ABB PQFS Installation, Operation And Maintenance Instructions

Installation, operation and maintenance instructions

— Table of contents 1 Introduction to this manual .............................................................................................................. 6 1.1 What this chapter contains............................................................................................................................ 6 1.2 Intended audience ........................................................................................................................................... 6 1.3 Compatibility .................................................................................................................................................... 6 1.4 Contents ............................................................................................................................................................. 6 1.5 Related publications ........................................................................................................................................ 6 2 Safety Instructions ............................................................................................................................. 8 3 Upon Reception ................................................................................................................................ 10 3.1 What this chapter contains.......................................................................................................................... 10 3.2 Delivery inspection ........................................................................................................................................ 10 3.3 Unpacking instructions ................................................................................................................................ 10 3.4 Lifting and transportation guidelines ....................................................................................................... 10 3.5 Identification tag ........................................................................................................................................... 13 3.6 Storage ............................................................................................................................................................. 13 4 Hardware description ...................................................................................................................... 14 4.1 What this chapter contains.......................................................................................................................... 14 4.2 Typical PQFS filter panel layout .................................................................................................................. 14 4.3 The PQF current generator hardware ....................................................................................................... 16 4.4 The PQF main controller ............................................................................................................................... 17 4.5 The PQF-Manager user interface................................................................................................................ 18 4.6 Location of the main PQFS components ................................................................................................. 25 4.6.1 Active filter components ................................................................................................................... 25 4.6.2 Active filter door components and protective grid .................................................................... 29 5 Mechanical design and installation ................................................................................................ 30 5.1 What this chapter contains......................................................................................................................... 30 5.2 Installation location requirements ........................................................................................................... 30 5.3 Airflow and cooling requirements .............................................................................................................. 31 5.4 Standard cubicle dimensions, fixing holes and clearances ................................................................. 32 5.5 Instructions for mounting the filter .......................................................................................................... 33 5.6 Filter noise level ............................................................................................................................................. 34 5.7 Instructions for mounting the PQF-Manager in enclosures ................................................................ 35 6 Electrical design and installation ................................................................................................... 36 6.1 What this chapter contains..........................................................................................................................36 6.2 Instructions for connecting the PQF-Manager to a filter system ...................................................... 37 6.3 Checking the insulation of the assembly - earth resistance ................................................................ 37 6.4 EMC considerations.......................................................................................................................................38 6.5 Earthing guidelines ........................................................................................................................................38 6.6 Selection of the power cable size ...............................................................................................................39 6.7 Selection of the power cable protection/filter input protection scheme ........................................42 6.8 Connection of the PQFS to the network.................................................................................................. 44 6.8.1 Connection of the PQFS in 3-wire mode ...................................................................................... 45 6.8.2 Connection of the PQFS in 4-wire mode ....................................................................................... 47 6.9 Selection of the current transformers ..................................................................................................... 48 6.10 Current transformer installation ............................................................................................................... 50 6.10.1 Basic rules for correct CT installation ........................................................................................... 50 6.11 Electrical interconnection of PQFS enclosures ....................................................................................... 52 6.11.1 Mechanical interconnection of the enclosures ............................................................................ 53 6.11.2 Control board cable interconnection ............................................................................................. 53 6.11.3 CT cable interconnection ................................................................................................................. 54 6.11.4 Connection of the power stage to the supply .............................................................................55 6.12 Electrical connections to the PQF-Manager user interface ................................................................ 56

6.12.1 Cabling of remote control functionality ........................................................................................ 57 6.12.2 Cabling of alarm functionality ........................................................................................................ 59 6.12.2.1 Alarm outputs .................................................................................................................... 59 6.12.2.2 Digital outputs.................................................................................................................... 62 6.12.3 Cabling of warning functionality .................................................................................................... 64 6.12.4 Cabling of the digital output contacts to monitor other filter operation modes than warnings and alarms .................................................................................................................................... 65 6.12.5 Cabling of main/auxiliary control functionality ......................................................................... 66 6.12.6 Implementation of local start/stop buttons ............................................................................... 67 6.13 Electrical connections of filter options and accessories ......................................................................70 6.13.1 External communication with PQF .................................................................................................70 6.13.2 Connection of the Modbus adapter ............................................................................................... 71 7 The PQF-Manager user interface .....................................................................................................72 7.1 What this chapter contains.......................................................................................................................... 72 7.2 PQF-Manager user interface description ................................................................................................. 72 7.3 PQF-Manager overview and navigation .................................................................................................... 73 7.4 Icons and main screen .................................................................................................................................. 73 7.5 The PQF-Manager behavior during filter initialization ......................................................................... 80 7.6 The PQF-Manager locking facilities ........................................................................................................... 81 7.7 The PQF start, stop and fault acknowledgement menu ....................................................................... 82 7.8 The ‘Measurements’ menu .......................................................................................................................... 84 7.8.1 The ‘Overview’ menu ......................................................................................................................... 84 7.8.2 The ‘System values’ menu ................................................................................................................ 86 7.8.2.1 Voltages .............................................................................................................................. 86 7.8.2.2 Line currents ...................................................................................................................... 88 7.8.2.3 Filter currents .................................................................................................................... 89 7.8.2.4 Total filter currents........................................................................................................... 90 7.8.2.5 Powers .................................................................................................................................. 91 7.8.2.6 Temperatures ..................................................................................................................... 91 7.8.3 The ‘Min-Max logging’ menu ............................................................................................................ 92 7.9 The ‘Settings’ menu .......................................................................................................................................93 7.9.1 The ‘Customer settings’ menu ....................................................................................................... 94 7.9.1.1 Settings up harmonics, reactive power and filter mode ......................................... 95 7.9.1.2 Temp unit ........................................................................................................................... 101 7.9.1.3 Activate menu ................................................................................................................... 101 7.9.1.4 Setting up alarms, warnings and digital inputs and outputs (D I/O) ................. 102 7.9.2 The ‘Commissioning’ menu ........................................................................................................... 104 7.9.2.1 Setting up the network characteristics and the filter synchro mode ................ 105 7.9.2.2 Setting up the filter characteristics ........................................................................... 106 7.9.2.3 Setting up the current transformer ratios and position ....................................... 108 7.9.2.4 Setting up the filter rating parameter ........................................................................ 114 7.9.2.5 Setting up the user’s requirements ............................................................................. 115 7.9.2.6 Commissioning of temperature probes ..................................................................... 116 7.9.3 The ‘Installation settings’ menu .................................................................................................... 117 7.9.3.1 Setting up the ‘standby’ function ................................................................................ 118 7.9.3.2 Setting up the ‘auto restart’ function ......................................................................... 120

7.9.3.3 Setting up the system clock .......................................................................................... 120 7.9.3.4 Setting Password ............................................................................................................. 121 7.9.3.5 Installation Locking ......................................................................................................... 121 7.9.4 Set Language ..................................................................................................................................... 122 7.10 The ‘PQF monitoring’ menu ....................................................................................................................... 122 7.10.1 The ‘Status of module’ menu ......................................................................................................... 123 7.10.2 The ‘Filter load’ menu ....................................................................................................................... 123 7.10.3 The ‘Event logging’ menu ................................................................................................................ 124 7.10.4 The ‘Active warnings’ menu ............................................................................................................ 128 7.10.5 The ‘Number of errors’ menu ......................................................................................................... 128 7.10.6 The ‘PQF operation’ .......................................................................................................................... 129 7.11 The ‘User Interface menu ........................................................................................................................... 130 7.11.1 Manufacturer setting ....................................................................................................................... 130 7.11.2 About PQF .......................................................................................................................................... 130 7.11.3 Screen configuration ....................................................................................................................... 131 7.11.4 Communication ................................................................................................................................. 132 7.11.4.1 Modbus RTU ...................................................................................................................... 133 7.11.4.2 MAC address ..................................................................................................................... 135 7.11.4.3 Ethernet settings ............................................................................................................. 135 7.11.4.4 IP address .......................................................................................................................... 139 8 Commissioning instructions .......................................................................................................... 141 8.1 What this chapter contains........................................................................................................................ 141 8.2 Step 1: Visual and installation check ........................................................................................................ 142 8.3 Step 2: Setting the address of each unit in a multi-unit filter and terminate the CAN bus ........ 142 8.4 Step 3: Voltage rating check/adaptation and phase rotation check .............................................. 145 8.5 Step 4: Basic commissioning parameters set up (using PQF-Manager) ....................................... 146 8.6 Step 5: Automatic and manual CT detection procedure ................................................................... 148 8.6.1 Automatic CT detection procedure ............................................................................................. 148 8.6.2 Manual CT detection procedure ................................................................................................... 149 8.6.2.1 PQF connection diagram .............................................................................................. 149 8.6.2.2 Material needed and hypotheses for correct measurements .............................. 150 8.6.2.3 Checking the correct connection of the CTs with a two-channel scopemeter 150 8.6.2.4 Checking the correct connection of the CTs with a Fluke 41B or similar equipment .......................................................................................................................................... 154 8.7 Step 6: Before starting the filter .............................................................................................................. 154 8.8 Step 7: Start the filter .................................................................................................................................. 154 8.9 Step 8: Generate filter load ........................................................................................................................ 155 8.10 Step 9: Set up the user requirements...................................................................................................... 156 8.11 Commissioning report ................................................................................................................................ 159 8.11.1 Filter identification .......................................................................................................................... 160 8.11.2 Inspection on site – verification of the active filter after installation .................................. 161 8.11.3 Programming ..................................................................................................................................... 162 8.11.4 Testing (with load) ........................................................................................................................... 163 8.11.5 Programmed parameters .............................................................................................................. 164 8.11.6 Comments ..........................................................................................................................................166 9 Operating instructions ...................................................................................................................167 9.1 What this chapter contains........................................................................................................................ 167 9.2 Starting and stopping the filter ............................................................................................................... 167 9.2.1 Starting the filter with the PQF-Manager ...................................................................................168

9.2.2 Stopping the filter with the PQF-Manager ................................................................................. 170 9.3 Modifying the user requirements............................................................................................................. 172 9.4 Changing the system temperature unit and PQF-Manager backlighting ...................................... 173 9.5 Consulting filter measurements............................................................................................................... 173 9.6 Consulting filter statistics and manufacturer data ............................................................................. 173 9.7 Filter behavior on fault – retrieving error information ........................................................................ 174 10 Maintenance instructions ...............................................................................................................176 10.1 What this chapter contains........................................................................................................................ 176 10.2 Maintenance intervals ................................................................................................................................. 176 10.3 Standard maintenance procedure ........................................................................................................... 177 10.3.1 Step 1: Check the ambient temperature conditions ................................................................ 177 10.3.2 Step 2: Record the filter operating status .................................................................................. 177 10.3.3 Step 3: Shut the filter down ............................................................................................................ 177 10.3.4 Step 4: Inspect and clean the filter ............................................................................................... 178 10.3.5 Step 5: Check the condition of the filter contactors and fuses ............................................. 178 10.3.6 Step 6: Check the tightness of the electrical and mechanical connections ....................... 178 10.3.7 Step 7: Correct any abnormal conditions found ....................................................................... 178 10.3.8 Step 8: Restart the filter .................................................................................................................. 178 10.4 Fan replacement ........................................................................................................................................... 179 10.5 DC capacitor change .................................................................................................................................. 180 10.6 DC capacitor reforming ............................................................................................................................. 180 10.7 Output filter board change ........................................................................................................................ 181 10.8 Servicing report ............................................................................................................................................ 181 10.8.1 Filter identification ........................................................................................................................... 182 10.8.2 Standard maintenance procedure ................................................................................................ 183 10.8.3 Special service actions .................................................................................................................... 185 10.8.4 Comments .......................................................................................................................................... 185 11 Troubleshooting guide .................................................................................................................. 186 11.1 What this chapter contains........................................................................................................................186 11.2 Fault treatment procedure ........................................................................................................................186 11.3 Spare part list for normal and dedicated filter servicing ...................................................................189 11.4 Troubleshooting guide .............................................................................................................................. 190 11.4.1 Verification of the PQF-Manager status and the system LEDs ............................................ 190 11.4.2 Fault tracing ....................................................................................................................................... 191 12 Technical specifications ................................................................................................................ 210 12.1 What this chapter contains........................................................................................................................ 210 12.2 Technical specifications ............................................................................................................................. 210

— 1 Introduction to this manual 1.1 What this chapter contains This chapter gives basic information on this manual. 1.2 Intended audience This manual is intended for all people that are involved in integrating, installing, operating and/or maintaining the PQFS active filter range products. People involved in the integration, installation and maintenance of the equipment are expected to know the standard electrical wiring practices, electronic components and electrical schematic symbols. End users should focus on the Operating instructions (Cf. Chapter 9) and Maintenance instructions (Cf. Chapter 10) of this manual. 1.3 Compatibility The manual is compatible with all filters of PQF range with PQF-Manager software versions or higher. − V1 : V26 r3001 − V2 : V11 r23 − V3 : V2 r0 − V4 : V0.1 r8 This product is not backward compatible with any other PQFx (x: A, B, L, T, I, M, K, S) filter product. 1.4 Contents − Chapter 1: Introduction to this manual − Chapter 2: Safety instructions − Chapter 3: Upon reception − Chapter 4: Hardware description − Chapter 5: Mechanical design and installation − Chapter 6: Electrical design and installation − Chapter 7: The PQF-Manager user interface − Chapter 8: Commissioning instructions − Chapter 9: Operating instructions − Chapter 10: Maintenance instructions − Chapter 11: Troubleshooting guide − Chapter 12: Technical specifications 1.5 Related publications − Power Quality Filters PQFI-PQFM-PQFS Catalogue [English]

− Power Quality Filter, Active Filtering Guide [English] − PQ-Link Installation and user’s guide [English] − PQF Modbus CD [English] − ABB PQF Active Filters - Raising system reliability to unprecedented levels [English] − ABB quick start

— 2 Safety Instructions These safety instructions are intended for all work on the PQFS. Neglecting these instructions can cause physical injury and death. All electrical installation and maintenance work on the PQFS should be carried out by qualified electricians. Do not attempt to work on a powered PQFS After switching off the supply to the PQFS, always wait at least 25 minutes before working on the unit in order to allow the discharge of DC capacitors through the discharge resistors. Always verify by measurement that the capacitors have discharged. DC capacitors may be charged to more than 800 Vdc. 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 installations. Also make sure that all local safety regulations are fulfilled. DANGER: To ensure safe access, supplies to each individual enclosure must be isolated before entry / opening. WARNING: This equipment contains capacitors that are connected between phase and earth. A leakage current will flow during normal operation. Therefore, a good earth connection is essential and must be connected before applying power to the filter. WARNING: There are AC capacitors & DC capacitors connected inside this filter. Before performing any maintenance work, please short and ground the three line terminals. The DC capacitor needs 25 mins to discharge after disconnection. Please wait for this duration before touching any live parts even after discharging the AC capacitors to avoid electrical shock. WARNING: Never discharge DC capacitors through short circuit. Always use a current limiting resistor of minimum 100Ω. WARNING: To avoid electrical shock due to residual voltage on the capacitors, the left side cover of the filter should not be removed once the filter is commissioned. WARNING: If the ground is not done properly, under certain fault conditions in the unit or in the system to which it is connected it can result in full line voltage between chassis and earth ground. Severe injury or death can result if the chassis and earth are touched simultaneously.

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

— 3 Upon Reception 3.1 What this chapter contains This chapter gives basic information on how to inspect, transport, identify and store the PQFS active filter. 3.2 Delivery inspection Each PQFS is delivered in a box designed to protect adequately the equipment during shipment. Upon reception of the equipment, make sure that the packing is in good condition. Verify the state of the shock and tilting indicators (if mounted on the enclosure). After removal of the packing, check visually the exterior and interior of your filter for transportation damage. 3.3 Unpacking instructions Figure 1: PQFS packing material opened After removal of the top cover, check visually the exterior and interior of your filter for transportation damage. Your filter equipment comes with a package. Verify that all items are present, i.e.: − this manual − the electrical drawing − the rubber seal to cover a knock-out (to be used for multi-unit operation) − the communication cable needed for multi-unit operation − the two eyebolts Any loss or damage should be notified immediately to your ABB representative. 3.4 Lifting and transportation guidelines Please note that filter equipment weighs approximately 130 kilograms. Care should be taken to ensure that correct handling facilities are used.

