Series

The new Italfarad PFC5 Power Factor Correction electronic regulator, fully controlled by microprocessor, incorporates a lot of innovative features when compared to the previous regulator designs, in particular the temperature control and a serial interface RS232. The interface RS232 allows the set-up of the regulator by computer, as well as by the push-buttons, and to check the operating parameters on a computer. It is also possible to verify the level of functioning of the automatic PFC equipment by means of special software.

The PFC5 regulator allows automatic set-up, without the need to set the capacity, the CT direction and the power of the first bank, if the power of the banks is a multiple of the first (binary system), i.e. 1 - 2 - 4 - 8 -16.

 5÷240 Seconds

 Main

 Inductive Load

 Capacitive Load

1.00  CONTROLLER MANUAL

1.01  GENERAL CHARACTERISTICS

·          Digital microprocessor power factor controller

·          TTL-RS232 serial interface for set-up and automatic testing via PC (Personal Computer)

·          Internal temperature sensor

·          Advanced functions for capacitor current overload measurement, average weekly power factor, maximum value logging

·          2 relays programmable as alarm and/or fan control

 1.02  FRONT PANEL

1.03  INSTALLATION

Install the controller according to wiring  diagrams.

The CT (Current Transformer) must be connected to the free phase, i.e. not on phases used to supply the unit, as  indicated in the wiring diagrams.

The controller automatically recognizes the CT current flow. In case of co-generation systems, disable this function (refer to “Advanced menu” section 1.18 “ADVANCED MENU SETTINGS”) and connect the CT correctly.

The CT secondary must be earthed/grounded.

 IMPORTANT!

 For three-phase connection, the voltage input must be connected phase to phase;

the current transformer must be connected on the remaining phase.

The polarity of the current/voltage input is indifferent.

WARNING! Disconnect the line and the supply when operating on terminals.

 1.04  POWER UP

At the first power up, the display shows --- which means no parameter has been programmed yet.

Under these conditions, a manual test of the steps can be conducted to check the connections.

Press the + or – key to connect or disconnect the steps.

WARNING! During this phase, the step control is totally manual and the unit does not control the reconnection time to allow the capacitors to discharge.

 1.05  PARAMETER SET-UP

There are various methods of setting parameters and commissioning the controller to operate properly, namely:

·          Section 1.06   MANUAL KEYPAD SET-UP

·          Section 1.09   QUICK SET-UP VIA PC

·          Section 1.11 AUTOMATIC SET-UP

1.06  MANUAL KEYPAD SET-UP

1.07  TABLE OF BASIC MENU PARAMETERS

1.08  DESCRIPTION OF BASIC MENU PARAMETERS

P.01 - CT primary current

For values higher than 1000, a flashing dot indicates “thousands”.

P.02 - Smallest step kvar

Rated power in kvar of the smallest installed capacitor bank.

Example: For 10 kvar, set 10.0

P.03 - Rated capacitor voltage

Rated voltage (nameplate) of the capacitors.

Example: For 460V, set 460

P.04 - Reconnection time of the same step in seconds

Minimum time needed for the capacitor to discharge and be ready to be used again.

Example: For 60 seconds, set 060

P.05 - Sensitivity

The sensitivity is a coefficient, which allows adjusting the controller operating speed. A low sensitivity provides faster adjustments but with a greater number of switchings. With high sensitivity, the regulation is slower but with fewer switchings.

The sensitivity value corresponds to the time the controller waits before responding to a reactive power demand which is equal to the smallest step (kvar). For higher power demands, the time will be quicker according to the criteria of inverse proportion.

Example: For 60 s/step, set 060

In this case with the smallest bank of 10kvar (P.02 = 10.0) and a system demanding 20kvar to achieve the set cosj (Dkvar = 20), the controller will wait for 60/2 = 30 seconds before beginning the capacitor connection procedure (indicated by the flashing AUT LED).

P.06 LED 1...n Step coefficients

The coefficients of the steps represent the power rating of each step in relation to the smallest capacitor bank, whose value is programmed at P.02. If a step has the same power rating of the smallest step, then its coefficient will be 1, while if it is double it will be 2 and so on up to a maximum of 16. By setting 0, the step will be disabled and will never be considered or used by the controller. The last two steps can be programmed to operate as normal steps or as alarm relay or again as fan control. If the penultimate step is linked to a function then the last step cannot be used as a normal step.

To select these functions, press - until the following codes are viewed:

noA = Normally open alarm (contact open in absence of alarm)

ncA = Normally closed alarm (contact closed in absence of alarm)

FAn = Fan control

N.B. For the alarms, see table on page 41. For fan control, refer to pages 36 and 38.

