1

NSTRUCTON MANUAL
FOR
PFC14 / PFC8
POWER FACTOR
CONTROLLER
2
CONTENTS
SECTION I Introduction .................... 2
SECTION II Installation .................... 3
2.1 Preliminary Check
2.2 ConIiguration Settings
2.3 Mounting & Wiring
SECTION III Operation ............... 16
3.1 Operation
3.2 Maintenance
SECTION IV Specifications ...... 21
4.1 Panel cutout drawing
SECTION V Wiring diagram ..... 24
ANNEXURE 1 C/K TABLE ..... 25
3
SECTION I
INTRODUCTION
Power Factor Controller Relay Model PFC 14 & PFC
8} is designed Ior automatic control oI capacitor banks
to maintain system power Iactor under varying load
conditions. It employs state-oI- the-art microprocessor
techniques Ior measurement oI reactive current, system
power Iactor and ensures hunt Iree operation. It can
control up to 14 (8)* capacitor banks. The parameters
such as number oI capacitor banks, switching program,
switching delay are user selectable. It also displays
system power Iactor continuously and indicates
whether it is lagging or leading with respect to set
power factor.
PFCR Power Factor Controller Relay} protects the
capacitor banks whenever power interruption occurs by
switching OFF` all capacitor banks and providing a
saIety lockout period oI minimum 60 sec. It also oIIers
4
over voltage protection by disconnecting all capacitor
banks in case oI over voltage conditions.
* Text written in parentheses corresponds to PFC 8
throughout this manual.
# For PFC 14 no. oI selectable capacitor banks are 4 to
14.
# For PFC 8 no. oI selectable capacitor banks are 4 to
8.
SECTION II
INSTALLATION
2.1 Preliminary Check
The relay packing consists oI:
1. PFC Relay
2. Mounting clamps
3. Instruction Manual
4. Test certiIicate
Check the PFCR Ior any obvious damage, iI Iound
5
inIorm nearest L&T oIIice or dealer.
Follow the instructions below Ior basic Iunctional
check:
a) Remove protective cover Irom the terminal block by
removing Iour screws and connect 415V AC supply
between terminals 22 & 23.
b) Switch ON` the supply voltage. All LEDs on the
Iront panel will Ilash twice and two digit seven
segment display will keep toggling between number
1` and 3`. Whenever number 1` is displayed, a
green LED marked OK` or Lead` or Lag` will
glow and a red LED marked ALARM-CODE` will
glow when number 3` is displayed.
A yellow LED marked AUTO` will glow
continuously. This indicates that PFCR is in AUTO
mode. All other LEDs will remain OFF`.
Whenever SET COS or SET C/K push buttons are
referred then the relav is to be in AUTO mode.
Whenever CAP or CAP- push buttons are referred,
6
relav is to be in MANUAL mode. This convention is
followed throughout this manual.
c) Press the button SET COS and turn the
potentiometer COS by keeping the button SET
COS in pressed condition. Observe that the display
indicates 80 when potentiometer is in extreme
counter clockwise position. Slowly turn the
potentiometer clockwise, the display will go on
increasing upto 99 and then show 1. Further turning
oI potentiometer in same direction will result in
display indicating again 99 and it will go on
decreasing to show 95 in extreme clockwise
condition. Release SET COS button, display should
start toggling between number 1` and 3` as beIore.
d) Now turn potentiometer C/K` by keeping the button
SET C/K in pressed condition. Observe that display
changes Irom 05 to 1 as the potentiometer is moved
Irom extreme counter clockwise position to extreme
clockwise position. Release SET C/K button, display
should start toggling between number 1` and 3`.
7
e) Press the middle button, LED marked AUTO` will
go OFF` and a red LED marked MANUAL` will
switch ON` indicating that PFCR is now in
MANUAL mode. In this mode keep the button
marked CAP in pressed condition continuously.
Observe that aIter about 70 sec. aIter saIety lockout
time} Iirst relay operates. This is indicated by a green
LED marked 1. Keep the switch CAP in pressed
condition. AIter about 3 sec green LED marked 2 will
glow indicating that second relay has operated. II
CAP switch continues to be in operated condition,
one by one all 14 (8) relays will switch ON` II no.
oI bank selected is 14 (8). ReI. section 2.2.3 Ior
setting } and all 14 (8) green LEDs will start glowing.
