EPCOS

Power Factor Correction &

Harmonic filter

Power Quality

Definition:
Power Factor, Harmonics, Transients,
Voltage and frequency variations and other
disturbances in electric power supply
networks

Examples for poor power quality

Adjustable Speed Drives

Flat topping of Drive input

voltage, heavily distorted
current

Notching on the input can

interfere with other loads on
the same branch circuit

Changing load structure

Past - load: most loads were linear

Induction-motors, heating, bulbs

voltage was followed by current - only a few problems
Features
Simple and rugged
design

Customer benefits
High reliability
Long lifetime
Favourably-priced

No commutator

Unrestricted operation for

partial- and overload
conditions
Low maintenance
(only the bearings)

High degree of protection

Can be universally used

Changing load structure

Todays - loads: most loads act non linear

Computer, motor-control, drives, etc.

Current is pulse shaped

Current is no longer following the sinusoidal wave shape

Result: Harmonics

- Increasing number of sources causing disturbances

- Equipment become more and more sensitive
- De-regulated energy market

Problems caused by harmonics

Origin of harmonics
Non linear loads
Loads which have non linear voltage-current characteristics are called non linear
loads. When connected to a sinusoidal voltage, these loads produce non
sinusoidal currents. Modern power electronic systems result into non sinusoidal
currents when connected to the sinusoidal networks.

The non linear devices can be classified under the following three major categories:
1. Power Electronics: e.g. rectifiers, variable speed drives, UPS systems, inverters, ...
2. Ferromagnetic devices: e.g. transformers (non linear magnetizing characteristics)
3. Arcing devices: Arcing devices, e.g. arc furnace equipment, generate harmonics due to the
non linear characteristics of the arc itself.

Harmonic disturbances are created by non-linear loads!

Modern drives a main source for harmonics

Voltage-source
DC link converter

Current-source
DC link converter

Cycloconverter

Design
~

~
=

=
~

=
~

M
3~

~
=

~
M
3~

Features

Voltage is impressed
in the DC link

Current is impressed
in the DC link

Drive
converter

SIMOVERT MASTERDRIVES
SIMOVERT MV
SIMOVERT ML

SIMOVERT A
SIMOVERT I
SIMOVERT S

M
3~

Cycloconverter, no DC link

SIMOVERT D

HARMONICS fed back by 6/12 pulse rectifier

Voltage
Voltagecharacteristic
characteristic
at
the
drive
at the driveconverter
converter
output
(PWM)
output (PWM)

100%

80%

6-pulse
12-pulse

60%

40%

20%

Current
Currentcharacteristic
characteristic
at
atthe
thedrive
driveconverter
converter
output
output

0%
6-pulse

11

13

17

19

23

25

100,00%

29,00%

9,00%

6,00%

3,50%

2,50%

2,00%

1,20%

1,10%

2,90%

0,90%

6,00%

3,50%

0,25%

0,20%

1,20%

1,10%

12-pulse 100,00%

Order number

Example for single phase Non-Linear load

Example of a non-linear load: Switched mode power supply

AC Current

Voltage
Current

LOAD

Understanding harmonics

Harmonic currents or voltages are integer

(whole number) multiples of the
fundamental frequency.

Harmonic
order
Frequency

3rd

5th

7th

50

150 250 350

Problems caused by HARMONICS

Overheating of transformers (K-Factor), and rotating equipment

Increased hysteresis losses

Neutral overloading / unacceptable neutral-to-ground voltages

Distorted voltage and current waveforms

HARMONICS

Fundame

Failed capacitor banks

h3

Breakers and fuses tripping

h7
Amplitude

Unreliable operation of electronic equipment,

h5

SUM

and generators

Erroneous register of electric meters
Time

Wasted energy / higher electric bills - KWD & KWH

Wasted capacity - Inefficient distribution of power

Increased maintenance cost of equipment and machinery

COST caused by HARMONICS

Additional investment due to faster equipment derating
Shorter life time of equipment
Higher energy consumption
Higher downtime of production equipment
Higher maintenance and repair cost
Reduced product quality
Reduced production output
Investment for stronger equipments/components
alternatively

