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1
Ministry of High Education
Shorouk Academy
The Higher Institute of Engineering Electrical Power and Machines Department
Power Factor Correction
using
Smart Relay
Under supervision of
Prof. Mohamed Morsy shanab
Dr. Abdel-Rahman Khatib
Prepared by
1. Ibrahim Abdel-Aziz Abdel-Gawad.
2. Ayman Ahmed Mohamed Zayed.
3. Hatem Mohamed Abdel-Rahman Seoudy.
4. Amr Mohamed Mosa.
5. Fayek Ali Fathy.
6. Maged Mahmoud Ibrahim.
2004-2005
2
Abstract
The aim of our project is to improve the power factor for a factory by
measuring the reactive power of the loads of the factory by using the
transducer and convert it to a voltage signal which enters into the controller
(Zelio).
The correction is done by chosen a capacitor steps according to the variation
of the reactive power needed by the loads.
These steps are converted to capacitor steps measured by μf, the capacitor
steps make combinations which satisfy the need of the loads.
Zelio make a decision to connect the steps or to disconnect it according to the
program used, which is programmed before.
The connection and disconnection of the capacitors improves the power
factor.
Improving the power factor reduce the bill paid by the factory, improves
voltage profile, and reduce the losses in cables, which reduced the current
used by the same loads.
3
Acknowledgment
Thanks Allah who gives us the power and hope to succeed.
We would like to record our deepest sense of thanks to Assistant Prof.
Abdel-Rahman Khatib for his excellent supervision, continuous
encouragement, simulating discussion, and scientific support, without which
the present study would not have been carried out.
We wish to express our thanks to Prof. Mohamed Morsy shanab the
chairman of Electrical Power and Machines Department for his valuable
support during the years of our study that led to the preparation of this work.
Our special thanks are also extended to all members of Electrical Power and
Machines Department.
4
Contents
Abstract 2
Acknowledgment 3
Contents 4
CHAPTER 1 INTRODUCTION 7
1.1 General 7
1.2 Electrical power network components 8
1.3 Power in resistive and reactive AC circuits 9
1.4 Project outlines 14
CHAPTER 2 ACTIVE, REACTIVE, AND APPARENT POWER 16
2.1 General 16
2.2 Introduction 16
2.3 Power Equations for different load 17
2.4 Understanding Power Factor 20
2.5 Causes of low power factor 23
2.6 Calculating power factor 24
2.7 Typical Percentage Power Factor Values 28
CHAPTER 3 POWER FACTOR CORRECTION 29
3.1 General 29
3.2 Power factor correction 29
3.3 Benefits of Power Factor Correction 36
3.4 Power factor correction sources 36
5
3.5 Advantages of power factor Improvement 37
3.6 Power factor improvement using shunt capacitors 38
3.7 Power factor improvement using synchronous condensers 42
3.8 Graphical calculations of kVAR Requirement 44
3.9 Practical power factor correction 44
CHAPTER 4 CAPACITOR SIZING 51
4.1 General 51
4.2 General rules for rating capacitors 56
4.3 Correction of power factor with capacitors 60
4.4 Power Factor Improvement 61
4.5 Power Factor Corrective Devices 63
4.6 Harmonics and Their Effects 65
CHAPTER 5 MICROCONTROLLER, PLC & CONVENTIONAL CONTROL 68
5.1. General 68
5.2. Microcontroller 68
5.2. Conventional control panel 72
5.3. Programmable Logic controller PLC 74
CHAPTER 6 LAB IMPLEMENTATION MODEL 89
6.1 General 89
6.2 Introduction 89
6.3 Loads 90
6.4 Transducer 91
6.5 The controller (Zelio) 97
6
CHAPTER 7 POWER FACTOR CORRECTION FOR PUMPING STATION 107
7.1 General 107
7.2 Pumping station 107
7.3 Pumping station Load 109
7.4 Pumping Station Capacitor Sizing 110
CHAPTER 8 CONCLUSIONS AND FUTURE WORK 111
8.1 Conclusion: 111
8.2 Future work 112
References 113
Appendex A A1
Appendex B B1
Appendex C C1
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Chapter 1
Introduction
1.1. General In general, electrical systems are made up of three components:
• Resistive.
• Inductive.
• Capacitive.
Resistive loads have a power factor of 1 (100%). This means that all the
power used by resistive equipment is working (real) power. Examples of
purely resistive equipment are heaters, and incandescent lights.
Inductive equipment requires an electromagnetic field to operate. Because of
this, inductive loads require both real and reactive power. The power factor
of inductive equipment is referred to as lagging, and is less than 1 (less than
100%). Examples of inductive equipment are transformers and motors.
Capacitive equipment, or capacitors, also utilizes reactive power; however,
the power factor is referred to as leading. Capacitors are opposite to inductors
in reactive energy consumption; therefore if present in a facility, they
counteract the negative effects of inductive loads.
In modern industrial, shop and office environment the most common of these
is the inductive load. Examples include transformers, fluorescent lights and
AC induction motors.
These types of equipment use windings in order to operate. Through the
proximity or movement of the windings an electromagnetic field is produced
8
which allows the motor or transformer to function. While an inductive load
uses energy in order to do its work, it also needs a certain amount of energy
simply to function properly.
So, there are two distinct types of power needed for an inductive load to
operate active power (measured in kW) which actually performs the work
reactive power (kVA) which sustains the electromagnetic field and does no
actual work.
The apparent power of a system is the total power consumed in operating that
system, or the combination of active power and reactive power.
1.2. Electrical power network components
Electrical power networks consist of three main parts:
A. The source of energy: It is the generators which supply the electrical
energy to the loads as a source or voltage source, its quantity changes with
time as a sinusoidal wave.
B. Loads: it is that components which absorb the electrical energy such as
motors, electrical heating furnaces heaters, lamps ...etc.
C. Distribution equipments: It describes an arrangement of electrical
equipment and components installed in a commercial, industrial, or other
type of facility that provides the necessary electrical power to operate
processes or to provide the desired service in a safe and reliable manner.
The components usually include, but are not limited to, the following
elements:
• Transformers
• Conductors (wire, cable, or bus duct)
• Switches
• Protective devices (fuses, circuit breakers, and relays with voltage and
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current sensing elements)
• Metering (either electro-mechanical or electronic)
• Line reactors, harmonic filters, and resistors
• Power factor correction capacitors
• Motors, drive systems, power and lighting panels, heaters, lights, and
other system loads.
1.3. Power in resistive and reactive AC circuits
Resistive load:
Consider a circuit for a single-phase AC power system, where a 120 volt, 60
Hz AC voltage source is delivering power to a resistive load:
In this example, the current to the load would be 2 amps, RMS. The power
dissipated at the load would be 240 watts. Because this load is purely
resistive (no reactance), the current is in phase with the voltage, and
calculations look similar to that in an equivalent DC circuit. If we were to
plot the voltage, current, and power waveforms for this circuit, it would look
like this:
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Figure (1.1) Voltage current, and Power relationship in Resistive circuit
Note that the waveform for power is always positive, never negative for this
resistive circuit. This means that power is always being dissipated by the
resistive load, and never returned to the source as it is with reactive loads. If
the source were a mechanical generator, it would take 240 watts worth of
mechanical energy (about 1/3 horsepower) to turn the shaft.
Also note that the waveform for power is not at the same frequency as the
voltage or current! Rather, its frequency is double that of either the voltage or
current waveforms. This different frequency prohibits our expression of
power in an AC circuit using the same complex (rectangular or polar)
notation as used for voltage, current, and impedance, because this form of
mathematical symbolism implies unchanging phase relationships. When
frequencies are not the same, phase relationships constantly change.
11
Inductive reactance:
For comparison, let's consider a simple AC circuit with a purely reactive
load:
Figure (1.2) Voltage current, and Power relationship in inductive circuit
Note that the power alternates equally between cycles of positive and
negative. This means that power is being alternately absorbed from and
returned to the source. If the source were a mechanical generator, it would
take (practically) no net mechanical energy to turn the shaft, because no
power would be used by the load. The generator shaft would be easy to spin,
and the inductor would not become warm as a resistor would.
12
RL circuit:
Now, let's consider an AC circuit with a load consisting of both inductance
and resistance:
We already know that reactive components dissipate zero power, as they
equally absorb power from, and return power to, the rest of the circuit.
Therefore, any inductive reactance in this load will likewise dissipate zero
power. The only thing left to dissipate power here is the resistive portion of
the load impedance. If we look at the waveform plot of voltage, current, and
total power for this circuit, we see how this combination works:
13
Figure (1.3) Voltage current, and Power relationship in capacitive circuit
As with any reactive circuit, the power alternates between positive and
negative instantaneous values over time. In a purely reactive circuit that
alternation between positive and negative power is equally divided, resulting
in a net power dissipation of zero. However, in circuits with mixed resistance
and reactance like this one, the power waveform will still alternate between
positive and negative, but the amount of positive power will exceed the
amount of negative power. In other words, the combined inductive/resistive
load will consume more power than it returns back to the source.
Looking at the waveform plot for power, it should be evident that the wave
spends more time on the positive side of the center line than on the negative,
indicating that there is more power absorbed by the load than there is
returned to the circuit. What little returning of power that occurs is due to the
reactance; the imbalance of positive versus negative power is due to the
resistance as it dissipates energy outside of the circuit (usually in the form of
heat). If the source were a mechanical generator, the amount of mechanical
energy needed to turn the shaft would be the amount of power averaged
between the positive and negative power cycles.
The phase angle for power means something quite different from the phase
angle for either voltage or current. Whereas the angle for voltage or current
represents a relative shift in timing between two waves, the phase angle for
power represents a ratio between power dissipated and power returned.
Because of this way in which AC power differs from AC voltage or current,
14
it is actually easier to arrive at figures for power by calculating with scalar
quantities of voltage, current, resistance, and reactance than it is to try to
derive it from vector, or complex quantities of voltage, current, and
impedance that we've worked with so far.
1.4. Project outlines
The projects consists of 8 chapters
Chapter one: is introduction chapter taking about the power system and its
component and the circuits describing it. It also contains the project out lines.
Chapter two: discuss the active, reactive, and apparent power and their
equations for different loads then we would understand the power factor and
its definitions after understanding the power factor we would know the
causes of low power factor and its disadvantages then we would calculate the
power factor and at last there is a typical power factor values for different
load types in the practical life.
Chapter three: discuss the power factor correction and its meaning then show
the benefits of power factor correction. There are different sources of power
factor correction such as static capacitors, synchronous motors, and
synchronous condensers. After discussing the power factor correction sources
we would discuss the advantages of power factor improvement. Then discuss
in brief correcting the power factor by static capacitors and synchronous
motors. Then we must do the power factor correction in practice. So we had
to discuss practical power factor correction.
Chapter four: discuss how capacitors correct the power factor, the capacitors
in single phase and three phase power factor correction applications, general
rules for rating capacitors, size of capacitors for power factor improvement,
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measurement of capacitor current, power factor choices, correction of power
factor using capacitors, power factor improvement, power factor correction
devices, and harmonics and their effect.
Chapter five: discuss control systems such as microcontroller technique,
conventional methods of control, and plc different techniques.
Chapter six: discuss the lab implementation model its loads, transducer,
Zelio, and some photos of our work.
Chapter seven: discuss correction of power factor for a pumping station. First
there some data of the station and its work and the single line diagram of it.
Then there is some reading taken from it describing its loads. And last is a
capacitor sizing for the station for power factor correction.
Chapter eight: It a conclusion of the project and the future work that can be
done.
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Chapter 2
Active, Reactive, and Apparent power
2.1 General
In this chapter we will discuss the active, reactive, and apparent power and
their equations for different loads then we would understand the power factor
and its definitions after understanding the power factor we would know the
causes of low power factor and its disadvantages then we would calculate the
power factor and at last there is a typical power factor values for different
load types in the practical life.
2.2 Introduction
We know that reactive loads such as inductors and capacitors dissipate zero
power yet the fact that they drop voltage and draw current gives the deceptive
impression that they actually do dissipate power. This is called reactive
power, and it is measured in a unit called Volt-Amps-Reactive (VAR), rather
than watts. The mathematical symbol for reactive power is Q. The actual
amount of power being used, or dissipated, in a circuit is called true power or
active power, and it is measured in watts (symbolized by P). The combination
of reactive power and true power is called apparent power, and it is the
product of a circuit's voltage and current, without reference to phase angle.
Apparent power is measured in the unit of Volt-Amps (VA) and is symbolized
by S.
As a rule, true power is a function of a circuit's dissipative elements, usually
resistances (R). Reactive power is a function of a circuit's reactance (X).
Apparent power is a function of a circuit's total impedance (Z).
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2.3 Power Equations for different load
There are several power equations relating the three types of power to
resistance, reactance, and impedance:
Please note that there are two equations each for the calculation of true and
reactive power. There are three equations available for the calculation of
apparent power, P=IE being useful only for that purpose. Examine the
following circuits and see how these three types of power interrelate.
Resistive load only:
18
Reactive load only:
Resistive/reactive load:
These three types of power -- true, reactive, and apparent -- relate to one
another in trigonometric form. We call this the power triangle:
19
22 )()( POWERREACTIVEPOWERTRUEPOWERTOTAL +=
The angle "Φ" in the power triangle is called the power factor angle and is
mathematically equal to:
On a single-phase circuit, the current will usually lag behind the voltage. The
amount of the lag can be measured in degrees (360° for one complete cycle).
The cosine of this phase angle also equals the power factor.
20
2.4 Understanding Power Factor
"Power Factor" is an electrical term used to rate the degree of the
synchronization of power supply current with the power supply voltage. This
term is often misunderstood by ourselves and our customers, or simply
ignored.
It is important that we clearly understand the meaning of "Power Factor" and
its effect on the electrical supply system for the following reasons:
1. a low power factor can increase the cost of power to the user
2. a low power factor can increase the cost of power transmission
equipment to the user
3. a customer may request assistance in selecting equipment to correct a
low power factor
4. Over-correction of power factor by the addition of excessive
capacitance is sometimes dangerous to a motor and the driven
equipment. (above 95% power factor)
5. A customer may, to some extent, use motor power factor rating as a
power factor rating as a criterion in choosing among competing
motors, especially when a large motor is involved.
The power factors in industrial plants are usually lagging due to the inductive
nature of induction motors, transformers, lighting, induction heating furnaces,
etc. This lagging power factor has two costly disadvantages for the power
user. First, it increases the cost incurred by the power company because more
current must be transmitted than is actually used to perform useful work. This
increased cost is passed on to the industrial customer by means of power
factor adjustments to the rate schedules. Second, it reduces the load handling
capability of the industrial plants electrical transmission system which means
that the industrial power user must spend more on transmission lines and
21
transformers to get a given amount of useful power through his plant. This is
shown in the figure below.
Figure (2.1) what is power factor
Power factor is defined as the ratio of the actual power (Watts) to the
apparent power (Volt-amperes). Power factor=Actual Power/Apparent Power
Figure (2.2) relation among active, reactive, and apparent power
From figure 2.2 above, it can be seen that the apparent power which is
transmitted by the power plant is actually composed vectorially of the actual
power and the reactive power. The active power is used by the motor and
results in useful work. The reactive power is wasted and merely bounces
energy back and forth between the motor and the generators at the power
company's plant. If the power factor is corrected, figure (2) shows how the
reactive power element decreases in size and the apparent power element
approaches the size of the actual power used. This means that less power
need to be generated to obtain the same amount of useful energy for the
motor. Power factor correction is discussed below. Power factor is also
22
numerically equal to the cosine of the angle of the lag of the primary input
current with respect to its voltage.
Figure (2.3) relation voltage and current in lagging power factor circuit
From Figure (2.3) above, it can be seen that the current is lagging the voltage
by an angle 0. An ideal power supply would have no lag on lead angle and
the power transmitted to the motor would be a useful power. The equation for
useful or actual power is:
P = El cos Ø
Or
Power = Volts x Current x Cosine of the lag angle 0
Where:
Cos Ø = Power Factor
El = KVA
El cos Ø = KW
If the lag Ø is zero then the cos Ø is equal to one, and the useful or actual
power equals E*l and no power is lost due to reactance in the system.
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2.5 Causes of low power factor
Low power factor is undesirable from economic point of view.
Normally the power factor of the whole load on the supply system is lower
than 0.8. The following are the causes of low power factor:
• Most of the AC motors are of induction type (1-Φ and 3-Φ induction
motors) which have low lagging power factor. These motors work at a
power factor which is extremely small on light loads (0.2 to 0.3) and rises
to 0.8 or 0.9 at full load.
• Arc lamps, electric discharge lamps and industrial heating furnaces
operate at low lagging power factor.
• The load on the power system is varying; being high during morning and
evening and low at other times. During low load period, supply voltage is
increased which increases the magnetization current. This results in the
decreased power factor.
2.4.1 Low power factor disadvantages
The disadvantages of low power factors are three. The first is that
transmission lines and other power circuit elements are usually more reactive
than resistive. Reactive components of current produce larger voltage drops
than resistive components, and add to the total IZ = (I(R + LX)) drop,
therefore, the system-voltage regulation suffers more and additional voltage-
regulating equipment may be required for satisfactory operation of the
equipment using power. The second disadvantage is the inefficient utilization
of the transmission equipment since more current flow per unit of real power
transmitted is necessary due to the reactive power also carried in the power
lines. If the current necessary to satisfy reactive power could be reduced,
more useful power could be transmitted through the present system. The third
disadvantage is the cost of the increased power loss in transmission lines. The
24
increased power loss is due to the unnecessary reactive power which is in the
system. The reactive power losses vary as the square of the reactive current
or as the inverse of the power factor squared.
2.6 Calculating power factor
As was mentioned before, the angle of this "power triangle" graphically
indicates the ratio between the amount of dissipated (or consumed) power and
the amount of absorbed/returned power. It also happens to be the same angle
as that of the circuit's impedance in polar form. When expressed as a fraction,
this ratio between true power and apparent power is called the power factor
for this circuit. Because true power and apparent power form the adjacent and
hypotenuse sides of a right triangle, respectively, the power factor ratio is
also equal to the cosine of that phase angle. Using values from the last
example circuit:
It should be noted that power factor, like all ratio measurements, is a unit less
quantity.
For the purely resistive circuit, the power factor is 1 (perfect), because the
reactive power equals zero. Here, the power triangle would look like a
horizontal line, because the opposite (reactive power) side would have zero
length.
For the purely inductive circuit, the power factor is zero, because true power
equals zero. Here, the power triangle would look like a vertical line, because
the adjacent (true power) side would have zero length.
25
The same could be said for a purely capacitive circuit. If there are no
dissipative (resistive) components in the circuit, then the true power must be
equal to zero, making any power in the circuit purely reactive. The power
triangle for a purely capacitive circuit would again be a vertical line (pointing
down instead of up as it was for the purely inductive circuit).
Power factor can be important; because any power factor less than 1 means
that the circuit's wiring has to carry more current than what would be
necessary with zero reactance in the circuit to deliver the same amount of
(true) power to the resistive load.
Poor power factor can be corrected, paradoxically, by adding another load to
the circuit drawing an equal and opposite amount of reactive power, to cancel
out the effects of the load's inductive reactance. Inductive reactance can only
be canceled by capacitive reactance, so we have to add a capacitor in parallel
to our example circuit as the additional load. The effect of these two
opposing reactances in parallel is to bring the circuit's total impedance equal
to its total resistance (to make the impedance phase angle equal or at least
closer, to zero).
