BPC CXPLUSR Bedienungsanleitung

Operating Instructions – General Instructions inserted in each relay box

Power Factor Control Relay

CXPLU R (CONTACTOR WITCHING)

CXPLU T (THYRI TOR WITCHING)

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

Contents

1.0 CONNECTION TO UPPLY Page 2

1.2 - Current Transformer notes

1.3 - Earthing the relay

1.4 - Connecting the relay

1.5 - Removing the short circuit link on -L

1.6 - Wiring Diagrams

1.6.1 - Wiring diagram – Contactors Page 3

1.6.2 - Wiring diagram – Thyristors Page 4

2.0 ENERGI ING THE RELAY Page 4

2.1 Lockout time 75 secs

2.2 Measured Values in the Display

croll through Menu – What do the symbols mean? Page 5

3.0 THE QUICK TART MENU 100 TO ET CT AND VT RATIO

How to get into Setup Menu 100 Page 6

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 Page 7

Setting the target power factor – CPI

Setting Step switch time – St

Selecting the type of switching for each individual step OUt

4.0 MANUAL WITCHING Page 7

5.0 THE INFO MENU Page 8

6.0 ALARM – What do they mean? Page 8

7.0 DEFAULT ETTING – And what each menu does Page 9

8.0 TROUBLE HOOTING Page 10

9.0 TECHNICAL DATA Page 11

Page 1 of 11

1.0 CONNECTION TO UPPLY

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 U . 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 -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 ‘ ’ 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

Page 2 of 11

1.6 Wiring diagram

1.6.1 (CXPLU ..R – Contactor switching)

Page 3 of 11

1.6.2 (CXPLU ..T – Thyristor switching)

2.0 ENERGI ING THE RELAY

2.1 The CXPLU 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. ou set the CT ratio in section C.T of the 100 Menu, below.

Page 4 of 11

The croll through Menu – What do the ymbols 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 phase – phase voltage

U phase – neutral voltage

I** phase Amps on phase CT is connected

P** 3 phase kW assuming balanced load

Q** 3 phase kvar ( total ) assuming balanced load

∆Q** 3 phase kvar required to reach target Cosphi assuming balanced load

S** 3 phase VA assuming balanced load

THD U 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)

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

15-17-19

harmonic voltages as % of fundamental

0.--i

cos

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

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

countries

PF True rms power factor including all harmonic currents and voltages

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

F Supply frequency

t Real Time Ambient temperature

thi Max Ambient temp. To date

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

tAn Tangent of phase angle phi

Page 5 of 11

3.0 THE QUICK TART MENU 100 TO ET CT AND VT RATIO

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 etting

The first value you see is the Un. This is the phase – phase voltage., not Phase-Neutral. So for the U for

example the setting for Un is 415v. This is the factory default setting for relays made in the U 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 etting

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 micro-

processor memory.

▼

PFC – tep 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.

Page 6 of 11

▼

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.

▼

t – witching 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 – etting of Output for each tep

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 WITCHING

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)

Page 7 of 11

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.

To examine the behaviour of any one step enter that step with and as you scroll down you see the►

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 ALARM – What do they mean?

In the case of Alarm, the display will flash alternately

The display will show one of the following alarms:

UMeasured voltage outside %

tolerance set in menu 204

thi The second ambient temp set in

menu 514 has been exceeded.

Sequential switching off of steps to

bring ambient temp down will

commence

I Lo Measured current below 15mA.

Check for open circuit or short

circuited CT, or insufficient load

OPH The limit set for operating hours

between servicing has been reached.

Call the service engr.

I Hi Measured current too high. CT

saturated and inaccurate

OPC/-- The limit set in menu 508 for

number of switching operations for

contactor indicated has been

reached. Default=80,000

HAr 5% harmonic voltage distortion

exceeded.., or setting put in menu

503. If reactors fitted this %setting

can be increased

PFC Target Cosphi not reached. More

capacitors needed or need

replacing,.

tP /-- The step indicated is faulty. Check

fuses contactor, capacitor on that

step

Ai/Abrt Automatic Start Up ( self

commissioning) aborted.

PL /-- The step indicated has lost more than

30% of its initial kvar value when first

commissioned

PL /-- PL /-- alarm cannot be cancelled

using the◄ esc. button. If you have

the PL alarm, the step indicated has

lost 30% or more than 30% of its

initial kvar value. Call your supplier

if PL /-- alarm activates for advice.

Page 8 of 11

......... /

ALARM

TO CANCEL ALL ALARM –

EXCEPT THE PL/... ALARM

HOLD THE E CAPE KEY◄

FOR ABOUT 3 EC . THE

ALARM HOULD THEN CLEAR

To cancel PL/... see the table

below

7.0 DEFAULT ETTING – AND WHAT EACH MENU DOE

Page 9 of 11

Default Default

Un 415 Set L-L system volts PFC ON Selects whether steps are on AUTO-HOLD-ON-OFF

t 1 Set CT ratio :1 CPI 1 Target Cosphi

Pt 1 Set VT ratio :1 St 10S Switching Time

Ai NO Automatic Initialisation?YES/NO OUt AUTO Selects what each output does.

