Vishay ESTAmat PFC-N User manual

Vishay Electronic GmbH
Hofmark-Aich-Str.36
D-84030 Landshut
Telefon [phone]
www.vishay.com
Document number: 13157 - Rev. 02
__________________________________________________________________________________________
QUALITY MANAGEMENT
Certified by VDE according to
DIN EN ISO 9001
Reg. No. 2556/QM/03.94
Power Factor Correction Controller
ESTAmat PFC-N
Operating Instruction MV1181
___________________________________________________________________________

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 2 of 36
Revision history
Date
Name
Revision
Change
19.04.11
16.11.11
rjo
rjo
00
01
initial document release
advise on HV operation
27.04.18
kop
02
measurement voltage 750V

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 3 of 36
1 INSTALLATION AND CONNECTION..........................................................................4
1.1 Wiring diagram ..........................................................................................................4
1.2 Connection data..........................................................................................................6
2 COMMISSIONING ...........................................................................................................7
2.1 ESTAMAT PFC-N is parameterized:........................................................................7
2.2 ESTAMAT PFC-N is not parameterized:..................................................................7
3 DISPLAY...........................................................................................................................8
4 MENU ESTAMAT PFC-N................................................................................................9
4.1 Measurement menu....................................................................................................9
4.2 Info (Step database)..................................................................................................10
4.3 Manual (step switching manual)..............................................................................11
4.4 Setup (Quick start menu)..........................................................................................12
5 EXPERT MENU ESTAMAT PFC-N..............................................................................13
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.......................................................................................................23
5.6 600 Resetmenu.........................................................................................................25
6 TECHNIAL DATA..........................................................................................................26
7 TROUBLESHOOTING...................................................................................................27
8 APPLICATIONS .............................................................................................................29
8.1 Fan Control...............................................................................................................29
8.2 Switching on target Pf 2 via digital input.................................................................30
8.3 Problems with the Step recognition. ........................................................................31
8.4 Transformer compensation.......................................................................................32
8.5 Reset defective steps respectively add aditional steps .............................................33
9 CUSTOMER SETTINGS................................................................................................34
10 INDEX .........................................................................................................................35
11 APPENDIX..................................................................................................................36
11.1 Settings phase angle.................................................................................................36
11.2 Connections for mixed measurement.......................................................................36

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 4 of 36
INSTALLATION AND CONNECTION
Only qualified staff is allowed to perform the installation. Also there have to be
kept all valid rules from government! Before connecting the device check that all
lines are without voltage and shorten current transformer.
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
!

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 5 of 36
Operation of ESTAmat PFC-N
in High Voltage compensation panels
The below list is showing the parameters of the ESTAmat PFC-N which
need special attention for operation in High Voltage compensation
panels.
Attention: When putting the ESTAmat PFC-N in operation, the
countdown for “AI” has to be stopped by pushing the “esc”
button.
Un = Adjust the nominal voltage to local conditions
Ct = Adjust the Ct ratio to local conditions
Pt = Adust the Pt ratio to local conditions
St = Adjust the switching time to local requirements
208 = Set item 208 to “No” and switch off the countdown for “AI”
308 = Set item 308 to “Yes” and switch off the automatic step size
detection.
401 = Adjust discharging time to local conditions
402 = Adjust step sizes
Attention: When resetting the ESTAmat PFC-N by using menu
item 601 or 602, all adjusted values are set to factory settings.
When using factory settings for High voltage compensation
a proper and save operation is not possible!

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 6 of 36
1.2 Connection data
Supply voltage
Measurement voltage
Range 90-300VAC.
Terminals L / N
Range 90-690V.
Terminals UM1 / UM2
With using of VT's 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 Outputs
Assembly with 6 or 12 Regulation Outputs possible.
Regulation Outputs volt free with common root.
Terminals A 1-12
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 target Pf.
Terminals T1 / T2
Setting are explained in the Alarm menu.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 7 of 36
2 COMMISSIONING
2.1 ESTAmat PFC-N is parameterized:
After the supply voltage is applied, in ESTAmat PFC-N starts a countdown with 90 sec. Cancel the
countdown by pressing the (esc) button or expire the countdown. After expiring the countdown,
starts the adjusted discharge time for the capacitors (default 75 sec.). Only then the regulations
starts with preset parameters.
2.2 ESTAmat PFC-N is not parameterized:
During the countdown, the auto-initialization can be start by pushing the () button. The
regulator determine which control outputs are not used and blocks them. A wrong connection of
voltage and current will be determined and corrected. After expiration of the auto-initialization, the
controller start the regulation and recognize automatically the step sizes of the capacitors. 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

