Hitachi PQF Troubleshooting guide

Power Quality Filter PQF
Quick start-up guide

PREPARED
2022-09-06 Marie Pilliez
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TITLE
Power Quality Filter PQFM
OWNING ORGANIZATION
Capacitors and Filters
DOCUMENT ID
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Contents
Components location ........................................................................................................................................ 4
1. Introduction to this manual ......................................................................................................................... 9
1.1. What this chapter contains .................................................................................................................. 9
1.2. Compatibility ........................................................................................................................................ 9
2. Safety Instructions ....................................................................................................................................... 9
3. Knowing your filter..................................................................................................................................... 10
3.1. Location of the main PQFI components ............................................................................................ 12
3.1.1. PQFI active filter bottom part components ........................................................................ 12
3.1.2. PQFI active filter middle part components......................................................................... 12
3.1.3. PQFI active filter top part components .............................................................................. 13
3.2. Location of the main PQFM components .......................................................................................... 13
3.3. Location of the main PQFS components........................................................................................... 13
3.4. The PQF main controller ................................................................................................................... 14
3.5. The PQF-Manager user interface...................................................................................................... 16
4. Upon reception ........................................................................................................................................... 19
4.1. Identification tag ................................................................................................................................ 21
4.2. Storage .............................................................................................................................................. 21
5. Quick start up ............................................................................................................................................. 22
5.1. Step 1: Visual and installation check ................................................................................................. 22
5.2. Step 2: Setting the address of each unit in a multi-unit filter and terminate the CAN bus ................. 23
5.3. Step 3: Voltage rating check/adaptation and phase rotation check................................................... 24
5.4. Step 4: Basic commissioning parameters set up (using PQF-Manager)........................................... 27
5.5. Step 5: Automatic and manual CT detection procedure .................................................................... 28
5.5.1. PQF connection diagram................................................................................................... 28
5.5.2. Automatic CT detection procedure .................................................................................... 29
5.5.3. Manual CT detection procedure ........................................................................................ 29
5.6. Step 6: Before starting the filter ......................................................................................................... 29
5.7. Step 7: Start the filter......................................................................................................................... 30
5.8. Step 8: Generate filter load................................................................................................................ 30
5.9. Step 9: Set up the user requirements................................................................................................ 31
5.10. Commissioning report........................................................................................................................ 33
5.10.1. Filter identification.............................................................................................................. 34
5.10.2. Inspection on site – verification of the active filter after installation................................... 35
5.10.3. Programming ..................................................................................................................... 36
5.10.4. Testing (with load).............................................................................................................. 37

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5.10.5. Programmed parameters................................................................................................... 38
5.10.6. Comments ......................................................................................................................... 40

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Components location
2
3
1
4
Figure 1
2
3
1
4
Figure 2
3
1
4
2
Figure 3
3
1
4
2
Figure 4

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3
1
4
2
Figure 5
9
7
8
5
6
1
1
1
1
Figure 6
9
7
8
5
6
10
1
1
1
1
Figure 7

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18
17
16
15
Figure 8
19
20
21
Figure 9
22
23
25
24
Figure 10
22
23
25
24
26
Figure 11

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27
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32
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34
35
36
37
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40
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42
Figure 12
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45
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47
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55
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59
60
61
62
63
64
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Figure 13

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65
67
68
69
66
Figure 14
70
71
72
73
74
75
76
77
78
79
Figure 15

