Vishay ESTAmat PFC-N Product guide

Technical Documentation Rev. 04
Power Factor Regulator ESTAmat PFC-N
Vishay Electronic GmbH
Division ESTA
Hofmark-Aich-Strasse 36
D-84030 Landshut, Germany
Phone [phone],
Fax +49-(0)871 - 86 25 12
REFERENCE BOOK
POWER FACTOR REGULATOR
ESTAmat PFC-N

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Power Factor Regulator ESTAmat PFC-N
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1 INSTALLATION AND CONNECTION..........................................................................4
1.1 Wiring diagram ..........................................................................................................4
1.2 Connection data..........................................................................................................5
2 COMMISSIONING ...........................................................................................................6
2.1 Commissioning manual:.............................................................................................6
2.2 Commissioning automatically:...................................................................................6
3 DISPLAY...........................................................................................................................7
4 MENU ESTAmat PFC-N...................................................................................................8
4.1 Measurement menu....................................................................................................8
4.2 Info (Step database)....................................................................................................9
4.3 Manual (step switching manual)..............................................................................10
4.4 Setup (Quick start menu)..........................................................................................11
5 EXPERT MENU ESTAmat PFC-N.................................................................................12
5.1 100 Quick start menu...................................................................................................13
5.2 200 Measurement settings.......................................................................................15
5.3 300 Setup Control System.......................................................................................17
5.4 400 Setup Step Database.........................................................................................21
5.5 500 Setup Alarm......................................................................................................22
5.6 600 Resetmenu ........................................................................................................24
6 TECHNIAL DATA..........................................................................................................25
7 TROUBLESHOOTING...................................................................................................26
8 APPLICATIONS .............................................................................................................28
8.1 Fan Control...............................................................................................................28
8.2 Switching on COS 2 via digital input...................................................................29
8.3 Problems with the Step recognition. ........................................................................30
8.4 Transformer compensation.......................................................................................31
8.5 Reset defective steps respectively add aditional steps .............................................32
9 CUSTOMER SETTINGS................................................................................................33
10 APPENDIX..................................................................................................................34
10.1 Settings Phase-angle.................................................................................................34
10.2 Connections for mixed measurement.......................................................................34

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Document history
Date
Name
Revision
Comment
22.07.09
Le
01
initial document release
25.01.10
Le
02
Examples added, changes to software
version 1.04
16.06.10
Le
03
Add features of software version 1.06
09.09.10
Le
04
Editorial changes

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1 INSTALLATION AND CONNECTION
Only qualified staff is allowed to perform the installation. All legal rules have to
be observed and technical standards have to be met. Before connecting the
device check that all connecting leads are de-energized and that current
transformers are bypassed.
1) Compare auxiliary-, measurement-, control voltage, frequency and the current path of the
device (see type label) with the data of the electricity network.
2) Assemble the relay in the switch panel with the 2 mounting clips. If the device is not
fitting in the cut out the small plastic bars on the side of the case can be removed with a
knife.
3) Connect protective ground to the terminal link of the case.
4) Connect in accordance to the wiring diagram. Pay special attention to the cross section
size of the CT connections! A combined power supply and measurement ensures a safe
shutdown of capacitors at low voltage.
5) Remove short circuit links of the current transformer.
1.1 Wiring diagram
!
Load
T
K L Um1 Um2 AM
MS 112 1-12T1 T2
external
temperaturesensor upto max. 12
switching output Fan is contacted to a switching output
Indication:
in order
(contact
closed)
K1 K12
K1-K12
L1
L2
L3
N
PE
ESTAmat PFC-N
TTL
Interface
X/1A or X/5A
15mA- 6A Measurement Voltage
90V - 690V
Feed-in from
utility
L
NSupply Voltage
90-300 VAC

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1.2 Connection data
Meas.- Supply voltage
Combined measurement and Power supply
Range 90-550V.
Terminals UM1 / UM2
With using of VT a ratio can be adjusted.
Range 1-350
Current measurement
Current measurement
Range 15mA –6A,
Measurement transformer types x/1A or also x/5A can be used.
Terminals K (S1) / L (S2)
CT ratio is 1-9600
(Devices with Firmware before 1.04 had the adjustable range
from 1-4000)
Regulation exits
Assembly with 4, 6, 8, 10, 12, 14 Regulation exits possible.
Regulation exits volt free with common root.
Terminals A 1-14.
max. breaking capacity 5A/250VAC
Alarm contact
Opens in case of alarm and grid failure (Life Contact).
Terminals M / MS
max. breaking capacity 5A/250VAC
Temperature sensor / Digital
Input
Temperature measurement or Digital Input to switch over to
second COS .
Terminals T1 / T2
Setting is explained in the Alarm menu.

