Vishay ESTAmat PFC User manual

Issue February 2002
Document Number: 13124
ESTAmat® PFC
Mounting Instructions
MV1161
VISHAY ELECTRONIC GMBH - Geschäftsbereich ROEDERSTEIN, ESTA und Hybride
Hofmark-Aich-Str. 36 - Phone [phone] - Fax [phone] - D-84030 Landshut - Germany
www.vishay.com
Version 1.2.1

Issue February 2002
Document Number: 13124
Digital display
The four-digit display indicates
actual values, faults,
and the set parameters.
Trend LEDs
"ind" and "cap":
switching steps in or out.
green lettering:
Alternate display of step
current "Ic"
number of switching
operations "Σ"
(step LEDs 1 to 12)
Step LEDs
The LEDs indicate the energized
capacitor steps.
yellow lettering:
fundamental current I fund (LED1)
root-mean-square current I eff
(LED 6)
orange lettering:
display of harmonic current
Front Panel Controls
Keyboard
LED indicators
Selected operating mode
or parameter
Connection diagram
(Rear view of the
controller)

Issue February 2002
Document Number: 13124 - 1 -
Table of Contents
1. CONCISE OPERATING INSTRUCTIONS ...................................................................................................................3
1.1. SETTINGS.......................................................................................................................................................................3
1.2. MOUNTING AND CONNECTION OF THE ESTAMAT PFC CONTROLLER...........................................................................3
1.3. START-UP PROCEDURE...................................................................................................................................................3
2. GENERAL ..........................................................................................................................................................................5
2.1. ESTAMAT PFC CONTROLLER– APPLICATION AND OPERATION...................................................................................5
2.2. AUTOMATIC IDENTIFICATION OF C.T. LOCATION AND OF CAPACITOR STEP OUTPUT ......................................................5
2.3. C/K VALUE.....................................................................................................................................................................5
2.4. SWITCHING IN CIRCULAR SEQUENCE..............................................................................................................................5
2.5. OPTIMIZED SWITCHING PERFORMANCE ..........................................................................................................................6
2.6. GENERATOR OPERATION (4-QUADRANT OPERATION).....................................................................................................6
2.7. SWITCHING DELAY TIME ................................................................................................................................................6
2.8. BLOCKING DELAY TIME FOR RE-SWITCHING...................................................................................................................6
2.9. HARMONIC CURRENT - ROOT-MEAN-SQUARE CURRENT ................................................................................................7
2.10. MEASUREMENT OF TEMPERATURE...............................................................................................................................7
2.11. SUMMATION CURRENT TRANSFORMER.........................................................................................................................7
2.12. PARALLEL OPERATION .................................................................................................................................................8
2.13. INTERFACE...................................................................................................................................................................8
3. CONNECTION OF THE ESTAMAT PFC CONTROLLER........................................................................................9
3.1. TERMINALS ALLOCATION ..............................................................................................................................................9
3.2. GENERAL CONNECTION INSTRUCTIONS ..........................................................................................................................9
3.3. CONNECTION INSTRUCTIONS FOR CURRENT TRANSFORMER...........................................................................................9
4. START-UP PROCEDURE..............................................................................................................................................11
4.1. VISUAL CONTROL ........................................................................................................................................................11
4.2. VERIFICATION OF SUPPLY VOLTAGE ............................................................................................................................11
4.3. VERIFICATION OF SET VALUES .....................................................................................................................................11
4.4. INITIALIZATION :..........................................................................................................................................................12
4.4.1. Fully automatic initialization
AU1 .......................................................................................................................12
4.4.1.1. Part 1 : Current transformer location .............................................................................................................................12
4.4.1.2. Part 2 : Determination of the current of capacitor steps...............................................................................................13
4.4.1.3. Memorizing the C.T. location with AU1..........................................................................................................................13
4.4.2. Semi-automatic initialization AU2 .....................................................................................................................14
4.4.3. Manual Initialization
AU3
.................................................................................................................................14
4.5. TEST MODE ..............................................................................................................................................................14
5. OPERATING THE ESTAMAT PFC CONTROLLER- MAIN MENU .....................................................................15
5.1. MODE AUTO – AUTOMATIC OPERATING MODE ..........................................................................................................15
5.2. MODE MAN - MANUAL OPERATING MODE.................................................................................................................16
5.3. MODE CURRENT , YELLOW LETTERING ........................................................................................................................16
5.4. MODE TARGET COSϕ..................................................................................................................................................17
5.5. MODE SWITCHING DELAY TIME....................................................................................................................................17
5.6. MODE IC / ΣSWITCHINGS, GREEN LETTERING .............................................................................................................18
5.7. MODE HARMONIC CURRENT [%] , ORANGE LETTERING................................................................................................18
6. PARAMETER: SETTING AND DISPLAY ..................................................................................................................19
6.1. PARAMETER IN THE MAIN MENU .................................................................................................................................19
6.2. PARAMETERS IN THE SETTING MENU............................................................................................................................19
6.2.1. Setting menu - call-in ..........................................................................................................................................19
6.2.2. Setting menu – Modifying the parameter............................................................................................................20
6.2.3. Setting menu – Completing and memorizing the parameter...............................................................................20