Operating button marked CAP- will switch OFF` the
relays one by one starting Irom Iirst relay.
This completes the Iunctional check oI PFCR. Switch
OFF` the relays by disconnecting the supply.
2.2 Configuration Settings
8
User can set Iive diIIerent parameters while installing
the PFCR, they are:
Setting the:-
- Desired Power Iactor COS}.
- C / K value.
- No. oI capacitor banks in PFC 14 4 to 14}, PFC 8 (4
to 8).
- Capacitor bank conIiguration.
- Capacitor Bank switching delay.
2.2.1 Setting The Power Factor cos ]
The desired power Iactor can be set as Iollows :
Select AUTO mode.
Press the button marked SET COS. Display will show
the set power Iactor.
Rotate the potentiometer COS keeping the button
SET COS pressed to get the display oI desired power
Iactor.
9
2.2.2 Setting The C/K Value
C/K value is the measure oI Threshold Reactive
Current. It is a ratio oI minimum capacitor bank size
and CT ratio as given below:
Pc
C/K 0.66 ---------------------------
V * (3) * CT RATIO
Where ,
Pc Minimum capacitor bank size kVAR},
V Supply Voltage 415 V},
CT RATIO Ratio oI current transIormer used
Ior Ieeding current to PFCR.
Eg. II CT used is 1000:5A, then CT RATIO is 200.
The C/K setting can be done in two wavs, manuallv or
automatic.
10
2.2.2.a Manual Setting Of C/K
Calculate the value oI C/K using the above Iormula or
get C/K value using C/K TABLE ANNEXURE 1}.
Select AUTO mode.
Press the button marked SET C/K. Display will show
the SET C/K value.
Rotate the potentiometer C/K` keeping the button SET
C/K pressed to get the display oI desired C/K value.
2.2.2.b Automatic C/K Setting
In this mode PFCR actually measures the capacity oI
the bank and adjusts the C/K value. Hence it is more
accurate than manual setting. Follow these
instructions below Ior automatic C/K setting.
Disconnect the load.
Connect only the least capacitor bank to relay 1 R1,
Terminal No.1}, iI Capacitor bank conIiguration is
11
1:1:1:1. II not connect least capacitor bank to R14 i.e.,
terminal No. 15 Ior PFC 14 (or R8 i.e., terminal No. 8
Ior PFC 8).
Switch ON` the input voltage to PFCR by keeping
SET COS and SET C/K buttons pressed. Display will
indicate number 8` and Code LED will glow
indicating that Auto C/K mode has been selected.
Enter the CT RATIO in Iour digits as Iollows:
a) Select MANUAL mode by pressing Auto/Manual
button. LED marked Lead` will glow indicating that
user can enter most signiIicant two digits oI CT
RATIO using C/K` potentiometer.
b) Rotate C/K` potentiometer till display shows two
most signiIicant digits oI the CT RATIO.
e.g.: For a CT oI 1000:5, ratio is 200 and CT RATIO
code to be entered is 0200. Adjust C/K control till
display shows 02}.
c) Press CAP- button. PFCR will accept two most
signiIicant digits oI CT RATIO and LED marked
12
Lag` will start glowing indicating that user can enter
least signiIicant two digits oI CT RATIO.
d) Rotate COS potentiometer till display indicates
required value In above example it is 00}.
e) Press CAP button. PFCR will accept least
signiIicant two digits. This completes the entering oI
CT RATIO code.
I) Return to AUTO mode by pressing AUTO /
MANUAL button. PFCR will switch ON` the least
valued capacitor. Rotate C/K` potentiometer till LED
marked OK` glows.
This completes the setting procedure. Press SET
COS and SET C/K buttons together, PFCR will
return to normal mode oI operation.
NOTE : DIP Switch
8 Way DIP switch is located at the right hand bottom
corner oI the Iront panel as shown in FIG 1. By this
13
DIP switch it is possible to select no. oI capacitor
banks, testing oI relays, capacitor bank conIiguration &
capacitor bank switching delay.