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1. Introduction to this manual
1.1. What this chapter contains
This quick start-up guide is intended to assist the users in installing and commissioning of PQF range of filters. This is
a simplified version of the detailed operation, installation and maintenance manual available in a CD-ROM supplied
with your filter. These detailed manuals are available in English only.
In case of trouble shooting or detailed information on any topic, please refer to the relevant topic/chapter from the
manual corresponding to your filter type.
1.2. Compatibility
The manual is compatible with all filters of PQF-range with color touchscreen PQF-Manager of the following versions
or higher.
– V1 : V26 r3001
– V2 : V11 r23
– V3 : V2 r0
– V4 : V0.1 r8
This product is not backward compatible with any other PQFx (x: A, B, L, T, I, M, K, S) filter product.
2. Safety Instructions
These safety instructions are intended for all work on the PQF. Neglecting these instructions can cause physical injury
and death. All electrical installation and maintenance work on the PQF should be carried out by qualified electricians.
Do not attempt to work on a powered PQF.
Before manipulating current transformers, make sure that the secondary is short-circuited. Never open the secondary
of a loaded current transformer.
You must always wear isolating gloves and eye-protection when working on electrical installations. Also make sure
that all local safety regulations are fulfilled.
DANGER: To ensure safe access, supplies to each individual enclosure must be isolated before entry/ open-
ing.
WARNING: This equipment contains capacitors that are connected between phase and earth. A leakage cur-
rent will flow during normal operation. Therefore, a good earth connection is essential and must be con-
nected before applying power to the filter.
WARNING: There are AC capacitors & DC capacitors connected inside this filter. Before performing any
maintenance work, please short and ground the three line terminals. The DC capacitor needs 25 minutes to
discharge after disconnection. Please wait for this duration before touching any live parts even after

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discharging the AC capacitors to avoid electrical shock. Never discharge DC capacitors through short circuit.
Always use a current limiting resistor of minimum 100Ω.
WARNING: To avoid electrical shock due to residual voltage on the capacitors, the left side cover of the filter
should not be removed once the filter is commissioned.
WARNING: If the ground is not done properly, under certain fault conditions in the unit or in the system to
which it is connected it can result in full line voltage between chassis and earth ground. Severe injury or
death can result if the chassis and earth are touched simultaneously.
WARNING: The neutral current in a PQFS filter may be as high as 3 times the line current hence do not use a
4 pole breaker to connect this type of filter as the rating of the neutral pole may not be adequate.
3. Knowing your filter
The PQF range of active filter is modular in design. It consist of mainly an IGBT based inverter (current generator)
and digital control system together with a user interface (PQF Manager). A simplified schematic with external connec-
tions to the PQF is described in the diagram below:
Compensation current
Current measurements
Non-linear load(s)
- Three-phase
- Single-phase
Supply
PQF Filter panel
PQF main
controller
PQF current
generator 1
PQF Manager
1
2
3
5
4
6
Figure 16: PQF schematic overview with user connections
The user connection description is given in Table 3.

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Table 1: User connections for PQF
Item
User connections
Connection requirement
1
CT connections
Mandatory
2
Power cable connection to the supply
Mandatory
3
Programmable digital outputs (warnings…)
Not mandatory
4
Remote control contact connection or/and
local on/off buttons or/and
main/auxiliary settings control
Not mandatory
5
Modbus communication connection or serial communication
Not mandatory
6
Earth connections from the enclosure to installation earth
Mandatory
Note: When a filter system consists of more than one filter unit, a RJ45 communication cable and earth interconnec-
tion cable must be installed between the different units.
The CT connections must be provided to all filter units connected in parallel. The CT circuit of all the parallel units
must be in series, fed from same CT secondary.
Mandatory connections are connections that must be present to make the filter operational. Connections that are not
mandatory can be made to enhance the filter’s basic functionality.
All hardwired connection such as digital input/output, communication ports etc. are specific to a PQF-Manager except
for those connected to the PQF-Manager of the real master. The hardwired connection for digital input/output and
communication connections to master PQF-Manager is effective for the entire filter system.
For more information on cabling the user connections, please refer to Chapter 6 of the detailed manuals.
Following description and tables relate to the figures 1 to 11 provided at the beginning of this guide.
Figure 1 shows a typical PQFI master filter panel in CE version.
Figure 2 shows a typical PQFI master filter panel in cULus version.
Figure 3 shows a typical PQFM master filter panel in CE version.
Figure 4 shows a typical PQFM master filter panel in cULus version.
Figure 5 shows a typical PQFS master filter enclosure.
Note that in the cULus version of PQFI, the filter panel breaker is mounted in a separate cubicle. This separate cubi-
cle can be used both as top cable entry cubicle and as bottom cable entry cubicle.
The input/output connections and protection description is given in the table below.
Table 2: Input/Output connections (Figure 1, Figure 2, Figure 3, Figure 4, Figure 5)
Item
Input/output connections
1
CT connection terminals
2
Filter panel breaker (PQFI) – main protection fuse (PQFM UL)
3
Auxiliary fuse protection
4
PQF
-Manager user interface with connection terminals for user I/O (e.g. alarm contact) and communica-
tion interfaces
Up to 8 master panels can be connected in parallel providing full redundancy to the customer. In addition to using
master panels only, PQFS units can be connected in a master-slave arrangement.

