VISHAY BLR-CX-R Power Factor Regulator Owner’s Manual

BLR-CX-R Power Factor Regulator

Product Information

The product is the Power Factor Regulator BLR-CX-R / BLR-CX-T,
manufactured by Beluk GmbH. It is also known as Iskra PFC-CXR and
Vishay Estamat PFC-XN. The reference manual for this product is
Rev. 07, released in July 2018.

Contact Information:

• Company: Beluk GmbH
• Address: Taubenstrasse 1, 86956 Schongau, Germany
• Telephone: +49/(0)8861/2332-0
• Fax: +49/(0)8861/2332-22
• Email: blr@beluk.de
• Website: http://www.beluk.de

Product Usage Instructions

1. Installation and Connection

Refer to the wiring diagram provided in the manual (page 5) for
proper installation. Follow the connection data instructions (page
6) to connect the Power Factor Regulator BLR-CX-R / BLR-CX-T to the
appropriate power source.

2. Commissioning

Follow the instructions provided in the manual (page 7) to
properly commission the Power Factor Regulator BLR-CX-R /
BLR-CX-T.

3. Display

Learn about the display features and functionalities of the
Power Factor Regulator BLR-CX-R / BLR-CX-T by referring to the
manual (page 8).

4. Operation

Understand the keys and their functions (page 10) for operating
the Power Factor Regulator BLR-CX-R / BLR-CX-T. Follow the
instructions for inputting numerical values (page 10).

5. Menu BLR-CX

Refer to page 11 of the manual for information on the menu
options available in the Power Factor Regulator BLR-CX-R /
BLR-CX-T.

8. Troubleshooting

If you encounter any issues with the Power Factor Regulator
BLR-CX-R / BLR-CX-T, refer to the troubleshooting section in the
manual (page 31) for possible solutions.

9. Applications

Learn about specific applications of the Power Factor Regulator
BLR-CX-R / BLR-CX-T, such as fan control (page 33) and transformer
compensation (page 36).

10. Customer Settings

Page 38 of the manual provides instructions on how to customize
settings for the Power Factor Regulator BLR-CX-R / BLR-CX-T.

11. Appendix

The appendix section of the manual (page 39) includes additional
information on phase-angle settings and connections for mixed
measurement.

Reference Manual BLR-CX-R / BLR-CX-T
(Iskra PFC-CXR) (Vishay Estamat PFC-XN)
REFERENCE MANUAL

Rev. 07 2018-07

POWER FACTOR REGULATOR BLR-CX-R / BLR-CX-T

Beluk GmbH Taubenstrasse 1 86956 Schongau Germany

Tel.: Fax: E-Mail: Web:

+49/(0)8861/2332-0 +49/(0)8861/2332-22
blr@beluk.de http://www.beluk.de

Reference Manual BLR-CX-R / BLR-CX-T

Rev. 07 2018-07

1 INSTALLATION AND CONNECTION …………………………………………………………………………. 4

1.1 Wiring diagram …………………………………………………………………………………………….. 5 1.2 Connection data …………………………………………………………………………………………… 6 2 COMMISSIONING ………………………………………………………………………………………………… 7

3 DISPLAY………………………………………………………………………………………………………………. 8

4 OPERATION……………………………………………………………………………………………………….. 10

4.1 Keys ………………………………………………………………………………………………………….. 10 4.2 Input of numerical values…………………………………………………………………………….. 10 5 MENU BLR-CX ……………………………………………………………………………………………………. 11

5.1 Measurement menu……………………………………………………………………………………. 11 5.2 Info (Step database) ……………………………………………………………………………………. 12 5.3 Manual (step switching manual) …………………………………………………………………… 13 5.4 Setup (Quick start menu) …………………………………………………………………………….. 14 6 EXPERT MENU BLR-CX ………………………………………………………………………………………… 15

6.1 100 Quick start menu ………………………………………………………………………………….. 16 6.2 200 Measurement settings ………………………………………………………………………….. 18 6.3 300 Setup Control System ……………………………………………………………………………. 20 6.4 400 Setup Step Database …………………………………………………………………………….. 24 6.5 500 Setup Alarm …………………………………………………………………………………………. 26 6.6 600 Resetmenu ………………………………………………………………………………………….. 28 7 TECHNIAL DATA …………………………………………………………………………………………………. 30

8 TROUBLESHOOTING …………………………………………………………………………………………… 31

9 APPLICATIONS …………………………………………………………………………………………………… 33

9.1 Fan Control ………………………………………………………………………………………………… 33

9.2

……………………………………………………………. 34

9.3 Problems with the Step recognition. …………………………………………………………….. 35

9.4 Transformer compensation………………………………………………………………………….. 36

9.5 Reset defective steps respectively add aditional steps ……………………………………. 37

10 CUSTOMER SETTINGS……………………………………………………………………………………… 38

11 APPENDIX ……………………………………………………………………………………………………… 39

11.1 Settings Phase-angle …………………………………………………………………………………… 39 11.2 Connections for mixed measurement……………………………………………………………. 39

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Reference Manual BLR-CX-R / BLR-CX-T

Rev. 07 2018-07

Date 22.07.09
25.01.10
16.06.10 09.02.11 14.06.16 13.03.17 17.07.18

Name Le
Le
Le Le RH RH SO

Document history

Revision

Comment

01

initial document release

02

Examples added, changes to software version 1.04

03

Add features of software version 1.06

04

Add features of software version 1.08

05

Content correction

06

Content correction

07

Content correction

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Reference Manual BLR-CX-R / BLR-CX-T

Rev. 07 2018-07

ATTENTION!
The installation of the BLR-CX must be performed by technically qualified persons only, since improper use can cause an electric shock. The appropriate safety regulations in the country of installation must be strictly adhered to. Equipment with damaged casing or terminals must not be used and must be disconnected from the mains supply immediately.

