instructions manual pqfl power quality filter

Instructions Manual PQFL Power Quality Filter

ABB Jumet

PQFL Instructions Manual

__________________________________________________________________________ Asea Brown Boveri Jumet S.A.

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Table of contents

1. SAFETY INSTRUCTIONS ................................................................................................................... 5

2. UPON RECEPTION ............................................................................................................................ 6

2.1. DELIVERY INSPECTION........................................................................................................................ 6 2.2. IDENTIFICATION TAG ........................................................................................................................... 6 2.3. STORAGE.......................................................................................................................................... 6 2.4. LONG STORAGE PERIOD AND REFORMING ............................................................................................. 6

3. PQFL PRINCIPLE AND CHARACTERISTICS .................................................................................... 7

3.1. REASONS FOR LIMITING HARMONICS .................................................................................................... 7 3.2. GENERAL PRINCIPLE OF ACTIVE FILTERING............................................................................................ 8 3.3. THE ABB ACTIVE FILTER: THE PQFL................................................................................................... 9 3.4. THE PQFL: PERFORMANCES ............................................................................................................ 11

3.4.1. Filtering ................................................................................................................................. 11 3.4.2. Reactive power...................................................................................................................... 12 3.4.3. EMC ...................................................................................................................................... 12

4. COMPONENTS DESCRIPTION AND IDENTIFICATION................................................................... 13

4.1. COMPONENTS DESCRIPTION ............................................................................................................. 13 4.1.1. PQF current generator........................................................................................................... 13 4.1.2. The control ............................................................................................................................ 14

4.2. COMPONENTS IDENTIFICATION .......................................................................................................... 15

5. MECHANICAL INSTALLATION........................................................................................................ 21

5.1. GENERALITIES ................................................................................................................................. 21 5.2. IP00 PLATE..................................................................................................................................... 23

5.2.1. Mounting of the plate ............................................................................................................. 23 5.2.2. Master cubicle door accessories............................................................................................ 24 5.2.3. Slave cubicle door ................................................................................................................. 24

6. ELECTRICAL INSTALLATION ......................................................................................................... 25

6.1. OVERVOLTAGE ................................................................................................................................ 25 6.2. POWER CABLES AND EXTERNAL PROTECTION ...................................................................................... 25 6.3. CURRENT TRANSFORMERS/CONTROL CABLES SELECTION..................................................................... 28 6.4. CURRENT TRANSFORMERS INSTALLATION ........................................................................................... 30

6.4.1. CT’s connection to the PQFL................................................................................................. 30 6.4.2. CT’s connection topology: cases............................................................................................ 32

6.4.2.1. Case 1: Global compensation – one feeding transformer........................................................................32 6.4.2.2. Case 2: Individual compensation – one feeding transformer...................................................................33 6.4.2.3. Case 3: global compensation – transformer busbar not accessible. .......................................................34 6.4.2.4. Case 4: two independent feeding transformers. .......................................................................................36 6.4.2.5. Case 5: back up generator .........................................................................................................................38

6.5. CONNECTION OF LAMPS AND BUTTONS (IP00 VERSION) ....................................................................... 39 6.6. PRECAUTIONS WITH CAPACITORS ...................................................................................................... 39

7. MASTER-SLAVE INTERCONNECTIONS ......................................................................................... 41

7.1. INTRODUCTION ................................................................................................................................ 41 7.2. MECHANICAL INSTALLATION (CUBICLE VERSION) .................................................................................. 41 7.3. ELECTRICAL CONNECTIONS............................................................................................................... 42

7.3.1. Connections between sections............................................................................................... 42 7.3.1.1. Power connection........................................................................................................................................42 7.3.1.2. Control connection......................................................................................................................................43 7.3.1.3. Domino boards connection.........................................................................................................................44 7.3.1.4. Earth connection .........................................................................................................................................44

7.3.2. Connections to the supply...................................................................................................... 44


_____________________ _____________________________________________________ Asea Brown Boveri Jumet S.A.

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7.3.2.1. Power connection................................ ................................ ................................ ................................ ........44 7.3.2.2. Protective earth ................................ ................................ ................................ ................................ ........... 44

8. PQF-PROG INSTALLATION AND PC CONNECTION ...................................................................... 46

8.1. SYSTEM REQUIREMENTS................................ ................................ ................................ ................... 46 8.2. INSTALLING PQF-PROG ON YOUR PC ................................ ................................ ................................ 46 HARDWARE CONNECTION................................ ................................ ................................ .............................. 46

9. COMMISSIONING.............................................................................................................................47

9.1. STEP 1 ................................ ................................ ................................ ................................ ........... 47 9.2. STEP 2 ................................ ................................ ................................ ................................ ........... 47 9.3. STEP 3 ................................ ................................ ................................ ................................ ........... 48

9.3.1. PQF connection diagram ....................................................................................................... 48 9.3.2. Material needed & hypotheses for correct measurements ...................................................... 49 9.3.3. Checking the correct connection of the CTs with a two channel scopemeter........................... 49

9.3.3.1. Measurement of CT in phase L1................................ ................................ ................................ ................ 49 9.3.3.2. Measurement of CT in phase L2 and L3................................ ................................ ................................ ...51

9.3.4. Checking the correct connection of the CTs with two current probes. ..................................... 52 9.3.5. Checking the correct connection of the CTs with a Fluke 41B................................................. 52

9.4. STEP 4 ................................ ................................ ................................ ................................ ........... 53 9.4.1. With PQF-Prog ...................................................................................................................... 53 9.4.2. With the PQF-Manager.......................................................................................................... 54

9.5. STEP 5 ................................ ................................ ................................ ................................ ........... 55 9.6. STEP 6 ................................ ................................ ................................ ................................ ........... 55 9.7. STEP 7 ................................ ................................ ................................ ................................ ........... 55 9.8. STEP 8 ................................ ................................ ................................ ................................ ........... 55

10. OPERATION..................................................................................................................................... 57

10.1. NORMAL WORKING SEQUENCE ................................ ................................ ................................ .......... 57 10.2. OPERATION WITH CAPACITORS ................................ ................................ ................................ .......... 62 10.3. BEHAVIOR IN CASE OF POWER OUTAGE ................................ ................................ .............................. 62 10.4. BUTTONS, LIGHTS AND LED’S SIGNIFICATION ................................ ................................ ...................... 63

10.4.1. Master cubicle. ...................................................................................................................... 63 10.4.2. Slave cubicle ......................................................................................................................... 63 10.4.3. PQF-Manager........................................................................................................................ 64 10.4.4. Control rack........................................................................................................................... 65

10.5. PROGRAMMING WITH PQF-PROG ................................ ................................ ................................ ...... 66 10.5.1. Filter operation principle......................................................................................................... 66 10.5.2. Starting.................................................................................................................................. 67 10.5.3. Programming the filter............................................................................................................ 69

10.6. PROGRAMMING WITH PQF-MANAGER................................ ................................ ................................ 71 10.6.1. Filter operation principle......................................................................................................... 71 Keys identification.............................................................................................................................. 72 10.6.3. Programming the filter............................................................................................................ 73

10.7. PQFL AND NETWORK MONITORING WITH THE PQF-MANAGER................................ .............................. 77 10.7.1. Filter status............................................................................................................................ 77 10.7.2. Network status....................................................................................................................... 78 10.7.3. Waveform.............................................................................................................................. 79 10.7.4. Spectrum............................................................................................................................... 80

10.8. REMOTE CONTROL AND ALARM CONTACT................................ ................................ ............................ 81 10.8.1. Remote control ...................................................................................................................... 81 10.8.2. Alarm contact......................................................................................................................... 82

10.9. PROTECTIONS ................................ ................................ ................................ ................................ . 82

11. FAULT HANDLING AND TROUBLESHOOTING.............................................................................. 83

11.1. FAULT HANDLING................................ ................................ ................................ ............................. 83 11.1.1. Type of faults......................................................................................................................... 83 11.1.2. Fault handling and fault clearance procedure......................................................................... 83


_____________________ _____________________________________________________ Asea Brown Boveri Jumet S.A.

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11.2. TROUBLESHOOTING ................................ ................................ ................................ ......................... 86 11.2.1. Frequent problems occurring at commissioning stage............................................................ 86 11.2.2. Error codes meaning.............................................................................................................. 86 11.2.3. Faults not related to error codes............................................................................................. 90 11.2.4. Restarting the filter after fault correction................................................................................. 90

12. MAINTENANCE................................................................................................................................91

12.1. MAINTENANCE FREQUENCY................................ ................................ ................................ ............... 91 12.2. MAINTENANCE PROCEDURE................................ ................................ ................................ .............. 91 12.3. FAN................................ ................................ ................................ ................................ ................ 92 12.4. CAPACITORS REFORMING ................................ ................................ ................................ ................. 92


Asea Brown Boveri Jumet S.A. 5

1. Safety instructions These safety instructions are intended for all work on the PQFL. Neglecting these instructions can cause physical injury and death. All electrical installation and maintenance work on the PQFL should be carried out by qualified electricians. Do not attempt to work on a powered PQFL. After switching off the mains, always wait at least 5 minutes before working on the unit in order to allow the discharge of DC capacitors through the discharge resistors. DC capacitors might be charged to more than 1000V. Before manipulating current transformers, make sure that the secondary is short-circuited. Never open the secondary of a loaded current transformer. You must always wear isolating gloves and eye-protection when working on electrical installation. Also make sure that all local safety regulations are fulfilled.



2. Upon reception 2.1. Delivery inspection Each PQFL is delivered in a sealed package designed to protect adequately the equipment during shipment. Upon receipt of the equipment, make sure that the packing is in good condition. After removal of the packing, check visually the exterior and interior of your filter. Any loss or damage should be notified immediately. Care should be taken to ensure that correct handling facilities are used. 2.2. Identification tag Each PQFL is fitted with a nameplate for identification purposes. The nameplate includes the type of filter, nominal frequency, voltage and current as well as a serial number and an ABB internal article code. This information should always remain readable to ensure proper identification during the whole life of the filter. 2.3. Storage PQFA packing is made for a storage period of maximum six months (transport time included from delivery date EXW ABB Jumet factory). Packing for longer storage period can be done on request. If your PQFL 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 –15°C and 70°C with a maximum relative humidity of 95%, non-condensing. Before installing and operating your PQFL, you should read very carefully this instructions manual and you should make sure that the information given on the nameplate corresponds to your network. 2.4. Long storage period and reforming If your PQFL is non-operational or stored for more than one year, the DC capacitors need to be reformed (re-aged). Without reforming, capacitors may be damaged when the filter starts to operate. The reforming methods are described in chapter 12 (maintenance).



