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Manual Book
INSTRUCTIONS MANUAL
CIRCUTOR S.A.
Version 1.4
AFQ Instructions Manual
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AFQ Instructions Manual
Table of content
2 GENERAL DESCRIPTION.............................................................................................................7
5 POWERSTUDIO APPLICATION.................................................................................................53
6 MAINTENANCE.............................................................................................................................54
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SAFETY INSTRUCTIONS
The following safety instructions are for all operations performed on the active
filter.
Check that the ground connection is properly done before energize the device.
An earth fault may damage the device and cause electrical shock.
Before manipulate the current transformer, check that the secondary is short-
circuited. An open secondary of a loaded current transformer can generate
dangerous voltage.
Never energize or start the active filter with the open door or the side covers
removed.
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After unpacking the equipment, check the AFQ-4W corresponds to type and
size you ordered and that it has not suffered any damage during transport.
Check that supply voltage in your site is according to the equipment
characteristics (see nameplate on the back of the front door).
Check that neutral is available in the site you are going to connect the Active
Harmonic Filters of four wires (AFQ-4W.)
The active filter (AFQ-4W) must be rated according to the harmonic currents to
be filtered and the electrical characteristics of the installation. Check paragraph
“3.1 Dimensioning the AFQ rated current” to define the correct range of active
filter. Skip the recommendations may cause improper operation of active filter
and the impossibility to properly compensate harmonic currents.
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2 General description
2.1 Introduction
Harmonics
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The operating principle of Active Filters is to detect the difference between the
required sinus wave and the signal deformed by the effect of the harmonics.
Therefore the Active Filter injects the difference of currents between both
waves.
AFQ-4W is connected between the supply line and the coupling point of the
loads in parallel. Current measurements will be made at load side (downstream
the AFQ-4W connection point).
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The reason of this effect is that the load does not behave as a current source.
Increasing the harmonic current absorbed by the filter causes an increase of the
harmonics generated by the load. The load could generate more than double of
the initial harmonics current.
To avoid this effect it’s necessary to oversize the active filter multiplying the
initial harmonics current measured for a safety factor (FSh).
I load ⋅ THD ( I )%
I filter = ⋅ FS h
100
Equation 3: Dimensioning the AFQ range current.
To calculate the safety factor it’s necessary to estimate previously the short-
circuit relation (RSC) in the converter connection point (CNL) (no in the
installation input). The short-circuit relation is defined as the relation between
the short-circuit current of the mains and the rated current of the no lineal
converters (ICNL).
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I SC
RSC =
I CNL
Equation 4: Calculate the short-circuit relation.
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3.2 Placing
Install the AFQ-4W in an indoor area, maintain an ambient temperature range of
0ºC to 40ºC, maximum humidity of 90% non condensation.
Do not install the active filter near a heat source and avoid the directly exposed
to sunlight.
Warning!
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Warning!
After long storage time without connect the active filter to the mains is
recommended to apply a process to regenerate the dielectric layers inside the
capacitors. Next table shows the commissioning depending on the storage time.
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3.4 Wiring
AFQ-4W requires the following external connections:
L1, L2, L3, N - Power connection to mains: 3 phases + neutral. Use
the required wire size according to current. The minimum cable
sections according to the range of the filter are shown in the table
below.
Wire size
2
10 16 35 70 95
(mm )
a ≤ 10 a ≤ 10 a ≤ 10 a ≤ 10 a ≤ 10
L1 L2 L3 Terminal b ≤ 20 b ≤ 20 b ≤ 20 b ≤ 20 b ≤ 20
(mm) c ≤ 21 c ≤ 21 c ≤ 21 c ≤ 21 c ≤ 21
Ø>8 Ø>8 Ø>8 Ø>8 Ø>8
Wire size
2
25 50 95 2x95 2x95
(mm )
LN Terminal
Ø>8 Ø > 10 Ø > 10 Ø > 10 Ø > 10
(mm)
Torque (Nm) 12 20 25 30 30
Wire size
2
25 50 95 95 95
(mm )
Ground Terminal
Ø>8 Ø>8 Ø > 10 Ø > 10 Ø > 10
(mm)
Torque (Nm) 12 20 25 30 30
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All power cables and load current measurements should enter the cabinet at the
bottom to ensure the IP and to protect users against high voltage parts.