Since we know that the uncorrected reactive power (inductive), so we need to
calculate the correct capacitor size to produce the same quantity of
(capacitive) reactive power. Since this capacitor will be directly in parallel
with the source (of known voltage), we'll use the power formula which starts
from voltage and reactance:
26
Let's use a rounded capacitor and see what happens to our circuit:
The power factor for the circuit, overall, has been substantially improved.
The main current has been decreased, while the power dissipated at the load
resistor remains unchanged. The power factor is much closer to being 1:
27
Since the impedance angle is still a positive number, we know that the circuit,
overall, is still more inductive than it is capacitive. If our power factor
correction efforts had been perfectly on-target, we would have arrived at an
impedance angle of exactly zero, or purely resistive. If we had added too
large of a capacitor in parallel, we would have ended up with an impedance
angle that was negative, indicating that the circuit was more capacitive than
inductive. [2]
It should be noted that too much capacitance in an AC circuit will result in a
low power factor just as well as too much inductance. You must be careful
not to over-correct when adding capacitance to an AC circuit. You must also
be very careful to use the proper capacitors for the job (rated adequately for
power system voltages and the occasional voltage spike from lightning
strikes, for continuous AC service and capable of handling the expected
levels of current).
If a circuit is pure inductive, we say that its power factor is lagging (because
the current wave for the circuit lags behind the applied voltage wave).
Conversely, if a circuit is pure capacitive, we say that its power factor is
leading. Thus, our example circuit started out with a power factor of 0.705
lagging, and was corrected to a power factor of 0.999 lagging.
28
2.7 Typical Percentage Power Factor Values In industrial and commercial facilities, the majority of electrical equipment
acts like resistors or inductors. Resistive loads include incandescent lights,
baseboard heaters, and cooking ovens. Inductive loads include fluorescent
lights, AC induction motors, arc welders, and transformers.
Typical percentage power factor values for some inductive loads are:
Load Power Factor (% lagging)
Induction motors 70-90
Small adjustable speed drives 90-98
Large adjustable speed drives 40-90
Fluorescent lights:
Magnetic ballast 70-80
Electronic ballast 90-95
Arc furnaces 75-90
Arc welders 35-80
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Chapter 3
Power Factor Correction
3.1 General
In this chapter we will discuss the power factor correction and its meaning
then show the benefits of power factor correction. There are different sources
of power factor correction such as static capacitors, synchronous motors, and
synchronous condensers. After discussing the power factor correction sources
we would discuss the advantages of power factor improvement. Then discuss
in brief correcting the power factor by static capacitors and synchronous
motors. Then we must do the power factor correction in practice. So we had
to discuss practical power factor correction.
3.2 Power factor correction
Capacitive Power Factor correction is applied to circuits which include
induction motors as a means of reducing the inductive component of the
current and thereby reduce the losses in the supply. There should be no effect
on the operation of the motor itself.
An induction motor draws current from the supply, which is made up of
resistive components and inductive components. The resistive components
are:
1) Load current.
2) Loss current and the inductive components are:
3) Leakage reactance.
4) Magnetizing current
30
The current due to the leakage reactance is dependant on the total current
drawn by the motor, but the magnetizing current is independent of the load
on the motor. The magnetizing current will typically be between 20% and
60% of the rated full load current of the motor. The magnetizing current is
the current that establishes the flux in the iron and is very necessary if the
motor is going to operate. The magnetizing current does not actually
contribute to the actual work output of the motor. It is the catalyst that allows
the motor to work properly. The magnetizing current and the leakage
reactance can be considered passenger components of current that will not
affect the power drawn by the motor, but will contribute to the power
dissipated in the supply and distribution system. Take for example a motor
with a current draw of 100 Amps and a power factor of 0.75.The resistive
component of the current is 75 Amps and this is what the KWh meter
measures. The higher current will result in an increase in the distribution
losses of (100 x 100) / (75 x 75) = 1.777 or a 78% increase in the supply
losses.
In the interest of reducing the losses in the distribution system, power factor
correction is added to neutralize a portion of the magnetizing current of the
motor. Typically, the corrected power factor will be 0.92 - 0.95 some power
retailers offer incentives for operating with a power factor of better than 0.9,
while others penalize consumers with a poor power factor. There are many
ways that this is metered, but the net result is that in order to reduce wasted
31
energy in the distribution system, the consumer will be encouraged to apply
power factor correction.
Power factor correction is achieved by the addition of capacitors in parallel
with the connected motor circuits and can be applied at the starter, or applied
at the switchboard or distribution panel. The resulting capacitive current is
leading current and is used to cancel the lagging inductive current flowing
from the supply.
a) Capacitors connected at each starter and controlled by each starter is
known as "Static Power Factor Correction" while capacitors connected at a
distribution board and controlled independently from the individual starters is
known as "Bulk Correction".
b) The Power factor of the total current supplied to the distribution board is
monitored by a controller which then switches capacitor banks in a fashion to
maintain a power factor better than a preset limit. (Typically 0.95) Ideally,
the power factor should be as close to unity as possible. There is no problem
with bulk correction operating at unity.
32
3.1.1 Static Correction
As a large proportion of the inductive or lagging current on the supply is due
to the magnetizing current of induction motors, it is easy to correct each
individual motor by connecting the correction capacitors to the motor starters.
With static correction, it is important that the capacitive current is less than
the inductive magnetizing current of the induction motor. In many
installations employing static power factor correction, the correction
capacitors are connected directly in parallel with the motor windings. When
the motor is Off Line, the capacitors are also Off Line. When the motor is
connected to the supply, the capacitors are also connected providing
correction at all times that the motor is connected to the supply. This removes
the requirement for any expensive power factor monitoring and control
equipment. In this situation, the capacitors remain connected to the motor
terminals as the motor slows down. An induction motor, while connected to
the supply, is driven by a rotating magnetic field in the stator which induces
current into the rotor. When the motor is disconnected from the supply, there
is for a period of time, a magnetic field associated with the rotor. As the
motor decelerates, it generates voltage out its terminals at a frequency which
is related to its speed. The capacitors connected across the motor terminals,
33
form a resonant circuit with the motor inductance. If the motor is critically
corrected, (corrected to a power factor of 1.0) the inductive reactance equals
the capacitive reactance at the line frequency and therefore the resonant
frequency is equal to the line frequency. If the motor is over corrected, the
resonant frequency will be below the line frequency. If the frequency of the
voltage generated by the decelerating motor passes through the resonant
frequency of the corrected motor, there will be high currents and voltages
around the motor/capacitor circuit. This can result in severe damage to the
capacitors and motor. It is imperative that motors are never over corrected or
critically corrected when static correction is employed.
Static power factor correction should provide capacitive current equal to 80%
of the magnetizing current, which is essentially the open shaft current of the
motor.
The magnetizing current for induction motors can vary considerably.
Typically, magnetizing currents for large two pole machines can be as low as
20% of the rated current of the motor while smaller low speed motors can
have a magnetizing current as high as 60% of the rated full load current of the
motor. It is not practical to use a "Standard table" for the correction of
induction motors giving optimum correction on all motors. Tables result in
under correction on most motors but can result in over correction in some
cases. Where the open shaft current can not be measured, and the
magnetizing current is not quoted, an approximate level for the maximum
correction that can be applied can be calculated from the half load
characteristics of the motor. It is dangerous to base correction on the full load
characteristics of the motor as in some cases, motors can exhibit a high
leakage reactance and correction to 0.95 at full load will result in over
correction under no load, or disconnected conditions
34
Static correction is commonly applied by using on a contactor to control both
the motor and the capacitors. It is better practice to use two contactors, one
for the motor and one for the capacitors. Where one contactor is employed, it
should be up sized for the capacitive load. The use of a second contactor
eliminates the problems of resonance between the motor and the capacitors.
35
3.1.2 Inverter
Static Power factor correction must not be used when the motor is controlled
by a variable speed drive or inverter. The connection of capacitors to the
output of an inverter can cause serious damage to the inverter and the
capacitors due to the high frequency switched voltage on the output of the
inverters.
The current drawn from the inverter has a poor power factor, particularly at
low load, but the motor current is isolated from the supply by the inverter.
The phase angle of the current drawn by the inverter from the supply is close
to zero resulting in very low inductive current irrespective of what the motor
is doing. The inverter does not however, operate with a good power factor.
Many inverter manufacturers quote a cos Ø of better than 0.95 and this is
generally true, however the current is non sinusoidal and the resultant
harmonics cause a power factor (KW/KVA) of closer to 0.7 depending on the
input design of the inverter. Inverters with input reactors and DC bus reactors
will exhibit a higher true power factor than those without.
The connection of capacitors close to the input of the inverter can also result
in damage to the inverter. The capacitors tend to cause transients to be
amplified, resulting in higher voltage impulses applied to the input circuits of
the inverter, and the energy behind the impulses is much greater due to the
energy storage of the capacitors. It is recommended that capacitors should be
at least 75 Meters away from inverter inputs to elevate the impedance
between the inverter and capacitors and reduce the potential damage caused.
Switching capacitors, Automatic bank correction etc, will cause voltage
transients and these transients can damage the input circuits of inverters. The
energy is proportional to the amount of capacitance being switched. It is
36
better to switch lots of small amounts of capacitance than few large amounts.
[6]
3.3 Benefits of Power Factor Correction
By optimizing your energy use you can:
• Reduce electricity costs by eliminating power factor surcharges
• Enhance equipment operation by improving voltage
• Improve energy efficiency
• Reduce line losses
• Delay costly upgrades
• Free up transformer and distribution system capacity
3.4 Power factor correction sources We improve the power factor by decreasing the desired reactive power from
the feeding source. The following sources of reactive power are used in
improving the power factor:
1. Synchronous motors.
2. Synchronous condensers.
3. Static capacitors.
When we use the suitable source of reactive power we use it corresponding to
the following factors:
1. The reliability of the equipment.
2. The equipment life time.
3. The cost of the buying and installation.
4. The running cost.
5. The maintenance cost.
6. The requirements of the place and easiest of the installation.
7. System requirements.
37
8. Effect on the environment.
3.5 Advantages of power factor Improvement
Installation of power factor improvement device, to raise the power
factor, results in one or more of the following effects and advantages:
1. Reduction in circuit current.
2. Increase in voltage level at load.
3. Reduction in copper losses in the system due to reduction in current.
4. Reduction in investment in the system facilities per kW of the load
supplied.
5. Improvement in power factor of the generators.
6. Reduction in kVA loading of the generators and circuits. This
reduction in kVA loading may relieve an overloaded condition or
release capacity for additional growth of load.
Reduction in kVA demand charges for large consumers. To encourage large
consumers to install power factor improvement devices at their premises,
supply authorities charge such customers as per two part tariff, the first part
being proportional to the maximum kVA demand. To reduce this charge
large industrial consumers install power factor improvement devices. The
power factor can be improved if the lagging kVAR of the equipment is
balanced by a leading kVAR. This can be done either by use of static
capacitors or synchronous condensers.
38
3.6 Power factor improvement using shunt capacitors
3.5.1 General.
Shunt capacitors are used in rating from 15 kVAR to 10000 kVAR.
Small banks of capacitors, up to a few hundred kVAR rating are used on
individual distribution circuits of customers. Capacitor banks of 500-3000
kVAR are used in small distribution substations and those with still larger
rating at large substations.
Capacitors are installed either in groups at one central location, say at
the primary or the secondary of transformer or individually on each motor or
branch circuit feeding a group of motors. They are arranged in 3-phase banks
connected in star or delta.
It is not economical to raise the power factor to unity for the following
reasons:
1. If the power factor is improved to unity for full load conditions, the
power factor would become leading when the load is less than full
load (unless some capacitors are switched off which is generally
difficult).
2. As the power factor approaches unity, the capacity of power
improvement device increases more rapidly e.g. the power factor of an
installation can be improved from 0.8 to 0.9 by a much smaller
capacitive kVAR than which will be needed to raise the power factor
from 0.9 to unity.
3. Improvement in power factor means a reduction in kVA charge.
However installation of power factor improvement devices needs
capital investment. The power factor should be improved to such an
extent that the savings are the maximum.
39
3.5.2 Most economic power factor when kW demands constant.
The fig shows the phasor diagram of an installation having an active power
requirement of P kW. Through installation of capacitors the power factor is
improved from cos Φ1 to cos Φ2 thus causing a reduction in kVA from S1 to
S2. The capacitor kVAR is Q. The losses in capacitors can be ignored.
Let annual charges per kVA of maximum demand per year = A
Annual interest and depreciation charges for capacitor installation = B
per kVAR
Annual savings = A (S1 - S2)
= AP ⎟⎟⎠
⎞⎜⎜⎝
⎛Φ
−Φ 21 cos
1cos
1
Annual cost of capacitor installation = B.Q.
= B.P. (tan Φ1- tan Φ2)
40
Net savings = AP ⎟⎟⎠
⎞⎜⎜⎝
⎛Φ
−Φ 21 cos
1cos
1 - BP (tan Φ1- tan Φ2)
For maximum net savings, 2
)(ΦdsavingNetd should be zero.
AP (0 - sec Φ2 tan Φ2) – BP (0 – sec2 Φ2) = 0
Or sin Φ2 = AB =
demandofkVApereschAnnualkperoninstallaticapacitoroneschAnnual
.maxargvararg
Thus maximum savings are achieved when power factor is improved to
cos Φ2, where Φ2 is given in the last Eq.
3.5.3 Most economic power factor when kVA demand is constant.
The supply authorities try to improve the power factor to reduce the cost of
the plant. The investment in plant is proportional to kVA while the revenue is
a function of active power (kW). The phasor diagram is shown in fig. The
41
kVA output remains constant at S kVA. Addition of leading kVAR in the
system improves the power output from P1 to P2.
Let annual charges on capacitor installation = C per kVAR
Net return per kW of installation per year = D
Annual increase in return = D (P2 – P1)
=D S (cos Φ2 - cos Φ1)
Annual charges on capacitor installation = CQ
= C S (sin Φ1 - sin Φ2)
Net savings = DS (cos Φ2 - cos Φ1) - C S (sin Φ1 - sin Φ2)
For maximum net savings, 2
)(ΦdsavingNetd should be zero.
- DS sin Φ2 + CS cos Φ2 = 0
OR tan Φ2 = DC =
oninstallatiofkWperreturnAnnualcapacitorsofkVARpereschAnnual arg
Thus the most economic power factor is cos Φ2, where Φ2 is given by
the last Eq.
42
3.7 Power factor improvement using synchronous condensers
When the kVAR requirement is small, it can be met through static
capacitors. However when requirement exceeds 10,000 kVAR it is generally
more economical to use the synchronous condensers.
A synchronous condenser is essentially an over excited synchronous
motor. Generally it does not supply any active mechanical power. The
excitation of the machine is varied to provide the necessary amount of the
leading kVAR. The advantages and disadvantages of using synchronous
condensers as compared to static capacitors are as under:
1. A synchronous condenser can supply kVAR equal to its rating and
absorb kVAR up to 50 % of its capacity. Thus a synchronous
condenser of certain kVAR is equal to a static capacitor of that kVAR
and a shunt reactor of 50 % kVAR.
2. By the use of synchronous condenser a finer control is possible than by
use of static capacitors.
3. A synchronous condenser can be overloaded for short periods but a
static capacitor cannot be overloaded.
4. A momentary drop in voltage causes the synchronous condenser to
supply greater kVAR to the system whereas in the case of static
capacitor, the kVAR supplied is reduced.
5. The inertia of the synchronous condenser improves the system stability
and reduces the effect of sudden changes in load.
6. The power loss in a synchronous condenser is much greater than that in
a capacitor.
7. For small kVAR requirements, static capacitors are preferable and
economical. For requirements above 10,000 kVAR or so synchronous
condensers are more economical.
43
8. Static capacitor installations can be distributed in the system. Thus
capacitors can be located near the loads and are more effective.
However small size synchronous condensers are very uneconomical.
As such the synchronous condensers have to be installed at one point
only.
9. The rating of a static capacitor bank can be changed very easily as per
requirements. Capacitor units can be add to the bank or taken away
from it. This is not possible with synchronous condensers.
10. Installation of a static capacitor bank is easy.
11. A failure of one unit of capacitor bank affects that unit only. The
remaining units continue to do their job. However failure of a
synchronous condenser means loss of total condenser is very small as
compared to the failure rate of a capacitor bank.
12. Synchronous condenser adds to the short circuit currents in the system
and increase the circuit breaker ratings.
Synchronous condensers are mostly used by utilities at large sub-stations
to improve the power factor and voltage regulation. Machines up to 100
MVAR ratings or even higher have been used. The field current is regulated
automatically to give a desired voltage level. A typical instance is of 150
MW to be transmitted over a distance of 240 km. If the receiving end power
factor is 0.85, the sending end power factor is 0.65 and sending end voltage
1.5 times receiving end voltage. Addition of 75 MVAR synchronous
condenser at receiving end improves the sending end power factor to 0.88and
reduces the voltage drop in transmission line by 50%. In addition the
synchronous condenser reduces the switching surges due to the sudden
connection or disconnection of the line to the system. [1]
44
3.8 Graphical calculations of kVAR Requirement
If the kW and initial power factor of an installation are known, the
capacitor kVAR required to improve the power factor to a new value is given
by
)tan(tan 21 Φ−Φ= PQ
Where Q = Capacitor kVAR
P = kW requirement
cos Φ1 = initial power factor
cos Φ2 = new power factor
The capacitor kVAR can also be determined by using the fig which has
been drawn between kVAR and kW for different values of power factors. It
is evident that any intercept (say OK) represents kVA whose horizontal
components OF is the corresponding kW and vertical component kF is the
kVAR.
3.9 Practical power factor correction
When the need arises to correct for poor power factor in an AC power
system, you probably won't have the luxury of knowing the load's exact
inductance in henrys to use for your calculations. You may be fortunate
enough to have an instrument called a power factor meter to tell you what the
power factor is (a number between 0 and 1), and the apparent power (which
can be figured by taking a voltmeter reading in volts and multiplying by an
ammeter reading in amps). In less favorable circumstances you may have to
use an oscilloscope to compare voltage and current waveforms, measuring
45
phase shift in degrees and calculating power factor by the cosine of that
phase shift.
Most likely, you will have access to a wattmeter for measuring true power,
whose reading you can compare against a calculation of apparent power
(from multiplying total voltage and total current measurements). From the
values of true and apparent power, you can determine reactive power and
power factor. Let's do an example problem to see how this works:
First, we need to calculate the apparent power in kVA. We can do this by
multiplying load voltage by load current:
As we can see, 2.308 kVA is a much larger figure than 1.5 kW, which tells us
that the power factor in this circuit is rather poor (substantially less than 1).
