ESTA und Hybride
Hofmark-Aich-Str. 36 - Phone (49)-871/86-0 - Fax (49)-871/86 25 12 - D-84030 Landshut - Germany
www.vishay.com
Version 1.2.1
Issue February 2002
Document Number: 13124
Front Panel Controls
Trend LEDs
"ind" and "cap":
switching steps in or out.
green lettering:
Alternate display of step
current "Ic"
number of switching
operations "Σ"
(step LEDs 1 to 12)
Digital display
The four-digit display indicates
actual values, faults,
and the set parameters.
Step LEDs
The LEDs indicate the energized
capacitor steps.
yellow lettering:
fundamental current I fund (LED1)
root-mean-square current I eff
(LED 6)
orange lettering:
display of harmonic current
LED indicators
Selected operating mode
or parameter
Keyboard
Connection diagram
(Rear view of the
controller)
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Document Number: 13124
Table of Contents
1. CONCISE OPERATING INSTRUCTIONS ...................................................................................................................3
1.1. SETTINGS .......................................................................................................................................................................3
1.2. MOUNTING AND CONNECTION OF THE ESTAMAT PFC CONTROLLER ...........................................................................3
1.3. START-UP PROCEDURE ...................................................................................................................................................3
2. GENERAL ..........................................................................................................................................................................5
2.1. ESTAMAT PFC CONTROLLER– APPLICATION AND OPERATION ...................................................................................5
2.2. AUTOMATIC IDENTIFICATION OF C.T. LOCATION AND OF CAPACITOR STEP OUTPUT ......................................................5
2.3. C/K VALUE .....................................................................................................................................................................5
2.4. SWITCHING IN CIRCULAR SEQUENCE ..............................................................................................................................5
2.5. OPTIMIZED SWITCHING PERFORMANCE ..........................................................................................................................6
2.6. GENERATOR OPERATION (4-QUADRANT OPERATION).....................................................................................................6
2.7. SWITCHING DELAY TIME ................................................................................................................................................6
2.8. BLOCKING DELAY TIME FOR RE-SWITCHING...................................................................................................................6
2.9. HARMONIC CURRENT - ROOT-MEAN-SQUARE CURRENT ................................................................................................7
2.10. MEASUREMENT OF TEMPERATURE ...............................................................................................................................7
2.11. SUMMATION CURRENT TRANSFORMER.........................................................................................................................7
2.12. PARALLEL OPERATION .................................................................................................................................................8
2.13. INTERFACE...................................................................................................................................................................8
3. CONNECTION OF THE ESTAMAT PFC CONTROLLER........................................................................................9
3.1. TERMINALS ALLOCATION ..............................................................................................................................................9
3.2. GENERAL CONNECTION INSTRUCTIONS ..........................................................................................................................9
3.3. CONNECTION INSTRUCTIONS FOR CURRENT TRANSFORMER ...........................................................................................9
4. START-UP PROCEDURE..............................................................................................................................................11
4.1. VISUAL CONTROL ........................................................................................................................................................11
4.2. VERIFICATION OF SUPPLY VOLTAGE ............................................................................................................................11
4.3. VERIFICATION OF SET VALUES .....................................................................................................................................11
4.4. INITIALIZATION :..........................................................................................................................................................12
4.4.1. Fully automatic initialization AU1 .......................................................................................................................12
4.4.1.1. Part 1 : Current transformer location .............................................................................................................................12
4.4.1.2. Part 2 : Determination of the current of capacitor steps...............................................................................................13
4.4.1.3. Memorizing the C.T. location with AU1..........................................................................................................................13
4.4.2. Semi-automatic initialization AU2 .....................................................................................................................14
4.4.3. Manual Initialization AU3 .................................................................................................................................14
4.5. TEST MODE ..............................................................................................................................................................14
5. OPERATING THE ESTAMAT PFC CONTROLLER- MAIN MENU .....................................................................15
5.1. MODE AUTO – AUTOMATIC OPERATING MODE ..........................................................................................................15
5.2. MODE MAN - MANUAL OPERATING MODE.................................................................................................................16
5.3. MODE CURRENT , YELLOW LETTERING ........................................................................................................................16
5.4. MODE TARGET COSϕ ..................................................................................................................................................17
5.5. MODE SWITCHING DELAY TIME ....................................................................................................................................17
5.6. MODE IC / Σ SWITCHINGS, GREEN LETTERING .............................................................................................................18
5.7. MODE HARMONIC CURRENT [%] , ORANGE LETTERING................................................................................................18
6. PARAMETER: SETTING AND DISPLAY ..................................................................................................................19
6.1. PARAMETER IN THE MAIN MENU .................................................................................................................................19
6.2. PARAMETERS IN THE SETTING MENU ............................................................................................................................19
6.2.1. Setting menu - call-in ..........................................................................................................................................19
6.2.2. Setting menu – Modifying the parameter ............................................................................................................20
6.2.3. Setting menu – Completing and memorizing the parameter ...............................................................................20
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6.3. SETTING MENU – DESCRIPTION OF THE PARAMETER ....................................................................................................21
6.3.1. Parameter -1- : Modes of initialization.............................................................................................................21
6.3.2. Parameter -2- : Type of measuring voltage ......................................................................................................22
6.3.3. Parameter -3- : Connection of measuring voltage............................................................................................22
6.3.4. Parameter -4- : Type of switching program.....................................................................................................22
6.3.5. Parameter -5- : C/k value.................................................................................................................................23
6.3.6. Parameter -6- : Number of switching steps......................................................................................................24
6.3.7. Parameter -7- : Blocking delay time for re-switching......................................................................................24
6.3.8. Parameter -8- : Switching-in delay time ..........................................................................................................25
6.3.9. Parameter -9- : Switching-out delay time ........................................................................................................25
6.3.10. Parameter -10- : Switching in circular or series mode...................................................................................25
6.3.11. Parameter -11- : Fixed steps ............................................................................................................................25
6.3.12. Parameter -12- : Locking of keyboard operation...........................................................................................26
6.3.13. Parameter -13- : Functioning of the alarm relay............................................................................................26
6.3.14. Parameter -14- : Switching out the capacitor steps in case of alarm .............................................................27
6.3.15. Parameter -15- : Permitted maximum temperature ........................................................................................27
6.3.16. Parameter -16- :Current factor RMS current/fundamental frequency current................................................28
6.3.17. Parameter -17- : Maximum permissible values for the harmonic current .......................................................28
6.3.18. Parameter -18- : C.T. transformation ratio k..................................................................................................28
6.3.19. Parameter -19- : Time delay for switching out steps in case of ≡I and ≡E .................................................28
7. FAULT ELIMINATION .................................................................................................................................................29
7.1 OPERATION AND FAULT DISPLAY ..................................................................................................................................29
7.2 GENERAL FAULTS .........................................................................................................................................................32
8. TECHNICAL DATA........................................................................................................................................................33
8.1. MEASURING CIRCUIT ...................................................................................................................................................33
8.2. CONTROL CIRCUIT .......................................................................................................................................................33
8.3. MONITORING ...............................................................................................................................................................33
8.4. ELECTRICAL CONNECTION ...........................................................................................................................................33
8.5. MECHANICAL DETAILS ................................................................................................................................................34
9. FLOWDIAGRAM OF PARAMETERS IN THE SETTING MENU ......................................................................... 35
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1. Concise Operating Instructions
1.1. Settings
The ESTAmat PFC Controller will be supplied with the following standard setting :
Supply voltage
: 230 VAC or 120 VAC
Measuring voltage connection : phase to neutral
Frequency
: 50 Hz or 60 Hz
Type of initialization AU1
: fully automatic identification of - measuring voltage connection,
- C.T. location and
- output of the connected capacitor
steps.
1.2. Mounting and connection of the ESTAmat PFC Controller
A cut-out of 138 by 138mm is required for mounting the Controller. The added springs for attachment
shall be pushed into the slots at the device's rear until they have reached the switchboard and have
locked in place.
Terminals
1
2
4
5
7, 8
10
12
15-20
21-26
Connection
C.T. connection k (S1), X/5 A or X/1 A
C.T. connection l (S2), X/5 A or X/1 A
Mains connection N, 230 VAC or 120VAC
Mains connection L1, 230 VAC or 120VAC
Potential-free alarm contact, normally open
Measuring voltage L or N
Measuring voltage L
Control terminals for contactors 1-6
Control terminals for contactors 7-12 (only PFC12)
In case of standard setting
as per item 1.1 above, the
measuring voltage can be
connected to the mains
supply, i.e. terminal 4 shall
be bridged to terminal 10,
and terminal 5 is to be
bridged to terminal 12.