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2 COMMISSIONING
2.1 Commissioning manual:
After the supply voltage is applied, in ESTAmat PFC-N starts a countdown with 90 sec.
Cancel the countdown by pressing the (esc) button. Enter the “SETUP” menu and control
respectively adjust the parameters. To enter the “SETUP” menu, please follow the arrows (
) as shown at menu 4.4. All parameters of the “SETUP” menu are explained in the
corresponding chapter.
2.2 Commissioning automatically:
During the countdown, the auto-initialization can be start by pushing the () button.
Automatic initialization is switching all exits. During this test it can get information, which
exits are working and it can correct the connection of the measuring channels for voltage and
current by internal settings.
Automatic initialization can be started only when the voltage and current are ok. Settings of
c/K value and the switching sequence is not required.
When mains conditions are not suitable for auto-initialization, it will be interrupted. The
controller shows the message
„Ai Abrt“. If multiple repetition do not lead to any result, the following chapters shall be
considered.
Display „Auto“: Indication „Auto“ shows that the control is working. If „Auto“ is not
displayed then control function is stopped. This can happen for the following Reasons:
manual mode is active, control function is switched off, temperature is to high, measured
current is less than 15mA, voltage or the harmonic content is outside the admissible range.
Over-and undervoltage monitoring: The ESTAmat PFC-N is equipped with an over and
undervoltage monitoring. The admissible voltage range refers to the adjusted nominal voltage.
If the measured voltage is outside of the admissible range the message U Alarm appears.
Then the setting of nominal voltage has to be adapt to local ratings. The nominal voltage is
independent of the connection always the line voltage.
Activation of the measured value display: see chapter 4.1

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AUTO, MANUAL: cosphi
SETUP, INFO: Nummer Untermenü
3 DISPLAY
In case of an alarm will flash alternately at ESTAmat PFC-N with "ALARM" an error code in
the display. The table below gives an overview of all possible error codes.
To reset pending alarms hold the (esc) button pressed for 5 seconds.
measured voltage is outside the set tolerance
measured current is less than 15mA (check the short
circuit bridge K and L and the entire current path
measured current is to high
The controller cannot achieve the target COS 
The set limit for the THD of the voltage is exceeded
/
One or more steps are broken. The defective step is
blinking with the alarm message.
/
One or more step's have fallen below 70% of initial
power. step number and error code will flash alternately.
For devices with software version before 1.04 the alarm is
triggered at 50% of initial power.
The second temperature limit is exceeded. Stage were
switched off successively.
Set limit of operation hours has been exceeded
/
Set limit of the max. allowable operation cycles, for one
or more steps, has been exceeded.
/
Abort of auto-initialization.
INFO:
Capacitor database
AUTO:
automatic control is running
MANUAL:
manual mode
SETUP:
setup menu
ALARM:
blinking in case of alarm
NT:
COS 2 active
EXPORT:
export of active energy
1 –14:
control exits

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4 MENU ESTAmat PFC-N
4.1 Measurement menu
All grey fields are hidden in the factory settings and will only appear if the CT ratio is set in
the "SETUP" menu. For devices with software version before 1.04 the complete measurement
menu is hidden and must be activated by adjusting the CT ratio.
1.00 i
1.00 i
U400 V
Voltage
L - L
1.00 i
cos0,999
Pf
three digit
1.00 i INFO
1.00 i
U230 V
Voltage
L - N
PF
0,888
Power factor
ratio
P/S
1.00 i MANUAL
1.00 i
I40,45 A
current in
measured
phase
APF
1.000
Average
Power factor
1.00 i SETUP
1.00 i
P30,37 kW
Active power
3 phase
F
50
Frequency
1.00 i
Q82,89Var
Reactive
power
3 phase
t
58 °C
Temperature
1.00 i
▲Q80,08
Var
control
deviation in
kvar
thi
88 °C
Highest
measured
Temperature
1.00 i
S30,68 kVar
Apparent
power
3 phase
OPH
188.9 h
Counter
operation
hours
1.00 i
THD U 1,41 %
Harmonic
distortion
U total
3
HarU 0,40 %
Odd single
harmonics
3 - 19

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4.2 Info (Step database)
In the "INFO" menu for each connected step the number of switching cycles, the current step
size and the step size in relation to the initial step size is stored.
Using these data, conclusions can be drawn on the condition of the site and the condition of
single step's. Step sizes are shown in kVar only when in the CT ratio is set in "Setup"
menu.
1.00 i
Choose step with
Confirm with
View values with
1.00 i INFO
INFO
CC
25 kVar
Display of step size only if
CT ratio is set, otherwise---
1
2
3
3
4
max.
1
2
3
4
max.
1.00 i MANUAL
INFO
98 %
Current step size in %
related to initial step size
1
2
3
4
max.
1
2
3
4
max.
1.00 i SETUP
INFO
OC
808
switch cycles
1
2
3
4
max.
1
2
3
4
max.
Auto
auto: step is okay
foff: step is permanent off
fon: step is permanent on
Al: output for fan control
Flty: step detected as faulty
1
2
3
4
max.
INFO
CC
25 kVar
Display of step size only if
CT ratio is set, otherwise---
1
2
3
4
max.
1
2
3
4
max.
Auto
auto: step is okay
foff: step is permanent off
fon: step is permanent on
Al: output for fan control
Flty: step detected as faulty
1
2
3
4
max.

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4.3 Manual (step switching manual)
To enter in manual mode, please select “manual” in main menu and push ► for 3 seconds. By
entering this submenu the manual mode for the regulator is active. The automatic control is
stopped and the exits can be switched manually. By the means of the -keys the
referring step can be selected. Changing the switching state is possible by pushing the ►-key.
Manual switching is only possible when measurement voltage is in allowed
range. Otherwise over- and undervoltage protection will block this function.
After switching off an active step the discharge time is active. Only after this
time is over the step can be switched on manually again.
1.00 i
1.00 i INFO
Choose step with
Switch on / off
with
At each switching
operation the
current Pf is
shown
1.00 i MANUAL
0,95 i MANUAL
1
1.00 i MANUAL
1
1
1.00 i SETUP
0,95 i MANUAL
2
1.00 i MANUAL
2
2
0,95 i MANUAL
14
1.00 i MANUAL
14
14
!