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CALMANUAL
POWER FACTOR CORRECTION
APPLICATION GUIDE
INC.
CALMANUAL
HOW TO APPLY CAPACITORS TO
LOW VOLTAGE POWER SYSTEMS.
SECTION INDEX
SECTION I
POWER FACTOR
UNDERSTANDING POWER FACTOR........................ PG 3
IMPROVING POWER FACTOR................................... PG 4
SECTION II
ADVANTAGES OF MAINTAINING
A HIGH POWER FACTOR
ELIMINATION OF PENALTY DOLLARS...................... PG 5
ADDITIONAL CAPACITY IN ELECTRICAL
SYSTEM ......................................................................PG 5
REDUCTION OF I2R LOSSES..................................... PG 5
SECTION IV
SECTION V
SECTION VI
ENGINEERING DATA
DEFINITIONS ..............................................................PG 12
MYRON ZUCKER
INC.
PAGE - 2
SECTION I
POWER FACTOR
KW or KW-HRS
(Active Power)
Figure 1:
O
KVA or KVA-HRS
(Total Power )
KVAR or
KVAR-HRS
( Reactive Power )
PF = KW = COS O
KVA
PAGE - 3
KVA = 1160
PF =
KVAR = 828
812
x 100 = 70%
1160
KW = 812
COS O = .89
KVA = 913
PF =
KVAR =
828 - 410 = 418
812
x 100 = 89%
913
The user, doing the same amount of work, but now with
capacitors installed, has eliminated the $650.00 monthly penalty.
This would be an annual savings of $7,800.00. The capacitors
and the labor to install them cost $7,351.00, a payback of less
then 12 months.
The utility has to generate 247 less KVA (1160 - 913 = 247),
and the user has the 1500 KVA transformer now loaded only
to 60% of capacity. This will allow the addition of more load
in the future to be supplied by the transformer.
PAGE - 4
SECTION II
THE ADVANTAGES
OF MAINTAINING
A HIGH POWER
FACTOR
A high power factor can help you utilize the full capacity of
your electrical system. To refresh our memory, lets look again at
the power triangle story, shown on Pages 3 & 4, Figures 1, 2 ,
and 3. Remember that KVA is a measure of the total power
generated by the utility for you to accomplish your KW of work.
Remember that the KVA figure is the amount of power passing
through your plant transformer, and limited by its rated size: e.g.
750 KVA, 1500 KVA, 2500 KVA, etc. In the previous example,
we reduced your transformer loading from 1160 to 913 KVA, thus
allowing for more load to be added in the future.
REDUCTION OF I 2R LOSSES
PAGE - 5
SECTION III
HOW TO
DETERMINE
AMOUNT OF
KVAR REQUIRED
STEPS:
1. Locate .72 (original power factor) in column (1).
2. Read across desired power factor to .95 column.
We find .635 multiplier
3. Multiply 627 (average KW) by .635 = 398 KVAR.
4. Install 400 KVAR to improve power factor to 95%.
Now that we have determined that capacitors totaling 400
KVAR must be installed, we must decide where to locate them.
PAGE - 6
TABLE 1: MULTIPLIERS TO DETERMINE CAPACITOR KVAR REQUIRED FOR POWER FACTOR CORRECTION
Original
Power
Factor
0.60
PAGE - 7
SECTION IV
LOCATION OF
REQUIRED
CAPACITORS
Starter
MOTOR
Capacitor
B
Location A
Capacitor
A
PAGE - 8
TABLE2:SUGGESTEDMAXIMUMCAPACITORRATINGSUSEDFORHIGH
EFFICIENCYMOTORSANDOLDERDESIGN(PRE"T-FRAMES")MOTORS*
*For use with 3-phase, 60 hertz NEMA Classification B Motors to raise full load power factor to approximately 95%
TABLE3:SUGGESTEDMAXIMUMCAPACITORRATINGS
"T-FRAME"NEMA"DESIGNB"MOTORS*
*For use with 3-phase, 60 hertz NEMA Classification B Motors to raise full load power factor to approximately 95%
PAGE - 9
SECTION V
HARMONIC
DISTORTION
PROBLEMS
PAGE - 11
SECTION VI
C: Capacitance (farads)
KW: Kilowatts, measure of active power
KVA: Kilovolt-amperes, measure
of apparent power
KVAR: Kilovolt-amperes reactive
F: Microfarads, measure of capacitance
(farads x 10 - 6 )
f: Frequency of voltage or current in Hz
I c : Capacitor current in amperes
W: Dissipated power, in watts
V: Voltage (Volts)
I or A: Current (Amperes)
R: Resistance (ohms)
K VA R =
KVA 2 KW 2
KVAR x lO 3
C in F = (2 f) x (KV) 2
W = I2 R
KVA =
3 x V x A (3-phase)
10 3
IC = KVAR x 10 3 (3-phase)
3xV
Applied Voltage 208V 240V 480V 600V
Amps / KVAR 2.78 2.41 1.20 0.96
240 VOLTS
KVAR
Current*
(Amps)
Fuse
(Amps)
C.B.
