Power Factor Controller

BR 6000

Manual EPCOS AG
Power Capacitors
Version 2.0 E P.O. Box 80 17 09
D-81617 Munich
St.-Martin-Str. 53
PFC-Hotline
Tel. ++49 89 636 - 23817
Telefax ++49 89 636 - 22748
e-mail: [email protected]
internet: http://www.epcos.com
Power Factor Controller BR6000

Version 2.0 E from 30/05/03

EPCOS FK PM PFC Version 2.0E, June 2003

Power Factor Controller BR6000

CONTENTS
Section 1 General 3

Section 2 Installation of the controller / connection diagram 5

2.1 Current measurement

2.2 Switching outputs
2.3 Alarm output / fault messages

Section 3 Operating modes and programming 7

3.1 Automatic operation / display functions

3.2 Programming
3.3 Programming lock

Section 4 Manual operation / Programming of fixed stages 13

Section 5 Service menu 14

Section 6 Expert mode 14

Section 7 Initial operation 16

Section 8 Control principle 16

Section 9 Troubleshooting 17

Section 10 Interface 18

Section 11 Maintenance and warranty 18

Section 12 Type series 18

Section 13 Technical data 19

Annex: Annex 1 Table of control series 20

Description of control-series editor
Annex 2 Default settings 21
Annex 3 Controller coupling 22
Annex 4 MODBUS Protocol 23

Operating diagram (Brief programming)

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 Power Factor Controller BR6000

Section1 General

The BR 6000 power factor controller is the first of a new generation of controllers
incorporating innovative ideas and a broad diversity of functions.
It is distinguished by user-friendly operation based on menu-guided displays in plain
text. Its new features permit an intuitive mode of operation. Easy-to-understand symbols
and texts in the local language combine simplest operability with self-evident displays.

Another highlight is the option of a user-edited control series - in addition to a set of

integrated control series - allowing the controller to be used in all compensation
networks. The display of diverse line parameters as well as storage of various values of
the compensation network permit simple fault analysis and system monitoring. Several
analog instruments can be obviated thanks to integrated display functions.

The basic version contains a number of additional features:

! Six or 12 switching outputs (depending on the version)

! Switching outputs with a relay or transistor output
! Twenty pre-programmed control series with a self-optimized intelligent control
response
! Control-series editor for user-defined control series
! Complete menu-guided operation and display
! Illuminated graphic display with 2 x 16 characters
! Four-quadrant operation
! Display of various line parameters (V, I, F, Q, P, S...)
· Display of voltage and current harmonics
· Display of temperature
· Monitoring of the individual capacitor power values
! Storage of maximum line-parameter and switching-operation values as well as
of the turn-on times of individual capacitor contactors
! Manual / automatic operation
! Programming of fixed stages and the option of skipping individual outputs
! No-voltage turn-off
! Fault detection for various statuses and interference-message output
! Switchboard-integrated housing 144x144x55 mm

The BR 6000 extended version offers the following options:

BR6000.../ F

· Second target cos phi can be selected externally (tariff conversion)

· Coupling of two controllers (master / slave operation) or extension over 12
stages
· Additional user programmable message relay for cabinet fan, energy supply
message, undercurrent, harmonics limit values, etc.

BR6000.../S

· All features of option F with additional

· RS 232 or 485 interface , MODBUS or ASCII

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Power Factor Controller BR6000
The controller is supplied as standard for an operating voltage of 230 VAC (L-N), a
measuring voltage of 30...300 VAC (L-N) 50/60 Hz and a measuring current of 5A or 1A
(programmable). A voltage converter is required for different operating voltages.

Fig. 1 BR 6000 front view

Operating mode
- Automatic
- Programming
- Manual operation
- Service
COS j =0 , 98 I ND - Expert mode

Enter / OK
Confirm and
1 2 3 4 5 6 7 8 9 10 11 12
store values
Power Factor Controller BR 6000
Blindleistungsregler
Reguladores Automaticos
de Energia Reactiva Auto
Program Increase
Manual
Service selected
parameter
Enter
OK
cos j
Reduce
selected
parameter

Fig. 2 BR 6000 rear view

power factor controller BR6000-R12

BR6000-R12-
meas. voltage: 30 -300V L-N 50/60Hz
supply voltage: 230V L-N 50/60Hz
Ser.No.:

supply- meas. meas. current 1. capacitor-

voltage voltage Im (5A/1A) branch
Ub Um
k l
L1 (R)
L2 (S)
L3 (T)
N
PE
T 6,3A
T 2A

T 2A

only BR6000- 12

L N L N k l RS 232 *

Ub Um Im P1 P2
K1
power factor * option
controller
BR6000

a b 1 2 3 4 5 6 7 8 9 10 11 12

alarm- 2.relay * target COSPHI2 *

relay
capacitor capacitor
contactors 1-6 contactors 7-12

supply meas. meas. alarm-

voltage voltage current relay

L N L N k l a b P1 K1 K2 K3 K4 K5 K6

P2 K7 K8 K9 K10 K11 K12

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 Power Factor Controller BR6000

Section 2 Installation and connection of the controller

The BR 6000 is designed to be incorporated into the front panel of a PFC-cabinet. It

requires a switchboard section of 138 x 138 mm to DIN 43 700. The controller is inserted
from the front and is attached by means of the appended clamps. The controller may
be inserted only by qualified technicians and must be operated in accordance with the
specified safety regulations.
Before the BR 6000 is connected up, all leads and cables must be checked to ensure that
no current is flowing through them and the current converter must be short-circuited.
Care should be taken to ensure that the measuring voltage and current are in the correct
phase position. The measuring-current circuit must be wired with copper leads of
2
2.5mm . The connection should be set up as shown in Fig. 3. The specified safety
regulations must be observed.
The measuring voltage may lie in the range from 30 - 300 V and is connected between
L1-N (corresponds to 50 - 525 V L-L ). A connection between L-L is possible when a
measuring-voltage converter is used and the corresponding phase shift U-I is
programmed (see Programming).
The operating voltage is 230 V +/- 10% and can be connected between L1 - N in a 400-V
power line and between L - L in a 110-V power line.

