Panasonic PT-D7500U, PT-D7600U User Manual

™

Sine Wave Filter

Installation, Operation and Maintenance Manual

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Table of Contents

Safety Instructions ...........................................................................................	5
Overview..................................................................................................................................................	5
Warnings and Cautions .........................................................................................................................	5
General Safety Instructions ...................................................................................................................	6

Introduction.......................................................................................................	7
Intended Audience..................................................................................................................................	7
Additional Information ..........................................................................................................................	7
Installation Checklist..............................................................................................................................	7

Receiving Inspection and Storage	................................................................. 8
Receiving Inspection...............................................................................................................................	8
Warranty Information ...........................................................................................................................	8
Storage Instructions ...............................................................................................................................	8

Product Description .........................................................................................	9
MotorGuard Sine Wave Filter ..............................................................................................................	9
Nameplate Data ....................................................................................................................................	10
Model Number Encoding.....................................................................................................................	11
Standard Product Ratings and Dimension Tables.............................................................................	11
Product Technical Specifications ........................................................................................................	14

Pre-installation Planning	............................................................................... 15
Verify the Application..........................................................................................................................	15
Select a Suitable Location ....................................................................................................................	15
Power Wiring........................................................................................................................................	15
Control Wiring......................................................................................................................................	16
Optional Features .................................................................................................................................	16

Installation Guidelines	................................................................................... 17
Mounting ...............................................................................................................................................	17
Wiring....................................................................................................................................................	17
MotorGuard Operation...................................................................................	19
Adjustments ..........................................................................................................................................	19
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Start Up (Commissioning)...................................................................................................................	19
Operation ..............................................................................................................................................	19
Maintenance and Service...............................................................................	20
MotorGuard Reliability and Service Life ..........................................................................................	20
Periodic Maintenance ..........................................................................................................................	20
Troubleshooting ...................................................................................................................................	21
Replacement Parts ...............................................................................................................................	25
Factory Contacts and Tech Support...................................................................................................	25
Drawings ..........................................................................................................	25
Typical Isometric Drawings and Schematic Diagrams.....................................................................	25

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Safety Instructions

Overview

This section provides the safety instructions which must be followed when installing, operating and servicing the MotorGuard. If neglected, physical injury or death may follow, or damage may occur to the MotorGuard or equipment connected to the MotorGuard. The material in this chapter must be read and understood before attempting any work on, or with, the product.

The MotorGuard is intended to be connected to the output terminals of a variable frequency drive (VFD). An AC motor is connected to the output terminals of the MotorGuard and receives power from the VFD through the MotorGuard. The instructions, and particularly the safety instructions, for the VFD, motor and any other related equipment must be read, understood and followed when working on any of the equipment.

Warnings and Cautions

This manual provides two types of safety instructions.

Warnings caution readers about conditions, which can, if proper steps are not taken, lead to a serious fault condition, physical injury, or death.

Cautions are used to draw attention to instructions. Failure to properly follow such instructions may lead to a malfunction and possible equipment damage.

Warnings

Readers are informed of situations that can result in serious physical injury and/or serious damage to equipment with warning statements marked with the following symbols:

Warning Dangerous Voltage Warning: warns of situations in which a high voltage can cause physical injury and/or equipment damage. The text next to this symbol describes ways to avoid the danger.

Warning General Warning: warns of situations that can cause physical injury and/or equipment damage by means other than

! electrical. The text next to this symbol describes ways to avoid the danger.

Warning Electrostatic Discharge Warning: warns of situations in which an electrostatic discharge may damage equipment. The text next to this symbol describes ways to avoid the danger.

Cautions

Readers are informed of situations that can lead to a malfunction and possible equipment damage with caution statements:

Caution General Caution: identifies situations that can lead to a malfunction and possible equipment damage. The text describes ways to avoid the situation.

