APFC-03 in Manual
Contents
1. Balanced 3 Phase Reactive Power Compensation because of 3 wire balanced Connected Capacitor Bank Operating temperature 0 to 55 C Storage Temperature 0 to 65 C Relative Humidity 10 to 95 Non condensing 10 Output Stages Standard Models with 4 8 12 or 16 Outputs 11 AC Mains Auxiliary Input amp Measurement supply frequency 47Hz to 53Hz 57 Hz to 63 Hz TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 6 of 55 TM JA ek MECHANICAL DIMENSIONS 152 mm _ _ or oie CUTOUT TAS POWERTEK PVT LTD VERSION 1 1 Page 7 of 55 138 0 137mm Updated on FEB 16 2015 werTek TERMINAL ARRANGEMENT BACK SIDE TERMINAL Load C T input VOR TAU Common Fuse for Banks C9 to C16 Fast blow 5A 240V AC Banks C9 to C16 Power Factor Controller APFC 03 Aux amp Meas Voltage 1 Sr So 530008140000 S00 Volts AC SSO Tir TAS POWERTEK P Auxiliary output 1 N O contact TAS POWERTEK PVT LTD VERSION 1 1 Page 8 of 55 AUR amp MEAS Auxiliary amp Measurement Inputs Fuse Slow blow 0 75Amps 500 VAC Auxiliary and measurement supply voltage 100V 500VAC 50 60 Hz E FREORACA Common Fuse for Banks C1 to C8 Fast blow 5A 240V AC Banks C1 to C8 Auxiliary output 2 N O contact Updated on2. T i TA AUTOMATIC POWER FACTOR CONTROLLER APFC 03 USER MANUAL 123456789170 1121341516 Automatic Power Factor Controlle AUTO SETUP PRESS SIMULTANEOUSLY B ZA TA APFC 03 TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 1 of 55 werTek NOTE These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchasers purposes the matter should be referred to our factory The contents of this User Manual shall not become part of or modify any prior or existing agreement or relationship Any statements contained herein do not create new warranties or modify the existing warranty The reproduction transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for damages All rights are reserved CAUTIONS 1 High voltage 2 APFC only be used indoor 3 Make sure that the discharge time set in the controller matches the capacitor discharge time 4 This User Manual corresponds to the APFC 03Controller Firmware Version 1 0 2 Because of continuous improvements efforts by TAS PowerTek in their Product s Features and Specifications the Product as well as the conten
3. werTek On Off Command Output Terminals Terminals marked with C1 Cnn and COM COM This is the Common terminal The voltage applied to this terminal would appear at the output terminals Cnn if output relay for that Step is turned ON Cnn These are the Bank On Off command terminals When a specific capacitor bank is to be turned on it connects the relay switch to the COM terminal Normally a phase voltage is given to COM terminal The Cnn terminals are connected to actuation coils of the contactor The other terminals of contactor actuation coil are connected to Neutral Please refer the further connection diagrams on page no 8 amp 9 for the terminal connection detail Note that the external Contactor Coil should be of nominal 230V AC rating Use of a 320 V 20 mm Dia MOV directly across the Contactor Coil is highly recommended to extend the Relay Contact Operational life as well as avoid EMI EMC related issues In case MOV are NOT immediately available then Series Connector Resistor Capacitor Networks as RC Snubbers are to be placed directly across EACH Contactor Coil This Resistor amp Capacitor are to be connected in Series by soldering the leads and to be covered in an Heat Shrink able Insulating Tube No PCB is required for this assembly The Specifications for the R C Components of the Snubber required are 1 Capacitor El Ci Ar India Make Capacitor Type KP 14 Capacitance Value 0 1
4. Parameter settings Parameter Min Max Default General IO Mode password Basic or Expert 0000 9999 0001 Program password Only for Expert 0000 9999 0002 configuration Load default Yes 1 No 0 No 0 Aux OP 1 0 None 0 3 1 Trip on fault 1 Trip on fault 2 Over temperature 3 Out of step Aux OP 2 0 None 0 3 2 Over temperature 1 Trip on fault 2 Over temperature 3 Out of step System Power meas Mode L L 1 L N 0 L L 1 Rated Supply Vtg L L 110 500 440 L N 63 5 288 5 288 CT ratio 1 6500 1000 PF Target Ind 1 Cap 0 Ind 1 PF Target 0 700 0 999 0 999 Power on auto sync Yes 1 No 0 No 0 Faults Over voltage fault If enable then Enable 1 Disable 0 action is Fast Off Over voltage limit 105 125 110 Under voltage fault If enable then Enable 1 Disable 0 action is Fast Off Under voltage limit 70 95 85 Temperature fault If enable then Enable 1 Disable 0 action is Fast Off Temperature limit Deg Celsius 50 65 60 Harmonic overload Enable 1 Disable 0 Enable 1 V THD threshold limit 1 20 5 I THD threshold limit 3 150 25 Harmonic Fault Reset Enable 1 Disable 0 Enable 1 Harmonic Fault Reset Timer in seconds 10 180 180 Step health check Enable 1 Disable 0 Disable 0 Bank kVAr fault tolerance of rated 3 50 20 TAS POWERTEK PVT LTD VERSION 1 1 U
5. 1 1 primary secondary This is for voltage feedback TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 52 of 55 TAS werTek Parameter As on date As on date As on date General IO Mode password Program password Load default Yes 1 No 0 Aux OP 1 0 None 1 Trip on fault 2 Over temperature 3 Out of step Aux OP 2 0 None 1 Trip on fault 2 Over temperature 3 Out of step System Power meas Mode L N 0 L L 1 Rated Supply Vtg L L L N CT ratio PF Target Ind 1 Cap 0 PF Target Power on auto sync Yes 1 No 0 Faults Over voltage fault Enable 1 Disable 0 Over voltage limit Under voltage fault Enable 1 Disable 0 Under voltage limit Temperature fault Enable 1 Disable 0 Temperature limit Harmonic overload Enable 1 Disable 0 V THD threshold limit I THD threshold limit Harmonic Fault Reset Enable 1 Disable 0 Harmonic Fault Reset Timer Step health check Enable 1 Disable 0 Bank kVAr fault tolerance Out of step Enable 1 Disable 0 TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 53 of 55 TAS werTek As on Date As on Date As on Date Step Correction time seconds Discharge time seconds Steps connected
