SYCON 55xxSS Automatic Power Factor Controller

SYCON 55xxSS Automatic Power Factor Controller Systems & Controls (Sangli) Pvt. Ltd.

Introduction 2 Automatic Power Factor Controller SYCON 55xxSS 2 Features 2 Models 3 Control Principle 3 Installation 4 Electrical connection diagram 4 Operation 5 At Power ON 5 Default Mode 5 DISPLAY Mode 7 CT Primary display 7 Target PF display 8 SET1 Mode 8 Set CT Primary 8 Target PF 9 SET2 Mode 10 Auto Identification Mode 10 Manual Feed Mode 11 TEST Mode 12 Low Current Mode 13 Troubleshooting 13 Appendices 14 Appendix 1 Technical Data 14 Appendix 2 Default Settings 15 Appendix 3 Test Certificate 16 1

Introduction Some electrical loads such as motors found in large machines, air conditioners etc can cause electrical system to be inductive, resulting in severely lagging power factor. This means energy is being wasted, consumer has to pay large electricity charges. The simple solution to this is to connect or disconnect power factor correction capacitors according to the requirement. Manual switching of these capacitors is not suitable for the rapid fluctuating loads. Such systems therefore require continuous personal attention to make necessary corrections. So some kind of automatic control system is required to ensure maximum benefit from these capacitors. This is achieved by SYCON Automatic Power Factor Controller. The main use of the APFC unit is to switch ON or OFF the capacitors according to the capacitive KVAR requirement to balance the inductive KVAR produced in the system by inductive loads. If the same APFC relay can provide many other features such as display of system KVA, system KW and system KVAR is advantageous to the user because it helps user to understand the system loads at the same time. This relay will provide such additional features than the existing APFC model in this range. Automatic Power Factor Controller SYCON 55xxSS SYCON 55**SS is automatic power factor controller equipped with a variety of functions. Features SYCON 55**SS comes with many modern features at incredibly low cost. It enables user to get maximum 2

benefits from it. SYCON 55**SS is an example of stateof-the-art technology". Some of the salient features listed down here, o Complete menu guided programming and operation. o Four digit LED display. o Smart switching of capacitors. o Automatic or Manual capacitor value feed. o Adjustable CT primary and Target PF settings. o Display of system KVA, KW, KVAR, and Shortfall KVAR. o Test mode facility at no load for panel builders. Models SYCON 55**SS comes in various models as listed below. SYCON 5504SS SYCON 5506SS SYCON 5508SS SYCON 5512SS SYCON 5516SS 04 Steps 06 Steps 08 Steps 12 Steps 16 Steps Control Principle SYCON 55**SS controls the capacitors switching with smart fit algorithm. First the accurate power factor is computed with continuously monitoring the voltage and current. Considering target power factor required to maintain PF at set PF value, the shortfall is calculated. From all the available capacitors (Capacitors which are already ON or which are recently switched OFF are not considered as they are discharging) the smart fit 3

capacitor is selected and switched ON or OFF according to shortfall condition. This mode of operation ensures the smart use of all the capacitors to achieve an average power factor which is nearest to the target PF. Installation SYCON 55**SS is easy to install with its compact size and low weight. It is easily mounted on the panel door with minimum efforts. A cutout of 138mm X 138mm is required to be cut in the panel door where you wish to install the product. Electrical connection diagram The typical wiring diagram is shown in figure below. Supply voltage is phase to phase voltage. But the current transformer (CT) must be in the remaining third phase. CT must have been placed before the load for which we wish to control the power factor. Capacitors contactors are connected to the relay as shown in figure below. Phase to neutral connection is recommended for the contactors. R Y B N To Load To Capacitors R Y B CT C C1 C2 C3 C4 C5 C6 4

Operation SYCON 55**SS is a menu guided control system apart from its basic function of smart capacitor switching. It provides various other functions to the user which can be used to enrich the overall quality of power system. At Power ON When instrument is switched ON, it will display SYCN (SYCON) for few seconds and then it will display APFC. The startup display will look like this If CT polarity is wrong the display will flash the message b Ct, then reverse the CT correction and restart. (Note: It is advisable to put on the inductive load on while checking for CT connection) Default Mode This is the most basic and widely used mode. In this mode, capacitor switching is automatically managed. Also during this mode, user can see various basic operating parameters. The state chart diagram is as shown in figure below. 5

