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Siemens MJ-5 User Manual

Siemens MJ-5
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MJ-5 Control Panel Manual Version 3 Siemens Industry, Inc.
MJ-5(TM) Voltage Regulator Control
Panel
Installation and Operations Manual

Table of Contents

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Siemens MJ-5 Specifications

General IconGeneral
BrandSiemens
ModelMJ-5
CategoryControl Panel
LanguageEnglish

Summary

1 Introduction

About This Manual

Outlines the manual's purpose and structure to help users understand the MJ-5 Control Panel.

MJ-5 Control Panel Features

Details standard MJ-5 Control Panel features including display, metering, data logging, and various control functions.

2 Using the MJ-5 Operator Panel and Controls

Front Panel Overview and Navigation

Covers the front panel layout, display screen, and methods for navigating data using menu and fast-path keys.

Operator Controls and Indicators

Details various operational controls like keys, switches, indicators, ports, fuses, and binding posts.

Switches and Connections

Control Switches and Modes

Explains the Power Switch, Auto/Off/Manual switch, and Remote/Local settings for controlling the panel.

Binding Posts and Terminal Strips

Describes binding posts and terminal strip connections for external devices and control panel wiring.

Fuses and Terminal Strip Details

Fuse Protection

Details the purpose and rating of the MJ-5 Control Panel's internal and external power fuses.

Terminal Strip Connections Description

Describes terminal strip connections for various control functions and current transformer routing.

Data Ports for Communication

USB Serial Port and SD Card Functionality

Explains the use of USB and SD card ports for data transfer, configuration, and communication.

3 Viewing and Changing MJ-5 Data Items

Data Item Viewing Methods

Describes two methods for viewing data: using menu selection keys and fast-path keys.

Understanding MJ-5 Menus

Explains how MJ-5 data is organized into menus and data items, divided into setup and operational categories.

Changing MJ-5 Data

Procedure for Changing Data Items

Details the steps to change configuration parameters and alpha/numeric settings using panel keys.

Using Fast-Path Keys for Data Changes

Explains how fast-path keys can be used as shortcuts to view and change frequently used data items.

4 Setting Up the MJ-5 Control Panel

Setup Overview and Process

Outlines the MJ-5 Control Panel setup process, including configuration, set points, logging, security, and communication.

<CONFIGURE> and <ADV CONFIGURE> Menus

Explains how to define regulator parameters and system settings using the CONFIGURE and ADV CONFIGURE menus.

<ADV CONFIGURE> Menu Parameters

Data Item Descriptions in ADV CONFIGURE

Provides detailed descriptions of data items found within the MJ-5's Advanced Configuration menu.

Regulator Type and System Configuration

Defining Regulator Type

Explains how to identify and configure the regulator type (ANSI Type A or B) and its characteristics.

System Configuration Settings

Details configuration for Delta or Wye-connected systems, including wiring arrangements and polarity.

<CONFIGURE> Menu Details

Tap Changer and Transformer Settings

Describes settings for tap changer type, regulator type, system configuration, and transformer voltage ratios.

Power Flow Modes and Current Settings

Details settings for power flow modes, current transformer ratio, and full load current specifications.

<CONFIGURE> Menu: Time, Date, and Demand

Time, Date, and Daylight Savings Settings

Explains how to set the real-time clock, date format, and daylight savings time for the MJ-5 Control Panel.

Demand Calculation Methods

Details the Sliding Window and Thermal averaging methods used for accumulating demand values.

<CONFIGURE> Menu: Voltage and Polarity Settings

Utility Polarity and Voltage Transformer Ratios

Explains how to set utility polarity and configure U2 and P2 potential transformer ratios for accurate voltage scaling.

Power Flow and Current Transformer Settings

Details settings for Delta Power, Power Flow Modes, and Current Transformer ratios for system analysis.

<CONFIGURE> Menu: Power Flow and Current

Power Flow Mode Selection

Describes different power flow modes (Forward Locked, Reverse Locked, etc.) and their operational implications.