Example: With a PFC7 installed in a control panel with 6 capacitor banks, 5, 10, 20, 20, 20, 20 kvar respectively at rated 460V and the last step is to be used as alarm, the parameters must be programmed as follows:

P.02 = 5.00 (Smallest step = 5kvar)

P.03 = 460 (Rated voltage 460V)

P.06 LED 1 = 001 (5 kvar = 1 times P.02)

P.06 LED 2 = 002 (10 kvar = 2 times P.02)

P.06 LED 3 = 004 (20 kvar = 4 times P.02)

P.06 LED 4 = 004 (20 kvar = 4 times P.02)

P.06 LED 5 = 004 (20 kvar = 4 times P.02)

P.06 LED 6 = 004 (20 kvar = 4 times P.02)

P.06 LED 7 = noA (Normally open alarm)

1.09  QUICK SET-UP VIA PC

For quick set-up via PC, it is necessary to use the relative automatic test and remote control software that includes the PC software and the connection cable. For this reason, all the controller models are provided with a communication port at the rear. All parameters are displayed on the PC monitor. The settings can be transmitted and stored with a few simple clicks of the mouse.

If a number of controllers must be programmed with the same settings, the set-up can be downloaded on a file and reused later by programming all the parameters with maximum ease and security. 

For use of the programming software, see Chapter 2.

 1.10  RAPID CT SET-UP

When the CT to be used at the moment of the installation is not known, the parameter

P.01 for CT primary current can remain set to OFF while all the others can be programmed.

In this case during the system installation and once the controller is powered up, the display will view a flashing Ct (Current Transformer). The CT primary can be set directly by pressing + and -.

Once programmed, press MAN/AUT to confirm. The unit will store the setting and directly restart in automatic mode.

 1.11  AUTOMATIC SET-UP

CAUTION!

Never use if a complete panel has been purchased.

The setting is useful if it is not possible to access the C.T. or else when the characteristics of the capacitor banks are not known.

The automatic set-up of parameters allows the unit to be placed in service without having to program any parameter.

To activate the automatic set-up when the unit is in MAN or --- mode, simultaneously press MODE and MAN/AUT keys for 5 seconds.

The wording ASE (Automatic Set-up) flashes indicating that the automatic set-up of the parameters is in progress.

The procedure will last a few minutes during which the controller measures the power rating of the connected steps. This measurement will then be continuously updated during the normal operation.

If the load of the system varies frequently, the same step may have to be measured several times. In this case, the procedure may last longer.

At the end of the automatic set-up, the controller is ready for automatic operation.

IMPORTANT!

It is recommended to avoid substantial current variations as much as possible during the automatic set-up. During this automatic set-up, the controller is not able to monitor certain data such as CT primary current, rated capacitor voltage.

Therefore we shall have as follows:

·          The current cannot be viewed in Amperes but only as a percentage.

·          The Dkvar and Skvar measurements are not available.

·          The measurement and protection for capacitor overload are not accessible.

·          All of the relays are considered as normal capacitors banks. So no alarm relay or fan control configuration is possible.

·          The capacitors installed must be with a power rating which is a multiple of 1, 2, 4, 8 or 16 times the smallest capacitor step.

·          The unused steps must be placed at the higher step numbers.

Note: After termination of  the automatic set-up, if access is gained in manual mode to setting the parameters, the controller will consider all the parameters present as valid. Therefore, all of the measurements and functions will be available once again.

 1.12 DISPLAY OF MEASUREMENTS AND REQUIRED COSj SETTING

 Normally, the display shows the cosø of the system together with the IND and CAP LED’s. The flashing decimal point indicates the negative sign (inverse energy flow).

By pressing the MODE key, the V, A, Dkvar, etc. LEDs are switched on one after another and the relative measurement of each is shown.

An optional function is available for each LED and indicated on the front panel, which can be displayed by pressing the + and - keys (the LED flashes quickly thereafter).

When the SET COSj LED lights up, the set-point of the required cosj can be programmed; the + and - keys increase or decrease the value respectively. The set cosj can be adjusted between 0.80 IND and 0.80 CAP.

The following table summarises all the available measurements.

1.13 MAXIMUM VALUE CLEARING

The maximum values of Voltage, Current, Overload and Temperature along with average weekly power factor can be cleared by simultaneously pressing the + and - keys for 3 seconds. Once clearing is complete, the display views CLr.

1.14 OPERATING MODE

The AUT and MAN LED’s indicate the automatic or manual operating mode.

To change mode, press the MAN/AUT key for at least 1 second.

When the SET COSj LED is lit up, no mode change is possible.

The operating mode remains stored even if power is removed.

1.15 MANUAL OPERATION

When the controller is in manual mode, one of the steps can be selected and manually connected or disconnected. If a measurement other than cosj is viewed, press MODE until all the LED’s of the measurements go out.

To select one of the steps, use the + and - keys. The LED of the selected step starts flashing quickly. Press MODE to connect or disconnect the selected step. If the reconnection time of the selected step has not elapsed, the MAN LED flashes to indicate the operation has been confirmed and will be conducted in due time.

