BPC CXPLUSR User manual

Operating Instructions – General Instructions inserted in each relay box
Power Factor Control Relay
CXPLU R (CONTACTOR WITCHING)
CXPLU T (THYRI TOR WITCHING)
These instructions apply from Ser. No. 1136054 Software 2.00 – Re 6 issue date 29.6.2012
Contents
1.0 CONNECTION TO UPPLY Page 2
1.2 - Current Transformer notes
1.3 - Earthing the relay
1.4 - Connecting the relay
1.5 - Removing the short circuit link on -L
1.6 - Wiring Diagrams
1.6.1 - Wiring diagram – Contactors Page 3
1.6.2 - Wiring diagram – Thyristors Page 4
2.0 ENERGI ING THE RELAY Page 4
2.1 Lockout time 75 secs
2.2 Measured Values in the Display
croll through Menu – What do the symbols mean? Page 5
3.0 THE QUICK TART MENU 100 TO ET CT AND VT RATIO
How to get into Setup Menu 100 Page 6
Setting the nominal system Voltage L-L., Un
Setting the CT ratio – Ct
Setting the VT ratio – Pt
Selecting Automatic Self Commissioning Ai
Selecting AUTO-OFF-HOLD for all the steps Page 7
Setting the target power factor – CPI
Setting Step switch time – St
Selecting the type of switching for each individual step OUt
4.0 MANUAL WITCHING Page 7
5.0 THE INFO MENU Page 8
6.0 ALARM – What do they mean? Page 8
7.0 DEFAULT ETTING – And what each menu does Page 9
8.0 TROUBLE HOOTING Page 10
9.0 TECHNICAL DATA Page 11
Page 1 of 11

1.0 CONNECTION TO UPPLY
1.1 Installation must only be carried out by suitably qualified personnel. All local safety regulations must of
course be followed including IEE wiring regulations 17th edition if installation is in the U . The power
supply to the relay is taken from the phase – phase 50 or 60hz voltage and connected via a fuse 6A max to
Um1 and Um2. The CXPLUS accepts any voltage across Um1-Um2 in the range 90-550V 50/60Hz. Voltage
Transformers for different supply voltages are a thing of the past. Check that the supply voltage is within the
limits of the relay rated voltage, and the CT has 1A or 5A output, at full load.
1.2 Current Transformer
The current supply to the relay is taken from a current transformer, which can be split core or ring type
Class 1., with 5VA rating. The current transformer (CT) must be kept short circuited until connections have
been securely applied to terminals -L. The CT is normally mounted on a different phase to L2-L3 for the
voltage supply. Other connections are possible – see phase offset menu 206. It is essential to ensure:
a) That the CT is measuring the total load of the feeder to be corrected – including the PFC capacitor
current
b) The ratio of the CT is such that full load current is about 75% of the CT ratio e.g. for a Max load of
500 amps, select a CT ratio of 800/5 – not 5000/5. This is because at the lower current ranges C T's
are less accurate.
c) Do not use a CT with too low a ratio for the measured load. e.g. If the load is 750
Amps, and you use a 500/5 CT ., the CT will then be saturated and will give inaccurate results.
When mounting the CT, ‘P’ should be pointing in the direction of the incoming supply and ‘L’ towards the
load. S1 on the CT should be connected to ‘ ’ on the relay and S2 to ‘L’ on the relay. The output from the CT
can be 1A or 5A. The Max ratio of the CT must be such that the smallest step of switched capacitance will
produce a current of not less than 15mA. Reactive – preferably 20mA.
Example:
The smallest step size is 25 kvar., at 415v 3ph 50 Hz. What is the highest CT ratio permissible?.
25 kvar at 415v = 34.7 amps. Capacitor will switch at 60% of nominal kvar = 20.8 amps.
Minimum current = 20mA reactive ., so Max CT ratio = 20.8/.02=1040/1 or 5200/5 for a 25 kvar capacitor
operating at 415v/3ph/50 hz. A 5000/5 would normally be selected as a max ratio
1.3 Connect the earth tag link on the instrument case to earth
1.4 Connect in accordance with the wiring diagram for contactors or thyristors
1.5 Remove any short circuit links from the CT and relay
Page 2 of 11