3. PQFL principle and characteristics 3.1. Reasons for limiting harmonics Power electronics based equipment is the main source of the harmonic pollution in electric networks. Examples of such equipment include drives (AC or DC), UPS’s, welders, PCs, printers etc. In general, the semiconductor switches in this equipment conduct only during a fraction of the fundamental period. This is how such equipment can obtain their main properties regarding energy saving, dynamic performance and flexibility of control. However, as a result a discontinuous current containing a considerable amount of distortion is drawn from the supply. Harmonic pollution causes a number of problems. A first effect is the increase of the RMS-value and the peak-value of the distorted waveform. This is illustrated in figure 3.1. that shows the increase of these values as more harmonic components are added to an initially undistorted waveform. The RMS-value and the peak-value of the undistorted waveform are defined as 100 %. The peaks of the fundamental component and the distortion components are assumed to be aligned. It may be seen that the distorted waveform, which contains harmonics up to the 25th harmonic, has a peak value that is twice the value of the undistorted waveform and a RMS-value that is 10 % higher.

Peak: 100 % 133 % 168 % 204 % RMS: 100 % 105 % 108 % 110 %

Figure 3.1. Evolution of the increase in peak-value and the RMS-value of a waveform as more harmonic components are added

The increase in RMS-value leads to increased heating of the electrical equipment. Furthermore, circuit breakers may trip due to higher thermal or instantaneous levels. Also, fuses may blow and capacitors may be damaged. kWh meters may give faulty readings. The winding and iron losses of motors increase and they may experience perturbing torques on the shaft. Sensitive electronic equipment may be damaged. Equipment, which uses the supply voltage as a reference may not be able to synchronise properly and either applies wrong firing, pulses to switching elements or switch off. Interference with electronic communications equipment may occur.

100 % H1 + 33 % H3 + 20 % H5 … + 4 % H25



Distorted networks may also cause generators malfunctions. Overall it may be concluded that an excessive amount of harmonics leads to a premature ageing of the electrical installation. This is an important motivation for taking action against harmonics. 3.2. General principle of active filtering The active filter measures the harmonic currents and generates actively a harmonic current spectrum in opposite phase to the measured distorting harmonic current. The original harmonics are thereby cancelled. The principle is shown in figure 3.2.

Figure 3.2. Principle of active filtering

The control of the active filter in combination with the active generation of the compensating current allows for a concept that may not be overloaded. Harmonic currents exceeding the capacity of the active filter will remain on the network, but the filter will operate and eliminate all harmonic currents up to its capacity. The principle of active filter showing currents and spectra is clarified in Figure 3.3.

PQFA

Supply LoadFundamental only

- 1 . 3

1 . 3

0 360

- 1 . 3

1 . 3

0 3 6 0

- 1 . 3

1 . 3

0 360

idistortion

icompensation



Figure 3.3. Active filter principle illustrated in time and frequency domains

3.3. The ABB Active filter: the PQFL. As we have just seen, the active filter is basically a compensating current generator. The most important parts are then the current generator and the control system. The compensating current is in a first step created by a three-phase Insulated Gate Bipolar Transistors (IGBT) inverter bridge that is able to generate any given voltage waveform with PWM (Pulse Width Modulation) technology. The IGBT bridge uses a DC voltage source realised in the form of a DC capacitor. The inverter bridge is in fact the same technology than in AC drives. The generated voltage is coupled to the network via reactors and a small filter circuit. The desired current generator is thereby achieved. The DC capacitors are loaded actively through the inverter bridge and there is no need of external power source. Obviously, the DC voltage level must always be higher than the peak value of the network voltage in order to be able to inject currents to the network. To control the active filter the choice stands between open loop and closed loop current control. Under open loop current control, the harmonics currents are measured on the load side of the active filter that computes the required compensating current and injects it into the network. Closed loop current control as performed by the PQFL is shown in Figure 3.4. In this topology the resulting current to the network is measured and the active filter operates by injecting a compensating current minimising this resulting current. In this configuration, the filter directly controls its effect on the filtration.

+= Load current

1 5 7 1 1 1 3 1 7 1 9

- 2 0

0

2 0

4 0

1 5 7 1 1 1 3 1 7 1 9

Active Filtercurrent

1 5 7 1 1 1 3 1 7 1 9

- 2 0

0

2 0

4 0

1 5 7 1 1 1 3 1 7 1 9

Cleanfeedercurrent

1 5 7 1 1 1 3 1 7 1 9

- 2 0

0

2 0

4 0

1 5 7 1 1 1 3 1 7 1 9

Wav

efor

ms

Har

mon

ics

- 1 . 3

1.3

0 3 6 0

- 1 . 3

1 . 3

0 3 6 0

- 1 . 3

1 . 3

0 360



Figure 3.4. Closed loop control

In addition to being more precise, the closed loop control system also allows for a direct control of the degree of filtering. Furthermore, the closed loop control system ensures that measurement errors do not result in a higher distortion. To fully exploit the potential of an active filter we need a digital measurement and control system that is fast enough to operate in true real time. We need to be able to track the individual harmonics and control the compensating current according to the requirements of the plant and this with full control at every instant in time. To achieve this, we need advanced Digital Signal Processors, DSP’s. Among the physical signals needed by the PQFL, the three line currents have obviously to be measured. Standard CTs with 5A secondary are usually sufficient. Those analogue signals must first be acquired, levelled and antialias-filtered before digitalisation. Fast and high precision analogue-to-digital converters are used to create a digital representation of the analogue signals. The digitised signals are then sent to the powerful DSP that controls all measurements and calculations in real time, and builds the PWM references for the inverter. It is another processor, a microcontroller, which handles all digital input/output (including the command of the PWM inverter). More dedicated to control than to calculations, this microcontroller ensures for instance the closing of the relays and contactors. One control is needed per PQFL system and can handle more than one power module simultaneously.

Control

AF

Target

Measurement Feedback

Output



3.4. The PQFL: performances 3.4.1. Filtering The main requirement for an active filter installed in an industrial installation is to attenuate the harmonics produced by the non-linear loads of the installation. The ideal active filter should allow the user to choose freely which harmonic components to filter and should offer an adjustable degree of filtering. It is also worth noting that the total harmonic voltage distortion at the point of common coupling (PCC) is often calculated up to the 40th [1] or the 50th [2] harmonic. Furthermore, the total number of harmonics that can be filtered determines directly the quality of the resulting current. This is illustrated in figure 3.5., which shows the filtered waveforms obtained by filtering up to different harmonic levels. (a) Filtering up to the 13th harmonic. (b) Filtering up to the 25th harmonic. (c) Filtering up to the 50th harmonic.

Figure 3.5. Waveforms obtained by eliminating the harmonic components of a rectangular periodic signal up to the (a) 13th harmonic,

(b) the 25th harmonic and (c) the 50th harmonic

This figure highlights the need for an active filter that can operate up to sufficiently high harmonic frequencies. The PQFL can filter simultaneously 20 (15) independent harmonics up to the 50th for 50Hz (60Hz) based networks. The number of harmonics to be filtered as well as their frequencies is completely programmable by the user.



Besides the harmonic selection functionality, the user has also the possibility to specify a filtration level for each selected harmonic. The PQFL will filter the selected harmonics until by the user and may be different for each selected harmonic. This functionality is especially useful when the objective is to fulfil the requirements of a standard and results in a better use of the available compensation power. It also allows the installation of active filters on networks already fitted with a fixed passive filter. We can see that we are very close to the ideal filter: the choice of which harmonic components to filter is free and the degree of filtering is adjustable according to the wishes of the user. Moreover, all typical harmonics generated by three-phase non-linear loads may be filtered simultaneously. 3.4.2. Reactive power Besides the filtering functionality, reactive power compensation is also possible with the active filter. Compared to traditional capacitor banks, the reactive compensation of the PQFL is continuous (‘stepless’), fast and smooth (no transients at switching). The compensation can be either capacitive or inductive. Two types of compensation are available: automatic compensation where a target power factor has to be set, and fixed compensation based on a predefined amount of kvar. 3.4.3. EMC The PQFL has been verified for compliance with EU (European Union) directives for EMC (electromagnetic compatibility) for operation at 50 Hz and bears the CE-mark to this effect. When an apparatus is used in a system, EU directives may require that the system is verified for EMC compliance.



4. Components description and identification 4.1. Components description As already explained, the active filter is basically composed of two parts: the current generator and the control system.

4.1.1. PQF current generator. The power circuit of the ABB active filter PQF is represented hereafter.

OutputFilter

PWM inverter

Main Breaker

PowerLines

+

-

PWM Reactors

Preload

The main components are: - PWM inverter - PWM reactors - Output filer - Preloading circuit The current generator is physically organised in power modules, each including a PWM inverter, three PWM reactors and the output filter.

