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Active multi-function filterAFQ-4W-25 AFQ-4W-100

AFQ-4W-50 AFQ-4W-150 AFQ-4W-200

USER MANUAL(M98241701-03-13B)

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Instruction Manual 3

SAFETY PRECAUTIONS

Follow the warnings described in this manual with the symbols shown below.

DANGERWarns of a risk, which could result in personal injury or material damage.

ATTENTIONIndicates that special attention should be paid to a specific point.

If you must handle the unit for its installation, start-up or maintenance, thefollowing should be taken into consideration:

Incorrect handling or installation of the unit may result in injury to personnel as well

as damage to the unit. In particular, handling with voltages applied may result in

electric shock, which may cause death or serious injury to personnel. Defective

installation or maintenance may also lead to the risk of fire.

Carefully read this manual before connecting the unit. Follow all installation and

maintenance instructions throughout the unit's operating life. Pay special attention

to the installation standards of the National Electrical Code.

Refer to the instruction manual before using the unit.

In this manual, if the instructions marked with this symbol are not respected or

carried out correctly, it can result in injury or damage to the unit and /or

installations.

CIRCUTOR, SAreserves the right to modify features or the product manual without prior notification.

DISCLAIMER

CIRCUTOR, SAreserves the right to make modifications to the device or theunit specifications set out in this instruction manual without prior notice.

CIRCUTOR, SA, on its web site, supplies its customers with the latest versionsof the device specifications and the most updated manuals.

www.circutor.com
http://www.circutor.com/http://www.circutor.com/http://www.circutor.com/

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4 Instruction Manual

CONTENTS

SAFETY PRECAUTIONS.................................................................................................................... 3

DISCLAIMER........................................................................................................................................ 3

CONTENTS.......................................................................................................................................... 4

LOG OF REVISIONS........................................................................................................................... 7

1.- VERIFICATION UPON RECEIPT.................................................................................................. 8

1.1.-RECEPTIONPROTOCOL............................................................................................................8

1.2.-TRANSPORTANDHANDLING ...................................................................................................9

1.3.-STORAGE.....................................................................................................................................10

2.- PRODUCT DESCRIPTION.......................................................................................................... 11

2.1.AFQ-4W-25.....................................................................................................................................12

2.2.AFQ-4W-50.....................................................................................................................................13

2.3.AFQ-4W-100 ..................................................................................................................................14

2.4.AFQ-4W-150ANDAFQ-4W-200...................................................................................................15

3. UNIT INSTALLATION.................................................................................................................... 16

3.1.-PRELIMINARYRECOMMENDATIONS....................................................................................16

3.2.-INSTALLATIONLOCATION........................................................................................................17

3.3.-STORAGEFORLONGPERIODS.............................................................................................18

3.4.-SIZINGTHENOMINALCURRENTOFTHEAFQ-4W............................................................19

3.5.-CONNECTIONS...........................................................................................................................21

3.5.1. THREE-PHASE MAINS TO NEUTRAL CONNECTION.................................................22

3.5.2. CURRENT TRANSFORMER CONNECTION..................................................................23

3.6.-PARALLELCONNECTIONOF2TO8ACTIVEFILTERS......................................................25

3.7.-CONNECTINGTHEFILTERTOTHEMAINS..........................................................................26

3.8.-FILTERSTART-UP.......................................................................................................................27

3.8.1- CONFIGURATION................................................................................................................27

3.8.1.1.- CONFIGURATION OF THE CURRENT TRANSFORMER........................ ........................ .... 27

3.8.1.2.- PARALLEL MODULE CONFIGURATION ................................................................................ 28

3.8.1.3.- WORK MODE CONFIGURATION............................................................................................. 28

3.8.2- UNIT VERIFICATION...........................................................................................................29

3.8.3- ACTIVE FILTER START-UP................................................................................................31

4. OPERATION................................................................................................................................... 33

4.1.-OPERATINGPRINCIPLE ...........................................................................................................33

4.1.1.- HARMONICS........................................................................................................................33

4.1.2.- BASIC CONCEPTS.............................................................................................................33

4.1.3.- MOST COMMON HARMONICS .......................................................................................35

4.1.4.- HARMONIC COMPENSATION.........................................................................................35

4.1.5.- OPERATING PRINCIPLE...................................................................................................36

4.2.-DISPLAY........................................................................................................................................37

4.2.1.- MAIN SCREEN ....................................................................................................................37

4.2.2.- DISPLAY SCREENS...........................................................................................................38

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4.2.2.1.- BROWSING DIAGRAM .............................................................................................................. 39

4.2.2.2.- Voltage and current display screen ........................................................................................... 40

4.2.2.3.- General power screen ................................................................................................................. 40

4.2.2.3.1.- Load power display screen ................................................................................................ 41

4.2.2.4.- General THD(I) screen ................................................................................................................ 43

4.2.2.4.1.- THD Display screen of the phase 1 load current............................................................ 434.2.2.4.2.- THD Display screen of the phase 2 load current............................................................ 44

4.2.2.4.3.- THD Display screen of the phase 3 load current............................................................ 44

4.2.2.4.4.- THD Display screen of the phase 1 mains current......................................................... 45



4.2.2.4.7.-Display screen of the total THD(I) ...................................................................................... 46

4.2.2.5.- Display screen of the alarm log.................................................................................................. 47

4.3.-CONFIGURATION .......................................................................................................................48

4.3.1.- BROWSING DIAGRAM......................................................................................................49

4.3.2.- OPERATION MODE CONFIGURATION..........................................................................504.3.2.1.- FUNCTION SELECTION ............................................................................................................ 51

4.3.2.2.- SELECTIVE FILTERING............................................................................................................. 52

4.3.2.3.- ENABLE ALARM .......................................................................................................................... 53

4.3.3.- CONFIGURATION OF PARAMETERS............................................................................55

4.3.4.- FILTER DATA .......................................................................................................................57

4.3.5.- SCREEN CONFIGURATION.............................................................................................58

4.3.6.- PASSWORD.........................................................................................................................59

4.4.-RS-485COMMUNICATIONS.....................................................................................................60

4.4.1. MODBUS FRAMES..............................................................................................................62

4.4.2. PowerStudio SOFTWARE...................................................................................................62

5.- MAINTENANCE............................................................................................................................ 63

5.1.STANDARDMAINTENANCE......................................................................................................64

5.2.COOLINGTURBINESANDFANS..............................................................................................65

5.2.1. INDUCTOR COOLING FANS..............................................................................................66

5.2.1.1. AFQ-4W-25 A / 50 A / 100 A MODELS ....................................................................................... 66

5.2.1.2. AFQ-4W-150 A / 200 A MODELS ................................................................................................ 68

5.2.2. COOLING FANS/TURBINES OF THE IGBTs...................................................................71

5.2.2.1. AFQ-4W-25 A / 50 A MODELS .................................................................................................... 71

5.2.2.2. AFQ-4W-100 A / 150 A / 200 A MODELS ................................................................................... 75

5.3.DCBUSCAPACITORS ................................................................................................................81

6.- SOFTWARE UPDATE.................................................................................................................. 81

6.1.CONTROLLERSOFTWAREUPDATE ......................................................................................81

6.2.DISPLAYSOFTWAREUPDATE.................................................................................................83

7.- TECHNICAL FEATURES............................................................................................................. 87

8.- MAINTENANCE AND TECHNICAL SERVICE.......................................................................... 89

9.- GUARANTEE................................................................................................................................ 89

10.- CE CERTIFICATE....................................................................................................................... 90

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APPENDIX A: DISPLAY MESSAGES............................................................................................. 91

ACTIVEFILTERSTOPPED.................................................................................................................91

ACTIVEFILTERINALARMSTATUS.................................................................................................93

ACTIVEFILTEROPERATING ............................................................................................................95

ACTIVEFILTERINCONFIGURATION..............................................................................................95

APPENDIX B: MODBUS MAP.......................................................................................................... 97

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LOG OF REVISIONS

Date Revision Description11/10 Version 1.0 Original version02/11 Version 1.1 Display change

11/11 Version 1.2Modification of the sections:

Installation and start-up. User screen.