1.6 Wiring diagram
1.6.1 (CXPLU ..R – Contactor switching)
Page 3 of 11

1.6.2 (CXPLU ..T – Thyristor switching)
2.0 ENERGI ING THE RELAY
2.1 The CXPLU has a default lockout time of 75 seconds and will start counting down, after energising.
This to ensure that capacitors are not switched in immediately after power loss and an emergency
generator start up - for example. Also, this 75 second default time operates when any one step has been
switched. This is to ensure that it cannot be switched in again until that step has discharged. This enables
the short step switching time of 10 secs to be set – but you can adjust step switch time in the quick start
menu.
2.2 Measured Values in the Display
The three larger digits at the top show system 50 hz power factor.
e.g. 0.91i = lagging p.f. 0.91., 0.98c = leading p.f 0.98
If you have a known lagging power – inductive load – then ‘i’ should be displayed in the LCD. If you see ‘c’
and you are certain the load is lagging., switch off and swap over Um1 and Um2. This is better than
swapping over a load carrying CT – which may produce excessive voltages on open circuit. To access the
scroll down values press ►
The scrolled values▲ ▼ have the following meanings. These are the readings the end user can readily
access.
NB If you do not set the CT ratio, and leave it at the factory setting of 1 ., then the items marked ** will
not be shown. ou set the CT ratio in section C.T of the 100 Menu, below.
Page 4 of 11

The croll through Menu – What do the ymbols mean?
To see these readings, when you are in the main display and the Cosphi power factor is displayed ., press
enter ► and you see U ., now press▼ to scroll through the other readings
U phase – phase voltage
U phase – neutral voltage
I** phase Amps on phase CT is connected
P** 3 phase kW assuming balanced load
Q** 3 phase kvar ( total ) assuming balanced load
∆Q** 3 phase kvar required to reach target Cosphi assuming balanced load
S** 3 phase VA assuming balanced load
THD U Total Harmonic voltage distortion of L2 – L3
( if this figure is above 5% check the current taken by the capacitors since high THDU can
result in harmonic overload of the capacitor steps. Harmonic Blocking reactors must
then be fitted to limit harmonic overload current)
3-5-7-9-11-13-
15-17-19
harmonic voltages as % of fundamental
0.--i
cos
Top figure = Fundamental 50/60hz Cosphi to 2 decimal places.
Bottom figure =Fundamental Cosphi to three decimal places as required in certain
countries
PF True rms power factor including all harmonic currents and voltages
APF Average RMS power factor ( kW/kVA) since relay commissioned
F Supply frequency
t Real Time Ambient temperature
thi Max Ambient temp. To date
OPh Counter for number of hours relay has been in service, since last reset
tAn Tangent of phase angle phi
Page 5 of 11

3.0 THE QUICK TART MENU 100 TO ET CT AND VT RATIO
The 100 Menu allows you to set the CT ratio- voltage measurement values, target power factor setting.,
and switching time per step. This is the menu the Commissioning Engineer can use on site. Other settings
in the expert menus can be made with the help of a qualified Engineer or Technician.
Values of kW/kVA/kvar will not be correct unless the correct setting is made for voltage
(Un) and current. (Ct)
In order to make these settings we have to go into the commissioning menu 100.
How to get into menu 100:
press ◄ repeatedly to get back to the value 0....i
Now press ▼ and you see 'INFO' in the top right corner
Press ▼ again and you see 'MANUAL'
Press ▼ again and you see 'SETUP'
Press ► and release .'100' shows in the display
Press ► again – you are now in the commissioning menu 100. The 100 menu allows you to make the
essential settings are marked in bold
Un – Voltage etting
The first value you see is the Un. This is the phase – phase voltage., not Phase-Neutral. So for the U for
example the setting for Un is 415v. This is the factory default setting for relays made in the U after serial
number 1123596
If you need to change this press ► and the first digit starts flashing – using ▲▼adjust as needed and key ► to
adjust the second figure and so on. Press ► to confirm and the digits stop flashing.
It is important to have the correct voltage setting Un because the alarm thresholds are defaulted to operate
when the voltage is +-10% from nominal Un setting.
▼
C.T etting
To set the CT ratio key ► and the first digit starts flashing.
Assume the CT ratio is 1000/5., which is 200/1. Always set the CT ratio as a multiplication factor to 1 so for
the CT ratio 1000/5 we set Ct to 200. The same sequence with ▼ and ► is used for all the other settings.
▼
Pt – Voltage Transformer ratio setting
This is only used when the relay is used on MV/HV systems. The default setting is 1., but if the relay is
working on an 11kv system with 110v voltage input ., the setting for Pt is 100
▼
Ai – Automatic Initialisation
This is defaulted to NO and we recommend it is left on NO
If set to 'YES' – when the relay is first commissioned it will switch each step one by one. It will correct any
mistaken wiring of the CT.., and store the kavar values per step in its menu. We do not recommend use of
this Ai feature unless you do not know which phase the CT is on.
If Ai is ‘NO’ then no automatic switching on initial energising will take place, and the steps will be switched
in for the first time when they are required. Each time they switch their kvar value is recorded in the micro-
processor memory.
▼
PFC – tep switching Control
This control allows you to decide how you want the steps to be switched. The possible selections are :
ON - Normal switching of steps on/off as the reactive demand changes. This is the normal AUTO control
OFF – Reactive control de-activated and all steps in circuit will be switched off
HOLD – The steps switched in will remain on. The reactive control is de-activated
The default setting is 'ON'- automatic switching of steps.
Page 6 of 11

