Page 1 Power Quality Filter PQFS Installation, operation and maintenance instructions...
Page 2: Table Of Contents
6.6 Selection of the power cable size ................ 38 6.7 Selection of the power cable protection/filter input protection scheme ....41 6.8 Connection of the PQFS to the network .............. 43 6.8.1 Connection of the PQFS in 3-wire mode............. 44 6.8.2 Connection of the PQFS in 4-wire mode.............
Page 3 7.8.5 The ‘Total number of errors’ menu [/Welcome/PQF monitoring/Number of errors] ........................107 7.8.6 The ‘PQF operation’ and ‘Fan operation’ parameters ....... 107 7.8.7 The ‘Trip. Phase’ parameter ..............107 Manual Power Quality Filter PQFS ç Table of contents 3...
Page 4 10.3.5 Step 5: Check the condition of the filter contactors and fuses ....143 10.3.6 Step 6: Check the tightness of the electrical and mechanical connections ........................143 10.3.7 Step 7: Correct any abnormal conditions found ........143 4 Table of contents ç Manual Power Quality Filter PQFS...
Page 5 11.4.1 Verification of the PQF-Manager status and the system LEDs....153 11.4.2 Fault tracing ....................154 12 Technical specifications ..................166 12.1 What this chapter contains ................166 12.2 Technical specifications ..................166 Contact us ........................170 Manual Power Quality Filter PQFS ç Table of contents 5...
Page 6: Introduction To This Manual
Chapter 10) of this manual. Compatibility The manual is compatible with all filters of the PQFS-range with PQF-Manager software version v2.10.r0 or higher. Technical specifications of this product range are given in Chapter 12 of this manual. This product is not backward compatible with any other PQFx (x: A, B, L, T, I, M, K, S) filter product.
Page 7: Safety Instructions
These safety instructions are intended for all work on the PQFS. Neglecting these instructions can cause physical injury and death. All electrical installation and maintenance work on the PQFS should be carried out by qualified electricians. Do not attempt to work on a powered PQFS.
Page 8 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 9: Upon Reception
PQFS active filter. Delivery inspection Each PQFS is delivered in a box designed to protect adequately the equipment during shipment. Upon reception of the equipment, make sure that the packing is in good condition. Verify the state of the shock and tilting indicators (if mounted on the enclosure or on the filter panels).
Page 10 · Remove the top cover of the protecting box (see Figure · Remove the 4 panel securing screws at the outer ends of the enclosure (see Figure Figure 2: Locating the 4 panel securing screws 10 Upon reception ç Manual Power Quality PQFS...
Page 11 Figure 5: Position of the filter fixation screws that need to be removed · Use the lifting tools which are available inside the PQFS. The lifting tools contained into the PQFS accessories package are the lifting ribbon and the two...
Page 12 Figure 6: Lifting ribbon and the two pieces of rubber from the PQFS accessories package · Place the lifting ribbon and the two pieces of rubber as shown in the Figure 7. Figure 7: Way to install the lifting ribbon and the two pieces of rubber ·...
Page 13 Figure 9: Lifting a PQFS unit from a horizontally position may damage the lifting ribbon · Use the lifting ribbon from the both soft eyes to lift the filter from the wooden support. It can then be positioned at the desired location (see Figure 10).
Page 14: Identification Tag
ABB internal article code. 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-...
Page 15: Hardware Description
Hardware description What this chapter contains This chapter describes a typical PQFS-filter system and discusses its main components. Typical PQFS filter panel layout The PQFS active filter is basically composed of two parts (Figure 12): · A filter controller that determines the anti-harmonic current to be injected based on the line current measurements and the user’s requirements.
Page 16 For more information on cabling the user connections, please refer to Chapter Figure 13 shows a typical PQFS master filter panel. Figure 13: Example of a typical PQFS master filter panel The input/output connections and protection description is given in Table Table 4: Input/Output connections...
Page 17: The Pqf Current Generator Hardware
Up to 4 PQFS master panels can be connected in parallel providing full redundancy to the customer. In addition to using master panels only, PQFS units can be connected in a master-slave arrangement. The PQF current generator hardware The power circuit of a PQFS unit is represented hereafter.
Page 18: The Pqf Main Controller
The current generator is physically organized in power units. Each filter enclosure contains one power unit. A PQFS filter can contain up to 4 power units. Power units can be combined in a master-slave arrangement, or in a master-master arrangement, the latter giving full operational redundancy.
Page 19: The Pqf-Manager User Interface
All units have their own AC-connection and main contactor protection. A PQFS active filter system consists of up to 4 units of equal rating. Additional units to the first master unit may be master or slave units. Slave units do not have a PQF- Manager.
Page 20 The PQF-Manager also acts as connection point for external user I/O communication. Connections are made at the rear side of the PQF-Manager. Figure 17 depicts the terminals that are present on the PQF-Manager rear side. 20 Hardware description ç Manual Power Quality Filter PQFS...
Page 21 · Selection of main filter settings or auxiliary filter settings (e.g. different filter settings for the day and for the night) The PQF-Manager is used to associate the required functionality with the chosen digital input. The digital inputs can also be disabled. Manual Power Quality Filter PQFS ç Hardware description 21...