05/12 Version 1.3Modifications in the section:

configuration screen.

12/12 Version 1.4

Modification of the sections: User screen.

Introduction of the sections: PowerStudio application. Maintenance.

11/13 M98241701-01-13B Modifications throughout the manual.

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1.- VERIFICATION UPON RECEIPT

1.1.- RECEPTION PROTOCOL

Make sure that the unit has not been damaged during transport.

Check that the unit received matches that described in your order and

that its electrical features are suitable for the mains where it is to be

connected. See features label on the rear of the door.

(Figure 1)

Figure 1: Features label of the AFQ-4W

Make sure that it is equipped with the following accessories:

- Main switch handle.- 2 keys for locking the door.

- Manual.

TheAFQ-4W-25 also has:- 4 DIN 580-M8 suspension eye bolts (male).

- 4 DIN 963, M8x16 screws.

Check the shipping documentation. The dispatch note number must

coincide with the number marked on the outer part of the unit. Unload and

transport the unit following the instructions in section 1.2.- TRANSPORT

AND HANDLING

Inspect the unit externally and internally before connecting.

Check that all the unit's items on the packing list are present.

If any problem is noticed upon reception, immediately contact the

transport company and/or CIRCUTOR's after-sales service.

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1.2.- TRANSPORT AND HANDLING

The transport, loading and unloading and handling of the unit must

be carried out with proper precautions and using the proper manual

or mechanical tools to prevent damage to the unit.

If the unit is not to be immediately installed, it must be stored at a

location with a firm and level floor, and the storage conditions listed in

the section must be observed.1.3.- STORAGE

In such a case, the unit should be kept in its original protective

packaging.

To move the unit a short distance, the unit's floor support profiles facilitate

handling with a pallet jack or forklift. (Figure 2)

The centre of gravity of some units may be found at a considerable

height. Therefore, when handling with a forklift, it is recommended

that the unit be securely fastened and that no abrupt operations are

made. The unit should not be lifted more than 20 cm off the ground.

Figure 2: Transport with pallet jack

When unloading and moving the unit, use a forklift with forks long enough to

support the entire length of the base. Otherwise, the forks should be long

enough to support at least of said depth. The forks must be flat and supported

firmly by the base. The cabinet must be raised by placing the forks underneath

the profile that supports the unit. (Figure 3).

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There might be an offset in the centre of gravity from the centre of

the cabinet, as a result of the uneven distribution of loads in

equipment. The necessary precautions must be taken to prevent the

equipment from tipping over during abrupt operations.

Figure 3: Unloading with a forklift

1.3.- STORAGE

The unit should be stored according to the following recommendations:

Avoid placing it on uneven surfaces.

Do not store in outdoor areas, humid areas or areas exposed to the

splashing of water. Avoid hot spots (maximum environmental temperature: 45C)

Avoid saline and corrosive environments.

Avoid storing the unit in areas where a lot of dust is generated or where

the risk of contamination by chemical agents or other types of pollution is

present.

Do not place any weight on top of the unit's cabinets.

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2.- PRODUCT DESCRIPTION

TheAFQ-4W parallel multi-function active filters enable the following functions to

be performed: Reduction of harmonic currents up to order 50 (2500 Hz).

Correcting unbalanced current consumption in each phase of the

electrical installation.

Reactive power compensation. Both inductive and capacitive currents.

CIRCUTORhas 5 different filter models:

Models AFQ-4W-25 AFQ-4W-50 AFQ-4W-100 AFQ-4W-150 AFQ-4W-200

Harmonic phasecurrent

25A RMS 50A RMS 100A RMS 150A RMS 200A RMS

Harmonic neutralcurrent

75A RMS 150A RMS 300A RMS 450A RMS 600A RMS

Harmonic peakcurrent

50A PEAK 100A PEAK 200A PEAK 300A PEAK 400A PEAK

Table 1: AFQ-4W models

All active filter models have the following:

An LCD 5.7" touch display. An RS-485 connection.

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2.1. AFQ-4W-25

AFQ-4W-25 components seen from the front (Figure 4):

Figure 4: AFQ-4W-25 front v iew.AFQ-4W-25internal components (Figure 5):

Figure 5: AFQ-4W-25 interior.

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2.2. AFQ-4W-50


Figure 6: AFQ-4W-50 front v iew.

AFQ-4W-50internal components (Figure 7):


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2.3. AFQ-4W-100


Figure 8: AFQ-4W-100 front view.

AFQ-4W-100internal components (Figure 9):


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2.4. AFQ-4W-150 and AFQ-4W-200

AFQ-4W-150 and AFQ-4W-200 components seen from the front (Figure 10):

Figure 10: AFQ-4W-150 and AFQ-4W-200 front view.

AFQ-4W-100andAFQ-4W-200internal components(Figure 11):

Figure 11: AFQ-4W-150 and AFQ-4W-200 interior.

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Never power or start up the active filter with the front door open or

the side or rear covers removed.

Check that there is a neutral in the place where three-phase active filter

connections are made with neutral,AFQ-4W.

The active filter must be of the correct size for the harmonic currents it has to

filter and for the installation's electrical features.

Check the section 3.4.- SIZING THE NOMINAL CURRENT OF THE

AFQ-4W to define the correct unit size. Failing to observe the

recommendations described in this section might cause the active

filter to work incorrectly and prevent proper compensation of the

installation's current harmonics.

Connect a reactor of at least 3% of the impedance on the input of

each of the loads.

3.2.- INSTALLATION LOCATION

The unit must be installed in an environment where the temperature outside the

cabinet is between 0C and 40C, with a maximum humidity of 90% without

condensation.

Do not install the unit close to a hot spot and keep it out of direct sunlight.

Ventilation spaces must be left on the side and rear to allow for the use of fans.

There must also be sufficient space at the front of the cabinet to be able to openthe door if necessary (Figure 12):

200 mmon the sides of the cabinet.

200 mmbetween the top of the cabinet and the ceiling.

800 mmat the front of the cabinet.

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Figure 12: Active filter spaces for ventilation .

Install the AFQ-4W in a place protected from water, flammable

liquids, gases and corrosive substances.

Make sure there are no reactive compensation units installed in the

same mains as the AFQ-4W. If there are any compensation units,

these must be untuned in order to avoid interference between them

and theAFQ-4W.

3.3.- STORAGE FOR LONG PERIODS

If the unit is not installed after receipt, the following recommendations must be

observed to keep the unit in a good state:

Keep the unit in a dry atmosphere and at a temperature of between 0C

and 50C.

Avoid exposure to direct sunlight.

Keep the unit in its original packaging.

If the active filter is stored for a long time disconnected from the mains, a

process must be applied to restore the internal dielectric layers of the DC bus

capacitors. Table 2shows the recommendations for starting the unit depending

on the length of its storage period.

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Storage time Process< 1 year No special treatment required.

1-2 yearsConnect theAFQ-4Wto the mains at least onehour before starting up the unit.

> 2 years

Connect theAFQ-4Wto the mains at least one

hour before starting up the unit. Restrict the

maximum load current to 5 mA.

Table 2: Start-up process depending on storage time.

3.4.- SIZING THE NOMINAL CURRENT OF THE AFQ-4W

The purchased active filter must be sized for the harmonic currents it has to filter.

The nominal current of the AFQ-4W must be at least 20% higher than the

maximum level of harmonics to be filtered. This factor may be higher depending

on the installation features.

The active filters can suffer from overloading when trying to cancel the harmonic

currents in high-impedance, short-circuit mains. The clearest symptom for

detecting such cases is that they originally start from a THD(V)(under voltage)

of over 3%. It has been seen that the higher the initial THD(V), the greater the

chance of filter overload.

The reason for this behaviour is that the load does not behave as a current

source, but rather the larger the harmonic current absorbed by the filter the more

harmonics are produced by the load, which can produce up to more than double

what was initially measured.

To avoid this phenomenon, it is best to oversize the active filter by multiplying the

initial current of harmonics measured in the load by a safety factor (SFh). In

other words:

Ifilter(AFQ) = [SFh Iload THD(I) ]Where:

Ifilter(AFQ):nominal current of the active filterSFh:safety factor > 1.2.