The DIP switch should be selected when unit is in
OFF` condition. Change in Dip switch position
when PFCR is ON` will not come into effect except
switch no. 3 by which PFCR will come out of relay
test mode.
14
15
16
2.2.3 Selection of Number Of Capacitor Banks
Set the positions oI DIP switch number 6, 7 and 8 as
indicated in the TABLE-1 & FIG 2.a & FIG 2.b to get
the required number oI capacitor banks.
NO. OF
BANKS
S/W
6
S/W
7
S/W
8
4 OFF OFF OFF
5 OFF OFF ON
6 OFF ON OFF
7 OFF ON ON
8 ON OFF OFF
* 10 ON OFF ON
* 12 ON ON OFF
* 14 ON ON ON
TABLE 1: Selection of no. of capacitor banks.
* These options are not available in PFC 8.
CAUTION. IF SWITCH NO. 3 IS KEPT IN ON POSITION,
PFCR GOES IN RELAY TEST MODE. {REFER SECTION
3.1.2.a FOR DETAILS} ENSURE THAT SWITCH NO. 3 IS
IN OFF POSITION FOR NORMAL OPERATION.
17
2.2.4 Selection of Capacitor Bank Configuration:
Positions oI DIP switch number 1 and 2 should be set
as indicated in TABLE-2 & FIG 2.a & FIG 2.b to
match the capacitor bank conIiguration available.
Cap. Bank
ConIiguration
S/W
1
S/W
2
1:1:1:1:1:...:1 OFF OFF
1:2:2:2:2:...:2 ON OFF
1:2:4:4:4:...:4 OFF ON
1:2:4:8:8:...:8 ON ON
TABLE 2: Capacitor bank configuration.
2.2.5 Selection of switching Delay
Set the position oI DIPswitch number 4 and 5 as
indicated in TABLE-3 & FIG 2.a & FIG 2.b to get the
required delay.
Switching
Delay
S/W
4
S/W
5
10 Sec. OFF OFF
20 Sec. OFF ON
40 Sec. ON OFF
60 Sec. ON ON
TABLE 3: Switching delay selection.
18
After setting the required configuration fix the cover
strip back with the help of two screws.
2.3 Mounting And Wiring
PFCR is designed Ior Ilush mounting on the panel.
ReIer. Section IV FIG 3} Ior panel cutout dimensions
and space required behind the panel. Fix the mounting
clamps supplied along with, to both the sides oI the
relay. Insert the relay through the panel cutout and hold
it Iirmly against the panel, tighten the screws on the
mounting bracket.
Wire the relay terminals as shown in the wiring
diagram ReIer FIG 4.a & FIG 4.b}. Relay terminals
are suitable Ior 2.5 mm. sq. lugs. Fix the protective
cover back on the terminal block with the help oI Iour
screws aIter completing the wiring.
NOTE: 1. ENSURE PROPER EARTH CONNECTION
TO THE RELAY.
2. IT IS RECOMMENDED TO REMOVE THE RELAY
FROM THE PANEL DURING TRANSPORTATION.
19
2.3.1 CT/ PT Connections
PFCR has a built-in CT which can accept
current input Irom 1Amp or 5Amp CT. This input is to
be taken Irom R phase CT output. Connect the current
input to terminals 19 and 20 iI it is Irom 1Amp CT and
to terminals 19 and 21 Ior 5Amp CT.
PFCR has a built-in PT, which accepts 415V
AC RMS voltage input. This input should be taken
between Y and B phases. Connect terminal 22 to Y
phase and 23 to B phase.
NOTE . MAINTAIN PHASE CONNECTION AS SHOWN IN
WIRING DIAGRAM {FIG 4.a & FIG 4.b}.
2.3.3 Wiring Of Capacitor Banks
PFC 14 (PFC 8) has 14 (8) relays each with one N/O
contact available on terminals 1to 15(8). One pin oI all
N/O contacts is shorted together internally and this
common point is available on terminal 12. Using these
contacts an external contactor can be switched ON`
or OFF` to connect or disconnect a capacitor bank as
indicated in the wiring diagram FIG 4.a & FIG 4.b}.
