APQline Active Harmonic Filters N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI 53051 P. (262) 754-3883 F. (262) 754-3993 www.apqpower.com
Power electronic equipment and AC-DC power conversion equipment contribute to power distortion. Protect your sensitive electronics and eliminate distortion on your power system. Meet IEEE harmonic limits with active cancellation solutions! Reduce system energy losses Reduce heating caused by harmonic frequencies Lower transformer loading Reduce RMS and peak current demands Improve product lifespan Operate electrical equipment more efficiently for improved equipment life Meet IEEE-519 harmonic limits Meet utility requirements to limit harmonic distortion Protect sensitive electronic equipment Reduces equipment interference Improve application uptime Eliminate nuisance circuit breaker tripping and fuse blowing Extend equipment life expectancy Reduce equipment heating due to harmonic frequencies Protect power factor correction capacitors Keep harmonic frequencies from overloading capacitors Reduce generator loading Lower wasteful harmonics to improve generator operation Manage fluctuating electrical loads Dynamically adjust harmonic mitigation based on load transitions The information provided within this product catalog is subject to change without notice. For complete product details, please contact APQ, LLC. 2 APQline Active Harmonic Filters
THE CHALLENGE: ACTIVELY RECOGNIZE, MEASURE, AND CANCEL HARMONIC CURRENTS Intelligent Power Quality Harmonics are caused by non-linear loads such as variable frequency drives (VFDs), uninterruptible power supplies (UPSs), arc furnaces, welding equipment, and fluorescent lighting. This type of load draws power in pulses, which creates distortion in both the current and voltage waveforms. Such distortion can cause electrical equipment to fail prematurely and sensitive electronics to malfunction. The APQline Solution Dynamic Harmonic Mitigation The APQline Active Harmonic Filter utilizes the latest IGBT technology to achieve dynamic cancellation of harmonics caused by three phase non-linear loads. This system will actively monitor the load current and actively correct each individual harmonic from the 5th to the 51st. Through the injection of equal and opposite harmonic currents, the APQline Active Harmonic Filter will significantly reduce the harmonics on the power system upstream from the installation location. System Flexibility Traditional passive solutions offer optimum performance when operating at the rated voltage and current. System changes require additional harmonic mitigation equipment or additional engineering analysis to ensure continued performance. The APQline Active Harmonic Filter can maintain optimum harmonic mitigation across the full operational range of the system. The units cannot be overloaded. If additional harmonic mitigation is required, the units will continue to provide its maximum current correction capability. If additional harmonic mitigation is required, a total of six individual APQline filters can be paralleled to reach the desired levels of harmonic mitigation. Meet IEEE 519 Requirements Energy efficient equipment assists modern facilities in the management of their energy usage, but there are some power side effects that must be addressed. The additional non-linear load causes distortion on the utility grid itself. The limits set forth by IEEE-519 1992 limits the amount of harmonic distortion allowed at the point where the utility feeds an individual location. This allows the utility to provide clean power to other users on the same system. Combine Mitigation Technologies APQ offers multiple harmonic mitigation solutions. Passive technology can be combined with the APQline product in various configurations to provide a facility with the most cost effective solutions available. The APQ team can analyze a facility single line diagram and provide a simulation to predict actual harmonic distortion with various solution configurations. 600/690 Volt Systems The APQline Active Harmonic Filter is offered at 600 and 690 volts. The system offered by APQ consists of a step down transformer and a 480V APQline product. This configuration requires the corrective current of the 480V unit to be de-rated by 20%. For example, a 100 amp 480V APQline unit in a 600V system would arrive with a transformer and would provide 80 amps of corrective current. Input Impedance The APQline Active Harmonic Filter offering requires line reactors, or other impedance type devices, to be installed at the input of each variable frequency drive on the serviced system. This impedance will not only reduce the amount of harmonic distortion that the filter must correct, but it also slows the rise time of the harmonic frequencies so that the filter is able to provide efficient corrective currents. The minimum suggested impedance of the installed equipment is 3%. APQline Active Harmonic Filters 3
