PowerAct Active Filter

PowerAct Active Filter

Installation Manual

The information contained in this document is subject to change without notice. POWERSIDE MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR USE. Powerside shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. If you do not accept this limitation on liability, please return the product to Powerside prior to use.

If you find information in this manual that is incorrect, misleading, or incomplete, we would appreciate your comments and suggestions.

Powerside

7850 TransCanada Hwy 980 Atlantic Ave.

Saint-Laurent, Quebec Alameda, CA

514-333-8393 510-522-4400

1.

Product Identification and version

The product identification plate is in the cabinet door. Prior to installation

and commissioning verify the system configuration with site conditions.

Product description: PowerAct Active filter PowerAct: 3W, 480V or 600V/up to 4 x125 A modules

Vac Amps Engineering P/N NEMA 3R NEMA 1 NEMA 12

480 125 PSAF-01255.1/0Bxx-0 PF5R025PL-3R PSAF0125.5-01 PSAF0125.5-12 480 250 PSAF-02505.2/0Bxx-0 PF5R040PL-3R PSAF0250.5-01 PSAF0250.5-12 480 375 PSAF-03755.3/0Bxx-0 PF5R050PL-3R PSAF0375.5-01 PSAF0375.5-12 480 500 PSAF-05005.4/0Bxx-0 PF5R060PL-3R PSAF0500.5-01 PSAF0500.5-12

600 125 PSAF-01257.1/0Bxx-0 PSAF0125.7-3R PSAF0125.7-01 PSAF0125.7-12 600 250 PSAF-02507.2/0Bxx-0 PSAF0250.7-3R PSAF0250.7-01 PSAF0250.7-12 600 375 PSAF-03757.3/0Bxx-0 PSAF0375.7-3R PSAF0375.7-01 PSAF0375.7-12 600 500 PSAF-05007.4/0Bxx-0 PSAF0500.7-3R PSAF0500.7-01 PSAF0500.7-12 xx is a placeholder for enclosure NEMA type: 3R, 01 and 12

Contents

1.

Product Identification and version ... 2

2.

Safety Warnings and Instructions ... 4

3.

Active filter overview ... 5

4.

Environmental ... 7

5.

Installation ... 9

6.

Commissioning and Initial operation Check List ... 12

7.

Front Panel Operation ... 13

8.

Preventive Maintenance Inspection (PMI) Checklist ... 14

2.

Safety Warnings and Instructions

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions that should be followed during installation and maintenance of the active filter. Please read through the Operating Instructions carefully prior to installation. The Operating Instructions explain how to operate the product safely.

 The system contains LETHAL VOLTAGES. All repairs and service should be performed by AUTHORIZED PERSONNEL ONLY.

 Death, serious injury, or fire hazard could result from improper connection or operation of this instrument. Read and understand this manual before connecting the device.

 This equipment may present an arc flash hazard. Personal Protection Equipment may be required. Refer to NFPA 70E for the section related to Standard for Electrical Safety in the Workplace.  This system contains energy storage devices (capacitors) that may present a shock hazard even

with primary power disconnected

 Ensure that the current transformer’s secondary circuit is short-circuited (CT shorting block provided by others) prior to working on current transformer circuits. Under no circumstances should the secondary circuit of the CT be operated in the open state as lethal voltages may be present.  The voltage of the DC link may be above 1000V. Allow 60 minutes discharging time before work.

Verify voltage levels using appropriate instrument.

 All local applicable standards and specifications in addition to the generally recognized codes of practice must be observed.

 If configured for remote communications an unintended/remote start may occur if input power is available. Remove power if personal safety makes it essential to prevent an unintentional start.  All people who are involved in the setting up, commissioning, operation, maintenance or repair of the

device must be adequately professionally qualified and must read, and following, operating instructions provided. If you are unsure TAKE NO ACTION without contacting qualified personnel.

 Do not install or operation this system close to a gas or electric heat source

 The operating environment should be maintained within the parameters stated in this manual  Keep area surrounding the PowerAct uncluttered, clean, and free from excessive

moisture and atmospheric particulates.

DANGER

WARNING

3.

Active filter overview

 General—PowerAct, the latest generation in industrial grade active filter.

Today, every industry is looking to improve its efficiency and productivity and while reducing operations costs. This requires equipment which operates more precisely with frequency- or speed-controlled drives and other electronically switched power consumption.

