How to Maintain your Power Factor Correction Unit?

You have a power factor correction unit up and running, the power factor is being well
maintained but how are you going to ensure that this will continue as the years roll along?
The obvious killer of capacitors is heat. A standard capacitor bank with detuned reactors will
generate 8-9 watts of heat per kVAr. If your unit is a 200kVAR unit, the heat dissipation will be
up to 1800w or 1.8kW of heat. So you have heat dissipation equivalent to a domestic electric
heater being generated within an enclosure. It is obvious that if this heat is not removed that
problems will occur.
Action 1 Check cooling fan and any grill filters for cleanliness every three months. Clean or
replace filters if necessary. In a dusty environment, blockage of filters can restrict airflow. Check
fan bearings for mechanical play and audible noise. If in doubt, order a replacement fan and
install when it arrives.
Action 2 Most power factor correction controllers have a relay that can be configured as an
over temperature alarm. Below is description of over temperature alarm operation in a
Schneider Varplus Logic Power Factor Correction Controller. Consider configuring this alarm
and connecting this to a site monitoring system or independent alarm. If over temperature
conditions do exist, capacitor bank steps will be taken off line to protect capacitors so your
power factor level will be compromised.
Capacitor switching contactors are rated for a certain number of operations very high
numbers!
Schneider Capacitor switching contactors are rated for 100 240 switching operations per hour
and when switching 400V are rated for a total of 300,000 operating cycles. Some power factor
correction controllers will monitor this for you. The Schneider Varplus Logic controller monitors
the number of operation cycles for each step. An Alarm Relay can be configured to operate
when maximum number of operation cycles has been exceeded for one or more steps.

Action 3 - Check your power factor correction controller to see if it offers this feature. If it does,
consider configuring this alarm and connecting this to a site monitoring system or independent
alarm. Set the alarm at >250,000 operations. If this alarm is activated, replace capacitor
switching contactors to prevent future failure.

Capacitor Performance can be easily monitored by measuring current drawn. When the power
factor correction unit is fully functional, measure current drawn and note down for future
reference. Check current drawn at least annually and keep records. Capacitor performance over
time will then be able to be monitored which will allow more informed decisions to be made
when deciding if a capacitor needs replacement. Use a clamp on ammeter to measure current
draw either at capacitor terminals or downstream from capacitor switching contactors,
whichever is more accessible.

Action 4 Set up a spreadsheet to record current draw in each line of each capacitor and date
recorded. Measure current drawn and record in spreadsheet. Use this spreadsheet for
permanent documentation of capacitor performance.

Alternatively, a comprehensive preventive maintenance spreadsheet as shown below can be

set up to keep maintenance records.

Power Factor Correction Unit Maintenance Log

Date Task Comments

Annual Preventive Maintenance Check

(1) Measure Current Draw in each Line for Each Capacitor Record Current Drawn
Step 1 - 25kVAr Line 1
Step 1 - 25kVAr Line 2
Step 1 - 25kVAr Line 3
Step 2 - 25kVAr Line 1
Step 2 - 25kVAr Line 2
Step 2 - 25kVAr Line 3
Step 3 - 50kVAr (two caps) - CAP 1 - Line 1
Step 3 - 50kVAr (two caps) - CAP 1 - Line 2
Step 3 - 50kVAr (two caps) - CAP 1 - Line 3
Step 3 - 50kVAr (two caps) - CAP 2 - Line 1
Step 3 - 50kVAr (two caps) - CAP 2- Line 2
Step 3 - 50kVAr (two caps) - CAP 2 - Line 3
Step 4 - 50kVAr (two caps) - CAP 1 - Line 1
Step 4 - 50kVAr (two caps) - CAP 1 - Line 2
Step 4 - 50kVAr (two caps) - CAP 1 - Line 3
Step 4 - 50kVAr (two caps) - CAP 2 - Line 1
Step 4 - 50kVAr (two caps) - CAP 2- Line 2
Step 4 - 50kVAr (two caps) - CAP 2 - Line 3
Step 5 - 50kVAr (two caps) - CAP 1 - Line 1
Step 5 - 50kVAr (two caps) - CAP 1 - Line 2
Step 5 - 50kVAr (two caps) - CAP 1 - Line 3
Step 5 - 50kVAr (two caps) - CAP 2 - Line 1
Step 5 - 50kVAr (two caps) - CAP 2- Line 2
Step 5 - 50kVAr (two caps) - CAP 2 - Line 3
Comments
(2) Clean all air filters - replace filters if necessary

(3) Check Fan operation - Check for mechanical play and

audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary

(2) Check Fan operation - Check for mechanical play and

audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary
(2) Check Fan operation - Check for mechanical play and
audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary

(2) Check Fan operation - Check for mechanical play and

audible bearing noise

Annual Preventive Maintenance Check

(1) Measure Current Draw in each Line for Each Capacitor Record Current Drawn
Step 1 - 25kVAr Line 1
Step 1 - 25kVAr Line 2
Step 1 - 25kVAr Line 3
Step 2 - 25kVAr Line 1
Step 2 - 25kVAr Line 2
Step 2 - 25kVAr Line 3
Step 3 - 50kVAr (two caps) - CAP 1 - Line 1
Step 3 - 50kVAr (two caps) - CAP 1 - Line 2
Step 3 - 50kVAr (two caps) - CAP 1 - Line 3
Step 3 - 50kVAr (two caps) - CAP 2 - Line 1
Step 3 - 50kVAr (two caps) - CAP 2- Line 2
Step 3 - 50kVAr (two caps) - CAP 2 - Line 3
Step 4 - 50kVAr (two caps) - CAP 1 - Line 1
Step 4 - 50kVAr (two caps) - CAP 1 - Line 2
Step 4 - 50kVAr (two caps) - CAP 1 - Line 3
Step 4 - 50kVAr (two caps) - CAP 2 - Line 1
Step 4 - 50kVAr (two caps) - CAP 2- Line 2
Step 4 - 50kVAr (two caps) - CAP 2 - Line 3
Step 5 - 50kVAr (two caps) - CAP 1 - Line 1
Step 5 - 50kVAr (two caps) - CAP 1 - Line 2
Step 5 - 50kVAr (two caps) - CAP 1 - Line 3
Step 5 - 50kVAr (two caps) - CAP 2 - Line 1
Step 5 - 50kVAr (two caps) - CAP 2- Line 2
Step 5 - 50kVAr (two caps) - CAP 2 - Line 3
Comments
(2) Clean all air filters - replace filters if necessary
 (3) Check Fan operation - Check for mechanical play and
audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary

(2) Check Fan operation - Check for mechanical play and

audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary

(2) Check Fan operation - Check for mechanical play and

audible bearing noise

Quarterly Preventive Maintenance Check

Comments
(1) Clean all air filters - replace filters if necessary

(2) Check Fan operation - Check for mechanical play and

audible bearing noise

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