Page 22 : When using this function, the filter stop and start can be controlled by one digital input leaving the other one available for an additional remote control or switching between main and auxiliary settings. 22 Hardware description ç Manual Power Quality Filter PQFS...
Page 23 : More information on the standby function is given in Section 7.7.3.2 : Different programmable warnings and alarms can be defined. More information on this subject is given in Section 7.7.1.2 Manual Power Quality Filter PQFS ç Hardware description 23...
Page 24 The maximum continuous alarm contact ratings are: 250 Vac/1.5 A. Lock switch Allows locking the settings of the filter panel. This switch is documented in Section 7.4 24 Hardware description ç Manual Power Quality Filter PQFS...
Page 25: Location Of The Main Pqfs Components
Location of the main PQFS components 4.6.1 Active filter components Figure 18 shows a picture of the PQFS without cover panel. Figure 18: PQFS main components The component identification is given in Table Manual Power Quality Filter PQFS ç Hardware description 25...
Page 26 CAN bus connectors for use in a multi-module filter arrangements. The main controller board is shown in Figure Figure 19: PQF main controller board The designation of the principal terminals is given in Table 26 Hardware description ç Manual Power Quality Filter PQFS...
Page 27 Address 7: Position of the 3 switches starting from left: L H H Address 8: Position of the 3 switches starting from left: H H H Note: In a multi-master arrangement, the master which is operational and which Manual Power Quality Filter PQFS ç Hardware description 27...
Page 28: Active Filter Cover Components
For physical locations of customer CT connection terminals, please refer to Figure 18 item 4.6.2 Active filter cover components An active filter master panel cover contains the PQF-Manager user interface. This interface is routed on to the main control board. 28 Hardware description ç Manual Power Quality Filter PQFS...
Page 29: Mechanical Design And Installation
In case you have a problem, please notify it to our service support mail box: jumet.services@be.abb.com. Installation location requirements The PQFS is suitable for indoor wall-mount installation, in a well-ventilated area without dust and excessive aggressive gases where the ambient operating conditions do not exceed the following values:...
Page 30: Standard Enclosure Dimensions And Clearances
Standard enclosure dimensions and clearances Standard PQFS enclosures have dimensions of 588 x 310 x 705 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.
Page 31 M8 bolts is 1.4 Nm (max.) Over tightening may result in deformation of this bar which may damage other components inside the filter Manual Power Quality Filter PQFS ç Mechanical design and installation 31...
Page 32: Filter Noise Level
Airflow and cooling requirements The PQFS dissipates an amount of heat that has to be evacuated out of the room where the filter is located. Otherwise, excessive temperature rise may be experienced. Please note that life of the electrical equipment decreases drastically if the operating temperature exceeds the allowable limit (divided by 2 every 10°C/23°F).
Page 33: Instructions For Mounting The Pqf-Manager In Enclosures
In the design of the air conditioning systems, the filter heat losses have to be taken into account. Table 15 gives an overview of the PQFS heat losses for the different power units. For multi-unit filters, the values of Table 15 have to be multiplied by the number of filter units.
Page 34 Manager is secured in place. Repeat steps 3 to 5 for the bottom-mounting bracket. Once the PQF-Manager has been installed, it has to be connected electrically (Cf. Section 6.2) 34 Mechanical design and installation ç Manual Power Quality Filter PQFS...
Page 35: Electrical Design And Installation
It also gives electrical connection examples for popular filter options. WARNING: The PQFS is able to operate on networks in a voltage range 208-240 V and 380-415 V with a tolerance range of +/- 10 % (inclusive of harmonics but not transients).
Page 36: Instructions For Connecting The Pqf-Manager To A Filter System
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 female connector attached to the filter hardware.
Page 37: Emc Considerations
EN/IEC 61000-6-2, Industrial level: Immunity standard for industrial environments. EN/IEC 61000-6-4, Class A: Emission standard for industrial environments. Earthing guidelines Each PQFS plate has one marked earth points (PE). The earth point is situated at the bottom right side of the filter plate (Figure...
Page 38: Selection Of The Power Cable Size
(with x < 1). In order to compensate for this “loss of section”, the cable has to be oversized such that the total equivalent section through which the current flows taking into account the skin effect is acceptable. 38 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 39 Any further derating due to local standards and/or installation conditions (e.g. distance between cables, number of cables connected in parallel …) have to be taken into account by the company responsible for the PQF cable connection. Manual Power Quality Filter PQFS ç Electrical design and installation 39...
Page 40 Note that in 4-wire systems, the neutral may have to carry up to 3 times the line current rating of the filter. 40 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 41: Selection Of The Power Cable Protection/Filter Input Protection Scheme
The protection only needs to protect the phases and not the neutral. It is recommended to use fuses of type gG/gL with the RMS current ratings given in Table Manual Power Quality Filter PQFS ç Electrical design and installation 41...
Page 42 The active filter power circuit is internally connected to the network by means of a main contactor of type ABB AF 75. The PQFS control circuit and DC bus preload system is protected by a fuse protection scheme, the characteristics of which are given in Table 42 Electrical design and installation ç...