While these electronic loads, also called non-linear loads, improve the operational and energy efficiency of an industry, they generate harmonic currents which negatively impact the voltage waveform inside the factory/facility. The consequence is financial, such as losses of productivity from unexpected breaker tripping and transformer failures, equipment which operate erratically affecting production quality and yield, and shortened equipment life cycle due to overheating. Fixing this requires the addition of filters which improve the power factor and, additionally clean the voltage waveform. But in today’s increasingly fast and dynamic environment, the correction equipment needs to be more flexible and more powerful to respond adequately to constantly changing and unpredictable electrical loads.

PowerAct is an active filter which is specifically designed for this type of dynamic environment. Compared with conventional passive filters, PowerAct is a future-proof investment which can be set to accurately compensate for the immediate and most complex problems. PowerAct can respond to an evolving environment by simply adding modules and changing the priority settings to meet future challenges.

PowerAct, Smart power quality protection you can count on

Compared to other active filters in the market, PowerAct offers several advantages, namely - Compensation for any of the 51st _{harmonics, without any limitation on the number;}

- Up to 4 (vs. 2) priority settings for compensation of harmonics, reactive power, voltage control and unbalance loads;

- Compensation based on current or voltage control with up to 4 different sensing points - Superior correction of high frequency harmonics (>20th_);

- Capacity to grow up to 500A inside a single cabinet;

- Advanced 3-level inverter topology which consumes less energy, produces less ripple current and which can operate at full power up to 800V;

- Sophisticated control algorithm offering anti-resonance prevention in case of network changes;

- A dedicated cooling chimney for superior thermal management of the high-power electronics

- A larger touch screen for easier local interfacing. Most flexible, most comprehensive compensation

Whether the electrical power network is polluted by the presence of different harmonics, by the consumption of reactive power, by the presence of voltage drops or unbalanced phase current, PowerAct dynamically and accurately compensates for these problems.

Specifically, PowerAct can perform simultaneously up to four (4) corrective actions to improve the power quality of a network:

1. Harmonics filtering based on current or voltage measurement, up to 51st _{order with no}

2. Reactive power compensation (inductive and capacitive) of the fundamental frequency 3. Volt/Var compensation (voltage control)

4. Phase load balancing

Each system can be connected with up to four (4) measurement points, and configured to prioritize the type, the limits or the capacity to be allocated, and, if needed, the amount of compensation including each individual harmonic. This provides assurance that even the most challenging scenarios can be addressed now, and in the future.

 Operating Principles — Simplified Diagram

Active filters reliably and accurately compensate for power quality problems by measuring current and voltage to supply precisely the amount of current required. The filter current is added to the normal load current resulting in the corrected current required.

4.

Environmental

Vibration test EN60068-2-6

Relative humidity Max. 95% (IEC 721-3-3; Class 3K3 [non-condensing] during operation

Ambient temperature with full output

current [short-term t <2h] Max. 40 °C/104 °F Ambient temperature at full output current

[t> 24 hours] Max. 35 °C/95 °F

Minimum ambient temperature during

operation 0 °C/32°F

Temperature during storage and transport -20 °C to +70 °C/—4°F to +158 °F Max. height above sea level without

derating 1000 m

Table 4-1: Ambient conditions

 Cooling and Air Flow

Power electronics cooling airflow is bottom entry exit through top chimney. Control electronics cooling is front entry. See maintenance chapter on changing filters. Do not obstruct vents

Room cooling must be able to support the following heat rejection.

Product variants Max thermal power

loss at Pnom, Unom

Cooling air flow rate Engineering P/N PSAF-01255.1/0Bxx-0 2175 W 725 m³/h PSAF-02505.2/0Bxx-0 4350 W 1450 m³/h PSAF-03755.3/0Bxx-0 6525 W 2175 m³/h PSAF-05005.4/0Bxx-0 8700 W 2900 m³/h PSAF-01257.1/0Bxx-0 3150 W 725 m³/h PSAF-02507.2/0Bxx-0 6300 W 1450 m³/h PSAF-03757.3/0Bxx-0 9450 W 2175 m³/h PSAF-05007.4/0Bxx-0 12600 W 2900 m³/h

xx is a placeholder for enclosure NEMA type: 3R, 01 and 12 Table 4-4: unit heat rejection based on modules

 Input Rating and External Wiring Requirements

Because of the high-harmonic content, the recommend feeder is for 1.2 times the rated current. Please refer to Table 4-2 for minimum recommendations based on system rating. Refer to national and local electric codes for acceptable external wiring practices.