Iload:load maximum current

THD(I):load current harmonic distortion

Equation 1: AFQ-4W nominal cur rent

To calculate this safety factoryou must first know the parameter called short-

circuit ratio RSC at the connection point of the PCL transducers (not on the

installation input). The short-circuit ratio is defined as the ratio between the short-

circuit current of a mains (ISC) and the nominal current of the set of non-linear

transducers (INLC) producing the harmonics to be filtered. (Equation 2)

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CNL

SC

SC

I

IR =

Equation 2: Calculating the short-circuit ratio RSC.

In a real installation, the short-circuit current (ISC)in the PCL can be assessed by

having the voltage at the said point for two different load currents. For example,

full load, IAand 10% load, IB. If VOCis the rated voltage in a vacuum, the ISC, can

be calculated using the formula shown inFigure 13:

Figure 13: Graphic for calculating ISC.

Figure 14The safety factor (SFh) can be obtained from the graphic in:

Figure 14: Approximate graphic for calculating the SFh.

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3.5.- CONNECTIONS

All power and current reading cables must enter the electrical cabinet

by the cover on the bottom, guaranteeing the IP and the userprotection against the parts of the cabinet with high voltages

( Figure 18).

Figure 15: Cable entry from the bottom of t he electrical cabinet.

Perform the drilling and/or milling out of the area for this

(Figura 15)puts at risk the integrity of the equipment and users,

as well as the loss of the warranty.

Drilling the cover cable entry out of the electrical cabinet to

avoid drilling debris may affect the functioring of the AFQ.

The connection diagram in Figure 16 must be used when performing the

electrical connections in the electrical cabinet:

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Figure 16: Connection diagram of the AFQ-4W.

3.5.1. THREE-PHASE MAINS TO NEUTRAL CONNECTION

The connections of the three-phase mains to neutral (L1, L2, L3, Nand Earth)

are identified in the active filter as inFigure 17.

Figure 17: Mains connection points in the AFQ-4W.

Use cables of a cross-section suitable for the filter nominal current.

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The minimum cable cross-section will depend on the filter range (Table 3).

AFQ-4W 25A 50A 100A 150A 200A

L1

L2

L3

Cross-section(mm 2)

10 16 35 70 95

Terminal (mm)

a 10b 20c 21 > 8

a 10b 20c 21 > 8

a 10b 20c 21 > 8

a 10b 20c 21 > 8

a 10b 20c 21 > 8

Torque (Nm) 7.6 7.6 7.6 14.4 14.4

N

Cross-section(mm 2)

25 50 95 2x95 2x95

Terminal (mm) > 8 > 10 > 10 > 10 > 10Torque (Nm) 12 20 25 30 30

Earth

Cross-section(mm 2)

25 50 95 95 95

Terminal (mm) > 8 > 8 > 10 > 10 > 10Torque (Nm) 12 20 25 30 30

Table 3: Minimum cross-section of input cables connected to the AFQ-4W.

Make sure that the AFQ-4W is correctly earthed to avoid the risk of

electrical discharge.

3.5.2. CURRENT TRANSFORMER CONNECTION

Current transformersTI1, TI2 andTI3, are located on the load side (downstream

of the filter) and are used for measurement and control purposes. In the active

filter, connections S1/L1, S1/L2, S1/L3S2/L1, S2/L2, S2/L3 have to be made as

shown inFigure 18.

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Figure 18: Transformer connection points in the AFQ-4W.

Class 0.2Stransformers of the CTor TCHseries are recommended.

The use of class 0.2, 0.5s or 0.5 transformers will slightly jeopardise the

behaviour of the active filter although they always provide acceptable harmonic

filtering replies.

The use of transformers with ratios close to the current to be

measured is recommended.

Current transformers TI1, TI2, TI3must be correctly connected for the

AFQ-4W filters to work properly. If the phases L1, L2 and L3 are

switched in the secondary, the filter will not work properly.

Check the connections and make sure that:

TI1 measures phase 1 and the transformer output cables are

connected in posts S1/L1and S2/ L1of the filter cabinet.

TI2 measures phase 2 and the transformer output cables areconnected in posts S1/L2and S2/ L2of the filter cabinet.

TI3 measures phase 3 and the transformer output cables are

connected in posts S1/L3and S2/ L3of the filter cabinet.

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3.6.- PARALLEL CONNECTION OF 2 TO 8 ACTIVE FILTERS

You can connect up to 8 active filters by connecting the three phases plus the

neutral in parallel. The load current measurement connects in series so that all of

the filters are using the same measuring transformers on the load. (Figure 19)

Figure 19: Parallel connection of 2 to 8 fil ters.

Section 4.3.3. explains how to configure the active filter to work with different

active filters in parallel.

All of the active filters connected in parallel must have exactly the

same configuration in the WORK MODEand PARAMETERS. Refer

to section4.3.- CONFIGURATION

MAINS side LOAD side

AFQ-4W AFQ-4W AFQ-4W

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3.7.- CONNECTING THE FILTER TO THE MAINS

Once the connections specified in the above sections have been checked, the

main switchof the active filter will be switched on. When the unit is started, the

messages NOT INITIAL CONDITIONS and Starting must appear on thedisplay (Figure 20).

Figure 20: Start -up message of the AFQ-4W.

A few seconds later, the message Set Up transformer ratio will appear

(Figure 21).

Figure 21: Home screen d isplayed dur ing the AFQ-4W's start-up.

Another message may appear if there is some problem in the filter connections

or the power supply. The section APPENDIX A: DISPLAY MESSAGES of this

manual describes all of the causes of malfunction and their corrective measures.

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3.8.- FILTER START-UP

Finally, start-up the AFQ-4W. To consult all of the configuration parameters in

detail, see4.3.- CONFIGURATION of this manual.

Before starting up the AFQ-4W, carefully follow the steps given in

Configuration 3.8.1and Verification of the unit 3.8.2.

3.8.1- CONFIGURATION

3.8.1.1.- CONFIGURATION OF THE CURRENT TRANSFORMER

Access the parameter configuration screen by pressing SETUPand select thePARAMETERS option (Figure 22):

Figure 22: Configuration of the transformer ratio and the number of modules in parallel.

Configure the TRANSFORMER RATIO parameter with the ratio between the

primary and secondary of the load current measurement transformer.

The AFQ-4W admits the following transformation ratios: 5/5, 10/5, 15/5, 20/5,

25/5, 30/5, 40/5, 50/5, 60/5, 75/5, 100/5, 125/5, 150/5, 200/5, 250/5, 300/5,

400/5, 500/5, 600/5, 700/5, 750/5, 800/5, 1000/5, 1200/5, 1500/5, 1600/5,

2000/5, 2500/5, 3000/5, 4000/5 and 5000/5.

If the transformer ratio is not that of the transformer installed, theAFQ-4Wwill not work properly.

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3.8.1.2.- PARALLEL MODULE CONFIGURATION

Configure the number of units in parallel in the PARALLEL MODULES

parameter (Figure 22). If there is a single unit in parallel, leave the default value

(1).

3.8.1.3.- WORK MODE CONFIGURATION

In order to configure the work mode, return to the home screen, press START

and access the work mode configuration screen.

Start the harmonic filtering, phase balancing and/or reactive compensation

functions depending on the needs of the installation (Figure 23). (For further

information on all of the functions, refer to section4.3.- CONFIGURATION )

Figure 23: Configu ration o f the functions of the AFQ-4W.

An incorrect configuration may significantly affect the performance of

the AFQ-4W. Consult the technician or qualified personnel to select

the unit configuration, depending on the needs of the installation.

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3.8.2- UNIT VERIFICATION

3.8.2.1.- VERIFICATION OF THE MAINS VOLTAGE AND FREQUENCY

The voltage and current screen (Figure 24) can be accessed from the home

screen by pressing onVIEW:

Figure 24: Verify mains voltages, currents and frequency.

Make sure the mains voltage measurements correspond to the real

voltages of the installation.