The coil voltage for the capacitor contactors and the measuring voltage must be drawn
from the same phase conductor, as only the measuring voltage is monitored. (Protection
against direct reconnection of the capacitor contactors in the event of momentary single-
phase power failure)

Fig. 3: BR 6000 Connection plan

Power feed Load side
supply meas. meas.current 1. capacitor
voltage voltage Im (5A/1A) branch
Vb Vm
k l
L1 (R)
L2 (S)
L3 (T)
N
PE
T 6,3A
T 2A

T 2A

only for 12-stage

controllers

L N L N k l RS 232 *

Ub Um Im P1 P2
K1
power factor * only option
controller
BR6000

a b 1 2 3 4 5 6 7 8 9 10 11 12

interference 2.relay* target cos phi2 /

message external *
relay capacitor capacitor
contactors 1-6 contactors 7-12

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Power Factor Controller BR6000

2.1 Current measurement

When installing the current converter, care should be taken to ensure that the load
current flows through it. The outputs of the compensation network must be installed
behind the current converter (in the direction of current flow). If the BR 6000 is
connected up via sum-current converters, the overall conversion ratio is entered.
Current converter clamps should be grounded on one side!

Measurement via sum current converter

Feed 1 Feed 2

K k k K

L l l L
K L K L

k l

k l
Current
measurement
BR6000

2.2 Switching outputs

The switching outputs may take the form of relay outputs (see Fig. 3) or of transistor
outputs. The relevant version is indicated on the controller type-plate.
Transistor outputs require an additional auxiliary voltage (10-24 VDC) for the direct
control of thyristor switches for dynamic power-factor correction (e.g. TSM-C...).

Block circuit of the transistor output

X2:1

to thyristor module
( e.g. TSM-C...)

X2:2

Further stages

X2:6 (12)

J X2:P 200mA
+ -
24VDC

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Power Factor Controller BR6000

2.3 Alarm output / fault messages

The alarm contact is closed in normal operation and opens in the event of a fault. The
relevant fault is simultaneously shown on the display in plain text (alternating with the
standard display in automatic operation). The following fault messages are displayed:

! UNDER-COMPENSATED Display and relay output

! OVER-COMPENSATED Display and relay output
! OVERCURRENT Display and relay output
! MEASURING VOLTAGE ? Display and relay output
! OVERTEMPERATURE Display and relay output
! OVERVOLTAGE Display and relay output
! UNDERVOLTAGE Display and relay output

! HARMONICS Warning / relay programmable

! MEASURING CURRENT < Only display (warning)
! SWITCHING OPERATIONS Only display (warning)

! REMOTE IN* Operating status displays

! REMOTE OUT* For remote access (remote)
! REMOTE STOP* *=only optional

Checking the alarm output

The alarm output can be checked, for example, by generating an artificial fault
'MEASURING VOLTAGE'. This is done by interrupting the voltage supply of the measuring
voltage. A fault message appears after 10 minutes.
(Display: MEASURING VOLTAGE / relay is activated)

Section 3 Operating modes and programming

When the operating voltage is switched on, the BR 6000 briefly displays its designation
and software version, then changes to its normal operating status (automatic operation).
The active cos-phi value is always displayed in the upper line and the currently connected
capacitors are shown as symbols in the lower line (operating display).

Automatic operation The control direction is symbolized

by a closed arrow

Display of 2nd active Connecting-in

Display of active power-line cos phi message relay Connecting-out
The connecting-in arrow is always
located after the maximum possible
number of stages (end stop)
COS j =0, 98 CA P R
An open arrow indicates that the
required blocking time (discharge
1 2 3 4 5 6 7 8 9 10 11 12 time) is running before an impending
switching step

Active capacitor Control direction Supply display (for A double arrow symbolizes fast
branches (here connected-in) 4-quadrant operation) switching of several branches

The power values of the individual capacitors are monitored constantly. If a capacitor is
defective or if the deviation from the rated power is excessive, the corresponding
capacitor is displayed inversely.

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 Power Factor Controller BR6000

Repeated pressing of the "Operating Mode” key takes the user to the various menus in
sequence: Automatic operation - Programming - Manual (manual operation)-
Service - Expert mode and back.

Automatic oper. Programming Manual operation Service Expert mode

to display operation to programming to manual operation to value buffer to special functions

3.1 Automatic operation - display functions

The BR 6000 is set to automatic operation as standard. Capacitor stages are then
automatically connected in or out in order to reach the target power factor. This happens
when the required reactive power exceeds the value of the smallest capacitor stage.
In automatic operation, various network parameters can be displayed by repeatedly
pressing the "ENTER” key:

Action Display

ENTER 1 LINE VOLTAGE in V

ENTER 2 APPARENT CURRENT in A
ENTER 3 REACTIVE POWER in kvar
ENTER 4 ACTIVE POWER in kW
ENTER 5 APPARENT POWER in kVA
ENTER 6 DIFF. kVAR TO TARGET COS
ENTER 7 FREQUENCY in Hz
ENTER 8 TEMPERATURE in °C
ENTER 9 HARMONICS (3.-19) V / %, I / %
Selection via arrow-keys
ENTER 10 THD-V, THD-I in %
ENTER Software version
ENTER Return to: 1 LINE VOLTAGE

The power value specifies the total power (3-phase) assuming symmetrical load. If no
key is pressed for 60 seconds, the display automatically returns to the operating status!

3.2 Programming:
,
Pressing the "Operating mode” key once takes the user from automatic operation to
Programming mode. Parameter 1 ( I-CONVERTER) is reached by pressing "ENTER”.
The upper display always shows the parameter and the lower one the set value. The
values are changed by pressing the é / ê keys. Subsequent pressing of the "ENTER” key
stores the value and takes the user to the next parameter.
To quit programming mode in any step, press the "Operating mode” key.

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LANGUAGE SELECTION: This selects the language of the operating menu

(currently German, English, Spanish)

1 I-CONVERTER PRIM: This selects the primary current of the current converter.
Adjustment is via the é / ê keys. (5...7500A) Save and continue
with ENTER

2 I-CONVERTER SEC: This sets the secondary current of the current converter
(5A or 1A possible). Selection via é / ê. Save and continue with
ENTER

3 END STOPP: By setting the end stopp, the number of active capacitor branches is
matched to the respective capacitor bank. This is done via the é / ê
keys. The visible symbols of the capacitors correspond to the connected
outputs. The maximum possible number of capacitor branches is pre-
set at the works (BR 6000-R12:12 branches). The setting is confirmed
and saved with the ENTER key.