Non-linear load(s) (three-phase or single-phase)

PQF Digital Control

Compensation current

Current measurement

PQF current generator



Each PQFL plate or cubicle contains one power module. Protection is realized through fuses and there is one preloading circuit. The PWM inverter is composed of DC capacitors and an IGBT inverter bridge. This system is able to generate any voltage waveform with PWM technology. The physical layout of a PWM inverter module is shown hereafter. Each PWM inverter is fitted with a local electronic control called the domino board. The domino board is controlled by the central DSP. The domino board is fitted with jumpers noted JP100, JP101, JP102, JP103, JP104, JP105, JP106, JP109 and JP110 (JP107 and JP108 are off). In case of several power modules, only the domino board of the last slave is fitted with jumpers. The PWM reactors convert the voltage created by the PWM inverter into currents that will be injected in the network. The output filter consists in line reactors and an RC shunt circuit. The function of the preloading circuit is to avoid at start-up high inrush currents that could damage the power electronics or create transients in the network. 4.1.2. The control For best performances, the control of the PQFA is Digital Signal Processor (DSP) based. The three lines currents are measured by external CT. Those analogue signals must first be acquired, levelled and antialias-filtered before

DC capacitors

Inverter

Heatsink



digitalisation. Fast and high precision anlogue-to-digital converters are used to create a digital representation of the analogue signals. The digitised signals are then sent to the powerful DSP that controls all measurements and calculation in real time, and builds the PWM references for the inverter. It is another processor, a microcontroller, which handles all digital input/output (including the command of the PWM inverter). More dedicated to control than to calculations, this microcontroller ensures for instance the closing of relays and contactors. One control unit may command up to 4 power modules. 4.2. Components identification

Control

Output filter capacitor

Auxiliary voltage transformer

PQF Manager

PWM inverter

Fan



A more detailed identification is given in the following pages. The identification hereafter is related to the drawings of the following pages. Internal views indicate the position of identified components but fixation details are not included. Although visible on the drawings, some components may actually be hidden in the real structure. Mains connection F102/103/104: mains fuses K10: mains contactor Fan M101: fan motor K101: fan contactor Auxiliaries Q101: breaker for auxiliaries T101: auxiliary voltage transformer PWM inverter U11: module A67: AC voltage board A77: Domino interface A104: DC voltage converter A117: module domino board Output filter C1XX Output filter capacitor R11/12/13 Output filter resistor L1 Line reactor PWM reactor L2 PWM reactor Preloading circuit K11 Preload contactor R14/15 Preload resistor U1 Preload bridge



Control rack A111 Digital I/O board A112 Interface board – IGBT’s and DSP A113 Digital Signal Processor A119 Interface PQF Manager board A114 Current input board A115 Analog input board A116 +24V power supply board U100 Power supply ? 15V U109 Power supply + 5V X1 Terminal block digital I/O wiring X4 Terminal block current input wiring X2 Terminal block analog input wiring X10 Terminal power supply wiring X6 Terminal current input wiring Door components S102 RESET push button S101 RUN push button S104 Remote local switch H101 White lamp: controller connected to supply (auxiliary

breaker closed) H102 Red lamp: MCB closed H103 Green lamp: MCB open A120 PQF-Manager Other components A121 +24V switching power supply B101/102/103 Internal current sensors K104 Alarm contactor K12 Remote contactor X5 Terminal block backplane wiring (external CT connection) X12 Terminal signalling wiring X20 Terminal intercabinets wiring



Master + slave IP00



K11

K101

1.1.1.

K104 Q101

X12

X5



Control rack details



5. Mechanical installation 5.1. Generalities The PQFL is suitable for indoor installation, on firm foundations, in a well-ventilated area without dust and excessive aggressive gases where the ambient parameters do not exceed the following values: 40°C max; 30°C (average temperature) over 24 hours; Minimum temperature: +5 °c Humidity less than 95% RH non-condensing Altitude: max. 1000m without derating. For units with nominal voltage above 415V, the rear side of the cubicles must be located at least at 100mm from the wall. PQFL cubicles (IP23 version) have standard dimensions of 600 x 600 x 2150 mm (width x depth x height). PQFL plates (IP00 version) have standard dimensions of 498 x 400 x 1896 mm (width x depth x height). Each cubicle or plate is fitted with one power module, its own bottom cable entry, fuses and contactor. Standard dimensions for PQFL with up to 3 power modules are shown on page 23. A maximum of 4 power modules may be connected in parallel. !!!!!!!!!!!!!!!! Only modules of the same ratings may be paralleled !!!!!!!!!!!!!!!!!!!!!!!



CAUTION The PQFL dissipates significant amounts of heat that have to be evacuated out of the room where the filter is located. Otherwise, you may experience excessive temperature rise. For proper cooling of the PQFL, a minimum airflow of 610 m3/h of cooling air has to be supplied to the each fan of the unit. Please ensure 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 cannot exceed 40°C under any operating condition. The hot exhaust air has also to be properly ducted away.



5.2. IP00 plate 5.2.1. Mounting of the plate The IP00 mounting plate is to be fixed in your own cubicle by means of the four holes located in the corners of the plate. The dimensions of the plate and of the holes are given here below.



5.2.2. Master cubicle door accessories The dimensions of the cut-out to be made on the master cubicle door are represented here below. There are 6 holes for buttons and lamps (same dimensions) and the cut-out for the PQF-Manager (if delivered). The buttons and lamps are provided with the filter. The positions of the cutout are those of the IP23 version and are given for indication only.

5.2.3. Slave cubicle door Two lamps are provided to be installed on slave cubicle doors. The dimension of the cutout is the same than for the master cubicle door (diameter: 23 mm).



6. Electrical installation Your PQFL is a parallel active filter: it is installed in parallel with the load(s). Connection implies:

? ? 3 power cables ? ? 3 CT (one per phase) ? ? 6 control wires for the CT ? ? Ground/PE

6.1. Overvoltage The PQFL is able to withstand continuously an overvoltage (inclusive of harmonics but not transients) of up to 110 % of the rated voltage. Higher voltages than the rated one would imply an operation at limited power of the filter. Since operation at the upper limits of voltage and temperature may reduce its life expectancy, the PQFL should not be connected to systems for which it is known that the overvoltage will be sustained indefinitely. 6.2. Power cables and external protection Each cubicle is fitted with its own fuses (bottom cable entry) and needs to be individually connected to the supply. The power cable size should be rated on the basis of X times the nominal current of the corresponding cubicle (one or two power modules) where X is a multiplication factor which allows to take into account the skin effect. This multiplication factor is the result of an iterative calculation and can be determined by means of the following process: Important remark: please note that the following process is made to take into account the skin effect only. Other deratings due to local standards and/or installation conditions (as e.g. cables proximity, number of cables connected in parallel,… ) have to be taken into account by the company responsible for the PQF cable connection. Step 1: as initial value of this iterative process, determine the preliminary cable section on the basis of the nominal current. Step 2: based on the previously determined cable section, find in the table here below the multiplication factor that must be applied. Step 3: determine the cable section on the basis of the value of the multiplication factor times the nominal current.

- if the cable section found is equal to the previously found cable section, the process can be stopped.



The cable section is then determined taking into account the skin effect. (see examples below) - If the cable section found is bigger than the previously found value, step 2 and 3 have to be repeated until the cable sections are equal (see example below).

Remark: during this process, it can be found that more than one cable per phase is needed. The process has then to be applied on each cable as shown in the example n°3 below.

SSeeccttiioonn 50Hz 60Hz

[mm2] Al Cu Al Cu 16 1.01 1.01 1.01 1.01 25 1.01 1.02 1.01 1.03 35 1.02 1.03 1.02 1.04 50 1.03 1.06 1.04 1.08 70 1.05 1.1 1.06 1.13 95 1.08 1.16 1.10 1.21

120 1.11 1.30 1.15 1.30 150 1.16 1.30 1.21 1.39 185 1.22 1.41 1.28 1.50 240 1.31 1.55 1.40 1.66 300 1.41 1.70 1.52 1.84

Table: Multiplication factors for different cable types

Examples: Please note that the following examples are given for information only (see important remark above). Example n°1:

PQF-L 80A 480V 60hz

Step 1: IN = 80A ? cable section (*) = 25 [mm2]

Step 2: multiplication factor for a 25 [mm2] copper cable at 60hz = 1.03

Step 3: I = IN x 1.03 = 80A x 1.03 = 83 A

Step 4: I = 83A ? cable section (*) : 25 [mm2]

This section is equal to the section found in the previous step.

Result : one copper cable of 25 [mm2] per phase



Example n°2:

PQFA-A 155A 480V 60hz



Step 3: I = IN x 1.13 = 155A x 1.13 = 175 A

Step 4: I = 175A ? cable section (*) : 95 [mm2]


Step 6: I = IN x 1.21 = 155A x 1.13 = 187,5 A

Step 7: I = 187,5A ? cable section (*) : 95 [mm2]


Result : one copper cable of 95 [mm2] per phase

Example n°3:

PQFA-B 427A 400V 50hz



Step 3: I = IN x 1.70 = 427 A x 1.70 = 726 A

Step 4: I = 726A ? cable section (*) : 2 x 185 [mm2]


Step 6: I = IN x 1.41 = 427A x 1.41 = 602 A ? which means 301 A per cable

Step 7: I= 301 A ? cable section (*) : 185 [mm2]


Result : two copper cable of 185 [mm2] per phase

(*) given for information only. If single core cables are used an alloy gland plate is recommended.



6.3. Current transformers/control cables selection Three CT’s are needed since the PQFL monitors the three phases of the network. The proper operation of the PQFL does not require any special CT’s. The requirements are minimum:

? ? 5A of secondary ? ? 15 VA minimum for up to 30 meters of 2.5 mm² cable ? ? Class 1 accuracy or better ? ? Ratio limit above maximum line current

In case the CT’s are shared with other loads, the VA burden shall be adapted and the connection of the different loads (including the PQFL) must be in series. Twin 2.5 mm² control cable is the most suitable for this application. In order to determine the suitable CT’s for your application, please refer to the following chart.



Max

imum

rms

curr

ent o

f the

dow

nstre

am lo

ads

(incl

udin

g st

artin

gcu

rren

t of D

C d

rives

):

X1

= ….

. Arm

s

Mul

tiply

X1

by1.

6:

X2

= ….

Arm

s

CT

cabl

es >

30

met

ers

?

Sel

ect 3

iden

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CT’

s suc

h th

at:

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ing

at p

rim

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at s

econ

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: 5A

- Bur

den ?

15 V

A- C

lass

1 a

ccur

acy

or b

ette

r

NO

Sec

tion

of C

T ca

bles

:

2.5

mm

²? (r

ecom

men

ded)

Det

erm

ine

the

leng

th o

fC

T ca

bles

(met

ers)

L =

… m

X3

= (L

x 0

.007

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5) +

10

X3

= …

VA

Sel

ect 3

iden

tical

CT’

s suc

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at:

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ing

at p

rim

ary ?

X2

- rat

ing

at s

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: 5A

- Bur

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ss 1

acc

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ter

Det

erm

ine

the

leng

th (m

) and

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stan

ce (?

/m)o

fC

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bles

(met

ers)

L =

… m

R =

… ?