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 8 of 36
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 PF
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:
Pf 2 active
EXPORT:
export of active energy
1 –12:
control outputs

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 9 of 36
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
cosphi0,999
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
missing
reactive power
to target PF
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

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 10 of 36
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 only shown in kVar when in the "Setup" menu the CT ratio is
set.
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
1
1.00 i MANUAL
INFO
98 %
Current step size in %
related to initial step size
2
1
1.00 i SETUP
INFO
OC
808
switching cycles
3
1
Auto
steptype
1
INFO
CC
25 kVar 12
Display of step size only if
CT ratio is set, otherwise---
12
Auto
steptype
12

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 11 of 36
4.3 Manual (step switching manual)
For testing purposes, it's possible at ESTAmat PFC-N that the outputs are switched by hand.
In the "MANUAL" menu, the automatic control stopped. In order to avoid that control stop
accidentally this menu item is protected by key lock. Hold button pressed for 3 sec. to
enter this menu. As soon as you leave the menu, the system start automatically and switches
off unnecessary step's. Also observed during the manual switching of the outputs is set
discharge time. This applies for re-energizing of step's as well as for the blocking time after
the start countdown is expired
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
12
1.00 i MANUAL
12
12

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 12 of 36
4.4 Setup (Quick start menu)
To commission the control settings are not needed. When you start the auto-initialization the
ESTAmat PFC-N checks the connection of the measurement and the outputs. With these data,
the control starts automatically. However, the ESTAmat PFC-N offers some option's for
optimal adaptation to the conditions in the system and display system data.
1.00 i
1.00 i INFO
1.00 i MANUAL
Un = nominal voltage
Setting of nominal voltage. From
this value the upper and lower limits
for voltage monitoring is calculated
1.00 i SETUP
1.00 SETUP
Un SETUP
400
ct SETUP
20
Input current transformer CT ratio
e.g 250/5 = 50
pt SETUP
1
Input voltage transformer ratio
when no VT is used the value is 1
ai SETUP
no
"Yes" the controller performs the
auto-initialization
pfc SETUP
on
"ON" automatic control
OFF" automatic control off
"HOLD" freeze control
cpi SETUP
1
Target PF of control
st SETUP
10
Latency between switching the
steps

