Power factor correction system
Installation, maintenance and commissioning manual.
power QUALITY
NHP Electrical Engineering Products Pty Ltd
Sales 1300 NHP NHP
nhp.com.au
Commissioning record.....................................................................3
Commissioning manual...................................................................8
Preliminary 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.........................................................................56
Maintenance 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...........................................................................................71
A. 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
commissioning record
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 by
Employee:
Company:
Signature:
Date:
End user signoff:
End user name:
Recommendations / comments:
3
commissioning record
BLR-CX Controller settings
Refer to Section 4.1.1 for further information to the settings shown below.
MENU
FACTORY
SETTING
NHP
SETTING
CUSTOMER
SETTING
100
FACTORY
SETTING
NHP
SETTING
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
503
20 %
7%
200
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
2k
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
513
30 °C
30 °C
300
4
MENU
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
2s
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
YES
1.
For unused stops set to Foff.
2.
Steps switched off if THVD exceeds threshold for specified time.
CUSTOMER
SETTING
commissioning record
BLR-CM Settings
Adjust controller settings to NHP settings. For NHP settings not specified, leave as factory setting.
Factory
setting
nhp
setting
Factory
setting
nhp
setting
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, D
Synchronisation 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, D
CT Type 1A
No
-
Limit Harmonics I
50%
20%
Discharge Time
75s
-
Alarm overload P
No
-
Normal
-
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
Disabled
Switch Interval Step Exchange
2s
10s
Limit Temperature 1
25°C
55°C
Asymmetry Factor
1
-
Hysteresis temperature 1
1.0°C
-
Step Recognition
On
-
Alarm temperature 2
M, D, O
No
Switch 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
-
M, D
-
Synchronisation DI Input
Off
-
M
-
Setup DI input
High
-
MENU
Language
Step Type
Control Alarm
No Current Alarm
1.
1
menu
For unused stops set to Foff.
POWER FACTOR CORRECTION SYSTEM
5
commissioning MANUAL
commissioning MANUAL
Preliminary 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
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........................................................................................................................................................................................ 14
3. Current transformer..................................................................................................................................... 15
3.1 Specification................................................................................................................................................................................... 15
3.2 Installation........................................................................................................................................................................................ 15
3.3 Connection...................................................................................................................................................................................... 15
3.4
CT Wago connection diagram............................................................................................................................................ 16
4. 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.......................................................................................... 53
Appendix.............................................................................................................................................................. 71
8
Appendix A - Cable requirements .......................................................................................................................................................... 71
Appendix B - BLR-CX setup menus ....................................................................................................................................................... 72
Appendix C - BLR-CX expanded setup menu ................................................................................................................................. 73
commissioning MANUAL
Preliminary check
Before 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.
POWER FACTOR CORRECTION SYSTEM
9
commissioning MANUAL
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.
10
commissioning MANUAL
ii) PFC system with CM controller
MEAS. VALUES
HARMONICS
STEPINFO
SETUP
SETUP MENU
PASSWORD 2402
MAIN MENU
MEASUREMENT MENU
MEASUREMENT
CT FACTOR
STEP
VT FACTOR
CONTROL
NOMINAL VOLT.
MEASUREMENT
DISPLAY
ALARM
MANUAL
MODBUS
RESET
CONFIGURATION
CONNECTION
MEASUREMENT
EXTENDED
STEP MENU
DISCHARGE TIME
STEP TYPE
RESET
Q (VALUES)
With reference to the pathways outlined on this page
Settings to be entered:
CONTROL MENU
1. Enter CT ratio. An example is: A 500/5A CT is used then we
input “100” for the CT Factor
COS PHI I
2. Enter VT ratio. If there are no Voltage Transformers then this
setting should be left on one
SWITCH INTERVAL
COS PHI 2
3. Set Nominal Voltage value.
SWITCH INTERVAL
STEP EXCHANGE
4. Select how the measuring lines are connected (typically L-L).
EXTENDED
5. Set up Capacitor Steps:
• Discharge time should be set should be set to
70 seconds or more
• All steps that are not switching capacitor steps should be
switched to the “Off” position
ALARM MENU
CONTROL ALARM
NO CURRENT
STE FAULT
6. Enter COS PHI 1 (Target Power Factor)
STEP WARNING
7. Adjust SWITCH INTERVAL TIME as required, typically
40 seconds.
POWER FACTOR
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.
HARMONICS I
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
HARMONICS U
OVERLOAD P
OVERLOAD Q
P-EXPORT
TEMP1
TEMP2
DI INPUT
P 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 11
commissioning MANUAL
1.Introduction
Before Installation read this manual carefully and
keep it as a reference for future maintenance and
operation requirements.
A microprocessor based regulator, switching a group
of capacitors to achieve a pre set Power Factor value
controls the Power Factor correction (PFC) system.
