Power Factor Correction in presence of harmonics

When Power Factor Correction is necessary we have to bear in mind that nowadays
many loads generate harmonic currents that must be taken into account when
designing the PFC system. Therefore it’s very important for the reliability, durability and
safety of the installation to carefully analyze the load and grid to determine the proper
PFC technologies to be applied.

Selecting the proper PFC technologies:

Once determined the KVAR requirements or effective power to take the load to the
desired higher PF, it’s time for the mentioned analysis. It should really start by analyzing
the load change speed and this will determine the first PFC technology approach.
If we know the load changes within minutes, seconds or tenths of a second we should
think from the very beginning in a dynamic PFC system (basically a system switched by
thyristor switches) while if we determine that the load will change along hours, a
standard contactor switched system will be fine. Another criterion would be the
expected switchings of the PFC system. A reasonable limit to choose a technology or
the other would be 50 switchings per day. For more than this, a dynamic system is
really necessary.

Once chosen standard or dynamic switching technology it’s time to analyze the
harmonic contents of the load, and this is properly done by taken measurements with a
harmonics analyzer, but only once the normal operating conditions of the load have
been identified and all existing capacitors have been disconnected because we need to
determine the real harmonics contents of the load, without any PFC system connected.

The harmonics analysis has to clearly identify the total voltage distortion THD-V% , the
total current distortion THD-I% and the harmonics spectrum. This means that we have
to know which harmonics are present and how high they are.

If we determine that THD-V% is higher than 3% or THD-I% is higher than 10% a

harmonics filtered PFC system will be necessary.

The effects that the harmonics can cause in an installation is dependant on the
transformer that is supplying the energy, the smaller the transformer the more
significant the effect will become on the installation, and it’s also dependant on capacitor
bank power to be connected for PFC purposes.
Objectives when correcting PF in presence of harmonics:

We must have clear in mind which our objectives are when we face a PFC project in
presence of harmonics. These objectives are here below described and set in their
proper priority:

1. Correct the low Power Factor: this is the main intention of the project.
And we have to do it in a reliable and safe way, even in presence of harmonics.

2. Avoid parallel resonance: this is a very dangerous phenomenon that appears

when we put capacitors in parallel with a transformer while we have harmonics
currents. So avoiding this is definitely a restriction imposed by the conditions.

3. Partially filtering the dominant harmonic: this maybe a collateral benefit if we

apply the proper filtering PFC technology.

When correcting the power factor with the proper technology it is possible to achieve
these three objectives, but it must be clear that Power Factor Correction is the main
objective and not harmonics elimination, although sometimes, some partial filtering of
the dominant harmonics can be obtained with relatively simple Detuned PFC
technology.

Non Linear Loads: harmonics generators.

Some electrical loads, when sinusoidal voltage is applied to them, do not generate a
sinusoidal current. These are called Non Linear Loads.
 V IL
I1

I7
I5

π π
The periodical distorted current that they generate is equivalent to having a sinusoidal
current of the fundamental frequency plus many other sinusoidal currents of frequencies
multiple of the fundamental and of different amplitudes. This can be mathematically
demonstrated by the Fourier Series analysis.

Some non linear loads, like a motor drive or a rectifier, generate a discrete and well
defined harmonics spectrum while some others like welders generate a changing and
random spectrum.

Indeed any of them can have low PF as well and therefore PFC must be applied even
under these conditions, but in such cases, only using the proper PFC technology will be
possible to do it in a reliable and safe way, otherwise these totally unexpected high
frequency currents will overload the system and might cause dangerous effects.

Typical non linear loads harmonics spectrums:

A single-phase full wave rectifier generates the following harmonics spectrum:

Adjustable speed drives produce highly distorted current and notching on the voltage
due to pulse rectifiers switching.

Common problems caused by harmonic currents:

• Overheating of transformers and rotating equipment

• Neutral overloading and unacceptable neutral-to-ground voltages
• Failed capacitor banks
• Breakers and fuses tripping
• Unreliable operation of electronic equipment
• Erroneous energy meters
• Wasted energy and higher electricity bills (kW and KWh)
• Wasted power distribution capacity
• Higher maintenance costs of equipment and machinery

Harmonics amplification caused by standard PFC systems:

Capacitors impedance decreases as a function of the frequency and that means high
frequency harmonic currents will find a low impedance path thru the capacitors.
Harmonic currents will flow thru the capacitors without any control and will overload
them, perhaps beyond their admissible current overload capacity.

