Schrack Technik CX plus Series FRACXP06R- User Manual
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Schrack Technik CX plus Series FRACXP06R- User Manual

Power factor controler
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USER MANUAL
POWER FACTOR CONTROLER
CX plus
FRACXP06R-, FRACXP12R, FRACXP12RM

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Summary of Contents for Schrack Technik CX plus Series FRACXP06R-

  • Page 1 USER MANUAL POWER FACTOR CONTROLER CX plus FRACXP06R-, FRACXP12R, FRACXP12RM...

  • Page 2: Table Of Contents

    Content SAFETY NOTES INSTALLATION AND COMMISSIONING WIRING DIAGRAMS -12R PLUS IST OF OPTIONS CONNECTION DATA COMMISSIONING QUESTIONS DURING COMMISSIONING INDICATIONS ON THE DISPLAY OPERATION OF THE CONTROLLER MENU CX PLUS EASUREMENT MENU INFO (S TAGE DATABASE MANUAL (M ANUAL OPERATION ANUALLY SWITCH STEPS ON AND OFF SETUP (S ETUP MENU...
  • Page 3 LARM MEMORY MENU TROUBLESHOOTING APPLICATIONS DDITIONAL SWITCHING OUTPUT FOR A STAGE AN ACTIVATION TEMPERATURE SWITCH OFF STAGES THD-U / THD-I PROTECTION  WITCHING TO TARGET VIA THE DIGITAL INPUT I-LOW- UPPRESSION OF THE ALARM BY THE DIGITAL INPUT XTERNAL ALARM OVER DIGITAL INPUT ETECTION OF STAGE POWER LOSS TAGE OWER...
  • Page 4 OMBI FILTER ROGRESSIVE FIFO TRANSFORMER COMPENSATION ETTING OF THE REACTIVE POWER OFFSET IXED MEASUREMENT DEFAULT AND CUSTOMER SETTINGS TECHNICAL SPECIFICATIONS ANNEX ETTING OF PHASE CORRECTION ANGLES DEPENDING ON THE CONNECTION ONNECTION IN CASE OF MIXED MEASUREMENT...

  • Page 5: Safety Notes

    Safety notes Read these safety notes and instructions attentively and carefully first. Familiarise yourself with the device prior to installation, commissioning and operation. The following symbols are used in the manual and on the device label on the back of the device in order to indicate dangers and problems or to give specific instructions.

  • Page 6: Installation And Commissioning

    Installation and commissioning Before installation, the connection data of the CX plus must be compared with the data of the supply network and of the installation. The working RANGE must be disconnected from voltage and secured against unauthorised and unintentional restart. The absence of voltage must be verified with a standardised instrument / testing device.

  • Page 7: Wiring Diagrams

    Wiring diagrams -12R PLUS IST OF OPTIONS Designation Explanation CX plus -06R 6 output / stage relay -12R 12 output / stage relay Modbus RTU – Connection via RS485 3-wire bus...

  • Page 8: Connection Data

    Connection data Measuring and supply voltage Combined voltage measurement and supply Range: 90 – 550 V AC, 45 – 65 Hz Terminals: U1 / U2 A transformer factor can be set when using voltage transformers. Range 1.0 – 350.0 Current measurement Current measurement Range: 5 mA –...

  • Page 9: Commissioning

    Commissioning The CX plus is pre-programmed with default values, which enable an operation almost without further settings, if connected to a 400 V supply network according to the wiring diagram. ! CAUTION Exception: The current transformer factor (SETUP/Ct) must be entered in order to correctly calculate the measurement values and to correctly identify the stage sizes.

  • Page 10: Questions During Commissioning

    Questions during commissioning “AUTO” is not displayed  control stopped or switched off. Possible causes: Manual operation, control has been stopped or switched off in the setup menu. Current is less than 5 mA, voltage of THD of voltage or current are out of tolerance, temperature is too high, “Automatic initialisation (AI)”...
  • Page 11 Measuring voltage or current has been connected at a twisted angle of 180° from the direction of connection (U2 / U1 instead of U1 / U2 resp. S2 / S1 instead of S1 / S2). Solution: Correct the connection, execute the “Automatic initialisation (AI)” or add 180° to resp. subtract 180°...
  • Page 12 Stage outputs are immediately switched off again. Possible causes: The nominal value of a stage saved in the stage database is not correct anymore (after changing a capacitor, the value must be entered manually again or the entire stage database must be reset). Stage is defective ...
  • Page 13 Solution: Enter the current transformer factor correctly (SETUP/100/Ct), enter the stage sizes manually (SETUP/402) or reset the stage database (SETUP/602). Heavy load fluctuations during the stage identification Solution: Enter the stage sizes manually (SETUP/402) or reset the stage database (SETUP/602). The set phase correction angle does not correspond to the connection of measuring voltage and current.