Page 43: Connection Of The Pqfs To The Network
The PQF may refuse to start or may not function correctly when such a device is present. For best PQF performance, these devices have to be removed or bypassed. Manual Power Quality Filter PQFS ç Electrical design and installation 43...
Page 44: Connection Of The Pqfs In 3-Wire Mode
In this mode, the active filter can compensate 20 individual harmonic components. In order to connect the PQFS in 3-wire mode, follow the below guidelines: Fix the filter mechanically to the wall (Cf.
Page 45 Figure 35: Position of the wires ‘N’ for networks with nominal voltage 208-240V Remark: the other wires labeled ‘N’ and also on the terminal X02-1 but on the other side cannot be removed (see Figure 36). Manual Power Quality Filter PQFS ç Electrical design and installation 45...
Page 46: Connection Of The Pqfs In 4-Wire Mode
(Cf. Figure Figure 37: 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 ·...
Page 47: Selection Of The Current Transformers
…) It is strongly recommended that the three CTs have the same characteristics. WARNING: The connection of different filter units in a PQFS system, as well as other loads, on the same CT must be in series.
Page 48 Figure 40: Flow chart for CT determination 48 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 49: Current Transformer Installation And Connection
This must be done through a daisy chain connection configuration. By default, the PQFS active filter is provided with CT terminals that are not shorted. A set of shorting plugs is provided with the filter. They should always be kept with the filter and accessible for service engineers.
Page 50 Figure 41: Basic CT connection example for a single unit active filter. Figure 42: Location of the CT connection terminal X21 in the PQFS The terminal block X21 can handle control cable wiring with sections from 2.5 mm² to 10 mm².
Page 51: Electrical Interconnection Of Pqfs Enclosures
K = P1, L = P2, k = S1, l = S2 Figure 43: 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.
Page 52: Mechanical Preparation Of The Enclosures
Description Control board intercommunication cable through CAN bus (RJ45 cable) CT interconnection cable 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 preparation of the enclosures ·...
Page 53: Ct Cable Interconnection
In a multi-unit PQFS-system, all units have to be supplied with the CT –measurement results. In order to do this the CT’s have to be cabled to each unit in a daisy chain fashion.
Page 54: Connection Of The Power Stage To The Supply
The same connection approach as used for the other filter units must be adopted. More information on how to connect a PQFS filter unit to the power supply can be found in Section 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.
Page 55 Case 2: Cabling of alarm functionality. Case 3: Cabling of warning functionality. Case 4: Cabling of the digital output contacts to monitor other filter operation modes than warnings and alarms. Manual Power Quality Filter PQFS ç Electrical design and installation 55...
Page 56: Cabling Of Remote Control Functionality
Cabling of main/auxiliary control functionality. Case 6: Implementation of local start/stop buttons. It is recommended that for additional functions that are cabled to the PQFS, a connector approach is used such as is the case for the internal communication and PQF-Manager power supply.
Page 57 Manager to the digital input setup menu and setting the digital input considered to ‘Disabled’. · The remote control functionality can also be implemented on the Digital Input 2 Manual Power Quality Filter PQFS ç Electrical design and installation 57...
Page 58: Cabling Of Alarm Functionality
Figure 51 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 58 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 59 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 Manual Power Quality Filter PQFS ç Electrical design and installation 59...
Page 60 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 60 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 61 PQFS over current fault Internal current higher than allowed PQFS IGBT fault IGBT hardware reports internal permanent error PQFS IGBT over temperature IGBT hardware reports internal over temperature Manual Power Quality Filter PQFS ç Electrical design and installation 61...
Page 62: Cabling Of Warning Functionality
By monitoring the digital output, the customer will then know when the network voltage becomes too high and subsequently he can take appropriate action. 62 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 63: Cabling Of The Digital Output Contacts To Monitor Other Filter Operation Modes Than Warnings And Alarms
Table 9 gives an overview of the other functions that can be monitored with the digital outputs in addition to the already discussed warnings and alarms. Manual Power Quality Filter PQFS ç Electrical design and installation 63...
Page 64: Cabling Of Main/Auxiliary Control Functionality
When implementing the function described above, please note that according to the setup done with the PQF-Manager for the input considered, the filter may behave differently. Table 27 shows the filter behavior as a function of the PQF-Manager settings. 64 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 65: Implementation Of Local Start/Stop Buttons
Otherwise the filter may behave erratically. The PQFS active filter is equipped with a start/stop function integrated in the PQF- Manager user interface. If the customer desires this however, he can add extra start/stop buttons (not provided) to the filter system.
