BLUE JAY BJ-CB212 Automatic Power Factor Controller User Manual

: June 10, 2024
: BLUE JAY

Table of Contents

BLUE JAY BJ-CB212 Automatic Power Factor Controller
TECHNICAL PARAMETER
LCD DISPLAY & KEYPAD
Electrical parameters
INSTALLATION
WIRING DIAGRAM
OPERATING MODE
RS485 COMMUNICATION PORTOCOL
Example
TROUBLESHOOTING
TECHNICAL SERVICE
References
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BLUE JAY BJ-CB212 Automatic Power Factor Controller

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When you use BJ CB212 P power factor controller, be sure to carefully read this user manual, and be able to fully understand the implications, and the correct guidance of operations in accordance with a user manual, which will help you make better use of BJ CB212 P power factor controller and help to solve the various problems at the scene. The material in this guide is for information only and is subject to change without notice. Blue Jay Technologies Co., Ltd reserves the right to make changes in the product design without reservation and without notification to its users.

Before the meter turns on the power supply, be sure that the power supply is within the provisions of the instrument;
When installation, the current input terminal must be non-open, and voltage input terminals must have a Nonshort circuit;
The communication terminal (RS232 or RS485) is strictly prohibited to impose high pressure;
Be sure the instrument wiring is consistent with the internal system settings;
When communicating with the PC, instrument communication parameters must be consistent with the PC

Please read carefully before using this user manual
Please save this document

SUMMARIZE
This product is intended for use in an industrial environment. This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection. This manual shows how to install and operate the CB212 power factor controllers. Please read this manual carefully before installation. Keep it for maintenance and operation.

Safety

Installation, maintenance, and operation of the CB212 Controller must be performed by qualified technicians.
Make sure that the working voltage of the controller is between 415V AC 20% to 415V AC + 10% 10%, 50Hz 10%.
Do not open the cover of the controller. The user should not try to fix it.
The CB212 Controller is connected to a current transformer. Do not unplug the current transformer connections before making sure the current transformer is short-circuited, or connected to another low-impedance load. Failure to do so may cause dangerous high voltages.

Application conditions

Environment temperature: 25 to +55
Altitude: less than 2000 m
Humidity: Maximum 90%

TECHNICAL PARAMETER

The standard applied: The Electric Industry Standard of the People’s Republic of China: < DL / T 597 1996

Basic parameters

Operating voltage : 415V AC ( 20% ~ +10 %%), 50Hz ±
Sampling current: 0 5A, AC
Power consumed: ≤ 10VA
Measuring sensitivity: 100mA
Measuring accuracy: Voltage: 0.5 class;
Current: 0.5 class;
Power factor: 0.5 class;
Power: 1.0 class;
Reactive power: 2.0 class;
Frequency: 0.1 Hz.
Overall Size: 144 X 144 X 110 mm.
Mounting dimensions: 138 X 138 mm.

Functions

Control object: Reactive power. Stable in all ranges.
Detect phase sequence automatically: Controller will detect the CT polarity internally, as well as the voltage phase Ub and Uc.
Multiple output modes are available.

LCD DISPLAY & KEYPAD

A. LCD Display

Outputs
Electrical parameters
Operating state
Numerical display
Main menu

Main menu

AUTO: Automatic operating mode
MAN: Manual operating mode
SET: Setting parameters
TEST: Testing mode

Electrical parameters

Q（kvar）………… Reactive power
P（kw） …………Power
U (V) ………… Voltage
COS ………… Power factor
I（A） …………Current
F ##.# …………Frequency (Hz)
THD%U …………Total harmonic voltage distortion ratio
THD% I ………… Total harmonic current distortion ratio

Operating states

The load is in an inductive state.
The load is in a capacitive state.
Maximum voltage. High voltage alarm setting. All capacitors will be cut off if the voltage is over this setting.
Minimum voltage. Low voltage alarm setting. All capacitors will be cut off if the voltage is below this setting.
Maximum total harmonic voltage distortion. Alarm setting. All capacitors will be cut off if total harmonic voltage distortion over this setting.
Maximum total harmonic current distortion. Alarm setting. All capacitors will be cut off if total harmonic current distortion over this setting.
The capacitor is going to be turned on.
The capacitor is going to be turned off.

B. Keypad

ESC key: Press this button to exit the current state and return to the main menu.
↑ key: In AUTO Mode: press this button, and the LCD will display U, I, P, Q, COS, and Frequency in turn; In SET Mode; press this button, and the number will increase by 1, from 0 to 9.
→ key: In AUTO Mode, press this button to display the next parameter; In SET Mode, press this button to set the next number
key: In SET Mode, press this button to save the setting in memory and go to the next setting; In MAN Mode, press this key to switch on the capacitor, press the button again to switch the same capacitor off.