1.3. Start-up procedure
After the supply voltage has been applied to it, the ESTAmat PFC Controller starts a self-test. The
following data will be displayed for about 2 seconds:
The type of program
e.g.: 1.2.1.
•
The mode of initialization
e.g.: AU1 *)
•
The set target cosϕ
e.g.: 1.00
•
The switching delay time
e.g.: LOAD
•
with AU1 the type of measuring voltage e.g.: L-0, must be changed to L-L by the operator, if the
•
measuring voltage is to be connected between
phase to phase. Refer to item 4.4. and 6.3.2.
with AU2 and AU3
•
the connection of measuring voltage e.g.: L1-0,
must be adapted to a different connection of
measuring voltage and current transformer
location . Refer to item 4.4. and 6.3.3.
*) with AU3, the additional display of :
the switching program and number of engaged relay steps e.g.: 1111 and with LED zzzzzz
•
•
the C/k-value
e.g.: 0.025
Owing to the basic setting made at the factory, the ESTAmat PFC Controller changes into the fully
automatic initialization AU1. This means that no further settings need to be made by the operator.
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Prerequisite for starting the fully automatic initialization:
• The C.T. secondary current must be at least 25 mA.
• The current of the smallest capacitor connected must be at the C.T. secondary side in the range of
0.025 to 1.00 A.
Sequence of the fully automatic initialization :
Display
Function
The Controller starts with step 1 and continues switching in steps until the
location of the current transformer has been determined due to the changes in
current. The trial runs are counted and evaluated. The C.T. location is determined
only after 5 consecutive trial runs producing all the same result. The Controller starts
at the meter reading -1- and stops, in the normal case, at -5- after 5 trial runs.
In cases of unfavourable conditions of the mains supply, the value of the meter
AU1
reading may reduce again. If the value -3- is not reached, either the setting AU2 or
-1- to -5AU3 should be selected. Refer to item 6.3.1 in this case.
NO
Continuous changes of display between AU1 and NO indicates that the Controller
has already stored a connection value for the C.T. location. The Controller will start
at AU2 after the re-switching blocking delay time has elapsed. Refer to item 4.4.1.3
for this.
An activated blocking delay time for re-switching for one step is indicated by a
flashing decimal point
Having identified the location of the current transformer, the current or output ratings of the capacitor
steps will be determined.
Display
Function
Starting with step 1, the Controller switches in each individual step briefly, and
AU2
switches it out again immediately. (PFC6 : 6 steps, PFC12: 12 steps).
2.1 to 2.3
The procedure is repeated three times.
Normally, the ESTAmat PFC Controller terminates a successful initialization after approximately 5
minutes, and correctly determines the configuration of the plant, and indicates the actual power factor.
If one of the following symbols is on display, the following conditions may be the cause:
Display
Condition
Remedy
The
measuring
current
is
less
than
25
mA.
Check C.T. electric circuit
≡I
The measuring current is in excess of 5.3A.
C.T. transformation ratio is too
≡0
small
The measuring voltage is missing.
Check connection of Controller
≡U
AU1 could not be carried out correctly. Possible Set AU2. Refer to item 6.3.1.
≡AU1
causes: quick reversals of load, insufficient
compensation output, load too low.
AU2 could not be carried out correctly. Possible Set AU3. Refer to item 6.3.1.
≡AU2
causes: quick reversals of load, no switching of
capacitor steps.
SLE
The faults ≡AU1 or ≡AU2 have appeared five
Set AU3. Refer to item 6.3.1.
times in succession. This condition can be
modified only upon fundamental change of load.
A target factor of 1.00 is preset as standard.
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2. General
2.1. ESTAmat PFC Controller– Application and Operation
The ESTAmat PFC Controller can be applied wherever automatic control of the power factor is
required. All functions of the ESTAmat PFC are controlled by a microprocessor. A protective gear
(watchdog) continously monitors the processor to guarantee its faultless operation. There are no
internal time or date functions.
The measurable variables current and voltage are conducted across a 50/60Hz band-pass filter.Thus
harmonics existing in the network cannot affect the measurement process. Both measurement entries
are potential-free. The measuring voltage shall be in the range of 58V-690V and may be connected, at
option, between phase to neutral or phase to phase. The current measuring range is 25mA to 5A, and
there is no need to differentiate between X/1A or X/5A current transformer.
A measuring cycle lasts 0.5 seconds and comprises the measurement of values, the calculation of all
required parameters, such as power factor, current, harmonic current, etc., and if necessary, the
initialization of certain actions, e.g. switching the steps, activating alarm, etc.
2.2. Automatic identification of C.T. location and of capacitor step output
The ESTAmat PFC Controller is capable of determining by itself , during the start-up procedure, the
location of the current transformer as well as the output rating of the connected capacitor steps by
means of test switchings.
Three modes of initialization are possible:
Fully automatic initialization AU1
•
The ESTAmat PFC Controller identifies the location of the current transformer, the output
and number of capacitor steps, and the switching program.
Semi-automatic initialization AU2
•
The ESTAmat PFC Controller identifies, upon presetting of the C.T. location, the output and
number of capacitor steps, and the switching program.
Manual initialization AU3
•
The C.T. location, output and number of capacitor steps, and the switching program have to be
set by the operator.
2.3. C/k value
The C/k-value is the pick-up value of the ESTAmat PFC Controller. The value represents the
reactive current response threshold of the Controller in Ar (ampere reactive). In case the reactive
current portion of the load exceeds the set C/k value, one of the two LEDs "ind" or "cap" will indicate
the trend. The calculation of the C/k value is described under item 6.3.5.
2.4. Switching in circular sequence
Switching in circular sequence means that capacitors which have been switched in first, will also be
switched out again first. Switching follows the FIFO principle: First-IN-First-OUT. If the switching-in
follows the order 1-2-3-4-5, then also the switching-out of the capacitors will follow that same order .
1-2-3-4-5.
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The circular switching mode distributes the load uniformly on all elements such as contactors and
capacitors. A further advantage of this mode is that a capacitor step, when switched out, has enough
time for discharging before it is switched in again.
The advantages of the circular switching sequence are also applicable for the so-called hunting
programs. With the switching sequence 1:2:2:2:2:2, for example, the "double-size" steps are likewise
switched in circular switching sequence. The "single-size" step will then be used only for fine tuning.
With the switching programs of equivalent hunting steps, e.g. 1:1:2:2:4, the hunting steps of same size
(1:1 or 2:2) will also be switched alternately.
2.5. Optimized switching performance
The ESTAmat PFC Controller measures continuously the demand for reactive power and the
variations of it and, due to the optimized switching performance, switches in or out the largest possible
capacitor step. In case of, for example, a power factor correction equipment of 25 : 25 : 50 : 50 : 50
kvar, the ESTAmat PFC Controller will immediately switch in a step of 50 kvar instead of gradually
switching in steps of 25kvar. This way, the number of switching operations is reduced, which results
in an increased life expectancy of both the capacitors and the contactors.
2.6. Generator operation (4-quadrant operation)
The increasing use of renewable energy sources (e.g. wind, solar, biogas) and thermal regeneration,
as also the application of emergency power supply systems, require that state-of-the-art power factor
controllers operate trouble-free in case of a feed-back of active power into the general supply mains
(generator operation). In both cases of energy supply and of energy feed-back, the ESTAmat PFC
Controller can identify correctly the inductive reactive power and compensate it.
2.7. Switching delay time
The period between lighting-up of one of the light-emitting diodes (LED) ("ind","cap") and the
switching in or out of capacitor steps is defined as switching delay time. The switching delay time can
either be determined by the ESTAmat PFC Controller as a function of load, or preset by the
operator.
2.8. Blocking delay time for re-switching
The period between switching out a certain capacitor step and the earliest possible re-switching in
of the same step is defined as re-switching blocking delay. With the ESTAmat PFC Controller, this
blocking delay for re-switching can be either 20, 60, 180 or 300 seconds. This period is necessary in
order to allow the voltage existing at the capacitor after the switching-out to reduce to an acceptable
level. The blocking delay for re-switching shall be selected in accordance with the existing
discharging device. Switching-in shall be effected only when the residual voltage is less than 10% of
the operating voltage.
