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Power factor correction system

power QUALITY

Installation, maintenance and commissioning manual.

Sales 1300 NHP NHP nhp.com.auNHP Electrical Engineering Products Pty Ltd

Commissioning record .................................................................... 3

Commissioning manual .................................................................. 8Preliminary Check................................................................................................................................................................................................ 9

Quick Start ................................................................................................................................................................................................................ 10

i) PFC System with CX controller ............................................................................................................................................ 10

ii) PFC System with CM controller .......................................................................................................................................... 11

1. Introduction ................................................................................................................................................................................................ 12

2. Installation .................................................................................................................................................................................................... 13

3. Current Transformer .............................................................................................................................................................................. 15

4. Beluk Controller ........................................................................................................................................................................................ 17

4.1 BLR-CX Series Regulator .......................................................................................................................................................... 17

4.2 BLR-CM Series Regulator ......................................................................................................................................................... 33

5. Power Factor Correction System Fault Finding .................................................................................................................... 53

Maintenance record ........................................................................ 56Maintenance of NHP PFC Systems ........................................................................................................................................................... 56

PFC-P Current Envelope, Voltage Reference at Bus Connection ........................................................................................... 62

Maintenance Parts List ..................................................................................................................................................................................... 66

Recommended Torque Settings for specific system components...................................................................................... 65

Appendix .......................................................................................... 71A. Cable Requirements ..................................................................................................................................................................................... 71

B. BLR-CX Setup Menu...................................................................................................................................................................................... 72

C. BLR-CX Expanded Setup Menu ............................................................................................................................................................. 73

Any installation or commissioning difficulties or comments can be forwarded to the NHP Power Quality Department.

Due to continuous product technical development and improvement the information contained in this document is subject to change without notice.

2

3

c o m m I s s I o n I n g r e c o r d

End user details:Customer :

Site address :

Switchboard designation :

Installation:Company: Employee:

Date:

Unit details:Part no. : Shop order no.:

kVAr installed: Date of manufacture:

kVAr max. : Controller model:

Amps max.: CT ratio:

System voltage: Controller serial no:

Upstream circuit breaker (make/model/reference):

Commissioning details: Target Power Factor: Switching time delay:

CT current present at controller: Confirmed phase rotation:

Switch all steps individually and record phase currents in maintenance log:

Turn off unused steps:

Commissioned byEmployee: Company:

Signature: Date:

End user name: End user signoff:

Recommendations / comments:

4

BLR-CX Controller settingsRefer to Section 4.1.1 for further information to the settings shown below.

MENU FACTORY SETTING

NHP SETTING

CUSTOMER SETTING

MENU FACTORY SETTING

NHP SETTING

CUSTOMER SETTING

100 400

Un 400 V 415V 401 75 s -

Ct 1 Set on site 402 5 var (1-max.) -

Pt 1 1 403 AUTO (1-max.) AUTO1

Ai NO NO 404 0 (1-max.) -

PFC ON ON 500

CP1 1 0.96 501 NO NO

St 10 s 40 s 502 NO YES

200 503 20 % 7 %

201 400 V 415V 504 NO YES2

202 1 Set on Site 505 60 s 60 s

203 1 1 506 NO NO

204 10% 10% 507 NO YES

205 NO YES 508 262 k 2 k

206 90º 90º 509 65.5 k h 65.5 k h

207 NO NO 510 NO NO

208 YES NO 511 NO NO

209 AUTO AUTO 512 NO NO

300 513 30 °C 30 °C

301 60% 60% 514 55 °C 55 °C

302 1 0.96% 515 NO NO

303 0,95 i 0.9% 516 NO YES

304 NO NO 517 NO YES

305 10 s 40 s 518 NO NO

306 2 s 10 s 600

307 YES YES 601 NO NO

308 NO YES 602 NO NO

309 YES YES 603 NO NO

310 ON ON 604 NO NO

311 1 1 605 NO NO

312 0 0 606 NO NO

313 1 1 607 1.xx 1.xx

314 NO YES1. For unused stops set to Foff.2. Steps switched off if THVD exceeds threshold for specified time.


5P O W E R F A C T O R C O R R E C T I O N S Y S T E M

BLR-CM SettingsAdjust controller settings to NHP settings. For NHP settings not specified, leave as factory setting.

MENU

FACTORY SETTING

NHP SETTING

MENU

FACTORY SETTING

NHP SETTING

Language English - Step Fault M, D -CT Ratio 1 Set on Site Step Warning M, D -VT Ratio 1 - Limit Step Warning 50% -Nominal Voltage 400V 415V Limit Switch Cycles 100000 -Connection L-N L-L Alarm power factor Disabled M, DSynchronisation frequency Auto - Limit cos phi min 0.90 c -Phase compensation 90° - Limit cos phi max 0.90 i -V-tolerance min 10% - Time delay 300s -V-tolerance max 10% - Alarm harmonics U M, D -Countdown Start AI Yes - Limit harmonics U 20% 5%Temperature Offset 0°C - Alarm Harmonics I Disabled M, DCT Type 1A No - Limit Harmonics I 50% 20%Discharge Time 75s - Alarm overload P No -Step Type Normal1 - Limit overload P 1.00kW -Control On - Alarm overload Q Disabled -Cos Phi 1 1.00 0.96 i Limit Overload Q 1.00kVAr -Cos Phi 2 0.95 i 0.90 i Alarm P Export Disabled -Switch Interval 10s 40s Alarm temperature 1 DO DisabledSwitch Interval Step Exchange 2s 10s Limit Temperature 1 25°C 55°CAsymmetry Factor 1 - Hysteresis temperature 1 1.0°C -Step Recognition On - Alarm temperature 2 M, D, O NoSwitch Cycle Balancing No - Limit temperature 2 70°C -Switch Cycle Balancing % 10% - Hysteresis temperature 2 1.0°C -Step Exchange Yes - DI Input Alarm Disabled -Control Sensitivity 60% - DI Trigger High -Control Algorithm Auto - Frequency Alarm Disabled -Q Offset 0 kVAr - Limit Low Frequency 45.0 Hz -I < limit freeze steps No - Limit High Frequency 65.0Hz -Q cap. Steps turn off No Yes Modbus Baudrate 9600 -Fast measure delay 50 periods - Modbus Parity 8E1 -Fast max step value 0 kVAr - Modbus address 1 -Fast measure mean 0 periods - Storage Interval 0 min -Control Alarm M, D - Synchronisation DI Input Off -No Current Alarm M - Setup DI input High -1. For unused stops set to Foff.


c o m m I s s I o n I n g m A n U A L

8

Preliminary check ................................................................................................................................................ 9Quick start ........................................................................................................................................................... 10 i) PFC system with CX controller ........................................................................................................................................... 10 ii) PFC system with CM controller .......................................................................................................................................... 111. Introduction .................................................................................................................................................. 122. Installation .................................................................................................................................................... 13 2.1 Location ............................................................................................................................................................................................ 13 2.2 Preparation...................................................................................................................................................................................... 13 2.3 Current transformer ................................................................................................................................................................... 13 2.4 Cable ................................................................................................................................................................................................... 14 2.5 Power connection ...................................................................................................................................................................... 14 2.6 Control wiring ............................................................................................................................................................................... 14 2.7 Ventilation ....................................................................................................................................................................................... 143. Current transformer..................................................................................................................................... 15 3.1 Specification .................................................................................................................................................................................. 15 3.2 Installation ....................................................................................................................................................................................... 15 3.3 Connection ..................................................................................................................................................................................... 15 3.4 CT Wago connection diagram............................................................................................................................................ 164. Beluk controller ............................................................................................................................................ 17 4.1 BLR-CX series regulator ........................................................................................................................................................... 19 4.1.1 Familiarization with the BLR-CX controller .......................................................................................................... 20 4.1.2 Setting up the BLR-CX controller............................................................................................................................... 21 4.1.3 Menu Structures ................................................................................................................................................................... 24 4.1.4 Setting phase compensation for different connections ............................................................................. 29 4.1.5 BLR-CX schematic ............................................................................................................................................................... 30 4.1.6 BLR-CX regulator alarm codes ..................................................................................................................................... 31 4.2 BLR-CM series regulator .......................................................................................................................................................... 33 4.2.1 Getting familiar with the BLR CM Controller ...................................................................................................... 35 4.2.2 Setting up the Beluk regulator to measure voltage and current .......................................................... 37 4.2.3 Setting up the Beluk regulator’s capacitor steps ............................................................................................. 41 4.2.4 Setting up target power factor ................................................................................................................................... 43 4.2.5 Setting up switch interval time between steps ............................................................................................... 43 4.2.6 Commencement of power factor regulation .................................................................................................... 44 4.2.7 Connection issues ............................................................................................................................................................... 44 4.2.8 Setting up the Beluk regulator to compensate for different connections ...................................... 45 4.2.9 Alarm settings ........................................................................................................................................................................ 46 4.2.10 BLR-CM schematic .............................................................................................................................................................. 52

5. Power factor correction system fault finding ......................................................................................... 53Appendix ............................................................................................................................................................. 71

Appendix A - Cable requirements ......................................................................................................................................................... 71 Appendix B - BLR-CX setup menus ...................................................................................................................................................... 72 Appendix C - BLR-CX expanded setup menu ................................................................................................................................ 73



Preliminary checkBefore energising the PFC system.

1. Ensure that all connections are tight.

2. Ensure that all fuses have been installed and that the fuse handle is fully closed on to the fuse base.

3. Ensure that all contactors have free movement of contacts.

4. Ensure the discharge resistors have not been damaged in transport.

5. Ensure correct phase connection/rotation at input to PFC system. Rotation must be clockwise (Red-White-Blue).

6. Ensure CT is correctly connected on the red phase.

7. Ensure the current reference of the regulator is connected to L1 (refer section 3.0)

8. System voltage of 400V ± 10%. Operation exceeding this system voltage may damage equipment.

9. At this stage, if all is in order according to points above, the Current Transformer shorting links can be removed and the Power Factor correction system can be switched on. Allow the Power Factor regulator time to go through its start up procedure. (Up to 90 seconds depending on the type of regulator.)

10. The Current Transformer and Potential Transformer (if used) ratios must be programmed. All Beluk regulators will accept connections from current transformers with a secondary current of either 1A or 5A.

11. For the BLR CM-RMB regulator, ensure appropriate alarm functions have been selected and the alarm limits entered. This will be dependant on what the customer has specified. Refer to section 4.2.