Current Transformer Ratio and Full Load Current

Details how to set current transformer ratio and full load current for accurate system monitoring and protection.

<ADV CONFIGURE> Menu Settings

Meter Scaling and Current Thresholds

Explains settings for meter voltage scaling, low current thresholds for tap change inhibition, and current shift.

Time, Load Current, and PT Threshold Settings

Covers settings for time, maximum load current, and potential transformer thresholds for tap change control.

<ADV CONFIGURE> Menu: Demand and Timing

Demand Method and Timeout Settings

Details settings for demand calculation methods, min/max data timeouts, and screen timeouts.

Quick List and AutoVari-Amp Settings

Explains configuration for the Quick List feature and the AutoVari-Amp capability for tap position adjustments.

<ADV CONFIGURE> Menu: Tap Control and Alerts

Tap Limit, Tap Alert, and Resync Settings

Configures tap limits, enables/disables tap alerts, and sets tap resynchronization behavior for improved operation.

Communication Inhibit and LED Settings

Covers settings for communication auto-inhibit, lower LED behavior, and P2 calculation options.

4.4 Setting Control Levels—The <REGULATOR> Menu

Regulator Set Points

Defines operating limits for automatic mode, including voltage level and bandwidth set points for forward and reverse power flow.

Line Drop Compensation (LDC)

Explains how to set line drop compensation values to account for voltage drop between the regulator and the load center.

Voltage Reduction Control (VRC) Items

VRC Configuration and Modes

Details VRC settings, modes (Local, Remote, Auto), and how to configure VRC activation via terminal contacts.

ALT Delay and VRC Status

Explains the ALT Delay feature and how to view the current VRC status, including reduction percentage and mode.

VRC Modes and Automatic VRC

VRC Mode: OFF, LOCAL, REMOTE

Describes the VRC modes: OFF (disables function), LOCAL (immediate reduction), and REMOTE (contact-activated reduction).

Automatic VRC with Remote Override

Explains automatic VRC operation based on load current and how remote override or terminal contacts can influence it.

Voltage Limit Control (VLC) and Data Logging

Voltage Limit Control Configuration

Details how to activate VLC and set upper and lower voltage limits to prevent tap changes outside defined ranges.

<LOG SETUP> Menu for Data Logging

Explains how to configure Event and Interval logging requirements, including enabling logging and defining data capture.

Data Logging and Security Setup

Viewing and Clearing Log Data

Describes how to view Event and Interval logs, and procedures for clearing log data from the panel.

Password Security Protection Overview

Introduces the MJ-5 password protection system, including System Key and Level 1/Level 2 security.

Password Security System

Password Levels and System Key

Details the hierarchical password system (System Key, Level 1, Level 2) for controlling access to settings and changes.

<PASSWORD> Menu Functions

Explains the purposes of the PASSWORD menu: entering passwords, defining passwords, and managing security system state.

Setting Up MJ-5 Security System

Entering and Managing the System Key

Guides users on entering and changing the System Key, which controls security system configuration and access.

Changing and Enabling Passwords

Provides instructions for changing Level 1 and Level 2 passwords and enabling password checking for enhanced security.

4.7 Communications Definition—The <COMMUNICATIONS> Menu

Setting Up the Local Data Port

Details configuration of the Local Data Port, including baud rate, parity, addressing, and regulator identification.

Using the Communications Module

Briefly mentions the Communications Module's role in remote communications and refers to its installation manual.

4.8 Regulator Maintenance—The <MAINTENANCE> Menu

Using the Maintenance Menu for Status

Explains how to view tap changer contact statuses (Excellent, Good, Worn, Replace) and operations counters.

Maintenance Approximation Algorithm

Describes the algorithm that approximates wear and tear on tap changer contacts and how to enable/disable it.

4.9—The <DIAGNOSTICS> Menu

Diagnostic Menu Items for Calibration

Lists diagnostic items for calibration, including voltage, current, and timing parameters for tap changer operation.