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

Expert Menus 200 – 600

To get into these please call your

supplier

200 MEA URING 400 CAPACITOR DATABA E

201 415 Sets system Voltage Level Un

( repeat of Un in Menu 100 )

401 75 secs Set discharge time to prevent

re-energisation on quick switching sequence

202 1 Sets CT ratio:1 (repeat of Menu

100)

402 5 var

(1.max)

Manual entry of kvar values per step

203 1 Set VT ratio:1 (repeat of Menu

100)

403 AUTO

All

steps

Select what each output does

Same as Out setting in 100 menu

204 10% Tolerance % of Un Voltage Setting 404 0 Step switch counter

Initial value 0 increases with each switching

205 YES Select L-L or L-N as measurement

voltage

500 ALARM

206 90º Select Phase Angle U - I 501 YES Select if alarm display is cancelled when fault cleared or

not

207 NO Ai ( Automatic Initialisation) start 502 YES THD Alarm setting YES = on

NO =off

208 NO Activate Step kvar Recognition 503 5% % setting for THD alarm if on

209 AUTO Frequency setting for low quality

networks

504 NO Select if steps are switched off if THDU above target level

210 0ºC Temp setting offset 505 60 secs Select time delay of THDU alarm

506 NO Freeze exits if no CT current

300 CONTROL 507 YES YES=Service alarm operates when max operating hours or

switchings on any step is reached.

301 60% % value of kvar for step switching. 508 80,000 Set No. of contactor operations for Alarm

302 1.00 Target PF 1 509 9,000 Set No. of operating Hours for Alarm

303 0.95i Target PF 2 510 NO Temperature sensor is set to monitor temp and show it in

the LCD Display.

304 NO Target PF when exporting 511 NO Select if Digital input is n/c or n/o

305 10 S Switch Time per step in seconds 512 NO Temp. Alarms 513/514 ON/OFF

306 2S Step switch swap over time 513 30ºC Temp Setting for exit relay nominated as fan control

307 YES Activation of Step swap over 514 70ºC Emergency switch off of steps one by one if temp exceeds

target setting – default = 70ºC

308 NO Stop Automatic kvar step

detection

515 NO Target Cosphi setting

309 YES Blocking defective Capacitor Steps 516 YES YES= Alarm for defective step if no step kvar output after

3 attempts

310 ON AUTO-OFF-HOLD setting 517 YES Step power loss alarm

311 1 Selection of switching sequence.

1=Auto.,2=Last in first

out,3= ombifilter ,4=Progressive

600 ALARM RE ET

312 0 Reactive kvar offset 601 NO All alarms back to factory default

313 1 Assymetrical Switching

fast in slow out etc.

602 NO Resets all recorded data of kvar per step+kvar output of

each step

314 NO Switch off steps if cosphi is

leading. Used for aux.generators

603 NO Resets Operating Hours to zero

604 NO Resets Average PF

605 NO Rests Highest Ambient Temp

606 NO Reset all alarms

607 NO Displays software version

608 NO Gives password

8.0 TROUBLE HOOTING

FAULT PO IBLE CAU E UGGE TED REMEDY

No indication in

the display

No power supply to terminals

UM1-UM2

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

these terminals

Display shows

U ALARM

Power supply is outside voltage

tolerance setting.

Check the setting entered on menu 201 and 204

Display shows

I LO

Measured Current is below 15mA Check CT circuit. Are summated CT’s in opposition? Has

short circuit link been removed? Is CT circuit broken?

Display shows

wrong value of

Voltage or

Current

Incorrect CT or VT ratio has been

submitted

Check settings of VT and CT. Remember the settings

are :1 so a 1000/5 CT = setting of 200

Display shows

wrong value of

Power Factor

Capacitor Step Size has not been

recognised, or phase angle setting has

been wrongly entered in 206

Start Ai in the set up menu, Check the setting of phase

angle in 206 and rectify if necessary

Power factor does

not improve after

stepping steps in.

Steps won’t

switch out

CT in wrong position – see notes 1.2 of

these operating instructions.

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.

Display shows

I Hi ALARM

Output from CT is too high – above 5

amps.

Check the CT ratio selected. Change if necessary

Display shows

PFC ALARM

Continuous over compensation or

continuous under compensation

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

Display Shows

Leading

Cosphi....c

When you know

there is lagging

load

Voltage or current connections wrong

way around.

Phase angle incorrectly entered

( 206)

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

Certain steps

don’t switch in or

out

Wrong selection on the OUt menu Check to see if some steps have been set as FON or

FOFF ( permanently on or off ) instead of AUTO

Steps are shown

as defect.,

FLTY.

Capacitor step faulty or fuse or

contactor has failed

Check capacitor current with clamp on power meter

and compare with rated current are fuses and

contactor operating correctly? Replace as required.

Steps won’t ever

switch in,

but there is

nothing wrong

with them

Capacitor step sizes are too big. Provide more steps of lower kvar per step

EXPORT shows in

the display but

there is no export.

CT reversed Swap over Um1 /Um2 to correct.

Alt the Ai feature has caused this to show. Defeat Ai by

setting 208=NO

Page 10 of 11

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