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POWER FACTOR CONTROLLER

MODEL - PFC9055

INDUSTRIAL CONTROLS & DRIVES (INDIA) PVT. LIMITED

New No: 33 Old No:10, Mettukuppam Road, (via) Alapakkam Road,
Maduravoyal, Chennai - 600 095.
Website: www.icdipl.com e-mail : [email protected]
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INDEX

1. GENERAL FEATURE

2. ALARM FUNCTIONS

3. WIRING DIAGRAM

4. FRONT PANEL FEATURE

5. CONTROL OPERATIONS

6. PROGRAMMING INSTRUCTIONS

7. HEADING DISPLAY FORMATS

8. TECHNICAL SPECIFICATION
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POWER FACTOR CONTROLLER

1.General Features
The Power Factor Controller PFC 9055 measures the power
φ) and reactive power (kVAr) of power system and displays
factor (cosφ
them on a digital display. The power factor controller performs the
automatic connection and disconnection of capacitors in function of the power
factor and set point programmed.
Designed with latest state of art technology using micro controller, the
power factor controller becomes an intelligent equipment, able to
accurately measure the power factor and to take complex decisions for
switching on/off the capacitors.
The power factor controller performs the true R.M.S measurement of
reactive power and power factor including harmonics. The power
measurement is done for the full four quadrants. The power factor is
displayed on a 12.5 mm high visibility red LED display. Four keys are
provided on the front panel for programming purpose.
The power factor controller is provided with 12 output relays with the
possibility of an additional alarm relay. The power factor controller is housed
in a PVC enclosure with the dimension of 144(H)x144(W)x150(D) mm

Installation
General consideration
The meter is panel mountable and fits into a cut out of 138 X 138 mm
dimension. Place the meter through the panel cut out and fix the mounting
clamps provided with the meter on each side of the meter. Tighten the fixing
clamps with limit amount of force so as to hold the meter firmly.
The power factor controller is used to measure power factor, when
mounted in instrument panels and is to be installed only by trained
electricians and technicians. The PT’s and CT’s used for measurement
should be of instrument class 1 or better for accurate measurement
results. Also PT’s and CT’s should have adequate VA rating to support the
burden on the secondaries.
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The power factor controller must be protected by the fuses in each

voltage circuits. The current circuits must be provided with CT shorting
blocks to reduce the possibility of accidental disconnection. The CT
connections of the meter must not be disconnected while current is flowing
in the primary of the CT.

2. ALARM FUNCTIONS

ALARM - 01 = UNDER COMPENSATION

After all outputs are ON, required kVAr(Lag) > 70% of 1st
capacitor value, the alarm LED will be ON and the display shows ALr 01

ALARM - 02 = OVER COMPENSATION

After all outputs are OFF, required kVAr(Lead) > 70% of 1st
capacitor value, the alarm relay will be ON and the display shows ALr 02

ALARM - 03 = OVER VOLTAGE PROTECTION

Phase voltage > 115% of rated voltage, the alarm LED will be ON
& step output are switched OFF and the display shows ALr 3r / y/ b
R, Y, B.

ALARM - 04 = OVER CURRENT PROTECTION

Phase current > 110% of rated current, the alarm relay will be ON,
step relays are switched OFF and the display shows ALr 4 r / y / b.

Note
Index (#) key is used to acknowledge the alarm relay.
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NO 1 Output Relay - 1 NO 7 Output Relay 7

NO 2 Output Relay – 2 NO 8 Output Relay 8
NO 3 Output Relay – 3 NO 9 Output Relay 9
NO 4 Output Relay – 4 NO 10 Output Relay 10
NO 5 Output Relay – 5 NO 11 Output Relay 11
NO 6 Output Relay – 6 NO 12 Output Relay 12
COM - Relay common for 1 to 6 COM- relay common for 7 to 12
NC P NO relay contacts for Alarm