One time investment for harmonic filter

Effect of harmonics
Tripping of circuit breakers and fuses
Due to resonance effects, the current levels may rise to multifold levels which results into tripping of
circuit breakers and melting fuses. This situation results into serious problems in industries which rely
on the quality of power for the continuous operation of their sensitive processes (e.g. semiconductor)
Overloading / decrease of life time of transformers
Transformers are designed to deliver power at network frequency (50/60Hz). The iron losses are
composed of the eddy current loss (which increase with the square of the frequency) and hysteresis
losses (which increase linearly with the frequency). With increasing frequencies the losses also
increase, causing an additional heating of the transformer.
Overloading of the capacitors
Capacitive reactance decreases with the frequencies. Even smaller amplitudes
of the harmonic voltages result into higher currents which are detrimental to
the capacitors: I = U * 2 * 3.14 * f * C.
Losses in distribution equipment
Harmonics in addition to the fundamental current cause additional losses in
the cables, fuses and also the bus bars.

Effect of harmonics
Excessive currents in the neutral conductor
Under balanced load conditions without harmonics, the phase currents cancel each other in neutral,
and resultant neutral current is zero. However, in a 4 wire system with single phase non linear loads,
odd numbered multiples of the third harmonics (3rd, 9th, 15th) do not cancel, rather add together in the
neutral conductor.
In systems with substantial amount of the non linear single phase loads, the neutral currents may rise
to a dangerously high level. There is a possibility of excessive heating of the neutral conductor since
there are no circuit breakers in the neutral conductors like in the phase conductors.
Malfunctioning of the electronic controls and computers
Electronic controls and computers rely on power quality for their reliable operation. Harmonics result
into distorted waveforms, neutral currents and over voltages which affect the performance of the
these gadgets.
Measurement errors in the metering systems
The Accuracy of metering systems is affected by the presence of harmonics. Watt-hour meters
accurately register the direction of power flow at harmonic frequencies, but they have magnitude
errors which increase with frequency.
The accuracy of demand meters and VAr meters is even less in the presence of harmonics.
Wrong multi meter readings. Use true RMS meter!

3rd harmonic in the neutral conductor

3rd harmonic in the neutral conductor

Synthesis of a wave form

Limit for harmonics

Summary

Consumer structure has changed from linear to non linear loads

Harmonics in the net are increasing

Increasing unknown energy losses

Unknown overloads

Problems in the net become more complex

Beside convent. PFC, filters become more and more important

De-tuned filters for most applications

Active filters for a niche market

EPCOS Harmonics solution

Unlike other solutions that:

Waste energy
Connect in series
Generate higher harmonics (through injection)
Have limited fixed sizes and are not expandable
Are bulky and expensive

The Solution EPCOS AG offers:

 Specific harmonic filtering of any magnitude
 Enhanced power quality
 Elimination of associated wasted energy
 Modular and expandable circuitry, to include additional load

Resonance
1. Harmonics can overload PFC capacitors due to over voltage and over
current created by the harmonic source and reduced reactance of PFC
capacitors at higher frequencies.
2. But more critical are applications in which the application configuration
(PFC capacitor and transformer) form a resonance circuit with an
frequency close to existing harmonic frequencies. In such a case
harmonic currents stimulate the resonance circuit and create resonance
amplification with harmful over voltages and over currents.

Resonance is one of the main reasons for failed PFC

capacitors or short life cycle of PFC capacitors!

Parallel resonance

Harmonics MAGNIFICATION

H#

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31

100.0
0.4
2.1
1.6
0.2
0.4
0.7
0.1
0.2
0.1
0.1
0.0
0.1
0.0
0.1
0.2

0
1 16
2 72
41
1 33
11
36
68
37
69
3 27
69
301
158
319
20

K-f ac tor: 1.0 41

H#
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

Meter: 0001
H#

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31

100.0
0.4
12.3
5.5
0.7
1.3
0.1
0.3
0.3
0.0
0.1
0.0
0.1
0.0
0.1
0.0

0
29
53
3 56
2 99
7
2 10
29
2 85
2 10
90
2 10
29
29
29
29

%
0.0
0.1
0.0
0.0
0.0
0.0
0.1
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0

69
68
69
70
68
68
68
68
158
158
69
69
8
248
309
68

V olts : 27 7
T.H.D.:

K-f ac tor: 1.5 33

H#
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

%
0.5
0.1
0.4
0.1
0.2
0.1
0.0
0.0
0.0
0.1
0.0
0.0
0.1
0.1
0.1
0.0

1 00
119
66
91
29
29
29
119
29
90
29
119
29
119
119
209

2.8 %

Fr equenc y :60.01 Hz
max :

A mps : 17 16
T.H.D.:

13.6%

2 .9%

min:

0.5%

Frequenc y :60.01 Hz
max :

1 8.1%

min:

2.1%

Meter: 000 1
H#

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31

100 .0
0.5
18.8
1.2
0.0
0.1
0.0
0.1
0.0
0.0
0.1
0.0
0.1
0.1
0.0
0.1

0
352
203
126
80
312
80
116
320
319
192
169
259
259
259
31

K-f a c tor : 1.829

H#
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

Meter: 000 1
H#

1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31

100 .0
1.0
150.0
8.7
1.5
1.6
1.7
1.2
0.5
1.0
1.5
1.2
0.5
0.9
0.7
0.6

0
169
263
141
280
259
279
79
260
331
259
339
180
182
349
292

%
0.1
0.3
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0

26
31
25 9
25 9
20 0
25 9
80
20 0
16 9
25 9
25 9
34 9
25 9
34 9
25 9
79

K-f ac tor: 32.3 8

H#
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

%
2.3
2.9
3.8
1.2
1.5
0.8
0.5
1.1
0.3
0.5
0.5
0.1
0.6
0.3
0.2
0.0

9
79
25 9
30 0
25 9
31 0
25 9
29 4
8
25 9
31 2
25 9
34 9
30 7
19
25 9

V olts : 2 90
T.H.D.:

18.8%

A mps : 2033
T.H.D.:

89.5%

Frequen c y :5 9.97 Hz
max :

21.6%

min:

1.9%

Voltage

Meter: 0001

With PFC capacitors

Freq uenc y : 5 9.97 Hz

max : 152.3%

min:

3.6%

Current

No PFC capacitors

Real case of parallel resonance in KL/Malaysia

Parallel resonance

Harmonics present on LV side of the transformer

Transformer together with PFC capacitors on LV-side
acts as a parallel resonant circuit
X N , network
im pedance

At resonant frequency the inductive reactance is

equal the capacitive reactance

point of view

XT
transform er

In

The resultant impedance of the circuit increases to

very high value at resonant frequency

Excitation of a parallel resonant circuit results into a
high voltage across the impedances and very high
circulating currents inside the loop

Transformers and capacitors are additionally loaded
which may cause overloading of them

harm onic
load

XL
m otor

XC
cap acitor

Parallel resonance
What happens in case of parallel resonance?
1) I is constant and imprinted
2) Impedance Z

I
AC
DC

Ic

1) + 2) voltage U (ohmic law)

3) With U Ic = IL

IL

Parallel resonance: example

U = 20 KV
Sk = 500 MVA

S = 1000 kVA
Transformer
uk = 6%

U = 400 V

AC

Qc = 400kvar

DC
P = 500 KW, 6-pulse
I50 Hz = 720A
I250 Hz = 144A
I350 Hz = 103A
I550 Hz = 65A
I650 Hz = 55A
I850 Hz = 42A
I950 Hz = 38A

P = 100 KW
I350 Hz =

720
7

f R = 50

Parallel resonance: example

STr
SKLV =

ST 100
QC u K

100

uk

1000 kVA
AC
DC

SKLV =

100 = 16.67MVA
6

SKLV
frp = 50Hz
Qc
16.67 MVA

= 322 Hz

frp = 50 Hz
0.4 Mvar

Attention:
close to the 7th
harmonic!

Parallel resonance: example

51.5V

12.7%

400V

AC
DC

System bus bar:

impedance vs. frequency

I350 Hz = 103 Amp

0.5

322Hz

1,6
1,4
1,2
1
0,8
0,6
0,4
0,2
0

o
50

150

250

350

450

550

Frequency Hz

322 Hz is close to the 7th harmonic

350 Hz
Resulting harmonic voltage for 350 Hz :
U350 = 0.5 * 103A = 51.5V

Resonance?

if fr = f

132 kV level

Xc
0

Ic

11 kV level

Transformer
1000 kVA, uk = 5 %

415 V level

Transformer
630 kVA, uk = 5 %
Series
resonance

Parallel
resonance

415 V level

DC drive
600 kW
cos = 0.65

...
Capacitor
bank

300 kW
cos = 0.65

...
Capacitor
bank

Series resonance
Series resonant circuit formed by combination of inductive

Series resonant circuit

and capacitive reactance. The impedance behavior of this

circuit is as illustrated in the diagram. It is seen that at

resonant frequency the impedance reduces to a minimal

value. Thus the circuit offers very low impedance at the input
C

signal at this frequency which results into multiple fold

increase in the current. The voltage drop on the individual
component increases moving closer to resonant frequency.

