1. business and industrial
2. energy
3. electricity

Verification of Performance
Power Metrics International – Sensor Perfect 1000
(Model A) Power Factor Correction System
KCE-140315
Engineering Report, August 2014
Green Energy Management, Inc.
2029 Lemoine Avenue
Fort Lee, New Jersey 07024
United States
Tom Spinelli & Hamid Pishdadian
Power Metrics International, Inc.
1961 Richmond Terrance
Staten Island, New York 10302
United States
Joe & Melissa Guiddo and Paul Pape
American Energy Solutions, Inc.
1961 Richmond Terrance
Staten Island, New York 10302
United States
KCE Engineering Project Manager
P. Keebler
KCE Engineering, LLC
3202 Tazewell Pike; Knoxville, Tennessee 37918 USA 865-660-9915
pfkeebler@kceengineeringllc.com
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
ACCOUNT OF WORK SPONSORED BY GREEN ENERGY MANAGEMENT, INC., AMERICAN
ENERGY SOLUTIONS, INC. AND KCE ENGINEERING, ANY SUBCONTRACTOR, THE
ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)
WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR
SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR
INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL
PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S
CIRCUMSTANCE; OR
(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER
(INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF KCE OR ANY KCE REPRESENTATIVE
HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR
SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD,
PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.
ORGANIZATION(S) THAT PREPARED THIS DOCUMENT
KCE Engineering, LLC
NOTE
For further information about KCE Engineering, please call 865-660-9915 or email
pfkeebler@kceengineeringllc.com.
KCE Engineering LLC and IMPROVING OUR WORLD…ONE TECHNOLOGY AT A TIME are pending
registered service marks of the KCE Engineering, LLC.
Copyright © 2014 KCE Engineering, LLC. All rights reserved.
CITATIONS
This report was prepared by
KCE Engineering, LLC
3202 Tazewell Pike
Knoxville, Tennessee 37918
Principal Investigator
P. Keebler
[other employee]
[employee first name initial and last name]
This report describes the results of a photometric site analysis sponsored by Green Energy
Management, Inc., Power Metrics International, Inc., and American Energy Solutions, Inc. and
conducted by KCE Engineering, LLC.
This publication is a corporate document that should be cited in the literature in the following
manner:
Verification of Performance: Power Metrics International – Sensor Perfect 1000 (Model A).
Green Energy Management, Inc., Fort Lee, NJ: 2014. KCE-140315.
iii
CONTENTS
1 INTRODUCTION .................................................................................................................... 1-1
2 TEST LOADS FOR THE LOAD BANK .................................................................................. 2-1
3 NOMINAL VOLTAGE TESTS ................................................................................................ 3-1
4 OTHER TEST RESULTS ....................................................................................................... 4-1
5 CONCLUSION ........................................................................................................................ 5-1
A BIBLIOGRAPHY ................................................................................................................... A-1
v
LIST OF FIGURES
Figure 1-1 The PMI SP1000 Model A Test System ................................................................... 1-2
Figure 2-1 Multi-Channel Linear and Non-Linear Load Bank .................................................... 2-2
vii
1 INTRODUCTION
The continued growth of electrical/electronic products in customer facilities is improving
peoples’ lives but increasing grid load at tremendous rates. Many of today’s products are aimed
at increasing energy efficiency and intelligent use of electronic loads. The purpose of these two
activities is to counterbalance load growth and postpone the construction of power plants.
Modern electrical/electronic products have non-linear load (NLL) characteristics which place a
strain on building electrical systems and the grid. NLLs range from a few watts (e.g., your cell
phone charger) to thousands of watts (e.g., a power supply for a large server) and are specialized
electronic circuits that convert AC grid energy to energy (AC or DC) to power modern electronic
devices.
Today’s modern electronic loads are called NLLs because they utilize a series of switching
power transistors that simply act as switches to control the flow of current from the facility (grid)
to charge a series of capacitors. These capacitors act as energy “tanks” to provide energy to the
microelectronic circuits that make up our electronic loads.