  • Page 14: Indications On The Display

    Indications on the display The currently selected main menu is shown on the right side of the display. INFO: Stage database AUTO: Control is active: Stages are switched on and automatically. MANUAL: Manual operation: Stages can be switched on and off manually.
  • Page 15 In case of an alarm, an alarm message is flashing on the display in addition to the display “ALARM” at the CX plus. The table below offers an overview of all possible alarm messages. In order to reset the active alarms, keep the  (ESC) key pressed for 3 s. Alarm messages: Measuring voltage is out of the set tolerance.
  • Page 16 Set limit value of the operating hours has been exceeded. ALAR Set limit of the maximum permissible switching cycles of one or several stages has been exceeded. ALAR Error code and stage number are flashing alternatingly. Only the smallest affected stage number is displayed. Set limit of the maximum permissible operating hours of one or several stages has been exceeded.
  • Page 17 NOTE: If the menus INFO, MANUAL, SETUP or ALARM are selected in the main menu, only error and status messages are displayed. NOTE: If the submenus INFO, MANUAL, SETUP or ALARM are active, no alarm, error or status messages are displayed. abrt hold NOTE: The messages...

  • Page 18: Operation Of The Controller

    Operation of the controller The CX plus is operated using 4 keys. Increase values, select previous measurement value, menu item and stage number Open menus, Exit menus, moves the cursor to the moves the cursor to the right, left, accept the set value reset alarms (keep the key pressed for approx.

  • Page 19: Menu Cx Plus

    Menu CX plus EASUREMENT MENU All measurement values with a grey background are hidden in factory setting and are only displayed, if the current transformer factor is set in the menu “SETUP/100/Ct”. NOTE: If the device is reset to factory settings (SETUP/602), the current transformer factor must be entered again so that all measurement values are displayed again.
  • Page 20 Odd harmonic 0.40 U 3 - 19 Harmonic 1.00 distortion 1.67 I total Odd harmonic I 0.74 3 - 19 1.00  0.999 three-digit cosϕ Power factor ratio 0.888 Average power factor 1.000 Frequency Temperature °C Highest measured temperature °C Operating hours counter 188.9...
  • Page 21  0.99 Highest measured voltage L - L Maximum measured 2.66 harmonic distortion U total Jump upwards Voltage L - L...

  • Page 22: Info (Stage Database )

    INFO (S TAGE DATABASE The switching cycles, the operating hours, the stage type / status, the current stage power and the stage power with regard to the initial power (in %) are displayed in the “INFO” menu for each stage. With these data it is possible to draw conclusions about the condition of the system and the condition of the individual stages.

  • Page 23: Manual (Manual Operation : Manually Switch Steps On And Off )

    INFO Display of the stage size is only active, if the CT has been kVar set, otherwise ---- max. max. Operating hours of the stage max. MANUAL (M ANUAL OPERATION ANUALLY SWITCH STEPS ON AND OFF It is possible to manually switch the step outputs of the CX plus for test purposes. The automatic control is stopped in the “MANUAL”...
  • Page 24 We recommend executing the automatic initialisation (AI) for commissioning. This identifies the connection of the controller (phase between voltage and current) and automatically determines the correct phase correction angle (SETUP/206). The CX plus performs a connection type identification of the measuring voltage (L-L / L-N) depending on the set nominal voltage.
  • Page 25 of the occupied and non-occupied switching outputs (AUTO-INIT). “ON” control ON, “OFF” control OFF, “HOLD” control is stopped SETUP Target COS ϕ 1 of the control SETUP Switching time, waiting time between switching the individual stages on and S SETUP Setting of the stage type for each individual stage: Select the stage number with buttons...

