KBR F144-MS-1V1C6-6RO-6DO-3 User manual

25361_EDEBDA0281-2320-1_EN
User manual
Technical Parameters
System IEnglish
4-quadrant controller
multicomp
F144-MS-1V1C6-6RO-6DO-3

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1 Introduction ...................................................................................................................................4
1.1 User manual.....................................................................................................................................4
1.3 Safety notes.....................................................................................................................................6
1.4 Product liability ..............................................................................................................................7
1.5 Disposal.............................................................................................................................................7
1.6 Overvoltage and lightning protection ..................................................................................7
2 Functional Principle of the Controller....................................................................................8
3 Control and Display Panel ........................................................................................................10
4 Setting Range of the Congurable Parameters:...............................................................14
5 Installation and Electrical Connection of the System.....................................................16
5.1 General, very important information...................................................................................16
5.2 Current transformer connection and measuring voltage.............................................16
5.3 Current transformer dimensions............................................................................................16
5.4 Standard connection diagram................................................................................................17
5.5 Measuring voltage connection Ph-N....................................................................................18
5.6 Measuring voltage connection Ph-Ph .................................................................................19
Table of Contents
KBR Kompensationsanlagenbau GmbH does not accept any liability for any loss
or damage resulting from printing errors in or changes to this manual.
In addition, KBR Kompensationsanlagenbau GmbH does not accept any liability for
any loss or damage caused by defective devices or devices manipulated by the user.
Copyright 2020 by KBR Kompensationsanlagenbau GmbH
Subject to change.
Table of contents

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6 Commissioning the System.....................................................................................................20
6.1 General Notes on Commissioning.........................................................................................20
7 Navigation and Device Displays.............................................................................................22
8 Device Displays of the Main Menus......................................................................................24
9 Description of the Individual Display Windows ...............................................................26
9.1. Initialization window:.................................................................................................................26
9.2 Commissioning window if no stage power is programmed........................................26
9.3. Start menu window:..................................................................................................................30
9.4 Stage state window:...................................................................................................................32
9.5 Service window:...........................................................................................................................33
9.6 Commissioning window:..........................................................................................................34
9.7 Switching performance window: ..........................................................................................37
9.8 Error message window:.............................................................................................................39
9.9 Extras window: .............................................................................................................................40
10 Notes on Troubleshooting........................................................................................................44
11 System and Safety Device Maintenance.............................................................................45
12 Technical Data...............................................................................................................................46
12.1 Measuring and display values.................................................................................................46
12.2 Measuring accuracy....................................................................................................................47
12.3 Measuring principle....................................................................................................................47
12.4 Device memory............................................................................................................................47
12.5 Limits:...............................................................................................................................................47
12.6 Power supply.................................................................................................................................47
12.7 Hardware inputs and outputs.................................................................................................48
12.7.1 Hardware inputs...........................................................................................................................48
12.7.2 Hardware outputs ......................................................................................................................48
12.8 Electrical connection..................................................................................................................49
12 Selection of Cables and Fuses.................................................................................................51
14 Data point description for the Modbus protocol.............................................................52
14.1 Modbus commands supported..............................................................................................53
14.2 Data formats..................................................................................................................................53
14.3 Interface parameters..................................................................................................................56
14.4 Device settings.............................................................................................................................56
14.5 Data points.....................................................................................................................................62
15 Device information .....................................................................................................................65
Table of contents

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1 Introduction
Thank you for choosing this KBR quality product.
To become familiar with the operation and programming of the device and to use the
full range of functions of this high-quality product at all times, you should read this user
manual carefully.
The individual chapters explain the technical details of the device and show how damage
can be avoided through proper installation and commissioning.
1.1 User manual
This user manual describes the device version multicomp F144-3. This user manual must
be accessible to the user at all times (e.g. in the switchgear cabinet). Even if the device is
resold to third parties, the manual remains an inherent part of the device.
Although the utmost care has been taken in writing this user manual, errors may still oc-
cur. We would be very grateful if you would notify us of any errors or unclear descriptions
you may notice.
Introduction