In order to transport the equipment use a forklift or similar equipment. PQFS enclosures are best transported horizontally. Table 1: Maximum allowed ambient conditions during transportation Transportation (in the protected package) Temperature -25 to 70°C (-13 to 158°F) Relative humidity Max. 95% Contamination levels (IEC 60721-3-3) Chemical class 3C3(a) Mechanical class 3S3(b) Remarks: (a) Locations with normal levels of contaminants, experienced in urban areas with industrial activities scattered over the whole area, or with heavy traffic. Also applies to locations with immediate neighborhood of industrial sources with chemical emissions. (b) Locations without special precautions to minimize the presence of sand or dust. Also applies to locations in close proximity to sand or dust sources. In order to lift the equipment once it is at the installation location: − Remove the top cover of the protecting box (see Figure 1). − Remove the 4 panel securing screws at the bottom and the top of the enclosure (see Figure 2). Bottom side Top side Figure 2: Locating the 4 panel securing screws − Remove first the right side of the protective cover and put it aside (see Figure 3). Figure 3: Lifting the right protective cover and putting it aside

− Unplug the PQF-Manager from the main system (see Figure 4). Then the protective cover can be safely put aside. Figure 4: Unplugging the PQF-Manager from the main system − Remove the two screws fixing the filter unit to the wooden support (see Figure 5). Right side Bottom Figure 5: Position of the filter fixation screws that need to be removed − Fix the two eyebolts provided with the filter (see Figure 6). Figure 6: Fix the eyebolts before lifting the PQFS

− Fix an appropriate lifting device to the eyebolts to lift the filter from the wooden support. It can then be positioned at the desired location (see Figure 7). Figure 7: Lifting a PQFS unit by using the lifting lugs 3.5 Identification tag Each PQFS is fitted with nameplates for identification purposes. The filter nameplate is located at the top left of the master panel door, at the outside. The nameplate information should always remain readable to ensure proper identification during the whole life of the filter. The main filter nameplate includes the filter type, the nominal voltage range and frequency as well as a serial number and an ABB internal article code. 3.6 Storage If your PQFS is not installed once unpacked, it should be stored in a clean indoor, dry, dust free and non-corrosive environment. The storage temperature must be between - 25°C (-13°F) and 70°C (158°F) with a maximum relative humidity of 95%, non-condensing. Table 2: Maximum allowed ambient conditions for storage Storage (in the protected package) Temperature -25 to 70°C (-13 to 158°F) Relative humidity Max. 85% Contamination levels (IEC 60721-3- 3) Chemical class 3C3(a) Mechanical class 3S3(b) Remarks: (a) Locations with normal levels of contaminants, experienced in urban areas with industrial activities scattered over the whole area, or with heavy traffic. (b) Locations without special precautions to minimize the presence of sand or dust. Also applies to locations in close proximity to sand or dust sources.

— 4 Hardware description 4.1 What this chapter contains This chapter describes a typical PQFS-filter system and discusses its main components. 4.2 Typical PQFS filter panel layout The PQFS active filter is basically composed of two parts (Figure 8): − A filter controller that determines the anti-harmonic current to be injected based on the line current measurements and the user’s requirements. The line current measurements are obtained from current transformers (CTs) provided by the customer. The CTs must be connected upstream of the connection point of the filter and the loads. The user enters his requirements by means of the PQF- Manager user interface. This device also acts as the user’s connection point for the alarm/warning contacts, the remote control functionality, the other digital input functionality and the interface for external communication. − A current generator (power unit) that converts the control signals generated by the filter controller into the filter compensation current. The current generator is connected in parallel with the load(s). Up to eight power units may be connected in parallel in one filter unit. The enclosure(s) containing the/a filter GUI controller are referred to as master units. The other enclosures are referred to as the slave units. In an active filter system more than one master unit can be present. Compensation current Current measurements Non-linear load(s) - Three-phase - Single-phase Supply PQFS Filter panel PQF main controller PQF current generator 1 PQF Manager 1 2 3 5 4 6 Figure 8: PQFS schematic overview with user connections The user connection description is given in Table 3.

Table 3: User connections for PQFS Item User connections Connection requirement 1 CT connections Mandatory 2 Power cable connection to the supply (including neutral connection if 4-wire operation is desired) Mandatory 3 Programmable digital outputs (warnings…) Not mandatory 4 Remote control contact connection or/and local on/off buttons or/and main/auxiliary settings control Not mandatory 5 PQ-link (USB-Ethernet) – Modbus RTU – Modbus TCP communication connection Not mandatory 6 Earth connections from the enclosure to installation earth Mandatory Mandatory connections are connections that must be present to make the filter operational. Connections that are not mandatory can be made to enhance the filter’s basic functionality. For more information on cabling the user connections, please refer to Chapter 6. Figure 9 shows a typical PQFS master filter panel. 1 2 4 5 3 Figure 9: Example of a typical PQFS master filter panel The input/output connections and protection description is given in Table 4. Table 4: Input/Output connections Item Input/output connections 1 CT connection terminals 2 Main power connection 3 Auxiliary fuse protection 4 PQF-Manager user interface with connection terminals for user I/O (e.g. alarm contact) and communication interfaces. 5 Neutral connection

Up to 8 PQFS master panels can be connected in parallel providing full redundancy to the customer. In addition to using master panels only, PQFS units can be connected in a master-slave arrangement. 4.3 The PQF current generator hardware The power circuit of a PQFS unit is represented hereafter. N Preload resistor Output filter IGBT Inverter Master Unit N AC power supply L L 1 2 3 4 5 6 7 8 Figure 10: Power circuit diagram of a PQFS active filter The description of the main components is given in Table 5. Table 5: Main components of a PQFS active filter Item Main components 1 IGBT inverter 2 DC bus capacitors 3 PWM reactor 4 Output filter 5 Preload resistor 6 Main contactor 7 Auxiliary fuses 8 Neutral cable connection (not mandatory)

The current generator is physically organized in power units. Each filter enclosure contains one power unit. A PQFS filter can contain up to 4 power units. Power units can be combined in a master-slave arrangement or in a master-master arrangement, the latter giving full operational redundancy. The current rating of different units in a filter must be the same. Please refer to Chapter 12 for more information on the possible unit ratings. In Figure 10 it may be seen that each current generator consists of an IGBT-inverter bridge (1) that is controlled using PWM-switching technology. Information from the filter controller is sent to the IGBTs through one flat cable. At the output of the inverter a voltage waveform is generated which contains the desired spectral components (imposed by the filter controller) as well as high frequency noise (due to the IGBT switching technology). Coupling impedance consisting of a reactor (3) and a high frequency rejection filter (4) ensures that the useful voltage components are converted into a useful current while the high frequency noise is absorbed. The IGBT-inverter is equipped with DC capacitors that act as energy storage reservoirs (2). In active filters containing more than one power unit the control information between different units passes through a CAN control cable. If a master-master configuration of filter is chosen, all power units incorporate a PQF- Manager display. If a master-slave configuration of filter is chosen, only the master enclosure contains a PQF-Manager display. All units contain a DC capacitors preloading resistor (5) which charges the DC capacitors of the filter unit once the auxiliary fuse box of the unit(s) is closed. This approach ensures a smooth filter start-up without excessive inrush currents. 4.4 The PQF main controller The PQF main controller controls the complete active filter system. Its tasks include: − Accepting and executing customer requests to stop and start the equipment. − Calculating and generating IGBT-inverter control references based on the line current measurements and the user requirements. − Interface to the IGBT-inverters. − Measurement of system voltages and currents for control, protection and presentation purposes. Figure 11 depicts the controller interface diagram of the PQFS active filter.

PQF Manager PQF Power Stage CAN Bus Direct Interface Modbus & PQ-Link interface Programmable Digital I/O 3∼ AC Out First unit Second unit User interface CT signals(a) PQF main controller CAN bus (1) PQF Power Stage 3∼ AC Out PQF main controller PQF Manager (b) (a) CT signals to different units (master or slave) must be routed through daisy chain principle with return path. (b) If second unit is a slave unit, it will not have a PQF-Manager. If second unit is a master unit, it will CT’s Figure 11: Controller interface diagram of the PQFS active filter When the filter consists of a master unit only, the customer has to: − Wire the CT signals (on a designated terminal), − Connect the AC power lines (with or without neutral), − Set up the installation parameters and user’s requirements with the PQF- Manager. He may also want to wire the communication interface (Modbus or Ethernet) and the programmable digital I/O (e.g. alarm contact, remote control). When a second unit is added, it is connected to the first enclosure by means of a CAN bus communication link (1). In addition, the CT measurements have to be supplied to each unit, i.e. through a daisy chain link with return path. All units have their own AC-connection and main contactor protection. A PQFS active filter system consists of up to 8 units of equal rating. Additional units to the first master unit may be master or slave units. Slave units do not have a PQF- Manager. 4.5 The PQF-Manager user interface All user interaction with the filter is channeled through the PQF-Manager. In multi-unit filters consisting of only one master, only the master has a PQF-Manager. In multi-unit filters consisting of more than one master, all the master units have a PQF- Manager. However, only the PQF-Manager that is connected to the master unit which

has the overall control will be active. The PQF-Manager installed on the unit’s operating as "slaves" are capable of displaying the relevant information about that specific unit only. Certain parameters which are specific to that unit (e.g. related to temperature probes) can be set or changed locally using the PQF-Manager installed on that unit. The PQF-Manager on the master unit has a "unit selection" button which allows the user to select the unit number which he wants to consult. The data then displayed on the master PQF-Manager is specific to that particular unit number. This unit selection button is "deactivated" on the slave Managers. Figure 12 shows the front side of the PQF- Manager. Figure 12: Front side of the PQF-Manager Five main parts can be distinguished (see Table 6) Table 6: Front side of the PQF-Manager Item Description 1 Menu display By navigating through the menus with the , , and buttons, the filter can be set-up and controlled. On-line help is available by pressing the button. 2 Master/slaves units monitor 3 Locking status / Alarm and fan contact indicator / Digital output contact indicator When the PQF-Manager closes one of its output relays, the corresponding symbol lights up. The digital outputs of the PQF-Manager are discussed later in this section. 4 Filter selection 5 Start stop acknowledgment fault

The PQF-Manager also acts as connection point for external user I/O communication. Connections are made at the rear side of the PQF-Manager. Figure 13 depicts the terminals that are present on the PQF-Manager rear side. 1 2 3 4 5 6 7 8 9 10 Figure 13: PQF-Manager rear side terminal designation The terminal designation is given in Table 7. Table 7: Terminal designation Item Customer terminals 1 Digital input 1 and 2 2 Digital outputs 1 to 6 with one common point 3 Alarm outputs (2 outputs with complementary signals) and fan outputs 4 Lock switch 5 Modbus adapter interface (optional) connection 6 CAN bus connection interface (routed to PQF-Manager connector) 7 Power supply terminals (routed to PQF-Manager connector) 8 Ethernet 9 USB 10 Temperature probes The terminal explanation is given next: 1 Digital input 1 and 2 The digital inputs can be used for three different functions: − Implementation of remote control functionality; − Implementation of local on/off buttons (not provided);

− Selection of main filter settings or auxiliary filter settings (e.g. different filter settings for the day and for the night) The PQF-Manager is used to associate the required functionality with the chosen digital input. The digital inputs can also be disabled. WARNING: If a function is assigned to a digital input, the same function must never be assigned to the other digital input. Otherwise the filter may behave erratically. The external voltage source needed to drive the digital inputs has to comply with the following characteristics: − Vlow: 0 Vdc − Vhigh: 15-24 Vdc − Driving current: 13 mA @ 24 Vdc (Rint = 1.88 kΩ) The digital inputs have free of potential contacts (opto-isolated). When implementing any of the functions described above, please note that according to the setup done with the PQF-Manager for the input considered, the filter may behave differently. Table 8 below gives an overview of the possible settings and the resulting filter behavior. Table 8: Overview of possible digital input settings and resulting filter behavior Function Vlow applied to digital input Vhigh applied to digital input Remote control PQF-Manager setup for digital input: Remote ON(a) Filter off Filter on Selection of main/auxiliary settings PQF-Manager setup for digital input: Activ. Main(a) Auxiliary settings are used Main settings are used Selection of main/auxiliary settings PQF-Manager setup for digital input: Activ. Aux.(a) Main settings are used Auxiliary settings are used Local ON/OFF buttons PQF-Manager setup for digital input: Edge ON(a) (b) No effect Filter starts on rising edge Local ON/OFF buttons PQF-Manager setup for digital input: Edge OFF(a) (b) No effect Filter stops on rising edge

Local ON/OFF buttons PQF-Manager setup for digital input: Edg ON/OFF(a) (c) No effect Filter starts on first rising edge, stops on second rising edge etc. Remarks: (a): In order for this function to be activated, the PQF-Manager has to be set up accordingly. To do this, navigate to [/Welcome/Settings/Customer set./Digital Inputs] (b): When using the Edge ON function the filter can only be switched on by applying voltage to the digital input considered. It is therefore recommended in that case to configure and cable the second digital input as Edge OFF. (c): When using this function, the filter stop and start can be controlled by one digital input leaving the other one available for an additional remote control or switching between main and auxiliary settings. Information on cabling the digital input contacts is given in Section 6.12. Information on setting up the digital inputs with the PQF-Manager is given in Section 7.9.1.4. By default, the digital inputs are disabled. In a master-master filter arrangement, only the master that has the control over the complete system will monitor its digital outputs. For full redundant functionality, it is recommended to cable the digital inputs of all the units in the filter system. 2 Digital Outputs 1 to 6 With each digital output different filter conditions can be associated. The association between the filter condition and the digital outputs is done with the PQF-Manager. Table 9 gives an overview of the possible PQF-Manager settings for a digital output and the effect on the corresponding digital output relay. Table 9: Filter conditions that can be related to the digital outputs PQF-Manager setting for digital output(a) Output relay closes when… Auxil. ON The auxiliary power is present in the main filter enclosure and the main controller is communicating with the PQF-Manager PQF running The active filter is ‘on’ (IGBTs switching) or in ‘standby’ (main contactor closed but IGBTs not switching) Full load The active filter is running under full load condition Armed The filter is ON or is in the startup procedure, or it is stopped in fault condition but will restart as soon as the fault has disappeared T limit The filter temperature limit has been reached and the filter is derating itself to run at a safe temperature In standby The filter is in standby(b) Activ. Main The main active filter settings are activated

Activ. Aux The auxiliary active filter settings are activated Unit miss. One of the filter units in a multi-unit arrangement is not available (e.g. due to a permanent error), or has not yet been commissioned. Pg. alarm 1 The programmable alarm 1 is activated(c) Pg. alarm 2 The programmable alarm 2 is activated(c) Pg. alarm 3 The programmable alarm 3 is activated(c) Warning 1 The programmable warning 1 is activated(c) Warning 2 The programmable warning 2 is activated(c) Warning 3 The programmable warning 3 is activated(c) Remarks: (a): In order to set up this function, navigate to [/Welcome/Settings/Customer set./Digital Outputs] (b): More information on the standby function is given in Section 7.9.3.1 (c): Different programmable warnings and alarms can be defined. More information on this subject is given in Section 7.9.1.4.1 Further it should be noted that: − Whenever a digital output is activated the corresponding icon on the PQF- Manager display will change. − In a master-master filter arrangement, only the master that has the control over the complete system will activate its digital outputs. For full redundant functionality, it is recommended to monitor the digital outputs of all the units in the filter system. − The default set-up for the digital contacts is given in Table 10. Table 10: Default set-up for the digital output contacts Digital output number Default function 1 Auxil. ON 2 PQF running 3 Full Load 4 Armed 5 Unit miss. 6 T Limit − The customer can change the default output settings by means of the PQF- Manager. − The digital outputs contacts have a common point and are of the NO-type (normal open). The contact ratings are: • Maximum continuous ac rating: 440 Vac/1.5 A; • Maximum continuous dc rating: 110 Vdc/0.3 A; • The common is rated at 9A/terminal, giving a total of 18 A.

Information on cabling the digital output contacts is given in Section 6.12. Information on setting up the digital outputs with the PQF-Manager is given in Section 7.9.1.4 3 Alarm outputs and fan outputs Apart from the digital outputs, one potential free relay with a NO and a NC alarm output is available. This relay contact is activated if any error condition is present during a preset time. The relay contact is deactivated if the error condition has disappeared for another preset time. Information on changing the alarm activation/deactivation time is given in Section 7.9.1.4.1. In a master-master filter arrangement, only the master that has the control over the complete system will activate its alarm contact. For full redundant functionality, it is recommended to monitor the alarm contacts of all the units in the filter system. The maximum continuous alarm contact ratings are: 250 Vac/1.5 A. A fan relay can be activated if a temperature probe detects an overtemperature. 4 Lock switch Allows locking the settings of the filter panel. This switch is documented in Section 7.9.3.5. 5 Modbus RTU adapter interface (optional) connection The Modbus adapter interface is connected at this location. The output of the interface is an RS-485 socket. The interface is described in the Modbus RTU interface manual. 6 CAN bus connection interface The PQF-Manager communicates with the main controller through a CAN bus. This bus consists of three terminals, i.e.: − Pin H: CAN High signal − Pin L: CAN Low signal − Pin Shield: shielding The CAN bus wiring terminates into the PQF-Manager connection plug and is subsequently routed to the main control (Cf. Section 4.6.1). It is used for PQF internal communications only. 7 Power supply terminals The PQF-Manager power supply is provided by the filter itself. The corresponding terminals on the PQF-Manager labeled “Power supply” are connected to the PQF- Manager connection plug.

