SecuRite APFCS

Automatic Power
Factor Correction System

- Automatic Power Factor Correction SysIntroduction

Modern Power network cater to a wide variety of electrical
and power electronic loads, which create a varying power
demand on the supply system. It therefore becomes
practically difficult to maintain a consistent power factor
by the use of fixed compensation i.e. fixed capacitor to be
manually switched ON and OFF to suit the variation of the
load. This will lead to situation where the installation can
have a low power factor causing higher demand charges
and levy of power factor penalties.
In addition to not being able to achieve the desired power
factor that the use of fixed compensation can result
in leading power factor under certain load conditions,

Range
Output Rating: 15-350 kVAr (Other kVAr rating on
request )
Voltage Rating: 440 V
Ref. Standard
IEC 61921/ IS 8623
Salient Features
Correction to Unit Power Factor.
Modular Design which allows easier assembly,
installation and maintenance by the user.
Designed to minimize installation time and cost.
Advanced Microprocessor relay
The incomer MCCB provided has upto 35 KA fault
interrupting capability.
Manual Capacitor Switching Capability.
Indicating light for Capacitor stage display.
Industrial Duty, Safety disconnects Metallized dielectric
capacitors, less than 0.2 watts per kVAr losses.
Colour Siemens Grey RAL.
Special cable used hence it can withstand temperature.
2

which is unhealthy for the installation as it can result in

over voltages, saturation of transformers, mal-operation
of diesel generating sets, penalties by electricity supply
authorities etc.
It is therefore necessary to automatic switching operation of
the suitable capacitor depending upon the load fluctuations
without manual intervention. This compensation is best
suited to the load requirements.
It can be achieved by using Automatic Power Factor
Correction (APFC) System which can maintain consistently
high power factor, without leading power factor operation.

Step Switching.
Capacitor Duty Contactor with dumping resistance.
Switch option Auto or Manual.
Bus bar is made of copper.
Provision of Rotor handle for incomer MCCB.

Principle Operation
To continuously sense and monitor the load conditions
by the use of the external CT (whose output is fed to
the control relay).
To automatically switch ON and switch OFF relevant
capacitor steps to ensure consistent power factor.
To ensure easy user interface for enabling reliable
understanding of system operation, such as display of
real time power factor, number of switching operations
carried out etc.
To protect against any electrical faults in a manner that
will ensure safe isolation of the power factor correction
equipment.

Disadvantages of having poor power factor are generally

understood as follows:
More kVA demand for the given kW load and penalty for
poor power factor, hence higher running cost (electricity
bill).
More line current for the given kW load and hence higher
rated transformer, switchgears and cables are required,
hence higher capital cost.
More the line current for the given kW load and hence
higher losses at the transformer, switchgears and cables,
hence higher running cost.
More line current for the given kW load- poor utilization of
all electrical distribution network and hence poor return
on investment.
Higher voltage drops in the distribution network hence
poor performance of electrical equipments resulting in
production loss.
Higher voltage fluctuations hence damage to electrical
equipments resulting in production loss.
Need to correct the poor power factor:
If we are able to correct the poor power factor to near
unity on all occasions at all loads, we can bring down
the kVA demand, line losses, increase the utilization of
the distribution equipments, increase the performance
of electrical equipments, avoid damages to electrical
equipments and avoid production losses due to power
related problems. Another major advantage is that unity
power factor not only avoids penalty but also brings in
incentive from Electricity Board for higher power factor. All
the above savings in revenue expenditures improves the
bottom line of the company directly adding to the profit.
Hence the investment on a good power factor correction
system will give an attractive payback. Subsequently the
return on the investment will be high.
Various Methods Of Power Factor Correction System
Using Power Capacitors, the poor power factor can be
corrected in the following methods:
By providing fixed value of capacitors to the distribution
network at various points. They will be switched in/out as
per the load manually.
Principle of Reactive Energy Management
Active Power (kW )
It is power used by the loads to meet the functional
output requirement

