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ABB PQFS, Installation, Operation And Maintenance Instructions

ABB PQFS offers a comprehensive user manual packed with precise Installation, Operation, and Maintenance Instructions. This essential manual is available for free download at manualshive.com, ensuring users have easy access to all the information they need to maximize the potential of this outstanding product.

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Manual Power Quality Filter PQFS   

 Commissioning instructions 141   

— 

8

 

Commissioning instructions 

8.1

 

What this chapter contains 

This chapter presents the steps to follow to commission the active filter. The 
commissioning of your PQF should be conducted in strict accordance with this 
procedure. 

 

 

 

Before applying the commissioning procedure, make sure that you are familiar with: 

−

 

The filter hardware (discussed in 

Chapter 4

). 

−

 

The mechanical installation requirements (discussed in 

Chapter 5

). 

−

 

The electrical installation requirements (discussed in 

Chapter 6

). 

−

 

The PQF programming interface PQF-Manager (discussed in 

Chapter 7

). 

−

 

If the Modbus option has been installed, please refer to the document 
“2GCS212013A0050-RS-485 Installation and Start-up guide” for more information 
on this item. 

The commissioning procedure consists of 9 steps that should be strictly followed. 

Table 52: Steps to follow to commission the active filter 

Steps 

Actions 

Step 1 

Visual and installation check 

Step 2 

Setting the address of each unit in a multi-unit filter and terminate the CAN 
bus 

Step 3 

Voltage rating and phase rotation check 

Step 4 

Basic commissioning parameters setup  

Step 5 

Automatic and manual CT detection procedure 

Step 6 

Before starting the filter 

Step 7 

Start the filter 

Step 8 

Generate filter load 

Step 9 

Set up the user requirements 

 

Section 8.11

 presents the commissioning report to be filled in when commissioning the 

filter. 

Summary of Contents for PQFS

Page 1: ... INSTRUCTION MANUAL Power Quality Filter PQFS Installation operation and maintenance instructions ...

Page 2: ...tandard cubicle dimensions fixing holes and clearances 32 5 5 Instructions for mounting the filter 33 5 6 Filter noise level 34 5 7 Instructions for mounting the PQF Manager in enclosures 35 6 Electrical design and installation 36 6 1 What this chapter contains 36 6 2 Instructions for connecting the PQF Manager to a filter system 37 6 3 Checking the insulation of the assembly earth resistance 37 6...

Page 3: ...acilities 81 7 7 The PQF start stop and fault acknowledgement menu 82 7 8 The Measurements menu 84 7 8 1 The Overview menu 84 7 8 2 The System values menu 86 7 8 2 1 Voltages 86 7 8 2 2 Line currents 88 7 8 2 3 Filter currents 89 7 8 2 4 Total filter currents 90 7 8 2 5 Powers 91 7 8 2 6 Temperatures 91 7 8 3 The Min Max logging menu 92 7 9 The Settings menu 93 7 9 1 The Customer settings menu 94 ...

Page 4: ...heck adaptation and phase rotation check 145 8 5 Step 4 Basic commissioning parameters set up using PQF Manager 146 8 6 Step 5 Automatic and manual CT detection procedure 148 8 6 1 Automatic CT detection procedure 148 8 6 2 Manual CT detection procedure 149 8 6 2 1 PQF connection diagram 149 8 6 2 2 Material needed and hypotheses for correct measurements 150 8 6 2 3 Checking the correct connection...

Page 5: ...10 3 5Step 5 Check the condition of the filter contactors and fuses 178 10 3 6Step 6 Check the tightness of the electrical and mechanical connections 178 10 3 7 Step 7 Correct any abnormal conditions found 178 10 3 8Step 8 Restart the filter 178 10 4 Fan replacement 179 10 5 DC capacitor change 180 10 6 DC capacitor reforming 180 10 7 Output filter board change 181 10 8 Servicing report 181 10 8 1...

Page 6: ...structions Cf Chapter 10 of this manual 1 3 Compatibility The manual is compatible with all filters of PQF range with PQF Manager software versions or higher V1 V26 r3001 V2 V11 r23 V3 V2 r0 V4 V0 1 r8 This product is not backward compatible with any other PQFx x A B L T I M K S filter product 1 4 Contents Chapter 1 Introduction to this manual Chapter 2 Safety instructions Chapter 3 Upon reception...

Page 7: ... Introduction 7 Power Quality Filter Active Filtering Guide English PQ Link Installation and user s guide English PQF Modbus CD English ABB PQF Active Filters Raising system reliability to unprecedented levels English ABB quick start ...

Page 8: ...vidual enclosure must be isolated before entry opening WARNING This equipment contains capacitors that are connected between phase and earth A leakage current will flow during normal operation Therefore a good earth connection is essential and must be connected before applying power to the filter WARNING There are AC capacitors DC capacitors connected inside this filter Before performing any maint...

Page 9: ...FS Safety Instructions 9 WARNING The neutral current in a PQFS filter may be as high as 3 times the line current hence do not use a 4 pole breaker to connect this type of filter as the rating of the neutral pole may not be adequate ...

Page 10: ...terior of your filter for transportation damage 3 3 Unpacking instructions Figure 1 PQFS packing material opened After removal of the top cover check visually the exterior and interior of your filter for transportation damage Your filter equipment comes with a package Verify that all items are present i e this manual the electrical drawing the rubber seal to cover a knock out to be used for multi ...

Page 11: ...ttered over the whole area or with heavy traffic Also applies to locations with immediate neighborhood of industrial sources with chemical emissions b Locations without special precautions to minimize the presence of sand or dust Also applies to locations in close proximity to sand or dust sources In order to lift the equipment once it is at the installation location Remove the top cover of the pr...

Page 12: ...y put aside Figure 4 Unplugging the PQF Manager from the main system Remove the two screws fixing the filter unit to the wooden support see Figure 5 Right side Bottom Figure 5 Position of the filter fixation screws that need to be removed Fix the two eyebolts provided with the filter see Figure 6 Figure 6 Fix the eyebolts before lifting the PQFS ...

Page 13: ...as well as a serial number and an ABB internal article code 3 6 Storage If your PQFS is not installed once unpacked it should be stored in a clean indoor dry dust free and non corrosive environment The storage temperature must be between 25 C 13 F and 70 C 158 F with a maximum relative humidity of 95 non condensing Table 2 Maximum allowed ambient conditions for storage Storage in the protected pac...

Page 14: ...ser s connection point for the alarm warning contacts the remote control functionality the other digital input functionality and the interface for external communication A current generator power unit that converts the control signals generated by the filter controller into the filter compensation current The current generator is connected in parallel with the load s Up to eight power units may be...

Page 15: ...ure to installation earth Mandatory Mandatory connections are connections that must be present to make the filter operational Connections that are not mandatory can be made to enhance the filter s basic functionality For more information on cabling the user connections please refer to Chapter 6 Figure 9 shows a typical PQFS master filter panel 1 2 4 5 3 Figure 9 Example of a typical PQFS master fi...

Page 16: ... power circuit of a PQFS unit is represented hereafter N Preload resistor Output filter IGBT Inverter Master Unit N AC power supply L L 1 2 3 4 5 6 7 8 Figure 10 Power circuit diagram of a PQFS active filter The description of the main components is given in Table 5 Table 5 Main components of a PQFS active filter Item Main components 1 IGBT inverter 2 DC bus capacitors 3 PWM reactor 4 Output filte...

Page 17: ...onverted into a useful current while the high frequency noise is absorbed The IGBT inverter is equipped with DC capacitors that act as energy storage reservoirs 2 In active filters containing more than one power unit the control information between different units passes through a CAN control cable If a master master configuration of filter is chosen all power units incorporate a PQF Manager displ...

Page 18: ...equirements with the PQF Manager He may also want to wire the communication interface Modbus or Ethernet and the programmable digital I O e g alarm contact remote control When a second unit is added it is connected to the first enclosure by means of a CAN bus communication link 1 In addition the CT measurements have to be supplied to each unit i e through a daisy chain link with return path All un...

Page 19: ...is specific to that particular unit number This unit selection button is deactivated on the slave Managers Figure 12 shows the front side of the PQF Manager Figure 12 Front side of the PQF Manager Five main parts can be distinguished see Table 6 Table 6 Front side of the PQF Manager Item Description 1 Menu display By navigating through the menus with the and buttons the filter can be set up and co...

Page 20: ...ignation Item Customer terminals 1 Digital input 1 and 2 2 Digital outputs 1 to 6 with one common point 3 Alarm outputs 2 outputs with complementary signals and fan outputs 4 Lock switch 5 Modbus adapter interface optional connection 6 CAN bus connection interface routed to PQF Manager connector 7 Power supply terminals routed to PQF Manager connector 8 Ethernet 9 USB 10 Temperature probes The ter...

Page 21: ...ions described above please note that according to the setup done with the PQF Manager for the input considered the filter may behave differently Table 8 below gives an overview of the possible settings and the resulting filter behavior Table 8 Overview of possible digital input settings and resulting filter behavior Function Vlow applied to digital input Vhigh applied to digital input Remote cont...

Page 22: ...omplete system will monitor its digital outputs For full redundant functionality it is recommended to cable the digital inputs of all the units in the filter system 2 Digital Outputs 1 to 6 With each digital output different filter conditions can be associated The association between the filter condition and the digital outputs is done with the PQF Manager Table 9 gives an overview of the possible...

