Beluk BLR-CX-R User manual

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
Beluk GmbH
Taubenstrasse 1
86956 Schongau
Germany
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Web: http://www.beluk.de
REFERENCE MANUAL
POWER FACTOR REGULATOR
BLR-CX-R / BLR-CX-T

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
2
1 INSTALLATION AND CONNECTION ..................................................................................... 4
1.1 Wiring diagram........................................................................................................... 5
1.2 Connection data ......................................................................................................... 6
2 COMMISSIONING ............................................................................................................... 7
3 DISPLAY............................................................................................................................... 8
4 OPERATION....................................................................................................................... 10
4.1 Keys .......................................................................................................................... 10
4.2 Input of numerical values......................................................................................... 10
5 MENU BLR-CX ................................................................................................................... 11
5.1 Measurement menu................................................................................................. 11
5.2 Info (Step database) ................................................................................................. 12
5.3 Manual (step switching manual).............................................................................. 13
5.4 Setup (Quick start menu) ......................................................................................... 14
6 EXPERT MENU BLR-CX...................................................................................................... 15
6.1 100 Quick start menu............................................................................................... 16
6.2 200 Measurement settings ...................................................................................... 18
6.3 300 Setup Control System........................................................................................ 20
6.4 400 Setup Step Database ......................................................................................... 24
6.5 500 Setup Alarm....................................................................................................... 26
6.6 600 Resetmenu ........................................................................................................ 28
7 TECHNIAL DATA................................................................................................................ 30
8 TROUBLESHOOTING ......................................................................................................... 31
9 APPLICATIONS .................................................................................................................. 33
9.1 Fan Control ............................................................................................................... 33
9.2 ...................................................................... 34
9.3 Problems with the Step recognition. ....................................................................... 35
9.4 Transformer compensation...................................................................................... 36
9.5 Reset defective steps respectively add aditional steps ........................................... 37
10 CUSTOMER SETTINGS................................................................................................... 38
11 APPENDIX ..................................................................................................................... 39
11.1 Settings Phase-angle ................................................................................................ 39
11.2 Connections for mixed measurement...................................................................... 39

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
3
Document history
Date
Name
Revision
Comment
22.07.09
Le
01
initial document release
25.01.10
Le
02
Examples added, changes to software
version 1.04
16.06.10
Le
03
Add features of software version 1.06
09.02.11
14.06.16
13.03.17
Le
RH
RH
04
05
06
Add features of software version 1.08
Content correction
Content correction
17.07.18
SO
07
Content correction

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
4
ATTENTION!
The installation of the BLR-CX must be performed by technically qualified persons only, since
improper use can cause an electric shock.
The appropriate safety regulations in the country of installation must be strictly adhered to.
Equipment with damaged casing or terminals must not be used and must be disconnected
from the mains supply immediately.
1INSTALLATION AND CONNECTION
1) Check that the mains voltage and CT current input are suitable for the relay!
2) Disconnect panel from mains voltage, and check that the voltage is off
3) Ensure CT short-circuited or not in operation.
An open circuit CT produces a high voltage, which endangers people and equipment. It will
also damage the CT and affect ist accuracy.
4) Disconnect and remove any previous pfc-relay.
5) Mount BLR-CX in the control panel with the two mounting clips. (cutout 138x138mm)
6) Connect the earth protection cable to ‘PE’ on BLR-CX metal case.
7) Connect BLR-CX according to wiring diagram.(CT/P1 towards incoming feeder, CT/P2
towards load!)
8) Remove short-circuit from CT
9) Connect mains voltage to panel.
10) If relay has been correctly connected and the mains voltage and CT output comply with
the ratings and settings of BLR-CX, the LCD will show AUTO and the control function will
start automatically!