2.9. Harmonic current - Root-mean-square current
By means of the FFT-analysis (Fast-Fourier-Transformation), the ESTAmat PFC Controller can
determine harmonic currents of the 3rd, 5th, 7th, 11th, 13th, 17th and 19th harmonic. The presentation
is in percentage with regard to the current of the basic frequency. The Controller displays the
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percentage values up to the 17th harmonic. If harmonic generators exist and if the resonance frequency
between the compensation equipment and the line transformer is on a typical harmonic frequency, the
percentage part of this harmonic increases excessively. This may activate alarms by means of various
limit-value profiles. This may be, for example, an audible or an optical signal via the alarm relay.
The root-mean-square current is determined by calculation on the basis of the current's curve shape.
Non-linear consumers distort the sinusoidal shape of the current. Fundamental frequency current and
root-mean-square current are of different values in case of harmonic load. The higher the portion of
harmonic load the higher is the deviation between the values of the fundamental frequency current and
of the root-mean-square current. A factor which is created from these two values is a parameter
portraying the harmonic status, and can be determined by means of settable limit values to be used for
the alarm.
2.10. Measurement of temperature
Via an internal temperature sensor the ESTAmat PFC Controller can permanently measure the
ambient temperature. Although the sensor is installed within the device, the measuring can be carried
out with sufficient precision because of the existing venting slots which allow sufficient air circulation.
When the Controller is mounted into a switch cabinet, there is the possibility of monitoring the
cabinet's internal termperature. By setting limit values, an alarm function can be activated.
2.11. Summation current transformer
When several transformers supply one single L.V. bus bar, the individual currents shall be measured
by means of current transformers and then added together via a summation current transformer.
Special attention shall be given to the correct polarity because, otherwise, the current intensities of the
individual transformers will subtract.
The calculation of the C/k-value is described under item 6.3.5. It is important to remember that the
transformation ratios of the individual current transformers shall be added up.
k = k1 + k2 + k3 ...
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k = ∑ C.T. transformation ratios
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2.12. Parallel operation
In case two network sections, each with independent power factor control equipment, are
interconnected, the two power factor controllers influence each other, because the currents distribute
across the two transformers. In such a case, to avoid hunting of the two power factor controllers, the
C/k-values should be set differently. The result will be a so-called "lead-follow" - behavior because
both controllers react at a different speed. The power factor controller with the lower C/k value is
quicker in switching than the one with the higher C/k value.
The target cosϕ values of both power factor controllers should be the same. If this is not the case, the
power factor controller with the higher setting would try to switch in steps which the power factor
controller with the lower setting would again switch out immediately. This would also result in an
unacceptable hunting between the switch-in and switch-out operations.
2.13. Interface
The ESTAmat PFC is equipped with a serial interface RS232. By means of a computer, all relevant
measuring values and Power Factor Controller data can be requested. Furthermore, all Power Factor
Controller's parameters can be modified via a computer. The computer software and the connection
cable ESTAmat PFC to the computer are available at option.
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3. Connection of the ESTAmat PFC Controller
3.1. Terminals allocation
The power factor controller is connected by means of a 20-terminal plug. The ESTAmat PFC12 is
provided with an additional 6-terminal plug for the steps 7 to 12. The connections are shown at the
rear of the power factor controller's casing.
Terminal allocation of the plug:
Terminals
1
2
4
5
7, 8
10
12
15-20
21-26
Connection
C.T. connection k (S1), X/5 A or X/1 A
C.T. connection l (S2), X/5 A or X/1 A
supply connection N, 230 VAC
supply connection L1, 230 VAC
potential-free fault alarm contact, normally open
measuring voltage L or N
measuring voltage L
control outputs for contactors 1-6
control outputs for contactors 7-12 (only PFC12)
3.2. General connection instructions
1.
The power factor controller is internally protected by means of a fine-wire fuse 100 mA (glass
tube fuse 5 x 20 mm). This fuse is not accessible from the outside.
2.
The rating of the external fuse is a function of the current consumption of the connected
contactors. It should, however, be taken into account that an individual control contact may
certainly be loaded with a maximum of 5A, but the external fuse must not exceed the value of
10A.
3.
Under normal circumstances, the measuring voltage is identical with the operating voltage, i.e. the
terminals 4-10 and 5-12 shall be connected by means of bridging links. If measuring voltage and
operating voltage are connected separately, the terminals 10 and 12 are each to be protected by a
quick-acting fuse of 2 A.
4.
All control contacts, except for the fault alarm contact (7 and 8), are bridged by a spark-quenching
unit (RC element). The impedance of the RC element is 30 kΩ at 50 Hz.
5.
When using capacitors with attached discharge resistors, the necessary time for discharging will
be 60 or 180 seconds, which has to be observed for any switching-in of steps. The re-switching
blocking delay time of the ESTAmat PFC must be set accordingly via parameter 7.
3.3. Connection instructions for current transformer
1.
In case of an unbalanced load of the phases, the current transformer should be connected to the
phase which is most highly loaded.
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2.
The current transformer shall be installed at a position which ensures that all the subsequent
consumer current, including the capacitor current, will flow through it. Normally, this position is
next to the feed-in transformer and on the load side of the tariff meter reading.
3.
The connecting cable to the current transformer, with a maximum length of 10 m, should have a
minimum conductor cross section of 2.5 mm². If the cable is longer than 10 m, a larger conductor
cross section or a current transformer of a higher rating shall be used.
4.
When an already existing current transformer can be made use of, then all the current paths of the
individual devices shall be connected in series with the ESTAmat PFC Controller. Attention
should be paid that the rating of the current transformer be sufficient.
5.
The primary current of the current transformer should coincide with the actual current
consumption of the factory. If the current transformer is overdimensioned, the ESTAmat PFC
Controller receives too small a measuring signal and, consequently, will work incorrectly or not at
all, and will signalize the fault "undercurrent ≡I ".
6.
The C/k value is set automatically by the ESTAmat PFC Controller in the initialization modes
AU1 und AU2. Attention shall be paid, however, that the current of the smallest capacitor step at the
transformer secondary is in the range of 0.025 up to a maximum 1.5 A.
7. In case of several supplies, a summation current transformer is required. In this case, it is
definitely necessary that the terminals k (S1) and l (S2) of the individual current transformers be
connected correctly.
Advice concerning the replacement of the P.F. Controller :
When working at the C.T. secondary circuit (e.g. removal of the ESTAmat PFC), attention
should always be paid that the C.T. secondary terminals be short-circuited and remain so until
the work is completed (e.g. re-installation of P.F. Controller).
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4. Start-up procedure
In the following text, the keys to be activated are marked black..
means that the key IN shall be pressed. The display - - - - symbolizes an
Example:
identified keyboard operation, no further keyboard operation is necessary.
4.1. Visual control
Upon completion of the installation, all connections to the main circuit and the control-circuit
terminals and the screws for fixing the socket connector are to be checked.
4.2. Verification of supply voltage
Operating voltage and frequency are to be checked to confirm that they correspond with the relevant
data given on the rating plate at the rear of the P.F. Controller!
230 VAC or 120 VAC?
-
50 Hz or 60 Hz ?
4.3. Verification of set values
Upon application of the supply voltage, the display will show for 2 seconds respectively:
type of program
e.g.: 1.2.1.
•
initialization mode
e.g.: AU1 *)
•
set target cosϕ
e.g.: 1.00
•
switching delay time
e.g.: LOAD
•
with AU1 the type of measuring voltage e.g.: L-0, must be changed to L-L by the operator, if the
•
measuring voltage is to be connected between
phase to phase. Refer to item 4.4. and 6.3.2.
with AU2 and AU3
•
the connection of measuring voltage e.g.: L1-0,
must be adapted to a different connection of
measuring voltage and current transformer
location . Refer to item 4.4. and 6.3.3.
*) with AU3, the additional display of :
the switching program and number of engaged relay steps e.g.: 1 1 1 1
•
the C/k value
e.g.: 0.025
•
The ESTAmat PFC Controller is supplied with the following standard setting:
initialization mode
: AU1
target cosϕ
: 1.00
switching delay time
: LOAD
blocking delay for re-switching : 20
locking of the keyboard
: NO (not activated)
If the ESTAmat PFC Controller had been turned to manual operation, the P.F. Controller will
automatically go back to manual operation upon return of the supply voltage. Then all capacitor steps
which had before been switched in, observing the re-switching blocking delay, will be re-switched in
again.
