INSTRUCTIONS MANUAL
CIRCUTOR S.A.
Version 1.4
2-80
Table of content
1
GENERAL DESCRIPTION.............................................................................................................7
2.1
INTRODUCTION ..........................................................................................................................7
2.2
3.2
PLACING .................................................................................................................................. 11
3.3
3.4
W IRING ....................................................................................................................................13
3.4.1
3.4.2
3.5
3.6
COMMISSIONING......................................................................................................................19
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.4
4.4.1
4.4.2
Power screen....................................................................................................................40
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.5
PASSWORD ..............................................................................................................................47
4.6
POWERSTUDIO APPLICATION.................................................................................................53
MAINTENANCE.............................................................................................................................54
6.1
6.2
6.2.1
6.2.2
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6.4
6.4.1
6.4.2
6.4.3
4-80
SAFETY INSTRUCTIONS
The following safety instructions are for all operations performed on the active
filter.
The
electrical
installation,
commissioning
and
5-80
Check that neutral is available in the site you are going to connect the Active
Harmonic Filters of four wires (AFQ-4W.)
The active filter (AFQ-4W) must be rated according to the harmonic currents to
be filtered and the electrical characteristics of the installation. Check paragraph
3.1 Dimensioning the AFQ rated current to define the correct range of active
filter. Skip the recommendations may cause improper operation of active filter
and the impossibility to properly compensate harmonic currents.
6-80
2 General description
2.1 Introduction
Harmonics
Harmonics are generated by power electronic devices such as rectifiers,
inverters, motors drives etc. These loads generate currents formed by a
fundamental frequency component of 50 or 60Hz, plus a series of
superimposed currents in multiples of the fundamental frequency.
7-80
AFQ-4W is connected between the supply line and the coupling point of the
loads in parallel. Current measurements will be made at load side (downstream
the AFQ-4W connection point).
8-80
I filter =
I load THD ( I )%
FS h
100
To calculate the safety factor its necessary to estimate previously the shortcircuit relation (RSC) in the converter connection point (CNL) (no in the
installation input). The short-circuit relation is defined as the relation between
the short-circuit current of the mains and the rated current of the no lineal
converters (ICNL).
9-80
RSC =
I SC
I CNL
10-80
3.2 Placing
Install the AFQ-4W in an indoor area, maintain an ambient temperature range of
0C to 40C, maximum humidity of 90% non condensation.
Do not install the active filter near a heat source and avoid the directly exposed
to sunlight.
Leave minimum clearances between AFQ-4W cabinet and surrounding cabinets
and walls:
Warning!
Install the AFQ-4W in an environment protected from water,
flammable liquids, gases and corrosive substances.
11-80
Warning!
Check that there is not compensation systems installed in the same
grid as AFQ. In case there are compensation systems, these must
be detuned to avoid interaction problems between AFQ and
compensation systems.
Procedure
< 1 year
No special procedure
1-2 years
> 2 years
12-80
3.4 Wiring
AFQ-4W requires the following external connections:
L1, L2, L3, N - Power connection to mains: 3 phases + neutral. Use
the required wire size according to current. The minimum cable
sections according to the range of the filter are shown in the table
below.
AFQ-4W-
AFQ-4W-
AFQ-4W-
AFQ-4W-
AFQ-4W-
25A
50 A
100 A
150 A
200 A
10
16
35
70
95
a 10
a 10
a 10
a 10
a 10
Terminal
b 20
b 20
b 20
b 20
b 20
(mm)
c 21
c 21
c 21
c 21
c 21
>8
>8
>8
>8
>8
7,6
7,6
7,6
14,4
14,4
25
50
95
2x95
2x95
>8
> 10
> 10
> 10
> 10
12
20
25
30
30
25
50
95
95
95
>8
>8
> 10
> 10
> 10
12
20
25
30
30
Wire size
2
(mm )
L1 L2 L3
Torque (Nm)
Wire size
2
(mm )
LN
Terminal
(mm)
Torque (Nm)
Wire size
2
(mm )
Ground
Terminal
(mm)
Torque (Nm)
13-80
All power cables and load current measurements should enter the cabinet at the
bottom to ensure the IP and to protect users against high voltage parts.