6. If auto synchronization was successful then entering into TEST mode will only show the second screen which is above in which all the bank kVAr values are to be fed in the controller in terms of percentage The value would be ratio of Capacitor Bank KVAr at rated volt AND Rated kVA of supply system Note that rated kVA in 3 phase system is V3 Vi CT primary rated Amp A Changing configuration menu From basic to expert configuration In CHANGE MODE screen there are two configurations Expert 1 Basic 0 The default password for changing configuration is 00017 TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 27 of 55 TM IA ek Enter the 4 digit Password by using 2 qJ Pev keys If correct mode password is entered then expert configuration is enabled The controller enters into Expert configuration and expert configuration parameter gets displayed Password Correct TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 28 of 55 TM TAA ek 2 Expert Configuration menu In this menu all the parameters are user settable Only a technical person well conversant with electrical engineering and power factor correction should enter into this configuration All the values of the parameters are displayed on the LCD in their absolute engineering units A y TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 29
7. THD THRESHOLD This is for voltage harmonics User can set the limits in percentage If the percentage value of voltage harmonics exceeds the set limit then VH fault would be indicated on the LCD display gt I THD THRESHOLD This is for current harmonics User can set the limits in percentage If the percentage value of current harmonics exceeds the set limit then IH fault would be indicated on the LCD display gt HARMONIC FAULT AUTO RESET This has two options namely 0 Disable and 1 Enable If this screen is set for enabled then the following screen appears gt HAMONIC FAULT RESET SECONDS This allows user to set the reset time for the voltage or current harmonic fault This can be set within the range of 10 to 180 seconds gt STEP HEALTH CHECK APFC 03 carries out on line monitoring of the KVAr values of every step This is when the step is put in the circuit In case the tolerance limit defined here is exceeded that specific bank is declared faulty If step health check is enabled then only its bank tolerance limit screen would be visible gt OUT OF BANKS FAULT This is only with 0 Disable and 1 Enable Indicative option If on 1 then unit will indicate this fault as OB if PF is inductive beyond set target PF compensation range and all the healthy capacitor banks are in ON state If this option is enabled then only this fault can be assigned to auxiliary output 1 or
8. changes against the hunting TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 19 of 55 TAS werTek FRONT LCD DISPLAY gt Simultaneous pressing of left key and right key for a second would put the APFC 03 in auto initialization mode Automatic synchronization would start This feature is common for both Expert as well as for Basic configuration gt On powering up the unit there is power on discharge time given for the capacitors to discharge completely However if the user is sure that the capacitors are discharged then on pressing the left key would allow the controller to come out of the discharge time and thus user need not wait for the discharge time to get complete and thus saves time gt The contrast of the LCD can be adjusted by using the keys or The left key will make the contrast darker and right key will make it lighter Multiple continuous operations of these keys will achieve this gt The front LCD Display under default condition displays the various parameter readings There are number of screens that show the various parameters that are measured or derived These various screens can be displayed by pressing the Scroll keys Viz UP key DOWN key TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 20 of 55 za TAA ek Power up Display Screen Only for first 1 sec PF 1 000 B A OK gg N ae en er ae This is the
9. factory set default screen The PF part is to indicate that the value following that is Power Factor This indicates the PF that is sensed by the unit near the load sensing CT position Le the transformer supply grid side The PF is with OR sign Sign indicates Power Factor is lagging and sign indicates Power Factor is leading The next digit indicates the configuration i e in which configuration the controller is operating There are two configurations in which the controller can operate Viz Basic Configuration indicated by B OR the Expert Configuration indicated by E The next digit on the upper line of display shows the operational mode There are two modes Viz Auto mode indicated by A and Manual mode indicated by M The last digit on the upper line of display shows the Health status of APFC 03 OK indicates that all conditions are fine for normal operation TAM OK Health Monitor LED flashing Amber colour LED indicates the controller health status is Healthy This LED is located at the extreme right hand side on the top of the front panel enclosed by a heart shape as viewed by the user TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 21 of 55 werTek The last two characters represent the following status Voltage Harmonics a Kinamama zo The bottom line of the LCD display shows the capacitor bank status The num
10. type rear side terminals suitable for fork type lugs for easy field wiring 17 Optional Expert Configuration allows Line to Neutral as voltage sensing input TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 4 of 55 TAS werTek 18 Wide range SMPS for Auxiliary Supply with externally accessible input fuse protection 19 The most important and advanced feature is the BASIC Configuration 20 Controller in this configuration has the following features gt Automatic detection and usage of the optimum capacitor step gt Fully automatic capacitor bank value setting and self adapting gt System parameters voltage current active power reactive power apparent power Maximum values of these parameters kVAr value of every bank that are connected are displayed in terms of percentage of its rated values TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 5 of 55 TAS werTek 8 9 Specifications Operating Auxiliary and Measurement voltage 100V to 500V AC Line to Line value with supply frequency as 50 Hz or 60 Hz nominal One CT supply current Input from CT secondary 1A or 5A selectable at the terminal block Relay output N O contact rating Max 250Vac 0 5Amp resistive inductive load continuous Measurement accuracy Class 1 for Active amp Class 2 for Reactive Power In measured phase Unpacked Net Weight of the Unit 650 gm