Page 66 This leaves the other digital input available for the implementation of other functions. Table 29 shows the PQF-Manager setup for the input considered and the resulting effect when applying voltage to this input. 66 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 67 · Note that in a multi-unit filter system in which more than one master system is present, the digital inputs of all masters have to be set up and cabled in the same way to obtain full redundancy. Manual Power Quality Filter PQFS ç Electrical design and installation 67...
Page 68: Electrical Connections Of Filter Options And Accessories
Note however that in this case the 68 Electrical design and installation ç Manual Power Quality Filter PQFS...
Page 69: Connection Of The Modbus Adapter
(e.g. line voltage data, line current data etc.) 6.13.2 Connection of the Modbus adapter For the connection setup of the Modbus adapter, please refer to the document “2GCS212012A0050-RS-485 Installation and Start-up guide”. Manual Power Quality Filter PQFS ç Electrical design and installation 69...
Page 70: The Pqf-Manager User Interface
The PQF-Manager is the default device to be used to start and stop the filter system. Further it is used to acknowledge and reset faults reported by the system. 70 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 71 Manager on the master controlling the system has full functionality whereas the PQF-Managers on the other masters have limited functionality. Figure 61 outlines the principle menus that are accessible through the ‘Welcome’ screen. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 71...
Page 72 Total filter cur. Rating Power Start-Stop set. Temperatures Clock Min-Max logging Communication Voltages Install. Lock Line currents Change Password Power Frequency Temperatures Figure 61: Principle menus of the PQF-Manager 72 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 73 On some items, help is not available. In that case pressing the Help key will have no effect. Depending on the menu, this key has a different meaning. Depending on the menu, these keys have a different meaning. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 73...
Page 74 The only PQF-Manager menu in which it is possible to change the position of the parameters displayed is the ‘Measurements-overview’ menu. · Pressing successively from any menu will bring up the main ‘Welcome’ screen. 74 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 75: The Pqf-Manager Behavior During Filter Initialization
During this process the PQF-Manager retrieves the data structure to be displayed from the PQF main controller. When the PQF-Manager is setting up the user interface, the following message is displayed (Figure 66): Manual Power Quality Filter PQFS ç The PQF-Manager user interface 75...
Page 76: The Pqf-Manager Locking Facilities
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 limited functionality. In practice, the functions 76 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 77: The Pqf Start, Stop And Fault Acknowledgement Menu
The filter system can be restarted at any time and the units that are available will operate normally. Acknowledging of a fault which resulted in a complete filter system shut down has two possible consequences: Manual Power Quality Filter PQFS ç The PQF-Manager user interface 77...
Page 78: The 'Measurements' Menu
THDI Total harmonic distortion of all the line currents. PQF Irms RMS value of all the filter currents Active power in the network at the location of the CTs 78 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 79: The 'System Values' Menu [/Welcome/Measurements/System Values]
The network voltage waveforms for all phases (Figure All waveforms are synchronized with the rising edge zero crossing of the voltage V (L1-N) (4-W mode) or V (L1-L2) (3-W mode) Manual Power Quality Filter PQFS ç The PQF-Manager user interface 79...
Page 80 Irms, I1 and THDI in table format The line current waveforms for all phases (3-W mode) and the neutral current waveform (4-W mode). The graph layout is similar to the one of 80 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 81 ‘Filter currents’-menu. · The power in the system at the location of the CTs: (Refer to Table 34 for an explanation of the symbols). Active power P Reactive power Q Manual Power Quality Filter PQFS ç The PQF-Manager user interface 81...
Page 82: The 'Min-Max Logging' Menu [/Welcome/Measurements/Min-Max Logging]
[/Welcome/Settings/Customer set. /Temp unit]. Temperature of the hottest IGBT (‘T IGBT’) and the hottest phase (‘Hot phase’) of the unit selected by the ‘Select unit’-option. For PQFS filters, the hottest phase function is not available and a default value ‘1’ is shown.
Page 83: The 'Settings' Menu
The customer settings menu is intended to be used by people that are authorized to change the filter operation settings. Refer to Section 7.4 for determining appropriate locking facilities for this menu. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 83...
Page 84: Settings Up Harmonics, Reactive Power And Filter Mode
Produce or absorb reactive power including load balancing The user can put the emphasis on one of the above effects by selecting the filtering mode. Table 36 shows the three available modes: 84 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 85 The harmonics that can be selected are presented in a table such as presented Table When the PQFS is operating in 4-W mode, 15 harmonics can be selected. When the PQFS is operating in 3-W mode, 20 harmonics can be selected.
Page 86 This may be useful e.g. when the commissioning engineer realizes that the CTs have been installed wrong and an intervention is required to correct the problem. · Selecting the reactive power compensation and balancing options 86 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 87 ‘L-L & L-N’: Both loads connected between phase and neutral as well as loads connected between phases are balanced. This mode is only available when the filter is connected in 4-W mode. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 87...