  • Page 26: Expert Setup Menu Cx Plus

    SETUP XPERT MENU PLUS In order to change from the quick START SETUP menu to the EXPERT SETUP menu of the CX plus, press the key “” or “”. Now a PIN has to be entered. Here, the standard PIN is 242. NOTE: The PIN can be changed in the SETUP menu 608.

  • Page 27: 100 Quick Start Setup

    100 Q START UICK SETUP Contains all settings important for commissioning. 100 Quick START setup MENU FUNCTION RANGE Nominal voltage measurement = phase voltage 100...242000 V It is necessary to correctly enter the nominal voltage, because the upper and lower limit of the voltage monitoring are calculated from the nominal voltage (see tolerance range nominal voltage).
  • Page 28 Control ON/OFF/Hold Starting, stopping and switching off the automatic control. The following settings are available: Control is ON and works in normal operation. OFF: Control is OFF and active stages are switched off one by one at 3 second intervals. Hold: Control is stopped and the active stages remain switched on.

  • Page 29: User - Guided Initial Commissioning "First Setup

    “F ” GUIDED INITIAL COMMISSIONING IRST ETUP The user-guided initial commissioning facilitates the first commissioning of the power factor controller BLR-CX plus. The user is guided through various settings, which are essential to operate the BLR- CX plus correctly. A “First Setup” step-by-step guide can be found below. The device can be handled by pushing the four buttons on the front side.
  • Page 30 FIrST Setting of the nominal voltage: Un = phase-phase voltage. This value SEtUP V SETUP is required for the monitoring of the voltage tolerance. The stage sizes saved in the stage database also refer SETUP to the nominal voltage. FIrST Entry of voltage transformer factor SEtUP SETUP...

  • Page 31: 200 Settings Measurement

    The notification “First SETUP OK” FiRST completes the procedure of the user- SEtUP guided initial commissioning. SETUP 200 S ETTINGS EASUREMENT Contains settings in order to adjust the measurement of the CX plus to the network conditions. 200 Settings Measurement MENU FUNCTION RANGE...
  • Page 32 automatically determines the connection type of the voltage measurement. This cannot be changed manually. If the measured voltage is out of this tolerance, the connection type of voltage measurement can be set manually. Phase correction angle 0...345° Depending on the connection of measuring voltage and current, a phase shift can occur.

  • Page 33: 300 Settings Control

    300 S ETTINGS CONTROL CONTAINS SETTINGS IN ORDER TO ADJUST THE CONTROL TO THE SYSTEM REQUIREMENTS AND TO OPTIMISE IT. 300 Settings control MENU FUNCTION RANGE 55…100 % Control sensitivity The control sensitivity indicates the switching threshold for switching stages on and off.
  • Page 34 This function is useful when stages of different sizes are available. If all available stages have the same power this function should be deactivated, because unnecessary switching cycles may occur. NOTE: The stage exchange function is always deactivated in the control algorithms “COMBI filter”, “LIFO”, “FIFO”...
  • Page 35 OFF: Control is OFF and active stages are switched off one by one at 3 second intervals. Hold: Control is stopped and the active stages remain switched on. If the control is set to “OFF”, “PFC” and “OFF” appear alternatingly on the display.
  • Page 36 COMBI FILTER: A special algorithm for combi filter systems with two different degrees of choking. The controller works according to the “BEST-FIT” principle. The difference is that the controller always has switched-on more or the same amount of compensation power at the odd switching outputs, as it is available at the even outputs.
  • Page 37 FIFO “First IN, First OUT”: (cyclic control): The controller starts with stage 1 and switches on the stage of the next higher number each time, if necessary. When switching off, the controller starts with stage 1 and switches off the stage of the next higher number each time, if necessary.

  • Page 38: 400 Settings Of Stage Database

    ! CAUTION This function cannot be transferred to “inductive” stages the other way round. Distribute switching operations of the stages via the operating hours of the individual stages “NO”: The switching operations of stages of the same stage size are distributed via the switching cycles of the individual stages.
  • Page 39 and the automatic stage recognition is deactivated, the current stage size of all stages is reset to the original value (entered value). and the automatic stage recognition is activated, the current and the original stage size (the value which was accepted after the completion of the stage identification) of all stages is reset to the initial value of 3 var capacitive.