4 CONTROL SERIES: The ratio of the capacitor branch powers determines the control
series, the power of the first capacitor always being assigned the value
1. The control series required for the compensation network is again
selected via the é/ê keys. If the required control series should
exceptionally not be present (Annex 1), the user may define a special
one (control series "E”).More on this point in the control-series editor in
Annex 1. The selected series is entered with the ENTER key, which also
takes the user to the next step.

5 CONTROL PRINCIPLE: The control preference may be selected here:

! SEQUENTIAL connection
! LOOP connection
! INTELLIGENT loop connection (default setting)
! COMBINED CHOKE
See Section 8 for an explanation of the various control modes.
Selection with é / ê keys and confirmation with ENTER leads to the
next point:

6 POWER 1. STAGE: To determine the controller's response sensitivity, the dimensions

of the network's smallest capacitor (stage 1) must be known. They are
entered in two steps in kvar. The integral kvar values (before the
comma) are initially selected via the é / ê keys and saved with
ENTER. The positions after the comma are then selected, again via the
é / ê keys. Saving with the ENTER key leads to the next point.

7 TARGET COS PHI: By setting the target cos phi, the power factor to be attained via
the PF correction is defined. It is also set via the é / ê keys. The
range may be selected from 0.8 inductive to 0.8 capacitive. Confirming
and saving the value with ENTER leads to the next point.

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Power Factor Controller BR6000

8 MEASURING VOLTAGE: Programming the measuring voltage (L-N) of the system

(direct measurement) or the L-N voltage on the primary side of a measuring-voltage
converter. The values programmed here always refer to the voltage L-N in the
system! The voltage is selected via the é /ê keys. Save and continue with ENTER.

9 V - CONVERTER RATIO: Standard setting - NO - (direct measurement)

When a measuring-voltage converter (e.g. for HV- measurement) is used, its
conversion ratio should be programmed here. E x a m p l e : Vo l t a g e
converter 20000V:100 V => Conversion ratio: 200 Selection via the é /ê keys.
Save and continue with ENTER.

Connection of the BR6000 via measuring -voltage converter ( L-N )

operating - meas - meas.current

voltage voltage Im (5A/1A)
Vb Vm k l
L1 (R)
L2 (S)
L3 (T)
N
PE
T 2A

T 2A

BR6000
L N L N k l

Vb Vm Im

10 CONNECTING TIME: This refers to the time between connecting the capacitors to
increase the momentary network capacitance. It should be noted that in practical
operation the real connection time is affected by the discharge time (locking time).
Setting range: 1 sec. ... 20 min. (long time for HV- networks)
Default setting: 10 sec.
Selection is performed via the é /ê keys. Continue with ENTER

11 DISCONNECTING TIME: This refers to the time between disconnecting the

capacitors to reduce the momentary network capacitance.
Setting range: 1 sec. ... 20 min. (long time for HV- networks)
Default setting: 10 sec.
Selection is performed via the é /ê keys. Continue with ENTER

12 DISCHARGE TIME: This is the time for which an individual output is blocked
between connecting and disconnecting. This blocking time has priority over
connecting and disconnecting times. It depends on the capacitor discharge rating
and thus is specified by the compensation network. The discharge time of a
conventional network without additional fast-discharge resistors or chokes should be
set to no less than 40 seconds.
For setting of a second discharge time see 'Expert Mode' point 10
Setting range: 1 sec ...20 min. Default setting: 60 sec.
Selection is performed via the é /ê keys. Continue with ENTER

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Power Factor Controller BR6000

13 ALARM TEMP:

The temperature inside the BR 6000 is measured and converted to the internal
temperature of the switching cabinet. This value can be shown on the display.
The alarm temperature programmed here is the temperature at which the
capacitor stages are disconnected in steps. The controller’s alarm relay
responds after ten minutes. At the same time the display shows the cause of the
alarm (over-temperature). If the temperature drops again, the required
branches are automatically re-connected in steps.
The selection is performed with the é /ê keys. Save and continue with ENTER.

The following parameters are available only for controllers with the/F or /S
options

14 MESSAGE RELAY:

The message relay can be programmed for one of the following options as required:

"Fan”: Relay switches the external cabinet fan.

(Default) The switching threshold can be programmed under point 15.
Display: "R”
"Supply": Message when active power is supplied. Display: "R”

"Undercurrent”: This message appears whenever the measuring current is not

reached. Display: "R” The signal is generated when the value drops
below the response sensitivity of the controller.

"External”: The relay switches if an external input signal (230 VAC) is sent to
the "cos-phi2 /external” input. This function may be used to directly
compensate a larger load, for example - the required 40-second
reconnection delay is already integrated.
Display: Capacitor symbol at the top right of the first line.
When this function is selected, the input cannot be used for the
signal 'target cos phi2' and the output cannot be used for the fan.

"Harmonics”: This message appears when the limit of the total harmonic distortion
THD-V is exceeded. This value can be set under "17 Harmonics” in%

"Remote control R1”: Coupling of two controllers via remote control input,
R1= Controller is configured as controller 1 (master)

"Remote control R2”: Coupling of two controllers via remote control input,
R2= Controller is configured as controller 2 (slave).
A description for the coupling of two controllers can be found in the
annex. When this function is selected, the input cannot be used for
the signal 'target cos phi2' and the output cannot be used for the
fan.

Selection is via the é /ê keys. Save and continue with ENTER.

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Power Factor Controller BR6000

15 and 16 Parameters for message-relay option:

Depending on the programming of the message relay, the following parameters may be
selected here:

! Fan option: Input of the switching threshold for the fan (30-70°C) Only active
when option 'Fan' is selected (temperature input as described under point 13)
! Target cos phi2: Input of the second target cos phi as described under point 7,
e.g. tariff conversion.
Input signal 230 VAC at input cos phi => target cos phi 2.
At the active input, the display shows: 2 cos j …

17 HARMONICS (harmonic limit):

A limit for the total harmonic distortion THD-V (in%) can be entered here. When
this threshold is exceeded, a message is given. THD-V is the ratio of the
geometric sum of the uneven harmonics to the fundamental. A warning is always
shown in the display; an output via message relay only takes place when this
was selected under point 14. Selection is performed via the é /ê keys.
Save and continue with ENTER

CONTRAST

The display contrast can be changed with this menu point. The contrast depends
to a certain degree on the viewpoint of the observer, i.e. on the insertion height
of the equipment in the switching cabinet. The é /ê keys can be used to set an
optimal contrast. The contrast changes after a slight delay.

