EPCOS Product Profile (India) 2013

Power Factor Correction

Power Quality Solutions

www.epcos.com
Preview

U I

I U

Linear loads: Non linear load produce

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

General How reactive power is generated

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

energy is called reactive power. S2

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

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

Higher energy consumption and achieved by individual or fixed compensation

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

4 EIPL 2013
Preview

Power Quality Solution strategy

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

Uninterruptible Power supply Power Factor Correction (PFC)

and Harmonic Filtering
EMC filter
C

DC link Tuned Linear load Dynamic Passive Active

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

EIPL 2013 5
PQS Key Components Overview

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

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

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

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

current selectable selectable selectable selectable

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

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

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

BR Series and Ordering Details

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

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

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

8 EIPL 2013
Important Notes

The following applies to all products named in this 4. In order to satisfy certain technical requirements,some of
publication: the products described in this publication may contain
1. Some parts of this publication contain statements about substances subject to restrictions in certain jurisdictions
the suitability of our products for certain areas of appli- (e.g. because they are classed as hazardous).
cation. These statements are based on our knowledge Useful information on this will be found in our Material
of typical requirements that are often placed on our prod- Data Sheets on the Internet (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
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.

Features Alarm output Cautions:

Display - Insufficient compensation 1. Discharge time: Make sure that
- Large and multifunctional LCD - Overcompensation the discharge time set in controller
(2 x 16 characters) - Undercurrent matches the capacitor
- Graphic and alphanumeric - Overcurrent discharge time. See page 84
LCD illumination - Overtemperature 2. Number of switchings: LV PFC
Intelligent control - Harmonics exceeded capacitors according to standard
Menu-driven handling - Threshold value programmable IEC 60831 are designed
(plain language) - Internal error storage for up to 5000 switching operations.
Self-optimizing control capability - Programming of 2nd signal relay Make sure that 5000 switching
Recall function of recorded values random operations per year are not exceeded.
Four-quadrant operation - Undervoltage and overvoltage
(e.g. stand-by generator) Recall recorded values
Large measuring voltage range - Number of contactor
Powerful alarm output switching operations
Display of numerous of system - Maximum voltage V (Vmax)
parameters - Maximum reactive power,Q (KVAr)
- System voltage (V AC) - Maximum value of harmonic
- Reactive power (KVAr) - Maximum active power,P (kW)
- Active power (kW) - Maximum apparent power,S (KVA)
- Frequency - Maximum temperature (°C)
- THD-V, THD-I - Operation time of all capacitors
- Individual harmonics up to 19th* - Complete 2nd parameter set
- Monitoring of individual available
capacitor currents - Automatic initialization
- Apparent power (KVA) - Dynamic PFC (transistor output)
- Apparent current (A) - Thyristor switching
- Temperature (oC) Dual target power factor setting
- Real-time cos j (EB and DG) is available in
- Target cos j selected models
- KVAr value to target cos j

38 EIPL 2013
PF Controllers BR6000 Series
Intelligent l
User-friendly l
Cost-effective l
Version 5.0

PF controller BR6000 R-12 : Relay output

PF Controller BR6000 T- 6/12 : Transistor output

PF Controller BR6000 R-12 (RS 485) : Relay output

EIPL 2013 39
PF Controllers BR6000 Series
Intelligent l
User-friendly l
Cost-effective

Selection table for controllers

BR6000 relay output BR6000 transistor output

Steps 6 STEP 12 STEP 6 STEP 12 STEP

Switching Contactor Contactor Thyristor Thyristor
Ordering code B44066R6006R230N1 B44066R6012R230N1 B44066R6106R230N1 B44066R6112R230N1
Auxiliary supply 1-Phase, 2-Wire, 245 Vac 1-Phase, 2-Wire, 245 Vac 1-Phase, 2-Wire, 245 Vac 1-Phase, 2-Wire, 245 Vac
(-20% to+20%) (-20% to+20%) (-20% to+20%) (-20% to+20%)
Measurement voltage 30-525 V AC (L-N) or (L-L) 30-525 V AC (L-N) or (L-L) 1Ph 30-300 V AC (L-N) 1Ph 30-300 V AC (L-N)
Load CT Input current 1/5A 1/5A 1/5A 1/5A
No. of outputs 6 12 6 12
Alarm outputs 1 No. 1 No. 1 No. 1 No.
- Insufficient Yes Yes Yes Yes
Compensation
- Overcompensation Yes Yes Yes Yes
- Over / under voltage Yes Yes Yes Yes
- Overcurrent Yes Yes Yes Yes
Automatic Initialisation Yes Yes YesYes
Communication RSXXX No No* No No
interface
Parameters displayed
System voltage Yes Yes Yes Yes
Load current Yes Yes Yes Yes
Capacitor current No No No No
Active power Yes Yes Yes Yes
Reactive power Yes Yes Yes Yes
Apparent power Yes Yes Yes Yes
Frequency Yes Yes Yes Yes
Individual harmonics 19 19 19 19
measurement upto
THD - V Yes Yes Yes Yes
THD - I Yes Yes Yes Yes
Monitoring of Yes - Health check Yes - Health check No No
individual capacitor
current
Apparent current Yes Yes Yes Yes
Overtemperature Yes Yes Yes Yes
Real time cos j Yes Yes Yes Yes
Target cos j Yes Yes Yes Yes
KVAr value to target Yes Yes Yes Yes
cos j
Switching and
discharge time range
- Correction time 1 sec - 20 min 1 sec - 20 min 20-1000 m sec 20-1000 m sec
- Discharge time 1 sec - 20 min 1 sec - 20 min 20-1000 m sec 20-1000 m sec
Number of 20 + E series 20 + E series 20 + E series 20 + E series
control series
Weight (in kG) 1kG 1kG 1kG 1kG
Dimensions 144 x 55 x 144 mm 144 x 55 x 144 mm 144 x 53 x 144 mm 144 x 53 x 144 mm
(L x D x H in mm)