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
5
1.1 Wiring diagram
BLR-CX-R
BLR-CX-T
T
K L Um1 Um2 AM
MS 114 1-14T1 T2
Controll exits can
be parametered
for fan controll
K1 K14
K1-K14
L1
L2
L3
N
PE
BLR-CX
TTL
X/1A or X/5A
15mA- 6A 90V - 550V
power-input
utility
Interface
load
external
temperature sensor
or temperature switch
(parallel use of sensor
and switch is possible)
signal:
in order
(life-contact)
up to 14
control exits
external
temperature sensor
or temperature switch
(parallel use of sensor
and switch is possible)
T
LUm1 Um2 AM
MS 112T1 T2
BLR-CX
TTL
15mA - 6A 90V - 550V
+-
Triggerinput
BEL-TSXX
K
L1
L2
L3
PE
N
L
LF
X/1A or X/5A
power-input
utility
power-input
utility
Interface
load
signal:
in order
(life-contact)
Fan control up to 12
control exits

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
6
1.2 Connection data
Meas.- Supply voltage
Combined measurement and Power supply
Range 90-550V.
Terminals UM1 / UM2
With using of VT a ratio can be adjusted.
Range 1-350
Current measurement
Current measurement
Range 15mA –6A,
Measurement transformer types x/1A or also x/5A can be
used.
Terminals K (S1) / L (S2)
CT ratio is 1-9600
(Devices with Firmware before 1.04 had the adjustable range
from 1-4000)
Regulation exits
Assembly with 4, 6, 8, 10, 12, 14 Regulation exits possible.
Regulation exits volt free with common root.
Terminals A 1-14.
max. breaking capacity 5A/250VAC
Static outputs
Assembly with 6 or 12 static outputs possible.
open-collector, breaking capacity: 8 –48V DC / 100mA
Alarm contact
Opens in case of alarm and grid failure (can be changed by
software). Terminals M / MS
max. breaking capacity 5A/250VAC
Separate fan control
(only BLR-CX-T)
Closes terminals L / LF when exceeding temperature limit 1
max. breaking capacity 5A/250VAC
Temperature sensor /
Digital Input
Temperature measurement or Digital Input to switch over to
Terminals T1 / T2
Setting is explained in the Alarm menu.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
7
2COMMISSIONING
The BLR-CX comes with factory settings, which allows operation in 400V grid without any
settings, if the connection is correct.
After applying voltage, the display shows the measured cosand displays „Auto“. The
measured cosshould be inductive (displayed by a small „i“ behind first line). With applying
the voltage to the BLR-CX the discharge blocking time for the capacitors starts ( Factory setting
75 sec.). After the discharge blocking time the regulation starts. Stepsizes will be detected
automatically. Control exits which are not used, become adjusted to step status “Fix-Off” after
three switching cycles without success. These outputs are blocked for the control.
To display values, which are depending on the current, it’s necessary to adjust the ct ratio.
This setting is not necessary for the control.
FAQ during Commissioning:
1) No indication AUTO -> the relay does not switch
Cause: Relay is set to manual operation
In SETUP/100 menu the selection for PFC is on OFF or HOLD, temperature is too high,
current < 15mA, voltage or THD U is out of tolerance.
2) Indication U ALARM -> voltage out of tolerance
Check settings for nominal voltage (SETUP/Un) and voltage transformer (SETUP/Pt)
3) Indication I Lo ALARM ->CT current < 15mA
Cause: connection error of CT; short-link of CT is not removed; CT-ration is too high compared
to real current; no current
4) Indication EXPORT -> kW export
if there is no real kW export, voltage and current connection to BLR-CX has to be checked! See
Wrong Connections / AI
5) Wrong Cos j indication -> wrong connection
voltage and current connection to BLR-CX has to be checked! See Wrong Connection / AI
6) Steps switch in and then quickly switch out again
See Stepsize Detection / Defective Capacitors
7) Frequent switching of steps
size of capacitors has not been completly detected