8 The PQF-Manager communicates with Modbus TCP and PQ-link thanks to the Ethernet connection. For background information on the Modbus RTU and TCP communication interface refer to the dedicated Modbus manual. For background information on the PQ-link communication interface refer to the dedicated PQ-link manual. 9 The PQF-Manager can communicate with PQ-link (PC software) also through USB. . For background information on the PQ-link communication interface refer to the dedicated PQ-link manual. 10 External temperature probes can be added. The PQF-manager can handle until 8 temperature probes connected in a daisy chain way. Please refer to the Temperature probe User’s guide for more information. For information on how to cable external systems (e.g. remote control, Modbus interface) to the PQF-Manager, refer to Chapter 6. For information on how to use the PQF-Manager, refer to Chapter 7. For background information on the Modbus RTU and TCP communication interface refer to the dedicated Modbus manual. For background information on the PQ-link communication interface refer to the dedicated PQ-link manual. 4.6 Location of the main PQFS components 4.6.1 Active filter components Figure 14 shows a picture of the PQFS without cover panel. 2 3 4 5 6 7 8 1 11 13 14 10 9 15 12 16 Figure 14: PQFS main components The component identification is given in Table 11. Table 11: PQFS main components description Item Description Circuit diagram designation 1 Main contactor (MC) (underneath controller boards) K01 2 Fuse holder auxiliaries circuit Q02

3 DC voltage power supply 24V U002 4 CT connection terminal X21 5 Preload circuit resistors R1, R2 6 Main earth connection point - 7 IGBT inverter with DC capacitors U01 8 PQF main controller board A005 9 IGBT heat extraction fans M1, M2 10 PCB EMC neutral A003 11 PCB EMC line A002 12 PCB output filter preload A001 13 Main power supply terminals (phases) (underneath controller boards) L1, L2, L3 14 Main power supply neutral connection (not mandatory) (underneath controller boards) N 15 Auxiliary transformer T001 16 Fuse preload circuit PF1, PF2 The PQFS filters are provided with the preload circuit and the output filter mounted on a PCB. This design substantially reduces the time needed for replacement of the same. It also gives a more robust design compared to the previous generation of filters. The power supply to the exhaust fan at the top of the filter are connected to the terminal block shown which make the replacement of the same easy during periodic maintenance. The fuse on the PCB is of very special characteristics and must be replaced only with the same type. Please refer to our recommended list of spare parts. The preload circuit is shown in Figure 15. 2 3 4 1 5 6 Figure 15 Preload circuit main components

The component identification is given in Table 12. Table 12: Preload circuit main components description Item Description Circuit diagram designation 1 Fuse preload circuit PF1 2 Fuse preload circuit PF2 3 Preload circuit resistors R1 4 Preload circuit resistors R2 5 Capacitors 6 Terminal block for top fans P3 The PQF Main controller board has connectors which are predominantly pre-wired for use within the filter. However, it also contains a DIP-switch used to set the identification address and CAN bus connectors for use in a multi-module filter arrangements. The main controller board is shown in Figure 16. 10 2 6 7 8 9 15 3 12 11 4 13 14 5 16 17 18 21 22 19 20 1 Figure 16: PQF main controller board The designation of the principal terminals is given in Table 13.

Table 13: PQF main controller board description Item Description Circuit diagram designation 1 System connector: 24 V power supply to control board P2 2 CAN bus connection from previous filter unit P20 3 CAN bus connection to next filter unit P21 4 System connector: Power supply and CAN communication to PQF Manager P4 5 System connector: 230 V power supply to control board P3 6 System connector P19 7 System connector: Main contactor control P18 8 System connector P17 9 System connector P16 10 System connector P25 11 System connector P7 12 System connector: Coming from CT terminal X21 (internal) P5 13 System connector: Supply and DC link voltage measurement P6 14- 15-16 System connectors P9, P10, P11 17 System connector: control of IGBT-module P12 18 Voltage selector DIP-switch 19 System LED’s (top to bottom with ABB Logo at top left side) LED 3: ON: Critical error in filter unit considered (red LED) LED 3: OFF: No critical error in filter unit considered LED 2: ON: PQF unit running or in startup process (Armed) LED 2: OFF: PQF unit off and not in startup process LED 1: Blinking at regular interval (1 s): Microcontroller running properly LED 1: ON, OFF or blinking irregularly: Microcontroller not running properly 20 System LED’s (top to bottom with ABB Logo at top left side) LED 5: ON: Filter unit is acting as the master of the complete system LED 5: OFF: Filter unit is acting as a slave in the filter system LED 4: Blinking at regular interval (1 s): DSP processor running properly LED 4: ON, OFF or blinking irregularly: DSP processor not running properly 21 PQ-Link communication opto-isolated serial link connector 22 Filter unit address selector (3 Left most DIP switches with ABB Logo at top left side) and CAN bus termination (Right hand DIP switch): Symbols used: L: low – H: high Address 1: Position of the 3 switches starting from left: L L L Address 2: Position of the 3 switches starting from left: H L L Address 3: Position of the 3 switches starting from left: L H L Address 4: Position of the 3 switches starting from left: H H L Address 5: Position of the 3 switches starting from left: L L H Address 6: Position of the 3 switches starting from left: H L H Address 7: Position of the 3 switches starting from left: L H H Address 8: Position of the 3 switches starting from left: H H H Note: In a multi-master arrangement, the master which is operational and which has the lowest address controls the system. The default address setting is L L L CAN bus termination (Right hand DIP switch):

Must be High (H) for the units that are at the extremity of the CAN bus (maximum 2 units in a multi-unit filters, typically the first one and the last one of the chain). This setting is also applicable to single-unit filters. Must be Low (L) for units in the middle of a chain. The default factory setting is H. Remark: (a) For physical locations of customer CT connection terminals, please refer to Figure 14, item 4. 4.6.2 Active filter door components and protective grid The active filter master panel door contains the PQF-Manager and a protective grid connected to the filter frame. At the bottom of the protective grid a cooling fan is mounted.

— 5 Mechanical design and installation 5.1 What this chapter contains This chapter gives the information required for the mechanical design and installation of the filter system. In case you have a problem, please notify it to our service support mail box: [email protected]. 5.2 Installation location requirements The PQFS is suitable for indoor wall-mount installation, in a well-ventilated area without dust and excessive aggressive gases where the ambient operating conditions do not exceed the following values: Table 14: Ambient operating conditions for PQFS operation Altitude Nominal output at 0 to 1000m (3300ft) above sea level (a) Minimum temperature -10°C (23°F), non-condensing Maximum temperature 40°C (104°F) (b) Maximum average temperature (over 24 h) 35°C (95°F) Relative humidity Max. 95% non-condensing Contamination levels (IEC 60721-3-3) Chemical class 3C2 (c) Mechanical class 3S2 (d) Remarks: (a) At sites over 1000m (3300ft) above sea level, the maximum output current must be derated by 1% every additional 100m (330ft). The derating factor must be entered at commissioning. (b) Above 40°C (104°F), the maximum output current must be derated by 2% every additional 1°C (1.8°F) up to 50°C (122°F) maximum limit. The derating factor must be entered at commissioning. (c) Locations with normal levels of contaminants, experienced in urban areas with industrial activities scattered over the whole area, or with heavy traffic. (d) Locations without special precautions to minimize the presence of sand or dust, but not situated in proximity to sand or dust sources. The filter installation must be indoor and it should be taken into account that the standard protection class is IP30. WARNING: Conductive dust may cause damage to this equipment. Ensure that the filter is installed in a room where no conductive dust is present.

5.3 Airflow and cooling requirements The PQFS dissipates an amount of heat that has to be evacuated out of the room where the filter is located. Otherwise, excessive temperature rise may be experienced. Please note that life of the electrical equipment decreases drastically if the operating temperature exceeds the allowable limit (divided by 2 every 10°C/23°F). Each PQFS power unit has its own cooling fans. The air intakes are located at the bottom of the unit. From the bottom, the air flows through the enclosure and is then routed to the top of the enclosure. For proper cooling, a minimum airflow of cooling air has to be supplied to each unit. Table 15 gives the airflow requirements for different unit ratings. Table 15: Airflow requirement Unit rating Airflow requirement (m³/h) 30A - 60A 520 m³/h 70A - 100A 520 m³/h 120A 710m³/h Please ensure that the air used for cooling is regularly renewed and does not contain conductive particles, significant amounts of dust, or corrosive or otherwise harmful gases. The cooling air intake temperature must not exceed 40°C under any operating condition. The hot exhaust air also has to be properly ducted away. Figure 17 shows the cooling air flow diagram for a single unit PQFS. Bottom view Top view Figure 17: Cooling air flow for a single unit PQFS When the natural cooling capacity at the location where the filter is installed is not sufficient, air conditioning systems have to be installed to the room. In the design of the air conditioning systems, the filter heat losses have to be taken into account. Table 16 gives an overview of the PQFS heat losses for the different power units. For multi-unit filters, the values of Table 16 have to be multiplied by the number of filter units.

Table 16: Filter unit heat losses (maximum values) Unit rating (Arms) Heat loss (kW) 30 1.5 45 1.8 60 2.1 70 2.6 80 2.9 90 3.2 100 3.5 120 4.3 5.4 Standard cubicle dimensions, fixing holes and clearances Standard PQFS enclosures have dimensions of 588 x 326 x 795 mm (width x depth x height). Each enclosure contains one power unit and is fitted with its own main contactor. Power cables with protecting fuses can be connected to each PQFS from the bottom. A spacing of 30 mm between the filter sides and walls or other enclosures is recommended. However the filter can rest on its back against a wall. A spacing of 500 mm below the filter bottom and above the filter top is recommended. Figure 18 shows a view of a typical PQFS with characteristic dimensions.

Figure 18: View of a typical PQFS with characteristic dimensions If a filter system consists of more than one filter unit, the units should be installed next to each other. If it is not otherwise possible, additional units can be mounted above the existing unit(s). However, care has to be taken that the hot air of the bottom unit cannot be sucked in by the fans of the unit mounted above. An example of such an arrangement is given in Figure 19. Figure 19: Example of an installation where PQFS units are mounted above each other 5.5 Instructions for mounting the filter The wall on which the filter unit is mounted must be able to support the weight of the filter, which is about 130 kilograms. Please note that one enclosure contains always one unit. In order to mount a filter unit on to the wall, follow the steps outlined below: − Unpack the filter as per Section 3.3 − Set the 2 eyebolts on the top of the filter cubicle. They will be used to lift the filter properly. − Pull out the 2 fixation plates (Figure 20) Figure 20: Top view of the PQFS filter with the fixation plates − 2 bolts M8 are needed to install the filter on the wall (Figure 21). Use a spirit level to ensure horizontal fixation.

Figure 21: Eyebolts and fixation of PQFS − Carefully lift the enclosure and slide it down over the 2 fixation bolts until it is supported by the 2 fixation plates. Screw the 2 bolts to ensure a good fixation of the filter. Then the lifting tool can be disengaged. − By means of a lower end fixation screw (not provided) the enclosure can be pushed against the rear support at the bottom also (see Figure 22). Figure 22: Lower end fixation For additional units, the same procedure has to be followed. 5.6 Filter noise level Active filters produce a certain level of noise when they operate. The noise level depends on the operating conditions of the unit and on the rating of the filter. These values should be taken into account when choosing a location for the filter. Table 17: Noise level Unit rating Noise (dBA) at one meter 30A - 60A 65.3 typically 70A - 100A 68.4 typically 120A 70.9 typically

5.7 Instructions for mounting the PQF-Manager in enclosures The PQF-Manager user interface is mounted on to the front panel. In case it needs to be relocated to another enclosure, follow the guidelines presented next (Figure 23) Step 2 Step 1 (a) (b) Step 3 Step 4 (c) (e) Step 5 Repeat steps 3 to 5 for the bottom Mounting Bracket. (d) Figure 23: Mechanical installation of the PQF-Manager Step 1: Slide the PQF-Manager (a) perpendicularly to the Capacitor Bank Cubicle (b). Step 2: Rotate the PQF-Manager to insert it into the Capacitor Bank Cubicle. Note: cut out dimensions are 138 x 138 mm. Step 3: Insert the Mounting Bracket (c) in the corresponding Fixation Holes (d) of the PQF-Manager. Step 4: Pull the Mounting Bracket backwards. Step 5: Turn the Screw (e) into the Mounting Bracket and tighten until the PQF-Manager is secured in place. Once the PQF-Manager has been installed, it has to be connected electrically (Cf. Section 6.2).

— 6 Electrical design and installation 6.1 What this chapter contains This chapter gives the data required for integrating the PQFS active filter successfully in an electrical installation. It also gives electrical connection examples for popular filter options. WARNING: The PQFS is able to operate on networks in a voltage range 208-240 V and 380-415 V with a tolerance range of +/- 10 % (inclusive of harmonics but not transients). Since operation at the upper limits of voltage and temperature may reduce its life expectancy, the PQFS should not be connected to systems for which it is known that over voltages will be sustained indefinitely. Excessive voltage levels may lead to filter damage. WARNING: The PQFS is not designed to be connected to systems where one phase serves as neutral. Connection of a PQFS to such a system is only authorized after explicit approval by ABB. The active filter must be connected to the network in parallel with the loads. WARNING: The PQFS does not incorporate protective power line fuses or main contactor. Hence the customer has to ensure that the feeding cables to each filter panel are adequately protected taking into account the filter rating and the cable section used. More information on this topic is presented in Section 6.7. Basic filter functionality can be obtained after connection of: − Ground (PE) (per cubicle). − Four power cables including neutral. The neutral connection is not mandatory for filtering three phase loads. The power lines must be protected by appropriately sized fuses or a contactor. − 3 CTs (one per phase, to be connected to each filter unit in a filter system through a daisy chain method with return path). More advanced filter features (e.g. external monitoring of the filter status) require some more connections. The connections for these advanced features have to be made on the PQF-Manager. WARNING: Ensure that the filter supply is isolated upstream during filter installation. If the system has been connected to the supply before, wait for 25 mins after

disconnecting the mains power in order to discharge the capacitors. Always verify by measurement that the capacitors have discharged. DC capacitors may be charged to more than 800 Vdc. The DC capacitors of PQFS units are automatically charged once the auxiliary circuit is energized, regardless of whether the filter is switched off or not. Do not touch the DC capacitor link when the auxiliary fuse box is closed. The active filter control board carries dangerous voltages and shall not be touched once the the auxiliary circuit is energized, regardless of whether the filter is switched off or on. Once the auxiliary circuit is opened, high voltage levels can still be present on the control board. Respect a delay of 25 minutes after disconnecting the mains power before touching the control board. 6.2 Instructions for connecting the PQF-Manager to a filter system PQFS filter master units are by default equipped with the PQF-Manager user interface. In some cases however it may be needed to remove and reconnect the PQF-Manager to the filter. In order to successfully connect the PQF-Manager to a PQFS filter unit, it suffices to plug the male connector attached to the PQF-Manager into the corresponding female connector attached to the filter hardware. This is illustrated in Figure 24. Figure 24: Connection of the PQF-Manager user interface to the PQFS filter hardware The female connector associated with the filter hardware is situated at the top right side of the control board and becomes visible after removing/lifting slightly the filter protective cover. Note that the connector incorporates the following signals: − The 230 V power supply connection − The internal CAN bus connection 6.3 Checking the insulation of the assembly - earth resistance WARNING: Follow the procedure outlined below to check the insulation of the filter assembly. Applying other methods may damage the filter.

Every filter has been tested for insulation between the main circuit and the chassis/frame at the factory. Therefore, do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on the inverter units. Check the insulation of the assembly by measuring the insulation resistance of the filter between the Protective Earth (PE) and all 3 phases shorted together, with main contactor shorted. The auxiliary fuse box may remain closed, but it is mandatory to disconnect P2 (24V supply), P3 (230Vac in), P4 (PQF-Manager if master), P12 (IGBT) and P20-P21 (to other units) from the main control board (see Table 13). WARNING: Making the test without disconnecting the abovementioned connectors may damage the filter. Use a measuring voltage of 500 Vdc. The insulation resistance must be higher than 500 kΩ per enclosure. 6.4 EMC considerations The CE version of active filter complies in its standard version with the following EMC guidelines: − EN/IEC 61000-6-2: Immunity standard for industrial environments, Industrial level. − EN/IEC 61000-6-4: Emission standard for industrial environments, Class A. 6.5 Earthing guidelines Each PQFS plate has one marked earth points (PE). The earth point is situated at the bottom right side of the filter plate (Figure 25). Earth point (PE) Figure 25: Identification of the earth point on the PQFS hardware For safety reasons and for proper operation of the filter the earth point of each enclosure must be connected to the installation’s earth (PE). A copper (Cu) cable of minimum size 16 mm² is recommended but local regulations should also be taken into account. Remark: in PEN systems, the earth connection of the filter must be connected to the installation’s earth (PE) and not to the N-conductor. Further, the following rules should be respected: − When the PQFS consists of only one enclosure, the enclosure’s PE-point must be connected directly to the installation’s PE-point.