S=signal source

Induc tanc e

Se rie s re so na nce
16

R eac tanc e

14

Im pedanc e

Impedance

12

fr

10

The point of series resonance is

given by the following formula:

100
vR = S N
QC1 eK

6
4
2
0
50

100

150

200
250
Freque ncy

300

350

400

Remedial measures

Limiting total output of harmonic sources

Limiting the number of simultaneously operating harmonic sources

Balanced connection of single phase loads to the three phases

Pull in extra neutral wires

Isolated ground separated from the safety ground

Tuned filter circuits

De-tuned HARMONIC filters

Using equipment with higher pulse number

Active harmonic filter

Harmonic proof capacitors

Various supplier of capacitors offer so called Harmonic proof capacitors.

Harmonic proof capacitors are special designed capacitors, e.g. mixed
dielectric, ALL PP or MPP with thicker dielectric

As explained before the main problem for capacitor failures is resonance
amplification due to series or parallel resonance

Both cases can not be solved with harmonic proof capacitors

From physical point of view only one passive solution is known:

Harmonic filter circuits (de-tuned or tuned)

Harmonic filter circuits

Filter circuits, which are in series connected reactors and capacitors, form a series
resonance circuit. Design and dimensioning of the components has to be done in such
a way, that one of the following points will be fulfilled:
De-tuned filter circuit
The main purpose of de-tuned filter is to avoid resonance condition of the capacitor
with the transformer inductance. Depending of the de-tuning frequency more or less
harmonic currents will be sucked from the grid. Very common is a de-tuning to a
frequency of 189 Hz (7 %) with a reduction of harmonics of app. 30-50 %.
Tuned filter circuit
The tuning has to be done for each harmonic frequency, means each harmonic
frequency requires its own filter circuit. The harmonic current will be reduced by
approximately 90 %.

For the fundamental frequency both types are reactive and are working with nearly its
full kvar load as a PFC capacitor.

De-tuned harmonic filters

Customer benefits of detuned filters

Improvement of Power Factor

Reduction of harmonics

Reduction of ohmic losses, real kW energy savings

Elimination of reactive energy consumption

Elimination of power utilities penalties on low power factor

Power Quality improvement

Climatic protection, reduction of greenhouse gas emissions

Reduction of new investment for distribution equipment
(transformers, LV switchgear, )

Reduction of equipment maintenance cost and down time of
production equipment

Improvement of production process stability

De-tuned harmonic filter

De-tuned harmonic filter

WHAT IS THE DEGREE OF DETUNING?
The most common degree of detuning is p = 7 %.
At fn=50Hz as the fundamental network frequency,
this degree of detuning corresponds to a resonance
frequency fres of 189 Hz, which can be calculated
as follows:

fres =

fn
p/%
100

p = (f / fres) 100 (in %)

EXAMPLES FOR
DETUNING-FACTORS (f=50Hz)
5%
5.5 %
5.67 %
6%
7%
8%
12.5 %
14 %

224 Hz
213 Hz
210 Hz
204 Hz
189 Hz
177 Hz
141 Hz
134 Hz

De-tuned harmonic filter

Calculation of a 7%-detuned filter:
Supply Voltage Un + Overvoltage:
fn:

50 Hz

p:

7%

400 V

Nc / kvar:
Uc:

430 V

25

50

440 V

Design: Ucr:
Qcr / kvar:

Un =

189 Hz

fres:

28.13

56.27

1.534

0.767

Cy / F:

462.78

925.56

C / F:

154.26

308.52

400 V
Ln / mH:

430 V

De-tuned harmonic filter

Previous Example, now for 7%-detuned filter
Resulting harmonic voltage e.g. :
AC
DC

