Power factor is a measure of how well your plant uses the current it draws. Motors and transformers create a lagging load that wastes part of that current. Electricity boards notice this and may charge a penalty on your bill. An APFC panel fixes the problem automatically by switching capacitors in and out as the load changes.
How an APFC panel corrects power factor
The heart of the panel is a power factor controller. It keeps checking the load and decides how many capacitor steps are needed to hold the power factor near the target, usually close to unity. Each step has its own contactor and fuse or breaker, and the steps are sized to match how your load varies through the day.
One thing we always check is harmonics. If your plant has many drives, UPS units or LED lighting, plain capacitors can overheat or even fail. In such cases we use detuned reactors along with the capacitors, or heavy-duty capacitors rated for the conditions. Skipping this step is a common reason APFC panels burn out.
Power factor controller
Reads load and switches capacitor steps automatically.
Multiple capacitor steps
Sized to follow the way your load varies during the day.
Detuned reactors
Protect capacitors in plants with drives and non-linear loads.
Heavy duty capacitors
Rated for harmonic conditions where needed.
Proper switching
Capacitor-duty contactors and protection for each step.
Digital display
Shows power factor, steps in use and alarms.
Harmonics, sizing and savings
Sizing is done from your electricity bills and connected load, so we are not just guessing a kVAR value. Too little correction leaves the penalty in place, and too much can push the power factor leading, which also causes trouble. We aim for a sensible middle that fits your actual usage.
If you have a recent bill or load details, send them across. We will suggest a panel rating with the number of steps and give you a quotation. Most customers see the panel pay for itself through lower bills, though the exact time depends on your tariff and load.
Where it is commonly used
Before you place an order
Before ordering, check your electricity bill. Most bills show the power factor or a related penalty or incentive. If your figure is regularly below the utility's target, an APFC panel will likely help. If it is already close to the target, you may need only a small unit or none at all.
Maintenance is light but not zero. Capacitors age, contactors wear and fans clog. A quick look every few months and an annual check of capacitor values keep the panel doing its job. Neglected APFC panels often sit for years with several steps quietly dead.