BR5600R Operations Manual Rev 113-09-2023
BR5600R Operations Manual Rev 113-09-2023
Operations Manual
NOTE
Operations manual for BR 5600 R (16-step output NO relay contacts controller) for
LV/HV Capacitor switching applications.
This manual does not claim to cover all details or variations of the device or to consider all
possible contingencies related to installation, operation, or maintenance.
If further information is desired or special problems arise that are not adequately covered for
the buyer's purposes, the matter should be referred to our office.
The contents of this operations manual shall not become part of or modify any prior or existing
agreement or relationship. The statements contained herein do not create any new warranties
or modify any existing warranty.
1. High voltage!
2. BR 5600 R for indoor use only!
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BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
TABLE OF CONTENTS
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BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ORDERING INFORMATION
BR 5600 R
B-Code: B44066R5615A415
Feedback voltage:
A. 3-phases 4 / 3 wire.
B. 2-phases 2 wire.
C. 1-phase 2 wire.
Additional Function: Providing add-on protection. The product does not come under
“Protection Relay” category / standards.
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BR 5600 R power factor controller
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Operations manual
FEATURES
Total 16nos. (sixteen) Capacitor banks control. Relay contacts with 0.5Amp / 250V~ inductive
load NO-type. Out of 16nos., 15 are regular steps control and 1 is Auxiliary output configurable.
Capacitor Current measurement and Capacitor banks health monitoring through Current
Transformers of either 5Amp or 1Amp ratings.
Auxiliary input with AC voltage measurement. Highly useful feature when configured for
Contactor actuator voltage health monitoring with protection tripping & avoiding chatter.
Auxiliary outputs – Total 3nos. For various Alarm and Control functions. (User set functions).
One Auxiliary output can be configured as Capacitor switching relay.
Harmonics Measurement (Odd & Even) up to 31st harmonic. For measurement Voltage,
measurement Current and capacitor Current. (THD-F%, THD-Value, TDD%).
Four quadrant measurement – highly suitable for co-generation usages with solar or wind
power.
Accuracy for Reactive and Active Power & Energy of Class-2.0. This is as per accuracy standard
IEC-62053 part 21 for Active (P), part 23 for Reactive (Q).
Data Logging records for Faults/Events, Regular Intervals (user set time interval), Daily logs.
Digital Communication two ports. One RS-232 for GPRS modem or Logged data download.
Another RS-485 for MODBUS-RTU or MODBUS-ASCII or Logged data download.
Wide range Voltage and Current measurement through Potential Transformers & Current
Transformers.
High reliability wide ranging Auxiliary Power Supply with AC or DC voltage input.
Automatic & Manual synchronization of Voltage & Current feedback. Without physical wiring
connection change.
Plug – Socket rear side terminals for reliability, easy maintenance, and manufacturing.
Added functions: Easy Edit, Expert Edit, Individual Phase mitigation, HV & LV functionality etc.
make versatile applicability.
Volt-Amp feedback Vector position selection facility. Used when Voltage and Current sensing
are carried out on different sides of the Transformer.
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BR 5600 R power factor controller
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Operations manual
SPECIFICATIONS
Sub-
Function Parameter Condition Minimum Maximum
function
Measured
Values
Supply Voltage (V) 3-Phase & Neutral – fund. 50V~ L-N 315V~ L-N
Sinusoidal 3-Phase (3-wire) – fund. 85V~ L-L 550V~ L-L
2-Phase – fund. 85V~ L-L 550V~ L-L
1-Phase & Neutral – fund. 50V~ L-N 315V~ L-N
Current (I) 5 Amp IN: - fund. 75mA(cl-2), 5mA 7.5 Amp
Sinusoidal 1 Amp IN: - fund. 200mA(cl-2), 5mA 1.5 Amp
Frequency Frequency (Hz) 47Hz (for 50Hz) 53Hz (for 50Hz)
(Fundamental Supply Voltage 57Hz (for 60Hz) 63Hz (for 60Hz)
measurement of frequency) meas. range 45Hz meas. range 65Hz
Power / IEC-62053 pt.21 & 23 5Amp range: Class 2: P & Q
Energy 4 quadrant measurement 1Amp range >200mA: Class 2 P & Q
Maximum S (VA), P (W) 1min. sliding Window time Window time
Demand window. Window time user set. 5 - Minutes 60 - Minutes
Harmonics Voltage - L-L & L-N Spectrum: 2nd to 31st Harmonic.
Current - per L (RYB) & N For Voltage and Current.
VA Burden Voltage at 550V~ L-L <1.13VA per ph., <3.40VA total 3-ph
Voltage at 415V~ L-L <0.65VA per ph., <1.95VA total 3-ph
Current at 7.5Amp~ S-CT <1.0VA per ph., <3.0VA total 3-ph
Current at 5.0Amp~ S-CT <0.5VA per ph., <1.5VA total 3-ph
Current at 1.0Amp~ S-CT <0.05VA per ph., <0.15VA total 3-ph
Capacitor Current 5 Amp IN: 75mA(cl-2)25mA<0 7.5 Amp
1 Amp IN: 15mA(cl-2)05mA<0 1.5 Amp
Harmonics Cap. Current - per Ph 2nd to 31st Harmonic
VA Burden Current at 5.0Amp~ C-CT <0.5VA per ph., <1.5VA total 3-ph
Current at 1.0Amp~ C-CT <0.05VA per ph., <0.15VA total 3-ph
Bank VAR value Fund. Voltage, Cap. Ampere & % of capacitor current CT rating.
frequency normalized value. Accuracy 3%: 10% to 100% C-CT rated
Accuracy 10%: 2% to 10% C-CT rated
Offset to target % above the target PF setting 0% 100%
Capacitor
Control
PF Target PF Displacement Power Factor Inductive: 0.000 Capacitive: 0.000
Correction setting
VAR margin Smallest capacitor bank VAR …X … X 1.1 … X 9.9
Offset to target % above the target PF setting 0% 100%
ON/OFF Algorithm Optimal value to target. Single target PF with adjustable No action
control VAR tolerance band
Bank Utilization Limit = C = 01 (00 Disable.) C = 99
(Number of switch ONs / C) + T = 01 (00 Disable.) T = 99
(On duration in Minutes / T)
Relay Contacts Group of 5 numbers X 3 group 5Amp Resistive / 0.5Amp Inductive Amp~
"NO" contacts. 250V~ voltage contact rating.
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BR 5600 R power factor controller
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Operations manual
SPECIFICATIONS:
Sub-
Function Parameter Condition Minimum Maximum
function
Auxiliary
Supply
Voltage AC supply 90 V~ 485 V~
for energizing unit
DC supply 100V 550V
VA AC supply VA 90V~ to 485V~: metering -- 7.5 VA
consumption With full Control loading -- 15.0VA
DC supply VA 100V to 550V metering -- 7.5 VA
With full Control loading -- 15.0VA
Auxiliary
Functions
Add-on Actions Indicative: LDATA
Fault Regular trip: NTRIP
Instant trip: INS-X
detection:
Recovery Automatic Timer Reset Depending upon fault type.
Manual Reset (Refer details)
Auxiliary Voltage~ Rating AC supply input (abs. max.
290 Volt ~
Input rating) 0 - (Zero) Volt ~
1 (One): > 68
AC measurement range < 3 Volt ~
Volt ~
Digital range
Auxiliary NO contact Galvanically isolated 5Amp Resistive / 0.5Amp Ind. Amp~
Output contacts. 250V~ voltage contact rating.
Hardware Enclosure Type Fire retardant ABS grade
Enclosure / Dimensions Front Facia + depth 146 (H) x 146 (W) x 75 (D) mm
Panel cutout dimensions 138 x 138 mm
Display /
Keyboard / Weight Unpacked unit weight < 0.9 KG with mounting clamps
Packed unit weight <= 1.25 KG
Connectors
IP Class Front Facia: IP-54
Back side Inside Panel: IP-20
Display LCD backlit Yellow Green with LED 16 Graphic Character X 2 Lines
Backlit
Contrast/view Adjust Min - Max 25 key Left key: Light Right key: Dark
presses
Keyboard Isolated tact 7 - Key - User Friendly Up, Down, Left, Right
switch 4 Navigation keys
Enter: For value entering
Selection: Mode & Para. selection
Save: Saving key
Connectors Plug - Socket Voltage Measuring 7.62mm pitch - Pin type lugs
Current Measuring 5.08mm pitch - Screw lockable
Output / Aux Control 7.62mm pitch
Communication & Pt-100 3.81mm pitch
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BR 5600 R power factor controller
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Operations manual
SPECIFICATIONS:
Sub-
Function Parameter Condition Minimum Maximum
function
Communication
& Data Logging
Comm. RS-485 Protocol MODBUS- (RTU & ASCII),
PC App data D/L & U/L
RS-232 GPRS Modem & Data AT+ for MODEM,
download PC App data D/L & U/L
Data non-volatile Interval Records: As per user selected
Logging memory Event Records: Communication mode & Data
Daily Records: logging structure.
User Settings Parameters:
Date / Time Real Time RTC maximum deviation. ±1-min in 30-days within op. temp.
Management Clock. (RTC) range
Power down Power down RTC Back-up 30-days minimum back-up time
time backup time with Super-Capacitor range if temp. maintained within
usage. 10°C to 40°C ambient.
Temperature
sensing
Internal unit For Unit right Range within unit operating 0°C +65°C
temperature functioning temperature
PT-100 For PF panel Range within the PF 0°C +100°C
temperature temperature correction panel operating
temperature.
Environmental /
Safety - Type
tests
IEC61326-1 EMC Electromagnetic Compatibility Compliance
EMI Electromagnetic Interference Compliance
IEC61010-1 Safety Safety Standards with Low Compliance
Standards Voltage instruments directive
(category III)
RoHS 2002/95/EC Regulation on Hazardous Compliance
RoHS 3.0 Substances usage.
CE Compliance
IEC60068-2 Dry Heat Storage condition +70°C for Compliance
72Hrs.
Cold Test Storage condition -25°C for Compliance
72Hrs.
Damp Heat Power-up condition Compliance
Cyclic Test At RH 93% +40°C & +25°C
12-12Hrs. cyclic 144Hrs.
Temperature Operating Surrounding Ambient 0°C +60°C
temperature
Storage Surrounding Ambient -10°C +70°C
temperature
Humidity 95%RH
RH% Relative Humidity 10%RH
non-condensing
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BR 5600 R power factor controller
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Operations manual
Typical Schemes:
Applicability:
For LV supply system ranging from 85V~LL to 550V~LL, 50Hz / 60Hz, 3-phases with or without
Neutral connection.