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3.1. Location of the main PQFI components
3.1.1. PQFI active filter bottom part components
Figure 6 shows a picture of the PQFI bottom part in CE version and Figure 7 shows the PQFI bottom part in cULus
version.
The component identification is given in the table below.
Table 3: PQFI bottom part description (Figure 6 and Figure 7)
Item
Description
Circuit diagram designation
5
Motorized circuit breaker (MCB)
Q1
6
Fuse holder auxiliaries circuit
Q2
7
Auxiliary voltage transformer
T1
8
DC voltage power supply 24V (behind transformer)
U2
9
Preload contactor
K1
10
CT connection terminal
X21
11
PWM reactor
L12
12
Output reactor
L11
13
Earth bar
-
14
Surge arrester protection (for cULus version only)
F8-F9-F10
Note:
– In CE versions of PQFI, EMC compliance circuitry is standard present
– In cULus versions of PQFI, EMC compliance circuitry is optional
3.1.2. PQFI active filter middle part components
Figure 8 shows a picture of the PQFI middle part.
The component identification is given in the table below.
Table 4: PQFI middle part description (Figure 8)
Item
Description
Circuit diagram designation
15
IGBT inverter with DC capacitors
U1
16
IGBT heat extraction fans
M1, M2, M3
17
DC capacitor discharge resistors
R5, R6
18
Terminals for heat extraction fans
X23
The PQF Main controller board has connectors which are predominantly pre-wired for use within the filter. However, it
also contains a DIP-switch used to set the identification address and CAN bus connectors for use in a multi-module
filter arrangements.
The main controller board is shown in Figure 13.

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3.1.3. PQFI active filter top part components
Figure 9 shows a picture of the PQFI top part with the IP protection removed.
The PQFI top part description is given in the table below.
Table 5: PQFI top part description (Figure 9)
Item
Description
Circuit diagram designation
19
Output filter reactor
L10
20
Output filter resistors
R2, R3, R4
21
Output filter capacitors
C1, …, C9
The output filter is connected to the main power lines between the reactors L11 and L12 (bottom part).
3.2. Location of the main PQFM components
Figure 10 shows a picture of the PQFM master filter panel in in CE version and Figure 11 shows the PQFM master
filter panel in cULus version.
The input/output connections and protection description is given in the table below.
Table 6: Input/Output connections (Figure 10 and Figure 11)
Item
Input/Output connections
22
CT connection terminals
23
Main power connection
24
Auxiliary fuse protection
25
PQF
-Manager user interface with connection terminals for user I/O (e.g. alarm contact) and
communication interfaces
26
Filter panel main fuse protection (option for CE version)
3.3. Location of the main PQFS components
Figure 12 shows a picture of the PQFS without cover panel. The component identification is given in table below.
Table 7: PQFS main components description
Item
Description
Circuit diagram designation
27
Main contactor (MC) (underneath controller boards)
K01
28
Fuse holder auxiliaries circuit
Q02
29
DC voltage power supply 24V
U002
30
CT connection terminal
X21
31
Preload circuit resistors
32
Main earth connection point
-
33
IGBT inverter with DC capacitors
U01
34
PQF main controller board
A005
35
IGBT heat extraction fans
M1, M2
36
PCB EMC neutral
A003

