Panasonic PT-DZ8700U, PT-DS8500U, PT-DW8300U User Manual

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Table of Contents
Introduction .........................................................................................................................	2
Receiving Inspection and Storage .......................................................................................	4
Pre-installation Planning.....................................................................................................	5
Installation Guidelines........................................................................................................	6
HG7 Harmonic Filter Operation .........................................................................................	8
Installation .........................................................................................................................	9
Maintenance and Service...................................................................................................	10
Product Description...........................................................................................................	14
Drawings ..........................................................................................................................	17
Standard Filter (ST) ...........................................................................................................	23
Contactor Option (STC).....................................................................................................	24
Power Monitor Package Option (XM)................................................................................	25
HG7 “XM” Option Operation............................................................................................	29
The HG2TM Protection Monitor .........................................................................................	30
Component Package Option (CP).....................................................................................	47
Installation ........................................................................................................................	49

i	HG7 I, O, & M Manual

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I N T R O D U C T I O N

Introduction

Safety Instructions Overview

This section provides the safety instructions which must be followed when installing, operating, and servicing the HG7 harmonic filter. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the HG7 harmonic filter. The material in this chapter must be read and understood before attempting any work on, or with, the product.

The HG7 harmonic filter is intended to be connected to the input terminals of one or more adjustable speed drives. Three-phase power is connected to the input terminals of the HG7 and power is supplied to the drive or drives through the HG7. The instructions, and particularly the safety instructions, for the drives, motors 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 are used to call attention to instructions, which describe steps, which must be taken to avoid conditions, which can lead to a serious fault condition, physical injury or death.

Cautions are used to call attention to instructions that describe steps that must be taken to avoid conditions that can 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 highlighted by the following symbols:

Warning	Dangerous Voltage Warning: warns of situations in which a
	high voltage can cause physical injury and/or damage
	equipment. 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 damage equipment 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 can 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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I N T R O D U C T I O N

General Safety Instructions

These safety instructions are intended for all work on the HG7. 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 HG7 harmonic filter.
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 HG7 filter.
Warning	The HG7 harmonic filter, drive, motor, and other connected
	equipment must be properly grounded.
Warning	After switching off the power, always allow 5 minutes for the
	capacitors in the HG7 filter and in the drive to discharge before
	working on the HG7, the drive, the motor, or the connecting
	wiring. It is a good idea 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.

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I N T R O D U C T I O N

Receiving Inspection and Storage

Thank you for selecting the HG7 Drive-Applied Harmonic Filter. TCI has produced this filter for use in many variable speed drive applications that require input power line harmonic current reduction. This manual describes how to install, operate and maintain the HG7 harmonic filter.

Receiving Inspection

The HG7 harmonic filter 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.

TCI Limited Warranty Policy

TCI, LLC (“TCI”) warrants to the original purchaser only that its 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 the period described below:

Product Family

Warranty Period

KLR, KDR

KLC, KLCUL, KMG,

V1k

HG7, KH, 3H, KRF KCAP, KTR, KMP

All Other Products

For the life of the drive with which they are installed. One (1) year of useful service,

not to exceed 18 months from the date of shipment.

Three (3) years from the date of shipment. Five (5) years from the date of shipment.

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 HG7 harmonic filter 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 Table 2 (HG7 Harmonic Filter Technical Specifications). Store the unit in its original packaging.

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I N T R O D U C T I O N

Pre-installation Planning

Verify the Application

HG7 Ratings

Make sure that the HG7 harmonic filter is correct for the application. The voltage ratings of the filter must match the input voltage rating of the connected drive. The horsepower and current ratings of the filter must be adequate for the connected load. The kVar rating of the HG7 filter should be 30% of the horsepower rating for 3-phase diode bridge rectifier loads such as PWM AC drives.

Select a Suitable Location

Environment

Locating the HG7 in a suitable environment will help assure proper performance and a normal operating life. Refer to the environmental specifications listed in Table , marked on the unit's nameplate and/or noted on the drawings furnished with the unit.

Warning	Unless specifically labeled as approved for such use, this equipment is not
	suitable for use in an explosive atmosphere or in a "Hazardous (Classified)
	Location" as defined in article 500 of the National Electrical code.

The unit must be installed in an area where it will not be exposed to:

♦Direct sunlight

♦Rain or dripping liquids (unless filter is in a 3R enclosure)

♦Corrosive liquids or gasses

♦Explosive or combustible gases or dust

♦Excessive airborne dirt and dust

♦Excessive vibration

Working Space

Provide sufficient access and working space around the unit to permit ready and safe installation, operation and maintenance. Make sure that the installation conforms to all working space and clearance requirements of the National Electrical Code (NEC) and/or any other applicable codes. Provide sufficient unobstructed space to allow cooling air to flow through the unit.

Mounting an Open Panel Unit

If you are mounting an open panel unit in your own enclosure, you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating. The rating and dimension tables for open panel units list the watts of heat loss that is dissipated by the HG7 harmonic filter. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).