1 INSTALLATION AND CONNECTION

1. Check that the mains voltage and CT current input are suitable for the relay! 2) Disconnect panel from mains voltage, and check that the voltage is off 3) Ensure CT short-circuited or not in operation. An open circuit CT produces a high voltage, which endangers people and equipment. It will also damage the CT and affect ist accuracy. 4) Disconnect and remove any previous pfc-relay. 5) Mount BLR-CX in the control panel with the two mounting clips. (cutout 138x138mm) 6) Connect the earth protection cable to `PE’ on BLR-CX metal case. 7) Connect BLR-CX according to wiring diagram.(CT/P1 towards incoming feeder, CT/P2
   towards load!) 8) Remove short-circuit from CT 9) Connect mains voltage to panel. 10) If relay has been correctly connected and the mains voltage and CT output comply with
   the ratings and settings of BLR-CX, the LCD will show AUTO and the control function will start automatically!

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Reference Manual BLR-CX-R / BLR-CX-T

1.1 Wiring diagram

BLR-CX-R
power-input utility L1 L2 L3

X/1A or X/5A

Rev. 07 2018-07
load

KL
15mA – 6A

Um1 Um2
90V – 550V

BLR-CX

T1 T2
T

N
PE
external temperature sensor or temperature switch (parallel use of sensor and switch is possible)

M

A

Interface TTL

K1-K14

MS

1

14

1-14

K1

K14

signal: in order (life-contact)

up to 14 control exits

Controll exits can be parametered for fan controll

BLR-CX-T
power-input utility L1
L2
L3

X/1A or X/5A

load

KL
15mA – 6A

Um1 Um2
90V – 550V

BLR-CX

T1 T2
T
N PE
external temperature sensor or temperature switch (parallel use of sensor and switch is possible)

Interface

M

LA

TTL

MS

LF 1

12

signal: in order (life-contact)

Fan control

up to 12 control exits

+-

Triggerinput BEL-TSXX
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Reference Manual BLR-CX-R / BLR-CX-T

Rev. 07 2018-07

1.2 Connection data

Meas.- Supply voltage
Current measurement
Regulation exits
Static outputs Alarm contact Separate fan control (only BLR-CX-T) Temperature sensor / Digital Input

Combined measurement and Power supply Range 90-550V. Terminals UM1 / UM2 With using of VT a ratio can be adjusted. Range 1-350
Current measurement Range 15mA ­ 6A, Measurement transformer types x/1A or also x/5A can be used. Terminals K (S1) / L (S2) CT ratio is 1-9600 (Devices with Firmware before 1.04 had the adjustable range from 1-4000)
Assembly with 4, 6, 8, 10, 12, 14 Regulation exits possible. Regulation exits volt free with common root. Terminals A 1-14. max. breaking capacity 5A/250VAC
Assembly with 6 or 12 static outputs possible. open-collector, breaking capacity: 8 ­ 48V DC / 100mA
Opens in case of alarm and grid failure (can be changed by software). Terminals M / MS max. breaking capacity 5A/250VAC
Closes terminals L / LF when exceeding temperature limit 1 max. breaking capacity 5A/250VAC
Temperature measurement or Digital Input to switch over to
Terminals T1 / T2 Setting is explained in the Alarm menu.

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Rev. 07 2018-07

2 COMMISSIONING

The BLR-CX comes with factory settings, which allows operation in 400V grid without any settings, if the connection is correct.
After applying voltage, the display shows the measured cos and displays ,,Auto”. The measured cos should be inductive (displayed by a small ,,i” behind first line). With applying the voltage to the BLR-CX the discharge blocking time for the capacitors starts ( Factory setting 75 sec.). After the discharge blocking time the regulation starts. Stepsizes will be detected automatically. Control exits which are not used, become adjusted to step status “Fix-Off” after three switching cycles without success. These outputs are blocked for the control.
To display values, which are depending on the current, it’s necessary to adjust the ct ratio. This setting is not necessary for the control.

FAQ during Commissioning:

1. No indication AUTO -> the relay does not switch Cause: Relay is set to manual operation In SETUP/100 menu the selection for PFC is on OFF or HOLD, temperature is too high, current < 15mA, voltage or THD U is out of tolerance.
2. Indication U ALARM -> voltage out of tolerance Check settings for nominal voltage (SETUP/Un) and voltage transformer (SETUP/Pt)
3. Indication I Lo ALARM -> CT current < 15mA Cause: connection error of CT; short-link of CT is not removed; CT-ration is too high compared to real current; no current
4. Indication EXPORT -> kW export if there is no real kW export, voltage and current connection to BLR-CX has to be checked! See Wrong Connections / AI
5. Wrong Cos j indication -> wrong connection voltage and current connection to BLR-CX has to be checked! See Wrong Connection / AI
6. Steps switch in and then quickly switch out again See Stepsize Detection / Defective Capacitors
7. Frequent switching of steps size of capacitors has not been completly detected

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Reference Manual BLR-CX-R / BLR-CX-T
3 DISPLAY

Rev. 07 2018-07

On the right side of the display, the actual chosen main menu is

shown.

INFO:

Capacitor database

AUTO:

automatic control is running

MANUAL: manual mode

SETUP:

setup menu

In the top menu level in the first line, the actual cos is shown. The i respectively the c indicates leading or lagging cos. In submenu level the codes for the submenus or the abbreviations for the measured values are displayed.

The second line shows measurement and set values with the corresponding units. Also the alarm codes which are shown during and alarm event are indicated there. All alarm codes are shown and explained in the table on the next page.

Active regulation outputs are shown in the bottom line. Steps, which are detected as defective (three switching cycles without success), are blinking.

NT: EXPORT:

COS 2 active export of active energy

ALARM: blinking in case of alarm

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Rev. 07 2018-07

In case of an alarm will flash alternately at BLR-CX with “ALARM” an error code in the display. The table below gives an overview of all possible error codes. To reset pending alarms hold the (esc) button pressed for 5 seconds.

/ /
/ /

measured voltage is outside the set tolerance measured current is less than 15mA (check the short circuit bridge K and L and the entire current path measured current is to high The controller cannot achieve the target COS The set limit for the THD of the voltage is exceeded One or more steps are broken. The defective step is blinking with the alarm message. One or more step’s have fallen below 70% of initial power. step number and error code will flash alternately.
For devices with software version before 1.04 the alarm is triggered at 50% of initial power. The second temperature limit is exceeded. Stage were switched off successively. Set limit of operation hours has been exceeded Set limit of the max. allowable operation cycles, for one or more steps, has been exceeded. Abort of auto-initialization.

