Liebert AF2 Active Harmonic Filter
GUIDE SPECIFICATIONS
for 380/400/415V 35A to 960A (50/60Hz) Active Harmonic Filter
1.0 GENERAL
1.1
SUMMARY
These specifications describe requirements for a Modular, scalable, rack/wall/floor mountable
Active Harmonic Filter (AHF) consisting of a Control Module plus several scalable paralleled
Power Modules (up to 4 units), parallel extendable up to eight such sets. The Active Harmonic
Filter (herein after called AHF) operation should include correction of both fundamental
displacement power factor (lag or lead) correction as well as load harmonic current correction. The
AHF shall be expandable by paralleling additional modules to provide for modular redundancy or
capacity growth requirements.
The manufacturer shall design and furnish all materials and equipment to be fully compatible with
electrical, environmental, and space conditions at the site. It shall include all equipment to properly
interface the AC power source to the intended load and be designed for unattended operation.
1.2
STANDARDS
The AHF and all associated equipment and components shall be manufactured in accordance with
the following applicable standards:
•
EN 50178: General and Safety requirements.
•
IEC 61000-6-2: Generic standards — Immunity for industrial environments.
•
IEC 61000-6-4: Generic standards — Emission standard for industrial environments
•
EN 60529: Degrees of protection provided by enclosures (IP Code)
The AHF shall be CE marked in accordance with EEC directives 73/23 “low voltage” and 93/68
“electromagnetic compatibility.”
The Quality System for the engineering and manufacturing facility shall be certificated to conform
to Quality System Standard ISO 9001 for the design and manufacturing of power protection
systems for computers and other sensitive electronics.
1.3
SYSTEM DESCRIPTION
1.3.1
Design Requirements
A. One Control Module shall be able to handle up to four (4) paralleled Power Modules.
B. Each Power Module shall be sized to provide a maximum harmonic correction current of 35A.
C. When Two (2) or above Power Modules work in power scalable or redundancy configuration,
each power module will be downgraded automatically from 35A to 30A.
D. The AHF shall be expandable by paralleling additional modules to provide for module
redundancy or load growth requirements. The maximum parallel operation configuration is up to 8
control modules, thus expanding to total AHF capacity to 960A harmonic current compensation.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
-1-
Guide Specifications
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04 August, 2008 ; Rev.1
E. The AHF should be able to correct both ‘fundamental displacement power factor (lead or lag)’
and ‘harmonic current compensation up to 50th order of harmonic currents’.
F. The same AHF should be able to operate under 3-phase 3Wire or 3-phase 4-wire application
without any change in it’s design except for using an additional Current Transformer (CT) for
neutral compensation under 3-phase, 4-wire applications.
1.3.2
Performance Requirements
When connected at the input of legacy UPS system of 6-pulse or 12-pulse rectifier topology, with
or without it’s passive filters (5th Harmonic passive filter for 6-pulse rectifier UPS and 11th
Harmonic passive filter for 12-pulse rectifier UPS), the AHF should be able to achieve UPS input
Total Harmonic Current distortion (THDi) level to <3% and UPS input power factor to 0.95 under
UPS input voltage harmonic distortion level (THDv) of <1%.
1.3.2.1 Electrical Specification
A. Voltage Range: 400V +15%, -20%, L-L, should be able to operate under 380v or 415v L-L
native voltage conditions, under it’s voltage boundaries.
B. Frequency Range: 50/60Hz ±3Hz
C. Input phase: Should be able to operate for both 3 phase 3 wires and 3 phase 4 wires systems.
For 3phase 4wires system application, the AHF shall have capability to compensate neutral
line harmonic current.
D. Power Scalablity: One Control Module shall be able to handle up to four paralleled Power
Modules. Up to eight (8) such sets shall be parallel-able to scale up the AHF capacity up to
960Amps.
E. Phase Current Rating: The AHF shall be able maximize its operation for full rated
Displacement Power Factor (DPF) correction or full rated harmonic correction. The vector
sum of reactive and harmonic absorption cannot exceed the AHF rating. The maximum
compensation current of one power module should be up to 35A. When 2 and above Power
Modules work in power scalable configuration, the power module will downgrade
automatically from 35A to 30A. This means total rating of AHF will be
60A/90A/120A/150A/…../960A, while 2/3/4/5/…../32 power modules will work in parallel
connection.