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By pressing the key
this process can be aborted.
4.4. Initialization :
The P.F. Controller offers three modes of initialization:
•
Fully automatic initialization AU1 (= standard setting)
The ESTAmat PFC determines the location of the current transformer, the output and number of
the capacitor steps, and the switching program. The operator must only set the measuring voltage
mode phase to phase L-L or phase to neutral L-0 . (refer to 6.3.1 and 6.3.2).
•
Semi-automatic initialization AU2
The ESTAmat PFC Controller determines, after presetting the location of the current
transformer, the output and number of the capacitor steps, and the switching program.
•
Manual initialization AU3
The operator has to set the location of the current transformer, the output and number of capacitor
steps, and the switching program.
The P.F. Controller is supplied with the fully automatic initialization mode AU1 set, which is the normal
application. The fully automatic initialization may not be successful in case of strong oscillations in
the public mains. In such a case, the semi-automatic AU2 or the manual initialization AU3 can be
applied. The initialization mode is stored as parameter -1- (item 6.3.1).
How to change the initialization mode is described under items 6.2 and 6.3.1 .
4.4.1. Fully automatic initialization AU1
With this mode of initialization, the current transformer may be connected to any phase. Connection of
both the current transformer k/l (S1/S2) and the measuring voltage is also at option. The mode of
measuring voltage will have to be set either phase to phase L-L or phase to neutral L-0 (=standard
setting). Refer to items 6.2 and 6.3.2.
When the supply voltage is applied, the setting values will be displayed as described under item 4.3.
The fully automatic initialization AU1 comprises :
- part 1 : determination of current transformer location and
- part 2 : recording the currents of the capacitor steps
4.4.1.1. Part 1 : Current transformer location
First of all, the set re-switching blocking delay is effective. During this time, AU1 is being displayed
and a decimal point is flashing. When the display alternates between AU1 and NO, it means that there is
still stored a C.T. location of a previous application. Refer to item 4.4.1.3. If this is not the case, the
ESTAmat PFC Controller switches capacitor steps in and out several times after the re-switching
blocking delay has elapsed and subject to the mains conditions. The number of switching cycles
carried out will be displayed after the last step has been switched out. This number may range between
-0- and -5- . When the display shows the figure -5- , part 1 of the initialization is completed.
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If a value of 2 or even less is displayed after several switching cycles have been carried out, it is
recommended to set the semi-automatic initialization AU2 or the manual initialization AU3.
If wrong results are caused by load variations during the measuring period, the display will show ≡AU1
and the result of the measurement will be rejected. If due to special mains conditions, a clear
determination of the connection mode during initialization is impossible, then five further trial runs
will be made observing the re-switching blocking delay. After five abortive trial runs in succession
displaying ≡AU1, the power factor controller switches into a stand-by position and will resume
initialization only after the load conditions have fundamentally changed. The stand-by position is
indicated by the letters SLE (Sleep).
Again in this case, the semi-automatic initialization AU2 or the manual initialization
recommended.
AU3 is
4.4.1.2. Part 2 : Determination of the current of capacitor steps
At first, the set re-switching blocking delay is effective. During this time, AU2 is displayed and a
decimal point is flashing. For the determination of the currents of the capacitor steps, 6 (or 12) steps
will be switched in and out, one after the other. This procedure will be repeated three times. The
respective switching cycle is displayed as 2.1, 2.2 and 2.3. The measured reactive current changes will
be stored as step currents. Upon completion of the initialization, the power factor controller changes
into automatic operation mode and the actual power factor is displayed.
In case of a fault, e.g.: measuring voltage missing ≡U, measuring current insufficient ≡I or measuring
current too large ≡0, the initialization will be interrupted. The elimination of the fault's cause will be
detected by the power factor controller, and the initialization will automatically be re-started.
4.4.1.3. Memorizing the C.T. location with AU1
When the set target power factor has been reached for the first time during the automatic operation
mode, the C.T. location will be stored permanently. If this is the case, there will appear in the display
of the ESTAmat PFC Controller, directly after application of the supply voltage, alternatively AU1
and NO during the period of the re-switching blocking delay. Thereafter, the ESTAmat PFC
Controller performs part 2 AU2 (item 4.4.1.2).
A stored C.T. location can be erased by changing the alternating display AU1 and NO into AU1 and YES.
This can be realized by means of the keys
or
The selected value is to be confirmed by pressing the key
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NO : The ESTAmat PFC Controller takes over the stored C.T. location and starts with part 2 =
determination of the currents of the capacitor steps.
YES : The ESTAmat PFC Controller erases the stored C.T. location and performs part 1 and part 2
of the initialization AU1
4.4.2. Semi-automatic initialization AU2
The semi-automatic initialization AU2 should be selected when the fully automatic initialization does
not produce a satisfying result due to strong load changes. Attention will have to be paid to the fact
that the phase connection of the measuring voltage has to be explicitly specified. Refer to items 6.2
and 6.3.2.
The initialization runs in accordance with part 2 of the initialization mode AU1 (item 4.4.1.2).
4.4.3. Manual Initialization AU3
In case of manual initialization AU3, the operator must set:
-
measuring voltage connection
the type of switching program
the C/k value
the number of steps
(parameter -3-,
(parameter -4-,
(parameter -5-,
(parameter -6-,
item 6.3.3.),
item 6.3.4.),
item 6.3.5.) and
item 6.3.6.).
The procedure to set the parameters is described under item 6.2.
During the first start-up procedure, parameters -4- and -5- must be verified. For this, both parameters
must be called-in and, if necessary, be modified in the setting menu. If this is not done ≡PAR will be
displayed, and after a delay of 2 seconds, the controller will automatically change to the setting menu
of the parameter concerned.
The step outputs will be determined by means of the C/k value, the number of switching steps and the
switching program. No readjustment of the step outputs will occur while switching the capacitor steps
during operation.
4.5. TEST MODE
During the start-up procedure of the controller, if the measuring current ≡I, or the measuring
voltage ≡U is missing, a test mode can be activated to switch steps in the manual operating mode.
During AU1 and AU2, the switching program of 1:1:1:1, the C/k value of 0.05 and the maximum
number of switching steps are automatically preset. Only during AU3, the already set parameters (4, 5
and 6) will remain. The test mode is activated by means of the key
.
Thereafter, the selected menu is displayed alternately with TEST. For deactivation of the test mode, the
operating voltage of the controller must be disconnected. For example, this can be achieved by
temporarily removing the control fuse of the capacitor bank.
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5. Operating the ESTAmat PFC Controller- main menu
In the following text, the keys to be activated are marked black..
Example:
means that the key IN shall be pressed. The display - - - - symbolizes an
identified keyboard operation, no further keyboard operation is necessary.
On the front plate of the ESTAmat PFC Controller six main menu points are laid out. Important
control parameters, measuring values, and control characteristics can be enquired for or can be set by
means of this main menu.
By means of the key
By means of the key
they can be increased.
the respective menu point can be engaged.
the values can be reduced, or by the key
The selected value will be stored by pressing the key
If one of the following menu points current, target-cosϕ, switching delay, Ic/Σ switching
operations or harmonic current is called upon, and no key is being operated for a period of 30
seconds, the ESTAmat PFC Controller switches to the AUTO mode.
5.1. Mode AUTO – automatic operating mode
In the automatic operating mode, the capacitors are automatically switched in or out depending on the
demand for reactive power. The actual power factor is shown in the display. A minus in front of the
power factor means that the power factor is capacitive.
For the purpose of testing, capacitors can be switched in or out manually at any time in the automatic
operating mode.
By means of the key
steps can be switched in.
By means of the key
steps can be switched out.
As long as the decimal point flashes in the display, the re-switching blocking delay is still effective.
However, the operation of the key is stored and the capacitor step will be switched in after the reswitching blocking delay has elapsed.
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5.2. Mode MAN - manual operating mode
The manual operating mode can be called upon from any other mode. When the MAN mode is set, the
automatic operating mode is ineffective, i.e. no capacitor steps are switched.