Page 88: Setting Up Alarms, Warnings And Digital Inputs And Outputs (D I/O)
Outputs] For full redundancy with multi-master filters, these functions need to be set up in each master unit of the filter system and the functions should be cabled accordingly. 88 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 89 PQFS internal preload error Prel. Err. PQFS over current fault Overcur. PQFS IGBT fault IGBT fault PQFS over temperature fault IGBT temp. PQFS control board over temperature fault T ctrl max Manual Power Quality Filter PQFS ç The PQF-Manager user interface 89...
Page 90 Vrms min Supply voltage imbalance higher than preset value Imbalance PQFS IGBT Temperature higher than preset value IGBT temp. PQFS control board temperature higher than preset value T ctrl max 90 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 91: Setting Up The Unit For Temperature Measurements
These items are discussed next. For commissioning the active filter follow the commissioning procedure presented in Chapter Remarks: · The commissioning window incorporates the start, stop and fault acknowledgement menu (Cf. Section 7.5) Manual Power Quality Filter PQFS ç The PQF-Manager user interface 91...
Page 92: Setting Up The Network Characteristics And The Filter Synchro Mode
In that case choose three phase synchronisation (Three ph.). WARNING: This parameter shall only be changed by experienced commissioning engineers or after advice from the ABB service provider. Using the wrong synchro mode will lead to filter malfunctioning.
Page 93: Setting Up The Filter Characteristics
· The filter needs to be stopped before the unit ratings menu can be accessed. Attempting to access the menu while the filter is running will result in a fault message being displayed. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 93...
Page 94: Setting Up The Current Transformer Ratios And Position
Inject a small current into the supply Record the current measured by the CTs and calculate the filter CT ratios and positions Display a message indicating whether the CT identification ended successfully or not 94 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 95 If any other key than is pressed, the automatic CT detection program will be quit. The CT parameters existing before the automatic CT detection program was started will be restored. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 95...
Page 96 The CT identification required an abnormally high DC voltage. The most common causes for these messages are: § CTs not connected or shorted § CTs connected in open loop configuration 96 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 97 ‘-Line 2’. for the CT connected to the filter CT terminals X21/5-6 (Input 3): § in which line (phase) is it installed (Line 1, Line 2, Line 3) Manual Power Quality Filter PQFS ç The PQF-Manager user interface 97...
Page 98: Setting Up The Filter Rating Parameter
7.7.2.4 Setting up the filter rating parameter For entering the rating parameter, go to [/Welcome/Settings/Commissioning/Rating] The permissible ambient conditions for PQFS operation are laid out in Table · If the filter is installed at locations higher than 1000 m (3300 ft) above sea level, the maximum filter output current must be derated by 1% every additional 100m (330ft).
Page 99: Setting Up The User's Requirements
WARNING: The installation settings menu is intended to be used by qualified commissioning engineers that are authorized to change the filter’s advanced settings. The filter’s advanced settings include: · the auto restart function Manual Power Quality Filter PQFS ç The PQF-Manager user interface 99...
Page 100: Setting Up The 'Auto Restart' Function
The ‘standby’ function when enabled puts the filter in standby, a preset time after the load requirement disappears. In this condition, the IGBTs stop switching while the main contactor remains closed (filter remains connected to the network). This way the filter 100 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 101 Time Figure 73: Illustration of the filter standby parameters Remarks: · The filter load requirement is determined from the user settings for harmonic filtration, reactive power compensation and balancing Manual Power Quality Filter PQFS ç The PQF-Manager user interface 101...
Page 102: Setting Up The System Clock
More information on these locks is given in Section 7.4. The ‘PQF monitoring’ menu The ‘PQF monitoring’ menu can be accessed in the main Welcome screen [/Welcome/PQF monitoring]. 102 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 103: The 'Status Of Units' Menu [/Welcome/Pqf Monitoring/Status Of Units]
The ‘event logging’ window stores the events that are recorded by the filter controllers. The event buffer stores the 200 most recent events. Figure 74 gives an example of the event window. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 103...
Page 104 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 104 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 105 Unstable mains frequ. The network frequency is varying too fast. Wrong phase rotation The filter is fed by a supply system, which has the wrong phase Manual Power Quality Filter PQFS ç The PQF-Manager user interface 105...
Page 106 · If the message ‘IGBT check cooling’ appears, this implies that the system is stopped due to an over temperature problem. In that case, check the cooling of the system (fans, filters) and of the switchgear room (air conditioning system etc.) 106 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 107: The 'Active Warnings' Menu [/Welcome/Pqf Monitoring/Active Warn.]
The value shown in the menu is by default 0. If a trip due to an overtemperature occurs, the value will become 1 for the unit in which the problem occurred. Manual Power Quality Filter PQFS ç The PQF-Manager user interface 107...
Page 108: The 'About Pqf' Menu