− When the PQFs consists of more than one enclosure, each enclosure’s PE-points must be connected directly to the installation’s PE-point. 6.6 Selection of the power cable size Several types of power cable can be used to connect the filter to the network. Local regulations and habits often determine the user’s choice. Note however that due to the high frequency output filter of the PQF, there is no radiated emission through the feeding cables. The following steps have to be followed to determine the section of the power cables feeding the filter: 1. Determine the RMS current rating of the enclosure for which the cable has to be rated (Irms). The rating is marked on the enclosure label. Each enclosure has to be individually connected to the supply and bottom cable entry has to be used. If required an optional cable connection box can be added to allow for multi-cable termination. The minimum cable section to be used for the power conductors is 16 mm². The RMS current for which the cable has to be rated equals the current rating of the unit to be connected to the supply. Note that the neutral connection has to be able to carry three times the unit current rating. 2. Determine the factor X and the cable section required taking into account the skin effect. The multiplication factor X is a factor that takes into account that the current that will flow through the filter connection cables is predominantly a harmonic current, i.e. a current of which the frequency of the most important components is higher than the network base frequency. Due to the frequency being higher than the network base frequency a physical phenomenon called ‘skin effect’ comes into play. This effect implies that for higher frequencies the current will not flow through the complete cross section of the cable but will have the tendency to flow at the cable surface. The result is that although one may use a cable of A mm², the section through which the current flows is only X*A mm² (with X < 1). In order to compensate for this “loss of section”, the cable has to be oversized such that the total equivalent section through which the current flows taking into account the skin effect is acceptable. The multiplication factor X to be used depends on the cable material (e.g. copper [Cu], aluminum [Al]) and on the base frequency of the network on which the filter will be installed. For a given installation its value can be determined using the following process: Step 1: Determine in a conventional way (e.g. using cable manufacturer’s tables) the cable section A (mm²) for the RMS current Irms obtained in 1 above. Step 2: Using the cable section A, the cable material and the network frequency as entry points in Table 18, determine the multiplication factor X.

Table 18: Multiplication factors X for different cable sections Cable section [mm²] Network frequency 50Hz Network frequency 60 Hz Al-cable Cu-cable Al-cable Cu-cable 16 1.00 1.00 1.00 1.00 25 1.00 1.01 1.00 1.01 35 1.01 1.01 1.01 1.02 50 1.01 1.03 1.02 1.04 70 1.02 1.05 1.03 1.06 95 1.04 1.08 1.05 1.10 120 1.05 1.11 1.07 1.14 Step 3: Determine in a conventional way the cable section A2 (mm²) for the current rating found by multiplying Irms by X. If the new cable section A2 is equal to the initially found cable section A, the right cable section taking into account the skin effect has been found. If the new cable section A2 is bigger than the initially found cable section A, steps 2 and 3 have to be repeated with the new values until the cable section A2 found is equal to the cable section A. Remark: During this process it may be found that more than one cable per phase is needed. The process then has to be applied to each cable. As an illustration of the cable sizing process consider the following example: PQFS 60 A/50Hz, 3-wire connection, cable material: Cu (copper) Step 1: IN = 60A  cable section = 16 [mm2] Step 2: multiplication factor for a 16 [mm2] copper cable at 50 Hz = 1.00 Step 3: I = IN x 1.00 = 60A x 1.00 = 60 A Step 4: I = 60A  cable section: 16 [mm2] This section is equal to the section found in the previous step. Conclusion: one copper cable of 16 [mm2] per phase is sufficient. Remark: The cable sizing process discussed in point 2 above only takes into account the skin effect. Any further derating due to local standards and/or installation conditions (e.g. distance between cables, number of cables connected in parallel …) have to be taken into account by the company responsible for the PQF cable connection. As an example of the cable sizing procedure, consider Table 19 and Table 20, which show the allowed current for different parameters noting typical cable manufacturer data.

WARNING: Consult your cable manufacturer for the applicable cable manufacturer data. Table 19: Allowed cable current for different cable sections noting the skin effect and typical cable manufacturer data – Network frequency 50Hz Copper Aluminum Cross section Nr of parallel cables Derating due to paralleling Rated current [Arms] Reduction factor Allowed current [Arms] Rated current [Arms] Reduction factor Allowed current [Arms] [mm²] [AWG] 16 6 1 1 100 0.997 100 75 0.999 75 25 4 1 1 130 0.993 125 100 0.997 100 35 2 1 1 160 0.987 158 120 0.994 119 50 1-1/0 1 1 190 0.975 185 145 0.989 142 70 2/0 1 1 230 0.955 220 180 0.98 176 95 3/0 1 1 285 0.93 265 220 0.965 210 120 4/0 1 1 325 0.904 290 250 0.95 238 150 300MCM 1 1 365 0.877 320 285 0.93 265 185 350MCM 1 1 415 0.844 350 325 0.908 295 240 500MCM 1 1 495 0.804 390 385 0.876 335 300 600MCM 1 1 550 0.768 420 425 0.843 358 16 6 2 0.8 160 0.997 159 120 0.999 120 25 4 2 0.8 208 0.993 205 160 0.997 160 35 2 2 0.8 256 0.987 250 192 0.994 190 50 1-1/0 2 0.8 304 0.975 290 232 0.989 229 70 2/0 2 0.8 368 0.955 350 288 0.98 282 95 3/0 2 0.8 456 0.93 420 352 0.965 340 120 4/0 2 0.8 520 0.904 470 400 0.95 380 150 300MCM 2 0.8 584 0.877 510 456 0.93 424 185 350MCM 2 0.8 664 0.844 560 520 0.908 472 240 500MCM 2 0.8 792 0.804 630 616 0.876 540 300 600MCM 2 0.8 880 0.768 675 680 0.843 573 Remark: The highlighted values in Table 19 refer to cable sizes that correspond to typical filter ratings. Note that in 4-wire systems, the neutral may have to carry up to 3 times the line current rating of the filter.

Table 20: Allowed cable current for different cable sections noting the skin effect and typical cable manufacturer data – Network frequency 60Hz Copper Aluminum Cross section Nr of parallel cables Derating due to paralleling Rated current [Arms] Reduction factor Allowed current [Arms] Rated current [Arms] Reduction factor Allowed current [Arms] [mm²] [AWG] 16 6 1 1 100 0.996 99 75 1 75 25 4 1 1 130 0.99 128 100 1 100 35 2 1 1 160 0.981 157 120 0.99 119 50 1-1/0 1 1 190 0.965 183 145 0.98 143 70 2/0 1 1 230 0.941 216 180 0.97 175 95 3/0 1 1 285 0.911 260 220 0.95 210 120 4/0 1 1 325 0.88 286 250 0.93 233 150 300MCM 1 1 365 0.85 310 285 0.91 260 185 350MCM 1 1 415 0.817 339 325 0.89 288 240 500MCM 1 1 495 0.775 383 385 0.85 326 300 600MCM 1 1 550 0.738 406 425 0.81 346 16 6 2 0.8 160 0.996 159 120 1 120 25 4 2 0.8 208 0.99 205 160 1 160 35 2 2 0.8 256 0.981 250 192 0.99 190 50 1-1/0 2 0.8 304 0.965 293 232 0.98 228 70 2/0 2 0.8 368 0.941 346 288 0.97 280 95 3/0 2 0.8 456 0.911 415 352 0.95 336 120 4/0 2 0.8 520 0.88 457 400 0.93 374 150 300MCM 2 0.8 584 0.85 496 456 0.91 416 185 350MCM 2 0.8 664 0.817 542 520 0.89 460 240 500MCM 2 0.8 792 0.775 613 616 0.85 522 300 600MCM 2 0.8 880 0.738 649 680 0.81 553 Remark: The highlighted values in Table 20 refer to cable sizes that correspond to typical filter ratings. Note that in 4-wire systems, the neutral may have to carry up to 3 times the line current rating of the filter. 6.7 Selection of the power cable protection/filter input protection scheme Once the power cables have been selected, a suitable cable and equipment protection has to be selected. The protection only needs to protect the phases and not the neutral. It is recommended to use fuses of type gG/gL with the RMS current ratings given in Table 21.

Table 21: RMS current ratings for protection fuses Filter nominal current rating (Arms) Minimum fuse protection (Arms) Maximum fuse protection (Arms) 30 40 125 45 63 125 60 80 125 70 100 160 80 100 160 90 125 160 100 125 160 Voltage rating of the fuses should be in accordance with the network voltage. As an alternative to fuse protection, MCCB protection of appropriate sizing can also be used. When the customer protection is in place, the following PQFS input protection will result. L1 L2 L3 To PQFS power stage To PQFS control circuit and DC bus loading circuit 2.5mm² reinforced 6A (10X38 for up to 415V) N Customer added protection PQFS filter unit Note: neutral connection only needed for 4-wire connection Figure 26: Symbolic representation of the PQFS input protection The active filter power circuit is internally connected to the network by means of a main contactor of type ABB UA50 or UA95 (depending on the current rating). The PQFS control circuit and DC bus preload system is protected by a fuse protection scheme, the characteristics of which are given in the table below.

Table 22: Control circuit fuse characteristics for PQFS filters Nominal network voltage (Vrms) Control circuit fuse type Irms fuse (Arms) Isc(a) fuse (kA) at rated voltage Rated Voltage (Vrms) 208 ≤ Ue ≤ 415 French Ferrule 10 X 38 gG/gl 6 ~ 120 500 Remark: (a) fuse short circuit current capability WARNING: Once the auxiliary fuse box is closed, the DC bus is automatically charged when the upstream network is live. Therefore, close the auxiliary circuit only when the upstream power circuit is not live. Failure to adhere to this guideline may result in injury or death. 6.8 Connection of the PQFS to the network WARNING: The PQF has to be installed in parallel with the loads, preferably on a free feeder. Local regulations and requirements prevail in determining how the equipment has to be connected to the network. The feeding cables to the filter must be protected by their own cable and equipment protection device (see Section 6.7). WARNING: The PQF can operate on networks with nominal voltage in the range 208- 240 V and 380-415 V. The unit must be configured for the operation range it will be used on. Follow the guidelines in this section to ensure that the hardware is configured properly. Failure to do so may lead to filter damage. For applications where predominantly 3 phase loads are present and where there is no need for neutral current filtering nor line to neutral balancing, connect the active filter in 3-Wire mode. For applications where predominantly single-phase loads are present and where there is a need for neutral current filtering and/or line to neutral balancing, connect the active filter in 4-Wire mode. NOTE: When installing an active filter in installations containing power factor correction capacitor banks, it is recommended to use detuned capacitor banks and to connect the capacitor banks upstream of the filter measurement CTs.

NOTE: The PQF active filter is not compatible with high impedance devices installed upstream of the filter in the neutral. The PQF may refuse to start or may not function correctly when such a device is present. For best PQF performance, these devices have to be removed or bypassed. 6.8.1 Connection of the PQFS in 3-wire mode Use the 3-wire connection mode for installations where there is no need for neutral current filtering or line to neutral balancing. In this mode, the active filter can compensate 20 individual harmonic components. In order to connect the PQFS in 3-wire mode, follow the below guidelines: 1. Fix the filter mechanically to the wall (Cf. Section 5.7) 2. Ensure that an appropriately selected protecting device is connected upstream and that the power supply cables are not live 3. Remove the protective cover present at the bottom right side of the filter (Cf. Figure 27) Figure 27: Removing the Aluminum protective cover at the bottom side of the active filter enclosure 4. Make holes in the protective cover of appropriate section corresponding to the power cable section used. Also make holes for the earth cable, the CT wire and any other control wires that may be needed, e.g. for implementing remote control functionality. When finished, slide the cover over the feeding cables and the earth cable. 5. Connect the earth cable (Cf. Section 6.5) 6. Connect the three power cables to the reactor terminals (Cf. Figure 28). WARNING: The power cables are directly connected by the customer at the line reactor terminals. In order to safeguard the terminals from mechanical stress, it is recommended that the weight of the power cable is properly supported using a cable tray or a suitable cable connection box.

Figure 28: Connecting the three power cables to the filter reactor terminals Remarks: − The left reactor terminal corresponds to phase L1 (R, A) − The middle reactor terminal corresponds to phase L2 (Y, B) − The right reactor terminal corresponds to phase L3 (B, C) The cable lugs of the feeding cables should comply with: − Maximum lug width: in accordance with terminal width − Minimum lug eye diameter: M8 Appropriate torque (20Nm) must be applied to ensure that cables are properly fixed. 7. Slide the bottom protective cover up and fix it with the screws to seal off the power supply terminals 8. In addition to the power cables and the earth connection cable, the CT connection cable and any other control cables used for enhanced functions can at this stage be passed through the protective cover into the filter panel. 9. Preparation of the filter to match the networks voltages: The active filter nominal voltage setting must be adapted to the actual network voltage by adjusting the tap setting of the auxiliary transformer. If the tap setting for your network voltage is not available, then choose a tap just above the network voltage present (e.g. for 390V network choose 400V tap setting). The auxiliary transformer is situated at the bottom right side of the filter (Cf. Figure 14, item 15). Ensure that the filter panel is isolated before changing the transformer tap setting. By default the tap setting of the auxiliary transformer is set at the highest voltage position at the filter production stage. WARNING: The tap setting of the auxiliary transformer’s primary must be adapted according to the network voltage to avoid a too high or too low auxiliary voltage. If the tap setting for your network voltage is not available, then choose a tap just above the network voltage present (e.g. for 390V network choose 400V tap setting). Excessive (auxiliary) voltage levels will lead to filter damage.

6.8.2 Connection of the PQFS in 4-wire mode Use the 4-wire connecting mode for installations where there is a need for neutral current filtering and/or line to neutral balancing. In this mode, the active filter can compensate 15 individual harmonic components. In order to connect the PQFS in 4-wire mode, follow the guidelines of Section 6.8.1 with the exception that: 4. Make also a hole for the neutral cable in the protective cover noting the larger section required for the neutral. 6. Connect the three power cables and the neutral cable. Whereas the three power cables can be connected as describes in item 6 of Section 6.8.1, the neutral cable has to be connected to the neutral connection point (Cf. Figure 29). Figure 29: Connection of the neutral cable when using the PQFS in 4-wire mode The cable lugs for the neutral cables should comply with: − Maximum lug width: in accordance with terminal width − Minimum lug eye diameter: M8 Appropriate torque must be applied to ensure that cables are properly fixed. Other points in the connection procedure are as per previous Section. Remarks: In case of regenerative loads (e.g. loads that may inject active energy to the network, usually called 4Q-loads), it is very important to connect the PQF outside the protection of this load. Indeed, consider Figure 30 where a common protection is installed for both the regenerative load and for the PQF. When the load re-injects energy to the network and the mains protection trips, the whole energy may be pushed into the PQF, which may damage it severely. Figure 31 shows the admitted protection scheme for regenerative loads. In this case, if the breaker of the load trips, the PQF is isolated from the energy fed back by the drive.

PQF 4Q load Figure 30: Incorrect connection in the case of 4Q-loads PQF 4Q load Figure 31: Correct connection in the case of 4Q-loads 6.9 Selection of the current transformers Each filter unit in a filter system has to monitor the line current in order to determine the harmonic load and function correctly. This is done by three current transformers (CTs). For proper operation of the PQFS standard accuracy CTs with the following minimum specifications have to be used: − 5 A secondary current rating. − 15 VA burden for up to 30 meters of 2.5 mm² cable. For longer cables lengths refer to the chart in Figure 32. In case the CTs are shared with other loads, the VA burden shall be adapted accordingly. Note that the burden requirement for a complete filter system (consisting of up to 8 filter units) is 5 VA, excluding connecting cables. − Class 1 accuracy or better. − Primary side current rating sufficient to monitor the total line current (including transient phenomena such as drive/motor starts …). It is strongly recommended that the three CTs have the same characteristics. WARNING: The connection of different filter units in a PQFS system, as well as other loads, on the same CT must be in series. In order to determine the suitable CTs for your application, please refer to the chart in Figure 32. Remark: In some applications two or more power supplies exist (e.g. a network transformer supply and a generator supply). When the current into both supplies has to be filtered, summing CTs have to be used. All summing CTs must have the same ratio. More information on how to install the summing CTs is given in next section.