Capacitors along with the inductance of the transformer make a parallel resonant circuit,
that if not controlled, it may increase the impedance at a frequency of an existing and
constant harmonic current therefore generating over voltage at that frequency and
increasing the current at this frequency inside the parallel this circuit. A behavior of
harmonics amplification.

No PFC With PFC

capacitors
Meter: 0001

H# % φ H#
K-f actor: 1.041

% φ T.H.D.:
V olts : 277

2.8% max:
Frequency:60.01 Hz

2.9% min: 0.5% H#

capacitors
Meter: 0001

% φ H#
K-f actor: 1.829

% φ
V olts: 290

T.H.D.: 18.8%
Frequency:59.97 Hz

max: 21.6% min: 1.9%

1 100.0 0 2 0.0 69 1 100.0 0 2 0.1 26
3 0.4 116 4 0.1 68 3 0.5 352 4 0.3 31
5 2.1 272 6 0.0 69 5 18.8 203 6 0.0 259
7 1.6 41 8 0.0 70 7 1.2 126 8 0.0 259
9 0.2 133 10 0.0 68 9 0.0 80 10 0.0 200
11 0.4 11 12 0.0 68 11 0.1 312 12 0.0 259
13 0.7 36 14 0.1 68 13 0.0 80 14 0.0 80
15 0.1 68 16 0.0 68 15 0.1 116 16 0.0 200
17 0.2 37 18 0.0 158 17 0.0 320 18 0.0 169
19 0.1 69 20 0.0 158 19 0.0 319 20 0.0 259
21 0.1 327 22 0.0 69 21 0.1 192 22 0.0 259
23 0.0 69 24 0.0 69 23 0.0 169 24 0.0 349
25 0.1 301 26 0.0 8 25 0.1 259 26 0.0 259
27 0.0 158 28 0.0 248 27 0.1 259 28 0.0 349
29 0.1 319 30 0.0 309 29 0.0 259 30 0.0 259
31 0.2 20 32 0.0 68 31 0.1 31 32 0.0 79

Meter: 0001 K-f actor: 1.533 A mps : 1716 Frequency:60.01 Hz Meter: 0001 K-f actor: 32.38 A mps: 2033 Frequency: 59.97 Hz

H# % φ H# % φ T.H.D.: 13.6% max: 18.1% min: 2.1% H# % φ H# % φ T.H.D.: 89.5% max: 152.3% min: 3.6%
1 100.0 0 2 0.5 100 1 100.0 0 2 2.3 9
3 0.4 29 4 0.1 119 3 1.0 169 4 2.9 79
5 12.3 53 6 0.4 66 5 150.0 263 6 3.8 259
7 5.5 356 8 0.1 91 7 8.7 141 8 1.2 300
9 0.7 299 10 0.2 29 9 1.5 280 10 1.5 259
11 1.3 7 12 0.1 29 11 1.6 259 12 0.8 310
13 0.1 210 14 0.0 29 13 1.7 279 14 0.5 259
15 0.3 29 16 0.0 119 15 1.2 79 16 1.1 294
17 0.3 285 18 0.0 29 17 0.5 260 18 0.3 8
19 0.0 210 20 0.1 90 19 1.0 331 20 0.5 259
21 0.1 90 22 0.0 29 21 1.5 259 22 0.5 312
23 0.0 210 24 0.0 119 23 1.2 339 24 0.1 259
25 0.1 29 26 0.1 29 25 0.5 180 26 0.6 349
27 0.0 29 28 0.1 119 27 0.9 182 28 0.3 307
29 0.1 29 30 0.1 119 29 0.7 349 30 0.2 19
31 0.0 29 32 0.0 209 31 0.6 292 32 0.0 259

Detuned PFC Filters theory:

Let’s pretend we have a simple installation with a transformer supplying energy to one
linear load and to one non linear load. The circuit below shows an inductor representing
the transformer inductance LT plus the grid short-circuit inductance LSC, although for in
practice LSC, is neglectable compared to LT because usually in a LV installation the
short circuit power is imposed by that of the transformer as the grid is immensely
powerful compared to the transformer.