14-80
Warning!
Check the AFQ-4W is properly grounded to reduce the risk of
electric shock.
15-80
Caution!
Voltage and current connections must match phases. Otherwise, Active Filter
will not work properly.
Please review that following connections are correct:
Current transformer 1 (TI1) has to measure L1 and
transformer wires must be connected to S1/1L and S2/L1
cabinet.
Current transformer 2 (TI2) has to measure L2 and
transformer wires must be connected to S1/2L and S2/L2
cabinet.
Current transformer 3 (TI3) has to measure L3 and
transformer wires must be connected to S1/3L and S2/L3
cabinet.
16-80
secondary
in AFQ-4W
secondary
in AFQ-4W
secondary
in AFQ-4W
Caution!
All active filters (AFQ-4W) connected in parallel must have identical
configurations on OPERATION MODE and PARAMETERS. See (4.3 Setup
screens)
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If there is a problem in the wirings or in the power supply, the screen may show
another message. In the section 4.6 Warning descriptions in this manual
describes all the causes of malfunctions and their solutions.
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3.6 Commissioning
The following describes the steps for starting the active filter (AFQ-4W). To see
in detail all configuration parameters, check section 4.3 Setup screens of this
manual.
Caution!
Follow the steps for configuration of the equipment before starting the AFQ-4W.
Step 1.
Setup of the load current transformer and the number of modules in parallel
Set the number of modules in parallel. Leave the default value (1) if there
is one AFQ-4W.
Figure 14: Step 1: Ratio of the transformer and number of modules in parallel.
19-80
Step 2.
Configuration of the AFQ-4W functions
reactive
Caution
Improper configuration can significantly affect the performance of the AFQ-4W.
Consult the technician to select the configuration of equipment according to the
needs of the facility.
20-80
Step 3.
Checking the network voltage and frequency
Ensure that the voltage measurements correspond with the real tensions
of the plant.
21-80
Step 4.
Verification of active and reactive power
Verify that the active power measurement of the load corresponds to the
power levels of the facility.
Check that power factor in the three phases. If there were very low power
factors that would indicate an error in the order of phases. In this case,
you should check the wiring to mains and to the current transformers,
read 3.4.1 Wiring of active filter (AFQ-4W) paragraph for the AFQ-4W
connections.
Once verified the real power, reactive power and the power factor, you may
return to the main screen for starting the active filter (AFQ-4W). Press MAIN
button to access to main screen.
22-80
Step 5.
Starting the active filter (AFQ-4W):
If there were no problem in connecting and configuring the AFQ-4W, the
message STOP should be displayed in the main screen.
23-80
If an alarm trips, a message will appear in the main menu describing the
problem. Check 4.6 Warning descriptions for alarm descriptions.
Press RESET ALARM button to start AFQ-4W again when the problem has
been solved.
24-80
4 Display panel
4.1 Screen navigation
25-80
1 START/STOP: Start and stop control key. Filter status must be STOP to
start the Active Filter.
2 RESET ALARM: Alarm recovery key. Recovers the AFQ-4W from an alarm
and brings it to STOP mode.
3 VIEW: Access to the visualization screens.
4 SETUP: Access to the parameters and configuration screens..
5 Additional information of Filter performance: 4.6 Warning descriptions
section contains the explanation of the messages displayed in this box.
6 Filter status:
a. NO INITIAL CONDITIONS: Initial conditions for the AFQ-4W
starting are not fulfilled.
b. STOP: The AFQ-4W is ready to start.
c. RUN: The AFQ-4W is working.
d. ALARM: The AFQ-4W is under alarm.