Economic sustainability for any customer today is largely a function of reducing the cost of
operating their facilities. Customers demand lower energy and maintenance costs and increased
productivity, therefore improving the bottom line to sustain profits. Currently, the largest growth
in non-linear loads is seen in energy-efficient technologies—electronic lighting, variable speed
drives (VFDs, also called adjustable speed drives), and smart appliances to name a few. Rapid
growth in consumer electronic equipment (e.g., LED, plasma and LCD televisions) also
continues to rapidly increase non-linear grid load. Load research indicates that facility loads are
nearly all non-linear. Moreover, the linear loads that are still in use today are being transformed
into essentially non-linear loads by adding power electronics on the front end to increase
efficiency.
Aside from increased use of energy-efficient technologies and consumer electronics is the
increased use of renewable energy resources (RER), also called distributed energy resources
(DER) or distributed generation resources (DGR) systems. These resources include wind
turbines, microturbines, photovoltaic (PV) solar systems and fuel cells among others. While the
primary purpose of these systems is to convert mechanical, thermal or solar power to electrical
power at large power levels (i.e., high power energy conversion system), they also utilize power
to carry out the energy conversion process. Power electronic systems (e.g., converters, inverters,
etc.) change the energy they capture and inject it back into the grid. This process generates
steady-state and transient electrical disturbances including harmonic currents which flow back
into the grid and into the customer facility. The tremendous growth in the use of these resources
is causing a rapid increase in harmonics and distortion in the quality of voltage and current. Any
electrical system that produces harmonic currents also affects the quality of the voltage which
1-1
Introduction
adds harmonics to the voltage. Increases in harmonic voltage distortion add reactive power
demand to a customers’ electrical system.
An additional concern is the growing need for petroleum-free vehicles which is spawning the
growth in development, manufacture and use of electric vehicles (EV). EVs require charging of
their batteries, both at the place where the vehicle is typically parked (e.g., a residence or
business) at the end of a driving period and at vehicle stopping points. EV charging systems,
whether they are part of the on-board electrical system inside the vehicle or stand-alone charging
stations, also use inverters that change AC power to DC power to charge the batteries. If a utility
dispatches the need for energy stored in EV batteries in parked vehicles, energy is again inverted
and injected back into the grid. This process also generates harmonics and distortion which can
easily combine with other harmonics on the grid and in a facility.
What is a Sensor Perfect (SP) 1000?
The Sensor Perfect (SP) 1000 system is an intelligent electronic system developed and
manufactured by Power Metrics International (PMI) in Staten Island, New York. This system
electronically senses several electrical power quality conditions and specific characteristics of a
facility electrical system at its point-of-installation. Each SP1000 product utilizes a set of
microprocessors to sense these conditions and characteristics and make specific decisions to
provide dynamic control of one or more sets of internal capacitor banks available at each phase
(A, B, and C).
Figure 1-1
The PMI SP1000 Model A Test System
1-2
Introduction
The SP1000A
Specifications
The current specifications for the SP1000A units tested are shown in Table 1-1. The SP1000A is
a three-phase system designed for 208Y/120V facility electrical systems. Each unit contains 180
microfarads per phase which can be switched into and out of each phase in increments. Each unit
can provide as little as 0.05 kVARs of power factor correction or as much as 3 kVARs of
correction per phase. Each unit contains immunity protection against voltage surges on each
phase. (Evaluation of surge protection was not included in this project.) Because the SP1000A
(and the other SP1000 products) contains multiple micro-electronic components including three
microprocessors, high-performance surge protection of the SP1000A electronics is critical to its
proper operation and life. For these and other safety reasons, the performance of its surge
protection should be evaluated by a third-party engineering firm. The SP1000A requires overcurrent protection at 30 amps per phase.