BASIC SETTING: Selection YES / NO

When the selection is made with YES and confirmed with ENTER, all parameters
are reset to the basic setting made by the PFC-system manufacturer.
(Optimal network values when the controller was supplied with a complete PFC-
system). If the controller is supplied from the works, this point corresponds to
the default setting.
CAUTION: All user settings are lost!

Programming is now completed. The controller has returned to point 1 of the

programming menu.

3.3 Programming lock

The BR 6000 is equipped with a programming lock to ensure protection from

unauthorized or inadvertent changes to the system parameters. The lock can be
activated in expert mode. If the lock is active, all parameters can be checked but not
changed.

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Section 4 Manual operation (initial operation, maintenance, service)

Programming of fixed stages

In manual operation, capacitor branches can be connected/disconnected in the set

control series and switching time - irrespective of prevailing power-line conditions.
The starting condition is STOPP (no stages connected). Connections are made by
pressing the é key. Pressing ê initially leads back to STOPP mode. Repeated pressing of
ê leads to the disconnection of stages. The active operating status and active power
factor are always shown on the display (self-explanatory).

Manual operation
ST OP P C 0, 98 CAP

1 2 3 4 5 6 7 8 9 10 11 12

Pressing ENTER takes the user to the menu point "Programming of fixed stages”. In the
normal case, all stages are programmed for automatic operation (default setting).

Setting of fixed stages

C1: AUT O

1 2 3 4 5 6 7 8 9 10 11 12
Currently selected stage blinks

In special cases, all controller outputs (C1 - C12) may be permanently defined in
succession (continued switching via ENTER) for the following statuses:

! AUTO: Automatic (normal) operation

The relevant output is marked by a capacitor symbol.
! FIXED: The output is continuously connected, e.g. for fixed PFC. The output is
marked by an underlined capacitor symbol.
! OFF: The output is continuously disconnected - e.g. for temporarily disconnecting a
defective capacitor. The capacitor symbol for this output is faded out. Underlining
appears.

The active stage is marked by blinking. The required status is set via é /ê. By pressing
ENTER, the user saves this step and moves to the next stage.
The programmed statuses for the outputs also remain visible on the display in automatic
operation.
After the required settings have been made, pressing the "Operating Mode” key takes the
user to the next menu ("Service”) or further to "Automatic Operation”.

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 Power Factor Controller BR6000

Section 5 Service menu

The service menu is reached by the operating-mode key.

The stored maximum values of the network parameters can be displayed here as well as
the number of switching operations of the individual capacitors and their operating time.
The desired stages [in square brackets] can be selected via the arrow keys.
In addition, a fault memory is available, in which the last 8 fault states of the system are
stored with fault code and in plain text. (This allows, for example, capturing short lived
events of overtemperature or overvoltage)

Action Display

ENTER 1 max. VOLTAGE in V

ENTER 2 max. REACTIVE POWER in kvar
ENTER 3 max. ACTIVE POWER in kW
ENTER 4 max. APPARENT POWER in kVA
ENTER 5 max. TEMPERATURE in °C
ENTER 6 max. THD - V / THD - I in %
ENTER 7 RESET the maximum values
ENTER 8 SWITCHING OPERATIONS C [1] - ...
+/- to C [12]
ENTER 9 OPERATING TIME C [1] - ... in h
+/- to C [12]
ENTER FAULT MEMORY E [1] - .... in plaintext
ENTER FAULT MEMORY RESET
ENTER Back to 1

Section 6 Expert mode

Expert mode is used to set values which remain unchanged for normal operation. This
level has an access code to protect it from improper operation.

· Menu point 1: PASSWORD 6343

· 2 BASIC SETTING NEW [NO] (available: NO/YES)

Storage of active programming as a new basic setting (usually performed by the
PFC-system manufacturer). Caution: The original values are overwritten in the
process!

· 3 SWITCHING OPERATIONS RESET [NO] (available: NO/YES)

The stored switching operations of the capacitor stages are reset to zero. Caution:
No information is then available about the switching frequency of the stages and
thus the status of the network.

· 4 OPERATING TIME RESET [NO] (available: NO/YES)

The stored operating times of the individual outputs are set to zero.

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 Power Factor Controller BR6000

· 5 INTEGRATION TIME [1] s (1...255 sec.)

The integration time (the time required to form the mean values of a
measurement) can be changed for special applications.

· 6 C/k- FACTOR [0.66] (0.4...0.9)

The C/k value calculated from the programmed network values can be matched by
changing this factor. It should not be changed in the normal case!

· 7 SWITCHING POWER max [100] kvar (multiples of the smallest stage)

This factor specifies the maximum power which may be switched in one switching
step. It can be used to control the intelligent control system, which switches several
stages as a function of the power-factor requirement.

· 8 OPERATING LOCK [NO] (NO / YES / 24H)

· 9 SWITCHING OPERATIONS WARNING [10] T (1...255)
After an output has performed this number of switching operations (in thousands), a
warning message is displayed.

· 10 FAST DISCHARGE [NO] (NO or X for the desired stages)

If only some stages of a network are equipped with fast discharge equipment, those
stages can here be indicated with X. In this case, the desired discharge time for these
stages can be specified in the next menu point. Otherwise, menu point 11 is omitted.

· 11 DISCHARGE TIME [1] s (1s ..programmed normal discharge time)

Only available when fast discharge is programmed. The specified discharge time is
then also included in the normal display.

· 12 PHASE U/I [ 0 °] ( 0°, 90°, 180°)

Phase correction between voltage and current in the measuring system.
Normal: 0°, i.e. measuring voltage: L1 - N, current: L1
Example: 90°; measuring voltage: L2 - L3, current: L1
As shown in the example, this setting makes it possible to measure also in systems
without neutral. However, the measuring voltage is not allowed to exceed 300 V (if
necessary, a voltage converter must be used).

· 13 C-TEST [YES] ( YES / NO)

The power of the individual capacitor stages is calculated before and after each
switching operation and compared with the preset value (stage power) of the
capacitor. For a specified deviation from the rated value, a fault message is issued!
This test can be deactivated here.

· 14 C-FAULT [50] % (20...75 %)

The deviation from the rated value of the capacitor, for which a fault message is
generated, can be specified here (see point 13)

· 15 TEST ATTEMPTS [5] ( 2...9)

When at least this number of successive measurements has resulted in a fault in the
capacitor power, a C-fault message is output.