This manual details the correct installation and
commissioning procedures for a NHP Power Factor
correction 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.
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 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.
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.
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.
12
commissioning MANUAL
2. Installation
Installation 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.
2.1Location
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.
2.2Preparation
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.
P 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 13
commissioning MANUAL
2.4Cable
2.6 Control wiring
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.
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.
Guidelines to determine the appropriate cable size.
• Maximum current rating of PFC system.
• Fault rating of system.
• Physical location of PFC system in relation to main
switchboard.
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.
14
2.7Ventilation
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).
commissioning MANUAL
3. Current transformer
A 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 (bluered-white).
3.1Specification
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.
P 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 15
commissioning MANUAL
3.4 CT Wago connection diagram
282CT2
CT test / disconnect terminal
1 2
1 2
Test plugs
Switches
Jumper
k l
Normal Operation
Figure 2. CT terminal connection
16
k l
Transformer Short Circuit
commissioning MANUAL
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.
P 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 17
commissioning MANUAL
Display and Navigation
The display and controls of the BLR-CX regulator are shown and explained below.
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.
18
commissioning MANUAL
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
P 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 19
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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
function key must
item is displayed along the right hand side of the screen. To select a menu item the
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
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20
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INFO
1.00i
MANUAL
1.00i
SETUP
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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.
SETUP
Press the
function key to enter the setup menu. A 100 should appear on the screen.
100
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.
Un
415 v
SETUP
function key. The value must be changed
This is the L-L voltage and can be adjusted by pressing the
digit by digit starting from the left. A digit can be increased by pressing the
function key or decreased
function key. When the correct digit has been selected, you can continue and repeat the
by pressing the
process by pressing the
function key. Once the Nominal voltage has been set press the
function key
to move to the next parameter.
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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.
Ct
1
SETUP
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.
Ai
NO
SETUP
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.
function key. The value can be increased by pressing the
To adjust the target power factor press 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.
CP1i
0.96
SETUP
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
function key. The value must
between switching different steps. To adjust the switching time press the
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.
St
40 s
22
SETUP
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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
or
function keys to choose an option. Press the
function key when the
function key then use the
desired option is highlighted, press the esc key to return to the menu.
The options are:
•
•
•
•
Auto – Step is controlled according to switching algorithm of regulator.
Fon – Step is permanently switched on.
Foff – Step is permanently switched off.
Al – If temperature limit 1 is exceeded the step is switched as fan output.
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.
OUt
SETUP
Step 8 – Set discharge time for Steps
and
function keys. Once the setup menu
Navigate to the setup menu from the main screen using the
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
100
SETUP
To navigate to the capacitor step setup menu press the
below. If a PIN code is required enter ‘242’.
400
Press the
function key until the 400 menu is displayed as seen
SETUP
function key to select the menu and the capacitor discharge time will be displayed as seen below.
401
75 s
SETUP
function key again on 401 to adjust the discharge time for the capacitors. This should be set to
Press the
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.
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4.1.3 Menu Structures
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.
1.00i
INFO
- Step Information Menu
INFO
CC
50 k var
1 2 3 4 5 6
1 2 3 4 5 6
100 %
1 2 3 4 5 6
OC
1 2 3 4 5 6
Auto
1 2 3 4 5 6
INFO
1 2 3 4 5 6
CC
25 k var
1 2 3 4 5 6
100 %
1 2 3 4 5 6
OC
1 2 3 4 5 6
Auto
1 2 3 4 5 6
24
commissioning MANUAL
Info menu – Step 1
function key. When the INFO light
To navigate to the INFO menu, start at the home screen and press the
function key. All of the available steps will be
is illuminated on the right hand side of the display, press the
displayed along the bottom of the screen with the selected step flashing. In this case it will be the 1st step.
INFO
1 2 3 4 5 6
Step 2
and
function keys can be used to navigate through the steps. Navigate to the 3rd step and press
The
the
function key when the 3 is flashing. This will display the original step size of the 3rd step as seen
similar to below.
CC
50 k var
INFO
1 2 3 4 5 6
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.
100 %
INFO
1 2 3 4 5 6
Percentage of original step size
remaining
OC
2
INFO
1 2 3 4 5 6
Number of Switch Cycles Completed
Auto
INFO
1 2 3 4 5 6
Mode of Operation
Step 4
To step backwards press the esc key and the other steps can then be navigated to using the
function keys. Press the esc key again to return to the home screen.
and
P 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 25
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4.1.3 Menu Structures cont'd
Manual menu
The manual menu can be used to manually turn off and on any of the available steps.
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MANUAL
1.00i
MANUAL
- MANUAL OPERATION Menu
1.00i
1
MANUAL
1.00i MANUAL
2
26
1.00i
3
MANUAL
1.00i
4
MANUAL
1.00i
5
MANUAL
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MANUAL
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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.