PowerAct models Compensation

current

Recommended breaker size [A]

Minimum conductor AWG [mm²] Engineering P/N PSAF-01255.1/0Bxx-0 125Aeff 250 4/0 [120] PSAF-02505.2/0Bxx-0 250Aeff 400 2x 4/0 [2x 120] PSAF-03755.3/0Bxx-0 375Aeff 600 2x 500MCM PSAF-05005.4/0Bxx-0 500Aeff 800 3x 350MCM PSAF-01257.1/0Bxx-0 125Aeff 250 4/0 [120] PSAF-02507.2/0Bxx-0 250Aeff 400 2x 4/0 [2x 120] PSAF-03757.3/0Bxx-0 375Aeff 600 2x 500MCM PSAF-05007.4/0Bxx-0 500Aeff 800 3x 350MCM

xx is a placeholder for enclosure NEMA type: 3R, 01 and 12

Table 5-3: Wiring minimum ratings

Ratings based on NEC table 310.104[A] and table 310.15[B][2][a] sized with 75 °C insulation rated copper conductor at an ambient temperature of 50 °C.

5.

Installation

 Receiving and physical placement

 Thoroughly inspect the transport protection for possible shipping damage. Note that the active filter may weigh up to 1300 lb. [600 kg]

 Using a forklift or pallet jack, move the packaged cabinet to the installation site.  Caution: center of gravity is to the rear of the unit. Pick up from rear

whenever possible. Avoid tilting.

 Position the active filter as close as possible to the operating site before unpacking it to prevent damage due to transport.

 Set the pallet on a firm, level surface and remove the unit from the pallet.  Remove remaining protection/packing material and inspect for shipping damage.

Compare items received with the bill of lading.  Distances [clearance] to walls/other systems

Side Rear wall Ceiling Front

---- ---- 8 in [20 cm] 48 in [door _{full open]} Table 5-1: Equipment Clearance

 Dimensions and Access

Fig. 5.3: Cabinet dimension  Wiring Internal View

Designations Power Connections L1, L2, L3 Input bus bar

TB3 1–2 CT Phase A [1—k, 2—l]) TB3 3–4 CT Phase B (3 — k, 4—l) TB3 5–6 CT Phase C (5 — k, 6 — l)

Table 5-2: Power Wiring location

Digital OUT Digital IN

TB8:1 DO 1 relay NO/NC TB8:9 DI 1—DC (GND) TB8:2 DO 1 relay COM TB8:10 DI 1 +24 V DC TB8:3 DO 2 relay NO/NC TB8:11 DI 2—DC (GND) TB8:4 _{DO 2 relay COM TB8:12 DI 2 +24 V DC} TB8:5 DO 3 relay NO/NC TB8:13 DI 3—DC (GND) TB8:6 DO 3 relay COM TB8:14 DI 3 +24 V DC TB8:7 DO 4 relay NO/NC TB8:15 DI 4—DC (GND) TB8:8 DO 4 relay COM TB8:16 DI 4 +24 V DC

DO rating: 250 Vac (3A)/110 Vdc (0.7A)/24 Vdc (1A) DI Rating: optically isolated, 24 Vdc (10 mA)

Table 5-3: Communications Wiring location

 Primary Power Connection

 Connect input power to busbar L1, L2, L3. See Figure 5.4  Install the cables at the connection point with torque:

M10=40 Nm, M12=70 Nm  Digital Inputs and Outputs

The digital inputs and outputs (DI/DO) are connected directly to the terminal TB8 (see table 5.3). Individual DI/DO functions can be set up from the front panel (see communications section of this manual).

 Current Transformer Connection

The current transformers must be connected via terminal strip X6 on the PowerAct active filter. See table 5-2.

 Current Transformer (CT) Installation

Proper placement and polarity of the current transformers are critical to the operation of the active filter. Refer to engineering design study (supplied by others) for location.

Note that wiring polarity (k and l) is critical to the proper function of this active filter. If k and l are reversed, the current signal can be corrected by entering a negative primary current in at the front panel control. See communications set-up section of this manual.

 IGBT Power Unit Fuses

Replacement fuse Class T, current-limiting, extremely fast-acting 200A, 600Vac, knife blade. Edison Catalog Number: TJS200

6. Commissioning and Initial operation Checklist

Review all safety information at the front of this manual prior to proceeding PRIOR TO CLOSING FEED BREAKER TO ENERGIZE THE SYSTEM _____ General visual inspection to both exterior and interior

_____ Ensure the system and work area is clean of any contaminants or debris _____ Check electrical connections for proper torque specifically L1, L2, L3

_____ Verify current transformers (CT) are connected to the right terminals with correct phase rotation (ABC) and current direction

_____ Verify CT shorting block is open (connected)

APPLY POWER TO THE SYSTEM BY CLOSING UPSTREAM FEED BREAKER

_____ Close the control logic Circuit Breaker CB001-CB006 (fewer power modules will have fewer circuit breakers).

_____ Close the switch S1 (on interior door, above controller) and verify the following _____ the control computer LED lights are illuminated

_____ the 24 VDC PSU LED lights are illuminated _____ the fans start correctly

_____ the front-panel graphics display responds

CLOSE THE DOOR. THE SYSTEM CAN NOW BE APPROACHED BY NON-TRAINED PERSONNEL.

