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TAS PowerTek TPF-56 User Manual

Lt intelligent automatic power factor controller & data logger for capacitor-duty thyristor switches, for high-speed power factor correction
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TPF-56
LT Intelligent Automatic Power Factor Controller
& Data Logger
For Capacitor-Duty Thyristor Switches,
For High-Speed Power Factor Correction
User Manual
Version 1.1.5
Updated on: 22
March 2016.
nd

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Summary of Contents for TAS PowerTek TPF-56

  • Page 1 TPF-56 LT Intelligent Automatic Power Factor Controller & Data Logger For Capacitor-Duty Thyristor Switches, For High-Speed Power Factor Correction User Manual Version 1.1.5 Updated on: 22 March 2016.
  • Page 2 3. Make sure that the discharge time set in the controller matches the capacitor discharge time! 4. This Automatic Power Factor Controller (APFC), TPF-56, is to be used indoor only. 5. Make sure that the Capacitor Bank Discharge Time set in the PF Controller matches with the actual Capacitor Bank Discharge Time.

  • Page 3: Table Of Contents

    Intelligent Power Factor Controller TPF-56 Index Section Page No.  Index page -- 3  Ordering Information -- 4  Features -- 5  Specifications -- 8  Functional block diagram -- 15  PF correction technique -- 16  Typical wiring scheme -- 18 ...

  • Page 4: Ordering Information

    Please specify the “nn” while quoting, ordering, buying etc. Note that the Isolated +12 V DC Supply is from User Side, and the “Return” for all Command Outputs of TPF-56/nn are “Commoned” to 0 V of the +12 V DC Supply, at the TAS Thyristor Switches Side.

  • Page 5: Features

    Intelligent Power Factor Controller TPF-56 Features: • Totally Micro-Controller based logic for measurements, monitoring, analysis & control. • Functionality Suitability: LT PF correction application for Distribution Transformers secondary side used by Electricity Distribution Companies, Private Industries, Offices, Establishments etc. • Protection and Functionality to take care of Supply System abnormalities and various faults.
  • Page 6 Intelligent Power Factor Controller TPF-56 Features (Continued): • Capacitor Banks actual value measurement in terms of KVAr (reactive power) normalized values for rated supply voltage and frequency, for monitoring it’s health. This is on-line monitoring with complex algorithm for getting right values under variable loading conditions authentically.
  • Page 7 • Data Mobilizer – In future, we will add Hand Held Unit (HHU-01) as a separate unit, that can be procured separately for transfer of data from remote site located TPF-56 Unit that can be further uploaded to PC having “Data View” software. Such Unit even have added facilities like fixed set parameter uploading (5 pre-programmed sets of Parameters to be programmed in TPF- 56).

  • Page 8: Specifications

    Intelligent Power Factor Controller TPF-56 Specifications of TPF-56/xx Unit: Rated supply values: 3 – Phase, 4 – Wire supply system. Line-to-Line rated voltage 440V sinusoidal. Rated frequency 50Hz(+/-3Hz) Or 60Hz(+/-3Hz) 2. Auxiliary Supply: Line to Line sinusoidal voltage range 100V - 500V ...
  • Page 9  is Maximum 6 months. Recommended period < 3months. 8. Data Log Non-Volatile Memory: Used for TPF-56 Program Parameter storage, 1 Hour, 30min,15min,10min  interval data log, latest 1024 events data log and Power-down values storage with “Early-Warning-Power-Failed (EWPF)” sequence.
  • Page 10 Intelligent Power Factor Controller TPF-56 Specifications (continued): 9. Mechanical Dimensions: 146 mm 95 mm All Dimensions in mm. Mounting Clamps All 4 sides. •Un-packed net weight of the Unit: 880 gm. 10 of 56 Version 1.1.5 22 March, 2016...
  • Page 11 Intelligent Power Factor Controller TPF-56 Specifications (continued): Front fascia LCD Display Key pad Leds for indication I AM OK LED of status of (Controller Capacitor Banks RS-232 port with “Health” dedicated protocol. status LED) 11 of 56 Version 1.1.5 22...
  • Page 12 Intelligent Power Factor Controller TPF-56 Specifications (continued): Back side terminals Note: Use appropriately rated and type, while replacing the fuse(s) in the field Measurement voltage F3: Fuse for Capacitor (Line To Neutral 300VAC max) Output commands Banks 9 to 16...
  • Page 13 RTCC Battery is replaced, user will have to set RTCC once again to correct date & time. Side view of TPF-56 for seeing Battery insertion slot. The unit after mounting in panel is compatible for enclosure protection class as per DIN 40 050: Front side: IP-54.
  • Page 14 Intelligent Power Factor Controller TPF-56 Specifications (continued): 9. Jumper Selection for RS485 and GSM communication (Continued): DI (RS485) Selecting positions 1 & 2 in both JP1 and JP2 enables RS232 communication for external GSM TX 1 Modem. TXD1 (RS232) Selecting positions 2 & 3 in both JP1 and JP2...