Table 1-1
SP1000A Technical Specifications
1-3
Introduction
The above specifications indicate that the losses (i.e., power to operate the SP1000A) are 1.2
watts per kVAR. Thus, for correction at 3 kVAR, the maximum losses should be 3.6 watts. The
power consumption with the SP1000A in its quiescent state (i.e., with no correction taking place)
was measured and is reported in Chapter 3 – Nominal Voltage Tests.
Spider Software Used during Testing
The Spider software used during the testing was Version 5.4.
Non-Linear Loads (NLLs), Harmonic Currents and Reactive Power
Operation of NLLs on any facility electrical system today produces dynamic power quality
problems which result in waste of electrical energy. The dynamic power quality problems that
occur in these systems occur because

NLLs draw irregularly sine-wave shaped (or distorted) current on each phase,

NLLs draw unbalanced distorted current on each phase,

Facility electrical systems were not designed to support NLLs very well (e.g., losses and
heating result from harmonic currents flowing in conductors and transformers),

Harmonic currents produced by NLLs cause harmonic voltages to develop in
transformers (facility and utility).
Electrical energy waste occurs and cost the customer money because
1-4

Harmonic currents drawn by NLLs must flow through the facility electrical system (i.e.,
conductors and transformers). This flow of unwanted current causes I2R heating in
conductors and transformers which consumes power and results in the drop and distortion
of voltage at the end of the system where the loads are connected.

Harmonic currents flowing in a facility electrical system combine in an upstream fashion
with the highest harmonic currents being at the main service entrance where the utility
revenue meter is located. Some harmonic current cancellation occurs within the facility
electrical system, but the overall result is that some amount (typically large) of reactive
power must be provided to the NLLs. This results in a demand for reactive power that the
utility must provide to ensure the system operates correctly according to the laws of
physics. The utility cannot provide reactive power to a facility for no cost. Utilities have
different policies and rules for measuring how much reactive power is required and how
to bill customers for it.

Harmonic currents (individually and summed) can be higher than the usable 60-hertz
current that performs work (i.e., turns motors and lights lamps). The 60-hertz current is
the only current that performs work for the customer. Harmonic currents perform no
work and only add to the cost of operating a facility. High harmonic currents equate to
Introduction
high reactive power demands. When harmonic currents are high, power cables and
transformers experience higher temperatures. Higher temperatures not only reduce the
life of cables and transformers, but also add to the building heat load which airconditioning systems must work against.
NLLs require reactive power to operate, and they do not care where it comes from. Providing
reactive power to NLLs via the utility power grid can be costly and results in a higher usage of
power to cover the losses that reactive power flow imposes on facility electrical systems.
Providing a reactive power source (i.e., the SP1000) closer to the NLL is a much more cost
effective approach that providing it from the utility or from fixed capacitor banks staged out
across a facility electrical system.
1-5
2 TEST LOADS FOR THE LOAD BANK
The loads in commercial and industrial facilities are made up of a complex arrangement of loads.
Some of the loads are linear and some non-linear. The ratio of linear to non-linear loads depends
on a number of factors related to the type of business the customer is carrying out in their
facility. Most of today’s loads are non-linear. Non-linear loads draw non-linear current and
reactive power from the utility power system. Drawing non-linear current causes harmonic
currents to flow from the utility which also circulate in the facility electrical system. Allowing
non-linear current to enter a facility and circulate in a facility electrical system causes energy
losses both in the utility power system and in the customer’s facility electrical system.
Designing and implementing a controlled electrical environment is a requirement when testing
any electrical or electronic system or device in a laboratory testing environment. When testing a
system designed to provide reactive power to a customer’s facility electrical system, laboratory
control over the load is required. Loads in customer facilities vary too much to determine or
verify any electrical-related performance of the SP1000A.
The SP1000A is designed to monitor electrical conditions on a circuit, determine when injection
of reactive power is required on that circuit and switch banks of capacitors in and out of the
circuit. The switching of the capacitors inside the SP1000A is under microprocessor control and
occurs very frequently when an SP1000A is installed inside an actual facility. Real linear and
non-linear loads are used in the CLB. Although the power drawn by any load will drift, using
fewer loads in a test load bank subjects the SP1000A to a much lesser degree of drift. This
enables the investigator to more precisely determine the performance of the SP1000A.