Power Factor
The power factor is the cosine of the angle between Active
power and Apparent power.
Power Factor (cosf) = Active power (kW)/ Apparent
power(kVA)
kVA = {(kW)2+(kVAr)2}
kW = kVA x cosf
tanf = kVAr/ kW
Using APFC panel at various points of the distribution
network- Here automatic power factor correction takes
place with the help of power factor controller and
power contactors by switching in/out 4/6/8/12 steps of
capacitor banks as the power factor varies.
Effects of Reactive Energy
It is now obvious that both active and reactive energy
are necessary inputs in all electrical systems however
the flow of reactive power has certain negative aspects
which results in the increased cost of electrical systems
and also drops in the efficiency of systems operations
The increased flow of reactive power results in the
following. Adverse condition
Overloading of transformers
Higher kVA demand on system
Higher voltage drop throughout the systems.
Increase I R losses leading to additional heating and loss
of energy
Increase in the rating of switchgear cable and other
protective device
Reduction of voltage at the load end
Power Factor Correction
Capacitors are most cost effective and reliable static devices
which can generate and supply reactive power (energy).
Capacitors consume virtually negligible active power and
able to produce reactive power locally, thus enabling Power
Factor Correction for inductive loads.
The vector diagram given aside summarize the concept of
power factor correction/ improvement by reactive power
compensation with capacitors.
cosf1 = Initial power factor
cosf2 = Target power factor
kVA2<kVA1

Reactive Power (kVAr)

It is power used by the loads to meet its magnetic field
equipments and the requirements of magnetic losses
The reactive power is always 90 out of phase with
respects to the active power
The unit normally used to express the reactive power is
VAR ( in practical usage kVAr)
The apparent power kVA is the vector some of active and
reactive power

Benefits of Reactive Energy Management

By providing proper Reactive management systems the adverse effects of flow of reactive energy can be minimized
Following table provides some of the benefits of reactive energy.
Reduction in Electricity bill
Reduction in kVAr Demand
Reduction in kVA Demand
Reduction in Line Current

Reduced Loading on Transformer

Reduction in Switchgear Rating
Reduction in line losses / Cable losses
Reduction in voltage regulations

Savings on the electricity bill

Decrease in kVA demand
Eliminate penalties on reactive energy
Reduce power loss in transformers
Example:
Loss reduction in a 630 kVA transformer
PW = 6500 W (assumed) with an initial Power Factor = 0.7
With power factor correction we obtain a final power
factor = 0.98
The losses become : 3316 W i.e. a reduction of 49%
Increase in available power
A high power factor optimizes an electrical installation.
Fitting PFC equipment on Low Voltage side of transformers
increases available power at secondary of LV transformers.
The table shows the increased available power at the
transformer output by improving power factor from 0.7 to1.
Example :
Calculation for additional load in KW that can be connected
by improving Power Factor
Load
= 500kVA
Initial PF (cosf1)
= 0.7
Target PF(cosf2)
= 0.95
cosf1 = kW1/kVA
kW1 = kVA x cosf1
= 350 kW
kW2 = kVA x cosf2
= 475 kW
Additional kW that can be connected
= 475-350
= 125 kW
% of additional load
= 125 /350 x100
= 36%
4