7 Date and time: Visualization of date and time.
26-80
27-80
28-80
OFF
ON
Harmonic filtering
Phase balancing +
reactive compensation
PRIORITY
Prioritization of functions
Phase balancing +
reactive compensation
Harmonic filtering
29-80
want
neutralize.
AFQ
Selected
30-80
31-80
Low temperature alarm: Enable or disable the low temperature alarm. This
alarm avoids starting the active filter when the temperature in the cabinet is
under 0C or there is a problem
This option is set by default. It is recommended not to disable the alarm.
Resonance alarm: The resonance alarm protects the device against resonant
currents between AFQ and load. When a harmonic content load increases
above the limit, resonance alarm disables these harmonic. Before disable the
resonance alarm is necessary to check there is no resonant current.
CAUTION
Before disable the resonance alarm is necessary to check there is no resonant
current. Resonant currents may damage the active filter and other devices
connected on the grid.
32-80
Warning!
Avoid using 2 temporal mode except your supplier recommends it for your
installation. This method may produce resonance problems in specific
installations.
Parallel modules: Access to the screen to setup the number of parallel AFQ4W modules installed.
Power limit: This parameter allows limiting the maximum power of the active
filter. The value is the percent of the rated power of active filter. The value must
be between 20% and 100%.
Lock/Unlock parameters: key to lock/unlock the configuration parameters.
Main: Access to the main screen.
Back: Back to configuration screen.
34-80
35-80
36-80
37-80
38-80
39-80
Power load: Access to the active, reactive and apparent powers load screen.
Power mains: Access to the active, reactive and apparent powers mains
screen.
Power filter: Access to the power filter screen. This screen shows the power
filter used in percentage of the rated power filter.
Main: Access to the main screen.
Back: Back to view screen.
40-80
41-80
THD(I) content load: Access to the load current harmonic spectrum screens.
THD(I) content mains: Access to the mains current harmonic spectrum
screens.
THD(I) total: Access to the view of the total THD(I) of each phase with bar
graph.
42-80
Phase 2
43-80
44-80
L1/L2/L3: Access to the view of the current harmonic content of another phase.
Main: Access to the main screen.
Back: Back to THD(I) screen.
Figure 46: Display of the total THD(I) in load and mains side.
45-80
46-80
4.5 Password
All the setup options can be password protected. To enable or disable the
protection, you must press LOCK/UNLOCK PARAMETERS key. This key is in
the FUNCTION SELECTION, SELECTIVE FILTERING, ENABLE ALARMS
and PARAMETRES screens.
To lock or unlock the edition of parameters you must enter the password using
the virtual keyboard that appears on the screen after pressing the "LOCK /
UNLOCK Parameters" button.
47-80
Caution!
Lock the password again after modifying setup options to avoid accidental
modifications of AFQ-4W configuration.
48-80
Warning!
Turn off the main breaker before performing any maintenance
operation on the AFQ-4W. Do not attempt to manipulate the inside of
the equipment until 5 minutes after disconnection. Check there is no
voltage on dc capacitors.
This chart shows messages that may appear before AFQ-4W starting
NO INITIAL CONDITIONS
Message
Description
Corrective action
Wait until the AFQ-4W has finished
the starting up.
Starting
AFQ-4W is starting
Setup
transformer
ratio
MIN. Load
current
MIN. Mains
Voltage
MIN. DC Bus
Frequency
error
49-80
DC bus
unbalance
NTC connector
failure
ALARMS
Message
Temperature
NTC1
Temperature
NTC2
Temperature
Inductor
MAX. DC Bus
MAX. Positive
DC Bus
MAX. Negative
DC Bus
MAX. Current
MAX. Mains
Voltage
Description
Corrective action
Check fans and turbines, of the
Desaturation
Initial
conditions error
state
50-80
Resonance
alarm
properly
DC bus charge
error
Contactor
failure
Press ALARM RESET in main screen to recover Active Filter, if the cause of
the alarm has disappeared or has been solved.