Make sure the frequencymeasured by theAFQ-4Wis the real frequency

of the installation.

Make sure the load current measurementscorrespond to the installation

current levels.

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3.8.2.2.- VERIFICATION OF THE ACTIVE AND REACTIVE POWER

The load power screen (Figure 25)can be accessed from the home screen by

pressingVIEW:

Figure 25: Verify active and reactive power and load power factor readings.

Make sure the active powermeasurement of the load equals the power

levels of the installation.

Make sure the reactive power measurement of the mains equals the

reactive power levels of the installation. Check the power factorin the three phases. If there are phases with very

high reactive power and very low active power levels, this might indicate

an error in the phase order. In this case, check the connections of the

three-phase mains power supply cables with neutral and the load current

reading cables, as described in sect ions 3.5.1 and 3.5.2.

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3.8.3- ACTIVE FILTER START-UP

Having checked the active and reactive power and power factor of the

installation, you can return to the main screen to start up theAFQ-4W.

If there is no problem with the connections, the home screen should show the

message STOP (Figure 26).

Figure 26: Message displayed when the unit is ready for start-up.

By pressing START, the active filter will take action to neutralise the harmonics,

balance the phases and/or compensate reactive power.

If it has started up correctly, the screen will show the message RUN(Figure 27).

Figure 27: Message displayed when the uni t is running.

If there is any problem in the connections of the filter or in the configuration, the

NOT INITIAL CONDITIONS message will be shown along with a description of

the malfunction (Figure 28).

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Figure 28: Message displayed when the uni t is not ready for start-up.

TheAPPENDIX A: DISPLAY MESSAGESof this manual contains all of the causes

of malfunction and their corrective measures.

If an alarm is tripped, the ALARM message will be shown along with a

description of the problem (Figure 29).

Figure 29: Message displayed when the unit is in an alarm state.

Refer to sectionAPPENDIX A: DISPLAY MESSAGES to see the causes of the

alarm and to be able to apply the corrective measures.

The RESET ALARM button rearms the unit if the cause of the alarm has

disappeared or been solved.

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4. OPERATION

4.1.- OPERATING PRINCIPLE

4.1.1.- HARMONICS

Non-linear loads such as: rectifiers, inverters, speed drives, ovens, etc, absorb

periodic non sine-wave currents from the mains.

These currents are composed of a fundamental frequency component, rated at

50 or 60 Hz, plus a series of overlapping currents, with frequencies that are

multiples of the fundamental frequency; they are defined as HARMONICS.

Figure 30: Distorted wave shape decomposition.

The result is a deformation of the current and, as a result, of the voltage, causing

a series of associated side effects. These can be machinery overload, electric

cable heating, circuit breaker disconnection, damage to sensitive units, etc.

Order (n)Mains frequency

Fundamental: 50 Hz Fundamental: 60 Hz

3 150 Hz 180 Hz

5 250 Hz 300 Hz

7 350 Hz 420 Hz

Table 4: Frequency of each harmonic.

4.1.2.- BASIC CONCEPTS

It is best to define some terms related to harmonics, fundamental for interpretingany measurement and study:

Fundamental frequency (f1): Original wave frequency (50/60 Hz).

Order of a harmonic (n): A whole number given by the ratio between thefrequency of a harmonic and the fundamental frequency. The orderdetermines the frequency of the harmonic (E.g.: 5th harmonic 550 Hz =250 Hz).

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Fundamental component (U1oI1): A sine wave component of order 1 of theFourier frequency serial development equal to the original periodic wave.

Harmonic component (UnoIn): A sine wave component of order over 1 ofthe Fourier frequency serial development a whole multiple of the original

frequency.

Individual distort ion rate (Un% oIn%): A ratio in % between the RMS valueof the voltage or harmonic current (Un o In) and the RMS value of thefundamental component (U1o I1).

Equation 3: Individual distortion rate

True root mean square value (TRMS): The square root of the sum of the

squares of all components forming the wave.

Equation 4: True root mean square value

Harmonic content: The difference between the total voltage or current andthe corresponding fundamental value.

Harmonic distortion rate (THD): The ratio between the RMS value of theharmonic content of the voltage and/or current and the value of the

fundamental component.

Equation 5: Harmonic distortion rate.

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4.1.3.- MOST COMMON HARMONICS

Table 5lists the most common harmonic generator loads and the wave shape ofthe current they consume, as well as their harmonic spectrum.

Type of load Wave shape Harmonic spect rum THD(I)6-pulse transducers:

- Speed drives

- UPS

- Three-phase rectifiers

- Transducers for

electrolysis and baths

- Discharge lamps

- Single-phase transducers

- Lighting lines

- Computer lines

- Sound and image units

Table 5: Most common harmon ics.

4.1.4.- HARMONIC COMPENSATION

Active filters are units responsible for the compensation of harmonic currents.

Compensation is achieved by injecting harmonic currents equal to those in the

installation in counter phase.

This means that upstream of the filter connection point, the signal shows virtually no

harmonic distortion. (Figure 31).

Figure 31: General connection d iagram of an active fil ter

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4.1.5.- OPERATING PRINCIPLE

Active filters are based on the following principle:

IFILTER= IMAIN- ILOAD

Equation 6: Operating principle

In other words, they detect the difference between the required current sine

wave (IMAIN) and the signal deformed by the harmonics (ILOAD). And they inject

the difference between both waves (IFILTER).

Figure 32show the wave shapes of the currents injected by the active filters.

These show the required wave, the existing deformed wave and the filter current

(IFILTER).

Figure 32: Current in the load, in the filt er and in the mains.

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4.2.- DISPLAY

The active filter has a touch display with different screens used for display and

configuration purposes.

4.2.1.- MAIN SCREEN

The main screen contains information regarding the filter status, the start and

stop controls, the alarm rearm process and the accesses to the configuration

and display variables.

Figure 33: Main screen.

As we can see inFigure 33we can distinguish the following parts:

1- START/STOP key:The start and stop active filter key. The AFQ-4W must

be "STOPPED" before it is started.

2- RESET ALARM key: Alarm rearm key. If the cause of the alarm has not

been resolved, this key allows us to restart the unit.

3- VIEWkey:Access to the display screens.

4- SETUP. key:Access to the configuration screens.

5- A message with additionalAFQ-4Wstatus information: TheAPPENDIX A:

DISPLAY MESSAGESexplains all of the messages that can appear along

with the filter status. This information is particularly useful for detecting

and resolving operational problems with the unit and for determining its

work conditions.

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6- Message indicating the filter status (Table 6):Message Status

NO CONNECTION Initial state of the display.

NOT INITIAL CONDITIONS TheAFQ-4Winitial start-up conditions are not met.STOP TheAFQ4Wis stopped and ready to start.

RUN TheAFQ-4Wis operatingALARM TheAFQ-4W has a tripped alarm.

Table 6: Filter status messages.

7- Date and time: Display of the unit date and time.

4.2.2.- DISPLAY SCREENS

On pressing VIEW in the home screen (Figure 33), you access the general

display (Figure 34), from where you can access all of the display screens.

Figure 34: General disp lay screen.

The display screens are organised into 4 groups:

Voltage and current: this option gives us access to the voltage and

current display screen.

Power:Access to the power display screen.

THD I:Access to the display screen of the total harmonic distortion of the

load and mains current.

LOG:Access to the alarm log display screen.

Click on the MAIN key toopen the home screen.

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4.2.2.1.- BROWSING DIAGRAM

Figure 35: Display screen browsing diagram.

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4.2.2.2.- Voltage and current display screen

This screen (Figure 36)gives the readings of the effective voltages of the three

phases, the effective load currents, the effective mains current and the mains

frequency.

Figure 36: Voltage and current display screen.

Click on the Main key toopen the home screen.

Click on the Backkey to return to the general display screen.

4.2.2.3.- General power screen

This screen (Figure 37)gives access to the power display screens.

Figure 37: General power screen.

Organised into 3 groups:

Power Load: Access to the active and reactive and apparent power

display screens of the three load phases.

Power Mains : Access to the active and reactive and apparent power

display screens of the three mains phases.

