 Automatic power factor correction

Automatic power factor correction adjusts a correction device as the measured load changes, rather than leaving one fixed compensating setting connected. In a staged capacitor bank, a controller uses terminal electric potential difference and electric current information to choose which stages are connected. The controlled quantity and target must distinguish active power, signed reactive power, waveform distortion and the chosen lead/lag convention.

For an original single-phase sinusoidal model, available stages each supply $q_s$ of capacitive reactive power at the operating electric potential difference. With $k$ connected stages,At fixed $P>0$, maximizing the magnitude of the power factor chooses the available integer $k$ minimizing $|Q_L-k{q}_s|$. Away from the end limits, nearest-stage rounding leaves $|Q_{\mathrm{net}}|\le q_s/2$. This capacitor-stage quantization error can be positive or negative. A policy forbidding leading operation instead restricts $k{q}_s\le Q_L$, so it can choose a different setting.

Suppose $P=1000\mathrm{W}$, $Q_L=640\mathrm{var}$ and $q_s=250\mathrm{var}$. Three stages leave $-110\mathrm{var}$ and factor about $0.9940$ leading; two stages leave $+140\mathrm{var}$ and factor about $0.9903$ lagging. Both outcomes are consistent with their respective objectives. If the load changes to $P=200\mathrm{W}$, $Q_L=100\mathrm{var}$, leaving all three stages connected produces $-650\mathrm{var}$; zero stages is closer to cancellation than one. A stored stage decision must therefore be updated when the load changes.

Actual feedback must measure the corrected network. The Eaton paper places the current transformer so it senses the relevant load and capacitor contribution, and explains how a wrong phase, polarity or location produces misleading feedback.^[ref] Measuring only the correction branch would not establish the combined source power factor.

A proposed controller test varies a known resistive-inductive load through several operating points, recording stage state, signed reactive power, RMS electric current and synchronized terminal waveforms. Check both increasing and decreasing demand, including small excursions around a stage threshold. A dead band and timing rules can prevent repeated switching in response to small fluctuations; they must be specified along with the target. Stage size, switching transients and the load's harmonic components require additional checks beyond the ideal rounding model.