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Reference Manual BLR-CX-R / BLR-CX-T
4 OPERATION
4.1 Keys
Increase values, select menu items Escape menu, move cursor left, push 3 sec to clear
alarms

Rev. 07 2018-07
Enter menu, move cursor right, confirmation of settings

Decrease values, select menu items
4.2 Input of numerical values
Whenever the BLR CX prompts for the input of a value, the routine will be the same:
A preset-value will be displayed with the first (highest) digit blinking. This digit can now be changed by use of the and keys. Use the button to change to the next smaller digit. After changing, the next digit will be also blinking and can now be altered just like the first one. When arriving the last digit, press the key once more. This position allows to set multipliers M (Mega) or k (kilo). To store the value, press the key once more, and the new value will be saved and used.
In case, that an adjusted value cannot be stored respectively another value is shown after confirmation with button, it’s possible that the adjusted value is outside of the allowed range. For further information’s about possible ranges, please check the table on the last page. At any time, one can go back to the menu he came from without changing the value by pressing the key. In this case, the modified value will not be used!

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Rev. 07 2018-07

5 MENU BLR-CX

5.1 Measurement menu

All grey fields are hidden in the factory settings and will only appear if the CT ratio is set in the

“SETUP” menu. For devices with software version before 1.04 the complete measurement

menu is hidden and must be activated by adjusting the CT ratio.

1.00 i

1.00 i U 400 V

Voltage L – L

1.00 i 0,999

Pf three digit

1.00 i INFO

1.00 i U 230 V

Voltage L – N

PF 0,888

Power factor ratio P/S

1.00 i MANUAL

1.00 i I 40,45 A

current in measured
phase

APF 1.000

Average Power factor

1.00 i SETUP

1.00 i

Active power

F

P 30,37 kW

3 phase

50

Frequency

1.00 i Q 82,89Var

Reactive power 3 phase

t 58 °C

Temperature

1.00 i

control

deviation in

Q 80,08 Var

kvar

thi 88 °C

Highest measured Temperature

1.00 i S 30,68 kVar
1.00 i THD U 1,41 %

Apparent power 3 phase
Harmonic distortion
U total

OPH 188.9 h

Counter operation
hours

3 HarU 0,40 %

Odd single harmonics
3 – 19

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Rev. 07 2018-07

5.2 Info (Step database)

In the “INFO” menu for each connected step the number of switching cycles, the current step size and the step size in relation to the initial step size is stored.

Using these data, conclusions can be drawn on the condition of the site and the condition of single steps. Step sizes are displayed in kVar only when in the CT ratio is set in “Setup” menu.

1.00 i

Choose step with View values with

Confirm with

1.00 i INFO

INFO 1 2 3 3 4 max.

CC 25 kVar
1 2 3 4 max.

Display of step size only if CT ratio is set, otherwise—

1.00 i MANUAL

INFO 1 2 3 4 max.

98 Current step size in %

%

related to initial step size

1 2 3 4 max.

1.00 i SETUP

INFO 1 2 3 4 max.

OC 808
1 2 3 4 max.

switch cycles

INFO 1 2 3 4 max.

Auto
1 2 3 4 max.
CC 25 kVar
1 2 3 4 max.

auto: step is okay foff: step is permanent off fon: step is permanent on Al: output for fan control Flty: step detected as faulty
Display of step size only if CT ratio is set, otherwise—

auto: step is okay

Auto

foff: step is permanent off fon: step is permanent on

1 2 3 4 max. Al: output for fan control

Flty: step detected as

faulty

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Rev. 07 2018-07

5.3 Manual (step switching manual)

To enter in manual mode, please select “manual” in main menu and push for 3 seconds. By

entering this submenu, the manual mode for the regulator is active. The automatic control is

stopped and the exits can be switched manually. By the means of the

-keys the referring

step can be selected. Changing the switching state is possible by pushing the -key.

Manual switching is only possible when measurement voltage is in allowed

!

range. Otherwise over- and undervoltage protection will block this function.

After switching off an active step, the discharge time is active. Only after this

time is over the step can be switched on manually again.

1.00 i

1.00 i INFO 1.00 i MANUAL 1.00 i SETUP

Choose step with
Switch on / off with

At each switching operation the current Pf is shown

0,95 i MANUAL 1

1.00 i MANUAL 1
1

0,95 i MANUAL 2

1.00 i MANUAL 2
2

0,95 i MANUAL 14

1.00 i MANUAL 14
14

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Rev. 07 2018-07

5.4 Setup (Quick start menu)

1.00 i 1.00 i INFO 1.00 i MANUAL 1.00 i SETUP

To start the control, it’s only necessary that the nominal voltage is correct. All other settings are only for optimal adaptation to the conditions in the system and display system data. To change a setting, enter the setting by

pushing the button. Change the value with

and confirm with

. When you start the auto-initialization the BLR-CX checks the connection

of the measurement and the exits. With these data, the regulation starts

automatically.

1.00 SETUP

Un SETUP 400

Un = nominal voltage Setting of nominal voltage. From this value the upper and lower limits for voltage monitoring is

ct SETUP Input current transformer ratio

20

e.g. 250/5 = 50

pt SETUP Input voltage transformer ratio

1

when no VT is used the value is 1

ai SETUP “Yes” the controller performs the

no

auto-initialization again

pfc “ON” automatic control SETUP

“OFF” control off

on

“HOLD” control freeze

cpi SETUP 1

st Interval between switching the SETUP steps
10

Out Possible types of output: SETUP auto: step is used for regulation foff: step is permanent off fon: step is permanent on Al: output for fan control (V1.06)

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Rev. 07 2018-07

6 EXPERT MENU BLR-CX

To enter the BLR-CX expert menu, select menu item “SETUP” and confirm with ( ). Push or and enter the requested PIN (242) and confirm with ( ). The submenus can be

selected by pushing

buttons. The expert menu of BLR-CX is divided into six groups,

where the menu items are logically grouped together.