Usage of 3-phases Balance capacitors. Suitable for balanced load requirement.
Capacitor switching contactors with coil (actuator) supply ranging from 100V~ to 250V~.
3-Phases 3-Wire (without Neutral) Connection to Auto-PF System.
Need Auxiliary supply transformer for contactor coil supply voltage with secondary output
voltage as per contactor coil rating. It should be minimum 100V~ and maximum 250V~.
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
Applicability:
For LV supply system ranging from 175V~LL to 433V~LL, 50Hz / 60Hz, 3-phases with Neutral
connection.
Usage of 3-phases Balance capacitors. Suitable for balanced load requirement.
Capacitor switching contactors with coil (actuator) supply ranging from 100V~ to 250V~. Note
the usage restricted with supply system up to maximum 433V~LL and minimum 175V~LL, so
that maximum LN voltage is 250V~ and minimum LN voltage is 100V~.
3-Phases 4-Wire (with Neutral) Connection to Auto-PF System.
Need a strong Neutral connection from supply system to Auto-PF System. (To prevent Neutral
floating issues)
If control supply is provided through step down transformer (Limited between 100V~ to 250V~)
for BR5600R Auxiliary supply and for Contactor’s coil supply, then the supply system can be
used for higher voltage up to 550V~LL value. (With usage of capacitors with right rated voltage)
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
Applicability:
For LV supply system ranging from 175V~LL to 433V~LL, 50Hz / 60Hz, 3-phases with Neutral
connection.
Usage of 3-phases Balance capacitors as well as 1-phase capacitors. Suitable for un-balanced
load requirement.
Capacitor switching contactors with coil (actuator) supply ranging from 100V~ to 250V~. Note
the usage restricted with supply system up to maximum 433V~LL and minimum 175V~LL, so
that maximum LN voltage is 250V~ and minimum LN voltage is 100V~.
3-Phases 4-Wire (with Neutral) Connection to Auto-PF System.
Need a strong Neutral connection from supply system to Auto-PF System. (To prevent Neutral
floating issues)
If control supply is provided through step down transformer (Limited to 250V~ max) to Auxiliary
supply and for Contactor’s coil supply, then the supply system can be used for higher voltage
up to 550V~LL value (with usage of capacitors with right rated voltage).
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
L(V)H(A) H(V)L(A)
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
Applicability:
For higher number of Capacitor banks (steps). More than 16nos. Two numbers of BR5600R
units are used with Digital Input and Digital Output 1 connections as shown in the diagram.
Capacitor Banks Controlled by Master and by Follower are recommended to be 1 to 1 matching.
Even though this is not a mandatory requirement, the recommendation is for achieving better
reactive power control. This is useful with KVAH billing reduction.
Settings on BR5600R
Master: <MODE EXPERT EDIT> <AUX I/O> <AUX I/P FUNCTION: 32S-MI
<MODE EXPERT EDIT> <AUX I/O> <AUX O/P No.1: 32S-MO (auto set)
Follower: <MODE EXPERT EDIT> <AUX I/O> <AUX I/P FUNCTION: 32S-FI
<MODE EXPERT EDIT> <AUX I/O> <AUX O/P No.1: 32S-FO (auto set)
Master & Follower controllers that are used with matching capacitor bank sizes, the
Configurations and settings should be made identical except for Aux. I/O as specified
hereabove.
For LV supply system ranging from 85V~LL to 550V~LL, 50Hz / 60Hz, 3-phases with or without
Neutral connection.
Usage of 3-phases Balance capacitors. Suitable for balanced load requirement.
Note the supply current measurement CTs (S-CT) for Master and Slave unit are in series
connection.
Capacitor switching contactors with coil (actuator) supply ranging from 100V~ to 250V~.
3-Phases 3-Wire (without Neutral) Connection to Auto-PF System.
Need Auxiliary supply transformer for contactor coil supply voltage with secondary output
voltage as per contactor coil rating. It should be minimum 100V~ and maximum 250V~.
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BR 5600 R power factor controller
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Operations manual
CONNECTIONS & WIRING:
Typical control wiring of the PFC output command for Capacitor bank ON/OFF control
through Electro-mechanical contactor switching.
The R-C snubber is recommended for long term reliable operation of Contactor and PFC relay contacts.
Values in the diagram for R & C are typical values. For higher rating contactors (>100Amp~ rating)
C=0.22F and R=22 values are recommended.
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BR 5600 R power factor controller
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Operations manual
On LV supply system:
Configuration No. 3: 2-W (LL) / 1-CT Configuration No.4: 2-W (LN) / 1-CT
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BR 5600 R power factor controller
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Operations manual
Measurement Feedback Configurations:
On HV supply system:
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BR 5600 R power factor controller
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Operations manual
Measurement Feedback Configurations:
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BR 5600 R power factor controller
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Operations manual
BR5600R
BR5600R
Galvanically isolated
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BR 5600 R power factor controller
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Operations manual
MECHANICALS
Front View:
BR5600R
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BR 5600 R power factor controller
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Operations manual
MECHANICALS:
Side Views:
Top View:
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BR 5600 R power factor controller
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Operations manual
MECHANICALS:
Back View:
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS
Backlit Capacitor
LCD Bank number.
Status on
LCD
Model No.
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS:
st
1 SET
5-Capacitor
Control
Relays
Supply CT + 1 Aux.
Current fb Output
Relay
Capacitor CT
Current fb
nd
2 SET
5-Capacitor
Control
Relays
+ 1 Aux.
Output
Relay
Auxiliary
Input
rd
3 SET
Auxiliary Supply (PT) 5-Capacitor
Supply Voltage fb Control Relays
+ 1 Aux. Output
Relay (can be
th
used as 16 step
of capacitor.
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS:
PT – 100 (3 wire)
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS:
Remove the Right-hand side plugs terminal (communication) and Upper side plug terminal
(External Temperature sensor PT-100).
Insert BR5600R unit from front of panel door. Insert and secure the mounting clamps as per
instructions here above.
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS:
Keyboard
UP Key
DOWN Key
Navigation
RIGHT Key
ENT Key
Control
MODE Key
Keys
SAVE Key
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BR 5600 R power factor controller
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Operations manual
OPERATIONAL PARTS:
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BR 5600 R power factor controller
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Operations manual
INITIAL CHECKS
1. Inspect BR5600R unit for any physical damage and for tamper-proof seals in torn
state. In case of any of these issues, the unit should not be used and should be
replaced with the good one.
2. Check BR5600R unit is securely mounted on PF correction system panel door with all
the 4 clamps. As per earlier given instructions.
3. Ensure the Wiring to BR5600R is as per the required scheme. The 1.5mm2 Cu gauge
and 1.1kV insulation wires for all Voltage / relay terminals are used. The 2.5mm2 Cu
gauge and 1.1kV insulation wires for all Current (CTs) terminals are used.
4. Check that Supply current CTs and Capacitor current CTs are kept in shorting
condition. (CT Shorting external to BR5600R unit)
5. Ensure that right type of lugs (Pin type) is properly crimped to wires for connection to
BR5600R. Tightening of the screws of the terminals with Maximum 1.5Nm torque.
6. Check that Supply Current CT terminals and Capacitor Current CT socket terminals
are secured by terminal side screws with its plug terminals parts.
7. Ensure the right capacity RC Snubber circuits are used across the Actuator (inductive
coil) of the “Capacitor switching duty contactor”. (For HV capacitor switching, ensure
RC Snubber circuits for intermediate buffering relay Actuator coils too)
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BR 5600 R power factor controller
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Operations manual
Seconds
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
↑ or ↓ symbol:
Step No. used as FIXED. Its OFF Steps Fixed & OFF: 1 No. (14)
Step No. used as FIXED. Its ON Steps Fixed & ON: 1 No. (4)
Step No. Utilization limit reached. Masked Steps masked due to utilization limit: 1 No (13)
Note:
At Power up, all the capacitor status are in “Discharge” – D state. In case user wishes to
bypass this waiting time, can do so by pressing < (Left) key.
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
The adjustment is possible on “Default display” by ◄ - LEFT key or ► - RIGHT key. Multiple
strokes of the ◄ key increases the darkness. Similarly, multiple strokes of the ► key reduces
the darkness, making display lighter. After the adjustment, pressing of ◙ - SAVE key ensures
saving the contrast adjustment.
View Parameters
Contrast Contrast
Dark Light
MODE Settings
Save LCD
Contrast View Parameters
The diagram view of “Default Screen” with various keyboard functionalities is self-explanatory.
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
-.- ↑ IOK
MODE
SELECTION
SAVE SETTINGS /
CONFIGURATION
SETTINGS
&
CONFIGURE
VIEW
Various
Parameters
(Within group)
As can be seen from the diagram above, there are two primary Display functions achieved:
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
PFrms = 0.978 C PF-rms. Last letter ‘I’ or ‘C’ for ind. Or cap.
DPF = 0.995 C DPF – Displacement Power Factor
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
VIEW
PHASE VALUES
continued-----------
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
Phase Values
continued-----------
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
Viewing Harmonics
VIEW
HARMONICS
OVERALL THD-F % and THD value
R-Cap.Amp R-Volt-N RY-Volt R-Amp
Y-Cap.Amp Y-Volt-N YB-Volt Y-Amp
B-Cap.Amp B-Volt-N BR-Volt B-Amp
Note that Harmonics for Voltage are displayed as THD-F% and THD-F Value.
Harmonics for Supply current and Capacitor current are displayed as THD-F% and TDD-F%.
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
VIEW
MAXIMUM VALUES
VLN-MAX 244.5 V Supply Voltage Line to Neutral AC rms
252.8 V 255.2 V maximum values for R, Y & B phases.
continued
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Operations manual
DISPLAY – LCD VIEWING:
continued
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BR 5600 R power factor controller
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Operations manual
DISPLAY – LCD VIEWING:
VIEW
STEP UTILIZATION
For Example:
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Operations manual
DISPLAY – LCD VIEWING:
Viewing Auxiliary Functions
This Screen cannot be viewed in
VIEW EASY EDIT – mode “ENAB” (enabled)
AUX. FUNCTION
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BR 5600 R power factor controller
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Operations manual
CONFIGURATION / SETTINGS
All the MODE SELECT group are for setting up various configurations.
* Expert Edit Screen would not appear when Easy Setup Enabled
There are various settings and configurations available in BR5600R. This makes the unit versatile for
most varieties of applications. It’s worth noting that the settings carried out for a specified application
would be totally different than the other application type. Some settings mandate some other functions
& related settings screens to be disabled.