Page 23: ...e information on this subject is given in Section 7 9 1 4 1 Further it should be noted that Whenever a digital output is activated the corresponding icon on the PQF Manager display will change In a master master filter arrangement only the master that has the control over the complete system will activate its digital outputs For full redundant functionality it is recommended to monitor the digital...

Page 24: ... filter system The maximum continuous alarm contact ratings are 250 Vac 1 5 A A fan relay can be activated if a temperature probe detects an overtemperature 4 Lock switch Allows locking the settings of the filter panel This switch is documented in Section 7 9 3 5 5 Modbus RTU adapter interface optional connection The Modbus adapter interface is connected at this location The output of the interfac...

Page 25: ...to the Temperature probe User s guide for more information For information on how to cable external systems e g remote control Modbus interface to the PQF Manager refer to Chapter 6 For information on how to use the PQF Manager refer to Chapter 7 For background information on the Modbus RTU and TCP communication interface refer to the dedicated Modbus manual For background information on the PQ li...

Page 26: ...Auxiliary transformer T001 16 Fuse preload circuit PF1 PF2 The PQFS filters are provided with the preload circuit and the output filter mounted on a PCB This design substantially reduces the time needed for replacement of the same It also gives a more robust design compared to the previous generation of filters The power supply to the exhaust fan at the top of the filter are connected to the termi...

Page 27: ...sistors R2 5 Capacitors 6 Terminal block for top fans P3 The PQF Main controller board has connectors which are predominantly pre wired for use within the filter However it also contains a DIP switch used to set the identification address and CAN bus connectors for use in a multi module filter arrangements The main controller board is shown in Figure 16 10 2 6 7 8 9 15 3 12 11 4 13 14 5 16 17 18 2...

Page 28: ...ocontroller running properly LED 1 ON OFF or blinking irregularly Microcontroller not running properly 20 System LED s top to bottom with ABB Logo at top left side LED 5 ON Filter unit is acting as the master of the complete system LED 5 OFF Filter unit is acting as a slave in the filter system LED 4 Blinking at regular interval 1 s DSP processor running properly LED 4 ON OFF or blinking irregular...

Page 29: ...plicable to single unit filters Must be Low L for units in the middle of a chain The default factory setting is H Remark a For physical locations of customer CT connection terminals please refer to Figure 14 item 4 4 6 2 Active filter door components and protective grid The active filter master panel door contains the PQF Manager and a protective grid connected to the filter frame At the bottom of...

Page 30: ...95 F Relative humidity Max 95 non condensing Contamination levels IEC 60721 3 3 Chemical class 3C2 c Mechanical class 3S2 d Remarks a At sites over 1000m 3300ft above sea level the maximum output current must be derated by 1 every additional 100m 330ft The derating factor must be entered at commissioning b Above 40 C 104 F the maximum output current must be derated by 2 every additional 1 C 1 8 F ...

Page 31: ...Airflow requirement Unit rating Airflow requirement m h 30A 60A 520 m h 70A 100A 520 m h 120A 710m h Please ensure that the air used for cooling is regularly renewed and does not contain conductive particles significant amounts of dust or corrosive or otherwise harmful gases The cooling air intake temperature must not exceed 40 C under any operating condition The hot exhaust air also has to be pro...

Page 32: ...s of 588 x 326 x 795 mm width x depth x height Each enclosure contains one power unit and is fitted with its own main contactor Power cables with protecting fuses can be connected to each PQFS from the bottom A spacing of 30 mm between the filter sides and walls or other enclosures is recommended However the filter can rest on its back against a wall A spacing of 500 mm below the filter bottom and...

Page 33: ...ample of an installation where PQFS units are mounted above each other 5 5 Instructions for mounting the filter The wall on which the filter unit is mounted must be able to support the weight of the filter which is about 130 kilograms Please note that one enclosure contains always one unit In order to mount a filter unit on to the wall follow the steps outlined below Unpack the filter as per Secti...

Page 34: ... provided the enclosure can be pushed against the rear support at the bottom also see Figure 22 Figure 22 Lower end fixation For additional units the same procedure has to be followed 5 6 Filter noise level Active filters produce a certain level of noise when they operate The noise level depends on the operating conditions of the unit and on the rating of the filter These values should be taken in...

Page 35: ...acket d Figure 23 Mechanical installation of the PQF Manager Step 1 Slide the PQF Manager a perpendicularly to the Capacitor Bank Cubicle b Step 2 Rotate the PQF Manager to insert it into the Capacitor Bank Cubicle Note cut out dimensions are 138 x 138 mm Step 3 Insert the Mounting Bracket c in the corresponding Fixation Holes d of the PQF Manager Step 4 Pull the Mounting Bracket backwards Step 5 ...

Page 36: ... ABB The active filter must be connected to the network in parallel with the loads WARNING The PQFS does not incorporate protective power line fuses or main contactor Hence the customer has to ensure that the feeding cables to each filter panel are adequately protected taking into account the filter rating and the cable section used More information on this topic is presented in Section 6 7 Basic ...

Page 37: ...ctions for connecting the PQF Manager to a filter system PQFS filter master units are by default equipped with the PQF Manager user interface In some cases however it may be needed to remove and reconnect the PQF Manager to the filter In order to successfully connect the PQF Manager to a PQFS filter unit it suffices to plug the male connector attached to the PQF Manager into the corresponding fema...

Page 38: ...nclosure 6 4 EMC considerations The CE version of active filter complies in its standard version with the following EMC guidelines EN IEC 61000 6 2 Immunity standard for industrial environments Industrial level EN IEC 61000 6 4 Emission standard for industrial environments Class A 6 5 Earthing guidelines Each PQFS plate has one marked earth points PE The earth point is situated at the bottom right...

Page 39: ...d taking into account the skin effect The multiplication factor X is a factor that takes into account that the current that will flow through the filter connection cables is predominantly a harmonic current i e a current of which the frequency of the most important components is higher than the network base frequency Due to the frequency being higher than the network base frequency a physical phen...

Page 40: ...mark During this process it may be found that more than one cable per phase is needed The process then has to be applied to each cable As an illustration of the cable sizing process consider the following example PQFS 60 A 50Hz 3 wire connection cable material Cu copper Step 1 IN 60A cable section 16 mm2 Step 2 multiplication factor for a 16 mm2 copper cable at 50 Hz 1 00 Step 3 I IN x 1 00 60A x ...

Page 41: ...3 265 220 0 965 210 120 4 0 1 1 325 0 904 290 250 0 95 238 150 300MCM 1 1 365 0 877 320 285 0 93 265 185 350MCM 1 1 415 0 844 350 325 0 908 295 240 500MCM 1 1 495 0 804 390 385 0 876 335 300 600MCM 1 1 550 0 768 420 425 0 843 358 16 6 2 0 8 160 0 997 159 120 0 999 120 25 4 2 0 8 208 0 993 205 160 0 997 160 35 2 2 0 8 256 0 987 250 192 0 994 190 50 1 1 0 2 0 8 304 0 975 290 232 0 989 229 70 2 0 2 0...

Page 42: ...38 406 425 0 81 346 16 6 2 0 8 160 0 996 159 120 1 120 25 4 2 0 8 208 0 99 205 160 1 160 35 2 2 0 8 256 0 981 250 192 0 99 190 50 1 1 0 2 0 8 304 0 965 293 232 0 98 228 70 2 0 2 0 8 368 0 941 346 288 0 97 280 95 3 0 2 0 8 456 0 911 415 352 0 95 336 120 4 0 2 0 8 520 0 88 457 400 0 93 374 150 300MCM 2 0 8 584 0 85 496 456 0 91 416 185 350MCM 2 0 8 664 0 817 542 520 0 89 460 240 500MCM 2 0 8 792 0 7...

Page 43: ...stomer protection is in place the following PQFS input protection will result L1 L2 L3 To PQFS power stage To PQFS control circuit and DC bus loading circuit 2 5mm reinforced 6A 10X38 for up to 415V N Customer added protection PQFS filter unit Note neutral connection only needed for 4 wire connection Figure 26 Symbolic representation of the PQFS input protection The active filter power circuit is ...

Page 44: ...to the network The feeding cables to the filter must be protected by their own cable and equipment protection device see Section 6 7 WARNING The PQF can operate on networks with nominal voltage in the range 208 240 V and 380 415 V The unit must be configured for the operation range it will be used on Follow the guidelines in this section to ensure that the hardware is configured properly Failure t...

Page 45: ...g device is connected upstream and that the power supply cables are not live 3 Remove the protective cover present at the bottom right side of the filter Cf Figure 27 Figure 27 Removing the Aluminum protective cover at the bottom side of the active filter enclosure 4 Make holes in the protective cover of appropriate section corresponding to the power cable section used Also make holes for the eart...

Page 46: ...el 9 Preparation of the filter to match the networks voltages The active filter nominal voltage setting must be adapted to the actual network voltage by adjusting the tap setting of the auxiliary transformer If the tap setting for your network voltage is not available then choose a tap just above the network voltage present e g for 390V network choose 400V tap setting The auxiliary transformer is ...