Tap Tracking and Control Parameters

Details parameters related to tap tracking, such as R/L OnTime, R/L OffTime, TapIn, and Neutral signal inputs.

4.10 Setting up the Quick Key

Adding and Removing Items from Quick List

Explains how to customize the Quick List by adding frequently accessed menu items or removing existing ones.

5 Reading and Interpreting MJ-5 Control Panel Data

Source and Load Definitions

Defines "Source" and "Load" for power flow analysis and explains how U2 and P2 terminals relate to these definitions.

P2 Voltage Calculation Feature

Describes the P2 Calc feature that calculates P2 voltage when a measured value is unavailable, requiring tap position data.

<METER> Menu Data Items

Details meter data items like voltage, current, power, and power factor, including instantaneous, max, and min values.

Meter Data Details and Calculations

Viewing Meter Data and Min/Max Values

Explains how to view meter data items and their min/max values, including time and date stamps.

Understanding Power Factor and kVA

Details the meaning of power factor (leading/lagging) and apparent power (kVA) calculations as displayed by the MJ-5.

Demand Data and Event Logging

<DEMAND> Menu Data Items

Describes demand data, which are time integration functions of metered values, maintained separately for forward and reverse power flow.

<EVENT LOG> Menu Functionality

Explains how the MJ-5 records meter data at the time of specific events, such as power up or tap changes.

Interval Logging and Log Clearing

<INTERVAL LOG> Menu Details

Describes how the MJ-5 records data at specific time intervals, logging values for voltage, current, power, and tap position.

Clearing Log Data and Resetting Min/Max

Explains how to clear Event and Interval logs and reset min/max values at the start of each interval.

5.7 Operation Counter Data - The <COUNTERS> Menu

Counter Data Items and Dead Reckoning

Details operation counter data for tap changer steps and explains the dead reckoning procedure for tracking tap position.

5.8 Alerts—The <Alert> menu

Viewing and Understanding Alerts

Explains how MJ-5 alerts represent exception conditions and how to view and interpret alert messages and indicators.

Acknowledging Alerts

Describes the procedure to acknowledge an alert using the Cancel/Reset key, and the effect on the alert indicator.

5.9 Harmonics Data—The <HARMONICS> menu

Harmonics Data Calculation and Display

Details how harmonics data for voltage and current are calculated and presented, including THD and harmonic components.

5.10 VRC Status - the <REGULATOR> Menu

Explains how VRC Status indicates the current level of Voltage Reduction Control, including percentage and mode.

6 MJ-5 Control Panel Automatic Mode

MJ-5 Control Modes Explained

Describes the four operating modes: local manual, local automatic, remote control, and Off, selected via the Auto/Manual switch.

Summary of Control Mode Operations

Provides a summary table comparing the behavior of MJ-5 control modes under different switch and LED configurations.

Automatic Control Algorithm

Algorithm Operation and Hierarchy

Details how the automatic control algorithm maintains output voltage within limits and the hierarchy for resolving conflicts.

Automatic Control Algorithm Inputs

Lists the factors the control algorithm considers, such as voltage, set points, LDC, VRC, current, and power flow.

Voltage Sensing and Limit Control

Voltage Sensing and Measurement Correction

Explains how the control program senses regulator output voltage and performs software scaling for accurate readings.

Voltage Limit Control Function

Details how VLC monitors output voltage against set points, inhibiting tap changes and returning voltage within limits.

Reverse Power Flow and Current Bias

Reverse Power Flow Handling

Explains how the MJ-5 senses and adjusts operation for power flow reversals, alternating between Forward and Reverse modes.

Current Bias and Bias Percent Settings

Describes the Current Bias feature, active in Bi-Directional mode, and how Bias Percent affects tap changes based on current magnitude.

6.5.4 Power Flow Modes

Forward Locked and Reverse Locked Modes

Details F LOCK (inhibits tap changes under reverse flow) and R LOCK (inhibits tap changes under forward flow) modes.