Program the Power Factor regulator. Refer to section 4 for CX regulator and the advanced CM regulator. Use this manual in conjunction with the manufacturer’s manual for more advanced settings.

WARNING! - To protect your new investment the PFC system will automatically turn off in the event that the ambient temperature inside the system is too high. For systems relying on the demand capacity provided by the PFC system, please make use of the provided remote fault indication terminals within the PFC system to initiate load shedding until the environment affecting the PFC system returns to acceptable levels.


10

Quick start

i) PFC System with CX controller

The CX controller has a specific menu (100) designed to incorporate all parameters required for a quick start process.

This menu can be navigated to by using the ↓ function key from the top level menu structure. Once the setup light is illuminated on the right hand side of the screen, press the ↵ function key to enter the setup menu. The number 100 should be displayed on the screen, press the ↵ function key again to enter the quick start menu.

Settings to be entered:

1. Un – nominal Voltage Set the nominal voltage value.

2. ct – current Transformer ratio Enter the current transformer ratio. Eg. 500 turns primary to 50 turns secondary = 10

3. Pt – Voltage Transformer ratio Enter the voltage transformer ratio. If a voltage transformer is not used leave as 1.

4. Ai – Auto Initialize Set the automatic initialization to yes. This process will switch all outputs and gain information to correctly account for voltage and current measurement connections.

5. PFc – Power Factor correction The power factor correction should be set to Yes to enable the controller to compensate for any reactive loads.

6. cP1 – cos Phi 1 Set the target power factor.

7. st – switch Interval Set the switching time interval (Time delay between switching steps).

8. oUt – step output Type Set the step outputs to auto.



ii) PFC system with CM controller

With reference to the pathways outlined on this page

Settings to be entered:

1. Enter CT ratio. An example is: A 500/5A CT is used then we input “100” for the CT Factor

2. Enter VT ratio. If there are no Voltage Transformers then this setting should be left on one

3. Set Nominal Voltage value.

4. Select how the measuring lines are connected (typically L-L).

5. Set up Capacitor Steps:

• Dischargetimeshouldbesetshouldbesetto 70 seconds or more

• Allstepsthatarenotswitchingcapacitorstepsshouldbeswitched to the “Off” position

6. Enter COS PHI 1 (Target Power Factor)

7. Adjust SWITCH INTERVAL TIME as required, typically 40 seconds.

8. Once the regulator has checked the voltage and current then a “Happy” face will appear and the regulator will switch steps in and out according to the variation of the load.

9. Ensure power factor is on inductive side – i.e. “i” is displayed on screen.

Note: For specific instructions see section 4.2 BLR-CM Series Regulator

MAIN MENU

MEAS. VALUES

HARMONICS

STEPINFO

SETUP

SETUP MENU

MEASUREMENT

STEP

CONTROL

DISPLAY

ALARMMANUAL

MODBUS

RESET

CONFIGURATION

MEASUREMENT MENU

CT FACTOR

VT FACTOR

NOMINAL VOLT.MEASUREMENT

CONNECTIONMEASUREMENT

EXTENDED

STEP MENU

DISCHARGE TIME

STEP TYPE

RESET

Q (VALUES)

CONTROL MENU

COS PHI I

COS PHI 2

SWITCH INTERVAL

SWITCH INTERVAL STEP EXCHANGE

EXTENDED

ALARM MENU

CONTROL ALARMNO CURRENT

STE FAULT

STEP WARNING

POWER FACTOR

HARMONICS U

HARMONICS I

OVERLOAD P

OVERLOAD Q

P-EXPORT

TEMP1

TEMP2

DI INPUT

PASS

WO

RD 2

402


12

1. IntroductionBefore Installation read this manual carefully and keep it as a reference for future maintenance and operation requirements.

This manual details the correct installation and commissioning procedures for a NHP Power Factor correction system.

Power Factor is a measure of how efficient the electrical power is being used. A higher power factor value generally indicates a more efficient electrical distribution system.

Electrical power (Apparent power) consists of Active power (the part that actually does the work) and Reactive power (the part that develops and maintains magnetic fields required by windings in inductive loads).

The Power Factor of a load is defined as the ratio of active power to apparent power, i.e. kW / kVA. The closer the Power Factor is to unity, the less reactive power is drawn from the supply.

Improved power factor results in greater electrical efficiency, which in turn means less electrical generating capacity and smaller transformers, bus bars, cables and other distribution system devices that are required to be installed. Therefore, the cost of electricity is reduced and the savings are passed onto the consumers.

A microprocessor based regulator, switching a group of capacitors to achieve a pre set Power Factor value controls the Power Factor correction (PFC) system.

The Power Factor regulator requires a current signal, which reflects the load. This can be achieved by using a current transformer appropriately sized in comparison to the load that will be compensated.

The current transformer measures the power consumption. The power factor regulator switches on or off the capacitor steps depending on the system reactive power requirements at any one time until the desired Power Factor is achieved.

The NHP Power Factor correction systems are delivered fully assembled and are factory tested in accordance with NHP quality procedures.

Any installation or commissioning difficulties or comments can be forwarded to the NHP Power Quality Department.

Due to continuous product technical development and improvement the information contained in this document is subject to change without notice.



2. InstallationInstallation is to be undertaken only by authorised and qualified personnel and is to comply with IEC831-1&2, AS3000 and local supply Authority Rules and Installation instructions.

It is recommended that the PFC system be installed as per the diagram shown below, to ensure correct operation and maximum benefit. Additional recommendations for correct installation are also described.

WARNING! – To protect your new investment the PFC system will automatically turn off in the event that the ambient temperature inside the system is too high. For systems relying on the demand capacity provided by the PFC system, please make use of the provided remote fault indication terminals within the PFC system to initiate load shedding until the environment affecting the PFC system returns to acceptable levels.

2.1 Location

The PFC system should be installed indoors (unless specifically designed otherwise) and must be situated in well-ventilated areas where the ambient temperature does not exceed a maximum of 40° Celsius. It is recommended that the PFC system is installed as close as possible to the main switchboard electrically, but with mechanical separation.

2.2 Preparation

Check that the rated voltage of the PFC system is the same as that of the switchboard to which it is to be

connected. All components and connections should be checked for tightness after transport and prior to installation.

2.3 Current transformer

The current transformers (CT) are an important part of the installation process. The selection of the CT will depend upon site considerations including bus bar / cable size, mains load and switchboard layout.

For information regarding installation and connection of the current transformer refer to Section 3.


14

2.4 Cable

The selection of cables for a PFC system shall be in accordance with AS3000, AS3008 and local supply authority regulations. Consideration should be given to possible future expansion of the PFC system in terms of maximum current carrying capacity. Also refer to Appendix C.

Guidelines to determine the appropriate cable size.

• MaximumcurrentratingofPFCsystem.

• Faultratingofsystem.

• PhysicallocationofPFCsysteminrelationtomainswitchboard.

Cables should be over rated 1.35 times the nominal capacitor current of the total PFC system as per AS/NZS 3000:2007 Section 4.15.2.3 Current-carrying capacity of supply conductors. Therefore the cable current carrying capacity can be calculated by current per capacitor step X number of steps X 1.35.

Example:

300 kVAr PFC system. Number of steps = 6 x 50 kVAr. Current per 50 kVAr step = 75 A.

Cable current carrying capacity =

6 x 75 x 1.35 = 608 Amps.

2.5 Power connection

Using the calculated cable size, connect supply to terminals (L1, L2 and L3) in the PFC system. Ensure correct phase rotation of cables from the main switchboard to the incoming connections of PFC system.

The main earth should be rated at 30 % of phase current with the maximum earthing conductor size being 120 mm. Refer to AS3000 (Table 5.1) for minimum copper earthing conductor sizes.

Neutral connection is required for auxiliary supply to both BLR-CX and BLR-CM RMB regulators.

2.6 Control wiring

We recommend that control wiring from the current transformer for cable runs up to 10 meters be 2.5mm² cross section, flexible cable as a minimum. Increase cable diameter for longer runs.

2.7 Ventilation

Extra care is required when installing PFC systems, to ensure that the capacitors are not damaged by excessive temperature rise within the enclosures. Unlike other electrical equipment, it is not possible to de rate the capacitors when high internal temperatures are encountered. Correct installation requires that air temperature surrounding the capacitor does not exceed the specified limits.

Ambient air temperatures are assumed not to exceed +40ºC, with an average over a 24-hour period not to exceed +35ºC (in accordance with AS 4388 and IEC 890).

Life of the capacitors will be greatly reduced if its operating temperature exceeds 55ºC. Given the above, ambient temperatures inside the capacitor enclosure should not be greater than 10-15ºC above that of the external ambient air temperature

When modules with reactors are used, fan assisted cooling is required to limit the rise in air temperature around capacitors to less than 50ºC. Without fan assistance the temperature will quickly reach levels that will damage the capacitors.

A normally open thermostat (blue) set to 35º C should also be located at the top of the cubicle. If the temperature is exceeded the control circuit should be arranged to switch induced ventilation to minimise cubicle temperature.

A normally closed thermostat (red) set to 50ºC should be located to sense the temperature at the top of the cubicle. If this temperature is exceeded the control circuit should be arranged to raise an alarm and shut down the PFC system.

In addition to the above guidelines important installation requirements are specified in AS3000 (clause 2.4.3).



3. Current transformerA current signal, which reflects the load, is required by the controller in order to determine power factor correction requirements. The Regulator takes a voltage reference from the white and blue phases, assuming rotation to be red–white–blue. Therefore the current transformer must be installed on the red phase.

However, it may not always be possible to install the current transformer in the red phase. In these situations the voltage references must be altered to ensure a current reference from one phase and a voltage reference from the other remaining phases in the correct rotation sequence. For example if the CT is mounted on the blue phase, then voltage reference L2 on the regulator shall be red phase and L3 shall be white phase to ensure correct phase rotation (blue-red-white).

3.1 Specification

The Current transformer (CT) should be Class 1 minimum with a 15 VA burden and 1A or 5A secondary current rating. This specification accounts for the Beluk power factor correction regulator and up to 30 metres of 2.5mm² cable. CT with smaller burdens can be used but length and size of the cable must be taken into account.

3.2 Installation

The CT must be installed in a position to measure the total load current including the PFC system, a shown in figure 1 in Section 2. For centralised compensation this will normally be close to the incoming supply metering position. Ensure the current transformer is earthed, preferably at the CT secondary, at one point only.

3.3 Connection

CT’s are normally marked P1/P2 and S1/S2 and should be positioned so that P1 faces the incoming supply while P2 faces the load side.

Control wires from S1 should be connected to the terminal marked 18 and from S2 to terminal marked 19 in the Power Factor correction system. When the connection has been made the shorting links in the Wago terminal (orange jumper) must be removed.

When a multi ratio split core CT is used connect S1 to terminal 18 and the selected appropriate ratio (S2, S3 or S4) to terminal 19. The CT should be selected as near as possible to suit the load current.

When a summation CT is used the terminal markings will usually be P1, P2, P3, P4 and S1, S2. Connect S1 and S2 of first CT to P1 and P2 of the summation CT, then S1 and S2 of the second CT to P3 and P4 on the summation CT. It is important that all CT’s monitor current in the same direction.

In some cases existing customer metering CT’s (e.g. from energy meters, ammeters) can be used. Connect the Power Factor controller in series with these instruments after verifying the burden of the CT and meters.

WARNING!

Dangerous voltages can be present on CT terminals. Always disconnect load or short circuit CT terminals before changing CT polarity if required.

Do NOT open CT disconnect terminal levers without inserting the orange CT shorting jumper. Failure to do so could result in permanent damage to the CT, usually associated with an audible continuous humming.


16

3.4 CT Wago connection diagram

282CT2

CT test / disconnect terminal

Figure 2. CT terminal connection

1

k l

2 1

k l

2

Test plugs

Switches

Jumper

Normal Operation Transformer Short Circuit



4. Beluk controller

4.1 BLR-CX Series Regulator

General Overview

The Beluk CX series regulator incorporates an LCD panel for graphical display and four function keys to navigate the menu structure and adjust settings. Upon providing power to the regulator a 90 sec countdown begins. During the countdown the esc key can be pressed to abort the automatic setup and begin manual setup of the controller. To engage the automatic setup the user can either wait for the countdown to expire or simply press the ↵ key.

The following sections provide an overview of the controller and describe required settings for basic operation. For further customization the user can consult the Beluk reference guide.


18

Display Parameters Explained

NT There are two target power factors capable of being set on the CX controller. When the secondary target power factor is active the NT light is illuminated on the display.

EXPORT In conditions where the PFC unit is running in conjunction with a generator, the export light will be illuminated if active power is being exported to the grid (i.e. leading PF). If there is no generator in the circuit and the light is illuminated it is likely there is a connection problem.

INFO The info menu provides information regarding each step of the PFC unit. This includes the size of the step in kVAr (only if the CT ratio is set), the size of the step as a percentage of the initial size, the number of switch cycles and the operation of the step (automatic, permanently on or off, etc).

AUTO The two modes of operation for the controller are automatic or manual. In automatic mode the controller decides which steps are necessary to achieve the target power factor dependent upon the chosen switching algorithm. The Auto light is illuminated when the controller is in this mode.

Display and Navigation

The display and controls of the BLR-CX regulator are shown and explained below.



4.1 BLR-CX Series Regulator cont'd

MANUAL The manual mode of operation is used when the user wants direct control of which steps should be on, off, etc. The manual light is illuminated when the controller is in this mode.

SETUP The setup menu has all settings that are required to configure the controller. There is an advanced menu which can only be accessed by holding the select/continue button until the 100 menu appears. In some instances a pin code may be required to access these menus. The PIN code is 242. Once entered the user can navigate to all of the other menus (200, 300, 400, 500, 600).

ALARM The Alarm light flashes when an alarm has been activated. The details of the alarm will be displayed flashing beneath the reading of the power factor. To reset an alarm the user must hold the esc key for 3-5 seconds. If the reason for the alarm has not been rectified, the alarm will continue.

SYMBOLS FOR NAVIGATION AND FUNCTIONS

FUNCTION

Move up menu structure / increase selected value

Move down menu structure / decrease selected value

Select/Continue

ESC Step backwards


20

4.1.1 Familiarization with the BLR-CX Controller

The top level menu structure is shown below and further elaborated on in the following pages. The and function keys can be used to scroll between these menu items and the current menu item is displayed along the right hand side of the screen. To select a menu item the function key must be pressed. To step backward in the menu structure or get back to the home screen the esc key should be pressed.

TOP LEvEL STRUCTURE

1.00i

1.00i

1.00i

1.00i

INFO

MANUAL

SETUP



4.1.2 Setting up the BLR-CX Controller

There are certain settings that need to be configured for basic operation of the CX controller. Upon first powering up the controller a 90 second countdown will begin. Once the countdown has completed or the user has pressed the function key the automatic initialization process will begin. The following settings will need to be configured by the user.

Step 1 - Navigate to the setup menu

The settings below are located in the quick setup menu of the controller. From the home screen navigate down using the function key until the setup light is illuminated on the right hand side.

Press the function key to enter the setup menu. A 100 should appear on the screen.

Step 2 – Set the Nominal Voltage

Press the function key again to enter the quick setup. The nominal voltage is indicated by Un on the display as shown below.

This is the L-L voltage and can be adjusted by pressing the function key. The value must be changed digit by digit starting from the left. A digit can be increased by pressing the function key or decreased by pressing the function key. When the correct digit has been selected, you can continue and repeat the process by pressing the function key. Once the Nominal voltage has been set press the function key to move to the next parameter.

SETUP

100

Un415 v SETUP


22

4.1.2 Setting up the BLR-CX Controller

Step 3 – Set the Current Transformer Ratio

The current transformer ratio is indicated by Ct on the display. To adjust the CT ratio press the function key. The CT ratio is given by the primary to secondary ratio (eg.250:5 = 250/5 = 50 ratio). The value must be changed digit by digit starting from the left. A digit can be increased by pressing the function key or decreased by pressing the function key. When the correct digit has been selected, you can continue and repeat the process by pressing the function key. Press the function key twice and proceed to the next step.

Step 4 – Run the Automatic Initialization (if necessary)

The automatic initialization option is indicated by Ai on the display. If the automatic initialization process needs to be repeated press the function key, then press the function key to select yes and hit the function key to start the initialization process again.

Note the process required for automatic initialization will take a minute or two of the controller switching in each of the steps. Else if Automatic Installation is not required, press the function key twice and proceed to the next step.

Step 5 – Set the Target Power Factor

The target power factor is indicated as CP1 on the display. The default target power factor should be 0.96. To adjust the target power factor press the function key. The value can be increased by pressing the

function key or decreased by pressing the function key. The i or c next to CP1 indicates whether the target i s inductive or capacitive.

Step 6 – Set the Step Interval Switching Time

The step interval switching time is indicated by St on the display. This is the interval of time that must pass in between switching different steps. To adjust the switching time press the function key. The value must be changed digit by digit starting from the left. A digit can be increased by pressing the function key or decreased by pressing the function key. When the correct digit has been selected, you can continue and repeat the process by pressing the function key. Once complete press the function key and proceed to the next step.

AiNO

SETUP

CP1i0.96 SETUP

St40 s

SETUP

Ct1

SETUP



Step 7 – Set Step Output type

The step outputs are indicated by OUt on the display. The step output type determines how each step is controlled. Exits that have no step connected should be set to permanently off (Foff). All other steps should be left as auto for automatic control unless otherwise desired. To adjust the output type,s press the function key. The different steps can be accessed using the or function keys. To select a step press the function key then use the or function keys to choose an option. Press the function key when the desired option is highlighted, press the esc key to return to the menu.

The options are:

• Auto–Stepiscontrolledaccordingtoswitchingalgorithmofregulator. • Fon–Stepispermanentlyswitchedon. • Foff–Stepispermanentlyswitchedoff. • Al–Iftemperaturelimit1isexceededthestepisswitchedasfanoutput.

Once the desired option has been highlighted press the function key to accept the change. When all steps are configured press the ESC button until back at the home screen.

Step 8 – Set discharge time for Steps

Navigate to the setup menu from the main screen using the and function keys. Once the setup menu light is showing on the right hand side, hold the function key (this accesses the advanced menus) until 100 appears on the screen as seen below

To navigate to the capacitor step setup menu press the function key until the 400 menu is displayed as seen below. If a PIN code is required enter ‘242’.

Press the function key to select the menu and the capacitor discharge time will be displayed as seen below.

Press the function key again on 401 to adjust the discharge time for the capacitors. This should be set to at least 75seconds. The value must be changed digit by digit starting from the left. A digit can be increased by pressing the function key or decreased by pressing the function key. When the correct digit has been selected, you can continue and repeat the process by pressing the function key.

For other specific settings that can be configured refer to the Advanced Settings section which contains the full menu structure.

OUt SETUP

100 SETUP

400 SETUP

40175 s

SETUP


24

Info menu

The info menu is not used for configuration but rather to display information relevant to each step of the system. For each connected step the information menu gives the original step size in kVAr, the current step size as a percentage of the original step size, the number of switching cycles undertaken by that step and the step’s mode of operation. All steps are shown in the information menu.

- STEP INfORMATION MENU1.00i

CC50 k var

100 %

OC

Auto

CC25 k var

100 %

OC

Auto

INFO

1 2 3 4 5 6

INFO

1 2 3 4 5 6

INFO

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

4.1.3 Menu Structures



Info menu – Step 1

To navigate to the INFO menu, start at the home screen and press the function key. When the INFO light is illuminated on the right hand side of the display, press the function key. All of the available steps will be displayed along the bottom of the screen with the selected step flashing. In this case it will be the 1st step.

Step 2

The and function keys can be used to navigate through the steps. Navigate to the 3rd step and press the function key when the 3 is flashing. This will display the original step size of the 3rd step as seen similar to below.

Step 3

To navigate through the step information use the and function keys. The second screen displays a value indicating the current size of the step as a percentage of the original size. The third screen displays OC and a value that corresponds to the number of switch cycles completed by the selected step. The last screen displays the mode of operation of the step.

Step 4

To step backwards press the esc key and the other steps can then be navigated to using the and function keys. Press the esc key again to return to the home screen.

INFO

1 2 3 4 5 6

CC50 k var

INFO

1 2 3 4 5 6

100 %INFO

1 2 3 4 5 6

OC2

INFO

1 2 3 4 5 6

AutoINFO

1 2 3 4 5 6

Percentage of original step size remaining

Number of Switch Cycles Completed Mode of Operation


26

Manual menu

The manual menu can be used to manually turn off and on any of the available steps.