The Load Bank
Figure 2-1 illustrates the multi-channel load bank custom-designed for the SP1000A testing
project. This load bank is operated at 208 volts and is comprised of linear and non-linear loads.
The power chain shown illustrates the flow of power from the voltage source to the load bank.
The voltage source is a standard 50-kVA multi-tap transformer which is the most common drytype transformer used in commercial and industrial facilities. The voltage derived from the
transformer is fed to a 5.5-kVA power amplifier. The power amplifier maintains the integrity of
the voltage during the testing. (The amplifier is kept in idle mode (i.e., direct power passthrough) during Test 1 – Nominal Voltage Tests.) The purpose of the amplifier is to inject
voltage distortion into the voltage waveform when necessary during Test 4 – Voltage Distortion
Tests.
The three-phase power meter measures the power parameters during the testing. This
measurement documents the performance of the SP1000A during testing as the load in the load
bank is varied. The power from the meter flows into the Load Switching Network (LSN). The
2-1
Test Loads for the Load Bank
LSN is designed to switch a number of linear and non-linear loads into and out of the circuit
which varies the load detected by the SP1000A (when it is connected to the circuit). The
SP1000A can also be switched into and out of the load bank circuit. This is the approach used to
determine the performance of the SP1000A. The LSN can accommodate up to five SP1000A
units so they can be operated in parallel.
Figure 2-1
Multi-Channel Linear and Non-Linear Load Bank
Loads in the Load Bank
The most common loads in any facility are lighting loads, computer loads, mechanical (e.g.,
motors), purely resistive heater loads and miscellaneous non-linear loads. Lighting loads are
quickly becoming non-linear loads. The majority of fluorescent lighting fixtures use electronic
ballasts which contain switch-mode power supplies. High-intensity discharge (HID) lighting
fixtures still primarily use magnetic (i.e., inductive) ballasts—transformers that draw non-linear
current shifted from the voltage. Electronic ballasts are frequently used in HID lighting to
improve efficiency and reduce energy consumption but have still not captured the market share.
Induction lighting fixtures, a form of fluorescent lighting, all use electronic ballasts because reentry point into the market came when it was not practical to use magnetic ballasts. Lightemitting diode (LED) fixtures also all use electronic ballasts (frequently called electronic drivers)
to power their LEDs. With lighting becoming all electronic, the increase in reactive power
requirements from the utility grid and the degradation of power factor will continue. This will
increase the need for the SP1000 technologies. For these reasons, the load bank incorporates
three metal halide lamps driven by magnetic ballasts rated at 1,000 watts each and three 400-watt
induction lamps driven by electronic ballasts.
2-2
Test Loads for the Load Bank
All computer loads are non-linear loads as all computers contain a switch-mode power supply
(SMPS). Computers are no longer operated by transformer-based power supplies. The load bank
incorporates six SMPS-based computer power supplies rated at 650 watts each.
The load bank also incorporates two forms of mechanical loads—pure electric motor load rated
at three horsepower powered directly from the AC line and a 15 horsepower motor powered by
an adjustable-speed drive (ASD) rated for this motor.
The load bank also contains three high-power rheostats to increase the ratio of linear to nonlinear load.
Power Parameters Measured
In the area of energy and power quality performance, a number of power parameters can be
measured. Two of the most important parameters are real power and true power factor. Real
power is measured in watts and is what consumers pay for at the end of the day. In commercial
and industrial facilities, commercial and industrial customers sometimes pay for exceeding a
utility-prescribed limit on either true power factor, reactive power or apparent power or any
combination of these parameters.