Maximum rms current of the downstream loads (including starting current of DC drives): X1 = ….. Arms Multiply X1 by 1.6: X2 = …. Arms CT cables > 30 meters ? Select 3 identical CT’s such that: - rating at primary ≥ X2 - rating at secondary: 5A - Burden ≥ 15 VA - Class 1 accuracy or better NO Section of CT cables: 2.5 mm²? (recommended) Determine the length of CT cables (meters) L = … m X3 = (L x 0.007 x 25) + 10 X3 = … VA Select 3 identical CT’s such that: - rating at primary ≥ X2 - rating at secondary: 5A - Burden ≥ X3 VA - Class 1 accuracy or better Determine the length (m) and resistance (Ω/m)of CT cables (meters) L = … m R = … Ω/m X4 = (L x R x 25) + 10 X4 = … VA Select 3 identical CT’s such that: - rating at primary ≥ X2 - rating at secondary: 5A - Burden ≥ X4 VA - Class 1 accuracy or better NO YES YES Figure 32: Flow chart for CT determination

6.10 Current transformer installation 6.10.1 Basic rules for correct CT installation The location of the CTs is critical to ensure the proper operation of the active filter. The CTs are the “eyes” of the filter and it will react in accordance with the information supplied by them. WARNING: Special care has to be taken for the connection and location of the CTs: wrong CT installation is the most common source of problems found at the commissioning stage. WARNING: In a filter system consisting of more than one unit, the CT information has to be supplied to all the units. This must be done through a daisy chain connection with return path configuration. By default, the PQFS active filter is provided with CT terminals that are not shorted. A set of shorting plugs is provided with the filter. They should always be kept with the filter and be accessible for service engineers. WARNING: When connecting the CTs of a live system to the PQFS, the secondaries of the CTs have to be shorted. Failure to do so may result in CT explosion and consequent damage to the installation. Once the connections to the filter have been made, the shorting links must be removed. The basic rules for successful CT installation are given next (Cf. Figure 33): − The three filter CTs have to be positioned for closed loop control, i.e. the CT must monitor the load current and the filter current. In some cases, summation CTs may be needed to fulfil the closed loop requirement (Cf. examples further down this section). − The CTs must be positioned in the correct direction around the power cable: the K (P1) side should be in the direction of the supply and the L (P2) side should be in the direction of the load. − Each CT must have its own guard circuit, i.e. one terminal of each CTs secondary terminals (k (S1) or l (S2)) should be earthed. Once a terminal is chosen (e.g. k- terminal), the same terminal should be earthed for all the CTs. − The CT monitoring a phase should be connected to the filter terminal dedicated to the same phase. In practice this means that: • The k (S1) terminal of the line 1 CT (L1, Red, U) must be connected to terminal X21-1 of the filter.

• The l (S2) terminal of the line 1 CT (L1, Red, U) must be connected to terminal X21-2 of the filter. • The k (S1) terminal of the line 2 CT (L2, Yellow, V) must be connected to terminal X214 of the filter. • The l (S2) terminal of the line 2 CT (L2, Yellow, V) must be connected to terminal X21-5 of the filter. • The k (S1) terminal of the line 3 CT (L3, Blue, W) must be connected to terminal X21-7 of the filter. • The l (S2) terminal of the line 3 CT (L3, Blue, W) must be connected to terminal X21-8 of the filter. − The CT connection terminal X21 is located at the middle of the top plate of the filter (Cf. Figure 34). L1 L2 L3 Load side Supply side K L k l K L k l K L k l PQF X21.1 X21.2 X21.3 X21.4 X21.5 X21.6 X21.7 X21.8 X21.9 L1 L2 L3 To X21.1/X21.2 To X21.4/X21.5 To X21.7/X21.8 K = P1, L = P2, k = S1, l = S2 N N Figure 33: Basic CT connection example for a single unit active filter CT connection terminal X21 Figure 34: Location of the CT connection terminal X21 in the PQFS The terminal block X21 can handle control cable wiring with sections from 2.5 mm² to 10 mm². In addition to the 6-wire CT cabling approach shown in Figure 33 above, a 4-wire approach may also be used. This approach is illustrated in Figure 35. In this case the CT secondary terminal to which the guard circuit is connected is interconnected between the CTs and also on the filter terminal X21. One common cable is used for this terminal.

Note that this cable must be able to withstand three times the secondary current rating of the CTs. Note that this cable must be able to withstand three times the secondary current rating of the CTs. L1 L2 L3 Load side Supply side K L K L K L PQF L1 L2 L3 To X21.2 To X21.5 To X21.8 K = P1, L = P2, k = S1, l = S2 N N X21.1 X21.2 X21.3 X21.4 X21.5 X21.6 X21.7 X21.8 X21.9 Figure 35: Four wires CT wiring approach that may be used with a single unit PQFS active filter In case a filter system consists of more than one unit, all units have to be supplied with the CT measurement information. This is done by cabling the CTs in a daisy chain fashion between the different units. This is illustrated in Section 6.11.3. 6.11 Electrical interconnection of PQFS enclosures This section explains how to electrically interconnect different PQFS enclosures. Figure 36 shows schematically which interconnections have to be made between two filter enclosures.

N Preload resistor Output filter Unit 1 Unit 2 Output filter Power Unit 1 Master Unit Power Unit 2 Master or Slave Unit N AC power supply L L … (2) (1) Figure 36: Overview of the connections to be made between two filter enclosures The interconnection description is given in Table 23. Table 23: Interconnections between two filter cubicles Item Description 1 Control board intercommunication cable through CAN bus (RJ45 cable) 2 CT interconnection cable Four steps have to be followed to electrically interconnect a new PQFS unit with an existing filter. They are outlined in the next four paragraphs. 6.11.1 Mechanical interconnection of the enclosures All cables to the PQFS unit such as power cable as well as interconnection cable between modules must pass through the bottom cable entry hole provided in the PQFS box. 6.11.2 Control board cable interconnection WARNING: Failure to interconnect the control boards in an appropriate way will result in filter malfunctioning and possibly sever damage of the unit. Interconnect the control boards of a following unit with a previous filter unit by an RJ45- based communication cable. This cable is provided with each unit.

Figure 37: shows the way to interconnect the control boards. Control board in the ‘previous’ unit Control board in the ‘next’ unit From previous unit (if present) To next unit (if present) Figure 37: Control board interconnection cable connection method. − The RJ45 control cable coming from the preceding filter unit is plugged in the left hand side RJ45-socket at the top of the filter control board. − The RJ45 control cable leaving for the next filter unit is plugged in the right hand side RJ45-socket at the top of the filter control board. − Repeat the same procedure for any other filters to be connected. Notes: − In the first unit of a filter system, the left hand RJ45-socket will always be empty. − In the last unit of a filter system, the right hand RJ45-socket will always be empty. − During the commissioning phase, a unique address has to be assigned to each unit in a filter system through dip switch (see Chapter 8). 6.11.3 CT cable interconnection WARNING: Failure to connect the CT’s to all units in a filter system in an appropriate way will result in filter malfunctioning and possibly sever damage of the unit. In a multi-unit PQFS-system, all units have to be supplied with the CT-measurement results. In order to do this the CT’s have to be cabled to each unit in a daisy chain fashion. The connection principle is shown in Figure 38 for the CT of phase which is fed to four filter units. The same approach has to be implemented for the other phases too.

Figure 38: Principle of the CT interconnection circuit for multi-unit filters. Note that the overall burden requirement for a complete filter system is 5 VA. To this value has to be added the burden requirement of the interconnection cables to obtain the total burden requirement of the CT’s to be used. 6.11.4 Connection of the power stage to the supply As a final step in the interconnection process, the power stage of the new unit has to be connected to the supply. The same connection approach as used for the other filter units must be adopted. More information on how to connect a PQFS filter unit to the power supply can be found in Section 6.8. WARNING: Make sure that the phase rotation of the power cable connection is clockwise at the filter terminals and that the L1, L2 and L3 terminal in each filter unit is connected to the same phase for all units. Failure to do so may lead to the filter being damaged upon startup. WARNING: Once a new filter unit has been added to a filter system, this unit has to be given a unique address (through DIP switch setting on its control board). In addition, the filter unit has to be recommissioned. If more than one unit is added, it is recommended to first finish the hardware modifications and then set up the controller accordingly. More information on how to change the filter controller unit settings can be found in Section 7.9.2.2 and Section 8.5. After making and verification of all the electrical connections: − Set a unique address on each filter unit control board − Close the auxiliary fuse box of the filter units

− Restore the top cover(s) of the filter units 6.12 Electrical connections to the PQF-Manager user interface The PQF-Manager is the user interface between the outside world and the filter controller. It is mounted on the filter cover panel. Depending on the user requirements, less or more electrical connections have to be made to it. Figure 39 shows the rear side layout of the PQF-Manager. In order to get access to the rear side of the PQF-Manager, remove the PQFS top cover (Cf. guidelines in Section 3.3.) Figure 39: Rear side layout of the PQF-Manager user interface When looking at the PQF-Manager from the rear, on the left side can be found a 15-pole terminal block and on the right side an 8 pole terminal block (top-right) and a 45-pole terminal block (bottom right). Intermediate contacts are not used. In order to make control connections to any of these terminals, the following procedure has to be applied: 1. Push the lever of the connector backwards with a screwdriver. 2. Insert the control wires (from 0.75 mm² to 2.5 mm² single core without cable shoe or max. 1.5 mm² for multi-strand wire) in the corresponding connection hole while keeping the pressure on the lever. 3. Release the screwdriver. 4. The wire is then properly connected.

Figure 40: PQF-Manager lead connections The remainder of this section gives examples of how to cable different functions, i.e. Case 1: Cabling of remote control functionality. Case 2: Cabling of alarm functionality. Case 3: Cabling of warning functionality. Case 4: Cabling of the digital output contacts to monitor other filter operation modes than warnings and alarms. Case 5: Cabling of main/auxiliary control functionality. Case 6: Implementation of local start/stop buttons. It is recommended that for additional functions that are cabled to the PQFS, a connector approach is used such as is the case for the internal communication and PQF-Manager power supply. WARNING: Before cabling any of the circuits discussed below, switch off the power supply to the filter. When the filter has already been installed on site, this is done by opening the protection system located just upstream of the filter and opening the auxiliary fuse box present in the filter. Wait at least 25 minutes to allow for the DC capacitors to discharge when the filter has been connected to the network before. Failure to do so may result in the lethal injury or death. After making and verification of all the electrical connections − Close the auxiliary fuse box of the filter units starting from the last slave and ending with the master unit. − Restore the top cover(s) of the filter units including the connection of the PQF- Manager to the master unit − The power to the filter may then be restored. 6.12.1 Cabling of remote control functionality The PQFS has the possibility to be controlled by remote control. An example of this approach is a drive that is switched on at a location and which automatically gives a start command to the filter. When the drive is then stopped, the drive sends automatically a

stop command to the filter too. This section gives an example of how the cabling has to be done on the filter side. Any of the two digital inputs on the PQF-Manager (Cf. Figure 39) can be used to cable the remote control functionality. The electrical requirements of the digital inputs are given in Table 63 (Filter characteristics section). Figure 41 gives an example of how to implement the remote control functionality on Digital Input 1. Switch controlled by external process 24 Vdc external power supply(b) S + - 1 (a) 2 (a) + - PQF-Manager Digital input 1 (15-24Vdc) Remarks: (a) Left hand terminal block when looking from rear, counting from top to bottom (b) Acceptable power supply range: 15Vdc-24 Vdc, driving current 13mA@24Vdc Figure 41: Implementation of remote control functionality on Digital Input 1 of the PQF-Manager WARNING: If a function is assigned to a digital input, the same function must never be assigned to the other digital input. Otherwise the filter may behave erratically. Once the cabling has been finished: − The auxiliary fuse box may be closed − The filter top cover may be replaced including the connection of the PQF-Manager to the master unit − The power to the filter may then be restored Then, the PQF-Manager has to be used to associate the remote control functionality with Digital Input 1. This is done by going to the digital input setup menu and selecting ‘Remote ON’ for digital input 1. When this is done the filter will switch on when the switch S shown in Figure 41 is closed and the filter will switch off when the switch S is opened. Refer to Section 7.9.1.4 for guidelines on how to navigate to the digital input setup menu. In a multi-master arrangement, the master that has the control over the system (i.e. the master which is operational and which has the lowest address) will monitor the digital inputs. Therefore, in order to obtain full redundancy with filters consisting of more than

one master unit, the digital inputs of all the units in a multi-master arrangement have to be set up and cabled in the same way. Remarks: − When the remote control functionality has been activated this function has priority over a local start/stop command. When the local command has to be given, deactivate first the remote control functionality by navigating with the PQF-Manager to the digital input setup menu and setting the digital input considered to ‘Disabled’. − The remote control functionality can also be implemented on the Digital Input 2. 6.12.2 Cabling of alarm functionality An alarm represents an error condition that makes the filter trip. Two types of error conditions exist: − External error condition: These are conditions that are imposed on to the filter from the outside world. Consider the example of the network voltage that increases well above the filter safe operation level for a certain time. In that case the filter will disconnect from the network reporting a network overvoltage. When the network voltage returns to a normal level however, the filter will reconnect to the network and continue filtering providing that the same problem does not occur systematically. − Internal error conditions: These are error conditions that are reported by internal controls of the filter itself. They may indicate an internal filter problem. Two ways to cable the alarm functionality exist: 6.12.2.1 Alarm outputs The PQF-Manager alarm outputs located at the bottom right side (when looking at the PQF-Manager from the rear) are triggered (return to default position) whenever: − A permanent internal or external error condition is present. In order to avoid transient switching of the contacts, the error has to be present for 3 minutes before the alarm relays are activated. − No power is supplied to the filter. Table 26 further down this section gives an overview of all the error conditions that lead to the alarm contact being triggered. Two alarm contacts exist, one being of type ‘normally open’ (NO) and the other of type ‘normally closed’ (NC). The alarm contacts are: − Free of potential. − Rated for a maximum of 250 Vac/1.5 A or 30 Vdc/5 A. When using a 24 Vdc power supply, a minimum current of 25 mA should be drawn by the circuit connected to the alarm contact.

Table 24 shows the status of the alarm contacts for different operation modes of the filter. Table 24: Status of the alarm contacts for different filter operation modes Filter state Normally open alarm contact state Normally closed alarm contact state Disconnected from the supply Open Closed Filter (auxiliaries) connected to the supply, no error present Closed Open Filter (auxiliaries) connected to the supply, error appears Opens when error present for 3 minutes Otherwise, remains closed Closes when error present for 3 minutes Otherwise, remains open Filter (auxiliaries) connected to the supply, error disappears When open before, closes when error disappears When closed before, remains closed When closed before, opens when error disappears When open before, remains open Figure 42 shows an example of an alarm contact cabling scheme using the NC alarm contact. Using this scheme the bulb B will be on when the power supply to the filter is interrupted or the filter trips due to an error. Otherwise the bulb will be off. 15 16 (a) 17 (a) PQF-Manager Alarm outputs NO NC 230 Vac external power supply External bulb alarm indicator B Remark: (a) Right hand terminal block when looking from rear, counting from top to Figure 42: Alarm bulb cabling scheme using the NC alarm contact on the PQF-Manager When the filter system consists of multiple master-units and an alarm contact is needed to signal when the complete system is off, then the NC alarm contacts of all the master units have to be cabled in series. An example is given in Figure 43 for 2 master filters.

B Note: Contacts drawn in non-alarm position 230 Vac external power supply NC Alarm contact of master 1 NC Alarm contact of master 2 Alarm bulb Figure 43: Cabling of the alarm status of a multi-unit filter consisting of masters only, using the NC alarm contact on each filter. In the Figure 43, the alarm bulb will be activated when both master units are in alarm. Figure 44 shows a cabling scheme using a 24 Vdc supply in conjunction with the NO alarm contact. The scheme assumes that an external digital input monitors the alarm contact of the filter. In this case the voltage applied to the digital input will be low when: − The filter is disconnected from the supply OR. − The filter trips due to an error OR. − The external 24 Vdc power supply fails. The voltage applied to the external digital input is high when: − The filter is connected to the supply and is not in error AND − The external 24 Vdc power supply is in working order. 15 (a) 16 (a) 17 Alarm outputs NO NC 24 Vdc external supply Remark: (a) Right hand terminal block when looking from rear, counting from top to External digital input + - + - PQF-Manager Figure 44: Alarm cabling example using NO alarm contact and external digital input When the filter system consists of multiple master-units and an alarm contact is needed to signal when the complete system is off, then the NO alarm contacts of all the master units have to be cabled in parallel. An example is given in Figure 45 for 2 master filters.