20
Depending on conIiguration oI capacitor banks,
connect all banks to PFCR through contactor as
mentioned below :
1. If the capacitor banks are in the ratio of 1:1:1:1...,
i.e., all banks are of same value, then connect the
capacitor banks to relays R1 to Rn where :n' is the
number of banks selected.
2. If the capacitor banks are in the ratio of 1:2:2:2...,
then connect the smallest capacitor bank to relay
R14 (R8) and remaining banks to relays R1 to Rn-1
where :n' is number of capacitor banks selected.
3. If the capacitor banks are in the ratio of 1:2:4:4...,
then connect the smallest capacitor bank to relay
R14 (R8), the next higher to R13 (R7) and
remaining banks to relays R1 to Rn-2 where :n'
is number of capacitor banks selected.
4. If the capacitor banks are in the ratio of
1:2:4:8:8..., then connect the smallest capacitor
bank to relay R14 (R8), the next higher to R13
(R7), the next one to R12 (R) and remaining
banks to relays R1 to Rn-3 where :n' is number
21
of capacitor banks selected.
2.3.4 Wiring Of Alarm Contacts
PFCR incorporates one relay to give alarm indication.
One sC/O contact is available on terminal 16, 17 and
18 which can be used to initiate remote alarm.
Aote that this relay is wired in Fail-Safe mode
i.e., it remains energized under healthy conditions.
The wiring diagram shows the contact position in
power OFF` condition alarm relay de-energized},
hence under healthy` condition terminal 16, 17 will be
open and terminal 17, 18 will be shorted.
Alarm relay drops out to initiate alarm under Iollowing
conditions:
Over Joltage
Under Compensation
Over compensation
Under current
22
2.3.5 Commissioning
Switch ON` voltage and current inputs to PFCR.
Check input connections polarity Refer Section 3.1.2].
Verify the number of banks selected Refer Section 3.1.3].
Adjust C/K control Refer Section 2.2.2 and Annexure I].
Set the desired power factor Refer Section 2.2.1].
SECTION III
OPERATION
3.1 Operation
PFCR continuously monitors the reactive current
drawn by the load and computes the power Iactor
which will be displayed continuously. It compares the
load power Iactor with set power Iactor and switches
the relays inside ON` or OFF` which in turn can be
used to connect or disconnect the capacitor banks.
To achieve hunt Iree operation, iI reactive current
measured is less than 66 oI the available bank size, it
will not be switched ON`.
23
PFCR switches the capacitors in cyclic order so that all
the capacitors are used equally and allows longer
discharge time. This increases the liIe oI the capacitor
bank.
In cyclic switching, iI capacitor banks are in the ratio
oI 1:1:1:1.. always bank no. 1 is switched ON` Iirst.
The capacitor that was switched ON` or OFF` Iirst
will be switched OFF` or ON` Iirst aIter utilizing all
capacitors.
II it is other than 1:1:1.., then all capacitor banks oI
equal size will be used Ior rotational scheme.
3.1.1 Auto/Manual mode
PFCR can be used in AUTO or MANUAL mode.
Normally aIter power ON` it will be in AUTO mode,
indicated by a LED marked AUTO`. In this mode
PFCR automatically connects or disconnects the
capacitor banks to maintain the load power Iactor as
close as possible to the set power Iactor. The switching
24
delay between two consecutive banks can be set at 10,
20, 40 or 60 secs by the user ReI. Sec. 2.2.5 Ior
details}.
Pressing Auto/Manual switch will change the operating
mode oI the unit Irom Auto to Manual or vice-versa.
Operating mode is indicated by glowing oI appropriate
LED. In MANUAL mode user can switch ON` or
OFF` the capacitor banks by operating the buttons
marked CAP or CAP- respectively. The switching
delay between two consecutive banks is Iixed at 3 sec
in MANUAL mode irrespective oI the switching delay
selected by the user Ior AUTO mode operation.
A row oI Iourteen (eight) LEDs marked 1 to 14 (8)
indicates ON`/`OFF` status oI each relay in AUTO as
well as MANUAL mode.
3.1.2 Testing Of Input Connections
Any time aIter power ON`, correctness oI input
connections CT and PT connections Ior proper phase
relation} can be checked as Iollows:
25
Select MANUAL mode by pressing Auto/Manual
button.