1.00i MANUAL - MANUAL OPERATION MENU

1.00i MANUAL1.00i

1MANUAL

1.00i2

MANUAL

1.00i3

MANUAL

1.00i4

MANUAL

1.00i5

MANUAL

1.00i6

MANUAL


4.1.3 Menu Structures cont'd


Manual menu – Step 1

From the home screen scroll down to the manual menu using the function key. Once the manual light is illuminated on the right hand side of the screen (as pictured right) press and hold the

function key to enter the manual menu.

Step 2

The first step is displayed in the centre of the screen indicating the current step (as pictured right). Use the and function keys to navigate to the step you would like to turn on or off. The step can be turned on or off (dependent on its current state) by pressing the function key.

Step 3

To turn on the first step (assuming it is off) press the function key. The first step will now be highlighted at the bottom of the screen as shown right.

Step 4

To turn off the step press the function key again and the first step will no longer be highlighted at the bottom of the screen. Note that the step cannot be switched back on until the specified discharge time has elapsed.

Step 5

To move back to the home screen press the esc function key twice.

1.00i MANUAL

1.00i1

MANUAL

1.00i1

MANUAL1

1.00i1

MANUAL


28

Measurement Menu – Navigation

This menu of the controller is for displaying key measurements and is not configurable. The measurement menu is accessed from the home screen. The home screen is identified by when the right hand menu column is blank as indicated in the diagram below. All of the available measurement displays are shown. Those highlighted in grey are not shown in the menu unless the CT ratio has been configured in the setup menu.

Step 1

To navigate to the Measurement menu, start at the home screen or press the ESC key until the right hand column of menus is blank as indicated above. Once at this screen press the function key.

Step 2

Navigate through the available options using the and function keys. To Step back to the home screen press the esc key.

MEASUREMENT MENU1.00i

Voltage L-L

Voltage L-N

Current in measured phase

Active 3 phase power

1.00i

Reactive 3 phase power

Control deviation in kvar

Apparent 3 phase power

Total harmonic Distortion

Odd single harmonics

3 digit PF

Power factor ratio P/S

Average PF

Frequency

Temperature

Highest measured Temperature

Counter operation Hours


4.1.3 Menu Structures cont'd


4.1.4 Setting phase compensation for different connections

In a situation where the connection of the CT or phases can’t be altered to suit the default connection described in the manual, the regulator can be set to compensate for any connection sequence. The following table describes the required compensation angle for any given connection

The compensation angle can be set in the measurement 200 menu.

Step 1

The user must navigate to the setup menu from the main screen using the and function keys.

Once the setup menu light is showing on the right hand side, the user must hold the function key until 100 appears on the screen.

To navigate to the measurement setup menu press the function key and select the 200 menu using the function key. If a PIN code is required enter ‘242’.

Step 2

The user can scroll down to menu item 206 using the function key and then select using the function key.

The compensation angle can then be adjusted using either the or function keys to decrease or increase the compensation angle in 15⁰ increments according to the connection as shown above. Once the correct angle has been specified, it can be saved using the function key.

To navigate back to the home scren, press the esc key.

2060 s SETUP

1.00iSETUP

100SETUP

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

CT L1 L2 L3 L2 L3 L1 L3 L1 L2

Phase-angle 0⁰ 0⁰ 0⁰ 240⁰ 240⁰ 240⁰ 120⁰ 120⁰ 120⁰

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

CT L1 L2 L3 L2 L3 L1 L3 L1 L2

Phase-angle 90⁰ 90⁰ 90⁰ 330⁰ 330⁰ 330⁰ 210⁰ 210⁰ 210⁰


30

4.1.5 BLR-CX-Schematic



FAULT DISPLAY CAUSE REMEDIAL ACTIONS

Over or Under VoltageCheck nominal voltage and set tolerances and adjust if necessary

Measured current may be too small.

Check CT connection. Ensure shorting link has been removed from the CT

Measured Current is higher than tolerance.

Check secondary output of CT. Change CT if necessary.

Permanent Over Compensation

Permanent Under Compensation

Check if a step may be set as Fon (permanently on) or if a contact may have welded

Check Capacitors and fuses and see if all steps are coming in. Step switching tolerance may need to be adjusted.

THVD Outside of Defined Limits

Check Limits. If THVD is > 7 % specific harmonic mitigation is necessary.

Three unsuccessful switches (not affecting PF)

Check output of controller step, fuses and contactor.

A faulty step has been detected

A step has fallen below 70 % of its initial power (kVAr value)

Temperature 2 limit exceeded

Check ventilation and thermostats.

Operating Hours Limit Exceeded

Schedule maintenance and reset operation hours.

Operation Cycle Limit Exceeded

Schedule maintenance and reset operation cycles

Problem determining step sizes

Check connections to controller for correct phases

Export light is displayed

If a generator is not in circuit, voltage and current measurement may be on the wrong phases

Check which phase CT is connected to. If necessary apply phase compensation as per steps listed previously.

Incorrect display of current or voltage Incorrect Transformer Ratio

Check the CT ratio or VT ratio as set in the 100 menu

4.1.6 BLR-CX Regulator Alarm Codes


32


No display Auxiliary voltage missingCheck correct connection of auxiliary voltage, if necessary rectify

Display “U<>LIMIT”

Measurement voltage out of range Wrong settings for voltage measurement

Check correct connection of measurement voltage, if necessary rectifyCheck settings in menu “SETUP / MEASUREMENT”, if necessary rectify

Display “I<LIMIT” Measurement current too small

Check connection of CT, a probable break in the lineCT ratio too high, if necessary replace CTRemove short circuit link of the CT

Wrong display of current or voltage Wrong transformer ratio

Check settings PT- or CT-ratio in menu “SETUP / MEASUREMENT”, if necessary

Wrong power factor is displayed

Wrong settings at the regulator

Check settings “NOMINAL VOLTAGE” and “CONNECTION” in menu “EXTENDED”, if necessary rectify

Power factor doesn’t change after switching on a step, step is switched off again

CT mounted in wrong position

Check mounting position referring to circuit diagram (current of load and capacitors have to be measured), if necessary rectify

Alarm “overcurrent” Current higher than allowedCheck CT ratio, probably replace by suitable transformer type

Alarm “Control”

Permanent overcompensation Permanent Under compensation

Check settingsCheck contactors, probably contactors stick togetherCheck settingsCheck capacitors, probably fuse defectiveCheck dimensioning of the compensation unit

Reversed Control Mode Current or voltage clamps interchanged

Correct connection or adapt phase compensation

Single steps are not switched on or off Wrong settings

Check, if referring steps are defined as fix steps (permanently on or off)

Steps are detected as defective Step defective

Check capacitor steps, probably fuse, capacitor or contactor defective

Steps are not switched on Step size too largeNecessary reactive power smaller than switching threshold of step size of the smallest step

Regulator still doesn’t work properly Contact NHP Power Quality Department

4.1.6 BLR-CX Regulator Alarm Codes cont'd



4.2 BLR-CM Series RegulatorThe Beluk Regulator requires correct phase rotation. Typically The CT should be mounted on the red phase and the secondary’s connected to the terminals inside the PFC system.

Typically S1 of the CT will connect to terminal 18 and S2 will connect to terminal 19 in the PFC unit. The white phase and blue phase voltage references are connected internally.

Once the connections to the power factor correction unit have been confirmed and all pre commissioning checks carried out then the current transformer shorting link can be taken out and the power factor correction system switched on.

Figure 6. BLR-CM Controller

If the connection of the phases and the CT are not correct then refer to “Setting up the Beluk Regulator to compensate for different connections” Section 4.2.8.

The Beluk regulator incorporates a combination of a graphical LCD display and 4 function keys. The function keys can double for navigation of the menu and inputting the settings. Where the graphic LCD screen presents a symbol above the function key then the symbol will indicate what the function key will do. Arrows generally represent navigation and the + and – symbols represent data input.

The following describes a basic setup that will allow the regulator to operate without causing needless alarms. If the user wishes to further customise the settings then they may do so by referring to Beluk’s reference guide. The reference guide covers all of the regulators functions which include alarms for various out of limit conditions.


34

Display of current COS Φ

Display of inductive (i) or capacitive (c) load Top display area

for information and measurement values

Regulator status " " shows regulator functioning normally. " " shows regulator is missing vital data

Digital Output status.

= Active = Inactive

Alarm relay status.

= Active = Inactive

Digital input status

= Active = InactiveFunction keys

Capacitor step in use

Capacitor step available

Capacitor step “SWITCHED OFF”. No step attached to relay output

Regulator step “FIXED OFF”. Faulty step or discharge time of capacitor

Symbols for navigation and functions

The BLRCM advanced regulator is supplied pre programmed and factory tested. The display and controls are shown below.

Figure 7. BLR-CM Controller LCD ScreenTable 1. Key for BLR-CM navigation

SYMBOLS FOR NAVIGATION AND FUNCTIONS

FUNCTION

Go to submenu or scroll to enter a value

Leave submenu

Scroll up or down in menus

Cursor

Increase or decrease selected parameter

Confirmation or storage of values

Scrolls between options



The list below (figure 8 (a)) contains all the sub menu options accessible from the main screen of the controller. Figure 8(b) shows the main menu as displayed on the controller screen. To access any of the sub menu options listed in figure 8(a) we need to scroll down by pressing the function key. Required sub menus utilised in the commissioning process is shown on the following page.

If the wrong function key is pressed and the user is unable to navigate the controller appropriately, please return to the main screen by pressing the leave submenu function key until you reach the “Main Menu” screen. From the “Main Menu” the process can begin again.

MEAS. VALUES

HARMONICS

STEPINFO

> SETUP <

DEVICE INFO

(a)

(b)

Figure 8. BLR-CM Controller LCD Screen

Helpful Tips:

• Toentertherightsubmenufromthe“MainMenu”,the cursor MUST be pointing to the required option.

• Forexample,thecursorinfigure8(a)ispointingto the “SETUP” option and figure 8(b) shows the cursor pointing to “MEAS. VALUES”. To enter the “SETUP” sub menu simply press the function key corresponding to and proceed into the “SETUP” sub menu. To exit from the sub menu simply press the function key until the Main Menu is reached , which is evident when the is no longer displayed as an option.