In order to activate the MAN mode, one must keep pressing the key
until
the display shows 8888 after about 5 seconds. Manual operation is manifested by the flashing of the
LED AUTO.
In the MAN mode, capacitor steps can be switched in or out manually:
By pressing the key
steps can be switched in.
By pressing the key
steps can be switched out.
As long as the decimal point flashes in the display, a re-switching blocking delay is still effective.
However, the operation of the key is stored and the capacitor step will be switched in after the reswitching blocking delay has elapsed.
To de-activate the MAN mode, press key
The MAN mode remains active even after a voltage interruption has occurred. When the voltage has
returned, the P. F. Controller goes back to MAN mode by itself. Capacitors which had been switched
in before the voltage interruption occurred will be switched in again taking into account the reswitching blocking delay.
By pressing the key
this procedure can be stopped.
5.3. Mode current , yellow lettering
The apparent current in Ampere is displayed.
By means of the key
the root-mean-square value of the current and
by means of the key
the fundamental frequency current can be called upon.
This is displayed by means of the step LEDs 1 and 6 . The lettering I fund defines the fundamental
frequency current, I eff the root-mean-square value of the current.
Ifund :
Ieff :
current value of the mains frequency 50 or 60 Hz
current value comprising the mains frequency plus the harmonic component.
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The transformation ratio of the current transformer can be set by means of the parameter -18- . (Refer
to item 6.3.18). This way, the actual primary C.T. current can be displayed.
The portion of harmonics will increase as a function of the increased deviation between root-meansquare current and fundamental frequency current.
5.4. Mode target cosϕ
By means of the keys
and
the target power factor can be
set in the range of 0.85 inductive ( 0.85 ) up to 0.95 capacitive ( -0.95 ). A minus in front of the
power factor means that the power factor is capacitive.
the standard setting 1.00 for the
When pressing simultaneously the keys
target cosϕ is produced. The value shown when the setting mode for the target cosϕ is left will be
stored.
5.5. Mode switching delay time
The period between surpassing the hysteresis and starting the switching procedure is defined as
switching delay time. The condition of surpassing must be given permanently during the determined
switching delay time. The switching delay time can be determined by the ESTAmat PFC Controller
as a function of load, or it can be fixed by the operator.
The following fixed switching delay times are possible: 10 , 30 , 60 , 120 , 180, 300 and 500 seconds.
Determination of the switching delay time as a function of load is activated when the display indicates
LOAD . The switching delay time may range between 2 and 500 seconds.
By means of the key
or
the desired switching delay
time or the function LOAD can be selected.
the standard setting LOAD is produced.
By pressing simultaneously
The selected value is stored by means of the key
changes to the next menu.
and the menu indicator
By means of the parameters 8 and 9 (items 6.3.8 and 6.3.9), fixed switching delay times can be set
separately for the switching-in and the switching-out of capacitors. In this case, the flashing LED IND
signalizes a fixed presetting for the switching-in delay time while the flashing LED CAP indicates a
fixed presetting for the switching-out delay time.
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5.6. Mode Ic / Σ switchings, green lettering
In this mode the capacitor steps are examined. The capacitor current and the number of switching
operations of the selected step are alternately displayed.
By means of the key
or
a step can be called upon.
The step LEDs 1 to 12 show for which step the values are being displayed. By means of the LEDs "Σ"
and "Ic", the displayed value can be identified:
Ic = Current in Ampere of the selected capacitor step. The current is readjusted via the current
transformer's transformation ratio which is set under parameter -18- .
Σ switching operations = Number of switching operations of the contactor of the selected
capacitor step. The point symbolizes the thousandth place.
Range of switching cycles
0 – 9999
10,000 - 99,999
100,000 –999,999
Display
8.888
88.88
888.8
The capacitor contactors will have to be replaced after about 100,000 switching operations. A regular
check is strongly recommended.
By pressing simultaneously
reset.
the switching counter of the selected step can be
5.7. Mode harmonic current [%] , orange lettering
By means of the FFT-type analysis (Fast-Fourier-Transformation), the ESTAmat PFC Controller
can determine harmonic currents of the 3rd, 5th, 7th, 11th, 13th, 17th and 19th harmonic. They are
displayed in percentage of the current of the fundamental frequency. These percentage values are
displayed up to the 17th harmonic. ( Har.: 3 5 7 11 13 17 )
By means of the key
or
a harmonic can be selected.
In the step display one can see which harmonic has been selected.
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6. Parameter: setting and display
The parameter can be set in two different ways:
• at the Controller and
• with a PC via the serial interface of the Controller.
6.1. Parameter in the main menu
In the following text, the keys to be activated are marked black..
Example:
means that the key IN shall be pressed. The display - - - - symbolizes an
identified keyboard operation, no further keyboard operation is necessary.
The target power factor and the switching delay time can be modified directly by means of the main
menu.
By means of the key
the respective menu point can be selected.
The values can be reduced by means of the key
or can be increased by means of
the key
The selected value is stored via the key
6.2. Parameters in the setting menu
6.2.1. Setting menu - call-in
In a specific setting menu, another 19 parameters can be modified. This menu
can be activated by simultaneous pressing of the keys
The keys must be kept pressed until the display shows the value 8888 after about 5 seconds.
Thereafter, the parameter - 1- and in alternation its actual occupancy, e.g.: AU1 , is shown.
A parameter can be selected by pressing key
or
6.2.2. Setting menu – Modifying the parameter
If the parameter is to be modified, press key
display.
The set value flashes in the
The value can be modified by pressing the keys
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or
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The set value is stored via the key
Thereafter, the parameter is displayed in alternation with the modified value.
6.2.3. Setting menu – Completing and memorizing the parameter
By means of the keys
or
the parameter's number
is to be modified until the display indicates DONE . This display will appear at the moment when the
number of the parameter changes from -1- to -19- or from -19- to -1- .
is to be pressed. The display SAFE flashes.
Thereafter, the key
By means of the keys
commutated between
SAFE , RST and [AN
SAFE
RST
[AN
or
the display can now be
The display continues flashing.
=
The modified parameter values will be stored.
=
All parameters will be returned to their RESET values.
=
The menu is exited. Any modification will not be stored.
By pressing the key
the selection will be confirmed. Thereafter, the Controller
runs a new start-up of the program or, in case no significant parameters have been modified, it returns
to the calling menu position.
A new start-up of the program without modification of the parameter will also be carried out if, after
activating the setting menu, no key operation takes place for a period of 2 minutes.
6.3. Setting menu – Description of the parameter
In the setting menu, 19 parameters can be modified.
Number
- 1- 2- 3- 4- 5-
Implication
Modes of initialization AU1, AU2 or AU3
Type of measuring voltage L-N or L-L, only to be set in case of AU1
Connection of measuring voltage, to be set in case of AU2 and AU3
Switching program, to be set in case of AU3
C/k value, to be set in case of AU3
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- 6- 7- 8- 9-10-11-12-13-14-15-16-17-18-19-
Number of capacitor steps, to be set in case of AU3
Re-switching blocking delay time
Switching-in delay time
Switching-out delay time
Switching in circular or series mode
Number of fixed steps, settable only in case of circular switching mode.
Key operation blocked
Mode of functioning of the alarm relay
Release of steps switch-out
Temperature limit value
Limit values for the ratio between r.m.s. current and fundamental wave current (Ieff/Ifund)
Limit values for harmonic current
Transformation ratio of the C.T.
Waiting time for switching-out steps in case of undercurrent and of energy feed-back, if the
respective function has been released via parameter 14 .
6.3.1. Parameter -1- : Modes of initialization
Three modes of initialization are possible:
Initialization mode
Fully automatic
Semi-automatic
Manual
Display
AU1
AU2
AU3
If RST is selected (see page 20), AU1 is reset.
•
Fully automatic initialization
AU1
The ESTAmat PFC Controller determines the current transformer location, the output and
number of capacitor steps, and the switching program.
•
Semi-automatic initialization
AU2
The ESTAmat PFC Controller determines, after the current transformer location has been set,
the output and number of capacitor steps and the switching program.
•
Manual initialization
AU3
The operator will have to set the current transformer location, the output and number of capacitor
steps, and the switching program.
6.3.2. Parameter -2- : Type of measuring voltage
The type of measuring voltage determines whether the measuring voltage is connected between phase
to phase or phase to neutral. Since this information is required only for the initialization mode AU1, this
parameter will only be displayed in case AU1 has been selected.
