Beluk CX plus Reference Manual
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Beluk CX plus Reference Manual

Reactive power controller
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Technical documentation
Rev. 02
Reactive Power Controller CX plus
REFERENCE MANUAL
REACTIVE POWER CONTROLLER
CX plus
Beluk GmbH
Taubenstrasse 1
D-86956 Schongau
Germany
Tel.: +49/(0)8861/2332-0
Fax: +49/(0)8861/2332-22
E-Mail:
blr@beluk.de
http://www.beluk.de

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  • Page 1 Technical documentation Rev. 02 Reactive Power Controller CX plus REFERENCE MANUAL REACTIVE POWER CONTROLLER CX plus Beluk GmbH Taubenstrasse 1 D-86956 Schongau Germany Tel.: +49/(0)8861/2332-0 Fax: +49/(0)8861/2332-22 E-Mail: blr@beluk.de http://www.beluk.de...

  • Page 2: Table Of Contents

    INFO (step database) ......................24 MANUAL (manual operation: Manually switch steps on and off)......... 26 SETUP (setup menu) ......................28 Expert SETUP menu CX plus ....................31 100 Quick START setup ...................... 33 200 Settings Measurement ....................35 300 Settings control ......................37 400 Settings step database....................

  • Page 3: Safety Notes

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 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 4 Reactive Factor Controller CX plus ! DANGER During the installation of the CX plus, there is a risk of electric shock. For this reason, installation, commissioning and maintenance may exclusively be performed by a skilled electrician with the necessary qualification. A skilled electrician is a person who has the ability, experience and knowledge necessary for the construction, installation and operation of electrical equipment and systems and who is trained in the detection and prevention of potential hazards.

  • Page 5: Installation And Commissioning

    Reactive Factor Controller CX plus 2 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 area must be disconnected from voltage and secured against unauthorised and unintentional restart.

  • Page 6: Wiring Diagrams

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 3 Wiring diagrams CX plus-12R List of options Designation Explanation CX plus -06R 6 output / step relay -12R 12 output / step relay Modbus RTU – Connection via RS485 3-wire bus...

  • Page 7: Connection Data

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 4 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.
  • Page 8 Technical documentation Rev. 02 Reactive Factor Controller CX plus Service interface. For service purposes only. ! CAUTION Exception: The current transformer factor (SETUP/Ct) must be entered in order to correctly calculate the measurement values and to correctly identify the step sizes.

  • Page 9: Commissioning

    From this moment on, the discharge time lock of the capacitors is active (factory setting: 75 sec.). After the discharge time lock, the CX plus starts controlling. In the process, the step sizes are determined automatically. Step outputs which are not occupied are set to the step type “FOFF”...

  • Page 10: Questions During Commissioning

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 6 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 Technical documentation Rev. 02 Reactive Factor Controller CX plus Solution: Correct the connection, execute the “Automatic initialisation (AI)” or add 180° to resp. subtract 180° from the set phase correction angle (SETUP/206) (new angle < 360°). Please observe the separate notes at the end of the chapter for the setting of the phase correction angle.
  • Page 12 Technical documentation Rev. 02 Reactive Factor Controller CX plus The step sizes may be too small. Solution: Enter the phase correction angle (SETUP/206) manually and switch on the control again (SETUP/100/PFC or SETUP/310). If the “Automatic initialisation” (AI) is not successful after several attempts, it is alternatively possible to manually set the correct phase correction angle (SETUP/206).
  • Page 13 Technical documentation Rev. 02 Reactive Factor Controller CX plus Possible causes: The initial values of the step power of the individual steps are still saved in the step database. By switching the steps, the step powers of the individual capacitors are identified and saved in the step database.
  • Page 14 Technical documentation Rev. 02 Reactive Factor Controller CX plus Prior to disconnecting the current measurement path at the device resp. at the current transformer, the current transformer must be short-circuited. Otherwise, there may be a life- threatening voltage at the connections of the current measurement path resp. of the transformer.

  • Page 15: Indications On The Display

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 7 Indications on the display The currently selected main menu is shown on the right side of the display. INFO: Step database AUTO: Control is active: Steps are switched on and off automatically.
  • Page 16 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.
  • Page 17 Technical documentation Rev. 02 Reactive Factor Controller CX plus The second temperature limit has been exceeded. Steps will be or were already switched off one by one. Set limit value of the operating hours has been exceeded. Set limit of the maximum permissible switching cycles of one or several steps has been exceeded.
  • Page 18 Technical documentation Rev. 02 Reactive Factor Controller CX plus Status messages: Temperature limit 1 has been exceeded; switching output fan is switched on. NOTE: The activation of the switching output fan and the display of the fan message only occur, if the function Use switching output FAN as step switching output (SETUP/406) is deactivated (NO).

