BPC CXPLUST Operating Instructions Manual

Operating Instructions – General Instructions inserted in each relay box

Power Factor Control Relay

CXPLUSR (CONTACTOR SWITCHING)

CXPLUST (THYRISTOR SWITCHING)

These instructions apply from Ser. No. 1136054 Software 2.00 – Rev 6 issue date 29.6.2012

Contents

1.0 CONNECTION TO SUPPLY

1.2 - Current Transformer notes

1.3 - Earthing the relay

1.4 - Connecting the relay

1.5 - Removing the short circuit link on K-L

1.6 - Wiring Diagrams

1.6.1 - Wiring diagram – Contactors

1.6.2 - Wiring diagram – Thyristors

2.0 ENERGISING THE RELAY

2.1 Lockout time 75 secs

2.2 Measured Values in the Display

Scroll through Menu – What do the symbols mean?

3.0 THE QUICK START MENU 100 TO SET CT AND VT RATIOS

How to get into Setup Menu 100

Setting the nominal system Voltage L-L., Un

Setting the CT ratio – Ct

Setting the VT ratio – Pt

Selecting Automatic Self Commissioning Ai

Selecting AUTO-OFF-HOLD for all the steps

Setting the target power factor – CPI

Setting Step switch time – St

Selecting the type of switching for each individual step OUt

4.0 MANUAL SWITCHING

5.0 THE INFO MENU

6.0 ALARMS – What do they mean?

7.0 DEFAULT SETTINGS – And what each menu does

8.0 TROUBLE SHOOTING

9.0 TECHNICAL DATA

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1.0 CONNECTION TO SUPPLY

1.1 Installation must only be carried out by suitably qualified personnel. All local safety regulations must of

course be followed including IEE wiring regulations 17th edition if installation is in the UK. The power supply to the relay is taken from the phase – phase 50 or 60hz voltage and connected via a fuse 6A max to

Um1 and Um2. The CXPLUS accepts any voltage across Um1-Um2 in the range 90-550V 50/60Hz. Voltage

Transformers for different supply voltages are a thing of the past. Check that the supply voltage is within the limits of the relay rated voltage, and the CT has 1A or 5A output, at full load.

1.2 Current Transformer

The current supply to the relay is taken from a current transformer, which can be split core or ring type

Class 1., with 5VA rating. The current transformer (CT) must be kept short circuited until connections have been securely applied to terminals K-L. The CT is normally mounted on a different phase to L2-L3 for the voltage supply. Other connections are possible – see phase offset menu 206. It is essential to ensure: a)

That the CT is measuring the total load of the feeder to be corrected – including the PFC capacitor

current

b) The ratio of the CT is such that full load current is about 75% of the CT ratio e.g. for a Max load of

500 amps, select a CT ratio of 800/5 – not 5000/5. This is because at the lower current ranges C T's are less accurate.

c) Do not use a CT with too low a ratio for the measured load. e.g. If the load is 750

Amps, and you use a 500/5 CT ., the CT will then be saturated and will give inaccurate results.

When mounting the CT, ‘P’ should be pointing in the direction of the incoming supply and ‘L’ towards the load. S1 on the CT should be connected to ‘K’ on the relay and S2 to ‘L’ on the relay. The output from the CT can be 1A or 5A. The Max ratio of the CT must be such that the smallest step of switched capacitance will produce a current of not less than 15mA. Reactive – preferably 20mA.

Example:

The smallest step size is 25 kvar., at 415v 3ph 50 Hz. What is the highest CT ratio permissible?.

25 kvar at 415v = 34.7 amps. Capacitor will switch at 60% of nominal kvar = 20.8 amps.

Minimum current = 20mA reactive ., so Max CT ratio = 20.8/.02=1040/1 or 5200/5 for a 25 kvar capacitor operating at 415v/3ph/50 hz. A 5000/5 would normally be selected as a max ratio

1.3 Connect the earth tag link on the instrument case to earth

1.4 Connect in accordance with the wiring diagram for contactors or thyristors

1.5 Remove any short circuit links from the CT and relay

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1.6 Wiring diagram

1.6.1 (CXPLUS..R – Contactor switching)

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1.6.2 (CXPLUS..T – Thyristor switching)

2.0 ENERGISING THE RELAY

2.1 The CXPLUS has a default lockout time of 75 seconds and will start counting down, after energising.

This to ensure that capacitors are not switched in immediately after power loss and an emergency generator start up - for example. Also, this 75 second default time operates when any one step has been switched. This is to ensure that it cannot be switched in again until that step has discharged. This enables the short step switching time of 10 secs to be set – but you can adjust step switch time in the quick start menu.