Now, we figure the power factor of this load by dividing the true power by
the apparent power:
46
Using this value for power factor, we can draw a power triangle, and from
that determine the reactive power of this load:
To determine the unknown (reactive power) triangle quantity, we use the
Pythagorean Theorem "backwards," given the length of the hypotenuse
(apparent power) and the length of the adjacent side (true power):
47
If this load is an electric motor, or most any other industrial AC load, it will
have a lagging (inductive) power factor, which means that we'll have to
correct for it with a capacitor of appropriate size, wired in parallel. Now that
we know the amount of reactive power (1.754 kVAR), we can calculate the
size of capacitor needed to counteract its effects:
Rounding this answer off to 80 µF, we can place that size of capacitor in the
circuit and calculate the results:
48
An 80 µF capacitor will have a capacitive reactance of 33.157 Ω, giving a
current of 7.238 amps, and a corresponding reactive power of 1.737 kVAR
(for the capacitor only). Since the capacitor's current is 180o out of phase
from the load's inductive contribution to current draw, the capacitor's reactive
power will directly subtract from the load's reactive power, resulting in:
This correction, of course, will not change the amount of true power
consumed by the load, but it will result in a substantial reduction of apparent
power, and of the total current drawn from the 240 Volt source:
49
The new apparent power can be found from the true and new reactive power
values, using the standard form of the Pythagorean Theorem:
22 )()(Re powerTruepoweractivepowerApparent +=
kVApowerApparent 50009.1=
This gives a corrected power factor of (1.5kW / 1.5009 kVA), or 0.99994,
and a new total current of (1.50009 kVA / 240 Volts), or 6.25 amps, a
substantial improvement over the uncorrected value of 9.615 amps! This
50
lower total current will translate to less heat losses in the circuit wiring,
meaning greater system efficiency (less power wasted).
51
Chapter 4
Capacitor Sizing
4.1 General
In this chapter we will discuss how capacitors correct the power factor, the
capacitors in single phase and three phase power factor correction
applications, general rules for rating capacitors, size of capacitors for power
factor improvement, measurement of capacitor current, power factor choices,
correction of power factor using capacitors, power factor improvement,
power factor correction devices, and harmonics and their effect.
4.1.1 How capacitors correct power factor?
Capacitors are characterized by leading kVAR in the phasor diagram or
power triangle. This is opposite to the inductive kVAR (refer to the following
diagram).
Figure (4.1) Phasor diagram for power factor correction
cosφ = P/S
sinφ = Q/S
Q = P tanφ
52
Q = S sinφ
Φ = phase displacement angle
S1 = uncompensated apparent power
S2 = compensated power with capacitors for compensation
The angle φ: is the phase angle between the voltage and current waveforms.
The reactive power is defined by
A capacitor of Q kVAR will compensate for the inductive kVAR and
produce cos φ= 1.
It is not common practice to produce cos φ= 1 with capacitors because this
may result in overcompensation due to load changes and the response time of
the controller. Generally public utilities specify a value (cos φ2) to which the
existing power factor (cos φ1) should be corrected.
The reactive power to be compensated is determined as follows.
Connection and rating of capacitors
A general expression for the kVAR rating of a capacitor (single-phase
connection) is:
53
4.1.2 Capacitor in single-phase PFC application
The capacitor is connected across the phase and neutral and is subjected to
the phase voltage. The above equation, without any change, is applicable to
such capacitors.
4.1.3 Capacitor in three-phase PFC application
4.1.3.1 Star connection
The partial capacitor is subjected to a voltage of
Thus total kVAR compensation of all three partial capacitors:
Figure (4.2) Star connection
54
4.1.3.2 Delta connection
The capacitor is subjected to line voltage UN, phase to phase.
Thus total kVAR compensation:
Figure (4.3) Delta connection
From the above equations it follows that for the desired Q kVAR:
Thus for the same amount of kVAR compensation a star connection requires
the triple capacitance of a delta connection. On the other hand, for the same
nominal voltage UN in delta connection a 3 thicker dielectric film is
required to get similar values of electric field strength.
Calculation of capacitor ratings using standard tables
Capacitors can be rated by multiplying the active power P given on the rating
plate of the motor by the value in the table below.
To find the right value, choose your existing power factor (here 0.7), then
move horizontally to the column of the desired power factor (here 0.9). The
value you find there is the one to multiply by the active power of the motor
(0.54).
55
Thus, for the last example:
Capacitor output in case of operating voltage and/or frequency different to
nominal ratings
Note:
1) U (new) < UN
2) f (new): 50 or 60 Hz; in case of higher frequencies, losses have to be taken
into consideration, thermal data sheet can be used.
Desired power factor (cos φ2) Existing power
factor (cos φ1)
1.0
0.98
0.96
0.94
0.92
0.90
0.85
0.80
0.75
0.70
0.40 2.29 2.09 2.00 1.93 1.86 1.81 1.67 1.54 1.41 1.27
0.45 1.99 1.79 1.70 1.63 1.56 1.51 1.37 1.24 1.11 0.97
0.50 1.73 1.53 1.44 1.37 1.30 1.25 1.11 0.98 0.85 0.71
0.55 1.52 1.32 1.23 1.16 1.09 1.04 0.90 0.77 0.64 0.50
0.60 1.33 1.13 1.04 0.97 0.90 0.85 0.71 0.58 0.45 0.31
0.65 1.17 0.97 0.88 0.81 0.74 0.69 0.55 0.42 0.29 0.15
0.70 1.02 0.82 0.73 0.66 0.59 0.54 0.40 0.27 0.14 -
0.75 0.88 0.68 0.59 0.52 0.45 0.40 0.26 0.13 - -
0.80 0.75 0.55 0.46 0.39 0.32 0.27 0.13 - - -
0.85 0.62 0.42 0.33 0.26 0.19 0.14 - - - -
0.90 0.48 0.28 0.19 0.12 0.05 - - - - -
56
4.2 General rules for rating capacitors
In a plant that is still in the design phase an average power factor of cos φ1 =
0.7 can be assumed for the reactive power loads. To compensate to cos φ=
0.9, the value 0.54 for (tan φ1–tan φ2) can be taken from the table above. In
this case a capacitor rating of about 50 % of the active power rating would be
selected.
With existing operating plant the necessary values can be taken by
measurements.
To determine the correct capacitor rating, accurate values of the connected
power and operating times should be known.
This calculation is only valid where the load conditions are more or less
constant. Under extreme load variations, e.g. heavy motor loads (inductive)
during production hours and only heating and lighting during the night, the
average values used to determine capacitor ratings would not be sufficient for
peak inductive loads. In such cases it is recommended to take meter readings
during a one-day period, for example, to obtain exact instantaneous values of
current, voltage and cos φ
4.2.1 Size of capacitors for power factor improvement The size of capacitors to improve the power factor of the system at certain
point can be computed with the help of the computer studies of the system.
Manual calculations can also be made of comparatively small distribution
system for the capacitor kVAR required to improve the power factor say
from cos φe (existing) to cos φd (desired) with the following equation:
KVAR = KW (tan φe – tan φd)
Or
KVAR = Kw * MF Where MF = multiplying factor
57
The monogram shown in fig. 15.12 solves this equation. With the help of this
monogram the MF for any improvement in the power factor can be read
directly. Capacitor kvars required for this improvement shall be the simple
multiplication of MF and KW as shown in the following example.
Fig (4.4) Nomogram for calculating multiplying factor required to determine
capacitor kVAR; Multiplying factor (MF) = tan φe – tan φd
Example: We are required to find out the capacitor rating to improve the
power factor of 100 kw load from 65 % to 85 %(desired power factor) on the
respective scales and extend to the multiplying factor scale to get MF as 0.55.
Then the required kVAR rating of capacitor is 100*0.55 = 55.0.
4.2.2 Measurement of capacitor current
The current drawn in each phase of an LT capacitor may be measured by
means of a low rang tong tester and these values are compared with the
standard values for the capacities mentioned below in Table 15.5 at different
operating voltages within a tolerance of 5 to 10%.
These values are based on the relation:
(KVAR) 2 = (kVAR) 1*(V2/V1) ^2; (kVAR) 1 =3V1 I1
58
Where, (kVAR) 2 and V2 are the rated values and (kVAR) 1 is the kVAR at
measured voltage V1 and I1.
The difference in the amperage drawn from supply mains with and without
capacitors at the normal operating load can be noted and the values for the
following capacities of motors can be compared with the current values given
against each.
3HP 1 kVAR 0.65-0.92 A
5 HP 2 kVAR 1.0-1.5 A
7.5 HP 3 kVAR 1.45-1.75 A
10 HP 4 kVAR 2.5-3.4 A
Table (4.1)
KVAR
390 V
(A)
400 V
(A)
415 V
(A)
430 V
(A)
440 V
(A)
1 1.30 1.34 1.39 1.42 1.47
2 2.6 2.65 2.78 2.84 2.94
3 3.9 4.0 4.16 4.23 4.40
4 5.25 5.35 5.56 5.72 5.87
5 6.5 6.7 6.96 7.2 7.34
6 7.85 8.5 8.32 8.62 9.81
7.5 8.80 10.00 10.40 10.60 11.20
10 13.00 13.40 13.9 14.40 14.7
12.5 16.3 16.8 17.4 18.00 18.4
15.0 19.4 20.0 20.8 21.5 21.87
20.0 26.0 26.6 27.8 28.5 29.40
25 32.6 33.5 34.8 36.0 38.00
59
If the difference in amperage agrees with the above value for that particular
rating of the motor, the capacitor may be taken as genuine.
4.2.3Power Factor choices
Power Factor correction can be done when you are moving, building or
releasing new premises. In this case you should ensure that your assessments
of power costs include an analysis of Power Factor. In the near future you
will probably be charged according to your Power Factor, particularly if you
are a large user.
Power Factor correction can also be improved in existing facilities. Initially,
you should measure the Power Factor at your workplace and discuss your
options with your power supplier or consultant.
The use of Power Factor correction equipment has a number of advantages:
• In the form of a capacitor bank, it can be installed as close as possible
to the meter point or the equipment that is the main culprit. This
reduces the total current supplied by the electricity utility to your
premises, but has no detrimental impact on plant.
• It has often been used to increase the power-carrying capacity of long
cables. For example, new equipment may need to be installed which
will overtax the amp rating in existing underground cabling. Instead of
replacing cables or installing new switchboard equipment—an
expensive task–it is possible to increase capacity through Power Factor
correction equipment.
• It can be an economical solution to the problem of filtering out the
spikes that cause equipment failure. An increase in the use of
electronic equipment in offices and manufacturing situations means
that this is an expensive problem that needs to be dealt with.
60
• Installing filter reactor equipment in series with the capacitor bank
increases the continuity and integrity in your supply. This results in
fewer fluctuations and circuit breaks, and reduced equipment damage.
Installing capacitors will have a typical pay back period of one year.
4.3 Correction of power factor with capacitors
4.3.1 Description
Power factor is the relationship (phase) of current and voltage in AC
electrical distribution systems. Under ideal conditions current and voltage are
"in phase" and the power factor is "100%." If inductive loads (motors) are
present, power factors less than 100 % (typically 80 to 90 % can occur)
Low power factor, electrically speaking, causes heavier current to flow in
power distribution lines in order to deliver a given number of kilowatts to an
electrical load.
4.3.2 The Effects
The power distribution system in the building, or between buildings, can be
overloaded by excess (useless) current.
Electrical costs are increased, generating and power distribution systems have
their capacity measured in KVA (kilovolt amps).
KVA = VOLTS X AMPS X 1.73 (three phase System) ÷ 1,000
With unity power factor (100%), it would take 2,000 KVA of generating and
distribution network capacity to deliver 2,000 KW. If the power factor
dropped to 85%, however, 2,353 KVA of capacity would be needed. Thus we
see that low power factor has an adverse effect on generating and distribution
capacity.
61
Low power factor overloads generating, distribution, and networks with
excess KVA.
If there is a large building, there should be considering correcting poor power
factor for either or both of these reasons:
• To reduce additional power factor charges and
• To restore the (KVA) capacity of overloaded feeders within the
building or building complex. [5]
4.4 Power Factor Improvement
When using power factor correction capacitors, the total KVAR on the load
side of the motor controller should not exceed the value required to raise the
no-load power factor to unity. Over corrective ness of this value may cause
high transient voltages, currents, and torques that can increase safety hazards
to personnel and possibly damage motor driven equipment.
Never connect power factor correction capacitors at motor terminals on
elevator motors, plugging or jogging applications, multi-speed motors or
open transition, wye-delta, auto-transformer starting and some part-winding
start motors.
If possible, capacitors should be located at position 2 (see diagram). This
does not change the current flowing through motor overload protectors.
Connection of capacitors at position 3 requires a change of overload
protectors. Capacitors should be located at position 1 for applications listed in
paragraph 2 above. Be sure bus power factor is not increased above 95%
under all loading conditions to avoid over excitation.
62
Diagram
Desired Power Factor Percent
Original Power Factor Percent
80% 85% 90% 95% 100% 0.583 0.713 0.849 1.004 1.333 60% 0.516 0.646 0.782 0.937 1.266 62% 0.451 0.581 0.717 0.872 1.201 64% 0.388 0.518 0.654 0.809 1.138 66% 0.328 0.458 0.594 0.749 1.078 68% 0.270 0.400 0.536 0.691 1.020 70% 0.214 0.344 0.480 0.635 0.964 72% 0.159 0.289 0.425 0.580 0.909 74% 0.105 0.235 0.371 0.526 0.855 76% 0.052 0.182 0.318 0.473 0.802 78% 0.026 0.156 0.292 0.447 0.776 79%
0.130 0.266 0.421 0.750 80% 0.104 0.240 0.395 0.724 81% 0.078 0.214 0.369 0.698 82% 0.052 0.188 0.343 0.672 83% 0.206 0.162 0.317 0.646 84% 0.136 0.291 0.620 85% 0.109 0.264 0.593 86% 0.083 0.238 0.567 87% 0.028 0.183 0.512 89% 0.155 0.484 90% 0.127 0.456 91% 0.097 0.426 92% 0.066 0.395 93%
63
0.034 0.363 94% 0.329 95% 0.292 96% 0.251 97% 0.143 99%
Assume Total plant load is 100 KW at 60% power factor. Capacitor KVAR rating necessary to improve power factor to 80% is found by multiplying KW (100) by the multiplier in table (0.583) which gives KVAR (58.3), nearest standard rating (60 KVAR) should be used.
4.5 Power Factor Corrective Devices
4.5.1Capacitors
Power factor correction capacitors are the most common method of
correcting power factor. They can be:
• Installed at various locations on your electrical system
• Switched on by large loads such as electric motors
4.5.2Controlling capacitors
A controller provides automatic switching of capacitor units and
maintains the power factor level under any changes in operation or
load.
4.5.3 Adjusting existing capacitors
Existing capacitors may be correctly sized but incorrectly controlled,
leading to poor overall power factor. Blown protection fuses on
capacitors take the capacitor off-line.
Looking at the condition and control of existing capacitors and fuses,
especially after a shutdown, may solve some power factor problems.
64
4.5.4 Installing the right size motor
Over sizing motors without proper power factor correction is a leading
cause of low power factor. One of the most effective means of
improving power factor is by installing correctly sized motors for the
job. This will also reduce energy consumption and your total energy
bill.
4.5.5 Power Quality Effects
Harmonics, a power quality phenomenon, may be generated by some
electrical equipment, such as:
• Adjustable speed drives
• Switched power supplies
• Electric smelters
These installations require carefully designed power factor capacitors
or in some cases harmonic filters to avoid amplifying harmonics which
may damage components of your electrical system. The presence of
harmonics in your electrical system points to a power quality problem.
65
4.6 Harmonics and Their Effects
4.6.1 Introduction
Disturbances are caused in the electrical supply system by non-linear
loads, and particularly by present day equipment. These modern equipments
are designed to offer optimum performance at lower running costs, but in turn
they play havoc with the supply and hence affect the performance of other
equipment connected in the system. These disturbances include harmonic
distortions, voltage unbalance, voltage surges, voltage impulses etc. The
effect of voltage and current harmonics can be noted at far of places in
equipment connected to the same circuit. This paper discusses briefly the
cause of harmonics, effect of electrical equipment with stress on the effect of
harmonics distortion on capacitors.
4.6.2 Sources & Effect of Harmonics
Harmonics distortion is produce due to the presence of non-linear
loads. These non-linear loads draw non-sinusoidal currents, which when
flow through the system result in non-sinusoidal voltage distortion. The
amount of distortion in a system depends on the characteristics of the
transmission and distribution system.
Following are some of the sources of harmonics:
1. Transformers under no loads and light loads.
2. Saturated reactors.
3. Rotating machines.
4. Arc furnaces.
5. Induction furnaces.
6. Gas discharge lighting.
7. Rectifiers.
66
8. Industrial drives.
9. Electrolysis plants.
10. Energy conservation devices like soft starters, electronics chokes for
tubular fluorescent lamps, electronic fan regulators, etc.
11. Equipment with switched mode power supplies such as T.V. receivers
& personal computers.
4.6.3 Effect on Capacitors
The impedance of a capacitor is inversely proportional to the
frequency. Hence capacitor offers a low impedance path for the harmonic
currents.
The fact effects of harmonics on capacitors are:
1. Increased capacitor current.
2. Increased kVAR losses.
3. Higher temperature rise.
4. Blowing of fuses.
5. Bursting of capacitors.
6. Resonance between the capacitors and the system inductance.
The capacitors can be mathematically modeled to find the effect of harmonics
on them. The Dielectric losses depend on the loss angle (tand) of the
capacitor. The loss angle increases with the increase in the harmonic order.
This results in increase in the dielectric losses.
67
4.6.4 Reduction of Harmonic Distortion
Harmonic currents can be significantly reduced in an electrical system by
using a harmonic filter.
In its basic form, a filter consists of a capacitor connected in series with a
reactor tuned to a specific harmonic frequency. In theory, the impedance of
the filter is zero at the tuning frequency; therefore, the harmonic current is
absorbed by the filter. This, together with the natural resistance of the circuit,
means that only a small level of harmonic current will flow in the network.
4.6.5 Harmonic Analysis
The first step in solving harmonic related problems is to perform an analysis
to determine the specific needs of your electrical distribution system. To
determine capacitor and filter requirements, it is necessary to establish the
impedance of the supply network and the value of each harmonic current.
Capacitor, reactor and filter bank equipment are then specified under very
detailed and stringent computer analysis to meet your needs. [8]
68
Chapter 5
Microcontroller, PLC & conventional control
5.1. General
In this chapter we will discuss control systems such as microcontroller
technique, conventional methods of control, and plc different techniques.
5.2. Microcontroller
5.1.1 Introduction
The easiest way to meet the requirements Specified by the project’s objective
with a limited amount of hardware was by the use of a microcontroller. But
the decreased complexity in hardware offered by the microcontroller results
in increased complexity in the software within it. It was natural to expect that
this project would require a considerable amount of software, but also
hardware skills. Before going into details about these three units, a
description of all the components Used to build them will be given.
5.1.2 What is a Microcontroller?
“A microcontroller is a computer-on-a-chip, or, if you Prefer, a single-chip
computer. Micro suggests that the Device is small, and controller tells you
that the device Might be used to control objects, processes, or events.”
1. “Primarily, the microcontroller is capable of storing and Running a
program (its most important feature). The Microcontroller contains a
CPU, RAM, ROM, I/O lines, Serial and parallel ports, timers, and
sometimes other Built in peripherals such as A/D and D/A
converters.”
2. The “heart” of each of the three devices Described in this project is
in fact a microcontroller. Two different models were used; the
69
AT90S2313 [Figure 2] and the more powerful AT90S8515 [Figure
1]. Both are 8 bit Microcontrollers with RISC architecture
manufactured by Atmel. They belong to a family of microcontrollers.