Interface settings (only option .../S)

· 16 BAUD RATE [9600] (4800...19200) Transmission rate

· 17 PROTOCOL [MODBUS] (Modbus or ASCII) Transmission protocol
· 18 ADDRESS [1] ( 1...64 ) Address

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Power Factor Controller BR6000

Section 7 Initial operation

The controller must have been installed before being set up and operated.
All network-specific parameters are fully programmed as described in Section 3.2
(Programming) by being entered in sequence and stored. The controller is then set to
automatic operation with the operating mode key. It is now ready for operation.

Section 8 Control principle

The control response of the BR 6000 can be selected in programming mode. In principle,
the controller has four different control modes:

1. Sequential connection
In sequential connection, the required capacitor stages are successively connected
and disconnected in stages (last in - first out). The ranking of each step always
corresponds to the power of the smallest stage.
Advantage: Exact definition of the next capacitor to be connected in each case
Disadvantage: Long settling time, high switching frequency of the small stages

In order to shorten the settling time, the BR 6000 switches several stages
simultaneously for a large power-factor requirement. This applies to all
control types. The maximum dimensions of the simultaneously switching
branches can be changed in expert mode. If the value of the smallest stage
is pre-selected, the conventional sequential connection is obtained.

2. Loop connection
In this variant, the controller operates in loop mode (first in - first out) which
minimizes the wear on the capacitor bank, i.e. where stages are of equivalent
dimensions, the stage which was disconnected for the longest period of time is
always connected next.
Advantage: Balanced utilization of equivalent stages and thus an increased
operating life of the capacitor bank.
Disadvantage: This mode can only be used in control series with groups of the same
stage power and long settling time, as every switching step corresponds to the value
of the smallest stage.

3. Intelligent loop connection (default setting )

The intelligent control principle combines the advantages of the network-sparing
loop connection (first in - first out) with a much faster settling time, even for large
load skips, and reaches this goal with the fewest possible switching operations of the
capacitor stages. The optimized time response is achieved by the simultaneous
switching of several or larger capacitor groups as a function of the missing power
factor in the power line. Both the number of real switching frequencies of the
capacitors as well as the turn-on times of the branches are considered.
Advantage: Reaches the target cos phi in a fast-optimized settling time with a low
switching frequency of the capacitors.

4. Combined de-tuning (special case for combined de-tuned banks)

Within a combined de-tuned application, 2 adjoining equal steps are switched with
just one joint choke. This pairwise de-tuning requires an appropriate closed control
series (i.e. 1:1:1:1..., 1:1:2:2..., 1:1:2:2:4:4... or similar)
The condition for the switching behavior is defined in such a way that the number of
activated odd steps is always greater than or equal to the number of activated even
steps. The controller complies with the requirements of the control regime while
largely conforming to the intelligent switching behavior.

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 Power Factor Controller BR6000

Section 9 Troubleshooting

Fault Check / Solution

At target cos phi=1 and inductive load, Check terminals of the measuring voltage and
switch-off or connection of capacitor in current (l and k)!
the corrected line Check phase position
Supply / Drawing mismatched

Wrong line cos phi is displayed See above

Display:"UNDER CURRENT” Current in measuring range?

Line interruption?
Wrong current-converter factor?
Current transformer short-circuited?
Display: "OVERCURRENT” Check current-converter ratio
Alarm relay: after 10 min. Go through measuring current range
Check connection and phase position!
Display: "UNDERCOMPENSATED” All stages connected - target cos phi not
Alarm relay: after 10 min. reached: compensation network sufficiently
dimensioned?

Display: "OVERCOMPENSATED” Check connection and phase position!

Alarm relay: after 10 min. Capacitive grid, although all stages
disconnected

Display: "MEASUREMENT VOLTAGE ???” No measurement voltage!

Alarm relay: after 10 min.

Display: "OVERTEMPERATURE” Cabinet temperature too high: Outputs are

Alarm relay: after 10 min. switched off in stages irrespective of power-line
conditions
If a target cos phi is set which deviates from 1
Stages are disconnected for an inductive despite an inductive line load, the display <-
line or connected for a capacitive line (disconnect stages) may light up. The arrows
indicate the control direction and not the line
conditions.

The controller does not connect all Check END STOPP!

stages, or cos phi does not change at the
last stages

In automatic operation, individual stages Check whether individual stages are

are not connected or disconnected: programmed as fixed stages or OFF in the
"Manual operation / Fixed stages” menu!

In strongly asymmetrically loaded lines, Line measurements allow the most favorable
differences may occur between control phase for measuring the power factor to be
response and power-factor determined. The current converter is set
measurement, as the power factor is accordingly for the measuring current.
measured in single phase.

No operating voltage Note: No display, alarm relay is closed

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Power Factor Controller BR6000

Section 10 Interface *

The BR 6000 is equipped with an RS 232 or RS 485 interface as an option.

It can be used to implement the following functions:

! Full parametrization of the controller via a PC

! Remote read-out of all operating statuses and displays via a PC
! Connection of a remote display (system accessories) for clear read-out of all
measurements on large seven-segment triple displays
! Selection of MODBUS or ASCII (output of network parameters in ASCII format for
input as text file for own applications)

Section 11 Maintenance and warranty

The BR 6000 should need no maintenance if the operating conditions are observed.
However, it is recommended that a functional check of the controller be performed in
conjunction with the regular checking of the capacitor bank. In the event of any
interventions in the controller during the warranty period, all warranty claims lapse.

Section 12 Type series and accessories

BR6000-R6 6 relay outputs, 1 fault message output

BR6000-T6 6 transistor outputs, 1 fault message output, 2.message relays

BR6000-R12 12 relay outputs, 1 fault message output

BR6000-T12 12 transistor outputs, 1 fault message output, 2.message relays

Option / F Additional message relay, input for second target cos phi
Option / S As option F, with additional serial interface RS 232 or RS 485

The controllers with transistor outputs are designed for dynamic PFC.
Thyristor switches of type TSM-C... can be controlled directly.

The options are only available for BR6000-R12.

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Power Factor Controller BR6000

13 Technical data

Type series BR 6000....