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Power Filter:Access to the display screen of the percentage of theAFQ-

4Wpower used with respect to the nominal power of the three phases.



4.2.2.3.1.- Load power display screen

This screen (Figure 38) shows the active, reactive, apparent powers and the

power factor of the three load phases.

Figure 38: Load power disp lay screen.


Click on the Backkey to return to the general power screen.

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4.2.2.3.2.- Mains power display screen

This screen (Figure 39) shows the active, reactive, apparent powers and the

power factor of the three mains phases.

Figure 39: Mains power display screen


Click on the Backkey to return to the general power screen.

4.2.2.3.3.- Filter power display screen

This shows the instant power used in the three phases L1, L2, L3 of the active

filter as a percentage with respect to the programmed power limit (Figure 40).

Figure 40: Filter power display screen

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4.2.2.4.- General THD(I) screen

This screen (Figure 41)gives access to the different THD(I) display screens.

Figure 41: General THD(I) screen

THD(I) Content Load: Access to the display screen of the spectrum in

load current frequencies.

THD(I) Content mains : Access to the display screen of the spectrum in

mains current frequencies.

THD(I) Total: Access to the display screen of the total mains and load

THD(I) for the three phases.



4.2.2.4.1.- THD Display screen of the phase 1 load current

This screen (Figure 42)will show the THD(I) of the phase 1 load.

Figure 42: THD Display screen of t he phase 1 load current.

Click on the Main key toopen the home screen.Click on the Backkey to return to the general THD(I) screen.

The view L2key gives us access to the THD screen of the phase 2 load current.

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Figure 43: THD Display screen of t he phase 2 load current.


Click on the Backkey to return to the general THD(I) screen.




Figure44: THD Display screen of the phase 3 load cur rent.


Click on the Backkey to return to the general THD(I) screen .


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4.2.2.4.4.- THD Display screen of the phase 1 mains current

This screen (Figure 45)will show the THD(I) of the phase 1 mains.

Figure45: THD Display screen of the phase 1 mains current.



The view L2 key gives us access to the THD screen of the phase 2 mains

current.

4.2.2.4.5.- THD Display screen of the phase 2 mains currentThis screen (Figure 46)will show the THD(I) of the phase 2 mains.

Figure 46: THD Display screen of the phase 2 mains current.




current.

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4.2.2.4.6.- THD Display screen of the phase 3 mains current

This screen (Figure 47)will show the THD(I) of the phase 3 mains.

Figure 47: THD Display screen of the phase 3 mains current.




current.

4.2.2.4.7.-Display screen of the total THD(I)

This screen (Figure 48)shows the reading of the total THD(I) of the mains and

load phases.

Figure 48: Display screen of the total THD(I).



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4.2.2.5.- Display screen of the alarm log

This screen (Figure 49)shows the log of events in the active filter, and indicates

the date and time when each event starts and ends.

Figure 49: Display screen of the alarm log.



Click on the CLEAR ALLkey, all of the incidents are deleted.

Click on the CLEAR SELECT, the selected incident is deleted.

Click on the key to view the messages on the previous page.

Click on the key to view the messages on the following page.

Click on the key to view the messages on the above line.

Click on the key to view the messages on the following line.

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4.3.- CONFIGURATION

Press SETUPon theAFQ-4Whome screen to open the setup menu.

Figure 50: General conf iguration screen.

The different sub-menus can be accessed through the initial configuration screen

(Figure 50):

Operation mode, In this sub-menu, you can select the harmonic

neutralising, phase balancing and reactive current compensation options.

Parameters, Contains the list of the measuring transformers, the

minimum current required to start up the AFQ-4W, the choice of the

control algorithm, the selection of the number of AFQ-4Win parallel and

the filter power limit.

Filter data,Description of the technical features of the unit.

Panel setup, Configuration of the language, date, time and

activation/deactivation of the screen sound.


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4.3.1.- BROWSING DIAGRAM

Figure51: Configuration browsing diagram.

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4.3.2.- OPERATION MODE CONFIGURATION

In this menu (Figure 52), users can access different screens to perform the

following:

Figure 52: Work mode menu.

Function selection: Activation or deactivation of the functions of the

AFQ-4W: harmonic filtering, reactive compensation and phase current

balancing.

Selective fil tering: Select the mains compensated harmonics.

Enable Alarms: enable or disable the different alarms.

The password protection must be unlocked to change all of these parameters.

Refer to section 4.3.6to unlock the unit configuration.


Click on the Backkey to return to the general configuration screen.

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4.3.2.1.- FUNCTION SELECTION

Use this screen (Figure 53)to select the functions of theAFQ-4W:

Figure53: Function selection screen.

Harmonic filtering:Current harmonic neutralisation. (This option is enabled by

default.)

Phase balancing:Balancing of the current between phases. (This option is not

enabled by default.)

Reactive compensation:A function that allows the shifting of the cos to be

compensated. (This option is not enabled by default.)Function priority Order:The AFQ-4Wallows the functions to be prioritised in

the event of filter current saturation by overload. When the Function priori ty

order function is disabled, priority is given to the current harmonic filtering and

reactive compensation and overload balancing are penalised. If Function

priorityorder is activated, priority is given to current balancing between phases

and reactive current compensation, ahead of harmonic neutralisation. (This

option is not enabled by default.)

Function priority order

PRIORITY

-

+

OFF ON

Harmonic filteringPhase balancing +

reactive compensation

Phase balancing +

reactive compensationHarmonic filtering

Table 7: Configuration of the order of pr iorities.

Click on the Main key toopen the home screen.Click on the Backkey to return to the work mode screen.

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Click on the Lock/Unlock parameters key to lock or unlock the configuration

parameters. (Refer to section 4.3.6)

4.3.2.2.- SELECTIVE FILTERING

Select the harmonics to be filtered on this screen (Figure 54):

Figure 54: Selective filtering screen.

If the unit is configured with the control 1algorithm (Frequency mode)

(refer to section4.3.3.- CONFIGURATION OF PARAMETERS , select the

harmonics you wish to neutralise from the 3rd to the 25th. (3rd, 5th, 7th bydefault)

If the unit is configured with the control 2algorithm (Temporary mode)

(refer to section4.3.3.- CONFIGURATION OF PARAMETERS,you can (use

this option only if recommended by your supplier):

Leave all harmonics unselected. The AFQ-4W will automatically

filter all harmonics from the 3rd to the 50th.

Select the harmonics NOT to be filtered. The selected harmonics

will not be filtered.


Click on the Backkey to return to the work mode screen.

Click on the Lock/Unlock parameters key to lock or unlock the configuration

parameters. (Refer tosection 4.3.6)

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4.3.2.3.- ENABLE ALARM

This screen (Figure 55)allows us to control the different alarms:

Figure 55: Alarm activation screen.

Polarity alarm:

With the polarity alarm enabled, the active filter detects the direction of the load

measuring transformer current and if it detects inverse polarity (current towards

the mains) it returns to the initial conditions and restarts with the new conditions

in measuring the current. In the case of regenerative loads temporarily injecting

current into the mains, the polarity alarm will be activated.

With the polarity alarm disabled, if the load is injecting energy into the mains,the AFQ-4W will measure negative active power and will stop neutralising

harmonics, balancing phases and compensating reactive energy. It will only

adjust the bus to the operating voltage.

When the active power is positive again, it will reperform all of the filtering

functions.

Disable the polarity alarm only in installations with loads temporarily

injecting current into the mains.

This option is enabled by default and it is recommended not to

disable it.

Before starting the active filter with the polarity alarm disabled, check

the connection and polarity of the load measuring transformers.

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Low temperature Alarm:

This alarm is activated to prevent the unit from starting when the temperature

inside the active filter is below 0C or when there is a problem in the connections

of the temperature probes.


disable it.

Resonance Alarm:

The resonance alarm protects the unit against possible resonating currents

between the AFQ-4W and the load. This alarm is tripped when the level of a

harmonic in the load current rises considerably.


disable it.

Before disabling the resonance alarm, it is essential to make sure

there is no resonating current between the active filter and the load.

Resonating currents can damage the active filter and other devices

connected to the installation.