The manual configuration of the steps is maintained even when voltage is removed. When power returns, the original state of the steps is restored.

 1.16 AUTOMATIC OPERATION

In automatic mode, the controller calculates the optimum configuration to achieve the set cosj value.

The selection criteria take into consideration many variables such as: power rating of each step, the number of operations, the total time of usage, reconnection time, etc.

The controller displays the imminent connection or disconnection of the step by the AUT LED flashing. The LED flashing can last in cases when the connection of a step is not possible because of the reconnection time (i.e. capacitor discharge time). 

1.17 KEYPAD LOCK

It is possible to enable a function to exclude any modification to the operating parameters, however viewing of the measurements is still provided.

To lock and unlock the keypad, press and hold down the MODE key. Next press the + key three times and the - key twice, then release MODE. The display will show LOC when the keypad is locked and UnL when unlocked.

When the lock is enabled, it is not possible to make the following operations:

·          Change from automatic and manual mode

·          Access set-up menus

·          Change the cosj set-point

·          Clearing of MAX values.

When attempting to perform the above operations, the display will show LOC to indicate the locked keypad state.

1.18 ADVANCED MENU SETTINGS

With the controller in MAN mode, press the MODE key for at least 5 seconds.

The wording SEt will appear to indicate access to basic menu parameters.

At this point, simultaneously press the + and - keys for 5 seconds until AdS appears on the display to indicate access to advanced menu parameters.

1.19 ADVANCED MENU TABLE OF PARAMETERS

1.20 DESCRIPTION OF ADVANCED MENU PARAMETERS

P.11 - Type of connection

Programs either single-phase or three-phase connection.

P.12 - CT connection recognition

When set to Automatic, the controller operates in 2 quadrants and at power on, it recognizes direction of current flow in the C.T.

When set to Direct, the controller operates in 4 quadrants and can be used both in normal or co-generation systems. It is however necessary to check the correct CT connection by making sure the decimal point of the cosj measurement is not flashing with energy import conditions. If not, the CT connections (S1 and S2 terminals) must be inverted or more simply set Inverse.

WARNING! Before disconnecting the S1 and S2 terminals, check that the CT secondary terminals are shorted.

P.13 - Mains frequency recognition

Automatic selection, fixed 50Hz or fixed 60Hz.

P.14 - Step power adjustment

When this function is enabled and during normal operation, the unit allows automatic measurement of  the power rating of the steps and modification of the operating parameters in case the steps are worn (i.e. by making many operations).

Note:

·          When this function is used, the time between the connection of one bank and the next is 20 seconds.

·          If the automatic set-up is used, the function is automatically enabled.

P.15 - Standard or Band regulation mode

In Standard mode, the controller adjusts the system cosj to the set value. In Band mode, the capacitors are connected when the system cosj is lower than the set value and are disconnected when in capacitive conditions. The Band mode is used to further reduce the number of capacitor connections and disconnections.

Note: The Band mode configuration does not allow programming of capacitive cosφ.

P.16 - Standard or Linear connection mode

In Standard mode, the controller freely selects the steps according to the logic described in the Automatic operation section above. In Linear mode, the steps are connected only by progression from left to right following the step number and according to the LIFO (Last In First Out) logic. The controller will not connect a step when the system steps are of different power ratings and by connecting the next step, the set-point value would be exceeded.

P.17 - Co-generation cosj set-point

This parameter is programmed when a 4-quadrant operation is required, i.e. when the system is in the condition of consuming or producing energy. When the parameter is set to OFF, the cosj set-point is the only one and corresponds to the value programmed with SET COSj (see page 36). On the other hand, when it is set to a numeric value then the set-points are two: under normal conditions (system consumes mains energy, positive cosj), the set-point value is considered as programmed by SET COSj.

Under co-generation conditions (system produces energy, negative cosj), it is used as programmed to P.17.

P.18 - Disconnection sensitivity

With this parameter at OFF, the sensitivity value set to P.05 (see basic menu) adjusts the reactive speed during both the connection and disconnection phases. However, if P.18 is set to a different value, the programmed value of P.05 is considered for the connection while the value P.18 is used for the disconnection of the steps.

P.19 - Step disconnection at change to MAN mode

When this parameter is enabled, the connected steps are disconnected in sequence when changing from AUT to MAN mode. At the end of the disconnection, the normal manual mode function is restored.

P.20 - Capacitor overload alarm threshold

By using this parameter, it is possible to adjust the tripping threshold of alarm Capacitor Overload. The percentage of current flowing in the capacitors (calculated by the waveform of the phase voltage) is compared with this threshold. If the threshold value is exceeded, after the delay, the alarm is generated and the steps disconnected.