INSTALLATION

Push the controller slightly into the hole on the panel.
Insert the Mounting Brackets in the corresponding holes (both sides) of the controller.
Turn the Screw in the Mounting Bracket and tighten it.

WIRING DIAGRAM

Input voltages are Ub and Uc 415V ). Input current is Ia. (current phase must be different from voltage phases)

OPERATING MODE

AUTO Mode

Turn on the power, the controller will enter AUTO mode. Press the button, and the display will show all parameters one by one automatically. Press the “→” button, the display will show the next parameter.

MAN mode

Press the ESC button in the main menu, and the “AUTO” will flash. Press the button “→”, and the “MAN” will flash. Then press the button ” to enter “MAN” Mode, as the figure shows below.

Manual operation
In this mode, the capacitor can be switched on/off manually. Pressing the button will switch the capacitor (the flashing number) on, pressing the button again will switch the same capacitor off. Press the button to go to the next left output (capacitor); press the button “→” to go to the next right output (capacitor). Press the button “ESC” which will return to the AUTO mode and switch off all capacitors. In Manual mode, if a capacitor is switched off, the controller will wait a “Waiting Time” before the same capacitor switching on again, to give the capacitor a discharge time.

SET mode

Press the ESC button in “AUTO” mode, then press the “→” button twice to choose SET mode, then press the button to enter “SET” Mode.
Press the “↑” and “→” buttons to set the selected (flashing digit) parameter, press the button to save the parameter, and go next.
SET 1: Number of outputs: Press the button”↑”↑”, and the number will increase by l in the range of 0-9. Press the button “→”, and the cursor will go to the next position. Press the button ” to save the number of outputs. The maximum number of outputs are 12.
SET 2: Delay time (Second): The controller continues to monitor the state for a period of time, to confirm that the circuit always requires adding (switch on) a capacitor for this period of time. Usually, the delay time is set to 30~40s
SET 3: Maximum voltage (V): If the voltage is higher than this setting, the controller will switch off one capacitor every 0.5 seconds. Only after the voltage is lower than the setting by 6V, will the capacitor be allowed to switch on again.
SET 4: Minimum voltage (V): If the voltage is lower than this setting, the controller will switch off one capacitor every 0.5 seconds. The capacitor is allowed to switch on again as soon as the voltage is above the setting.
SET 5: Target COS: Target power factor. Usually set to 0.980 ~ 0.99.
SET 6: CT ratio: The current transformer ratio setting. If the current transformer (CT) is 500 / 5, the setting should be 100 (not 500).
SET 7: CCapacitor capacity (kvar). The capacity of a single capacitor. If the controller is set to 1-2-2-2 or another code output mode, it is the capacity of the first capacitor (the smallest one).
SET 8: Capacitor coefficient: The capacitor capacity × capacitor coefficient = Switch on the limit. When the Q power ≥ Switch on the limit, the controller will add (switch on) a capacitor into the circuit. Usually, it sets to 1.100 ~1.200
SET 9 : Switch off limit: Usually set to 000.0
SET 10: Switching sequence: Following switching sequences are available:
Circulation switching: 1111 …… 1
Coded switching: 1122 …… 2
1222 …… 2
1244 …… 4
SET 11: Waiting time (second): To allow the capacitor time to discharge. Usually, the delay time is set to 120 ~ 180 seconds.
SET 12: Maximum total harmonic voltage distortion. Alarm setting. All capacitors will be cut off if total harmonic voltage distortion over this setting.
SET 13: Maximum total harmonic current distortion. Alarm setting. All capacitors will be cut off if total harmonic voltage distortion over this setting. If you choose the RS485 port
SET 12: UNIT SEQ: Set the slave device address, the user can be free to set 1~32
SET 13: Baud ratio: The user can free to set 2400/4800/9600/14400/19200/28800/38400 Thdu and the following the SET 13 When parameter setup is completed, press the ESC button back to “AUTO” mode.

TEST mode

Press the ESC button in “AUTO” mode, then press the button”→” three times, the LCD will show “TEST”. Then press the button to enter “TEST” Mode. Shown as below:

In this mode, the controller switches capacitors on and off one by one in the cycle, alternatively for 5 seconds. Each capacitor will follow the rule of Waiting Time (i.e. 180 seconds) before switching on again.

RS485 COMMUNICATION PORTOCOL

MODBUS © protocol
The composition of the RS-485 cabling must be carried out with a meshed screen cable (minimum 3 wires), a diameter of not less than 0.5mm2, with a maximum distance of 1,200 m between the CB212 and the master unit. This Bus may connect a maximum of 32 CB212

Note

For communication with the master unit, customers can choose the RS 232 to RS 485 c converter to use
Not all the CB212 with RS485 ports, please check your ordered product to confirm if the meter has a remote communication function
The Communication Baud ratio is standard 4800/9600 adaptive.

Due to product modifications or custom requirements, the interface pin place may be changed. For details, please refer to the product label on the rear board.

Modbus RTU Frame Format

Address code 1 BYTE Slave device address 1-247
Function code 1 BYTE Indicates the function codes like read coils/inputs
Data code 4 BYTE Number of registers, high byte Number of registers, low byte
Error Check code 2 BYTE Cyclical Redundancy Check ( CRC )

Example

Host to Slave

Address| Fun| Data Address

(high)

| Data Address

(low)

| Data Number

(high)

| Data number

(low)

| CRC16

(low)

| CRC16

(high)

---|---|---|---|---|---|---|---
01H| 03H| 00H| 00H| 00H| 08H| 44H| 0CH

Slave to Host

Address| Fun| Byte

count

| Data1

low

| Data1

high

| Data2

low

| Data2

high

| Data3

low

| Data3

high

| Data4

low

| Data4

high

---|---|---|---|---|---|---|---|---|---|---
01H| 03H| 10H| AAH| 02H| 72H| 0FH| 83H| 02H| F4H| 01H
Data5

low

| Data5

high

| Data6

low

| Data6

high

| Data7

low

| Data7

high

| Data8

low

| Data8

high

| CRC16

high

| CRC1

6 low

|
2AH| 01H| 40H| 01H| 00H| 00H| 00H| 00H| 1BH| 19H|

Register address table

Address	Parameter	Date Range	Word mode	property
0000H	Power factor (Resolution 0.001)	0~0.999	Word	R
0002H	Phase to phase Voltage Vbc

(Resolution 0.1)

| 0~999.9| Word| R
0004H| Current Va

(Resolution 0.1)

| 0~999.9| Word| R
0006H| Frequency (Resolution 0.1)| 0~999.9| Word| R
0008H| Active power (Resolution 0.1)

unit: KW

| 0~999.9| Word| R
000AH| Reactive power (Resolution 0.1)

unit: KVar

| 0~999.9| Word| R
000CH| Capacitor switching status| 0~9999| Word| R
000EH| Fault status| 0~9999| Word| R

Example of three decimal (power factor): 02AAH = 682 ( decimal ) real value 0.682
Example of one decimal (frequency): 01F4H = 500 ( decimal ) real value 50.0

Note

For capacitor switching status
Each bit represents one step switch state 1 for switch closed, 0 for switch open
Example

| D0| D1| D2| D3| D4| D5| D6| D7| D8| D9| D10| D11
---|---|---|---|---|---|---|---|---|---|---|---|---
data| 1| 0| 1| 0| 0| 0| 1| 0| 1| 1| 0| 0

Mean steps 1, 3, 7, 9, and 10 switches closed (the capacitor connected to the Step 2, 4, 5, 6, 8, 11, and 12 switch open (do not connect in.

For Fault status

	D0	D1
Normal	0	0
Overvoltage	1	0
Under voltage	0	1

TROUBLESHOOTING

After power is turned on, the controller shows a capacitive state, Capacitor is not switched on.
- A. The wiring is not correct. Please check the voltage and current phases sequence (refer to the wiring diagram).
- B. If another capacity compensation device is running on the load side, it may make the load a real capacitive circuit.
After a capacitor is switched on, the Power Factor remains unchanged.
The current transformer may not be in the right position. The current go through capacitors should also go through the CT. (refer to wiring diagram).
After the capacitor is switched on, the Power Factor decrease.
- A. The wiring is not correct. Please check the voltage and current phases sequence (refer to the wiring diagram).
- B. Turn off all power to the capacitor cabinet, then turn on the power again (reset the system).
The controller can not follow the change of the load fast enough.
The load changes too fast, such as welding machine, derrick, crane, etc. Use a dynamic power factor control system in these cases
After the capacitor is switched on, the current go through the capacitor raises too high.
The circuit may have high harmonic current and/or harmonic voltage.
- Add an inductor in each capacitor, it protects the harmonic current going through the capacitor, but can not eliminate the harmonic current of the network.
- Install the harmonic current filter. If the harmonic current is too big, installing a harmonic current filter is an effective way to limit the harmonic current.