Note: Contacts drawn in non-alarm position 24 Vdc external supply NO Alarm contact of master 1 NO Alarm contact of master 2 External digital input + - Figure 45: Cabling of the alarm status of a multi-unit filter consisting of masters only, using the NO alarm contact on each filter. In the Figure 45 above, the external input will be low if: − Both master units are in alarm OR − The external 24 V power supply fails OR − Both filter units are disconnected from the supply. 6.12.2.2 Digital outputs A second method to implement the alarm functionality is to use the PQF-Manager’s programmable digital output contacts. Use this approach when the condition for alarm is uniquely defined, e.g. an alarm has to be given only when the filter trips due to an unacceptably high network voltage or when the filter trips due to a well-defined internal error. This type of alarm has to be cabled on the 8 pin terminal block situated at the top right corner when looking at the PQF-Manager from the rear (Cf. Figure 39). The digital output contacts have a common point (cabled on contacts 1 and 2) and are of the NO-type (normally open). The contact ratings are: − Maximum continuous ac rating: 440 Vac/1.5 A. − Maximum continuous dc rating: 110 Vdc/0.3A. − The common is rated at 9 A/terminal, giving a total of 18 A. − When using a power supply of 24Vdc, a minimum current of 10 mA should be drawn by the circuit connected to the digital output contact. Table 25 shows the status of a digital output contact configured as alarm contact for different operation modes of the filter. Table 25: Status of a digital output contact configured as alarm contact for different filter operation modes Filter state Normally open digital contact state Disconnected from the supply Open Filter (auxiliaries) connected to the supply, no error present Open

Filter (auxiliaries) connected to the supply, predefined error appears Closes when error present for 3 minutes. Otherwise, contact remains open. Filter (auxiliaries) connected to the supply, predefined error disappears When closed before, opens when error disappears. When opened before, remains open. The alarm conditions that can be assigned to a digital output are given in Table 26. The assignment must be made with the PQF-Manager. Any of the six digital outputs can be used to cable an alarm. A maximum of 3 alarms can be assigned to the digital outputs. Note however that by default the digital outputs have been set up for monitoring other functions than alarms (cf. Table 10) Refer to Section 7.9.1.4 for guidelines on how to navigate to the digital output setup menu. Table 26: List of possible alarm conditions that may trigger the alarm/digital outputs Alarm condition Criteria to be fulfilled before contact is activated Supply voltage (RMS) unacceptably high Vrms_max > 110% Vnominal Supply voltage (RMS) unacceptably low Vrms_min < 90% Vnominal One of the phases of the supply is missing Vrms_min < 60% Vnominal Network imbalance unacceptably high Vimbalance > 2% Frequency variation unacceptably high Frequency variation > 20%/s PQFS DC bus voltage unacceptably high Vdc > 105% Vdc_max_allowed PQFS internal preload error DC capacitor voltage rise too low in preload phase or the DC capacitors could not be preloaded in an acceptable time. PQFS overcurrent fault Internal current higher than allowed PQFS ground fault Internal ground current higher than allowed PQFS IGBT fault IGBT hardware reports internal permanent error PQFS IGBT overtemperature IGBT hardware reports internal overtemperature Control board temperature too high Internal control board temperature probe reports too high temperature PQFS internal power supply fault Internal control voltage too low or not present PQFS control board fault Internal control board reports an error PQFS unit down (i.e. not operational due to error) Any of the units in a multi-unit arrangement is not running although the start-command has been given. Remark: the alarm trigger levels cannot be changed by the user. For cabling the digital output contacts as alarm contact, the same approach as shown in Figure 44 can be adopted. Note however that the following behavior will result: − The voltage applied to the external monitoring device will be low when:

o The filter is disconnected from the supply or when there is no error. − The voltage applied to the external monitoring device will be high when: o The predefined error is present for the predefined time (minimum 180s) AND o The external 24 Vdc power supply is in working order. The different electrical characteristics of the digital output contacts compared to the alarm contact characteristics must be respected. Note also that all digital outputs have the same common which is located at the pins 1 and 2 of the right hand terminal of the PQF-Manager (rear view, counting from top to bottom). This is clearly indicated in Figure 39 above. A second use of the digital outputs is to monitor the status of individual master units in a multi-filter system. This can be done by assigning the function ‘Unit missing’ (‘Unit miss.) to a digital output. In that case the digital output of the master controlling the complete system will activate the digital output considered when one of the units in a filter system is not operational due to error. In order to obtain full redundancy with filters consisting of more than one master unit, the digital outputs of all the units in a multi-master arrangement have to set up and cabled in the same way. The cabling scheme is given in Figure 45. Once the cabling has been finished: − The auxiliary fuse box may be closed − The filter top cover may be replaced including the connection of the PQF-Manager to the master unit − The power to the filter may then be restored 6.12.3 Cabling of warning functionality A warning condition is a condition that can be set up by the user in such a way that if the condition is met, a digital output contact of the PQF-Manager user interface (Cf. Figure 39) is closed. As an example consider a case where the user has set up an upper warning level for the network voltage. If the level measured by the filter becomes higher than the predefined warning level and this condition remains valid for a preset time, the associated digital output will be closed. By monitoring the digital output, the customer will then know when the network voltage becomes too high and subsequently he can take appropriate action. Note that the warning functionality is not associated with a filter trip. It only has a monitoring function. Table 27 describes the behavior of the digital output contact configured as warning contact for different filter operating modes. Table 27: State of a digital output contact configured as warning contact for different filter operation modes Filter state Normally open digital contact state Disconnected from the supply Open

Filter (auxiliaries) connected to the supply, no warning present Open Filter (auxiliaries) connected to the supply, predefined warning present Closes when warning present for pre-defined time. Otherwise, contact remains open. Filter (auxiliaries) connected to the supply, predefined warning disappears When closed before and warning disappears for at least the predefined time, contact opens. When closed before and warning disappears for a time smaller than predefined time, contact remains closed. Otherwise, contact remains open. Table 28 gives a list of the warning conditions that can be assigned to a digital output. Table 28: List of possible warning conditions that can be assigned to a digital output Warning condition Supply voltage (RMS) higher than preset value. Supply voltage (RMS) lower than preset value. Supply voltage imbalance higher than preset value. Ground current level higher than preset value. IGBT Temperature higher than preset value. Control board temperature higher than preset value. Remark: All warning levels can be changed by the user. Any of the six digital outputs can be used to cable warning functionality. A maximum of 3 warnings can be assigned to the digital outputs. However, by default the digital outputs of the PQF-Manager have been set up for monitoring other functions than warnings (cf. Table 10). Refer to Section 7.9.1.4 for guidelines on how to set up warning conditions and how to associate them with digital output contacts. For cabling the digital output contacts as warning contact, the same approach as shown in Figure 44 can be adopted. The electrical characteristics of the digital output contacts and the points to pay attention to are discussed in Section 6.12.2. In order to obtain full redundancy with filters consisting of more than one master unit, the digital outputs of all the units in a multi-master arrangement have to be set up and cabled in the same way. The wiring diagram given in Figure 45 can be used to implement the monitoring of the warnings in multi-master units. 6.12.4 Cabling of the digital output contacts to monitor other filter operation modes than warnings and alarms Table 9 gives an overview of the other functions that can be monitored with the digital outputs in addition to the already discussed warnings and alarms.

For cabling the digital output contacts to monitor other filter operation, the same approach as shown in Figure 44 can be adopted. The electrical characteristics of the digital output contacts and the points to pay attention to are discussed in Section 6.12.2. In order to obtain full redundancy with filters consisting of more than one master unit, the digital outputs of all the units in a multi-master arrangement have to be set up and cabled in the same way. The wiring diagram given in Figure 45 can be used to implement the monitoring of these functions in multi-master units. 6.12.5 Cabling of main/auxiliary control functionality The active filter features main and auxiliary control setup modes. This implies that two different compensation characteristics can be defined, e.g. one for the day and one for the night or one for normal network operation and one for backup generator operation. With the PQF-Manager a set up can be made to either use always the main or the auxiliary settings. In addition, the possibility exists to switch between main and auxiliary settings ‘automatically’ according to a signal applied to a digital input of the PQF-Manager (Cf. Figure 39). Any digital input can be configured to act as the deciding factor for switching between the main and auxiliary settings. Moreover, both normal and inverse logic can be used to drive the digital inputs. Note that in a multi-unit filter system in which more than one master system is present, the digital inputs of all masters have to be set up and cabled in the same way to obtain full redundancy. The electrical requirements of the digital inputs are as discussed in Chapter 12. Figure 46 gives an example of how to implement the main/auxiliary control switching functionality on Digital Input 2. It is assumed that normal control logic is used. External switch for switching between main and auxiliary filter settings 24 Vdc external supply + - 3 (a) 4 (a) PQF-Manager Digital input 2 (15-24Vdc) Remark: (a) Left hand terminal block when looking from rear, counting from top to bottom Figure 46: Example of how to cable the 2nd digital input of the PQF-Manager for main/auxiliary control switching functionality When implementing the function described above, please note that according to the setup done with the PQF-Manager for the input considered, the filter may behave differently. Table 29 shows the filter behavior as a function of the PQF-Manager settings.

WARNING: If a function is assigned to a digital input, the same function must never be assigned to the other digital input. Otherwise the filter may behave erratically. Table 29: Filter behavior as a function of the PQF-Manager settings for main/auxiliary switching PQF-Manager setup for digital input Vlow applied to digital input Vhigh applied to digital input Activ. Main Auxiliary settings are used Main settings are used Activ. Aux. Main settings are used Auxiliary settings are used Remark: Vlow = 0 Vdc, Vhigh = 15-24 Vdc In order to obtain full redundancy with filters consisting of more than one master unit, the digital inputs of all the units in a multi-master arrangement have to be set up and cabled in the same way and the individual PQF-Managers have to be set up accordingly. Once the cabling has been finished: − The auxiliary fuse box may be closed − The filter top cover may be replaced including the connection of the PQF-Manager to the master unit − The power to the filter may be restored Refer to Section 7.9.1.4 for guidelines on how to set up the digital inputs according to the function required. 6.12.6 Implementation of local start/stop buttons WARNING: If a function is assigned to a digital input, the same function must never be assigned to the other digital input. Otherwise the filter may behave erratically. The PQFS active filter is equipped with a start/stop function integrated in the PQF- Manager user interface. If the customer desires this however, he can add extra start/stop buttons (not provided) to the filter system. The start and stop button has to be connected to the PQF-Manager’s digital inputs and the PQF-Manager has to be set up accordingly.

Note that in a multi-unit filter system in which more than one master system is present, the digital inputs of all masters have to be set up and cabled in the same way to obtain full redundancy. Two connection approaches exist: − The first approach is to use one digital input for the start function and the second digital input for the stop function. Table 30 shows the PQF-Manager setup for the input considered and the resulting effect when applying voltage to this input. Table 30: Filter behavior as a function of the PQF-Manager settings for local start/stop and using 2 digital inputs PQF-Manager setup for digital input Vlow applied to digital input Vhigh applied to digital input Edge ON No effect Filter starts on rising edge Edge OFF No effect Filter stops on rising edge Remark: Vlow = 0 Vdc, Vhigh = 15-24 Vdc When using the Edge ON function the filter can only be switched on by applying voltage to the digital input considered. It is therefore recommended in that case to configure and cable the second digital input as Edge OFF. Refer to Section 7.9.1.4 for guidelines on how to set up the digital inputs according to the function required. The electrical requirements of the digital inputs are as discussed in Section 4.5. Figure 47 shows a cabling diagram for implementing a start function on the first digital input and a stop function on the second digital input. External stop push 24 Vdc external supply + - 1 (a) 2 (a) 3 (a) 4 (a) PQF-Manager Digital input 1 (15-24Vdc) Digital input 2 (15-24Vdc) Remark: (a) Left hand terminal block when looking from rear, counting from top to bottom External start push Figure 47: Cabling diagram for implementing start on digital input 1 and stop on digital input 2

− The second approach is to use one digital input for both the start function and the stop function. This leaves the other digital input available for the implementation of other functions. Table 31 shows the PQF-Manager setup for the input considered and the resulting effect when applying voltage to this input. Table 31: Filter behavior as a function of the PQF-Manager settings for local start/stop and using 1 digital input PQF-Manager setup for digital input Vlow applied to digital input Vhigh applied to digital input Edge ON/OFF No effect Filter starts on first rising edge, stops on second rising edge, etc Remark: Vlow = 0 Vdc, Vhigh = 15-24 Vdc Refer to Section 7.9.1.4 for guidelines on how to set up the digital inputs according to the function required. The electrical requirements of the digital inputs are as discussed in Section 4.5. Figure 48 shows a cabling diagram for implementing a start function and a stop function on the first digital input. External start/stop push button 24 Vdc external supply + - PQF-Manager Digital input 1 (15-24Vdc) Remark: (a) Left hand terminal block when looking from rear, counting from top to bottom 1 (a) 2 (a) 3 (a) 4 (a) Figure 48: Cabling diagram for implementing start and stop on digital input 1 Once the cabling has been finished: − The auxiliary fuse box may be closed − The filter top cover may be replaced including the connection of the PQF-Manager to the master unit − The power to the filter may be restored Remarks:

− The implementation of local start/stop buttons does not inhibit the usage of the start/stop function on the PQF-Manager. − When remote control functionality is implemented (cf. Section 6.12.1) at the same time as local start/stop buttons, the remote control has priority over the local start/stop buttons. When the local start/stop command has to be given, deactivate first the remote control functionality by navigating with the PQF-Manager to the digital input setup menu and setting the digital input associated with the remote control to ‘Disabled’. − Note that in a multi-unit filter system in which more than one master system is present, the digital inputs of all masters have to be set up and cabled in the same way to obtain full redundancy. 6.13 Electrical connections of filter options and accessories Filter options must be ordered in advance and are cabled in the factory. For these options, refer to the wiring diagram provided with your filter to identify the electrical connections if desired. For some accessories however, the customer may have to do the cabling on site. These accessories include: − The connection of the USB or Ethernet cable used for PQ-Link software communication (optional) − The connection of the Ethernet cable used for Modbus TCP communication (optional) − The connection of the RS485 Modbus RTU adapter (optional) The connections of the aforementioned accessories are discussed next. WARNING: Before cabling any of the circuits discussed below, switch off the power supply to the filter. When the filter has already been installed on site, this is preferably done by opening the protection system located just upstream of the filter and opening the auxiliary fuse box present in the filter. Wait at least 25 minutes to allow for the DC capacitors to discharge when the filter has been connected to the network before. Failure to do so may result in the lethal injury or death. 6.13.1 External communication with PQF The PQF Filter communicates with a computer in three possible ways: − Using our in-house communication software called PQ-Link (TCP/IP-USB) − Using any communication system supporting the Modbus TCP protocol − Using any communication system supporting the Modbus RTU protocol

While using the PQ-Link software, the computer can be connected either through the Ethernet port using standard cable (RJ45) or through the USB port using standard USB cable. Figure 49: Ethernet cable & USB cable for PC-filter interconnection For communication over Modbus TCP, the computer can be connected through the Ethernet port using standard cable (RJ45). For communication over Modbus RTU, we need a RS485 Modbus adapter (as shown in Figure 50). This adapter has to be connected to the rear side of the PQF-Manager. This is done by inserting the adapter plug firmly in the dedicated socket. Figure 50 shows the location at the rear of the PQF-Manager where the plug has to be inserted. The user can use custom software where the standard Modbus RTU protocol is implemented or any other standard software (OPC server, SCADA …). Figure 50: Location at rear of PQF-Manager where the serial communication cable has to be inserted More information on the PQ-Link software or Modbus communication can be found in the ‘PQ-Link installation and user’s guide’ and 2GCS214017A0070_PQF-Manager communication with Modbus RTU, Modbus TCP and PQ-Link protocols. 6.13.2 Connection of the Modbus adapter For the connection setup of the Modbus adapter, please refer to the document “2GCS212013A0050-RS-485 Installation and Start-up guide”.

— 7 The PQF-Manager user interface 7.1 What this chapter contains This chapter presents the features and operating instructions for the PQF-Manager user interface (Figure 51). Use the contents of this chapter as background information for the next chapters, which explain how to commission, operate and troubleshoot the active filter and how to set up various communication interfaces based on RS485 or Ethernet. Some of the functions discussed in this chapter require cabling of external I/O to the connection terminals at the rear of the PQF-Manager. Refer to Section 6.12 for guidelines on how to do this. Figure 51: Front view of the PQF-Manager user interface 7.2 PQF-Manager user interface description The PQF-Manager is based on a touch screen user interface hence there are no hardware buttons used. All user actions like moving from one to another menu or data entry are done directly by touching the soft buttons or icons on the “touch sensitive” screen. The screen is made of high quality scratch resistance glass. The screen is “resistive touch screen” and hence the user may use any object such as finger or any blunt object like a pen, screw driver etc. Care must be taken not to damage the screen by accidental hard tapping by a sharp object. The main screen of the PQF-Manager is given in Figure 52.