• RefertoTable2fornavigationsymbolsandfunctions.

• Refertothepathwaysoutlinedonthefollowingpage for reference whilst navigating through the controller.

The following pages of the BLR CM section contains instructions on the key settings required to be inputted.

4.2.1 Getting familiar with the BLR CM Controller


36

Navigating through the BLR-CM RMB Controller

• Thepathwaysandhighlightedmenuoptionsindicated on this page highlight the settings related to setting up the Beluk-CM RMB controller for operation.

• Allsubmenuoptionsrequiredforinputofsettingsisaccessible via the “SETUP” sub menu. To access this sub menu we are required to enter a password. The default password is “2402”.

• Thekeysubmenuoptionswithinthe“SETUP”submenu include “MEASUREMENT”, “STEP”, “CONTROL” and “ALARM”.

• Withinthe“MEASUREMENT”submenutheinputsettings of the CT, VT, nominal voltage, and connection settings are required to configured appropriately.

• Aswiththe“STEP”submenu,theinputsettingsofthe discharge time and step type are required to configured appropriately.

• The“CONTROL”submenurequirestheCOSPHII (target PF) as well as switch interval time to be inputted as required and the alarm menu, although not always necessary, can be configured as desired.

• Theusercanmovebackandforthbetweenthesub menus highlighted on this page by using the appropriate function keys. If necessary, the use can navigate to the “MAIN MENU” screen and begin again.

MAIN MENU

MEAS. VALUES

HARMONICS

STEPINFO

SETUPDEVICE INFO

SETUP MENU

MEASUREMENT

STEP

CONTROL

DISPLAY

ALARM

MANUAL

MODBUS

RESET

CONFIGURATION

MEASUREMENT MENU

CT FACTOR

VT FACTOR

NOMINAL VOLT.MEASUREMENT

CONNECTIONMEASUREMENT

EXTENDED

STEP MENU

DISCHARGE TIME

STEP TYPE

RESET

Q (VALUES)

CONTROL MENU

COS PHI I

COS PHI 2

SWITCH INTERVAL

SWITCH INTERVAL STEP EXCHANGE

EXTENDED

ALARM MENU

CONTROL ALARMNO CURRENT

STE FAULT

STEP WARNING

POWER FACTOR

HARMONICS U

HARMONICS I

OVERLOAD P

OVERLOAD Q

P-EXPORT

TEMP1

TEMP2

DI INPUT

PASS

WO

RD 2

402



Step 1 – Navigate and proceed through the “SETUP” sub menu

• Fromthe“MainMenu”(seefigure9(a))pressthefunction key correlating to the symbol to scroll down to “SETUP” (see figure 9 (b)).

• Nowpressthefunctionkeywiththe symbol and this will bring up the password screen as shown in figure 9(c).

(a)

(b)

(c)

Figure 9. Navigating through to the “SETUP” sub menu

Step 2 – Enter Password

• Thedefaultpassword“2402” needs to be entered.

• Todothis,acursor will appear under the first digit.

• Pressthefunctionkeyswiththe and the to enter the first digit.

• Thenpressthe once to advance the cursor to the next digit.

• Use the function keys with the and the to enter the second digit.

• Repeatthisprocesstoinputthefinaltwodigits(seefigure 10 (a)).

• ThispasswordcanbechangedbyreferringtotheBeluk Reference guide.

• Oncethepasswordhasbeenenteredthenpressthe key and this will bring up the password protected menu as shown in figure 10(b).

(a)

(b)

Figure 10. (a) Password screen (b) Display screen shown when password entered correctly

4.2.2 Setting up the Beluk Regulator to measure voltage and current


38

• Notethatthecursorisnowpointingto“MEASUREMENT” as shown in figure 10(b).

• Nowpressthefunctionkeycorrespondingtothe arrow to bring up the first of the data input

screens (see figure 11 (a). This screen allows the current transformer (CT) ratio to be inputted.

• Thenpressthe arrow which brings up the input screen as shown in figure 11(b).

• AswithenteringthepasswordtheCTFACTORscreen displays a cursor under the digit and the plus and minus sign above the middle two keys.

• The arrow advances the cursor.

• TheCTratioisdividedoutandtheresultentered.

For example, if a 500/5A CT is being used then we divide 500 (Primary) with 5 (secondary) which give us a result of 100. We then input “100” for the CT Factor as shown in figure 11(c).

• Whenwegettothelastdigit,the arrow changes to a return symbol which when pressed will bring us back to the “CT FACTOR” menu with the new value showing.

(a)

(b)

(c)

(d)

Figure 11. Entering the CT Value

Step 3 – Enter CT Value

NAVIGATION: SETUP PASSWORD MEASUREMENT: cT FAcTor

4.2.2 Setting up the Beluk Regulator to measure voltage and current cont'd



• Press once to take us to the VT FACTOR (Voltage Transformer). See figure 12.

• Thesameprocessusedinstep3above(inputtingthe current transformer value) can be followed to enter the Voltage Transformer (VT) ratio.

• IftherearenoVoltageTransformersthenthissetting should be left on one. Figure 12. VT ratio display screen

• OncetheVTFACTORhasbeenenteredthenpress to bring up the nominal voltage value. The

minimum and maximum voltage limits are taken from this value.

• Toinputthenominalvoltagepress and enter the values by following the cursor and using the

, and as in previous steps. This is typically set to what the voltage of the system is. For example, 400 V AC or 415 V AC.

• AswithenteringtheCTratio,whenthelastdigitis reached the return symbol is displayed and when pressed will take us back to the nominal voltage screen as displayed in figure 13.

Figure 13. Nominal Voltage screen display

Step 4 – Enter VT Value

NAVIGATION: SETUP PASSWORD MEASUREMENT: VT FAcTor

Step 5 – Enter Nominal Voltage

NAVIGATION: SETUP PASSWORD MEASUREMENT: nomInAL VoLT


40

• Toselecthowthemeasuringlinesareconnectedpress and the Measurement option will be highlighted as shown in figure 14.

• TypicallythesearesettoU=L-Lbecausethemeasuring lines are internally connected within the PFC system and should not require modification.

• ThissettingcanbesettoeitherL-LtoL-Nbypressingthe key function as shown in figure 14. (a)

(b)

Figure 14. Setting the Line Connection. (a) L- L (b) L- N

Step 6 – Setting the Line Connection

NAVIGATION: SETUP PASSWORD MEASUREMENT: connecTIon


4.2.2 Setting up the Beluk Regulator to measure voltage and current cont'd


• Enter“STEP”submenu.

• TheStepDischargetimescreen,asshowninfigure15, is the first in this submenu.

The discharge time locks the capacitor out for the time that is inputted once it has been switched out by the regulator. This allows the capacitor time to discharge below 10% before being available to be switched back in again. The discharge time must be set for each capacitor step.

• Thedischargetimeshouldbesetto70secondsormore.

• Pressthe to access the input field.

• AspreviouslydonewhenenteringtheCTratio,follow the cursor and use the , and .

• Asbefore,whenthelastdigitisreachedthereturnsymbol is displayed and when pressed will take us back to the discharge time sub menu for the 1st step.

• Pressingthe sign increments to the next step and the process can be repeated for each step.

Figure 15. Setting the discharge time for step 01

Step 1 – Setting the discharge time for each step

NAVIGATION: SETUP PASSWORD STEP: dIscHArge TIme

4.2.3 Setting up the Beluk Regulator’s capacitor steps


42

• ScrolltoandenterSTEPTYPEsubmenu.

All steps that are not switching capacitor steps need to be switched to the “Off” position.

This will stop the Beluk controller from testing these unused steps and causing nuisance alarms.

• Toupdatethestepsrequiredtobeselectedas“OFF”, press the “ ” function key to cycle through to the first required step.

(Figure 16(a) shows step 12 has been selected and its status is “NORMAL”).

• Tochangethestatusto“OFF”press a few times to scroll through a few options starting from “NORMAL” then “FIX-OFF” followed by “FIX-ON” and then once more, leaving the display indicating “OFF”.

Figure 16(b) shows the status of step 12 as being “OFF” for example.

• Cyclethroughtothenextrequiredstepandrepeatthe process.

(a)

(b)

Figure 16. Updating the status of relevant steps

Step 2 – Updating status of steps

NAVIGATION: SETUP PASSWORD STEP: sTeP TYPe


4.2.3 Setting up the Beluk Regulator’s capacitor steps cont'd


• Enter“CONTROL”submenu.Thescreendisplayshould now resemble figure 17.

• Press to enter COS PHI 1.

• FollowthesamemethodusedwhenenteringtheCT ratio. Note, when we get to the last digit, changes to the return symbol which when pressed will bring us back to the “COS PHI 1” menu with the new value showing.

Figure 17. First “CONTROL” sub menu screen

NAVIGATION: SETUP PASSWORD CONTROL: cos PHI 1

4.2.4 Setting up target power factor

• Scrolltothe“SWITCHINTERVAL”displayscreen(seefigure 18).

• Pressthe function key to bring up the input field.

• Thevaluesareenteredbyfollowingthecursorandusing the , and .

• AswithenteringtheCTratio,whenthelastdigitisreached the return symbol is displayed and when pressed will take us back to the switch interval screen as displayed in figure 18.

Figure 18. Setting switch interval time

NAVIGATION: SETUP PASSWORD CONTROL: sWITcH InTerVAL

4.2.5 Setting up switch interval time between steps

Additional note:

Typically the switch time will be set for 40 seconds when the unit is tested at NHP’s premises. Shorter switching times will capture load variations more accurately but will switch the contactors more frequently. A longer switching time will help preserve the life of the contactors by minimising rapid compensation to short term load variation.


44

After making the above settings then the Beluk regulator will check the measuring lines and current transformer. (Voltage at UM1 and UM2 for nominal voltage and rotation of phases and what is measured from the current transformer.)

Once the regulator has checked the voltage and current then the “smiley” face will appear and the regulator will switch steps in and out according to the variation of the load – see figure 19.

Figure 19. Commencement of PF Regulation.

If the following screen shown in figure 20 appears for longer than 5 seconds then it means that the voltage is out of tolerance. Go back to Section 4.2.2 - Setting up the Beluk Regulator to measure voltage and current and check that the inputted values match what the unit is connected to. Also check the voltage is within tolerance.