WARNING: When communicating with your ABB representative on a specific filter, please provide always the data shown in the ‘About PQF’ menu. For multi-master filters, this data can be obtained for each individual unit. 108 The PQF-Manager user interface ç Manual Power Quality Filter PQFS...
Page 109: Commissioning Instructions
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. Manual Power Quality Filter PQFS ç Commissioning instructions 109...
Page 110: Step 1: Visual And Installation Check
1 for the next slave etc. · In master-master arrangements, the lowest address must be assigned to the master unit that is considered as the main controlling unit. When the main 110 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 111 The filter identification DIP switch consists of 4 switches that can be put in low or high position (facing the board with the ABB logo at the top left side). The three left hand DIP switches determine the filter unit address.
Page 112: Step 3: Voltage Rating Check/Adaptation And Phase Rotation Check
Figure Note that in addition to configuring the unit hardware for a certain voltage range, the network voltage also has to be set up in the filter controller software (commissioning window). 112 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 113 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...
Page 114: Step 4: Basic Commissioning Parameters Set Up (Using Pqf-Manager)
7.7.2.1): The parameters to enter are the nominal network voltage, network frequency and filter synchronisation mode. The filter synchronisation mode shall normally not be changed unless specifically instructed by the ABB service provider. · The filter characteristics (Cf. Section 7.7.2.2): This consists of setting up the filter connection mode: 3-wire (no neutral connected) or 4-wire (neutral connected).
Page 115: Step 5: Automatic And Manual Ct Detection Procedure
Section 7.7.2.3. Section 8.6.2 discusses a way to check the CT installation if the automatic CT detection procedure is not used or does not find the correct results. Manual Power Quality Filter PQFS ç Commissioning instructions 115...
Page 116: Manual Ct Detection Procedure
Load side To X21.1/X21.2 To X21.5/X21.6 To X21.3/X21.4 X21.1 X21.2 X21.3 X21.4 X21.5 X21.6 K = P1, L = P2, k = S1, l = S2 Figure 77: Basic CT connection diagram 116 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 117: Material Needed And Hypotheses For Correct Measurements
X21.1 and the arrow indicating positive direction of the current should point towards the PQF. Do not forget to remove the shorts on the CT secondary (if present) before making the measurement. Manual Power Quality Filter PQFS ç Commissioning instructions 117...
Page 118 ° • • 1 where T1 is the fundamental period duration. For an inductive and non-regenerative load, the current signal should lag the voltage by a phase shift lower than 90°. 118 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 119 Supply side Load side X21.1 Positive direction X21.2 X21.3 X21.4 X21.5 X21.6 Figure 82: Connection of the scopemeter for checking CT in phase L2 Manual Power Quality Filter PQFS ç Commissioning instructions 119...
Page 120 Figure 84: Connection of the scopemeter for checking the CT in phase L1 by comparing the currents This operation has to be repeated for the remaining two phases for a complete check. The current probes have to be changed accordingly. 120 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 121: Checking The Correct Connection Of The Cts With A Fluke 41B Or Similar Equipment
Step 7: Start the filter Fit the filter top cover before starting the filter. The PQFS contains a main contactor that is controlled by the filter controller. WARNING: Under no circumstances close the main contactor manually. Failure to adhere to this guideline may result in physical danger and in filter damage.
Page 122: Step 8: Generate Filter Load
· For setting up the filter’s main reactive power feature go to [/Welcome/Settings/Customer set./Main settings/Main PFC/Bal.] · For setting up the filter’s auxiliary harmonics selection go to [/Welcome/Settings/Customer set./Auxiliary settings/Aux. PFC/Bal.] 122 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 123: Step 9: Set Up The User Requirements
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 Manual Power Quality Filter PQFS ç Commissioning instructions 123...
Page 124 2, 3 14 % For other types of detuned bank please contact your ABB Service provider to evaluate the resonance frequency 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.
Page 125: Commissioning Report
8.11 Commissioning report The commissioning report is designed to help the person in charge of the commissioning. Before installation and operation of the PQF, read the relevant sections of the Instruction Manual. Manual Power Quality Filter PQFS ç Commissioning instructions 125...
Page 126: Filter Identification
Read on identification tag located at the outside of each enclosure. After the filter has been commissioned, navigate with the PQF-Manager to [/Welcome/About PQF]. Select whether this unit is a master (M) or a slave (S) unit. 126 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 127: Inspection On Site - Verification Of The Active Filter After Installation
– Check the setting and operation of the protective apparatus – PQFS neutral current can be up to 3 times the PQFS phase current! – Check rated current of the power supply cable fuses (if applicable) – Check tightness of conductor fixations –...
Page 128: Programming
For full redundancy, configure/cable digital outputs on all masters of a multi- master system – Configure programmable warnings if applicable – For full redundancy, configure programmable warnings on all masters of a multi-master system 128 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 129: Testing (With Load)
Refer to Section 8.9 of the manual for more information on this topic. Refer to Section 8.10 of the manual for more information on this topic. Manual Power Quality Filter PQFS ç Commissioning instructions 129...