▼
CPI – or Target Power factor setting
Set to the required target PF. Note if you press ▲ when the CPI is 1 you will go into a leading pf setting. You
can target up to 0,70 lead., which is an unlikely setting but when the PFC is on the LV side of a transformer
and the customer is paying for energy on the HV side it may be useful to target to about 0.99 lead so as to
compensate for transformer reactive current which is creating I²R losses in the windings on no load.
▼
t – witching time per step
Adjustable from 1 second – 999 seconds. For longer times there is also the possibility to have 'k' ( x 1000 )
and 'M' x 1 Million if needed. If the switch time is set to 1 second per step, for a rapidly changing load, of
course it cannot switch back in again after a delay of only 2 seconds, due to the charge held on the
capacitor. In this case the relay will wait until the programmed discharge time set in menu 401. Default
setting on menu 401 is 75 secs.
▼
OUt – etting of Output for each tep
This setting allows you to select each step setting either as:
Auto – normal automatic relay controlled step switching
AL – This step operates an alarm contact. When the temperature is above the target setting – this contact
can be used to start up the ventilation fan. If you select AL for one of the exit relays, the default switching
temperature is 30ºC, when this contact will close.
FOFF – This step is permanently off (Fixed off)
FON – this step is permanently on (Fixed on)
Default setting is AUTO
4.0 MANUAL WITCHING
4.1 Sometimes there is no load on the system when the relay is commissioned. In order to test everything is
working correctly, the best way is to switch steps in manually and watch the increase in the Cos Phi display
until a leading power factor is achieved, and then to return the relay to AUTO to make sure the relay
switches out to reach the target power factor.
Press ◄ repeatedly to get back to Cosphi in the display
▼- INFO
▼- MANUAL
Now enter manual mode , ►by holding down the ► key for 3 secs , Scroll up ▲ and the figure 1 is in the
display. This is step 1 – to switch step 1 on key ►., to switch off ► again. Now move through the steps using
▲ to get to the next step and ► to switch it on. Under low loads on the system this will create a leading
power factor.
To switch back to Automatic control, so as to check the relay is working correctly, press ◄ repeatedly until
MANUAL-INFO-SETUP disappear from the right hand side of the display, so the relay is now in its normal
AUTO switching function , and if the Cos phi is leading it should switch steps out to achieve the target
Cosphi
(as set in 3.8)
Page 7 of 11

5.0 THE INFO MENU
To get into the INFO press escape ◄ a few times and then ▼., and you see INFO in the top right corner of
the display. Enter the INFO programme with ►.
Now you see the steps in the bottom section of the display.1-6 ., or 1-12., or 1-14 depending on the number
of steps on this relay.
The INFO programme is extremely useful since it tells you exactly how each step has been performing since
installation. You can move to interrogate each step by using the ▼▲ keys.
To examine the behaviour of any one step enter that step with and as you scroll down you see the►
following symbols:
C: This is the real time kvar output of this step –
but remember this is only correct if the CT has been set to the correct ratio
%: This shows the % loss in kvar per step since that step was first energised
(very useful to check capacitor quality and possible over stress due to harmonics)
OC number of switchings of that contactor
AUTO-FOFF-FON-AL – to indicate how that step has been allocated in the Quick Start Menu
6.0 ALARM – What do they mean?
In the case of Alarm, the display will flash alternately
The display will show one of the following alarms:
UMeasured voltage outside %
tolerance set in menu 204
thi The second ambient temp set in
menu 514 has been exceeded.
Sequential switching off of steps to
bring ambient temp down will
commence
I Lo Measured current below 15mA.
Check for open circuit or short
circuited CT, or insufficient load
OPH The limit set for operating hours
between servicing has been reached.
Call the service engr.
I Hi Measured current too high. CT
saturated and inaccurate
OPC/-- The limit set in menu 508 for
number of switching operations for
contactor indicated has been
reached. Default=80,000
HAr 5% harmonic voltage distortion
exceeded.., or setting put in menu
503. If reactors fitted this %setting
can be increased
PFC Target Cosphi not reached. More
capacitors needed or need
replacing,.
tP /-- The step indicated is faulty. Check
fuses contactor, capacitor on that
step
Ai/Abrt Automatic Start Up ( self
commissioning) aborted.
PL /-- The step indicated has lost more than
30% of its initial kvar value when first
commissioned
PL /-- PL /-- alarm cannot be cancelled
using the◄ esc. button. If you have
the PL alarm, the step indicated has
lost 30% or more than 30% of its
initial kvar value. Call your supplier
if PL /-- alarm activates for advice.
Page 8 of 11
......... /
ALARM
TO CANCEL ALL ALARM –
EXCEPT THE PL/... ALARM
HOLD THE E CAPE KEY◄
FOR ABOUT 3 EC . THE
ALARM HOULD THEN CLEAR
To cancel PL/... see the table
below