Figure 5.1. Pin description of AT90S8515
Figure 5.2. Pin description of AT90S2313
Table (5.1) is a comparison between the AT90S2313 and AT90S8515
microcontrollers.
AT90S2313 AT90S8515 Units
Program Memory 2 8 KB
RAM 128 512 Bytes
EEPROM 128 512 Bytes
Max Clock Speed 10 8 MHz
UART Yes Yes
SPI No Yes
8bit timer Yes Yes
16bit timer Yes Yes
I/O Lines 15 32
Power Consumption 2.8 3 mA(at 4MHz, 3V)
70
The I/O Ports are of course essential to a microcontroller, for its ability to
Control. The AT90S8515 delivers four ports with 8 pins each, a total of 32
I/O pins. Any pin can be configured as an input or an output, and this pin
Assignment does not have to remain static but can change dynamically in
runtime. All signal levels are Digital, so the microcontroller can connect only
to digital devices. The pressure sensor used in the altimeter unit is an
analogue device. Therefore for it to interact with the microcontroller, an ADC
was used, to convert from analogue to digital signal levels. Two
timers/counters an 8bit and a 16bit, are available in both microcontrollers for
counting and timing Purposes. The number of bits determines the accuracy of
the measurement. A timer is for example used for measuring the width of a
pulse in the Camera Trigger Unit.
5.1.3 Using of microcontrollers:
A lot of microcontrollers are used in modern equipment and electronic
devices. Some of them are used by small companies in control, measurement
or other equipment; others are used for serious applications by the military,
security services, banks, medical services etc. Each microcontroller executes
the algorithm or program uploaded into its memory. Usually this algorithm is
written in Assembler (even if you write the program in C it will be translated
into Assembler during compilation); rarely the algorithm is written in Basic
or Java. If you write a program for a microcontroller you are interested in
your work being protected against unauthorized access or copying, so you
want to control distribution of your devices. Each microcontroller should be
programmed before using. There are different techniques to do it depend on
manufacturer and type of microcontroller.
71
5.1.4 How we can use microcontroller in power factor correction?
As modern appliance designs begin implementing variable speed Induction
(IM), Brushless DC (BLDC) and Switched Reluctance (SR) motors, the use
of an Active Power Factor Correction (APFC) circuit will become
Unavoidable Unlike universal motors, in which the speeds are controlled by
varying the firing angle of TRIACs, these motors require multi-phase
inverters that operate from a DC bulk power supply. While a simple diode
bridge and capacitors are commonly used in generating a DC voltage for
small equipment, applying this technique for appliances with large motors
will cause excessively high current harmonic content on the power line.
Many of the new appliances will need an APFC circuit to satisfy the IEC
61000-3-2 current harmonic requirements. An APFC circuit will also give a
close-to-unity power factor, thus significantly reducing the RMS current
drawn from the AC supply. Therefore, depending on the power level, using
an APFC circuit can eliminate the need for special AC power wiring, giving
the end-user more flexibility in powering the appliance. An APFC circuit has
a bank of capacitors at its output to function as a reservoir and to supply the
instantaneous current demands from the load. The circuit draws power from
the AC mains to keep the storage capacitors charged at a constant average
voltage. The APFC controller shapes its input current waveform on the AC
mains to maximize its power factor and minimize harmonic contents. With a
72
properly designed circuit, the AC mains recognize the APFC circuit as an
ideal resistor.
5.1.5 Microcontroller benefits
Implementing an APFC circuit using a microcontroller is more involved than
using a stand-alone chip solution. The most obvious impact is a longer
development time, therefore cost. The microcontroller-based solution,
however, does offer several benefits as discussed below.
Manufacturing flexibility: The first obvious benefit is manufacturing
flexibility. Using a microcontroller-based APFC design gives manufacturing
the flexibility to build one design for multiple products.
Monitoring complex conditions: Having a microcontroller on board also adds
the ability to monitor complex conditions and implement advanced safety
features that can not easily be implemented in a purely analog solution. For
example, if the design incorporates a temperature sensor, a programmable
current or power limit as a function of temperature can be implemented.
Digital communication: While communication may not be applicable for
most appliances today, the ability for the APFC circuit in future appliances to
communicate to other systems may be required. Having a microcontroller on
board will enable this capability.
5.2. Conventional control panel
At the outset of industrial revolution, especially during sixties and seventies,
relays were used to operate automated machines, and these were
interconnected using wires inside the control panel. In some cases a control
panel covered an entire wall. To discover an error in the system much time
was needed especially with more complex process control systems. On top of
73
everything, a lifetime of relay contacts was limited, so some relays had to be
replaced. If replacement was required, machine had to be stopped and
production too. Also, it could happen that there was not enough room for
necessary changes. Control panel was used only for one particular process,
and it wasn’t easy to adapt to the requirements of a new system. As far as
maintenance, electricians had to be very skillful in finding errors. In short,
conventional control panels proved to be very inflexible. Typical example of
conventional control panel is given in the following picture.
In this photo you can notice a large number of electrical wires, time relays,
timers and other elements of automation typical for that period. Pictured
control panel is not one of the more “complicated” ones, so you can imagine
what complex ones looked like. [11]
74
Disadvantages of a classic control panel
- Too much work required in connecting wires
- Difficulty with changes or replacements
- Difficulty in finding errors; requiring skillful work force
- When a problem occurs, hold-up time is indefinite, usually long.
5.3. Programmable Logic controller PLC
5.3.1 Introduction
Of all the devices that are used to control manufacturing operations. The
programmable logic controller (PLC) is one of the most important. The first
PLCS were introduced in the early 1960S. Mainly by the automobile industry
up until then the automatic control of manufacturing equipment was achieved
using hundreds, and even thousands, of relays enclosed in metal cabinets.
The annual automobile-model changes required frequent modifications to the
production lines and their associated relay-control system. Because the
control systems were complex, the modifications took a lot of time, and
errors often occurred when making connections. For these reasons, control
engineers developed a computerized programmable system to replace the
relay racks.
This presented a big challenge for many companies. In effect, computers that
had previously been used to do accounting jobs were modified to respond to
the needs of industry. Little by little, the techniques were improved and more
users of the new technology were found. However, a full decade went by
before the new concept was systematically adopted by manufacturers.
Today, the programmable logic controller is the main control devise used in
industry. More than 50 manufacturers offer hundreds of different models.
75
5.3.2 What exactly a Plc?
The programmable controller is basically a computer controlled
System containing a micro processor that is programmed with a
programming panel or keyboard.
The PLC receives input signal and sends output signal in response to the
programmer logic. The program generally consists of contacts timers
counters and math function. Chart of programmable controller developments:
Nature of developments Year
Programmable controller concept developed 1968
Hardware CPU controller, with logic instructions, 1k of memory and 128 I/O points
1969
Use of several (multi) processors within a PLC – timers and counters; arithmetic operations; 12k of memory and 1024 I/O points.
1974
Remote input / output systems introduced 1976
Microprocessor-based PLC introduced 1977
Intelligent I/O modules developed Enhanced communications facilities Enhanced software features (e.g. documentation) Use of personal microcomputers as programming aids
1980
Low cost small PLCs introduced 1983
Networking of all levels of PLC, computer and machine under standard, hierarchical control of industrial plants
1985 on
76
5.3.3 Programmable logic controller consists of 5 basic parts
1. A central processing unit (CPU), which is a computer that can
simulate the required relay contacts and relay coils, as well as the
connections between them.
2. An input module, which serves as an interface between the actual
control devices and the CPU.
3. An output module, which serves as an interface between the CPU and
the actual devices that are being controlled.
4. A programming unit consisting of a keyboard and monitor to program
the CPU. It enables us to select different types of relays and contacts
that the computer can simulate, as well as the way they are to be
connected.
5. A power supply that furnishes the power needed by the CPU by the
input / output modules. And by the programming unit.
The five parts of a PLC
Output Module
CPU
Central Processing
Unit
Input Module
Control Devices
ControlledDevices
ProgrammingUnit
Power Supply
77
5.3.4 Logic circuit
1- AND circuit
L S2 S1 0 0 0 0 1 0 0 0 1 1 1 1
2- OR- circuit
H S2 S1 0 0 0 1 1 0 1 0 1 1 1 1
3- NOT circuit L S 1 0 0 1
S1 S2
L
+
ـــ
HS1
S2
+
ــــ
L
S
& S1 LS2
≥ S1 LS2
S L
78
5.3.5 Coils and contacts
All programmable controllers receive input signals and send output signals.
The programmable controller must have a program in its memory to react to
when it receives these input signals and sends output signals.
The program symbols for a PLC input will look like a normally open or
normally closed contact used in typical electrical diagrams.
These symbols are shown in fig (5.3).
The program symbol for a PLC output will also look similar to symbols
used in typical electrical diagrams. In fig (5.4) we can see close together.
The easiest way to be introduced to these program symbols is to see a
typical electrical diagram of a start-stop switch controlling a motor starter
converted to a PLC program. Figure (5.5) shows this
In fig 5.5 we can see that normally open and normally closed push-
button switch symbols are used to represent the start and stop switches, and a
contacts symbol is used to represent the motor starter auxiliary contacts,
Typical PC normally open contact symbol
Typical PC normally closed contact symbol
Figure 5.3
Tropical P.C. output symbols
MS1
MS1 Stop
Typical electrical diagram converted to a P.C. program.
Figure 5.5
Figure 5.4
Start
79
which are used to seal the normally open start push button. A circle is
normally used to represent coils.
5.3.6 Counters:- The function of the counters is like to the timers, but the counters are
recording the number of times that the two ends of the counter can touch each
others, where the timer is counting periods.
Fig is showing the main idea for the function of simple counters that when
we conduct the tow points of counting (100/03) , the stored number will be
increased by the value of (1) and will be stored in the record number (046) ,
and we be stored in the record number (046) , and we can see here in this
example that the final value of counting is (100)and the accumulated value is
(80)so the rest will be (20) , and when the counting reaches to (100)the point
(046/15)will be changed from (0) to ( 1 ) so the output (010/02)will be
changed too.
5.3.7 Function block counter The block is containing a
number called (preset value)
and a middle symbol of counter
(CTR) ,and there is a recorder
at the bottom , which stores the
times of switching off the keys
, at the right there are tow
inputs , the first for counting
and the other for preset . and also at the right, there are tow outputs, the first
at the top, and the output signal will be sent through it, that this signal will be
(0), when the counting is less than the preset value, and when the counting
Preset Value
CTR
Storage Register
Enable(Count)
Reset
Output
Not Outpu
80
reaches to this value (0) the output will be changed from (0) to (1) and the top
output and the bottom output will be opposite to each other.
5.3.8 The up counting and the down counting:-
There are many kinds of counters with different applications. There is a kind
which is counting by up counting that when the input signal will be positive
(+), the accumulated value will be (0) and the counting will start to increase,
when the two ends will be conducted. Also, there is counter that the counting
is starting from the preset value and the counting will be decreased by the
value of (1) when we conduct the two ends, and every time we repeat this
process, the accumulated counting will be decreased until it reaches to (0),
here the position will be sent.
010
02
046
15
CTU Pr 100 AC 80
046
20
CTR
4003 0007
4
CTR
4003
1003
0007
1003
0005
0005
81
The reset end:- Here, the accumulated value will be (0) and the counting will start again, and
there are two outputs for the counter, one is at the top which called (output),
and the other will be at bottom. Shape 37 will show the different applications
for the different kinds of counter which have been pre explained.
5.3.9 Timers:-
Clock in fig (1) is set for
10 seconds. When switch 1
closes and the clock motor
has operated for 10
seconds, which is the
preset time, the timer's
20
CTR
4003
0006
20
CTR
4003
1003
0006
0006
1004
01
12
TMR 1
10 Second
Lamp 1
Lamp 2
TMR 1
TMR 1
Up(Storage Register)S12DOWN
CLEAR =900(Preset value)
01
12
CTR
82
contacts change. This means that normally closed contacts would open and
de-energize lamp 2, and the normally open contacts would close and energize
lamp 1.
The TON timer in fig 2 is reset by opening the enable contacts that are marked
111\01. This means that any time these contacts open, timer 030
accumulative value returns to zero. When the accumulative value of a timer is
0, it is said to be in the reset condition. When the contacts close again, the
timer will begin timing and the accumulative value will increase until the
accumulative value equals the preset time or until the enabled contacts are
open again.
Fig 3 shows the program for retentive timer with the RTR reset instruction.
We can see that the retentive
timer can keep track of the
accumulative times when the
motor is running. Any time the
motor is not running, the enabled
contacts are opened, and the
timer stops. When the motor
begins running again, the timer
starts accumulating time again. When the motor accumulates enough running
time for maintenance, the timer can be reset to record running time until the
next maintenance interval.
The timer in fig 4 consists of several basic parts, there are two sets of
contacts used with this timer that control it but are not actually a part of the
timer .the contacts on the top left side of the timer function block are the
timer enable contacts.
The contacts on the bottom left side of the timer function block are called
reset that mean the timers accumulative value resets to 0.
03
111
RTO 02
111 031
031
RTR
83
5.3.10 Math Function:-
1-Addition
2-subtraction 3-multiplication 4-Division
4 xxx
Preset Value
Time Base
4XXX
Register where Accumulative value
Stored
10
T 1 .0
4003
1005
1006
0002
111
11
030G
520
031G
514 1034+
111
03
033G
742
034G
100 642-035
111
04
036G
20
038G
24 000X
039X
480
040
111
05
041G
150
042G
025 006X
0٤٣X
000
044
84
5- Data comparison
5.3.11 PLC programming method
1. Ladder diagram (LAD)
2. Control System Flowchart (CFS)
3. Statement List (STL)
5.3.12 Programming the PLC
In order to program a PLC, we must ''write'' the operations it has to perform.
These instructions are typed on the programming unit keyboard, observed on
the monitor, and stored in the CPU memory. From the very beginning,
particular attention was devoted to the method of programming. The
technical criteria stipulated that the system should be quickly and easily
programmable and reprogrammable by the user. The plc was therefore
carefully designed to make it simple to use. However, it is useful to have
some computer knowledge to program a PLC.
110
00
070G
100
075=
100 00
010
110
00
070G
050
075
100 00
010>
110
00
075G
100
070
050 00
010<
85
5.3.13 How PLC controller works
Basis of a PLC function is continual scanning of a program. Under scanning
we mean running through all conditions within a guaranteed period. Scanning
process has three basic steps:
Step 1
Testing input status. First, a PLC checks each of the inputs with intention to
see which one of them has status ON or OFF. In other words, it checks
whether a sensor or a switch etc. connected with an input is activated or not.
Information that processor thus obtains through this step is stored in memory
in order to be used in the following step.
Step 2
Program execution. Here a PLC executes a program, instruction by
instruction. Based on a program and based on the status of that input as
obtained in the preceding step, an appropriate action is taken. This reaction
can be defined as activation of a certain output, or results can be put off and
stored in memory to be retrieved later in the following step.
Step 3
Checkup and correction of output status. Finally, a PLC checks up output
status and adjusts it as needed. Change is performed based on the input status
that had been read during the first step, and based on the results of program
execution in step two. Following the execution of step 3 PLC returns to the
beginning of this cycle and continually repeats these steps. Scanning time is
defined by the time needed to perform these three steps, and sometimes it is
an important program feature.
86
5.3.14 Advantages of PLCs over relay cabinets:-
There are many reasons for the universal popularity of PLCS we list them as
follows:
1. The PLC is flexible. Because it is programmable, it is easy to modify
as the need arises. In the case of control system using physical relays,
any change means replacing relays and reconnecting them. This is
risky because connection errors can easily be made.
2. The flexibility of PLCs is extraordinary. Thus, when ever a given
control system is no longer required, it can readily be reprogrammed
for a completely different system. With relay racks, such a change
over is not feasible and the racks would simply be scrapped, replaced,
and rewired.
3. The PLC is much less bulky than a conventional relay control system
for example, a CPU having a volume of 0.1m3 replaces hundreds of
control relays, as well as the hard wiring needed to connect the
contacts and holding coils furthermore, the PLC consumes for less
energy.
4. A PLC is more reliable than a relay cabinet. One important reason is
the absence of moving parts relays have moving parts that deteriorate
as the equipment gets older. Relay contacts wear out and have to be
replaced. All of which requires a sustained maintenance program.
"Relay coil" and "contacts" in CPUs never wear out.
5. In addition, the opening and closing of relay contacts, while rapid,
takes a certain time. The time interval is not the same for all relays and
moreover, it may change with time. In some applications where the
opening and closing sequence is important, the time variations may
introduce control errors. Such errors are very difficult to diagnose
because of their random nature. In the case of PLCs, the "contact"
opening and closing times are fixed. Consequence operations are
87
never a problem the relay cabinet has to be assembled by hand-
hundreds and even thousands of wires must be connected between the
contacts and relay coils, which imply a big chance of making errors.
These errors are difficult to locate. By contrast, with a PLC, all that is
needed in to draw a ladder diagram according to a plan. Here again, if
an error is made, the hand-held programming unit (or the more
sophisticated computer) contains utility functions that make it easy to
correct a mistake.
5.3.15 Control panel with a PLC controller
With invention of programmable
controllers, much has changed in
how a process control system is
designed. Many advantages
appeared. Typical example of
control panel with a PLC controller
is given in the following picture.
5.3.16 Advantages of control panel that is based on a PLC controller:
1. Compared to a conventional process control system, number of wires
needed for connections is reduced by 80%.
2. Consumption is greatly reduced because a PLC consumes less than a
bunch of relays.
88
3. Diagnostic functions of a PLC controller allow for fast and easy error
detection.
4. Change in operating sequence or application of a PLC controller to a
different operating process can easily be accomplished by replacing a
program through a console or using a PC software (not requiring changes
in wiring, unless addition of some input or output device is required).
5. Needs fewer spare parts.
6. It is much cheaper compared to a conventional system, especially in cases
where a large number of I/O instruments are needed and when operational
functions are complex.
7. Reliability of a PLC is greater than that of an electro-mechanical relay or a
timer.
89
Chapter 6
Lab Implementation Model
6.1 General
In this chapter we would discuss the lab implementation model its loads,
transducer, Zelio, and some photos of our work.
6.2 Introduction
To build the practical model we have to:
• Choose suitable loads.
• Measure the reactive power needed by the load, and convert it to
analog signal.
• Use the analogue signal as an input to the controller (Zelio).
• Program Zelio (the controller) to decide to connect or disconnect the
capacitors.
• Connect the output to contactors and connect the contactors to the
capacitors to connect or disconnect it after the controller decides
according to the program.
• Connect the capacitors in parallel with the loads to give it the reactive
power needed, if it is connected.
The practical model consists of:
1. Loads.
2. Transducer.
3. Controller (Zelio).
4. Contactors.
5. Capacitors.
90
6.3 Loads
The first step that we have done in the practical model was chosen the loads.
We have chosen 4 different loads to cover almost all types of loads that may
be in a factory, these loads are:
1. Shock coil
This load is a representation for a pure inductive load. The power
factor of the pure inductive load is 0 theoretically, but practical the chock coil
has a small resistance of coil itself. So the real power factor of the chock coil
is 0.1. And to have different values of power factor we put a resistive load in
series with it. This resistive load is a tungsten lamp. The lamp is 60W. By
adding the lamp in series with the coil the net power factor becomes 0.89.