/m

X4

= (L

x R

x 2

5) +

10

X4

= …

VA

Sel

ect 3

iden

tical

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s suc

h th

at:

- rat

ing

at p

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: 5A

- Bur

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VA

- Cla

ss 1

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ter

NO

YE

S

YE

S



6.4. Current transformers installation Special care has to be taken for the connection and location of the CT’s: it is the most current source of problems occurring at commissioning stage. WARNING: when connecting the CT’s to the PQFL, the secondaries of the CT’s have to be short-circuited. First of all, the CT’s have to be positioned for closed loop control: they have to monitor the resulting current after filtering. The CT’s must also be positioned in the correct direction around the power cable: the K (or P1) side should be in the direction of the supply and the L (or P2) side should be in the direction of the load. 6.4.1. CT’s connection to the PQFL The connections between the CT’s and the filter must satisfy the following scheme: ? ? The k terminal of line 1 CT is connected to terminal X5-1 of the filter ? ? The l terminal of line 1 CT is connected to terminal X5-2 of the filter ? ? The k terminal of line 2 CT is connected to terminal X5-3 of the filter ? ? The l terminal of line 2 CT is connected to terminal X5-4 of the filter ? ? The k terminal of line 3 CT is connected to terminal X5-5 of the filter ? ? The l terminal of line 3 CT is connected to terminal X5-6 of the filter



L1

L2

L3Load sideSupply side

K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

X5



6.4.2. CT’s connection topology: cases The location of the CT’s is critical to ensure the proper operation of the active filter. The CT’s are the “eyes” of the filter and it will react in accordance with the information supplied by them. The location of the CT’s must always be in closed loop configuration. This means that the CT’s must see the load current and the filter current. In some cases, summation CT’s might be needed to fulfil the closed loop requirement. Typical circuit topologies and adequate CT’s location are described hereafter in the following order: Case 1: Global compensation – one feeding transformer. Case 2: Individual compensation – one feeding transformer. Case 3: Global compensation – transformer busbar not accessible. Case 4: Two independent feeding transformers. Case 5: Back up generator. Please bear in mind that the active filter always needs 3 CT’s: one per phase. 66..44..22..11.. CCaassee 11:: GGlloobbaall ccoommppeennssaattiioonn –– oonnee ffeeeeddiinngg ttrraannssffoorrmmeerr This is the most frequent configuration: one transformer feeds several non-linear loads. The active filter is installed in central position and filters the combined harmonic currents. This configuration and the proper location of the CT’s is represented hereafter.

Figure 6.1. Global compensation – one feeding transformer.

The connection of the CT’s to the active filter must be as represented herafter:

PQF LOAD LOAD LOAD



L1

L2


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Figure 6.2. CT’s connection to the active filter.

66..44..22..22.. CCaassee 22:: IInnddiivviidduuaall ccoommppeennssaattiioonn –– oonnee ffeeeeddiinngg ttrraannssffoorrmmeerr Instead of installing one active filter in central position, it also possible to connect the active filter and its CT’s so that it compensates one particular load only. In the example hereafter, the active filter PQF is connected to compensate Load 1 only. It does not see load 2.

Figure 6.3. Individual compensation – one feeding transformer

The connection of the 3 CT’s to the active filter is described in 6.4.1.

LOAD 2

LOAD 1 PQF

K = P1, L = P2, k = S1, l = S2



66..44..22..33.. CCaassee 33:: gglloobbaall ccoommppeennssaattiioonn –– ttrraannssffoorrmmeerr bbuussbbaarr nnoott aacccceessssiibbllee.. The active filter is required to filter the loads of side A and side B but the transformer busbar not being accessible, the CT’s cannot be installed in central position.

Figure 6.4. Transformer busbar with no access: single-line diagram

For this configuration, three CT’s (one per phase) have to be installed on side A et on side B (in total, 6 CT’s). Those CT’s will then feed 3 summation CT’s (one per phase) that are connected to the active filter. This CT topology is represented in figure 6.5.

LOADS (Side A)

LOADS (Side B) PQF



Figure 6.5. Transformer busbar with no access: CT connection (to be done for each phase)

The CT’s installed in each phase of side A et B (CT1 and CT2) must be identical (X / 5) and feed a summation CT whose secondary is 5A (5+5/5A). The summation CT is then connected to the active filter in accordance with chapter 6.4.1. A total of 3 summation CT’s (one per phase) must be used. The CT ratio to be programmed in the filter is: 2X / 5. The CT – summator – PQF connection is represented here below. This has to be done for each phase.

LOADS (Side A) LOADS

(Side B)

PQF

Summation CT (one per phase) Primary 1: 5 A Primary 2: 5A Secondary: 5A

CT 1 (one per phase) Primary: X Secondary: 5A CT 2 (one per

phase) Primary: X Secondary: 5A



Figure 6.6. Connection between CT1, CT2 , the summation CT and PQF for one phase.

66..44..22..44.. CCaassee 44:: ttwwoo iinnddeeppeennddeenntt ffeeeeddiinngg ttrraannssffoorrmmeerrss.. Two independent transformers (the tie is normally open) feeds two different set of loads. One active filter is fitted on each LV busbar. This system may however also work in degraded mode: the tie is closed and only one transformer feeds the whole LV system. By connecting the CT’s as described hereafter, it is still possible to filter properly the harmonics and to correct the power factor.

Figure 6.7. Two independent transformers: single-line diagram

PQF PQF

T1 T2

S1, k

S2, l

S1, k

S2, l

P1

P2

P1

P2

S1

S2

k

l

PQF

Side A Side B

P1, K

P2, L

P1, K

P2, L



Figure 6.8. Two independent transformers: CT connection for one phase.

For each phase, 3 CT’s must be installed: - one to measure I1 - one to measure I2 - one to measure I0. Those CT’s must be identical: X/5 A. CT I1 and CT I0 feed a summation CT which is connected to PQF1. CT I2 and CT I0 feed a summation CT which is connected to PQF2. Those summation CT’s must be 5+5 / 5 A. Condition 1: the tie is open. PQF1 sees I1 and PQF2 sees I2 (I0 = 0). The two transformers work independently and the total current to be compensated is I1 + I2. Condition 2: the tie is closed but both transformers feed the loads. In this configuration, PQF1 sees (I1-I0) and PQF2 sees (I2+I0). The total current seen by the two filters is I1 + I2.

S1, k

S2, l

P1 P2 P1 P2

S1 S2

S1, k

S2, l

S1k

S2l

P1 P2 P1 P2

S1 S2

I1 I2I0

I’1-I’0

PQF 1

I’2+I’0

PQF 2

k l k l

T1 T2

P2, L

P1, K P1, K

P2, LP1K

P2L



Condition 3: the tie is closed but only one transformer feeds the loads (degraded mode). If only T1 feeds the loads with the tie closed, PQF1 sees (I1-I0) and PQF2 sees I0 (I2 is zero). If only T2 feeds the load, I1 will be zero. The above described connection must be done for each phase. The CT ratio to be programmed in the filter is: 2X/5. 66..44..22..55.. CCaassee 55:: bbaacckk uupp ggeenneerraattoorr Many installations are fitted with back up generators to ensure the proper operation of the installation in case of mains power outage. A typical configuration is given here below.

Figure 6.9. Back-up generator: typical single-line diagram

The CT connection must be such that the active filter works whatever the type of supply: generators or transformer-MV network. For each phase, one CT is installed in the transformer feeding and one in the generator. Those two CT’s must be identical (X / 5 A) and are connected to a summation CT rated 5+5 / 5 A. The CT ratio to be programmed in the filter is: 2X/5.

G

LOAD PQF



Figure 6.10. Back-up generator: CT connection (for one phase)

6.5. Connection of lamps and buttons (IP00 version) The buttons and lamps have to be connected to terminal X20 according to the following table:

Item Connection points Green lamp (H103) X20-4 / X20-3 Red lamp (H102) X20-5 / X20-3 White lamp (H101) X20-6 / X20-3 Local-remote switch (S104) X20-7 / X20-8 (local) / X20-9 (remote) Run button (S101) X20-8 / X20-10 Reset button (S102) X20-8 / X20-11

6.6. Precautions with capacitors In the presence of power capacitors (LV or MV), harmonics below the resonance frequency of the capacitor bank should not be handled by the filter to avoid any risk of resonance. Those harmonics have to be deselected (see chapter 10 on programming the filter). Networks where the PQFL is installed have large harmonic content and it is highly recommended that capacitor banks be fitted with detuning reactors. The harmonics below the tuning frequency of the bank have also to be deselected. The following table indicates the harmonics to be deselected for main types of detuned banks.

S1, k

S2, l

S1, k

S2, l

P1

P2

P1

P2

S1

S2

k

L

PQF

G

P1, K

P2, L P1, K

P2, L



Detuned bank type Harmonics to be deselected

5.67% 2, 3, 4. 6% 2, 3, 4. 7% 2, 3. 14% 2.

For other types of detuned bank or in the case of plain capacitors, please contact your ABB Service provider to evaluate the resonance frequency and the harmonics to be deselected.



7. Master-slave interconnections 7.1. Introduction

This section explains how to connect PQF sections (Master-Slave or Slave-Slave) when they do not come connected from the factory or in case of on-site extension. The section starts with mechanical installation. Electrical connections are then described: interconnections between sections and with the supply. All cables needed to make the connections are supplied with the units. A maximum of 4 power modules may be connected in parallel. !!!!!!!!!!!!!!!! Only modules of the same ratings may be paralleled !!!!!!!!!!!!!!!!!!!!!!! 7.2. Mechanical installation (cubicle version)

The side panels of the cubicles to be interconnected have first to be removed (except the outside one of the Master and last Slave cubicles). The provided divider panel seal has to be fixed on the interior frame between cubicles. Cubicles are then interconnected at 6 fixation points as indicated in Figure 3.1. The baying kit is provided with the cubicles (not the tools).



Figure 7.1. Mechanical installation

7.3. Electrical connections 7.3.1. Connections between sections 77..33..11..11.. PPoowweerr ccoonnnneeccttiioonn The DC bus of the master and slave sections must be connected. Each slave section comes from the factory with two cables connected on the + and - poles of the DC bus. Those cables are then fixed to the terminals of the DC bus of the next section.