Copper loss = (PF1/PF2)2 x Full load

Copper loss = (0.7/0.98)2 x Full load

= (0.7/0.98)2 x 6500

= 3316 W
Savings
= 6500W 3316W

= 3183 W
Power Factor

Additional available

power (kW)
0.7

0%

0.8

+14%

0.85

+21%

0.90

+29%

0.95

+36%

1.00

+43%

Multiplication Factor Table

Calculation of Capacitor Rating-kvar
Initial P.F

Target P.F
0.9

0.91

0.92

0.93

0.94

0.95

0.4

1.807

1.836

1.865

1.896

1.928

1.963

2.041

2.088

2.149

0.42

1.676

1.705

1.735

1.766

1.798

1.832

1.869

1.91

1.958

2.018

0.44

1.557

1.585

1.615

1.646

1.678

1.712

1.749

1.79

1.838

1.898

0.46

1.446

1.475

1.504

1.535

1.567

1.602

1.639

1.68

1.727

1.788

0.48

1.343

1.372

1.402

1.432

1.465

1.499

1.536

1.577

1.625

1.685

0.5

1.248

1.276

1.306

1.337

1.369

1.403

1.44

1.481

1.529

1.59

0.52

1.158

1.187

1.217

1.247

1.28

1.314

1.351

1.392

1.44

1.5

0.54

1.074

1.103

1.133

1.163

1.196

1.23

1.267

1.308

1.356

1.416

0.56

0.995

1.024

1.053

1.084

1.116

1.151

1.188

1.229

1.276

1.337

0.58

0.92

0.949

0.979

1.009

1.042

1.076

1.113

1.154

1.201

1.262

0.6

0.849

0.878

0.907

0.938

0.97

1.005

1.042

1.083

1.13

1.191

0.62

0.781

0.81

0.839

0.87

0.903

0.937

0.974

1.015

1.062

1.123

0.64

0.716

0.745

0.775

0.805

0.838

0.872

0.909

0.95

0.998

1.058

0.66

0.654

0.683

0.712

0.743

0.775

0.81

0.847

0.888

0.935

0.996

0.68

0.594

0.623

0.652

0.683

0.715

0.75

0.787

0.828

0.875

0.936

0.7

0.536

0.565

0.594

0.625

0.657

0.692

0.729

0.77

0.817

0.878

0.72

0.48

0.508

0.538

0.569

0.601

0.635

0.672

0.713

0.761

0.821

0.74

0.425

0.453

0.483

0.514

0.546

0.58

0.617

0.658

0.706

0.766

0.75

0.398

0.426

0.456

0.487

0.519

0.553

0.59

0.631

0.679

0.739

0.76

0.371

0.4

0.429

0.46

0.492

0.526

0.563

0.605

0.652

0.173

0.78

0.318

0.347

0.376

0.407

0.439

0.474

0.511

0.552

0.599

0.66

0.8

0.266

0.294

0.324

0.355

0.387

0.421

0.458

0.499

0.547

0.608

0.82

0.214

0.242

0.272

0.303

0.335

0.369

0.406

0.447

0.495

0.556

0.84

0.162

0.19

0.22

0.251

0.283

0.317

0.354

0.395

0.443

0.503

0.85

0.135

0.164

0.194

0.225

0.257

0.291

0.328

0.369

0.417

0.477

0.86

0.109

0.138

0.167

0.198

0.23

0.265

0.302

0.343

0.39

0.451

0.87

0.082

0.111

0.141

0.172

0.204

0.238

0.275

0.316

0.364

0.424

0.88

0.055

0.084

0.114

0.145

0.177

0.211

0.248

0.289

0.337

0.397

0.89

0.028

0.057

0.086

0.117

0.149

0.184

0.221

0.262

0.309

0.37

0.9

0.029

0.058

0.089

0.121

0.156

0.193

0.234

0.281

0.342

0.03

0.06

0.093

0.127

0.164

0.205

0.253

0.313

0.031

0.063

0.097

0.134

0.175

0.223

0.284

0.032

0.067

0.104

0.145

0.192

0.253

0.034

0.071

0.112

0.16

0.22

0.037

0.078

0.126

0.186

0.91
0.92
0.93
0.94
0.95

0.96

0.97

0.98

0.98

Calculation of Capacitor ratings kVAr

For Industrial / Distribution Networks
In electrical installations, the operating load kW and its average power factor (PF) can be ascertained from electricity bill.
Alternatively it can be easily evaluated by formula
Average PF = kWH/kVAH
Operating load kW = kVA demand x Average PF
The average PF is considered as the initial PF and final PF can be suitably assumed as target PF.
The required Capacitor kvar can be calculated as shown in example :
Initial PF 0.85,
Target PF 0.98,
KVAR = kW x multiplying factor
= 800 x 0.417
= 334 kVAr required.
5