2. Fluorescent lamps:
This load is a representation for a lighting load in a factory. There are 3
lamps each lamp is connected to single phase of the 3 phase. The power
factor of the fluorescent lamps is about 0.4.
3. No load motor:
The last 2 loads are static loads. This load can be classified as a
dynamic load. This motor is taken at no load to improve that the motor at no
load have a worst power factor. The power factor of this motor is 0.15.
4. Loaded motor:
This load is a dynamic one too. As we know all the mechanical
processes are driven by an electric motors. So we take a loaded motor to be a
representation for that motors which drive the mechanical load. The motor
loading of the motor is variable, so it can represent different values of power
factor. This load also improves that the power factor is improved by loading
the motor. In other words the motor has the best power factor at full load. The
power factor of full load of this motor is 0.8. Most of the AC motors are of
induction type (1-Φ and 3-Φ induction motors) which have low lagging
91
power factor. These motors work at a power factor which is extremely small
on light loads (0.2 to 0.3) and rises to 0.8 or 0.9 at full load.
From load 3, 4 we can notice the different power factor from no load to
full load in motors.
A1: chock coil + lamp
A2: florescent lamp
A3: no load motor
A4: loaded motor
A4*: loaded motor at no load
The following readings were taken from the loads we have chosen:
Load pf(cos Φ) Q P A1 0.89 22 46 A2 0.41 66 30 A3 0.16 95 17.5 A4 0.81 68 92
A1A2 0.64 88 76 A1A3 0.48 116 65 A1A4 0.84 89 140 A2A3 0.29 160 50 A2A4 0.69 133 132 A3A4 0.57 160 113
A1A2A3 0.45 181 95 A1A2A4 0.75 154 170 A1A3A4 0.65 180 163 A2A3A4 0.53 225 145
A1A2A3A4 0.6 250 190
6.4 Transducer
To improve the power factor for the loads we must measure the reactive
power that the load need. And connect a source of reactive power to feed
the load, instead of the power source so we reduce our consumption of the
reactive power from the public electricity network. We need a device that
92
measure the load reactive power and the output of that device is a signal
of voltage or current that connected after that to the controller.
This device is a transducer, which is defined as:" A transducer is a sensor
that changes energy from one form to another. More technically a
transducer converts a physical parameter into another form". With
electronic-measuring systems, the input transducer converts a quantity to
be measured (temperature, humidity, flow rate, weight) in our project
reactive power into an electrical parameter (voltage, current) that can be
processed by an electronic instrument or system. The output signal is dc
signal.
The transducer that we use called "smart power transducer" and it can
measure the following parameters:
• Active power (W).
• Apparent power (VA).
• Reactive power (VAR).
• Average active power (Wavg).
• Power factor (cosφ).
• Maximum current (I max).
• Average phase to phase voltage.
• Phase to neutral voltage for each phase.
• Frequency.
The transducer that we use can be programmed so we can choose the
quantity to be measure.
In our project we have the reactive power to be measured by the
transducer, so the transducer is measuring the reactive power (Q) and
convert it to DC analogue signal (0-20mA).
The full description and programming procedure is (as follows) mentioned
in the attached catalogue.
93
After we know the programming and the connection of the transducer we
now able to make a calibration for it to cover all of the range of the
reactive power of the loads.
This calibration done in the laboratory using the loads mentioned before.
Q I mA
22 5
70 7.9
70 7.8
95 9
95 9
105 9.8
125 10.8
142 11.5
160 12.9
174 13
175 13.1
195 14.5
195 14
240 16.8
260 17.5
The following curve is between Q on horizontal and I mA on vertical.
94
ImA
0
5
10
15
20
0 100 200 300
ImA
And by using curve fitting we have:
Chart Title
y = 0.0522x + 4.1145
05
101520
0 100 200 300
ImA
Linear (ImA)
The equation 1145.40522.0 += xy represents the relation between the
measured Q and the output signal I mA and it can be 1145.40522.0 += QmA
The controller we use only accepts dc voltage (0-10V) so we had to add at
the output of the transducer a resistance of 500Ω and take a voltage of 0-
10V from its terminals to connect it to the controller (Zelio).
So we have to make a calibration for the transducer with V, and it will be
as follows:
95
Q V 22 2.83 66 3.72 95 4.35 68 3.73 88 4.19
116 4.79 89 4.18
160 5.77 133 5.08 160 5.68 181 6.15 154 5.51 180 6.13 225 7.02 250 7.46 82 4.04
104 4.5 150 5.41 170 5.88 180 6.07 200 6.51 246 7.42 270 7.9
Chart Title
y = 0.0206 x + 2.3713
0
2
4
6
8
10
0 100 200 300
VLinear (V)
The following curve is between Q on horizontal and V on vertical.
V
02468
10
0 100 200 300
V
And by using curve fitting we have:
96
Chart Title
y = 0.0261x + 2.0572
02468
10
0 100 200 300
VLinear (V)
The equation 0572.20261.0 += xy represents the relation between the
measured Q and the output signal V and it can be 0572.20261.0 += QV
After we have calibrated the transducer with voltage, we have to make
steps in voltage ranges which help us in programming Zelio. These ranges
are as follows:
load fixed(1uF) 2uF 3uF 4uf 6uf V A1 √ 2.6 ـــ ـــ ـــ ـــ A2 √ 3.71 ـــ ـــ √ ـــ A4 √ 3.73 ـــ ـــ √ ـــ
A1A4 √ √ √ 4.27 ـــ ـــ A1A2 √ √ √ 4.28 ـــ ـــ
A3 √ √ √ 4.43 ـــ ـــ A1A3 √ 5.01 ـــ √ √ ـــ A2A4 √ √ 5.41 √ ـــ ـــ
A1A2A4 √ 5.95 √ ـــ √ ـــ A2A3 √ 6.14 ـــ √ √ ـــ A3A4 √ ـــ 6.17 √ √ ـــ
A1A3A4 √ √ √ 6.66 √ ـــ A1A2A3 √ √ √ 6.7 √ ـــ A2A3A4 √ √ √ √ √ 8
A1A2A3A4 √ √ √ √ √ 8.42
97
A1 2.9>=Ib 0V:2.9V A2 3.4-0.4<=Ib<=3.4+.4 3V: 3.8V A3 4.1-0.2<=Ib<=4.1+0.2 3.9V:4.3V A4 4.6-0.2<=Ib<=4.6+0.2 4.4V:4.8V A5 5.2-0.3<=Ib<=5.2+0.3 4.9V: 5.5V A6 5.9-0.3<=Ib<=5.9+0.3 5.6V:6.2V A7 6.4-0.1<=Ib<=6.4+0.1 6.3V:6.5V A8 6.7-0.1<=Ib<=6.7+0.1 6.6V:6.8V A9 7.2-0.3<=Ib<=7.2+0.3 6.9V:7.5V AA 7.8-0.2<=Ib<=7.8+0.2 7.6V:8.0V AB 8.1<=Ib 8.1V:9.9V
6.5 The controller (Zelio)
It is designed for use in small automation systems up to 40 I / O, zelio logic
smart relays, from Telemecanique, are suitable for all types of installation
and repetitive applications, also their extreme and ease of setting-up provides
a competitive alternative to solutions based on cabled logic or specific cards.
Zelio logic compact
Optimized range for simple automation systems with up to 20 I/O. its ease of
setting-up and operation provides savings in time for programming and
installation, thus reducing the overall cost. This range comprises 3 models
with 10, 12 and 20 I/O .in our project we use 10 I/O, as we need, two
versions are available:
1- With display and buttons for easy programming on the front face,
2- Without display and without buttons for improved economy and
confidentiality of the applications. Zelio logic compact can easily fit in
applications as Automatic transfer switch (ATS) 1 out of 2, pump sequence
control, 3 trials generator timer,…etc.
98
Programming
For both ranges, programming is simple:
1- Directly using 6 buttons on the module display
2- On a PC using Zelio soft ergonomic software, allowing the choice of
programming using function block (FBD) or LADDER
3- You can also simulate your application off-line on PC to insure the
performance of your program
4- Full support and training from a specialized team to help the customer in
understanding and programming the product.
The input of Zelio can be analog or digital.-In some models digital
only-. We would use the analog one. Now we would make a program for
Zelio to decide to connect the capacitors or disconnect it. And the program
would be as follows:
99
100
101
After we show some of the main parts of our project, the single line diagram of the system we have build is as follows:
This is the system before correcting the power factor.
This is the system after correcting the power factor.
102
6.6 Pictures of our project.
The following is some pictures of our experiments in the laboratory before
making the panel and followed by some pictures for different parts in the
project.
The connection we were use in our experiments before connecting the zelio
and the contactors.
The connections after connect the controller and the contactors.
103
Some of loads used in our project.
The transducer
104
The controller (Zelio)
Contactors and Capacitors
105
The meter used to measure currents in each phase, phase and line voltage, cosφ for each phase and the average between two phases.
The panel form outside
106
The panel form inside
107
Chapter 7
Power factor correction for pumping station
7.1 General
In this chapter we will discuss correction of power factor for a pumping
station. First there some data of the station and its work and the single line
diagram of it. Then there is some reading taken from it describing its loads.
And last is a capacitor sizing for the station for power factor correction.
7.2 Pumping station
Pumping station for feeding the water to the new cities as (New Cairo
city and Obour city….etc)
It's feed by the electricity from Abu Zaabal station "500 KV"
By entering four cables "11 KV" connected from Abu Zaabal station it's
the main source and these cables entered on switch board of Obour 1
which follow Engineering of EL-Bar El-Sharky which follow the
controller of South Sharkeia which follow canal electricity distribution
company.
In which the station pulling the water from El Ismaielia Canal and
pumping it in pipes has a diameter of "1" meter by using motors set
on number of "8" pumps and every motor has a parameter
KW 1700
V 3150
A 381
P.F 0.85
R.P.M 991
In this station there are 3 transformers, which reduce Volt from 11
KV to 3.3 KV.
108
Every transformer has a parameter of
Rated power 10000 KVA
Rated voltage 3300 V
Rated current 1750 A
There are 2 generators for feeding the station in case of failure of main
supply
Every generator has the following parameters:
KW 3200
KVA 4000
V 3150
A 733
R.P.M 1000
P.F 0.8
There is main service transformer for feeding indoor lighting for station
and has a parameter of
Rated power 10000 KVA
Rated voltage 4000 V
Rated current 14443.37 A
109
7.3 Pumping station Load
kwh kVAR kv P Q P.F 905585 570672 11 0.63 906912 571531 11 1327 859 0.83 908543 572515 11 1631 984 0.83 910210 573659 11 1667 1144 0.83 911767 574675 11 1557 1016 0.83 913396 575749 11 1629 1074 0.82 915045 576837 11 1649 1088 0.82 916674 577918 11 1629 1081 0.83 918286 578995 11 1612 1077 0.83 920031 580171 11 1745 1176 0.82 921671 581273 11 1640 1102 0.82 923296 582318 11 1625 1045 0.85 924920 583350 11 1624 1032 0.84 926540 584375 11 1620 1025 0.85 928274 585458 11 1734 1083 0.83 929835 586434 11 1561 976 0.85 931718 587603 11 1883 1169 0.83 933257 588566 11 1539 963 0.84 934258 589167 11 1001 601 0.84 935433 589882 11 1175 715 0.84 936603 590599 11 1170 717 0.84
110
7.4 Pumping Station Capacitor Sizing
P.F Selected capacitor
New P.F steps
0.63 0.83 12.5 0.96 10.5+2 0.83 12.5 0.95 10.5+2 0.83 17.1 0.96 10.5+6.60.83 14.5 0.96 7.9+6.6 0.82 17.1 0.97 10.5+6.60.82 17.1 0.97 10.5+6.60.83 17.1 0.97 10.5+6.60.83 17.1 0.97 10.5+6.60.82 17.1 0.96 10.5+6.60.82 17.1 0.96 10.5+6.60.85 14.5 0.96 7.9+6.6 0.84 14.5 0.96 7.9+6.6 0.85 14.5 0.96 7.9+6.6 0.83 14.5 0.96 7.9+6.6 0.85 14.5 0.96 7.9+6.6 0.83 17.1 0.96 10.5+6.60.84 14.5 0.97 7.9+6.6 0.84 8.4 0.96 6.6+1.8 0.84 10.5 0.97 10.5 0.84 10.5 0.96 10.5
111
Chapter 8
Conclusions and future work
8.1 Conclusion: After we have done our project we have learned a lot of things such as:
1. The different type of loads.
2. The transducer and how to program it.
3. The function of the transducer.
4. PLC, its programming kinds such as large PLC, mini PLC and
micro PLC such as what we have used in our project (Zelio).
5. Zelio program and how to program it.
6. The contactors and how it work.
7. Miniature circuit breaker and hoe does it work.
8. Capacitors, it usage, how it charge, discharge, and how it is act as a
source of reactive power.
9. Power world program as a simulator for a power systems.
10. Designing panels, choosing the suitable size for the panel, design
the wiring diagram, and how to apply it.
11. We have already design our panel and make the wiring for it.
12. How to measure the loads in factories or companies, make a
capacitor sizing for it, and choose suitable way to correct the power
factor.
112
8.2 Future work In future, we can:
Build the transducer we use instead of buying it.
Use micro controller instead of Zelio or PLC or use any other
controller.
Increase the load size and as a result use current transformers, as
the transducer and the meter withstand only 5A.
Study the effect of harmonics in details.
113
References
1. Generation of Electrical Energy, by B.R.GUPTA. Third Edition 1996.
2. www.allaboutcircuits.com
3. www.enspecpower.com www.bchydro.com 4. www.bchydro.com
5. www.dakotaelectric.com
6. www.lmphotonics.com
7. www.endpcnoise.com
8. www.subodhancapacitor.com
9. www.kele.com
10. www.circutor.com
11. Introduction to PLC controllers on-line free, author: Nebojsa Matic.
GENERAL:EPM-0X Series Multimeters are designed for measuring electrical parameters in 3-phase networks :
3-phase A V Hz Max.Demand Max/Min cosjVoltages
EPM-03 •EPM-04 • •EPM-05 • • • •EPM-06 • • • • • •
EPM-03 Digital Ammeter: It measures AC RMS current. Measuring range is between 0– 5A. Current transformers (1-10000/5A) are necessary for higher AC current inputs.
EPM-04 Digital Multimeter:Using phase select key ( ), it displays all the (VL1-N, VL2-N, VL3-N, VL1-L2, VL2-L3, VL3-L1) voltages in order.• The measured voltages are displayed on 1 display in a circularly rotating form allowing one of 6 different voltages (VL1-N, VL2-N, VL3-N, VL1-L2, VL2-L3, VL3-L1), that advances by keystroke.
EPM-05 Digital Multimeter with Frequency, Maximum Demand, Maximum and Minimum VoltagesEPM-05 is a multimeter which measures :- 3 phase currents (IL1, IL2, IL3) ,- AC RMS values of 6 different line voltages (VL1-N, VL2-N, VL3-N, VL1-L2, VL2-L3, VL3-L1), - Frequency- Maximum demand values in adjustable periods,- Maximum and minimum voltages
EPM-06 Digital Multimeter with Frequency, Cosj, Maximum Demand, Maximum and Minimum Voltages :EPM-06 is a multimeter that measures :- 3 phase currents (IL1, IL2, IL3),- AC RMS values of 6 different line voltages - (VL1-N, VL2-N, VL3-N, VL1-L2, VL2-L3, VL3-L1), - Frequency, - Cosj of each phase or the average of 3 phases - Maximum demand values in adjustable periods, - Maximum and minimum voltages EPM -06 has 3 displays for currents, 1 selective display for voltages,1 shared display by cosj & frequency.
Frequency-meter functionAs a frequencymeter, EPM-05 & EPM-06 measure and display the frequency of the network with a seperate display on the panel.The EPM-05 has 5 seperate displays; 3 of them are monitoring phase currents, 1 of them is monitoring phase to phase and phase to neutral voltages by “scrolling selection key”, and the 5th one is for frequency monitoring.If VL1-L3 is selected, EPM-06 displays the frequency value on its cosj & frequency shared display.
Demand & Maximum Demand Function EPM-05 and EPM-06 monitor demand and maximum demand values. Demand value is defined as the moving average RMS value measured in demand time.Maximum Demand value is the maximum valve of the average RMS values recorded during demand time. EPM-05 and EPM-06 record this maximum value in its memory and keep continuously measuring maximum demand as defined, comparing it with the last recorded value. If it is bigger than the last recorded value, it replaces last record in memory.
Cosj functionAs a cosj meter, the EPM-06 measures seperately the cosj value of the each phase and the average cosj value.These values are displayed by scrolling UP and DOWN keys on its cosj & frequency shared display.However to display the the related average cosj value, VL1-L2 or VL2-L3 must be selected.
Maximum & Minimum Voltages FunctionIn the Maximum and Minimum Voltages Function; EPM-05 and EPM-06 stores, the maximum and minimum phase-neutral and phase-phase voltages except 0V , in its memory.• Flush mounting form suitable for panel installations. • Connections are made through terminals.• When the current transformer ratio is set over 1000/5A, the “k” “kiloampere”
light is activated depending on the measured current.• Power supply is provided by auxiliary wiring, with a phase-neutral
connection with fuse protection.
Current Transformer Ratio Setup:( for EPM-03 / EPM-04 / EPM-05 / EPM-06)
Press the Set key for 3 sec.to start selecting current transformer ratios.
Press Set again and enter the CT Ratio setup menu
Press UP / DOWN keys to select required CT ratio.
Press the Set key to save the required CT ratio.
If you don’t touch any key for about 3 sec. the device returns automatically to the measurement mode.
Displaying the Phase-Neutral and Phase-Phase voltages: (for EPM-04 / EPM-05 / EPM-06)
This screen displays the measured value of VL1-N as default and L1 LED lights
Press phase select key once to see the voltage value of VL2-N, L2 LED lights
Press phase select key again to have the value of the next voltage: VL3-N, L3 LED lights
Press phase select key again to display the value of the next voltage: VL1-L2, L1 and L2 LEDS light
Press phase select key again to display the value of the next voltage: VL2-L3, L2 and L3 LED light
Press phase select key again to display the value of the next voltage: VL3-L1, L1 and L3 LED light
Demand Time Setup:
Press Set key for 3 sec to start demand time setup.
Press DOWN key multiple times until arriving to the demand time (dt)
Press Set key to enter demand time Setup.Preset value will be displayed. Set the required demand time by UP/DOWN keys.
Press Set key to save the required demand time. If you don’t touch any key for about 3 sec. the device returns automatically to the measurement mode.
Displaying the Maximum and Minimum Voltages:(for EPM-05 and EPM-06)
Press phase select key until you see the phase which you want to know the maximum and minimum.
Press UP key continuously to display the maximum value of this voltage
When you release the UP key, the screen returns to the real time voltage of the selected lines.
Press DOWN key continuously to display the minimum value of this voltage.
When you release the DOWN key, the screen returnsautomatically to the measurement mode, to display the real time voltage of the selected lines.