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Warning!
Check the AFQ-4W is properly grounded to reduce the risk of
electric shock.
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Caution!
Voltage and current connections must match phases. Otherwise, Active Filter
will not work properly.
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Figure 11 shows the connection of 2 or more AFQ-4W in parallel with the same
load. Notice that all AFQ-4W use the same current transformers.
Caution!
All active filters (AFQ-4W) connected in parallel must have identical
configurations on OPERATION MODE and PARAMETERS. See (“4.3 Setup
screens”)
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Once all electrical connections stated above have been checked, switch on the
circuit breaker to start the AFQ-4W. When starting the filter, the display will light
on and the following messages will appear: “NO INICIAL CONDITIONS” and
“Starting…”
A few seconds after, the following messages will appear: “NO INICIAL
CONDITIONS” and “Setup transformers ratio”
If there is a problem in the wirings or in the power supply, the screen may show
another message. In the section “4.6 Warning descriptions” in this manual
describes all the causes of malfunctions and their solutions.
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3.6 Commissioning
The following describes the steps for starting the active filter (AFQ-4W). To see
in detail all configuration parameters, check section “4.3 Setup screens” of this
manual.
Caution!
Follow the steps for configuration of the equipment before starting the AFQ-4W.
Step 1.
Setup of the load current transformer and the number of modules in parallel
• Set the number of modules in parallel. Leave the default value (1) if there
is one AFQ-4W.
Figure 14: Step 1: Ratio of the transformer and number of modules in parallel.
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Step 2.
Caution
Improper configuration can significantly affect the performance of the AFQ-4W.
Consult the technician to select the configuration of equipment according to the
needs of the facility.
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Step 3.
• Ensure that the voltage measurements correspond with the real tensions
of the plant.
• Verify that the frequency measured by the AFQ-4W corresponds to the
real frequency of the installation.
• Ensure that the load current measurements correspond to the current
levels of installation.
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Step 4.
• Verify that the active power measurement of the load corresponds to the
power levels of the facility.
• Check that power factor in the three phases. If there were very low power
factors that would indicate an error in the order of phases. In this case,
you should check the wiring to mains and to the current transformers,
read “3.4.1 Wiring of active filter (AFQ-4W)” paragraph for the AFQ-4W
connections.
Once verified the real power, reactive power and the power factor, you may
return to the main screen for starting the active filter (AFQ-4W). Press “MAIN”
button to access to main screen.
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Step 5.
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If an alarm trips, a message will appear in the main menu describing the
problem. Check “4.6 Warning descriptions” for alarm descriptions.
Press “RESET ALARM” button to start AFQ-4W again when the problem has
been solved.
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4 Display panel
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1 START/STOP: Start and stop control key. Filter status must be “STOP” to
start the Active Filter.
2 RESET ALARM: Alarm recovery key. Recovers the AFQ-4W from an alarm
and brings it to “STOP” mode.
6 Filter status:
a. NO INITIAL CONDITIONS: Initial conditions for the AFQ-4W
starting are not fulfilled.
b. STOP: The AFQ-4W is ready to start.
c. RUN: The AFQ-4W is working.
d. ALARM: The AFQ-4W is under alarm.
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Panel setup: Contains the options of selecting the language, set date and time
and enable/disable sound.
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Selective filtering: Access to the screen to select the number of harmonics you
want to neutralize.
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Function selection:
Function priority order: The AFQ-4W sets a priority order in case of overload.
When the “Function priority order” is enabled, the harmonic filtering is the first
priority and phase balancing and reactive compensation are reduced. If the
“Function priority order” is disabled, the first priority is the phase balancing and
the reactive compensation. The harmonic filtering is reduced in case of
overload. This option is not set by default.
Prioritization of functions
OFF ON
PRIORITY
Phase balancing +
Harmonic filtering
+
reactive compensation
Phase balancing +
Harmonic filtering
-
reactive compensation
Table 4: Function priority.
Lock/Unlock parameters: Key to lock/unlock the configuration parameters.