While carrying out the EXPERT EDIT settings, one can observe that some of the screens shown in
further part of the topic of “Settings for BR5600R configuration” may not be seen due to some other
area settings. Users are advised to take note of this.
The details of various functions and their interlocks with regards to other functions are given as a part
of Operations Manual.
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BR 5600 R power factor controller
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Operations manual
CONFIGURATION / SETTINGS:
Function = DISS<
Val=415 Sel= 50
As above 50 or
Function = ENAB 60Hz selection Shift Curser
Val=415 Sel= 50<
Change
Function = ENAB Values
Function = ENAB Val=415<Sel= 50
Val=415<Sel= 50 Function = ENAB
SAVE Val=415<Sel= 50
Function = ENAB
Val=415<Sel= 50
The above flowchart is the general representation for “Navigating” and “Editing” and “Saving” the various
user defined Settings / Configurations.
Note Various actions defined in the flow diagram.
Pressing the ENTER Key on the MODE SELECT screen puts the unit into “User Setting”.
The < symbol would appear next to the Editable Parameter. < symbol shows the variable to be
selected for EDITING.
The < symbol can be moved around the same screen for different variable selection. This can
be done by using the LEFT ARROW Key .
Once the < symbol is seen next to the variable that is to be EDITED, the ENTER key can
be used for EDITING the variable. The variable digit would be seen with a blinking curser.
The variable digit to be edited can be selected by LEFT or RIGHT ARROW Keys.
The digit value can be increased or decreased respectively by UP or DOWN ARROW
Keys.
Note that some digits of the variable may not be increased or decreased due Limit value is
reached. In such case change the other digit of the variable to bring the value within limit.
On completing the editing of a variable, the ENTER Key pressing would save the value
temporarily.
Various screens can be selected by UP or DOWN ARROW Keys.
On completing the Editing of all the settings and configurations, the SAVE Key should be
pressed to permanently save the EDITED variable values. For discarding all the edited settings,
the MODE Key should be pressed.
No Activity for 5-minutes on MODE SETTINGS will bring unit without saving to default screen.
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Operations manual
CONFIGURATION / SETTINGS:
MODE SELECT : EASY EDIT
MODE SELECT
Pressing SAVE Key Saves
EASY EDIT the EASY EDIT settings.
Adjustment of Supply-CT:
EASY EDIT S-Amps Supply measurement Current feedback CT.
PRIM:3500<SEC:5< Primary (PRIM) current Ampere value
Secondary (SEC) current Amp value (1 or 5)
The Capacitor step value is defined in terms of KVAR – Kilo-Volt-Amp-Reactive. This value is at rated
supply Voltage value. The rated supply voltage value is defined by user in EASY EDIT first screen here
above. (L-L: value). User is requested to take the note that KVAR value may not be capacitor name
plate KVAR. As it may be defined at different voltage. The capacitor bank if used along with “Anti-
resonant Detuned Reactors”, the value needs to be calculated by taking inductor effect into account.
The details of capacitor Bank step KVAR calculation can be seen from Annexure-A.
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BR 5600 R power factor controller
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Operations manual
CONFIGURATION / SETTINGS:
For testing the Capacitor Steps Manually, this option is used. This permit turning ON and turning OFF
the capacitor steps by complete user control.
MODE SELECT
TEST CAP STEPS
Checking the control wiring in APFC system for turn ON & OFF the capacitor duty contactors
(or equivalent electro-mechanical devices).
Checking the individual Capacitor banks by turning them ON & OFF. Capacitor health can be
monitored by checking the current through them.
Checking if the supply system parameters are correctly controlled – Reactive Power -Q.
Masking or Un-Masking the capacitor steps manually. Un-Masking the capacitor steps that are
Masked due to “Capacitor health monitoring feature”.
Declaring the capacitor as “FIXED”. By this feature, some banks can be kept permanently ON
during regular Automatic PF correction operation. This is to be done only if User desires the
Fixed capacitive compensation.
During manual ON / OFF capacitor steps, the effect of capacitors can be seen on regular LCD
display parameter view.
Added Note: The arrow down symbol “↓” on LCD display is for indicating steps testing. The symbol is
additionally used for indicating Digital Input status as 0 (zero) = ↑ and 1 (one) = ↓. The digital Input
functionality if enabled, the arrow symbol is prioritized for its functionality and testing mode would not
be controlling the arrow display on LCD. Users are advised to take note.
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CONFIGURATION / SETTINGS:
The wiring setup is to ensure the right Voltage Phases & right Current feedback sequence is connected
to BR5600R from Supply system. Ensuring the Current feedback CTs (Current Transformers) are with
right polarity and synchronized with the right Voltage phases.
In case the wiring sequence is wrongly connected, using the “SETUP WIRING” can correct supply
Voltage & Current synchronization without physically changing the wires.
There are two methods used for setting up wiring without physically change of wiring.
Manual Synchronization allows user to switch ON / OFF the capacitors and check the right values of
fundamental Power (Active & Reactive) by selecting the right Voltage / Current combination and the
Current CT polarity.
For Manual Wiring Setup, a good understanding of the 4 – Quadrant Power and Power Factor Correction
is necessary. With this, the 100% success rate for synchronization can be achieved in Manual
Synchronization.
Automatic Synchronization carries out the supply Voltage & Current feedback synchronization
automatically. For automatically carrying out the job, it needs to turn ON and turn OFF the capacitor
banks. Therefore, it is necessary to complete the User settings by either EASY EDIT or EXPERT EDIT.
Note: Automatic Synchronization option is available to the user if balanced 3-phase capacitor banks are
available. This also means that Automatic Synchronization would not be available if capacitor banks
declared by user are either “Individual Single-Phase Banks” or “Banks are not connected”.
Disclaimer:
The Automatic wiring Setup in case of highly fluctuating loading conditions may sometimes fail to detect
the right wiring sequence. In such case it will force user to carry out the Manual Wiring Setup. The
success chances for Automatic wiring setup are lower with
• Load fluctuations are high and abrupt.
• APFC reactive power injection capacity is far lower than the supply system loading.
This feature therefore should be used as a convenience feature. User should understand that there is a
possibility of failure and in such case Manual Wiring setup or the Physical Wiring change would be
mandatory.
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CONFIGURATION / SETTINGS:
MODE SELECT
SETUP WIRING
ON SUCCESS ON FAILURE
Note that once the Wiring Setup is a Success, the unit BR5600R would remember the success sequence
throughout its life. Auxiliary Supply Powering down would not disturb this memorized sequence.
In case of any physical changes in the wiring, the Automatic Wiring Setup can be run. In case user
wishes to abort the Automatic Wiring process, can do so by pressing the ENTER Key.
There is an option in EXPERT EDIT to automatically get into the “Automatic Wiring Setup” at BR5600R
Powering Up. If such an option is selected, the unit would perform the Automatic Wiring Setup at every
Power Up of Auxiliary supply. Number of tries for Automatic Wiring can be user defined.
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CONFIGURATION / SETTINGS:
MODE SELECT
SETUP WIRING
WIRING POSITION
WIRING POSITION R-Phase +<SCT-R
R-Phase + SCT-R< + or - change
WIRING POSITION
Y-Phase + SCT-Y< As in
above
WIRING POSITION screen
B-Phase +<SCT-B
RP1= 365.10 K
RQ1= 102.78 K
YP1= 365.10 K
YQ1= 102.78 K
CAPACITOR TEST < BP1= 365.10 K
BQ1= 102.78 K
CAPACITOR TEST <
As per the previous page keyboard / display navigation structure, user can shift between the:
2. Fundamental Power P1 & Q1 (Active & Reactive) screens (per Phase screens)
In manual wiring, one can try declaring various combinations of CT phase positioning and CT polarity.
With right combination, the Power of R, Y, B phases would remain unaltered for P1 – Active Power and
would change Q1 – Reactive Power as per the value of capacitor added / removed.
The right combination should be checked for all the three phases.
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CONFIGURATION / SETTINGS:
There are various settings with regards to time and values that need to be reset by the User. Such
operations are performed in this section.
MODE SELECT
RESET TIME-Val
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CONFIGURATION / SETTINGS:
Expert Edit is used for Configuring and carrying out various settings. It has multiple Sub-Headings.
These are shown hereunder:
MODE SELECT This screen can be seen only if EASY EDIT is disabled.
EXPERT EDIT
Pressing ◙ Key SAVEs the
EXPERT EDIT settings.
Expert Edit:
The “EXPERT EDIT” Mode is enabled only if the “EASY EDIT” is kept Disabled (DISS).
The Expert Edit menu is used for getting access to the Specialized and Refined functionality
settings of BR5600R.
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CONFIGURATION / SETTINGS:
MODE SELECT : EXPERT EDIT : MEASUREMENT
EXPERT EDIT
Measurement on supply Voltage / Current configuration:
MEASUREMENT There are different configurations.
Viz. 1 – Voltage 3-ph / 3 or 4 wires. Current 3 CT
2 – Voltage 3-ph / 3 wires. Current 2 CT
3 – Voltage 2-ph / 2 wires (L–L) Current 1 CT
MEAS VA conf: 1< 4 – Voltage 1-ph / 2 wires (L–N) Current 1 CT
(Refer the diagrams in initial part of this Operations Manual.)
CAP. CT conf: 3< Capacitor current CT feedback configuration: There are 4
different configurations for Capacitor current feedback.
Viz. 0 – No capacitor current feedback connected.
1 – One number capacitor current feedback CT.
2 – Two number capacitor current feedback CTs.
3 – Three number capacitor current feedback CTs.
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CONFIGURATION / SETTINGS:
Aux.INPUT Offset
Vac:238 0950<
The last Screen in measurement section is for calibration of Auxiliary Input AC voltage measurement.
The Calibration settings are to be carried out by user if and only if the Auxiliary input functionality as
CONT-V. Otherwise, there is no need to carry out any calibration process, and screen would not be
available for user to edit.
A new BR5600R Auxiliary input is factory calibrated for perfect sinusoidal AC voltage input. The
Operating conditions at site of commissioning may be different. The voltage may differ from perfect
sinusoidal waveshape. Calibration is needed only under such conditions. For a given site, it is
normally carried out just once. (At the time of commissioning)
Instrument needed: AC voltage measurement meter (RMS value). Range 0 to 300Vac. Accuracy 1%.
Apply AC voltage that is going to be used Auxiliary Input channel.
Check the AC voltage with a measurement meter.
Check the AC voltage displayed on the BR5600R screen.
Adjust the Offset count suitably so as to match the BR5600R screen displayed reading equal
to the meter displayed value.