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1.2 Safety keys
This manual contains instructions that you must follow for your personal safety and to
avoid material damage. These instructions are identied by a warning sign or information
symbol, depending on the degree of hazard they warn about.
DANGEROUS VOLTAGE
„Warning“ means that death, major injuries or damage may occur if suitable safety pre-
cautions are not taken.
CAUTION
„Caution“ means that minor injuries or damage may occur if the appropriate safety pre-
cautions are not taken.
NOTE
„Note“ is an important piece of information on the product, its operation or the respec-
tive part of the operating instructions to which special reference is being made.
Disclaimer
The contents of these operating instructions have been carefully reviewed in terms of
the hardware and software described. Nonetheless, deviations cannot be ruled out, and
the manufacturer cannot guarantee 100% conformity. The specications made in these
operating instructions are reviewed on a regular basis; any corrections required will be
included in the next revision.
Introduction

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1.3 Safety notes
In order to prevent operating errors, device operation is kept as simple as possible. This
will enable you to start your device up quickly.
It is in your own interest to read the following safety instructions carefully. The applicable
DIN/VDE regulations must be observed for installation!
Power supply connection, setup and operation of the device must be performed by
qualied personnel only. Qualied personnel as dened in the safety notes in this user
manual are those authorized to set up, ground and mark devices, systems and circuits in
accordance with applicable standards and regulations.
To prevent re and electric shock, do not expose the device to rain or moisture!
Before connecting the device to the power supply, check whether the local power supply
conditions comply with the specications on the device nameplate.
CAUTION
Incorrectly connecting the device can damage it.
For device connection, the data given in the connection diagram must be complied with
(see chapter“Connection diagram”) and the connection lines must be voltage-free. When
wiring, always ensure that all wiring material used is neither damaged nor defective and
that the polarity is correct!
Proper and safe operation of the product requires correct transport, storage, installation
and assembly as well as careful operation and maintenance.
If the device has any visible damage it is considered unt for use and must be disconnect-
ed from the power supply!
Troubleshooting, repairs and maintenance work may only be carried out at our plant or
after contacting our customer service team. If the device is opened without authoriza-
tion, any warranty or guarantee claim is forfeited. Correct functioning can no longer be
guaranteed!
Opening the device may expose live parts. Capacitors in the device may still be charged,
even if the device has been disconnected from all power sources. Do not operate open
devices under any circumstances!
Systems that are at risk from lightning strikes must feature lightning protection for all
input and output lines.
Introduction

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1.4 Product liability
You have purchased a high-quality product. Only top-quality components with excep-
tional reliability are used.
Each device undergoes a long-term test before delivery.
With regard to product liability, please see our general terms and conditions for electron-
ic devices, which you can read at www.kbr.de.
The warranty on device characteristics only applies if the device is operated in accor-
dance with its intended use!
1.5 Disposal
Please dispose of defective, out-of-date or no longer used devices properly.
If required, we will dispose of the device for you.
1.6 Overvoltage and lightning protection
To protect your purchased high-quality devices from damage, we strongly recommend
that you take overvoltage protection measures. Protect control voltage inputs, pulse and
bus lines.
Introduction