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
8
3DISPLAY
On the right side of the display, the actual chosen main menu is
shown.
INFO: Capacitor database
AUTO: automatic control is running
MANUAL: manual mode
SETUP: setup menu
In the top menu level in the first line, the actual cosis shown.
The i respectively the c indicates leading or lagging cos.
In submenu level the codes for the submenus or the
abbreviations for the measured values are displayed.
The second line shows measurement and set values with the
corresponding units. Also the alarm codes which are shown
during and alarm event are indicated there. All alarm codes are
shown and explained in the table on the next page.
Active regulation outputs are shown in the bottom line. Steps,
which are detected as defective (three switching cycles without
success), are blinking.
NT: COS φ2 active
EXPORT: export of active energy
ALARM: blinking in case of alarm

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
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In case of an alarm will flash alternately at BLR-CX with "ALARM" an error code in the display.
The table below gives an overview of all possible error codes.
To reset pending alarms hold the (esc) button pressed for 5 seconds.
measured voltage is outside the set tolerance
measured current is less than 15mA (check the short
circuit bridge K and L and the entire current path
measured current is to high
The controller cannot achieve the target COS φ
The set limit for the THD of the voltage is exceeded
/
One or more steps are broken. The defective step is
blinking with the alarm message.
/
One or more step's have fallen below 70% of initial
power. step number and error code will flash alternately.
For devices with software version before 1.04 the alarm
is triggered at 50% of initial power.
The second temperature limit is exceeded. Stage were
switched off successively.
Set limit of operation hours has been exceeded
/
Set limit of the max. allowable operation cycles, for one
or more steps, has been exceeded.
/
Abort of auto-initialization.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
10
4OPERATION
4.1 Keys
Increase values, select menu items
Escape menu,
move cursor left, Enter menu,
push 3 sec to clear move cursor right,
alarms confirmation of settings
Decrease values, select menu items
4.2 Input of numerical values
Whenever the BLR CX prompts for the input of a value, the routine will be the same:
A preset-value will be displayed with the first (highest) digit blinking. This digit can now be
changed by use of the and keys. Use the button to change to the next smaller digit.
After changing, the next digit will be also blinking and can now be altered just like the first
one. When arriving the last digit, press the key once more. This position allows to set
multipliers M (Mega) or k (kilo). To store the value, press the key once more, and the new
value will be saved and used.
In case, that an adjusted value cannot be stored respectively another value is shown after
confirmation with button, it’s possible that the adjusted value is outside of the allowed
range. For further information’s about possible ranges, please check the table on the last page.
At any time, one can go back to the menu he came from without changing the value by
pressing the key. In this case, the modified value will not be used!

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
11
5MENU BLR-CX
5.1 Measurement menu
All grey fields are hidden in the factory settings and will only appear if the CT ratio is set in the
"SETUP" menu. For devices with software version before 1.04 the complete measurement
menu is hidden and must be activated by adjusting the CT ratio.
1.00 i
1.00 i
U400 V
Voltage
L - L
1.00 i
0,999
Pf
three digit
1.00 i INFO
1.00 i
U230 V
Voltage
L - N
PF
0,888
Power factor
ratio
P/S
1.00 i MANUAL
1.00 i
I40,45 A
current in
measured
phase
APF
1.000
Average
Power factor
1.00 i SETUP
1.00 i
P30,37 kW
Active power
3 phase
F
50
Frequency
1.00 i
Q82,89Var
Reactive
power
3 phase
t
58 °C
Temperature
1.00 i
▲Q80,08 Var
control
deviation in
kvar
thi
88 °C
Highest
measured
Temperature
1.00 i
S30,68 kVar
Apparent
power
3 phase
OPH
188.9 h
Counter
operation
hours
1.00 i
THD U 1,41 %
Harmonic
distortion
U total
3
HarU 0,40 %
Odd single
harmonics
3 - 19