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Item
Description
Circuit diagram designation
37
PCB EMC line
A002
38
PCB output filter preload
A001
39
Main power supply terminals (phases) (underneath controller boards)
L1, L2, L3
40
Main power supply neutral connection (not mandatory) (underneath con-
troller boards)
N
41
Auxiliary transformer
T001
42
Fuse preload circuit
-
3.4. The PQF main controller
The PQF main controller controls the complete active filter system. Its tasks include:
– Accepting and executing customer requests to stop and start the equipment.
– Calculating and generating IGBT-inverter control references based on the line current measurements and the user
requirements.
– Interface to the IGBT-inverters.
– Measurement of system voltages and currents for control, protection and presentation purposes.
Figure 17 depicts the controller interface diagram of the PQF active filter.
PQF
Manager
PQF
Power
Stage
CAN
Bus
Direct Interface
Modbus & PQ-Link interface
Programmable Digital I/O
3∼AC Out
First
unit
Second
unit
User interface
CT signals
(a)
PQF
main
controller
CAN bus (1)
PQF
Power
Stage
3∼AC Out
PQF
main
controller
PQF
Manager
(b)
(a)
CT signals to different units (master or slave) must be routed through daisy chain principle with return path.
(b)
If second unit is a slave unit, it will not have a PQF-Manager. If second unit is a master unit, it will have a
PQF-Manager.
CT’s
Figure 17: Controller interface diagram of the PQF active filter
When the filter consists of a master unit only, the customer has to:

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– Wire the CT signals (on a designated terminal).
– Adapt the auxiliary transformer tap settings to the network voltage.
– Connect the AC power lines and earth connection.
– Set up the installation parameters and user’s requirements with the PQF-Manager.
He may also want to wire the communication interface (Modbus or Ethernet) and the programmable digital I/O (e.g.
alarm contact, remote control).
When a second unit is added, it is connected to the first enclosure by means of a CAN bus communication link (1). In
addition, the CT measurements have to be supplied to each unit, i.e. through a daisy chain link with return path. Also,
the earth points of the different units have to be interconnected.
All slave units have their own AC-connection and breaker (or contactor) protection.
A PQF active filter system consists of up to 8 units. Additional units to the first master unit may be master or slave
units. Slave units do not have a PQF-Manager.
The active filter master panel door contains the PQF-Manager and a protective grid connected to the filter frame. At
the bottom of the protective grid a cooling fan is mounted.
Figure 13 shows the PQF main controller board parts.
The designation of the principal terminals is given in the table below.
Table 8: PQF main controller board description (Figure 13)
Item
Description
Circuit diagram
designation
43
System connector: 24 V power supply to control board
P2
44
CAN bus connection from previous filter unit
P20
45
CAN bus connection to next filter unit
P21
46
System connector: Power supply and CAN communication to PQF Manager
P4
47
System connector: 230 V power supply to control board
P3
48
System connector: Preload control
P19
49
System connector:
Main breaker closing signal (PQFI) – main contactor control
(PQFM/S)
P18
50
System connector: Main breaker opening signal (PQFI) – not used for PQFM/S
P17
51
System connector: fan control
P16
52
System connector: monitoring temperature of PWM and line reactors
P25
53
System connector: Spare
P7
54
System connector: Coming from CT terminal X21 (internal)
(a)
P5
55
System connector: Supply voltage and DC link voltage measurement
P6
56-57-58
System connectors: Control of IGBT-modules (PQFI)
P9, P10, P11
59
System connector: Control of IGBT-modules (PQFM/S)
P12
60
Voltage selector DIP-switch: not used in PQFS (single voltage)