Page 47: ...re 29 Connection of the neutral cable when using the PQFS in 4 wire mode The cable lugs for the neutral cables should comply with Maximum lug width in accordance with terminal width Minimum lug eye diameter M8 Appropriate torque must be applied to ensure that cables are properly fixed Other points in the connection procedure are as per previous Section Remarks In case of regenerative loads e g loa...

Page 48: ...shall be adapted accordingly Note that the burden requirement for a complete filter system consisting of up to 8 filter units is 5 VA excluding connecting cables Class 1 accuracy or better Primary side current rating sufficient to monitor the total line current including transient phenomena such as drive motor starts It is strongly recommended that the three CTs have the same characteristics WARNI...

Page 49: ...uracy or better NO Section of CT cables 2 5 mm recommended Determine the length of CT cables meters L m X3 L x 0 007 x 25 10 X3 VA Select 3 identical CT s such that rating at primary X2 rating at secondary 5A Burden X3 VA Class 1 accuracy or better Determine the length m and resistance Ω m of CT cables meters L m R Ω m X4 L x R x 25 10 X4 VA Select 3 identical CT s such that rating at primary X2 r...

Page 50: ...e system to the PQFS the secondaries of the CTs have to be shorted Failure to do so may result in CT explosion and consequent damage to the installation Once the connections to the filter have been made the shorting links must be removed The basic rules for successful CT installation are given next Cf Figure 33 The three filter CTs have to be positioned for closed loop control i e the CT must moni...

Page 51: ... plate of the filter Cf Figure 34 L1 L2 L3 Load side Supply side K L k l K L k l K L k l PQF X21 1 X21 2 X21 3 X21 4 X21 5 X21 6 X21 7 X21 8 X21 9 L1 L2 L3 To X21 1 X21 2 To X21 4 X21 5 To X21 7 X21 8 K P1 L P2 k S1 l S2 N N Figure 33 Basic CT connection example for a single unit active filter CT connection terminal X21 Figure 34 Location of the CT connection terminal X21 in the PQFS The terminal ...

Page 52: ... X21 5 X21 6 X21 7 X21 8 X21 9 Figure 35 Four wires CT wiring approach that may be used with a single unit PQFS active filter In case a filter system consists of more than one unit all units have to be supplied with the CT measurement information This is done by cabling the CTs in a daisy chain fashion between the different units This is illustrated in Section 6 11 3 6 11 Electrical interconnectio...

Page 53: ...le Four steps have to be followed to electrically interconnect a new PQFS unit with an existing filter They are outlined in the next four paragraphs 6 11 1 Mechanical interconnection of the enclosures All cables to the PQFS unit such as power cable as well as interconnection cable between modules must pass through the bottom cable entry hole provided in the PQFS box 6 11 2 Control board cable inte...

Page 54: ... connected Notes In the first unit of a filter system the left hand RJ45 socket will always be empty In the last unit of a filter system the right hand RJ45 socket will always be empty During the commissioning phase a unique address has to be assigned to each unit in a filter system through dip switch see Chapter 8 6 11 3 CT cable interconnection WARNING Failure to connect the CT s to all units in...

Page 55: ...on 6 8 WARNING Make sure that the phase rotation of the power cable connection is clockwise at the filter terminals and that the L1 L2 and L3 terminal in each filter unit is connected to the same phase for all units Failure to do so may lead to the filter being damaged upon startup WARNING Once a new filter unit has been added to a filter system this unit has to be given a unique address through D...

Page 56: ...uidelines in Section 3 3 Figure 39 Rear side layout of the PQF Manager user interface When looking at the PQF Manager from the rear on the left side can be found a 15 pole terminal block and on the right side an 8 pole terminal block top right and a 45 pole terminal block bottom right Intermediate contacts are not used In order to make control connections to any of these terminals the following pr...

Page 57: ...e filter When the filter has already been installed on site this is done by opening the protection system located just upstream of the filter and opening the auxiliary fuse box present in the filter Wait at least 25 minutes to allow for the DC capacitors to discharge when the filter has been connected to the network before Failure to do so may result in the lethal injury or death After making and ...

Page 58: ...NG If a function is assigned to a digital input the same function must never be assigned to the other digital input Otherwise the filter may behave erratically Once the cabling has been finished The auxiliary fuse box may be closed The filter top cover may be replaced including the connection of the PQF Manager to the master unit The power to the filter may then be restored Then the PQF Manager ha...

Page 59: ...vervoltage When the network voltage returns to a normal level however the filter will reconnect to the network and continue filtering providing that the same problem does not occur systematically Internal error conditions These are error conditions that are reported by internal controls of the filter itself They may indicate an internal filter problem Two ways to cable the alarm functionality exis...

Page 60: ...n error disappears When closed before remains closed When closed before opens when error disappears When open before remains open Figure 42 shows an example of an alarm contact cabling scheme using the NC alarm contact Using this scheme the bulb B will be on when the power supply to the filter is interrupted or the filter trips due to an error Otherwise the bulb will be off 15 16 a 17 a PQF Manage...

Page 61: ...o the digital input will be low when The filter is disconnected from the supply OR The filter trips due to an error OR The external 24 Vdc power supply fails The voltage applied to the external digital input is high when The filter is connected to the supply and is not in error AND The external 24 Vdc power supply is in working order 15 a 16 a 17 Alarm outputs NO NC 24 Vdc external supply Remark a...

Page 62: ...twork voltage or when the filter trips due to a well defined internal error This type of alarm has to be cabled on the 8 pin terminal block situated at the top right corner when looking at the PQF Manager from the rear Cf Figure 39 The digital output contacts have a common point cabled on contacts 1 and 2 and are of the NO type normally open The contact ratings are Maximum continuous ac rating 440...

Page 63: ...f the supply is missing Vrms_min 60 Vnominal Network imbalance unacceptably high Vimbalance 2 Frequency variation unacceptably high Frequency variation 20 s PQFS DC bus voltage unacceptably high Vdc 105 Vdc_max_allowed PQFS internal preload error DC capacitor voltage rise too low in preload phase or the DC capacitors could not be preloaded in an acceptable time PQFS overcurrent fault Internal curr...

Page 64: ...n a multi master arrangement have to set up and cabled in the same way The cabling scheme is given in Figure 45 Once the cabling has been finished The auxiliary fuse box may be closed The filter top cover may be replaced including the connection of the PQF Manager to the master unit The power to the filter may then be restored 6 12 3 Cabling of warning functionality A warning condition is a condit...

Page 65: ...l warning levels can be changed by the user Any of the six digital outputs can be used to cable warning functionality A maximum of 3 warnings can be assigned to the digital outputs However by default the digital outputs of the PQF Manager have been set up for monitoring other functions than warnings cf Table 10 Refer to Section 7 9 1 4 for guidelines on how to set up warning conditions and how to ...

Page 66: ...ings automatically according to a signal applied to a digital input of the PQF Manager Cf Figure 39 Any digital input can be configured to act as the deciding factor for switching between the main and auxiliary settings Moreover both normal and inverse logic can be used to drive the digital inputs Note that in a multi unit filter system in which more than one master system is present the digital i...

Page 67: ...bled in the same way and the individual PQF Managers have to be set up accordingly Once the cabling has been finished The auxiliary fuse box may be closed The filter top cover may be replaced including the connection of the PQF Manager to the master unit The power to the filter may be restored Refer to Section 7 9 1 4 for guidelines on how to set up the digital inputs according to the function req...

Page 68: ...starts on rising edge Edge OFF No effect Filter stops on rising edge Remark Vlow 0 Vdc Vhigh 15 24 Vdc When using the Edge ON function the filter can only be switched on by applying voltage to the digital input considered It is therefore recommended in that case to configure and cable the second digital input as Edge OFF Refer to Section 7 9 1 4 for guidelines on how to set up the digital inputs a...

Page 69: ...n second rising edge etc Remark Vlow 0 Vdc Vhigh 15 24 Vdc Refer to Section 7 9 1 4 for guidelines on how to set up the digital inputs according to the function required The electrical requirements of the digital inputs are as discussed in Section 4 5 Figure 48 shows a cabling diagram for implementing a start function and a stop function on the first digital input External start stop push button 2...

Page 70: ...e electrical connections if desired For some accessories however the customer may have to do the cabling on site These accessories include The connection of the USB or Ethernet cable used for PQ Link software communication optional The connection of the Ethernet cable used for Modbus TCP communication optional The connection of the RS485 Modbus RTU adapter optional The connections of the aforement...

Page 71: ... is done by inserting the adapter plug firmly in the dedicated socket Figure 50 shows the location at the rear of the PQF Manager where the plug has to be inserted The user can use custom software where the standard Modbus RTU protocol is implemented or any other standard software OPC server SCADA Figure 50 Location at rear of PQF Manager where the serial communication cable has to be inserted Mor...

Page 72: ... at the rear of the PQF Manager Refer to Section 6 12 for guidelines on how to do this Figure 51 Front view of the PQF Manager user interface 7 2 PQF Manager user interface description The PQF Manager is based on a touch screen user interface hence there are no hardware buttons used All user actions like moving from one to another menu or data entry are done directly by touching the soft buttons o...

Page 73: ...veral master units in parallel in a single filter the PQF Manager on the Master unit has all the menus and options active The PQF Manager s on the Slave unit s have different screens in the sense that certain items menu buttons etc are non active and may appear greyed In case the maser unit fails and the next unit in the order takes over as new master due to redundancy feature of PQF the menu of t...