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Functional principle
2 Functional Principle of the Controller
The multicomp F144-1V1C6DO6RO- 3 hybrid controller has 12 outputs to control capac-
itive compensation stages. Outputs 1 to 6 are designed to control thyristor modules (by
optocoupler outputs) and outputs 7 to 12 to control capacitor contactors (by oating
relay contacts).
To make optimal use of the thyristor modules' or capacitor contactor modules' switching
performance, you can set the following parameters separately:
for thyristor stages
Switching interval 50 to 9999 milliseconds
Discharge time 20 to 9999 milliseconds
Idle time 20 to 9999 milliseconds
for contactor stages
Switching interval 0 to 10 seconds
Discharge time 0 to 900 seconds
Idle time 0 to 300 seconds
The controller's microprocessor records the mains voltage and current consumption of
the entire plant by measuring transformer inputs (A/D converter) and, on the basis of this,
calculates the active and reactive power ratio of the mains. The controller operates in four
quadrants.
Energy recovery in generator operation is detected and indicated by a "G" ashing
on the LCD display. During this time, compensation to cos phi 1.00 (output cos phi) is
performed. To prevent alternating switching operations, this target cos phi is main-
tained for 15 minutes after generator operation.
The compensated power required for the target cos phi is calculated continuously. If the
power dierence corresponds to the set hysteresis (switch-on and switch-o hysteresis),
the stages are switched depending on the required compensation power. Manually
switched stages are, however, not included in the optimization. In case of identical
stages with identical power, the stage that has been switched o for the longest time is
switched on.
Having fewer switching operations results in optimum adjustment. Even for large sys-
tems, sensitive controls can be set up with just a few modules. Stage ratios do not need to
be considered. After compensation, switching operations are interrupted for a cong-
urable time. To prevent alternating switching operations, you can increase the stage
switch-o delay by up to 150% of the smallest stage's power.
After an adaption time of 60 seconds, the thyristor stages are switched by contactor stag-
es of the same size. This guarantees that the fast control characteristics can be kept.
In low load operation (secondary measuring current under the limit), the stages are
switched o after the set delay time.
The integrated temperature measurement input monitors the temperature in the reac-

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Functional principle
tive power compensation system and causes the fan to be switched on if a predened
temperature threshold is exceeded and switched o again when the temperature drops
below the reset temperature.
To prevent the fan from switching unnecessarily often, it has a run-on time of 30 minutes.
You can switch the fan (relay output 12) on or o permanently using the "Stage status"
menu. If you select "Auto", the fan output is controlled by the temperature measuring
input.
You can also protect the system by dening a switch-o temperature. This makes it pos-
sible to switch stages o in time if there is a risk of damage due to overheating. Once the
temperature drops below the reset temperature, the stages are switched on again one
after the other.
The settings are saved on an EEPROM so that they are not lost in the event of a power
failure.
The measuring cycle of the controller used to record the necessary network parameters
takes approx. 20 ms.
NOTE
Limit for overvoltage switch-o = measuring voltage + 10% (taking the measuring volt-
age ratio into account). This value cannot be changed and serves to protect the compen-
sation system.
In the event of an error, the compensation stages are switched o. The alarm relay switch-
es and "Overvoltage" is displayed.
CAUTION
The discharge times are automatically predened, in the capacitor contactor stage, for
the following programmed stage powers. However, these must be checked and corrected
if they dier from the capacitor specications.
Capacitor power Discharge resistance Discharge time
0.1 kvar – 9.9 kvar 300 kOhm 60 seconds
10 kvar – 19.9 kvar 300 kOhm 120 seconds
20 kvar and above 300 kOhm 180 seconds
A discharge time changed later on is retained however, as long as the stage power is not
changed.
In the thyristor stages, irrespective of the stage power, the discharge time is always
entered as 20milliseconds, both when reprogramming and when changing the stage
power.

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Control and display panel
1
2
3 4
3 Control and Display Panel
Operating elements:
1 LCD displaying the current status and user prompts
2 Number of possible controller output lines
3 Two sensor buttons for parameter conguration
4 Two sensor buttons for menu selection
multicomp F144-3 hybrid 6RO-6DO