DIGITAL MULTIMETEREPM-03 / EPM-04 / EPM-05 / EPM-06
“ISO 9001 Q.M.S. Certificate”
~VL1L2L3
~VL1L2L3
~VL1L2L3
~VL1L2L3
~VL1L2L3
~VL1L2L3
Set
Set
MeasurementMode
Set
500
300
200
221
219
380
379
382
2
30
Set
Set
MeasurementMode
Set
~VL1L2L3
~VL1L2L3
~VL1L2L3
~VL1L2L3
~VL1L2L3
380
414
380
352
380
250
250
~A ok
~A ok
To Reset the Maximum and Minimum Voltage and Maximum Demand Values of the Measured Voltages:(for EPM-05 and EPM-06)
Press UP and DOWN keys simultaneously.EPM-05 and EPM-06 resets the maximum -minimum voltages and maximum demand values. Then device returns to the measurement mode within 3 seconds automatically.
To Display the Frequency: (for EPM-05 and EPM-06)
Press the Phase Select key multiple times until arriving to the voltage, e.g. VL3-L1
At the voltage VL3-L1, the lowest display reverts to show the frequency of L3-L1 phase-phase voltage and Hz indicator lights.
To Display Demands:(for EPM-05 and EPM-06)
Press UP key to display maximum demands of each phase on the top 3 displays titled ~A. Press DOWN key to display demand values. Note: When the key is released, the current displays revert to display the actual currents of the lines.
To Display the Cosj and frequency values:Using the phase select key, when voltage is at L1, the cosj LED lights and the cosj of VL1-N is displayed
Using the phase select key, when voltage is at L2, the cosj LED lights and the cosj of VL2-N is displayed
Using the phase select key, when voltage is at L3, the cosj LED lights and the cosj of VL3-N is displayed
Using the phase select key, when voltage is at L1-L2, cosj LED lights and the average cosj is displayed
Using the phase select key, when voltage is at L2-L3, cosj LED lights and the average cosj is displayed
Using the phase select key, when voltage is at L1-L3, Hz LED lights and the frequency value is displayed
PRECAUTIONS FOR INSTALLATION AND SAFE USE
Failure to follow those instructions will result in death or serious injury.* Disconnect all power before working on equipment.* When the device is connected to the network, do not remove the front
panel.* Do not try to clean the device with solvent or the like. Only clean the
device with a dry cloth.* Verify correct terminal connections when wiring.* Electrical equipment should be serviced only by your competent seller.
No responsibility is assured by the manufacturer or any of its subsidiaries for any consequences arising out of the use of this material.
* Only for rack panel mounting.
Dimensions
Connecting Diagram
* Warning: a) A switch or circuit breaker must be connected between the network and
the auxiliary supply input of device.b) Connected switch or circuit breaker must be in close proximity to the
device.c) Connected switch or circuit breaker must be marked as the disconnecting
device for the equipment.d) The type of the used fuse must be FF type and the current of the used
fuse must be 1A.
Technical data Auxiliary supply (Un) : 115VAC or 230 VAC Operating range : (0,9 – 1,1)xUnOperating frequency : 50 / 60HzMeasuring ranges Ammeter :0-5A ~ Voltmeter :0-300VAC (Phase-neutral)
0-500VAC (Phase-Phase)Frequencymeter : 45-65Hz (Auxiliary supply)Current transformer ratio:1 ... 10000/5A Cable Diameter : 2,5mm2Measurement category :CAT IIIPower consumption : Aux. supply : <4VA, measurement inp: <1VA Accuracy : 1%±1digitDemand time (Average)15 minBox material : Nonflammable Operating range : - 5°C ; +50°CStorage range : - 25°C ; +70°CProtection class : IP 40 Equipment protection : Double Insulation ( )Standards : IEC 61010-1, IEC 61000-6, IEC 61000-4Dimensions : Type PR19Switchboard Cutout : 92x92Installation : Flush-mounting with rear terminalsWeight : 0,3kgPackage Dimensions : 36x24.5x24.7 cm.Package Weight : 5.5 kg.Pcs. per Package : 12 pcs.
DIGITAL MULTIMETEREPM-03 / EPM-04 / EPM-05 / EPM-06
“ISO 9001 Q.M.S. Certificate”
TYPE PR 19 (96*96)92mm
92m
m
TYPE 19 (96X96) 96mm
70mm
96m
m
90m
m
79.3mm
K L
EPM-03Digital Multimeter
k lL1
L2
L3
N
1
Current Measurement
3 4 5 6
7
2
8
IL1 IL2 IL3
Auxiliary Supply
L
N
1A
K L
k l K L
k l
K L
EPM-04/05/06Digital Multimeter
k lL1
L2
L3
N
1
Current Measurement
3 4 5 62IL1 IL2 IL3
K L
k l K L
k l
9 10 11 12
Voltage Measurement
L1 L2 L3 N
L1
L2
L3
N
7 8
Auxiliary Supply
L
N
1A
~VL1L2L3
~VL1L2L3
Tel :+90. 216. 313 01 10 (pbx)
L1
L3
Hz
Cos
L2K
K
K
K ~A
~A
~A
Clear
Kilo Leds
Display
VoltageDisplay
Frequency&Cosj Display
PhaseIndicator Led
Cosj &Hz Led
Up Button
Down Button
Phase Sellect &Set Button
601090604/04-04601090608/04-04
000
000
~VL1L2L3CosjHz
379-0.98
~VL1L2L3CosjHz
38250.0
~A ok
~A ok
~A ok
14.121.423.5
221
219
CosjHz-0.98
CosjHz-0.98
CosjHz-0.98
CosjHz-0.86
CosjHz-0.85
CosjHz50.0
~VL1L2L3
~VL1L2L3
~VL1L2L3
380
379
382
~VL1L2L3
220
TYPE PR 19
70mm
Wall
50mm
79.3mm
90m
m
Specifications are subject to change without notice (29.10.99) 1
• 16-bits µP-based smart power meter• Measurements of: W, Wavg, VA, VAr, PF, Wh, VAh, VArh,
Imax (among the phases), Vdelta avg, VL1-N, VL2-N, VL3-N, Hz L1.
• TRMS measurement of distorted waves (voltage/current)• All configuration functions selectable by
built-in key-pad• Password protection of programming parameters• Degree of protection (front): IP 50• Optional independent alarm setpoint• Optional analogue output (20 mA DC/ ±10 mA DC/
±5 mA DC/10 VDC/±1VDC)• Optional serial RS 422/485 output• MODBUS, JBUS protocol.
Product DescriptionModelRange codeMeasurementPower supplyAuxiliary output1st output/input2nd output
Ordering Key SPT-DINAV51DXA X16-bit µP-based smart powermeter with a built-in configu-ration key-pad. The house is
for DIN-rail mounting andensures a degree of protecti-on (front) of IP 50
Current and Voltage ControlsSmart Power MeterType SPT-DIN
Type SelectionMeasurement
1: One phase, three- phase system(3 or 4 wires, balan-ced load)
3: Three phase system(3 or 4 wires, unba-lanced load)
Range code
AV1: 100/√3/100 VAC-1 AAC(max. 130/√3 (L-N)/130 V (L-L) - 1.2 A) 1)
AV3: 100/√3/100 VAC-5 AAC(max. 130/√3 (L-N)/130 V (L-L) - 6 A) 1)
AV4: 250/433 VAC - 1 AAC(max. 300 V (L-N)/520 V (L-L) - 1.2 A) 1)
AV5: 250/433 VAC - 5 AAC(max. 300 V (L-N)/520 V (L-L) - 6 A) (standard)
Power supply
A: 24 VAC, -15% +10%, 50/60 Hz 1)
B: 48 VAC, -15% +10%,50/60 Hz 1)
C: 115 VAC, -15% +10%,50/60 Hz 1)
D: 230 VAC, -15% +10%,50/60 Hz (standard)
Auxiliary output
X: No output (standard)D: Alarm set-point, static,
AC type 1)
P: Pulse, static, DC type 1)
1st output/input
D: 3 digital inputs (managed only by means of the serial communication) 1)
A: Analogue output, 20 mADC (standard)
B: Analogue output, ±10 mA 1)
C: Analogue output, ±5 mA 1)
V: Analogue output, 10 VDC 1)
U: Analogue output, 0 to ±1 VDC 1)
2nd output
X: No output (standard)S: Serial output, RS 485
multidrop bidirec-tional 1)
A: Analogue output, 20 mADC 1)
B: Analogue output, ±10 mA1)
C: Analogue output, ±5 mA1)
V: Analogue output, 10 VDC 1)
U: Analogue output, 0 to ±1 VDC 1)
Note: Only for B and C out-puts, the 2nd output canonly be a B, C or S one.
Rated inputCurrent 2 (measurement code: 1)
6 (measurement code: 3)Voltage 2 (measurement code: 1)
4 (measurement code: 3)Digital 4, for 3 free of voltage con-
tacts (inputs managed only by the serial communication)Reading voltage/current: 24 VDC/1 mA
AccuracyVoltage/current/energy ±0.5% f.s. includes also:
frequency, power supply and output load influences
Frequency ±0.5% f.s. (45 to 500 Hz)Active power
(@ 25°C ± 5°C, R.H. ≤ 60%) ±0.5% f.s. (cos ϕ 0.7 L/C,0.6 to 1 In, 0.9 to 1.1 Un)±1% f.s. (cos ϕ 0.3 L/C,0.2 to 1.2 In, 0.7 to 1.2 Un)
Input Specifications
1)On request
2 Specifications are subject to change without notice (29.10.99)
Serial output (on request)Type RS422/RS485;
Multidrop bidirectional (static and dynamic variables)
Connections 2 or 4 wires, max. distance 1200m, termination and/or line bias by means of DIP-switches directly on the transducer
Adresses 255, selectable by key-padProtocol MODBUS/JBUSData (bidirectional)
Dynamic (reading only) System variables:P, PAVG, S, Q, cos ϕ, VL-L, f, energy and status of digital inputs, setpoint output and status of the energy over-flow bit,Single phase variables: PL1, SL1, QL1, Cos ϕL1, VL1-N, IL1,PL2, SL2, QL2, Cos ϕL2, VL2-N, IL2, PL3, SL3, QL3, Cos ϕL3, VL3-N, IL3
Static (writing only) All programming data, reset of energy, reset of energy overflow bit, activation of static output.Stored energy (EEPROM) ≥ 250,000.000 kWh
Data format 1-start bit, 8-data bit, no parity/even parity, 1 stop bit
Analogue outputsNumber of outputs 1 (standard) + 1 (on request)Range 0 to 20 mADC,
0 to ±10 mADC,0 to ± 5 mADC0 to 10 VDC,0 to ± 1 VDC
Scaling factor Programmable within the whole range of retransmis-sion; it allows the retrans-mission management of all values from 0 to 20 mA, 0 to ±10 mADC,0 to ±5 mADC0 to 10 V, 0 to ± 1 VDC
Response time ≤ 250 ms typical (filter excluded)
Temperature drift 300 ppm/°CLoad: 20 mA output ≤ 500 Ω
±10 mA output ≤ 500 Ω±5 mA output ≤ 1000 Ω10 V output ≥ 10 kΩ±1 V output ≥ 10 kΩ
Analogue outputs Insulation By means of optocouplers,
2000 Vrms output to measuring input 4000 Vrms output to supply input
SPT-DIN
Output Specifications
Accuracy (cont.)Reactive power
(@ 25°C ± 5°C, R.H. ≤ 60%) ±0.5% f.s. (sen ϕ 0.7 L/C,0.6 to 1 In, 0.9 to 1.1 Un)±1% f.s. (sen ϕ 0.3 L/C,0.2 to 1.2 In, 0.7 to 1.2 Un)
Apparent power(@ 25°C ± 5°C, R.H. ≤ 60%) ±0.5% f.s.,
(0.6 to 1 In, 0.9 to 1.1 Un)±1% f.s.,(0.2 to 1.2 In, 0.7 to 1.2 Un)
Additional errorsHumidity < 0.3%, 60% to 90% R.H.Input frequency < 0.4%, 62 to 400 HzMagnetic field < 0.5% @ 400 A/m
Ripple ≤ 1% according to IEC 60688-1and EN 60 688-1
Sampling rate 1900 HzDisplay 7-segment, LED, h 14.2 mmMax. and min. indication Max. 999, min. -999Measurements W, Wavg, VA, VAr, PF, Wh,
VAh, VArh, Imax (among the phases), Vdelta avg, VL1-N, VL2-N, VL3-N, Hz L1.TRMS measurement of a dis-torted wave voltage/currentCoupling type : DirectCrest factor: ≥ 3
Ranges (impedances)AV1: 100 V /√3/100 V (250 kΩ) -
1 AAC (≤ 0.3 VA)AV3: 100 V /√3/100 V (250 kΩ) -
5 AAC (≤ 0.3 VA)AV4: 250 V/433 V (1 MΩ) -
1 AAC (≤ 0.3 VA)AV5: 250 V/433 V (1 MΩ) -
5 AAC (≤ 0.3 VA)Frequency range 48 to 62 HzOver-load protection
Continuous: voltage/current 1.2 x rated inputFor 1 s
Voltage: 2 x rated inputCurrent: 20 x rated input
Keyboard 3 keys: ”S” for enter programming phase and password confir-mation,”UP” and “DOWN” for value programming/functionselection
Input Specifications (cont.)
Specifications are subject to change without notice (29.10.99) 3
SPT-DIN
Password Numeric code of max. 3 di-gits; 2 protection levels of the programming data
1st level Password “0”, no protection2nd level Password from 1 to 499, all
data are protectedMeasurement selection System’s active power (W),
system’s apparent power (VA), system’s reactive power (VAr), average active power (Wavg), system’s power factor (cos ϕ), maxi-mum current (I max), avera-ge phase-phase voltage, phase-neutral voltage-phase 1, phase-neutral vol-tage-phase 2, phase-neutralvoltage-phase 3, frequency-phase 1. System’s (+) active energy, system’s apparent energy,
Measurement selection (cont.) system’s reactive energy, system’s (+/-) active energy
Transformer ratio For CT up to 5000 A, For VT up to 100 kV (1MV)
Scaling factorOperating mode Electrical scale: compression/
expansion of the input scale to be connected to 1 or 2 ana-logue outputs and to the alarm output.
Electrical range Programmable within the whole measuring range
FilterFilter operating range 0 to 99.9% of the
input electrical scaleFiltering coefficient 1 to 255Filter action Both analogue and serial
outputs (fundamental vari-ables:V, I,W and their derived ones)
Software Functions
Serial output (cont.)Baud-rate 1200, 2400, 4800 and 9600
selectable baudsInsulation By means of optocouplers,
4000 Vrms output to measuring inputs4000 Vrms output to supply input
Temperature drift 200 ppm/ºCPulse output
Type From 1 to 999 programmablepulses for kWh, KVAh, KVArh, MWh, MVAh, MVArh, open collector (NPN transistor)VON 0.6 VDC/ max. 4 mAVOFF 26 VDC max.
Pulse duration 20 ms (ON), ≥ 20 ms (OFF)Insulation By means of optocouplers,
4000 Vrms output tomeasuring input, 4000 Vrms output tosupply input.
Alarms (on request)Number of setpoints 1 independent Alarm type Up alarm, down alarmSetpoint adjustment 0 to 100% of the electrical
scaleHysteresis 0 to 100% of the electrical
scaleOn-time delay 0 to 255 sRelay status Normally de-energizedOutput type Static by TRIAC; performan-
ces: 24 VAC to 250 VAC, max 50 mA.
Min. response time 300 ms, filter excluded,setpoint on-time delay: ”0”
Insulation 2000 Vrms output to measuring input, 4000 Vrms output to supply input
Output Specifications (cont.)
AC voltage 230 VAC (standard),-15%+10% 50/60 Hz 24 VAC, 48 VAC, 115 VAC(on request),-15%+10% 50/60 Hz
Power consumption ≤ 10 VA
Supply Specifications
4 Specifications are subject to change without notice (29.10.99)
SPT-DIN
Function Description
Figure AThe sign of measured quant-ity and output quantity re-mains the same. The outputquantity is proportional to themeasured quantity.
Input and output scaling capabilityWorking of the analogue outputs (y) versus input variables (x)
Figure BThe sign of measured quant-ity and output quantity chan-ges simultaneously. The out-put quantity is proportional tothe measured quantity.
Figure CThe sign of measured quant-ity and output quantity re-mains the same. On the ran-ge X0...X1, the output quant-ity is zero. The range X1...X2is delineated on the entireoutput range Y0 = Y1...Y2and thus presented in strong-ly expanded form.
Figure FThe sign of the measuredquantity remains the same,that of the output quantitychanges as the measuredquantity leaves range X0...X1and passes to range X1...X2and vice versa.
Figure EThe sign of the measuredquantity changes but that ofthe output quantity remainsthe same. The output quant-ity steadily increases fromvalue X1 to value X2 of themeasured quantity.
Figure DThe sign of measured quant-ity and output quantity re-mains the same. With themeasured quantity beingzero, the output quantityalready has the value Y1 = 0.2 Y2. Live zero output.
0 50 A 100 A
0 10 mA 20 mA
-100 kW 0 100 kW
-1 kW 0 1 kW
80 V 100 V 120 V
0 5 mA 10 mA
0 50 A 100 A
4 12 mA 20 mA
-100 kW 0 100 kW
0 10 mA 20 mA
0 50 A 100 A
-1 V 0 1 V
Operating temperature 0 to +50°C (32 to 122°F)(R.H. < 90% non-condensing)
Storage temperature -10 to +60°C (14 to 140°F)(R.H. < 90% non-condensing)
Insulation reference voltage 300 Vrms to groundInsulation 4000 Vrms betweenall inputs/
outputs to groundDielectric strength 4000 Vrms for 1 minuteNoise rejection
CMRR 100 dB, 48 to 62 HzEMC EN 50 081-2, EN 50 082-2
Safety standardsSafety requirements: IEC 601010-1, EN 61010-1Products requirements: IEC 60688-1, EN 60 688-1
Connector Screw-type, max. 2.5 mm2 wires
HousingDimensions 6 DIN modules,
58.5 x 89 x 107 mmMaterial ABS,
self-extinguishing: UL 94 V-0Degree of protection Front: IP50Weight Approx. 500 g
(packing included)
General Specifications
Specifications are subject to change without notice (29.10.99) 5
SPT-DIN
Mode of OperationAccuracy class of the meter as a relation of PI/PN and cos ϕ
Trends of the ”E” error depending on the SR scale ratio
* V = 0.9 to 1.1, Un,I = 0.6 to 1 In, f = 48 to 62 Hz
** V = 0.7 to 1.2 Un, I = 0.2 to 1.2 In, f = 48 to 100 Hz
80º 70º 60º 50º 40º 30º 20º 10º 0º0.34º 0.64º 0.86º 0.98º
0.17º 0.5º 0.76º 0.94º 1º
E %
SR
COS ϕ
PI/PN
Input Star Delta Current voltage voltage
AV1 Un: 100 V/√3 Un: 100 V In: 1 AAV3 Un: 100 V/√3 Un: 100 V In: 5 AAV4 Un: 230 V Un: 398 V In: 1 AAV5 Un: 230 V Un: 398 V In: 5 A
PI: (installation power)One phase system:
PI = UI · II · cos ϕ
Three phase, 3-wire system:PI = √3 · UI · II · cos ϕ
Three phase, 4-wire system:PI = 3 · UI · II · cos ϕ
where:UI = the real star voltage ofthe electrical system beingmeasured.II = the maximum phase cur-rent of the electrical systembeing measured.Cos ϕ = the average cos ϕ ofthe electrical system beingmeasured.