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	General Safety Instructions
	These safety instructions are intended for all work on the MotorGuard. Additional safety instructions
	are provided at appropriate points on other sections of this manual.
Warning	Be sure to read, understand, and follow all safety instructions.
Warning	Only qualified electricians should carry out all electrical installation and maintenance work on the
	MotorGuard.
Warning	All wiring must be in accordance with the National Electrical Code (NEC) and/or any other codes that
	apply to the installation site.
Warning	Disconnect all power before working on the equipment.
	Do not attempt any work on a powered MotorGuard.
Warning	The MotorGuard, VFD, motor, and other connected equipment must be properly grounded.
Warning	The MotorGuard receives power from two or more sources.
	Three-phase power from the output terminals of the VFD is connected to the main input terminals of
	the MotorGuard.
	Power from a single-phase 120, 240 or 480 volt supply is connected to the MotorGuard for the cooling
	fan and monitor board.
	The monitor board alarm contacts may be connected to a circuit that receives power from another
	source.
	All of these sources of power must be disconnected before working on the MotorGuard.
Warning	After switching off the power, always allow 5 minutes for the capacitors in the MotorGuard and in the
	VFD to discharge before working on the MotorGuard, the VFD, the motor, or connecting wiring. It is
	good practice to check with a voltmeter to make sure that all sources of power have been disconnected
	and that all capacitors have discharged before beginning work.
Warning	The VFD output terminals and the motor cables are at a dangerously high voltage when power is
	applied to the VFD regardless of motor operation.

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Introduction

Thank you for selecting the TCI MotorGuard High Performance Output Filter. TCI has produced this filter for use in many PWM variable frequency drive (VFD) applications that require low distortion sine wave output power. This manual describes how to install, operate, and maintain the MotorGuard filter.

	Intended Audience
	This manual is intended for use by all personnel responsible for the installation, operation, and
	maintenance of the MotorGuard. Such personnel are expected to have knowledge of electrical wiring
	practices, electronic components, and electrical schematic symbols.
	Additional Information
Caution	This manual provides general information describing your MotorGuard filter. More specific
	information is provided by the drawings shipped with the unit. Be sure to carefully review the
	information provided by these drawings. Information provided by the drawings shipped with the unit
	takes precedence over the information provided in this manual.
	Installation Checklist
	The following are the key points to be followed for a successful installation. These points are
	explained in detail in the following sections of this manual.
			Make sure that the installation location will not be exposed to direct sunlight, corrosive or
			combustible airborne contaminants, excessive dirt, or liquids.
			Select a mounting area that will allow adequate cooling air and maintenance access.
			Make sure that all wiring conforms to the requirements of the National Electric Code (NEC)
			and/or other applicable electrical codes.
			Connect the MotorGuard equipment grounding lug to the system ground of the premises wiring
			system. Use a properly sized grounding conductor.
			Wire the output power terminals of the VFD, T1(U), T2(V), & T3(W) to the input terminals of
			the MotorGuard, U, V, & W.
			Wire the output power terminals, of the MotorGuard, T1, T2, & T3 to the motor.
			Connect control power to the MotorGuard.
			Connect the MotorGuard fault relay contact to the appropriate fault monitoring circuit.
			Check the MotorGuard configuration switch settings.
			Make sure that the VFD is set for operating modes and ranges that are compatible with the
			MotorGuard.
			Check everything thoroughly before operating the equipment.

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Receiving Inspection and Storage

Receiving Inspection

The MotorGuard has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment.

When you receive the unit, you should immediately inspect the shipping container and report any damage to the carrier that delivered the unit.

Verify that the part number of the unit you received is the same as the part number listed on your purchase order.

Warranty Information

Trans-Coil, Inc. (“TCI”) warrants to the original purchaser only that MotorGuard products will be free from defects in materials and workmanship under normal use and service for a period originating on the date of shipment from TCI and expiring at the end of One (1) year of useful service, not to exceed 18 months from the date of shipment. The foregoing limited warranty is TCI’s sole warranty with respect to its products and TCI makes no other warranty, representation or promise as to the quality or performance of TCI’s products. THIS EXPRESS LIMITED WARRANTY IS GIVEN IN LIEU OF AND EXCLUDES ANY AND ALL EXPRESS OR IMPLIED WARRANTIES INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

This warranty shall not apply if the product was:

a)altered or repaired by anyone other than TCI;

b)applied or used for situations other than those originally specified; or

c)subjected to negligence, accident, or damage by circumstances beyond TCI’s control, including but not limited to, improper storage, installation, operation or maintenance.