Page 130: Programmed Parameters
Target cos j Target cos j Balance load Balance load Disabled Disabled Harmonics Main settings (Main PFC/Bal.) Auxiliary settings (Aux. PFC/Bal.) Selected Selected H. Order Curve (A) H. Order Curve (A) 130 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 131 Start-Stop set. Communication Stdby status Protocol Standby level Modbus Stdby del off Baud rate Standby hyst Parity Stdby del con Stop bit Auto start Slave Address Auto st. del. Modbus lock Manual Power Quality Filter PQFS ç Commissioning instructions 131...
Page 132: Comments
Project: LV Active Filters PQF Issued by: Date: Commissioning report Page 7 of 7 8.11.6 Comments Commissioning Engineer Customer’s representative Name Signature Date 132 Commissioning instructions ç Manual Power Quality Filter PQFS...
Page 133: Operating Instructions
Starting and stopping the filter The PQFS contains a main contactor that is controlled by the filter controller. The main contactor should never be activated manually for normal filter operation.
Page 134 More information on the Modbus lock is available in the document “2GCS212012A0050-RS-485 Installation and Start- up guide” When power is applied to the filter and it is started, the following startup sequence is conducted: 134 Operating instructions ç Manual Power Quality Filter PQFS...
Page 135 · 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 Manual Power Quality Filter PQFS ç Operating instructions 135...
Page 136: Stopping The Filter With The Pqf-Manager
More information on the Modbus lock is available in the document “2GCS212012A0050-RS-485 Installation and Start-up guide”. The stop sequence conducted when a stop command is given can be derived from the following flow chart. 136 Operating instructions ç Manual Power Quality Filter PQFS...
Page 137: Modifying The User Requirements
([/Welcome/Settings/Installation set.]). These advanced functions include: · the autorestart function (after power outage) · the standby function to switch off the IGBTs when the load requirement is low · the system clock setup Manual Power Quality Filter PQFS ç Operating instructions 137...
Page 138: Changing The System Temperature Unit And Pqf-Manager Contrast
· Firmware version numbers for the PQF-Manager, the mcontroller and the DSP controller When communicating with your ABB representative on a specific filter, please provide always the data shown in the ‘About PQF’ menu. Filter behavior on fault – retrieving error information Under normal conditions the filter is either running or stopped and the PQF-item in the PQF-Manager ‘Welcome’...
Page 139 ‘ACK. FAULT’ and the filter will refuse to start; The ‘Armed’ indicator on the PQF-Manager will be OFF and both the green and red main controller LEDs will be OFF too. Manual Power Quality Filter PQFS ç Operating instructions 139...
Page 140 (low signal). Alternatively, the remote control functionality can be disabled by disabling the corresponding digital input functionality. Then, the fault can be acknowledged locally. Refer to Chapter 11 for advanced troubleshooting of the filter. 140 Operating instructions ç Manual Power Quality Filter PQFS...
Page 141: Maintenance Instructions
10.2 Maintenance intervals Table 52 lists the routine maintenance intervals recommended by ABB. Depending on the operating and ambient conditions, the intervals of Table 52 may have to be reduced.
Page 142: Step 2: Record The Filter Operating Status
Pay special attention to this item if the filter has experienced shut downs due to over temperature in the past. · Ensure that no loose particles are left in the unit that could cause consequential damage 142 Maintenance instructions ç Manual Power Quality Filter PQFS...
Page 143: Step 5: Check The Condition Of The Filter Contactors And Fuses
Fan failure is often preceded by increasing noise from the bearings and rise of the heatsink temperature despite cleaning. It is recommended to replace the fan once these symptoms appear. Contact your ABB service provider for replacement fans for your system.
Page 144: Dc Capacitor Change
· The filter is now ready for normal operation If the filter has been left more than 2 years without operation, please contact your ABB service provider. 144 Maintenance instructions ç Manual Power Quality Filter PQFS...
Page 145: Servicing Report
10.7 Servicing report The Servicing report is designed to help the person in charge of servicing. The report can be used for each individual unit of a multi-unit filter. Manual Power Quality Filter PQFS ç Maintenance instructions 145...
Page 146: Filter Identification
Read on identification tag located at the outside of each enclosure. After the filter has been commissioned, navigate with the PQF-Manager to [/Welcome/About PQF]. Select whether this unit is a master (M) or a slave (S) unit. 146 Maintenance instructions ç Manual Power Quality Filter PQFS...
Page 147: Standard Maintenance Procedure
Project: LV Active Filters PQF Issued by: Date: Servicing report Page 2 of 4 10.7.2 Standard maintenance procedure Ambient conditions and derating condition (filter running) · Check the ambient temperature (< 40°C/104°F) (if > 40°C/104°F, derating is required) · Check the installation altitude (< 1000m/3300ft) (if > 1000m/3300ft, derating is required) ·...
Page 148: Special Service Actions
Project: LV Active Filters PQF Issued by: Date: Servicing report Page 3 of 4 Condition of filter main contactor and fuses · Main contactor can 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 ·...
Page 149: Comments
Project: LV Active Filters PQF Issued by: Date: Servicing report Page 4 of 4 10.7.4 Comments Service Engineer Customer’s representative Name Signature Date Manual Power Quality Filter PQFS ç Maintenance instructions 149...
Page 150: Troubleshooting Guide