11. FEB 16 2015 TM JAA ek LEFT and RIGHT SIDE Terminal View As observed from rear side Left side terminal view Right side terminal view TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 9 of 55 TAS werTek INPUT AND OUTPUT CONNECTOR DETAILS Auxiliary Supply and Measurement Supply Auxiliary supply and measurement supply have common terminal Terminals are marked with L1 amp L2 An Auxiliary supply is for powering the internal SMPS Measurement supply is for measuring the Phase to Phase voltage Also Phase to Neutral voltage in case of EXPERT Configuration selected Mains CT load current feedback Terminals Terminals are marked with COM 5AMP amp 1AMP These are connected to secondary of the Mains current feedback CT secondary The rated secondary can be either 5Amp or 1Amp AC CT secondary standards are 5Amp and 1Amp In view of the same the user can use the feedback CTs as per suitability COM is the common terminal of CT common to 5Amp or 1Amp If the CT used is with 5 Amp secondary rated value then use the second terminal SAMP with COM terminal of the unit And If the CT used is with 1 Amp secondary rated value use the second CT terminal 1AMP with COM terminal of the unit Please refer to the terminal arrangement which is shown above back side terminal view TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 10 of 55
12. Fix bank setting CAP Bank Voltage L L Bank kVAr 1 Bank kV Ar 2 Bank kVAr 3 Bank kVAr 4 Bank kVAr 5 Bank kVAr 6 Bank kVAr 7 Bank kVAr 8 Bank kVAr 9 Bank kVAr 10 Bank kVAr 11 Bank kVAr 12 Bank kVAr 14 Bank kVAr 15 Bank kVAr 13 Bank kVAr 16 TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 54 of 55 werTek Contact The Sales amp Marketing The Customer Support amp Service Dept TAS PowerTek Pvt Ltd W 61 C o Pawar Industries Opp Machine House MIDC Industrial Area Ambad Nasik 422 010 via Mumbai Maharashtra State India Land Line Phones 009 1 253 6694956 Sales amp Marketing 009 1 253 6694955 Customer Support amp Service Fax 009 1 253 6694 955 Working Hours 9 30 AM to 6 30 PM Weekly Off Saturdays E mail sales taspowertek com Web www taspowertek com This Product is completely Designed Developed Manufactured Assembled Tested and Calibrated in India by TAS PowerTek Pvt Ltd Nasik 422 010 India werTek TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 55 of 55
13. HD F STEP 01 KVAr UTILIZATION VOLTAGE AGE CNTR 00085 1 0087 6 002 5 0001 0 BANK 1 000000 L L MEASURED MAX_CURR I THD F AUX OPI CURRENT ENT TRIP FLT 0009 5 70 0009 5 003 3 STATUS 0 ACTIVE MAX KW AUX OP2 BANK 16 000000 POWER OVR TEMP 000004 0 0007 9 STATUS 0 CLR BANK 1 CNTR REACTIVE MAX_ STEP 16 KVAr INT No 0 POWER KVAR TEMPERAT URE 000006 4 0006 4 0002 0 28 Deg C APPARENT MAX KVA POWER 000008 1 0008 2 CLR BANK 16 CNTR FREQUENCY RESET No 0 MAX_ VALUES 49 7Hz No 0 Step kVAr is dependent on the number of banks connected i e step kV Ar of only those banks that are detected in the automatic bank detection functionality would be displayed Note The line frequency parameter however is not shown in percentage but in absolute value in Hertz TAS POWERTEK PVT LTD VERSION 1 1 Page 42 of 55 Updated on FEB 16 2015 TAS werTek Calculation in terms of percentage in basic mode By Example Suppose the Line to Line voltage is 430V CT used is 1OOA SA i e CT ratio as 100 and total numbers of banks that are connected are 2 Both the banks kVAr values are 12 at 430Vac each For Controller in Basic Configuration The rated nominal Line to Line voltage is 500V The rated nominal CT ratio is 5000 Rated kVAr or kW or kVA Rated voltage 500 x Rated current 5000 x V3 1000 4330 is fixed Therefore the basic configuration will display the vo
14. LATION CONTROL SCHEMATIC DETAILED Typical Scheme of APFC 03 with Contactor switches APFC 03 ea AA AA AA II The above APFC connections are shown for Ouadrature mode operation TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 17 of 55 werTek PF CORRECTION TECHNIQUES With Lagging Inductive Target Power Factor kVAR Target PF 1 5 x kVAR Smallest a se kVAR _Zj7z Capacitor addition zone No Action zone WG Capacitor subtraction zone With Leading Capacitive Target Power Factor kVAR Yj 1 5 x kVAR Smallest Cap Bank kW Target PF kVAR Tj Capacitor addition zone zea No Action zone WW Capacitor subtraction zone VERSION 1 1 Updated on FEB 16 2015 TAS POWERTEK PVT LTD Page 18 of 55 E IA ek With Unity Target Power Factor kVAR a 1 5 x kVAR Smallest kVAR Capacitor addition zone No Action zone TLD Capacitor subtraction zone All the three conditions are specified in the diagram One should take note of No Action Zone which is created and prevents from hunting of the capacitor bank switching ON and OFF every correction cycle There is a single TARGET PF option No Action Zone is preset to minimum kVAr capacitor bank size equal to smallest bank kVAr 1 5 This band size normally takes care of all the variations in supply voltage frequency and harmonics
15. M TAA ek Operation in Auto mode Operation in Manual mode Auto synchronization and bank detection starts After the success of auto synchronization auto bank detection is done in basic mode It may take some more iterations upto 7 nos if it finds any bank not connected The screens are as follows TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 24 of 55 TM TAA ek SAVE TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 25 of 55 TM TAA ek TEST mode is to facilitate the user to enter into manual synchronization specifically if Auto Synchronization shows Failure Entering into this mode the first screen shows the mode of operation that is Line to Line for Basic Configuration After that the next screen is the selection of Phase According to the selected phase the user can see all the kW and kVAr values of the selected phase in terms of percentage User can also choose the polarity option in case CT polarity is physically reversed Once the user has completed editing has to press the SAVE key and the following screens would be displayed on the LCD display This SAVE command saves all the parameters edited in the TEST mode Thus the controller runs on the right sequence A v by manual synchronization TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 26 of 55 TM TAA ek