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Selective filtering:
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Enable alarms:
If the polarity alarm is enabled, the active filter detects automatically the load
current polarity. If there is a regenerative load that temporarily injects energy
into the mains, the polarity alarm will activate.
When the polarity alarm is disabled, the AFQ does not detect the load current
polarity. To verify the polarity of the current transformers, check if the active
power is positive when the load is consuming energy from the network. In case
that there is a regenerative load, the active power will be negative when the
load is injecting power into the network. Disable polarity alarm only when there
is a regenerative load and active power may be negative.
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CAUTION
Before starting the AFQ with the polarity alarm disabled, check the correct
wiring of the measurement transformers.
Low temperature alarm: Enable or disable the low temperature alarm. This
alarm avoids starting the active filter when the temperature in the cabinet is
under 0ºC or there is a problem
Resonance alarm: The resonance alarm protects the device against resonant
currents between AFQ and load. When a harmonic content load increases
above the limit, resonance alarm disables these harmonic. Before disable the
resonance alarm is necessary to check there is no resonant current.
CAUTION
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Minimum current: Load minimum current to start the AFQ-4W. When load
current is lower than minimum current, the AFQ-4W will stop. When load current
is higher, the AFQ-4W will start working.
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Warning!
Avoid using 2 temporal mode except your supplier recommends it for your
installation. This method may produce resonance problems in specific
installations.
Parallel modules: Access to the screen to setup the number of parallel AFQ-
4W modules installed.
Power limit: This parameter allows limiting the maximum power of the active
filter. The value is the percent of the rated power of active filter. The value must
be between 20% and 100%.
Lock/Unlock parameters: key to lock/unlock the configuration parameters.
Check “
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Power load: Access to the active, reactive and apparent powers load screen.
Power mains: Access to the active, reactive and apparent powers mains
screen.
Power filter: Access to the power filter screen. This screen shows the power
filter used in percentage of the rated power filter.
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THD(I) content load: Access to the load current harmonic spectrum screens.
THD(I) total: Access to the view of the total THD(I) of each phase with bar
graph.
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Phase 1
Phase 2
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Phase 3
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Phase 3
L1/L2/L3: Access to the view of the current harmonic content of another phase.
Figure 46: Display of the total THD(I) in load and mains side.
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4.5 Password
All the setup options can be password protected. To enable or disable the
protection, you must press “LOCK/UNLOCK PARAMETERS” key. This key is in
the “FUNCTION SELECTION”, “SELECTIVE FILTERING”, “ENABLE ALARMS”
and “PARAMETRES” screens.
To lock or unlock the edition of parameters you must enter the password using
the virtual keyboard that appears on the screen after pressing the "LOCK /
UNLOCK Parameters" button.
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Caution!
Lock the password again after modifying setup options to avoid accidental
modifications of AFQ-4W configuration.
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Warning!
This chart shows messages that may appear before AFQ-4W starting
NO INITIAL CONDITIONS
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ALARMS
MAX. Current Current in the AFQ-4W is too high Review equipment connections
MAX. Mains
Mains voltage amplitude is too high Check voltage levels in mains
Voltage
Review connections between
Desaturation Problem related with the drivers
control and driver boards
Initial Reiteration of no initial conditions
Review initial conditions
conditions error state
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Press “ALARM RESET” in main screen to recover Active Filter, if the cause of
the alarm has disappeared or has been solved.
This chart shows messages that may appear while AFQ-4W is running
RUNNING
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This chart shows messages that may appear during AFQ-4W configuration
CONFIGURATION
Filter Range
Filter range is not correct
Error
Parallel AFQ Number of parallel AFQ-4W is not Enter a valid value to all
Error correct parameters in the configuration.
Number of the control algorithm is not
Algorithm Error
correct If any messages of configuration
The software version of the screen appears, contact the technical
Software
does not match the software version service
version error
of the control board
The value of the power limit error is
Power limit
not correct. Set up a value between
error
20 % and 100 %
Table 8: Configuration messages.
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5 PowerStudio application
PowerStudio is an energy management software package and its main features
are the configuration, communication and monitoring of devices and creation of
SCADA screens and reports. It also has a set of tools such as events, filters,
calculated variables, and an images and styles manager to facilitate the user’s
interaction.
The communications cable RS-232 plugs into the back of the panel, according
to the following scheme.