Issue February 2002
Document Number: 13124 - 2 -
6.3. SETTING MENU – DESCRIPTION OF THE PARAMETER ....................................................................................................21
6.3.1. Parameter
-1- : Modes of initialization.............................................................................................................21
6.3.2. Parameter
-2- : Type of measuring voltage ......................................................................................................22
6.3.3. Parameter
-3- : Connection of measuring voltage............................................................................................22
6.3.4. Parameter
-4-
: Type of switching program.....................................................................................................22
6.3.5. Parameter
-5- : C/k value.................................................................................................................................23
6.3.6. Parameter
-6- : Number of switching steps......................................................................................................24
6.3.7. Parameter
-7-
: Blocking delay time for re-switching......................................................................................24
6.3.8. Parameter
-8- : Switching-in delay time..........................................................................................................25
6.3.9. Parameter
-9-
: Switching-out delay time ........................................................................................................25
6.3.10. Parameter
-10- : Switching in circular or series mode...................................................................................25
6.3.11. Parameter
-11-
: Fixed steps ............................................................................................................................25
6.3.12. Parameter
-12- : Locking of keyboard operation...........................................................................................26
6.3.13. Parameter
-13-
: Functioning of the alarm relay............................................................................................26
6.3.14. Parameter
-14- : Switching out the capacitor steps in case of alarm .............................................................27
6.3.15. Parameter
-15- : Permitted maximum temperature ........................................................................................27
6.3.16. Parameter
-16- :Current factor RMS current/fundamental frequency current................................................28
6.3.17. Parameter
-17-
: Maximum permissible values for the harmonic current .......................................................28
6.3.18. Parameter
-18- : C.T. transformation ratio k..................................................................................................28
6.3.19. Parameter
-19- : Time delay for switching out steps in case of ≡ I and ≡ E .................................................28
7. FAULT ELIMINATION .................................................................................................................................................29
7.1 OPERATION AND FAULT DISPLAY ..................................................................................................................................29
7.2 GENERAL FAULTS .........................................................................................................................................................32
8. TECHNICAL DATA........................................................................................................................................................33
8.1. MEASURING CIRCUIT ...................................................................................................................................................33
8.2. CONTROL CIRCUIT .......................................................................................................................................................33
8.3. MONITORING ...............................................................................................................................................................33
8.4. ELECTRICAL CONNECTION ...........................................................................................................................................33
8.5. MECHANICAL DETAILS ................................................................................................................................................34
9. FLOWDIAGRAM OF PARAMETERS IN THE SETTING MENU......................................................................... 35