Outputs 6 ( BR 6000 - 6)
12 ( BR 6000 -12)
Switching power of relay outputs 250 VAC, 1000 W
Number of active outputs Programmable
Operation and display Illuminated graphic display 2 x 16 characters
with convenient operating level
Number of control series 20
User-defined control series 1
Control principle Selectable
Sequential connection, loop connection or
self-optimized switching response
Four-quadrant operation
Operating voltage 230 VAC, 50 / 60Hz
Measuring voltage 30...300 VAC (L-N), 50 / 60Hz
Phase - shift possible
Measuring current X : 5 / 1A selectable
Power drawn < 5 VA
Sensitivity 40 mA / 10 mA
Target cos phi 0.8 inductive to 0.8 capacitive adjustable
Connecting time Selectable from 1 sec ... 20 min.
Disconnecting time Selectable from 1 sec ... 20 min.
Discharge time Selectable from 1 sec ... 20 min.
Fixed stages/ skipped stages Programmable
Alarm relay Standard
No-voltage triggering Standard
Display of power-line parameters Voltage, apparent current, frequency, power
factor, active power, apparent power, missing
kvar, temperature, harmonics
Storage of maximum values Voltage, power factor, active power, apparent
power, temperature, THD-V, THD-I
Storage of switching number Yes, each output
Storage of operating time Yes, each capacitor
Fault Memory Last 8 fault states are stored
Temperature measurement range 0 - 100°C
Housing Switchboard-integrated housing
DIN 43 700, 144 x 144 x 53 mm
Weight 1 kg
Operating ambient temperature -10 to +60°C
Protection type to DIN 40 050 Front: IP 54, Rear: IP 20

OPTIONS:
Option /F Input for second target cos phi
additional user programmable message relay
Controller coupling possible
Option /S 232 (485) As option /F with additional interface
RS232 or RS485

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Annex 1: Table of control series

No. Control series Loop connection

1 1:1:1:1:1:1:1:1:1:1:1:1 Possible
2 1:2:2:2:2:2:2:2:2:2:2:2 Possible
3 1:2:3:3:3:3:3:3:3:3:3:3 Possible
4 1:2:3:4:4:4:4:4:4:4:4:4 Possible
5 1:2:4:4:4:4:4:4:4:4:4:4 Possible
6 1:2:3:6:6:6:6:6:6:6:6:6 Possible
7 1:2:4:8:8:8:8:8:8:8:8:8 Possible
8 1:1:1:1:2:2:2:2:2:2:2:2 Possible
9 1:1:1:1:1:6:6:6:6:6:6:6 Possible
10 1:1:2:2:2:2:2:2:2:2:2:2 Possible
11 1:1:2:2:2:4:4:4:4:4:4:4 Possible
12 1:1:2:2:4:4:4:4:4:4:4:4 Possible
13 1:1:1:2:2:2:2:2:2:2:2:2 Possible
14 1:1:2:3:3:3:3:3:3:3:3:3 Possible
15 1:1:2:4:4:4:4:4:4:4:4:4 Possible
16 1:1:2:4:8:8:8:8:8:8:8:8 Possible
17 1:2:2:3:3:3:3:3:3:3:3:3 Possible
18 1:2:3:4:4:8:8:8:8:8:8:8 Possible
19 1:2:2:4:4:4:4:4:4:4:4:4 Possible
20 1:2:2:2:4:4:4:4:4:4:4:4 Possible

"E" Control-series editor Possible

Control -series editor (programming up to a rating of 20)

The control-series editor allows the user to simply define his/her own control series if the
required control series is not available for any reason.
The last control series - Control Series E - is selected by pressing the "Programming” key
(point 4: Control series) and confirmed with ENTER. This leads to the insertion of an
additional menu point in the main menu -> the control-series editor. It may be reached
via the "Operating Mode” key.

Automatic Programming Control series Manual operation Service Expert mode

editor

In the control-series editor, all stages can be set in succession to the desired value with
the selection keys é / ê. The next stage in each case is reached by pressing ENTER. An
intelligent pre-selection of the stages is integrated, so that only "meaningful”
control series can be generated. The maximum number of stages can be limited by a
programmed END STOPP < 12.
NEW: In the control series editor, the various steps may be programmed up to a rating of
20 (!). The rating >9 is indicated in the display as follows:
10=A, 11=B, 12=C, 13=D, 14=E, 15=F, 16=G, 17=H, 18=I, 19=J, 20=K

The user may quit the editor with the "Operating Mode” key.
EPCOS FK PM PFC - 20 - Version 2.0E, June 2003
Power Factor Controller BR6000

Annex 2: Default settings

Note: The following values for the default settings apply only if the controller is supplied
directly from the works. Otherwise, these values are replaced by the basic settings made
by the manufacturer of the compensation network (optimal values for the relevant
network).

No. Parameter Default setting Programmed values of this

network (to be entered by
network manufacturer or
operator)

0 LANGUAGE ENGLISH
1 I CONVERTER prim. 1000 A
2 I CONVERTER sec. 5 A
3 END STOPP 12 ( 6 )
4 CONTROL SERIES 1
5 CONTROL PRINCIPLE INTELLIGENT
6 POWER 1. STAGE 25.00 kvar
7 TARGET COS-PHI 0.98 IND
8 MEASURING VOLTAGE 230 V L-N
9 V- CONVERTER RATIO - NO -
10 SWITCH- IN TIME 10 sec.
11 SWITCH- OFF TIME 10 sec.
12 DISCHARGE TIME 60 sec.
13 ALARM TEMP. 55 °C
14 MESSAGE RELAY * FAN
15 TEMP. FAN ON 30 °C
16 TARGET COS-PHI 2 0,95 IND
17 HARMONICS THD-V 7,0 %

CONTRAST -7-

Capacitor stages AUTO

Password 6343 Cannot be changed
Integration time 1 sec.
C/k constant 0.66

Max. simultaneous 4 x smallest stage

switching power power

Operating lock - NO -
Switching operations 10,000
warning
Fast discharge - NO -
Phase shift U/I 0°
C - Test - YES -
C - Fail 50 %
Test Attempts 5
Baudrate 9600
Protocol MODBUS
Address 1

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Power Factor Controller BR6000

Annex 3: Controller coupling (Programming under "14 message relay")

For example, coupling is useful when two separate installations are operating on two
transformer supplies and a coupling exists for both systems. When the coupling is closed
(because only one supply is working), it is still possible to access the total compensation
power of both installations via the coupling of the controllers. The network is then
operating in master-slave mode. When all stages of the first controller are connected, the
second controller is taking over and switches the remaining stages.
It is therefore also possible to extend networks easily.
When coupling is requested, it is necessary to program "controller1” (as master) or
"controller2” (as slave) in this menu point.
For coupling, the controllers of the two installations have to be connected as follows:

Controller 1 Controller 2
L N L N k l L N L N k l

Ub Um Im Ub Um Im
Br6000 Br6000
external 2.relay external 2.relay

a b P1 1 2 3 4 5 6 P2 7 8 9 10 11 12 1 2 3 4 a b P1 1 2 3 4 5 6 P2 7 8 9 10 11 12 1 2 3 4

alarm- alarm-
relay relay
capacitor- capacitor- capacitor- capacitor-
contactors 1-6 contactors 7-12 contactors 1-6 contactors 7-12

Coupling switch

- 24V+

When the coupling switch is open, both installations are operating independently. When
the coupling is closed, master-slave operation is initiated automatically.
It is an advantage of this simple solution that an additional serial interface is not required.

NOTE: By coupling a BR6000 with a dynamic controller (BR6000-T), a mixed dynamic

system can be designed that implements economically the advantages of a dynamic fast
network. (Fast changing loads are compensated dynamically and basic loads and slowly
changing loads are compensated conventionally).

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Power Factor Controller BR6000

Annex 4: MODBUS-Protocol - Part 1: only read -register

F Modbus No Register / Function Range unit / digit BR6000

1 0 Reactive Pwr H-Part 32 Bit Long 1 var A-3

1 Reactive Pwr L-Part
2 Active Power H-Part 32 Bit Long 1W A-4
3 Active Power L-Part
4 Apparent Pwr H-Part 32 Bit Long
5 Apparent Pwr L-Part
6 Diff.React.Pwr H-Teil 32 Bit Long
7 Diff.React.Pwr L-Teil

20 Line voltage 16 Bit 1V A-1

21 Apparent current 16 Bit 1A A-2
22 Frequency 16 Bit 1 Hz A-7
23 Temperature (cabinet) 16 Bit 1 °C A-8
24 Temperature (controller) 16 Bit 1 °C System
30 Outputs (relays) 16 Bit Bit1= Rel 1 A-0
31 3. Harmonics – voltage 16 Bit 0,1 % A9.1
32 5. Harmonics – voltage A9.2
33 7. Harmonics – voltage A9.3
34 9. Harmonics – voltage A9.4
35 11. Harmonics – voltage A9.5
36 13. Harmonics – voltage A9.6
37 15. Harmonics – voltage A9.7
38 17. Harmonics – voltage A9.8
39 19. Harmonics – voltage A9.9
40 THD – voltage 16 Bit 0,1 % A-10
41 3.Harmonics – current 16 Bit 0,1 % A9.1
42 5.Harmonics – current A9.2
43 7.Harmonics – current A9.3
44 9.Harmonics – current A9.4
45 11.Harmonics – current A9.5
46 13.Harmonics – current A9.6
47 15.Harmonics – current A9.7
48 17.Harmonics – current A9.8
49 19.Harmonics – current A9.9
50 THD – current 16 Bit 0,1 % A-10
51 Cos Phi ( 100=1.00) 16 Bit 0.01 A-0
60 Failure - register 16 Bit Bit 0-7 A-0
61 Warning - register 16 Bit Bit 0-7 A-0
71...82 Relays 1...12 16 Bit 0 = OFF
1 = ON
101 Language 0–2 1=English P–0
102 I - Converter primary 0 – 255 0=5A... P–1
103 I - Converter secondary 6–7 6=1A... P–2
104 Endstopp 1 – 12 P–3
105 Control series 1 – 21 P–4
106 Control mode 12 – 15 12=Sequ.. P–5
107 Power First Stage 1 0 – 255 P – 6.0
108 Power First Stage 2 0 – 99 P – 6.1
109 Target cos-Phi 1 80 – 120 80=0,8cap. P–7
110 Meas. Voltage 29 – 255 Volt P–8
111 Voltage converter ratio 1 – 126 Ratio P–9
112 Switching – ON Time 1 – 138 Sec / min P – 10
113 Switching – OFF Time 1 – 138 Sec / min P – 11
114 Discharge Time 1 – 138 Sec / min P – 12
115 Alarm temperature 50 – 85 °C P – 13
116 Message relay 19 – 25 19=extern.. P – 14
117 FAN temperature 30 – 70 °C P – 15
118 Target cos-Phi 2 80 – 120 80=0,8cap. P – 16
119 Harmonics THD-voltage 5 – 200 5=0,5%... P – 17
120 Contrast 0 – 10 P
121 Basic settings 0–1 0=No P

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Power Factor Controller BR6000
only – read - register:

F Modbus No Register / Function Range unit / digit BR6000

1 131...142 Rating step 1...12 16 Bit 0-9

151...162 Status: 1 – OFF 16 Bit 1-3 Manual
2 – AUTO
3 – FIXED
170 Control direction: 1 - C – 16 Bit 1-3
2 - STOPP
3 - C+
171 Max. switching power 16 Bit 1-3 Ex
181...191 Discharge time C1 ... C12 16 Bit 1s -----

Part 2: - only – write - register:

F Modbus No Register / Function Range unit / digit BR6000

10 1 Language 0–2 1=English P–0

2 I - Converter primary 0 – 255 0=5A... P–1
3 I - Converter secondary 6–7 6=1A... P–2
4 Endstopp 1 – 12 P–3
5 Control series 1 – 21 P–4
6 Control mode 12 – 15 12=Sequ.. P–5
7 Power First Stage 1 0 – 255 P – 6.0
8 Power First Stage 2 0 – 99 P – 6.1
9 Target cos-Phi 1 80 – 120 80=0,8cap. P–7
10 Meas. Voltage 29 – 255 Volt P–8
11 Voltage converter ratio 1 – 126 Ratio P–9
12 Switching – ON Time 1 – 138 Sec / min P – 10
13 Switching – OFF Time 1 – 138 Sec / min P – 11
14 Discharge Time 1 – 138 Sec / min P – 12
15 Alarm temperature 50 – 85 °C P – 13
16 Message relay 19 – 25 19=extern.. P – 14
17 FAN temperature 30 – 70 °C P – 15
18 Target cos-Phi 2 80 – 120 80=0,8cap. P – 16
19 Harmonics THD-voltage 5 – 200 5=0,5%... P – 17
20 Contrast 0 – 10 P
21 Basic settings 0–1 0=No P