Once the readings on BR5600R and the meter are matched, ensure SAVE Key is pressed.
Now the unit is calibrated as per site conditions.
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CONFIGURATION / SETTINGS:
EXPERT EDIT
CAPACITOR STEPS
Details on Power Factor settings + Resolution + Offset is
explained in Annexure-C.
TARGET PF GRID< TARGET D-PF: The desired Power Factor is set on this
VALUE IND<0.996< screen. It is normally set for GRID (EB supply) & can be set
for GENR (Generator) for Aux.Input functionality is selected
for GRID / GENERATOR. The target value can be IND
(inductive) or CAP (capacitive). The Target Value can be set
up to 3 digits after decimal.
RESOLUTION x1.5< RESOLUTION MULTIPLIER: The value of multiplier can be
OFFSET: 070%< set from 1.1 to 9.9.
OFFSET: The No action Band “Offset” can be adjusted from
000% to 100%. Default value is 050%.
continued-----------
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CONFIGURATION / SETTINGS:
USAGE CONSTANTS:
In the above Usage Count formula, the Constants C and T are
USAGE CONSTANTS user set value depending upon the type of capacitors, site
C: 01< T: 10< conditions of Voltage fluctuations, Harmonics etc.
As per the manufacturer of capacitor – these constants may
change. Giving these editable constants is to keep flexibility
of adjustments.
When C is set to zero, the on / off consideration is removed &
when T is set to zero, the time consideration is removed.
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CONFIGURATION / SETTINGS:
EXPERT EDIT
FAULTS
FAULT OCF:006< Screen selects Fault Number, Selected Fault is Enabled ENAB
ENAB< ACT:LDATA< or Disabled DISS and if selected, the Action ACT on fault detection
OCF LMT:130.0%< This screen is accessed immediately after a specified Fault no. is
RST:120.0%< Enabled. Set the Fault value Limit LMT and Resume RST value.
AUTO-RESET: OCF If the fault resume is to by User pressing ENT Key or after a
TIME< Sec: 060< specific time, these can be set on the screen.
Faults-
There are multiple type of faults that are detected. BR5600R can detect 47 different faults. The action
against the detected faults can be of different nature. The detailed Faults listing is in the next pages of
this document.
Based on the Fault Number, the abbreviation showing 3 characters would appear.
E.g., OCF : Over Current Fault
UVF : Under Voltage Fault
Fault can be enabled ENAB or disabled DISS. In present version of BR5600R, there are 27 Faults.
Trip limit for the selected fault appears on this next screen.
Limit Value: LMT can be set as per the requirement &
Resume Value (Reset of Fault): RST is set.
This is to avoid fault hunting by introduction of hysteresis between LMT & RST.
Some faults can be “auto-reset” by timer or by pressing the key on front keyboard.
Timer-Reset / Human-Reset can be set to decide reset action. For timer, the time in Seconds Sec: is
to be adjusted & set.
The Last screen above can be set for: LIMT – Limit set auto-reset.
ENTR – By pressing ENT Key by user.
TIME – Automatically after the time elapse.
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CONFIGURATION / SETTINGS:
011 CUF Capacitor Under Current detection in any one or more phases. CUR
CUY
CUB
CUF
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CONFIGURATION / SETTINGS:
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023 AVH Auxiliary Input AC Voltage is Higher than the set limit. AVH
024 UBV Unbalance in Voltages of Phase to Neutral exceeding the set UBV
limit
025 UBA Unbalance in Supply current is exceeding the set limit UBA
026 UBC Unbalance in Capacitor banks current is exceeding the set limit UBC
027 VhF Line to Line Voltage Over harmonics detection in any one or VhR
more phases. VhY
VhB
VhF
For User convenience, the number of Fault settings for three phases have been put together. This is
done to reduce & limit the number of fault settings to 27.
All the individual faults in data logging are logged as overall faults as well as individual phase faults.
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CONFIGURATION / SETTINGS:
EXPERT EDIT
AUX. I/O
Auxiliary Input- BR5600R has one Aux. input channel. It
is used with AC Sinusoidal Voltage ranging from 0V~ to
300V~. It can be assigned with one function. This function
AUX INPUT user can select from list available. Total six (6) different
FUNCTION NONE< functions list is available.
Details of all these functions is in subsequent part of this
document.
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CONFIGURATION / SETTINGS:
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CONFIGURATION / SETTINGS:
The last function assigned to AO1 is automatically selected when Auxiliary Input function of 32S-MI or
32S-FI is selected.
In this case AO1 can only be assigned as 32S-FO or 32S-MO functionality.
Specifically, if Auxiliary Input is: 32S-MI then Auxiliary Output (AO1) is assigned 32S-MO functionality.
If Auxiliary Input is: 32S-FI then Auxiliary Output (AO1) is assigned 32S-FO functionality.
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EXPERT EDIT
COM 1-RS-232 COM 1 post usage- COM 1 (RS-232) serial communication
port used for either the PC-App RS-232 communication or for
AT+ communication with GPRS modem confirming.
3GPP TS 51.010-1 Rev.
TCP-V01 Https:/
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CONFIGURATION / SETTINGS:
TCP-V01
TCP-V01 communication option is provided in BR5600R for maintaining compatibility with the earlier
version of PF controller model (BR5508HTG). It is recommended to use the TCP-V01 option only in the
case of direct replacement of BR5508HTG unit. For new installations, selection of this option is not
recommended.
With TCP-V01 communication protocol selected, the data logging is kept compatible with BR5508HTG
unit.
Details of TCP-V01 communication with GPRS modem connection is available on the TDK’s Application
Note Named Communication Protocol of BR5508-HTG Controller Rev5.pdf. Users are recommended to
go through the details before selecting this communication option.
Https:/
The Communication document files can be availed from TDK India offices on request.
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CONFIGURATION / SETTINGS:
EXPERT EDIT
COM 2-RS-485
COM 2- Usage is RS-485 serial communication port.
Communication Options
0: DISABLE – COM 2 is not used
PROTOCOL USAGE 1: MODBUS-RTU – Works with Protocol Modbus-RTU
1:MODBUS-RTU < 2: MODBUS-ASC – Works with Protocol Modbus-ASCII
3: PC-Comm – Communication with PC-App software
PC-App software is “PF-Explorer V2.1”.
“PFC DATAVIEW V1.0” software is a Windows* OS based PC software. This software communicates
with BR5600R on RS-232 and / or RS-485 communication ports. It is useful for Logged data download
and viewing in MS-Excel* format. The details of the PC-App communication are detailed in “PF
Explorer V2.1” software Operations Manual.
The software can be availed from TDK India offices on request.
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2
Various types of Data are stored in BR5600R non-volatile memory (E PROM):
Data Logging in BR5600R is linked through modes of communication.
TCP-V01 Communication protocol is old protocol. This feature is maintained in BR5600R for the purpose
of maintaining upward compatibility with earlier model (BR5508HTG). But this puts some restrictions on
“Data Storage formats”. Therefore, for TCP-V01 communication protocol selection, the “User accessible
data” is restricted with following limitations.
o Data for first 8 capacitor banks is available.
o Data record length is fixed as 128-Bytes.
o User accessible data availability of Faults/Events & Interval only.
Therefore, it is advisable to use TCP-V01 protocol only if unit is used as direct replacement for
BR5508HTG. For other applications, it’s advisable to select other options of communication to have a
regular data log method.
Settings in BR5600R:
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DATA Logs with any mode of communication except TCP-V01, Ask for Data Logging Parameters Listing
Excel document from TDK office. Due to size, it is not accommodated as part of this document.
The following Table is useful to know the “Time Period” for which the data can be stored.
For https:/, PC-App communication selection, the logged data in following time frame can be acquired
from internal memory of BR5600R.
Following Table is useful to know the “Time Period” for which the authentic data can be stored. For
TCP-V01 communication protocol selection, the logged data in BR5600R memory is.
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CONFIGURATION / SETTINGS:
MODE SELECT : EXPERT EDIT : GENERAL
EXPERT EDIT
GENERAL
TIME SET TO : N< Time Setting- Time needs to be set while first time power up
or if unit is kept in Power-Off condition for more than 10 days.
HOURS:10<MIN:20< Setting Y & HH (Hour) MM (Minutes) + save is needed.
Remote Operation Type 1 (REM1) : The supply measurement parameters like Voltage, Current, Power
(P1 & Q1) are written through MOD-Bus communication from Remote Master MOD-Bus Server. The
Capacitor switching action is carried out by BR5600R in REM1 by using the measurement values from
Remote master.
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Non-Volatile Memory Reading / Writing operation Status AND Error / Information messages
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STATUS & ERROR MESSAGES:
Non-Volatile Memory Reading / Writing operation Status AND Error / Information messages
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STATUS & ERROR MESSAGES:
Non-Volatile Memory Reading / Writing operation Status AND Error / Information messages
Interval Data Data acquired for every interval is logged in the Non-volatile
LOG memory.
Event Data Data acquired for Event detected (including fault) is logged in the
LOG Non-volatile memory.
Daily Data Data acquired for 24Hrs Daily log (at change of date detection) is
LOG logged in the Non-volatile memory.
BANK SETUP In “Easy Edit” => “Auto Configuration”, displays this message
***SUCCESS*** when Capacitor Banks VAR values are successfully acquired.
BANK SETUP In “Easy Edit” => “Auto Configuration”, displays this message
:::FAIL::: when Capacitor Banks VAR values can-not be acquired.
BANK SETUP In “Easy Edit” => “Auto Configuration”, displays this message
NOT Possible
WIRING SETUP when other settings do not permit the auto-config process.
BANK SETUP In “Easy Edit” => “Auto Configuration”, displays this message
ABORT when user action of aborting the process by pressing key.
Log Data Erasing In MODE SELECT => RESET TIME-VAL => DATA LOGGING if
InProcess 82.3% selected “Y” for RESET, this screen appears. to abort process
Note that all the Message Convey screens would appear on the front LCD display screen for a short
time span. These are information messages about some specific action carried out by the unit.