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MANUAL
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.
1.00i
1
MANUAL
Step 3
function key.
To turn on the first step (assuming it is off) press the
The first step will now be highlighted at the bottom of the screen as shown right.
1
1.00i
1
MANUAL
Step 4
function key again and the first step will no
To turn off the step press the
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.
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MANUAL
Step 5
To move back to the home screen press the esc function key twice.
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4.1.3 Menu Structures cont'd
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.
Measurement Menu
1.00i
1.00i
Voltage L-L
Odd single
harmonics
Voltage L-N
3 digit PF
Current in
measured phase
Power factor
ratio P/S
Active 3 phase power
Average PF
Reactive 3 phase power
Frequency
Control deviation
in kvar
Temperature
Apparent 3 phase
power
Highest measured
Temperature
Total harmonic
Distortion
Counter operation
Hours
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
To Step back to the home screen press the esc key.
28
and
function keys.
commissioning MANUAL
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
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
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.
1.00i
SETUP
Once the setup menu light is showing on the right hand side, the user must hold the
appears on the screen.
function key until 100
100
SETUP
To navigate to the measurement setup menu press the
function key. If a PIN code is required enter ‘242’.
function key and select the 200 menu using the
Step 2
The user can scroll down to menu item 206 using the
key.
206
0 s
function key and then select using the
function
SETUP
or
function keys to decrease or increase
The compensation angle can then be adjusted using either the
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.
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4.1.5BLR-CX-Schematic
30
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4.1.6 BLR-CX Regulator Alarm Codes
Fault Display
Cause
Remedial Actions
Over or Under Voltage
Check 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
Check if a step may be set as Fon
(permanently on) or if a contact may have
welded
Permanent Under
Compensation
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
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4.1.6 BLR-CX Regulator Alarm Codes cont'd
Fault Display
Cause
Remedial Actions
No display
Auxiliary voltage missing
Check 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 rectify
Check settings in menu “SETUP /
MEASUREMENT”, if necessary rectify
Display “I<LIMIT”
Measurement current too
small
Check connection of CT, a probable break in
the line
CT ratio too high, if necessary replace CT
Remove 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 allowed
Check CT ratio, probably replace by suitable
transformer type
Alarm “Control”
Permanent
overcompensation
Permanent Under
compensation
Check settings
Check contactors, probably contactors stick
together
Check settings
Check capacitors, probably fuse defective
Check 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 large
Necessary reactive power smaller than
switching threshold of step size of the smallest
step
Regulator still doesn’t work
properly
32
Contact NHP Power Quality Department
commissioning MANUAL
4.2 BLR-CM Series Regulator
The 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.
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.
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.
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The BLRCM advanced regulator is supplied pre programmed and factory tested. The display and controls are
shown below.
Display of inductive (i) or
capacitive (c) load
Display of current COS Φ
Capacitor step in use
Top display area
for information and
measurement values
Regulator status
" " shows regulator
functioning normally.
" " shows regulator is
missing vital data
Capacitor step available
Capacitor step “SWITCHED
OFF”. No step attached to
relay output
Digital Output status.
= Active
Regulator step “FIXED
OFF”. Faulty step or
discharge time of capacitor
Alarm relay status.
Symbols for navigation
and functions
Digital input status
= Active
Function keys
Figure 7. BLR-CM Controller LCD Screen
Table 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
34
= Inactive
= Active
= Inactive
= Inactive
commissioning MANUAL
4.2.1 Getting familiar with the BLR CM Controller
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
until you reach the “Main
submenu function key
Menu” screen. From the “Main Menu” the process can
begin again.
Helpful Tips:
• To enter the right sub menu from the “Main Menu”,
the cursor MUST be pointing to the required
option.
• For example, the cursor in figure 8(a) is pointing
to 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
function key until the Main
simply press the
Menu is reached , which is evident when the
is no longer displayed as an option.
• Refer to Table 2 for navigation symbols and
functions.
• Refer to the pathways outlined on the following
page for reference whilst navigating through the
controller.
MEAS. VALUES
HARMONICS
STEPINFO
>
SETUP
<
DEVICE INFO
The following pages of the BLR CM section
contains instructions on the key settings
required to be inputted.
(a)
(b)
Figure 8. BLR-CM Controller LCD Screen
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MEAS. VALUES
HARMONICS
STEPINFO
SETUP
DEVICE INFO
SETUP MENU
PASSWORD 2402
MAIN MENU
MEASUREMENT MENU
MEASUREMENT
CT FACTOR
STEP
VT FACTOR
CONTROL
NOMINAL VOLT.