Power Wiring

When selecting a mounting location for the HG7 filter, plan for the routing of the power wiring.

Route the conduit and wiring from the power source to the filter and then to the variable speed drive.

The HG7 is provided with internal fuses. Additional fuses may be required at the connecting point to protect the tap conductors. Refer to the National Electrical Code (NEC) and/or any other applicable codes.

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I N T R O D U C T I O N

Installation Guidelines

Mounting

The HG7 must be mounted vertically on a smooth, solid surface, free from heat, dampness, and condensation.

Wiring

Cable Entry Locations

The enclosed HG7 harmonic filters are not provided with enclosure wiring knockouts. A selection can be made at the time of installation. Typical or recommended cable entry locations are shown in the drawings section of this manual.

Field Wiring Connection Terminals

Compression type terminals are provided for all field wiring connections. The control circuit terminals will accommodate 18 AWG to 10 AWG wire and should be tightened to 7 lbs. - in. torque. The wire size capacity ranges and tightening torque for the grounding and power terminals are listed in the drawings and other information shipped with the unit.

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I N T R O D U C T I O N

Grounding

The HG7 panel equipment-grounding lug must be connected to the ground of the wiring system. The equipment grounding connection must conform to the requirements of the National Electric Code (NEC) and/or any other codes that apply to the installation site. The ground connection must be made using a wire conductor. Metallic conduit is not a suitable grounding conductor. The integrity of all ground connections should be periodically checked.

Power Wiring

Caution	Use copper wire that is appropriate for the voltage and current rating of the
	equipment. The wire selection must conform to the requirements of the
	National Electrical Code and/or other applicable electrical codes.
	For units rated less than 100 amps, use wire with an insulation temperature
	rating of 60°C or higher.
	For units rated 100 amps or more, use wire with an insulation temperature
	rating of 75°C or higher.

Connect three-phase power of the appropriate voltage and current capacity to the branch circuit protective device to the HG7 input power terminals. Note: in large units, the input power conductors are connected directly to the input terminals on the line reactors.

Connect the output terminals of the HG7 to the input power terminals of the adjustable speed drive. Note: in large units, the output power conductors are connected directly to the output terminals on the line reactors. Refer to the adjustable speed drive installation instructions for additional information.

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I N T R O D U C T I O N

HG7 Harmonic Filter Operation

Caution	Thoroughly check the installation before applying power and operating
	the equipment for the first time.

Before Applying Power for the First Time

Inspect the installation to make sure that all equipment has been completely and correctly installed in accordance with the Installation Guidelines section of this manual.

♦Check to see that the cooling fan(s) are operating in units so equipped.

Operation

Since the HG7 is a passive filter, it is always operating whenever the drive is operating.

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I N T R O D U C T I O N

Installation

Intended Audience

This manual is intended for use by all personnel responsible for the installation, operation and maintenance of the HG7 harmonic filters. 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 HG7 harmonic filter.
	Be sure to carefully review the more specific information that is provided by the
	drawings shipped with the unit. Information provided by the drawings takes
	precedence over the information provided in this manual.
	The ratings, dimensions and weights given in this manual are approximate and
	should not be used for any purpose requiring exact data. Contact the factory in
	situations where certified data is required. All data is subject to change without
	notice.

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 HG7 equipment-grounding lug to the system ground of the premises wiring system. Use a properly sized grounding conductor.

Connect three-phase power to the input terminals of the HG7, L1, L2 & L3.

Connect the output power terminals, of the HG7, T1, T2 & T3, to the input power terminals of the variable frequency drive.

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I N T R O D U C T I O N

Maintenance and Service

HG7 Harmonic Filter Reliability and Service Life

The HG7 has been designed to provide a service life that equals or exceeds the life of the variable speed drive. It has been thoroughly tested at the factory to assure that it will perform reliably from the time it is put into service. The following periodic maintenance is recommended to assure that the HG7 filter will always perform reliably and provide the expected service life.

Periodic Maintenance

Warning	Only qualified electricians should carry out all electrical installation and
	maintenance work on the HG7 filter.
	Disconnect all sources of power to the drive and HG7 before working on the
	equipment. Do not attempt any work on a powered HG7.

Check to see that the installation environment remains free from exposure to excessive dirt and contaminants. Refer to the Pre-installation Planning section of this manual.

Check to make sure that the enclosure ventilation openings are clean and unobstructed.

Clean the air filter in units that have filtered air inlets. Clean as often as necessary to prevent dirt buildup from impeding air flow.

Check the operation of the cooling fan.

Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the enclosure whenever excess dirt has accumulated.

Check the integrity of all power and ground wiring connections.