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 13 of 36
5 EXPERT MENU ESTAmat PFC-N
To open the expert menu of ESTAmat PFC-N, choose menu item "SETUP" and hold ()
button until "100" appears. By using the buttons the submenus can be selected. The
expert menu of ESTAmat PFC-N is divided into six groups, where the menu items are
logically grouped together. The following groups exist:
5.1 100 Quick start menu
Contains all important points for commission:
100 Quick start menu
MENU
FUNCTION
RANGE
Un
Nominal voltage measurement = phase voltage
100...241500 V
Setting the correct nominal voltage is needed because from this
value the upper and lower limits for voltage monitoring is calculated
(See. tolerance Nominal voltage). The Step sizes stored in Step
database relate to the adjusted nominal voltage.
Ct
Current transformer ratio
1...9600
Setting the CT factor.
Value must be entered as the ratio (eg 1000 / 5 = 200)
At devices with software version 1.04 is the adjustment range from
1-4000.
Pt
Voltage transformer ratio
1...350
Stetting the VT factor.
Value must be entered as the ratio. If the device is directly
connected to the measurement the value 1 has to be used.
Ai
Auto-Initializing Start
Yes/No
"YES" starts auto-initializing
"NO" nothing happen
If the auto-initializing starts, the controller is testing all step's with
step type "AUTO" and "FOFF" again and the step type is newly
stored in the step database. Steps that are programmed to "FON" or
"AL" will be not considered in case of new auto-initialization.
At devices with software revision before 1.04, stages which are set
to "FOFF" were not retested.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 14 of 36
PFC
Start / Stop / Hold PF-control
On/Off/Hold
Stopping the automatic control. The following options are available:
On: Control in automatic mode
Off: Control stops and active steps were disconnected successive
Hold: Control Stops and active step's remain switched on.
If "OFF" or "HOLD" is selected, will appear in the display "PFC"
alternating with "OFF" or "HOLD". To start the control, select
"ON".
CP1
Target Pf 1
0.70 c...0.70 i
With the setting of the target Pf 1, the power factor is set to be
achieved by power factor correction.
St
Switching time latency
1...6500 s
The switching time is the time what is waited between the switching
of individual steps in the normal control algorithm. This value
should be adapt to the site.
When setting the switching time, the following points should be
considered:
1. The switching time is to protect the relays from unnecessary
switching operation and to rapid wear.
2. During the switching time the need of reactive power is
averaged. This function compensates fast load changes.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 15 of 36
5.2 200 Measurement settings
Contains settings to adapt the measurement of the ESTAmat PFC-N to the surrounding
network conditions.
200 Measurement settings
MENU
FUNCTION
RANGE
201
Nominal voltage measurement = phase voltage
100...241500 V
Setting the correct nominal voltage is needed because from this
value the upper and lower limits for voltage monitoring is calculated
(See. Nominal voltage tolerance range). The Step sizes stored in
Step database relate to the adjusted nominal voltage.
202
Current transformer ratio
1...9600
Setting the CT factor.
Value must be entered as the ratio (e.g. 1000 / 5 = 200)
At devices with software version 1.04 is the adjustment range from
1-4000.
203
Voltage transformer ratio
1...350
Stetting the VT factor.
Value must be entered as the ratio. If the device is directly
connected to the measurement the value 1 has to be used.
204
Nominal voltage tolerance range
0...100 %
The setting of this value is in percent related to the nominal voltage.
By means of the set value, the upper and lower limits of the
permissible voltage range are calculated. e.g. 10% at 400V nominal
voltage is a permissible range from 360V to 440V.
205
Connection voltage measurement
Yes/No
"YES" voltage measurement L-L
"NO" voltage measurement L-N
Based on the set voltage, the controller automatically detects the
voltage for both types of connection (LL and LN). If these are
within the set tolerance (factory setting +/- 10%) the controller shall
determine the voltage measurement. This cannot be changed by
hand.
If the measured voltage is outside this tolerance, the measurement
can be adjusted by hand.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 16 of 36
206
Phase-offset
0...345
This menu contains the correction angle for current and voltage
measurement determined during the auto-initialization. This value
should not be changed, because then the control not longer works
correctly.
Is auto-initialization failed due to adverse network conditions, by
hand a correction angle can be set or the incorrectly recognized can
be corrected. Table 11.1 gives an overview of the connection options
with corresponding phase angles.
207
Start auto-initializing
Yes/No
YES" starts auto-initializing
"NO" nothing happen
If the auto-initializing starts, the controller is testing all step's with
step type "AUTO" and "FOFF" again and the step type is newly
stored in the step database. Steps that are programmed to "FON" or
"AL" will be not considered in case of new auto-initialization.
At devices with software revision before 1.04, stages which are set
to "FOFF" were not retested.
208
Auto-initializing by regulator restart
Yes/No
"YES" The controller starts after every restart the countdown to the
auto-initialization.
"NO" The control starts after restart with the saved values.
209
Frequency synchronization
Auto/Fix50/Fix60
For the highest accuracy of measurement, the samples need to be
synchronized to the grid frequency.
Strong voltage commutation notches can, in spite of the internal
filtering, result that automatic synchronization is disturbed.
This could result in large measurement errors. For this reason the
following settings can made.
Automatic synchronization:
For maximum accuracy at mains voltage without commutation
notches.
FIX-50HZ: For safe operation in the 50Hz grid with extremely poor
power quality.
FIX-60HZ. For safe operation in the 60Hz grid with extremely poor
power quality.
210
Temperature offset (from software revision 1.04)
-10-10°C
This menu allows the setting of an additional temperature offset to
correct temperature dependent deviations of the components.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 17 of 36
5.3 300 Setup Control System
The items in the menu "control system" allow an optimization of the control or an adaptation
to specific site requirements.
300 Setup Control System
MENU
FUNCTION
RANGE
301
Control sensitivity
55...100 %
The control sensitivity indicates the switching threshold for
switching of the steps. A low values allows a more accurate
compensation result. However, this increases the likelihood the
controller tends to oscillate.
The adjustment range is between 55% and 100%.
The factory setting is 60% of the available steps.
302
Target Pf 1
0.70 c...0.70 i
With the setting of the target Pf 1, the power factor is set to be
achieved by power factor correction.
303
Target Pf 2
0.70 c...0.70 i
With the setting of the target Pf 2, the power factor is set to be used
when P-export is detected or switch over to NT.
304
Target Pf 2 for P Export
Yes/No
"YES" the controller operates in P-export with the target Pf 2 as
control target.
"NO" the controller operates in P-export with the target Pf 1.
305
Switching time latency
1...6500 s
The switching time is the time what is waited between the switching
of individual steps in the normal control algorithm. This value
should be adapt to the site.
When setting the switching time, the following points should be
considered:
1. The switching time is to protect the relays from unnecessary
switching operation and to rapid wear.
2. During the switching time the need of reactive power is
averaged. This function compensates fast load changes.
306
Switching time Step exchange
1...6500 s
This is the time between the disconnection of an active step and the
switch on of a better in the identified need for reactive power
matching step. When step exchange, normal switching time is not
respected.