If, within the warranty period, any product shall be found in TCI’s reasonable judgment to be defective, TCI’s liability and the Buyer’s exclusive remedy under this warranty is expressly limited, at TCI’s option, to (i) repair or replacement of that product, or (ii) return of the product and refund of the purchase price.

Such remedy shall be Buyer’s sole and exclusive remedy. TCI SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL DAMAGES OR FOR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF INCOME, LOSS OF TIME, LOST SALES, INJURY TO PERSONAL PROPERTY, LIABILITY BUYER INCURS WITH RESPECT TO ANY OTHER PERSON, LOSS OF USE OF THE PRODUCT OR FOR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS.

The foregoing warranties do not cover reimbursement for removal, transportation, reinstallation, or any other expenses that may be incurred in connection with the repair or replacement of the TCI product.

The employees and sales agents of TCI are not authorized to make additional warranties about TCI’s products. TCI’s employees and sales agents oral statements do not constitute warranties, shall not be relied upon by the Buyer and are not part of any contract for sale. All warranties of TCI embodied in this writing and no other warranties are given beyond those set forth herein.

TCI will not accept the return of any product without its prior written approval. Please consult TCI Customer Service for instructions on the Return Authorization Procedure.

Storage Instructions

If the MotorGuard is to be stored before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in this manual. Store the unit in its original packaging.

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Product Description

MotorGuard Sine Wave Filter

The MotorGuard is a low-pass sine wave filter designed and developed by TCI to deliver conditioned power to motor loads driven by PWM drives at a variety of lead lengths. The MotorGuard is available for 460/480 volt and 575/600 volt systems.

The MotorGuard is a passive filter connected in series with the output terminals of the variable frequency drive. It is designed to remove the carrier frequency distortion from the output voltage waveform. The use of this low-pass, L-R-C device will result in a nearly pure sine wave voltage profile. This design will reduce the effects of the reflected wave phenomenon, (dv/dt), such as insulation damage or premature failure in motors, transformers and VFD output cables. The MotorGuard will also reduce the effects of stray high frequency harmonic currents, thereby reducing VFD ground fault problems and noise interference in transducer signals. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting within an enclosure provided with the VFD or other equipment. The MotorGuard is suitable for all lead lengths extending as far as 15,000 feet.

The MotorGuard consists of the following standard features and components:

♦An R-L-C power filter circuit with:

A TCI 3-phase reactor specifically designed for the MotorGuard

Power resistors

High-endurance, harmonic-rated capacitors

♦Bleeder resistors to ensure safe capacitor discharge upon filter shutdown.

♦Compression terminals for ease and integrity of all power wiring.

♦Cooling fans to ensure adequate cooling and safe operating temperatures.

♦A filter performance monitor and alarm circuit with:

Monitor board with relay and status indicating lights

Control transformer for control voltage power

Compression terminal blocks for all control wiring

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Nameplate Data

Figure 1 shows an example of a MotorGuard nameplate. The following information is marked on the nameplate:

♦Part number: encoded model number explained on the following page

♦FLA: the rated continuous operating current (RMS amps)

♦System Voltage: the maximum VFD output voltage (fundamental)

♦Hz: the maximum VFD output frequency (fundamental)

♦Phase: 3 – The MotorGuard is designed for use only with 3 phase motors.

♦Drawing #: outline and mounting dimension drawing number

♦Schematic #: schematic diagram drawing number

♦Manufacturing #: for TCI internal use

♦Enclosure Type: NEMA/UL designation or "Open" panel construction

Figure 1 – Example of MotorGuard Nameplate

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