2.2 Measured Values in the Display

The three larger digits at the top show system 50 hz power factor. e.g. 0.91i = lagging p.f. 0.91., 0.98c = leading p.f 0.98

If you have a known lagging power – inductive load – then ‘i’ should be displayed in the LCD. If you see ‘c’ and you are certain the load is lagging., switch off and swap over Um1 and Um2. This is better than swapping over a load carrying CT – which may produce excessive voltages on open circuit. To access the scroll down values press

►

The scrolled values▲ ▼ have the following meanings. These are the readings the end user can readily access.

NB If you do not set the CT ratio, and leave it at the factory setting of 1 ., then the items marked ** will not be shown. You set the CT ratio in section C.T of the 100 Menu, below.

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The Scroll through Menu – What do the Symbols mean?

To see these readings, when you are in the main display and the Cosphi power factor is displayed ., press enter

► and you see U ., now press▼ to scroll through the other readings

U

U

I**

P**

Q**

∆Q**

S**

THD U

3-5-7-9-11-13-

15-17-19

0.--i cos phase – phase voltage phase – neutral voltage phase Amps on phase CT is connected

3 phase kW assuming balanced load

3 phase kvar ( total ) assuming balanced load

3 phase kvar required to reach target Cosphi assuming balanced load

3 phase KVA assuming balanced load

Total Harmonic voltage distortion of L2 – L3

( if this figure is above 5% check the current taken by the capacitors since high THDU can result in harmonic overload of the capacitor steps. Harmonic Blocking reactors must then be fitted to limit harmonic overload current)

harmonic voltages as % of fundamental

PF

APF

F t

Top figure = Fundamental 50/60hz Cosphi to 2 decimal places.

Bottom figure =Fundamental Cosphi to three decimal places as required in certain countries

True rms power factor including all harmonic currents and voltages

Average RMS power factor ( kW/kVA) since relay commissioned

Supply frequency

Real Time Ambient temperature thi

OPh tAn

Max Ambient temp. To date

Counter for number of hours relay has been in service, since last reset

Tangent of phase angle phi

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3.0

The 100 Menu allows you to set the CT ratio- voltage measurement values, target power factor setting., and switching time per step. This is the menu the Commissioning Engineer can use on site. Other settings in the expert menus can be made with the help of a qualified Engineer or Technician.

Values of kW/kVA/kvar will not be correct unless the correct setting is made for voltage

(Un) and current. (Ct)

In order to make these settings we have to go into the commissioning menu 100.

How to get into menu 100:

press

◄ repeatedly to get back to the value 0....i

Now press ▼ and you see 'INFO' in the top right corner

Press ▼ again and you see 'MANUAL'

Press ▼ again and you see 'SETUP'

Press

► and release .'100' shows in the display

Press

► again – you are now in the commissioning menu 100. The 100 menu allows you to make the essential settings are marked in bold

Un – Voltage Setting

The first value you see is the Un. This is the phase – phase voltage., not Phase-Neutral. So for the UK for example the setting for Un is 415v. This is the factory default setting for relays made in the UK after serial number 1123596

If you need to change this press

► and the first digit starts flashing – using ▲▼adjust as needed and key ► to adjust the second figure and so on. Press

► to confirm and the digits stop flashing.

It is important to have the correct voltage setting Un because the alarm thresholds are defaulted to operate when the voltage is +-10% from nominal Un setting.

▼

C.T Setting

To set the CT ratio key

► and the first digit starts flashing.

Assume the CT ratio is 1000/5., which is 200/1. Always set the CT ratio as a multiplication factor to 1 so for the CT ratio 1000/5 we set Ct to 200. The same sequence with ▼ and

► is used for all the other settings.

▼

Pt – Voltage Transformer ratio setting

This is only used when the relay is used on MV/HV systems. The default setting is 1., but if the relay is working on an 11kv system with 110v voltage input ., the setting for Pt is 100

▼

Ai – Automatic Initialisation

This is defaulted to NO and we recommend it is left on NO

If set to 'YES' – when the relay is first commissioned it will switch each step one by one. It will correct any mistaken wiring of the CT.., and store the kavar values per step in its menu. We do not recommend use of this Ai feature unless you do not know which phase the CT is on.