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Type of measuring voltage
Phase / Neutral
Phase / Phase
Display
L-0
L-L
If RST is selected (see page 20), L-0 is reset.
6.3.3. Parameter -3- : Connection of measuring voltage
The connection of the measuring voltage needs to be indicated only in case of semi-automatic (= AU2)
and manual initialization (= AU3). The table shows all the possible connection combinations to the
terminals 12 and 10 of the ESTAmat PFC Controller.
Connection of
measuring
voltage
L1 – N
L2 – N
L3 – N
N - L1
N - L2
N - L3
L1 - L2
L2 - L3
L3 - L1
L2 - L1
L3 - L2
L1 - L3
Setting value as a function
of the C.T. location
L1
L2
L1-0
L3-0
L2-0
L1-0
L3-0
L2-0
0-L1
0-L3
0-L2
0-L1
0-L3
0-L2
L1L2
L3L1
L2L3
L1L2
L3L1
L2L3
L2L1
L1L3
L3L2
L2L1
L1L3
L3L2
L3
L2-0
L3-0
L1-0
0-L2
0-L3
0-L1
L2L3
L3L1
L1L2
L3L2
L1L3
L2L1
If RST is selected (see page 20), U-0 is reset.
The identifiers L1-N, L2-N, etc. indicate the connection of the measuring voltage. The setting value
has to be read in the column which indicates the correct C.T. phase.
6.3.4. Parameter -4- : Type of switching program
The switching program has to be set only in case of the manual initialization mode (= AU3) . The
figures indicate the relation between the various step outputs. For example, the switching program
1:2:4:4:4 reveals that step 2 is double the size of step 1. Step 3 and the following steps have four times
the output of step 1 (e.g.: 50kvar : 100kvar : 200kvar : 200kvar ... etc.). The steps with equal output are
regarded also as equal with regard to controlling (=circular steps) and can be switched in accordance
with the principle of circular switching.
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Switching program
1:1:1:1:1
1:1:2:2:2
1:1:2:2:4
1:1:2:3:3
1:1:2:4:4
1:1:2:4:8
1:2:2:2:2
1:2:3:3:3
1:2:3:4:4
1:2:3:6:6
1:2:4:4:4
1:2:4:8:8
Display
1111
1122
11224
1123
1124
11248
1222
1233
1234
1236
1244
1248
If RST is selected (see page 20), 1 1 1 1 is reset.
6.3.5. Parameter -5- : C/k value
The C/k value is the pick-up value of the ESTAmat PFC Controller. This value is the reactive
current responding threshold of the Controller in reactive Ampere. If the reactive current portion of the
load exceeds the set C/k value, this will be displayed by one of the two LEDs ("ind" or "cap").
The C/k value can be calculated as follows:
Q
C/k =
3 ⋅ U ⋅ kct
Q =
U =
kct =
output of the smallest step [var]
phase conductor voltage (Phase-Phase) [V]
C.T. transformation ratio
Example : Q=25kvar, U=400V, kct=1000:5 = 200
C/k = 25000var / (1.732 · 400V · 200) = 0.18A
The setting range of the C/k value is 0.025A up to a maximum 1.5A. The maximum value is a function
of the selected switching program. The C/k value has to be set only with the initialization mode AU3.
Conditional on the minimum C/kmin-value of 0.025A and a specified C.T. transformation ratio, the
smallest possible capacitor step Qmin can be calculated as follows:
Qmin = 3 ⋅ U ⋅ kct ⋅ C / kmin
Example:
U
= phase conductor voltage (phase to phase) [V]
kct
= C.T. transformation ratio
C/kmin = smallest C/k value (=0.025A)
U=400V, kct=1000:5A
Qmin = 1.732 · 400V · 200 · 0.025A = 3.46kvar
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Table with C/k values for 400V:
current
transformer
C/k values for 400 V
smallest capacitor step [kvar]
5
10
12.5
15
16.7
20
50:5 0.72 1.44
75:5 0.48 0.96 1.20 1.44
100:5 0.36 0.72 0.90 1.08 1.21 1.44
150:5 0.24 0.48 0.60 0.72 0.80 0.96
200:5 0.18 0.36 0.45 0.54 0.60 0.72
250:5 0.14 0.29 0.36 0.43 0.48 0.58
300:5 0.12 0.24 0.30 0.36 0.40 0.48
400:5 0.09 0.18 0.23 0.27 0.30 0.36
500:5 0.07 0.14 0.18 0.22 0.24 0.29
600:5 0.06 0.12 0.15 0.18 0.20 0.24
800:5 0.05 0.09 0,11 0.14 0.15 0.18
1000:5 0.04 0.07 0.09 0.11 0.12 0.14
2000:5 0.02 0.04 0.05 0.05 0.06 0.07
0.03 0.04 0.04 0.05 0.07
2500:5
0.02 0.03 0.04 0.04 0.05
3000:5
0.02 0.02 0.03 0.03 0.04
4000:5
If RST is selected (see page 20), 0.05 is reset.
25
1.20
0.90
0.72
0.60
0.45
0.36
0.30
0.23
0.18
0.09
0.07
0.06
0.05
30
1.44
1.08
0.87
0.72
0.54
0.43
0.36
0.27
0.22
0.11
0.09
0.07
0.05
40
1.44
1.5
0.96
0.72
0.58
0.48
0.36
0.29
0.14
0.12
0.10
0.07
50
1.44
1.20
0.90
0.72
0.60
0.45
0.36
0.18
0.14
0.12
0.09
60
1.44
1.08
0.87
0.72
0.54
0.43
0.22
0.17
0.14
0.11
100
1.44
1.20
0.90
0.72
0.36
0.29
0.24
0.18
150
1.35
1.08
0.54
0.43
0.36
0.27
6.3.6. Parameter -6- : Number of switching steps
The number of the connected steps can be set by means of the LED step display. The setting range
comprises 1-6 or12 steps respectively. The number of steps has to be set in case of initialization mode
AU3. The minimum number of steps is determind by the switching program. In case the number of set
steps is lower than the allowed minimum number of steps, the number of steps will be adjusted
respectively.
If RST is selected (see page 20), 6 (PFC6) or 12 (PFC12) is reset.
6.3.7. Parameter -7- : Blocking delay time for re-switching
The time between switching out a certain capacitor step and the earliest moment of switching it in
again is defined as blocking delay time for re-switching. This time is required in order to reduce the
voltage existing at the capacitor to an acceptable level. The re-switching blocking delay time will have
to be selected in accordance with the existing discharge device. Switching-in must take place only
after the residual voltage has fallen below 10% of the operating voltage. The standard setting of the
blocking delay time is 20 seconds.
Re-switching blocking delay time
Display
20 sec
20
60 sec
60
180 sec
180
300 sec
300
If RST is selected (see page 20), 20 is reset.
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6.3.8. Parameter -8- : Switching-in delay time
The time for switching-in and switching-out can be set either processor-controlled as a function of
load, or as fixed time presetting. It is also possible to set the switching-in time separately from the
switching-out time. The setting range for the fixed time presetting is 2 to 500 seconds. This option is
not effective in case of setting OFF , i.e. fixing of the switching delay time is carried out in accordance
with the setting in the main menu.
If RST is selected (see page 20), OFF is reset.
6.3.9. Parameter -9- : Switching-out delay time
As already mentioned in 6.3.8., the switching-out delay time can be set independently of the
switching-in delay time. The setting range is likewise 2 to 500 seconds. This option is not effective in
case of setting OFF , i.e.. fixing of the switching delay time is carried out in accordance with the setting
in the main menu.
If RST is selected (see page 20), OFF is reset.
6.3.10. Parameter -10- : Switching in circular or series mode
Steps of equal output can be switched in different sequence. In case of circular switching, the step
which had been switched out for the longest time will be switched in, and the step which had been
switched in for the longest time will be switched out. The advantage of this method is that there is
equal switching stress and operating time for all steps. The series switching mode is applied where the
compensation is assembled of filter circuits with different tuning frequencies and also when a certain
switching sequence has to be maintained.
Switching sequence
circular switching
series switching
Display
[]
--
If RST is selected (see page 20), [] is reset.