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4.3.3.- CONFIGURATION OF PARAMETERS

This menu (Figure 56)contains the parameters that have to be configured during

the installation of the active filter. To be modify these parameters, you have to

unlock the password (refer to4.3.6.- PASSWORD)and have the filter in STOP

mode.

Figure 56: Parameter configuration screen.

Transformer ratio:

The ratio between the load transformer primary and secondary.

The active filter admits the following transformation ratios: 5/5, 10/5, 15/5, 20/5,

25/5, 30/5, 40/5, 50/5, 60/5, 75/5, 100/5, 125/5, 150/5, 200/5, 250/5, 300/5,

400/5, 500/5, 600/5, 700/5, 750/5, 800/5, 1000/5, 1200/5, 1500/5, 1600/5,

2000/5, 2500/5, 3000/5, 4000/5 and 5000/5.

Minimum current:

The minimum load current to start the active filter. The AFQ-4Wwill stop when

the load current is below the entered value and will start when it is higher.

Control algorithm:Control algorithm selection:

1, Frequency mode: Harmonic filtering based on the selection of the

harmonics to be neutralised from the 3rd to the 25th. (Option enabled by

default.)

2, Temporary mode: Harmonic filtering based on the total and instant

neutralisation of the 3rd to 50th harmonics.

When the temporary mode is active, theAFQ-4Wresets all the harmonics

selected in Selective filtering (Section 4.3.2.2) to completely neutralise

the harmonics.

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Do not use the Temporary mode (2) if the supplier has not

recommended this for their installation. This method can cause

resonance in certain installations.

Power limi t

This parameter allows the maximum power of the active filter to be limited. The

value is configured as a percentage with respect to the unit's nominal power. The

minimum configurable value is 20%, and the maximum is 100%.

Parallel Modules :

Access to the configuration screen of the number of active filters set out in

parallel with the same load (Figure 57).

Figure 57: Parallel module configuration screen.

A maximum of 8 AFQ-4Wunits can be installed in parallel, with different power

ratings.

All of theAFQ-4Wmust use the same load transformer. Refer to the

section3.6.- PARALLEL CONNECTION OF 2 TO 8 ACTIVE FILTERS

to install more than one active filter in parallel.

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4.3.4.- FILTER DATA

This menu (Figure 58)contains the features of theAFQ-4W.

Figure 58: Filter data screen.

This information is factory set and cannot be changed by the user.

Filter range:AFQ-4Wnominal current.

Serial number: Identification of theAFQ-4W.

Setup code:An internal code used to configure the unit.

Software version:Software version in the unit.

Panel version:Screen software version.


Click on the Backkey to return to the general configuration screen.

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4.3.5.- SCREEN CONFIGURATION

This screen (Figure 59)enables all of the screen parameters to be configured.

Figure 59: Screen configuration.

Language:Panel language selection.

Date: .Date configuration.

Time: Time configuration.

Sound:Panel beep sound enabling and disabling.

Click on the Main key toopen the home screen.Click on the Backkey to return to the general configuration screen.

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4.3.6.- PASSWORD

All configuration options of the active filter can be password protected. To lock or

unlock the configuration, press on the LOCK/UNLOCK PARAMETERS key on

the different screens (Figure 60)

Figure 60: Parameter locking key.

When the locking function is active, the unlocking option appears;

When the locking function is inactive, the activation option appears;

To activate or deactivate the parameter locking function, the password must be

entered on the virtual keyboard on the screen after pressing the

LOCK/UNLOCK PARAMETERS key. (Figure 61)

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Figure 61 : Password screen.

The default password is:1 2 3 4.The password is confirmed by pressing Enter.

Press ESCto return to the previous screen.

After changing the configuration, the password must be reactivated to

avoid accidental changes in the future.

4.4.- RS-485 COMMUNICATIONS

The active filters have a RS-485 communications port with the MODBUS RTU

communications protocol.

The RS-485 communication cable is connected to the back of the display, as

shown inFigura 62:

Figure 62: Position of t he RS-485 connector in the AFQ-4W

RS-485

connector

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The RS-485 connection is shown inFigure 63:

Figure 63: RS-485 connection.

The Modbus configuration of theAFQ-4Wis shown inTable 8:

Variable ValueProtocol MODBUS RTUslavePeripheral no. 2Baud Rate 9600

Parity NoData bits 8Stop bits 1

Table 8: Modbus configuration.

The permitted Modbus functions are (Table 9):

Permitted Modbus functions

Read (R) 03

Write (W) 10(1)

Values expressed as hexadecimals

Table 9: Permitted Modbus functions

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4.4.1. MODBUS FRAMES

Variable reading

Question:

Peripheral

number

Modbus

function

Start

addressNo. logs

CRC 16

(Modbus)02 03 H L H L H L

Response:

Peripheral

number

Modbus

function

No. bytes

(2 x number of logs)

Data

(2 x number of logs)

CRC 16

(Modbus)

02 03 1 Byte H L H L

Variable write Question:

Peripheral

number

Modbus

function

Start

addressNo. logs

No. bytes

(2 x number of

logs)

Data

(2 x number of

logs)

CRC 16

(Modbus)

02 10 H L H L 1 Byte H L H L

Response:

Peripheral

number

Modbus

function

Start

addressNo. logs

CRC 16

(Modbus)

02 10 H L H L H L

NoteAll of the values are expressed as hexadecimals.

In Appendix B: In Modbus Mapyou can see the memory map of the parameters

that can be viewed via RS-485.

4.4.2. PowerStudio SOFTWARE

CIRCUTOR uses the PowerStudio energy management software for the

configuration, communication and monitoring of theAFQ-4W.

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5.- MAINTENANCE

TheAFQ-4Wactive filter requires a minimum of preventive maintenance.

It is recommended to follow the notes described in this chapter to

avoid premature damage to the unit's components.

Table 10shows the maintenance jobs with their respective time intervals.

Description IntervalStandard maintenance 5,000 to 9,000 hours

Cooling turbines (forAFQ-4W-100,AFQ-4W-150andAFQ-4W-200)

40,000 h

Cooling fans 100,000 h

DC bus capacitors 200,000 h

Table 10: Active f ilter maintenance.

Note: The time intervals of the maintenance operations can vary depending on

the unit's operating conditions and environmental factors.

Follow the safety instructions given in SAFETY PRECAUTIONS

before any maintenance operation in theAFQ-4Wfilters.

Failure to follow these instructions may result in injury or even

death.

Certain components in the unit can reach high temperatures.

Al low the unit to cool down before per forming any maintenance

operations.

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5.1. STANDARD MAINTENANCE

Perform maintenance in 6 to 12monthly intervals, depending on the

environmental dirt and operation of the unit.

The points to be followed are:

1.-Set theAFQ-4Win STOPmode and turn off the main switch

(OFFposition).

2.-Wait 5 minutes for the capacitors to discharge.

3.-Clean the ventilation grilles, the inside of the unit and fans.

4.-Check the state and tightness of the electrical connections.

5.-Replace the display battery if necessary.

The display uses a CR20323V battery. The LED in the bottom left corner of the

display indicates the state of the battery.

Green: the battery is correct.

Red: low battery level.

Figure 64: Rear of the display.

The battery display is in its rear, as indicated inFigure 64.

It is best to note the configuration of the AFQ-4W, refer to 4.3.-

CONFIGURACIN.

When the panel battery is changed, the language, date and time of the unit have

to be reconfigured. (refer to4.3.5.- SCREEN CONFIGURATION).

Display battery

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5.2. COOLING TURBINES AND FANS

The cooling fans and turbines must work properly to avoid

overheating in the active filter components.

Table 11gives the number of fans and/or turbines required to cool the inductors

and the semiconductors according to the active filter model.

AFQ modelInductor

cooling fansIGBT cooling fans

IGBT cooling

turbines

AFQ-4W-25 A 3 2 -

AFQ-4W-50 A 3 4 -AFQ-4W-100 A 3 - 1

AFQ-4W-150 A 6 - 2

AFQ-4W-200 A 6 - 2

Table 11 : Cooling components depending on the active fil ter model.