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 18 of 36
307
Activate Step exchange
Yes/No
"YES" for an optimal compensation result, the controller can switch
off active steps and replace them with more suitable steps.
"NO" This function is deactivated.
This function is useful when different step sizes are available. If all
available step have the same step size, then this feature should be
disabled otherwise is may lead to unnecessary switching cycles.
308
Step recognition "OFF"
Yes/No
"YES": Step sizes have to be programmed by hand. The step sizes
have to be programmed by hand if:
a) there is in the system quickly changing loads and problems
with the automatic step size detection occurs.
b) the automatic detection of defective steps is not desired.
c) the contactors have a delay of more than 200msec.
"NO" Step sizes are automatically determined during operation and
losses of step sizes were tracked and considered at the control.
309
Blocking of defective capacitors
Yes/No
"YES" If a step is switched in three times without measurable
network reaction, the controller is blocking the step and doesn't use
it for the control.
Is a Step recognized to be defective, blinks in the display the
corresponding output and in the step database and menu "403" it's
displayed as step type "flty".
"NO" Steps are connected even if no network reaction is
measurable. This results unnecessary switching cycles.
Steps that are stored as defective will be tested every 24 hours or
after the controller is restarted.
310
Start / Stop / Hold PF-control
On/Off/Hold
Stopping the automatic control. The following options are available:
On: Control in automatic mode
Off: Control stops and active steps were disconnected successive
Hold: Control Stops and active step's remain switched on.
If "OFF" or "HOLD" is selected, will appear in the display "PFC"
alternating with "OFF" or "HOLD". To start the control, select
"ON".

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 19 of 36
311
Control algorithm
1/2/3/4
1. Automatic: The controller operates on the "Best Fit"
principle. This means the controller compares before each
switching operation, all in the step database stored step sizes
with the identified need for reactive power and choose
always the step which is the closest to the control target. If
the controller has several equal steps available, the number
of switching cycles automatically distributed to these steps.
2. LIFO: „Last In, First Out“ Switch on the outputs is always
done in the switching sequence 1-2-3-4-max. The switch off
is in the switching sequence been turned upside max-4-3-2-1.
3. Kombifilter: Special algorithm for combined filter banks.
The controller operates on the "best fit" principle as in
automatic mode. Unlike to automatic mode the controller is
connecting always at least the same or more capacitance
which is connected to the odd numbered outputs with the
even numbered outputs. If the controller has several equal
steps available, the number of switching cycles automatically
distributed to these steps.
4. Progressive: The controller switches if required, several
steps in sequence with a shorter switching time. From
software 1.04, the controller uses independently of the set
switching time always 1 sec. as switching time. Furthermore,
the automatic step size detection is disabled and the step
sizes need to enter by hand. The input of the step sizes
should be as accurate as possible, because the regulator
would otherwise tend to oscillate. Leaving the "Progressive"
algorithm and use a different algorithm, the set switching
time is used the step size detection is re-enabled.
312
Offset reactive power
Ct*Pt*7000
The set here offset reactive power is always added to the measured
reactive power. This means that the system can be capacitive, but
measurement of the utility records the required Pf. The set offset
reactive power also goes into the calculation of ▲Q, Pf, apparent
power, current and active power. The max. offset reactive power
that can be entered is calculated from the set current and voltage
transformer ratios.
313
Switching time asymmetrical
-127...127
The set factor multiplies the selected switching time in the
capacitive direction (fast switch on of steps and slow switch off). If
this factor is set with –as sign the function works vice versa.
Factory setting "1" (means symmetrical switching times for both
directions)

ESTAmat PFC-N D.No.13157 - Rev. 02
Operating Instruction MV1181 Page 20 of 36
314
Switch-off in leading condition
Yes/No
"YES" As soon as a capacitive condition is recognized, the
controller switches off without keeping the switching time, the
necessary step power in order to prevent leading network conditions.
"NO" The controller works only with the set target Pf.