THE APQline Active Harmonic Filter System THE UNIT The APQline Design REACTORS For Connected Variable Frequency Drives THE APQline CONTROLLER Operational Intelligence TRANSFORMER For Higher System Voltages Individual systems available from 25 200 Amps Up to six (6) units can be paralleled for maximum flexibility Designed for 2000:1 current transformers (other ratios available upon request) Various impedance levels available for any application Increase harmonic frequency rise time Minimal losses, audible noise, and stray magnetic fields Eight function keyboard for operation, programming, and diagnostics Display information up to the 31st harmonic Analyze waveform data Multiple communication options available Step up Transformer to 600V Specific impedance design for maximum system performance Provided as a separate component with 600V part numbers Non- Linear loads draw distorted current Current sensing C/T Active Filter reduces the source current distortion to less than 5% I-THD THID Active Harmonic Filter Active Filter supplies only the distortion current demanded by non-linear loads 4 APQline Active Harmonic Filters
THE APQline Active Harmonic Filter Product Specifications Electrical Specifications: Power Systems: 3-phase, 3-wire System Voltage: Frequency: 60Hz or 50 Hz, ± 3 Hz Compensating Current: 25 1200 Amps (See Unit Combination Chart) Steady State Response: <40ms detection time at 100% step load Control Topology: Inrush Current: Less than Rated Current Current Limitation: At Full Correcting Current Input Fuses: 200 kaic Protection, Class J Disconnect Switch: Current Transformers: Operating Conditions: Available for 208 480 V, ± 15% (600/690 V available with step-up transformer) Fully digital with DFT (discrete fourier transform) algorithm 3-wire (Response Time <20 ms) Not Included (External device required, review local code and NEC requirements) 2,000:1 (Consult Factory for additional CT ratio requirements) Voltage: 208/60, 240/50, 240/60, 380/50, 415/50, 480/60 600/60 and 690/50 with Step-up Transformer Voltage Tolerance: -15% to +15% Phase Imbalance: -1.5% to +1.5% Frequency: 50 Hz 47 Hz to 53 Hz 60 Hz 57 Hz to 63 Hz Temperature: Storage: -4 F to 158 F (-20 C to 70 C) Operating: +32 F to 104 F (0 C to 40 C) Altitude: Relative Humidity: General Specifications: <1,000 meters (3,280 ft.) <95% non-condensing Controller: Switching Speed: Loss of Power: Overload: Cooling: Paralleled Units: Communications: Soft Start: Filter Performance: MTBF: Digital DSP Design (Global, Selectable) 20 khz Configurable Restart Filter Units Cannot be Overloaded Fan Cooled Up to 6 Units Can be Used in Parallel RS232 (standard), RS422, RS485, RJ45, USB, TCP/IP (optional) 10 Sec 5th to 51st Order >120,000 Hours Applicable Standards: Safety: EMI: Surge Immunity: Harmonic Guidelines: Enclosure: UL 508 / EN50178 FCC Part 15 / EN55011 ANSI C62.41, IEEE587 / EN61000-4-5 IEEE519-1992 / EN61000-3-4 NEMA 1 (IP20) 14 Gauge Steel with Textured Gray Finish (NEMA 12 / 3R Optional) APQline Active Harmonic Filters 5
THE APQline Active Harmonic Filter Basics of Harmonics Non-linear loads such as variable frequency drives (VFDs), uninterruptible power supply (UPS) systems, or high efficiency fluorescent lamps draw power in pulses rather than sinusoidal waves. This variation in power draw will cause both the current and voltage waveforms to become deformed. These non-linear waveforms are actually independent frequencies that combine with the fundamental frequency. For example, in a 60 Hz system, the 5th harmonic is 300 Hz, whereas the 7th harmonic is 420 Hz. These additional frequencies cause additional losses within other electrical components such as transformers, generators, and electrical conductors. Beyond the losses, circuit