Troubleshooting

Warning	Only qualified electricians should carry out all electrical installation and
	maintenance work on the HG7 harmonic filter.
	Disconnect all sources of power to the drive and HG7 before working on the
	equipment. Do not attempt any work on a powered HG7 harmonic filter.
	The harmonic filter contains high voltages and capacitors. Wait at least five
	minutes after disconnecting power from the filter before you attempt to
	service the harmonic filter. Check for zero voltage between all terminals on
	the capacitors. Also, check for zero voltage between all phases of the line side
	of the fuses, Fu1(a)–Fu2(a)–Fu3(a). All setup, maintenance, and
	troubleshooting must be done by a qualified electrician. Failure to follow
	standard safety procedures may result in death or serious injury.

Note: when disconnecting wires from components and terminations, mark the wires to correspond to their component and terminal connection.

Reference Drawings

When troubleshooting, refer to the drawings provided for the specific equipment. Typical drawings are provided in this manual.

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I N T R O D U C T I O N

Fuse Specifications

Table 1a through 1d list the specifications for the LC filter power circuit fuses in the HG7. Refer also to the drawings and other information shipped with the unit.

Table 1a – Fuse Specifications for HG7 240 Volt Models

	HG7		Power Circuit
	Rating		Fuse Ratings
	(kVar)
		Amps	Type
	3	15	Class CC Bussmann
	3	15
			type KTK-R
	5	25
			or equivalent
	6	25
	8	35
	10	45	Class T
	15	60
			Bussmann
	15	60
			type JJS
	20	80
			or equivalent
	25	100
	30	125

Table 1b – Fuse Specifications for HG7 400 Volt Models

	HG7		Power Circuit
	Rating		Fuse Ratings
	(kW)
		Amps	Type
	4	5
	5	6
	7.5	7
	9.3	9	Class CC Bussmann
	11	12	type KTK-R
	15	15	or equivalent
	18.5	25
	22	25
	30	30
	37	35
	45	45
	55	60
	75	80
	90	90
	110	110
	132	150	Class T
	160	150
			Bussmann
	200	200
			type JJS
	250	250
			or equivalent
	315	300
	355	350
	400	400
	450	450
	500	500
	560	600
	630	600

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Table 1c – Fuse Specifications for HG7 480 Volt Models

	HG7		Power Circuit
	Rating		Fuse Ratings
	(kVar)
		Amps	Type
	3	10
	5	15	Class CC Bussmann
	6	15	type KTK-R
	10	30	or equivalent
	15	30
	20	40
	25	50
	30	60
	40	80
	45	100
	60	125	Class T
	75	175
			Bussmann
	90	200
			type JJS
	105	225
			or equivalent
	120	250
	150	300
	180	400
	210	450
	240	500
	270	600

Table 1d – Fuse Specifications for HG7 600 Volt Models

	HG7		Power Circuit
	Rating		Fuse Ratings
	(kVar)
		Amps	Type
	5	10	Class CC Bussmann
	10	25
			type KTK-R
	15	30
			or equivalent
	15	30
	20	35
	25	40
	30	50
	40	70
	45	80
	60	100
	75	125	Class T
	90	150	Bussmann
	105	175	type JJS
	120	200	or equivalent
	150	250
	150	250
	180	300
	210	350
	240	400
	270	450

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I N T R O D U C T I O N

Replacement Parts

If replacement parts are needed, please contact your TCI representative. To ensure that the HG7 harmonic filter continues to perform to its original specifications, replacement parts should conform to TCI specifications.

Factory Contacts and Tech Support

For technical support, contact your local TCI distributor or sales representative.

You can contact TCI directly at 800-TCI-8282. Select "Customer Service" or "Tech Support" and have your HG7 harmonic filter nameplate information available.

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Product Description

HG7 Drive-Applied Harmonic Filter

The HG7 is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 is available for 240, 480, 600 (60 Hz) and 400 (50 Hz) volt systems. It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC drives.

The HG7 is a passive filter connected in series with the input terminals of a variable speed drive or several drives that operate as a group. It is designed to provide a low impedance path for the major harmonic currents demanded by the drive. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the drive. It is also available on an open panel for mounting within an enclosure with the drive or other equipment.

The HG7 filters consist minimally of the following features and components:

♦A KDR input series reactor to prevent system interaction and improve filter performance.

♦An L-C harmonic filter circuit with:

A TCI 3-phase tuning reactor specifically designed for the HG7 filter

High-endurance, harmonic-rated capacitors

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

♦Cooling fans (on select models) to ensure adequate cooling and safe operating temperatures.

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

♦Fuses to protect caps from over-current

Nameplate Data

Figure 1 shows a typical HG7 harmonic filter nameplate. The following information is marked on the nameplate:

♦Part number: encoding is explained on the following page

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

♦System Voltage: the rated 3-phase line voltage (RMS volts)

♦Hz: the rated frequency (60 Hz/50 Hz)

♦Phase: 3 – The HG7 filter is designed for use only with 3-phase power.

♦Drawing #: outline and mounting dimension drawing number

♦Schematic #: schematic diagram drawing number

♦Manufacturing #: for TCI internal use

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

Figure 1 – Typical HG7 Harmonic Filter Nameplate

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