Figure 52 Main screen of the PQF-Manager 7.3 PQF-Manager overview and navigation All user inter-action with the filter is channeled through the PQF-Manager. It provides for the following main functions (Cf. Figure 51): − Filter starting, filter stopping and acknowledgement of faults − Selection of power module for which the relevant data is displayed − Measuring, analyzing, logging − Setting up the filter − Monitoring the filter load, event logging and status of individual units − Providing filter identification information Figure 53 outlines the principle menus that are accessible through the ‘Welcome’ screen. In a multi master configuration (several master units in parallel in a single filter), the PQF-Manager on the “Master” unit has all the menus and options active. The PQF- Manager(s) on the “Slave” unit(s) have different screens in the sense that certain items (menu, buttons etc.) are “non-active” and may appear “greyed”. In case the maser unit fails and the next unit in the order takes over as new master (due to redundancy feature of PQF), the menu of the new master automatically adapts to this new situation. 7.4 Icons and main screen Following icons and menu are present on the main screen: Table 32 Filter status icons Filter status Menu display Touching the button results in … Filter stopped, no critical error present (i.e. ‘normal’ stop condition) PQF START Starting the filter unit Filter running, no critical error present (i.e. ‘normal’ running condition) PQF STOP Stopping the filter unit Filter stopped on critical fault ACK. FAULT Acknowledging the fault

The module status indicator: there are 8 numbered icons present on the left bottom of the screen, each representing a power module. The active modules are displayed in blue color; the faulty ones in red and those modules which are not present are greyed. Table 33 Module status icons Icons Status Ready: the unit considered does not have a fault and can run normally Fault: the unit considered has been stopped due to an error. By pressing Ack. Fault, the reason for the fault will be displayed and an attempt will be made to clear the fault. When doing this, the complete filter system will be shut down. If the fault could be cleared, the unit status will become ‘ready’. If the fault could not be cleared, the unit status will remain ‘Ack. Fault’. In the fault clearing process, the complete filter system will be shut down. The filter can be restarted after the fault clearing process has ended. Not present: the unit considered has been excluded of the normal filter operation due to either fault or the unit is not present Master An alarm icon showing when the PQF-Manager’s alarm contact has been activated (Cf. Figure 51) changes its appearance when the alarm condition exists. When the alarm condition has disappeared, the respective alarm icon takes back the normal appearance. The status of protection (locked/unlocked) is also displayed by a dedicated icon. Hardware lock and software locks have separate icons. Table 34 Alarm/lock status icons Icons Status Software lock Software unlock Hardware lock Hardware unlock Communication lock status Communication unlock status Alarm status Fan status Alarms

Programmed alarm can: − activate any digital output relay 1-6 if selected − activate global alarm NO/NC relay Tprobe alarm 1 to 8 can activate global alarm NO/NC relay. Warnings Programmed warning can activate any digital output relay 1-6 if selected. Tprobe warning 1 to 8 can activate global fan NO relay. Digital output contact icons are located at the bottom of the screen (Cf. Figure 52).These icons are numbered 1 to 6 when they are disabled. If these output contacts are programmed, the corresponding icon changes. When the PQF-Manager closes one of its six digital output relays (Cf. Chapter 6) the corresponding symbol changes its appearance as described in the Table 35. When the relay considered opens again, the symbol takes back the original appearance. If a digital output is ‘Disabled’ the default icon is shown. Example: Table 35 Digital outputs status icons Icons PQF-Manager setting for digital output Output relay closes when… Auxil. ON Auxil. OFF The auxiliary power is present in the main filter enclosure and the main controller is communicating with the PQF- Manager PQF running PQF not running The active filter is ‘on’ (IGBTs switching) or in ‘standby’ (main contactor closed but IGBTs not switching) Not full load Full load The active filter is running under full load condition Armed The filter is ON or is in the start-up procedure, or it is stopped in fault condition but will restart as soon as the fault has disappeared

Not armed Within T limit T limit reached The filter temperature limit has been reached and the filter is derating itself to run at a safe temperature In standby The filter is in standby Activ. Main The main active filter settings are activated Activ. Aux The auxiliary active filter settings are activated Unit miss. One of the filter units in a multi-unit arrangement is not available (e.g. due to a permanent error), or has not yet been commissioned. Pg. alarm 1 The programmable alarm 1 is activated Pg. alarm 2 The programmable alarm 2 is activated Pg. alarm 3 The programmable alarm 3 is activated Warning 1 The programmable warning 1 is activated(c) Warning 2 The programmable warning 2 is activated(c) Warning 3 The programmable warning 3 is activated(c) Following are the default functions set for the six digital output contacts: Table 36 Main screen Digital output number Default function 1 Auxil. ON 2 PQF Running 3 Full Load 4 Armed 5 Unit miss. 6 T Limit

Measurements Overview Vrms THDV V1 Frequency Vdc Irms THDI I1 PQF Irms P Q S PF Cos ϕ T Control T Control max T IGBT T IGBT Max System values Voltages Global Values Waveforms Spectrum Harm. Table Line currents Global Values Waveforms Spectrum Harm. Table Filter currents Waveforms Spectrum Harm. Table Total filter curr. Waveforms Spectrum Harm. Table Powers P Q S PF Cos ϕ Temperatures T Control T Control Max T IGBT T IGBT Max T PQF Manager T Probe (1…8) Min-Max logging Voltages Line currents Power Frequency Temperatures Settings Customer set. Main settings Main Harmonics Main PFC/Bal. Deselect all Filtering Mode Aux settings Aux Harmonics Aux PFC/Bal. Deselect all Filtering Mode Temp unit (C/F) Activate (M/A) Alarms Prog. alarms Temp. alarm levels Warnings Prog. warnings Warnings levels Digital inputs Digital outputs Commissioning Network charact. Vnom fnom Synchro mode Filter Charac. Unit current 3W or 4W Auto CT detection Manual CT settings Derating User Main harmonics Main PFC/Bal. Filter mode T Commissioning Installation set. Network charact. Filter charact. CT Installation Derating Start-Stop set. Clock Password Installation lock Set language PQF monitoring Status of module Filter load Event logging Active warn. Number of errors PQF operation User interface Manufacturer set. About PQF Screen config. Touchscreen calibration Backlighting Communication Modbus Ethernet settings MAC address IP address Communication locking PQF Start Stop Ack fault Welcome Figure 53: Principle menus of the PQF-Manager

In order to navigate through the menus of the PQF-Manager, the touch screen (Cf. Figure 51) has to be used. The starting point for the navigation after a power up is the ‘Welcome’ screen. The item selected is activated and its submenu appears on the screen (e.g. the ‘Measurements’ menu in Figure 51). The name of the parent menu is displayed at the top of the screen. Figure 54: Sub-menu Measurements Please note that: − Sometimes the complete item list in a menu cannot be shown on the display. This is indicated by a small symbol that appear(s) at the bottom right (Cf. Figure 55). Pressing this button takes the menu to the next screen where more items are available to choose from. Figure 55: Illustration of arrow symbol on the PQF-Manager display − Sometimes, when the number of items or variables exceeds the limit of full screen size, a sliding bar appears on the side of the screen. Sliding down (up) this bar displays the remaining (previous) items as shown below: Figure 56: Illustration of sliding bar on the PQF-Manager display

When any of these symbols is visible, the user can scroll down/up beyond the limit of the screen. The item list will be adjusted accordingly. To come back (up) in the menu ladder or to quit any screen, the button available in each screen (top right corner) should be used. − When a menu button is selected, any submenu under it appears in the screen. − The ‘Select Unit’-function is accessible at different places in the menu structure and allows selecting the measurements and data as reported by different units in a multi-unit filter system. Figure 57: Illustration of different menu item types The next sections discuss the four main submenus of the ‘Welcome’ screen. Remark: This manual uses a directory structure convention to indicate a submenu. The main ‘Welcome’ screen is referenced as [/Welcome]. Example: [/Welcome/Measurements/System values] indicates that the ‘System values’ menu can be accessed by: − Press button (on the top right corner of any screen) successively until the ‘Welcome’ screen is reached − Press the ‘Measurements’ menu in the main ‘Welcome’ screen which opens the ‘Measurements’ menu. − Similarly, other submenus can be opened by pressing the respective button. In all menus as well as sub menu, the help symbol is present which offers a user friendly contextual help. If this icon is touched, its color changes to yellow and the user is then expected to touch any button for which a help is required. A new window pops-up with a brief explanation about that button which was touched by the user. For example, is a help on the "Voltage" button is requested in the menu "System Values", following help will appear:

7.5 The PQF-Manager behavior during filter initialization During powering up the filter or after a system reset, the filter is initialized. This includes initialization of the PQF-Manager also. Depending on the type of reset, the initialization process of the PQF-Manager results in following message displayed on the screen: Case 1: If a filter is powered up first time or after a complete power shut down, following screens with ABB logo appear: − Step 1 Figure 58: PQF-Manager display during communication initialization − Step 2 Figure 59: PQF-Manager display when the user interface is set up Once the communication channel has been initialized, the user interface is set up. During this process the PQF-Manager retrieves the data structure to be displayed from the PQF main controller.

Case 2: If a system reset is done while the PQF-Manager is still powered (example the power to the main controller is reset), the initialization process takes place without the ABB logo appearing on the screen. During this process, following two messages appear one after another: − “Initializing communication, please wait” followed by: − “Setting up user interface, please wait”. Above messages can be observed when looking closely at the PQF-Manager. Case 3: When the commissioning parameters are changed or a fault is acknowledged by the user, the filter resets and the following messages are displayed on the screen − “Please wait….” − “Resetting system….” Table 37 gives an overview of the initialization steps for common reset conditions. Table 37: Overview of common reset conditions and corresponding PQF-Manager initialization steps Reset condition after… PQF-Manager initialization steps Applying power to the filter first time or after a complete isolation of filter Case 1 Resetting power only to the main controller Case 2 Setting up commissioning parameters Case 3 Acknowledging fault successfully Case 3 7.6 The PQF-Manager locking facilities In order to prevent unauthorized modification of any of the active filter settings, switch on the hardware lock (Figure 13 item 4). The hardware lock is switched on by pushing the blue button located at the bottom rear side of the PQF-Manager with a pointed object (e.g. pencil). When the lock is set: − will appear bottom potion of the graphics display − Most setting values can be consulted Once the PQF-Manager is locked, it can be unlocked by pushing the blue button again. In order to prevent unauthorized modification of the core installation settings of the active filter but still giving them access to typical user settings (e.g. harmonics selection, programming digital outputs, …), switch on the software lock. The communication lock is applied when the corresponding parameter is set through the menu interface. When the lock is set: − will appear when the settings can be changed only through the communication The software lock is applied when the corresponding parameter is set through the menu interface. When the lock is set:

− will appear. No modification can be made to the settings The software lock is switched on in the menu [/Welcome/Settings/Installation set./Password]. In order to unlock the system go to the same menu. After giving the appropriate password, the system will be unlocked. The password is a four-digit number, which is set by default to: 1234 Entering the password is done by choosing the right value numeric keyboard which appears on the screen. The password can be changed in the menu [/Welcome/Settings/Installation set/Change Password]. Entering the new password is done the same way and confirming the password by re-entering the same. If hardware and software lock are combined, the hardware lock has priority over the software lock. Note: In active filter systems consisting of more than one master, the PQF-Manager of the master that has the control over the system has full functionality and the PQF- Managers of the other master units have limited functionality. The hardware lock in the master has no effect on access level of parameters in the slave modules like warning (alarm …). To disable these settings the hardware lock of each PQF-Manager must be engaged. 7.7 The PQF start, stop and fault acknowledgement menu WARNING: The active filter should only be started when it has been installed and commissioned according to the guidelines of this manual. Failure to adhere to this guideline may damage the filter and void warranty. Refer to Chapter 8 for more information on commissioning the filter. ‘The PQF start, stop and fault acknowledgement’ menu can only be accessed in the main ‘Welcome’ screen [/Welcome/PQF] ‘The start, stop and fault acknowledgement’ menu is the default menu for starting, stopping and resetting the filter. As can be seen in Table 38 the ‘start, stop and fault acknowledgement’ menu behaves differently depending on the filter status.

Table 38: ‘Start, stop and fault acknowledgement’ menu functionality according to the filter status Filter status Menu display Pushing results in… Filter stopped, no critical error present (i.e. ‘normal’ stop condition) PQF START Starting the filter(a) (b) Filter running, no critical error present (i.e. ‘normal’ running condition) PQF STOP Stopping the filter(a) (b) Filter stopped on critical fault ACK. FAULT Acknowledging the fault(a) (b) Filter controlled by remote control PQF START or PQF STOP or ACK. FAULT No action on filter behavior Display shows message that filter is controlled by digital input Remark: (a) After pushing this button, there is always a validation phase. (b) In multi-master filter units, this function is available on the master unit that has the control over the system. In a multi-unit system, the PQF start, stop and fault acknowledgement menu will only switch to the ACK. FAULT message when the complete filter system is shut down. If one of the units of a multi-unit system is shut down due to a fault, this fault can be acknowledged and reset in the PQF Monitoring menu [/Welcome/PQF Monitoring/Status of module]). Note that in the reset process the whole system will be shut down. If the fault of the unit cannot be reset, the ACK. FAULT message will be displayed again for the unit considered. The filter system can be restarted at any time and the units that are available will operate normally. Acknowledging of a fault which resulted in a complete filter system shut down has two possible consequences: − If the fault is permanent (e.g. permanent network under voltage due to phase loss), it cannot be cleared and the message ‘ACK. FAULT’ will remain on the display. In this case the cause of the problem has to be identified and removed before the filter can be restarted. − If the fault is not present anymore when the ‘ACK. FAULT’ command is given, the menu will change into ‘PQF START’ to indicate that the filter can be restarted. Fault analysis can be done by consulting the ‘PQF Monitoring’ menu [/Welcome/PQF Monitoring]. For more information on the ‘PQF monitoring’ menu, refer to Section 7.10. If the filter is set up for remote control operation, the local start/stop command has no effect. Disable the digital inputs to override the remote control [/Welcome/Settings/Customer set./Digital inputs].

7.8 The ‘Measurements’ menu This menu allows monitoring a variety of variables (e.g. voltage, current …) in a variety of formats (e.g. RMS-values, spectra, time domain waveforms). Its submenus are discussed next. In multi-unit filters, several parameters are measured by the individual units. In order to consult measurements from a specific unit, select the unit with the ‘Select Unit’ option (where available). The order of the unit is determined by the DIP switch unit identification setting at the moment of commissioning. 7.8.1 The ‘Overview’ menu The Overview menu summarizes the following characteristic parameters (Table 39). These parameters are expressed as numerical values in a list.

Table 39: Summary of parameters displayed in the ‘Overview’ menu Parameter name Unit Description Vrms V 4-wire mode: RMS value of all the line-to-neutral voltages 3-wire mode: RMS value of all the line-to-line voltages THDV % 4-wire mode: Total harmonic distortion of all the line-to-neutral voltages 3-wire mode: Total harmonic distortion of all the line-to-line voltages V1 V 4-wire mode: RMS value of the fundamental component of all the line-to-neutral voltages 3-wire mode: RMS value of the fundamental component of all the line-to-line voltages Frequency Hz Network frequency V dc bus V Active filter DC capacitor voltage Imbalance % Indicates the imbalance in supply voltage (%value) Irms A 4-wire mode: RMS value of all the line currents and the neutral current 3-wire mode: RMS value of all the line currents THDI % Total harmonic distortion of all the line currents. I1 A RMS value of the fundamental component of all the line currents PQF Irms A RMS value of all the filter currents, including neutral current for 4- wire configuration P W, kW, MW Active power in the network at the location of the CTs P > 0: Load absorbing active power P < 0: Load generating active power Q var, kvar Mvar Reactive power in the network at the location of the CTs Q > 0: Inductive reactive power Q < 0: Capacitive reactive power S VA, kVA, MVA Apparent power in the network at the location of the CTs PF - Power factor: calculation based on the fundamental and the harmonic values of the measurements. Measurement only valid for quasi-balanced loads. cos ϕ - Displacement power factor: calculation based on the fundamental values of the measurements. : System has inductive behavior : System has capacitive behavior cos ϕ > 0: load absorbing active power cos ϕ < 0: load generating active power T Control °C/°F Main control board temperature of the selected module T Control max °C/°F Main control board temperature of the hottest module in the group

T IGBT °C/°F IGBT module temperature of the selected module T IGBT max °C/°F IGBT module temperature of the hottest module in the group On the display, the parameters are organized in such a way that a maximum of information is obtained without having to scroll down. The user may customize the display to his particular needs. To do this, follow the steps given below: − Select the measured parameter that has to be moved. The selected parameter gets highlighted in green color background. − Select a new location for this parameter by touching the preferred location on the list of parameters. − The selected parameter relocates to the new place. 7.8.2 The ‘System values’ menu The ‘System values’ menu gives detailed information on the following parameters. 7.8.2.1 Voltages Refer to Table 39 for an explanation of the parameters.