Figure 20. Voltage out of toleration

If the following screen shown in figure 21 appears for longer than 5 seconds then it means that the current is out of tolerance. Go back to Section 4.2.2 - Setting up the Beluk Regulator to measure voltage and current and check that the inputted values match what the regulator is connected to. Also check that CT shorting links have been removed.

Figure 21. Current out of toleration

4.2.6 Commencement of power factor regulation

4.2.7 Connection issues



If there is a situation where the connection of the CT or phases can’t be altered and are different from the connection diagram shown in figure 2 and figure 27, then the Beluk regulator can be set up to compensate for any connection sequence.

PHASE COMP. allows the phase rotation to be corrected at the regulator. For example, if the connection to the PFC system had the CT on the line 2 (White Phase) then by looking at table 2 we can see that the phase compensation will have to be set to 240+90° because we know that the PFC system already has the measuring lines connected to line 2 and line 3 inside the PFC system.

4.2.8 Setting up the Beluk Regulator to compensate for different connections

• EntertheMEASUREMENTsubmenu(i.e.indicatedpathwayaboveorseesection4.2.2formoredetail).

• Nowscrollthroughthe“MEASUREMENT”submenuoptionsandenterthe“EXTENDED”submenuoption.TheSYNCHRONISATION FREQUENCY AUTOMATIC screen is displayed as shown in figure 22(a).

• Press once to bring up the “PHASE COMP” screen as shown in figure 22 (b).

• Normallythisfieldwillbeseton000°+90°.

• Pushthefunctionkeyuntilthecompensationissettorequiredphaseoffsetasindicatedbytable3(Figure22(c) is an example where the phase offset was altered to “240+90°”.)

Step 1 – Navigating through to the “PHASE COMP” screen

NAVIGATION: SETUP PASSWORD MEASUREMENT exTended

Voltage Connection(UM1 – UM2)

L2 – L3 L3 – L1 L1-L2 L2-L3 L3 – L1 L1 – L2 L2 – L3 L3 – L1 L1 – L2 Reversed CT

Location of CT L1 L2 L3 L2 L3 L1 L3 L1 L2 Any

*Phase offset 0° + 90° 0° + 90° 0° + 90°240° + 90°

240° + 90°

240° + 90°

120° + 90°

120° + 90°

120° + 90°

180° + 90°

(a) (b) (c)

Figure 22. Setting to compensate for different connections.

Table 2. Phase compensation depending on voltage and CT location

Step 2 – Changing the “PHASE COMP”

NAVIGATION: SETUP PASSWORD MEASUREMENT exTended: PHAse comP


46

Table 3 below describes the alarms featured on the BLR CM controller. Table 4 on the following page details the settings that the PFC unit will be set to at time of factory testing. The alarms that are preset are for a basic installation. The flexibility and programmability of the alarms is very extensive and utilising the reference guide the user can program the alarm outputs to suit most site requirements.

Table 3. BLR-CM alarm descriptions and associated limits

ALARM TRIGGER LIMITS

Control Alarm Not achieving power factor after 50 times switching time -

No Current Not being able to measure current -

Step Fault Step size detection not recognised -

Step WarningA) Step size falls below an adjustable percentage range

B) Step switching have exceed adjustable limit

A) 15-80 %

B) 1 - 9999999

Power Factor COS PHI is outside of adjustable range

MIN: c0.80 – i0.91

MAX: i0.80 – c0.91

∆T: 1 -36000 s

Harmonics U THD adjustable Voltage limits has been exceeded 1 – 99.9 %

Harmonics I THD adjustable Current limits has been exceeded 1 – 99.9 %

Overload P Amount of P exceed the adjustable 1 – 99999.9 kW

Overload Q Amount of Q exceed the adjustable 1 – 99.9 kVAr

P-export Alarm will be triggered as soon as P-Export is recognised -

Temp1/Temp2 Ambient temperature has exceeded the limits

Temp 1: 20 – 68 °C ∆T – 0.5 – 9.9

Temp 2: 27 – 70 °C ∆T – 0.5 – 9.9

DI (Digital Input) Voltage received at the digital input -

Over CurrentWhen Current exceeds the measuring range of the regulator

Cannot deactivate this alarm.Alarm not shown in ALARM sub menu.

-

Over/Under Voltage

When Voltage exceeds the adjustable limit

Cannot deactivate this alarm. Alarm not shown in ALARM sub menu. Alarm settings are adjustable in Extended menu under the MEASUREMENT sub menu.

MIN: - 2 – 90%

MAX: +2 – 30%

4.2.9 Alarm settings



ALARM EVENTS

M-RelaysThe M-Relay is a volt free output and can be used as a N0 / NC contact. Max fuse 6A, breaking capacity 250V AC / 5A.

Digital outThe digital output is a volt free output. Is only a NO contact max. fuse 6A, breaking capacity 250V AC / 5A.

DisplayShows Alarm on display.

Control sleepAll steps are put on hold, control is stopped.

Control haltAll steps are switched off, control is stopped.

Cos phi 2Switch to second target COS PHI.

Figure 23. Alarm options as shown on the BLR CM display

This is a brief attempt at explaining how the alarm menu is navigated and the various alarms can be either enabled or disabled. It also attempts to address how certain functions can be selected to operate under certain alarm conditions.

Each alarm can be enabled or disabled and alarm actions such as the M relay or D – display can be assigned to chosen alarms.

As featured on the previous page, a list of alarms featured in the “ALARM” sub menu on the BLR CM controller include:

• ControlAlarm • Nocurrent • StepFault

• StepWarning • PowerFactor • HarmonicsU

• HarmonicsI • OverloadP • OverloadQ

• P-Export • TEMP1 • TEMP2

• DIInput


48

• First,fromthemainmenuweneedtonavigateuntilthe“SETUP”submenuoptionishighlightedandpress to enter.

• Asbeforewemustthenenterthepassword.(FormoredetailseeSection4.2.2).

• Press until the “ALARM” sub menu is highlighted (see figure 24 (a)) and press to enter into the sub menu. See figure 24(b).

• Nowweshouldsee“CONTROLALARM”onthedisplaywitheithernothingwrittenbeloworalarmfunction(s)already configured. This is evident if “=>M D” etc. is displayed (figure 24 (b) shows no functions have been selected).

• Ifwepressthe symbol then the alarm will be disabled as shown in figure 24(c).

• Pressing again will enable the alarm though no functions have been selected.

Step 1 – Disabling / Enabling the “CONTROL ALARM”.

NAVIGATION: SETUP PASSWORD ALArm: conTroL ALArm

(a) (b) (c)

Figure 24. Disabling / Enabling the “CONTROL ALARM.”

4.2.9 Alarm settings cont'd



• Nowpress to move the symbol in front of the symbol as shown in figure 25 (a) and (b).

• Thenpress to scroll through the alarm actions that can be assigned to the control alarm.

• TheoperationoftheMrelaycanbeselectedbypressing which will confirm the selection by changing “NO” to a “YES” (see figure 25 (c) and (d)).

• IftheBelukregulatorgoesintoCONTROLalarmbecausethetargetpowerfactorisnotreachedthentheMrelay will operate.

Step 2 – Assigning the M relay to the “CONTROL ALARM”

NAVIGATION: SETUP PASSWORD ALArm: conTroL ALArm / m reLAY

(a)

(c)

(b)

(d)

Figure 25. Assigning the M relay to operate when the “CONTROL ALARM” is triggered.


50

• Usethe to scroll to the next alarm action. • Infigure26(a),ifwedecidethatwedon’twantthe“DO”orDigitalOutputtooperatewhenthecontrolalarm

activates then press to scroll past it. • Figure26(b)showsthatwhenthecontrolalarmisactivatedthemessageisnotoutputtedontothecontrollers

display. • Toenablethisfeaturepress and this option is now enabled as shown in figure 26 (c). • Wecanscrollthroughtherestofthealarmactionsbypressing and make selections to suit (see figure

26(d)-(f)). • Figure26(g)showstwoalarmfunctionsthatwehaveselected,whicharetheMrelayandamessageonthe

graphical display. • Usingthe we can move the symbol to point at “CONTROL ALARM” as shown in figure 26 (h). • Wecannowscrollthroughtothenextalarmtypebypressing . • Thesameprocessasabovecannowberepeatedfortherestofthealarmtypes.• Pressing will exit the “ALARM” sub menu.

Step 3 – Further alarm actions

NAVIGATION: SETUP PASSWORD ALArm: conTroL ALArm / [ALArm AcTIons]

(a)

(d)

(g)

(b)

(e)

(h)

(c)

(f)

Figure 26. Alarm Settings





No display Auxiliary voltage missingCheck correct connection of auxiliary voltage, if necessary rectify

Display “U<>LIMIT”

Measurement voltage out of range Wrong settings for voltage measurement

Check correct connection of measurement voltage, if necessary rectifyCheck settings in menu “SETUP / MEASUREMENT”, if necessary rectify

Display “I<LIMIT” Measurement current too small

Check connection of CT, a probable break in the lineCT ratio too high, if necessary replace CTRemove short circuit link of the CT

Wrong display of current or voltage Wrong transformer ratio

Check settings PT- or CT-ratio in menu “SETUP / MEASUREMENT”, if necessary

Wrong power factor is displayed

Wrong settings at the regulator

Check settings “NOMINAL VOLTAGE” and “CONNECTION” in menu “EXTENDED”, if necessary rectify

Power factor doesn’t change after switching on a step, step is switched off again

CT mounted in wrong position

Check mounting position referring to circuit diagram (current of load and capacitors have to be measured), if necessary rectify

Alarm “overcurrent” Current higher than allowedCheck CT ratio, probably replace by suitable transformer type

Alarm “Control”

Permanent overcompensation Permanent Under compensation

Check settingsCheck contactors, probably contactors stick togetherCheck settingsCheck capacitors, probably fuse defectiveCheck dimensioning of the compensation unit

Reversed Control Mode Current or voltage clamps interchanged

Correct connection or adapt phase compensation

Single steps are not switched on or off Wrong settings

Check, if referring steps are defined as fix steps (permanently on or off)

Steps are detected as defective Step defective

Check capacitor steps, probably fuse, capacitor or contactor defective

Steps are not switched on Step size too largeNecessary reactive power smaller than switching threshold of step size of the smallest step

Regulator still doesn’t work properly Contact NHP Power Quality Department

BLR-CM regulator alarm codes

52

4.2.10 BLR-CM schematic

4.3 Parallel controller set-up

When commissioning larger PFC systems it is often necessary to connect two regulators to control the required number of steps.