Start the DC buses interconnection with the last slave and proceed similarly with each section until reaching the Master. An example of DC bus interconnection is given below (PQFL-master + 2 slaves) in Figure 7.2.

Be very careful about the polarity when connecting the DC bus.



Figure 7.2. DC bus interconnection

77..33..11..22.. CCoonnttrrooll ccoonnnneeccttiioonn ? ? The following terminals of the master unit and the first slave unit must be

interconnected (three interconnections):

Master Slave 1 A X21-1 connected to X21-4 B X21-2 connected to X21-5 C X21-3 connected to X21-6

? ? The following terminals of the first slave unit and the second slave unit

must be interconnected (three interconnections):

Slave 1 Slave 2 A X21-1 connected to X21-4 B X21-2 connected to X21-5 C X21-3 connected to X21-6

? ? The following terminals of the second slave unit and the third slave unit

must be interconnected (three interconnections):


Master

Control

+-

Slave 1 +-

+- +

- Internal connection

External connection to perform

Slave 2 +-

+-



? ? The following terminals of the third slave unit and the fourth slave unit must be interconnected (three interconnections):


77..33..11..33.. DDoommiinnoo bbooaarrddss ccoonnnneeccttiioonn The inter-domino boards connection is achieved with flat cables. Each slave section is fitted with a loose flat cable. The other end of this flat cable has to be connected to the first plug of domino board A118 of the next cubicle, starting at the last slave. Make sure that the plug-in pattern of the connector and plug is respected. The last domino of the chain must be fitted with termination jumpers on positions JP100, JP101, JP102, JP103, JP104, JP105, JP106, JP109 and JP110 (JP107 and JP108 are off). An example of domino boards interconnection is given in Figure 7.3 (PQFA-B+D+C). 77..33..11..44.. EEaarrtthh ccoonnnneeccttiioonn The earth cable of each slave cubicle has to be connected to the earth connection point of the master cubicle. Make sure that the cables run along the floor, not over components. 7.3.2. Connections to the supply

77..33..22..11.. PPoowweerr ccoonnnneeccttiioonn Three power cables (L1, L2, L3) have to be connected to each circuit breaker (one in each cubicle). Make sure that L1, L2 and L3 in each cubicle are connected to the same phases. 77..33..22..22.. PPrrootteeccttiivvee eeaarrtthh The protective earth point of each cubicle has to be connected to earth. The connections to the supply are represented in Figure 7.3.



Figure 7.3. Flat cables connection and connections to power supply

Slave 1

Domino

A118

L1 L2 L3 PE

Control

Master

Domino

A118

L1 L2 L3 PE

Internal connection

External connection to perform

Slave 2

Domino

A118

L1 L2 L3 PE



8. PQF-Prog installation and PC connection The PQF-Prog, included in the standard PQFL package, allows for the complete programming of the filter. It consists of two Micro Floppy Disks delivered with the filter. 8.1. System requirements Windows NT 4.0 Service Pack 3 minimum. At least one free COM:port (RS232 - DB 9). One standard RS232 cable (male-female non twisted) 8.2. Installing PQF-Prog on your PC 1. Insert disk 1 of PQF-Prog in drive A 2. In the Start Menu, choose Run 3. In the Command Line box enter a:\setup

4. Follow the instructions in the dialog boxes to: ? ? Specify the drive and directory (c:\ Program Files \ Pqf is the

default) ? ? Complete the installation

8.3. Hardware connection

A111 A112 A113 A119 A114 A115 A116 U100 U109DIG INT DSP GUI LIC LVI ALIM/GND ±15V +5V

YELLOW LEDGREEN LEDRED LED

1 2

3

21

3

21 21 21 1

21 1 2

3 4 3

RS232-port

If your filter is equipped with the PQF-Manager, you just have to plug the DB 9 connection in the RS232 port situated at the front of the PQF-Manager. If your filter is not equipped with the PQF-Manager, you have to plug the connection in the RS232 port located on the control rack (A111: digital I/O board) as shown here after.



9. Commissioning The commissioning of your PQFL should be conducted in strict accordance with the following procedure. Warning: Before applying the commissioning procedure, make sure that you become familiar with programming instructions (see chapter 10, programming with PQF-Prog and PQF-Manager). Pay particular attention to the presence of capacitors on the network. The commissioning procedure consists in 8 steps that should be followed very carefully.

Step 1 Installation check Step 2 Voltage phase rotation Step 3 Current transformer check Step 4 System set-up Step 5 Before starting the filter Step 6 Start the filter Step 7 Stop the filter Step 8 Start filtering

9.1. Step 1

Step 1: Visual and installation check Check first that mechanical and electrical installations fulfil requirements described in chapter 4 and 5 of the present manual. Check also visually the conditions of the filter and the tightness of connections. In particular, verify that all connections on the control rack, domino board and IGBT are properly plugged in. 9.2. Step 2

Step 2: Voltage phase rotation Voltage phase rotation must be clockwise (L1 -> L2 -> L3 -> L1). Wrong phase rotation may damage the filter.



9.3. Step 3

Step 3: Current transformer check Improper CT connection is the most frequent cause of problems during commissioning. The following procedure will allow you to check the CT connection. Warning: The secondary circuit of a loaded CT must never be opened

otherwise extremely high voltages may appear which can lead to physical danger or destruction of the CT itself.

9.3.1. PQF connection diagram Figure 9.1. shows the normal connection of the PQF. 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, ? ? One secondary terminal of the CT must be earthed.

L1

L2


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Figure 9.1. PQF connection



It is also seen that terminal X5.1 and X5.2 are related to the CT located in phase L1, terminal X5.3 and X5.4 are related to the CT located in phase L2 and terminal X5.5 and X5.6 are related to the CT located in phase L3. 9.3.2. Material needed & hypotheses for correct measurements A two channel scopemeter with one voltage input and one current input is needed. Adequate sensors are also needed. A power analyser like the Fluke 41B can also be used. Some minor knowledge of the load is also required. For instance, the method explained below is based on the fact that the load is inductive and not regenerative (i.e. the load current lags by less than 90° the phase voltage). If a capacitor bank is present, it is better to disconnect it before making measurements in order to ensure an inductive behaviour of the load. It is also assumed that the load is approximately balanced. 9.3.3. Checking the correct connection of the CTs with a two channel

scopemeter. The first channel of the scopemeter must be connected to the phase voltage referenced to the neutral or to the ground if the neutral is not accessible. The second channel must measure the associated current flowing from the network to the load as seen by the CT input of the PQF. 99..33..33..11.. MMeeaassuurreemmeenntt ooff CCTT iinn pphhaassee LL11 For the voltage measurement (channel 1), the positive (red) clamp must be connected to the phase L1 and the negative clamp (black) must be connected to the neutral (ground). For the current measurement (channel 2), the clamp should be inserted into the wire connected on terminal X5.1 and the arrow indicating positive direction of the current should point towards the PQF. Do not forget to remove the short on the CT secondary before making the measurement.

L1

L2


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Positive directionCh1 Ch2

Figure 9.2. Connection of the scopemeter for checking CT in phase L1.



On the scopemeter screen, two waveforms should appear. The voltage waveform should be approximately a sine wave1 and the current waveform would 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 9.3).

I

I1

Figure 9.3. Extrapolation of fundmental component from a distorted

waveform.

From the fundamental component of both signals, the phase shift must then be evaluated (Figure 9.4). The time ?T between zero crossing of the rising (falling) edge of both traces must be measured and converted to a phase shift ? by the following formula:

??? 360*1TT?

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°.

? T

T1

U

I1

Figure 9.4. Phase shift evaluation between two waveforms.

1 If the earthing of the system is bad, the phase to ground voltage may appear like a very distorted waveform. In this case, it is better to measure the phase to phase voltage (move the black clamp to the phase L2) and substract 30° on the measured phase shift.



99..33..33..22.. MMeeaassuurreemmeenntt ooff CCTT iinn pphhaassee LL22 aanndd LL33 The same operations as those described in the previous paragraph must be repeated with the phase L2 (Figure 9.5) and phase L3 (Figure 9.6). 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


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Positive direction

Ch1 Ch2


L1

L2


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Positive direction

Ch1 Ch2




9.3.4. Checking the correct connection of the CTs with two current probes. If the main bus bar is available and all security rules are taken, it is possible to use the two channel scope meter in order to see if the current measured through the CT is matching the real current in the bus. Connecting the current probes as shown on Figure 9.7., the two traces must be in phase and of the same shape (the magnitude could be different as the gain are different) if the wiring is correct.

L1

L2


K L

k l

K L

k l

K L

k l

PQF

X5.2X5.3X5.4X5.5X5.6

X5.1

L1 L2 L3

Ch1 Ch2Positive direction

Positive direction

Figure 9.7. Connection of the scopemeter for checking 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. 9.3.5. Checking the correct connection of the CTs with a Fluke 41B. The Fluke 41B is a power analyser that allows measurements of one voltage and one current wave. Unfortunately, the device does not allow simultaneous display of both waveforms on the screen. But it is possible to synchronise the triggering on either the voltage or on the current. All phaseshift measurements are then referenced to the chosen origin. To read directly the phaseshift between the fundamental components, just select the spectrum window of the signal which is not chosen as the origin. The instrument must be configured in single phase measurements. The probes must be connected as shown on Figure 9.2, Figure 9.5 and Figure 9.6.



9.4. Step 4

Step 4: System set-up 9.4.1. With PQF-Prog Once the PQF-Prog software has been successfully installed and your PC is properly connected (see chapter 8), select Programs in the Start menu and click on PQF. If you did not install PQF-Prog in the Program Files directory, create a shortcut to PQF_Prog.exe. After launching PQF-Prog, a text box indicating that Station 0 has been found will appear. Click ‘Done’. You then enter the PQF-Prog main Window. In the Login box, type the User name and the password. Station must be “0”.

If you use the appropriate User name and password, four icons appear on the toolbar: Login, Filter Operation, Hardware set-up and Configuration.