The following groups exist:

100 Quick start menu Contains all important points for commission. 200 Measurement settings Contains settings to adapt the measurement of the BLR-CX to the surrounding network conditions. 300 Setup Control System The items in the menu “control system” allow an optimization of the control or an adaptation to specific site requirements.

400 Setup Step Database In the step database, all settings and data are combined which are required to adjust and adapt the steps. 500 Setup Alarm The alarm menu of BLR-CX. Here, all the alarms and monitoring functions can be activated and the limits configured. 600 Resetmenu Allows you to reset all settings made by the controller and stored data. Additionally, it contains the software version of the device (displayed from 1.04) and the possibility to change the password for the setup menu.

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6.1 100 Quick start menu

Contains important information for commission:

MENU Un

100 Quick start menu

FUNCTION

RANGE

NOMINAL VOLTAGE = PHASE – PHASE

100…241500 V

Function of the setting of nominal voltage is to make a definition

about the nominal voltage of the system. The threshold levels for

under- and overvoltage are based on this as well as the ratings of the

capacitor sizes in step database, which are used for control and

monitoring. The capacitor sizes, which are stored in step database,

are also rated to the nominal voltage.

Ct

CT-FACTOR

1…9600

The CT FACTOR is the ratio of current transformer.

(e. g. 1000/5 = ratio 200).

At devices with software version 1.04 is the adjustment range from

1-4000.

Pt

VT-FACTOR

1…350

VT FACTOR is the ratio of the voltage transformer.

If the regulator is connected directly to the measurement voltage

without VT the value 1 has to be used.

Ai

AUTO-INITIALIZING START

“YES” starts auto-initializing

Yes/No

Automatic initialization is switching all exits. During this test it can

get information, which exits are working and it can correct the

connection of the measuring channels for voltage and current by

internal

settings.

Automatic initialization can be started only when the voltage and

current are ok. Steps with step type “FON” or “AL” will be not

considered in case of new auto-initialization.

AUTOMATIC INITIALIZATION is only able to work, when capacitors are used for compensation. If BLR-CX has to switch reactors for compensation of capacitive load, this feature will cause failures. AI is working at best, when there are stable load conditions!

At devices with software revision before 1.04, stages which are set to “FOFF” were not retested.

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PFC START / STOP / HOLD PF-CONTROL

On/Off/Hold

Stopping the automatic control. The following options are available:

On: Control in automatic mode

Off: Control stops and active steps were disconnected successive

Hold: Control Stops and active step’s remain switched on.

If “OFF” or “HOLD” is selected, will appear in the display “PFC” alternating with “OFF” or “HOLD”. To start the control, select “ON”.

CP1 COS 1

0.70 c …0.70 i

This is the setting for target COS 1. It will be valid during normal

operation.

St

SWITCH INTERVAL

1…6500 s

The switch interval is the time delay between switching steps in

regulation.

The switch interval has two different functions:

1. Protecting the contactors by reducing the number of switching cycles.

2. Building of the average of the reactive power in the time of the switch interval.

Out TYPE OF OUTPUT With the exception of step type “flty” the follwing step types can be selected: Auto = Step is used for normal regulation algorithm.
Alarm = If the set temperature limit 1 is exceeded this step is switched as fan output.
Fon = Step is permanently switched on (Step is still monitored and shut down in critical situations).
Foff = Step is permanently switched off. Not used steps should be adjusted to this type to avoid unnecessary alarm.
Flty = Step was switched three time without success and is not longer used for automatic control.
As “flty” stored steps can be set to desired step type in this menu.

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6.2 200 Measurement settings

Contains settings to adapt the measurement of the BLR-CX to the surrounding network

conditions.

MENU 201

200 Measurement settings

FUNCTION

RANGE

NOMINAL VOLTAGE = PHASE – PHASE

100…241500 V

Function of the setting of nominal voltage is to make a definition

about the nominal voltage of the system. The threshold levels for

under- and overvoltage are based on this as well as the ratings of the

capacitor sizes in step database, which are used for control and

monitoring. The capacitor sizes, which are stored in step database,

are also rated to the nominal voltage.

202 CT-FACTOR

1…9600

The CT FACTOR is the ratio of current transformer.

(e. g. 1000/5 = ratio 200).

At devices with software version 1.04 is the adjustment range from

1-4000.

203 VT-FACTOR

1…350

VT FACTOR is the ratio of the voltage transformer.

If the regulator is connected directly to the measurement voltage

without VT the value 1 has to be used.

204 V-TOLERANCE

0…100 %

The setting of this value is in percent related to the nominal voltage.

By means of the set value, the upper and lower limits of the

permissible voltage range are calculated. e.g. 10% at 400V nominal

voltage is a permissible range from 360V to 440V.

205 CONNNECTION MEASUREMENT “YES” voltage measurement L-L “NO” voltage measurement L-N

Yes/No

CONNECTION MEASUREMENT the setting if measuring of voltage is connected between two phases or between phase and neutral phase. It is normally detected automatically at every start of BLR-CM. This is done by comparing the setting NOMINAL VOLTAGE and the real measured voltage. This cannot be changed by hand. If the measured voltage is outside this tolerance, the measurement can be adjusted by hand.

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206 PHASE COMPENSATION

0…345

The phase compensation enables the user to connect the current-

and voltage measurement channels in any way. This compensation

angle complies with the phase angle between connected active

current and voltage. This setting has to be made correct, because

otherwise correct regulation is not possible! If the current

transformer is connected inverted, additionally a phase

compensation of 180° has to be respected.

Is auto-initialization failed due to adverse network conditions, by hand a correction angle can be set or the incorrectly recognized can be corrected. Table 11.1 gives an overview of the connection options with corresponding phase angles.

207 START AUTO-INITIALIZING “YES” starts auto-initializing

Yes/No

Automatic initialization is switching all exits. During this test it can

get information, which exits are working and it can correct the

connection of the measuring channels for voltage and current by

internal

settings.

Automatic initialization can be started only when the voltage and

current are ok.