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Control and display panel
General notes on operating the sensor buttons:
Ubutton Start conguration and reset input
Vbutton Change values during conguration
Wbutton Navigate through submenus
X button Navigate through main menus and save button during
conguration
Button combinations:
Uand Vbuttons Delete accumulated values and reset the system
Default controller settings after reset:
Consumption target cos phi: 0.95 inductive
Recovery target cos phi: 1.00 (cannot be changed)
Alarm cos phi: 0.92 inductive
Main transformer current: Primary current 1000 A
Secondary current 5 A
Measuring voltage: Primary voltage 400 V Ph-Ph (corresponds to 230V Ph-N )
Secondary voltage 400 V Ph-Ph (corresponds to 230V Ph-N )
Rot. eld U: L1-N
Rot. eld I: L1
Current attenuation coecient: 0
Voltage attenuation coecient: 0
Attenuation coecient Qmiss: 0
Alarm delay: 20 minutes (1200 s)
Thyristor idle time 30 msec.
Contactor idle time 30 sec.
Thyristor switching interval: 50 ms
Contactor switching interval 8 sec.
Hysteresis connection: 100% of lowest stage power
Hysteresis switch-o: 100% of lowest stage power
Switching performance Priority Operation cycles, 24hours Switching o
Operating cycle limit: 80000
Operating cycle count: Activated by set limit

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Control and display panel
Stage switching mode: Automatic
Sampling rate: Automatic
Harmonics monitoring: Activated by set limit
Limit THD: 8%
Stage power: Not set
Max. stage pow. per switch. cycle 0 kVar
Thyristor discharge time: 20 ms
Contactor discharge time: 180sec.
Password: No password
(9999, meaning all functions are accessible)
Language display: English
Contrast setting: 4
Brightness setting: 5
Dimmer brightness: 0
Low load limit: 15 mA
Low load delay: 60minutes
Temperature measurement: On
Output 12 as stage or fan: Fan
Alarm relay as error message
or fan: Error message
Fan switch-on temperature: > 28 °C
Fan switch-o temperature: < 23 °C
System switch-o temperature: > 48°C
System switch-on temperature: < 43°C
Learning mode menu display: O
Key sounds: On
Error message dialog after reset:
No measuring voltage: Message and alarm relay
No stage power: Message and alarm relay
Facility too small: Message and alarm relay
THD too high: Message and alarm relay
Operating cycle limit exceeded: Message and alarm relay
No measuring current: Message and alarm relay
Low load operation: Message and alarm relay
Temperature switch-o: Message and alarm relay

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Control and display panel
The controls in the compensation systems are preset.
The following parameters need to be checked or set:
Target cos phi in accordance with the electricity supplier regulations (for kVA tari cos phi = 1)
Primary current and secondary current in accordance with input current transformer.
Voltage transformer ratio, if required
NOTE
Upon delivery, the bus protocol is set to:
Modbus RTU, baud rate 38400, parity even
This setting can only be changed manually on the device.
Performing a "Reset to default settings" has no eect on changed settings.

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Setting ranges
4 Setting Range of the Congurable Parameters:
Stage state:
Stage switching mode Automatic, Manual o, Manual on
Commissioning:
Password 4 digits, numerical, no password = 9999
(meaning all functions are accessible)
Primary current 1 A to 999999 A
Secondary current 1 and 5 A
Consumption target cosφ ind. 0.80 to cap. 0.80
Recovery target cosφ ind. 1.0 (cannot be changed)
Primary voltage 1 V to 99999 V Ph-Ph
Secondary voltage 1 V to 999 V Ph-Ph
Rot. eld U L1N, L2N, L3N, L12, L23, L31
Rot. eld I L1, L2, L3, -L1, -L2, -L3
Stage power learning mode Yes, No
Stage power 0 to 999.9 kvar
Thyristor stage discharge time 0 to 9999 ms
Contactor stage discharge time 0 to 900 seconds
Switching performance:
Hysteresis connection 70 to 150 %
Hysteresis switch-o 70 to 150 %
Switching performance Priority Operation cycles, runtime
Alarm relay time 3 to 3000 sec.
Thyristor stage idle time 20 to 9999 ms
Contactor stage idle time 0 to 300 seconds
Thyristor stage switching interval 50 to 9999 ms
Contactor stage switching interval 0 to 10 seconds
FTS alarm cosφ ind. 0.70 to 1.0
Attenuation coecient Qmiss 0 to 9
Attenuation coecient voltage 0 to 9
Attenuation coecient current 0 to 9