7.8.2.1.1 Global values Vrms, V1 and THDV in table format. 7.8.2.1.2 Waveforms The network voltage waveforms for all phases (Figure 60). All waveforms are synchronized with the rising edge zero crossing of the voltage V (L1-N) (4-W mode) or V (L1-L2) (3-W mode). Figure 60: Time domain waveform of line voltage displayed by the PQF-Manager (3-W mode example) 7.8.2.1.3 Spectrum The network voltage spectrum for all phases in chart format (Figure 61). The spectral components up to the 49th order are expressed as a % of the fundamental component with absolute values also shown in the top right corner. The two buttons with “+” and “- “ mark help changing the voltage level resolution (i.e. Y-axis value in the chart). Figure 61: Spectrum of the network voltage in chart format displayed by the PQF-Manager (4-W mode example)

7.8.2.1.4 Harmonic table The network voltage spectrum for all phases in table format (Figure 62). Both the absolute values and the % of the fundamental component values are shown for each spectral component up to the 49th rank. Figure 62: Spectrum of the network voltage in table format displayed by the PQF-Manager (4-W mode example) Following parameters are displayed in the sub-menu “Voltages” itself in a tabular form. − The network frequency − The network imbalance − The active filter DC bus voltage of the selected unit − The active filter DC bus voltage (max.) 7.8.2.2 Line currents Refer to Table 39 for an explanation of the parameters.

7.8.2.2.1 Global values Irms, I1 and THDI are displayed in table format. 7.8.2.2.2 Waveforms The line current waveforms for all phases (3-W mode) and the neutral current waveform (4-W mode). The graph layout is similar to the one of the voltages (Figure 60). All waveforms are synchronized with the rising edge zero crossing of the voltage V (L1-N) (4-W mode) or V (L1-L2) (3-W mode). 7.8.2.2.3 Spectrum The line current spectrum for all phases (3-W mode) and the neutral current spectrum (4- W mode) in chart format. The chart layout is similar to the one of the voltages (Figure 61). 7.8.2.2.4 Harmonic table The line current spectrum for all phases (3-W mode) and the neutral current spectrum (4- W mode) in table format. The table layout is similar to the one of the voltages (Figure 62). 7.8.2.3 Filter currents Refer to Table 39 for an explanation of the parameters. PQF Irms in table format for the unit selected with the ‘Select Unit’ option.

7.8.2.3.1 Waveforms The filter current waveforms for all phases for the unit selected with the ‘Select unit’ option. The graph layout is similar to the one of the voltages (Figure 60). All waveforms are synchronized with the rising edge zero crossing of the voltage V (L1-N) (4-W mode) or V (L1-L2) (3-W mode). 7.8.2.3.2 Spectrum The filter current spectrum for all phases (3-W mode) and the neutral current spectrum (4-W mode) in chart format for the unit selected with the ‘Select unit’ option. The chart layout is similar to the one of the voltages (Figure 61) but the values are expressed in absolute terms. 7.8.2.3.3 Harmonic table The filter current spectrum for all phases (3-W mode) and the neutral current spectrum (4-W mode) in table format for the unit selected with the ‘Select unit’ option. The table layout is similar to the one of the voltages (Figure 46) but only absolute current values are shown. 7.8.2.4 Total filter currents Refer to Table 39 for an explanation of the parameters. PQF Irms in table format for the complete filter system. 7.8.2.4.1 Waveforms The filter current waveforms for all phases for the complete filter system. The graph layout is similar to the one of the voltages (Figure 60). All waveforms are synchronized with the rising edge zero crossing of the voltage V (L1-N) (4-W mode) or V (L1-L2) (3-W mode). 7.8.2.4.2 Spectrum The filter current spectrum for all phases (3-W mode) and the neutral current spectrum (4-W mode) in chart format for the complete filter system. The chart layout is similar to the one of the voltages (Figure 61) but the values are expressed in absolute terms. 7.8.2.4.3 Harmonic table

The filter current spectrum for all phases (3-W mode) and the neutral current spectrum (4-W mode) in table format for the complete filter system. The table layout is similar to the one of the voltages (Figure 46) but only absolute current values are shown. Note: For a multi-unit filter system, the total filter current is an approximate value. More detailed values for the individual units can be obtained in the ‘Filter currents’-menu. 7.8.2.5 Powers The power in the system at the location of the CTs: (Refer Table 39 for an explanation of the parameters). − Active power P − Reactive power Q − Apparent power S − Power factor PF − Displacement power factor cos ϕ 7.8.2.6 Temperatures Refer to Table 39 for an explanation of the parameters. − Temperatures may be expressed in °C and in °F. For changing the temperature unit, go to [/Welcome/Settings/Customer set. /Temp unit].

− Temperature of the hottest IGBT (‘T IGBT’) of the unit selected by the ‘Select unit’- option. Temperature of the hottest IGBT (T IGBT max) in a multi-unit system − Temperature of the control board (‘T Control’) of the unit selected by the ‘Select unit’-option − Temperature of the hottest control board (‘T control max’) in a multi-unit system − Temperature recorded by the optional temperature probes (up to 8 probes can be connected on each PQF-Manager) 7.8.3 The ‘Min-Max logging’ menu The ‘Min-Max logging’ function allows for the user to log for each significant measured item and since the last reset: − The maximum (or minimum) value − The duration above (or below) the threshold Once a threshold has been set the PQF-Manager starts recording the maximum (or minimum) value automatically as well as the total duration until a reset is performed. Figure 63 illustrates this. Figure 63: Illustration of the threshold and the maximum recorded value used in the Min/Max logging function The parameters that can be used with the logging function are voltages (Vrms, THDV), currents (Irms), Power (P, Q, S), frequency and temperature (T IGBT and Tcontrol) along with temperatures recorded by the probes (max. 8 probes possible). All information about temperature are specific to the probe connected to the PQF-Manager where the probe is connected. Refer to Table 39 for an explanation of the parameters. For the frequency, minimum values and duration below a threshold can also be recorded. The recorded information may be cleared by selecting and validating the ‘Reset’ item.

If the hardware lock is engaged, the logging function cannot be started nor reset (Cf. Section 7.6) Figure 64 shows an example in which the network voltage between L1 and L2 is monitored. The nominal network voltage is assumed to be 400 V. The threshold was initially set at 1000 V and is changed to 420 V. Figure 64: Example of the Min/Max logging function (4-W mode) 7.9 The ‘Settings’ menu The ‘Settings’ menu [/Welcome/Settings] has four main levels: − The customer level which allows the user to set up the typical user requirements such as harmonic filtration settings, the reactive power settings, sets up the digital inputs and outputs and defines the programmable warnings and alarms. At this level, the user can also change the temperature unit used by the system. The customer level is accessed through [/Welcome/Settings/Customer set.] − The commissioning level which allows the commissioning engineer to set up the equipment according to the customer’s installation. Typical parameters that need to be entered are the network voltage and frequency, the CT parameters and a derating factor that needs to be applied when the installation is at great height above sea level or in conditions where excessive ambient temperatures are present. At the commissioning level the possibility also exists to set up the user’s requirements for harmonic filtration and reactive power compensation. The commissioning level is accessed through [/Welcome/Settings/Commissioning].

− The installation settings level allows for the commissioning engineer to set up advanced system functions such as the filter auto restart and standby functions, the clock, the communication of Modbus and PQ-Link and the setting of a system lock with password. For information purposes the installation settings level also shows the settings for the network voltage and frequency, the rating of the filter unit(s), the CT parameters and the derating factor that has been set-up at the commissioning level. The installation settings level is accessed through [/Welcome/Settings/Installation set.] − Apart from above three, the fourth button allows the language setting. The PQF- Manager supports six languages: English, French, German, Spanish, Chinese (simplified) and Korean. Note: In active filter systems consisting of more than one master, the PQF-Manager of the master that has the control over the system has full functionality and the PQF- Managers of the other master units have limited functionality. In practice, the functions that are not enabled on these units are locked and a symbol will appear. These functions are set up in the ‘real’ master and are automatically further dispatched to the other units by the control system. All functions and measurements (e.g. digital I/O, temperature) which are “hardwired” to a PQF-Manager provide data/control only for that specific filter unit. 7.9.1 The ‘Customer settings’ menu

The customer settings menu is intended to be used by people that are authorized to change the filter operation settings. Refer to Section 7.6 for determining appropriate locking facilities for this menu. 7.9.1.1 Settings up harmonics, reactive power and filter mode In multi-master units these functions need to be set up only in the master with the lowest hardware ID (0001 in case of single module and 0000 in case of multiple units) setting in the DIP switch. Setting up harmonics, reactive power and filter mode can be done in a main window [/Welcome/Settings/Customer set./Main settings] and in an auxiliary window [/Welcome/Settings/Customer set./Auxiliary settings]. By having two windows, the customer can set two sets of different settings, e.g. one set for mains operation and one set for generator operation, or one set for day settings and one set for night settings. Both main and auxiliary settings windows have the same setup possibilities, i.e. − Definition of the filter mode − Selection of the harmonics with setting of curve levels − Selection of reactive power compensation with balancing functionality − Deselection of all harmonics The filter has to be informed about whether the main window settings or the auxiliary window settings must be used. This is done by the ‘Activate’ flag [/Welcome/Settings/Customer set/Activate]. Possible values for this flag are given in Table 40. By default the filter uses the main filter settings. Table 40: Possible settings for the activate field ‘Activate’ field value Description Main Main window settings are always used Auxiliary Auxiliary window settings are always used Ext. input The filter switches between the main and the auxiliary settings according to a signal applied to the PQF-Manager’s digital input(a). Remark:

(a) Refer to detailed manuals for cabling instructions for this feature. Refer to Section 7.9.1.4 configuring the digital input for this feature. The external input must be provided to the PQF- Manager which acts like the “master” unit. 7.9.1.1.1 Setting up the filter mode For setting up the filter’s main filter mode go to [/Welcome/Settings/Customer set./Main settings/Filter mode]. For setting up the filter’s auxiliary filter mode go to [/Welcome/Settings/Customer set./Auxiliary settings/Filter mode]. 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 including load balancing The user can put the emphasis on one of the above effects by selecting the filtering mode. Table 41 shows the three available modes: Table 41: Available filter modes Highest priority level Lowest priority level Mode 1 Filtering to curve Maximum filtering Reactive compensation Mode 2 Filtering to curve Reactive compensation Maximum filtering Mode 3 Filtering to curve Reactive compensation - In Mode 1, the filter will first filter to the pre-programmed curve. Once the requirements are fulfilled, the 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 and load balancing will be performed as required. In Mode 2, the second priority after filtering to the curve is reactive power compensation and load balancing. Maximum filtering comes in third place and will be done if both the curve specification and the reactive power requirements including balancing are fulfilled. In Mode 3, the filter will first ensure that the harmonic curve specification is fulfilled. If then there are still resources available, the filter will do reactive power compensation and load balancing if requested by the user.

Figure 65 illustrates the principle of filtering to curve for one particular harmonic order. The flexibility of the PQF control is such that a specific curve level may be defined for each selected harmonic. Figure 65: Filtering to curve for harmonic order n The default filter mode is Mode 3. 7.9.1.1.2 Selecting the harmonics with setting of curve levels For setting up the filter’s main harmonics selection go to [/Welcome/Settings/Customer set./Main settings/Main harmonics] For setting up the filter’s auxiliary harmonics selection go to [/Welcome/Settings/Customer set./Auxiliary settings/Aux. harmonics] The harmonics that can be selected are presented in a table such as presented in Table 42. When the PQF is operating in 4-W mode, 15 harmonics can be selected. When the PQF is operating in 3-W mode, 20 harmonics can be selected.

Table 42: Example of harmonic settings table displayed by PQF-Manager Order Select(a) Curve(b) 3 Yes 0 A 5 Yes 10 A 7 Yes 0 A 9 No 0 A Remarks: (a) The ‘Select’ column may have three values: No: Harmonic not selected by user Yes: Harmonic selected by user and being filtered S: Harmonic selected by user but put in ‘standby’ by the filter. Refer to Section 8.10 for more information on the “harmonic standby” mode. (b) Curve settings for allowed current into the network are expressed in Amps In order to select the harmonics and set up a curve level (if desired) − Open the harmonic table by selecting the “Main harmonics”. The table has a default factory setting. − Select any row by touching it, a new window opens up with two drop down menu (one for harmonic order and another for select option) and a third one to enter the “curve” value. In the harmonic order all harmonics from 2nd to 49th order are listed but, only those harmonics which are not already chosen appears selectable and those which are already in the pre-selected list appear “greyed”. Once a new harmonic order is selected, the table automatically gets sorted in ascending order. In order to remove any harmonic order from this list, one has to touch that row and then from the dropdown menu, replace that harmonic order by any other harmonic of choice. − Note: Above procedure is only to include (or exclude) any harmonic order in the list. Further to that, the user must select specific harmonics by choosing Yes or No from the other dropdown menu for the filter to consider them for filtering − To set the curve value, the “curve” data entry window needs to be selected. As soon the window is touched, the numeric keypad appears allowing the user to set a desired curve level (in terms of Amp). Fractional values are not accepted and are rounded off to the nearest integer. Once all the harmonics are programmed, the harmonic selection table can be exit by pressing. The button at the top right corner.

7.9.1.1.3 Deselect all harmonics For deselecting all harmonics of the main window at once go to [/Welcome/Settings/Customer set./Main settings/Deselect all] For deselecting all harmonics of the auxiliary window at once go to [/Welcome/Settings/Customer set./Auxiliary settings/Deselect all] This function allows for the customer to quickly deselect all harmonics in the main or the auxiliary window. This may be useful e.g. when the commissioning engineer realizes that the CTs have been installed wrong and an intervention is required to correct the problem. 7.9.1.1.4 Selecting the reactive power compensation and balancing options For setting up the filter’s main reactive power and balancing mode go to [/Welcome/Settings/Customer set./Main settings/Main PFC/Bal.] For setting up the filter’s auxiliary reactive power and balancing mode go to [/Welcome/Settings/Customer set./Auxiliary settings/Aux. PFC/Bal.] The active filter can perform different reactive power tasks including balancing, each of which require the appropriate setup. Table 43 shows an overview of the possible tasks and shows how the filter set up should be done to implement this task. The parameters (italic print) referred to in Table 43 can be accessed in the ‘Main PFC/Bal.’ and ‘Aux. PFC/Bal.’ windows of the PQF-Manager.

Table 43: Reactive power tasks that the filter can perform Reactive power task requirement Description and filter set-up to be made No requirements PFC type: Disabled Balance load: Disabled The filter will not do any reactive power task, regardless of the values set for cos ϕ or static reactive power Power factor compensation with inductive power factor set point, no load balancing required(a) PFC type: Dyn. Ind. Target cos ϕ: Desired power factor between 0.6 and 1.0 The filter will do power factor compensation up to the cos ϕ set point, regardless of the value set for static reactive power(b) Power factor compensation with capacitive power factor set point, no load balancing required(a) PFC type: Dyn. Cap. Target cos ϕ: Desired power factor between 0.6 and 1.0 The filter will do power factor compensation up to the cos ϕ set point, regardless of the value set for static reactive power© Fixed capacitive power step with a rating of x kvar, no load balancing required(a) PFC type: Static cap. Q static: x kvar The filter will generate x kvar reactive capacitive power, regardless of the value set for the target cos ϕ Fixed inductive power step with a rating of x kvar, no load balancing required(a) PFC type: Static ind. Q static: x kvar The filter will absorb x kvar reactive inductive power, regardless of the value set for the target cos ϕ Remarks: (a) When load balancing is required, set the ‘Balance load’ flag to the desired mode. The following modes are available depending on the way the filter is connected (3-W or 4-W) - ‘Disabled’: No load balancing is done. - ‘L-L’: Loads connected between phases only are balanced. Loads connected between phases and neutral are not balanced. - ‘L-N’: Loads connected between phase and neutral are balanced. Loads connected between phases are not balanced. This mode is only available when the filter is connected in 4-W mode. - ‘L-L & L-N’: Both loads connected between phase and neutral as well as loads connected between phases are balanced. This mode is only available when the filter is connected in 4-W mode. Note: The modes ‘L-N’ and ‘L-L & L-N’ can be used to minimize the amount of fundamental frequency current flowing in the neutral. (b) If the measured cos ϕ is higher than the set point and is inductive (e.g. measured 0.97 inductive and set point 0.92 inductive, then the filter will not make any correction. If the measured cos ϕ is capacitive, the filter will correct the power factor to 1.0 (c) If the measured cos ϕ is higher than the set point and is capacitive (e.g. measured 0.97 capacitive and set point 0.92 capacitive, then the filter will not make any correction. If the measured cos ϕ is inductive, the filter will correct the power factor to 1.0