  • Page 40: 500 Settings Alarm

    If several stages of the same size are connected and the option “Distribute switching operations of the stages via the operating hours of the individual stages” is activated (SETUP/315 = YES), the controller automatically distributes the switching operations for these stages based on the operating hour counters of the individual stages, so that the operating hours for these stages are distributed evenly.
  • Page 41 500 Settings ALARM MENU FUNCTION RANGE Reset alarm manually Yes/No “YES”: Alarm messages (display and alarm relay) must be reset manually. In order to reset active alarms, keep the key  (ESC) pressed for approx. 3 s. “NO”: As soon as the alarm condition is no longer active, the alarm messages (display and alarm relay) is reset automatically.
  • Page 42 Adjustable delay time for THD-U- and THD-I-alarms. Stop the control if I == 0 Yes/No Measuring current refers to the current which is actually measured by the controller in the secondary circuit (without considering the current transformer factor). “YES”: If the measuring current is less than 5 mA, the control is stopped. All active stages remain switched on.
  • Page 43 NOTE: The limit value can only be entered as full hours. Max. operating hours of a stage 1...65500 h Limit value of the operating hours for the stages for the service alarm. If the service alarm is activated (SETUP/506 = YES) and if the limit value of the operating hours for the stages is exceeded by 1 h, the service alarm is signalled immediately and the message “OPH ”...
  • Page 44 3… Temperature limit 1 = fan (TEMP2-5K) °C If the temperature limit 1 is exceeded, the controller switches on the switching output of the fan. Additionally, the status message “FAN” flashes on the display in the bottom line of the main menu. If the temperature falls below the temperature limit 1 by 5 K, the controller switches off the switching output of the fan after 10 s.
  • Page 45 display. The alarm relay opens its contact. The alarm remains active while at least one stage is set to the stage type “Flty”. In order to reset the alarm, set the stage type of the affected stage to not equal to “Flty”. If the function “Manual reset” (SETUP/501 = NO) is deactivated, the alarm messages (display and alarm relay) are automatically reset.

  • Page 46: 600 Reset Menu

    stages have been switched off, the control stops for as long as one out of these three alarms is still active. THD-U / THD-I / TEMP 2 alarm = switch off active stages Yes/No “NO”: active stages are not switched off in case of an alarm. “YES”: If the digital input alarm is triggered after running out of the delay time of 10 s, all active stages (“AUTO”...
  • Page 47 RESET settings Yes/No “YES”: Resets all user settings including the setting of the discharge time of the stages (SETUP/401) and the function “Use switching output FAN as stage switching output” (SETUP/406) to factory settings. The function “First Setup” will be restarted immediately, the control will be stopped and all AUTO-stages will be switched off according to a switch-off sequence.
  • Page 48 “YES”: Resets all active alarm messages (display and alarm relay) and the alarm memory (menu ALARM). After confirming the setting with “YES”, the RESET takes place. The setting will automatically return to “NO”. NOTE: The alarm messages on the display are only reset, if the respective alarms are not active anymore.

  • Page 49: 700 Settings Modbus ( Communication Interface )

    700 S MODBUS ( ETTINGS COMMUNICATION INTERFACE Contains settings in order to parametrise the MODBUS-RTU communication interface (RS485). NOTE: This submenu is only available with the option -MB. 700 Settings MODBUS MENU FUNCTION RANGE 1,2k; 2,4k; 4,8k; 9,6k;19,2k; 38,4k; Baud rate 57,6k;...
  • Page 50 1.00 1.00 ALARM I Lo THDU...