AUTOMATIC INITIALIZATION is only able to work, when capacitors are used for compensation. If BLR-CX has to switch reactors for compensation of capacitive load, this feature will cause failures. AI is working at best, when there are stable load conditions!
Steps with step type “FON” or “AL” will be not considered in case of new auto- initialization.

At devices with software revision before 1.04, stages which are set to “FOFF” were not retested.

208 AUTO-INITIALIZING BY REGULATOR RESTART

Yes/No

YES = after starting the BLR-CX, a countdown is running. During this

countdown it is possible to start auto-initializing by pushing ( ).

“NO” the countdown is not shown. To start AI, you have to choose Quickstart SETUP.

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209 SYNCHRONISATION FREQUENCY

Auto/Fix50/Fix60

For a high precision of the measurement, the sampling rate has to be synchronized to the frequency of the grid. Caused by commutation notches of mainsvoltage it is possible that the automatic synchronizing will not work reliable. This creates failures in measurement. To avoid these problems, the following settings can be done: Automatic synchronizing:
For best measurement results, when mains voltage is without commutation notches.
FIX-50HZ: For a safe operation at 50Hz grid with bad mains quality. FIX-60HZ: For a safe operation at 60Hz grid with bad mains quality.

210 TEMPERATURE OFFSET (from software revision 1.04)

-10-10°C

The temperature offset allows correction of temperature reading in

a range -10°C to +10°C.

6.3 300 Setup Control System

The items in the menu “control system” allow an optimization of the control or an adaptation to specific site requirements.

MENU 301

300 Setup Control System

FUNCTION

RANGE

CONTROL SENSITIVITY

55…100 %

Sensitivity is the switching threshold for switching-on or switching-

off the capacitors in percent (%). The range of the sensitivity can be

between 55% and 100% (factory setting is 60%. Due to this, the in

following explanation 60% is used.).

Sensitivity is used for two checks:

1. The controller is using sensitivity to check, if a switching operation is necessary or if it’s possible. If the demand for compensation is bigger as 60% of the
smallest for regulation available step, BLR-CM is selecting
from step database, if there are suitable steps to switch.

2. To avoid hunting, the controller is only using steps, which will not overshoot more than 40% (100%-60%) of its size.

302 COS 1

0.70 c …0.70 i

This is the setting for target cos1. It will be valid during normal

operation.

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303 COS 2

0.70 c …0.70 i

This is the setting for target cos2. It will be valid when a switch over

is caused by the digital input or another programmable action.

304 COS 2 FOR P EXPORT

Yes/No

“YES” the controller operates in P-export with the COS 2 as control

target. “NO” the controller operates in P-export with the COS 1.

305 SWITCH INTERVAL

1…6500 s

The switch interval is the time delay between switching steps in

regulation.

The switch interval has two different functions:

1. Protecting the contactors by reducing the number of switching cycles.

2. Building of the average of the reactive power in the time of the switch interval.

306 SWITCH INTERVAL STEP EXCHANGE

1…6500 s

For step exchange, a separate switch interval is used. This is the

delay-time between switching-off an active step and switching-in the

next step to get a better power-factor.

307 ACTIVATE STEP EXCHANGE

Yes/No

“YES” = Step exchange is active.

“NO” = Step exchange is disabled.

Step exchange is supporting automatic control and combined filter

control algorithm to reach an optimum result. If the controller

detects that target-pf is not reached it starts searching for a step

which gives better results. If step exchange is active, the controller

can replace a switched-in step against a step which matches better,

to reach the target. This function helps to reach target COS more exactly, when

capacitors have different sizes. If all capacitor banks have the same

size, this function makes no sense.

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308 STEP RECOGNITION “OFF”

Yes/No

“YES”: Step sizes have to be programmed by hand. The step sizes

have to be programmed by hand if:

1. When fast-oscillating load influences automatic stepsize recognition.
2. When recognition of defective steps is not wished
3. When capacitor contactors are switching with a delay of more than 200msec.

“NO” Stepsizes are detected and corrected automatically during normal operation. “Step recognition ON” is the factory setting. It allows monitoring of capacitor sizes and gives alarms when they are
faulty. Stepsizes which are programmed manually will be
overwritten by step recognition.

309 BLOCKING OF DEFECTIVE CAPACITORS

Yes/No

“YES” If a step is switched in three times without measurable

network reaction, the controller is blocking the step and doesn’t use

it for the control.

Is a Step recognized to be defective, blinks in the display the

corresponding output and in the step database and menu “403” it’s

displayed as step type “flty”.

“NO” Steps are connected even if no network reaction is measurable.

This results unnecessary switching cycles.

Steps that are stored as defective will be tested every 24 hours or

after the controller is restarted.

310 START / STOP / HOLD PF-CONTROL

On/Off/Hold

Stopping the automatic control. The following options are available:

On: Control in automatic mode

Off: Control stops and active steps were disconnected successive

Hold: Control Stops and active step’s remain switched on.

If “OFF” or “HOLD” is selected, will appear in the display “PFC” alternating with “OFF” or “HOLD”. To start the control, select “ON”.

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311 CONTROL ALGORITHM

1/2/3/4

1. Automatic: The controller is working with the principle of ,,Best Fit”. Before a switching operation, all capacitor-sizes in

step database are compared with control deviation. The

available step which gives the best results will be switched.

2. LIFO: “Last In, First Out” The controller starts with regulation with step 1 and is switching further exits step-by-step. Switching-off is done vice versa.

3. Combined Filter: Special algorithm for combined filter banks with two different detuned ratings. The controller is working like in automatic mode with the principle “Best Fit”. From odd numbered steps, there is at least or more of the capacitance connected as from even numbered steps. Threshold level of each step is checked separately. If steps different sizes, this can cause inaccuracy. Step recognition is working in this mode. If steps are detected as defective, they are skipped in this mode. If this is not accepted, the step recognition has to be deactivated and capacitor sizes have to be programmed manually.