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Setting ranges
Error message dialog:
No measuring voltage The settings Message or
No stage power Alarm relay or Message and
Facility too small Alarm relay or O
THD too high is identical for all errors!
Operating cycle limit exceeded
No measuring current
Light load
Temperature switch-o
Extras:
Display language German, English, French, Spanish
THD limit 0 to 10%, harmonics monitoring can be disabled
(0%)
Sampling rate Automatic, xed 50 Hz, xed 60 Hz
Reset Run
Contrast setting 0 to 10
Brightness setting 0 to 9
Dimmer brightness 0 to 9
Low-load limit 15 mA, 50 mA
Light load delay 1 minute to 60 minutes
Temperature measurement On / O
Output 12 Compensation stage, fan relay
Alarm relay Error message, fan relay
Fan switch on temperature > 0 °C to 60 °C
Fan switch o temperature < 0 °C to 60 °C
Switching threshold system o > 0 °C to 60 °C
System switch on temperature < 0 °C to 60 °C
Bus mode Modbus (eBus for production)
Learning mode menu display On / O
Key sounds On / O

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Installation and electrical connection of the system
5 Installation and Electrical Connection of the System
5.1 General, very important information
Tighten all screws and connections. Failure to do so will void the warranty.
Install and operate the device in accordance with the applicable VDE regulations (in
particular VDE 0100) and the electricity supplier's regulations.
Connection cross-sections and fuse protection table: see attachment
5.2 Current transformer connection and measuring voltage
If possible, mount the transformer in the phase that corresponds to L1 of the compensa-
tion system (determine by means of voltage measurement). All capacitor and consumer
currents must be determined. In case of unbalanced phase load (small systems), install
the transformer in the phase with the highest load.
P1 (K) to energy supply (indicated on the transformer).
P2 (L) to load outputs
S1 (k) with terminal k (controller terminal 20) and
Connect S2 (l) to terminal l (controller terminal 21) in the compensation system (use a
two-color cable!).
Wire cross section: up to 3 m =1.5mm², up to 6m =2.5mm². For longer distances, we
recommend using a 1 A transformer. The controller is designed for connection to 5 A and
1 A transformers; switching is done by rmware.
If you use existing transformers, the current paths must always be connected in series.
The secondary transformer current needs to be at least 15 mA. For lower currents, no
capacitors are connected ("No measuring current" is displayed).
Connect the measuring voltage in accordance with the connection diagram.
5.3 Current transformer dimensions
The current transformer is designed on the basis of the current consumption of the
consumers, not the capacitor current. If other measuring devices are connected to a
transformer in addition to the reactive power controller, the transformer power needs to
be dimensioned accordingly. Losses also occur in the current transformer cable that need
to be considered if there are long distances between the transformer and the controller.

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Installation and electrical connection of the system
5.4 Standard connection diagram
NOTE
The stage outputs 1 to 6 are optocoupler outputs. External voltage supply Terminal input
40 max. 30 VDC
(rated voltage 24 VDC), max. 35mA.
When connecting the phase (L1) to terminal 1 and the neutral conductor (N) to terminal 2
(Ph-N100V–240V+//10 % 50Hz/ 60 Hz/DC) the safety device and the disconnector in the
supply line to terminal 2 (N) are not required.
The safety device and the disconnector to terminal 2 (N) are only required for the follow-
ing connection variants:
Alternating voltage:
Terminal 1 (L1) and terminal 2 (L2):
US1 Phase-Phase 100V - 240V +/-10% 50Hz/60 Hz
Direct voltage:
Terminal 1 (+) and terminal 2 (-):
US1 100V - 240V +/-10% DC
Connection variants of the power supply
Terminal 1 Terminal 2 Voltage Safety device and
disconnector to
Terminal 2 required
Power supply unitUS1
Phase L Neutral
conductor N 100V - 240V +/-10% AC 50/60 Hz No
PhaseL1 PhaseL2 100V - 240V +/-10% AC 50/60 Hz yes
+ - 100V - 240V +/-10% DC yes