  • Page 15: Functional Block Diagram

    Intelligent Power Factor Controller TPF-56 Functional Description: Front-Panel RS-232 for Rear-Panel Data Downloading RS232/RS485 Functional Block Diagram Three channel 3Ph 4Wire Supply (load) Voltage feedback current feedback Serial Communication. Channels - 2 Ports. V, I, PF and Power Measurement Block RTCC &...

  • Page 16: Pf Correction Technique

    Intelligent Power Factor Controller TPF-56 Functional Description (Continued): PF correction technique Case-1: PF-UPPER & PF-LOWER both set as inductive: LOWER. LOWER. KVAR (Ind) smallest Capacitor bank kVAr x 1.5 width. UPPER. UPPER. KVAR (Cap) No change band. Capacitor addition band.
  • Page 17 (Cap) No change band. Capacitor addition band. Capacitor removal band. There are two PF set-points to be set in TPF-56/16. The UPPER limit and the LOWER limit. TPF-56 ensures that PF-UPPER is never exceeded. Additionally, “No change band” to minimum KVAR band size equal to smallest bank KVAR x 1.5 ensures no hunting during the low KW loading.

  • Page 18: Typical Wiring Scheme

    Intelligent Power Factor Controller TPF-56 Typical wiring diagram for PF correction 18 of 56 Version 1.1.5 22 March, 2016...

  • Page 19: Front Fascia

    Intelligent Power Factor Controller TPF-56 Front fascia – LCD screen PF=+1.000 A _ _ _ _ _ _ _ _ _ _ _ _ _ _ First line of display indicates the PF value, inductive / capacitive PF, mode of operation and fault /OK status: “PF = 1.000”...
  • Page 20 Intelligent Power Factor Controller TPF-56 Front fascia – LCD screen Example of a typical LCD display screen is show below: Meaning of this screen contents: Total no. of banks connected is 16. Power Factor at Load sensing CT is ‘+1.000’...
  • Page 21 Intelligent Power Factor Controller TPF-56 Front fascia – Keypad 21 of 56 Version 1.1.5 22 March, 2016...

  • Page 22: Lcd Display Contrast & Backlit

    Intelligent Power Factor Controller TPF-56 LCD Display Contrast & Back-light. The LCD display Contrast is adjustable by front keyboard. Repetitive strikes of “Right” key would increase the contrast Repetitive strikes of “Left” key would reduce the contrast of LCD display.

  • Page 23: Display Of Various Parameters

    Intelligent Power Factor Controller TPF-56 Display of various parameters Values of various parameters can be viewed by using UP / DN keys & then pressing ENT key. To exit a sub-menu press PROGRAM. PF=+0.980 A This is factory set default display screen giving ---------------------- information on PF, mode, bank &...

  • Page 24: Sub Menu For Display Of Parameters

    Intelligent Power Factor Controller TPF-56 Sub-menu for display of parameters Overall Max. Display Display Display Values Values Phase Power Energy Harmonics Average Maximum R-Phase R-Phase PF Vr-THD -F Voltage Voltage Voltage 1.000 IND 000000000.0 000.0 % 00000.0 (L-N) 0000.0 V 00000.0 (L-N)
  • Page 25 Intelligent Power Factor Controller TPF-56 continued.. Harmonic data of various current & voltage parameters can be viewed by pressing ENT on the respective parameter screen of the Harmonics menu. Following are the sub-menus giving the harmonic data of voltage, current & capacitor current for each phase.

  • Page 26: Method Of Keyboard / Display Usage

    Intelligent Power Factor Controller TPF-56 Method for keyboard / display usage Flowchart for entering into different modes: PRESS If Password Enable Disable Option is PF=+0.980 A OK Enable/Disable. _ _ _ _ _ _ _ _ _ _ _ _...
  • Page 27 Intelligent Power Factor Controller TPF-56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Default Display mode Select 1. Edit Parameter Select 2. Auto Operation Select 3. Manual Operation Continued on next page 27 of 56 Version 1.1.5 22...
  • Page 28 Intelligent Power Factor Controller TPF-56 Select Select Select 1. Edit Parameter 2. Auto Operation 3. Manual Operation PF= +0.980 A PF= +0.980 M OK _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

  • Page 29: Keyboard / Display Operations

    For functioning in automatic PF correction mode. Manual Operation: Pressing ENTER button, while on this screen, will put TPF-56 in Manual mode. If user has switched to Manual Mode and for 5 minutes no key on the keypad is pressed, then TPF-56 will automatically switch to Auto Mode.