UPPER TERMINALS

R Three phase voltage input

Y 415 VAC For LT meters
B 110 VAC For HT meters
N
M
IR
L

M Three phase current input

IY from external CT’s (1/5 A)
L

M
IB
L

Voltage Signal connections

The power factor controller can accept voltages upto 415 VAC R.M.S
+10% to – 20% in case of LT meters and 110 VAC R.M.S +10% to – 20%
in case of HT meters. The voltage input terminals has a burden on auxiliary
power supply less than 10VA.
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Current signal connections

The power factor controller is provided with current input terminals to ac-
cept 1/5 A R.M.S from external CT’s. The CT secondary value is not field
programmable and has to be specified at the time of ordering. The current
inputs has a overload capability of 120% and has a burden on less than
0.5VA per phase.

The CT must be placed at any point on the entrance of the power system
where the whole current consumed by both load and capacitors can be
measured.

Right connection Wrong connection Wrong connection

φ φ φ

M
CT
L
M
Capacitor

Capacitor

M
CT CT
Load

Load

L L
Load

Capacitor
System works
normally
All the capacitors are None of the capacitors
connected. The power are connected - No
system may be over compensation for PF
compensated
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3. Wiring diagram for various

types of systems
a) Three phase four wire LT systems (3 watt meter measurement)
Voltage Input : 415V AC RMS (L-L) (-20% to +10%)
Current Input : 5/1A provide through 3 CT’s

2 4 6 8 1 2 4 5 7 8

M L
R
IR CT’s
M L
Y
IY TO Load
B M L
IB
N
1/5 Amp
110/415 VAC

NO NO NO NO NO NO
C C 7 8 9 10 11 12

C C 1 2 3 4 5 6 NC P NO
NO NO NO NO NO NO ALARM
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Wiring Diagram
b) Three phase four wire HT systems (3 watt meter measurement)
Voltage Input : 110V AC RMS (L-L) (-20% to +10%)
Current Input : 5/1A provided through 3 CT’s

2 4 6 8 1 2 4 5 7 8

M L
R
IR CT’s
M L
Y
IY
B M L
IB
N
110/415 VAC 1/5 Amp

NO NO NO NO NO NO
C C 7 8 9 10 11 12

C C 1 2 3 4 5 6 NC P NO
NO NO NO NO NO NO ALARM
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Wiring Diagram
C) TThree phase three wire HT systems (2 watt meter measurement)
Voltage Input : 110 VAC (L - L)(Through PT)
Current input : 5/1A provided through 2 CT’sWir

2 4 6 8 1 2 4 5 7 8

M L
R
IR CT’s
Y
IY
B M L
IB
110/415 VAC 1/5 Amp

NO NO NO NO NO NO
C C 7 8 9 10 11 12

C C 1 2 3 4 5 6 NC P NO
NO NO NO NO NO NO ALARM
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Cross checking the wiring

The three phase voltage wiring and current wiring are to be properly done
for the correct measurement. Any wrong connections done either during
installation or rewiring can produce wrong measurement.

The reverse condition occurs when the voltages R,Y & B are not con-
nected in proper sequence and also when the respective current is not given
according to its respective voltage.

To avoid any accidental wrong connections the PFC 9055 is provided

with a connection diagnostic page of display. If the display shows Ct niL
then there is no reverse flow otherwise the reversed phase is shown. While
checking the reverse condition, make sure that the load current is more than
5% of full load current.

Relay Output Connections

The power factor controller connects/disconnects the capacitors through
output relays. The relays are rated for 3A at 240 VAC. So proper contactors
are to be used for switching the capacitors.
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240 VAC N
L
L C12

NO NO NO NO NO NO
7 8 9 10 11 12

C C
NO NO NO NO NO NO

C C 1 2 3 4 5 6 NC P NO
ALARM
240 VAC
L
L
C6
C1 C2 C3

Neutral

C1 - C12 are the coils of the contactors to which the capacitors are
connected. The coils are energised through 240 VAC supply via the output
relays.