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STATUS & ERROR MESSAGES:
Sr. No. Event / Events and Faults Description LCD Location Type
Fault display in Error
Word
1 IOK I am OK. No Event / Fault IOK EW8-15 Status
2 UVR Measurement Under Voltage. R-phase UVF EW1-1 S-Fault
3 UVY Measurement Under Voltage. Y-phase UVF EW1-3 S-Fault
4 UVB Measurement Under Voltage. B-phase UVF EW1-5 S-Fault
5 OVR Measurement Over Voltage. R-phase OVF EW1-0 S-Fault
6 OVY Measurement Over Voltage. Y-phase OVF EW1-2 S-Fault
7 OVB Measurement Over Voltage. B-phase OVF EW1-4 S-Fault
8 ZVR Measurement Zero Voltage. R-phase ZVF EW6-0 S-Fault
9 ZVY Measurement Zero Voltage. Y-phase ZVF EW6-1 S-Fault
10 ZVB Measurement Zero Voltage. B-phase ZVF EW6-2 S-Fault
11 SUF Measurement Under Frequency SUF EW2-3 S-Fault
12 SOF Measurement Over Frequency SOF EW2-2 S-Fault
13 OCR Measurement Over Current. R-Phase OCF EW1-6 S-Fault
14 OCY Measurement Over Current. Y-Phase OCF EW1-8 S-Fault
15 OCB Measurement Over Current. B-Phase OCF EW1-10 S-Fault
16 OCN Measurement Over Current. Neutral OCN EW2-10 S-Fault
17 ZCR Measurement Zero Current. R-Phase ZCF EW6-3 S-Fault
18 ZCY Measurement Zero Current. Y-Phase ZCF EW6-4 S-Fault
19 ZCB Measurement Zero Current. B-Phase ZCF EW6-5 S-Fault
20 COR Capacitor Over Current. R-Phase COF EW1-12 C-Fault
21 COY Capacitor Over Current. Y-Phase COF EW1-14 C-Fault
22 COB Capacitor Over Current. B-Phase COF EW2-0 C-Fault
23 CEL Capacitor Earth Leakage fault CEL EW3-7 C-Fault
24 CUR Capacitor Under Current. R-Phase CUF EW1-13 C-Fault
25 CUY Capacitor Under Current. Y-Phase CUF EW1-15 C-Fault
26 CUB Capacitor Under Current. B-Phase CUF EW2-1 C-Fault
27 VHR Measurement Voltage over Harmonics.R-phase VHF EW6-6 S-Fault
28 VHY Measurement Voltage over Harmonics.Y-phase VHF EW6-7 S-Fault
29 VHB Measurement Voltage over Harmonics.B-phase VHF EW6-8 S-Fault
30 CHR Measurement Current over Harmonics. R-phase CHF EW6-9 S-Fault
31 CHY Measurement Current over Harmonics. Y-phase CHF EW6-10 S-Fault
32 CHB Measurement Current over Harmonics. B-phase CHF EW6-11 S-Fault
33 ChR Cap. Current over Harmonics. R-phase ChF EW2-5 C-Fault
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STATUS & ERROR MESSAGES:
Sr. No. Event / Events and Faults Description LCD Location Type
Fault display in Error
Word
34 ChY Cap. Current over Harmonics. Y-phase ChF EW2-6 C-Fault
35 ChB Cap. Current over Harmonics. B-phase ChF EW2-7 C-Fault
36 ULR Measurement Under Load. R-phase. (i.t.o. Watt) ULF EW1-7 S-Fault
37 ULY Measurement Under Load. Y-phase. (i.t.o. Watt) ULF EW1-9 S-Fault
38 ULB Measurement Under Load. B-phase. (i.t.o. Watt) ULF EW1-11 S-Fault
39 EOT External Over Temperature (Thro' Pt-100) EOT EW2-11 Aux-Fault
40 MOT MCU Over Temperature MOT EW2-4 Aux-Fault
41 OBR Out of Banks - VAR shortage - R-phase OBF EW6-12 C-Fault
42 OBY Out of Banks - VAR shortage - Y-phase OBF EW6-13 C-Fault
43 OBB Out of Banks - VAR shortage - B-phase OBF EW6-14 C-Fault
44 PFR Leading Displacement Power Factor in R-phase PFL EW3-10 Status
45 PFY Leading Displacement Power Factor in Y-phase PFL EW3-11 Status
46 PFB Leading Displacement Power Factor in B-phase PFL EW3-12 Status
47 MDW Maximum Demand (Kilo-Watt) Exceed MDW EW3-2 S-Fault
48 MDV Maximum Demand (KVA) Exceed MDV EW3-3 S-Fault
49 AVL Aux. Input Control ac voltage low AVL EW3-13 Aux-Fault
50 AVH Aux. Input Control ac voltage high AVH EW3-14 Aux-Fault
51 UBV Unbalance in 3 phase voltage UBV EW3-4 S-Fault
52 UBA Unbalance in 3 phase meas. Current UBA EW2-9 S-Fault
53 UBC Unbalance in 3 phase cap. Current UBC EW3-5 C-Fault
54 VRH Measurement Voltage over Harmonics. R-Y VhF EW6-15 S-Fault
phases L-L voltage
55 VYH Measurement Voltage over Harmonics. Y-B VhF EW7-0 S-Fault
phases L-L voltage
56 VBH Measurement Voltage over Harmonics. B-R VhF EW7-1 S-Fault
phases L-L voltage
57 UVF Under voltage in any one or three phases - L-L or UVF EW7-2 S-Fault
L-N value.
58 OVF Over voltage in any one or three phases - L-L or L- OVF EW7-3 S-Fault
N value.
59 PFL Overall D-PF is leading PFL EW7-4 Status
60 OBF Out of banks for any one of the phases OBF EW2-8 C-Fault
61 ZVF Zero Voltage detected in all three phases ZVF EW3-1 S-Fault
62 OCF Over current in any 1 of 3 S-CT OCF EW7-5 S-Fault
63 ZCF Zero Current detected in all three S-CT ZCF EW3-0 S-Fault
64 COF Over current in any 1 of 3 C-CT COF EW7-6 C-Fault
65 CUF Under current in any 1 of 3 C-CT CUF EW7-7 C-Fault
66 VHF Over Voltage harmonics in any one of three phase VHF EW3-8 S-Fault
with L-N sensing.
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STATUS & ERROR MESSAGES:
Sr. No. Status / Status & System Errors Description Display Location Type
Errors in Error
Word
67 VhF Over Voltage harmonics in any one of three VhF EW7-8 S-Fault
phases with L-L sensing.
68 CHF Over Current harmonics in any one of three S-CTs. CHF EW3-9 S-Fault
69 ChF Over Current harmonics in any one of three C-CTs. ChF EW7-9 C-Fault
70 ULF Active Power under load detected in any one of the ULF EW7-10 S-Fault
three phases.
71 ERC EEPROM Read error 1 - calibration data (System ERC EW5-0 Sys-Fault
Error fault)
72 ERP EEPROM Read error 2 - parameter data (System ERP EW5-1 Sys-Fault
Error fault)
73 ERE EEPROM Read error 3 - EWPF data (System Error ERE EW5-2 Sys-Fault
fault)
74 ERL EEPROM Read error 4 - logged data (System ERL EW5-3 Sys-Fault
Error fault)
75 ERU EEPROM Read error 5 - Unit info data (System ERU EW4-2 Sys-Fault
Error fault)
76 EWC EEPROM Write error 1 - calibration data (System EWC EW5-4 Sys-Fault
Error fault)
77 EWP EEPROM Write error 2 - parameter data (System EWP EW5-5 Sys-Fault
Error fault)
78 EWE EEPROM Write error 3 - EWPF data (System Error EWE EW5-6 Sys-Fault
fault)
79 EWL EEPROM Write error 4 - logged data (System Error EWL EW5-7 Sys-Fault
fault)
80 EWU EEPROM Write error 5 - Unit info data (System EWU EW4-3 Sys-Fault
Error fault)
81 RTC RTC needs resetting (Real Time clock) (Unit RTC EW2-14 Status
Power down 30+days)
82 WDR Watch Dog timer Reset (System Error fault) WDR EW4-9 Sys-Fault
83 SyF Automatic Synchronization Failure SyF EW4-0 Aux-Fault
84 SyA Automatic Synchronization Aborted by user SyA EW4-10 Status
85 SyP Automatic Synchronization Pass SyP EW4-11 Status
86 CTM Capacitor Testing (Manual) Mode CTM EW4-1 Status
87 ASM Automatic Synchronization Mode(user) ASM EW4-12 Status
88 PEM Parameter Editing & Configuration Mode (not on PEM EW4-13 Status
LCD only log)
89 RM1 Operation in Remote 1 mode by COM 2 RM1 EW4-4 Status
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STATUS & ERROR MESSAGES:
Sr. No. Status / Status & System Errors Description Display Location Type
Errors in Error
Word
90 RM2 Operation in Remote 2 mode by COM 2 RM2 EW4-5 Status
91 CBF One or More Capacitors declared faulty. Bank VAR CBF EW3-15 C-Fault
out of tolerance
92 4GN GPRS modem on COM1 - Network weak 4GN EW4-15 Aux-Fault
93 PUP Unit Power UP event (not on LCD only log) PUP EW2-13 Status
94 PDW Unit Power DOWN event (not on LCD only log) PDN EW2-12 Status
95 HLD Hold status from Aux. Input command or 32S-Mi HLD EW4-7 Status
on Aux.Input function
96 DSB Disable status on Aux. input or as 32S-Fi on Aux. DSB EW4-6 Status
Input functionality
97 CM1 Com1 port RS-232 communication Error CM1 EW5-8 Aux-Fault
98 CM2 Com2 port RS-485 communication Error CM2 EW5-9 Aux-Fault
99 AMG Generator Mode in enable state AMG EW4-8 Status
100 PSV Parameters Saved Event (not on LCD only log) PSV EW5-10 Status
101 CRT Capacitor bank VAR values reset (not on LCD only CRT EW5-11 Status
log)
102 MRT Max. Values reset (not on LCD only log) MRT EW5-12 Status
103 UCR Cap. Bank utilization counter reset (even 1) (not on UCR EW5-13 Status
LCD only log)
104 WST Wiring positioning saved in Manual Sync. (not on WST EW5-14 Status
LCD only log)
105 EOF Energy Counters Overflow event EOF EW4-14 Status
106 NVF EEPROM fault (System Error fault) NVF EW2-15 Sys-Fault
107 VOL Voltage control - Under voltage cap additn VOL EW8-0 Status
108 VOH Voltage control - Over voltage cap remove VOH EW8-1 Status
109 VOR Voltage control Over-ride - VAR operation VOR EW8-2 Status
110 ASP Automatic Synchronizing pending ASP EW7-11 Status
111 ABD Auto Configuration(Easy Edit) operational ABD EW7-12 Status
112 ABP Auto Configuration (Easy Edit) is pending. ABP EW7-13 Status
113 MAN Power up manual mode MAN EW7-14 Status
114 BDF Auto Bank Detection Fail BDF EW8-3 Aux-Fault
115 BDA Auto Bank Detection Abort BDA EW8-4 Status
116 BDP Auto Bank Detection Pass BDP EW8-5 Status
76
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
Sr.