MEASUREMENT
DISPLAY
ALARM
MANUAL
MODBUS
RESET
CONFIGURATION
CONNECTION
MEASUREMENT
EXTENDED
STEP MENU
DISCHARGE TIME
STEP TYPE
RESET
Q (VALUES)
Navigating through the blr-cm rmb controller
• The pathways and highlighted menu options
indicated on this page highlight the settings related to
setting up the Beluk-CM RMB controller for operation.
• All sub menu options required for input of settings is
accessible via the “SETUP” sub menu. To access this
sub menu we are required to enter a password. The
default password is “2402”.
• The key sub menu options within the “SETUP” sub
menu include “MEASUREMENT”, “STEP”, “CONTROL”
and “ALARM”.
• Within the “MEASUREMENT” sub menu the input
settings of the CT, VT, nominal voltage, and connection
settings are required to configured appropriately.
• As with the “STEP” sub menu, the input settings of
the discharge time and step type are required to
configured appropriately.
• The “CONTROL” sub menu requires the COS PHI
I (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.
• The user can move back and forth between the
sub 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.
36
CONTROL MENU
COS PHI I
COS PHI 2
SWITCH INTERVAL
SWITCH INTERVAL
STEP EXCHANGE
EXTENDED
ALARM MENU
CONTROL ALARM
NO CURRENT
STE FAULT
STEP WARNING
POWER FACTOR
HARMONICS U
HARMONICS I
OVERLOAD P
OVERLOAD Q
P-EXPORT
TEMP1
TEMP2
DI INPUT
commissioning MANUAL
4.2.2 Setting up the Beluk Regulator to measure voltage and current
Step 1 – Navigate and proceed through the
“SETUP” sub menu
• From the “Main Menu” (see figure 9(a)) press the
function key correlating to the
symbol to scroll
down to “SETUP” (see figure 9 (b)).
• Now press the function key with the
symbol
and this will bring up the password screen as shown
in figure 9(c).
Step 2 – Enter Password
• The default password “2402” needs to be entered.
• To do this, a cursor
digit.
will appear under the first
• Press the function keys with the
enter the first digit.
• Then press the
the next digit.
and the
to
once to advance the cursor to
• Use the function keys with the
enter the second digit.
and the
to
• Repeat this process to input the final two digits (see
figure 10 (a)).
• This password can be changed by referring to the
Beluk Reference guide.
(a)
• Once the password has been entered then press
the
key and this will bring up the password
protected menu as shown in figure 10(b).
(b)
(a)
(c)
Figure 9. Navigating through to the
“SETUP” sub menu
(b)
Figure 10.
(a) Password screen
(b) Display screen shown when password entered
correctly
P 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 37
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4.2.2 Setting up the Beluk Regulator to measure voltage and current cont'd
Step 3 – Enter CT Value
NAVIGATION: SETUP
PASSWORD
MEASUREMENT: CT FACTOR
• Note that the cursor is now pointing to
“MEASUREMENT” as shown in figure 10(b).
• Now press the function key corresponding to the 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.
• Then press the
arrow which brings up the
input screen as shown in figure 11(b).
(a)
• As with entering the password the CT FACTOR
screen displays a cursor
under the digit and the
and minus
plus
sign above the middle two
keys.
• The
arrow advances the cursor.
• The CT ratio is divided out and the result entered.
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).
• When we get to the last digit, the
arrow
changes to a return symbol
which when
pressed will bring us back to the “CT FACTOR” menu
with the new value showing.
(b)
(c)
(d)
Figure 11. Entering the CT Value
38
commissioning MANUAL
Step 4 – Enter VT Value
NAVIGATION: SETUP
PASSWORD
MEASUREMENT: VT FACTOR
• Press
once to take us to the VT FACTOR (Voltage
Transformer). See figure 12.
• The same process used in step 3 above (inputting
the current transformer value) can be followed to
enter the Voltage Transformer (VT) ratio.
• If there are no Voltage Transformers then this
setting should be left on one.
Figure 12. VT ratio display screen
Step 5 – Enter Nominal Voltage
NAVIGATION: SETUP
PASSWORD
MEASUREMENT: NOMINAL VOLT
• Once the VT FACTOR has been entered then press
to bring up the nominal voltage value. The
minimum and maximum voltage limits are taken
from this value.
• To input the nominal voltage press
and enter
the values by following the cursor and using the
,
as in previous steps. This is
and
typically set to what the voltage of the system is. For
example, 400 V AC or 415 V AC.
Figure 13. Nominal Voltage screen display
• As with entering the CT ratio, when the last digit
is reached the return symbol
is displayed
and when pressed will take us back to the nominal
voltage screen as displayed in figure 13.
P 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 39
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4.2.2 Setting up the Beluk Regulator to measure voltage and current cont'd
Step 6 – Setting the Line Connection
NAVIGATION: SETUP
PASSWORD
MEASUREMENT: CONNECTION
• To select how the measuring lines are connected
press
and the Measurement option will be
highlighted as shown in figure 14.