Press both CAP and CAP- buttons together. Display
will show code 1` iI connections are correct and code
2` iI connections are reversed & ALARM Relay
operates}. Error Code LED will also glow.
II code 2` is displayed, then reverse either CT or PT
connections but not both}.
For correct indication oI CT and PT polarity, more than
10 oI the rated current should be Ilowing through the
PFCR.
3.1.2.a Testing Output relays
The output relavs can be tested bv switching ON DIP
switch 3 which is located at right corner of the front
panel. The DIP switch should be set ON before
powering the PFCR. Test will switch ON and OFF
the output relavs one after the other starting from one,
the front capacitor bank LED will indicate. The PFCR
26
will be in this mode as long as this DIP switch is ON.
So after one cvcle of testing switch it Off to come out
of test mode.
3.1.3 Verifying Number Of Capacitor Banks
Selected
User can select capacitor banks between 4 and 14 Ior
PFC 14 & between 4 and 8 Ior PFC 8 ReIer Sec 2.2.3
Ior details}. Number oI banks selected can be checked
anytime by pressing both SET COS and SET C/K
buttons in AUTO mode. The number will be displayed
on the seven segment display.
3.1.4 Power Factor Display
Load power Iactor is continuously displayed on two
seven segment LED displays at all load conditions.
Power Iactor display is available in both AUTO and
MANUAL modes. The three LEDs marked Lead`,
Lag` and OK`, mounted next to this display indicates
status oI load power Iactor with respect to set power
Iactor.
27
Eg. II Set Power Factor is 0.80 and actual power Iactor
is less than 0.80, then Lag` LED will glow. Whereas iI
actual power Iactor is greater than 0.80 Lead` LED
will glow even iI it is less than unity.
NOTE . THE DISPLAY INDICATES TWO DIGITS AFTER
THE DECIMAL POINT. THE DECIMAL POINT IS NOT
INDICATED.
3.1.5 Alarms and Protections
PFCR incorporates a separate relay which can be used
to initiate remote alarm under certain conditions. Alarm
conditions are also indicated on the Iront panel by
displaying various ERROR-CODES`.
3.1.6 Over Voltage Protection
II line voltage goes beyond 120 oI nominal voltage
415 V} Ior three seconds, all relays are switched
OFF` at once. Alarm relay operates and CODE 4` is
displayed. When voltage drops to less than 105 oI
nominal value, PFCR will start switching ON` the
capacitor banks again automatically.
28
3.1.7 Under Compensation
Even aIter switching ON` all the capacitor banks iI
measured reactive current inductive} is more than the
set C/K level i.e., measured power Iactor is lagging
with respect to set power Iactor} Under Compensation
CODE 5` will be displayed on the Iront panel and
Alarm relay will operate.
3.1.8 Over Compensation
Even aIter switching OFF` all the capacitor banks iI
measured reactive current capacitive} is more than
desired C/K level i.e., measured power Iactor is
leading with respect to set power Iactor} Over
Compensation CODE 6` will be displayed and Alarm
relay will operate.
3.1.9 Under Current Release
II load current is less than 10 oI the CT rating
1A/5A} then all banks will be switched OFF`
sequentially. Alarm CODE 3` is displayed.
29
3.2 Maintenance
PFCR does not need any routine maintenance during its
working liIe. It does not contain any user serviceable /
replaceable parts. In case oI Iailure oI the PFCR inIorm
nearest L & T oIIice or dealer.
30
31
SECTION IV
SPECIFICATIONS
Voltage Input
415VAC 20 , 50Hz .
Current Input 5A / 1A Field selectable}.
Accuracy oI PF Display 2 Irom 0.7 lag to 0.8 lead,
under Iull load condition}.
Desired Power Factor
setting
0.80 lag to 0.95 lead.
Threshold reactive current
setting C/K}
0.05 to 1 Amps reactive.
Capacitor bank selection 4-5-6-7-8-10-12-14PFC 14};
4-5-6-7-8 (PFC 8);
banks through DIP switch
setting.
Capacitor bank switching
delay
10, 20, 40, 60 sec /- 10.
SaIety lockout time 60 sec capacitor bank
switching.
Delay selected /- 10.