16. Page 12 of 55 TM JA FRONT PLATE INDICATIONS AND KEYBOARD TAM OK LED LCD DISPLAY D a 7 Ya IA ya 9 erTek 1234667 H89 ONnNRBMBo Automatic Power Factor Controller 7 r EAS ANA KEYBOARD TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 13 of 55 TM IA ek KEYPAD DESCRIPTION SOFT TOUCH KEYPAD UP key Used to scroll up the menu screen gt increment values when entering numbers Also used for changing the status of banks DOWN key Used to scroll down the menu screen decrement values when entering numbers Also use to change status of bank ______ RIGHT key Used to shift the cursor to right also used to increase the contrast of LCD in default display screen mode LEFT key Used to shift the cursor to left also used to decrease the contrast of LCD in default display screen mode ENTER key Used for entering a submenu or for setting up values MODE key Used for selecting modes of operation and editing of parameters SAVE key Used to save all the changes made in the Program mode menu TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 14 of 55 TM IA ek INSTALLATION CONTROL SCHEMATIC Voltage feedback Capacitor Conventional LT side PF E Y improvement system Schematic p w e As per this scheme the load sensing CT is put between the Source and the PF correct
17. Sub menu for display of parameters in Expert configuration MEASURED MAX VALUES HARMONICS STEP kVAr DISPLAY DISPLAY VALUES AUX UTILIZATION FUNCTION CNTR MEASURED MAX_VOLTAGE V THD F STEP 01 UTILIZATION VOLTAGE KVAr CNTR 00415 0V L L 0000 0 V 000 0 0001 0 BANK 1 000000 MEASURED MAX_CURRENT I THD F AUX OP1 TRIP CURRENT FLT 1000 5A 0000 0 A 000 0 STATUS 0 ACTIVE MAX_ KW AUX OP2 OVR BANK 16 000000 POWER TEMP 000000 0K W 0000 0 KW STATUS 0 CLR BANK 1 CNTR REACTIVE MAX_ KVAR STEP 16 INT No 0 POWER KVAr TEMPERATURE 000000 0 KVAr 0000 0 KVAR 0000 0 28 Deg C APPARENT MAX KVA POWER 000000 0KV A 0000 0 KVA CLR BANK 16 CNTR FREQUENCY RESET No 0 MAX VALUES 49 0Hz No 0 In Expert configuration all the values are displayed in their absolute engineering units Auxiliary function has two auxiliary outputs It shows the type of the auxiliary output functionality that the user has selected and also displays its status 0 low signal Relay contact open 1 High signal Relay contact closed TAS POWERTEK PVT LTD VERSION 1 1 Page 41 of 55 Updated on FEB 16 2015 ZA erTek E Sub menu for display of parameters in Basic configuration MEASURED MAX HARMONICS STEP kVAr DISPLAY DISPLAY VALUES VALUES AUX UTILIZATION FUNCTION CNTR MEASURED MAX_VOLT V T
18. ULT VH IH OV UV PRESENT Controller remains in Expert mode if any of the faults like VH IH OV or UV is present Basic mode will run on only line to line Quadrature connection TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 38 of 55 TM TAA ek Changing from Expert configuration to Basic configuration would cause all the parameter settings on the controller made by user to be lost While changing the mode from Expert to Basic mode a screen PARAM LOST CONT appears This indicates that while entering into Basic mode from Expert mode previous stored edited values of parameters in the Expert mode would be lost If the user still wishes to continue to enter into the Basic mode then one has to enter and press Yes 1 and press the SAVE key after which controller would in corporate all the default parameter values and automatic synchronization would start After it completes the automatic synchronization functionality the controller enters into the AUTO BANK DETECTION feature which is a unique feature provided in APFC 03 In this APFC 03 automatically detects all the physically connected capacitor banks without the requirement of user edited values as been done in the Expert mode menu TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 39 of 55 Si a wer7Tek Display of various parameters Values of various parameter
19. anks ON APFC 03 does not indicate the PF as improved Contactors controlled by this unit is are not turning ON OFF even if front LCD indication shows correct TAS POWERTEK PVT LTD Input supply not coming Input side fuses blown This is perfectly OK if unit is powered up there is a delay of correction time that is provided in the unit only after which units can turn on outputs However if the user is sure that the capacitors are discharged completely and does not want to wait for the discharge time then user can press the left key and come out of the discharge time Check that Load CT put is in correct phase and on mains source side Check if CT secondary terminal selected is 5Amp or 1Amp and check if wrongly wired Control wiring to contactor is open circuit Internal fuse at relay stage blown off due to some momentary short circuit in control VERSION 1 1 Page 50 of 55 Check the input supply to restore Check fuses in the unit for OK As this is normal action need not take any specific action Unit will start performing normally after the stipulated time delay Correct the wiring as per the scheme requirements and the CT positioning or run auto synchronization Check the continuity for any open circuit Replace the externally accessible fuse s of the unit While replacing make sure that the type and rating is the same Updated on FEB 16 2015 TAS werTek
20. auxiliary output 2 for indication to external system IF ENABLE IF DISABLE F IF ENABLE IF DISABLE TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 36 of 55 TM TAA ek CORRECTION TIME Defined in seconds This is the time between two consecutive kV Ar compensations DISCHARGE TIME Time defined here is the time for discharge of the capacitors to a level so that they can be turned ON again at the end of discharge time STEPS CONNECTED Defines the number of steps operational Depending on PF system banks this parameter is set FIX BANK SETTING Defines the banks that are to be declared as fixed These banks even in spite of overcompensation cannot be turned OFF The banks can only be turned OFF under fault conditions CAP BANK VOLTAGE Defines the capacitor banks voltage at which the bank kVAr value is defined It is given on the switching Capacitor BANK kVAr 1 16 In APFC 03 every bank kVAr is to be defined at rated Voltage APFC 03 has an in built intelligent algorithm to select the best possible combination to suit the exact kVAr requirement for compensation TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 37 of 55 TM TAA ek B Changing mode menu From Expert to basic configuration In CHANGE MODE screen there are two configurations Expert 1 Basic 0 NO YES FA