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Installation and electrical connection of the system
PE 1 2 10 11 20 21 30 31 70 71 90 91 92 40 41 42 42 44 45 46 47 48 49 50 51 52 53
L1
EVU Verbraucher / consumer
L2 L3
N
F1 F2 F3
L N k l
K L
A B
+ k1 k2 k3 k4 k5 k6
k7 k8 k9 k10 k11 k12
ϑ
Trenn- vorrichtung/ circuit breaker
weitere Stufen further stages
Kompensationsanlage power factor correction equipment
Steuer-
spannung
driving voltage
100-240V
+/- 10%
50/60 Hz/
DC
Steuerspannung
driving voltage
< 250 V
Relaisausgänge
relay outputs
Digitale Ausgänge
digital outputs
Mess-
spannung
Measuring
voltage
30 ... 690V
Temperatur-
fühler
temperature
probe
Bus
Kontakt bei
Störung und
im Stromlosen
Zustand oen
contact is open
by no power
and alarm
*) HINWEIS: k12 wahlweise Lüfteranschluss oder Kompensationsstufe (Werkseinstellung = Lüfteranschluss)
*) NOTE: k12 optional fan connection or compensation stage (factory default = fan connection)
Hinweis beachten!
Read information!
Messstrom / measuring current
Alarm
*)*)
+ 24 -
5.5 Measuring voltage connection Ph-N

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Installation and electrical connection of the system
PE 1 2 10 11 20 21 30 31 70 71 90 91 92 40 41 42 42 44 45 46 47 48 49 50 51 52 53
L1
EVU Verbraucher / consumer
L2 L3
N
F1 F2 F3 F4
L2 L3 k l
K L
A B
+ k1 k2 k3 k4 k5 k6
k7 k8 k9 k10 k11 k12
ϑ
Trenn- vorrichtung/ circuit breaker
weitere Stufen further stages
Kompensationsanlage power factor correction equipment
Steuer-
spannung
driving voltage
100-240V
+/- 10%
50/60 Hz/
DC
Steuerspannung
driving voltage
< 250 V
Relaisausgänge
relay outputs
Digitale Ausgänge
digital outputs
Mess-
spannung
Measuring
voltage
30 ... 690V
Temperatur-
fühler
temperature
probe
Bus
Kontakt bei
Störung und
im Stromlosen
Zustand oen
contact is open
by no power
and alarm
*) HINWEIS: k12 wahlweise Lüfteranschluss oder Kompensationsstufe (Werkseinstellung = Lüfteranschluss)
*) NOTE: k12 optional fan connection or compensation stage (factory default = fan connection)
Hinweis beachten!
Read information!
Messstrom / measuring current
Alarm
*)*)
+ 24 -
5.6 Measuring voltage connection Ph-Ph

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Commissioning
6 Commissioning the System
6.1 General Notes on Commissioning
Compensation unit with controller
The controller is congured as a compensation system component (see connection dia-
gram) by default. The following settings need to be congured or checked:
Target cos phi according to electricity supplier specications.
Primary and secondary current in the main circuit according to the transformer tted.
If required, set the measuring voltage transformer data.
If no stage powers have been programmed, the controller will switch to the Commis-
sioning menu after initialization. Next, stage power programming can be performed in
the settings menu, or using the learning process.
NOTE
You can start the learning process from the "Learning mode activate" submenu in the
Commissioning menu, using the Enter/Input buttons.
If the "Learning mode" window is not displayed, please check the following:
is Menu on set for "Learning mode" in the "Extras" menu?
The settings are saved on an EEPROM so that they are not lost in the event of a power
failure.
Switch on a sucient number of inductive consumers (e.g. motors) before switching
the compensation system on. A transformer current of at least 15 mA needs to be ow-
ing in the secondary circuit for the controller to be activated. Below this limit, the error
message "No transformer current" will be displayed.
Check the transformer connection (is the transformer ratio too high?).
If all connection conditions are OK, the instantaneous power factor cos phi should be
displayed after initialization, e.g. Normally, when no capacitors are connected, cos phi
lies in the range of 0.6 to 0.9 inductive, (e.g. cos phi 0.80 ind).