If Ai is ‘NO’ then no automatic switching on initial energising will take place, and the steps will be switched in for the first time when they are required. Each time they switch their kvar value is recorded in the microprocessor memory.

▼

PFC – Step switching Control

This control allows you to decide how you want the steps to be switched. The possible selections are :

ON - Normal switching of steps on/off as the reactive demand changes. This is the normal AUTO control

OFF – Reactive control de-activated and all steps in circuit will be switched off

HOLD – The steps switched in will remain on. The reactive control is de-activated

The default setting is 'ON'- automatic switching of steps.

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▼

CPI – or Target Power factor setting

Set to the required target PF. Note if you press ▲ when the CPI is 1 you will go into a leading pf setting. You can target up to 0,70 lead., which is an unlikely setting but when the PFC is on the LV side of a transformer and the customer is paying for energy on the HV side it may be useful to target to about 0.99 lead so as to compensate for transformer reactive current which is creating I²R losses in the windings on no load.

▼

St – Switching time per step

Adjustable from 1 second – 999 seconds. For longer times there is also the possibility to have 'k' ( x 1000 ) and 'M' x 1 Million if needed. If the switch time is set to 1 second per step, for a rapidly changing load, of course it cannot switch back in again after a delay of only 2 seconds, due to the charge held on the capacitor. In this case the relay will wait until the programmed discharge time set in menu 401. Default setting on menu 401 is 75 secs.

▼

OUt – Setting of Output for each Step

This setting allows you to select each step setting either as:

Auto – normal automatic relay controlled step switching

AL – This step operates an alarm contact. When the temperature is above the target setting – this contact

can be used to start up the ventilation fan. If you select AL for one of the exit relays, the default switching temperature is 30ºC, when this contact will close.

FOFF – This step is permanently off (Fixed off)

FON – this step is permanently on (Fixed on)

Default setting is AUTO

4.0 MANUAL SWITCHING

4.1 Sometimes there is no load on the system when the relay is commissioned. In order to test everything is working correctly, the best way is to switch steps in manually and watch the increase in the Cos Phi display until a leading power factor is achieved, and then to return the relay to AUTO to make sure the relay switches out to reach the target power factor.

Press

◄ repeatedly to get back to Cosphi in the display

▼

- INFO

▼

- MANUAL

Now enter manual mode ,

► by holding down the ► key for 3 secs

, Scroll up ▲ and the figure 1 is in the

display. This is step 1 – to switch step 1 on key

►., to switch off ► again. Now move through the steps using

▲

to get to the next step and ► to switch it on. Under low loads on the system this will create a leading power factor.

To switch back to Automatic control, so as to check the relay is working correctly, press ◄ repeatedly until

MANUAL-INFO-SETUP disappear from the right hand side of the display, so the relay is now in its normal

AUTO switching function , and if the Cos phi is leading it should switch steps out to achieve the target

Cosphi

(as set in 3.8)

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5.0 THE INFO MENU

To get into the INFO press escape

◄ a few times and then ▼., and you see INFO in the top right corner of the display. Enter the INFO programme with

►.

Now you see the steps in the bottom section of the display.1-6 ., or 1-12., or 1-14 depending on the number of steps on this relay.

The INFO programme is extremely useful since it tells you exactly how each step has been performing since installation. You can move to interrogate each step by using the ▼▲ keys.

► following symbols:

C: This is the real time kvar output of this step –

but remember this is only correct if the CT has been set to the correct ratio

%: This shows the % loss in kvar per step since that step was first energised

(very useful to check capacitor quality and possible over stress due to harmonics)

OC number of switchings of that contactor

AUTO-FOFF-FON-AL – to indicate how that step has been allocated in the Quick Start Menu

6.0 ALARMS – What do they mean?

In the case of Alarm, the display will flash alternately

The display will show one of the following alarms:

......... /

ALARM

TO CANCEL ALL ALARMS –

EXCEPT THE SPL/... ALARM

HOLD THE ESCAPE KEY◄

FOR ABOUT 3 SECS. THE

ALARM SHOULD THEN CLEAR

To cancel SPL/... see the table below

U

I Lo

I Hi

HAr

Measured voltage outside % tolerance set in menu 204

Measured current below 15mA.

Check for open circuit or short circuited CT, or insufficient load

Measured current too high. CT saturated and inaccurate

thi

OPH

OPC/--

The second ambient temp set in menu 514 has been exceeded.