or
Switch
(Amps)
2.4
3.6
4.8
6
7.2
9.6
12
14
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
120
126
132
144
156
168
180
192
216
240
300
360
480
540
600
720
14
14
14
14
14
12
12
10
10
8
8
6
6
4
4
2
2
2
1/0
1/0
1/0
2/0
2/0
3/0
3/0
3/0
4/0
4/0
4/0
300M
300M
350M
500M
500M
(2)4/0
(2)300M
(2)500M
(3)300M
(3)350M
(3)500M
5
6
10
10
I5
20
20
25
30
40
50
60
70
80
90
100
125
125
150
150
150
175
175
200
200
200
250
250
250
300
300
350
400
400
500
600
800
900
1000
1200
30
30
30
30
30
30
30
30
30
60
60
60
100
100
100
100
200
200
200
200
200
200
200
200
200
200
400
400
400
400
400
400
400
400
600
600
800
1200
1200
1200
1
1.5
2
2.5
3
4
5
6
7.5
10
12.5
15
17.5
20
22.5
25
27.5
30
32.5
35
37.5
40
42.5
45
50
52.5
55
60
65
70
75
80
90
100
125
150
200
225
250
300
350
400
450
500
550
600
600 VOLTS
480 VOLTS
Wire Size
9OC-Type
THHN
XHHW*
or Equiv.
Current*
(Amps)
Wire Size
90C-Type
THHN
XHHW*
or Equiv.
1.2
1.8
2.4
3.0
3.6
4.8
6
7.2
9
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
60
63
66
72
78
84
90
96
108
120
150
180
240
270
300
360
420
480
540
600
660
720
14
14
14
14
14
14
14
14
14
12
10
10
8
8
8
8
6
6
6
6
6
4
4
4
2
2
2
2
1/0
1/0
1/0
2/0
3/0
3/0
4/0
300M
500M
(2)4/0
(2)4/0
(2)300M
(2)350M
(2)500M
(3)300M
(3)350M
(3)500M
(3)500M
Fuse
(Amps)
C.B.
or
Switch
(Amps)
Current*
(Amps)
Wire Size
90C-Type
THHN
XHHW*
or Equiv.
3
3
5
6
6
10
10
15
15
20
25
30
35
40
50
50
60
60
65
70
75
80
90
90
100
110
125
125
150
150
150
175
200
200
250
300
400
500
500
600
700
800
900
1000
1100
1200
30
30
30
30
30
30
30
30
30
30
30
30
60
60
60
60
60
60
100
100
100
100
100
100
100
200
200
200
200
200
200
200
200
200
400
400
400
600
600
600
800
800
1200
1200
1200
1200
1
1.4
1.9
2.4
2.9
3.8
4.8
5.8
7.2
9.6
12
14
16
19
22
24
26
29
31
34
36
38
41
43
48
50
53
58
62
67
72
77
86
96
120
144
192
216
240
288
336
384
432
480
528
576
14
14
14
14
14
14
14
14
14
12
12
10
10
8
8
8
8
8
8
6
6
6
6
6
4
4
4
2
2
2
2
1/0
1/0
2/0
3/0
4/0
350M
500M
500M
(2)4/0
(2)300M
(2)350M
(2)400M
(2)500M
(3)300M
(3)350M
Fuse
(Amps)
C.B.
or
Switch
(Amps)
KVAR
3
3
3
5
5
6
10
10
15
20
20
25
30
35
35
40
45
50
50
60
60
65
70
75
80
80
90
100
110
125
125
150
150
175
200
250
350
400
400
500
600
700
750
800
900
1000
30
30
30
30
30
30
30
30
30
30
30
30
30
60
60
60
60
60
60
60
60
100
100
100
100
100
100
100
200
200
200
200
200
200
200
400
400
400
400
600
600
800
800
800
1200
1200
1
1.5
2
2.5
3
4
5
6
7.5
10
12.5
15
17.5
20
22.5
25
27.5
30
32.5
35
37.5
40
42.5
45
50
52.5
55
60
65
70
75
80
90
100
125
150
200
225
250
300
350
400
450
500
550
600
PAGE - 12