  • Page 19: Operation

    Reactive Factor Controller CX plus 8 Operation: The CX plus is operated using 4 keys. NOTE: If no key is pressed within 60 s, the backlighting is switched off. If the backlighting is switched off, the backlighting is first switched on by pressing one of the 4 keys.
  • Page 20 Technical documentation Rev. 02 Reactive Factor Controller CX plus You may cancel the entry of a value at any time with the key "": Press the key "" until the first digit (on the left) is selected. The entry is cancelled without accepting the new value by pressing the key...

  • Page 21: Menu Cx Plus

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 9 Menu CX plus Measurement value 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".
  • Page 22 Technical documentation Rev. 02 Reactive Factor Controller CX plus 1.00 Harmonic 1.41 distortion U total Odd harmonic 0.40 U 3 - 19 1.00 Harmonic distortion 1.67 I total Odd harmonic I 0.74 3 - 19 1.00  0.999 three-digit cos...
  • Page 23 Technical documentation Rev. 02 Reactive Factor Controller CX plus Highest measured temperature °C Operating 188.9 hours counter  0.99 Highest measured voltage L - L Highest measured 2.66 harmonic distortion U total Jump upwards Voltage L - L...

  • Page 24: Info (Step Database)

    Technical documentation Rev. 02 Reactive Factor Controller CX plus INFO (step database) The switching cycles, the operating hours, the step type / status, the current step power and the step power with regard to the initial power (in %) are displayed in the “INFO” menu for each step. With these data it is possible to draw conclusions about the condition of the system and the condition of the individual steps.
  • Page 25 Technical documentation Rev. 02 Reactive Factor Controller CX plus Jump upwards Display of the step size INFO Display of the step size is only active, if the CT has been kVar set, otherwise ---- max. max. Operating hours of the step...

  • Page 26: Manual (Manual Operation: Manually Switch Steps On And Off)

    MANUAL (manual operation: Manually 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” menu. In order to prevent an unintentional stopping of the control, this menu item is provided with a key lock (keep the key ""...
  • Page 27 Technical documentation Rev. 02 Reactive Factor Controller CX plus 1.00 1.00 Select the step The current COS INFO is displayed for with Switch a step on each switching operation. or off with Observe the discharge times! 1.00 0.95 1.00 1.00...

  • Page 28: Setup (Setup Menu)

    COS-PHI and of the step sizes is incorrect and the control does not work correctly or not at all. The CX plus can be adjusted to the system conditions and be optimised in the setup menu at any time.
  • Page 29 Technical documentation Rev. 02 Reactive Factor Controller CX plus 1.00 1.00 INFO 1.00 MANUAL 1.00 Setting of the nominal voltage Un = phase voltage. This value is required for the monitoring of the SETUP SETUP V SETUP voltage tolerance. The step sizes saved in the step database also refer to the nominal voltage.
  • Page 30 Technical documentation Rev. 02 Reactive Factor Controller CX plus Switching time, waiting time between switching the individual steps on and off S SETUP Setting of the step type for each individual step: SETUP Select the step number with Select the step with AUTO: Step is active.

  • Page 31: Expert Setup Menu Cx Plus

    Reactive Factor Controller CX plus Expert SETUP menu CX plus In order to change from the quick START SETUP menu to the EXPERT SETUP menu of the CX plus, press the key . You are now requested to enter a PIN. The standard PIN is 242.
  • Page 32 Technical documentation Rev. 02 Reactive Factor Controller CX plus 500 Settings ALARM Almost all alarms and monitoring functions can be activated / deactivated and limit values can be set in the alarm menu. 600 Reset menu Allows resetting all made settings, values saved by the controller and counters. Additionally, it is possible to call up the software version of the device and to set the password (PIN) for the expert setup menu.

  • Page 33: 100 Quick Start Setup

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 100 Quick START setup Contains all settings important for commissioning. Quick START setup MENU FUNCTION AREA 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 34 NOTE: The automatic initialisation (AI) can only identify the phase, if capacitors are connected to the switching outputs. If the CX plus compensates the reactive power by means of reactors, this function will cause errors. AI works best when there are constant load conditions.