Issue February 2002
Document Number: 13124 - 3 -
1. Concise Operating Instructions
1.1. Settings
The ESTAmat PFC Controller will be supplied with the following standard setting :
Supply voltage : 230 VAC or 120 VAC
Measuring voltage connection : phase to neutral
Frequency : 50 Hz or 60 Hz
Type of initialization AU1 : fully automatic identification of - measuring voltage connection,
- C.T. location and
- output of the connected capacitor
steps.
1.2. Mounting and connection of the ESTAmat PFC Controller
A cut-out of 138 by 138mm is required for mounting the Controller. The added springs for attachment
shall be pushed into the slots at the device's rear until they have reached the switchboard and have
locked in place.
Terminals Connection
1C.T. connection k (S1), X/5 A or X/1 A
2C.T. connection l (S2), X/5 A or X/1 A
4Mains connection N, 230 VAC or 120VAC
5Mains connection L1, 230 VAC or 120VAC
7, 8 Potential-free alarm contact, normally open
10 Measuring voltage L or N
12 Measuring voltage L
15-20 Control terminals for contactors 1-6
21-26 Control terminals for contactors 7-12 (only PFC12)
1.3. Start-up procedure
After the supply voltage has been applied to it, the ESTAmat PFC Controller starts a self-test. The
following data will be displayed for about 2 seconds:
•The type of program e.g.: 1.2.1.
•The mode of initialization e.g.: AU1 *)
•The set target cosϕe.g.: 1.00
•The switching delay time e.g.: LOAD
•with AU1 the type of measuring voltage e.g.: L-0, must be changed to L-L by the operator, if the
measuring voltage is to be connected between
phase to phase. Refer to item 4.4. and 6.3.2.
•with AU2 and AU3
the connection of measuring voltage e.g.: L1-0, must be adapted to a different connection of
measuring voltage and current transformer
location . Refer to item 4.4. and 6.3.3.
*) with AU3, the additional display of :
•the switching program and number of engaged relay steps e.g.: 1111 and with LED zzzzzz
•the C/k-value e.g.: 0.025
Owing to the basic setting made at the factory, the ESTAmat PFC Controller changes into the fully
automatic initialization AU1. This means that no further settings need to be made by the operator.
In case of standard setting
as per item 1.1 above, the
measuring voltage can be
connected to the mains
supply, i.e. terminal 4 shall
be bridged to terminal 10,
and terminal 5 is to be
bridged to terminal 12.

Issue February 2002
Document Number: 13124 - 4 -
Prerequisite for starting the fully automatic initialization:
•The C.T. secondary current must be at least 25 mA.
•The current of the smallest capacitor connected must be at the C.T. secondary side in the range of
0.025 to 1.00 A.
Sequence of the fully automatic initialization :
Display Function
AU1
-1- to -5-
NO
The Controller starts with step 1 and continues switching in steps until the
location of the current transformer has been determined due to the changes in
current. The trial runs are counted and evaluated. The C.T. location is determined
only after 5 consecutive trial runs producing all the same result. The Controller starts
at the meter reading -1- and stops, in the normal case, at -5- after 5 trial runs.
In cases of unfavourable conditions of the mains supply, the value of the meter
reading may reduce again. If the value -3- is not reached, either the setting AU2 or
AU3 should be selected. Refer to item 6.3.1 in this case.
Continuous changes of display between AU1 and NO indicates that the Controller
has already stored a connection value for the C.T. location. The Controller will start
at AU2 after the re-switching blocking delay time has elapsed. Refer to item 4.4.1.3
for this.
An activated blocking delay time for re-switching for one step is indicated by a
flashing decimal point
Having identified the location of the current transformer, the current or output ratings of the capacitor
steps will be determined.
Display Function
AU2
2.1 to 2.3
Starting with step 1, the Controller switches in each individual step briefly, and
switches it out again immediately. (PFC6 : 6 steps, PFC12: 12 steps).
The procedure is repeated three times.
Normally, the ESTAmat PFC Controller terminates a successful initialization after approximately 5
minutes, and correctly determines the configuration of the plant, and indicates the actual power factor.
If one of the following symbols is on display, the following conditions may be the cause:
Display Condition Remedy
≡IThe measuring current is less than 25 mA. Check C.T. electric circuit
≡0The measuring current is in excess of 5.3A. C.T. transformation ratio is too
small
≡UThe measuring voltage is missing. Check connection of Controller
≡AU1 AU1 could not be carried out correctly. Possible
causes: quick reversals of load, insufficient
compensation output, load too low.
Set AU2. Refer to item 6.3.1.
≡AU2 AU2 could not be carried out correctly. Possible
causes: quick reversals of load, no switching of
capacitor steps.
Set AU3. Refer to item 6.3.1.
SLE The faults ≡AU1 or ≡AU2 have appeared five
times in succession. This condition can be
modified only upon fundamental change of load.
Set AU3. Refer to item 6.3.1.
A target factor of 1.00 is preset as standard.