Let’s say our non linear load generates harmonic currents, from the 5th on, and these
currents are constant. Although the transformer is not applying any harmonic voltage,
the load generates from 5th harmonic currents on, therefore behaving like a constant
current generator, and so it’s represented in graphics. Let’s say in this example that the
5th is the highest harmonic, the dominant.

IZI Impedance
without
A capacitors

Lsc
+ In
LT

O loads
f1 f
f5 Existing hamonic
currents spectrum

These undesirable harmonic currents flow thru whatever is connected in parallel closing
the circuit until they return to the generator and on their way overloading everything that
comes across.

Let’s say this simple installation has low power factor so we have to install a capacitor in
parallel to correct it. In order to understand what would happen, let’s analyze the
impedance as a function of the frequency between points AO towards the transformer.
We have the impedance of the transformer represented by a positive slope straight line
meaning that its impedance grows as the frequency grows.
On the frequency axis we mark some particular points, first the fundamental frequency
f1 and then f5, the 5th harmonics, where the existing harmonic currents spectrum starts.
Between f1 and f5 we have a frequency range with no existing harmonic currents.

Now when we install a capacitor for PFC, a parallel resonant circuit is formed between
the transformer inductance and the capacitor’s capacitance. This parallel circuit has a
resonance frequency for which its impedance becomes very high, and this parallel
resonance frequency is determined by the values of the inductance and capacitance
according to this formulae:
 1 1
fp = =
2π ( LSC+LT ) C 2π LT C

In the following graphics we now also see represented the new impedance curve of this
resonant circuit, showing the parallel resonance frequency fp of high impedance falling
close to the 5th harmonics. So the 5th harmonic current which was constant now finds
high impedance at that frequency and therefore generates a considerable additional
voltage at that frequency. V5 = ZAO5 . I5

IZI Impedance
without
A Impedance capacitors
with
capacitors
Lsc
+ C In
LT

O loads f
f1 f5 fp Existing hamonic
currents spectrum (Hz)

V5 = ZAO5 . I5
If I5 is constant and ZAO5 has a considerable value, V5 is significant.
This is a voltage that will be overlapped to the fundamental voltage creating a higher
total peak voltage that stresses all isolations in the installation.

This parallel resonance phenomenon can be exited even by small currents of a

frequency close to that of the parallel resonant frequency determined by the values of L
and C. If this happens, a small harmonic current generated by the load may cause a
high current flow between the transformer and the capacitors overloading both of them
and generating over voltage for everything connected in parallel.

So far we have corrected the power factor at the fundamental by connecting but we
have created a very dangerous parallel resonant risk.

To avoid this we have top modify this parallel circuit in such a way that its parallel
resonance frequency falls somewhere between the fundamental and the first existing
harmonic current, in this example, between f1 and f5, a frequency range where we
know that there are no currents.

The circuit is modified by adding a reactor in series with the capacitor with an
inductance value selected in such a way to get the desired effect.

1
New fp = 2π ( LT+LR ) C

The now more complex circuit shifts the parallel resonance frequency to a safe place
where there’s no harmonic current while the reactor-capacitor set, at the fundamental
frequency, still behaves almost as if the reactor doesn’t exist.

IZI
Impedance Impedance Impedance
with with without
A Detuned Filter capacitors capacitors

LR
LT In
C

O loads
f1 fp fs f Existing hamonic f
5 currents spectrum

But this new reactor-capacitor set makes another new resonant circuit, now series,
which creates another new series resonance frequency, fs, which falls just below the
first existing harmonic current (in this example the 5th). At fs the impedance of this LC
set is almost zero, creating short-circuit path for a current of that frequency. This is
what’s called a Tuned Filter, exactly tuned at the frequency which has to be bypassed
from the rest the installation. But tuned filters, as they have zero impedance, have no
theoretical limit to the current at fs frequency except for the practical limitation imposed
by their components’ current transportation capability.
So if our non linear load sends 100 Amps of 5th harmonics it will flow across it (if
components resist it) and it will filtered out of the rest of the installation, but it would be
dangerous if there’s no control of the incoming harmonics because the filter is already
heavily loaded with the fundamental current.
By selecting the components values in such a way that fs falls a little below the
frequency of first dominant harmonics, the impedance of the filter is not zero but has a
certain low value at the first dominant harmonic current and therefore this impedance
limits the amount of this harmonics that flows into the filter. The impedance at this first
harmonic is controlled by detuning the filter, the closer it gets to the harmonic frequency
the more current if filters. Detuned filters are detuned in such a way that the harmonic
currents that flow into the filter do no exceed the maximum permissible current of the
capacitor and of the reactor that make up the filter, considering the fundamental current
used for PFC purposes.

