Incorrect handling or installation of the unit may result in injury to personnel as well
Refer to the instruction manual before using the unit.
SAFETY PRECAUTIONS
Follow the warnings described in this manual with the symbols shown below.
DANGER
Warns of a risk, which could result in personal injury or material damage
ATTENTION
Indicates that special attention should be paid to a specific point.
If you must handle the unit for its installation, start-up or maintenance, the
following should be taken into consideration:
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.
.
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, SA reserves the right to modify features or the product manual without prior notification.
.
DISCLAIMER
CIRCUTOR, SA
reserves the right to make modifications to the device or the
unit specifications set out in this instruction manual without prior notice.
CIRCUTOR, SA
, on its web site, supplies its customers with the latest versions
of the device specifications and the most updated manuals.
If any problem is noticed upon reception, immediately contact the
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.
The AFQ-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.
transport company and/or CIRCUTOR's after-sales service.
8 Instruction Manual
AFQ-4W
If the unit is not to be immediately installed, it must be stored at a
the storage conditions listed in
In such a case, the unit should be kept in its original protective
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.
location with a firm and level floor, and
the section must be observed. 1.3.- STORAGE
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 ¾ 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).
Instruction Manual 9
AFQ-4W
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: 45ºC)
• 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.
10 Instruction Manual
AFQ-4W
Models
AFQ-4W-25
AFQ-4W-50
AFQ-4W-100
AFQ-4W-150
AFQ-4W-200
Harmonic phase
current
Harmonic neutral
current
Harmonic peak
current
2.- PRODUCT DESCRIPTION
The AFQ-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.
CIRCUTOR has 5 different fil ter mo dels :
25A
75A
50A
50A
RMS
150A
RMS
100A
PEAK
100A
RMS
300A
RMS
200A
PEAK
Table 1: A FQ-4W models
All active filter models have the followi ng :
An LCD 5.7" touch display.
An RS-485 connection.
150A
RMS
450A
RMS
300A
PEAK
200A
RMS
600A
RMS
400A
PEAK
RMS
RMS
PEAK
Instruction Manual 11
AFQ-4W
2.1. AFQ-4W-25
AFQ-4W-25 components seen from the front (Figure 4):
Figure 4: AFQ-4W-25 front view.
AFQ-4W-25 internal components (Figure 5):
Figure 5: AFQ-4W-25 inte rio r.
12 Instruction Manual
AFQ-4W
2.2. AFQ-4W-50
AFQ-4W-50 components seen from the front (Figure 6):
Figure 6: AFQ-4W-50 front view.
AFQ-4W-50 internal components (Figure 7):
Figure 7: AFQ-4W-50 inte rio r.
Instruction Manual 13
AFQ-4W
2.3. AFQ-4W-100
AFQ-4W-100 components seen from the front (Figure 8):
Figure 8: AFQ-4W-100 front view.
AFQ-4W-100 internal components (Figure 9):
Figure 9: AFQ-4W-100 interior.
14 Instruction Manual
AFQ-4W
2.4. AFQ-4W-150 and AFQ-4W-200
AFQ-4W-150 and AFQ-4W-200 componen ts seen from the front (Figure 10):
Figure 10: A FQ-4W-150 and AFQ-4W-200 front view.
AFQ-4W-100 and AFQ-4W-200 internal components
(Figure 11):
Figure 11: AFQ-4W-150 and AFQ-4W-200 interior.
Instruction Manual 15
AFQ-4W
st only
In order to use the unit safely, it is critical that individuals who
Incorrect installation or configuration of the unit could cause serious
. Before starting any
maintenance, wait 5 minutes and check that there is no residual
Make sure the unit is properly earthed before powering up. Any
fault in the earth connection might cause a risk of electrocution to
the user and damage to the unit itself in the case of lightning or
, make sure the
secondary is short circuited. Never open a current transformer
3. UNIT INSTALLATION
3.1.- PRELIMINARY RECOMMENDATIONS
The unit installation and the maintenance operations mu
be carried out by authorised and qualified personnel.
handle it follow the safety measures set out in the standards of the
country where it is being used, use the necessary personal
protective equipment, and pay attention to the various warnings set
forth in this instruction man ual.
damage to the unit itself and to other devices of the installation.