This chart shows messages that may appear while AFQ-4W is running
RUNNING
Message
Description
Corrective action
The AFQ-4W is working properly
but under saturation. It is
recommended to reduce the
MAX. Load
number of harmonics to
51-80
CONFIGURATION
Message
Description
End Setup
Filter Range
Error
Corrective action
Parallel AFQ
Error
correct
Algorithm Error
Software
version error
Power limit
error
service
52-80
5 PowerStudio application
PowerStudio is an energy management software package and its main features
are the configuration, communication and monitoring of devices and creation of
SCADA screens and reports. It also has a set of tools such as events, filters,
calculated variables, and an images and styles manager to facilitate the users
interaction.
The communication protocol between PowerStudio and active filter is Modbus
RTU, with RS-232 cable.
The configuration parameters of the communication are shown in below table.
Serial Type
RS485
Protocol
Station number
Baud rate
9600
Data bit
Parity
none
Stop bit
The communications cable RS-232 plugs into the back of the panel, according
to the following scheme.
53-80
6 MAINTENANCE
The active filter requires minimal preventive maintenance. Follow the
maintenance instructions to avoid premature spoilage of the components.
The table below shows time interval and the maintenance operations.
Description
Interval
Standard maintenance
5.000 a 9.000 h
40.000 h
Cooling fans
100.000 h
DC bus capacitors
200.000 h
Table 10: Maintenance operations.
* The interval times of the maintenance operations may vary depending on the
operation conditions and environmental factors.
Danger
Follow the safety instructions described in the chapter
SAFTY INSTRUCTIONS before performance maintenance
on AFQ-4W.
Ignore these instructions may cause injury or even death.
Caution
Inside the cabinet there are components that reach hight
temperature. Wait to cool the AFQ-4W before performance
maintenance.
54-80
After replace the battery panel, its necessary to setup the language, the date
and time.
55-80
Cooling fans
Inductors
Cooling fans
Inductors
Cooling turbines
IGBT
AFQ-4W-25 A
AFQ-4W-50 A
AFQ-4W-100 A
AFQ-4W-150 A
AFQ-4W-200 A
56-80
- Replace damaged fan. Install the new fan in the right position, with the supply
connector in the lower right corner.
- Plug the supply wires
57-80
- Replace damaged fan. Use a 7mm. allen key to remove the fan from the
cover.
58-80
x: R, S, T phase.
Figure 57: Fans change on AFQ150, 200 and 100. Step 4.
59-80
- Lift the air hood, unplug the fan supply wire and remove the air hood.
60-80
- Install the new fan in the same position as the replaced fan.
- Plug the fan power and insert the air hood.
BOTTOM FANS
- Unplug the fan supply wire from the bottom of the heatsink.
- Remove the four screws that fix the fan on the heatsink.
61-80
- Replace damaged fans. Install new fan in the same position as removed fan.
- Connect the fan supply wire. Install the right cover. Check that the ground wire
is properly connected on the cover.
- Bring up the panel that holds electronic boards and insert the methacrylate
protection.
AFQ-4W-100 A / 150 A / 200 A
The following instructions are for replacing the heatsink fans AFQ-4W-100A,
AFQ-4W-150A and AFQ-4W-200A.
- Set AFQ in STOP mode and open the main switch (OFF position).
- Wait 5 minutes and check there is no voltage in the capacitors.
- Remove the methacrylate protection and bring down the panel that holds
electronic boards.
62-80
63-80
64-80
65-80
Plug the device supplied in the connector, close to the microswitches. Must
be connected with the flat part in the opposite side of the battery, the
bumped part close to the battery.