F. Neutral Line Harmonic Current compensation: The maximum harmonic current correction
in neutral line shall be 3 times as that of line harmonic currents.
G. Current Limitation: The AHF shall have current limiting capability, settable up to its full
rating to enable AHF safe working without shut down or malfunction, under overload
condition. It should work in its full compensation mode under such situation.
H. Inrush Current: AHF inrush current should be less than its rated current.
I.
Parallel: For increased rating, AHF shall be capable of parallel operation up to 8 control
module units and 32 power module units for achieving different capacity ratings up to 960A..
J.
Current Transformer (CT):
c Quantity: For 3 phase 4 wires application, 3 CTs have to be installed at source OR load
side in order to measure the current waveform for harmonic and power factor correction.
For 3 phase 3 wires application, 2 or 3 CTs will be needed.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
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Guide Specifications
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04 August, 2008 ; Rev.1
d CT Ratio: The secondary current ratio shall be 1A. The primary current ratio from 100A to
10000A shall be programmable in the AHF to offer a flexible CT selection from the
market.
e CT Location: The AHF should able to operate with the current transformer installed and
connected at source side or load side. For source side CT connection application, the AHF
controller will use close loop control to compensate harmonic current. For load side
application, open loop control will be used.
f CT Burden: The current transformer burden shall be greater than 1VA for one control
module. For example, 4 control modules operate in parallel the burden of current
transformer shall be at least 4VA.
1.3.2.2 Harmonic Correction
A. Harmonic Selection: The AHF should be able to compensate harmonic currents from 2nd to
51st harmonics. Harmonic correction from 2nd to 31st harmonic order shall be individually
selectable for maximum 12 harmonic orders. Harmonic order compensation above 31st
harmonic till 51st shall be compensated as group harmonic compensation that can be
enable/disabled.
B. Harmonic Reduction Ratio: The selected harmonic order shall have settable reduction ratio.
The settable reduction range of each order will be from 10% to 100%.
1.3.2.3 Power Factor Correction
The AHF shall able to correct for either a lagging or leading displacement power factor. The
displacement power factor can be set from 0.7 lag/lead to UNITY (1.0).
1.3.2.4 Earthing
The AC input neutral shall be electrically isolated from the AHF chassis. The AHF chassis shall
have an equipment earth terminal. Provisions for local bonding are to be provided.
1.4
ENVIRONMENTAL CONDITIONS
1.4.1 Operating Ambient Temperature
0ºC to 40ºC without derating.
1.4.2 Storage/Transport Ambient Temperature
-20ºC to 70ºC.
1.4.3 Relative Humidity
0 to 95%, non-condensing.
1.4.4 Altitude
Operating: To 1000 m above sea level without derating.
Storage: To 1000m above sea level for continuous storage.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
-3-
Guide Specifications
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04 August, 2008 ; Rev.1
1.4.5 Electrostatic Discharge
The AHF shall be able to withstand an electrostatic discharge compliant to IEC 61000-4-2 level 4
(15kVA through air, 8kV contact) without damage to equipment or the connected load.
1.5
AHF Delivery Submittals
The specified AHF shall be supplied with one user manual to include details of:
A. Functional description of the equipment with block diagrams.
B. Detailed installation drawings, including all terminal locations for power and control
connections for the AHF system.
C. Safety precautions.
D. Step-by-step operating procedures
E. General maintenance guidelines
The AHF shall be supplied with a record of pre-shipment final factory test report.
1.6
WARRANTY
1.6.1
AHF Warranty
The AHF manufacturer shall warrant the unit against defects in workmanship and materials for 12
months after initial start-up or 15 months after ship date, whichever comes first.
1.7
QUALITY ASSURANCE
1.7.1
Manufacturer Qualifications
The manufacturer shall be certified to ISO 9001.
1.7.2
Factory Testing
Before shipment, the system shall be fully and completely tested to ensure compliance with the
specification. These test results will be documented in the Factory Test Report
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
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Guide Specifications
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04 August, 2008 ; Rev.1
2.0 PRODUCT
2.1 FABRICATION
2.1.1 Materials
All materials of the AHF shall be new, of current manufacture, high grade and shall not have been
in prior service except as required during factory testing. All active electronic devices shall be
solid-state. Control logic and fuses shall be physically isolated from power train components to
ensure operator safety and protection from heat. All electronic components shall be accessible
from the front without removing sub-assemblies for service access.