Login

Filter Operation

Hardware set-up

Configuration



If a wrong or no login is entered, you will only have access to the Login, Filter Operation and Configuration icons. Click on the Hardware set-up icon. In the hardware set-up window, you will have to specify:

? ? The network frequency ? ? The grid nominal voltage ? ? The number of modules ? ? The three lines CT ratio

Click on ‘apply’ to validate. 9.4.2. With the PQF-Manager The 3 levels of the PQF-Manager are accessible from the window “Main menu”. To enter the “Main menu” window, press MENU.

Level 1 is for consulting, level 2 for filter programming and level 3 for commissioning. Select level 3 by pressing once the ? key.

Then press OK and enter the appropriate password for level 3.

The LED ‘SET’ will switch on. In the hardware set-up window, you will have to specify:

? ? The network frequency ? ? The grid nominal voltage ? ? The number of modules ? ? The three lines CT ratio

MAIN MENU

Level 1 Level 2 ? Level 3?



9.5. Step 5

Step 5: Before switching the filter on Before switching the filter ON, you have to ensure that all harmonics and reactive power compensation have been deselected. This can be done from the ‘Filter Operation’ menu of the PQF-Prog or level 2 of the PQF-Manager. Please refer to the detailed programming instructions of chapter 10. 9.6. Step 6

Step 6: Starting the filter With all harmonics and reactive power compensation deselected, you can start the filter by pushing the RUN button of the master cubicle. The main breaker should close within 30 seconds. One second after closing, the IGBT will start and the filter will work under no load condition. 9.7. Step 7

Step 7: Stop the filter Once the filter is connected to the network, stop it by pushing on the RESET button. 9.8. Step 8

Step 8: Start filtering Once you have checked that the filter can connect to the network, you may start filtering and reactive power compensation. After programming the filter according to the procedure of chapter 10, you can switch the filter on by pushing the RUN button. A start-up sequence will then be conducted. As represented on Figure 9.8, this sequence includes a network characterisation during which the filter may generated ‘musical’ sounds.



Figure 9.8. Start-up sequence

Start fan &preload

DC bus

Operation asprogrammed

Close MC

Start IGBT

Networkcharacterisation

Push RUN button

Start-up sequence



10. Operation 10.1. Normal working sequence After successful commissioning (refer to chapter 9), the procedure to operate the active filter is: 1. From the OFF position (auxiliary and main contactor open, no light on),

switch on the auxiliary breaker. If your PQFL system has more than two modules, the auxiliary breaker of slave cubicles should be switched on before the one of the master cubicle.

2. After 20 seconds, the system will reset. 3. The auxiliaries are then on but the main contactor is still open. The white light (ON) and the green one (OPEN) of the master cubicle are on, while the green light (OPEN) of the slave cubicles is on. Master cubicle lights and buttons: Slave cubicles lights:

If your PQFL is fitted with the PQF-Manager, the red LED ‘POWER’ is on.

CLOSE OPEN

RESET RUN LOC/REM ON CLOSE OPEN



4. Push the RUN button located on the master cubicle. 5. The filter then starts the start-up sequence:

- Start fan and preload DC bus - Close main contactor - Start IGBT - Network characterization

During the start-up sequence, the red LED ‘START-UP’ of the PQF-Manager is on.




Once the main contactor is closed, the red light (CLOSED) of the master and slave cubicles becomes on, while the green light (OPEN) switches off. Master cubicle Slave cubicles:

LED n°3 of board A111 on the control rack should be red: it indicates that the PQF is properly synchronized to the network (see illustration next page). 6. After the start-up sequence, the PQFL operates as programmed. The red

LED ‘OK’ of the PQF-Manager should be on. In the LED ‘FULL LOAD’ appears to be on, it only means that the filter cannot achieved the programmed requirements. Refer to the chapter on programming with the PQF-Manager for more information.

CLOSE OPEN




7. Pushing the button RESET of the master cubicle causes the main contactor to open and to come back at step 3 of this procedure.

The normal working sequence is represented on Figure 10.1.



1 2

3

21

3

21 21 21 1

21 1 2

3 4 3




Figure 10.1. Normal working sequence

OFF

20sec. Time delay

System reset

Auxiliaries ON

Start fan &preload

DC bus

Operation asprogrammed

Open MC

Close MC

Start IGBT


Switch on auxiliary breaker (Q101)

Push RUN button

Push RESET button

Start-up sequence



10.2. Operation with capacitors In the presence of power capacitors (LV or MV), harmonics below the resonance frequency of the capacitor bank should not be handled by the filter to avoid any risk of resonance. Those harmonics have to be deselected. Networks where the PQFL is installed have large harmonic content and it is highly recommended that capacitor banks be fitted with detuning reactors. The harmonics below the tuning frequency of the bank have also to be deselected. The following table indicates the harmonics to be deselected for main types of detuned banks.

Detuned bank type Harmonics to be deselected

5.67% 2, 3, 4. 6% 2, 3, 4. 7% 2, 3. 14% 2.

For other types of detuned bank or in the case of plain capacitors, please contact your ABB Service provider to evaluate the resonance frequency and the harmonics to be deselected. 10.3. Behavior in case of power outage In case of power outage, the PQFL will stop and automatically re-start after having re-conducted the network characterisation and synchronization procedures.



10.4. Buttons, lights and LED’s signification 10.4.1. Master cubicle. ? ? Push buttons:

RUN: starts the PQFL RESET: stops switching of the IGBTs and opens the main contactor.

? ? Local – remote switch: local or remote control of the filter. If remote is on, the push buttons are not operational.

? ? Lights: ON (white): the PQFL controller is connected to the supply (auxiliary breaker closed) CLOSE (red): the main contactor is closed (filter working) OPEN (green): the main contactor is open

Three light conditions are then possible: ON

(white) CLOSE

(red) OPEN (green)

No power connection (main contactor and auxiliary breaker open)

Controller connected (auxiliary breaker closed, main contactor open)

? ?

Filter working (aux. breaker and contactor closed)

? ?

10.4.2. Slave cubicle


CLOSE OPEN



? ? Lights:

CLOSE (red): the main contactor is closed (filter working) OPEN (green): the main contactor is open

10.4.3. PQF-Manager

Red LED’s:

? ? POWER: the controller is connected to the supply (auxiliary breaker closed).

? ? START-UP: the PQFL is in the start-up sequence.

? ? OK: the PQFL is working properly and fulfilling

programmed requirements.

? ? FULL LOAD: the filter is working at 100% of its nominal capacity and programmed requirements are not fulfilled.

? ? ALARM: the filter has stopped due to an error. ? ? SET: the programming or set-up level of the PQF-

Manager has been activated. The PQF-Manager is also fitted with a screw to adjust contrast. This screw is situated on the back metal plate of the PQF-Manager.



10.4.4. Control rack.



1 2

3

21

3

21 21 21 1

21 1 2

3 4 3

Board A111 DIG LED 1 (green) on: OK LED 2 (red) on: malfunction

LED 3 (red) on: PQF synchronised on network Board A112 INT LED 1 (green) on: OK LED 2 (red) on: malfunction Board A113 DSP LED 1 (green) and LED 3 (yellow) blinking: OK LED 2 (red) on: malfunction Board A114 LIC LED 1 (green) on: OK LED 2 (red) on: malfunction Board A115 LVI LED 1 (green) on: OK LED 2 (red) on: malfunction Board U100 LED 1 (green) on: OK LED 2 (red) on: power supply inhibited LED 3 (red) on: output 1 inhibited LED 4 (red) on: output 2 inhibited Board U109 LED 1 (green) on: OK LED 2 (red) on: power supply inhibited LED 3 (red) on: output 1 inhibited



10.5. Programming with PQF-Prog 10.5.1. Filter operation principle. The filter can have three types of effect on the network:

? ? Filter the selected harmonics until their magnitudes are close to zero

(Maximum Filtering); ? ? Filter the selected harmonics until their magnitudes reach the

residual level permitted by the user (Filtering to Curve); ? ? Produce or absorb reactive power.

The user can put the emphasis on one of the above effects by selecting the filtering mode. The following table shows the three available 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


?

In Mode 1, the PQFL will first filter to the pre-programmed curve. Once the requirements are fulfilled, remaining resources will be allocated to reducing the selected harmonics as close as possible to zero. If further resources are then available, reactive power compensation will be performed as required. In Mode 2, the second priority after filtering to the curve is reactive power compensation. Maximum filtering comes in third place. In Mode 3, two levels are defined: filtering to curve and reactive power compensation. In any case, filtering to curve is always the first priority. The alarm contact is activated (open) if the filtering to curve requirements are not fulfilled. Figure 10.2 here after illustrates the principle of filtering to curve for one particular harmonic order. The flexibility of the PQFL control is such that a specific curve may be defined for each selected harmonic.



Figure 10.2. Filtering to curve for harmonic order n

The programming procedure consists in: 1) Defining the Mode of operation. 2) Specifying the harmonics to be filtered and the permitted residual level

(=curve) for each of them. At 50 Hz, 20 harmonics between the 2nd and 50th may be selected. At 60 Hz, 15 harmonics between the 2nd and 50th.

3) Programming reactive power compensation parameters 10.5.2. Starting Once the PQF-Prog software has been successfully installed (see chapter 7), select Programs in the Start menu and click on PQF. If you did not install PQF-Prog in the Program Files directory, create a shortcut to PQF_Prog.exe. After launching PQF-Prog, a text box indicating that Station 0 has been found will appear. Click ‘Done’. You then enter the PQF-Prog main Window. In the Login box, type the User name and the password. Station must be “0”.

Filtered current

Remaining current

Before filtering After filtering

Permitted residual level

= curve

Load current for harmonic order n



If you use the appropriate User name and password, four icons appear on the toolbar: Login, Filter Operation, Hardware set-up and Configuration. If a wrong or no login is entered, you will only have access to the Login, Filter Operation and Configuration icons.

Login

Filter Operation

Hardware set-up

Configuration



10.5.3. Programming the filter Step 1: click on the Filter Operation icon. Step 2: Select the Filter Mode tab.

Step 3: Select the option button corresponding to your chosen mode of

operation. The priorities of the selected mode are indicated at the bottom of the window.

Click on ‘Ok’ if you wish to save your choice and leave the Filter

Operation mode. Click on ‘Apply’ if you wish to validate your choice and stay in Filter Operation mode.