In this testing project, the following parameters were measured for each phase (A, B and C)

Real power (in watts)

True power factor (no units)

Line voltage (in volts)

Line current (in amps)

Voltage distortion (in percent)
Reactive power and apparent power can be calculated from knowing the real power and true
power factor. If the SP1000A provides reactive power to the load (as it is designed to do) instead
of allowing it to be supplied from the utility, the power meter should show a reduction in real
power and an increase in power factor. (If reactive power is reduced, true power factor will
increase and real power will decrease; thus resulting in energy savings over time.)
Potential purchasers of SP1000 technologies will be looking to see if their energy bills can be
reduced by installation of these technologies at the correct locations within their electrical
systems. Performance of the SP1000A can be verified in a mixed (or any load environment
containing non-linear loads) load environment by examining the real power and true power
factor at the SP1000A installation point.
Power Factor
Generally speaking, power factor is a unit less measurement. It defines how the ratio between the
three power parameters: real power (in watts), reactive power (in VARs) and apparent power (in
volt-amperes). Non-linear loads cannot operate without reactive power—a source of reactive
2-3
Test Loads for the Load Bank
power must exist in any power system. However, the source of reactive power does not have to
be the utility. There are two types of power factor: true power factor and displacement power
factor. Displacement power factor is a measure of the shift between the voltage and current. (The
voltage and current are in phase (i.e., shift in time is equal to zero) if the load is purely linear
(i.e., contains no electronic components). However, in all of today’s facilities—residential,
commercial and industrial—no pure linear load exists. The majority, if not all, of the load is nonlinear.
2-4
3 NOMINAL VOLTAGE TESTS
Utility grids do not deliver nominal steady-state voltage to any customer load. The old adage
with respect to voltage and current states, “The voltage belongs to the utility, and the current
belongs to the customer.” In electrical engineering, students are taught that voltage is the
stimulus (i.e., like water pressure) and current is the response (i.e., like water flow). Without
loads, there would be no current, and the utility line voltage could be set to provide the exact
voltage needed which would never change, meaning that the voltage at any receptacle would be
the same at the substation. Zero current in a power cables means that the voltage at the end of the
cable is the same as that at the beginning of the cable. If no current flows in a power cable, no
voltage is dropped along that cable.
The utility power system employs a series of subsystems to monitor the voltage and adjust it up
and down as the load on the grid varies. Around 5:00 pm, utility customers are returning home to
cook dinner. Everyone is using a series of appliances everywhere. The load on the grid rises as
more current flows. More NLLs are operated resulting in a high demand for reactive power.
Utilities must provide a source of reactive power, typically at a substation or part of the service
entrance to a facility where power factor correction (PFC) correctors are used.
Two principle methods of providing voltage control originate from the operation of tap-changing
transformers located in substations and capacitor banks located at carefully selected points along
the power distribution system. Tap-changing transformers can step the voltage up and down in
present increments. Utilities carefully set up the operation of these transformers in efforts to
automatically control the voltage. Capacitor banks are typically switched on or off the grid
through automated (i.e., timed) switches. In many cases, capacitors in today’s system are
switched manually by a utility employee. Switching a bank of capacitors into a power
distribution line in a utility grid provides voltage support to the power system which is a source
of reactive power.
Characterization of the energy and power quality parameters under nominal voltage conditions
must be accomplished in order to provide useful and realistic comparison data when applying
real-world steady-state voltages to the SP1000A under real-world load conditions. Within Test 1,
KCE Engineering applied nominal steady-state voltage to a Custom Load Bank (CLB). The Load
Switching Network (LSN) was designed to accompany two SP1000A units. Power quality
parameters were measured at the input to the CLB at each loading point characteristic of the
loads found in various commercial and industrial facilities. Selected power quality parameters
were measured at the SP1000A interface point downstream of the voltage source (transformer)
upstream of the LSN and CLB. The nominal voltage for these tests was 208 volts.
3-1
Nominal Voltage Tests
Single-Load Tests
A single-load test is defined as a test where the power parameters are measured with a single
load type turned on with the SP1000A disconnected from the load bank and then the SP1000A
connected to the load bank. No multiple load configurations are included in this test set.