  • Page 35: 200 Settings Measurement

    Steps which are set to the step type “Flty” can be switched back to the desired step type in this menu. 200 Settings Measurement Contains settings in order to adjust the measurement of the CX plus to the network conditions. Settings Measurement MENU...
  • Page 36 NOTE: The automatic initialisation (AI) can only identify phases, if capacitors are connected to the switching outputs. If the CX plus compensates the reactive power by means of reactors, this function will cause errors. AI works best when there are constant load conditions.

  • Page 37: 300 Settings Control

    Technical documentation Rev. 02 Reactive Factor Controller CX plus AUTO: Automatic synchronisation for highest measurement accuracy at mains voltage without commutation notches. 50: FIX-50 HZ for a safe operation in 50 Hz mains with extremely poor mains quality. 60: FIX-60 HZ for a safe operation in 60 Hz mains with extremely poor mains quality.
  • Page 38 Technical documentation Rev. 02 Reactive Factor Controller CX plus switching on a step which fits more precisely to the determined need for reactive power. The normal switching time is not observed for the step exchange. Activate step exchange Yes/No "YES": The controller tries to better reach the control target by means of step exchange.
  • Page 39 Technical documentation Rev. 02 Reactive Factor Controller CX plus 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 steps are switched off one by one at 3 second intervals.
  • Page 40 Technical documentation Rev. 02 Reactive Factor Controller CX plus NOTE: The step exchange function and the switching distribution (switching cycles or operating hours) are always deactivated in case of steps of the same size. NOTE: It is not possible to switch the steps manually.
  • Page 41 Technical documentation Rev. 02 Reactive Factor Controller CX plus on, the control starts with step 1 next. It is checked individually for each step, if the switching operation is useful. This may lead to an unprecise compensation in case of steps of different sizes.

  • Page 42: 400 Settings Step Database

    Technical documentation Rev. 02 Reactive Factor Controller CX plus Distribute switching operations of the steps via the operating hours of the individual steps “NO": The switching operations of steps of the same step size are distributed via the switching cycles of the individual steps.
  • Page 43 Technical documentation Rev. 02 Reactive Factor Controller CX plus are not used should be set to this step type in order to prevent unnecessary switching operations and alarms.  Flty = Step was switched three times without success and identified as defective.
  • Page 44 Technical documentation Rev. 02 Reactive Factor Controller CX plus Switching output fan as further step output Yes/No "NO": The switching output fan works normally. The fan control function via the alarm system is active. "YES": Switching output fan is available as 7 resp.
  • Page 45 Technical documentation Rev. 02 Reactive Factor Controller CX plus Settings ALARM MENU FUNCTION AREA 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.
  • Page 46 Technical documentation Rev. 02 Reactive Factor Controller CX plus time is, at the same time, also the switch-off interval of the steps in case of an alarm, if the setting SETUP/503 is activated. Stop the control if I == 0...
  • Page 47 Technical documentation Rev. 02 Reactive Factor Controller CX plus before, if necessary. After this, manually set the operating hour counter of the controller under SETUP/603 back to 0 h. The alarm messages (display and alarm relay) are not reset automatically until the switching cycle counters of all steps have fallen below the set limit and the function “Manual reset“...
  • Page 48 Technical documentation Rev. 02 Reactive Factor Controller CX plus "NO" = LOW active: No signal is applied at the digital input  active Signal applied at the digital input  not active NOTE: The digital input can be used either for switching to the target COS ...
  • Page 49 Technical documentation Rev. 02 Reactive Factor Controller CX plus "NO": Control alarm is deactivated. Step alarm: Faulty steps Yes/No "YES": Alarm for faulty steps is activated. If the function SETUP/309 is activated and if a step is identified as faulty after 3 unsuccessful switching operations, the step alarm faulty steps is signalled.
  • Page 50 Technical documentation Rev. 02 Reactive Factor Controller CX plus "YES": Digital input can be used in order to supress the I-LOW alarm. Info: I-LOW alarm suppression For information purposes only. No settings possible. "YES" = Digital input is active; I-Low alarm is suppressed.

  • Page 51: 600 Reset Menu

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 9.10 600 RESET menu Enables the resetting of all settings made, of the values saved by the controller and of the counters. In addition, it is possible to request the software version of the device and to change the password (PIN) for the expert setup menu.