Kvar: 400

5th (250Hz):
0.025 Ohm 144A = 3.6V
0.9%
7th (350Hz):
0.045 Ohm 103A = 4.6V
1.1%

System busbar: impedance vs. frequency

0,14
0,12
0,1
0,08

0,06

0,04
0,02
0
50

150

250

350

450

550

De-tuned harmonic filter

I m p e d a n c e b e h a v i o u r o f a s e r ie s i n d u c t a n c e c i r c u i t
3
c a p a c it iv e
b e h a v io u r

in d u c t iv e
b e h a v io u r

In d u c t iv e r e a c t a n c e
C a p a c it iv e r e a c t a n c e
R e s u lt a n t im p e d a n c e

0
0

100

200

300

400

-1
re s o n a n t fre q . f r

-2

-3
F re q u e n c y

500

600

700

800

De-tuned harmonic filter

Summary: detuned filter

Impedance
0,14
0,12
0,1

0,08
0,06
0,04
0,02
0
50

150

189Hz

250

350

5th

7th

450

550

11th

Summary: detuned filter

Resonance frequency not close to any harmonic
Filter frequency ffilter < fharmonic
A certain reduction of harmonic distortion
Export of some harmonics content to the HV-system
Capacitors are blocked against resonance, therefore de-tuned
filters are also known as anti-resonance- filter

Tuned harmonic filter

Power factor correction & Filtering harmonics (cleaning the grid)

Tuned harmonic filter

Tuned harmonic filter

A typical tuned filter bank at 50Hz fundamental frequency
consists of :

1 filter for the 5th harmonic ( 250Hz),

tuned to 245 Hz
1 filter for the 7th harmonic ( 350Hz),
tuned to 345 Hz
1 filter for the 11th harmonic (550Hz),
tuned to 545 Hz

Tuned harmonic filter

Previous Example, now for a TUNED FILTER
Resulting harmonic voltage e.g.:
5th (250Hz): 0.01 Ohm 144 A = 1.4V
0.4%

AC
DC

5 th
kvar: 200

7 th
400

11 th
100

7th (350Hz): 0.01 Ohm 103 A = 1.0V
0.2%

System bus bar: impedance vs. frequency

0,4
0,35
0,3
0,25
0,2
0,15
0,1
0,05
0
50

150

250

350

Frequency Hz

o
450

550

Tuned harmonic filter

Switching sequence of tuned filter: LIFO
Switching in:
3rd

5th

7th

11th

5th

7th

11th

Switching out:
3rd

Summary: tuned filter

Resonance frequencies of the series filter circuits are very close to
existing harmonics
Excellent reduction of harmonics on the bus bars
Capacitors are charged with high harmonic currents

cleaning of the network
No export of additional harmonic load to the HV-system

torture for the capacitors, if they are not rated for this high
effective current
Risk of sucking-off harmonic currents from HV side!!

Summary: tuned filter

Impedance

0,4
0,35
0,3
0,25
0,2
0,15
0,1
0,05
0
50

150

250

350

5th

7th

o
450

550

11th

Harmonic filters
FINAL COMPARISON:
Remaining harmonic voltage level,
for instance for the 7th harmonic:
Capacitor bank
without reactors:

12.7%

7% - detuned filter:

1.1%

tuned filter:

0.2%

Return on Investment
s
g
n
i
Sav

EPCOS
PFC

11--Reduces
ReducesKW
KWDemand
Demand
22--Reduces
ReducesKWH
KWHConsumption
Consumption
33--Eliminates
EliminatesPower
PowerFactor
FactorPenalty
Penalty
44--Reduces
ReducesMonthly
MonthlyElectricity
ElectricityBill
Bill
55--Reduces
ReducesMaintenance
Maintenance&
&Downtime
Downtime
Up
Le
to
ss
34
tha
%
Sa
n2
vin
Ye
gs
ar
Pa
yba
ck

Satisfied
Customer

Pow
er

Qua

lity

11--Improves
ImprovesVoltage
Voltage
22--Balances
BalancesThree
ThreePhases
Phases
33--Filters
FiltersSurges,
Surges,Transients
Transients
44--Filters
FiltersHarmonics
Harmonics
55--Improves
ImprovesPower
PowerFactor
Factor
lity nce
a
Qu tena
r
in
we
a
o
M
dP e&
e
c
tim
an
n
h
E n Do w
d
ce
u
d
Re

All components for harmonic filters