Using Detuned PFC Filters, the three objectives for reliable and safe PFC in presence
of harmonics are achieved. At the fundamental frequency, it corrects the PF, the parallel
resonance is avoiding by shifting the resonance frequency to a value where there’s no
current of that frequency and the first dominant harmonic current can be partially filtered
out from the rest of the installation without overloading the capacitor bank.

Parallel resonance risk analysis:

For a given transformer and capacitor bank combination, the parallel resonance order
can be determined based on more know parameters like the short-circuit power of the
transformer and the capacitor bank power, according to the following formula:

Ssc
np=
Qc
Once identified the existing harmonic currents thru the harmonic analysis it’s easy to
check for those existing harmonic orders which capacitor bank powers might cause
resonance.

For example:

Let’s suppose we have an installation with low PF and we are going to connect a PFC
bank, so after taking measurements, we identify the 5th, 7th and 11th harmonic currents.
The transformer has a rated power of 1000kVAR and uk%=4%

We should check for every existing harmonic order which capacitor bank output power
would generate resonance. If the planned system to be installed might have a step
combination that could provide any of such power ratings, detuned technology would be
mandatory to avoid parallel resonance, even if the harmonic current at that resonance
frequency were not relevant in the measurements.
Example: Xmer S = 1000 kVA uk%= 4% Ssc=25000
kVA
Ssc 25000
Qc = 2 = 52 = 1000 kVAr
n 5

Ssc 25000
Qc = = 72
= 510 kVAr
7
n2

Ssc 25000
Qc = = 112
= 207 kVAr
11
n2

Selecting the proper detuning:

As explained, the proper detuned PFC Filter must be selected based on effective power
required at the fundamental and on the first dominant harmonic current found in the
harmonics analysis to be partially filtered.

Detuned filters are identified for the detune factor, a parameter that identifies the series
resonance frequency the filter is closely tuned below. Most common detune factors are
7% for systems with dominant 5th harmonic or higher, and 14% for systems with
dominant 3rd harmonics.

Usually in industrial installations where control of high power 3-phase loads, the 5th
harmonic is the dominant while in commercial installations like office buildings where
lighting is the main load, the dominant harmonic is the 3rd and therefore 14% systems
are the most suitable.

Selecting the components:

The reactors are selected according to the effective power to get at rated voltage and
fundamental frequency, and according to the required detune factor.

Capacitors are selected taken into account the over voltage generated by the detuning
and according to matching reactor to get the effective power when in series connected.

EPCOS provides tables included in its main PFC catalogue for selecting all the
necessary components: reactors, capacitors, contactors, fuses and cables.
 Example to get: Qe = 50 kVAr - 400V - 50Hz - 7 %

The reactor must be selected according to the effective power required at 400V
and for p=7% , therefore it will be a 50kVAr-400V-50Hz-7%
Although the grid has 480V, due to the detunig the voltage on the capacitor will be:

UC = UN . 100 = 400 V . 100 = 430 V a 440 V capacitor must be used.

100-p 100-7

Calculation of the capacitor rated power Qc especified at UC = 440V,

to get an effective power of 50 kVAr at 400V along with a 7% reactor

2 2
Qc = 1 - . UC . Qe = 1- . 440 . 50 kVAr = 56 kVAr (440V-50Hz)
p 100 UN 7 100 400

Panel assembly recommendations:

Detuned PFC filters use power reactors, these are components which dissipate quite
heat and therefore operate at high temperature, about 100°C.

Capacitors and contactors are components that should operate at much lower
temperature, so components placement inside the cabinet and forced ventilation are a
must for reliable, durable and safe operation of the system.
Mount capacitors on profiles or on separate mounting plate without thermal conduction
from the reactor and in different vertical lines to avoid heat transmission.

Mount reactors on profiles to allow cooling air flow over the reactor core.

Use abundant forced ventilation.

Connect reactor‘s thermal-switch in series with the contactors‘ coil circuit.

For more information on EPCOS PFC products and technologies visit:

www.epcos.com/pfc
Author:
Ricardo Garrido
EPCOS AG – Munich, Germany.
PFC Capacitors Marketing Manager August 2006