PQF-Manager ‘Welcome’ screen will display the label ‘ACK. FAULT. Note however that if the fault disappears fast, this label disappears too. Depending on the type of critical fault and the number of occurrences, the filter, when running, may either: 150 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 151 (low signal). Alternatively, the remote control functionality can be disabled by disabling the corresponding digital input functionality. Then, the fault can be acknowledged locally. Figure 90 shows the error treatment procedure in flowchart format. Manual Power Quality Filter PQFS ç Troubleshooting guide 151...
Page 152 Figure 90: PQF error treatment procedure in flowchart format 152 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 153: Spare Part List For Normal And Dedicated Filter Servicing
11.3 Spare part list for normal and dedicated filter servicing A standard set of spare parts for the PQFS filter is shown in Table Table 54: Standard set of spare parts for normal and dedicated filter servicing Recommended Ref.
Page 154: Fault Tracing
24 V power the PQF-Manager shows the main controller board supply and the main controller board. message ‘Initializing faulty. communication. Please wait… none of the LEDs of the main controller board is functioning. 154 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 155 Most likely the controller board has to be replaced. – After changing the main controller board, the filter has to be recommissioned. Manual Power Quality Filter PQFS ç Troubleshooting guide 155...
Page 156 – Disable reactive power compensation and balancing options to see if the problem persists. – Deselect the high frequency components to free DC bus resources and to see if the problem persists. 156 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 157 – Ensure that the Control board power supply is around 24 V. If significantly lower, check the 24 V power supply and the wiring between this supply and the Control board. Manual Power Quality Filter PQFS ç Troubleshooting guide 157...
Page 158 Different units in a filter system Recommission the filters have different ratings or If recommissioning does not solve different connections (e.g. 3- the problem, contact your ABB wire and 4-wire). service provider. 158 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 159 (PQF-Manager or PQF-Link). – Ensure that the AC voltage is properly measured. Do the checks discussed for the ‘Loss of phase’ fault. – Check the earthing of the unit. Manual Power Quality Filter PQFS ç Troubleshooting guide 159...
Page 160 (PQF-Manager or PQF-Link). – Ensure that the AC voltage is properly measured. Do the checks discussed for the ‘Loss of phase’ fault. – Check the earth of the unit. 160 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 161 P6-4). Remark: If the problem persists, contact your ABB service provider. Provide him with all the relevant information, i.e. Filter serial number and type, status of the control LEDs, Error messages displayed and filter behavior. Manual Power Quality Filter PQFS ç Troubleshooting guide 161...
Page 162 4 in the “set” status. – 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. 162 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 163 Remark: If the problem persists, contact your ABB service provider. Provide him with all the relevant information, i.e. Filter serial number and type, status of the control LEDs, Error messages displayed and filter behavior. Manual Power Quality Filter PQFS ç Troubleshooting guide 163...
Page 164 – If not possible, ensure that one implemented. filter is operating in Mode 1 and the other filter is operating in Mode 3. 164 Troubleshooting guide ç Manual Power Quality Filter PQFS...
Page 165 Remark: If the problems persist, contact your ABB service provider. Provide him with all the relevant information, i.e. filter serial number and type, status of the control LEDs, error messages displayed and filter behavior. Manual Power Quality Filter PQFS ç Troubleshooting guide 165...
Page 166: Technical Specifications
This chapter contains the technical specifications of the active filter PQFS. 12.2 Technical specifications The PQFS is an active filter for three phase networks with or without neutral for filtering of non zero-sequence and zero-sequence harmonics and reactive power compensation including balancing between phases.
Page 167 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) Manual Power Quality Filter PQFS ç Technical specifications167...
Page 168 Through RS-232 port with dedicated optional software (PQF-Link). Fuse information Main circuit fuses Not included Auxiliary circuit fuses: French Ferrule 10 x 38 gG/gl, 6A, 500V, Isc ~120kA Main options PQF-Link software RS 485 Modbus adapter 168 Technical specifications ç Manual Power Quality Filter PQFS...
Page 169 Easy connection box for power cables Cable extension kit for PQF-Manager Remark: Under exceptional circumstances other limits may be reached before the RMS current limit (e.g. temperature limit, peak current limit, peak voltage limit). Manual Power Quality Filter PQFS ç Technical specifications169...
Page 170: Contact Us
Contact us ABB n.v. Power Quality Products Avenue Centrale 10 Zoning Industriel de Jumet B-6040 Charleroi (Jumet), Belgium Phone: +32(0) 71 250 811 Fax: +32 (0) 71 344 007 E-Mail: Marketing : Power.Quality@be.abb.com Service: jumet.services@be.abb.com www.abb.com/lowvoltage...

ABB PQFS Installation, Operation And Maintenance Instructions

1 Introduction to this Manual

2 Safety Instructions

3 Upon Reception

4 Hardware Description

5 Mechanical Design and Installation

6 Electrical Design and Installation

7 The PQF-Manager User Interface

8 Commissioning Instructions

9 Operating Instructions

10 Maintenance Instructions

11 Troubleshooting Guide

12 Technical Specifications

Contact Us

Quick Links

Troubleshooting

Related Manuals for ABB PQFS

Summary of Contents for ABB PQFS

Table of Contents