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)

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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

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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

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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.

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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.

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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.

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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

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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

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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.

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3. Connection of the ESTAmat PFC Controller
3.1. Terminals allocation
The power factor controller is connected by means of a 20-terminal plug. The ESTAmat PFC12 is
provided with an additional 6-terminal plug for the steps 7 to 12. The connections are shown at the
rear of the power factor controller's casing.
Terminal allocation of the plug:
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
4supply connection N, 230 VAC
5supply connection L1, 230 VAC
7, 8 potential-free fault alarm contact, normally open
10 measuring voltage L or N
12 measuring voltage L
15-20 control outputs for contactors 1-6
21-26 control outputs for contactors 7-12 (only PFC12)
3.2. General connection instructions
1. The power factor controller is internally protected by means of a fine-wire fuse 100 mA (glass
tube fuse 5 x 20 mm). This fuse is not accessible from the outside.
2. The rating of the external fuse is a function of the current consumption of the connected
contactors. It should, however, be taken into account that an individual control contact may
certainly be loaded with a maximum of 5A, but the external fuse must not exceed the value of
10A.
3. Under normal circumstances, the measuring voltage is identical with the operating voltage, i.e. the
terminals 4-10 and 5-12 shall be connected by means of bridging links. If measuring voltage and
operating voltage are connected separately, the terminals 10 and 12 are each to be protected by a
quick-acting fuse of 2 A.
4. All control contacts, except for the fault alarm contact (7 and 8), are bridged by a spark-quenching
unit (RC element). The impedance of the RC element is 30 kΩat 50 Hz.
5. When using capacitors with attached discharge resistors, the necessary time for discharging will
be 60 or 180 seconds, which has to be observed for any switching-in of steps. The re-switching
blocking delay time of the ESTAmat PFC must be set accordingly via parameter 7.
3.3. Connection instructions for current transformer
1. In case of an unbalanced load of the phases, the current transformer should be connected to the
phase which is most highly loaded.

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2. The current transformer shall be installed at a position which ensures that all the subsequent
consumer current, including the capacitor current, will flow through it. Normally, this position is
next to the feed-in transformer and on the load side of the tariff meter reading.
3. The connecting cable to the current transformer, with a maximum length of 10 m, should have a
minimum conductor cross section of 2.5 mm². If the cable is longer than 10 m, a larger conductor
cross section or a current transformer of a higher rating shall be used.
4. When an already existing current transformer can be made use of, then all the current paths of the
individual devices shall be connected in series with the ESTAmat PFC Controller. Attention
should be paid that the rating of the current transformer be sufficient.
5. The primary current of the current transformer should coincide with the actual current
consumption of the factory. If the current transformer is overdimensioned, the ESTAmat PFC
Controller receives too small a measuring signal and, consequently, will work incorrectly or not at
all, and will signalize the fault "undercurrent ≡I ".
6. The C/k value is set automatically by the ESTAmat PFC Controller in the initialization modes
AU1 und AU2. Attention shall be paid, however, that the current of the smallest capacitor step at the
transformer secondary is in the range of 0.025 up to a maximum 1.5 A.
7. In case of several supplies, a summation current transformer is required. In this case, it is
definitely necessary that the terminals k (S1) and l (S2) of the individual current transformers be
connected correctly.
Advice concerning the replacement of the P.F. Controller :
When working at the C.T. secondary circuit (e.g. removal of the ESTAmat PFC), attention
should always be paid that the C.T. secondary terminals be short-circuited and remain so until
the work is completed (e.g. re-installation of P.F. Controller).

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4. Start-up procedure
In the following text, the keys to be activated are marked black..
Example: means that the key IN shall be pressed. The display - - - - symbolizes an
identified keyboard operation, no further keyboard operation is necessary.
4.1. Visual control
Upon completion of the installation, all connections to the main circuit and the control-circuit
terminals and the screws for fixing the socket connector are to be checked.
4.2. Verification of supply voltage
Operating voltage and frequency are to be checked to confirm that they correspond with the relevant
data given on the rating plate at the rear of the P.F. Controller!
230 VAC or 120 VAC? - 50 Hz or 60 Hz ?
4.3. Verification of set values
Upon application of the supply voltage, the display will show for 2 seconds respectively:
•type of program e.g.: 1.2.1.
•initialization mode e.g.: AU1 *)
•set target cosϕe.g.: 1.00
•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.: 1 1 1 1
•the C/k value e.g.: 0.025
The ESTAmat PFC Controller is supplied with the following standard setting:
initialization mode : AU1
target cosϕ:1.00
switching delay time : LOAD
blocking delay for re-switching : 20
locking of the keyboard : NO (not activated)
If the ESTAmat PFC Controller had been turned to manual operation, the P.F. Controller will
automatically go back to manual operation upon return of the supply voltage. Then all capacitor steps
which had before been switched in, observing the re-switching blocking delay, will be re-switched in
again.