Step 4: Select the Harmonics tab. In order to select a harmonic order, enter Y (yes) in the second

column. N (no) indicates that the corresponding harmonic has not been selected. The curve may be programmed in absolute terms (Amps), in % of the fundamental current or in % of the rms current. After choosing your appropriate reference by using the option button, program your target in the third column for the harmonics you have selected. The values there entered constitute the curve and the first priority of your PQFL will be to filter harmonics until each selected order becomes lower than its specified target.

Click on ‘Ok’ if you wish to save your choice and leave the Filter Operation mode. Click on ‘Apply’ if you wish to validate your choice and stay in Filter Operation mode.



Step 5: The filter may be switched on or off from the On/off tab.



10.6. Programming with PQF-Manager 10.6.1. Filter operation principle. The filter can have three types of effect on the network:

? ?Filter the selected harmonics until their magnitudes are close to zero (Maximum Filtering);

? ?Filter the selected harmonics until their magnitudes reach the residual level permitted by the user (Filtering to Curve);

? ?Produce or absorb reactive power. The user can put the emphasis on one of the above effects by selecting the filtering mode. The following table shows the three available modes:

Highest priority level

Lowest priority level

Mode 1 Filtering to curve Maximum filtering Reactive compensation


Maximum filtering


?

In Mode 1, the PQFL will first filter to the pre-programmed curve. Once the requirements are fulfilled, remaining resources will be allocated to reducing the selected harmonics as close as possible to zero. If further resources are then available, reactive power compensation will be performed as required. In Mode 2, the second priority after filtering to the curve is reactive power compensation. Maximum filtering comes in third place. In Mode 3, two levels are defined: filtering to curve and reactive power compensation. In any case, filtering to curve is always the first priority. The alarm contact is activated (open) if the filtering to curve requirements are not fulfilled. Figure 10.3 here after illustrates the principle of filtering to curve for one particular harmonic order. The flexibility of the PQFL control is such that a specific curve may be defined for each selected harmonic.



Figure 10.3. Filtering to curve for harmonic order n

The programming procedure consists in: 1) Defining the Mode of operation. 2) Specifying the harmonics to be filtered and the permitted residual level

(=curve) for each of them. At 50 Hz, 20 harmonics between the 2nd and 50th may be selected. At 60 Hz, 15 harmonics between the 2nd and 50th.

3) Programming reactive power compensation parameters 10.6.2. Keys identification.

Filtered current

Remaining current

Before filtering After filtering

Permitted residual level

= curve

Load current for harmonic order n

Numerical keypad

Arrow buttons

‘OK’ button

‘MENU’ button

Delete button



10.6.3. Programming the filter. Step 1: The 3 levels of the PQF-Manager are accessible from the

window “Main menu”. To enter the “Main menu” window, press MENU. Level 1 is for consulting, level 2 for filter programming and level 3 for commissioning. Select level 2 by pressing once the ? key.

Then press OK and enter the appropriate password for level 2. The LED ‘SET’ will switch on.

Step 2: Three options appear in the level 2 window: mode, harmonics and Q compensation.

Select Mode by using the ? key.

Press OK. Step 3: Select your preferred mode of operation with the ? key. The

priorities of the selected mode are indicated on the window.

MAIN MENU Level 1 ? Level 2? Level 3

LEVEL 2 ? Mode? Harmonics Q compensation

FILTER MODE MODE 1 2 3 FILTERING TO CURVE MAX FILTERING Q COMPENSATION



The selected mode only becomes operational once you press the OK button. Step 4: Press on ‘MENU’ to come back to level 2 main window, select

‘harmonics’ by using the ? key and press OK.

In the next window, you have to specify the unit in which the permitted residual level (= curve) is expressed. Three possibilities are offered: amps ’A’, percentage of the fundamental magnitude ’%I1’ and percentage of the RMS current ’%Irms’. Make your choice with the ? key and press OK. You will then enter in the Harmonics window.

FILTER MODE MODE 1 2 3 FILTERING TO CURVE Q COMPENSATION MAX FILTERING

FILTER MODE MODE 1 2 3 FILTERING TO CURVE Q COMPENSATION

LEVEL 2 Mode ? Harmonics ? Q compensation



HARMONICS

CURVE : AORDER SELECT CURVE

5 Yes 107 No 711 Yes 5

Use the ? ? keys to select an order and press ‘OK’ to activate the corresponding line. Once the line is activated, you may modify the order number by using the DEL button to delete the current value and the numerical keypad of the PQF-Manager to enter the new value. Press ‘OK’ to activate the Select column of the line. Use the ? button to switch between ‘Yes’ and ‘No’. Press ‘OK’ to activate the Curve column of the line and use the numerical keypad to enter your filtering objective. Once your parameters are entered, press ‘OK’ to activate your programming for the correspondent harmonic order. You can select and programme each individual harmonic by using the ? ? keys and following the same procedure.

Step 5: Press on ‘MENU’ to come back to level 2 main window, select ‘Q compensation’ by using the ? key and press OK.

In the first window, you have to specify whether reactive power compensation is requested. Use the ? key to make your choice and press ‘OK’ to validate.

LEVEL 2 Mode Harmonics ? Q compensation ?



If ‘ON’ is selected, you have to specify the type of reactive power

compensation: static or dynamic. Use the ? key to make your choice and press ‘OK’ to validate.

If you select static compensation, you have to specify the

amount of fixed reactive power (kvar) that is requested. A positive value means a capacitive injection while a negative value means an inductive consumption.

If you select dynamic compensation, you have to specify the

target cos? in the range 0.6 inductive to 0.6 capacitive. Press ‘ON’ to activate your choice. Step 6 Return to the main menu by pressing the ‘MENU’ button.

Q COMPENSATION Q COMP: OFF

Q COMPENSATION Q COMP: ON Q COMP: STEADY Q : 50

Q COMPENSATION Q COMP: ON Q COMP: DYNAMIC TARGET : 0.96



10.7. PQFL and network monitoring with the PQF-Manager The 3 levels of the PQF-Manager are accessible from the window “Main menu”. To enter the “Main menu” window, press MENU.

Level 1 is for consulting, level 2 for filter programming and level 3 for commissioning. Select level 1 by using once the ? key.

Then press OK. The consulting level gives you access to 4 submenus: the filter status, the network status, the waveform and the spectrum. To select one of those submenus, use the ? key and press OK. 10.7.1. Filter status. In the Consulting level window, select Filter status and press OK.

A horizontal bar graph appears. It depicts the percentage of the filter capabilities used as represented on figure 10.4.

MAIN MENU ? Level 1? Level 2 Level 3

LEVEL 1 ? Filter status? Network status Waveform Spectrum



0% 100%75%

Figure 10.4. Filter Status Window

If you press the ? key, you display a second window listing the value of each limiting factor:

- The percentage of use of the DC voltage capability; - The percentage of use of the peak current capability; - The percentage of use of the RMS current capability;

This second window also displays the error code if applicable. You can easily switch between the 2 Filter Status windows with the ? ? keys. To come back to the Consulting level menu from any of those windows, press MENU. 10.7.2. Network status In the Consulting level window, select Network status and press OK.

The following window appears:

LEVEL 1 Filter status ? Network status? Waveform Spectrum



NETWORK STATUS

U1-2 = 396 VI1 = 654 ATHDU1 = 17 %THDI1 = 74 %

Figure 10.5. Network Status

It gives you the RMS voltage between L1 and L2, the RMS current in L1 as well as the Total Harmonic Distortion on the same voltage and current. By pressing the ? key, you enter the second window displaying the RMS voltage between L2 and L3, the RMS current in L2 as well as the Total Harmonic Distortion on the same voltage and current. If you press once more the ? key, you enter the third and last window with the values of the RMS voltage between L3 and L1, the RMS current in L3 as well as the Total Harmonic Distortion on the same voltage and current. You can easily switch between those 3 windows with the ? ? keys. Press MENU and you come back to the consulting level menu. 10.7.3. Waveform In the Consulting level window, select Waveform and press OK.

The first Waveform window proposes a choice of 3 submenus: the network voltage, the line current and the filter current. Select the waveform you want to display with the ? key and press OK. Before displaying the waveform, you still have to choose the phase you want to visualise. You can make your selection in the next window with the ? key and you validate by pressing OK. You then see the waveform you have selected.

LEVEL 1 Filter status Network status ? Waveform ? Spectrum



Un2(V)

512

-512

Figure 10.6. Waveform Window

The graph indicates the unit, the waveform as well as the maximum positive and negative values of the scale. Press MENU and you come back to the Consulting level MENU. 10.7.4. Spectrum In the Consulting level window, select Spectrum and press OK.

The first Spectrum window proposes a choice of 3 submenus: the network voltage, the line current and the filter current. Select the spectrum you want to display with the ? key and press OK. Before displaying the spectrum, you still have to choose the phase you want to visualise. You can make your selection in the next window with the ? key and you validate by pressing OK. You then see the spectrum you have selected.

LEVEL 1 Filter status Network status Waveform ? Spectrum ?



60 AH: 015 A

In1

Figure 10.7. Spectrum Window

The graph indicates the maximum value of the scale. In the above right corner, you have the rank (0 is for DC) and the value in amps for the harmonic identified with the arrow (? ). Press the ? or ? key to shift your selected harmonic of one order. If you want to move faster in the spectrum, you can use the ? or ? key. You will then shift of 15 orders. Press MENU and you come back to the Consulting level MENU. 10.8. Remote control and alarm contact 10.8.1. Remote control The PQFL may be switched on and off from a remote location. The remote switch has to be connected to connection points X12-3 and X12-4 of terminal marked X12. The remote/local switch of the master cubicle door has to be switched in remote position.

Note: once remote is on, the push buttons of the door are not operational anymore.