Interlock Applicability Affected Function
No.
1 MODE - EASY EDIT selection - ENAB: Enabled Viewing - Auxiliary Function - Screen absent
MODE SELECT - EXPERT EDIT - Screen absent
2 MODE - EASY EDIT - C-Amps SEC: X Viewing - Overall Values - AmpC-Av = N/A A
Viewing - Overall Values - Unbalence C: N/A %
Viewing - Phase Values - AmpC-EL N/A A
Viewing - Harmonics - Cap. RYB ph. Amp screens absent
Viewing - Harmonics - Cap. RYB 2nd to 31st spectrum absent
Viewing - Max. Values - ACEL MAX N/A A
Viewing - Max. Values - AmpC-MAX screen absent
Viewing - Max. Values - CATDD MAX N/A A
MODE SELECT - SETUP WIRING - MANUAL SYNC - view P/Q/CQ. CQ absent
3 MODE - EXPERT EDIT - MEASUREMENT MODE SELECT - SETUP WIRING - AUTO SYNC. Screen is absent
MEASUREMENT VA CONF: 2 (2 S-CT) MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP CONFIG: Only BAL option
MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP No. BAL & NOT option
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
MODE SELECT - EXPERT EDIT - GENERAL - POWERUP: SYNCRO. option absent
4 MODE - EXPERT EDIT - MEASUREMENT Viewing - Overall Values - Unbalance for V: N/A & A: N/A is observed
MEASUREMENT VA CONF: 3 (1 S-CT Quadrature) Viewing - Overall Values - V-Phase Sequence Screen is absent
Viewing - Phase Values Screen is absent.
Viewing - Harmonics - Only R-ph S-CT and Y-B phases Voltage Harmonics seen
Viewing - Max. Values - VLL-MAX N/A A for Line to Line voltage values not measured.
Viewing - Max. Values - Amp-MAX N/A A for Line current values not measured.
Viewing - Max. Values - ASN-MAX N/A A for Neutral current values not measured.
Viewing - Max. Values - for fundamental power P1 & Q1 not seen.
MODE SELECT - SETUP WIRING - MANUAL SYNC. - S-CT position only for R-Voltage
MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP CONFIG: Only BAL option
MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP No. BAL & NOT option
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
5 MODE - EXPERT EDIT - MEASUREMENT MODE SELECT - EXPERT EDIT - MEASUREMENT - Rated Voltage is Line-Neutral
MEASUREMENT VA CONF: 4 (1 S-CT In-phase) Viewing - Overall Values - Unbalance for V: N/A & A: N/A is observed
Viewing - Overall Values - V-Phase Sequence Screen is absent
Viewing - Phase Values Screen is absent.
Viewing - Harmonics - Only R-ph S-CT and R-N phase Voltage Harmonics seen
Viewing - Max. Values - VLN-MAX N/A A for other Ph-N values not measured.
Viewing - Max. Values - Amp-MAX N/A A for other current values not measured.
Viewing - Max. Values - ASN-MAX N/A A for Neutral current values not measured.
Viewing - Max. Values - for fundamental power P1 & Q1 not seen.
MODE SELECT - SETUP WIRING - MANUAL SYNC. - S-CT position only for R-Voltage
MODE SELECT - EXPERT EDIT - MEASUREMENT - RATED MEAS VOLT - LN (not LL)
MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP CONFIG: Only BAL option
MODE SELECT - EXPERT EDIT - CAP. CONTROL - STEP No. BAL & NOT option
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
77
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
INTERLOCKS WITH CONFIGURATION SETTINGS
Sr.
Interlock Applicability Affected Function
No.
8 MODE - EXPERT EDIT - MEASUREMENT Viewing - Overall Values - AmpC-Av: NA A
CAPACITOR CT CONF: 0 (0 C-CT) Viewing - Overall Values - CQ1: NA *VAR Line on screen is absent
Viewing - Overall Values - Unbalence C: N/A %
Viewing - Phase Values - AmpC-RYB N/A A for Y and B phase capacitor current.
Viewing - Phase Values - AmpC-EL N/A A (value not shown)
Viewing - Max. Values - ACEL-MAX N/A A for other current values not measured.
Viewing - Max. Values - CATDD MAX N/A A
MODE SELECT - SETUP WIRING - MANUAL SYNC. - C-CT for R, Y & B not shown
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
MODE SELECT - EXPERT EDIT - Aux.I/O - AUX OUTPUT - Cap-EL 06 is not seen
Viewing - STEP VAR: Values takes minimum 10Nos ON/OFF of specific bank to update
9 MODE - EXPERT EDIT - CAP CONTROL MODE SELECT - SETUP WIRING screen is absent.
STEP CONFIG: UNBAL setting. MODE SELECT - EXPERT EDIT - GENERAL - POWERUP: SYNCRO. option absent
MODE SELECT - EXPERT EDIT - CAP CONTROL - STEP No. : BAL option absent
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
MODE SELECT - EXPERT EDIT - Aux.I/O - AUX OUTPUT - Cap-EL 06 is not seen
10 MODE - EXPERT EDIT - CAP CONTROL MODE SELECT - SETUP WIRING screen is absent.
STEP CONFIG: BAL+UNBAL setting. MODE SELECT - EXPERT EDIT - GENERAL - POWERUP: SYNCRO. option absent
MODE SELECT - EXPERT EDIT - FAULT - Some Faults cannot be enabled.
MODE SELECT - EXPERT EDIT - Aux.I/O - AUX OUTPUT - Cap-EL 06 is not seen
11 MODE - EXPERT EDIT - COM 1-RS-232 - USAGE: MODE SELECT - EXPERT EDIT - COM 1-RS-232: APN SET screen is absent.
Usage PC-Comm is set MODE SELECT - EXPERT EDIT - COM 1-RS-232: RT DATA FRAMEs screen absent.
MODE SELECT - EXPERT EDIT - COM 1-RS-232: URL (in HTTPS:/) screen is absent.
MODE SELECT - EXPERT EDIT - COM 1-RS-232: SERVER IP V4 (in TCP-V01) absent.
MODE SELECT - EXPERT EDIT - COM 1-RS-232: PORT (in TCP-V01) absent.
12 MODE - EXPERT EDIT - COM 1-RS-232 - USAGE: MODE SELECT - EXPERT EDIT - COM 1-RS-232: URL (in HTTPS:/) screen is absent.
Usage TCP-V01 is set MODE SELECT - EXPERT EDIT - DATA LOGGING - LOG.LEN: value cannot be set.
13 MODE - EXPERT EDIT - COM 1-RS-232 - USAGE: MODE SELECT - EXPERT EDIT - COM 1-RS-232: SERVER IP V4 (in TCP-V01) absent.
Usage Https:/ is set MODE SELECT - EXPERT EDIT - COM 1-RS-232: PORT (in TCP-V01) absent.
14 MODE - EXPERT EDIT - COM 2-RS-485 - USAGE: MODE SELECT - EXPERT EDIT - GENERAL: SET REMOTE MODE screen absent
Usage PC-Comm or DISABLE is set MODE SELECT - EXPERT EDIT - GENERAL: RM-OPERA TIMEOUT screen absent
15 MODE - EXPERT EDIT - GENERAL - ….. MODE SELECT - EXPERT EDIT - GENERAL: RM-OPERA TIMEOUT screen absent
SET REMOTE MODE: DISS
16 MODE - EXPERT EDIT - GENERAL - … User cannot enter MODE SELECT - EXPERT EDIT without setting correct password
PASSWORD SETTING: Enable
78
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
The accuracy of Power Factor correction system to correct the Power Factor is primarily dependent
upon the Capacitor bank value (VAR) selection. The bank selection gives the RESOLUTION of the VAR
adjustment.
Important Criteria for Capacitor bank selection.
Capacitor banks should be always selected in the configuration as X1:1:2:4:8….. Or
X1:1:3:6:12….. Or X1:2:4:8…. Etc. This ensures that with any combination of the capacitor
banks, the difference between the two successive combinations is “1”. Any other combination
like X1:3:3:4…. Will give difference between successive combinations as “2” in some cases and
“1” in some cases. This means the RESOLUTION of the PF correction system in second case
is “2”. In such case, the NO ACTION band is adjusted > 2, to avoid hunting of capacitor banks
switching.
The value of Capacitor Bank should be considered at supply rated voltage. (Capacitor Name
plate VAR values may be different at different voltages).
In case of usage of harmonic blocking reactors (anti-resonant detuned reactors) with capacitor
banks, the effective value of capacitor – reactor series combination at rated voltage should be
considered as Step reactive power.
For PF correction systems using 3-phase balanced capacitors + individual phase capacitors for
reactive power unbalance, RESOLUTION by smallest individual phase capacitors i.t.o. reactive
power – VAR should be equal to or less than 1/3 value of Balance capacitor smallest bank VAR.
A. Unit is for switching ON / OFF the capacitor Banks by usage of “Capacitor duty Electro-
mechanical Contactors”. (Thyristor switched Capacitor – TSC switched units usage mandates
the usages of BR5600T model, thus, BR5600R should not be used with such RTPFC systems)
B. Maximum supply AC voltage of 250V~ and maximum current loading up to 0.5Amp~ should be
available for Capacitor duty Contactor/s switch ON command from BR5600R. Usage of R-C
snubbers across the Contactor actuators is highly recommended for better maintenance
durability standards.
C. Contactor actuator voltage should be monitored for Under Voltage value. UV at actuator of
Capacitor duty contactors causes chatter. BR5600R Aux. Input can be used for AC volt
monitoring if not used for other functionality.
D. The measurement supply rated voltage availability at the BR5600R terminals should be within
a specification given range. For higher voltage systems feedback, usage of Potential
Transformers (PTs) is mandatory.
E. The measurement Current feedback should be from Class 1 accuracy (or better) measurement
class CTs. The VA burden offered by BR5600R across its terminals is < 1VA. User is advised
to use the right VA burden CT rating, depending upon the wire size and feedback wire length.
F. The capacitor Current feedback should be preferably from Class 0.5 accuracy (or better)
measurement class CTs. The VA burden across the terminals is <1VA. User is advised to use
the right VA burden CT rating, depending upon the CT usage (These CTs would be normally
placed within the PF correction system).
G. The auxiliary supply to the unit should be within the specifications given range of 90V~ to 485V~.
For Higher voltage systems, ensure the usage of step-down transformer for right Auxiliary
Voltage values.