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6 MAINTENANCE
The active filter requires minimal preventive maintenance. Follow the
maintenance instructions to avoid premature spoilage of the components.
The table below shows time interval and the maintenance operations.
Description Interval
Standard maintenance 5.000 a 9.000 h
Cooling turbines (for AFQ100A, AFQ150A y AFQ 200A) 40.000 h
Cooling fans 100.000 h
DC bus capacitors 200.000 h
Table 10: Maintenance operations.
* The interval times of the maintenance operations may vary depending on the
operation conditions and environmental factors.
Danger
Caution
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Set AFQ in STOP mode and open the main switch (OFF position).
Wait 5 minutes and check there is no residual voltage on the capacitors.
- Clean the dirt from fans, vents and inside the device.
- Check the torque of the electrical connections.
- Replace the panel’s battery if the low battery led is on.
The panel uses a 3V battery. CR2032. The led in lower left corner indicates the
state of battery.
- Green: correct battery level.
- Red: low battery level.
After replace the battery panel, it’s necessary to setup the language, the date
and time.
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The fans and turbines used for cooling the inductors and semiconductors in
each model of AFQ are described in table below.
- Set AFQ in STOP mode and open the main switch (OFF position).
- Wait 5 minutes and check there is no voltage in the capacitors.
- Unplug the fan supply wire. The connector is found in the lower right corner of
the fan.
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- Replace damaged fan. Install the new fan in the right position, with the supply
connector in the lower right corner.
- Plug the supply wires
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AFQ-4W-150 A / 200 A
The following instructions are for replacing inductor fans AFQ-4W-150A and
AFQ-4W-200A.
- Set AFQ in STOP mode and open the main switch (OFF position).
- Wait 5 minutes and check there is no voltage in the capacitors.
- Remove the methacrylate protection in front of fans.
- Replace damaged fan. Use a 7mm. allen key to remove the fan from the
cover.
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x: R, S, T phase.
Figure 57: Fans change on AFQ150, 200 and 100. Step 4.
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AFQ-4W-25 A / 50 A
The following instructions are for replacing the heatsink fans AFQ-4W-25A and
AFQ-4W-50A.
- Set AFQ in STOP mode and open the main switch (OFF position).
- Wait 5 minutes and check there is no voltage in the capacitors.
- Remove the methacrylate protection and bring down the panel that holds
electronic boards.
- Remove the right cover of the cabinet.
TOP FANS
- Remove the six screws that fix the air hood on the heatsink.
- Lift the air hood, unplug the fan supply wire and remove the air hood.
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- Install the new fan in the same position as the replaced fan.
- Plug the fan power and insert the air hood.
BOTTOM FANS
- Unplug the fan supply wire from the bottom of the heatsink.
- Remove the four screws that fix the fan on the heatsink.
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- Replace damaged fans. Install new fan in the same position as removed fan.
- Connect the fan supply wire. Install the right cover. Check that the ground wire
is properly connected on the cover.
- Bring up the panel that holds electronic boards and insert the methacrylate
protection.
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The active filter capacitors do not require maintenance, except for the
commissioning after al long storage time (see “3.3 Long storage time”)
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CAUTION
The control version and the panel version must match in number version. The
active filter can become out of service if two different software versions are
installed.
To check the software version access to filter data screen (“see 4.3.3 Filter data
screen”)
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- Plug the device supplied in the connector, close to the microswitches. Must
be connected with the flat part in the opposite side of the battery, the
bumped part close to the battery.
- Switch the filter on. It can be done with door opened, but work with extreme
caution. You can do it, but under your risk. In this case, you can follow the
upgrading procedure. A green LED will light during the updating process,
and will be off after that period. If you want to upgrading with the door
closed, switch on the filter, wait 2 minutes, and switch it off. The upgrading
procedure should be finished.
- Switch off the filter again. Wait 5 minutes.
- Unplug the device supplied. Switch the microswitches or jumper back to the
initial position “0000”.
- Mount the polycarbonate protection.
- The filter is updated.
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CAUTION
If the panel software is no updated, update this software before starting the
active filter (see 6.4.2 Update panel software”).