Lighting Load – Magnetically-Ballasted Metal Halide Lamps
Three 1,000-watt magnetically-ballasted metal halide lamps are the single load for this lighting
load test. Each ballast has a power loss of about 100 watts. From the results in the table, one can
see that the measured reduction in real power was about 14 % and measured improvement in true
power factor was about 40 %.
Table 3-1
Single-Load Tests – Magnetically-Ballasted 1,000-Watt Lamps
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no units)
1 – Off
120
29.1
3,495
0.57
1 – On
120
25.3
3,041
0.78
Savings (%)
-
-
12.9
36.8
2 – Off
120
29.1
3,495
0.57
2 – On
120
24.6
2,953
0.84
Savings
-
-
15.5
47.4
3-2
Nominal Voltage Tests
Lighting Load – Electronically-Ballasted Induction Lamps
Three 400-watt electronically-ballasted induction lamps are the single load for this lighting load
test. Each ballast has a power loss of about 20 watts. From the results in the table, one can see
that the measured reduction in real power was about 12 % and measured improvement in true
power factor was about 4%.
Table 3-2
Single-Load Tests – Electronically-Ballasted Induction Lamps
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
120
10.5
1,260
0.96
1 – On
120
9.5
1,140
0.99
Savings
-
-
9.5
3.1
2 – Off
120
10.5
1,260
0.96
2 – On
120
9.1
1,090
1
Savings
-
-
13.5
4.2
3-3
Nominal Voltage Tests
Lighting Load – Magnetically-Ballasted Metal Halide Lamps and Electronically-Ballasted
Induction Lamps
Three 1,000-watt magnetically-ballasted metal halide lamps and the 400-watt electronicallyballasted induction lamps are the single load for this lighting load test. From the results in the
table, one can see that the measured reduction in real power was about 12 % and measured
improvement in true power factor was about 14 %.
Table 3-3
Single-Load Tests – Combined Lamp Loads
3-4
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
120
39.6
4,755
0.76
1 – On
120
35.3
4,232
0.89
Savings
-
-
11.0
17.1
2 – Off
120
39.6
4,755
0.76
2 – On
120
34.6
4,157
0.83
Savings
-
-
12.6
9.2
Nominal Voltage Tests
Computer Load – One Computer Power Supply
One 650-watt loaded computer power supply is the single load for this computer load test. The
computer power supply has an efficiency of about 85 percent. From the results in the table, one
can see that the measured reduction in real power was about 7 % and measured improvement in
true power factor was about 6 %.
Table 3-4
Single-Load Tests – One Loaded Computer Power Supply
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
120
5.3
634
0.94
1 – On
120
5.0
594
0.99
Savings
-
-
6.3
5.3
2 – Off
120
5.3
634
0.94
2 – On
120
4.8
581
1
Savings
-
-
8.4
6.4
3-5
Nominal Voltage Tests
Computer Load – Six Computer Power Supplies
Six 650-watt loaded computer power supplies are the single load for this computer load test. The
computer power supply has an efficiency of about 85 percent. From the results in the table, one
can see that the measured reduction in real power was about 9 % and measured improvement in
true power factor was about 3 %.
Table 3-5
Single-Load Tests – Six Loaded Computer Power Supplies
3-6
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
120
32.3
3,874
0.95
1 – On
120
29.8
3,572
0.97
Savings
-
-
7.8
2.1
2 – Off
120
32.3
3,874
0.95
2 – On
120
28.9
3,471
0.99
Savings
-
-
10.4
4.2
Nominal Voltage Tests
Mechanical Load – Three-Horsepower Electric Motor
One three-horsepower electric motor is the single load for this mechanical load test. The electric
motor is rated for 208-volts has an efficiency of about 70 percent. From the results in the table,
one can see that the measured reduction in real power was about 15 % and measured
improvement in true power factor was about 31 %.