10.8.2. Alarm contact The PQFL is fitted with a normally open alarm contact (voltage free contact) allowing remote supervision of the unit. It is activated (open) if one of the following conditions is met:

? ? The filter is in error condition ? ? The filter is off ? ? The filter is working properly but not able to filter to the

pre-defined level (hardware limitation) When it is closed the filter is working properly and all filtering requirements are fulfilled. The exterior alarm has to be connected to connection points X12-1 and X12-2 of terminal X12. 10.9. Protections The PQFL is fitted with two types of protection: ? ? Slow protection ? ? Fast protection The role of the slow protection is to change on-line the way the filter is working according to the filter stress and programmed. This ensures that the filter is never overloaded and always has an optimal filtering effect. The fast protection is only activated in case of abnormal working conditions and ensures the integrity of the filter. The fast protection means include: ? ? Protection fuses. ? ? Blocking system of the IGBT bridge in case of:

? ? AC overvoltage on the mains ? ? DC overvoltage on the DC bus ? ? Filter over current ? ? IGBT over current ? ? IGBT over temperature If an error persists, the main breaker will also react.

? ? Short-circuit or overcurrent (peak & thermal) protection inside the IGBTs



11.Fault handling and troubleshooting 11.1. Fault handling 11.1.1. Type of faults Faults are classified into two basic families:

? ? Minor faults

? ? Critical faults Immediately after the fault occurrence, the error is cleared. If it has disappeared, the fault is said minor. In the other case, the fault is considered as critical. 11.1.2. Fault handling and fault clearance procedure After the occurrence of a fault, the IGBT’s are stopped and the filter determines the type of fault it is facing. If it is not critical, IGBT’s are restarted and the filter is back to normal operation. If the fault is critical, it is memorised and the filter conducts a fault clearance procedure. Fault handling procedure:

Normaloperation

Stop IGBT

Fault occurrence

Critical fault?

Memorise fault

Fault clearanceprocedure

Start IGBT

YN



The fault clearance procedure starts with the opening of the power circuit breaker. The system is reset and the filter conducts a modified start-up sequence as shown hereafter. Modified start-up sequence for fault clearance:

If within 30 seconds after the re-start of the IGBT’s no critical fault occurs, the initial fault is cleared and the filter comes back to normal operation. If a critical fault occurs during those 30 seconds, either it is a different fault than previously and a new fault clearance procedure is conducted or it is the same fault. If it is the same fault, a fault clearance procedure will be re-conducted until the same fault is detected 5 consecutive times. In this case, the power breaker is open, the filter definitively stopped and the error code is displayed on the PQF-Manager if installed. This procedure is shown in the next page.

Start fan for 10s

Preload DC bus

Close MC

Start IGBT




Sys

tem

res

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Sta

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pse

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Cri

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faul

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with

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Faul

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Dis

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11.2. Troubleshooting 11.2.1. Frequent problems occurring at commissioning stage Problems occurring at commissioning stage are mainly due to wrong CT connection or CT bridges not removed. Check carefully those connections in accordance with the commissioning procedure.

FAULT Possible causes Solutions No filtering nor reactive power compensation

- All CT’s are in correct phases but some are reversed

- Wrong phase rotation

- CT bridges not removed

- Check carefully CT wiring

- Remove CT bridges on CT secondary and PQFL terminal input

No dynamic reactive power compensation

All CT’s are in correct phases but all are reversed

- Modify CT connection accordingly, or

- Reversed CT’s may be corrected by software: a negative CT ratio has to be specified.

11.2.2. Error codes and messages After a filter trip, an error message is displayed on the PQF-Manager. At the same time, the corresponding error code is stored in the filter controller’s permanent memory. The error codes can be accessed by PQF-Prog users that have the appropriate password such as ABB service personnel. Below is explained how the error messages can be accessed with the PQF-Manager. If your filter is not fitted with this option, contact your ABB service provider for further support. In order to access the error code in the PQF-Manager, press MENU to access the “Main menu” window.

Select level 1 by using once the ? key.

Then press OK. Select the filter status submenu with the ? key and press OK.

MAIN MENU ? Level 1? Level 2 Level 3



Display the ? key to display the error message.

Error code

Error message Possible causes Actions

1 IGBT fault ? ? Too high IGBT temperature (thermal protection)

? ? Too high instantaneous current level (short-circuit protection)

? ? Supply voltage of IGBT drivers too low

? ? Visual inspection of IGBT bridge

? ? After checking bridge condition, push on the ‘RESET’ button of the door. If the red LED on the IGBT domino board remains on, contact immediately your ABB service provider

? ? Check correct rotation of fan, associated contactor (K101) and thermal relay.

2 Filter over-current

Too high output current of the filter (short-circuit protection)

? ? Inspect IGBT bridge ? ? Inspect ? 15V power

supply (U100) ? ? Inspect internal

current sensors (B101/102/103)

3 AC overvoltage Grid voltage rises to unacceptable levels

Measure AC RMS voltage for the three phases and check if it is within limits

4 DC overvoltage DC voltage on DC bus reaches unacceptable levels

? ? Check DC capacitors ? ? Inspect ? 15V power

supply (U100) ? ? Inspect internal

current sensor (B101/102/103)

? ? Inspect visually DC voltage divider and wiring

LEVEL 1 ? Filter status? Network status Waveform Spectrum



Error code


5 Connection fault

? ? Flat cable between the control rack and IGBT driver is disconnected or wrongly connected.

? ? Module number setting on board A112 does not correspond to the number of modules really present.

? ? The jumpers on the last domino board are missing or are on the wrong domino.

? ? Check flat cable connections

? ? Verify that only the domino board of the last power module is fitted with jumpers

? ? Check the number of modules set on the controller board A112

6 Power supply fault

One of the auxiliary power supplies is out of service.

? ? Check that no red LED is on the control rack (except LED 3 of A111). If yes, call your ABB service provider.

? ? Check fuses of power supplies

7 Control board fault

The microcontroller is not working properly.

Contact immediately your ABB service provider.

8 CAN bus fault The internal communication bus of the PQFA is not working properly.


16 DSP pgm corrupted

DSP program corrupted Contact immediately your ABB service provider.

32 Watchdog timeout

Software in unpredictable state.


96 Soft DC overvoltage

DC voltage on DC bus is out of normal range (overvoltage)

? ? Inspect ? 15V power supply (U100)

? ? Inspect internal current sensor (B101/102/103)

? ? Inspect visually DC voltage divider and wiring



Error code


97 Soft DC undervoltage

DC voltage on DC bus is out of range (undervoltage)

? ? Inspect DC voltage measurement circuit

? ? Inspect ? 15V power supply (U100)

? ? Inspect internal current sensor

98 Soft AC undervoltage

AC voltage is out of range (undervoltage)

? ? Check network voltages on three phases voltage

? ? Check AC measurement circuit

99 Soft synchro fault

The system desynchronises from the network

? ? Check phase rotation order of filter supply

? ? Check network frequency and variation to see one within acceptable limits

? ? Check voltage level of the supply system

112 Preload timeout

The preloading of the DC bus takes an abnormally long time.

Check preloading circuit system.

113 DSP stopped system

DSP decision to stop the system.


114 Main breaker trip

? ? Power breaker not closed after being energised

? ? Undervoltage on AC grid

? ? Check auxiliary contact of main breaker and associated circuit

? ? Check that grid AC voltage is high enough (within tolerance)

115 DSP bus fault The DSP has stopped communicating


116 EEPROM corrupted

Internal memory corrupted


117 PWM fault Internal timing problem Contact immediately your ABB service provider.



11.2.3. Faults not related to error codes ? ? Unstable filter. Check CT connection and the presence of plain capacitors. Bear in mind that harmonics below the resonance frequency of capacitor banks must be deselected (see chapter 10). ? ? Filter tripping during network characterization. In weak networks, it may happen that high harmonic orders could not be characterized. Those orders should be deselected. ? ? No display on PQF-Manager. Adjust the contrast of the PQF-Manager. Open the front door of the PQFA (main breaker open, auxiliary closed) and adjust the contrast screw located on the back metal plate of the PQF-Manager. ? ? No LED is on on boards A116, U100 or U109 (power supplies). Remove the board and check fuse(s) condition. Replace them if needed. 11.2.4. Restarting the filter after fault correction ? ? Press RESET button 2 times. ? ? Press RUN button. The filter will then start its start-up sequence and will attempt to work again.



12.Maintenance Although your PQFL has been designed for minimum maintenance, the following procedure should be carefully followed to insure the longest possible life to your investment. WARNING! All maintenance work described in this chapter should only be undertaken by a qualified electrician. The Safety Instructions section of this manual must be thoroughly followed. 12.1. Maintenance frequency Under normal working conditions and environment, maintenance every six months is recommended. In case of installation in a dirty or sandy environment, a more frequent maintenance programme should be implemented. 12.2. Maintenance procedure Step 1 Shut the filter down by pushing the ‘RESET’ button of the door

cubicle. Open the auxiliary circuit breaker. Wait at least 5 minutes for the discharge of DC capacitors. Step 2 Cleaning

All dust deposits have to be removed from all parts, especially the heatsink and fan. Indeed,the heatsink picks up dust from the cooling air and The PQFL might run into overtemperature faults if the heatsink is not cleaned regularly.

Step 3 Check breakers condition Step 4 Check tightness of all electrical connections Step 5 Check condition of discharge resistor on power modules



Step 6 Check ambient temperature and equipment ventilation operation.

Step 7 Restart the PQFL according to commissioning procedure. 12.3. Fan The cooling fan lifespan is about 5 years, depending on usage and ambient temperature. Fan failure is often preceeded 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. 12.4. Capacitors reforming If the filter has been non-operational for more than one year, DC capacitors must be reformed (re-aged) before use. Without reforming, capacitors may be damaged at start-up. Stocked or non-operational filters should be reformed once a year. The method indicated below assumes that the filter is stocked in a clean and dry environment. To reform the capacitors, switch the power on for about 2 hours, with all harmonics and reactive power deselected. If the filter has been left more than 2 years without operation, please contact your ABB service provider.

While all care has been taken to ensure that the information contained in this publication is correct, no responsibility can be accepted for any inaccuracy. The Company reserves the right to alter or modify the information contained herein at any time in the light of technical or other developments. Technical specifications are valid under normal operating conditions only. The Company does not accept any responsibility for any misuse of the product and cannot be held liable for indirect or consequential damages.

SIM.040.6029G01 ed. 5 01-10

Asea Brown Boveri Jumet S.A. Zoning Industriel de Jumet B-6040 Charleroi, Belgium Phone : +32 71 250 811 Fax : +32 71 344 007

instructions manual pqfl power quality filter

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