6.3.11. Parameter -11- : Fixed steps (only in circular mode)
A number of capacitor steps determined by the operator can be defined as fixed steps. These steps are
switched in permanently upon application of the supply voltage to the ESTAmat PFC Controller and
after the re-switching blocking delay time has elapsed. The desired number of fixed steps has to be set.
The ESTAmat PFC Controller switches in the respective number of steps starting with the highest
step digit. As a rule, all circular steps can be used as fixed steps. One cirular step, however, shall
remain for the control operation. In case of series connections, no fixed steps can be defined. If the
operating mode MAN is set, this parameter cannot be selected.
If RST is selected (see page 20), OFF is reset.
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6.3.12. Parameter -12- : Locking of keyboard operation
The parameters of the main menu, e.g.: target power factor, switching time, etc. and the manual
operating mode MAN, can be protected against unauthorized adjustment by locking the keyboard.
Locking is activated, when the display indicates ≡LO[ .
Keyboard operation
not locked
locked
Display
NO
YES
If RST is selected (see page 20), NO is reset.
6.3.13. Parameter -13- : Functioning of the alarm relay
During normal and trouble-free operation, the alarm relay is operative. The contact is open. In case of
faults and of a breakdown of the supply voltage, the contact closes. The fault situation to which the
alarm relay shall react can be selected by means of parameter 13.
Alarm signals
≡T
≡HAR
≡IEF
≡[
≡U
≡0
≡I
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X = Alarm relay reacts to this fault situation.
The different types of fault are described in the survey matrix under item 7.
If RST is selected (see page 20), 0 is reset.
Display
0
1
2
3
4
5
6
7
8
9
10
11
6.3.14. Parameter -14- : Switching out the capacitor steps in case of alarm
Capacitor steps can be switched out when certain alarm signals are given. The fault alarm which shall
cause a switch-out can be selected by means of parameter 14. The specific kind of fault alarm
determines the switch-out behavior. The numbers 1- 3 indicate the priorities.
1 = the capacitor steps will be switched out immediately without time delay.
2 = the capacitor steps will be switched out after a time delay which can be modified (parameter 19)
3 = steps will continue being switched out until the fault alarm has disappeared.
Issue February 2002
Document Number: 13124
- 26 -
Due to the switching-out of capacitor steps, it may be that the set power factor cannot be maintained.
This may cause reactive power costs.
Fault alarms
≡IEF
≡T
≡E
≡U
1
1
1
1
1
1
1
1
1
1
1
2
3
3
3
3
3
3
3
2
2
3
3
3
3
2
2
≡I
2
2
2
2
Display
OFF
1
2
3
4
5
6
7
8
9
10
11
If RST is selected (see page 20), 2 is reset.
6.3.15. Parameter -15- : Permitted maximum temperature
By means of an internal sensor, the ESTAmat PFC Controller can measure the ambient temperature.
When the preset maximum temperature is exceeded, the display of the fault alarm ≡T alternates with
the display of the actual power factor.
Advice: If for parameter -13- (function of the alarm relay) the value 6 has been selected, a cabinet
ventilator can be switched in via the alarm relay.
Permitted max. temperature
not active
35°
40°
45°
50°
55°
Display
OFF
35
40
45
50
55
If RST is selected (see page 20), OFF is reset.
6.3.16. Parameter -16- :Current factor RMS current/fundamental frequency current
This factor indicates the relation between fundamental frequency current (50Hz or 60Hz) and rootmean-square current. The higher this factor the greater is the portion of harmonic waves. This way, the
harmonic situation can be evaluated. Factors between 1.05 and 2.00 can be set. The step width is 0.05.
If the factor is exceeded, the fault alarm ≡IEF will be given after a time delay of 5 minutes. With the
setting OFF , this function is switched out.
If RST is selected (see page 20), OFF is reset.
Issue February 2002
Document Number: 13124
- 27 -
6.3.17. Parameter -17- : Maximum permissible values for the harmonic current
For the harmonic portions of the 3rd; 5th; 7th; 11th; 13th; 17th and 19th harmonic, 10 maximum value
profiles in percentage can be set. When at least one harmonic wave exceeds its set maximum value for
a period of 5 minutes, the fault alarm ≡HAR is triggered.
Maximum permissible value of harmonic in % of the fundamental
frequency current
3rd
5th
7th
11th
13th
17th
19th
not activated
10
10
7
5
4
3
3
15
15
12
8
6
5
4
20
20
14
9
8
6
5
25
25
18
11
10
7
7
30
30
21
14
12
9
8
35
35
25
16
13
10
9
40
40
29
18
15
12
11
45
45
32
20
17
13
12
50
50
36
23
19
15
13
Display
OFF
1
2
3
4
5
6
7
8
9
If RST is selected (see page 20), OFF is reset.
6.3.18. Parameter -18- : C.T. transformation ratio k
The current transformer transformation ratio k can be set by means of parameter 18. The displayed
current values and C/k values will be respectively multiplied by the set factor. Factors between 1 and
8000 can be selected. This is possible in all the initialization modes.
If RST is selected (see page 20), 1 is reset.
6.3.19. Parameter -19- : Time delay for switching out steps in case of ≡I and ≡E
If fault alarm is given as a consequence of undercurrent ≡I and energy feed-back ≡E , capacitor steps
can be switched out after the set waiting delay has elapsed. The switch-out function has to be released
via parameter 14. Waiting delays between 30 and 500 seconds can be set.
Step width is 10 seconds (range of 30 – 200), 20 seconds (range of 200 – 300) and 50 seconds (range
of 300 – 500).
If RST is selected (see page 20), 500 is reset.
Issue February 2002
Document Number: 13124
- 28 -
7. Fault elimination
7.1 Operation and fault display
Symbol
Type
≡I
failure of
current
≡0
overcurrent
≡[
undercompensation
≡U
measuring
voltage fault
≡T
excess
temperature
-1to
-5-
progress of
AUI
2.1
to
2.3
progress of
AU2
Description
Reaction of ESTAmat PFC
Fault elimination
- measuring current too low, C.T. may be too large.
capacitor steps will be
- connection to C.T. may have broken.
measuring current is below
switched out after a set delay
- in case of internal current generation, the C.T. current may
25mA
has elapsed if the function is
be zero if internal consumption and generator output are
activated.
about the same, and the target power factor is set to 1.00.
measuring current exceeds
- measuring current exceeds 5.3A because the C.T. may be too
none
5.3A
small.
- compensation output may be too small and the set target
the actual power factor is
power factor cannot be reached.
permanently below 0.9 lagging
none
- capacitors do not carry any current because either the stepfor 15 minutes at least
fuses are defective or the contactors are not connected.
capacitor steps are switched
measuring voltage is missing
- possibly the control-fuses are defective
out without delay
- internal temperature in the cubicle is too high.
capacitor steps are switched - check cubicle ventilation
ambient temperature has
out after a certain delay, if
- check ventilation filters for clogging
exceeded the set limit
the function is activated
- capacitors or chokes may be overloaded due to harmonic
currents
the figures 1 to 5 indicate the
- No fault display!
- when figures 1 to 4 alternate with =AUI, the Controller tries
progress of AUI. AUI is
none
to initialize under difficult load conditions. If this is the case,
completed when figure 5 is
it is recommended to change to AU2.
reached
the figures 2.1 to 2.3 indicate the
progress of AU2
none
Issue February 2002
Document Number: 13124
- 29 -
- No fault display!
Symbol
≡AUI
≡AU2
≡SLE
≡E
Type
fault during
initialization
mode AUI
fault during
initialization
mode AU2
Description
Reaction of ESTAmat PFC
Fault elimination
AUI could not be completed
without faults
five trial runs are made
- Controller cannot determine the C.T. location easily owing
to the quick load changes
AU2 could not be completed
without faults
five trial runs are made
- Controller cannot determine the C.T. location easily owing
to the quick load changes
AUI and AU2 have appeared five
times in succession. This
condition is changed only upon
fundamental change of load
the display appears when
feeding back
capacitor steps shall be
of energy
switched out in case of feeding
back of energy
stand by
mode
SLEEP
none
capacitor steps are switched
out after a certain delay, if
the function is activated
the relation between rms value
capacitor steps will be
and fundamental frequency
switched out one by one after
value of the current has
five minutes, if the function
exceeded a specified limit
is activated
≡IEF
current rms
value
≡HAR
harmonic
current
a specified percentage of a
harmonic has been exceeded
none
parameter
control
by the first start-up procedure,
the parameters -4- and -5- must
be verified.
after a delay of 2 seconds,
the controller will
automatically change to the
setting menu of the
parameter concerned.