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Item
Description
Circuit diagram
designation
61
System LED’s (top to bottom when ABB logo is positioned at top left)
LED 3: ON: Critical error in filter unit considered (red LED)
LED 3:
OFF: No critical error in filter unit considered
LED 2: ON: PQF unit running or in startup process (Armed)
LED 2: OFF: PQF unit off and not in startup process
LED 1: Blinking at regular interval (1 s): Microcontroller running properly
LED 1: ON, OFF or blinking irregularly: Microcontroller not running properly
62
System LED’s (top to bottom when ABB logo is positioned at top left)
LED 5: ON: Filter unit is acting as the master of the complete system
LED 5: OFF: Filter unit is acting as a slave in the filt
er system
LED 4: Blinking at regular interval (1 s): DSP processor running properly
LED 4: ON, OFF or blinking irregularly: DSP processor not running properly
63
PQ-Link communication opto-isolated serial link connector
64
Filter unit address
selector (ID0, ID1 and ID2) and CAN bus termination (CAN
TERM) switches:
Symbols used: OFF, Low or 0 & ON, High or 1.
When viewing the control board with its correct orientation i.e. when the ABB logo
on the control board is on the top left a shown in
Figure 13, these four switches are
position from left to right in the order ID0, ID1, ID2, CAN TERM. With this orienta-
tion, when a switch is LOW it is OF
F or 0. When the switch is HIGH, it is ON or 1.
In some type of filters, the orientation of the control card is rotated by 90 deg.
(clockwise) for the ease of connection and thus the position of the switches be-
come top to bottom in the same order(ID0, ID1,
ID2, CAN TERM). The ON position
is marked on the switch clearly.
3.5. The PQF-Manager user interface
All user interaction with the filter is channeled through the PQF-Manager.
In multi-unit filters consisting of only one master, only the master has a PQF-Manager.
In multi-unit filters consisting of more than one master, all the master units have a PQF-Manager. However, only the
PQF-Manager that is connected to the master unit which has the overall control will be active. The PQF-Manager in-
stalled on the units operating as "slaves" are capable of displaying the relevant information about that specific unit
only. Certain parameters which are specific to that unit (e.g. related to temperature probes) can be set or changed
locally using the PQF-Manager installed on that unit. The PQF-Manager on the master unit has a "unit selection"
button which allows the user to select the unit number which he wants to consult. The data then displayed on
the master PQF-Manager is specific to that particular unit number. This unit selection button is "deactivated" on the
slave Managers. Figure 14 shows the front side of the PQF-Manager.
Table 9: Front side of the PQF-Manager (Figure 14)
Item
Description
65
Menu display
By navigating through the menus with the
, , and buttons, the filter
can be set-up and controlled. On-line help is available by pressing the button.
66
Master/slaves units monitor

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Item
Description
67
Locking status / Alarm and fan contact indicator / Digital output contact indicator
When the PQF
-Manager closes one of its output relays, the corresponding symbol lights up. The digital
outputs of the PQF-Manager are discussed later in this section
68
Filter selection
69
Start stop acknowledgment fault
The PQF-Manager also acts as connection point for external user I/O communication. Connections are made at the
rear side of the PQF-Manager. Figure 15 depicts the terminals that are present on the PQF-Manager rear side.
The terminal designation is given in Table 10.
Table 10: Terminal designation (Figure 15)
Item
Customer terminals
70
Digital input 1 and 2
71
Digital outputs 1 to 6 with one common point
72
Alarm outputs (2 outputs with complementary signals)
73
Lock switch
74
Modbus adapter interface (optional) connection
75
CAN bus connection interface (routed to PQF-Manager connector)
76
Power supply terminals (routed to PQF-Manager connector)
77
Ethernet
78
USB
79
Temperature probes
The terminal explanation is given next:
69
Digital input 1 and 2
The digital inputs can be used for three different functions:
– Implementation of remote control functionality;
– Implementation of local on/off buttons (not provided);
– Selection of main filter settings or auxiliary filter settings (e.g. different filter settings for the day and for the night)
The PQF-Manager is used to associate the required functionality with the chosen digital input. The digital inputs can
also be disabled.
WARNING: If a function is assigned to a digital input, the same function must never be assigned to the other
digital input. Otherwise the filter may behave erratically.
The external voltage source needed to drive the digital inputs has to comply with the following characteristics:

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– Vlow: 0 Vdc
– Vhigh: 15-24 Vdc
– Driving current: 13 mA @ 24 Vdc (Rint = 1.88 kΩ)
The digital inputs have free of potential contacts (opto-isolated).
By default, the digital inputs are disabled.
In a master-master filter arrangement, only the master that has the control over the complete system will monitor its
digital outputs. For full redundant functionality, it is recommended to cable the digital inputs of all the units in the filter
system.
70
Digital Outputs 1 to 6
With each digital output different filter conditions can be associated. The association between the filter condition and
the digital outputs is done with the PQF-Manager.
Remarks:
– In order to set up this function, navigate to [/Welcome/Settings/Customer set./Digital Outputs]
– Different programmable warnings and alarms can be defined
The default set-up for the digital contacts is given in Table 11.
Table 11: Default set-up for the digital output contacts
Digital output number
Icons
Default function
1
Auxil. ON
2
PQF running
3
Full Load
4
Armed
5
Unit miss.
6
T Limit
The customer can change the default output settings by means of the PQF-Manager.
The digital outputs contacts have a common point and are of the NO-type (normal open). The contact ratings are:
Maximum continuous ac rating: 440 Vac/1.5 A;
Maximum continuous dc rating: 110 Vdc/0.3 A;
The common is rated at 9A/terminal, giving a total of 18 A.
Information on cabling the digital output contacts and on setting up the digital outputs with the PQF-Manager is given
in the detailed manuals.
71
Alarm outputs and fan outputs

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Apart from the digital outputs, one potential free relay with a NO and a NC alarm output is available. This relay contact
is activated if any error condition is present during a preset time. The maximum continuous alarm contact ratings are:
250 Vac/1.5 A. A fan relay can be activated if a temperature probe detects an overtemperature.
72
Lock switch
Allows locking the settings of the filter panel. This switch is documented in Section 5.4
73
Modbus RTU adapter interface (optional) connection
The Modbus adapter interface is connected at this location. The output of the interface is an RS-485 socket. The inter-
face is described in the Modbus RTU interface manual.
74
CAN bus connection interface
The PQF-Manager communicates with the main controller through a CAN bus. This bus consists of three terminals,
i.e.:
– Pin H: CAN High signal
– Pin L: CAN Low signal
– Pin Shield: shielding
The CAN bus wiring terminates into the PQF-Manager connection plug and is subsequently routed to the main con-
trol. It is used for PQF internal communications only.
75
Power supply terminals
The PQF-Manager power supply is provided by the filter itself. The corresponding terminals on the PQF-Manager la-
beled “Power supply” are connected to the PQF-Manager connection plug.
For information on how to cable external systems (e.g. remote control, Modbus interface) to the PQF-Manager, refer
to Chapter 6 of the instruction manuals. For information on how to use the PQF-Manager, refer to Chapter 7. For
background information on the Modbus RTU and TCP communication interface refer to the dedicated Modbus man-
ual.For background information on the PQ-link communication interface refer to the dedicated PQ-link manual.
4. Upon reception
For individual cubicles the lifting lugs should be employed. For multiple cubicles mounted on a base frame, lifting rods
(not provided) should be used.

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.
Figure 18: Lifting PQFI/M cubicle(s) by using the lifting lugs
PQFI & PQFM-cubicles must always be transported vertically. PQFS boxes are transported horizontally.
For PQFS enclosure, follow the procedure below:
– Remove the 4 panel securing screws at the bottom and the top of the enclosure (see Figure 19 item 1)
– Remove the right side of the protective cover and put it aside (see Figure 19 item 2)
– Unplug the PQF-Manager from the main system (see Figure 19 item 3). Then the protective cover can be safely
put aside.
– Remove the two screws fixing the filter unit to the wooden support (see Figure 19 item 4)
– Fix an appropriate lifting device to the eyebolts to lift the filter from the wooden support. It can then be positioned
at the desired location (see Figure 19 item 5).