EPCOS Power factor Controller

Description

The EPCOS Power Factor Controller (commonly the BR series) is a microprocessor-controlled APFC relay that continuously monitors and corrects the power factor by switching capacitor banks based on load requirements. Designed for automation and energy optimization, it offers intelligent control modes, phase compensation, dynamic switching, and advanced display/communication features.
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Specifications (Key Models)

• BR4000 Series (Compact 96 × 96 mm panel mount):

  • Stages: 4, 6, 8 outputs

  • Supply Voltage: 144–288 VAC (L-N)

  • Features: Auto CT detection, fault protection, LED display
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• BR5000 Series (Advanced, with data logging and 3-CT support):

  • Stages: 8, 16 outputs

  • Voltage: 415 VAC three-phase

  • Includes four-quadrant operation, energy parameters, remote comms
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• BR6000 Series (Rugged and versatile):

  • Stages: 6, 12 (relay or transistorized)

  • Wide measurement voltage: up to 525 VAC (L-N/L-L)

  • Features: LIFO/FIFO control, self-optimizing logic, large multifunctional LCD, RS-232/RS-485 interface, harmonic & alarm monitoring
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• BR7000 Series (High-end graphical interface):

  • Full graphic or OLED display

  • Voltage: 110–230 VAC; 30–760 VAC measurement range

  • Triple CT inputs, dual RS-485 interfaces, advanced alarms
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Features

• Microcontroller-based logic with intelligent control modes (LIFO, FIFO, self-optimizing)

• Dynamic switching with relay or thyristor (transistorized) outputs

• Wide display options: LED, LCD, graphical, OLED

• Fault detection: over/under voltage, current, temperature, harmonics

• Communication: RS-232/RS-485 interfaces for SCADA integration

• Energy & harmonics monitoring up to 19th order, logging and recall functions

• Flexible voltage sensing (L-N or L-L) and CT-configurations (1 or 3 CT)
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Applications

• Industrial systems with heavy inductive loads (motors, compressors, welding equipment)

• Commercial buildings and utilities aiming to avoid PF penalties

• Renewable energy setups (solar, wind) requiring PF compliance

• Motor Control Centers (MCCs) and distribution panels

• Systems requiring advanced load monitoring and reactive power optimization
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Advantages

• Maintains PF near unity (e.g., 0.99), reducing utility penalties

• Enhances energy efficiency and voltage stability

• Minimizes mechanical wear through intelligent switching logic

• Supports harmonic and energy monitoring

• Configurable displays and communication options for easy integration
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Disadvantages

• Higher initial cost than manual systems

• Requires careful commissioning and setup

• Capacitor banks need regular maintenance due to switching cycles

• Performance may be affected in environments with high harmonic distortion
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