Page 74: ...y If the fault could not be cleared the unit status will remain Ack Fault In the fault clearing process the complete filter system will be shut down The filter can be restarted after the fault clearing process has ended Not present the unit considered has been excluded of the normal filter operation due to either fault or the unit is not present Master An alarm icon showing when the PQF Manager s ...

Page 75: ... Cf Chapter 6 the corresponding symbol changes its appearance as described in the Table 35 When the relay considered opens again the symbol takes back the original appearance If a digital output is Disabled the default icon is shown Example Table 35 Digital outputs status icons Icons PQF Manager setting for digital output Output relay closes when Auxil ON Auxil OFF The auxiliary power is present i...

Page 76: ...a multi unit arrangement is not available e g due to a permanent error or has not yet been commissioned Pg alarm 1 The programmable alarm 1 is activated Pg alarm 2 The programmable alarm 2 is activated Pg alarm 3 The programmable alarm 3 is activated Warning 1 The programmable warning 1 is activated c Warning 2 The programmable warning 2 is activated c Warning 3 The programmable warning 3 is activ...

Page 77: ...tings Aux Harmonics Aux PFC Bal Deselect all Filtering Mode Temp unit C F Activate M A Alarms Prog alarms Temp alarm levels Warnings Prog warnings Warnings levels Digital inputs Digital outputs Commissioning Network charact Vnom fnom Synchro mode Filter Charac Unit current 3W or 4W Auto CT detection Manual CT settings Derating User Main harmonics Main PFC Bal Filter mode T Commissioning Installati...

Page 78: ... menu Measurements Please note that Sometimes the complete item list in a menu cannot be shown on the display This is indicated by a small symbol that appear s at the bottom right Cf Figure 55 Pressing this button takes the menu to the next screen where more items are available to choose from Figure 55 Illustration of arrow symbol on the PQF Manager display Sometimes when the number of items or va...

Page 79: ...This manual uses a directory structure convention to indicate a submenu The main Welcome screen is referenced as Welcome Example Welcome Measurements System values indicates that the System values menu can be accessed by Press button on the top right corner of any screen successively until the Welcome screen is reached Press the Measurements menu in the main Welcome screen which opens the Measurem...

Page 80: ...he PQF Manager results in following message displayed on the screen Case 1 If a filter is powered up first time or after a complete power shut down following screens with ABB logo appear Step 1 Figure 58 PQF Manager display during communication initialization Step 2 Figure 59 PQF Manager display when the user interface is set up Once the communication channel has been initialized the user interfac...

Page 81: ...filter Case 1 Resetting power only to the main controller Case 2 Setting up commissioning parameters Case 3 Acknowledging fault successfully Case 3 7 6 The PQF Manager locking facilities In order to prevent unauthorized modification of any of the active filter settings switch on the hardware lock Figure 13 item 4 The hardware lock is switched on by pushing the blue button located at the bottom rea...

Page 82: ...ster the PQF Manager of the master that has the control over the system has full functionality and the PQF Managers of the other master units have limited functionality The hardware lock in the master has no effect on access level of parameters in the slave modules like warning alarm To disable these settings the hardware lock of each PQF Manager must be engaged 7 7 The PQF start stop and fault ac...

Page 83: ...his fault can be acknowledged and reset in the PQF Monitoring menu Welcome PQF Monitoring Status of module Note that in the reset process the whole system will be shut down If the fault of the unit cannot be reset the ACK FAULT message will be displayed again for the unit considered The filter system can be restarted at any time and the units that are available will operate normally Acknowledging ...

Page 84: ...In multi unit filters several parameters are measured by the individual units In order to consult measurements from a specific unit select the unit with the Select Unit option where available The order of the unit is determined by the DIP switch unit identification setting at the moment of commissioning 7 8 1 The Overview menu The Overview menu summarizes the following characteristic parameters Ta...

Page 85: ...l harmonic distortion of all the line currents I1 A RMS value of the fundamental component of all the line currents PQF Irms A RMS value of all the filter currents including neutral current for 4 wire configuration P W kW MW Active power in the network at the location of the CTs P 0 Load absorbing active power P 0 Load generating active power Q var kvar Mvar Reactive power in the network at the lo...

Page 86: ... may customize the display to his particular needs To do this follow the steps given below Select the measured parameter that has to be moved The selected parameter gets highlighted in green color background Select a new location for this parameter by touching the preferred location on the list of parameters The selected parameter relocates to the new place 7 8 2 The System values menu The System ...

Page 87: ...me domain waveform of line voltage displayed by the PQF Manager 3 W mode example 7 8 2 1 3 Spectrum The network voltage spectrum for all phases in chart format Figure 61 The spectral components up to the 49th order are expressed as a of the fundamental component with absolute values also shown in the top right corner The two buttons with and mark help changing the voltage level resolution i e Y ax...

Page 88: ... each spectral component up to the 49th rank Figure 62 Spectrum of the network voltage in table format displayed by the PQF Manager 4 W mode example Following parameters are displayed in the sub menu Voltages itself in a tabular form The network frequency The network imbalance The active filter DC bus voltage of the selected unit The active filter DC bus voltage max 7 8 2 2 Line currents Refer to ...

Page 89: ...voltage V L1 N 4 W mode or V L1 L2 3 W mode 7 8 2 2 3 Spectrum The line current spectrum for all phases 3 W mode and the neutral current spectrum 4 W mode in chart format The chart layout is similar to the one of the voltages Figure 61 7 8 2 2 4 Harmonic table The line current spectrum for all phases 3 W mode and the neutral current spectrum 4 W mode in table format The table layout is similar to ...

Page 90: ... and the neutral current spectrum 4 W mode in table format for the unit selected with the Select unit option The table layout is similar to the one of the voltages Figure 46 but only absolute current values are shown 7 8 2 4 Total filter currents Refer to Table 39 for an explanation of the parameters PQF Irms in table format for the complete filter system 7 8 2 4 1 Waveforms The filter current wav...

Page 91: ...e total filter current is an approximate value More detailed values for the individual units can be obtained in the Filter currents menu 7 8 2 5 Powers The power in the system at the location of the CTs Refer Table 39 for an explanation of the parameters Active power P Reactive power Q Apparent power S Power factor PF Displacement power factor cos ϕ 7 8 2 6 Temperatures Refer to Table 39 for an ex...

Page 92: ...ove or below the threshold Once a threshold has been set the PQF Manager starts recording the maximum or minimum value automatically as well as the total duration until a reset is performed Figure 63 illustrates this Figure 63 Illustration of the threshold and the maximum recorded value used in the Min Max logging function The parameters that can be used with the logging function are voltages Vrms...

Page 93: ...s up the digital inputs and outputs and defines the programmable warnings and alarms At this level the user can also change the temperature unit used by the system The customer level is accessed through Welcome Settings Customer set The commissioning level which allows the commissioning engineer to set up the equipment according to the customer s installation Typical parameters that need to be ent...

Page 94: ...tings Installation set Apart from above three the fourth button allows the language setting The PQF Manager supports six languages English French German Spanish Chinese simplified and Korean Note In active filter systems consisting of more than one master the PQF Manager of the master that has the control over the system has full functionality and the PQF Managers of the other master units have li...

Page 95: ...ne set for mains operation and one set for generator operation or one set for day settings and one set for night settings Both main and auxiliary settings windows have the same setup possibilities i e Definition of the filter mode Selection of the harmonics with setting of curve levels Selection of reactive power compensation with balancing functionality Deselection of all harmonics The filter has...

Page 96: ...electing the filtering mode Table 41 shows the three available modes Table 41 Available filter modes Highest priority level Lowest priority level Mode 1 Filtering to curve Maximum filtering Reactive compensation Mode 2 Filtering to curve Reactive compensation Maximum filtering Mode 3 Filtering to curve Reactive compensation In Mode 1 the filter will first filter to the pre programmed curve Once th...

Page 97: ... is Mode 3 7 9 1 1 2 Selecting the harmonics with setting of curve levels For setting up the filter s main harmonics selection go to Welcome Settings Customer set Main settings Main harmonics For setting up the filter s auxiliary harmonics selection go to Welcome Settings Customer set Auxiliary settings Aux harmonics The harmonics that can be selected are presented in a table such as presented in ...

Page 98: ...c order all harmonics from 2nd to 49th order are listed but only those harmonics which are not already chosen appears selectable and those which are already in the pre selected list appear greyed Once a new harmonic order is selected the table automatically gets sorted in ascending order In order to remove any harmonic order from this list one has to touch that row and then from the dropdown menu ...

Page 99: ...intervention is required to correct the problem 7 9 1 1 4 Selecting the reactive power compensation and balancing options For setting up the filter s main reactive power and balancing mode go to Welcome Settings Customer set Main settings Main PFC Bal For setting up the filter s auxiliary reactive power and balancing mode go to Welcome Settings Customer set Auxiliary settings Aux PFC Bal The activ...

Page 100: ...C type Static ind Q static x kvar The filter will absorb x kvar reactive inductive power regardless of the value set for the target cos ϕ Remarks a When load balancing is required set the Balance load flag to the desired mode The following modes are available depending on the way the filter is connected 3 W or 4 W Disabled No load balancing is done L L Loads connected between phases only are balan...