  • Page 52: 700 Settings Modbus (Communication Interface)

    Technical documentation Rev. 02 Reactive Factor Controller CX plus RESET maximum measured temperature Yes/No “YES”: Resets the value of the maximum measured temperature. After confirming the setting with “YES”, the RESET takes place. The setting will automatically return to “NO”.

  • Page 53: Alarm Memory Menu

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 700 Settings MODBUS (communication interface) Contains settings in order to parametrise the MODBUS-RTU communication interface (RS485). NOTE: This submenu is only available with the option -MB. Settings MODBUS MENU FUNCTION AREA...
  • Page 54 Technical documentation Rev. 02 Reactive Factor Controller CX plus 1.00 1.00 INFO 1.00 MANUAL 1.00 SETUP 1.00 ALARM I Lo...

  • Page 55: Technical Specifications

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 10 Technical specifications 90 – 550 V AC, single-phase, 45-65 HZ, 6 VA, max. protection 6 A, Measuring and supply voltage: transformer factor adjustable from 1.0…350.0 5 mA – 6 A, single-phase, transformer factor adjustable from 1…9600...
  • Page 56 Technical documentation Rev. 02 Reactive Factor Controller CX plus IEC 61000 6- 2 IEC 61000 6- 4: level B IEC 61326- 1 UL 61010 Conformity and listing: CE, NRTL(UL), c NRTL (cUL), EAC Connection: Screw terminals, pluggable, max. 4 mm²...

  • Page 57: Troubleshooting

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 11 Troubleshooting Fault / alarm Possible cause Remedy  Measuring / supply voltage  Check, if the connected No notification on the display misses measuring voltage is in the range of 90…550 V AC.
  • Page 58 Technical documentation Rev. 02 Reactive Factor Controller CX plus measurement” (SETUP/205), correct it, if necessary (depends on the set nominal voltage)  Incorrect current transformer  Check the setting of the Incorrect display of the current ratio has been set.
  • Page 59 Technical documentation Rev. 02 Reactive Factor Controller CX plus overcompensation / under- settings. compensation  Check the power  (The controller could not contactors, the contactor reach the target COS-PHI contact may be stuck after a 75-fold switching time, together or the contactor because no suitable step is coil may be defective.
  • Page 60 Technical documentation Rev. 02 Reactive Factor Controller CX plus PHI is inductive. of S1 / S2). phase correction angle (new angle < 360°) and enter.  Step types incorrect settings  Check the settings of the Individual steps are neither...
  • Page 61 Technical documentation Rev. 02 Reactive Factor Controller CX plus  Step alarm step power loss:  Check the power loss of the Alarm affected steps (relation of  The ratio of the current to the the current to the original...
  • Page 62 Technical documentation Rev. 02 Reactive Factor Controller CX plus  NO = LOW active  YES = HIGH active  The function of the digital  Check the setting for the input is switched to switching between display notification “NT”, control “Suppression of I-LOW...

  • Page 63: Applications

    The controller has only 6 or 12 switching outputs. An additional switching output, however, is required for a step. Solution: The CX plus offers the possibility to use the switching output for the fan as additional switching output for a step. Procedure: ...

  • Page 64: Fan Activation

    The controller shall take over the fan activation depending on the temperature in the switch cabinet. Solution: The CX plus is equipped with a temperature sensor (NTC) integrated under the housing. The limit value, at which the switching output for the fan shall be activated, can be set in the alarm system.

  • Page 65: Over-Temperature Switch-Off Steps

    Solution: The CX plus is equipped with a temperature sensor (NTC) integrated under the housing. The limit value, at which the switching outputs of the active steps shall be switched off one by one while the temperature alarm is still active, can be set in the alarm system. In this way, the steps are protected against overheating and the temperature in the switch cabinet can return to normal.

  • Page 66: Thd-U / Thd-I Protection

    Solution: The alarm system of the CX plus can react when the set limit values of the entire harmonic distortion on the voltage (THD-U) or on the current (THD-I) is exceeded and it can switch off all active steps in order to protect the capacitors.