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By pressing the key this process can be aborted.
4.4. Initialization :
The P.F. Controller offers three modes of initialization:
•Fully automatic initialization AU1 (= standard setting)
The ESTAmat PFC determines the location of the current transformer, the output and number of
the capacitor steps, and the switching program. The operator must only set the measuring voltage
mode phase to phase L-L or phase to neutral L-0 . (refer to 6.3.1 and 6.3.2).
•Semi-automatic initialization AU2
The ESTAmat PFC Controller determines, after presetting the location of the current
transformer, the output and number of the capacitor steps, and the switching program.
•Manual initialization AU3
The operator has to set the location of the current transformer, the output and number of capacitor
steps, and the switching program.
The P.F. Controller is supplied with the fully automatic initialization mode AU1 set, which is the normal
application. The fully automatic initialization may not be successful in case of strong oscillations in
the public mains. In such a case, the semi-automatic AU2 or the manual initialization AU3 can be
applied. The initialization mode is stored as parameter -1- (item 6.3.1).
How to change the initialization mode is described under items 6.2 and 6.3.1 .
4.4.1. Fully automatic initialization AU1
With this mode of initialization, the current transformer may be connected to any phase. Connection of
both the current transformer k/l (S1/S2) and the measuring voltage is also at option. The mode of
measuring voltage will have to be set either phase to phase L-L or phase to neutral L-0 (=standard
setting). Refer to items 6.2 and 6.3.2.
When the supply voltage is applied, the setting values will be displayed as described under item 4.3.
The fully automatic initialization AU1 comprises :
-part 1 : determination of current transformer location and
-part 2 : recording the currents of the capacitor steps
4.4.1.1. Part 1 : Current transformer location
First of all, the set re-switching blocking delay is effective. During this time, AU1 is being displayed
and a decimal point is flashing. When the display alternates between AU1 and NO, it means that there is
still stored a C.T. location of a previous application. Refer to item 4.4.1.3. If this is not the case, the
ESTAmat PFC Controller switches capacitor steps in and out several times after the re-switching
blocking delay has elapsed and subject to the mains conditions. The number of switching cycles
carried out will be displayed after the last step has been switched out. This number may range between
-0- and -5- . When the display shows the figure -5- , part 1 of the initialization is completed.

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If a value of 2 or even less is displayed after several switching cycles have been carried out, it is
recommended to set the semi-automatic initialization AU2 or the manual initialization AU3.
If wrong results are caused by load variations during the measuring period, the display will show ≡AU1
and the result of the measurement will be rejected. If due to special mains conditions, a clear
determination of the connection mode during initialization is impossible, then five further trial runs
will be made observing the re-switching blocking delay. After five abortive trial runs in succession
displaying ≡AU1, the power factor controller switches into a stand-by position and will resume
initialization only after the load conditions have fundamentally changed. The stand-by position is
indicated by the letters SLE (Sleep).
Again in this case, the semi-automatic initialization AU2 or the manual initialization AU3 is
recommended.
4.4.1.2. Part 2 : Determination of the current of capacitor steps
At first, the set re-switching blocking delay is effective. During this time, AU2 is displayed and a
decimal point is flashing. For the determination of the currents of the capacitor steps, 6 (or 12) steps
will be switched in and out, one after the other. This procedure will be repeated three times. The
respective switching cycle is displayed as 2.1, 2.2 and 2.3. The measured reactive current changes will
be stored as step currents. Upon completion of the initialization, the power factor controller changes
into automatic operation mode and the actual power factor is displayed.
In case of a fault, e.g.: measuring voltage missing ≡U, measuring current insufficient ≡Ior measuring
current too large ≡0, the initialization will be interrupted. The elimination of the fault's cause will be
detected by the power factor controller, and the initialization will automatically be re-started.
4.4.1.3. Memorizing the C.T. location with AU1
When the set target power factor has been reached for the first time during the automatic operation
mode, the C.T. location will be stored permanently. If this is the case, there will appear in the display
of the ESTAmat PFC Controller, directly after application of the supply voltage, alternatively AU1
and NO during the period of the re-switching blocking delay. Thereafter, the ESTAmat PFC
Controller performs part 2 AU2 (item 4.4.1.2).
A stored C.T. location can be erased by changing the alternating display AU1 and NO into AU1 and YES.
This can be realized by means of the keys or
The selected value is to be confirmed by pressing the key