4. Progressive: The controller switches if required, several steps in sequence with a shorter switching time. From software 1.04, the controller uses independently of the set switching time always 1 sec. as switching time. Furthermore, the automatic step size detection is disabled and the step sizes need to enter by hand. The input of the step sizes should be as accurate as possible, because the regulator would otherwise tend to oscillate. Leaving the “Progressive” algorithm and use a different algorithm, the set switching time is used the step size detection is re-enabled.

312 OFFSET REACTIVE POWER

CtPt7000

OFFSET of reactive power in kvar. This feature allows compensating

a permanent reactive load, which cannot be measured (e.g. a

transformer).

The offset of reactive power affects the readings of the following

measuring

values:

current, reactive power, control deviation, apparent power, power factor PF and cos.

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313 ASYMMETRY FACTOR

-127…127

ASYMMETRY FACTOR of switch interval. The factor is the ratio

between switch interval for switching on and switching off. Switch

interval for step exchange is not affected by this setting.

X= 1 = equal

X = +2 to +127: delay switching off = switch interval multiplied by X

X = -2 to -127: delay switching on = switch interval multiplied by X

314 Q CAPACITIVE STEPS TURN OFF

Yes/No

“YES” As soon as a capacitive condition is recognized, the controller

switches off without keeping the switching time, the necessary step

power in order to prevent leading network conditions. “NO” The controller works only with the set target COS .

6.4 400 Setup Step Database

In the step database, all settings and data are combined which are required to adjust and adapt the steps.

MENU 401

400 Setup Step Database

FUNCTION

RANGE

DISCHARGE TIME

5…1200 s

The discharge time is defined once and is valid for all steps. The

discharging time is a blocking time, becoming active after switching

off a step. As long as this time is running this step is not available for

the regulation. Discharging time should be adapted to the capacitor

discharging unit.

402 STEP NOMINAL VALUE

CtPt7000

If STEP RECOGNITION is not active, it is required to do this setting,

to get proper function of the relay. The size of the capacitors can be

programmed manually in kvar. Before this programming, CT

FACTOR and NOMINAL VOLTAGE must be programmed correctly. A

change of CT FACTOR or NOMINAL VOLTAGE is automatically

changing the value of the capacitor size.

The programming can be done for each step individually in kvar. So

there is no special sequence necessary. A step can be programmed

as a capacitor (c) or as an inductor (i).

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403 STEP TYPE

Auto/Al/FOn/FOff

With the exception of step type “flty” the follwing step types can be

selected:

Auto = Step is used for normal regulation algorithm.

Alarm = If the set temperature limit 1 is exceeded this step is switched as fan output.

Fon = Step is permanently switched on (Step is still monitored and shut down in critical situations).

Foff = Step is permanently switched off. Not used steps should be adjusted to this type to avoid unnecessary alarm.

Flty = Step was switched three time without success and is not longer used for automatic control.
As “flty” stored steps can be set to desired step type in this menu.If defective steps should not be locked, you must disable this function under the menu item “309”. Steps which are identified as defective will be tested again by the controller every 24 hours or after a restart.

404 SWITCH CYCLES

0…262000

The BLR-CX is counting and showing the switching cycles of each

step in the “Info” menu. After a contactor has been exchanged, the

switching cycles can be set to “0” in this menu.

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6.5 500 Setup Alarm
The alarm menu of BLR-CX. Here, all the alarms and monitoring functions can be activated and the limits configured.

MENU 501

500 Setup Alarm

FUNCTION

RANGE

Reset Alarm manually

Yes/No

“YES” Alarms (display and alarm relays) must be reset manually. To reset upcoming alarms, hold the (esc) button pressed for 5

seconds.

“NO” As soon as the alarm condition is no longer valid, the alarms

drop out.

502 THD U Alarm

Yes/No

“YES” The set THD threshold under menu “503” is monitored.

Exceeding the set threshold will open the alarm contact and the

display will show the message ”

“.

“NO” THD is not monitored.

503 THD U Threshold Input of the threshold for THD monitoring.

1…200 %

504 THD U > Threshold = disconnect steps

Yes/No

“YES” Exceeding the set threshold for THD will switch off all active

steps successive.

Warning: Steps are only switched off when it is set at point 502 to

“YES”.

“NO” Exceeding the set threshold follows no action.

505 Interval time before triggers THD U and Temperature threshold 2 1…255 s Interval time after exceeding the threshold for THD U or temperature threshold 2.

506 Freeze control if I == 0

Yes/No

“YES” The measuring current drops below 15mA freezes the control.

All active steps remains switched on.

NO” Measuring current falls below 15mA, the controller shuts down

all active steps successive.

507 Service Alarm

Yes/No

“YES” the alarm contact opens when the max set switching cycles for

one or more steps have been exceeded or if the set threshold for

operation hours are reached.

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“NO” no alarm when exceeding the max. switching cycles or operation hours.

508 Max. switching cycles per step Threshold switching cycles for service alarm. Display indication

1…262000

509 Max. operation hours Threshold switching cycles for service alarm. Display indication

1…65535 h

510 Use temp. input as digital input

Yes/No

“YES” Temperature sensor is activated via a switch and causes a

(HT / NT)

Note: This menu item is locked against menu item “512”. If the

temperature alarm is set to “Yes”, this point will automatically

jump to “NO” and can not be altered.

“NO” the temperature input works with plug-in temperature sensors

and monitors the in menu 513 and 514 adjustable temperature

thresholds. Parallel to the temperature sensor, a thermostat can be

connected. In this case, the controller displays “HIGH” for closed

state and “LOW” for open state.

511 DI active at HIGH signal “YES” digital input is activated with closed terminals T1 & T2. “NO” digital input is activated with open terminals T1 & T2.

Yes/No

512 Temperature alarm

Yes/No

“YES” the controller monitors the temperature threshold 1 and 2 and

responses accordingly.

“NO” alarm disabled.

513 Temperature threshold 1

3-74 °C

By exceeding the temperature threshold 1 switches the controller as

“AL” declared step (fan on).

514 Temperature threshold 2

4-75 °C

When the temperature exceeds temperature threshold 2, the

controller switches all active steps (“AUTO” & “FON”) from

compliance with the under menu item 505 adjusted time in

succession off. In addition, in the display appears ”

”

and the alarm contact is opened.