21. banks by turning them ON OFF e While commissioning all the capacitor banks should be turned ON and should be checked regarding its healthy status For Declaring banks faulty or Resetting faulty banks In Manual mode default screen press ENT The cursor above bank 1 will start blinking Use 4 gt keys to select the specific bank Then use A key to declare the bank faulty To reset the faulty bank bring the blinking cursor to that bank and use W key to declare the bank as healthy Once the specific banks are declared faulty or reset from faulty to a healthy status press ENT key so that cursor stops blinking Note As the primary objective of APFC is to control PF it cannot be left in manual mode forever Therefore while the unit is in manual mode and if no key is pressed for two minutes then the APFC will be automatically switched to AUTO mode of control by putting off all the banks first TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 45 of 55 TM TAA ek 1 If current CT connections are not connected to the APFC O3unit i e if no current is detected or the detected current is below 0 5 of rated load current then APFC O3would show the following display on the LCD 2 If Harmonics overload fault is enabled and if the voltage or current THD exceeds the set NOTES limit then APFC O03would flash the message ENT TO MANUAL RESET on the LCD display Pressing the Enter key wou
22. bers 1 to 16 below the LCD display are for specific outputs Capacitor bank number that is controlled by APFC 03 The LCD display above this number gives the status of that specific output Capacitor bank During Power Up till the time all Banks are showing D status the keyboard would not be operational This is to ensure that at Power Up all the Capacitors are allowed to be Discharged Total blank indicates that the output is not used for control A small dash l indicates that Bank is connected but is in OFF state A symbol indicates that bank is connected and it is in ON state A symbol Ea indicates that bank is declared as fixed bank and is ON A symbol EJ indicates that bank is declared faulty and is OFF A symbol BA indicates that bank has just turned off and is discharging TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 22 of 55 TM JA ek Menu structure 1 Basic Configuration menu The basic configuration is default amp user friendly configuration on which the controller operates There is no parameter editing facility given to the user in this configuration All the parameters like average values maximum values amp step kVAr values are displayed in terms of This configuration can work only in Quadrature connection Following are the various screens that can be seen in the Basic mode TAS POWERTEK PVT LTD VERSION gt Updated on FEB 16 2015 Page 23 of 55 T
23. circuit is performed This mode should be normally selected with this controller once the system is totally commissioned Here the kVAr compensation values are calculated by this controller and the closest equivalent capacitor combination is inserted in the system so that the PF is maintained within the desired level This is as per the kW v s kVAr graphs shown earlier in PF compensation part On the default display the status of capacitor banks is seen as performed by this controller If any capacitor bank is sensed as faulty by this controller it would mask the said bank and PF relay would search for new nearest value bank combination to maintain the target PF During the turn on and turn off of the capacitor banks this controller does not turn them ON or OFF simultaneously Between two successive capacitor switching operation the delay of about 1 second is provided by this controller TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 44 of 55 TM IA ek Manual Operation Pressing ENT button on this screen will put the controller in Manual mode This mode will continue to run till it is purposefully changed or Power down This mode is normally used to perform the operation like e Resetting of faulty banks to healthy status e Declaring specific bank banks faulty Masking of the banks so that once auto mode is selected these faulty declared banks would not be used e Checking the capacitor
24. e the controller goes in the Auto bank detection mode In basic configuration controller does not have any edited or saved parameter values in it as it is there in the Expert configuration So it do es not have any information related to capacitor bank size number of banks connected etc In this case the smartest feature that is provided in APFC 03 is the Auto bank detection When the APFC 03 enters into the auto bank detection mode it displays CHECKING PH SEQ and BANK DETECTION message on the LCD In this it switches ON the first bank and switches OFF the same bank This is done for all sixteen banks one by one It detects the number of banks that are physically connected Sometimes controller would take some multiple attempts with same banks for sensing bank sizes accurately Once the bank detection logic is accomplished a message BANK DETECTION SUCCESS is displayed on the LCD screen However the banks that are less than 0 5 of the rated kVA of the system are declared as not connected bank zero KVAr Rated KVA of the system depends upon the maximum voltage and CT ratio In case of success in the auto bank detection algorithm the APFC 03 detects the number of banks that are physically connected as well as the kVAr values of the physically connected banks are displayed in the Step kVAr menu PF compensation is done based on the automatic bank size detected In basic configuration user does not
25. e over voltage fault if Fast off option is activated It has two options 0 Disable 4 Fast off OVER VOLTAGE LIMIT This screen would be visible only if the above screen i e the over voltage fault parameter is set to Fast off In this user can set the limit in percentage and if the voltage exceeds this limit then OV fault would be indicated on the LCD display and corrective action is taken UNDER VOLTAGE FAULT This would indicate the under voltage fault if Fast off option is activated It has two options 0 Disable 4 Fast off UNDER VOLTAGE LIMIT This screen would be visible only if the above screen i e the under voltage fault parameter is set to Fast off In this user can set the limit in percentage and if the voltage falls below this limit then UV fault would be indicated on the LCD display and corrective action is taken TEMPERATURE FAULT This has two options 0 Disable 1 Enable TEMPERATURE LIMIT This screen would be visible only if the above screen i e the temperature fault parameter is set to Fast off User can set the limit and if the APFC unit internal temperature exceeds this limit OT fault would be indicated on the LCD and corrective action is taken Updated on FEB 16 2015 TM TAA ek HARMONIC OVERLOAD This has two options 0 Disable 1 Enable If this parameter is enabled then only below three screens would get displayed gt V