When two regulators are utilised on one system the following steps should be taken.

1) Verify the burden of the CT will support two regulators and the associated cable length

2) Connect the CT in series through both controllers. (i.e. CT terminal S1 to Regulator 1 terminal l, regulator 1 terminal k to regulator 2 terminal l, regulator 2 terminal k to CT terminal S2).

3) Set regulator time delay’s to 5 seconds apart. I.e. regulator No.1 40 seconds, regulator No.2 45 seconds.

The above procedure should also be used when setting up two individual PFC systems at the same switchboard. By setting the regulator time delay 5 seconds apart the two systems will automatically share the compensation duty. This procedure will be effective if both regulators are of Beluk manufacture. The technology of other regulators may not allow this type of duty sharing.

Figure 27. BLR-CM Circuit Connections Line – Line Connection




5. Power factor correction system fault finding

General1. System will not energise If System is energised and regulator has Blank display. • Ensurethatnormallyclosedthermostat(red)issetcorrectly.Refertosection2.7forcorrectsettings. • EnsurethatCThasbeeninstalledcorrectly.Refersection3.0andasperattacheddiagram. • Ensureallcontrolfusesareinstalled.

2. Indication of capacitive load on regulator Indication of capacitive load (e.g. c 0.94) on digital display. • EnsurethatCTpolarityiscorrect.Refertosection3.3forcorrectconnection. • EnsurethatCThasbeeninstalledcorrectly.Refersection3.0andasperattacheddiagram. • EnsureCTwiringhasbeeninstalledtocorrectterminals.

3. Incorrect operation Switching additional capacity and PF (cos φ) decreases. • EnsurecorrectphaserotationthroughoutPFCsystem.Refersection2.5. • EnsurethatCThasbeeninstalledcorrectly.Refersection3.0andasperattacheddiagram

4. No change in PF If regulator switches steps on and off rapidly in 3 successive attempts, with no change in power factor: • Ensureallfusedisconnectoronfunctionaltraysarefullyclosed. • Checkfusesinfusedisconnectorforcontinuity

5. Regulator will not turn on any steps • Ensurenoneofthestepscontactorsareweldedin • Ensurethereissufficientinductiveloadforcompensation • Re-evaluatefunctionaltraystepkVArsizing,mayrequiresmallerkVArstepincrementstoachievePFtarget.

For example, 2 x 25 kVAr instead of 1 x 50 kVAr.

m A I n T e n A n c e r e c o r d

56


Maintenance of NHP PfC systemsAll electrical equipment requires maintenance of some sort. PFC equipment is no different. In fact, because capacitors are consumable devices and they have no moving parts, it is difficult to tell whether a capacitor is in need of replacement without regular maintenance.

The maintenance log is provided to help you periodically test your equipment and keep it in working order. The tasks outlined in the maintenance log are listed below with a brief explanation of how the maintenance should be applied.

Check tightness of all electrical connections: All electrical connections should be checked and tightened after transit, and as part of a twelve monthly check. As electrical connections heat up and cool down, they expand and contract, possibly causing the connection to loosen and result in a resistive joint.

Remove all dust and deposits, inside and outside: Over time dust will enter the PFC system and accumulate on surfaces, or if any work has been done on the system there may be deposits of some kind left behind. Once every twelve months vacuum the PFC system to remove all dust and deposits.

Visual inspection of system: Once every twelve months inspect the PFC system, inside and outside. Things to look for are signs of capacitor case warping, tools or objects left where they shouldn’t be, any liquids that have managed to find their way inside the system, etc.

Check function of fans and thermostats: Once every twelve months check that the fans and thermostats are fully operational by applying hot air from a hot air blower or hair dryer to the temperature switches. The fans should turn on at 35°C and the controller (and any active functional steps) should turn off at 50°C.

Clean/replace filters: Once every three months the filters should be cleaned. If the environment is dusty, dirty or corrosive, the filters may require more frequent cleaning or replacement.

Current measurements: Every six months each capacitor step should be checked. A log is provided to keep a history of how the capacitor steps are performing over time, which will help in diagnosing a problem before it becomes a hazard to your business.

This check involves taking the phase voltage readings (RMS voltage), and the current readings per phase. The two indicators of a depleted capacitor are:

1. The current drawn by the capacitor is below the cutoff current as indicated by the charts shown in Appendix A and Appendix B.

2. The current drawn by the capacitor varies across the three phases. Capacitor current draw should be balanced, so if it is unbalanced the capacitor could produce isolated hot spots within the capacitor leading to possible premature depletion.



General maintenance – every three monthsNote: The frequency of this task may need to be increased to suit individual site conditions, especially dusty or corrosive environments.

DATE TASk COMMENTS INITIALS

Clean/replace filters












General maintenance – Every twelve months

DATE TASk COMMENTS INITIALS

Check tightness of all electrical connections

Remove all dust and deposits, inside and outside

Visual inspection of system

Check function of fans and thermostats









58


Current measurements – every six monthsNote: The frequency of this task may need to be increased to suit individual site conditions, especially high ambient temperatures and excessive harmonics.

Step #1

DATE I1 [A] I2 [A] I3 [A] UL1L2 [V] UL1L3 [V] UL2L3 [V] COMMENTS INITIALS

Step #2


Step #3


Step #4





Step #5


Step #6


Step #7


Step #8


60



Step #9


Step #10


Step #11


Step #12





Step #13


Step #14


Step #15


Step #16


62

PfC-P Current envelope, voltage reference at bus connection


64

PfC-E Current envelope, voltage reference at bus connection


66


Maintenance parts listParts listed involve all possible items that may be required during maintenance on a NHP PFC system.

General items

ITEM DESCRIPTION ITEM NO.

Red LED Lamp BA9SRLA240VAC

Green LED Lamp BA9SGLA240VAC

Discharge Resistor 180kΩ – suited for 12.5 kVAr capacitors 27510010180

Discharge Resistor 120kΩ – suited for 25 kVAr capacitors 27510010120

6.25 kVAr capacitor 275546703803

12.5 kVAr capacitor 275176707700

25 kVAr capacitor 275398715401

50 kVAr capacitor(2 x 25 kVAr capacitors connected in parallel)

2 x 275398715401

Wall mount PfC unit specific


Spare filters – for 37.5 kVAr wall mount unit only AVAFAGN15

Spare filters – for 50 kVAr to 100 kVAr wall mount units AVAFAGN25

Spare grill & filter – for 37.5 kVAr wall mount unit only GKF15

Spare grill & filter – for 50 kVAr to 100 kVAr wall mount units GKF25

Fan, grill and filter for 37.5 kVAr wall mount unit GKV2000220

Fan, grill and filter for 50 kVAr to 100 kVAr wall mount units GKV2500220

6 A 1 phase MCB - Control DTCB6106C

16 A 3 phase MCB – for 6.25 kVAr capacitor DTCB6316D

32 A 3 phase MCB – for 12.5 kVAr capacitor DTCB6332D

63 A 3 phase MCB – for 25 kVAr capacitor DTCB6363D

PfC-P unit specific (previously cQ-PFc)


Spare filters AVAFAGN30

Spare grill & filter GKF30

Axial Fan – 3 are used in single Tier NHP PFC systems AC17320BTP

Control Fuse NNS4

DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 6.25 kVar tray N0016


DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 25 kVar tray N0063


6.25 kVAr functional tray FTSR6CQE

12.5 kVAr functional tray FTSR12CQE

25 kVAr functional tray FTSR25CQE

50 kVAr functional tray FTSR50CQE



PfC-E unit specific


Axial Fan – 3 are used in single Tier NHP PFC systems AC17320BTP

Control Fuse NNS4




12.5 kVAr capacitor 275 166 707 100

25 kVAr capacitor 275 189 714 301

50 kVAr capacitor 2 x 275 189 714 301

Recommended torque settings for specific system componentsThe table below lists the recommended torque settings for affixing PFC system components. These settings ensure that all connections are secure without damaging the nuts and bolts or the equipment itself.

ITEM TORQUE SETTING ( NM )

Mounting studs of capacitor 7

Screw connections of capacitor

6.25 kVAr Capacitor 1.2 … 2.0

12.5 kVAr Capacitor 2.5 … 3.0

25 kVAr Capacitor 3.2 … 3.7

Contactor

CA 7-16 1.5 … 2.5

CA 7-23 1.5 … 2.5

CA 7-37 1.5 … 3.5

CA 7-72 2 … 6

A P P e n d I x

70

A P P e n d I x

Preventative maintenanceProducts of the power factor correction unit have a finite lifespan. In particular, capacitors and contactors require regular performance analysis to ensure correct and reliable operation. When products do fail, it can lead to costly repair or production losses. Preventative maintenance can extend the life of products and it is possible to predict and avoid failures before they occur.

An integral component of the power factor correction unit, capacitors require stringent operating conditions to ensure reliable operation.

All components can succumb to wear and the ideal situation is to identify and replace these components before they pose a problem for your business.

The serviceWHAT nHP PoWer FAcTor correcTIon serVIce ProVIdes:

nHP power factor correction servicing involves multiple analysis and tests to certify the unit operation.

Service includes:

Current measurements – capacitor depletion analysis

Thermal testing – Imperative to component lifespan and function

Troubleshooting – Unit functional testing

Component replacement – Where required

General cleaning – maintain optimal operating environment

Our teamour team of qualified technicians is available for a variety of lifecycle services, including power factor correction, which involves:

• Productrepairsandservice• Onsiteemergencybreakdownservice• Preventativemaintenanceand• Commissioning

Economical advantageThrough regular maintenance nHP power factor correction systems will provide superior performance. In doing so, each power factor correction system will maintain its target power factor, passing on all economical benefits to the customer.

FIELD SUPPORT SERVICES - PFC

HOW DO I ARRANGE A SERVICE CONTRACT?

Arrangement of a servicing schedule can be organised through a nHP representative who can advise on further details.

NHP SERVICE PROVIDES A COMPREHENSIVE RANGE OF VALUE ADDED SERVICES THAT SUPPORT AND ENHANCE THE RELIABILITY AND PERFORMANCE OF NHP PRODUCTS


PFC SYSTEM RATING CABLE RATING

kVArNominal

Amps135% Nominal

AmpsMin. conductor

size (mm²)b)Max. current cap.