  • Page 67: Switching To Target Cos  2 Via The Digital Input

    Reactive Factor Controller CX plus 12.5 Switching to target Cos  2 via the digital input The CX plus shall be switched to the second target COS  via an external switching signal. Solution: The digital input of the controller may be used for switching to the set target COS  2.
  • Page 68 Technical documentation Rev. 02 Reactive Factor Controller CX plus “YES” = HIGH active “NO” = LOW active Function: If the digital input is activated, an active I-LOW alarm is suppressed. “YES” is shown on the status display for the I-LOW alarm suppression (SETUP/519).

  • Page 69: Detection Of Step Power Loss (Step Power Loss)

    Reactive Factor Controller CX plus 12.7 Detection of step power loss (Step Power Loss) The CX plus shall detect the power loss of the individual steps and switch off and permanently lock the affected steps in case the value falls below a limit value.

  • Page 70: Identification / Manual Entry Of Step Sizes

    13.1 Step identification is activated – Automatic identification of the step size If the step identification is activated (SETUP/308 = YES), the CX plus automatically determines the step size after switching on and after switching off a step, respectively. This value is saved as the current step size for this step in the step database after the first switching operation.

  • Page 71: Step Identification Is Deactivated / Manual Entry Of The Step Sizes

    The monitoring of the step power loss is active for this step from now on. The CX plus continuously adjusts the current step size to the determined value when switching a step on and off. The adjustment takes place softly, so that a heavy load fluctuation during the measurement does not falsify the step size.

  • Page 72: Identification / Resetting Of Defective Steps

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 14 Identification / resetting of defective steps If the controller has identified a step as defective (3 consecutive switching cycles without mains reaction) and blocked this (step type = “Flty”), this step is blocked for the control for 24 hours.

  • Page 73: Automatic Distribution Of Switching Operations To Steps

    16 Automatic distribution of switching operations to steps The CX plus automatically distributes the switching operations to all connected steps of the same size. This is realised either via the switching cycle counters of the individual steps (default setting) or via the operating hours of the individual steps.

  • Page 74: Procedure Of The Automatic Initialisation

    Technical documentation Rev. 02 Reactive Factor Controller CX plus whether or not steps are connected at the switching outputs. Not occupied switching outputs are set to the step type “FOFF”. NOTE: The “Automatic initialisation” does not perform an identification of the step sizes.

  • Page 75: Problems During The Ai / Cancellation Of The Ai

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 17.2 Problems during the AI / cancellation of the AI If the automatic initialisation cannot identify the phase angle during a maximum of 4 cycles, the AI is cancelled with error message: The messages are shown alternatingly on the display.

  • Page 76: Control Algorithm

    Rev. 02 Reactive Factor Controller CX plus 18 Control algorithm 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)

  • Page 77: Lifo

    Technical documentation Rev. 02 Reactive Factor Controller CX plus ! CAUTION The defective step is switched on and immediately switched off again. If the control target has not been reached yet, the affected step is continuously switched on and immediately switched off again in the cycle of the switching time.

  • Page 78: Progressive

    Technical documentation Rev. 02 Reactive Factor Controller CX plus times, this step will be skipped by the control. Steps which have been switched off by the alarm system via the step switch-off sequence and have been locked for max. 30 min. are also skipped.
  • Page 79 Technical documentation Rev. 02 Reactive Factor Controller CX plus switched on, the control starts with step 8 when switching on. If step 12 has been switched on and step 1 has not yet been switched on, the control starts with step 1 next. When switching off, the control starts with step 3.

  • Page 80: Transformer Compensation

    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. By setting an offset reactive power = reactive power of the transformer (SETUP/312), this is added to the measured reactive power (within the system).

  • Page 81: Mixed Measurement

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 19.2 Mixed 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...

  • Page 82: Default And Customer Settings

    Technical documentation Rev. 02 Reactive Factor Controller CX plus 20 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.
  • Page 83 Technical documentation Rev. 02 Reactive Factor Controller CX plus 75 s Step 1…max = 3 var c Step 1…max = AUTO Step 1…max = 0 Step 1…max = 0 h 60 s 500 k 65.5 kh 65.5 kh 30° C 55°...

  • Page 84: Revision List

    22.2 Connection in case of mixed measurement Vector group Current transformer Voltage L2-N N-L3 N-L1 L2-N N-L3 N-L1 L3-L2 L2-L1 L1-L3 L3-L2 L2-L1 L1-L3 Dy11 N-L2 Dy11 L3-N Dy11 L1-N Yz11 N-L2 Yz11 L3-N Yz11 L1-N Errors excepted and subject to modifications. Beluk GmbH, July 2017...

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