  • Page 30: Edit Parameters

    The types of parameters that can be edited are: General & I/O : For general settings. System : For TPF-56 system related settings. Fault : Fault settings. Step : Capacitor bank step settings.

  • Page 31: General & I/O

    Intelligent Power Factor Controller TPF-56 General & I/O Password: Enable or disable password. Password Disable Change Password: Set new value of password (4 digit). Factory default password is “0000”. Change Password : 0000 Load Default: Loads factory set default parameters.

  • Page 32: Fault

    Value for this Under-Load KW can be calculated as shown here. IF Fast off Temperature Flt •Over current: The TPF-56 detects if the supply system is Fast off : overloaded, then it is for warning indication. No capacitor Temperature banks are switched off with this detection.
  • Page 33 Intelligent Power Factor Controller TPF-56 KVAR (Ind) Under Load settings: LOWER. 1.5 x smallest UPPER. Capacitor bank Under- Load. No change band. Capacitor Addition band. KVAR (Cap) Capacitor Removal band. For PF Inductive and PF Inductive : UPPER LOWER 1.5 x Smallest Bank kVAr.
  • Page 34 Intelligent Power Factor Controller TPF-56 •Out of Banks Fault: This is only with Disable and …continued. Enable options. If Enabled, then unit will indicate the out of bank fault if for two consecutive correction cycles, PF is more inductive than Lower PF set point and all the healthy capacitor banks are in ON state.

  • Page 35: Steps

    .These parameters Unequal Bank [14] KVAR :125 are to be defined for each bank kVAr (at defined Capacitor Bank Voltage). TPF-56 has an in-built intelligent Unequal Bank [15] algorithm to select the best possible combination to suit KVAR :150 the exact kVAr requirement for compensation.

  • Page 36: Communication

    Erased from the EEPROM. Set Time • Baud Rate: selectable. HH:MM:SS 4800bps, 9600bps, 19200bps, 57600 bps. The Baud rate should match on both sides, TPF-56 & PC/HHU for communication. Set Date DD:MM:YY • Real Time Clock: Defines the Real Time Clock / Calendar setting.

  • Page 37: Utilization Counter

    • Baud Rate: selectable. 4800bps, 9600bps, 19200bps, 57600bps. The Baud Rate – COM 2 Baud rate should match on both sides, TPF-56 & GSM/GPRS for communication. 9600 • GSM Service Provider: GSM service provider number is to be given. It is a 10digit number. The...

  • Page 38: Notes On Protection And Functionalities

    Intelligent Power Factor Controller TPF-56 Notes on Protection and Functionalities: )If current CT connections are not connected to the TPF-56 unit i.e. if no current is detected or the detected current is below 1.5% of rated load current, then, TPF-56 would show the following display on the LCD.
  • Page 39 Intelligent Power Factor Controller TPF-56 (4)Battery Replacement: The RTCC Battery is Maxell Make, CR2032 type. This can be replaced without opening the Controller through the Slot provided on the Top Left-Hand side of the Controller. The Old Battery should be removed using insulated tip plier and a new Battery is to be placed using the same insulated tip plier.

  • Page 40: Fault Indications And Fault Actions

    Intelligent Power Factor Controller TPF-56 TPF-56 Controller fault indications and fault actions Status Programmable Status Indications Options Action taken appearing in on LCD provided on by TPF-56 Data Sr.No. Display Status / Fault Description Fault Fault description controller Logging Enable / Disable...

  • Page 41: Data Logging Facilities

    TPF-56. A separate User Manual is available for the “Data View” Software.  “Data View” is for not only for data downloading from the TPF-56 Units, but also for presenting the captured information in a User-Friendly manner.

  • Page 42: Power-Fail Monitoring

    PC and the TPF-56 Unit. Aux. Input AC Power “Early Warning Power-failed” monitoring (EWPF): The TPF-56 has the ability to detect the “power-failing” condition by way of an internal “Early-Warning” of impending AC Input Aux. Power Failure, and takes preventive measures for the following: ...