Technical Data & Limit Values

Details

Rating

Power Rating

15 kVAr

75-150 kVAr

175-250 kVAr

275-350 kVAr

Rated Voltage

3 phase 415 V - 20% 3 phase 415 V to 10%

20% to 10%

25-50 kVAr

3 phase 415 V 20% to 10%

3 phase 415 V 20% to 10%

3 phase 415 V - 20%

to 10%

Frequency

50Hz +/-3%

50Hz +/-3%

50Hz +/-3%

50Hz +/-3%

50Hz +/-3%

Protection when Voltage

sensing fails

C Curve

C Curve

C Curve

C Curve

C Curve

Alarms with relay output

OC, OV, Under

Compensation

OC, OV, Under

Compensation

OC, OV, Under

Compensation

OC, OV, Under

Compensation

OC, OV, Under

Compensation

Tolerance in kVAR

3.5

3.5

8.75

8.75

Corrected PF

1.0

1.0

1.0

1.0

1.0

Capacitor Bank ON
indication

By indication lamps

By indication lamps

By indication
lamps

By indication lamps

By indication lamps

kVAR/ current meter for

Capacitor

Optional- ICD Make

Optional- ICD Make

Optional- ICD
Make

Optional- ICD Make

Optional- ICD Make

Display of set/ actual

values

PF and kVAR

PF and kVAR

PF and kVAR

PF and kVAR

PF and kVAR

Panel Temperature Rise

20 degree C above
ambient

20 degree C above
ambient

20 degree C above
ambient

20 degree C above
ambient

20 degree C above
ambient

Panel Enclosure

IP20, Force Cooled

IP20, Force Cooled

IP20, Force Cooled IP20, Force Cooled

IP20, Force Cooled

Short Circuit Rating

upto 35 kA
105 % Continuous

Over Voltage

110 % for 8 Hours Daily

120 % for 5 Minutes
130% for 1 Minute

Over Current

200 % the Rated Current Continuously

Duty

Continuous

Power Supply

Three phase, four line

Relay voltage input signal

Tapped internally

Relay current input signal

-- / 5A, from CT on line

Ambient temperature

-5 C to + 40 C

Altitude

1000 metres above Sea level

Incomer

A three pole MCCB, Using FRLS cable, of adequate section

Internal wiring

Cylindrical, dry type three phase units (see table for step ratings)

Capacitors

MPP - SH, Normal duty cylinderical with over pressure Disconnector & Discharge Resistor.

Contactors

Three pole Capacitor duty contactors of adequate ratings for respective steps

Relay

A microprocessor based relay with 4, 8 & 12 output contacts for switching contactors

Controller Protection

Having PF indication, built in time delays, and alarm indication for CT reversal apart from the protections
associated with the capacitor itself, there is a thermostat which disconnects the entire panel in the event of
excessive temperature rise in the enclosure.
As a safety measure, an inter lock is provided so that when the front door is opened, the entire panel will trip.