40 Remote control 16 Bit

Byte H = max.Rating 1–9
Byte L = (1 – 4)
0–3
0 – Remote OFF
1 – Switching DOWN
2 – Stopp
3 – Switching UP

Part 3 example:

MODBUS – Function 1 (only read - register) MODBUS – Function 10 (only write - register)

example: Meas. voltage example: Remote control

answer (Remote switching-up) answer

Byte 1: Adress 1 Adress 1 Byte 1: Adress 1 1

Byte 2: Function 1 Function 1 Byte 2: Function 10 10
Byte 3: Register H: 0 Number of B. 2 Byte 3: Register H: 0 0
Byte 4: Register L: 20 Data H 0 Byte 4: Register L: 40 40
Byte 5: Number H: 0 Data L 233 Byte 5: Data 1: 1 1
Byte 6: Number L: 1 CRC L 120 Byte 6: Data 2: 3 3
Byte 7: CRC L 189 CRC H 114 Byte 7: CRC L 88 88
Byte 8: CRC H 206 Byte 8: CRC H 82 82

Data 1: Switching - up with max. 1 Step (1)

Data 2: Remote switching - up (3)
EPCOS FK PM PFC - 24 - Version 2.0E, June 2003
 AUTO MODE

C OS j =0 , 98 C AP PROGRAMMING CONTROL SERIES

EDITOR
1 2 3 4 5 6 7 8 9 10 1112
only available if control
In case of error serie “E” is selected
alternating display between
error and cos Phi

1 LINE VOLTAGE 0 LANGUAGE KVAR-RATIO C 2

400,0 V ENGLISH 11 2 2 2 2 2 2 2 2 2 2

2 APPARENT CURRENT 1 I-CT PRIMARY KVAR-RATIO C 3

88,88 A [ 1000 ] A / X 11 2 2 2 2 2 2 2 2 2 2

UNDERCOMPENSATED. 3 REACTIVE POWER 2 I-CT SECONDARY KVAR-RATIO C 4

88,88 kvar 1000 / [5] A 11 2 2 2 2 2 2 2 2 2 2

OVER-COMPENSATED 4 ACTIVE POWER 3 END STOPP KVAR-RATIO C 5

88,88 KW 11 2 2 2 2 2 2 2 2 2 2

UNDERCURRENT 5 APPARENT POWER 4 CONTROL SERIES

88,88 kVA 11 1 1 1 1 1 1 1 1 1 1 up to capacitor 6 / 12

OVERCURRENT 6 DIFF REACT POWER 5 CONTROL MODE KVAR-RATIO C 12

88,88 kvar [ INTELLIGENT ] 11 2 2 2 2 2 2 2 2 2 2

UNDERVOLTAGE 7 FREQUENCY 6 POWER 1.STAGE RETURN TO 1

50,0 Hz [ 25 ], 00 kvar

MEAS. VOLTAGE ??? 8 TEMPERATURE 7 TARGET COS PHI

25,0°C [ 0,8 ] IND

OVERTEMPERATURE 9 HARMONICS [ 3 ] 8 MEAS.VOLTAGE

U: 0,5% - I: 0,1% [ 230 ] V L -N

OVERVOLTAGE 10 HARMONICS THD 9 V - CT RATIO

U: 0,5% I: 0,3% - NO - Changing
of values
by buttons:
HARMONICS ! SOFTWARE 10 SWITCH - IN TIME
VERSION 2.0 / E [ 10 ] s

SWITCHING 11 SWITCH - OFF TIME

RETURN TO 1
OPERATIONS [ 10 ] s
After 60 sec. without pressing
any button, automatic change
to auto-mode 12 DISCHARGE TIME 16 TARGET COS PHI 2
[ 60 ] s [ 0,95 ] ind

13 ALARM TEMP. 17 HARMONICS

[ 55 °C ] THD-V [ 7 ] %

14 MESSAGE RELAY * CONTRAST

[ FAN ] -9-

15 FAN TEMP. BASIC SETTINGS

[ 30 °C ] RESET - NO -

BACK TO 1
 MANUAL MODE SERVICE EXPERT MODE

STOPP C 0,98 CAP 1 max VOLTAGE 1 PASSWORD ????

400,0 V ( **** )

C1 : AUTO (FIXED / OFF ) 2 max REACTIVE POWER 2 BASIC SETTINGS

88,88 kvar NEW ? [ NO ]

C2 : AUTO (FIXED / OFF ) 3 max ACTIVE POWER 3 SWITCH.OPERATION

88,88 kW RESET [ NO ]

C3 : AUTO (FIXED / OFF ) 4 max APPARENT PWR 4 OPERATING TIME

88,88 kVA RESET [ NO ]

C4 : AUTO (FIXED / OFF ) 5 max TEMPERATURE 5 INTEGRATION

70,0 °C TIME: [ 1 ] s

C5 : AUTO (FIXED / OFF ) 6 max THD U - I 6 C/k FACTOR

0% - 0% [ 0,66 ]

C6 : AUTO (FIXED / OFF ) 7 MAXIMUM VALUES 7 SWITCH. POWER

RESET - NO - max [ ... ] kvar

C7 : AUTO (FIXED / OFF ) 8 SWITCHING OPER. 8 PROGRAM LOCK

C [ 1 ] - 123 [ NO ]

C8 : AUTO (FIXED / OFF ) 9 OPERATION TIME 9 SWITCH. OPERATION

C [ 1 ] - 12h WARNING [ 10 ] T.

C9 : AUTO (FIXED / OFF ) ERROR MEMORY 10 FAST DISCHARGE

E [ 1 ] 08H .... [ NO ]

C10 : AUTO (FIXED / OFF ) ERROR MEMORY 11 DISCHARGE TIME

RESET [ NO ] [ 40 ] s

C11 : AUTO (FIXED / OFF ) 12 Phase U - I

Selecting of [ 0° ]
capacitors C1-C12

C12 : AUTO (FIXED / OFF ) 13 CAP - TEST

[ YES ]

BACK TO 1 BACK TO 1 14 CAP - FAILURE

[ 50 ] %

15 TEST ATTEMPT
[5]

Operating diagram (Brief programming) 16 BAUDRATE

[ 9600 ]
Power Factor Controller BR6000

17 PROTOCOL
[ MODBUS ]
BACK TO 2