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
12
5.2 Info (Step database)
In the "INFO" menu for each connected step the number of switching cycles, the current step
size and the step size in relation to the initial step size is stored.
Using these data, conclusions can be drawn on the condition of the site and the condition of
single steps. Step sizes are displayed in kVar only when in the CT ratio is set in "Setup" menu.
1.00 i
Choose step with
Confirm with
View values with
1.00 i INFO
INFO
CC
25 kVar
Display of step size only if
CT ratio is set, otherwise---
1
2
3
3
4
max.
1
2
3
4
max.
1.00 i MANUAL
INFO
98
%
Current step size in %
related to initial step size
1
2
3
4
max.
1
2
3
4
max.
1.00 i SETUP
INFO
OC
808
switch cycles
1
2
3
4
max.
1
2
3
4
max.
Auto
auto: step is okay
foff: step is permanent off
fon: step is permanent on
Al: output for fan control
Flty: step detected as
faulty
1
2
3
4
max.
INFO
CC
25 kVar
Display of step size only if
CT ratio is set, otherwise---
1
2
3
4
max.
1
2
3
4
max.
Auto
auto: step is okay
foff: step is permanent off
fon: step is permanent on
Al: output for fan control
Flty: step detected as
faulty
1
2
3
4
max.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
13
5.3 Manual (step switching manual)
To enter in manual mode, please select “manual” in main menu and push ►for 3 seconds. By
entering this submenu, the manual mode for the regulator is active. The automatic control is
stopped and the exits can be switched manually. By the means of the -keys the referring
step can be selected. Changing the switching state is possible by pushing the ►-key.
Manual switching is only possible when measurement voltage is in allowed
range. Otherwise over- and undervoltage protection will block this function.
After switching off an active step, the discharge time is active. Only after this
time is over the step can be switched on manually again.
1.00 i
1.00 i INFO
Choose step with
Switch on / off
with
At each switching
operation the
current Pf is
shown
1.00 i MANUAL
0,95 i MANUAL
1
1.00 i MANUAL
1
1
1.00 i SETUP
0,95 i MANUAL
2
1.00 i MANUAL
2
2
0,95 i MANUAL
14
1.00 i MANUAL
14
14
!

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
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5.4 Setup (Quick start menu)
1.00 i
To start the control, it’s only necessary that the nominal voltage is
correct.
All other settings are only for optimal adaptation to the conditions in the
system and display system data. To change a setting, enter the setting by
pushing the button. Change the value with and confirm with
. When you start the auto-initialization the BLR-CX checks the connection
of the measurement and the exits. With these data, the regulation starts
automatically.
1.00 i INFO
1.00 i MANUAL
Un = nominal voltage
Setting of nominal voltage. From
this value the upper and lower
limits for voltage monitoring is
calculated
1.00 i SETUP
1.00 SETUP
Un SETUP
400
ct SETUP
20
Input current transformer ratio
e.g. 250/5 = 50
pt SETUP
1
Input voltage transformer ratio
when no VT is used the value is 1
ai SETUP
no
"Yes" the controller performs the
auto-initialization again
pfc SETUP
on
"ON" automatic control
"OFF" control off
"HOLD" control freeze
cpi SETUP
1
st SETUP
10
Interval between switching the
steps
Out SETUP
Possible types of output:
auto: step is used for regulation
foff: step is permanent off
fon: step is permanent on
Al: output for fan control (V1.06)