• Typically these are set to U=L-L because the
measuring lines are internally connected within the
PFC system and should not require modification.
• This setting can be set to either L-L to L-N by pressing
the
key function as shown in figure 14.
(a)
(b)
Figure 14. Setting the Line Connection.
(a) L- L (b) L- N
40
commissioning MANUAL
4.2.3 Setting up the Beluk Regulator’s capacitor steps
Step 1 – Setting the discharge time for each step
NAVIGATION: SETUP
PASSWORD
STEP: DISCHARGE TIME
• Enter “STEP” sub menu.
• The Step Discharge time screen, as shown in figure
15, 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.
Figure 15. Setting the discharge time for step 01
• The discharge time should be set to 70 seconds or
more.
• Press the
to access the input field.
• As previously done when entering the CT ratio,
follow the cursor and use the
,
.
and
• As before, when the last digit is reached the return
symbol
is displayed and when pressed will
take us back to the discharge time sub menu for the
1st step.
• Pressing the
sign increments to the next step
and the process can be repeated for each step.
P 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 41
commissioning MANUAL
4.2.3 Setting up the Beluk Regulator’s capacitor steps cont'd
Step 2 – Updating status of steps
NAVIGATION: SETUP
PASSWORD
STEP: STEP TYPE
• Scroll to and enter STEP TYPE sub menu.
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.
• To update the steps required to be selected as
“OFF”, press the “
” function key to cycle through
to the first required step.
(a)
(Figure 16(a) shows step 12 has been selected and
its status is “NORMAL”).
• To change the status to “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”.
42
Figure 16(b) shows the status of step 12 as being
“OFF” for example.
(b)
• Cycle through to the next required step and repeat
the process.
Figure 16. Updating the status of relevant steps
commissioning MANUAL
4.2.4 Setting up target power factor
NAVIGATION: SETUP
PASSWORD
CONTROL: COS PHI 1
• Enter “CONTROL” sub menu. The screen display
should now resemble figure 17.
• Press
to enter COS PHI 1.
• Follow the same method used when entering the
CT ratio. Note, when we get to the last digit,
which when
changes to the return symbol
pressed will bring us back to the “COS PHI 1” menu
with the new value showing.
Figure 17. First “CONTROL” sub menu screen
4.2.5 Setting up switch interval time between steps
NAVIGATION: SETUP
PASSWORD
CONTROL: SWITCH INTERVAL
• Scroll to the “SWITCH INTERVAL” display screen (see
figure 18).
• Press the
field.
function key to bring up the input
• The values are entered by following the cursor and
using the
,
.
and
• As with entering the CT ratio, when the last digit is
reached 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
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.
P 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 43
commissioning MANUAL
4.2.6 Commencement of power factor regulation
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.
4.2.7 Connection issues
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
44
commissioning MANUAL
4.2.8 Setting up the Beluk Regulator to compensate for different connections
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.
Table 2. Phase compensation depending on voltage and CT location
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°
Step 1 – Navigating through to the “PHASE COMP” screen
NAVIGATION: SETUP
PASSWORD
measurement
extended
• Enter the MEASUREMENT sub menu (i.e. indicated pathway above or see section 4.2.2 for more detail).
• Now scroll through the “MEASUREMENT” sub menu options and enter the “EXTENDED” sub menu option. The
SYNCHRONISATION 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).
(a)
(b)
(c)
Figure 22. Setting to compensate for different connections.
Step 2 – Changing the “PHASE COMP”
NAVIGATION: SETUP
PASSWORD
measurement
EXTENDED: PHASE COMP
• Normally this field will be set on 000°+90°.
• Push the function key until the compensation is set to required phase offset as indicated by table 3 (Figure
22(c) is an example where the phase offset was altered to “240+90°”.)
P 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 45
commissioning MANUAL
4.2.9 Alarm settings
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
46
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 Warning
A) 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 Current
When 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%
commissioning MANUAL
Alarm Events
M-Relays
The 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 out
The digital output is a volt free output. Is only a
NO contact max. fuse 6A, breaking capacity 250V
AC / 5A.
Display
Shows Alarm on display.
Figure 23. Alarm options as shown on the BLR CM display
Control sleep
All steps are put on hold, control is stopped.
Control halt
All steps are switched off, control is stopped.
Cos phi 2
Switch to second target COS PHI.
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:
• Control Alarm
• No current
• Step Fault
• Step Warning
• Power Factor
• Harmonics U
• Harmonics I
• Overload P
• Overload Q
• P-Export
• TEMP1
• TEMP2
• DI Input
P 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 47
commissioning MANUAL
4.2.9 Alarm settings cont'd
Step 1 – Disabling / Enabling the “CONTROL ALARM”.