(A)b)100 139 188 95 230

150 209 282 150 310

200 278 376 240 425

250 348 470 2 x 120 1) 530

300 417 563 2 x 150 620

350 487 657 2 x 185 710

400 556 751 2 x 240 850

450 626 845 2 x 240 850

500 696 939 3 x 185 2) 1065

550 765 1033 3 x 185 1065

600 835 1127 3 x 240 1275

650 904 1221 3 x 240 1275

700 974 1315 4 x 185 3) 1420

750 1043 1409 4 x 185 3) 1420

1) Alternative – 1 x 300 mm² cable.2) Alternative – 2 x 300 mm² cables.3) Alternative – 3 x 300 mm² cables.

NHP recommend that the cable size be determined from maximum anticipated installed capacity of the PFC system.

Cable sizes are a guide only, always refer to AS/NZS3008 for specific requirements. Individual de-rating based on method of installation, cable lengths, volt drop, ambient temperature and cable configuration must be allowed for when sizing cable.

Appendix A: Cable requirements

Copper conductor, de-rating factor 1, UnenclosedIn accordance with:

a) AS 3000:2007b) AS3008.1.1:2009 – Table 8, column 9.

* Allowance for overloading and cables touching, unenclosed.

A P P e n d I x

72

A P P e n d I x

Appendix B: BLR-CX Setup Menu

Advanced Setup

The setup menu is broken down into 6 main groups represented by 100-600. They are described as follows.

Navigate to the setup menu from the main screen using the and function keys. Once the setup menu light is showing on the right hand side, hold the function key (this accesses the advanced menus) until 100 appears on the screen.

This is the quick start menu and contains all basic parameters required to start the PFC.

This is the measurement settings menu and contains all basic connections settings (VT, CT, Compensation angle).

This is the control optimisation menu and contains settings to improve and adjust performance.

This is the step setup menu and allows adjustment and adaptation of the steps.

This is the alarms menu and contains settings to configure all alarms and monitoring capabilities.

This is the reset menu and allows various aspects of the regulator to be reset or everything to be reset to factory standards.

1.00i SETUP

100 SETUP

200 SETUP

300 SETUP

400 SETUP

500 SETUP

600 SETUP


A P P e n d I x

Appendix C: BLR-CX Expanded Setup Menu

The following describes what each of the menu items are for the measurement (200), control optimization (300) and step setup (400) menu structures.

Measurement (200)

Menu No. Description Options

201 Nominal Voltage 100…245100V

202 Current Transformer Ratio 1…9600

203 Voltage Transformer Ratio (If not used, left at 1) 1…350

204Voltage Tolerance (percentage of nominal voltage) This tolerance sets the limits of permissible nominal voltage before an alarm is triggered.

0…100%

205Voltage Measurement Connection Yes – Line to Line connection. no – Line to neutral connection.

Yes / no

206 Phase Compensation To compensate for non standard measurement connections.

0…345

207

Auto Initialize Yes – starts switching all steps to calibrate and compensate. for measurement connections. Voltage and current must be in acceptable limits.

Yes / no

208Auto Initialize on Startup Yes – countdown to initialize is shown on starting the BLr-cx no – The countdown is not shown on startup.

Yes / no

209Synchronization Frequency setting the sampling rate to match the frequency of the grid supply if auto is too unreliable.

Auto / FIx50Hz / FIx60Hz

210Temperature Offset Allows correction of temperature reading. -10ºc…10ºc

74

Appendix C: BLR-CX Expanded Setup Menu cont'd

Control Optimization (300)


301Control Sensitivitysensitivity of the switching threshold. determines when the controller will switch in a step according to percentage terms of closest step size.

55…100%

302 Cos ø 1This is the primary power factor setting.

0.7…0.99

303Cos ø 2This is the secondary power factor setting which can be switched to by the digital input.

0.7…0.99

304Cos ø 2 for P Export Yes – The controller operates with cos ø 2 as a control target. no - The controller operates with cos ø 1 as a control target.

Yes / no

305Switch Interval The time delay in switching steps for regulation. Long enough to build an average reactive power and prolong contactor life.

0…6500s

306Switch Interval Step Exchange The time delay in swapping out an active step for another step to achieve a better power factor.

0…6500s

307Activate Step Exchange Yes – Uses combined filter control algorithm to find an optimum result with different step sizes.

Yes / no

308

Step Recognition “Off” Yes – step sizes have to be programmed by hand. no – step sizes are corrected and detected automatically and moni-tored for alarms. step sizes which are programmed manually will be overwritten.

Yes / no

309

Defective Capacitor Blocking Yes – If a step is switched in three times with no measurable reaction toPF,itisblockedandnolongerusedbythecontroller.Faultystepsare tested every 24hrs or when the controller starts up. no–Stepsarecontinuedtobeusedevenwithnonetworkreaction,causing unnecessary switching.

Yes / no

310

PF Controlon – Automatic control.oFF – control stops and active steps are disconnected successively.HoLd – control stops and active steps remain on.

on / oFF / HoLd

311

Control Algorithm1 - AUTo – Before each switching operation all available steps are com-pared against the control deviation and the best selected.2 - LIFo – The controller starts regulation by switching in step 1 and continuingwiththefollowingsteps.Whentakingoutstepsittakesoutthe last active step switched in.3 - comBIned FILTer–SpecialAlgorithmforcombinedfilterbankswithtwodifferentdetunedratings.Workinglikewithbestfit.4 - ProgressIVe – The controller can switch in multiple steps within small amount of switching time if required. step sizes must be set manually.

1 / 2 / 3 / 4

A P P e n d I x



312Offset Reactive PowerThis can be used to offset a permanent reactive load which cannot be measured (i.e. transformer).

0.0…900.0kvar

313

Asymmetry FactorThis factor is the ratio between switch interval for switching on and switching off.x = 1 = equalx = 2…127: delay switching off x = -2…-127: delay switching onresult = switch interval multiplied by x.

-127…127

314

Q Capacitive Steps Turn OffYes–Whenthenetworkconditionisconsideredcapacitive,thestepsare turned off.no – The controller only considers the cos ø control target.

Yes / no

Step Setup (400)


401

Discharge Time Thedischargetimeisablockingtimeforthecapacitorwhichstarts after it has been switched off. It cannot be used again until the discharge time has expired.

5…1200s

402

Step Nominal Value Thisallowseachstepsizevaluetobemanuallyenteredinkvar. The cT factor and nominal voltage mUsT be set beforehand as these values will affect capacitance step sizes.

0.0…999.9kvar

403

Step Type AUTo –Used for normal regulation Al – If temperature limit 1 is exceeded this step is switched as fan output. Fon – step is permanently on (still monitored and shutdown in critical situations). Foff – step is permanently off (should be used for inactive steps).

AUTo / Al / Fon / Foff

404 Switch Cycles Allows resetting of the switching cycles when a contactor is replaced.

0…262,000

A P P e n d I x

76

Appendix C: BLR-CX Expanded Setup Menu cont'd

Alarm Settings (500)Menu No. Description Options

501Reset Alarm Manually YES–Havetoholdesckeyfor5secondstoresetalarms no – once alarm condition is removed, alarm turns off.

Yes / no

502Total Harmonic Distortion Alarm Yes - exceeding threshold activates alarm. no - not monitored.

Yes / no

503 Total Harmonic Distortion Threshold 1-200%

504

Total Harmonic Distortion > Threshold Yes - exceeding the threshold will result in successively turning off all active steps (must have 502 as Yes) no - no response to exceeded threshold.

Yes / no

505Trigger interval time for THD and Temp Threshold 2 The time after the threshold has been breached before triggering an alarm.

1-255 sec

506

Freeze Control if I = 0 Yes – The controller is frozen when the measuring current drops below 15mA and all active steps remain on. no – The controller turns off all active steps successively when the measuring current drops below 15mA.

Yes / no

507

Service Alarm Yes - Alarm occurs when max amount of step switching cycles has been exceeded or threshold for operation hours has been exceeded. no – no alarm for exceeding step switching cycles or controller hours of operation.

Yes / no

508 Max switching cycles per step Threshold for cycles per step before alarm activates.

0-262,000

509 Max operation Hours Threshold for operation hours before alarm activates.

1-65535 hrs

510

Temperature input as digital input Yes – The temperature input is used as a digital input NO–Thetemperatureinputworkswithtemperaturesensorandthe thresholds are set as per 513 and 514.

Yes / no

511Digital input active at high signal Yes – dI is activated with closed terminals T1 & T2. no – dI is activated with open terminals T1 & T2.

Yes / no

A P P e n d I x



512

Temperature Alarm Yes – The temperature is monitored according to the thresh-olds and responds accordingly. no – no alarm for temperature.

Yes / no

513Temperature Threshold 1 When the first temperature threshold is breached, the AL step dedicated to the fan is switched on.

Yes / no

514

Temperature Threshold 2 When the second temperature threshold is breached, the con-troller successively turns off all active steps and the visual high temp alarm is activated.

Yes / no

515

Control Alarm (Target cos ø cannot be achieved) Yes - Alarm is activated after 75 attempts of switching resulting in over and under compensation. no – no monitoring for over/under compensation.

Yes / no

516

Defective Step Alarm Yes – After 3 unsuccessful switching attempts (causing no dif-ference to PF) the alarm is activated. no – The alarm is disabled.

Yes / no

517

Step Power Loss Alarm Yes - If the step size reduces to less than 70% of its initial value the alarm is triggered. no – capacitor power loss is not monitored.

Yes / no

Reset Settings (600)Menu No. Description Options

601 Reset SettingsSetallsettingsbacktofactorystandard.

Yes / no

602 Reset Step DatabaseSetallstepdatabacktofactorystandard.

Yes / no

603 Reset Operation HoursSetOperationHoursbackto0.

Yes / no

604 Reset Average Power Factor Yes / no

605 Reset Maximum Temperatureresets the highest measured temperature.

Yes / no

606 Reset Alarmsreset all existing active alarms.

Yes / no

607 Display software version of the controller 1.xx

A P P e n d I x

78

n o T e s

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NHP Electrical Engineering Products Pty LtdA.B.N. 84 004 304 812

NHPPFCM 01/12 © Copyright NHP 2012

AUSTRALIAnhp.com.au

SALES 1300 NHP NHP

FAX 1300 NHP FAX

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