Disconnect the main switch before starting any maintenance
task on the active filters.
The unit has DC and AC capacitors
voltage in the capacitors.
other transients.
Before operating on the current transformers
secondary under load.
16 Instruction Manual
AFQ-4W
Never power or start up the active filter with the front door open or
Check the section 3.4.- SIZING THE NOMINAL CURRENT OF THE
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
Connect a reactor of at least 3% of the impedance on the input of
the side or rear covers removed.
Check that there is a neutral in the place where three-phase active filter
connections are made w i th neutral , AFQ-4W.
The active filter must be of the correct size for the harmonic currents it has to
filter and for the install ati on's el ectr i c al fe atures.
AFQ-4W
installation's current harmonics.
each of the loads.
3.2.- INSTALLATION LOCATION
The unit must be installed in an environment where the temperature outside the
cabinet is between 0ºC and 40ºC, 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 open
the door if necessary (Figure 12):
200 mm on the sides of the cabinet.
200 mm between the top of the cabinet and the ceiling.
800 mm at the front of the cabinet.
Instruction Manual 17
AFQ-4W
in a place protected from water, flammable
Make sure there are no reactive compensation units installed in the
. If there are any compensation units,
oid interference between them
Figure 12: Active filter spaces for ventilation.
Install the AFQ-4W
liquids, gases and corrosive substances.
same mains as the AFQ-4W
these must be untuned in order to av
and the AFQ-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 0ºC
and 50ºC.
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 2 shows the recommendations for starting the unit depending
on the length of its storage period.
18 Instruction Manual
AFQ-4W
Storage time
Process
< 1 year
No special treatment required.
Connect the AFQ-4W to the mains at least one
Connect the AFQ-4W to the mains at least one
1-2 years
> 2 years
hour before starting up the unit.
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:
I
(AFQ) = [SFh · I
filter
Where:
I
SF
ITHD(I): load current harmonic distortion
(AFQ): nominal current of the active filter
filter
: safety factor > 1.2.
h
: load maximum current
load
Equation 1: AFQ-4W nominal current
· THD(I) ]
load
To calculate this safety factor you must first know the parameter called shortcircuit 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 shortcircuit current of a mains (ISC) and the nominal current of the set of non-linear
transducers (I
) producing the harmonics to be filtered. (Equation 2)
NLC
Instruction Manual 19
AFQ-4W
CNL
SC
SC
I
I
R=
Equation 2: Calculating the shor t-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, IA and 10% load, IB. If VOC is the rated voltage in a vacuum, the ISC, can
be calculated using the formula shown in Figure 13:
Figure 13: Graphic for calcula ting I
Figure 14 The safety factor (SF
Figure 14: Approximate graphic for calculating the SFh.
.
SC
) can be obtained from the graphic in:
h
20 Instruction Manual
AFQ-4W
All power and current reading cables must enter the electrical cabinet
guaranteeing the IP and the user
Perform the drilling and/or milling out of the area for this
,
cabinet to
3.5.- CONNECTIONS
by the cover on the bottom,
protection against the parts of the cabinet with high voltages
( Figure 18).
Figure 15: Cable entry from the bottom of the electrical cabinet.
(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
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:
Instruction Manual 21
AFQ-4W
Figure 16: Connection diagr am 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, N and Earth)
are identified in the active filter as in Figure 17.
Figure 17: Mains connection points in the AFQ-4W.
Use cables of a cross-section suitable for the filter nominal current.
22 Instruction Manual
AFQ-4W
AFQ-4W
25A
50A
100A
150A
200A
Cross-section
(mm2)
a ≤ 10
Ø > 8
a ≤ 10
Ø > 8
a ≤ 10
Ø > 8
a ≤ 10
Ø > 8
a ≤ 10
Ø > 8
Torque (Nm)
7.6
7.6
7.6
14.4
14.4
Cross-section
(mm2)
Terminal (mm)
Ø > 8
Ø > 10
Ø > 10
Ø > 10
Ø > 10
Torque (Nm)
12
20
25
30
30
Cross-section
(mm2)
Terminal (mm)
Ø > 8
Ø > 8
Ø > 10
Ø > 10
Ø > 10
Torque (Nm)
12
20
25
30
30
to avoid the risk of
The minimum cable cross-section will depend on the filter range (Table 3).