Bi-directional and Idle Reverse Modes

Explains Bi-DIR (regulation in both directions) and IDLE R (regulator idles at last tap position during reverse flow) modes.

Power Flow Modes: Neutral Reverse and Co-Generation

Neutral Reverse Mode Operation

Describes NEUT R mode, where reverse flow causes the tap changer to return to neutral position without stopping.

Co-Generation Mode Functionality

Explains CO-GEN mode for systems with consumer-generated power, using specific LDC values for forward and reverse flow.

7 Software for Communicating with the MJ-5 Control Panel

Communications Software Overview

Introduces MJXplorer and DNP Configure software for configuration, data download, and custom DNP point definition.

8 MJ-5 Control Panel Basic Troubleshooting

Troubleshooting Objectives and Indicators

Outlines basic troubleshooting procedures, focusing on identifying fault location and user-correctable issues.

Alert Messages for Diagnosis

Explains how alert messages from the <ALERTS> menu can help diagnose system and internal MJ-5 problems.

Visual Inspection and Calibration Checks

Visual Inspection Procedures

Lists checks for external source fuse, fuse connectors, jumpers, and terminal strip connections for proper installation.

Voltage Calibration Checks (U2 and P2)

Details how to check the U2 and P2 voltage calibration against applied voltage using a voltmeter.

Calibration Procedures

Calibrating the U2 Voltage

Provides step-by-step instructions to calibrate the U2 voltage reading on the MJ-5 panel using an external voltmeter.

Calibrating the Load Current

Details the procedure for calibrating the load current (C/C2) reading using an external ammeter and current source.

Appendix A: Specifications

Operational Requirements

Lists operating requirements for temperature, humidity, voltage range, and frequency for the MJ-5 Control Panel.

Accuracy and Electrical Transient Immunity

States metering accuracy and describes the MJ-5's immunity to electrical transients and RFI.

Appendix B: Physical Installation on Siemens Regulators

Switch Settings and Polarized Disconnect Switch

Details recommended switch settings for installation and explains the function of the Polarized Disconnect Switch (PDS).

Replacing Older Control Units

Provides guidance and notes for replacing older control units with the MJ-5 Control Panel, including specific panel types.

Appendix C: Regulator Control Diagrams

ANSI Type 'A' (Straight) Regulator Diagram

Presents a schematic diagram illustrating the control connections for an ANSI Type 'A' (Straight) regulator.

Control Panel Wiring Schematic

Shows the wiring schematic for the regulator control panel, detailing terminal connections and internal circuitry.

Appendix C: Regulator Control Diagrams (cont.)

ANSI Type 'B' (Inverted) Regulator Diagram

Presents a schematic diagram illustrating the control connections for an ANSI Type 'B' (Inverted) regulator.

Appendix D: Menu Parameters

<CONFIGURE> Menu: Leading and Lagging Regulators

Explains how to determine leading/lagging regulators in Delta configurations and set initial parameters.

<REGULATOR> Menu: Line Drop Compensation

Details the process for calculating and setting line drop compensation values using the "Load Center" method.

Appendix D: Menu Parameters (cont.)

<CONFIGURE> Menu: Transformer Polarity

Guides on determining and setting transformer polarity (NORM or REV) based on regulator nameplate schematics.

Single-Phase Straight Regulator Polarity

Details how to set polarity for single-phase straight design regulators based on tap position relative to E2.

Appendix D: Menu Parameters (cont.)

Single-Phase Straight Regulator Polarity

Details how to set polarity for single-phase straight design regulators based on tap position relative to E2.

Forced Air Cooling Polarity Settings

Explains polarity settings for regulators with forced air cooling, referencing nameplate schematics and connection tables.

Appendix D: Menu Parameters (cont.)

Three-Phase Regulators and Single Utility Winding

Discusses three-phase regulators with single utility windings and how to determine polarity based on connections.

Appendix D: Menu Parameters (cont.)

Multiple Utility Windings Configuration

Explains how to configure multiple utility windings for control, motor, and fan power based on phase winding usage.