Default State Power Factor Display DEC DEC DEC DEC KVA Display KW Display KVAR Display Shortfall Display DEC Power Factor Display Both TIME OUT TIME OUT TIME OUT OR (BOTH KEYS AND NOT Lo C) TIME OUT OR (BOTH KEYS AND NOT Lo C) DISPLAY MODE SET 1 MODE SET 2 MODE TEST MODE DEC DEC CT Primary Target PF BOTH CT Primary Target PF BOTH BOTH Auto Feed BOTH Manu Feed While displaying the Power Factor the LED shows the Lagging and Leading condition by glowing respective LED's. Here by using Increment OR Decrement keys user can choose the display of other parameters. The respective LED of that parameter glows while display is indicating the value of that parameter. The other parameters are listed below, 1. KVA 2. KW 3. KVAR 4. Short fall. 6

DISPLAY Mode User can see settings, other advanced parameters such as CT primary, Target PF and capacitors values in this mode. To enter display mode one should press both keys simultaneously in default state. The Stat chart for this mode is as shown below, DISPLAY MODE DEC CT Primary DEC BOTH Target PF BOTH Display CT Primary Display Target PF In this display mode first the display will look like this All the settings set by user are displayed in this mode. User can scroll up and down by pressing the required parameter by pressing the both keys simultaneously. CT Primary display Here user can see the CT primary setting. Here first display will show the message as - If user press both keys then user can see the CT primary display. And again by pressing both keys user will come back to previous menu. If user press key user 7

can go for next menu i.e. target power factor display and if user press DEC key then user can go for display mode. Target PF display Here user can see the target power factor setting. Here first display will show the message like - If user press both keys then user can see the target power factor setting. And again by pressing both keys user will come back to previous menu. If user press key user can go back to display mode. SET1 Mode When user Press both keys simultaneously, one can enter SET1 mode. Here two settings are provided for user, 1. CT primary Setting By pressing key 2. Target Power Factor Setting By pressing DEC key The SET1 will be displayed on the screen as follows - Set CT Primary In this mode, the selected CT primary is displayed as- This display flashes for few seconds. When user 8

presses the key, the CT primary is increased. When user presses DEC key, the CT primary is decreased. If user presses and DEC key at a time, the CT primary displayed at that time is saved as new CT primary. Display will show done message and system will exit to default mode. The increment and the decrement values are as CT Primary Range Increment/ decrement by 5 to 50 5 50 to 8000 50 Target PF In this mode, the target power factor is displayed as This display flashes for few seconds. In this mode, the target power factor can be set by the user. When user presses the key, the target power factor is increased. When user presses DEC key, the target power factor is decreased. If user presses and DEC key at a time, the target power factor displayed at that time is saved as new target power factor. Display will show done message and system will exit to default mode. To indicate whether the set power factor is lag or lead, respective LED is set to glow. 9

The increment and the decrement value are as Target Power Factor Range Increment/ decrement by 0.70 Lag to 0.80 Lead 0.01 SET2 Mode One can enter in to SET2 mode by pressing both keys simultaneously when display is showing SET1. SET2 mode is provided for two settings listed below. 1. Auto identification of Capacitor Value By pressing key 2. Manual Feeding of Capacitor Value By pressing DEC key The SET 2 will be displayed on the screen as follows - Auto Identification Mode When we press Increment key in SET2 mode we can enter in to this mode, in this mode auto identification is displayed as This display flashes for few seconds. Before the auto identification of the capacitor values, system will turn OFF all the ON capacitors. During auto identification the 10