79
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
COMMISSIONING INSTRUCTIONS:
Pre-Energizing instructions:
CT secondary terminals (for measurement CTs and Capacitor current CTs) should always be
kept shorted.
Ensure that PF system is checked for all the routine tests like, wiring continuity and megger /
HV insulation test.
Ensure the right tightening of the Power Connection terminals and joints and lugs crimping.
Keep the capacitor banks disconnected. (By either HRC fuse removal or SFU / MCCB / Circuit
breaker in off condition).
Post-Energizing instructions:
After Pre-Energizing process, turn-on the MCCB / Breakers / fuses for the capacitor banks.
Keeping the BR5600R in “TEST CAPACITOR STEPS”, turn ON the Capacitor bank steps one
by one. Check the capacitor current in all the three phases. (Can check by clamp on Ammeter
or check on the display of BR5600R). Ensure the right current value depending upon the step
VAR rating requirements.
In case of EASY EDIT the Capacitor bank VAR values and correct Voltage / Current feedback
synchronization be done with AUTO CONFIG.
Alternately, in EASY or EXPERT EDIT, capacitor banks VAR values to be manually stored in
BR5600R.
Check the Auxiliary Input function like ACV measurement value or any other assigned digital
input function.
Check the Auxiliary Outputs function assigned.
80
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
COMMISSIONING INSTRUCTIONS:
Continued …….
Go to the MODE SELECT – SETUP WIRING function. Either use the Automatic or Manual Sync
for ensuring that the supply is well synchronised. The synchronization correctness is checked
by observing the right Per Phase Active & Reactive Power values and their sign +/-.
In case BR5600R is set using EXPERT EDIT, ensure the right DATE / TIME is set on the unit.
For communication related requirement, ensure the right Baud rate and unit ID is set on the
unit. GPRS modem if connected, the right service provider and Server addresses are set.
Put the unit in Automatic (Normal) operation and observe the automatic Reactive Power
compensation to the desired level. Observe the Power Factor is near the Target Power Factor
setting.
After the confirmation of Automatic operation, refinement adjustment for achieving better results
through following Expert Edit parameters.
– Correction & Discharge time.
– No Action Band & Offset adjustments.
Observe the PF correction system for good performance for few hours.
81
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
Unit Screen is totally • Contrast for the LCD is not • Use Left & Right Arrow keys on
dark or totally bright and adjusted correctly the front of the unit with multiple
Backlight is ON. presses, the issue should be
resolved.
• Adjustment & Configuration • Refer the details of this
Any Communication or parameters are incorrectly done. operations manual for corrective
complex faults action.
82
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-A
In Power Factor Controllers (PFC), it’s important to set the right values of Capacitor Banks (Steps) in
terms of VAR (Volt-Amp-Reactive). The nameplate specified value of the capacitor may not be the value
that is seen by the supply system. The reasons for such ambiguity are:
• The Rated Voltage of the Electrical supply system may not be the voltage at which the name plate
VAR rating is defined.
• Capacitor Banks are connected in series with “Anti-resonant detuned Reactors”. The effective VAR
value of such inductor + capacitor combination gives different VAR value at supply system rated
voltage. This would certainly be different than the capacitor name plate VAR rating.
• Capacitors used for Power Factor correction are of different types. Many types are self-healing type.
Over a period of its usage, the value changes. This changed value of VAR would be different than
the name plate rating.
The PFC efficiency to correct the electrical supply system Power Factor is depends upon how accurate
the Capacitor banks VAR values are known. In case the Capacitor VAR values are incorrectly put, the
following undesirable phenomena can / may be seen.
Capacitor frequently turns ON and OFF. This is called hunting and reduces the life of the capacitors.
Target Power Factor set on PFC may not be accurately achieved and would differ from system
designed specifications.
Capacitor Health monitoring carried out by PFC may declare the Capacitor Steps as faulty and
would mask them for usage. This can hamper the Supply system Power Factor.
In case of Capacitors that are used without “Anti-Resonant Detuned Reactors”, the formula is simple.
Capacitor Step KVAR (setting on PFC) = VAR1 x (V R / VL1)2. (When used without series inductors.)
The formula becomes bit complex when Capacitor are used with “Anti-Resonant Detuned Reactors”.
It’s important to know the value (Henry) of the reactor. The value is dependent upon:
1. Supply rated frequency – 50Hz or 60Hz and nominal supply voltage.
2. Value of Capacitor VAR at specified Voltage. (Note if specified voltage is L-L or L-N.)
3. If Detuning frequency is for 5th harmonics upward spectrum and moderately high harmonics
thus using @ 7% drop reactors OR for 3rd harmonics upward spectrum and / or extra high
harmonics thus using @ 14% drop reactors.
a. For 50Hz, detuning frequency for 7% drop reactors usage is 189Hz.
b. For 50Hz, detuning frequency for 14% drop reactors usage is 134Hz.
c. For 60Hz, detuning frequency for 7% drop reactors usage is 227Hz.
d. For 60Hz, detuning frequency for 14% drop reactors usage is 161Hz.
Once the information from the above 3 points is available, the inductor value and the overall Capacitor-
Inductor combined VAR value at Nominal Supply Voltage can be calculated by standard formulae.
83
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE – A
Per Phase capacitor value (L-N) = ( 1000 x CKVARNP ) / ( 2 x x fR x VCR-LL2 ) Farad (unit)
Per Phase reactor value = fR x VCR-LL2 / ( 2 x x fRES2 x CKVARNP x 1000 ) Henry (unit)
Per Phase capacitor value (L-N) = ( 1000 x CKVARNP ) / ( 2 x x fR x VCR-LN2 ) Farad (unit)
Per Phase reactor value = fR x VCR-LN2 / ( 2 x x fRES2 x CKVARNP x 1000 ) Henry (unit)
It is advisable to use the above specified formulae and find out the exact capacitor step VAR at Nominal
Supply Voltage. The right value of Capacitors can ensure the efficient functioning of the Auto Power
Factor Correction system.
84
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-B
Consider the scheme where the supply measurement of Voltage and Current are on two different sides
of the transformer. In such a scheme, the Capacitors are switched ON / OFF on the Lower Voltage (LV)
side of the transformer.
As shown in the earlier part of the manual, the schemes can be:
H(V)L(A) L(V)H(A)
High Voltage fb-Low Voltage Ampere High Voltage Ampere-Low Voltage fb.
In the L(V)H(A) scheme, the voltage feedback can be direct (without PT) if the voltage range is within
BR5600R voltage measurement range.
The Distribution transformer can be of various types and can have input voltage to output voltage phase
angle relationship.
Based upon this phase relationship, transformers are declared as
DY-01 – 01 O’clock Phasor position - 030°
DY-05 – 05 O’clock Phasor position - 150°
DY-11 – 11 O’clock Phasor position - 330°
DY-07 – 07 O’clock Phasor position - 210°
DD-00 – 12 O’clock Phasor position - 000°
DD-06 – 06 O’clock Phasor position - 180°
YY-00 – 12 O’clock Phasor position - 000°
YY-06 – 06 O’clock Phasor position - 180°
And many more combinations with Z-winding & Scott-connected transformers with alternate set of phase
angle relationships.
Thus, BR5600R can be configured for 000°, 030°, 060°……...300°, 330° phase angle relationships if
the Voltage sensing and Current sensing is carried out on two different sides of the transformer. This
would ensure the right power calculations and ensure desirable Power Factor correction. Users are
advised to configure the correct phasor positioning angle.
When such feedback configurations are not used, the phase angle settings should be kept at 0°. i.e.,
sensing the Voltage and Current from the same supply bus (either HV bus OR LV bus). Any other setting
would cause the BR5600R to malfunction. Users are advised to take note of such settings.
85
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
The Target Power Factor settings can best be explained by depicting it on the 4-Quadrant Voltage-
Current and the Power Diagram.
86
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
Active Power “P” = V x I x cos(ø) is +ve in Quadrant 1 & Quadrant 4 / -ve in Quadrant 2 & Quadrant 3.
Reactive Power “Q” = V x I x sin(ø) is +ve in Quadrant 1 & Quadrant 2 / -ve in Quadrant 3 & Quadrant 4.
V-voltage value, I-current value, ø phase angle.
Thus, when the setting is Inductive, the Power Factor Controller (PFC) would be operating for
maintaining Power Factor in Quadrant 1 and Quadrant 2.
When the setting is Capacitive, the PFC would be operating for maintaining Power Factor in
Quadrant 4 and Quadrant 3.
87
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
Target PF Inductive
Target PF Capacitive
88
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
The Value of Target PF - cos(ø) is adjustable from 1.000 to 0.000 on PFC. Based upon the cos(ø) value,
the angle ø between the Target PF line and x-axis (P) would be seen on the Power diagram.
The primary objective of PFC units is to bring the Power Factor to the exact point on Target PF line.
This is to be accomplished by adjusting the Reactive Power (Q) on the supply system. The Active Power
(P) is due to connected load and PFC unit/s have no control on it.
The Reactive Power (Q) is adjusted by Switching-In and Switching-Out the Reactive components (like
Capacitors, in some cases the Inductors). Most of the electrical loads depict inductive loading, therefore
the Capacitors are used as Reactive components.
Capacitors of various ratings (VAR) are switched-in and switched-out by PFC. The action by PFC to
control switching-in/out of capacitors is to bring the supply system Power Factor to exact value of Target
Power Factor line. But this cannot be precisely carried out due to the minimum Capacitor VAR step size.
Either Power Factor can be adjusted on inductive side of Target PF line or on capacitive side.
For an example:
If the smallest adjustable capacitor bank is 5 KVAR, and requirement to Target PF line is just 3 KVAR,
then the best value that PFC can adjust is either switching-in 5 KVAR bank to get 2KVAR capacitive Q
value or keeping 5 KVAR off to get 3KVAR inductive Q.
89
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
One can see that when the Smallest Capacitor bank is inserted into Grid supply, the Power Factor is
over-compensated. i.e., on the capacitive side of Target PF.
And when the Smallest Capacitor bank is disconnected from Grid supply, the Power Factor is under-
compensated. i.e. on the inductive side of Target PF.
From the above explanation and example, its obvious that desired Target Power Factor can be either
Over-compensated or Under-compensated. The amount of Over or Under Compensation depends upon
the Smallest Capacitor bank Reactive Power VAR value.
Due to this phenomenon, the smallest capacitor would be switched On and switched Off on regular
basis. (Depending upon the correction time cycle). Such continuous ON or OFF is “Undesirable
Phenomenon”. The reasons are:
Reduction of Capacitor Life.
Reduction of the Switching Contactor Life.
Regular switching transients on the supply system.