CAUTION
Finished the update process could be necessary to setup again the filter
parameters. Before start the filter check the configuration parameters. (See
“6.4.3 Checking the configuration after complete the update”)
- Turn off active filter, wait until the capacitors are discharged (about 5
minutes). When the capacitors are discharged, plug in the memory stick into
the USB port found behind the panel.
- Power the active filter and wait until the screen has started. Check the filter
is STOP state. Access the FILTER DATA screen and change the setup code
number to 25.
Access the SETUP screen and push EXIT button.
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- Press “Download project”. Select the file Vx.yz (x.yz is the version number of
software) and press OK.
- Wait until the update is complete. After the udate, the panel will restart the
software.
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- Turn off the active filter, wait until the capacitors are discharged (about 5
minutes.) and unplug the memory stick.
- Reenergize the filter again.
If the message “End Setup” appears, you should change the setup code
number to 14 in the FILTER DATA screen. Back to main screen and verify
that the “End Setup” message is cleared.
CAUTION
If the AFQ software is no updated, update this software before starting the
active filter (see “6.4.1 Update AFQ software”).
CAUTION
Finished the update process could be necessary to setup again the filter
parameters. Before start the filter check the configuration parameters. (See
“6.4.3 Checking the configuration after complete the update”)
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7 Technical characteristics
Models
AFQ_4W-25 AFQ_4W-50 AFQ_4W-100 AFQ_4W-150 AFQ_4W-200
Harmonic phase current 25 A RMS 50 A RMS 100 A RMS 150 A RMS 200 A RMS
Harmonic neutral current 75 A RMS 150 A RMS 300 A RMS 450 A RMS 600 A RMS
Harmonic peak current 50 A PEAK 100 A PEAK 200 A PEAK 300 A PEAK 400 A PEAK
Electrical characteristics
Nominal Voltage 400 V ± 15%
Frequency 50 Hz / 60 Hz +/- 10%
Number of phases 3 phases plus neutral wire ( 4 wires)
Filter specifications
Current harmonics compensation 2nd to 50th harmonic
Specified harmonic selection 2nd to 25th harmonic
Load current balancing Yes
Reactive current compensation Yes
Controller Digital, DSP
Transient Response Time < 1ms
Current limitation Protection from over current by current limitation at filter nominal value
Graphic Display Panel LCD display, 5,7” 320x240 pixel
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Standards
Reference Harmonic Standard EN61000-3-4, IEEE519-1992
Reference Design Standard EN60146
Safety Standard EN50178
EN55011, EN50081-2, EN61000-4-2, EN61000-4-3, EN61000-4-4
Electromagnetic Compatibility
EN61000-4-5, EN61000-4-6, EN61000-6-2
Display functions
Controls Start, stop, reset alarm and filter status description
Configuration of all filter parameters including: harmonics filtering,
load balancing, reactive compensation, load transformer ratio,
Setup
minimum current, control algorithm and number off AFQ-4W in parallel.
Language, date and time and sound.
Voltages and currents measurements.
Real, reactive and apparent power and power factor measurements.
Electrical values display
Current harmonics and harmonic spectrum graph.
Internal temperatures and alarms history
Optional products
CVMk2 Three phase power quality analyzer
Power Studio SCADA software for online-instantaneous values and historical
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Environmental conditions
Operating Temperature +0ºC to +50ºC
Relative humidity 0 to 90% without condensation
Operating Alititude < 2000m
Mechanical characteristics
Figure 70: Dimensions of AFQ-4W (25A, 50A, 100A). Figure 71: Dimensions of AFQ-4W (150A 200A).
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Queda prohibida la reproducción total o parcial de esta publicación, sin para ello contar con la autorización previa y por escrito de CIRCUTOR, SA
En caso de cualquier duda de funcionamiento o avería del equipo.
Avisar al Servicio de Asistencia Técnica (S.A.T.) de CIRCUTOR CIRCUTOR, SA
Vial Sant Jordi, s/n – 08232 – Viladecavalls (Barcelona)
ESPAÑA: 902 449 459 Tel. +34 93 745 29 00 – Fax: +34 93 745 29 14
INTERNACIONAL: (+34) 93 745 29 00 Web: www.circutor.com – email: central@circutor.es
email: sat@circutor.es
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