Page 101: ...r Fahrenheit for all temperature measurements or settings 7 9 1 3 Activate menu The Activate function is used to select the setting Main or Aux with respect to harmonics PF Load balancing If the main is selected by the user in this menu the filter operated as per the data provided by the user in the main setting Same applies if Auxiliary is selected here If Ext Input is selected the filter changes...

Page 102: ...tact with two complementary outputs These contacts can be used to provide data to the filter e g remote control signals and get data out of the filter e g filter status information alarm information etc This section discusses the PQF Manager setup for controlling all the digital I O and creating warnings and alarms 7 9 1 4 1 Alarms and warnings Programmable alarms and warnings Temperature alarm an...

Page 103: ...Set up of the digital inputs of the PQF Manager For setting up the digital inputs go to Welcome Settings Customer set Digital Inputs 7 9 1 4 3Set up of the digital outputs of the PQF Manager For setting up the digital output go to Welcome Settings Customer set Digital outputs ...

Page 104: ...missioning menu is intended to be used by qualified commissioning engineers that are authorized to change the filter s core installation settings and to set up the user s requirements In multi master units these functions need to be set up only in the master with the lowest hardware ID setting The complete commissioning procedure must be executed each time a filter is re installed or when a unit i...

Page 105: ...e The nominal supply voltage This value has to be set up according to the nominal value of the grid voltage WARNING For PQFS filter the hardware is by default set for operation at voltages in the range 380 415V When the filter is used in networks with voltages in the range 208 240V its hardware configuration needs to be changed Refer to Section 6 7 for guidelines on how this needs to be done Failu...

Page 106: ...er is running will result in a fault message being displayed When involuntarily entering the menu walk through the menu by pressing the button or following the complete menu This way the menu can be quit without modifying any values 7 9 2 2 Setting up the filter characteristics Except for PQFS filter other filters PQFI and PQFM are always connected in 3 ph 3 wire mode i e no neutral connected is n...

Page 107: ... harmonics that are flowing between phases and make phase to phase balancing but cannot filter harmonics in the neutral nor make line to neutral balancing 4 W choose this mode when both the phases and the neutral are connected In this case the filter can filter harmonics between phases as well as harmonics in the neutral and can perform balancing of loads connected between phases as well as connec...

Page 108: ...t transformers connected to the filter units has to be entered into the filter system For single master units this has to be done only for that master For filter systems consisting of more than one unit this has to be done for all the units of the system Two methods can be used to do this Using the automatic CT detection feature Entering the CT ratios and positions manually These approaches are di...

Page 109: ...r personal safety reasons close the filter cover before launching the CT detection procedure Also ensure that the filter CT terminals X21 are not shorted When engaging the automatic CT detection procedure the filter will execute the following steps Deselect harmonics and reactive power balancing settings previously entered by the customer Display a warning message to wait for the identification pr...

Page 110: ...ut shown in the first column Line 1 CT connected in phase 1 L1 R U with correct orientation Line1 CT connected in phase 1 L1 R U with inversed orientation Line 2 CT connected in phase 2 L2 S V with correct orientation Line 2 CT connected in phase 2 L2 S V with inversed orientation Line 3 CT connected in phase 3 L3 T W with correct orientation Line 3 CT connected in phase 3 L3 T W with inversed ori...

Page 111: ... R U of the installation CT Ratio L2 a Ratio that will be used by the filter for the CT physically connected in phase 2 L2 S V of the installation CT Ratio L3 a Ratio that will be used by the filter for the CT physically connected in phase 3 L3 T W of the installation Remark a The first phase has to be acknowledged before the second phase is displayed After acknowledging the last phase with the fi...

Page 112: ...remely high ratio s 20000 5 This will result in an error message indicating inconsistent CT positions In this the ratio of the summation CTs that may be present should be included The presence of a low impedance directly downstream of the filter connection although the CTs have been correctly installed upstream of the filter connection This will result in wrong CT ratio s being found In that case ...

Page 113: ...onnected to the filter CT terminals X21 7 8 Input 3 in which line phase is it installed Line 1 Line 2 Line 3 does the CT cabling have the good orientation Line x or not Line x Remark If the CT installation is correct enter Line 3 If the CT is installed in the right phase but inversed enter Line 3 for the CT physically installed in Line 1 L1 R U the CT ratio which is always positive e g a CT of 500...

Page 114: ...imum filter output current must be derated by 1 every additional 100m 330ft Above 40 C 104 F the maximum output current must be derated by 2 every additional 1 C 1 8 F up to 50 C 122 F maximum limit The total required derating is the sum of all the deratings taking into account the installation height and the ambient temperature The PQF Manager rating menu shows the filter nominal rating which is ...

Page 115: ...xt step Setting up the harmonic selection table for the main settings After entering the desired values cf Section 7 9 1 1 press repeatedly until the next step is displayed Setting up the reactive power requirements including balancing for the main settings After selecting the desired values press to go to the next step After entering the data the main settings can be copied on to the auxiliary se...

Page 116: ...ognized one by one Connect the probe to the temperature probe input one probe only Click on a row to assign a probe number click on the Start button The PQF Manager recognize automatically the probe address Restart the same procedure for each probe When one of the probes has a problem it can be cleared by selecting that row and clicking the Clear button A unique address will be assigned to each ac...

Page 117: ...auto restart function Setting up the auto restart function Setting up the system clock Setting Password The aforementioned functions are discussed more in detail later in this section For convenience the installation settings menu also gives an overview of the installation settings More specifically the following settings can be read Settings for the nominal voltage frequency and synchro mode Welc...

Page 118: ...ion Rating setting Welcome Settings Installation set Rating Where applicable the settings for individual units in a filter system can be reviewed by selecting the appropriate unit Note that the settings of the above mentioned parameters can only be changed at the commissioning level Cf Section 7 9 2 7 9 3 1 Setting up the standby function ...

Page 119: ...fter the load requirement comes back The standby function is particularly interesting for applications where the load is present for a long time and subsequently switches off for another long time In order to set up the standby function five parameters have to be defined Stdby status When enabled the standby function is activated When disabled the standby function is deactivated Standby level and ...

Page 120: ...the filter will restart When the auto restart function is disabled the filter will not restart automatically after a power outage To enable disable the auto restart function go to Welcome Settings Installation set Start Stop set and enable the auto start option To program the delay after which the filter has restart once the power returns in the same menu specify the desired delay This delay in av...

Page 121: ...tware lock is removed A customer can choose a 4 digit password of his choice to activate the software lock During selection first the old password default 1234 needs to be entered followed by a new password The new password needs to be confirmed Now pressing the button saves the new password 7 9 3 5 Installation Locking For Installation locking go to Welcome Settings Installation set Install Lock ...

Page 122: ...onitor the filter load and to get an idea of its operating point compared to the nominal rating of the filter In addition logged warnings and faults can be retrieved for troubleshooting the filter operation and any abnormal network conditions Where applicable the different units in a filter system can be selected to get more detailed information on parameters of the individual unit The PQF monitor...

Page 123: ...ing this the complete filter system will be shut down If the fault could be cleared the unit status will become Ready If the fault could not be cleared the unit status will remain Ack Fault In the fault clearing process the complete filter system will be shut down The filter can be restarted after the fault clearing process has ended Not present The unit considered has been excluded of the normal ...

Page 124: ... filter controllers The event buffer stores the 200 most recent events Figure 66 gives an example of the event window Two buttons are available on this screen one scrolls to the next 10 events and the other the previous 10 events at a time 1 3 2 4 5 Figure 66 Example of an event window The explanation of the different items is given in Table 47 Table 47 Item explanation of the event window Item Ex...

Page 125: ...no more faults Power outage The system has detected a power outage Download DSP A DSP controller firmware upgrade attempt has been recorded DSP stop An internal stop command coming from the DSP controller has been recorded From Table 48 it can be seen that both the DSP controller and the µcontroller can record faults Where the faults reported by the µcontroller are predominantly relating to a cont...

Page 126: ...acceptable maximum value Over volt Transient SW The software transient over voltage protection has been triggered Over current RMS The system has detected RMS over current Over current peak SW The software peak current protection has been triggered Preload problem The DC capacitors could not be preloaded The voltage increase on the DC capacitors during the preload phase is not high enough Unbalanc...

Page 127: ... or microcontroller For guidelines on how to troubleshoot and solve the reported problems refer to Chapter 11 For multi unit filters this data can be obtained for each individual unit Internal system errors are most likely due to faulty hardware and thus the only solution may be to exchange the controller cards If the message IGBT check cooling appears this implies that the system is stopped due t...

Page 128: ...r to Section 7 9 1 4 and the list of possible warning in the detailed manuals Table 51 shows an overview of the warning messages that will be displayed and the corresponding warning condition For multi master filters this data can be obtained for each individual unit Table 51 Warning messages that can be displayed by the PQF Manager and corresponding warning conditions Warning condition Warning me...

Page 129: ...tes the total operating time of the filter filter on The Fan operation parameter indicates the total operating time of the fans cooling the filter The reset fan operation button resets the number of fan operation and should be used after a fan is replaced For multi master filters this data can be obtained for each individual unit If a problem exists an external intervention is required to solve th...

Page 130: ... allows the touch screen to be configured and Communication setting to be performed 7 11 1 Manufacturer setting This menu gives basic data on the filter Basic manufacturer settings such as filter type maximum voltage rating and filter serial number These settings can be accessed in Welcome User Interface Manufacturer set 7 11 2 About PQF ...