It is recommended to connect the common supply for the output relays

through four individual wires and also from a separate power source
especially not from ‘ R’ phase and also not from the terminal blocks of PFC
9055.
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4. FRONT PANEL FEAUTURE

PF CONTROLLER
0.5 “ 7
segment
red LED 8. 8. 8. 8. 8. 8. 8
Status
LED’s AUTO 1 2 3 4 5 6

MAN 7 8 9 10 11 12 ALARM

5 ↵
# 4 AUTO
MAN

ICD CHENNAI-95 PFC 9055

The display is a 0.5” 7 segment red LED. The LED display shows
power factor, Actual kVAr, Target kVAr, Alarm status (Alr 01/Alr 02/Alr
3r/y/b/Alr 4r/y/b) and CT polarity status.

The key pad consists of four key namely index, shift, increment and enter
key. These keys are used to program various control parameters and switch
on/off the capacitors in manual mode.

The AUTO/MANUAL LED is illuminated according to the mode of

control selected. The relay on LED 1 to 12 are illuminated whenever the
corresponding relay is switched on.
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5. Control operations

The power factor controller is provided with two type of control modes
namely Auto mode and Manual mode. The control mode is selected by
pressing ↵ key in run mode. The AUTO or MAN LED illuminates
Auto/man
according to the mode of control selected.

Auto mode
The power factor controller calculates the reactive power (kVAr)
and power factor (cosφ ) from the voltage and current inputs. It also
computes the reactive power necessary for the target PF. When required
reactive power exceeds the 70% of kVAr (lag) value of the smallest ca-
pacitor in the network, the capacitor stages are automatically connected.
Similarly when the required reactive power exceeds the 70% of kVAr
(lead) value of the smallest capacitor in the network, the capacitor stages
are automatically disconnected.

The capacitor connection/reconnection delay time of 5 to 240 seconds is

provided to allow sufficient time delay for switching on/off the capacitors in
the compensation network. This feature avoids hunting especially in highly
fluctuating loads and also allow the capacitors to discharge properly before
connecting them again in the network. The delay time has to be properly
chosen according to the load and design of capacitor network.
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Manual mode
In manual operation, the capacitor banks can be connected/disconnected
irrespective of system power factor and setting. The capacitors are discon-

nected by pressing 4 key. The capacitors are connected by pressing

4

key. A delay time of 5 seconds is permanently provided for the

connection/disconnection of the capacitors.

6. Programming Instructions
The power factor controller is provided with four keys for program-
ming purpose. The various functions of the keys are given below

Program mode Automode Manual mode

#
Index key To select P.F, kVar,
Target kVAr,
CT, Alarm status & 4 -DO -
Alarm acknowledge
4
Shift key Not applicable Switch off
capactors ( )
4

Increment key Not applicable Switch on

capacitors ( )

↵ Enter key To Select Auto mode To select manual

AUTO
MAN mode

All power factor controllers are to be programmed properly to work in a

particular installation. The various items that are to be programmed are
shown in the table below.
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Run mode display pages

Press # key one by one, run mode display pages as follows:

Page 1 - Ld 0.51 Power factor

Page 2 - q.692.4 Actual total kVAr

Page 3 - r.832.4 Target/required kVAr

Page 4 - CT nil CT/PT polarity status

Page 5 - Alr 01 Alarm status

The power factor controller is provided with pass word facility to

prevent alteration of configuration items by unauthorised persons. The
configuration items can be changed by following the sequence given
below.
With power applied to the meter, press4 &
4

keys together
for three seconds. The display indicates enter pass word as EP- - - -

The valid pass word set in configuration item new pass word has to
be entered by using shift, increment and enter keys (refer changing the
configuration items for using shift, increment and enter keys). After valid
pass word is entered the meter enters into program mode by showing it in
display as P r o g

Note: If the user enters the enter pass word for the first time, or if the user
fails to remember the pass word set in new pass word, the default pass
word ‘0386’ can be entered.
In program mode, the configuration items can be selected by pressing
the index (#) key. The heading displays are used to differentiate the various
configuration items.
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7. The heading display pages for various
configuration items are given below.
PRESS 4& 5KEYS TOGETHER
EP - - - Enter pass word