system will turn ON and OFF the capacitors one by one and store the capacitor value in the memory. When system turns OFF previous capacitor and turns ON next one, it will display the value of previous capacitor. Display will show done message after completing all stages and system will exit to default mode. Manual Feed Mode In this mode Manual Feed displayed as This display flashes for few seconds. Then it displays the CAP1. When we press increment in this mode we can change the capacitor number. In this mode Capacitor number is displayed as When we press key at the last capacitor number display or when we press the DEC key at the first capacitor number display, EXIT mode will appear as- When the user presses key, the mode will change to first capacitor number display and when user presses DEC key, the mode will change to last capacitor number display. When user presses both keys in this 11

mode, user can exit from capacitor manual feed mode to the default mode. When we press both keys in capacitor number display mode the display will show the capacitor value of that capacitor. We can change the capacitor value by pressing increment (to increment the value) and decrement (to decrement the value). If user presses and DEC key at a time, the Capacitor Value displayed at that time is saved as new Capacitor Value. Display will show done message and system will exit to capacitor number display. The increment and the decrement is done as Capacitor Value Range TEST Mode Increment/ decrement by 1 to 250 1 The TEST mode is operative only after confirmation of low current mode. To enter into TEST mode one has to press both keys simultaneously at SET2 mode. The TEST mode is displayed as This display flashes during entire TEST mode, and the system will return to the initial mode after completing the test mode automatically by displaying message done. During test mode the system will switch on all the capacitors in one run and the switch off all the capacitors in the second run by FIFO principle. 12

Low Current Mode When total load reduces to about 2% of the primary current rating of the rating of the CT the system automatically switches OFF all the capacitors one by one and the display will be shown as- This display flashes during Low Current mode. The system will return to the default mode after the load current is more than 2% of the CT primary current. Troubleshooting Problem Power Factor is very poor Display is blank OR instrument does not respond to any key Display shows Lo C (low current) Controller does not operate though inductive load is heavy. Possible Solution Check the target setting Wait for 10 seconds and if still the problem exists, check the power supply connections Check the current coming to CT connection of the controller. If it is below 2% of full load current, the instrument is in low current condition. Check the settings. 13

Appendices Appendix 1 Technical Data Specification Value Supply Voltage 440V +/- 15% Current Input CT --/5A Frequency 50 Hz +/- 5% Over Voltage (R-Y) 470V +/- 1% Low current Relay output Stages 4 to 16 Switching Program Target Power Factor Switching ON delay Discharge Time (OFF-ON delay) Mechanical Specifications 2% (70mA) In 4% (230mA) Out 10A at 250V AC Smart (KVAR based) 0.70 Lag to 0.80 Lead 5 sec 25 sec Size Weight Front bezel size Panel cutout size 137mm L x 137mm W x 86mm D 1 kg maximum 144mm x 144mm 138mm x 138mm 14

Appendix 2 Default Settings Settings Value Target Power Factor 1.00 CT Primary 5 ON Delay OFF Delay 5 Sec 25 Sec Stages 4/6/8/12/16 depending on the model 15

Appendix 3 Test Certificate Serial No. Type Date of Inspection Test Conditions Supply Voltage (R-Y) V Current in B phase Amp Output Contacts Load KVAR Display OK/Not OK Insulation Test OK/Not OK Power Factor 0.6 IND 0.7 IND 0.8 IND 0.9 IND 0.95 IND 1.0 0.95 CAP 0.9 CAP LOW Current Low current IN Low Current OUT Test Engineer For SYSTEM & CONTROL (SANGLI) PVT.LTD 16

Our Other Products Power Factor Controller t SYCON 66** t SYCON 66**SS t SYCON 55** t SYCON 55**2D t SYCON 5503ND Thyristorised Capacitor Switching Module Automatic KVA/KW Demand Controller t SYCON 4300SS t SYCON 4400 t SYCON 4400KW Comprehensive Motor Protection Relay t SYCON IMPR 2220 t SYCON MMR 2110 Earth Leakage Relay and Panel Meters SYSTEMS & CONTROLS (SANGLI) PVT.LTD C-24 M.I.D.C. Miraj 416410 SANGLI, MAHARASHTRA,INDIA Tel:91-233-2644320/2644765. FAX: 91-233-2645053. E-mail: sales@sycon.co.in, info@sycon.co.in Visit us at : www.syconindia.com