Page 131: ...11 3 Screen configuration These settings can be accessed in Welcome User Interface Screen Config Two main buttons Touch Screen Cal and Backlighting allows the user to calibrate the touch screen and adjust the backlighting to the optimal level The touch screen calibration is normally not needed in a reasonable use of the screen and in standard environmental conditions To prevent loss of the touch s...

Page 132: ...ations methods In this main menu it includes the settings for Modbus and Ethernet and the MAC and IP addresses More information regarding the Modbus USB and TCP IP protocol and programming please refer to manual 2GCS214017A0070_PQF Manager communication with Modbus RTU Modbus TCP and PQ Link protocols When the communication is unlocked see Figure 67 the user can change parameter setting of the fil...

Page 133: ...TCP IP based with help of PQ Link software In other words locking the communication is equivalent to using the hardware lock in the back side of the PQF Manager Figure 68 Communication locked 7 11 4 1 Modbus RTU The slave address is the one used by the Modbus master to address the PQF through Modbus Baud rate Parity Stop bit shall match exactly the communication settings of the Modbus master which...

Page 134: ...he Modbus network Refer to the 2GCS214013A0050 RS485 adapter User guide for more information on the RS485 Modbus Adapter Be careful that the RS485 MODBUS ADAPTER is the one with a text color 3 3V power supply The one with a text color is reserved for the old model 5V power supply That means the new Modbus adapter is not compatible to the old PQF Manager and the old Modbus adapter cannot be connect...

Page 135: ... address 7 11 4 3 Ethernet settings This menu displays the actual PQF IP address mask address and gateway IP address Depending on the DHCP status the displayed data may be different The below screens give the result for the above Example 1 and 2 Example 1 The below screen shows the actual IP address fixed with DHCP disabled ...

Page 136: ...k This IP address may be fixed and entered manually if DHCP is disabled The default address is 192 168 1 40 In case the IP address is given automatically by a gateway or Ethernet LAN set DHCP to enable Some examples are given below Example 1 The below screen shows the default settings to connect directly to a PC note that the PC need to be configured accordingly with a fixed IP address of 192 168 ...

Page 137: ...s about the communication settings can be found in the manual 2GCS214017A0070_PQF Manager communication with Modbus RTU Modbus TCP and PQ Link protocols Reboot the PQF Manager to initialize it with these parameters Ethernet TCP IP TCP IP connections can be indifferently initiated locally or remotely The TCP port used by default is 4250 The connection to the PQF Manager is an RJ45 Cat5e Ethernet ca...

Page 138: ...erface is used to present the PQF Manager as a serial interface on its USB port The computer is connected through a USB A male to USB Mini B male Caution The USB connection to the PQF Manager is not isolated It is mandatory to connect the protective EARTH connection when using the USB ...

Page 139: ...PQF Manager IP address is 192 168 1 40 which appears in the screen under the menu IP address Using the Menu Ethernet Setting the user can change this address and when the filter is reset the new IP address is copied in the window under menu IP address Figure 70 Ethernet settings If the DHCP client is enabled see Figure 70 the customer s system automatically assigns an IP address to the PQF Manager...

Page 140: ...ss In this case the IP address in the window under Menu Ethernet Setting Menu still remains what the user has set or the factory default value but has no influence in the communication as the PQF Manager s IP address is dynamically controlled by customer s communication network ...

Page 141: ...apter 7 If the Modbus option has been installed please refer to the document 2GCS212013A0050 RS 485 Installation and Start up guide for more information on this item The commissioning procedure consists of 9 steps that should be strictly followed Table 52 Steps to follow to commission the active filter Steps Actions Step 1 Visual and installation check Step 2 Setting the address of each unit in a ...

Page 142: ...filter panel may lead to equipment failure Check that the mechanical and electrical installation fulfils the requirements described in Chapter 5 and Chapter 6 of this manual Remove the filter lifting ribbon if it is still present Pay attention to the ambient temperature noting the filter cooling requirements Check visually the condition of the filter e g for transportation damage Remove the anti c...

Page 143: ...ter unit is faulty the master unit with the next lowest address will become the main controlling unit In order to set the address of each unit in a filter system the DIP switch module on the control board has to be set accordingly Figure 71 shows the location of the DIP switch on the control board Item 22 in the Figure 10 2 6 7 8 9 15 3 12 11 4 13 14 5 16 17 18 21 22 19 20 1 Figure 71 Location of ...

Page 144: ...right Assigning the same address to different filter units in one filter system will lead to the filter not being able to start up and go in error Bad Ratings When a filter consists of more than one unit attention has to be paid to the proper termination of the communication bus between the different units This communication bus is depicted in Figure 72 by the black lines interconnecting the diffe...

Page 145: ... also has to be set up in the filter controller software commissioning window WARNING The PQFS is able to operate on networks where the supply voltage is up to 10 higher inclusive of harmonics but not transients or lower than the voltage range it is set up for Since operation at the upper limits of voltage and temperature may reduce its life expectancy the PQFS should not be connected to systems f...

Page 146: ...running The DC capacitors will be charged The PQF Manager will initialize and show the Welcome screen Cf Figure 51 or will show a screen indicating that it is in slave mode If the voltage level or phase rotation is incorrect the installation should be corrected before applying power to the filter to avoid potential filter malfunctioning and or damage 8 5 Step 4 Basic commissioning parameters set u...

Page 147: ...ual CT detection procedure The Rating parameter If the filter is installed at locations higher than 1000m 3300ft or is running under ambient temperature conditions higher than 40 C 104 F the filter has to be derated For more information on how to calculate the derating required and how to enter the rating value refer to Section 7 9 2 4 Remarks Although the user requirements for harmonic filtering ...

Page 148: ... filter CT terminal X21 For multi filter configurations all the units of a filter system have to be supplied with the same CT information daisy chain principle with return path as shown in Figure 38 All shorting links in the CT path have been removed i e on the CTs on the filter CT terminal X21 CT shorting links are provided with the filter for servicing purposes but they are not installed by defa...

Page 149: ...its terminals which can lead to physical danger or destruction of the CT 8 6 2 1 PQF connection diagram Figure 73 shows the standard connection diagram for the PQF Cf Section 7 9 1 It must be noted that L1 L2 and L3 rotation must be clockwise The CTs must be on the supply line side of the PQF The CT monitoring a phase must be connected to the filter CT terminal dedicated to the same phase One seco...

Page 150: ... is approximately balanced Remark Other way to check the CT installation manually is to use the waveform displays of the PQF Manager In this it should be noted that all waveforms displayed are synchronized on the rising edge zero crossing of the voltage V L1 N Note however that this approach requires some experience 8 6 2 3 Checking the correct connection of the CTs with a two channel scopemeter T...

Page 151: ...ld normally be a well distorted wave because of harmonic distortion Usually it is quite easy to extrapolate the fundamental component as it is the most important one Figure 76 Remark If the earthing of the system is bad the phase to ground voltage may appear like a much distorted waveform In this case it is better to measure the phase to phase voltage move the black clamp to the phase L2 and subtr...

Page 152: ... Figure 78 and Figure 79 The same operations as those described in the previous paragraph must be repeated with the phase L2 Figure 78 and phase L3 Figure 79 For a balanced load which is usually the case in most of the three phase systems the phase shift should be approximately the same for all the three phases L1 L2 L3 Load side Supply side K L I k K L I k K L I k PQF L1 L2 L3 Positive direction ...

Page 153: ...les are taken it is possible to use the two channel scopemeter in order to see if the current measured through the CT is matching the real current in the bus Connect the current probes as shown on Figure 80 The two traces must be in phase and of the same shape the magnitude could be different as the gains are different if the wiring is correct L1 L2 L3 Load side Supply side K L I k K L I k K L I k...

Page 154: ...onics of the main filter settings at once go to Welcome Settings Customer set Main settings Deselect all For deselecting all harmonics of the auxiliary filter settings at once go to Welcome Settings Customer set Auxiliary settings Deselect all For deselecting the reactive power compensation option of the main filter settings disable the option PFC type in Welcome Settings Customer set Main setting...

Page 155: ...top menu reads ACK FAULT i e acknowledge fault the filter has encountered a fault that needs to be corrected before the filter can be started Refer to Chapter 11 for troubleshooting the problem If the filter when activating the start menu displays a message to indicate that it is remote control mode the filter either has to be started by remote control or the remote control mode has to be deactiva...

Page 156: ...Auxiliary settings Aux PFC Bal Set the PFC Type item to Static cap and choose the desired value for the item Q static For more information on the main and auxiliary settings concept refer to Section 7 9 1 1 Once the reactive power is selected analyze the filter current Refer to Section 7 8 2 for more information on displaying measurement results Refer to Chapter 11 in case of problems Disable the ...

Page 157: ...owards the load When consulting the harmonic selection table of the PQF Manager harmonics put in standby can be recognized by the label S that is displayed in the harmonic selection column which reads otherwise either Y or N The following possibilities exist to bring a harmonic out of standby The user restarts a network identification process by changing the S indication into a Y indication in the...

Page 158: ...ency and the harmonics that are recommended to be deselected When background distortion is present on the network and detuned capacitor banks are installed adjacent to the active filter but connected downstream of the filter CTs filter resources will be lost To overcome this it is recommended to either connect the detuned capacitor bank upstream of the filter CTs or to use the CT connection approa...