32
Capacitor bank
conIiguration
1:1:1:1:1:...1,
1:2:2:2:2:...2,
1:2:4:4:4:...4,
1:2:4:8:8:...8.
Auto / Manual operation AUTO/MANUAL`.
Relay output rating N/O contact,
230VAC, 5A.
Burden on
a) PT
b) CT
Operational indicator
Insulation
Impulse test
Noise interIerence test
On line testing
Less than 10VA
at nominal voltage}.
Less than 0.3VA
at nominal current}.
LED Ior all Relays,
LED Ior ALARM`,
LED Ior AUTO/MANUAL`,
7-Segment Display to show
PF` & Error Codes`.
As per IS : 3231-1986.
As per IS : 8686-1977.
As per IS : 8686-1977.
PFC relays can be tested
using DIP switch.
33
Operating temperature
Overall Dimension
0 to 55C.
144 144 mm;
depth 100 mm.
ConIorms to IS 3231-1986
Standards Ior all
requirements.
Fig. 3 : Panel Cutout Drawing
34
SECTION V
35
37
ANNEXURE 1.
KVAR
CT ratio
3 4 5 6 7.5 8.3 10 12.5 16.7 20 25 30 33.3 40 50
30/5 0.46 0.60 0.76 0.90
50/5 0.27 0.36 0.45 0.55 0.68 0.75
75/5 0.18 0.24 0.30 0.36 0.45 0.50 0.60 0.75
100/5 0.14 0.10 0.23 0.28 0.34 0.38 0.45 0.57 0.75 0.90
150/5 0.09 0.12 0.15 0.10 0.23 0.25 0.30 0.38 0.50 0.60 0.75 0.90
200/5 0.07 0.09 0.12 0.14 0.17 0.19 0.23 0.28 0.38 0.45 0.57 0.68 0.75 0.90
300/5 0.05 0.07 0.08 0.09 0.12 0.13 0.15 0.19 0.25 0.30 0.38 0.45 0.50 0.60 0.75
400/5 0.05 0.06 0.07 0.09 0.10 0.12 0.15 0.19 0.23 0.29 0.34 0.38 0.45 0.57
600/5 0.05 0.06 0.07 0.08 0.10 0.13 0.15 0.19 0.23 0.25 0.30 0.38
800/5 0.05 0.05 0.06 0.08 0.10 0.12 0.15 0.17 0.19 0.23 0.29
1000/5 0.05 0.06 0.08 0.09 0.12 0.14 0.15 0.18 0.23
1500/5 0.06 0.07 0.08 0.09 0.10 0.12 0.13
2000/5 0.05 0.06 0.07 0.08 0.09 0.12
2500/5 0.05 0.06 0.07 0.08 0.10
3000/5 0.05 0.06 0.07 0.08
4000/5 0.05 0.06
TABLE : C/K VALUES
39
WARRANTY
LARSEN & TOUBRO LIMITED ( L&T) warrants that the
protective Relay model PFC-14/PFC-8 will meet L&T s
published speciIications and will be Iree Irom deIects in
workmanship and materials Ior a period oI 12 months Irom
the date oI shipment. L&T`s obligation under this warranty
shall be limited to servicing or replacing the deIective parts
provided that notice oI such deIects and satisIactory prooI
thereoI is given to L&T by it`s customer within the warranty
period.
This warranty does not cover any deIect caused by accident,
misuse, neglect alteration, modiIication or substitution oI any
oI the components or parts or any attempts at internal
adjustment by unauthorized service personnel.
Under no circumstances shall L&T will liable Ior any
consequential damage, resulting injury, loss or expanse,
directly or indirectly, arising Irom the use oI this product.
This forgoing warranty is in lieu of all other warranties
expressed or implied and is the sole and exclusive remedy
for any claim arising from the defect in the product.
40
Manufactured by
LARSEN & TOUBRO LIMITED,
KIADB INDUSTRIAL AREA,
HEBBAL, HOOTAGALLY,
MYSORE - 570 018.
Visit us @ www.Intmps.com
www.Intebg.com
www.Iarsentoubro.com
Reach us @ mpsinfo@myw.Itindia.com
Part No. 4D060079 Rev 2