2.1.2 Wiring
Wiring practices, materials and coding shall be in accordance with the requirements of IEC. All
electrical power connections shall be torqued to the required value and marked with a visual
indicator.
Provision shall be made in the cabinets to permit installation of input, output, and external control
cabling. Provision shall be made for either top or bottom access, allowing for adequate cable bend
radius, to the input and output connections.
2.1.3 Construction
The AHF shall be housed in an IP20 enclosure, designed for rack mounting OR wall mounting OR
floor mounting. The floor mounting cabinet shall be structurally adequate and have provisions for
hoisting, jacking, and forklift handling. The floor mounting cabinet height shall be 1.95 meters and
110° front door opening. Active filter units will follow RAL7021, Black color scheme in epoxypolyester with orange peel texture.
2.1.4 Cooling
Adequate ventilation shall be provided to ensure that all components are operated well within
temperature ratings.
Temperature sensors shall be provided to monitor AHF module’s internal temperature. Upon
detection of temperatures in excess of manufacturer’s recommendations, the sensors shall cause
audible and visual alarms to be sounded at the AHF control panel.
On request shall be available the Fan Failure Alarm indicator that provide the Alarm on AHF
mimic and remotely when on or more fans are faulty
2.2 EQUIPMENT
2.2.1 AHF System
The AHF system shall consist of an appropriate number of AHF units to meet capacity and
redundancy requirements. Each AHF unit shall consist of a control module and one or up to 4
power module(s), and accessories as specified.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
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Guide Specifications
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04 August, 2008 ; Rev.1
2.2.2 Configurations
The AHF system shall consist of either a single AHF unit, or of two or more (up to a maximum of
eight) units. Systems having greater than one AHF unit shall operate simultaneously in a parallel
configuration with the load shared between the connected AHF units. With the exception of a
single module configuration, the system shall be redundant or nonredundant as stated elsewhere in
this specification.
A. Nonredundant system: All the AHF units shall supply the full rated load.
B. Redundant system: the AHF system shall have one or more AHF unit(s) than required to
supply the full rated load. The malfunction of one of the AHF units shall cause that AHF unit
to be disconnected from the critical load and the remaining AHF unit(s) shall continue to carry
the load. Upon repair of the AHF unit, it shall be reconnected to the critical load to resume
redundant operation. Any AHF unit shall also be capable of being taken off the critical load
manually for maintenance without disturbing the critical load bus. AHF unit redundancy level
shall be a predefined number of AHF units that are required to supply the full rated load. With
the number of connected AHF units equal to this value, a malfunction of another AHF unit
shall cause the load to be transferred automatically.
2.2.1 System Protection
The AHF shall have built-in protection against: surges, sags, over voltage and voltage surges from
AC source, and load switching and circuit breaker operation in the distribution system.
The AHF shall have built-in protection against permanent damage to itself for all predictable types
of malfunctions. Fast-acting current limiting devices shall be used to protect against cascading
failure of solid-state devices. Internal AHF malfunctions shall cause the power module to trip offline with minimum damage to the AHF and provide maximum information to maintenance
personnel regarding the reason for tripping off line. The status of protective devices shall be
indicated on a LED/LCD display on the front of the unit.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
-6-
Guide Specifications
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04 August, 2008 ; Rev.1
2.3 COMPONENTS
2.3.1 Fuse Protection:
The AHF shall be fuse protected. Each AC phase shall be individually fused with fast acting fuses
so that loss of any semiconductor shall not cause cascading failures.
2.3.2 Soft-start Circuit:
The AHF shall have a sot start circuit to pre-charge the DC bus capacitors for avoid any inrush
current while AHF start-up.
2.3.3 Electromagnetic Contactor
The AHF shall have an electromagnetic contactor between power converter and power system.
The electromagnetic contactor make the power converter truly connected with the power system
after turn on the AHF. When the AHF shut down or malfunctions the electromagnetic contactor
shall be open for disconnect the electric connection between power converter and power system.
The electromagnetic contactor shall be of the frame size to supply full rated load.
2.3.4 Ripple Current Filter:
The AHF shall have a ripple current filter to absorb the high frequency ripple current from IGBT
power converter.