26. have to involve much with manual efforts but can look into all the parameters in a user friendly manner For this mode to work correctly it is essential that the user connects all working banks starting from bank 1 in a consecutive manner without leaving any intermediate step unconnected TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 48 of 55 TAS werTek Commissioning Instructions Commissioning guidelines After the panel is powered up A Basic Configuration Because the Basic Configuration expects that the wiring in the panel is done perfi ec tly alright it attempts to switch on and switch off the banks to find the necessary bank kV Ar information as well as the total number of banks connected It is the user responsibility to do thorough checks of the panel wiring before switching on the power In Basic Configuration since no user inputs are required the controller should be put in Auto Setup by pressing Left and Right arrow keys of front keyboard simultaneously for a period of 1 second B Expert Configuration 1 Remove the fuses in series with every capacitor bank Connect the supply to the controller Keep the load feedback CTs in shorted condition 2 Turn On the supply to the panel and set various parameters as per the panel configuration For using Expert mode it is essential to understand the meaning of every parameter and then put the appropriate values in them Wrong value
27. ion Capacitor banks and load This is as per the diagram shown above The positioning of the CT in the Power Connection diagram is extremely important e The voltage feedback is taken from the LT bus system itself e This is the most common and conventional scheme TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 15 of 55 werTek INSTALLATION CONTROL SCHEMATIC V amp I Feedback control wiring Typical schematic L2 m j gt L2 N L3 gt a N n L3 a a m H 81 5 s 12 u a a 1 5 s t LI a i gt Ci Om T i c1 0m llf APFC 03 APFC 03 Ouadrature Connection In Phase Connection Default for Basic Configuration Can be selected in Expert Configuration In Quadrature Connection use any two phases for voltage monitoring and use the third phase for the current monitoring The In Phase Connection one phase and neutral is used for voltage monitoring The current monitoring CT too is put in the same phase Note that Auto synchronization feature or Manual synchronization feature can internally correct the connection errors by internal configuration and in case the Voltage or Current feedbacks are taken from other phases than shown in the diagram above physical connections need not be change Please refer the further section of Auto Synchronization for detailed explanation TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 16 of 55 TM IA ek INSTAL
28. ld reset the VA IH fault even if voltage current THD is above the set limit The fault indication would continue till the respective THD is above the set limit In case of THD above limit all capacitor banks are switched off to protect them TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 46 of 55 AS erTek Auto synchronization The APFC 03 is an intelligent Micro Controller based Automatic Power Factor Controller for switching on or off external capacitor banks to maintain the Power Factor PF as close as possible to the target PF set In normal industrial loads in the absence of any PF improvement the load PF is inductive lagging the inductive reactive power is compensated by using capacitive reactive power of the right magnitude to bring the PF close to unity The Quadrature scheme is possible only if the phase to phase voltage and the third phase load current feedback CTs are correctly wired to the PF controller For example the current of B Phase must be connected to the current input channel if R Y voltage is connected to the voltage input channel This should be with proper polarity as per the wiring diagram shown in this user manual However if it is observed that in the field during initial start up itself or later during maintenance this proper phase relationships phase to phase voltage and corresponding third phase current relationship gets disturbed due to wro
29. ltage current and step kVAr values as follows Line voltage 430 500 100 86 As the rated voltage in basic mode is 500 V ac which is the maximum operating controller voltage Load current The 100 value considered is 5000Amp As per the CT used the calculation would display its corresponding percentage Thus Bank kVAr is calculated amp then Displayed is as follows Bank kVAr at 500Vac is 12 x 500 430 16 225 kVAr Used CT primary ratio is 5000 100 i e ratio is 50 Thus effective kVAr of the Bank 16 225 x 50 811 25 kVAr at 500V and with normalized CT ratio Step 01 kVAr 811 25 4330 100 18 7 As bank is of 12 kVAr at 430V and as per CT of 100 Amp is to be defined at 500Vac rated voltage and 5000 Amp CT However the banks less than 0 5 of Rated kVA of the system cannot be detected Rated kVA of the system depends upon the maximum voltage and CT ratio TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 43 of 55 TM TAA ek Auto and Manual operation modes This controller has two modes of operation Auto and Manual Auto Operation On this screen pressing ENT key would put the unit in Auto Operation This mode would continue till alternate option mode is selected or unit is put in Power down condition This is the mode in which the unmanned operation of automatically putting the capacitor bank one bank at a time in and out of
30. micro Farad 100 nano Farad 100 nF Voltage Rating 1000 Volts DC 1 kV DC Leads Structure amp Shape Axial Leads Cylindrical Shape 2 Resistor Resistance Value 330 Ohms 330 E Resistance Value Tolerance 5 of the nominal value of 330 Ohms Resistor Wattage 1 Watt Resistor Type Axial Leads CFR Carbon Film Resistor 3 Wires for Connection to the Contactor 1 Square Milli Meter Reputed Make 7 Centi Meter Long The loose flying end of the Wires for the Contactor Connection to have a Fork Type Lug Soldered to the wire Note The Resistor Capacitor Assembly to be covered in appropriate size Heat Shrinkable Tube and heat shrinked TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 11 of 55 TAS werTek Auxiliary Outputs Two channels These are marked as AUX OUT 1 and AUX OUT 2 These are provided for inter locking with external master controllers such as PLC Alarm annunciation or equivalent These are potential free N O contacts Rating is 250Vac at 0 5Amp resistive or inductive load Auxiliary output is user programmable to become Close N C due to any of the following 1 PF controller tripping off capacitor banks on any fault 2 Over temperature Internal to APFC unit For triggering external cooling fan connection 3 Out of banks Insufficient capacitive kV Ar not able to attain target PF TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015