Prog Program mode

PRESS # KEY

nP0000 Pass word to prevent unauthorised persons entry

PRESS # KEY

SP-0.99 Target power factor setting (Lag 0.80 to lead 0.95)

PRESS # KEY
Cd 008 Time delay for connection / disconnection of capacitors
PRESS # KEY (Range : 5 - 240 secs.)
rCd 010 Time delay for reconnection (Range : 5 - 240 secs.)
PRESS # KEY

Ct 1000 Primary current setting

PRESS # KEY
U
C L005.0 Kvar value of the smallest capacitor in the compensation -
network
OP1.1.1.1.1
PRESS # KEY 1.2.4.8.8)
nC 12 Total number of capacitors in the compensation network

Changing the configuration items

After selecting the configuration item through index key, they can be altered by
using shift, increment and enter keys.
4
The shift key is is used to select the digit one by one. The selected
digit is shown by flashing that digit. In set point and number of capacitors mode
the shift key is used to decrement the value by one.
The increment key 5 is used to increment the selected digit.
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The increment key increments the digit from 0 to 9 and then wraps
down to 0 once again. In setpoint and number of capacitors mode, the
increment key is used to increment the values by one. Once the required
values are set in the configuration items press the enter key to store it in the
memory. If the change is accepted the display indicates E otherwise an error
message is displayed as Err. When number of capacitors and oprating
sequence are altered, the controller restarts again.
Once the configuration items are programmed hold in the 4&5keys
together for 3 seconds to come back to normal operating mode.

8. TECHINICAL SPECIFICATION
Type : ICD MAKE MICROCONTROLLER
BASED POWER FACTOR CONTROLLER
Model : PFC 9055
Voltage Circuit
Rated voltage : 415 V AC 3 phase R, Y & B phase for LT
110 VAC 3 phase R, Y & B phase for HT
Tolerance : -20% to 10%
Frequency : 40.00 to 60.00 Hz
Current Circuit
Rated current : 1A/5A 3phase, R,Y & B
Burden : Less than 0.5VA
Isolation : available through CT
Power Factor Measurement
1) Un- balanced load : From a 3phase voltage & 3 phase current
PF is computed
2) Balanced load : Using line to line voltage and current, PF is
computed
Indicating accuracy (PF) : ± 1% of reading + 2 least digit
Display parameter : Average P.F, Total kVAr, kVar required to
reach target P.F, CT NIL & Alarm status
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Indicating Resolution : 0.01 PF

Lead & lag indication : Available - shown on display
Reverse polarity indication : Shown on the display to correct
voltage and current polarity
Control PF setting : 0.80 Lag to 0.95 Lead
Output Relays : 4/6/8/12 steps
Capacitor Connection delay : 5 - 240 seconds (adjustable)
Capacitor reconnection delay : 5 - 240 seconds (adjustable)
Control Sensitivity : The step output added when required
kVAr in lag more than 70%of the
first capacitor bank, to attain preset
COS∅ ∅ and is removed when
required kVAr in lead more then 70%
of first capactitor bank
Keypad for settings and selections : Index, increment, shift & Enter keys
for P.F setttings, delay setting and
auto manual operation.
Protection : Available against
a) Over voltage 115% of the rated
voltage (Alr 3r/y/b)
b) Over current 110 % of the rated
current (Alr 4r/y/b)
c) Over compensation (Alr 02)
d) Under compensation (Alr 01)
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Alaram relay output : For the above protection

conditions aralm relay is ON
Output Relay : NO contact for each step
Contact rating : 3A at 230VAC
Relay ON indication : By LED lamps
Auto/manual selection : Available
Auto/manual indication : By LED
Manual selection of cap.banks : Through keypad
Rating humidity & temperature : 90% Rh at 25deg. &
55deg.celcius
Enclosure dimension : 144(H) x 144(W) x 150(D)
mm