P.21 - Overload threshold for immediate step disconnection

When the measured overload exceeds the value set  at P.21 , the capacitors are immediately disconnected and the capacitor overload alarm A07 is generated.

Note: The delay time of Capacitor overload alarm A07 operates inversely proportional to the overload entity, compared to the programmed thresholds of P.20 and P.21. When the overload is lower than the P.20 threshold, the alarm will not be generated. When the overload is equal to P.20, the delay time is equal to the one set for the alarm (3 minutes by default but can be changed via the PC). As the overload increases, the delay time becomes proportionally less until it attains zero once the value set to P.21 is reached. With P.20 at OFF, there is no tripping until the value P.21 is exceeded and the immediate disconnection of the steps takes place.

With P.21 at OFF, the delay TIME is also constant. With P.20 and P.21 both at OFF, the capacitor overload measurement is disabled as well as the alarm A07. In these conditions, the display indicates --- instead of the overload measurement. Whenever the capacitor banks are equipped with inductances to prevent harmonic overload, P.20 and P.21 must be at OFF .

P.22 - Overload event counter clear time

Each time an A07 Capacitor overload alarm is generated, the event is registered by an internal counter, which can be consulted by pressing the + key when the OVERLOAD % LED is lit up. The counter indicates the number of capacitor overload events that have taken place over the time period defined by P.22. This parameter also defines the number of hours during which the events remain stored. If no event has taken place during the set time period, the counter is cleared.

P.23 - Overload alarm reset time

Time period during which the A07 Capacitor overload alarm remains active even though the overload value has decreased below the alarm thresholds.

P.24 - Unit of measure for temperature

This defines the unit of measurement, in degrees Celsius or Fahrenheit, for displaying the temperature and the threshold settings related to it.

P.25 -Fan start temperature

Sets the temperature above which the fan relay is activated (if programmed in one of the last two steps).

P.26 -Fan stop temperature

Sets the temperature below which the fan relay is disactivated (if programmed in one of the last two steps).

P.27 - Temperature alarm threshold

Sets the temperature above which the Temperature too high alarm A08 is activated.

 1.21 ALARMS

When the controller detects an abnormal situation in the system, a flashing alarm code is displayed. By pressing any key, display of the alarm will be momentarily ignored to allow the user to check all the measurements. If no key is pressed for 30 seconds and the alarm conditions persist, the alarm code will be displayed once again.

Each alarm can cause diverse results such as the alarm relay tripping, the delayed or immediate step disconnection, etc., according to the programmed property. The property of each alarm can be changed (e.g. disabled, change the delay time or effect), by using a PC and the relative software, used for the quick parameter set-up.

The following table indicates the alarm codes and the relative meaning of each along with the default setting.

Note:

None of the above-indicated alarms are non-volatile.

In MAN mode the steps disconnection takes place only for the No voltage release (micro-breaking) alarm A09 - No-voltage release.

A01 - Under compensation

Capacitors are all connected and cosj is lower than the set-point value.

A02 - Over compensation

All capacitors are disconnected and cosj is higher than the set-point value.

A03 - Low current

Current value is lower than 2.5% full scale value. In automatic, the capacitors are disconnected after 2 minutes of the alarm activation.

A04 - High current

Current value is 120% higher than full scale value.

A05 -Low voltage

Voltage value is -15% lower than lower rated voltage.

A06 - High voltage

Voltage value is +10% higher than higher rated voltage.

A07 - Capacitor overload

Current value flowing in the capacitors is higher than the set threshold (refer to P.20 and P.21 of advanced menu).

A08 - Overtemperature

Internal temperature value is higher than the set threshold (refer to P.27 of advanced menu).

A09 - No-voltage release

Voltage failure duration is more than 8ms.

 1.22 TECHNICAL CHARACTERISTICS

1.24 EXTERNAL DIMENSIONS AND PANEL CUT-OUT

2. PROGRAMMING SOFTWARE MANUAL

2.01 FOREWORD

The programming software allows connection of a controller to a PC via a serial port RS232.

Thanks to this software the tasks of presetting set-up parameters and functional check of the power factor correction panel are quicker and easier. The software is also very useful in trouble shooting as all the measurements and dimensions can be easily monitored by the operator.

Above all, the following functions are available:

·          Graphic display of all the measurements supplied by the unit with numeric indication and bar-graphs.

·          For each step:

·          Display of the status (ON/OFF)

·          Display of the function (step/alarm/fan)

·          Display of the preset power

·          Display of the number of operations

·          Display of the total step operating time

·          Commands for manual closing/opening

·          Access to the Basic Setup and Advanced Setup menus

·          Access to the alarm properties

·          Possibility of saving/loading/printing the setup settings

·          Display via virtual front panel with provision for actuating the buttons

·          Switching from manual/automatic modes

·          Keypad lock function

 2.02    MINIMUM CONFIGURATION REQUIREM