2.3.5 Power Converter
The power converter shall denote the equipment and controls to convert the energy provided by
the power system to harmonic and reactive power compensated current, then feedback to the
power system to reduce harmonic current and improve the power factor. For increased
performance, the power converter shall be a pulse width modulated (PWM) design and utilise
insulated gate bipolar transistors (IGBTs), switching at high frequency.
2.3.5 Display and Controls
Each AHF control module shall be equipped with a LED or LCD display and control panel.
A. LED Display and Control Panel: This shall automatically provide all information relating to
the current status of the AHF.
B. LCD Display and Control Panel: This shall automatically provide all information relating to
the current status of the AHF as well as being capable of displaying metered values. The
display shall be menu-driven, permitting the user to easily navigate through operator screens.
C. Metered Values: The LCD display and control panel shall display all three-phase parameters,
waveforms, and harmonic current spectrum. All voltage and current parameters shall be
monitored using true RMS measurements. The following parameters shall be displayed:
•
•
•
•
•
•
•
•
•
•
•
•
SOURCE SIDE APPARENT POWER (LINE)
LOAD SIDE APPARENT POWER (LINE)
FREQUENCY
SOURCE SIDE POWER FACTOR
LOAD SIDE POWER FACTOR
AC VOLTAGE (LINE-LINE)
AC VOLATGE THDv%
SOURCE CURRENT (LINE)
LOAD CURRENT (LINE)
AHF CURRENT (LINE)
CURRENT THDi%
% LOAD RATE
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
-7-
Guide Specifications
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04 August, 2008 ; Rev.1
•
EVENT HISTORY
D. Alarms and Status Information: The LCD display and control panel shall report the alarms
and status information listed below. Each alarm shall be visually displayed in text form and an
audible alarm will sound for each alarm displayed.
PARALLEL CTA REVERSED
PARALLEL CTB REVERSED
PARALLEL CTC REVERSED
SYSTEM VOLTAGE ABNORMAL
SYSTEM UNDER VOLTAGE
SYSTEM OVER VOLTAGE
FREQUENCY ERROR
PHASE ROTATION ERROR
CONTROL BOARD ERROR
CONTROL BOARD EEPROM ERROR
CONTROL PANEL EEPROM ERROR
POWER SUPPLY ERROR
CURRENT CABLE DISCONNECTED
CAN BUS DISCONNECTED
PARALLEL DISCONNECTED
PARALLEL ID DUPLICATED
PARALLEL SETTING ERROR
MCCB TRIPPED
FUSE BLOWN
INPUT POWER ABNORMAL
IGBT FAULT
HIGH FREQUENCY RESONANCE
OVER PEAK CURRENT
OVER CURRENT
OVER TEMPERATURE (POWER)
FAN FAULT
TEMP. SENSOR DISCONNECTED
OVER TEMPERATURE(CONTROL)
DC BUS ERROR
DC BUS UNDER VOLTAGE
DC BUS OVER VOLTAGE
EXTERNAL CTA REVERSED
EXTERNAL CTB REVERSED
EXTERNAL CTC REVERSED
E. AHF ON/OFF: Each AHF control module shall be equipped with an ON/OFF switch which
will turn on or shutdown the AHF, if it is available. The ON/OFF switch shall be protected
against accidental operation. Additionally the AHF shall be able to be controlled, monitored,
configured with configuration software to be used by Manufacturers authorized service
representatives.
2.3.6 Optional Communications
A. Volt-free contacts: The AHF shall have volt-free alarm status contacts for a remote alarm
monitoring..
B. AHF Monitoring Software: Optional monitoring software shall be available for monitoring
all status, alarm and metered information at the AHF. All such information shall also be
available as a data history file as well as alarms that have activated. The software shall
provide a live copy of the AHF display mimic information. The software shall be available for
running on a PC running Microsoft Windows 98/XP from which external communication to
another remote PC via TCP/IP or dial-up networking may be executed. The software shall
provide on/off control of the AHF. Multiple numbers of AHF units should be able to be
monitored from a centralized location with help of AHF monitoring software.
C. Ethernet Card: The AHF shall have an optional, internally fitted, network interface card to
provide all alarm status information for connection to a 10-baseT Ethernet connection.
D. MODBUS/JBUS Interface: This interface shall allow the communication between the AHF
and Building Management System, by using the standard Modbus/Jbus RTU protocol.
Liebert AF2 Active Harmonic Filter
400V 35A to 960A
-8-
Guide Specifications
th
04 August, 2008 ; Rev.1