Regular maintenance of the PF correction system.
To prevent such undesirable phenomena, PFC creates a “NO Action VAR area” around the Target PF.
Referred as No Action Band.
90
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
Smallest Capacitor Bank VAR X Multiplying Factor = No Action Band VAR value
91
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-C
Normally the “No Action Band VAR value” must be higher than the smallest capacitor bank to take care
of VAR of smallest bank rising due to:
Over-Voltage
Over-Frequency
Harmonics in capacitor
Therefore, multiplying factor adjustment range is > 1.1
The Offset value default is 50%. This would be having the “No Action Band” to be equal on both the
sides of the Target PF. (Inductive & Capacitive).
Increasing the value would shift the band on Inductive side and decreasing would shift the band on
Capacitive side.
The Band shift is as per the site situation and electrical billing requirements.
Additionally note the “VAR compensation Line”. This line depicts the line which is targeted by BR5600R
for achieving the desired PF. With an offset value other than 50%, this value would be different than
user defined Target Power Factor. Users are advised to set Target Power Factor accordingly to achieve
the desired Target PF.
Does this mean that “No Action Band” feature causes Poor Power Factor and increase the
electricity Bills?
The answer is generally NO.
This means that the PFC feature of No Action Band is mandatory. But the efficient designing of the PF
correction system is the key factor for Power Factor maintenance and reduced Electricity billing.
The Electricity bills are calculated on monthly Energy consumption. The values of Active, Reactive and
Apparent Energy/s are used for calculation of Power Factor and KVAH units.
Therefore, during low loading conditions, the Power Factor may be low. But VAR on supply system too
is low (Even though the PF is poor). This is because VAR value is still within the “No Action Band”.
Therefore, Reactive Energy KVARH during lower loading conditions rise is meniscal. Therefore, the
impact on billing is negligible.
----
92
BR 5600 R power factor controller
for LV / HV Capacitor switching
Operations manual
ANNEXURE-D
Read Addresses:
M: Meas. Config. C: Cap. Config.
Display Parameters
3XXXX Read From Registers
All Registers: Floating type 1=Valid Value, 0=Invalid Value,-- =irrelevant
M M M M C C C C
Address R
1 2 3 4 3 2 1 0
SYM Description /
S-Measurement C-Measurement
Dec Hex W
Configuration Configuration
30000 7530 FREQ Supply Frequency R 1 1 1 1 -- -- -- --
30002 7532 1V Phase 1 to Neutral RMS Voltage R 1 0 0 0 -- -- -- --
30004 7534 2V Phase 2 to Neutral RMS Voltage R 1 0 0 0 -- -- -- --
30006 7536 3V Phase 3 to Neutral RMS Voltage R 1 0 0 0 -- -- -- --
30008 7538 V Avg Phase to Neutral RMS Voltage R 1 0 0 1 -- -- -- --
30010 753A 1V1 Phase 1 to N Fundamental Voltage R 1 0 0 0 -- -- -- --
30012 753C 2V1 Phase 2 to N Fundamental Voltage R 1 0 0 0 -- -- -- --
30014 753E 3V1 Phase 3 to N Fundamental Voltage R 1 0 0 0 -- -- -- --
30016 7540 V1 Avg Phase to N Fundamental Voltage R 1 0 0 1 -- -- -- --
30018 7542 12V Phase 1 to Phase 2 RMS Voltage R 1 1 0 0 -- -- -- --
30020 7544 23V Phase 2 to Phase 3 RMS Voltage R 1 1 0 0 -- -- -- --
30022 7546 31V Phase 3 to Phase 1 RMS Voltage R 1 1 0 0 -- -- -- --
30024 7548 VL Avg Phase to Phase RMS Voltage R 1 1 1 0 -- -- -- --
30026 754A 12V1 Phase 1 to Phase 2 Fund. Voltage R 1 1 0 0 -- -- -- --
30028 754C 23V1 Phase 2 to Phase 3 Fund. Voltage R 1 1 0 0 -- -- -- --
30030 754E 31V1 Phase 3 to Phase 1 Fund. Voltage R 1 1 0 0 -- -- -- --
30032 7550 VL1 Avg Phase to Phase Fund. Voltage R 1 1 1 0 -- -- -- --
30034 7552 1A Phase 1 RMS Current R 1 1 0 0 -- -- -- --
30036 7554 2A Phase 2 RMS Current R 1 1 0 0 -- -- -- --
30038 7556 3A Phase 3 RMS Current R 1 1 0 0 -- -- -- --
30040 7558 A Avg. Phase RMS Current R 1 1 1 1 -- -- -- --
30042 755A NA Neutral RMS Current R 1 0 0 0 -- -- -- --
30044 755C 1A1 Phase 1 Fundamental Current R 1 1 0 0 -- -- -- --
30046 755E 2A1 Phase 2 Fundamental Current R 1 1 0 0 -- -- -- --
30048 7560 3A1 Phase 3 Fundamental Current R 1 1 0 0 -- -- -- --
30050 7562 A1 Avg. Phase Fundamental Current R 1 1 1 1 -- -- -- --
30052 7564 NA1 Neutral Fundamental Current R 1 0 0 0 -- -- -- --
30054 7566 1CA Phase 1 RMS Capacitor Current R -- -- -- -- 1 1 1 1
30056 7568 2CA Phase 2 RMS Capacitor Current R -- -- -- -- 1 1 0 0
30058 756A 3CA Phase 3 RMS Capacitor Current R -- -- -- -- 1 1 0 0
30060 756C CA Avg. Phase RMS Capacitor Current R -- -- -- -- 1 1 0 0
30062 756E NCA Capacitor Neutral / Earth Leakage Current R -- -- -- -- 1 0 0 0
30064 7570 1CA1 Phase 1 Fundamental Capacitor Current R -- -- -- -- 1 1 1 1
30066 7572 2CA1 Phase 2 Fundamental Capacitor Current R -- -- -- -- 1 1 0 0
30068 7574 3CA1 Phase 3 Fundamental Capacitor Current R -- -- -- -- 1 1 0 0
30070 7576 CA1 Avg. Phase Fund. Capacitor Current R -- -- -- -- 1 1 0 0
30072 7578 1P Phase 1 RMS Active Power R 1 1 0 0 -- -- -- --
30074 757A 2P Phase 2 RMS Active Power R 1 1 0 0 -- -- -- --
30076 757C 3P Phase 3 RMS Active Power R 1 1 0 0 -- -- -- --
30078 757E P Total RMS Active Power R 1 1 1 1 -- -- -- --
30080 7580 1P1 Phase 1 Fundamental Active Power R 1 1 0 0 -- -- -- --
30082 7582 2P1 Phase 2 Fundamental Active Power R 1 1 0 0 -- -- -- --
30084 7584 3P1 Phase 3 Fundamental Active Power R 1 1 0 0 -- -- -- --
30086 7586 P1 Total fundamental Active Power R 1 1 1 1 -- -- -- --
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Remote Mode:
This is set in User Parameter Settings. Part of previous Modbus table is to be set accordingly
40870 9FA6 REM_MODE Remote Operation Mode RW
40872 9FA8 REM_TIMEOUT Remote Operation TIMEOUT RW
40874 9FAA REM_TMACT Remote Operation Timeout Action RW
Once the parameters Setting is carried out, the PF correction action would depend upon the Remote
mode parameters written.
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Important notes
1. Some parts of this publication contain statements about the suitability of our products
for certain areas of application. These statements are based on our knowledge of typical
requirements that are often placed on our products in the areas of application concerned.
We nevertheless expressly point out that such statements cannot be regarded as
binding statements about the suitability of our products for a particular customer
application. As a rule, we are either unfamiliar with individual customer applications or
less familiar with them than the customers themselves. For these reasons, it is always
ultimately incumbent on the customer to check and decide whether a product with the
properties described in the product specification is suitable for use in a particular customer
application.
2. We also point out that in individual cases, a malfunction of electronic components or
failure before the end of their usual service life cannot be completely ruled out in the
current state of the art, even if they are operated as specified. In customer applications
requiring a very high level of operational safety and especially in customer applications in
which the malfunction or failure of an electronic component could endanger human life or
health (e.g. in accident prevention or life-saving systems), it must therefore be ensured by
means of suitable design of the customer application or other action taken by the customer
(e.g. installation of protective circuitry or redundancy) that no injury or damage is sustained
by third parties in the event of malfunction or failure of an electronic component.
3. The warnings, cautions and product-specific notes must be observed.
4. In order to satisfy certain technical requirements, some of the products described in this
publication may contain substances subject to restrictions in certain jurisdictions
(e.g. because they are classed as hazardous). Useful information on this will be found
in our Material Data Sheets on the Internet (www.tdk-electronics.tdk.com/material). Should
you have any more detailed questions, please contact our sales offices.
5. We constantly strive to improve our products. Consequently, the products described in
this publication may change from time to time. The same is true of the corresponding
product specifications. Please check therefore to what extent product descriptions and
specifications contained in this publication are still applicable before or when you place an
order.
We also reserve the right to discontinue production and delivery of products.
Consequently, we cannot guarantee that all products named in this publication will always
be available.
The aforementioned does not apply in the case of individual agreements deviating from
the foregoing for customer-specific products.
6. Unless otherwise agreed in individual contracts, all orders are subject to our General
Terms and Conditions of Supply.
7. Our manufacturing sites serving the automotive business apply the IATF 16949
standard. The IATF certifications confirm our compliance with requirements regarding the
quality management system in the automotive industry. Referring to customer
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requirements and customer specific requirements (“CSR”) TDK always has and will
continue to have the policy of respecting individual agreements. Even if IATF 16949 may
appear to support the acceptance of unilateral requirements, we hereby like to emphasize
that only requirements mutually agreed upon can and will be implemented in our
Quality Management System. For clarification purposes we like to point out that
obligations from IATF 16949 shall only become legally binding if individually agreed upon.
8. The trade names EPCOS, CarXield, CeraCharge, CeraDiode, CeraLink, CeraPad,
CeraPlas, CSMP, CTVS, DeltaCap, DigiSiMic, ExoCore, FilterCap, FormFit, InsuGate,
LeaXield, MiniBlue, MiniCell, MKD, MKK, ModCap, MotorCap, PCC, PhaseCap,
PhaseCube, PhaseMod, PhiCap, PowerHap, PQSine, PQvar, SIFERRIT, SIFI, SIKOREL,
SilverCap, SIMDAD, SiMic, SIMID, SineFormer, SIOV, ThermoFuse, WindCap, XieldCap
are trademarks registered or pending in Europe and in other countries.
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