L1
L2
L3
N
Earth
Terminal (mm)
10 16 35 70 95
b ≤ 20
c ≤ 21
25 50 95 2x95 2x95
25 50 95 95 95
b ≤ 20
c ≤ 21
b ≤ 20
c ≤ 21
b ≤ 20
c ≤ 21
b ≤ 20
c ≤ 21
Table 3: Minimum cross-sectio n o f input cables connected to the AFQ-4W.
Make sure that the AFQ-4W is correctly earthed
electrical discharge.
3.5.2. CURRENT TRANSFORMER CONNECTION
Current transformers TI1, TI2 and TI3, 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 in Figure 18.
Instruction Manual 23
AFQ-4W
The use of transformers with ratios close to the current to be
Current transformers TI1, TI2, TI3 must be correctly connected for the
filters to work properly. If the phases L1, L2 and L3 are
ase 1 and the transformer output cables are
measures phase 2 and the transformer output cables are
3 and the transformer output cables are
Figure 18: Transformer connection points in th e AFQ-4W.
Class 0.2S transformers of the CT or TCH series 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.
measured is recommended.
AFQ-4W
switched in the secondary, the filter will not work properly.
Check the connections and make sure that:
TI1 measures ph
connected in posts S1/L1 and S2/ L1 of the filter cabinet.
TI2
connected in posts S1/L2 and S2/ L2 of the filter cabinet.
TI3 measures phase
connected in posts S1/L3 and S2/ L3 of the filter cabinet.
24 Instruction Manual
AFQ-4W
All of the active filters connected in parallel must have exactly the
MAINS side
LOAD side
AFQ-4W
AFQ-4W
AFQ-4W
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 filters.
Section 4.3.3. explains how to configure the active filter to work with different
active filters in parallel.
same configuration in the WORK MODE and PARAMETERS. Refer
to section
4.3.- CONFIGURATION
Instruction Manual 25
AFQ-4W
3.7.- CONNECTING THE FILTER TO THE MAINS
Once the connections specified in the above sections have been checked, the
main switch of the active filter will be switched on. When the unit is started, the
messages “NOT INITIAL CONDITIONS” and “Starting …” must appear on the
display ( 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 displayed du ring 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.
26 Instruction Manual
AFQ-4W
, carefully follow the steps given in
If the transformer ratio is not that of the transformer installed, the
3.8.- FILTER START-UP
Finally, start-up the AFQ-4W. To consult all of the configuration parameters in
detail, see 4.3.- CONFIGURATION of this manual .
Before starting up the AFQ-4WConfiguration 3.8.1 and 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 SETUP and select the
PARAMETERS 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.
AFQ-4W will not work properly.
Instruction Manual 27
AFQ-4W
An incorrect configuration may significantly affect the performance of
personnel to select
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 functi ons, refer to section 4.3.- CONFIGURATION )
Figure 23: Configuration of the functions of the AFQ-4W.
the AFQ-4W. Consult the technician or qualified
the unit configuration, depending on the needs of the installation.
28 Instruction Manual
AFQ-4W
3.8.2- UNIT VERIFICATION
3.8.2.1.- VERIFICATION O F THE MAINS VOLTAGE AND FREQUENCY
The voltage and current screen (Figure 24) can be accessed from the home
screen by pressing on VIEW:
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 frequency measured by the AFQ-4W is the real frequency
of the installation.
Make sure the load current measurements correspond to the installation
current levels.
Instruction Manual 29
AFQ-4W
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
pressing VIEW:
Figure 25: Verify active and reactive power and load power factor readings.
Make sure the active power measurement 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 fact or in 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 sections 3.5.1 and 3.5.2.
30 Instruction Manual
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