Page 159: ...ily resulting in a reduced overall filtering performance In installations where 2 non compatible masters are connected to the same CT respect the following guidelines for best performance 1 Select different harmonics on both units 2 If 1 above is not possible put one filter in Mode 1 and the other filter in Mode 3 Note Non compatible master units are master units that cannot or are not interconnec...

Page 160: ...gs serial number b Rating A Serial number Article code b Unit 1 M Unit 2 M S d Unit 3 M S d Unit 4 M S d Software version c PQF Manager software µcontroller software DSP software Installation location Remarks a Read from main identification tag located on the master enclosure b Read on identification tag located at the outside of each enclosure c After the filter has been commissioned navigate wit...

Page 161: ...m protection If filter connected to the supply before wait for 25 minutes to discharge DC capacitors Remove the right side of the protective cover of the filter Ensure that the left side of the protective cover is in place Disconnect PQF Manager if required Open auxiliary circuit fuse protection box DC capacitor voltage low enough to operate safely DC voltage measurement Change auxiliary transform...

Page 162: ...t running Program equipment b Network characteristics Supply voltage V Supply frequency Hz Synchro mode should normally not be changed default value is Single ph Filter ratings Connection mode 3 wire or 4 wire CT position and ratio for first unit Automatic detection feature used YES NO Filter terminal Input 1 is connected to the CT including sign c Line 1 2 3 1 2 3 Filter terminal Input 2 is conne...

Page 163: ...g Navigate with the PQF Manager to Welcome Settings Customer set Alarms 8 11 4 Testing with load Before starting the filter OK NOK Deselect all harmonics and reactive power balancing a Start the filter b While the filter is running c If harmonic load is present select for example the 11th harmonic Check the line current Irms 11th harmonic level and waveforms If harmonic load is not present generat...

Page 164: ...d Static ind Static ind Q static kvar Q static kvar Static cap Static cap Q static kvar Q static kvar Dyn ind Dyn ind Target cos ϕ Target cos ϕ Dyn cap Dyn cap Target cos ϕ Target cos ϕ Balance load Balance load Disabled Disabled L L L L Harmonics Main settings Main PFC Bal Auxiliary settings Aux PFC Bal 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 1...

Page 165: ...3 V min warn Alarm delay V max warn Alarm rst del Imbalance Ground fault Prog warnings Prog warn 1 Prog warn 2 Prog warn 3 Warning delay Warn rst del Digital Inputs Digital Outputs Dig In 1 Dig Out 1 Dig In 2 Dig Out 2 Dig Out 3 Dig Out 4 Dig Out 5 Dig Out 6 Start Stop set Communication Stdby status Protocol Standby level Modbus Stdby del off Baud rate Standby hyst Parity Stdby del con Stop bit Au...

Page 166: ...oning instructions Manual Power Quality Filter PQFS Project LV Active Filters PQF Issued by Commissioning report Date Page 7 of 7 8 11 6 Comments Commissioning Engineer Customer s representative Name Signature Date ...

Page 167: ...r Background information on the PQF Manager can be found in Chapter 7 Alternative ways to operate the filter are Using the optional PQ Link software Refer to the PQ Link installation and user s guide for more information on this subject Using Modbus RTU communication Refer to document 2GCS212013A0050 RS 485 Installation and Start up guide for more background information on this subject and to the ...

Page 168: ...once the filter is running Remarks If the start stop menu reads ACK FAULT i e acknowledge fault the filter has encountered a fault that needs to be corrected before the filter can be started Refer to Chapter 11 for troubleshooting the problem In filter systems consisting of more than one unit an ACK FAULT message will only occurs when all the masters in the system have failed In filter systems con...

Page 169: ... in the menu Welcome User interface Communication by ticking the check box More information on the Communication lock is available in the document 2GCS212013A0050 RS 485 Installation and Start up guide When power is applied to the filter and it is started the following startup sequence is conducted Figure 83 Filter start up sequence when power is applied and the start command is given In Figure 83...

Page 170: ...failing cooling system Peak current limit due to an a typical peak current requirement of the load Peak voltage limit due to an a typical DC link voltage requirement of the load or due to a high network voltage Under all these conditions the filter will run in limited mode and may not attain 100 of its nominal current rating 9 2 2 Stopping the filter with the PQF Manager In order to stop the filte...

Page 171: ...lock has have been engaged the filter cannot be started nor stopped neither by the local button nor by remote control In order to see which lock s has have been engaged push when the start stop menu is highlighted A message will appear to indicate which lock s has have to be disengaged If authorized disengage the relevant lock The hardware lock can be disengaged by pushing the blue button present ...

Page 172: ...settings to better suit his needs These settings can be accessed in the PQF Manager menu Welcome Settings Customer set The user requirements can be divided into the following categories Setting up the filter mode the harmonic requirements and the reactive power requirements Refer to Section 7 9 1 1 for detailed information on these topics Setting up alarms warnings and digital I O The digital I O ...

Page 173: ...6 Consulting filter statistics and manufacturer data In order to consult the filter statistics go to Welcome PQF Monitoring This menu allows to monitor the filter load and to get an idea of its operating point compared to the nominal rating of the filter In addition logged warnings faults and events can be retrieved for troubleshooting the filter operation and any abnormal network conditions Also ...

Page 174: ...ppears too Depending on the type of critical fault and the number of occurrences the filter when running may either Stop open the main contactor and await user intervention In this condition the alarm contact of the PQF Manager will switch on after a programmable delay and the Armed indicator will be OFF The green LED on the main controller board Cf Table 13 item 18 LED 2 will be off and the red L...

Page 175: ... active filter Only when an error becomes critical a problem may exist If ACK FAULT is present on the PQF Manager display look at the Armed indicator By default mapped to the 4th digital output of the PQF Manager to know whether the filter will restart automatically after clearance of the problem or not Armed indicator ON The filter waits for the problem to disappear and then restarts automaticall...

Page 176: ...ually Failure to adhere to this guideline may result in physical injury and or in filter damage 10 2 Maintenance intervals Table 55 lists the routine maintenance intervals recommended by ABB Depending on the operating and ambient conditions the intervals of Table 55 may have to be reduced Announced intervals assume that the equipment is operating under ABB approved operating conditions Cf Chapter ...

Page 177: ...ting its output current due to temperature problems By default the T Limit indicator is assigned to digital output 6 of the PQF Manager Make a note of the PQF operation hours Welcome PQF monitoring PQF operation and the fan operation hours Welcome PQF Monitoring Fan operation For units up to 60A if the fan operation indicator shows a multiple of 40000 hours it is recommended that the fan be replac...

Page 178: ...Ensure that the main contactor can move freely If bad fuses are found upstream or in the unit replace them If the fuse in one phase is bad it is good practice to change the fuses of all phases More information on the fuses to use is given in Section 6 7 Table 22 10 3 6 Step 6 Check the tightness of the electrical and mechanical connections Ensure that all electrical connections are properly fixed ...

Page 179: ... follow the instructions below Cf Figure 85 Ensure that the power to the filter is switched off upstream Wait for at least 25 minutes to allow for the DC capacitors to discharge Remove the cover on the right hand side of the filter and disconnect the fan terminals at the bottom of the filter next to the IGBT bridge for the fan in and on the top right of the PCB for the fan out Remove the screws th...

Page 180: ... refer to 9AKK107992A0401 Replacement of DC Capacitors in PQFS Before June 2010 specific detailed procedure for the change of the DC capacitors for PQFS older than June 2010 10 6DC capacitor reforming If the filter has been non operational for more than one year the DC capacitors must be reformed re aged before use Without reforming the DC capacitors may be damaged at start up Stocked or non opera...

Page 181: ...ent of output filter board in PQFS After October 2014 specific detailed procedure for the change of the output filter board IMPORTANT NOTE For PQFS filter older than October 2014 the design was different and the output filters capacitors must also be changed after 5 years Please refer to 9AKK107992A0175 Replacement of output filter board in PQFS Before October 2014 specific detailed procedure for ...

Page 182: ...rial number b Rating A Serial number Article code b Unit 1 M Unit 2 M S d Unit 3 M S d Unit 4 M S d Software version c PQF Manager software µcontroller software DSP software Installation location Remarks a Read from main identification tag located on the master enclosure b Read on identification tag located at the outside of each enclosure c After the filter has been commissioned navigate with the...

Page 183: ...mode due to temperature limitation o Temp load around 100 and other load indicators low Y N o T Limit indicator on digital output monitor on digital output 6 by default Y N If answer if Y to any of the two questions above check filter cooling PQF operation hours Fan operation hours o If fan operation hours are multiple of 40000 hrs for units up to 60A and of 35000 hrs 27000 hrs for units with high...

Page 184: ...move freely Y N Fuses are OK Y N If N describe the problems in the comments section of this report Tightness of electrical and mechanical connections Check tightness of all electrical connections Check the mechanical fixation of all components Retighten connections fixations if necessary Correct the outstanding problems Reclose the auxiliary fuse box and refit the filter protective cover Restart t...

Page 185: ...operating hours years Ambient filter conditions Describe follow the procedure 9AKK107992A0401 or 9AKK107992A0402 DC capacitor reforming CE versions only Filter storage time Reforming time Describe in the comments section of this report Output filter board change Filter operating hours years Describe follow the procedure 9AKK107992A0162 or 9AKK107992A0175 10 8 5 Comments Servicing Engineer Customer...