_____ Verify system configuration and factory set up via graphic touch control panel. Do not start system prior to configuration verification.

_____ Energize the PowerAct active filter via front panel control. See communications and control chapter.

7.

Front Panel Operation

After the active filter was switched on via the switch S1, the start button can now be pressed. The unit will now start in normal mode.

See Operations Manual for detailed information

Available function Active status Not applicable

Start

Pause

Stop

Table 7-1: Operator buttons and their meanings

 System Status:

Normal operations possible states:

Name (Nr.) Description

INIT Startup sequence of the entire system Load and all system parameters

IDLE Parameter set up completed

PRECHARGE The pre-charging unit is charging the DC link STOP-PRECHARGE Pre-charging process has been canceled CHARGED DC-link fully charged

READY The active filter is ready for operation Run The active filter is in the compensation mode ERROR

Output error message Stop PWM pulsing Stop of compensation [contact factory for error code and corrective action]

PAUSE Power output is regulated to zero DERATING Derating of the power output Table 7-2: Status messages and their meanings

8.

Preventive Maintenance Inspection (PMI) Checklist

Non-compliance with or incorrect performance of maintenance measures will void the warranty.

Recommended service interval is specified via the built-in operating-hours counter. Inspection should be performed at a maximum interval of 12 months. basis (shorter interval may be required for sites with harsh environmental condition) following this checklist: Review all safety information at the front of this manual prior to proceeding

 Inspection schedule

WHILE THE SYSTEM IS STILL ENERGIZED

____ From the front panel verify system status and record, if present, any error codes [contact factory]

____ Room environmental conditions are with specification

____ Open door and perform IR scan on all connection [WARNING: Exposed Voltage]. Note any hot spots

REMOVE POWER FROM THE SYSTEM BY OPENING UPSTREAM FEED BREAKER ____ General visual inspection to both exterior and interior

____ Clean the system inside and out of dust or other particulates using vacuum or compressed air if required

_____ Check electrical connections for proper torque

_____ Check the fans for function and clean if necessary. Replace every 2–3 years. _____ Clean ventilation openings

_____ Replace vent filters

RETORE POWER TO THE SYSTEM BY CLOSING UPSTREAM FEED BREAKER _____ From the front panel, test functions and start the system up again.

9.

Product Specifications and Details

PowerAct Family

Compensation Type Active Filter

Mounting Floor

Wall

Number of modules 1 2 3 4 1

Capacity @ 690V 150kvar 300kvar 450kvar 600kvar 150kvar

Rated Current 125A 250A 375A 500A 125A

Nominal Frequency 50Hz/60Hz Nominal Voltage 208/240/480/600 V

Inverter 3-Level IGBT with voltage link (DC film capacitors)

Peak current 200%

Cooling Air cooling

Filter function harmonics 1st…51st harmonic All harmonics can be filtered simultaneously

Additional functions

Dynamic reactive power compensation Load balancing (up to 100% of rated current)

Voltage stabilization via Q(U)-control Flicker compensation Power losses

<2.1% of compensation power maximum

<1.8% in typical operation <0.4% when idle <100w in standby Expandability Up to a maximum of 5 cabinets (3Mvar, 2.5kA)

Network harmonics High Load characteristics Dynamic

Controller Distributed control system with high-speed inter-module communication bus

Communication

Ethernet, Profibus, Modbus

4 x digital output (isolated, parameterized) for status messages) 4 x digital input (24 VDC, parameterized) for external control Maximum Voltage 800V continuous

Response time << 1ms Operating Temperature

(F/C) 32 to 104/0 to 40 without derating and internal heating. De-rated output above Enclosure rating NEMA 1 (optional NEMA 3R

Enclosure type, Dimensions (in/mm) Weight (lbs/kg) 480V and 600V Amperage HxWxD (in) HxWxD (mm) lbs/kg 125 90x40x25 2286x1016x635 834/379 250 90x40x25 2286x1016x635 1064/483 375 90x40x25 2286x1016x635 1295/588 500 90x40x25 2286x1016x635 1526/693

Powerside

7850 TransCanada Hwy 980 Atlantic Ave.

Saint-Laurent, Quebec Alameda, CA

514-333-8393 510-522-4400