31. ng connections of CT or of Voltage In such a situation a PF controller without Auto Synchronization will not be able to do its operation correctly or rather its operation would be totally erratic and unpredictable APFC 03 has an in built intelligence if enabled it automatically detects the correct voltage phase sequence as well as current input channel even if the proper connection order is not followed It is even intelligent enough to detect the reverse polarity of CT connections Even though Auto Synchronisation success probability is very high almost 98 in some cases where load fluctuations are extremely rapid or where system is highly under loaded current less than 5 of rated CT current there is a possibility of Auto Synchronisation failure In such case controller takes user to TEST MODE where User is expected to select right phase sequence CT polarity and Capacitor bank sizing If the operation was successful it is indicated on the LCD display TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 47 of 55 AS erTek Auto bank detection For individual bank kVAr and total number of banks APFC 03 has an intelligent algorithm that is Auto bank detection when it is set to operate in the basic mode When the controller is set to operate in the basic mode then it first incorporates all the load default parameters and starts auto synchronization After detecting the correct phas
32. ntroller based logic for measurements and control Suitable for balanced 3 Phase Compensation by capacitor switching 3 16 Character 2 Lines alpha numeric dot matrix LCD display with backlight 4 7 keys tactile keypad for user interaction 5 Front panel flashing LED indication for controller healthy status 6 Phase to Phase input voltage measurement with transient protection 7 One phase load current CT secondary input field selectable for 1Amp or 5Amp range 8 Various models suitable for 4 8 12 amp 16 capacitor banks control 9 Independent fuse protection for control outputs relay commands for banks 1 to 8 and 9 to 16 10 Potential free normally open relay contact outputs for external contactor switching control 11 Two auxiliary outputs normally open relay contacts for external interlocking 12 THD measurements of supply voltage and current Odd harmonics up to 15 13 Unequal bank size selection Including user defined bank values in kVAr in Expert mode 14 Capacitor banks protection against o Over Under voltage at measurement input o Harmonic overload both for voltage and current o Over temperature of controller o Over Under AC mains line frequency 15 DIN Standard 144 x 144 mm Panel Cut out for flush mounting arrangement Back side dimensions as 137 x 137 mm with recommended Panel door cutout as 138 x 138 mm Max Depth of 76 mm on back side of panel mounting door 16 Three Sides Closed Screw Terminal
33. of 55 TAS PowerTek SELECT EXPERT SELECT EXPERT SELECT EXPERT SELECT EXPERT 1 PROGRAM MODE 2 AUTO MODE 3 MANUAL MODE 4 AUTOSETUP MODE ENT PRG PWD PF 0 998 E A OK PF 0 998 E M OK KK Operation in Auto mode Operation in Manual mode ENT TO START AUTO_SETUP PROGRAM MODE General parameters GENERAL AND IO PROGRAM MODE Grid transformer APFC CHECKING PH SEQ SYSTEM system related parameters LLLLLLLLLLLLLLLL ILIIILLILIILIIILILII PROGRAM MODE f ji Auto synchronization starts raul Ship senrines In Expert configuration user FAULTS p 5 hasto feed the proper bank kVAr values number of banks that are connected and all the PROGRAM MODE other related parameters After Capacitor bank step aiken in as synchronization it displays the STEP settings following screen CHECKING PH SEQ SUCCESS TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 30 of 55 TM JAA ek TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 31 of 55 TM TAA ek Entering in the TEST mode of Expert Configuration menu allows the user to carry out synchronization manually For this first select the mode of operation whether Line to Line Quadrature or Line to Neutral In Phase mode After that the next screen is the selection of Phase According to the selected phase the user can see all the kW and kVAr values of the selected phase for getting j
34. pdated on FEB 16 2015 Page 51 of 55 TAS werTek Out of step Enable 1 Disable 0 Enable 1 Step Correction time seconds 1 1200 30 Discharge time seconds 1 1200 60 Steps connected 1 16 16 Fix bank setting CAP Bank Voltage L L 110 600 440 Bank kVAr 1 16 l 65535 FAULT FAULT ACTION Over voltage OV Fast OFF All banks simultaneously off Under voltage UV Fast OFF All banks simultaneously off Over temperature OT Fast OFF All banks simultaneously off Over frequency OF Normal banks Fixed banks OFF one bank off at a time Under frequency UF Normal banks Fixed banks OFF one bank off at a time Voltage harmonics VH Normal banks Fixed banks OFF one bank off at a time Current harmonics IH Normal banks Fixed banks OFF one bank off at a time Action of Fast off during fault means all banks are simultaneously turned off For others only one bank is turned off at a time The Auto synchronization pending AS fault is seen on the LCD display if any of the system faults like OV UV VH or IH exists and the user enters into auto initialization mode This fault would continue to exist until the above mentioned faults if all faults are cleared After the fault gets cleared the controller would start auto synchronization on its own Note The potential transformer PT ratio is internally set as