≡PAR
Issue February 2002
Document Number: 13124
- 30 -
- automatic initialization is not possible due to the actual
load condition. Upon change of the line conditions, the
Controller tries again an initialization. It is recommended
to change to AU3
- No fault function!
- due to harmonic currents, the rms current may clearly
differ from the fundamental frequency current. The
increased harmonic current may lead to overloading of the
capacitors. Dangerous resonance conditions can be
temporarily avoided by switching out capacitor steps.
However, the harmonic current situation will have to be
examined.
- dangerous resonance conditions can be temporarily
avoided by switching out capacitor steps. However, the
harmonic current situation will have to be examined.
- No fault function!
Symbol
Type
Description
Reaction of ESTAmat PFC
after the given alarm and
with a 5 minutes delay, steps
alarm ≡IEF or ≡T is given and will continue being switched
out.
switching out of capacitor steps
Attention: to achieve this,
is activated.
the controller will reduce
the set target power factor!
Fault elimination
≡COS
Switching
out of
capacitor
steps
≡LO[
keyboard is
locked
the keyboard is locked by
means of parameter 12
none
DAER
data memory
defective
during checks of the internal
memory, a fault occurred
Controller is defective
- return Controller to factory for repair
EPR
memory
defective
during checks of the program
memory, a fault occurred
Controller is defective
- return Controller to factory for repair
Issue February 2002
Document Number: 13124
- 31 -
- No fault function!, refer to ≡IEF and ≡T
- No fault function!, refer to item 6.3.12
7.2 General faults
Fault display
Cause
Display remains blank.
Controller does not react to changes; display shows actual cos ϕ
and LED 'AUTO' flashes.
Controller is hunting.
Controller displays a capacitive power factor while inductive
load is present, and no capacitor steps are switched in.
The set target power factor is reached but does not coincide with
the actual power factor of the plant.
The displayed current does not coincide with the actual current.
Upon switching it in, the Controller starts with initialization
mode AU2 and, after this mode is completed, operates
incorrectly.
Issue February 2002
Document Number: 13124
- 32 -
- supply voltage is missing.
- equipment fuse is defective. Possibly the applied supply voltage is too high.
- Controller has been changed to 'MAN', press key
to revert to automatic
operation.
- C/k value is too low (only with AU3 mode)
- C.T. connection k/l (S1/S2) is mixed up (only with AU3 mode)
- a wrong measuring voltage connection is set in mode AU2 or AU3.
- the current transformers connected to the summation current transformer are
wrongly 'poled'.Terminals k/l (S1/S2) are mixed up, i.e. the currents are not added
up but subtracted.
- the current measuring path of the Controller is connected in parallel with other
measuring equipment; current measuring paths should be connected in series.
- A wrong setting of the C.T. transformation ratio k (parameter 18) was made.
- Controller is set to AU1 and uses wrongly memorized data. Possibly the Controller
had been applied in another plant before, wiring of measuring connections were
changed, or a fault occurred with mode AU1.
- refer to items 6.0 and 6.3 'setting menu' in order to select the initialization mode
new.
8. Technical Data
8.1. Measuring circuit
Voltage range
Current range
Frequency
Input filter
Voltage connection
Current power input
Galvanic separation
Current continuous overloading
Current transformer
Precision U-I
Precision harmonic current
:
:
:
:
:
:
:
:
:
:
:
58 V to 690 V, stepless
25 mA to 5 A
50 Hz (60 Hz upon request)
each measuring circuit is provided with a band-pass filter
phase to phase or phase to neutral
1 VA maximum
potential-free connection with both measuring circuits
20% maximum
x/5A or x/1A, category 1
1%
The accuracy of harmonic current measurement is better
than 90 %.
:
:
6 or 12 steps
a function of reactive load (2 to 500 seconds) or,
settable to 10, 30, 60, 120, 180, 300, 500 seconds
settable to 20, 60, 180, 300 seconds
5A/265VAC, the contact is bridged with a 47 nF
anti-interference capacitor
8.2. Control circuit
Number of steps
Switching delay time
Re-switching blocking delay time :
Relay contact load-bearing capacity :
8.3. Monitoring
Watchdog
Temperature
Alarm relay
Display
Harmonic current
No-voltage release
:
:
:
:
:
:
monitoring correct function of the processor
monitoring ambient temperature
can be programmed with various alarm functions
showing symbols for the various types of faults
alarm signal
all capacitor steps will be switched out immediately upon
interruption of supply voltage. Switching-in can take place
only after the re-switching blocking delay has elapsed.
Operating voltage
Power input
Instrument fuse
Connection
:
:
:
:
Interface
:
230VAC ±15%, 50Hz (60Hz and/or 120VAC upon request)
8W maximum
100mA tr. 5 x 20 mm, inside the device
via 20-poles (PFC12: an additional 6-poles) multipoint
connectors, 2.5 mm², rigid or flexible cable
RS232, 3-poles multipoint connector
8.4. Electrical connection
Issue February 2002
Document Number: 13124
- 33 -
8.5. Mechanical details
Front panel
Panel cut-out
Depth
Weight
Design
:
:
:
:
:
Type of protection
:
Ambient operating temperature
Position of installation
:
:
Issue February 2002
Document Number: 13124
142 x 142 mm
138 x 138 mm
approximately 70 mm
0.65 kg maximum (PFC12)
to EN 50178, protective class II, and EN 61010-1,
EN50081-2, EN61000-6-2
IP 40 with multipoint connector mounted (IP 55 upon
request; but only for the frontside protected by a lockable
Controller cover, when controller is mounted in the cubicle
door)
-25°C up to +60°C
at option
- 34 -
9. Flow Diagram: Parameters in the setting menu
-1- Modes of initialization
AU2
AU1
AU3
-2Type of measuring
voltage
L-0 or L-L
-3- Connection of measuring voltage
(Setting value as a function of the C.T. phase)
Connection of
Connection of
measuring voltage
measuring voltage
L1 – N
L1 – N
...
...
L1 - L3
L1 - L3
-4- Type of switching program
1:1:1:1:1
...
1:2:4:8:8
-5- C/k value
-6- Number of switching steps
Display
-7- Re-switching blocking delay
time
20 sec
60 sec
180 sec
300 sec
20
60
180
300
-8- Switching-in delay time
LOAD or fixed time presetting is 2 to 500 seconds
(OFF: carried out according to the setting in the main menu)
-9- Switching-out delay time
LOAD or fixed time presetting is 2 to 500 seconds
(OFF: carried out according to the setting in the main menu)
-10- Switching in circular or series mode
Switching sequence
Display
circular switching
[]
series switching
--11- Fixed steps (only in circular mode)
Issue February 2002
Document Number: 13124
- 35 -
-12- Locking of keyboard operation (≡LO[ )
Keyboard operation
Display
not locked
NO
locked
YES
-13- Functioning of the alarm relay
Alarm signals
≡T
≡HAR
≡IEF
≡[
≡U
≡0
≡I
Display
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
0
1
2
3
4
5
6
7
8
9
10
11
-14- Switching out the capacitor steps in case of alarm
1 = the capacitor steps will be switched out immediately without time delay.
2 = the capacitor steps will be switched out after a time delay which can be modified (parameter -19- )
3 = steps will continue being switched out until the fault alarm has disappeared.
For table with relation between fault alarm and switch-out behavior, refer to item 6.3.14.
-15- Permitted maximum temperature
Permitted max. temperature
Display
not active
OFF
35°
35
40°
40
45°
45
50°
50
55°
55
-16- Current factor RMS current/fundamental frequency current
Factors between 1.05 and 2.00 can be set. The step width is 0.05.
-17- Maximum permissible values for the harmonic current
Maximum permissible value of harmonic
in % of the fundamental frequency
current
3rd 5th 7th 11th 13th 17th 19th Display
-18- C.T. transformation ratio k
Factors between 1 and 8000 can be selected.
-19- Time delay for switching out steps in case of ≡I and ≡E
The switch-out function has to be released via parameter -14Waiting delays between 30 and 500 seconds can be set.
Issue February 2002
Document Number: 13124
- 36 -