Table 3-6
Single-Load Tests – Three-Horsepower Electric Motor
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
10.6
2,215
0.65
1 – On
208
9.3
1,924
0.84
Savings
-
-
13.1
29.2
2 – Off
208
10.6
2,215
0.65
2 – On
208
8.8
1,836
0.87
Savings
-
-
17.1
33.8
3-7
Nominal Voltage Tests
Mechanical Load – Adjustable-Speed Drive-Powered 15 h.p. Electric Motor
One 15-horsepower electric motor powered by an adjustable-speed drive is the single load for
this mechanical load test. The electric motor is rated for 11-kW has an efficiency of about 88
percent. From the results in the table, one can see that the measured reduction in real power was
about 11 % and measured improvement in true power factor was about 32 %.
Table 3-7
Single-Load Tests – ASD-Powered 15 h.p. Electric Motor
3-8
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
52.7
10,953
0.61
1 – On
208
47.4
9,852
0.79
Savings
-
-
10.1
29.5
2 – Off
208
52.7
10,953
0.61
2 – On
208
46.2
9,618
0.82
Savings
-
-
12.2
34.4
Nominal Voltage Tests
Mechanical Load – Three-Horsepower Electric Motor and Adjustable-Speed DrivePowered 15 h.p. Electric Motor
One three-horsepower electric motor and one 15-horsepower electric motor powered by an
adjustable-speed drive are the single loads for this mechanical load test. From the results in the
table, one can see that the measured reduction in real power was about 12 % and measured
improvement in true power factor was about 32 %.
Table 3-8
Single-Load Tests – Combined Electric Motor Load Test
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
62.9
13,076
0.63
1 – On
208
57.1
11,874
0.81
Savings
-
-
9.2
28.6
2 – Off
208
62.9
13,076
0.63
2 – On
208
54.3
11,289
0.84
Savings
-
-
13.7
33.3
3-9
Nominal Voltage Tests
Mixed-Load Tests
A mixed-load test is defined as a test where the power parameters are measured with mixed load
types turned on with the SP1000A disconnected from the load bank and then the SP1000A
connected to the load bank. No single-load configurations are included in this test set.
Mixed Load Test – All Non-Linear Load
A mixed load test with all non-linear loads is the mixed load for this test. This mixed load
includes the three 1,000-watt metal halide lamps, the three 400-watt induction lamps, the six
loaded computer power supplies, the three-horsepower electric motor and the ASD-powered 15h.p. electric motor. From the results in the table, one can see that the measured reduction in real
power was about 11 % and measured improvement in true power factor was about 7 %.
Table 3-9
Mixed-Load Tests – All Non-Linear Loads
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
103.7
21,562
0.77
1 – On
208
92.6
19,264
0.81
Savings
-
-
10.7
5.2
2 – Off
208
103.7
21,562
0.77
2 – On
208
90.3
18,783
0.84
Savings
-
-
12.9
9.1
3-10
Nominal Voltage Tests
Mixed Load Test – Primarily Non-Linear Load with Some Linear Load
A mixed load test with primarily non-linear loads and some linear load (2,000 watts) is the
mixed load for this test. This mixed load which is primarily non-linear loads includes the three
1,000-watt metal halide lamps, the three 400-watt induction lamps, the six loaded computer
power supplies, the three-horsepower electric motor and the ASD-powered 15-h.p. electric
motor. The linear part of the load is represented by a rheostat loaded on each phase. From the
results in the table and one can see that the measured reduction in real power was about 8 %,
measured improvement in true power factor was about 4 %.
Table 3-10
Mixed-Load Tests – Primarily Non-Linear Load with Some Linear Load
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
113.3
23,562
0.79
1 – On
208
104.1
21,652
0.8
Savings
-
-
8.1
1.3
2 – Off
208
113.3
23,562
0.79
2 – On
208
102.6
21,349
0.82
Savings
-
-
9.4
3.8
3-11
4 OTHER TEST RESULTS
The remaining three tests that were conducted on the Model SP1000A power factor correction
units were
 Long-term undervoltage test
 Long-term overvoltage test
 Voltage distortion test
Surprisingly, the test results for these three test configurations were very acceptable and are
summarized in the following Table 4-1 through 4-3. These were conducted only for the
combined mixed load test with all non-linear loads active in the load bank.