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
15
6EXPERT MENU BLR-CX
To enter the BLR-CX expert menu, select menu item “SETUP” and confirm with (). Push
or and enter the requested PIN (242) and confirm with (). The submenus can be
selected by pushing buttons. The expert menu of BLR-CX is divided into six groups,
where the menu items are logically grouped together.
The following groups exist:
100 Quick start menu
Contains all important points for commission.
200 Measurement settings
Contains settings to adapt the measurement of the BLR-CX to the surrounding network
conditions.
300 Setup Control System
The items in the menu "control system" allow an optimization of the control or an adaptation
to specific site requirements.
400 Setup Step Database
In the step database, all settings and data are combined which are required to adjust and
adapt the steps.
500 Setup Alarm
The alarm menu of BLR-CX. Here, all the alarms and monitoring functions can be activated and
the limits configured.
600 Resetmenu
Allows you to reset all settings made by the controller and stored data. Additionally, it contains
the software version of the device (displayed from 1.04) and the possibility to change the
password for the setup menu.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
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6.1 100 Quick start menu
Contains important information for commission:
100 Quick start menu
MENU
FUNCTION
RANGE
Un
NOMINAL VOLTAGE = PHASE - PHASE
100...241500 V
Function of the setting of nominal voltage is to make a definition
about the nominal voltage of the system. The threshold levels for
under- and overvoltage are based on this as well as the ratings of the
capacitor sizes in step database, which are used for control and
monitoring. The capacitor sizes, which are stored in step database,
are also rated to the nominal voltage.
Ct
CT-FACTOR
1...9600
The CT FACTOR is the ratio of current transformer.
(e. g. 1000/5 = ratio 200).
At devices with software version 1.04 is the adjustment range from
1-4000.
Pt
VT-FACTOR
1...350
VT FACTOR is the ratio of the voltage transformer.
If the regulator is connected directly to the measurement voltage
without VT the value 1 has to be used.
Ai
AUTO-INITIALIZING START
Yes/No
"YES" starts auto-initializing
Automatic initialization is switching all exits. During this test it can
get information, which exits are working and it can correct the
connection of the measuring channels for voltage and current by
internal settings.
Automatic initialization can be started only when the voltage and
current are ok. Steps with step type "FON" or "AL" will be not
considered in case of new auto-initialization.
AUTOMATIC INITIALIZATION is only able to work, when capacitors
are used for compensation. If BLR-CX has to switch reactors for
compensation of capacitive load, this feature will cause failures. AI
is working at best, when there are stable load conditions!
At devices with software revision before 1.04, stages which are set
to "FOFF" were not retested.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
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PFC
START / STOP / HOLD PF-CONTROL
On/Off/Hold
Stopping the automatic control. The following options are available:
On: Control in automatic mode
Off: Control stops and active steps were disconnected successive
Hold: Control Stops and active step's remain switched on.
If "OFF" or "HOLD" is selected, will appear in the display "PFC"
alternating with "OFF" or "HOLD". To start the control, select "ON".
CP1
COS φ1
0.70 c ...0.70 i
This is the setting for target COSφ1. It will be valid during normal
operation.
St
SWITCH INTERVAL
1...6500 s
The switch interval is the time delay between switching steps in
regulation.
The switch interval has two different functions:
1. Protecting the contactors by reducing the number of
switching cycles.
2. Building of the average of the reactive power in the time of
the switch interval.
Out
TYPE OF OUTPUT
With the exception of step type “flty” the follwing step types can be
selected:
Auto = Step is used for normal regulation algorithm.
Alarm = If the set temperature limit 1 is exceeded this step is
switched as fan output.
Fon = Step is permanently switched on (Step is still monitored
and shut down in critical situations).
Foff = Step is permanently switched off. Not used steps
should be adjusted to this type to avoid unnecessary alarm.
Flty = Step was switched three time without success and is
not longer used for automatic control.
As “flty” stored steps can be set to desired step type in this menu.

Reference Manual
BLR-CX-R / BLR-CX-T
Rev. 07
2018-07
18
6.2 200 Measurement settings
Contains settings to adapt the measurement of the BLR-CX to the surrounding network
conditions.
200 Measurement settings
MENU
FUNCTION
RANGE
201
NOMINAL VOLTAGE = PHASE - PHASE
100...241500 V
Function of the setting of nominal voltage is to make a definition
about the nominal voltage of the system. The threshold levels for
under- and overvoltage are based on this as well as the ratings of the
capacitor sizes in step database, which are used for control and
monitoring. The capacitor sizes, which are stored in step database,
are also rated to the nominal voltage.
202
CT-FACTOR
1...9600
The CT FACTOR is the ratio of current transformer.
(e. g. 1000/5 = ratio 200).
At devices with software version 1.04 is the adjustment range from
1-4000.
203
VT-FACTOR
1...350
VT FACTOR is the ratio of the voltage transformer.
If the regulator is connected directly to the measurement voltage
without VT the value 1 has to be used.
204
V-TOLERANCE
0...100 %
The setting of this value is in percent related to the nominal voltage.
By means of the set value, the upper and lower limits of the
permissible voltage range are calculated. e.g. 10% at 400V nominal
voltage is a permissible range from 360V to 440V.
205
CONNNECTION MEASUREMENT
Yes/No
"YES" voltage measurement L-L
"NO" voltage measurement L-N
CONNECTION MEASUREMENT the setting if measuring of voltage is
connected between two phases or between phase and neutral
phase. It is normally detected automatically at every start of BLR-CM.
This is done by comparing the setting NOMINAL VOLTAGE and the
real measured voltage. This cannot be changed by hand.
If the measured voltage is outside this tolerance, the measurement
can be adjusted by hand.