NAVIGATION: SETUP
PASSWORD
ALARM: CONTROL ALARM
• First, from the main menu we need to navigate until the “SETUP” sub menu option is highlighted and press
to enter.
• As before we must then enter the password. (For more detail see Section 4.2.2).
• Press
until the “ALARM” sub menu is highlighted (see figure 24 (a)) and press
menu. See figure 24(b).
to enter into the sub
• Now we should see “CONTROL ALARM” on the display with either nothing written below or alarm function(s)
already configured. This is evident if “=>M D” etc. is displayed (figure 24 (b) shows no functions have been
selected).
• If we press the
• Pressing
(a)
symbol then the alarm will be disabled as shown in figure 24(c).
again will enable the alarm though no functions have been selected.
(b)
Figure 24. Disabling / Enabling the “CONTROL ALARM.”
48
(c)
commissioning MANUAL
Step 2 – Assigning the M relay to the “CONTROL ALARM”
NAVIGATION: SETUP
• Now press • Then press
PASSWORD
to move the
ALARM: CONTROL ALARM / M RELAY
symbol in front of the
symbol as shown in figure 25 (a) and (b).
to scroll through the alarm actions that can be assigned to the control alarm.
• The operation of the M relay can be selected by pressing
“NO” to a “YES” (see figure 25 (c) and (d)).
which will confirm the selection by changing
• If the Beluk regulator goes into CONTROL alarm because the target power factor is not reached then the M
relay will operate.
(a)
(b)
(c)
(d)
Figure 25. Assigning the M relay to operate when the “CONTROL ALARM” is triggered.
P 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 49
commissioning MANUAL
Step 3 – Further alarm actions
NAVIGATION: SETUP
PASSWORD
ALARM: CONTROL ALARM / [alarm actions]
to scroll to the next alarm action.
• Use the
• In figure 26 (a), if we decide that we don’t want the “DO” or Digital Output to operate when the control alarm
to scroll past it.
activates then press
• Figure 26 (b) shows that when the control alarm is activated the message is not outputted onto the controllers
display.
and this option is now enabled as shown in figure 26 (c).
• To enable this feature press
and make selections to suit (see figure
• We can scroll through the rest of the alarm actions by pressing
26(d)-(f)).
• Figure 26 (g) shows two alarm functions that we have selected, which are the M relay and a message on the
graphical display.
we can move the
symbol to point at “CONTROL ALARM” as shown in figure 26 (h).
• Using the
.
• We can now scroll through to the next alarm type by pressing
• The same process as above can now be repeated for the rest of the alarm types.
will exit the “ALARM” sub menu.
• Pressing
(a)
(b)
(c)
(d)
(e)
(f)
Figure 26. Alarm Settings
(g)
50
(h)
commissioning MANUAL
BLR-CM regulator alarm codes
Fault Display
Cause
Remedial Actions
No display
Auxiliary voltage missing
Check 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 rectify
Check settings in menu “SETUP /
MEASUREMENT”, if necessary rectify
Display “I<LIMIT”
Measurement current too
small
Check connection of CT, a probable break in
the line
CT ratio too high, if necessary replace CT
Remove 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 allowed
Check CT ratio, probably replace by suitable
transformer type
Alarm “Control”
Permanent
overcompensation
Permanent Under
compensation
Check settings
Check contactors, probably contactors stick
together
Check settings
Check capacitors, probably fuse defective
Check 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 large
Necessary reactive power smaller than
switching threshold of step size of the smallest
step
Regulator still doesn’t work
properly
Contact NHP Power Quality Department
P 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 51
commissioning MANUAL
4.2.10 BLR-CM schematic
Figure 27. BLR-CM Circuit Connections Line – Line Connection
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.
52
commissioning MANUAL
5. Power factor correction system fault finding
General
1.
System will not energise
If System is energised and regulator has Blank display.
• Ensure that normally closed thermostat (red) is set correctly. Refer to section 2.7 for correct settings.
• Ensure that CT has been installed correctly. Refer section 3.0 and as per attached diagram. • Ensure all control fuses are installed.
2.
Indication of capacitive load on regulator
Indication of capacitive load (e.g. c 0.94) on digital display.
• Ensure that CT polarity is correct. Refer to section 3.3 for correct connection.
• Ensure that CT has been installed correctly. Refer section 3.0 and as per attached diagram. • Ensure CT wiring has been installed to correct terminals.
3.
Incorrect operation
Switching additional capacity and PF (cos φ) decreases.
• Ensure correct phase rotation throughout PFC system. Refer section 2.5.
• Ensure that CT has been installed correctly. Refer section 3.0 and as per attached diagram
4.
No change in PF
If regulator switches steps on and off rapidly in 3 successive attempts, with no change in power factor:
• Ensure all fuse disconnector on functional trays are fully closed.
• Check fuses in fuse disconnector for continuity
5.
Regulator will not turn on any steps
• Ensure none of the steps contactors are welded in
• Ensure there is sufficient inductive load for compensation
• Re-evaluate functional tray step kVAr sizing, may require smaller kVAr step increments to achieve PF target. For example, 2 x 25 kVAr instead of 1 x 50 kVAr.
P 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 53
m ai n t e n a n c e r e c o r d
m ai n t e n a n c e r e c o r d
Maintenance of NHP PFC systems
All 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.
56
m ai n t e n a n c e r e c o r d
General maintenance – every three months
Note: 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
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
Clean/replace filters
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
Check tightness of all electrical connections
Remove all dust and deposits, inside and outside
Visual inspection of system
Check function of fans and thermostats
Check tightness of all electrical connections
Remove all dust and deposits, inside and outside
Visual inspection of system
Check function of fans and thermostats
P 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 57
m ai n t e n a n c e r e c o r d
Current measurements – every six months
Note: 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
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
Step #2
Date
Step #3
Date
Step #4
Date
58
m ai n t e n a n c e r e c o r d
Current measurements – every six months
Note: The frequency of this task may need to be increased to suit individual site conditions, especially high
ambient temperatures and excessive harmonics.
Step #5
Date
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
Step #6
Date
Step #7
Date
Step #8
Date
P 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 59
m ai n t e n a n c e r e c o r d
Current measurements – every six months
Note: The frequency of this task may need to be increased to suit individual site conditions, especially high
ambient temperatures and excessive harmonics.
Step #9
Date
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
Step #10
Date
I1 [A]
Step #11
Date
I1 [A]
Step #12
Date
60
I1 [A]
m ai n t e n a n c e r e c o r d
Current measurements – every six months
Note: The frequency of this task may need to be increased to suit individual site conditions, especially high
ambient temperatures and excessive harmonics.
Step #13
Date
I1 [A]
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
I2 [A]
I3 [A]
UL1L2 [V] UL1L3 [V] UL2L3 [V] Comments
Initials
Step #14
Date
I1 [A]
Step #15
Date
I1 [A]
Step #16
Date
I1 [A]
P 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 61
m ai n t e n a n c e r e c o r d
PFC-P Current envelope, voltage reference at bus connection
62
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P 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 63
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PFC-E Current envelope, voltage reference at bus connection
64
m ai n t e n a n c e r e c o r d
P 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 65
m ai n t e n a n c e r e c o r d
Maintenance parts list
Parts 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
Item Description
Item no.
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)
66
Item Description
Item no.
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 12.5 kVar tray
N0032
DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 25 kVar tray
N0063
DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 50 kVar tray
N00125
6.25 kVAr functional tray
FTSR6CQE
12.5 kVAr functional tray
FTSR12CQE
25 kVAr functional tray
FTSR25CQE
50 kVAr functional tray
FTSR50CQE
m ai n t e n a n c e r e c o r d
PFC-E unit specific
Item Description
Item no.
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 12.5 kVar tray
N0032
DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 25 kVar tray
N0063
DIN fuse links (Wöhner DIN fuse disconnector) – 3 required per 50 kVar tray
N00125
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 components
The 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
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
Contactor
P 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 67
A P P END I X
NHP SERVICE PROVIDES A COMPREHENSIVE RANGE OF
app e n d i x
VALUE ADDED SERVICES THAT SUPPORT AND ENHANCE
THE RELIABILITY AND PERFORMANCE OF NHP PRODUCTS
FIELD SUPPORT SERVICES - PFC
Preventative maintenance
Our team
Products 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.
Our team of qualified technicians is available for a
variety of lifecycle services, including power factor
correction, which involves:
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 service
•
•
•
•
Product repairs and service
On site emergency breakdown service
Preventative maintenance and
Commissioning
Economical advantage
Through 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.
WHAT 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
70
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.
app e n d i x
Appendix A: Cable requirements
Copper conductor, de-rating factor 1, Unenclosed
In accordance with:
a) AS 3000:2007
b) AS3008.1.1:2009 – Table 8, column 9.
* Allowance for overloading and cables touching, unenclosed.
PFC System Rating
Cable rating
kVAr
Nominal
Amps
135% Nominal
Amps
Min. conductor
size (mm²)b)
Max. current cap.
(A)b)
100
139
188
95
230
150
209
282
150
310
200
278
376
240
250
348
470
2 x 120 )
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
2
3 x 185 )
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 )
1420
750
1043
1409
4 x 185 )
1420
425
1
3
3
) Alternative – 1 x 300 mm² cable.
1
) Alternative – 2 x 300 mm² cables.
2
) Alternative – 3 x 300 mm² cables.
3
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.
P 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 71
app 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.
1.00i
SETUP
This is the quick start menu and contains all basic parameters required to start the PFC.
100
SETUP
This is the measurement settings menu and contains all basic connections settings (VT, CT, Compensation angle).
200
SETUP
This is the control optimisation menu and contains settings to improve and adjust performance.
300
SETUP
This is the step setup menu and allows adjustment and adaptation of the steps.
400
SETUP
This is the alarms menu and contains settings to configure all alarms and monitoring capabilities.
500
SETUP
This is the reset menu and allows various aspects of the regulator to be reset
or everything to be reset to factory standards.
600
72
SETUP
app 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
204
Voltage Tolerance (percentage of nominal voltage)
This tolerance sets the limits of permissible nominal voltage before an
alarm is triggered.
0…100%
205
Voltage 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
208
Auto Initialize on Startup
Yes – Countdown to initialize is shown on starting the BLR-CX
No – The countdown is not shown on startup.
Yes / No
209
Synchronization Frequency
Setting the sampling rate to match the frequency of the grid supply
if auto is too unreliable.
Auto / FIX50Hz /
FIX60Hz
210
Temperature Offset
Allows correction of temperature reading.
-10ºC…10ºC
P 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 73
app e n d i x
Appendix C: BLR-CX Expanded Setup Menu cont'd
Control Optimization (300)
Menu No.
74
Description
Options
301
Control Sensitivity
Sensitivity 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 1
This is the primary power factor setting.
0.7…0.99
303
Cos ø 2
This is the secondary power factor setting which can be switched to
by the digital input.
0.7…0.99
304
Cos 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
305
Switch Interval
The time delay in switching steps for regulation. Long enough to build
an average reactive power and prolong contactor life.
0…6500s
306
Switch Interval Step Exchange
The time delay in swapping out an active step for another step to
achieve a better power factor.
0…6500s
307
Activate 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 monitored 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
to PF, it is blocked and no longer used by the controller. Faulty steps
are tested every 24hrs or when the controller starts up.
No – Steps are continued to be used even with no network reaction,
causing unnecessary switching.
Yes / No
310
PF Control
On – Automatic Control.
Off – Control Stops and active steps are disconnected successively.
Hold – Control stops and active steps remain on.
On / Off / Hold
311
Control Algorithm
1 - Auto – Before each switching operation all available steps are compared against the control deviation and the best selected.
2 - LIFO – The controller starts regulation by switching in step 1 and
continuing with the following steps. When taking out steps it takes out
the last active step switched in.
3 - Combined Filter – Special Algorithm for combined filter banks
with two different detuned ratings. Working like with best fit.
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
app e n d i x
Menu No.
Description
Options
312
Offset Reactive Power
This can be used to offset a permanent reactive load which cannot be
measured (i.e. transformer).
0.0…900.0 kvar
313
Asymmetry Factor
This factor is the ratio between switch interval for switching on and
switching off.
X = 1 = equal
X = 2…127: delay switching off
X = -2…-127: delay switching on
Result = Switch interval multiplied by X.
-127…127
314
Q Capacitive Steps Turn Off
Yes – When the network condition is considered capacitive, the steps
are turned off.
No – The controller only considers the cos ø control target.
Yes / No
Step Setup (400)
Menu No.
Description
Options
401
Discharge Time
The discharge time is a blocking time for the capacitor which starts
after it has been switched off. It cannot be used again until the
discharge time has expired.
5…1200s
402
Step Nominal Value
This allows each step size value to be manually entered in kvar.
The CT factor and nominal voltage MUST be set beforehand as
these values will affect capacitance step sizes.
0.0…999.9 kvar
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
P 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 75
app e n d i x
Appendix C: BLR-CX Expanded Setup Menu cont'd
Alarm Settings (500)
Menu No.
76
Description
Options
501
Reset Alarm Manually
YES – Have to hold esc key for 5 seconds to reset alarms
NO – Once alarm condition is removed, alarm turns off.
Yes / No
502
Total 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
505
Trigger 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 – The temperature input works with temperature sensor and
the thresholds are set as per 513 and 514.
Yes / No
511
Digital 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
app e n d i x
Menu No.
Description
Options
512
Temperature Alarm
YES – The temperature is monitored according to the thresholds and responds accordingly.
NO – No alarm for temperature.
Yes / No
513
Temperature 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 controller 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 difference 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 Settings
Set all settings back to factory standard.
Yes / No
602
Reset Step Database
Set all step data back to factory standard.
Yes / No
603
Reset Operation Hours
Set Operation Hours back to 0.
Yes / No
604
Reset Average Power Factor
Yes / No
605
Reset Maximum Temperature
Resets the highest measured temperature.
Yes / No
606
Reset Alarms
Reset all existing active alarms.
Yes / No
607
Display software version of the controller
1.xx
P 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 77
NO T ES
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78
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P 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 79
AUSTRALIA
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