800A

800A

800A

325

350

630A

250

800A

630A

225

275

630A

200

300

400A

630A

150

175

250A

315A

100

125

125A

250A

125A

25

50

63A

kVAr Rating

75

Incomer
MCCB

15

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

CC

Capacitor

Contactor

C1

MCCB

16

16

16

16

16

16

16

16

16

16

16

16

MC

Capacitor

10

10

7.5

C2

Contactor

20

12

12

12

20

12

12

12

12

12

12

12

12

12

12

CC

MCCB

25

25

16

16

25

25

16

16

16

16

16

16

MC

Capacitor

15

12.5

15

10

7.5

C3

Contactor

20

20

12

12

20

20

12

12

12

12

12

12

12

12

12

CC

MCCB
32

25

25

25

32

25

25

16

16

16

16

16

10

10

10

MC

Capacitor
20

15

10

10

20

15

10

10

C4

Contactor
30

20

20

20

30

20

20

20

12

12

12

12

12

12

12

CC

MCCB
32

32

25

25

32

32

25

25

16

16

16

16

10

10

16

MC

Capacitor
25

15

15

15

25

20

15

12.5

7.5

C5

Contactor
50

20

20

20

50

30

20

20

12

12

12

12

12

12

CC

MCCB
63

32

32

32

63

32

32

25

25

16

16

16

16

10

MC

Capacitor
25

20

15

15

25

20

20

15

10

7.5

7.5

C6

50

30

20

20

50

30

30

20

20

12

12

12

12

12

CC

Contactor

Step 6

MCCB
63

32

32

32

63

32

32

32

25

25

16

16

25

16

MC

Capacitor
25

25

20

20

25

25

20

15

12.5

10

12.5

C7

Step 7

63

30

50

50

30

63

63

32

32

63

50
50

32

32

25

25

16

16

32

16

MC

MCCB

30

20

20

20

12

12

20

12

CC

Contactor

Step 5
Capacitor
25

25

25

25

25

25

20

20

15

12.5

7.5

15

C8

Step 8

50

50

50

50

50

50

20

30

20

20

12

12

20

12

CC

63

63

63

63

63

63

25

32

32

32

25

25

32

16

MC

MCCB

Capacitor Step in kVAR with Capacitor Duty Contactor and MCB / MCCB Rating

Contactor

Step 4
Capacitor
50

50

50

25

25

25

25

20

20

15

10

10

C9

Step 9

50

50

50

50

50

50

50

30

30

20

20

20

CC

Contactor

Step 3

MCCB
63

63

63

63

63

63

63

32

32

32

25

25

MC

Capacitor
50

50

50

50

25

25

25

25

25

20

12.5

15

C10

Step 10

50

50

50

50

50

50

50

50

50

30

20

20

CC

Contactor

Step 2

MCCB
63

63

63

63

63

63

63

63

63

32

25

32

MC

Capacitor
50

50

50

50

25

25

25

25

25

25

20

25

C11

Step 11

50

50

50

50

50

50

50

50

50

50

30

50

CC

Contactor

Step 1

MCCB
63

63

63

63

63

63

63

63

63

63

32

63

MC

Capacitor
50

50

50

50

25

25

25

25

25

25

25

C12

Step 12

50

50

50

50

50

50

50

50

50

50

50

CC

Contactor

Table of Step Rating

63

63

63

63

63

63

63

63

63

63

63

MC

MCCB

Control System

CRCA Sheet
Steel Cable Alley

Outgoing MCB
/ MCCB

Neutral
Assembley
Rotary Handle
Capacitor Bank
Cooling Fan

Panel Lock

Earthing Screw
8

Current Transformer

Contactor Section

Busbar
Assembley
CRCA Sheet
Steel Cable Alley

Incomer MCCB

Capacitor Bank

Base Chanel

CRCA Sheet Steel

Enclosure
9

10

11

12

13

14

15

GA Drawings 15 KVAr

Side

Front

Bottom

Foundation
16

GA Drawing 25 to 50 KVAr

Side

Front

Bottom

Foundation
17

GA Drawing 75 to 350 KVAr

IPFC Relay

Volt Meter

Amiter

MCCB

Front

Side

Bottom

Foundation

280
18

Ordering Information
Description- With Normal Duty(Hercules) Capacitor

Product Code

15 KVAr /440V Standard APFC Panel ND

QHCTRB5015X0

25 KVAr /440V Standard APFC Panel ND

QHCTRB5025X0

50 KVAr /440V Standard APFC Panel ND

QHCTRB5050X0

75 KVAr /440V Standard APFC Panel ND

QHCTRB5075X0

100 KVAr /440V Standard APFC Panel ND

QHCTRB5100X0

125 KVAr /440V Standard APFC Panel ND

QHCTRB5125X0

150 KVAr /440V Standard APFC Panel ND