7.0 DEFAULT ETTING – AND WHAT EACH MENU DOE
Page 9 of 11
Default Default
Un 415 Set L-L system volts PFC ON Selects whether steps are on AUTO-HOLD-ON-OFF
t 1 Set CT ratio :1 CPI 1 Target Cosphi
Pt 1 Set VT ratio :1 St 10S Switching Time
Ai NO Automatic Initialisation?YES/NO OUt AUTO Selects what each output does.
AUTO-Fon-Foff—AL( starts up ventilation fan )
Expert Menus 200 – 600
To get into these please call your
supplier
200 MEA URING 400 CAPACITOR DATABA E
201 415 Sets system Voltage Level Un
( repeat of Un in Menu 100 )
401 75 secs Set discharge time to prevent
re-energisation on quick switching sequence
202 1 Sets CT ratio:1 (repeat of Menu
100)
402 5 var
(1.max)
Manual entry of kvar values per step
203 1 Set VT ratio:1 (repeat of Menu
100)
403 AUTO
All
steps
Select what each output does
Same as Out setting in 100 menu
204 10% Tolerance % of Un Voltage Setting 404 0 Step switch counter
Initial value 0 increases with each switching
205 YES Select L-L or L-N as measurement
voltage
500 ALARM
206 90º Select Phase Angle U - I 501 YES Select if alarm display is cancelled when fault cleared or
not
207 NO Ai ( Automatic Initialisation) start 502 YES THD Alarm setting YES = on
NO =off
208 NO Activate Step kvar Recognition 503 5% % setting for THD alarm if on
209 AUTO Frequency setting for low quality
networks
504 NO Select if steps are switched off if THDU above target level
210 0ºC Temp setting offset 505 60 secs Select time delay of THDU alarm
506 NO Freeze exits if no CT current
300 CONTROL 507 YES YES=Service alarm operates when max operating hours or
switchings on any step is reached.
301 60% % value of kvar for step switching. 508 80,000 Set No. of contactor operations for Alarm
302 1.00 Target PF 1 509 9,000 Set No. of operating Hours for Alarm
303 0.95i Target PF 2 510 NO Temperature sensor is set to monitor temp and show it in
the LCD Display.
304 NO Target PF when exporting 511 NO Select if Digital input is n/c or n/o
305 10 S Switch Time per step in seconds 512 NO Temp. Alarms 513/514 ON/OFF
306 2S Step switch swap over time 513 30ºC Temp Setting for exit relay nominated as fan control
307 YES Activation of Step swap over 514 70ºC Emergency switch off of steps one by one if temp exceeds
target setting – default = 70ºC
308 NO Stop Automatic kvar step
detection
515 NO Target Cosphi setting
309 YES Blocking defective Capacitor Steps 516 YES YES= Alarm for defective step if no step kvar output after
3 attempts
310 ON AUTO-OFF-HOLD setting 517 YES Step power loss alarm
311 1 Selection of switching sequence.
1=Auto.,2=Last in first
out,3= ombifilter ,4=Progressive
600 ALARM RE ET
312 0 Reactive kvar offset 601 NO All alarms back to factory default
313 1 Assymetrical Switching
fast in slow out etc.
602 NO Resets all recorded data of kvar per step+kvar output of
each step
314 NO Switch off steps if cosphi is
leading. Used for aux.generators
603 NO Resets Operating Hours to zero
604 NO Resets Average PF
605 NO Rests Highest Ambient Temp
606 NO Reset all alarms
607 NO Displays software version
608 NO Gives password