  • Page 51: Troubleshooting

    Troubleshooting Fault / alarm Possible cause Remedy  Measuring / supply voltage is  Check, if the connected No notification on the display missing measuring voltage is in the range of 90…550 V AC.  Check the correct connection of the measuring voltage and correct it, if necessary.
  • Page 52  The phase correction angle  Or check the phase was set incorrectly or correction angle identified as incorrect by the (SETUP/206) in the SETUP menu, correct it, if  Offset reactive power necessary.  A transformer is also  (Q offset) is set. compensated by the compensation system.
  • Page 53 type to “AUTO”, if necessary.  Check the dimensioning of the system. The compensation power may not be enough anymore or the gradation of the stage sizes is too rough or the stage sizes may be oversized.  Phases via the connection of ...
  • Page 54 too rough or the stage sizes may be oversized.  Stages are locked, because  Check if the measuring No stages may be switched in  U-Alarm is active or the the manual mode. voltage is within the valid range and if the U alarm is discharge time of the stages signalled, enter the set is still running.
  • Page 55 wiring diagram (no internal connection to the root connection of the stage switching outputs)  I-LOW-alarm is suppressed  Check the INFO display No display notification I lo under SETUP/519  by the digital input. ALARM “YES” == I-LOW-alarm is even though the measuring suppressed by the digital current is less than 5 mA...

  • Page 56: Applications

    Applications DDITIONAL SWITCHING OUTPUT FOR A STAGE The controller has only 6 or 12 switching outputs. An additional switching output, however, is required for a stage. Solution: The CX plus offers the possibility to use the switching output for the fan as additional switching output for a stage.
  • Page 57  Set the temperature limit 1 in the SETUP/512. Set the temperature limit 1 in the SETUP menu 512. The temperature limit 2 (SETUP/513) may have to be increased, because the maximum setting range of the temperature limit 1 depends on = TEMP2 –...

  • Page 58: Over - Temperature Switch - Off Stages

    TEMPERATURE SWITCH OFF STAGES The controller shall switch off the active stages depending on over-temperature in the switch cabinet. Solution: The CX plus is equipped with a temperature sensor (NTC) integrated under its housing. The temperature limit for activation of the stage switch off sequence can be set in the alarm system. Hence, the stages are protected against overheating and the temperature in the switch cabinet is able to cool down to normal operation conditions.
  • Page 59 The alarm system of the CX plus can react as soon as the set limit values of the entire harmonic distortion of voltage (THD-U) or current (THD-I) is exceeded and is able to switch off all active stages in order to protect the capacitors. The limit values for THD-U and THD-I can be set individually in the alarm system.

  • Page 60: Switching To Target Cos  2 Via The Digital Input

     2 WITCHING TO TARGET VIA THE DIGITAL INPUT The second target cos  is able to be activated via an external digital input signal. Solution: The digital input of the controller may be used for switching to the set target cos  2. Procedure: ...

  • Page 61: External Alarm Over Digital Input

    NOTE: If the delay time has not run out yet and if the digital input is activated again, an active I-LOW- alarm is suppressed immediately. If the digital input is no longer activated, the delay time is restarted (60 s). I-LOW-alarm is signalled after the delay time has run out. XTERNAL ALARM OVER DIGITAL INPUT An external alarm (e.g.
  • Page 62 Function: If the current stage size of a stage fell below 75% of the original stage size, the stage alarm stage power loss is triggered. The message and the stage number of the affected stage are signalled ALARM alternatingly on the display and the contact of the alarm relay is activated. If several stages are affected, only the lowest stage number of the affected stages is displayed.

  • Page 63: Recognition / Manual Entry Of Stage Sizes

    Recognition / manual entry of stage sizes – A TAGE RECOGNITION IS ACTIVATED UTOMATIC RECOGNITION OF THE STAGE SIZE If the stage recognition is activated (SETUP/308 = YES), the CX plus automatically determines the stage size after switching on and after switching off a stage, respectively. This value is saved as the current stage size for this stage in the stage database after the first switching operation.

  • Page 64: Stage Recognition Is Deactivated Manual Entry Of The Stage Sizes

    In case of problems with the stage identification, it is possible that connected stages have been set to “FOFF” by the controller. Therefore, the stage size of the individual stages should be checked in the SETUP menu 100/OUt or 403 and be switched to “AUTO”, if necessary. ...

  • Page 65: Recognition / Resetting Of Defective Stages

    Recognition / resetting of defective stages If the controller has identified a stage as defective (3 consecutive switching cycles without mains reaction) and blocked this (stage type = “Flty”), this stage is blocked for the control for 24 hours. Defective stages are only locked, if the function “Lock faulty stages” is activated (SETUP/309 = YES). After this blocking time, the controller resets the stage type of this stage to “AUTO”...

  • Page 66: Adding Additional Stages

    Adding additional stages If an existing system is extended by one or several stages, the additional stages may be added in the stage database. For this purpose, the stage type of the additionally occupied switching outputs must be set to “AUTO” (SETUP/100/OUt or SETUP/403).

  • Page 67: Automatic Initialisation

    Automatic initialisation ! CAUTION The phase correction angle must be set depending on the connection of measuring voltage and current, so that the measurement of the active and reactive power, the COS-PHI, the power factor and the automatic recognition of the stage sizes works perfectly. This is a condition for a perfect functioning of the control.

  • Page 68: Problems During The Ai / Cancellation Of The Ai

    AI / ROBLEMS DURING THE CANCELLATION OF THE If the automatic initialisation cannot identify the phase angle during a maximum of 4 cycles, the AI is cancelled with error message: abrt The messages are shown alternatingly on the display. The control was switched off by the AI (“OFF”): The messages “PFC” and “OFF” are shown alternatingly on the display.

  • Page 69: Control Algorithms

    Control algorithms 5 different control algorithms are available in the CX plus. The control algorithm used by the controller can be set in the SETUP menu 311: 1 = BEST FIT (default) 2 = LIFO 3 = COMBI FILTER 4 = PROGRESSIVE 5 = FIFO BEST FIT (AUTO) The controller works according to the “BEST FIT”...

  • Page 70: Lifo

    LIFO “Last In, First Out”: The controller starts with stage 1 and switches on the stage of the next higher number each time, if necessary. The stages are switched off in reversed order. It is checked individually for each stage, if the switching operation is useful. This may lead to an unprecise compensation in case of stages of different sizes.

  • Page 71: Progressive

    ROGRESSIVE Works like the “BEST-FIT” algorithm, with the exception that the controller switches on and off several stages one by one with a shortened switching time, if necessary. The set switching time is ignored in the process. The stage sizes must be entered manually, because the stage recognition is always deactivated in this algorithm.

  • Page 72: Transformer Compensation

    Transformer compensation The compensation of a transformer for which no fixed stage is available can be solved in two ways with the CX plus: ETTING OF THE REACTIVE POWER OFFSET The current transformer is installed at the output side of the transformer  consequently, the reactive power of the transformer is not measured by the CX plus.

  • Page 73: Mixed Measurement

    IXED MEASUREMENT The reactive power caused by the transformer is measured by the medium-voltage current measurement and is also controlled via the connected compensation system. Procedure: Connect the measurement of the controller as shown on the diagram opposite and start the automatic initialisation (AI) (SETUP/100/Ai or SETUP/207).

  • Page 74: Default And Customer Settings

    Default and customer settings NOTE: Some settings which are important for commissioning from the SETUP menus 200, 300 and 400 are summarised again in the quick START menu 100. These are the same settings, e. g. nominal voltage: menu 100/ Un == menu 201, etc. The fields with a grey background either cannot be changed (status displays) or are reset (RESET menu) automatically to “NO”...
  • Page 75 75 s Stage 1…max = 3 var c Stage 1…max = AUTO Stage 1…max = 0 Stage 1…max = 0 h 60 s 500 k 65.5 kh 65.5 kh 30° C 55° C NO/YES xx.xx.xx...
  • Page 76 19.2 k EVEN 1800 s...

  • Page 77: Technical Specifications

    Technical specifications 90 – 550 V AC, single-phase, 45 – 65 Hz, 6 VA, max. protection 6 A, Measuring supply transformer factor adjustable from 1.0…350.0 voltage: 5 mA – 5 A, single-phase, transformer factor adjustable from 1…9600 Current measurement: Relay: Normally open, common supply, max. protection 10A Switching capacity contact: 250 V AC / 5 A Relay outputs:...

  • Page 78: Annex

    Annex ETTING OF PHASE CORRECTION ANGLES DEPENDING ON THE CONNECTION Voltage L1-N L2-N L3-N L1-N L2-N L3-N L1-N L2-N L3-N Current transformer Correction angle 0° 0° 0° 240° 240° 240° 120° 120° 120° Voltage L2-L3 L3-L1 L1-L2 L2-L3 L3-L1 L1-L2 L2-L3 L3-L1 L1-L2 Current transformer Correction angle 90°...
  • Page 80 a_fracxp_en.pdf 2019_05...

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