Issue February 2002
Document Number: 13124 - 5 -
2. General
2.1. ESTAmat PFC Controller– Application and Operation
The ESTAmat PFC Controller can be applied wherever automatic control of the power factor is
required. All functions of the ESTAmat PFC are controlled by a microprocessor. A protective gear
(watchdog) continously monitors the processor to guarantee its faultless operation. There are no
internal time or date functions.
The measurable variables current and voltage are conducted across a 50/60Hz band-pass filter.Thus
harmonics existing in the network cannot affect the measurement process. Both measurement entries
are potential-free. The measuring voltage shall be in the range of 58V-690V and may be connected, at
option, between phase to neutral or phase to phase. The current measuring range is 25mA to 5A, and
there is no need to differentiate between X/1A or X/5A current transformer.
A measuring cycle lasts 0.5 seconds and comprises the measurement of values, the calculation of all
required parameters, such as power factor, current, harmonic current, etc., and if necessary, the
initialization of certain actions, e.g. switching the steps, activating alarm, etc.
2.2. Automatic identification of C.T. location and of capacitor step output
The ESTAmat PFC Controller is capable of determining by itself , during the start-up procedure, the
location of the current transformer as well as the output rating of the connected capacitor steps by
means of test switchings.
Three modes of initialization are possible:
•Fully automatic initialization AU1
The ESTAmat PFC Controller identifies the location of the current transformer, the output
and number of capacitor steps, and the switching program.
•Semi-automatic initialization AU2
The ESTAmat PFC Controller identifies, upon presetting of the C.T. location, the output and
number of capacitor steps, and the switching program.
•Manual initialization AU3
The C.T. location, output and number of capacitor steps, and the switching program have to be
set by the operator.
2.3. C/k value
The C/k-value is the pick-up value of the ESTAmat PFC Controller. The value represents the
reactive current response threshold of the Controller in Ar (ampere reactive). In case the reactive
current portion of the load exceeds the set C/k value, one of the two LEDs "ind" or "cap" will indicate
the trend. The calculation of the C/k value is described under item 6.3.5.
2.4. Switching in circular sequence
Switching in circular sequence means that capacitors which have been switched in first, will also be
switched out again first. Switching follows the FIFO principle: First-IN-First-OUT. If the switching-in
follows the order 1-2-3-4-5, then also the switching-out of the capacitors will follow that same order .
1-2-3-4-5.

Issue February 2002
Document Number: 13124 - 6 -
The circular switching mode distributes the load uniformly on all elements such as contactors and
capacitors. A further advantage of this mode is that a capacitor step, when switched out, has enough
time for discharging before it is switched in again.
The advantages of the circular switching sequence are also applicable for the so-called hunting
programs. With the switching sequence 1:2:2:2:2:2, for example, the "double-size" steps are likewise
switched in circular switching sequence. The "single-size" step will then be used only for fine tuning.
With the switching programs of equivalent hunting steps, e.g. 1:1:2:2:4, the hunting steps of same size
(1:1 or 2:2) will also be switched alternately.
2.5. Optimized switching performance
The ESTAmat PFC Controller measures continuously the demand for reactive power and the
variations of it and, due to the optimized switching performance, switches in or out the largest possible
capacitor step. In case of, for example, a power factor correction equipment of 25 : 25 : 50 : 50 : 50
kvar, the ESTAmat PFC Controller will immediately switch in a step of 50 kvar instead of gradually
switching in steps of 25kvar. This way, the number of switching operations is reduced, which results
in an increased life expectancy of both the capacitors and the contactors.
2.6. Generator operation (4-quadrant operation)
The increasing use of renewable energy sources (e.g. wind, solar, biogas) and thermal regeneration,
as also the application of emergency power supply systems, require that state-of-the-art power factor
controllers operate trouble-free in case of a feed-back of active power into the general supply mains
(generator operation). In both cases of energy supply and of energy feed-back, the ESTAmat PFC
Controller can identify correctly the inductive reactive power and compensate it.
2.7. Switching delay time
The period between lighting-up of one of the light-emitting diodes (LED) ("ind","cap") and the
switching in or out of capacitor steps is defined as switching delay time. The switching delay time can
either be determined by the ESTAmat PFC Controller as a function of load, or preset by the
operator.
2.8. Blocking delay time for re-switching
The period between switching out a certain capacitor step and the earliest possible re-switching in
of the same step is defined as re-switching blocking delay. With the ESTAmat PFC Controller, this
blocking delay for re-switching can be either 20, 60, 180 or 300 seconds. This period is necessary in
order to allow the voltage existing at the capacitor after the switching-out to reduce to an acceptable
level. The blocking delay for re-switching shall be selected in accordance with the existing
discharging device. Switching-in shall be effected only when the residual voltage is less than 10% of
the operating voltage.
2.9. Harmonic current - Root-mean-square current
By means of the FFT-analysis (Fast-Fourier-Transformation), the ESTAmat PFC Controller can
determine harmonic currents of the 3rd, 5th, 7th, 11th, 13th, 17th and 19th harmonic. The presentation
is in percentage with regard to the current of the basic frequency. The Controller displays the