Page 186: ...y have to be made with the supply on and the filter protective cover removed These tests must be carried out only by authorized and qualified personnel in accordance with the local regulations Apply the safety guidelines that are presented in Chapter 2 Failure to adhere with the safety guidelines may result in lethal physical injury 11 2 Fault treatment procedure All faults that occur are stored i...

Page 187: ...y distance cf Section 6 12 4 Stop open the main contactor and restart automatically if the fault disappears In this condition the alarm contact of the PQF Manager will switch on after a programmable delay and the Armed indicator will be ON If it takes a long time before the fault disappears the user may decide to give a filter stop command This is done by highlighting the PQF ACK FAULT item in the...

Page 188: ...he corresponding digital input functionality Then the fault can be acknowledged locally Figure 88 shows the error treatment procedure in flowchart format Green LED is LED2 on the main controller board and is Armed indicator on PQF Manager Red LED is LED3 on the main controller board ...

Page 189: ...S filter is shown in Table 57 Table 57 Standard set of spare parts for normal and dedicated filter servicing Ref Description Order code Recommended quantity 1 Spare fuses for auxiliary circuit 2GCA100465A0420 3 2 Spare fuses for pre load circuit 2GCA113178A0420 2 3 PQF Manager filter controller touchscreen 2GCA291723A0075 1 4 Assy cooling fan in PQFS 30 100A 2GCA294292A0075 1 5 Assy cooling fan in...

Page 190: ...that for troubleshooting it may be necessary to remove the filter right protective cover Always remove power to the units and allow time for the DC capacitors to discharge min 25 mins before removing the filter cover When the filter right cover is removed and power is supplied again to the filter the status of the control card LEDs can be monitored Main controller board LEDs Figure 16 items 18 and...

Page 191: ...g properly The auxiliary transformer is not set according to the network voltage Check the selection of the tap on the auxiliary transformer Check the supply voltage to see that it is within the tolerance range of the nominal filter settings After applying auxiliary power to the system the PQF Manager shows the message Initializing communication Please wait none of the LEDs of the main controller ...

Page 192: ...LED 3 on the main controller board is on The filter is stopped due to an unacceptably high number of critical errors Check the filter event log to analyze the critical errors Refer to Table 60 to know what to do in order to solve the problem reported After resolving the problem the fault has to be acknowledged and the filter has to be restarted manually One of the two controller LEDs 1 4 on the ma...

Page 193: ...tomatic CT detection procedure has encountered a problem during the CT identification process Check that the CTs are installed on the supply side of the filter Check that the CTs are not shorted Check that the overall CT ratio including summing CTs is smaller than 20000 5 Set up the CTs manually Cf Section 8 6 DC overvoltage SW The DC software overvoltage protection has been triggered Check the co...

Page 194: ...ee if the problem persists DC undervoltage SW The DC software undervoltage protection has been triggered Check the connection between the DC voltage measurement connectors P6 5 and P6 7 and the DC capacitors Check flat cable connections between the Control Board and the IGBT module Analyze network voltage stability amplitude and phase Disable reactive power compensation and balancing options to se...

Page 195: ...Manual Power Quality Filter PQFS Troubleshooting guide 195 noting the ambient temperature and altitude ...

Page 196: ...could be automatically cleared by the system This error can be due to peak overcurrent or a too low control voltage for the IGBT drivers If the errors occur sporadically and the system rides through nothing has to be done If the system does not ride through too many transient errors in a short time Verify that the filter CTs are properly installed and are not shorted Verify that the unit current r...

Page 197: ...r PQF Manager or PQ Link Check the AC voltage measurement connectors P6 1 to and P6 4 for loose connections and component damage Check the connections between the auxiliary fuses and the AC voltage measurement connectors P6 1 to and P6 4 Check the filter parameters Cf Chapter 8 ...

Page 198: ...uency set up at the commissioning stage corresponds to the frequency of the network Cf Chapter 8 Reset the system by powering off and on again Out of mains freq Limit The system has detected that the network frequency is out of range Measure the network frequency and check if it is within limits Check the phase rotation only in case of modification at the installation Ensure that the AC voltage is...

Page 199: ...Manual Power Quality Filter PQFS Troubleshooting guide 199 Ensure that the AC voltage is properly measured Do the checks discussed for the Loss of phase fault Check the earthing of the unit ...

Page 200: ...nd order programmed at the commissioning stage corresponds to the rating and order physically present Verify the filter cooling system and check the IGBT temperature using the PQF Manager Deactivate harmonic and reactive power requirements and see if the problem persists Overvoltage RMS The RMS value of the supply voltage measured with the AC voltage measurement board is higher than the acceptable...

Page 201: ...Filter PQFS Troubleshooting guide 201 and R2 of the preload circuit A001 Inspect the DC bus for traces of damage that may have caused a short circuit on the DC side of the IGBT module or on the DC voltage measurement board ...

Page 202: ... Measure the line voltages e g voltmeter and compare them with the line voltages given by the filter PQF Manager or PQ Link Ensure that the AC voltage is properly measured Do the checks discussed for the Loss of phase fault Unstable mains frequ The network frequency is varying too fast Measure the network frequency and its variation and check if they are within limits Check the phase rotation only...

Page 203: ...r board Verify the ambient temperature and the cooling of the filter dust filters fans heatsinks If the ambient conditions and the filter cooling is ok the main control board is suspect Contact your ABB service provider The main control board may have to be replaced Reactor overtemperature Line reactor thermal switch has open Check the status of the reactors and the PCB output filter PWM check coo...

Page 204: ...C side of the IGBT module or on the DC voltage measurement board Several units same id Two or more units in a filter system have the same CAN_ID Check the CAN_ID of the different units in the set of filters each unit has to have one unique CAN_ID on the DIP switch S5 1 to S5 3 Reset the filter by switching off and on the power If the problem persists contact your ABB representative The controller ...

Page 205: ...st probably be replaced Real time clock problem Watchdog fault Internal µC fault Corrupted DSP code Corrupted µC code Internal system error Reset the filter by switching off and on the power If the problem persists contact your ABB representative The controller card must probably be replaced Different firmwares Different units in a filter system have different firmware version DSP or microcontroll...

Page 206: ...ter is working at 100 of its nominal capacity while the load is only at a fraction of the filter rating There is a problem in the CT connections or a hardware problem Check the CT installation CT location CT shorts Check the connection between the CT terminal block X21 and the main controller terminals P5 1 P5 6 Measure the line currents e g ammeter and compare them with the line currents given by...

Page 207: ...t your ABB representative Two master units are fed from the same CTs The setup guidelines for this installation setup have not been implemented Interconnect the units with an RJ 45 cable If this is not possible Select different harmonics on both filters If not possible ensure that one filter is operating in Mode 1 and the other filter is operating in Mode 3 The filter is running with low load indi...

Page 208: ...r Quality Filter PQFS represent realistic values The filter CTs is are not installed in a central position and therefore the filter does not eliminate the harmonics of all the loads Check that the CTs are installed at the desired location ...

Page 209: ...t the harmonic to see if the problem persists Leave the harmonic in standby The filter will automatically restart identifying filtering it when another harmonic component is successfully re identified The ACK FAULT message is present on the PQF Manager The alarm contact switches on after some delay The filter has stopped due to an error Acknowledge the fault to see a list of most recent critical e...

Page 210: ...rating refer to Table 14 Recommended maximum average temperature over 24 h 35 C 95 F Relative humidity Max 95 non condensing during operation Max 85 non condensing during storage Contamination levels IEC 60721 3 3 Chemical class 3C2 for more information refer to Table 14 Mechanical class 3S2 for more information refer to Table 14 Vibration IEC 60068 2 6 Max 0 3mm 2 9Hz Max 1m s2 9 200Hz Shock IEC ...

Page 211: ...twork voltage distortion Maximum 20 phase to phase Minimum network fault level 1 MVA Voltage notch limits No voltage notches allowed Line voltage imbalance Maximum 5 of phase to phase voltage Insulation voltage Ui 415V Auxiliary circuit voltage 230 Vrms Neutral connection systems if any IT TT TNC and TNS Earth current protection type and sensitivity must be chosen appropriately EMC Environment cla...

Page 212: ... the neutral is not connected Degree of filtering Programmable per harmonic in absolute terms Filtering efficiency Better than 97 of filter rating typically Response time 40 ms typically 10 90 filtering Reactive power Static dynamic Power factor programmable from 0 6 inductive to 0 6 capacitive Load balancing Off Phase to phase phase to neutral if neutral present both if neutral present Setting po...

Page 213: ... to earth resistance 1 67 MΩ filter unit Noise intensity 30A 60A 65 3 dBA typically 70A 100A 68 4 dBA typically 120A 70 9 dBA typically Communication Through PQF Manager display Through Modbus RTU with optional RS485 Modbus Adapter Through Modbus TCP with Ethernet Through dedicated optional software PQ link with USB Ethernet Programming Through PQF Manager display Through USB Ethernet with dedicat...

Page 214: ... technical changes or modify the contents of this document without prior notice With regard to purchase orders the agreed particulars shall prevail Hitachi ABB Power Grids Ltd does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any rep...

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