The following symptoms in the behaviour of the filter can indicate wear in the

fans or turbines:

Increased noise in the fan / turbine.

Increased temperature in the unit under the same environmental

conditions and load.

TheAFQ-4Wperiodically indicates the temperature alarm.

If any sign of wear is detected, the affected fan/turbine should be replaced.

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5.2.1. INDUCTOR COOLING FANS

5.2.1.1. AFQ-4W-25 A / 50 A / 100 A MODELS

Follow these instructions to replace the inductor cooling fans in the AFQ-4W-

25A,AFQ-4W-50AandAFQ-4W-100Amodels:

Figure 65: Position o f the inductor fans in the AFQ-4W-25, AFQ-4W-50 and AFQ-4W-100.

1.-Set theAFQ-4Wto STOPmode and turn off the main switch

(OFF position).

2.- Wait 5 minutes for the energy accumulated in the capacitors to discharge.

3.-Open the AFQ-4Wcabinet and disconnect the fan's power supply. (Figure

66)

The power supply terminals are located in the lower left corner of the fan. Grasp

the terminal firmly and pull to disconnect it.

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Figure 66: Disconnection of the fan power supp ly.

4.- Use a 3 mm Allen key to unscrew the 4 screws fixing the fan to the front

panel. (Figure 67)

Figure 67: Unscrew the 4 screws from the fan

5.- Replace the damaged fan, connecting the power supply terminals in the

bottom left corner.

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6.- Use the 3 mm Allen key to fix the fan to the front panel. (Figure 68)

Figure 68: Fix the fan to the front panel.

7.-Connect the power supply terminals.

5.2.1.2. AFQ-4W-150 A / 200 A MODELS

Follow these instructions to replace the inductor cooling fans in the AFQ-4W-

150A, andAFQ-4W-200Amodels:

Figure 69: Position of the inductor fans in the AFQ-4W-150 and AFQ-4W-200 filters.

1.- Set theAFQ-4Wto STOP mode and turn off the main switch

(OFFposition).

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3.-Remove the protection board from the inductor compartment.

(Figure 70)

Figure 70: Remove the protection board from the inductor compartment.

4.-Take off the inductor busbars and cables. (Figure 71)

Use a 10 mm socket spanner and 5 mm Allen key to take off the cables

from the inductors' side.

Use a 13 mm socket spanner and 13 mm open-end spanner to

disconnect the cable from the mains side.

Figure 71: Take off the induc tor busbars and cables.

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5.-Unscrew the compartment cover fasteners with a no. 20 Torx key and remove

the cover. (Figure 72).

Figure 72: Unscrew the cover fasteners

6.- Disconnect the power supply fans by firmly grasping the terminal and pulling

to disconnect it. (Figure 73)

Figure 73: Disconnect the power supply from the fans.

7.-Take out the fan being changed using a socket spanner or 7 mm spanner to

hold the rear nut and a flat or Phillips screwdriver to loosen the screw. (Figure

74)

Figure 74: Remove the fan.

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8.- Fix and connect the replacement fan.

9.-Fix the inductor compartment cover.

10.-Fasten the inductor cables and busbars.

11.-Fit the protection board.

5.2.2. COOLING FANS/TURBINES OF THE IGBTs

5.2.2.1. AFQ-4W-25 A / 50 A MODELS

TheAFQ-4W-25andAFQ-4W-50 active filters cool the IGBTs using fans.

The fans are fixed to the IGBT heatsink. Each unit has four fans: two on the top

and two on the bottom.

(Figure 75).

Figure 75: Posi tion of the IGBT upper and lower fans (AFQ-4W-25 and AFQ-4W-50).

The instructions that follow must be observed in replacing the fans:

1.- Place theAFQ-4Win STOPmode and turn off the main switch

(OFFposition).


3.-Remove the protection board and unfasten the front panel holding the

electronic boards. (Figure 76)

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Figure 78: Disconnect the power supply from the fans and remove the hood.

7.-Remove the four fan screws to extract them.(Figure 79)

Figure 79: Remove the fan screws.8.- Replace the damaged fans. Fit the fan, leaving the power supply pins on the

side of the IGBTs

9.-Pass the power supply cable through the drill hole on the hood.

10.-Connect the power supply of the two fans.

11.- Screw back on the extractor hood fasteners.

LOWER FANS

12.-Remove the power supply cable from the bottom heatsink fans. (Figure 80)

Figure 80: Remove the power supply cable

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13.- Reach into the fans from the side and remove the right fan fasteners. It is

best to follow the order of the steps shown inFigure 81.

Figure 81: Remove the fan fasteners on the right.

14.- Remove the left fan by unscrewing the four fasteners.

15.-Replace the left fan with a new one.

16.-Replace the fan on the right.

17.-Connect the fan power supply cables.

18.- Lift up and attach the front panel metal plate.


20.-Fit the side cover.

21.-Start up the unit and check that the fans operate correctly.

1 2

3

5

4

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5.2.2.2. AFQ-4W-100 A / 150 A / 200 A MODELS

TheAFQ-4W-100A,AFQ-4W-150AandAFQ-4W-200Aactive filters

cool the IGBTs using turbines.

Figure 82: Position o f the cooling turbine in the AFQ-4W-100.

Figure 83: Position of the cooling turbines in the AFQ-4W-150 and AFQ-4W-200 filters.

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The instructions that follow must be observed:


(OFFposition).


3.-Remove the front panel protection board.4.-Drop the front panel metal plate. (Figure 84)

5.-Remove the DC bus busbar. (Figure 84)

6.-Disconnect the earth wire from the front panel metal plate. (Figure 84)

7.-Remove the top crossbar. (Figure 84)

Figure 84: Steps 4, 5, 6 and 7

8-Remove the back cabinet cover. The side cabinet covers can be removed ifmore space or light is needed during these procedures.

9.-Disconnect the inverter bridge R-S-T phases. (Figure 85)

Figure 85: Disconnect the inverter bridge R-S-T phases.

5

4 6

5

7

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10.-Disconnect the IGBT connectors from the gate board. The top board must

first be removed to be able to disconnect the IGBTs from the bottom board.

11.-Disconnect the NTC connectors from the controller board

12.-Take the NTC probe cabling out of the channel.

13.-.Disconnect the turbine power supply.The location of the power supply depends on the turbine model.

If the turbine is black, the power supply is on the front part (Figure 86).

Figure 86: Disconnect the turb ine power supply (black turbine).

If the turbine has a steel finish, the power supply is on the rear part

(Figure 87).

Figure 87: Disconnect the turbine power supply (steel turb ine).

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14.-Unscrew the extractor hood fasteners on the back metal plate (Figure88).

Figure 88: Unscrew the fasteners from the extractor hood.

15.-Remove the screws fastening the heatsink to the hood. (Figure 89)

Figure 89: Remove the screws fastening the heatsink to the hood.

16.-Unscrew the bottom fasteners from the pack formed by the heatsink body,

the turbine and the IGBT bridge while the whole pack is held.

It is best to have two people do this task. (Figure 90)

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Figure 90: Unscrew the bottom fasteners.

17.-Move the pack towards the bottom until the heatsink comes out of the

extractor hood. (Figure 91)

18.-Tilt the pack towards the outside of the cabinet and remove it. (Figure 91)

Figure 91: Remove the pack from the cabinet.

19.-Place the pack on a flat, stable surface to unscrew the turbine fasteners.

(Figure 92)

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Figure 92: Unscrew the turbine fasteners

20.-Replace the turbine with the spare.

21.-Reinsert the pack into the cabinet.

22.-Fix the extractor hood.

23.-Connect the turbine power supply.

24.-Connect the R-S-T phases to the inverter bridge.

25.-Put the NTC probe cable back in the channel.

26.-Connect the NTC probe.

27.-Connect the IGBTs to the driver board and reinstall the driver board if

necessary.

Respect the R-S-T order of the connectors.

28.-Connect the DC bus busbar.

29.-Insert the top crossbar of theAFQ-4Wcabinet.

30.-Connect the earth wire to the front panel metal plate of theAFQ-4W.