breakers and fuses may trip or fail, transformers can overheat, switch gear can run hot, and sensitive electronics may malfunction. Harmonic Limits Harmonic distortion impacts the entire electrical supply chain. The ability of the utility to provide clean power to multiple users can be hindered by a facility that is generating excessive harmonics. For this reason, IEEE 519 standards were implemented to limit the amount of harmonic distortion allowable at the point where the utility feeds the facility. This point of common coupling, or PCC, is the location where a utility will determine if a facility s harmonic content meets the appropriate levels. Since harmonics will impact the efficiency of all electrical components, IEEE 519 limits are sometimes applied directly to the non-linear load. IEEE Standard 519 Limits For Harmonic Current and Voltage Distortion Harmonic Current Distortion I sc / I L TDD Limit Harmonic Voltage Distortion Systems THD-v Limit <20 5% Airports 3% 20 < 50 8% Hospitals 3% 50 < 100 12% General Systems 100 < 1000 15% Dedicated Systems 1000 and up 20% 5% 10% Active Harmonic Mitigation The APQ APQline Active Harmonic Filter utilizes the latest IGBT power electronics technology to achieve dynamic cancellation of harmonics caused by three phase non-linear loads. The system monitors the load current and dynamically corrects each individual harmonic from the 5th to the 51st. The filter actively injects equal and opposite currents into the load, significantly reducing the harmonic content and restoring the sinusoidal waveform. Copper Losses VS % THDi P(dist) /P (sine) 2.00 1.90 1.80 1.70 1.60 1.50 1.40 1.30 1.20 1.10 1.00 0 10 20 30 40 50 60 70 80 90 100 % Harmonic Current Distortion Copper losses increase when harmonic currents flow through electrical systems and equipment. Certain iron losses will increase based on the square of the frequency. Hidden Costs of Harmonics Increased system and equipment losses Increased equipment operating temperature Total power factor reduction Equipment life reduction Increased equipment failure Equipment interference/ malfunctions 6 APQline Active Harmonic Filters
APPLICATIONS The APQline Active Harmonic Filter is designed to be single source or bus applied, providing maximum flexibility for a wide variety of applications. The APQ Team can assist in the analysis of your power system to select the right units required for your installation. Line reactors, sold separately, should be installed in front of all VFDs serviced by an APQline filter. Oil & Gas Water / Wastewater HVAC Commercial Facilities Printing Pulp & Paper Automotive Metal Fabrication Hospitals Textiles Electroplating Data Centers Breweries Warehouses High Rises APQline Active Harmonic Filters 7
THE APQline Active Harmonic Filter Part Number System AHF 0150 480 03 01 S xxxx Product Designation Amp Rating 1200 Max Amps Nominal Voltage & Freq 240 Volts @ 60 Hz = 240 480 Volts @ 60Hz = 480 600 Volts @ 60 Hz = 600 Wire Connection 3- Wire = 3 4- Wire = 4 Enclosure Type Type 1 = 01 Type 3R = 3R Type 12 = 12 Internal CT Setup 2000 : 1 = S 2500 : 1 = 2 3000 : 1 = 3 4000 : 1 = 4 Options Step-Up Transformer = SU Communications = SC Fused Disconnect = FD Non-Fused Disconnect = ND External CTs = CT Circuit Breakers = CB Power Monitor = PM Application notes: Consult Factory for larger diameter CT s where needed. Door-Interlocked disconnect are not required with the APQline. The unit is constructed with UL dead front panels preventing exposure to voltage without removal of the panels. APQline units may require external disconnect switches or circuit breakers to meet local NEC codes. APQline Active Harmonic Filter Selection Requirements 1. APQ recommends that unit current ratings are 25% larger than actual RMS harmonic current. This compensates for any error in measurement and allows for increased loading conditions. 2. For best performance, it is recommended to use multiple smaller units closer to the harmonic producing loads on smaller downstream buses, rather than to attempt to place one large filter on a high current bus. The standard CT s are rated for this type of application. 3. AC or DC drives are required to have a minimum effective impedance of 3% through the use of 3% or greater ac line reactors, dc chokes, or isolation transformers, in order to achieve proper operation and performance. 4. For proper startup and operation of the APQline system, existing facility voltage distortion must be lower than 10% THD-v when the APQline unit is OFF. 5. For proper start-up and functioning of the APQline system, the facility voltage distortion should be lower than 5% THD-v when the unit is ON for proper/maximum performance. 6. WARNING: Do not connect APQline units and CTs to a system bus with current that exceeds 10X the ampere rating of the APQline unit. Example: 100A filters may be applied on 1000A bus or less. 7. WARNING: Do not connect APQline units to corner Grounded Delta Power Systems. 8. WARNING: Do not use source side CT connections when using multiple APQline units in parallel. 8 APQline Active Harmonic Filters
THE APQline Active Harmonic Filter Selection Chart 240 and 480 Volts Part Number Corrective Current Reactive Power Capacity Power Loss Audible Noise Mounting Type Dimensions (in.) kvar Amperes H x W x D WT AHF 0025 240 3 01 S 25 3.2 8.5.55 kw 60 dba Wall 35.00 16.20 15.40 131 AHF 0050 240 3 01 S 50 6.5 17.0.95 kw 60 dba Wall 35.00 16.20 15.40 166 AHF 0100 240 3 01 S 100 13.0 34.0 2.0 kw 63 dba Floor 76.00 24.00 32.00 643 AHF 0150 240 3 01 S 150 19.4 51.0 3.0 kw 63 dba Floor 76.00 24.00 32.00 714 AHF 0200 240 3 01 S 200 25.9 68.0 4.1 kw 65 dba Floor 76.00 48.00 32.00 1285 AHF 0250 240 3 01 S 250 32.4 85.0 5.0 kw 65 dba Floor 76.00 48.00 32.00 1356 AHF 0300 240 3 01 S 300 38.8 102.0 6.0 kw 65 dba Floor 76.00 48.00 32.00 1428 AHF 0400 240 3 01 S 400 51.8 136.0 8.0 kw 65 dba Floor 76.00 72.00 32.00 2070 AHF 0450 240 3 01 S 450 58.2 153.0 9.0 kw 65 dba Floor 76.00 72.00 32.00 2142 AHF 0600 240 3 01 S 600 77.6 204.0 12.0 kw 65 dba Floor 76.00 96.00 32.00 2856 AHF 0750 240 3 01 S 750 97.0 255.0 15.0 kw 65 dba Floor 76.00 120.00 32.00 3569 AHF 0800 240 3 01 S 800 103.5 272.0 16.1 kw 65 dba Floor 76.00 144.00 32.00 4141 AHF 0900 240 3 01 S 900 116.4 306.0 18.0 kw 65 dba Floor 76.00 144.00 32.00 4283 AHF 1000 240 3 01 S 1000 129.4 340.0 20.2 kw 65 dba Floor 76.00 192.00 32.00 5426 AHF 1200 240 3 01 S 1200 155.4 408.0 24.6 kw 68 dba Floor 76.00 288.00 32.00 7711 Part Number Corrective Current Reactive Power Capacity Power Loss Audible Noise Mounting Type Dimensions (in.) kvar Amperes H x W x D WT AHF 0025 480 3 01 S 25 15.6 18.8.55 kw 60 dba Wall 35.00 16.20 15.40 131 AHF 0050 480 3 01 S 50 31.3 37.4.95 kw 60 dba Wall 35.00 16.20 15.40 166 AHF 0100 480 3 01 S 100 62.5 75 2.0 kw 63 dba Floor 76.00 24.00 32.00 643 AHF 0150 480 3 01 S 150 93.8 113 3.0 kw 63 dba Floor 76.00 24.00 32.00 714 AHF 0200 480 3 01 S 200 124.8 150 4.1 kw 65 dba Floor 76.00 48.00 32.00 1285 AHF 0250 480 3 01 S 250 156.3 188 5.0 kw 65 dba Floor 76.00 48.00 32.00 1356 AHF 0300 480 3 01 S 300 187.6 226 6.0 kw 65 dba Floor 76.00 48.00 32.00 1428 AHF 0400 480 3 01 S 400 250.1 300 8.0 kw 65 dba Floor 76.00 72.00 32.00 2070 AHF 0450 480 3 01 S 450 281.4 339 9.0 kw 65 dba Floor 76.00 72.00 32.00 2142 AHF 0600 480 3 01 S 600 375.2 450 12.0 kw 65 dba Floor 76.00 96.00 32.00 2856 AHF 0750 480 3 01 S 750 469.0 450 15.0 kw 65 dba Floor 76.00 120.00 32.00 3569 AHF 0800 480 3 01 S 800 500.0 565 16.1 kw 65 dba Floor 76.00 144.00 32.00 4141 AHF 0900 480 3 01 S 900 469.0 678 18.0 kw 65 dba Floor 76.00 144.00 32.00 4283 AHF 1000 480 3 01 S 1000 624.8 750 20.2 kw 65 dba Floor 76.00 192.00 32.00 5426 AHF 1200 480 3 01 S 1200 748.8 900 24.6 kw 68 dba Floor 76.00 288.00 32.00 7711 *The information provided within this product catalog is subject to change without notice. For complete product details, please contact APQ. APQline Active Harmonic Filters 9
THE APQLine Active Harmonic Filter Selection Chart 600 Volts Part Number Corrective Current Reactive Power Capacity Power Loss Audible Noise Mounting Type Dimensions (in.) kvar Amperes H x W x D WT AHF 0020 600 3 01 S 20 12.5 15.0.55 kw 60 dba Wall 35.00 16.20 15.40 131 AHF 0040 600 3 01 S 40 25.0 29.9.95 kw 63 dba Wall 35.00 16.20 15.40 166 AHF 0080 600 3 01 S 80 50.0 60.0 2.0 kw 65 dba Floor 76.00 24.00 32.00 643 AHF 0120 600 3 01 S 120 75.0 90.4 3.0 kw 65 dba Floor 76.00 24.00 32.00 714 AHF 0160 600 3 01 S 160 99.8 120.0 4.1 kw 65 dba Floor 76.00 48.00 32.00 1285 AHF 0200 600 3 01 S 200 125.0 150.4 5.0 kw 65 dba Floor 76.00 48.00 32.00 1356 AHF 0240 600 3 01 S 240 150.0 180.8 6.0 kw 65 dba Floor 76.00 48.00 32.00 1428 AHF 0360 600 3 01 S 400 225.0 271.2 9.0 kw 65 dba Floor 76.00 72.00 32.00 2142 AHF 0480 600 3 01 S 480 300.1 361.6 12.0 kw 65 dba Floor 76.00 96.00 32.00 2856 AHF 0600 600 3 01 S 600 375.2 452.0 15.0 kw 65 dba Floor 76.00 120.00 32.00 3569 AHF 0720 600 3 01 S 720 450.2 542.4 18.0 kw 65 dba Floor 76.00 144.00 32.00 4283 AHF 0800 600 3 01 S 800 499.2 600.0 20.5 kw 65 dba Floor 76.00 240.00 32.00 6426 AHF 0960 600 3 01 S 900 599.0 720.0 24.6 kw 68 dba Floor 76.00 288.00 32.00 7711 *Data provided in this catalog represents only the information for the APQline filter. Data for the step down transformer is not included. For information regarding the specifics of the transformer, please contact APQ. APQline at 600 Volts The APQline Active Harmonic Filters offered at 600 Volts include a step down transformer and a 480 Volt APQline Active Harmonic Filter. Unless otherwise requested, these units are provided as separate system components. At 600 volts, the nominal current rating is at 80% of the nominal 480 volt APQline filter rating. For example, the 100 amp, 480 Volt APQline unit would be rated at 80 amps in a 600 Volt application. For paralleled units, APQ recommends that step down transformers are applied to each individual APQline unit versus one large step down transformer for all of the units. Type: Construction: 600 Volt Transformer Specifications Three-Phase auto transformer, general purpose Open Type Primary Voltage: 600 Volts, +5% Secondary Voltage (Full Load): Secondary Current: Primary Current: Impedance: ~1% Operating Frequency: Maximum Regulation: 1% 480 Volts Wye, ± 5 Volts KVA Dependent KVA Dependent 60 Hz Maximum Excitation: 10% (Nominal <5%) Winding/Core Construction: Cooling: Maximum Ambient Temperature: Maximum Temperature Rise: Insulation System: Copper Windings / M-36 Steel Natural Convection 40 C 135 C 200 C Applicable Standards: CSA Std. 22.2 No. 66-1988, Specialty Transformers 10 APQline Active Harmonic Filters
THE APQline Active Harmonic Filter Energy Saving Mode The APQline product offering is designed with the ability to employ an automatic start-up or shutdown based upon the current demand of the system. When load harmonic current is less than the minimum programmed current limit, the APQline Active Harmonic Filter will automatically shutdown until the load harmonic current is greater than the programmed harmonic current level. This unique feature is offered to save energy by turning off filtering whenever the load harmonic current is less than 5% of the APQline units rated current. It turns back on when the load harmonic current increases to greater than 10% of the rated filters rated current (factory settings). In this mode, the APQline will also turn off the fixed kvar provided by the filter, which also reduces the chance of having leading power factor. Refer to the installation, operation, and maintenance manual for program settings. Current Transformers The APQline Active Harmonic Filters are designed to be used in conjunction with current transformers rated 2000:1. Installations that require different CT ratios would require an internal component change in the APQline unit. Please be sure to review the application requirements prior to ordering a APQline solution. It is also important to note that the auxiliary current transformers are not provided with the standard filter. If auxiliary current transformers are desired, be sure to add the CT option indicator to the part number. Current transformers provided by APQ are a split core design and have an interior diameter of 8 inches. Communication Options The APQline Active Harmonic Filters offer RS-232 communication ports as standard in all units. Additional communication options include RS422, RS485, RJ45, USB, and TCP/IP ports. These additional options require communication cards that are sold separately. Monitoring Software APQ also offers additional software that allows for units to be remotely monitored and controlled. As with the unit controller, this software has the ability to display the harmonic frequency spectrum and will even display waveforms. Event logs are recorded to allow for simple issue diagnosis. A maximum of 255 units can be linked to the software for full global monitoring capabilities. APQline Active Harmonic Filters 11
N52 W13670 NORTHPARK DR. MENOMONEE FALLS, WI 53051 P. (262) 754-3883 F. (262) 754-3993 www.apqpower.com