  • Page 43: Commissioning Instructions

    Loose connection or open CT secondary will result in very high voltages getting developed at the CT Connection Terminals which will damage the CT and also damage the TPF-56 Unit as well. 43 of 56 Version 1.1.5 22...
  • Page 44 Wrong values entered can give the wrong performance of the panel. . Once the parameterization is complete, put the TPF-56 Unit in Manual mode to check every bank command is transmitted to the Thyristor switch .

  • Page 45: Fault Finding Guidelines And Trouble Shooting Procedures

    •Check fuse in the unit •Input side fuse blown. is OK & of Proper rating. Processor may be hanged. Switch OFF the TPF-56 Unit does turn ‘ON’ but ‘I AM OK’ LED Unit and again Switch it is steady ON or...
  • Page 46 Intelligent Power Factor Controller TPF-56 Troubleshooting procedure … continued Nature of Fault Probable Reason Action to be taken 1] Serial • • Baud rate and other Select proper baud Communication is communication rate and other not working with parameters selection is...

  • Page 47: Factory Default Settings

    Intelligent Power Factor Controller TPF-56 Factory Default Settings PARAMETER STEP SIZE FACTORY DEFAULT GENERAL I/O Password (Enable/ Enable Disable Disable Disable) Change password 0000 9999 0000 Load default (Yes/ No) THD to display (F–THD/ R- F-THD R- THD F-THD THD)
  • Page 48 Intelligent Power Factor Controller TPF-56 Factory Default Settings PARAMETER STEP SIZE FACTORY SETTINGS Faults Over Voltage limit (%) (resume % set) Over Voltage resume (%) (Limit % Set)-1 Under Voltage limit (%) (resume % set) -1 Under Voltage resume (%)
  • Page 49 Intelligent Power Factor Controller TPF-56 Factory Default Settings PARAMETER STEP SIZE FACTORY Setting STEP 1] Steps Connected : 16 2] Define KVAR Voltage 3] Smallest KVAr Safety Fact 3] Correction Time (cycles) 4] Discharge Time (Seconds) 6] IntrLeaving Dely (Second)
  • Page 50 Intelligent Power Factor Controller TPF-56 Factory Default Settings PARAMETER STEP FACTORY SIZE Settings Communication 1] Panel ID 00000000 99999999 00000001 2] ErasData 4 New ID (Yes/ No) 3] Baud Rate – COM1 4800 9600 4800 57600 57600 19200 57600 4] Set Time...
  • Page 51 Intelligent Power Factor Controller TPF-56 Factory Default Settings PARAMETER STEP SIZE FACTORY DEFAULT Utilization Counters (not editable in the field) 0000000000 1] Bank [1] 0000000000 9999999999 0000000000 2] Bank [2] 0000000000 9999999999 0000000000 3] Bank [3] 0000000000 9999999999 4] Bank [4]...

  • Page 52: Maintenance Copy (Blank Forms For User)

    Intelligent Power Factor Controller TPF-56 Maintenance Copy: PARAMETER As on Date As on Date As on Date As on Date GENERAL I/O Password (Enable/ Disable) Change password Load default (Yes/ No) THD to display (F–THD/ R- THD) Reset energy counter...
  • Page 53 Intelligent Power Factor Controller TPF-56 PARAMETER As on Date As on Date As on Date As on Date Faults Over Voltage limit (%) Over Voltage resume (%) Under Voltage limit (%) Under Voltage resume (%) Under Ld. KW Fault Disable , Off Step , Off Fix .
  • Page 54 Intelligent Power Factor Controller TPF-56 PARAMETER As on Date As on Date As on Date As on Date STEP 1] Steps Connected : 16 2] Define KVAR Voltage 3] Smallest KVAr Safety Fact 3] Correction Time (cycles) 4] Discharge Time (Seconds)
  • Page 55 Intelligent Power Factor Controller TPF-56 PARAMETER As on Date As on Date As on Date As on Date Communication 1] Panel ID 2] ErasData 4 New ID (Yes/ No) 3] Baud Rate – COM1 4800 9600 19200 57600 4] Set Time...

  • Page 56: Manufacturer's Contact Details

    India. Would you like to learn in-depth on the subject then, buy e-Book on-line from Amazon.com Book Title: Reactive Power Compensation on LV Supply. Author: Mr. Tushar P. Mogre, CEO, Director, TAS PowerTek Pvt. Ltd. e-Book Published by: Amazon.com http://www.amazon.com/gp/aw/d/B00o7YLLYY...

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