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Rev. 07
2018-07
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206
PHASE COMPENSATION
0...345
The phase compensation enables the user to connect the current-
and voltage measurement channels in any way. This compensation
angle complies with the phase angle between connected active
current and voltage. This setting has to be made correct, because
otherwise correct regulation is not possible! If the current
transformer is connected inverted, additionally a phase
compensation of 180° has to be respected.
Is auto-initialization failed due to adverse network conditions, by
hand a correction angle can be set or the incorrectly recognized can
be corrected. Table 11.1 gives an overview of the connection options
with corresponding phase angles.
207
START AUTO-INITIALIZING
Yes/No
"YES" starts auto-initializing
Automatic initialization is switching all exits. During this test it can
get information, which exits are working and it can correct the
connection of the measuring channels for voltage and current by
internal settings.
Automatic initialization can be started only when the voltage and
current are ok.
AUTOMATIC INITIALIZATION is only able to work, when capacitors
are used for compensation. If BLR-CX has to switch reactors for
compensation of capacitive load, this feature will cause failures. AI
is working at best, when there are stable load conditions!
Steps with step type "FON" or "AL" will be not considered in case of
new auto-initialization.
At devices with software revision before 1.04, stages which are set
to "FOFF" were not retested.
208
AUTO-INITIALIZING BY REGULATOR RESTART
Yes/No
YES = after starting the BLR-CX, a countdown is running. During this
countdown it is possible to start auto-initializing by
pushing ().
"NO" the countdown is not shown. To start AI, you have to choose
Quickstart SETUP.

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Rev. 07
2018-07
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209
SYNCHRONISATION FREQUENCY
Auto/Fix50/Fix60
For a high precision of the measurement, the sampling rate has to be
synchronized to the frequency of the grid. Caused by commutation
notches of mainsvoltage it is possible that the automatic
synchronizing will not work reliable. This creates failures in
measurement. To avoid these problems, the following settings can
be done:
Automatic synchronizing:
For best measurement results, when mains voltage is without
commutation notches.
FIX-50HZ: For a safe operation at 50Hz grid with bad mains quality.
FIX-60HZ: For a safe operation at 60Hz grid with bad mains quality.
210
TEMPERATURE OFFSET (from software revision 1.04)
-10-10°C
The temperature offset allows correction of temperature reading in
a range -10°C to +10°C.
6.3 300 Setup Control System
The items in the menu "control system" allow an optimization of the control or an
adaptation to specific site requirements.
300 Setup Control System
MENU
FUNCTION
RANGE
301
CONTROL SENSITIVITY
55...100 %
Sensitivity is the switching threshold for switching-on or switching-
off the capacitors in percent (%). The range of the sensitivity can be
between 55% and 100% (factory setting is 60%. Due to this, the in
following explanation 60% is used.).
Sensitivity is used for two checks:
1. The controller is using sensitivity to check, if a switching
operation is necessary or if it’s possible.
If the demand for compensation is bigger as 60% of the
smallest for regulation available step, BLR-CM is selecting
from step database, if there are suitable steps to switch.
2. To avoid hunting, the controller is only using steps, which will
not overshoot more than 40% (100%-60%) of its size.
302
COS φ1
0.70 c ...0.70 i
This is the setting for target cosφ1. It will be valid during normal
operation.