Switch the filter on. It can be done with door opened, but work with extreme
caution. You can do it, but under your risk. In this case, you can follow the
upgrading procedure. A green LED will light during the updating process,
and will be off after that period. If you want to upgrading with the door
closed, switch on the filter, wait 2 minutes, and switch it off. The upgrading
procedure should be finished.
Switch off the filter again. Wait 5 minutes.
Unplug the device supplied. Switch the microswitches or jumper back to the
initial position 0000.
Mount the polycarbonate protection.
The filter is updated.
66-80
CAUTION
If the panel software is no updated, update this software before starting the
active filter (see 6.4.2 Update panel software).
CAUTION
Finished the update process could be necessary to setup again the filter
parameters. Before start the filter check the configuration parameters. (See
6.4.3 Checking the configuration after complete the update)
Turn off active filter, wait until the capacitors are discharged (about 5
minutes). When the capacitors are discharged, plug in the memory stick into
the USB port found behind the panel.
Power the active filter and wait until the screen has started. Check the filter
is STOP state. Access the FILTER DATA screen and change the setup code
number to 25.
Access the SETUP screen and push EXIT button.
67-80
Press Download project. Select the file Vx.yz (x.yz is the version number of
software) and press OK.
Wait until the update is complete. After the udate, the panel will restart the
software.
68-80
Turn off the active filter, wait until the capacitors are discharged (about 5
minutes.) and unplug the memory stick.
Reenergize the filter again.
If the message End Setup appears, you should change the setup code
number to 14 in the FILTER DATA screen. Back to main screen and verify
that the End Setup message is cleared.
If the message Parallel AFQ error appears, you should access to
PARAMETERS screen and configure Parallel Modules option. (See 4.3.2
Parameters screen)
CAUTION
If the AFQ software is no updated, update this software before starting the
active filter (see 6.4.1 Update AFQ software).
CAUTION
Finished the update process could be necessary to setup again the filter
parameters. Before start the filter check the configuration parameters. (See
6.4.3 Checking the configuration after complete the update)
69-80
ENABLE ALARMS
MINIUM CURRENT
CONTROL ALGORITHM
PARALEL MODUELS
POWER LIMIT
70-80
7 Technical characteristics
Models
AFQ_4W-25
AFQ_4W-50
25 A RMS
50 A RMS
100 A RMS
150 A RMS
200 A RMS
75 A RMS
150 A RMS
300 A RMS
450 A RMS
600 A RMS
50 A PEAK
100 A PEAK
200 A PEAK
300 A PEAK
400 A PEAK
Electrical characteristics
Nominal Voltage
400 V 15%
Frequency
50 Hz / 60 Hz +/- 10%
Number of phases
Filter specifications
Current harmonics compensation
Yes
Yes
Controller
Digital, DSP
< 1ms
Protection from over current by current limitation at filter nominal value
71-80
Standards
Reference Harmonic Standard
EN61000-3-4, IEEE519-1992
EN60146
Safety Standard
EN50178
Electromagnetic Compatibility
Display functions
Controls
Setup
Optional products
CVMk2
Power Studio
72-80
Environmental conditions
Operating Temperature
+0C to +50C
Relative humidity
Operating Alititude
< 2000m
Mechanical characteristics
AFQ_4W-25
AFQ_4W-50
AFQ_4W-100
500x830x450
655x1350x450
665x1800x457
135
212
272
AFQ_4W-150
AFQ_4W-200
1190x1900x620x720 1190x1900x620x720
505
511
73-80
74-80
75-80
76-80
77-80
78-80
79-80
Queda prohibida la reproduccin total o parcial de esta publicacin, sin para ello contar con la autorizacin previa y por escrito de CIRCUTOR, SA
ESPAA:
INTERNACIONAL:
email:
sat@circutor.es
CIRCUTOR, SA
Vial Sant Jordi, s/n 08232 Viladecavalls (Barcelona)
Tel. +34 93 745 29 00 Fax: +34 93 745 29 14
Web: www.circutor.com email: central@circutor.es
80-80