Issue February 2002
Document Number: 13124 - 7 -
percentage values up to the 17th harmonic. If harmonic generators exist and if the resonance frequency
between the compensation equipment and the line transformer is on a typical harmonic frequency, the
percentage part of this harmonic increases excessively. This may activate alarms by means of various
limit-value profiles. This may be, for example, an audible or an optical signal via the alarm relay.
The root-mean-square current is determined by calculation on the basis of the current's curve shape.
Non-linear consumers distort the sinusoidal shape of the current. Fundamental frequency current and
root-mean-square current are of different values in case of harmonic load. The higher the portion of
harmonic load the higher is the deviation between the values of the fundamental frequency current and
of the root-mean-square current. A factor which is created from these two values is a parameter
portraying the harmonic status, and can be determined by means of settable limit values to be used for
the alarm.
2.10. Measurement of temperature
Via an internal temperature sensor the ESTAmat PFC Controller can permanently measure the
ambient temperature. Although the sensor is installed within the device, the measuring can be carried
out with sufficient precision because of the existing venting slots which allow sufficient air circulation.
When the Controller is mounted into a switch cabinet, there is the possibility of monitoring the
cabinet's internal termperature. By setting limit values, an alarm function can be activated.
2.11. Summation current transformer
When several transformers supply one single L.V. bus bar, the individual currents shall be measured
by means of current transformers and then added together via a summation current transformer.
Special attention shall be given to the correct polarity because, otherwise, the current intensities of the
individual transformers will subtract.
The calculation of the C/k-value is described under item 6.3.5. It is important to remember that the
transformation ratios of the individual current transformers shall be added up.
k = k1 + k2 + k3 ... k = ∑C.T. transformation ratios

Issue February 2002
Document Number: 13124 - 8 -
2.12. Parallel operation
In case two network sections, each with independent power factor control equipment, are
interconnected, the two power factor controllers influence each other, because the currents distribute
across the two transformers. In such a case, to avoid hunting of the two power factor controllers, the
C/k-values should be set differently. The result will be a so-called "lead-follow" - behavior because
both controllers react at a different speed. The power factor controller with the lower C/k value is
quicker in switching than the one with the higher C/k value.
The target cosϕvalues of both power factor controllers should be the same. If this is not the case, the
power factor controller with the higher setting would try to switch in steps which the power factor
controller with the lower setting would again switch out immediately. This would also result in an
unacceptable hunting between the switch-in and switch-out operations.
2.13. Interface
The ESTAmat PFC is equipped with a serial interface RS232. By means of a computer, all relevant
measuring values and Power Factor Controller data can be requested. Furthermore, all Power Factor
Controller's parameters can be modified via a computer. The computer software and the connection
cable ESTAmat PFC to the computer are available at option.