*RS 232-B44066R6312R230N1
*RS 485-B44066R6412R230N1

40 EIPL 2013
Copying of this document and giving it to others and the use or communication of the contents thereof, are forbidden without
express authority. Offenders are liable of the payment of damages. All rights are reserved in the event of the grant of a patent Page
of registration of a utitily model or design. Proprietary data, company confidential. All rights reserved. BR6000 Controller Setting Procedure 1 /2

Pre checks:

 Measurement voltage & measurement current (load CT) should be from same phase.

 Ensure that the controller relay output P1 & P2 common 230V supply should be drawn
from the measurement phase

Programming Procedure
Go to programming mode.

A. Press “Auto/Program/Manual/Service “ mode button – Programming will display. Press ENTER /OK button.

B. Language –set to English, Press ENTER /OK button.

C. I– CT Primary Ratio – Set the load CT primary current by pressing UP/DOWN key button. Press ENTER /OK
button.

D. I –CT secondary –Set load CT secondary current by pressing UP/DOWN key button. Press ENTER /OK
button.

E. END STEP (12) – Set the end step number as per total number of steps connected by pressing UP/DOWN
button. Press ENTER /OK button.

F. Control series 1 – Press UP button & go to control series E, Press ENTER /OK button.

G. Control Mode- set to’ Intelligent’ mode, Press ENTER /OK button.
st
H. Power of 1.Stage – Set 1 step minimum KVAR rating , Press ENTER /OK button.(*Ensure that the outputs
of controller (relay / transistor) are connected from min to max kVAr rating)

I. Target COS ø – Press UP/DOWN to set at desired limit.(Ideally 1 p.f)

El presente documento y su contenido es propiedad de Epcos Electronic Components, S.A. Su divulgación

J. Measurement voltage – Set to 230V , Press ENTER /OK button.

o uso sin autorización escrita de la empresa dará lugar a exigir del infractor plena responsabilidad penal y

K. V convert – Set to’ NO’, Press ENTER/OK button.

L. Switching ON Time – Press UP/DOWN button set to 30SEC (For BR6000/T – 1000ms), Press ENTER/OK

M. Switching OFF Time – Press UP/DOWN button set to 40SEC (For BR6000/T – 1000ms),Press ENTER/OK

N. Discharge Time – Press UP/DOWN button set to 60SEC (For BR6000/T – 1000ms),Press ENTER/OK

O. Alarm temp- Set to 55⁰C, Press ENTER /OK button.

civil (artículos 497 y 499 del Código Penal y 1.902 del Código Civil)

P. (27)Harmonics setting – Set at 6% (If it exceed the limit, controller will give step OFF signal) – (Not
Applicable for Harmonics setting in BR6000-T type )

Q. Basics Setting – set to ‘NO’ If made YES – Then all previous setting will change to default setting, Press
ENTER/OK.
1. Press Auto/Program/Manual/Service button
A. Control Series Editor
B. Press ENTER/OK
C. Set step according step rating

Example No : 01 : - if there are 6 steps of 25,25,50,50,100,100 then minimum step rating 25 Kvar will be
1 & 50 Kvar will be multiple of 25 kvar is 2 & ,100 kvar will be multiple of 25 Kvar is 4 hence setting would
be 1,1,2,2,4,4
st
Example No : 02 :- If step rating are-5,10,25,25,50,100 then controller can take multiple of 9 of 1
minimum step i.e 5Kvarx9=45Kvar which is lesser than 50 & 100 kvar step hence for 50 kvar step has to
assign A, 100 Kvar step B & so on. The final setting for above step will be = 1,2,5,5,A,B,
D. Press ENTER/OK.

N. Rajkumar 20/03/2015 ------ 2

Responsible: CSS Date Report number: Communication Issue
/2011
 El presente documento y su contenido es propiedad de Epcos Electronic Components, S.A. Su divulgación Copying of this document and giving it to others and the use or communication of the contents thereof, are forbidden without
o uso sin autorización escrita de la empresa dará lugar a exigir del infractor plena responsabilidad penal y express authority. Offenders are liable of the payment of damages. All rights are reserved in the event of the grant of a patent
civil (artículos 497 y 499 del Código Penal y 1.902 del Código Civil) of registration of a utitily model or design. Proprietary data, company confidential. All rights reserved.

N. Rajkumar
Responsible: CSS
Date
/2011
20/03/2015
Pictorial View

Report number:
BR6000 Controller Setting Procedure

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Communication
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