8.0 TROUBLE HOOTING
FAULT PO IBLE CAU E UGGE TED REMEDY
No indication in
the display
No power supply to terminals
UM1-UM2
Check for voltage in the range 90-550v 50/60hz on
these terminals
Display shows
U ALARM
Power supply is outside voltage
tolerance setting.
Check the setting entered on menu 201 and 204
Display shows
I LO
Measured Current is below 15mA Check CT circuit. Are summated CT’s in opposition? Has
short circuit link been removed? Is CT circuit broken?
Display shows
wrong value of
Voltage or
Current
Incorrect CT or VT ratio has been
submitted
Check settings of VT and CT. Remember the settings
are :1 so a 1000/5 CT = setting of 200
Display shows
wrong value of
Power Factor
Capacitor Step Size has not been
recognised, or phase angle setting has
been wrongly entered in 206
Start Ai in the set up menu, Check the setting of phase
angle in 206 and rectify if necessary
Power factor does
not improve after
stepping steps in.
Steps won’t
switch out
CT in wrong position – see notes 1.2 of
these operating instructions.
Check position of CT ensure it is measuring total
current including capacitor current and if split core
make sure the gap is fully closed up.
Display shows
I Hi ALARM
Output from CT is too high – above 5
amps.
Check the CT ratio selected. Change if necessary
Display shows
PFC ALARM
Continuous over compensation or
continuous under compensation
Check the capacitors and contactors.
Contactor could be welded in. Check that steps are not
in the FON setting
( PFC /Out in menu 100 )
Is the kvar supplied sufficient for the reactive demand?
If not under compensation will be reported
Display Shows
Leading
Cosphi....c
When you know
there is lagging
load
Voltage or current connections wrong
way around.
Phase angle incorrectly entered
( 206)
Switch off and swap over Um1 and Um2 ( This is better
than swapping over the CT connections since voltage
surges form open circuit CT are avoided)
If necessary check settings of 206
Certain steps
don’t switch in or
out
Wrong selection on the OUt menu Check to see if some steps have been set as FON or
FOFF ( permanently on or off ) instead of AUTO
Steps are shown
as defect.,
FLTY.
Capacitor step faulty or fuse or
contactor has failed
Check capacitor current with clamp on power meter
and compare with rated current are fuses and
contactor operating correctly? Replace as required.
Steps won’t ever
switch in,
but there is
nothing wrong
with them
Capacitor step sizes are too big. Provide more steps of lower kvar per step
EXPORT shows in
the display but
there is no export.
CT reversed Swap over Um1 /Um2 to correct.
Alt the Ai feature has caused this to show. Defeat Ai by
setting 208=NO
Page 10 of 11

9.0 TECHNICAL DATA
Measurement and Supply
Voltage
90 – 550V 45- 65hz 5VA max. Fused to Max. 6A
VT multiplication factor adjustable 1......350
Current Measurement 15mA ..... 6A single phase. Internal CT with Current Sensor 20 milliohm. CT
multiplication factor adjustable 1.......4500
Exit relay Ratings Max rating at 240v 50/60 hz phase-neutral Contactor coils 6A inrush
Max rating 415v 50/60 hz phase-phase Contactor Coils 2.5A inrush
Temperature
measurement
By varistor or thermocouple
Alarm Contact Volt free relay normally closed (N/C). Max fuse rating 2A., Switch contact 250V
2.5A
Air Ventilation Control Achieved by designating one of the exit relays as ventilation fan contact
Data Output BSTO software by TTL on back of relay
Operating Temperature -20+70ºC. Storage -40+85ºC
Humidity 0-95% - Dew droplets not permitted.
Over Voltage Category II Pollution Degree 3 (DIN VDE 0110 Part 1 / IEC 60664-1)
Standards Complied with DIN VDE 0110 part 1 IEC 60664-1:1992
VDE 0411 part 1 (DIN EN 61010-1 /IEC 61010-1:2001
VDE 0843 Part 20
DIN EN 61326/IEC 61326: 1997+A1: 1998+ A2:2000
Conformity Listings CE – UL – cUL
Connections Screw Terminals with plug in connectors to facilitate easy swap overs
Casing Front Plastic Facia (UL94-VO)., Rear - Metal case.
IP Ratings Front : IP50 – IP54 if transparent over cover fitted
Rear: IP20
Weight 0.60g Approx
Dimensions 144 x 144 x 58mm – Cut Out 138 (+0.5) x 138 (+0.5) mm
Page 11 of 11
YOUR SUPPLIER FOR SERVICING and FURTHER INFORMATION PFC / RE-ORDERING: