Active Power Filter (3P/4W) with neutral compensation

TECHNICAL SPECIFICATION:

Design, fabrication, assembly, testing, supply, installation and commissioning of

Active Power filter panel with 3 level topology. The active filter panel shall be
fabricated out of 1.6 for side doors and 2mm for structure and front door CRCA
sheet steel in cubicle compartment, free-standing, floor / wall mounted, dust and
vermin proof with reinforcement of suitable size, angle iron, channel, ‘T’ sections
and/or flats wherever necessary. Pre-treatment of the panel shall be carried out
before epoxy powder coating of minimum 120 um thickness with atleast nine tank
process shall be ensured. The panel shall adhere to IP 54 protection standard as per
IEC 60529. The color of powder coating shall be standard RAL 7035. Louvers shall be
of Rittal make.

Cable gland plates with minimum 3mm thickness shall be provided on bottom (or as
per client’s requirements) of the panel for top / bottom entry. Lifting hooks shall also
be provided at least on all four corners of the panel for proper lifting and placement.
The gland holes need to be cut in the gland plate before hand as per the cable rating
suggested for the respective rating.

The panel shall be suitable for 415V +/- 10%, 3 phase, 4 wire 50Hz +/- 5% supply
system. Two numbers of earthing terminals shall be provided on either side of the
panel with adequate size of busbar as per panel rating.

The panel shall comply and should be type tested through any third party testing
agency of international repute with IEC 601646: Safety for semiconductor converters
and IEC 61000-6-2 and IEC 61000-6-4 for EMI/EMC compliance. The type test report
shall be made available for all the active filter ratings individually for which the
vendor is quoting.

The active filter shall be designed for operation in an ambient temperature of 50⁰C
as per Indian environmental conditions. The audible noise level shall be lesser than
70db at a distance of 1m from the panel. Panel shall have an efficiency of atleast
98%. Temperature based de-rating shall be provided to ensure that the system
works upto 55 degC with 3% derating with every deg rise in temperature, to protect
the system and longer operational life. The response time for the active filter shall be
less than 50 usec.

The active filter panel shall, in its default configuration, implement the following:
a. Harmonics Compensation up to 51st order (1st Priority)
b. Step-less Power Factor Correction for both leading and lagging current (2nd
priority)
c. Load Current Balancing in the three phases (3rd priority)
d. Neutral compensation (4th priority)
Active filter should have the following protections to provide complete safety and
proper functioning inside the plant premises:
i. Over voltage (AC) protection
ii. Under voltage (AC) protection
iii. Over voltage (DC) protection
iv. Under voltage (DC) protection
v. Phase sequence protection
vi. Over current protection
vii. One phase disconnection (double phasing) detection/protection
viii. Over temperature protection
ix. Temperature sensor abnormality detection
x. Gate driver fault detection
xi. Grid abnormality detection

Active filter panel shall comprise:

1. Main Incomer
a. 4P MCCB (1.3 times the rating of the active filter) having microprocessor based
over-current and short-circuit protection and 36kA breaking capacity (Ics) as the
incomer of the panel 100% Icu breakers shall be used.
2. Metering and Indication
a.
Physical On/Off IP66 selector switch shall be provided on the front of the
active filter
b. IP66 7” color touch-screen HMI (human machine interface) with USB
connectivity to download log history with ease shall be provided.
3. Power Circuit
a. Active filter rating shall be designed with a single power module upto 400A to
ensure better efficiency and each phase shall be independently cooled to ensure
proper cooling above 300A rating.
b. Gate drivers shall be mounted directly on the IGBTs without any interface wires
to ensure minimal interference and drop.
c. Suitably sized three phase stack with provision to overload atleast 20% shall be
provided to avoid heat runway due to dust accumulation. For example, 60A filter
should be designed to run at 75A so that overloading due to thermal runway is
inbuilt in the system.
d. IGBT with minimum junction temperature of 175 deg C shall be used.
e. Toroidal single phase inductor chokes of suitable rating (with sufficient margin
for overload) for each of the three legs of the active filter
f. Electronic relay circuit boards should be used internally for long life
g. Semi conductor fuses from Bussmann shall be used to protect the IGBT stack
from any external damage.
h. DC capacitors shall be long life Aluminium electrolytic capacitors
i. LCL filtering circuit should be present to ensure maximum ripple filtration and to
avoid resonance with other loads in the facility. Film capacitors should be used
for ripple circuit without deviation.
j. Type 2 surge protection should be present in the system
k. Heavy duty exhaust fans from Nadi only shall be used and suitably placed
ventilation louvers for proper heat dissipation from the inverter stacks and
inductor choke shall be provided

4. Control Circuit
a. Control MCB of rating 10A-FP-10kA-C Curve to provide power supply to the
control circuit of the active filter which shall be accessible on opening the
front door of the active filter to switch off the control section when
necessary.
b. Advanced 32-bit DSP microprocessor controller which shall monitor the
voltage and current in the three phases (Red, Yellow, Blue) to compute the
exact power requirement in the three phases, and thus, implement the
following features - harmonic compensation, step-less compensation of
leading and lagging power factor and load balancing

5. The HMI (human machine interface) shall have the following features:
a. IP66 7-inch, colored touchscreen LCD interface
b. It must at-least have Ethernet port, USB port and SD card port
c. It must support MODBUS TCP communication protocol
d. Start, stop and trip status (with trip code) on the home screen
e. Internal CAN communication with the DSP controller for real time status of
filter parameters
f. The HMI must display the following (minimum) numerical parameters
i. Arms and A1 (fundamental) - All 3 phase currents + Neutral
ii. I and VTHD (%) - All 3 phase current and voltage harmonic distortion
iii. Aunb (%) - All 3 phase current unbalance
iv. Vrms and Urms - All 3 phase and line voltages
v. V1rms (Fundamental Voltage) - All 3 phase fundamental voltages
vi. Vunb (%) - All 3 phase voltage unbalance
vii. Grid Frequency
viii. Power parameters: kW, kVAR, kVA - All 3 phases + Total
ix. Power Factor (PF) and Displacement PF - All 3 phases + Total
Filter related parameters:
x. Apk - Peak Current of 3 phases of power stack
xi. Vdc - DC bus voltage of power stack
xii. Stack Temperature - Temperature of 3 phase IGBTs of power stack
xiii. Control Card Temperature
xiv. System Running hours
xv. Fan Running hours
g. Advanced logging capabilities
i. The HMI must save a minimum of 2,00,000 time stamped event logs
ii. The logs view must be password protected
iii. The logs should capture system events like System On/Off, System trip
event should be logged with associated trip code and time stamp
iv. User entry into settings, any failed user login attempt (wrong password)
and changes in user settings must be logged
 v. User must be able to export the logs to an external USB storage device
vi. HMI must have provision for Ethernet communication
h. The HMI must provide graphical information for the following (minimum)
data
i. Individual harmonic bar chart of 3 phase currents and voltages - upto
51st order
ii. Simultaneous graphical display of 3 phase currents and voltages on
single window with user select-able options

6. The active filter panel shall have the following features, in addition to those
already mentioned above:
a. Priority selection between Power Factor compensation, harmonics
compensation and load balancing - of the filter shall be programmable using
the HMI
b. In the default mode, harmonics compensation is set at 1st priority, PF
compensation is set at 2nd priority and load balancing is set at 3rd priority
c. Panel shall also have provision for selection of individual harmonic orders
upto 51st for compensation in the harmonic compensation mode through
the HMI
d. All live parts of the system shall be properly shrouded
e. Inspection terminal strip, number fer-ruling, and other labeling shall be
suitably provided
f. All terminals shall be marked with terminal markers.
g. Stickers with “DANGER” marking and other necessary safety stickers shall be
provided wherever required
h. Detailed drawings and manuals shall be provided wherever required
i. All components and wiring used in the system shall adhere to the relevant
ISI and IEC standard.

TECHNICAL DATASHEET

S.No. Active Power filter

1 Ratings 30A, 50A, 75A, 100A, 150A, 200A, 300A, 400A
2 System input/number of phases 3Ph 4W
3 Input Voltage, Max/Min. 415 Volt (+/-10%)
4 Frequency 50 Hz +/- 5%
APF FEATURES
5 Harmonic Range (2nd to 51st order) Entire range and all are selectable through HMI
6 Inverter technology Three Level Topology
7 System losses 2%
8 Harmonic Attenuation Ratio in % >97% at rated load
9 Power factor compensation (+/-) 100% inductive / capacitance
10 Load balancing and neutral compensation Yes
11 Response time 50 us
12 Parallel operation Upto 32 systems
MODBUS TCP, USB, Ethernet, SD Card,
13 Interface (Communication)
CAN (Internal)
14 Energy saving mode Yes
15 IGBT junction temperature 175 degC with TIM
16 Ripple Filtration circuit LCL type with solid powder cores and film capacitors
PHYSICAL CHARACTERISTICS
IP31 and higher on request upto IP55 available, IK10
17 Protection Class
compliant
18 Cooling Forced air cooling
19 Temperature rise of Panel body Less than 15deg C
20 Cable entry Top/Bottom as per site requirement
21 Cabinet Mounting Wall (upto 100A) / Floor mounted (above 100A)
ENVIRONMENTAL
22 Ambient Temperature (maximum) upto 45 Deg C (without derating)
23 De ration per degree rise in temperature (%) 3% deration per degree upto 55 Deg. C
24 Relative Humidity 95% (Non condensing)
25 Maximum operating altitude without derating 1500 m
26 Acoustic noise at 1m distance from panel < 70 dB
USER INTERFACE
27 User Parameter Setting IP66 front 7 inch LCD touch screen HMI
Vdc, IGBT Temperature, Control Card Temperature,
28 HMI parameters (Filter)
System Running hours, Fan Running hours
Arms, Apeak and Afund, Ithd and Vthd, Aunb, Vrms
29 Power parameters and Urms, V1rms, Vunb, Frequency, kW, kVAR, kVA,
Power Factor (PF) and Displacement PF
30 Bar charts and waveforms Upto 51st harmonics and all voltages and currents
Upto 2 lac events with password protection for
different user levels, should be able to export the
31 Logging capabilities
logs to an external USB storage device

PROTECTIONS AND STANDARDS

32 Surge protection Yes, Type 2
33 Semiconductor fuses Yes, as per system rating
DC under / over voltage, Over load trip, Over
temperature alarm & trip, Over current, AC over /
34 Alarms under voltage, No synchronization, Mains abnormal,
Gate driver fault, Single phase detection, Cooling
system failure
As per IEC 62477-1 (Safety) and
35 Certifications / Type test IEC 61000-6-2 and IEC 61000-6-4 (EMI/EMC)
CE-EMC certification