Table 4-1
Summary of Three Remaining Tests – Long-Term Undervoltage Test
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
187.2
116.1
21,732
0.78
1 – On
187.2
103.2
19,327
0.82
Savings
-
-
11.1
5.1
2 – Off
187.2
116.1
21,732
0.78
2 – On
187.2
101.5
18,993
0.84
Savings
-
-
12.6
7.7
4-1
Other Test Results
Table 4-2
Summary of Three Remaining Tests – Long-Term Overvoltage Test
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
228.8
91.6
20,963
0.75
1 – On
228.8
85.3
19,522
0.81
Savings
-
-
6.9
8.0
2 – Off
228.8
91.6
20,963
0.75
2 – On
228.8
84.5
19,329
0.83
Savings
-
-
7.8
10.7
Table 4-3
Summary of Three Remaining Tests – Voltage Distortion Test
4-2
SP1000A
Line Voltage
(volts)
Line Current
(amps)
Real Power
(watts)
True Power
Factor (no
units)
1 – Off
208
109.3
22,734
0.71
1 – On
208
95.5
19,873
0.82
Savings
-
-
12.6
15.5
2 – Off
208
109.3
22,734
0.71
2 – On
208
94.9
19,732
0.84
Savings
-
-
13.2
18.3
5 CONCLUSION
The SP1000 Model A system is a power factor correction (PFC) system. Its purpose is to sense
the degree of non-linearity in the voltage and current waveforms produced by the operation of
non-linear loads and apply a dynamic correction to a customer’s facility electrical system. Given
the nature of non-linear operation and the operation of these loads in today’s facility electrical
systems, integration of the SP1000 technologies overlaid onto an electrical system, energy
savings ranging from a few percent up to as much as 20 to 25 % can be realized in real customer
environments.
The results of the tests conducted in this study revealed that savings ranging from about 5 to 17
% were realized when the SP1000 Model A was applied to a load bank of real non-linear loads.
A slightly smaller amount of energy savings were realized using this exact same test
configuration when real-world electrical conditions were applied to the load bank with SP1000
Model A technologies actively providing power factor correction.
The SPIDER software was also evaluated during these tests. This evaluation was centered
around functionality of the SP1000 Model A not as an energy-savings measurement system. The
SPIDER software is designed to verify that the SP1000 technology is functioning correctly when
installed in a facility as a ground of PFC systems. If energy savings verification is needed for an
individual SP1000 installation (i.e., one unit installed in a facility even if the facility contains 100
units), then that should be done using a calibrated laboratory-grade instrument specifically
designed for energy savings measurements.
Lastly, the SP1000 Model A technology is by far the most advanced and dynamic PFC system
designed to invoke energy savings in a customer’s facility electrical system when operating nonlinear loads such as computers, electronic or magnetic lighting, electric motors and variable
frequency drives to name a few.
5-1
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an Effective EMC Management Program for Nuclear Power Plants, Eighth American Nuclear Society
International Topical Meeting on Nuclear Plant Instrumentation, Control and Human-Machine
Interface Technologies (NPIC&HMIT) 2010, San Diego, CA., July 22-26, 2012, on CD-ROM,
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104. Keebler, Philip F., D. Michael Evans and Nathan A. Reid, Practical Reasons for Shifting to the
Application of Dielectric-Independent EMI Filters with Integral Surge Protection in Product Designs,
ITEM Design Guide, October 2012.
105. Keebler, Philip F. D. Michael Evans and Nathan A Reid, Induction Lighting – Nikola Tesla’s Initial
Path to a Promising Light Source, Electrical, Construction & Maintenance (EC&M) magazine,
February 2013.
106. Keebler, Philip F. D. Michael Evans and Nathan A Reid, Dropping the Ball, or Dropping the Lights,
Electrical, Construction & Maintenance (EC&M) magazine, March 2013.
A-8