32.-Check that the turbine operates correctly.

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5.3. DC BUS CAPACITORS

The DC bus capacitors have a useful life of 200,000 hours (22 years). The

capacitor life depends on the operation of the active filter and the environmental

conditions and, especially, on the ambient temperature.

The active filter capacitors are maintenance-free, except when the unit is started

up after long storage (Refer to3.3.- STORAGE FOR LONG PERIODS.).

6.- SOFTWARE UPDATE

The AFQ-4Wsoftware can be updated with a memory that should be supplied

by the CIRCUTORtechnical service.

The complete software update of the unit is divided into two parts:

1.-Controller software update.

2.-Display software update.

The material required for the full update is:

CIRCUTOR memory stick

USB memory stick with the Vx.yz_CIRCUTORsoftware ( x.yz: software

version no.)

The version of the controller software and the display software must

be the same. Two different software versions can leave the active

filter inoperative.

To check the current version of the software, access the filter data screen

(Section4.3.4.- FILTER DATA).

6.1. CONTROLLER SOFTWARE UPDATE

Update the unit controller software as follows:


(OFFposition).


3.-Remove the protection board to access the controller board.

4.- Locate the controller board.If the board has micro-switches, move the two micro-switches closest to the

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battery. If the board has jumpers, move the two jumpers closest to the battery. If

the initial status was 0000, now it should be 0011. (Figure 93)

Figure 93: Change the position o f the jumpers (A) or mic ro swi tches (B)

5.- Connect the memory stick supplied by CIRCUTOR to port J12 next to the

micro-switches or jumpers.

It should be connected with the fat side facing the battery. (Figure 94)

Figure 94: Connect the memory st ick to port J12

6.- Close the filter door and power it up.

7.-Wait 2 minutes and turn off the AFQ-4Wonce more. The updating process

should have finished.

8.- Turn off the unit and wait 5 minutes for the energy accumulated in the

capacitors to discharge.

9.-Open the filter door.

10.-Disconnect the memory stick.

11.-Change the position of the micro-switches or the jumpers to the initial

configuration 0000.


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The controller software update is complete.

If the display software is not updated, update this software before

starting up the unit. (Section 6.2)

When the controller software update is complete, it may be necessary

to reconfigure the unit parameters. Before starting up the AFQ-4W

following an update, check all of the configuration

parameters.(Section 4.3.)

6.2. DISPLAY SOFTWARE UPDATE.

To update the panel software:

a USB memory stick

the update file Vx.yx_CIRCUTOR. ( x.yz: software version number)

Follow the steps below to update the display software:

1.-Copy the file XP_Projectin the root directory of the memory stick.

Omit this step if you have a CIRCUTORmemory stick

If the XP_Project file is compressed in a *.rar format, unzip the file and copy it to

the memory stick in the directory:

(USB memory root):\XP_Project\Vx.yz_CIRCUTOR


(OFF position).


4.-With the unit turned off, open the front door and plug the memory stick into

the USB port located behind the screen. (Figure 95)

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Figure 95: USB port

4.-Close the front door of the unit.

5.-Turn on the unit and wait for the screen to start up.6.-Check that the filter is STOP.

7.- Access the FILTER DATA menu (Section 4.3.4) and change the

configuration code14 for 25. (Figure 96)

Figure 96: Change the Configuration code.

8.-Access the screen configuration (Section 4.3.5) and press EXIT toaccess

the internal menu. (Figure 97)

USB port

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Figure 97: Press EXIT to access the screen setup menu.

9.-Press Storage Functionin the internal screen setup menu. (Figure 98)If the error message Cannot find any removable Storage appears,

disconnect the memory stick from the USB port and connect it again.

Figure 98: Press Storage Function

10.-Press the Project Download option (Figure 99).

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Figure 99: Press Project Download.

11.-Select the file Vx.yz_CIRCUTOR and press OK.

12.- Wait until the updating process ends. When the process ends, the active

filter main screen will appear.

13.- Turn off the active filter and wait for the energy accumulated in the

capacitors to discharge. Disconnect the memory stick.

14.-Power up the active filter once more.

If the End Configurationmessage appears, open the FILTER DATAscreen and

program the configuration code 14. Return to the main screen and check that themessage no longer appears.

If the Error in the modules in parallel message appears, open the

PARAMETERSscreen. Press MODULES IN PARALLELand enter the number

of active filters installed in parallel. Check section 4.3.3.- CONFIGURATION OF

PARAMETERS

If the controller software is not updated, update this software beforestarting up the unit. (Section 6.1)

When the display software update is complete, it may be necessary to

reconfigure the unit parameters. Before starting up the AFQ-4W

following an update, check all of the configuration

parameters.(Section 4.3.)

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7.- TECHNICAL FEATURES

Models AFQ-4W-25 AFQ-4W-50 AFQ-4W-100 AFQ-4W-150 AFQ-4W-200

Harmonic phase

current 25ARMS 50A RMS 100A RMS 150A RMS 200A RMS

Harmonic neutral

current75A RMS 150A RMS 300A RMS 450A RMS 600A RMS

Harmonic peak

current50A PEAK 100A PEAK 200A PEAK 300A PEAK 400A PEAK

Max.

consumption.1000W 1700W 3500W 5700W 6100W

ELECTRICAL FEATURES

Rated voltage 400 V 15%Mains frequency 50 Hz / 60 Hz - 4%

Connection 3 phases with neutral (4 wires)

FILTER SPECIFICATIONSHarmonic compensation from the 2nd to the 50th harmonic

Specific harmonics selection from the 2nd to the 50th harmonic

Phase balancing Yes

Reactive current compensation Yes

Controller Digital, DSP

Response time < 1ms

Saturation protectionYes, when the nominal current of the filter is

exceeded

User interface LCD Screen, 5.7 320x240 pixel

ENVIRONMENTAL FEATURESOperating temperature 0C to +40C

Relative humidity 0% to 90% (without condensation)

Maximum altitude < 2000 m

Storage temperature 0C to +50C

MECHANICAL FEATURESModels AFQ-4W-25 AFQ-4W-50 AFQ-4W-100

Dimensions (WxHxD) (mm) 500x830x450 655x1350x450 655x1470x450

Weight (kg) 135 212 272

Models AFQ-4W-150 AFQ-4W-200

Dimensions (WxHxD1xD2)

(mm)1190x1900x620x720 1190x1900x620x720

Weight (kg) 505 511

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Figure 100: Dimensions o f AFQ-4W (25A, 50A, 100A)

Figure 101: Dimensions o f AFQ-4W (150A, 200A)

STANDARDSHarmonic regulation EN61000-3-4, IEEE519-1992

Electrical specifications EN60146

Electrical safety EN50178

Electromagnetic compatibility

EN55011, EN50081-2, EN61000-4-2, EN61000-4-3,

EN61000-4-4, EN61000-4-5, EN61000-4-6,

EN61000-6-2

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8.- MAINTENANCE AND TECHNICAL SERVICE

In the case of any query in relation to unit operation or malfunction, please

contact the CIRCUTOR, SATechnical Support Service.Technical Assistance ServiceVial Sant Jordi, s/n 08232 - Viladecavalls (Barcelona)

Tel.: 902 449 459 (Spain) / +34 937 452 900 (outside of Spain)

email: [email protected]

9.- GUARANTEE

CIRCUTOR guarantees its products against any manufacturing defect for two

years after the delivery of the units.

CIRCUTORwill repair or replace any defective factory product returned during

the guarantee period.

No returns will be accepted and no unit will be repaired or replaced if it is

not accompanied by a report indicating the defect detected or the reason

for the return.

The guarantee will be void if the units has been improperly used or the

storage, installation and maintenance instructions listed in this manual

have not been followed. "Improper usage" is defined as any operating or

storage condition contrary to the national electrical code or that

surpasses the limits indicated in the technical and environmental

features of this manual.

CIRCUTORaccepts no liability due to the possible damage to the unit orother parts of the installation, nor will it cover any possible sanctions

derived from a possible failure, improper installation or "improper usage"

of the unit. Consequently, this guarantee does not apply to failures

occurring in the following cas

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