Sequential switching off of steps to bring ambient temp down will commence

The limit set for operating hours between servicing has been reached.

Call the service engr.

The limit set in menu 508 for number of switching operations for contactor indicated has been reached. Default=80,000

Target Cosphi not reached. More capacitors needed or need replacing,.

StP /--

SPL /--

SPL /--

5% harmonic voltage distortion exceeded.., or setting put in menu

503. If reactors fitted this %setting can be increased

The step indicated is faulty. Check fuses contactor, capacitor on that step

The step indicated has lost more than

30% of its initial kvar value when first commissioned

SPL /-- alarm cannot be cancelled using the

◄

esc. button. If you have the SPL alarm, the step indicated has lost 30% or more than 30% of its initial kvar value. Call your supplier if SPL /-- alarm activates for advice.

PFC

Ai/Abrt

Automatic Start Up ( self commissioning) aborted.

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7.0 DEFAULT SETTINGS – AND WHAT EACH MENU DOES

Default

Un 415 t 1

Pt

Ai

1

NO

200

201

202

203

204

205

206

207

208

209

210

300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

Set L-L system volts

Set CT ratio :1

Set VT ratio :1

Automatic Initialisation?YES/NO

Default

PFC ON

CPI 1

St

OUt

10S

AUTO

Selects whether steps are on AUTO-HOLD-ON-OFF

Target Cosphi

Switching Time

Selects what each output does.

AUTO-Fon-Foff—AL( starts up ventilation fan )

415

1

1

Expert Menus 200 – 600

To get into these please call your supplier

MEASURING

Sets system Voltage Level Un

( repeat of Un in Menu 100 )

Sets CT ratio:1 (repeat of Menu

100)

Set VT ratio:1 (repeat of Menu

100)

400

401

402

403

10% Tolerance % of Un Voltage Setting 404

75 secs

5 var

(1.max)

AUTO

All steps

0

YES

90º

NO

Select L-L or L-N as measurement voltage

Select Phase Angle U - I

Ai ( Automatic Initialisation) start

NO Activate Step kvar Recognition

AUTO Frequency setting for low quality networks

0ºC Temp setting offset

60% % value of kvar for step switching.

508 80,000

1.00

Target PF 1 509 9,000

0.95i

Target PF 2 510 NO

NO

10 S

2S

YES

NO

YES

ON

1

0

1

NO

CONTROL

Target PF when exporting

Switch Time per step in seconds

Step switch swap over time

Activation of Step swap over

500

501

502

503

504

YES

YES

5%

NO

505 60 secs

506

507

511

512

513

514

NO

YES

NO

NO

30ºC

70ºC

Stop Automatic kvar step detection

515

Blocking defective Capacitor Steps 516

AUTO-OFF-HOLD setting

Selection of switching sequence.

1=Auto.,2=Last in first out,3=Kombifilter ,4=Progressive

Reactive kvar offset

Assymetrical Switching fast in slow out etc.

Switch off steps if cosphi is leading. Used for aux.generators

517

600

601

602

603

NO

YES

YES

NO

NO

NO

604

605

606

607

608

NO

NO

NO

NO

NO

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CAPACITOR DATABASE

Set discharge time to prevent re-energisation on quick switching sequence

Manual entry of kvar values per step

Select what each output does

Same as Out setting in 100 menu

Step switch counter

Initial value 0 increases with each switching

ALARMS

Select if alarm display is cancelled when fault cleared or not

THD Alarm setting YES = on

NO =off

% setting for THD alarm if on

Select if steps are switched off if THDU above target level

Select time delay of THDU alarm

Freeze exits if no CT current

YES=Service alarm operates when max operating hours or switchings on any step is reached.

Set No. of contactor operations for Alarm

Set No. of operating Hours for Alarm

Temperature sensor is set to monitor temp and show it in the LCD Display.

Select if Digital input is n/c or n/o

Temp. Alarms 513/514 ON/OFF

Temp Setting for exit relay nominated as fan control

Emergency switch off of steps one by one if temp exceeds target setting – default = 70ºC

Target Cosphi setting

YES= Alarm for defective step if no step kvar output after

3 attempts

Step power loss alarm

ALARM RESETS

All alarms back to factory default

Resets all recorded data of kvar per step+kvar output of each step

Resets Operating Hours to zero

Resets Average PF

Rests Highest Ambient Temp

Reset all alarms

Displays software version

Gives password

8.0 TROUBLE SHOOTING

FAULT

No indication in the display

Display shows

U ALARM

Display shows

I LO

Display shows wrong value of

Voltage or

Current

Display shows wrong value of

Power Factor

Power factor does not improve after stepping steps in.