QHCTRB5150X0

175 KVAr /440V Standard APFC Panel ND

QHCTRB5175X0

200 KVAr/ 440V Standard APFC Panel ND

QHCTRB5200X0

225 KVAr/ 440V Standard APFC Panel ND

QHCTRB5225X0

250 KVAr/ 440V Standard APFC Panel ND

QHCTRB5250X0

275 KVAr/ 440V Standard APFC Panel ND

QHCTRB5275X0

300 KVAr/ 440V Standard APFC Panel ND

QHCTRB5300X0

325 KVAr/ 440V Standard APFC Panel ND

QHCTRB5325X0

350 KVAr/ 440V Standard APFC Panel ND

QHCTRB5350X0

Description- With Heavy Duty(Phantom) Capacitor

15 KVAr /440V Standard APFC Panel HD

QHKTRB5015X0

25 KVAr /440V Standard APFC Panel HD

QHKTRB5025X0

50 KVAr /440V Standard APFC Panel HD

QHKTRB5050X0

75 KVAr /440V Standard APFC Panel HD

QHKTRB5075X0

100 KVAr /440V Standard APFC Panel HD

QHKTRB5100X0

125 KVAr /440V Standard APFC Panel HD

QHKTRB5125X0

150 KVAr /440V Standard APFC Panel HD

QHKTRB5150X0

175 KVAr /440V Standard APFC Panel HD

QHKTRB5175X0

200 KVAr /440V Standard APFC Panel HD

QHKTRB5200X0

225 KVAr /440V Standard APFC Panel HD

QHKTRB5225X0

250 KVAr /440V Standard APFC Panel HD

QHKTRB5250X0

275 KVAr /440V Standard APFC Panel HD

QHKTRB5275X0

300 KVAr /440V Standard APFC Panel HD

QHKTRB5300X0

325 KVAr /440V Standard APFC Panel HD

QHKTRB5325X0

350 KVAr /440V Standard APFC Panel HD

QHKTRB5350X0

Note: Manual version also available

19

Regional & Branch Offices:

NORTH - REGIONAL OFFICE: Corporate Office: QRG Towers, 2D, Sector-126, Expressway, Noida-201304, Tel: 0120-3331000, Delhi: Tel: 011-47676700, 23888200,
Chandigarh: Tel: 0172-4232400-401, Dehradun: Tel: 0135-6670202, Noida / Haryana: Tel: 0120-3331000, Ludhiana: Tel: 0161-4676001 / 6024,
Jammu: Tel: 0191-2490424, Sri Nagar: Tel: 0194-2490431, Jaipur: Tel: 0141-3988210, Jodhpur: Tel: 0141-3914645, 3988210,
Lucknow: Tel: 0522-2201032, 2200938, Kanpur: Tel: 0512-6710400, 9935533753

WEST - REGIONAL OFFICE: Mumbai: 301, Everest House, 3rd Floor, 6, Suren Road, Chakala, Andheri (E). Mumbai - 400 093, Tel: 022-67298600-602,
Ahmedabad: Tel: 079-40061111, 40060738-740, Indore: Tel: 0731-2572340-41, 4009998 (Airtel), Rajkot: Tel: 0281-2481112, 2921212,
Nagpur: Tel: 0712-2240932, 2242692, 2242699 Pune: Tel: 020-64016413 / 14, Raipur: Tel: 0771-4243400 / 01,
Surat: Tel: 0261-2350137, 9979890137, Jabalpur: Tel: 0761-4064491
SOUTH - REGIONAL OFFICE: Chennai: Sigapi Achi Building, No. 18 / 3, 6th Floor, Rukmani Lakshmipathy Road, Egmore, Chennai-600008, Tel: 044-42280600, 605,
Bangalore: Tel: 080-49075000, Coimbatore: Tel: 0422-2305767, 2306199, 2305199, Hyderabad: Tel: 040-27533372, 27533355, 27533632, 66320407/0408/6401/6402,
Kochi: Tel: 0484-4099000, Vishakapatnam: Tel: 0891-6514339, Vizag: Tel: 0891-6514339, Vijayawada: Tel: 91+9247058847/57,
Calicut: 09895855499, Madurai: 09994493242, Trivandrum: 09633817795, Hubli: 09448146028, Trichy: 09944460160
Representative Offices: Goa Solapur Gwalior Kathmandu Bhopal

Havells India Ltd.

QRG Towers, 2D, Sector -126, Expressway, Noida - 201 304 (UP), Ph. +91-120-3331000,
E-mail: marketing@havells.com, www.havells.com
Consumer Care No.: 1800 11 0303, 1800 103 1313 (All Connections), 011-4166 0303 (Landline)
Join us on Facebook at www.facebook.com/havells and share your ways to save the planet!
CIN - L31900DL1983PLC016304.

ZHILE00004/DEC12/APR 14

EAST - REGIONAL OFFICE: Kolkata: ICC Tower, 5th Floor, 4 India Exchange Place, Kolkata-700001, Tel: 033-40129851 / 52, Bhubaneshwar:
Tel: 0674-6668101/102/103/104, Guwahati: Tel: 0361-2134521, 2458923, Siliguri: Tel: 0353-2525907, Jamshedpur: Tel: 0657-6542492, 09234369436,
Patna: Tel: 0612-2207221, 2207222, 2207223, 2655518