Pn: (rated power of transducer)One phase system:
Pn = Un · In · VT(ratio) · CT(ratio)
Three phase, 3-wire system:Pn = √3 · Un · In · VT(ratio) · CT(ratio)
Three phase, 4-wire system:Pn = 3 · Un · In · VT(ratio) · CT(ratio)
where:Un = the rated input voltage ofSPT-DIN depending on themodel, see table above.
In = the rated input current ofSPT-DIN depending on themodel, see table above.VT (ratio) = the value of thevoltage transformer ratio.CT (ratio) = the value of thecurrent transformer ratio.
Example 1:Model AV3.3 (3-wire system).
UI = 6 kV (delta voltage)II = 265 A (single phase cur-rent)Cos ϕ = 0.85 (system powerfactor)Un = 100 VIn = 5 A
VT (ratio) = 6 kV = 60100
CT (ratio) = 300 = 605
PI = √3 · UI · II · cos ϕ= √3 · 6000 · 265 · 0.85= 2.33 MW
Pn = √3 · Un · In· VT(ratio) · CT(ratio)= √3 · 100 · 5 · 60 · 60= 3.12 MW
PI
= 2.33
= 0.75Pn 3.12
Example 2:Model AV3.3 (4-wire system).
UI = 6 kV / √3II = 265 ACos ϕ = 0.85 Un = 100 V / √3In = 5 A
VT (ratio) = 6 kV / √3 = 60100 / √3
CT (ratio) = 300 A = 605 A
PI = 3 · UI · II · cos ϕ= 3 · 6000 / √3 · 265 · 0.85= 2.33 MW
Pn = 3 · Un · In · VT(ratio) · CT(ratio)= 3 · 100 / √3 · 5 · 60 · 60= 3.12 MW
PI
= 2.33
= 0.75Pn 3.12
In both examples the accura-cy of the measurement is 0.5% f.s. when consideringthe changing of the measur-ed voltage from 0.9 Un to 1.1Un and the measured cur-rent from 0.6 In to 1 In with acos ϕ of 0.85. The accuracyof the output is connected tothe accuracy of the measure-ment plus the scale ratio ofboth input (Hi.E - Lo.E) andoutput (Hi.A - Lo.A) as shownin the graph above (E% ver-sus SR).
Regarding SR:
SR = AFS · (Hi.A - Lo.A) ≤ 1.25100 · (Hi.E - Lo.E)
AFS= automatic electrical fullscale calculated value.SR = scale ratio.There is not any additionalerror on the output signal if SR ≤ 1.25.
Example 3:
AFS= 3.30 MWLo.E = 0 MWHi.E = 3.30 MWLo.A = 20%Hi.A = 99.9%
SR = 3.30 (99.9-20)
= 0.8100 (3.30-0)
0.8 ≤ 1.25 no additonal errors
Example 4:
AFS = 3.30 MWLo.E = 1.00 MWHi.E = 3.30 MWLo.A = 20%Hi.A = 99.9%
SR = 3.30 (99.9-20)= 1.32100 (3-1)
1.32 ≥ 1.25 means that thereis an additional error of 0.2%f.s. according to the graph atthe previous page.
6 Specifications are subject to change without notice (29.10.99)
Wiring DiagramsSingle phase input connectionsSPT-DIN AV1/AV3/AV4/AV5.1
CT connection Direct connection CT and VT connection
Three phase input connections - Balanced loadsSPT-DIN AV1/AV3/AV4/AV5.1
CT connection (3-wire system)Direct connection (3-wire system) CT and VT connection (3-wire system)
SPT-DIN
Fig. 1 Fig. 2 Fig. 3
Fig. 4 Fig. 5 Fig. 6
Waveform of the signals that can be measured
Figure GSine wave, undistortedFundamental content 100%Harmonic content 0%Arms = 1.1107 | A |
Figure HSine wave, indentedFundamental content 10...100%Harmonic content 0...90%Frequency spectrum 3rd to 16th harmonicRequired result: additional error < 1%
Figure ISine wave, distortedFundamental content 70...90%Harmonic content 10...30%Frequency spectrum 3rd to 15th harmonicRequired result: additional error < 0.5%
Mode of Operation (cont.)
Specifications are subject to change without notice (29.10.99) 7
CT connection (4-wire system)Direct connection (4-wire system) CT and VT connection (4-wire system)
Wiring Diagrams (cont.)
Three-phase, 3-wire ARON input connections - Unbalanced loadsSPT-DIN AV1/AV3/AV4/AV5.3
CT connection (3-wire system) CT and VT connection (3-wire system)
Three phase, 4-wire input connections - Unbalanced loadsSPT-DIN AV1/AV3/AV4/AV5.3
CT connection (4-wire system) Direct connection (4-wire system) CT and VT connection (4-wire system)
SPT-DIN
Fig. 7 Fig. 8 Fig. 9
Fig. 10 Fig. 11
Fig. 12 Fig. 13 Fig. 14
8 Specifications are subject to change without notice (29.10.99)
SPT-DIN
90 m
m
108 mm
107 mm
89 m
m
49.5 mm
58.5 mm
45 m
m
Dimensions
Front Panel Description
1
” ” and ” ”- Up and down keys for increasing or decreasing program-
ming values.- Selecting programming functions and transducer
configuration together with the ”S” key.
2. Display3 -digit (maximum read-out 999).
Alphanumeric indication by means of 7-segment display for:- Displaying only the configuration parameters
3. Connection terminal blocks
4. Dip-switch- For the selection of 2/4 wire connection, line biasing
and/or line termination (only in case of RS 485 option)
1. Key-padSet-up and programming procedures are easily controlled by the 3 pushbuttons.
“S”- Selection key to select programming function (transducer
configuration) and alarm detection.
2
3
4
2
Selection guide 0 Zelio Logic smart relays 0
Compact and modular smart relays
Smart relay type Compact smart relays
Number of I/O 10 12 20
Number of discrete inputs(of which analogue inputs)
6 (0) 8 (4) 12 (2/6)
Number of "relay" or "transistor" outputs 4 4 8
Supply voltage c 24 V, a 100...240 V c 12 V, c 24 V, a 24 V, a 100...240 V
I/O extensions No
Modbus communication module r No
Clock No Yes Depends on model
Display and programming buttons Depends on model
Programming language LADDER / FBD LADDER LADDER / FBD (1) LADDER LADDER / FBD (1)
References SR2 p101pp SR2 p121pp SR2 B122BD SR2 A201pp SR2 B20pppSR2 E201pp
Pages 14 14 14 14 14
(1) FBD: Function Block Diagramr Available: 1st quarter 2004.
3
00
Modular smart relays
10 26
6 (4) 16 (6)
4 10
c 24 V, a 24 V, a 100...240 V
Yes (6, 10 or 14 I/O)
Yes
Yes
Yes
LADDER / FBD (1)
SR3 B10ppp SR3 B26ppp
15 15
(1) FBD: Function Block Diagram
4
Presentation 0 Zelio Logic smart relays 0
Compact and modular smart relays
Zelio Logic smart relays are designed for use in small automated systems. They are used in both industrial and commercial applications. b For industry: v automation of small finishing, production, assembly or packaging machines.v decentralised automation of ancillary equipment of large and medium-sized machines in the textile, plastics and materials processing sectors,v automated systems for agricultural machinery (irrigation, pumping, greenhouses, ...).b For the commercial/building sectors: v automation of barriers, roller shutters, access control,v automation of lighting installations,v automation of compressors and air conditioning systems.Their compact size and ease of setting-up make them a competitive alternative to solutions based on cabled logic or specific cards. Simple programming, ensured by the universal nature of LADDER and function block diagram FBD (1) languages, meets all automation requirements and also the needs of the electrician.Compact smart relays are suitable for simple automated systems, up to 20 I/O.If required, modular smart relays can be fitted with I/O extensions and a module for communication on the Modbus network, for greater performance and flexibility, from 10 to 40 I/O.
Programming can be carried out:b independently, using the buttons on the smart relay (ladder language),b on a PC, using "Zelio Soft" software.When using a PC, programming can be carried out either in LADDER language, or in function block diagram language (FBD).
Backlighting of the display is programmable using “Zelio Soft” software and by direct action on the smart relay's 6 programming buttons.
The Zelio Logic smart relay has a backup memory which allows programs to be copied into another smart relay (examples: for building identical equipment, remote transmission of updates).The memory also allows a backup copy of the program to be saved prior to exchanging the product.When used with a smart relay without display or buttons, the copy of the program contained in the cartridge is automatically transferred into the smart relay at power-up.
Autonomous operating time of the clock, ensured by a lithium battery, is 10 years.Data backup (preset values and current values) is provided by an EEPROM Flash memory (10 years).
Zelio Logic smart relays can, if necessary, take the following I/O extensions:b 6, 10 or 14 I/O, supplied with c 24 V via the smart relay,b 6, 10 or 14 I/O, supplied with a 24 V via the smart relay,b 6, 10 or 14 I/O, supplied with a 100... 240 V via the smart relay.
A module for communication on the Modbus network will be available for Zelio Logic modular smart relays. It is supplied with c 24 V via the smart relay.
(1) FBD: Functional Block Diagram.(2) LCD: Liquid Crystal Display
Presentation
1094
46
SR2 B121BD
1094
58
1 2
Programming
LCD display backlighting (2)
Memory
Autonomy and backup
I/O extensions
Communication module r
Communication interface rrThe "communication" products in the Zelio Logic range include:b a communication interface connected between a smart relay and a modem,b analogue or GSM modems,b “Zelio Soft Com” software.They are designed for monitoring or remote control of machines or installations which operate without personnel.The communication interface, supplied with c 12/24 V, allows messages, telephone numbers and call conditions to be stored.
r Available 1st quarter 2004.rr Available 1st half 2004.
1 Modular smart relay(10 or 26 I/O)
2 I/O extension module(6,10 or 14 I/O)
5
Description 0 Zelio Logic smart relays 0
Compact and modular smart relays
Compact smart relaysWithout display - 10, 12 and 20 I/O With display - 10, 12 and 20 I/O
Compact smart relays have the following on the front panel:1 Two retractable fixing lugs2 Two power supply
terminals3 Terminals for connection of
the inputs4 Backlit LCD display with 4
lines of 18 characters5 Slot for a memory cartridge
and connection to a PC6 6 buttons for programming
and parameter entry7 Terminals for connection of
the outputs
Modular smart relays10 and 26 I/O
Modular smart relays have the following on the front panel:1 Two retractable fixing lugs2 Two power supply
terminals3 Terminals for connection of
the inputs4 Backlit LCD display with 4
lines of 18 characters5 Slot for a memory cartridge
and connection to a PC6 6 buttons for programming
and parameter entry7 Terminals for connection of
the outputs
I/O extension modules6 I/O 10 and 14 I/O
I/O extension modules have the following on the front panel:1 Two retractable fixing lugs2 Terminals for connection of
the inputs3 Terminals for connection of
the outputs4 A connector for connection
to the smart relay (powered by the smart relay)
5 Locating pegs
123
5
17
123
5
1
7
4
6
123
5
17
4
6
12
5
13
5
4
12
5
13
55
4
6
Functions 0 Zelio Logic smart relays 0
Compact and modular smart relays“Zelio Soft for PC” programming software
“Zelio Soft” software allows:b programming in LADDER language or in function block diagram language (FBD),b simulation, monitoring and supervision,b uploading and downloading of programs,b output of personalised files,b automatic compiling of programs,b on-line help.
“Zelio Soft” software monitors applications by means of its coherence test function. An indicator turns red at the slightest input error. The problem can be located by simply clicking the mouse. "Zelio Soft" software allows switching, at any time, to any of the 6 application languages (English, French, German, Spanish, Italian, Portuguese), and editing of the application file in the selected language.
"Zelio Soft" software allows Text function blocks to be configured, which can then be displayed on all smart relays which have a display.
2 test modes are provided: simulation and monitoring.
“Zelio Soft” simulation mode allows all the programs to be tested, without the smart relay, i.e.:b enable discrete inputs,b display the status of outputs,b vary the voltage of the analogue inputs,b enable the programming buttons,b simulate the application in real time or in accelerated time,b dynamically display (in red) the various active elements of the program.
“Zelio Soft” monitoring mode makes it possible to test the program executed by the smart relay, i.e.:b display the program "on line",b force inputs, outputs, control relays and current values of the function blocks,b adjust the time,b change from STOP mode to RUN mode and vice versa.
In simulation or monitoring mode, the monitoring window allows the status of the smart relay I/O to be displayed within your application environment (diagram or image).
“Zelio Soft for PC” (version 2.0)
Programming in LADDER languageCoherence test and application languages
Programming in FBD language
Inputting messages for display on Zelio Logic
Program testing
"Simulation" mode
"Monitoring" mode
7
Presentation 0 Zelio Logic smart relays 0
Compact and modular smart relays“Zelio Soft” programming software
LADDER languageDefinition
Text function block
Up/down counter
Analogue comparator
Control relay
LCD backlighting
Output coil
Timer
Fast counter
Clock
Counter comparator
Summer/Winter time switching
LADDER language allows a LADDER program to be written with elementary functions, elementary function blocks and derived function blocks, as well as with contacts, coils and variables.The contacts, coils and variables can be annotated. Text can be placed freely within the graphic.
b Control scheme input modes“Zelio input” mode enables users who have directly programmed the Zelio smart relay to find the same user interface, even when using the software for the first time.“Free input” mode, which is more intuitive, is very user-friendly and incorporates many additional features. With LADDER programming language, two alternative types of symbol can be used : v LADDER symbols,v electrical symbols."Free input" mode also allows the creation of mnemonics and notes associated with with each line of the program.Instant switching from one input mode to the other is possible at any time, by clicking the mouse.Up to 120 control scheme lines can be programmed, with 5 contacts and 1 coil per program line.
b Functions:v 16 time delay function blocks; parameters of 11 different types can be set for each of these (1/10th second to 9999 hours),v 16 up/down counter function blocks from 0 to 32767, v 1 fast counter (1 kHz),v 16 text function blocks,v 16 analogue comparator function blocks,v 8 clock function blocks, each with 4 channels,v 28 control relays,v 8 counter comparators,v automatic Summer/Winter time switching,v variety of coil functions, latching (Set/Reset), impulse relay, contactorv LCD screen with programmable backlighting.
FunctionsFunction Electrical scheme LADDER language Notes
Contact I corresponds to the real state of the contact connected to the input of the smart relay.i corresponds to the inverse state of the contact connected to the input of the smart relay.
Standard coil The coil is energised when the contacts to which it is connected are closed.
Latch coil (Set) The coil is energised when the contacts to which it is connected are closed. It remains tripped when the contacts re-open.
Unlatch coil(Reset)
The coil is de-energised when the contacts to which it is connected are closed.It remains inactive when the contacts re-open.
1314 22
21
or or
I
i
A1
A2
A1
A2
S
A1
A2
R
8
Presentation (continued) 0 Zelio Logic smart relays 0
Compact and modular smart relays“Zelio Soft” programming software
Function block diagram language (FBD) (1)
DefinitionFBD language allows graphical programming based on the use of predefined function blocks. This language provides the use of 23 pre-programmed functions for counting, time delay, timing, definition of switching threshold (temperature regulation for example), generation of impulses, time programming, multiplexing, display, etc.
Pre-programmed functionsZelio Logic smart relays provide a high processing capacity, up to 200 function blocks, including 23 pre-programmed functions:
TIMER AC TIMER BH TIMER BW
Timer. Function A/CON-delay and OFF delay
Timer. Function BH.(Adjustable pulsed signal)
Timer - Function BW(pulse on rising/falling edge)
TIMER Li BISTABLE SET- RESET
Pulse generatorON-delay, OFF delay
Impulse relay function Bistable latching - Priority assigned either to SET or RESET function
BOOLEAN CAM PRESET COUNT
Allows logic equations to be created between connected inputs Cam programmer Up/down counter UP DOWN COUNT PRESET H-METER TIME PROG
Up/down counter with external preset Hour counter(hour, minute preset)
Time programmer,weekly and annual
GAIN TRIGGER MUX
Allows conversion of an analogue value by change of scale and offset.
Defines an activation zone with hysteresis. Multiplexing functions on 2 analogue values
COMP IN ZONE ADD/SUB MUL/DIV
Zone comparison(Min. y Value y Max.)
Add and/or subtract function Multiply and/or divide function
DISPLAY COMPARE STATUS
Display of digital and analogue data, date, time, messages for Human-Machine interface.
Comparison of 2 analogue values using the operands =, >, <, y, u.
Access to smart relay status
ARCHIVE SPEED COUNT
Storage of 2 values simultaneously Fast counting up to 1 kHz
SFC functions (2) (GRAFCET) RESET-INIT INIT STEP STEP
Reinitialisable step Initial step SFC step
DIV-OR 2 CONV-OR 2 DIV-AND 2
Divergence to OR Convergence to OR Divergence to AND
CONV-AND 2
Convergence to AND
Logic functions AND OR NAND
AND function OR function NOT AND function NOR XOR NOT
NOT OR function Exclusive OR function NOT function(1) Functional Block Diagram.(2) Sequential Function Chart.