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NO : The ESTAmat PFC Controller takes over the stored C.T. location and starts with part 2 =
determination of the currents of the capacitor steps.
YES : The ESTAmat PFC Controller erases the stored C.T. location and performs part 1 and part 2
of the initialization AU1
4.4.2. Semi-automatic initialization AU2
The semi-automatic initialization AU2 should be selected when the fully automatic initialization does
not produce a satisfying result due to strong load changes. Attention will have to be paid to the fact
that the phase connection of the measuring voltage has to be explicitly specified. Refer to items 6.2
and 6.3.2.
The initialization runs in accordance with part 2 of the initialization mode AU1 (item 4.4.1.2).
4.4.3. Manual Initialization AU3
In case of manual initialization AU3, the operator must set:
- measuring voltage connection (parameter -3-, item 6.3.3.),
- the type of switching program (parameter -4-, item 6.3.4.),
- the C/k value (parameter -5-, item 6.3.5.) and
- the number of steps (parameter -6-, item 6.3.6.).
The procedure to set the parameters is described under item 6.2.
During the first start-up procedure, parameters -4- and -5- must be verified. For this, both parameters
must be called-in and, if necessary, be modified in the setting menu. If this is not done ≡PAR will be
displayed, and after a delay of 2 seconds, the controller will automatically change to the setting menu
of the parameter concerned.
The step outputs will be determined by means of the C/k value, the number of switching steps and the
switching program. No readjustment of the step outputs will occur while switching the capacitor steps
during operation.
4.5. TEST MODE
During the start-up procedure of the controller, if the measuring current ≡I, or the measuring
voltage ≡Uis missing, a test mode can be activated to switch steps in the manual operating mode.
During AU1 and AU2, the switching program of 1:1:1:1, the C/k value of 0.05 and the maximum
number of switching steps are automatically preset. Only during AU3, the already set parameters (4, 5
and 6) will remain. The test mode is activated by means of the key .
Thereafter, the selected menu is displayed alternately with TEST.For deactivation of the test mode, the
operating voltage of the controller must be disconnected. For example, this can be achieved by
temporarily removing the control fuse of the capacitor bank.

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5. Operating the ESTAmat PFC Controller- main menu
In the following text, the keys to be activated are marked black..
Example: means that the key IN shall be pressed. The display - - - - symbolizes an
identified keyboard operation, no further keyboard operation is necessary.
On the front plate of the ESTAmat PFC Controller six main menu points are laid out. Important
control parameters, measuring values, and control characteristics can be enquired for or can be set by
means of this main menu.
By means of the key the respective menu point can be engaged.
By means of the key the values can be reduced, or by the key
they can be increased.
The selected value will be stored by pressing the key
If one of the following menu points current, target-cosϕ, switching delay, Ic/Σswitching
operations or harmonic current is called upon, and no key is being operated for a period of 30
seconds, the ESTAmat PFC Controller switches to the AUTO mode.
5.1. Mode AUTO – automatic operating mode
In the automatic operating mode, the capacitors are automatically switched in or out depending on the
demand for reactive power. The actual power factor is shown in the display. A minus in front of the
power factor means that the power factor is capacitive.
For the purpose of testing, capacitors can be switched in or out manually at any time in the automatic
operating mode.
By means of the key steps can be switched in.
By means of the key steps can be switched out.
As long as the decimal point flashes in the display, the re-switching blocking delay is still effective.
However, the operation of the key is stored and the capacitor step will be switched in after the re-
switching blocking delay has elapsed.