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515 Control alarm (target cos can not be archived)

Yes/No

“YES” alarm is triggered after 75 time switching time with Q> smallest step (Over / under compensation). Controller opens the

alarm contact and indicates

in the Display.

“NO” no monitoring for over / under compensation.

516 Defective step alarm

Yes/No

“YES” After 3 unsuccessful switching actions alarm is triggered. The

controller opens the alarm contact and indicates

/

in the display. Steps recognized as defective flashing in the step indication. “NO” alarm disabled.

517 Step power loss alarm

Yes/No

“YES” If the current step size is less than 70% of the initial size, the

controller opens the alarm contact and indicates the error with

output number

/

. in the display.

“NO” Power loss of the capacitors is not monitored.

6.6 600 Resetmenu

Allows you to reset all settings made by the controller and stored data. Additionally, it

contains the software version of the device (displayed from 1.04).

MENU 601

600 Resetmenu
FUNCTION Reset Settings Sets all settings made back to factory settings.

RANGE
Yes/No

602 Reset Step database Sets all step data back to factory settings.

Yes/No

603 Reset operation hours Sets the counter for operation hours to “0”

Yes/No

604 Reset average PF Reset the average PF.

Yes/No

605 Reset max. Temperature Reset the highest measured Temperature.

Yes/No

606 Reset alarms Reset all upcoming alarm.

Yes/No

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607 Display software version Contains the software version of the device (display from 1.04)
608 Adjustment of the Setup password (from software 1.08) Here, a password can be entered.

Rev. 07 2018-07

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7 TECHNIAL DATA

Measuring- and supply voltage: Current measurement
Control exits

90 ­ 550V AC, single phase, 45-65HZ, 5VA, max. fuse 6A VT ratio from 1.-350.0 15mA ­ 6A, single phase, burden 20mOhm, CT-ratio from 1-9600 Before software version 1.04 the adjustable range is 1-4000
Relays: up to 14, n/o, with common point, max. fuse 6A breaking capacity: 250V AC / 5A

Static outputs: 6 or 12 static outputs possible. open-collector, breaking capacity: 8 ­ 48V DC / 100mA

Temperature measuring: By NTC

Alarm contact: Fan control

Relay, volt free, life contact, max. fuse 2A, breaking capacity: 250V AC / 5A By using one switching exit defined as “Alarm”.

Interface: Ambient temperature: Humidity: Voltage class: Standards:
Conformity and listing: Connection: Case:
Protection class:
Weight: Dimension:

Devices with transistor outputs us the contacts L / LF for fan control. TTL, rear Operation: -20°C ­ 70°C, storage: -40°C ­ 85°C 0% – 95%, without moisture condensation II, dirt class 3 (DIN VDE 0110, part 1 / IEC60664-1) 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) CE, UL, cUL, GOST-R Pluggable terminal block, screw type max. 4qmm Front: instrument case PC/ABS (UL94-VO), Rear: metal Front: IP50, (IP54 by using a gasket), Rear: IP20 ca. 0,6kg 144x144x58mm h x w x d, cut out 138 (+0,5) x 138 (+0,5)mm

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8 TROUBLESHOOTING

Fault

possible cause

No indication in display

aux. voltage missing

Remedy
Check the correct connection of power supply and correct if necessary.

Display

”

”

Voltage tolerance

outside

Check measurement voltage Check nominal voltage and
adjusted tolerance and correct if necessary.

Display ”

Measured current is check connection of CT,

”

to small

probably there is a break in the line

remove short circuit link of the

CT

wrong display of current or voltage

wrong transformer ratio

Check settings of transformer ratios in the “SETUP” (100) menu and correct if necessary.

The power factor is displayed incorrectly.

The

connection

detection was not

performed.

Start “Ai” in “SETUP” menu.

The phase angle was adjusted manually false.

Check point 206 in the “EXPERTMENU” and correct the phase angle if necessary.

Offset reactive power is adjusted.

With the compensation system, a transformer is compensated. The displayed Pf is in front of the transformer. The displayed Pf is in front of the transformer.

The power factor does not change after the switching of a step.

CT

incorrectly

positioned.

Check installation position of the current transformer according to wiring diagram (current of the load and the capacitors must be measured!).

Steps are switched off again.

Capacitor defect

Check capacitor, possible fuse, capacitor, or contactor defective.

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Display ”
Display ”
Opposite regulation behaviour Individual steps are not switched on or off.
Steps are detected as defective. Steps are switched off again.
Steps are not switched.

Current is higher than allowed.

permanent

over

compensation

permanent under compensation
Current or voltage connections swapped.
wrong setting

Step defective

The steps are to large.

Check the current transformer secondary current and possibly replace it with matching current transformer.
Check settings (possibly step with step type “FON”)
Check contactors, contactor contact may bonded.
Check capacitors and fuses. Dimensioning of the system
examined. correct connection or adapt
phase compensation.
Verify whether the steps were defined as Step type “FON” or “FOFF” (permanently on or off).
Check capacitor, possibly fuse, capacitor or contactor defective.
The required reactive power is below the switching threshold. Switching threshold is 60% of the smallest available step.

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9 APPLICATIONS

9.1 Fan Control
The fan control is to be regulated through the BLR-CX. Solution: If the BLR-CX is equipped with a temperature sensor (option ­L), can be via one of the switching exits, a fan to be controlled. Procedure:
Enable temperature alarm In the expert menu item 512 set to “YES” (temperature alarm on). Set temperature thresholds Set the following items 513 (temperature threshold 1) and 514 (temperature threshold 2the temperature thresholds. By exceeding the temperature threshold 1 is witched the fan output. When you exceed the temperature threshold 2, all steps are switched off to prevent overheating. Select fan output Select item 403 in expert menu and adjust for the step which shall work as the fan output step type “AL”. Features: In order to prevent hunting of the fan relay, the fan is turned off only at a temperature below the set limit by at least 3°C. If the BLR-CX is equipped with a temperature sensor, the current cabinet temperature is displayed and the highest measured temperature is stored in thi. Parallel to the temperature sensor can be connected a thermostat. By close of the thermostat, the temperature limit 2 is activated.