Steps won’t switch out

Display shows

I Hi

ALARM

Display shows

PFC

ALARM

POSSIBLE CAUSE

No power supply to terminals

UM1-UM2

Power supply is outside voltage tolerance setting.

Measured Current is below 15mA

Incorrect CT or VT ratio has been submitted

Capacitor Step Size has not been recognised, or phase angle setting has been wrongly entered in 206

CT in wrong position – see notes 1.2 of these operating instructions.

Output from CT is too high – above 5 amps.

Continuous over compensation or continuous under compensation

SUGGESTED REMEDY

Check for voltage in the range 90-550v 50/60hz on these terminals

Check the setting entered on menu 201 and 204

Check CT circuit. Are summated CT’s in opposition? Has short circuit link been removed? Is CT circuit broken?

Check settings of VT and CT. Remember the settings are :1 so a 1000/5 CT = setting of 200

Start Ai in the set up menu, Check the setting of phase angle in 206 and rectify if necessary

Check position of CT ensure it is measuring total current including capacitor current and if split core make sure the gap is fully closed up.

Check the CT ratio selected. Change if necessary

Check the capacitors and contactors.

Contactor could be welded in. Check that steps are not in the FON setting

( PFC /Out in menu 100 )

Is the kvar supplied sufficient for the reactive demand?

If not under compensation will be reported

Switch off and swap over Um1 and Um2 ( This is better than swapping over the CT connections since voltage surges form open circuit CT are avoided)

If necessary check settings of 206

Display Shows

Leading

Cosphi....c

When you know there is lagging load

Certain steps don’t switch in or out

Steps are shown as defect.,

FLTY.

Steps won’t ever switch in, but there is nothing wrong with them

EXPORT shows in the display but there is no export.

Voltage or current connections wrong way around.

Phase angle incorrectly entered

( 206)

Wrong selection on the OUt menu

Capacitor step faulty or fuse or contactor has failed

Capacitor step sizes are too big.

CT reversed

Check to see if some steps have been set as FON or

FOFF ( permanently on or off ) instead of AUTO

Check capacitor current with clamp on power meter and compare with rated current are fuses and contactor operating correctly? Replace as required.

Provide more steps of lower kvar per step

Swap over Um1 /Um2 to correct.

Alt the Ai feature has caused this to show. Defeat Ai by setting 208=NO

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9.0 TECHNICAL DATA

Measurement and Supply

Voltage

Current Measurement

Exit relay Ratings

90 – 550V 45- 65hz 5VA max. Fused to Max. 6A

VT multiplication factor adjustable 1......350

15mA ..... 6A single phase. Internal CT with Current Sensor 20 milliohm. CT multiplication factor adjustable 1.......4500

Max rating at 240v 50/60 hz phase-neutral Contactor coils 6A inrush

Max rating 415v 50/60 hz phase-phase Contactor Coils 2.5A inrush

By varistor or thermocouple Temperature measurement

Alarm Contact

Air Ventilation Control

Data Output

Operating Temperature

Humidity

Volt free relay normally closed (N/C). Max fuse rating 2A., Switch contact 250V

2.5A

Achieved by designating one of the exit relays as ventilation fan contact

BSTO software by TTL on back of relay

-20+70ºC. Storage -40+85ºC

0-95% - Dew droplets not permitted.

Over Voltage Category II Pollution Degree 3 (DIN VDE 0110 Part 1 / IEC 60664-1)

Standards Complied with DIN VDE 0110 part 1 IEC 60664-1:1992

VDE 0411 part 1 (DIN EN 61010-1 /IEC 61010-1:2001

VDE 0843 Part 20

DIN EN 61326/IEC 61326: 1997+A1: 1998+ A2:2000

Conformity Listings

Connections

Casing

IP Ratings

Weight

Dimensions

CE – UL – cUL

Screw Terminals with plug in connectors to facilitate easy swap overs

Front Plastic Facia (UL94-VO)., Rear - Metal case.

Front : IP50 – IP54 if transparent over cover fitted

Rear: IP20

0.60g Approx

144 x 144 x 58mm – Cut Out 138 (+0.5) x 138 (+0.5) mm

YOUR SUPPLIER FOR SERVICING and FURTHER INFORMATION PFC / RE-ORDERING:

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