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5.2. Mode MAN - manual operating mode
The manual operating mode can be called upon from any other mode. When the MAN mode is set, the
automatic operating mode is ineffective, i.e. no capacitor steps are switched.
In order to activate the MAN mode, one must keep pressing the key until
the display shows 8888 after about 5 seconds. Manual operation is manifested by the flashing of the
LED AUTO.
In the MAN mode, capacitor steps can be switched in or out manually:
By pressing the key steps can be switched in.
By pressing the key steps can be switched out.
As long as the decimal point flashes in the display, a re-switching blocking delay is still effective.
However, the operation of the key is stored and the capacitor step will be switched in after the re-
switching blocking delay has elapsed.
To de-activate the MAN mode, press key
The MAN mode remains active even after a voltage interruption has occurred. When the voltage has
returned, the P. F. Controller goes back to MAN mode by itself. Capacitors which had been switched
in before the voltage interruption occurred will be switched in again taking into account the re-
switching blocking delay.
By pressing the key this procedure can be stopped.
5.3. Mode current , yellow lettering
The apparent current in Ampere is displayed.
By means of the key the root-mean-square value of the current and
by means of the key the fundamental frequency current can be called upon.
This is displayed by means of the step LEDs 1 and 6 . The lettering I fund defines the fundamental
frequency current, I eff the root-mean-square value of the current.
Ifund : current value of the mains frequency 50 or 60 Hz
Ieff : current value comprising the mains frequency plus the harmonic component.

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The transformation ratio of the current transformer can be set by means of the parameter -18- . (Refer
to item 6.3.18). This way, the actual primary C.T. current can be displayed.
The portion of harmonics will increase as a function of the increased deviation between root-mean-
square current and fundamental frequency current.
5.4. Mode target cosϕ
By means of the keys and the target power factor can be
set in the range of 0.85 inductive ( 0.85 ) up to 0.95 capacitive ( -0.95 ). A minus in front of the
power factor means that the power factor is capacitive.
When pressing simultaneously the keys the standard setting 1.00 for the
target cosϕis produced. The value shown when the setting mode for the target cosϕis left will be
stored.
5.5. Mode switching delay time
The period between surpassing the hysteresis and starting the switching procedure is defined as
switching delay time. The condition of surpassing must be given permanently during the determined
switching delay time. The switching delay time can be determined by the ESTAmat PFC Controller
as a function of load, or it can be fixed by the operator.
The following fixed switching delay times are possible: 10 ,30 ,60 ,120 ,180,300 and 500 seconds.
Determination of the switching delay time as a function of load is activated when the display indicates
LOAD . The switching delay time may range between 2 and 500 seconds.
By means of the key or the desired switching delay
time or the function LOAD can be selected.
By pressing simultaneously the standard setting LOAD is produced.
The selected value is stored by means of the key and the menu indicator
changes to the next menu.
By means of the parameters 8 and 9 (items 6.3.8 and 6.3.9), fixed switching delay times can be set
separately for the switching-in and the switching-out of capacitors. In this case, the flashing LED IND
signalizes a fixed presetting for the switching-in delay time while the flashing LED CAP indicates a
fixed presetting for the switching-out delay time.

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5.6. Mode Ic / Σswitchings, green lettering
In this mode the capacitor steps are examined. The capacitor current and the number of switching
operations of the selected step are alternately displayed.
By means of the key or a step can be called upon.
The step LEDs 1 to 12 show for which step the values are being displayed. By means of the LEDs "Σ"
and "Ic", the displayed value can be identified:
Ic = Current in Ampere of the selected capacitor step. The current is readjusted via the current
transformer's transformation ratio which is set under parameter -18- .
Σswitching operations =Number of switching operations of the contactor of the selected
capacitor step. The point symbolizes the thousandth place.
Range of switching cycles Display
0 – 9999 8.888
10,000 - 99,999 88.88
100,000 –999,999 888.8
The capacitor contactors will have to be replaced after about 100,000 switching operations. A regular
check is strongly recommended.
By pressing simultaneously the switching counter of the selected step can be
reset.
5.7. Mode harmonic current [%] , orange lettering
By means of the FFT-type analysis (Fast-Fourier-Transformation), the ESTAmat PFC Controller
can determine harmonic currents of the 3rd, 5th, 7th, 11th, 13th, 17th and 19th harmonic. They are
displayed in percentage of the current of the fundamental frequency. These percentage values are
displayed up to the 17th harmonic. ( Har.: 3 5 7 11 13 17 )
By means of the key or a harmonic can be selected.
In the step display one can see which harmonic has been selected.