35. s can be viewed by the UP DOWN key and then pressing the ENTER key To exit a sub menu press MODE key This is factory set default screen giving information on PF functionality mode operating mode and controller health status Measured values give the measured values of the system parameters like V I kW kVAr kVA and frequency Max values gives the maximum values of V l kW kVAr and kVA detected after the last reset This also has the facility of resetting the maximum values manually which would be the actual instantaneous values and not zero Displays THD for voltage and current Also displays odd harmonics up to 15 Displays the measured kVAr values of each connected output step Displays the APFC unit s internal temperature status and selection of auxiliary input and auxiliary output Displays the bank utilization counter i e number of times the bank is utilized and also displays the clear bank counter to 0 This helps in proper maintenance of the contactors Displays the unique serial number of the particular APFC controller Displays the name and version of software The firmware version number may be different dependent on date of design update EXPERT mode will have all the values in absolute form whereas BASIC mode will display the values system parameters in terms of percentage TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 40 of 55 ZA erTek E
36. s entered can give the wrong performance of the panel 3 Once the parameterization is complete put the APFC 03 in Manual mode to check every bank Contactor is operational from APFC 03 This can be carried out by keeping the control supply to contactor coils ON By checking that on command from APFC 03 is reaching the specific Contactor by observing their respective ON OFF operations 4 Once all the switches are seen to be getting the correct commands switch off the supply to the panel and replace all the fuses or turn on MCBs if they are provided instead of fuses Turn on the panel 5 Put APFC 03 back in Manual mode and turn ON Off the individual steps Use Current measurement clamp on meter ac current measurement to check that current in all the three phase of the corresponding bank are OK 6 Keep all the banks in off mode Remove the shorting of Load feedback CT In case kW value is seen as negative CT is with wrong polarity Correct the polarity with proper physical connection Put the APFC 03 in Automatic mode Observe the panel performance for a period of about 2hrs after the commissioning TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 49 of 55 E werTek Fault finding Guidelines and Trouble shootin rocedures Fault finding guidelines Unit Does not turn ON LCD is blank with no Backlit Unit not turning ON any capacitor banks immediately after Power on With capacitor b
37. t of the User Manual is likely to get updated Therefore please always refer to the User Manual supplied to the customer along with the Product at the time of product dispatch TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 2 of 55 TAS werTek AA WY N Nn WN 8 9 10 11 12 13 13 14 14 15 16 17 18 19 INDEX Index Page Features Specifications Mechanical Dimensions Terminal Arrangement Front Plate indications Keyboard Installation Control Schematic PF correction techniques Front LCD Display Menu structure Basic Configuration Changing configuration menu Basic to Expert Expert Configuration menu Changing configuration menu Expert to Basic Display of various parameters Calculations in Basic configuration Auto and Manual Modes of operation Notes Auto synchronization Auto bank detection Commissioning Instructions Fault finding Guidelines and Troubleshooting procedures Parameters Manufacturer s Contact details TAS POWERTEK PVT LTD VERSION 1 1 Page 3 of 55 I li N N gt U on 15 14 15 18 20 gt a 93 s 9 29 s BS 40 EE ss HA 46 se AG 48 49 50 oe ji 55 Updated on FEB 16 2015 AS erTek Features 1 Power Factor Controller for universal application requires no settings and is self configuring in basic mode of functioning 2 Microco
38. udgement of right selection of Phase sequence amp polarity After selection Save key is to be pressed This SAVE command saves all the edited parameters in the TEST mode Controller runs on the right sequence by manual synchronization TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 32 of 55 TM TAA ek All the bank kVAr values are to be fed in the controller in their absolute value kW and kVAr values can be seen in their absolute engineering units Editing the user defined parameters gt TAS POWERTEK PVT LTD VERSION 1 1 Page 33 of 55 MODE PASSWORD is basically for changing the mode The 4 digit number that can act as a pass word can be changed by changing the value in this parameter PROGRAM PASSWORD is for entering into the Program mode parameters in Expert mode menu Only trained person should enter into this mode and edit the values Program default password is 0002 LOAD DEFAULT There are number of parameters that are loaded at the time of manufacturing In case if the user wishes to put these values the Load default can be put to Yes and then Save command would put the all parameters as set while manufacturing AUX OP1 FUNCTION Program the auxiliary output to become NC due to any of the following choices O none 1 Trip on fault 2 System fault 3 Out of step AUX OP2 FUNCTION Same as above As aux output function Note The auxiliar
39. y output 1 and output 2 functions are of auto reset types Updated on FEB 16 2015 TM TAA ek VOLT MEAS MODE This is the system parameter that defines the controller s connections of operation auxiliary supply to the controller These are two types Line line Quadrature and Line Neutral In Phase RATED SUPPLY VTG This is the system parameter that defines the controller s nominal supply voltage These are edited as per the Quadrature or In Phase mode select Line line Quadrature and Line Neutral In Phase CT RATIO PRIMARY This parameter tells the controller about the primary current rating of the grid transformer side connected CT PF TARGET User can set the target PF as Inductive 1 or Capacitive 0 PF TARGET The exact value can be set here User can set the value anywhere in between 0 700 to 1 000 POWER ON AUTO SYNCHRONIZATION Auto synchronization feature is enabled or disabled 0 Disable 1 Enable If enabled at every power ON this feature would get activated TAS POWERTEK PVT LTD VERSION 1 1 Updated on FEB 16 2015 Page 34 of 55 TM TAA ek gt IF FAST OFF IF DISABLE IF FAST OFF IF DISABLE IF FAST OFF IF DISABLE IF ENABLE TAS POWERTEK PVT LTD VERSION 1 1 Page 35 of 55 Fast off action In this all the banks that are switched ON are tripped at one go OVER VOLTAGE FAULT This would indicate th
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