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9.2 Switching on COS 2 via digital input

By using a switch, the BLR-CX will be switched to COS 2. Solution: Using the temperature input as digital input. Procedure:
Enable digital input Set item 510 in expert menu to “YES”. Using digital input as n/o or n/c “YES” digital input is activated with closed terminals T1 & T2. “NO” digital input is activated with open terminals T1 & T2. Features: The temperature input is used as a digital input, shows the controller at active input “high” and with not active input “low” instead of the temperature. The controller uses with active
and will show “NT” in the display.

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9.3 Problems with the Step recognition.

The controller is used in a system with rapid changes in load conditions and has problems with the automatic step recognition Solution: To solve this problem, the step sizes must be entered by hand, and the step recognition must be turned off. Procedure:
Stop control. Set item PFC to “OFF” in menu 100 (quick start menu).
switch off Step detection. Set item 308 to “Yes” (step recognition off) in the expert menu.
enter step sizes. Setting the nominal value of the capacitors connected at point 402 in the expert menu.
Check step type For problems with the step detection, it may happen that the connected steps will be stored by the controller incorrectly as “FIX-OFF”. Therefore, the step type of each step should be controlled under the menu item “403”. All steps of the automatic control used, must be use the step type “AUTO”. Features:
By switching off the automatic step recognition, a step failure or power loss is not reported. To monitor the system anyway, it is appropriate to enable the control alarm to be alerted in case of failure timely. (See alarm menu)

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9.4 Transformer compensation

The compensation of a transformer can be solved with the BLR-CX in two ways:

9.4.1 Setting a reactive power offset

Setting reactive power offset. This is added to the required compensation power within the system.

Procedure:

Determine the required capacitive reactive power to compensate the transformer. Enter the calculated value in the menu item “312”. Control will start immediately with the additional required reactive power.

Features:

The reactive power offset set here is always added to the measured reactive power. Therefore, it’s always the Pf appears before the transformer. This means that the system can capacitive, but the measurement of the utility the required Pf recoded.

9.4.2 Mixed measurement:

By the current measurement on the medium voltage side, the transformer caused reactive

power is measured and regulated by the connected compensation system.

20kV / 50Hz

Procedure:

Transformator 400V / 50Hz

Connect the measurement of the
controller as shown in the diagram
adjacent. Then start the automatic
initialization. The vector group ot the
transformer is automatically considered.
Last
Connection:

BLR-CX

When auto-initialization will be aborted, under item 11.2, the most common transformer vector groups are listed.

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9.5 Reset defective steps respectively add aditional steps

If the controller has recognized a step as defective (3 switching operations without result), it

will be excluded for 24 hours from the regulation. After this period, the step is tested again

from the controller. If the controller can detect the step, it will be included in the control. If

not, the step is blocked for 24hours again after 3 unsuccessful switching cycles. Defect steps

are in the “INFO” menu with the step type “flty” marked and flashing in the step indication.

When a compensation system need additional capacitors to be added, proceed as described

below:

Procedure:

Select item “403” in expert menu and use the

buttons to select the corresponding step.

Confirm with ( ) button and use the

buttons to adjust step type “AUTO”.

Feature:

If a step is exchanged, the nominal step size of the new step must be entered by hand. Select

the affected step in menu “402” and program the nominal step size.

If a defective contactor triggers the alarm upon the exchange took place, the accumulated switching operation under item “404” set to “0”.

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10 CUSTOMER SETTINGS

Menu Factory setting Customer setting

100

Un

400 V

Ct

1

Pt

1

Ai

NO

PFC

ON

CP1

1

St

10 s

200

201

400 V

202

1

203

1

204

10%

205

NO

206

0

207

NO

208

YES

209

AUTO

300

301

60%

302

1

303

0,95 i

304

NO

305

10 s

306

2 s

307

YES

308

NO

309

YES

310

ON

311

1

312

0

313

1

314

NO

Menu Factory setting Customer setting

400

401

75 s

402 5 var (1-max.)

403 AUTO (1-max.)

404

0 (1-max.)

500

501

NO

502

NO

503

20 %

504

NO

505

60 s

506

NO

507

NO

508

262 k

509

65.5 k h

510

NO

511

NO

512

NO

513

30 °C

514

55 °C

515

0 °C

516

NO

517

NO

518

NO

600

601

NO

602

NO

603

NO

604

NO

605

NO

606

NO

607

1.xx

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11 APPENDIX

11.1 Settings Phase-angle

Voltage L1-N L2-N L3-N L1-N

CT

L1 L2 L3 L2

Phase-angle 0° 0° 0° 240°

Voltage L2-L3 L3-L1 L1-L2 L2-L3

CT

L1 L2 L3 L2

Phase-angle 90° 90° 90° 330°

L2-N L3 240°
L3-L1 L3 330°

L3-N L1 240°
L1-L2 L1 330°

L1-N L3 120°
L2-L3 L3 210°

L2-N L1 120°
L3-L1 L1 210°

L3-N L2 120°
L1-L2 L2 210°

11.2 Connections for mixed measurement

Transformer vector group CT

Dy5

L1

Dy5

L2

Dy5

L3

Yz5

L1

Yz5

L2

Yz5

L3

Dx6

L1

Dx6

L2

Dx6

L3

Yy6

L1

Yy6

L2

Yy6

L3

Dy11

L1

Dy11

L2

Dy11

L3

Yz11

L1

Yz11

L2

Yz11

L3

Voltage L2-N N-L3 N-L1 L2-N N-L3 N-L1 L3-L2 L2-L1 L1-L3 L3-L2 L2-L1 L1-L3 N-L2 L3-N L1-N N-L2 L3-N L1-N

Beluk GmbH Taubenstrasse 1 86956 Schongau Germany

Tel.: Fax: E-Mail: Web:

+49/(0)8861/2332-0 +49/(0)8861/2332-22
blr@beluk.de http://www.beluk.de

Reference Manual BLR-CX-R / BLR-CX-T Notes

Rev. 07 2018-07

40

References

• Beluk GmbH
• Beluk GmbH

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