• Power Factor (PF) is the ratio of active power (kW) to apparent power (kVA). In industrial facilities, inductive loads such as transformers, electric motors, and plastic injection machines consume reactive power (kVAr), which lowers the power factor. This leads to utility penalties, cable overheating, and reduced system capacity.

Core Panel Components:

• PFC Controller: The microprocessor-based unit that monitors phase signals via Current Transformers (CTs) and switches capacitor steps dynamically.
• Capacitor Duty Contactors: Designed to handle high inrush currents during capacitor switching, typically equipped with damping resistors.
• Power Capacitors: Heavy-duty units designed to withstand system harmonics and supply leading reactive power.
• Protection Devices: HRC fuses and circuit breakers to isolate faults and prevent short circuits.

Common Faults & Maintenance:

• Contactor welding or capacitor bulging: Usually caused by high harmonic distortion or aged units. Installing detuned reactors (harmonic filters) is often necessary to protect the system.
• PF remains low despite step activation: Typically caused by a faulty CT connection, blown fuses on specific steps, or degraded capacitor capacitance.