9
Characteristics 0 Zelio Logic smart relays 0
Compact and modular smart relays
Environment characteristicsProduct certifications UL, CSA, GL, C-TICKConformity withthe low voltage directive
Conforming to 73/23/EEC EN 61131-2
Conformity withthe EMC directive
Conforming to 89/336/EEC EN 61131-2 (Zone B)EN 61000-6-2, EN 61000-6-3 and EN 61000-6-4
Degree of protection Conforming to IEC 60529 IP 20
Overvoltage category Conforming to IEC 60664-1 3Degree of pollution Conforming to IEC/EN 61131-2 2Ambient air temperaturearound the device
Operation °C -20... +55 (+40 in enclosure), conforming to IEC 60068-2-1 and IEC 60068-2-2
Storage °C -40... +70Maximum relative humidity 95 % without condensation or dripping waterMaximum operating altitude Operation m 2000
Transport m 3048Mechanical resistance Immunity to vibrations IEC 60068-2-6, test Fc
Immunity to mechanical shock IEC 60068-2-27, test Ea
Resistance to electrostatic discharge
Immunity to electrostatic discharge
IEC 61000-4-2, level 3
Resistance to HF interference(Immunity)
Immunity to electromagnetic radiated fields
IEC 61000-4-3, level 3
Immunity to fast transients in bursts
IEC 61000-4-4, level 3
Immunity to shock waves IEC 61000-4-5Radio frequency in common mode
IEC 61000-4-6, level 3
Voltage dips and breaks (a) IEC 61000-4-11Immunity to damped oscillation wave
IEC 61000-4-12
Conducted and radiated emissions
Conforming to EN 55022/11 (Group 1)
Class B
Connection to screw terminals(Tightened using Ø 3.5 screwdriver)
Flexible cable with cable end mm2 1 conductor: 0.25...2.5, cable: AWG 24... AWG142 conductors: 0.25...0.75, cable: AWG 24... AWG18
Semi-solid cable mm2 1 conductor: 0.2...2.5, cable: AWG 25... AWG14Solid cable mm2 1 conductor: 0.2...2.5, cable: AWG 25... AWG14
2 conductors: 0.2...1.5, cable: AWG 24... AWG16Tightening torque N.m 0.5
c 12 V supply characteristicsSmart relay type SR2 B121JD SR2 B201JD
Primary Nominal voltage V 12 12Voltage limits Including ripple V 10.4…14.4 10.4…14.4Nominal input current mA 120 200
Maximum nominal input current with extensions mA 144 250Power dissipated WA 1.5 2.5Micro-breaks Permissible duration ms y 1 (repeated 20 times)
Protection Against polarity inversion
c 24 V supply characteristicsSmart relay type SR2
p1p1BDSR2p1p2BD
SR2p2p1BD
SR2p2p2BD
SR3B101BD
SR3B102BD
SR3B261BD
SR3B262BD
Primary Nominal voltage V 24 24 24 24 24 24 24 24Voltage limits Including ripple V 19.2…30 19.2…30 19.2…30 19.2…30 19.2…30 19.2…30 19.2…30 19.2…30
Nominal input current mA 100 100 100 100 100 50 190 70Maximum nominal input current with extensions mA – – – – 100 160 300 180Power dissipated WA 3 3 6 3 3 4 6 5
Maximum power dissipated with extensions W – – – – 8 8 10 10Micro-breaks Permissible duration ms y 1 (repeated 20 times)Protection Against polarity inversion
a 24 V supply characteristicsSmart relay type SR2p1p1B SR2p2p1B SR3 B101B SR3 B261B
Primary Nominal voltage V 24 24 24 24Voltage limits Including ripple V 20.4…28.8 20.4…28.8 20.4…28.8 20.4…28.8
Nominal frequency Hz 50-60 50-60 50-60 50-60Nominal input current mA 145 233 140 280Power dissipated VA 4 6 4 7.5
Micro-breaks Permissible duration ms y 10 (repeated 20 times)rms insulation voltage V 1780 (50-60 Hz)
10
Characteristics (continued) 0 Zelio Logic smart relays 0
Compact and modular smart relays
a 100...240 V supply characteristicsSmart relay type SR2 p101FU SR2 p121FU SR2 p201FU SR3 B101FU SR3 B261FU
Primary Nominal voltage V 100…240 100…240 100…240 100…240 100…240
Voltage limits Including ripple V 85…264 85…264 85…264 85…264 85…264Nominal input current mA 80/30 80/30 100/50 80/30 100/50Maximum nominal input current with extensions mA – – – 80/40 80/60
Power dissipated VA 7 7 11 7 12Maximum power dissipated with extensions VA – – – 12 17Micro-breaks Permissible duration ms 10 10 10 10 10
rms insulation voltage V 1780 1780 1780 1780 1780
Processing characteristicsSmart relay type SR2/SR3
Number of control scheme lines
With LADDER programming 120
Number of function blocks With FBD programming Up to 200
Cycle time ms 10Response time ms 20Back-up time(in the event of power failure)
Day/time 10 years (lithium battery) at 25 °C
Program and settings 10 years (EEPROM memory)Program memory checking At each power-upClock drift 12 min/year (0 to 55 °C)
6 sec/month (at 25 °C and calibration)Timer block accuracy 1 % ± 2 of the cycle time
Discrete c 24 V input characteristicsSmart relay type SR2/SR3
Connection Screw terminal block
Nominal value of inputs Voltage V 24Current mA 4
Input switching limit values At state 1 Voltage V u 15
Current mA u 2.20At state 0 Voltage V y 5
Current mA < 0.75
Input impedance at state 1 KΩ 7.4Configurable response time State 0 to 1 ms 0.2
State 1 to 0 ms 0.3
Conformity to IEC 61131-2 Type 1Sensor compatibility 3-wire Yes PNP
2-wire No
Input type ResistiveIsolation Between supply and inputs None
Between inputs None
Maximum counting frequency kHz 1Protection Against inversion of terminals Control instructions not executed
Discrete a 100...240 V input characteristicsSmart relay type SR2/SR3
Connection Screw terminal blockNominal value of inputs Voltage V 100... 240
Current mA 0.6
Frequency Hz 47... 63Input switching limit values At state 1 Voltage V u 79
Current mA > 0.1750
At state 0 Voltage V y 40Current mA < 0.05
Input impedance at state 1 KΩ 350
Configurable response time State 0 to 1 (50/60 Hz) ms 50State 1 to 0 (50/60 Hz) ms 50
Isolation Between supply and inputs None
Between inputs NoneProtection Against inversion of terminals Control instructions not executed
11
Characteristics (continued) 0 Zelio Logic smart relays 0
Compact and modular smart relays
Integral analogue input characteristicsSmart relay type SR2/SR3
Analogue inputs Input range V 0...10 or 0...24
Input impedance KΩ 12Maximum non destructive voltage V 30Value of LSB 39 mV, 4 mA
Input type Common modeConversion Resolution 8 bit
Conversion time Smart relay cycle time
Precision at 25 °C ± 5 %at 55 °C ± 6.2 %
Repeat accuracy
at 55 °C ± 2 %
Isolation Between analogue channel and supply
None
Cabling distance m 10 maximum, with screened cable (sensor not isolated)
Protection Against inversion of terminals Control instructions not executed
Relay output characteristicsSmart relay type SR2ppp/ SR3 B101pp SR3 B261pp, SR3 XT141pp
Operating limit values V c 5...150. a 24...250
c 5...150. a 24...250
Contact type N/O N/O
Thermal current A 8 8 outputs: 8 A2 outputs: 5 A
Electrical durability for 500 000 operating cycles
Utilisation category
DC-12 V 24 24A 1.5 1.5
DC-13 V 24 (L/R = 10 ms) 24 (L/R = 10 ms)A 0.6 0.6
AC-12 V 230 230
A 1.5 1.5AC-15 V 230 230
A 0.9 0.9
Minimum switching capacity At minimum voltage of 12 V mA 10 10Low power switching reliability of contact
12 V - 10 mA 12 V - 10 mA
Maximum operating rate No-load Hz 10 10At Ie (operational current) Hz 0.1 0.1
Mechanical life In millions of operating cycles 10 10Rated impulse withstand voltage
Conforming to IEC 60947-1 and 60664-1
kV 4 4
Response time Trip ms 10 10Reset ms 5 5
Built-in protection Short-circuit NoneAgainst overvoltage and overload None
Transistor output characteristicsSmart relay type SR2/SR3
Operating limit values V 19.2...30Load Nominal voltage V c 24
Nominal current A 0.5Maximum current A 0.625 at 30 V
Drop out voltage At state 1 V y 2 for I=0.5 A
Response time Trip ms y 1Reset ms y 1
Built-in protection Against overload and short-circuits
Yes
Against overvoltage (1) Yes
Against inversions of power supply
Yes
(1) If there is no volt-free contact between the relay output and the load.
12
Curves 0 Zelio Logic smart relays 0
Compact and modular smart relays
Electrical durability of relay outputs(in millions of operating cycles, conforming to IEC 60947-5-1)
d.c. loadsDC-12 (1)
DC-13 (2)
(1) DC-12: switching resistive loads and photo-coupler isolated solid state loads, L/R ≤ 1ms.(2) DC-13: switching electromagnets, L/R ≤ 2 x (Ue x Ie) in ms, Ue: Rated operational voltage, Ie:
rated operational current (with protection diode on load, use the DC-12 curves and apply a coefficient of 0.9 to the millions of operating cycles value)
0 1,51 20,50,0
0,5
1,0
1,5
2,0
2,5
3,0
24 V
48 V
M
illio
ns o
f ope
ratin
g cy
cles
Current (A)
0,1 0,3 0,5 0,7 0,9 10,2 0,4 0,6 0,80,0
1,4
1,2
1,0
0,8
0,6
0,4
0,2
L/R = 10 ms 24 V
L/R = 10 ms 48 V
L/R = 60 ms 48 V
L/R = 60 ms 24 V
M
illio
ns o
f ope
ratin
g cy
cles
Current (A)
13
Curves (continued) 0 Zelio Logic smart relays 0
Compact and modular smart relays
Electrical durability of relay outputs (continued)(in millions of operating cycles, conforming to IEC 60947-5-1)
a.c. loadsAC-12 (1)
AC-14 (2)
AC-15 (3)
(1) AC-12: switching resistive loads and photo-coupler isolated solid state loads, cos ≥ 0.9.(2) AC-14: switching small electromagnetic loads whose power drawn with the electromagnet
closed is ≤ 72 VA, making: cos = 0.3, breaking: cos = 0.3.(3) AC-15: switching electromagnetic loads whose power drawn with the electromagnet closed is
> 72 VA, making: cos = 0.7, breaking: cos = 0.4.
0 0,5 1,5 2,5 3,5 4,51,0 2,0 3,0 4,0 50,0
0,5
1,0
1,5
2,0
2,5
3,0
24 V
48 V
110 V
230 V
M
illio
ns o
f ope
ratin
g cy
cles
Current (A)
0 0,2 0,6 1,0 1,4 1,80,4 0,8 1,2 1,6 20,0
0,5
1,0
1,5
2,0
2,5
24 V48 V
110 V
230 V
M
illio
ns o
f ope
ratin
g cy
cles
Current (A)
0,5 0,90,7 1,31,1 1,71,5 1,90,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
230 V 48 V
110 V
M
illio
ns o
f ope
ratin
g cy
cles
Current (A)
14
References 0 Zelio Logic smart relays 0
Compact smart relays
Compact smart relays with displayNumber of I/O
Discrete inputs
Of which0-10 V analogue inputs
Relay outputs
Transistor outputs
Clock Reference Weight
kg
Supply c 12 V12 8 4 4 0 Yes SR2 B121JD 0.25020 12 6 8 0 Yes SR2 B201JD 0.250
Supply c 24 V10 6 0 4 0 No SR2 A101BD (1) 0.25012 8 4 4 0 Yes SR2 B121BD 0.250
8 4 0 4 Yes SR2 B122BD 0.22020 12 2 8 0 No SR2 A201BD (1) 0.380
12 6 8 0 Yes SR2 B201BD 0.380
12 6 0 8 Yes SR2 B202BD 0.280
Supply a 24 V12 8 0 4 0 Yes SR2 B121B 0.250
20 12 0 8 0 Yes SR2 B201B 0.380
Supply a 100...240 V10 6 0 4 0 No SR2 A101FU (1) 0.250
12 8 0 4 0 Yes SR2 B121FU 0.25020 12 0 8 0 No SR2 A201FU (1) 0.380
12 0 8 0 Yes SR2 B201FU 0.380
Compact smart relays without displayNumber of I/O
Discrete inputs
Of which 0-10 V analogue inputs
Relay outputs
Transistor outputs
Clock Reference Weight
kg
Supply c 24 V10 6 0 4 0 No SR2 D101BD (1) 0.22012 8 4 4 0 Yes SR2 E121BD 0.220
20 12 2 8 0 No SR2 D201BD (1) 0.35012 6 8 0 Yes SR2 E201BD 0.350
Supply a 24 V12 8 0 4 0 Yes SR2 E121B 0.22020 12 0 8 0 Yes SR2 E201B 0.350
Supply a 100...240 V10 6 0 4 0 No SR2 D101FU (1) 0.22012 8 0 4 0 Yes SR2 E121FU 0.22020 12 0 8 0 No SR2 D201FU (1) 0.350
12 0 8 0 Yes SR2 E201FU 0.350
Compact "discovery" packsNumber of I/O
Pack contents Reference Weightkg
Supply c 24 V12 An SR2 B121BD compact smart relay with display,
a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR2 PACKBD 0.700
20 An SR2 B201BD, compact smart relay with display, a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR2 PACK2BD 0.850
Supply a 100...240 V12 An SR2 B121FU, compact smart relay with display,
a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR2 PACKFU 0.700
20 An SR2 B201FU, compact smart relay with display, a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR2 PACK2FU 0.850
(1) Programming on smart relay in LADDER language only.
1094
40
SR2 A201BD
1094
42
SR2 E121BD
5103
45
SR2 PACKppp
15
References 0 Zelio Logic smart relays 0
Modular smart relays
Modular smart relays with displayNumber of I/O
Discrete inputs
Of which 0-10 V analogue inputs
Relay outputs
Transistor outputs
Clock Reference Weight
kg
Supply c 24 V10 6 4 4 0 Yes SR3 B101BD 0.250
6 4 0 4 Yes SR3 B102BD 0.220
26 16 6 10 (1) 0 Yes SR3 B261BD 0.400
16 6 0 10 Yes SR3 B262BD 0.300
Supply a 24 V10 6 0 4 0 Yes SR3 B101B 0.250
26 16 0 10 (1) 0 Yes SR3 B261B 0.400
Supply a 100-240 V10 6 0 4 0 Yes SR3 B101FU 0.250
26 16 0 10 (1) 0 Yes SR3 B261FU 0.400
I/O extension modules (2)
Number of I/O
Discrete inputs
Relay outputs
Reference Weightkg
Supply c 24 V (for smart relays SR3 BpppBD)6 4 2 SR3 XT61BD 0.125
10 6 4 SR3 XT101BD 0.200
14 8 6 SR3 XT141BD 0.220
Supply a 24 V (for smart relays SR3 BpppB)6 4 2 SR3 XT61B 0.125
10 6 4 SR3 XT101B 0.200
14 8 6 SR3 XT141B 0.220
Supply a 100-240 V (for smart relays SR3 BpppFU)6 4 2 SR3 XT61FU 0.125
10 6 4 SR3 XT101FU 0.200
14 8 6 SR3 XT141FU 0.220
Communication module (2)
For use on Supply voltage Reference Weightkg
Modbus network c 24 V SR3 MBU01BD r 0.300
Modular "discovery" packsNumber of I/O
Pack contents Reference Weightkg
Supply c 24 V10 An SR3 B101BD, modular smart relay, a connecting
cable and “Zelio Soft” programming software supplied on CD-Rom.
SR3 PACKBD 0.700
26 An SR3 B261BD modular smart relay, a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR3 PACK2BD 0.850
Supply a 100...240 V10 An SR3 B101FU modular smart relay, a connecting
cable and “Zelio Soft” programming software supplied on CD-Rom.
SR3 PACKFU 0.700
26 An SR3 B261FU modular smart relay with display, a connecting cable and “Zelio Soft” programming software supplied on CD-Rom.
SR3 PACK2FU 0.850
(1) Including 8 outputs at maximum current of 8 A and 2 outputs at maximum current of 5 A.(2) Power supply to the I/O extension and communication modules is via the modular smart
relays
Note: The smart relay and its associated extensions must have an identical voltage.
1094
42
SR3 B101BD
1093
63
SR3 XT61BD
1093
69
SR3 XT141BD
r Available: 1st quarter of 2004.
16
References 0 Zelio Logic smart relays 0
Compact and modular smart relaysSeparate components
“Zelio Soft” software for PCDescription Reference Weight
kg“Zelio Soft” for PC multi-language programming software supplied on CD-Rom (1), compatible with Windows 95, 98, NT, 2000, XP and ME.
SR2 SFT01 0.200
Connecting cable between smart relay and PC (length: 3 m)
SR2 CBL01 0.150
Back-up memoryDescription Reference Weight
kgEEPROM back-up memory SR2 MEM01 0.010
Communication interfaceDescription Supply Reference Weight
kgCommunication interface c 12/24 V SR2 COM01 r 0.140
Converters for Optimum Pt100 probes (2)
Supply voltage c 24 V (20 %, not isolated)Type Temperature range Output signal Reference Weight
kg°C °FPt1002-wire, 3-wire and 4-wire
- 40...40 - 40...104 0...10 V or 4...20 mA RMP T13BD 0.116- 100...100 - 148...212 0...10 V or 4...20 mA RMP T23BD 0.1160... 100 32... 212 0...10 V or 4...20 mA RMP T33BD 0.116
0... 250 32... 482 0...10 V or 4...20 mA RMP T53BD 0.1160... 500 32...932 0...10 V or 4...20 mA RMP T73BD 0.116
Power supplies (3)
Input voltage
Nominal output voltage
Nominal output current
Reference Weightkg
a 100...240 V (47...63 Hz)
c 12 V 1.9 A ABL 7RM1202 0.180c 24 V 1.4 A ABL 7RM2401 0.182
DocumentationDescription Language Reference Weight
kgUser's manualfor direct programming on the smart relay
English SR2 MAN01EN 0.100
French SR2 MAN01FR 0.100German SR2 MAN01DE 0.100Spanish SR2 MAN01ES 0.100
Italian SR2 MAN01IT 0.100Portuguese SR2 MAN01P0 0.100
(1) CD-Rom containing "Zelio Soft" software, an application library, a self-training manual, installation instructions and a user's manual.
(2) See pages 20 to 25.(3) See pages 26 to 29.
SR2 SFT01
5103
5210
9369
SR2 MEM01
SR2 COM01
5103
53
ABL7 RM1202
5103
54
r Available: 1st half of 2004.
17
Dimensions 0 Zelio Logic smart relays 0
Compact and modular smart relays
Compact and modular smart relaysSR2 A101BD, SR2 D101FU, SR3 B101BD and SR3 B101FU (10 I/O)SR2 B121JD, SR2 B12pBD, SR2 B121B, SR2 A101FU, SR2 B121FU, SR2 D101BD, SR2 E121BD, SR2 E121B, SR2 E121FU (12 I/O)Mounting on 35 mm 5 rail Screw fixing (retractable lugs)
SR2 B201JD, SR2 A201BD, SR2 B20pBD, SR2 B201B, SR2 A201FU, SR2 B201FU, SR2 D201BD, SR2 E201BD, SR2 E201B, SR2 D201FU and SR2 E201FU (20 I/O)SR3 B26pBD and SR3 B261FU (26 I/O)Mounting on 35 mm 5 rail Screw fixing (retractable lugs)
I/O extension modulesSR3 XT61pp (6 I/O)Mounting on 35 mm 5 rail Screw fixing (retractable lugs)
SR3 XT101pp and SR3 XT141pp (10 and 14 I/O)Mounting on 35 mm 5 rail Screw fixing (retractable lugs)
71,2
90
==
107,
6
59,559,9 2xØ4
100
124,6
90
113,3
100
==
59,52xØ4
107,
6
35,5
==
59,525
100
110
90
2xØ4
7260
100
110
90
==
59,52xØ4
18
Schemes 0 Zelio Logic smart relays 0
Compact and modular smart relays
Input connections3-wire sensorsSR2 ppppBD, SR2 B121JD and SR3 ppppBD
(1) 1 A quick-blow fuse or circuit-breaker.
Analogue inputsSR2 B12pBD, SR2 B121JD and SR3 B10pBD SR2 B201BD, SR3 B26pBD and SR2 B201JD
(1) 1 A quick-blow fuse or circuit-breaker. (1) 1 A quick-blow fuse or circuit-breaker.
BN
BK
BLBN
BK
BL
+
SR2 B121JDc 12 VSR3 ppppBDc 24 V
SR2 ppppBDc 24 V
–
(1)
+ –
Q1 Q2 Q3 Q4
I1 I2 I3 I4 IB IC ID IE
+
SR2 B121JDc 12 V
SR2 ppppBDc 24 V
–
(1)
+ –
Q1 Q2 Q3 Q4
I1 I2 I3 I4 IB IC ID IE
Ca / Ta1
Ca / Ta2
c 0-10 V ANALOG.
10 m
max
imum
+ – ––I1 I2 I3 I4 I5 I6 IB IC ID IE IF IG
+SR2 B201BDSR3 B26pBDc 24 VSR2 B201JDc 12 V
–
(1)
Ca / Ta1
Ca / Ta2
c 0-10 V ANALOG.
10 m
max
imum