Appendix E: Hazards of Bypassing a Regulator off Neutral

Risks of Bypassing Off Neutral

Warns about the critical importance of neutral position for bypassing, highlighting risks of catastrophic failure from circulating current.

Deactivating the Control Panel Before Bypassing

Provides mandatory steps to completely disable the control panel before bypassing operations to prevent inadvertent tap operations.

Appendix F: Communications Module Installation

MJ-5 Communications Module Mounting

States that the MJ-5 Communications Module mounts directly to the Main Processor board and refers to the installation manual.

Appendix G: Menu Structure Quick Reference

Menu Structure Overview

Provides a quick reference to the MJ-5 menu structure, listing data items across Meter, Demand, Counters, Regulator, Configure, etc.

Appendix K: MJ-5 Operating Procedures

Viewing and Setting Voltage Level and Bandwidth

Guides on viewing and setting voltage level and bandwidth values using fast-path keys and menu navigation.

Managing Time Delay and Line Drop Compensation

Details procedures for viewing and setting time delay values and line drop compensation components (resistance/reactance).

Operating Procedures: Counters, Alerts, and Configuration

Viewing Operation Counters and Alerts

Explains how to view operation counters, active alerts, and acknowledge alerts using panel keys.

Configuring the Control Panel Settings

Guides on configuring the control panel, including menu navigation, changing values, and setting the clock/date.

Appendix J: Terminal Strip Connections

Terminal Strip TB1B Connections

Describes the connections for terminal strip TB1B, detailing signal names, descriptions, and I/O power for various functions.

Terminal Strip TB2A and TB2B Connections

Details connections for terminal strips TB2A (VRC, input pairs) and TB2B (output relays), outlining their functions.

Appendix K: MJ-5 Operating Procedures (cont.)

Tap Tracking and Fine Tuning

Provides instructions for fine-tuning tap tracking by adjusting settings like R/L OnTime and TapInPulse.

Voltage Calibration and Tap Position Setup

Guides on using a voltmeter for U2/P2 calibration and setting the tap position using the <COUNTERS> menu.

Appendix L: Retrofitting onto CL-6 Cooper

Removing the Cooper Control Panel

Provides step-by-step instructions for safely removing the existing Cooper control panel from the regulator.

Installing the MJ-5 Control Panel

Details the process of installing the MJ-5 control panel onto a CL-6 Cooper voltage regulator, including wiring and connection.

Appendix N: Retrofitting onto a GE Regulator

Removing the GE SM3 Control Panel

Guides on removing the GE SM3 control panel, including disconnecting plugs, circuit boards, and wiring.

Installing the MJ-5 Control Panel on GE

Details the installation of the MJ-5 control panel onto a GE regulator with an SM3 control panel, including mounting and wiring.

Appendix O: Retrofitting on GE Type VR-1

Removing the GE Control Panel

Provides instructions for removing the GE control panel, including disconnecting plugs, wires, and circuit boards.

Installing the MJ-5 Control Panel on GE VR-1

Details the installation of the MJ-5 control panel onto a GE Type VR-1 regulator, including wiring harness connections.

P: MJ-X Tap Tracking: Fine Adjustments and Troubleshooting

How Tap Tracking Works

Explains the tap tracking algorithm, sensing operations, and potential issues like lost tap position or incorrect direction.

Tap Track Errors

Identifies common tap track errors ("Tap Pos ???", "Tap Track Err") and their possible causes and initial correction steps.

Settings Related to Tap Tracking

Tap Changer Type and Neutral Settings

Explains configuration options for tap changer type, neutral signal input, and neutral count for different regulator manufacturers.

Synchronization and Diagnostic Parameters

Details synchronization methods (Siemens, GE, Cooper, LTC) and active diagnostic parameters influencing tap tracking.

Appendix Q: Tap Control Setup

Tap Control Algorithm Overview

Describes the new tap control algorithm's intent for robustness and universality, and its configurable parameters in the Diagnostics menu.

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