TCi HarmonicGuard HGL Series Installation, Operation And Maintenance Manual

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Page 1

Including information for:

Product No: 30799 Effective: 09/25/19

Version: E

HarmonicGuard® Series Drive-Applied

Harmonic Filter Installation, Operation,

and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-824-8282 Web Site: www.transcoil.com

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No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of TCI, LLC. The information in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. TCI, LLC assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

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Performance Guarantee

Select and install the appropriate HarmonicGuard® Low Capacitance Harmonic Filter in a variable torque, variable frequency AC drive application, within our published technical specifications and we guarantee that the input current distortion will be less than or equal to 5% THID for standard HGL Series filters at full load. If a properly sized and installed filter fails to meet its specified THID level, TCI will provide material for necessary modifications or replacement filter at no charge.

HG filters can also provide similar performance in other drive applications such as constant torque, DC drives and other phase-controlled rectifiers, but actual THID levels can vary by load and/or speed and therefore cannot be guaranteed.

Consult factory for assistance when applying HGL filters on these types of equipment.

MINIMUM SYSTEM REQUIREMENTS:

The guaranteed performance levels of this filter will be achieved when the following system conditions are met:

Frequency: 60Hz ± 0.75Hz System Voltage: Nominal System Voltage (line to line) ±10% Balanced Line Voltage: Within 0.5% Background Voltage Distortion: < 0.5% THVD

The input VFD current waveform shall be consistent with that of a VFD with 5% AC line reactance at full load and a 5% source impedance.

NOTE: The presence of background voltage distortion will cause motors and other linear loads to draw harmonic currents.

Additional harmonic currents may flow into the HGL filter if there is harmonic voltage distortion already on the system.

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Revision

Description

Date

Release

10/19/2017

Updated Part Number

Updates to Watts loss table

12/12/2018

Addition of PQvision App

09/25/2019

D Addition of PQconnect 08/21/2019

Added Additional Options

11/22/2017

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Table of Contents

1.0 Safety .................................................................................................................................................1

Safety Instructions Overview ....................................................................................................................1

Warnings and Cautions ............................................................................................................................1

General Safety Instructions ......................................................................................................................2

2.0 General Information .........................................................................................................................3

Intended Audience ....................................................................................................................................3

Receiving Inspection .................................................................................................................................3

Storage Instructions ..................................................................................................................................3

TCI Limited Warranty Policy .....................................................................................................................3

3.0 Pre-Installation Planning .................................................................................................................5

Verify the Application ................................................................................................................................5

HGL Drive-Applied Filter ...........................................................................................................................5

Nameplate Data ........................................................................................................................................5

Part Numbering System............................................................................................................................6

HGL Filter Overview .................................................................................................................................7

4.0 Installation Guidelines .....................................................................................................................9

Installation Checklist .................................................................................................................................9

Select a Suitable Location ........................................................................................................................9

Mounting ...................................................................................................................................................9

Power Wiring ......................................................................................................................................... 10

HGL Filter Operation .............................................................................................................................. 10

Caution................................................................................................................................................... 10

Fuse Specifications ................................................................................................................................ 11

SCCR Fusing Requirements ................................................................................................................. 11

5.0 PQconnect Connectivity ............................................................................................................... 15

HGL Drive-Applied Filter with PQconnect ............................................................................................. 15

PQvision PC application Screen Elements ............................................................................................ 15

Example Application Using “Simply Modbus Master 8.1.0” ................................................................... 18

USPTL4 RS485 Converter Dip Switch settings ..................................................................................... 19

Example Setup Instructions to Read Data from the PQconnect Unit: ................................................... 19

Example Setup Instructions to Write Data to the PQconnect Unit: ....................................................... 20

PQconnect Quick Start Unit Software Setup ......................................................................................... 21

PQconnect Bluetooth® App Setup ......................................................................................................... 21

PCB Connections .................................................................................................................................. 23

Modbus RTU .......................................................................................................................................... 25

Wiring and Configuration ....................................................................................................................... 25

PQvision Display Connections .............................................................................................................. 26

Register Map ......................................................................................................................................... 28

6.0 PQconnect Troubleshooting ........................................................................................................ 38

HarmonicGuard® Low Capacitance Filter Status Warning .................................................................... 38

Receiving Inspection .............................................................................................................................. 38

Connectivity Board Problem .................................................................................................................. 38

Communication Problems...................................................................................................................... 40

Debug Status Conditions ....................................................................................................................... 41

Contactor Problem ................................................................................................................................. 42

7.0 Maintenance and Service ............................................................................................................. 45

HGL Filter Reliability and Service Life ................................................................................................... 45

Troubleshooting ..................................................................................................................................... 45

Warning.................................................................................................................................................. 45

Replacement Parts ................................................................................................................................ 45

Factory Contacts and Tech Support ...................................................................................................... 45

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HGL Manual 1.0 Safety

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

this symbol describes ways

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

1.0 Safety

Safety Instructions Overview

This section provides the safety instructions which must be followed when installing, operating, and servicing the HarmonicGuard® Low Capacitance (HGL) filter. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the HGL filter. The material in this chapter must be read and understood before attempting any work on, or with, the product. The HGL filter is intended to be connected to the input terminals of one or more VFDs. Three-phase power is connected to the input terminals of the HGL and power is supplied to the VFD or VFDs through the HGL. The instructions, and particularly the safety instructions, for the VFDs, 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 that describe steps that must be taken to avoid conditions that 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 where high voltage can cause physical injury and/or damage equipment. The text next to this symbol describes ways to avoid the danger.

Warning

than electrical. The text next to to avoid the danger.

Warning

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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HGL Manual 1.0 Safety

Be sure to read, understand, and follow all safety

After switching off the power, always allow 5 minutes for

filter and in the drive to

voltmeter to make sure that all sources of power have been disconnected and that all capacitors have discharged before beginning work.

General Safety Instructions

These safety instructions are intended for all work on the HGL. Additional safety instructions are provided at appropriate points on other sections of this manual.

Warning

instructions.

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the HGL filter.

All wiring must be in accordance with the National Electrical Code (NEC) and/or any other codes that apply to the installation site.

Disconnect all power before working on the equipment. Do not attempt any work on a powered HGL filter.

The HGL filter, drive, motor, and other connected equipment must be properly grounded.

the capacitors in the HGL discharge before working on the HGL, the drive, the motor, or the connecting wiring. It is a good idea to check with a

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HGL Manual 2.0 General Information

Product Family

Warranty Period

For the life of the drive with which they are

installed.

MSD, V1K

One (1) year of useful service,

shipment.

HGP, HGL, KRF

Three (3) years from the date of shipment.

KCAP, KTR

Five (5) years from the date of shipment.

One (1) year of useful service,

shipment.

2.0 General Information

Thank you for selecting the HarmonicGuard® Low Capacitance (HGL) filter. TCI has produced this filter for use in many variable frequency drive (VFD) applications that require input power line harmonic current reduction. This manual describes how to install, operate and maintain the HGL filter.

Intended Audience

This manual is intended for use by all personnel responsible for the installation, operation and maintenance of the HGL filters. Such personnel are expected to have knowledge of electrical wiring practices, electronic components and electrical schematic symbols.

Receiving Inspection

The HGL 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.

Storage Instructions

If the HGL filter is to be stored before use, be sure that it is in a location that conforms to published storage humidity and temperature specifications stated in the HarmonicGuard Filter Technical Specifications. Store the filter in its original packaging.

Low Capacitance

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:

KLR, KDR

HGA, KLC,

KLCUL, KMG,

All Other Products

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

not to exceed 18 months from the date of

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HGL Manual 2.0 General Information

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 agent’s oral statements do not constitute warranties; these 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.

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HGL Manual 3.0 Pre-Installation Planning

3.0 Pre-Installation Planning

Verify the Application

Make sure that the HGL filter is correct for the application. The voltage rating of the filter must match the input voltage rating of the connected drive. The horsepower and current ratings of the filter must be appropriate for the connected load.

HGL Drive-Applied Filter

The HGL is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by VFDs. The published HGL voltage, Power (Hp or kW) and current ratings apply to matching power (Hp or kW) rated standard VFDs with six-pulse diode bridge rectifiers. The HGL may also be sized to filter other loads such as SCR six-step drives, SCR Direct Current (DC) motor drives, thyristor furnaces, battery chargers, electroplating supplies or other types of non-linear loads. In many cases, the filter power rating (Hp or kW) will differ from load power rating (Hp or kW). Please contact TCI Technical Support for additional information and support on sizing HGL harmonic filters for your non-six-pulse diode front end VFD applications.

The HGL is a passive filter connected in series with the input terminals of a VFD or several VFDs 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 HGL filters consist minimally of the following features and components:

• A KDR tuned series reactor to prevent system interaction and improve filter performance

• An L-C-L filter circuit with:

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

• High-endurance, harmonic-rated capacitors

• Larger filters may have multiple tuned circuits. Consult fuse tables to determine if the

filter in question has “parallel” branches.

• 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 sized to protect the capacitor wiring

Nameplate Data

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

• Phase: 3 – The HGL 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

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HGL Manual 3.0 Pre-Installation Planning

Part Numbering System

Figure 1 identifies the significance of each character in the HGL part number. The example part number, HGL0150AW1S0000 designates an HGL filter that is rated 150 HP, 480 volts, 60 Hz. It includes a line reactor, tuning reactor, and capacitors in a UL Type 1 enclosure. It is designed for use with a 150 HP drive.

Figure 1: HGL Part Number Encoding

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HGL Manual 3.0 Pre-Installation Planning

Voltage ratings

kVar rating

0.15 kVAR/HP

Load types

3-phase diode bridge rectifier loads such as PWM AC drives

depending on system voltage

current for no more than 3 minutes.

rating)

Maximum elevation

6,500 feet (2,000 meters) as standard.

Enclosed Panel.

provisions for operation above this temperature.

temperature

operating or storage

Insertion Impedance

10% at full load current

branch circuit

Performance Guarantee

5% AC line reactance at full load

Table 1: HGL Technical Specifications

Electrical Characteristics

60 Hz, 3 Phase: 480 V/600 VAC

Load power range

Current ratings

SCCR (short circuit current

Environmental Conditions

Maximum ambient operating temperature

Maximum ambient storage

Maximum humidity,

Agency approvals or certifications

Fusing and protection

20-900HP for 480 V/600 V units. Power range varies

The included series reactors can tolerate 200% of rated

Standard rating is 100kA.

50°C (122°F) – Open Panel; 40°C (104°F) –

Product must be equipped with special cooling

60°C (140°F)

95%, non-condensing.

UL and cUL Listed to UL508A

All units have internal fuse protection for the capacitor

To meet the requirements for the Performance Guarantee the minimum system conditions must conform to the following:

• At least a 5% Source inductance

• The input VFD current waveform shall be consistent with that of a VFD with

HGL Filter Overview

The HarmonicGuard® Low Capacitance (HGL) Filter provides a low impedance path for the major harmonic currents demanded by Variable Frequency Drives (VFDs). This greatly reduces the amount of harmonic currents flowing through the electrical power distribution system, bringing those harmonic currents in line with the IEEE-519 standard for harmonic distortion mandated by an increasing number of utilities.

The HGL Filter includes branch fuses on the harmonic trap circuit capacitors. These fuses are included in the design to prevent damage to the capacitors in the event of excessive harmonic trap current if the filter is misapplied.

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HGL Manual 3.0 Pre-Installation Planning

No Contactor Option (S)

The No Contactor (Standard) Option includes high quality harmonic-grade capacitors and line reactors. This filter will meet most application requirements found today. This cost-effective product is available as an open panel version, in a UL Type 1, UL Type 12, or in an UL Type 3R enclosure. The open panel is perfect for inclusion in a MCC section or easy installation into industry standard enclosures. The UL Type 1 enclosed units maintain the same vertical profile as the open panel design. This design is perfect for applications where floor space is at a premium. The UL Type 3R enclosure protects the filter from harsh conditions.

Contactor Option (C)

The contactor option shall allow the user to open and close a contact that will remove the capacitors from the circuit. Operation shall be controlled through a contact input on the customer’s equipment.

The Contactor Option includes a contactor, control power transformer and connection terminals in the filter circuit which allows the VFD user to control the insertion of this circuit using a relay contact in the VFD. It is recommended that the VFD contact be programmed to open the contactor below 33% motor power. For variable torque (fan) loads this will be approximately below 70% speed, so the at-speed contact may be used. This reduces the possibility of leading power factor interacting with other devices on the power system. Contactor logic should also maintain the contactor closed in cases where the VFD is bypassed and the filter is not bypassed.

Vibration Pad Option (V)

The Vibration Pad Option is intended for use in applications which require environmental noise protection. The resilient mounting material is placed between the reactor and the interior of the enclosure and dampens noise produced by the reactor.

The Vibration Pad option is available for all enclosure types.

Floor Stand Option (F)

The Floor Stand Option is intended for use in applications which require the HGL enclosure to be elevated from the floor. The Floor Stand option consists of 12” steel feet available for Type 3R enclosures 125hp and below.

Oilfield Duty Option (P)

The Oilfield Duty Option features components designed specifically for oil and gas field applications to handle the additional electrical stress. Designed for cyclical loads these units will be available in Type 3R enclosures and will be for use with HP ranges from 40 to 200HP.

Heater Option (H)

The Heater Option is intended for use in applications which require the environmental protection of a NEMA 3R enclosure. The heater is mounted to the interior of the enclosure and protects sensitive electronic equipment from the harmful effects of corrosion and condensation. When using a Type 12 or Type 3R Enclosure and in a high humidity environment, set thermostat to 37°C (100°F) or max temperature below 37°C (100°F).

The Heater option is available for all 3R enclosures.

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HGL Manual 4.0 Installation Guidelines

4.0 Installation Guidelines

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 Electrical Code

(NEC) and/or other applicable electrical codes.

 Connect the HGL 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 HGL, L1, L2 & L3.  Connect the output power terminals, of the HGL, T1, T2 & T3, to the input power terminals

of the VFD.

Select a Suitable Location

Environment

Locating the HGL in a suitable environment will help ensure proper performance and a normal operating life. Refer to the environmental specifications listed in Table 2 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 (NEC).

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

Working Space

Provide enough 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 enough unobstructed space to allow cooling air to flow through the unit. Keep the widest or deepest portion of the unit enclosure having ventilation openings a minimum of six inches from adjacent walls or other equipment. The unit enclosure sides that do not have ventilation openings should be kept a minimum of three inches from adjacent walls or other equipment.

Mounting

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

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 dissipated by the HGL filter. The maximum temperature of the air around the HGL filter capacitors, line reactor, and tuning reactor should not exceed 50°C (122°F).

• Direct sunlight

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

• Corrosive liquids or gasses

• Explosive or combustible gases or dust

• Excessive airborne dirt and dust

• Excessive vibration

Page 16

HGL Manual 4.0 Installation Guidelines

rating of 75°C or higher.

Power Wiring

When selecting a mounting location for the HGL 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 VFD. The HGL is provided with internal fuses.

Cable Entry Locations

The enclosed HGL filters are not provided with enclosure wiring knockouts. A location can be selected 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 wire size capacity range and tightening torque for all field wiring connections are listed in the drawings and other information shipped with the unit.

Grounding

The HGL 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 Electrical 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.

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 (NEC) 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

Connect three-phase power of the appropriate voltage and current capacity to the circuit protective device to the HGL 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 HGL to the input power terminals of the VFD.

Note: In large units, the output power conductors are connected directly to the output terminals on the line reactors. Refer to the VFD installation instructions for additional information.

HGL 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.

• Check to make sure power connections are torqued to recommended torque value.

Page 17

HGL Manual 4.0 Installation Guidelines

Only qualified electricians should carry out all electrical installation and maintenance work on the

east five minutes after

electrician. Failure to follow standard safety procedures may result in death or serious injury.

600

≤ 40

Use appropriately rated Class J, T, or L fuse less than or equal to 60 A

600

> 40

No requirement for SCCR

480

≤ 30

Use appropriately rated Class J, T, or L fuse less than or equal to 60 A

480

> 30

No requirement for SCCR

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

Warning

HGL filter. Disconnect all sources of power to the drive and HGL before working on the equipment. Do not attempt any work on a powered HGL filter. The harmonic filter contains high voltages and capacitors. Wait at l 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), and all input terminals L1, L2 and L3 of the line reactor (KDR). All setup, maintenance, and troubleshooting must be done by a qualified

Fuse Specifications

Always refer to the drawings and other information shipped with your unit. Consult applicable wiring codes, UL and NEC, for current limiting and disconnect requirements.

SCCR Fusing Requirements

See the table below for line fusing requirements that must be supplied to comply with the 100kA SCCR.

Table 2: Customer Installed Line Fuse Requirements to comply with the 100kA SCCR

Voltage Size

Customer Installed Line Fuse Requirements

to Comply with the 100 kA SCCR

Provisional 480 V Fuse Table

The fuse tables provided below show the fuse ratings of the included branch circuit fuse internal to the HGL unit as a fuse replacement reference.

The fuse tables also show a typical line fuse or circuit breaker current rating for overcurrent protection, given the unit’s nameplate power rating, if necessary, based on the installation. The line current fuses listed below are typical values given the unit power rating, not required values. Line fusing ratings are determined by the installer, based on input conductor sizing and protection required for downstream equipment. Any drawings or documentation included with the unit literature kit take precedence over the fuse tables below.

Note that to achieve a 100kA SCCR, the customer provided line fuse must be installed as per the requirements in Table 2 and sized following NEC (National Electrical Code) guidelines for the source conductors selected by the installer. The branch fuses are required to be installed at the shown ratings.

Page 18

HGL Manual 4.0 Installation Guidelines

(Included Internal to HGL Unit)

(J or T)

125

100

150

125

200

150

225

200

300

250

125

350

300

150

450

350

175

500

400

175

600

450

200

600

500

225

750

600

250

800

700

300

1000

800

350

1200

900

400

1300

(Included Internal to HGL Unit)

100

125

175

150

200

250

300

110

350

125

400

150

450

175

500

175

550

600

200

650

700

250

750

800

300

900

300

1000

Table 3: Fuse Table for HGL 480 Volt, 60Hz Models

HGL

Rating

(HP)

Branch Circuit Fuse Current Rating

Typical Line Current Fuse

or Circuit Breaker Rating

(Customer Supplied)

Table 4: Fuse Table for HGL 600 Volt, 60Hz Models

HGL

Rating

(HP)

Branch Circuit Fuse Current Rating

(J or T)

Typical Line Current Fuse or

Circuit Breaker Rating

(Customer Supplied)

Page 19

HGL Manual 4.0 Installation Guidelines

Open

Type 1

Type 3R

205

208

341

346

239

242

447

454

518

525

608

617

560

569

100

760

771

125

871

884

150

1046

1062

200

907

921

250

1217

1235

300

1454

1476

350

1411

1432

400

1548

1571

450

1842

1869

500

2053

2083

600

1976

2005

700

2225

2258

800

2419

2455

900

2577

2616

Table 5: 480 V HGL Watts loss

Page 20

HGL Manual 4.0 Installation Guidelines

Open

Type 1

Type 3R

338

343

304

309

293

297

341

346

511

519

600

609

734

745

100

736

747

125

920

934

150

1182

1200

200

976

991

250

1306

1325

300

1452

1474

350

1766

1792

400

1566

1589

450

2079

2110

500

1984

2014

600

2034

2064

700

2341

2376

800

2726

2766

900

3080

3126

Table 6: 600 V HGL Watts loss

Page 21

HGL Manual 5.0 PQconnect Connectivity

5.0 PQconnect Connectivity

HGL Drive-Applied Filter with PQconnect

The PQconnect is an integrated controls option for TCI’s industry leading passive harmonic filters used for filtering the input of variable frequency motor drives (VFDs). In a passive harmonic filter, the PQconnect provides basic tuned circuit contactor control and provides unit status detection, metering, waveforms and power quality data. The PQconnect data is made available via basic Modbus RTU over RS485 serial connection. The PQconnect is UL listed and intended for commercial and industrial applications. By default, the PQconnect is manufactured to close the contactor at 30% load.

*Please verify you have the latest manual version for your PQconnect software by visiting transcoil.com/products/HGL-5-passive-harmonic-filter/

Figure 2

: HGL Filter with PQconnect Typical Connection Diagram

PQvision PC application Screen Elements

This section focuses on the operation of the PQvision application. The PC application contains several screens that allow the user to monitor the status of the HarmonicGuard filter. Additionally, the PQvision application can be used for contactor control and basic setup of the HarmonicGuard

Please ensure the latest version of PQvision is downloaded to your PC by accessing the software at https://transcoil.com/products/HGP-5-passive-harmonic-filter/pqvision-software/

A RS485 to USB converter was included with your HGL with PQconnect purchase. To run the PQvision software the converter will need to be connected to terminal J5 on the PQconnect PCB with pin orientation as described in the table, the USB connector will need to be run to laptop or PC.

Low Capacitance filter. Enter password 08252014 to enable tech access.

Low Capacitance

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HGL Manual 5.0 PQconnect Connectivity

Options

Description

Communication Status and Communication Port

Modbus settings, then cycle power of the HarmonicGuard® Low Capacitance filter.

DSP Rev: Latest software revision will be displayed

required to perform the update”

Menu: Save settings, about screen, software update, tech access

Settings – Modbus, contactor control, kVAR settings, alert management view Figure 4.

Help – Direct links to the TCI Home page and tech support contact information.

(THVD) Displays the Total Harmonic Distortion of the utility Line/Load voltage as a percentage

(THID) Displays the Total Harmonic Distortion of the utility Line/Load current as a percentage

Displays three-phase real power (P) of the filter input/output in kW

Displays three-phase reactive power (Q) of the filter input/output in kVAR

Displays three-phase apparent power (S) of the filter input/output in kVA

Displays filters output power factor. 1.00 indicates unity power factor. A negative power factor indicates lagging power factor

Displays the current utility line frequency in Hz

Displays the supply voltage into the HarmonicGuard® Low Capacitance filter

Displays the filters input/output phase current in Amps RMS

Displays board temperature

Phase C – Blue

Harmonic Spectrum (Left toggle to zoom in on the spectrum and right to increase the spectrum to the 50th harmonic) the value of the fundamental is 100.

Status alerts for the input, output and of the filter will display according to severity of the

Hovering over status alert will give a brief description of what the problem may be.

Figure 3: PQvision Desktop Application

Table 7: PQvision PC Naviagation

To determine the COM port, go to Device Manager Ports (COM & LPT) and finding “USB Serial Port”

Note: If Modbus settings differ from the default values above; Set and save desired

Toolbar

Summary

Data

Waveforms

To update the software, select “Software Update” under the menu “Tech access is

The PQconnect PC application supports capture and display of real time system voltage and current data. Three phase waveform data can be viewed for Filter Line/Load Voltage, and Filter Line/Load Current.

Phase A – Black Phase B – Red

Status

Detections

alerts.

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HGL Manual 5.0 PQconnect Connectivity

To access the settings page as seen in Figure 4, under the Menu toolbar select Tech Access and Enter password 08252014 to enable. In the PQvision settings a user can set their desired Modbus settings. (Note: if changing Modbus settings, one must restart the PQconnect by cycling power to the HarmonicGuard® Low Capacitance filter) As well as controlling the contactor and enabling/ disabling alerts. The table below describes the settings menu.

Figure 4

: PQvision Settings

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HGL Manual 5.0 PQconnect Connectivity

Designators

Name

Description

Allows the user to change Modbus settings of the App and device. When

filter and re-energize the filter.

Enable and Disable status detections. Depending on which status

Relay Inputs are based on how the board is connected to digital inputs.

There are multiple ways to control the contactor.

the change final. Saving settings will open the contactor.

Table 8: Settings Menu

1. Modbus

Alert Management

Relay Input Configuration

Contactor Control

changing Modbus settings of the device the user will select apply and save settings. Afterwards the user will need to de-energize power to the

conditions the user would like to view

The column labeled Relay & LED will show the LED pattern of the status detection and send a warning.

The column labeled Contactor will open the contactor if the selected status is checked and send the warning.

After selecting desired status conditions, the user will need to select apply configuration and save settings to make the change final.

There is the option of having a thermal switch on the line reactor or tuning reactor. There is also an external control input option.

• J7 of the PCB is configured as Relay input 1

• J8 of the PCB is configured as Relay input 2

• Select and save desired relay action if applicable

If the user will be using the digital inputs, they must select relay under contactor control.

Force Open will leave the contactor in an open state. Force Closed will leave the contactor in a closed state. Auto Load will close the contactor based on the load percentage selected Relay will open/close the contactor depending on relay input configuration. By default, these are disabled. Auto kVAR: Based on the size of the filter the user can adjust their target kVAR settings to open/close the contactor

When changing the contactor control state, save settings to make

Example Application Using “Simply Modbus Master 8.1.0”

The Modbus RTU network interface port is configured for RS-485 signal levels. The following example uses an RS-485 to USB converter to connect the PQconnect to a laptop PC running the Modbus RTU master application. The picture below shows an example “B&B SmartWorx, Inc Model: USPTL4” model RS-422/485 converter. As another alternative RS-485 converter there is WINGONEER USB 2.0 to RS485 Serial Converter Adapter CP2104.

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HGL Manual 5.0 PQconnect Connectivity

USPTL4 Pin Out

J5 Header Pinout

No connect

TDA (-)

A (Pin 4)

GND

GND (Pin 3)

TDB(+)

B (Pin 2)

No connect

Figure 5: B&B SmartWorx, Inc Model: USPTL4 model RS-422/485 converter

With the example converter above, the user can make proper connections from the RS485 converter to the PQconnect J5 communication header. The table below indicates the positions where the RS485 connections lead to. Please ensure the correct dip switch settings are applied before installing.

Table 9: USPTL4 to J5 Header Connections

USPTL4 RS485 Converter Dip Switch settings

All four switches of the B&B converter from the factory should be set to the ON position and should look like the following.

Example Setup Instructions to Read Data from the PQconnect Unit:

• Connect the cable to the “J5” communication header

• Connect USB end to the computer

o Determine the assigned COM port number for the RS-485 to USB converter using the

computer device manager control panel.

o The converter used in this example typically enumerates between the range of COM5

to COM20 on a standard laptop computer running the Microsoft windows operating system

• Open the Simply Modbus Master software

o Can be downloaded from the link below: o http://www.simplymodbus.ca/manual.htm o The trial version of the software is free and fully functional for this task hence no

License key is necessary

• Next, configure the fields in the screen as shown below. These are again the default settings of the PQconnect COM port. o Note: The “notes” section of the display data registers is filled in manually

Figure 6: Dip Switch settings

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HGL Manual 5.0 PQconnect Connectivity

Example Setup Instructions to Write Data to the PQconnect Unit:

• To control the contactor in the unit, first the user will need tech access by writing the parameter keys

o Navigate to the settings menu and then select force open or force close button. o The contactor state box will indicate if the contactor is open or closed.

• Next, select the “WRITE” button on the screen shown above.

• The screen below will be shown. Configure the fields as shown in the picture.

• Select “0” in the field “Values to Write” to close the contactor or “1” to open the

contactor.

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HGL Manual 5.0 PQconnect Connectivity

Android OS 5.0 or higher Bluetooth 4.2

Installation Instructions

PQconnect Quick Start Unit Software Setup

• Verify connections to the PCB via ModbusRTU over RS485 before filter is energized

• Download PQvision software found on our website: https://transcoil.com/wp-

content/uploads/2018/11/PQvision-Setup-v1.zip

• Enter password: 08252014 to access software package

• Select communication port (Data should be shown after the board communicates)

o Note: Default Modbus settings of the application are below. o Baud rate: 115200 o Parity: Even o Slave Address: 10 o See PQconnect Display connections section for changing the default settings

PQconnect Bluetooth® App Setup

System Requirements:

1. Download the app using your mobile device.

2. Extract the contents of the downloaded zip folder.

3. Tap on the APK file to install. Note: The Android system may require permission to install apps from sources other than the Play Store.

4. A warning may appear. Click on settings and click slider for “allow from this source.”

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HGL Manual 5.0 PQconnect Connectivity

Pairing Instructions

Nameplate Example found on

1. Once installed, open the PQvision mobile app. (You must allow PQconnect to use Bluetooth.) Any Bluetooth capable PQconnect devices in range will be automatically displayed on the connection screen.

2. Tap CONNECT next to your target PQconnect device. Each PQconnect device in the app will be identified by their Device ID.

3. A prompt to enter the Bluetooth pairing passkey will pop up automatically. Enter the 6-digit serial number found on the product nameplate. Do not include the Device ID number.

The Serial number can be found on the product nameplate on the front of each passive filter.

outside of filter enclosure

4. Once the passkey is successfully entered, all filter data will be presented.

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HGL Manual 5.0 PQconnect Connectivity

Changing Settings

Troubleshooting

1. Ensure Bluetooth is enabled on the Android device.

1. Once connected to a PQconnect device, scroll to the bottom of the Summary page, and tap Settings to open the Settings screen

2. Change any setting or tap the unlock button to unlock parameter access.

3. If prompted, enter the tech password – 08252014 – to unlock parameter access.

2. If no PQconnect devices are displayed on the connect screen:

o Move closer to the unit to ensure the device is in range. o Verify that the PQconnect is powered on and that the CPU LED is blinking. o Restart the app.

3. If the pairing prompt does not appear automatically:

o Wait up to 15 seconds for the prompt to appear. o Close the app completely and reopen it.

Please report any issues to TCI: tech-support@transcoil.com

PCB Connections

Most customer connections to PQconnect will be made on the PCB. Refer to connection diagrams in Figure 7. The details of the power and communications terminals are shown in Table 10. Form C relays are available on the PCB, these connections are shown in Table 11. Two relay outputs are available on the PCB.

The relay contactor control command input connection on J11 of the PCB allows the user to open/close the contactor of the HarmonicGuard® Low Capacitance filter. The second relay (input connections on J12) is optional and could be used for a second contactor for dual tuned circuit filters or as a secondary status detection.

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HGL Manual 5.0 PQconnect Connectivity

Figure 7: PQconnect Connections

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HGL Manual 5.0 PQconnect Connectivity

Terminal

Description

Label

Rating

Phase A

Phase B

Phase C

1,2,3,4

Not Connected

N/A

5,6,7,8

Current transformer connections

For factory use; Only used for filters with dual tuned circuits

Not Connected

B (non-inverting)

Ground

A (inverting)

Not connected

Input Power from control power transformer

Neutral

Line

J14

1-14

Micro Programming

For factory use

N/A

Tightening

Torque

1, 2

Multi-functional digital Input 1

Customer contacts

3.5 lb.-in (0.4 Nm)

28-12 AWG

1, 2

Multi-functional digital Input 2

Customer contacts

3.5 lb.-in (0.4 Nm)

28-12 AWG

Normally Closed (NC)

Common (COM)

Normally Open (NO)

Normally Closed (NC)

Common (COM)

Normally Open (NO)

• DEFAULT: 0 = Disabled

• 2 = Line Reactor Thermal Switch Input

Table 10: Power & Communications Terminals

J1, J2, J3

J12

For factory use; Measurement connection points

RS485

600VAC

N/A

120 VAC

Note: The power terminals on the PQconnect accepts 28 to 14 AWG stranded wire, with a tightening torque of 4.4 in-lb. (0.5 Nm).

Table 11: Form C Relay Contacts

Terminal Pin Description Label

J11

J10

Digital output form C Contact 1

Digital output form C Contact 2

4.4 lb.-in (0.5 Nm) 28-14 AWG

Note: Form-C relay contacts are gold plated with a load rating of 5.0A @ 120VAC

The filter is set to control the contactor pickup/drop-out at 30% of load current by factory default. This setting can be changed in the tech access page from the settings menu.

Wire Range

Multi-functional digital inputs have the following functions:

Modbus RTU

Wiring and Configuration

• 1 = Tuning Reactor Thermal Switch Input

• 3 = Reset Command

• 4 = External Control Input

Digital Output form C Contact

• J11 reserved for contactor control

• J10 used for status detection

The PQconnect Modbus RTU network communication interface transmits and receives command and status data from the PQconnect Modbus master over a RS-485 serial link. Modbus RTU is a simple serial communications protocol originally developed by Modicon for use with Programmable Logic Controllers (PLCs) in control of industrial devices. Modbus RTU is commonly supported by most PLCs and is an open, royalty-free communications standard.

The PQconnect implements a Modbus RTU Master/Slave device, which supports two-wire RS-485 signal levels. The PQconnect communication port used for the Modbus RTU interface is connected directly to the PCB. The communication port is located on the side of the PQconnect board.

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HGL Manual 5.0 PQconnect Connectivity

J5 Header Pinout

Signal Name

Signal Type

No connect

- 2 B

RS-485 B (non-inverting)

GND

RS-485 SC/G

4 A RS-485 A (inverting)

No connect

Parameter

Default Value

Units

Baud Rate

115200

Data Bits

Bits

Stop Bits

Bits

Parity

Even

Slave ID

Modbus RTU

4 3

Connection

2 1

Figure 8: PQconnect Modbus RTU Connection

PQvision Display Connections

The hardware pinout for the J5 communication header and default settings is shown below.

Table 12: Modbus Connector Pin Definitions

The default protocol settings for the RS-485 Modbus RTU interface are shown below.

Table 13: Modbus RTU Protocol Settings

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HGL Manual 5.0 PQconnect Connectivity

1 – Enable 560Ω bias resistor on D-.

2 – Enable 120Ω termination resistor.

3 - Enable 560Ω pull-up on D+.

J20

Remove jumper to use default Modbus settings on next reboot.

The default settings can be modified via the PQconnect system menu. A Tech level access password is required to change these parameters. Ensure the board communicates to the desktop app and then First go to Menu  Settings  Device settings  Change to desired Modbus parameters  Apply  Menu  Save Settings. Finally cycle power to the HGL, this will reboot the PQconnect with the desired Modbus parameters.

The network interface on the PQconnect allows the user to control the contactor and show internal status data of the HGL filter. The PQconnect PC application (PQvision) access a ModbusRTU master device for the network interface (see the PQvision application display connections).

Table 14: Configuration Switches

SW1

The input registers from the HarmonicGuard® Low Capacitance filter are mapped to Modbus register address 40000, see Table 15 - Table 17 for definitions of the input register maps. The output registers are mapped to Modbus register address 40500, see Table 21 - Table 26. All input and output registers are two bytes in size and formatted as 16-bit signed integers.

Note: All parameters with an asterisk (*) in the description will require the Tech level access codes parameter key A: 0825 and parameter key B: 2014.

Configure Modbus Connection on J5 Header

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

9 = Save Current Values to Flash

200 = Restore Defaults to Flash

0 = Capture Done 1 = Start Capture

Trace Data points for waveforms

PARAM_KEY_A

503

Input

Enter Key A

PARAM_KEY_B

504

Input

Enter Key B

Dual Tuned Circuit Current

with dual tuned circuits

0 = Always Open

5 = No contactor

Contactor auto reclose, this

condition. *

1000 = 100 A Range: 3 to 1500 A

4800 = 480Vrms Range: 120 to 690 Vrms

50 = 50 Hz 60 = 60 Hz

Register Map

Write

Parameters:

Table 15: Network Interface INPUT/Setpoint Register Map

Parameter Name

PARAM_USER_CMD_REQ 500 Input

TRACE_GO_DONE 501 Input

SYS_RESET 502 Input

CT_RATIO 505 Input

SYS_CONTROL_MODE 510 Input

Address

Direction Data Values and Examples Description

21 = Set User Access 25 = Set Access to Tech Access (access key needs to be set to 0825 for key A and 2014 for key B) 150 = Load Values from Flash

0 = No Command 1 = Reset Contactor Closed

XXXX:5 where XXXX is the primary turns count of the CT 1000 = 1000:5 Range 5 to 10000

1 = Always Closed DEFAULT: 2= Auto load 3 = Auto kVAR 4 = External

Reset contactor

Read/write parameters under Tech Access

Transformer (CT) ratios*

Note: Only required for units

Contactor control; keep contactor always off/on, auto turn on/off based on desired load or kVAR, external relay input. *

SYS_AUTO_CONTACTOR_CLOSED 511 Input

RATED_CURRENT 520 Input

RATED_VOLTAGE 521 Input

RATED_FREQUENCY 522 Input

0 = Disable DEFAULT: 1 = Enable

will attempt to reclose the contactor after it has been open through a status

Filter rated current*

Filter rated voltage*

Filter rated frequency*

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

0 = Disabled

Range 0 to 65535

To Enable desired status detections, enter

detection bits. *

To Enable desired status detections, enter

detection bits. *

To Enable desired status detections, enter

detection bits. *

DEFAULT: 30 =

Range: 10 to 100 %

DEFAULT: 50 = 50

kVAR

DEFAULT: 10 =

Range: 5 to 100 %

DEFAULT: 5 = 5

seconds

DEFAULT: 5 = 5

seconds

Write Parameters:

Table 16: Network Interface INPUT/Setpoint Register Map

Parameter Name

STATUS_FILTER_A_RELAY_ACTION 540 Input

STATUS_FILTER_B_RELAY_ACTION 541 Input

STATUS_LINE_RELAY_ACTION 542 Input

STATUS_FILTER_LOAD_RELAY_ACTION 543 Input

Address

Direction

Data Values and

Examples

DEFAULT: 9

0 = Disabled DEFAULT: 49151 Range: 0 to 65535

0 = Disabled

DEFAULT: 71

Range: 0 to 65535

0 = Disabled

DEFAULT: 63

Range: 0 to 65535

Description

bit mask from table by converting to decimal.

If a status is active and the bit corresponding to that status in this mask is set, the relay will be activated.

Reference Table 18

bit mask from table by converting to decimal.

If a status is active and the bit corresponding to that status in this mask is set, the relay will be activated

Reference Table 19

bit mask from table by converting to decimal.

If a status is active and the bit corresponding to that status in this mask is set, the relay will be activated.

Reference Table 20

below for filter status

below for line status

below for load status

CNT_CLOSE_LOAD_THERSHOLD 570 Input

CNT_CLOSE_LOAD_HYSTERESIS 571 Input

CNT_CLOSE_KVAR_THERSHOLD 572 Input

CNT_CLOSE_KVAR_HYSTERESIS 573 Input

CNT_CLOSE_DELAY 574 Input

CNT_OPEN_DELAY 575 Input

30%

DEFAULT: 5 = 5% Range: 2 to 50 %

kVAR Range: 0 to 1000

10%

seconds Range: 1 to 3600

Contactor close threshold in percent rated current*

Contactor will open when it reaches the hysteresis *

Contactor close threshold for kVAR control*

Contactor will open when it reaches the hysteresis *

Contactor Close Delay*

Contactor Open Delay*

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

Filter Second Tuned Circuit kVAR

tuned circuits) *

DEFAULT: 11520 = 115200 baud

960 = 9600 baud rate

0 = None

DEFAULT: 2 = Even

DEFAULT: 0 = Disabled

4 = External Control Input

DEFAULT: 0 = Disabled

4 = External Control Input

Write Parameters:

Table 17: Network Interface INPUT/Setpoint Register Map

Parameter Name

SYS_PF_STEP_1_KVAR 576 Input

SYS_PF_STEP_2_KVAR 577 Input

CNT_AUTO_RECLOSE_DELAY 580 Input

CNT_POWER_ON_DELAY 581 Input

CNT_AUTO_RECLOSE_ATTEMPTS 582 Input

CNT_AUTO_RECLOSE_TIMESPAN 583 Input

MB_SLAVE_ADDRESS 600 Input

MB_BAUD_RATE 601 Input

Address

Direction Data Values and Examples Description

DEFAULT: 5 = 5 kVAR Steps

Range: 1 to 200 kVAR

DEFAULT: 5 = 5 kVAR Steps Range: 1 to 200 kVAR

DEFAULT: 10 = 10 seconds Range: 10 to 3600 seconds

DEFAULT: 1 = 1 second Range: 0 to 3600 seconds

DEFAULT: 5 = 5 attempts Range: 1 to 15

DEFAULT: 600 = 600 seconds Range: 300 to 3600 seconds

DEFAULT: = 10 Range: 0 to 255

rate 3840 = 38400 baud rate

Desired filter kVAR for contactor to enable*

(Only used for filters with dual

Contactor auto re-close delay time*

System Power on Delay*

Maximum number of contactors auto re-close attempts allowed*

Maximum number of contactors auto re-close attempts time span*

Modbus RTU Device Slave Address*

Modbus RTU Device Baud Rate*

MB_PARITY 602 Input

SYS_INPUT_1_CONFIG 610 Input

SYS_INPUT_2_CONFIG 611 Input

PHASE_ROTATION 693 Input

SYS_CNT_MIN_OFF_TIME 800 Input

1 = Odd

1 = Tuning Reactor Thermal Switch Input 2 = Line Reactor Thermal Switch Input 3 = Reset Command

DEFAULT: 1 = ABC Rotation Expected 2 = ACB Rotation Expected

DEFAULT: 10 = 10 seconds Range: 10 to 300 seconds

Modbus RTU Device Parity*

Customer external control input 1*

Customer external control input 2*

Filter expected input phase orientation*

Contactor Minimum open time*

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HGL Manual 5.0 PQconnect Connectivity

16-bit values

Bit

Status Detection

TUNE_PHASE_LOSS_A

TUNE_PHASE_LOSS_B

TUNE_PHASE_LOSS_C

TUNE_BALANCE_LOSS_A

TUNE_BALANCE_LOSS_B

TUNE_BALANCE_LOSS_C

TUNE_UNDERCURRENT_A

TUNE_UNDERCURRENT_B

TUNE_UNDERCURRENT_C

TUNE_OVERCURRENT_A

TUNE_OVERCURRENT_B

TUNE_OVERCURRENT_C

UNDER_TEMP

OVER_TEMP

CPU_ERROR

TUNE_REACTOR_THERMAL_SW

RECLOSE_LIMIT

LINE_REACTOR_THERMAL_SW

16-bit values

Bit

Status Detection

PHASE_LOSS_A

PHASE_LOSS_B

PHASE_LOSS_C

OVERVOLTAGE_A

OVERVOLTAGE_B

OVERVOLTAGE_C

FILTER_FREQ_MISMATCH

HIGH_VOLTAGE_THD

LINE_PHASE_ROTATION

16-bit values

Bit

Status Detection

BALANCE_A

BALANCE_B

BALANCE_C

OVERCURRENT_A

OVERCURRENT_B

OVERCURRENT_C

Table 18: Filter Status References

Table 19: Filter Line Status References

Table 20: Filter Load Status References

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

Two 8bit ASCII Characters 0x0141 = ASCII for "A1"

DSP_MODEL_NUM_RO

Output

102 = HGL

System Model Number

4800 = 480 Vrms Range: 120 to 690 Vrms

60 = 60 Hz 50 = 50 Hz

1 = ABC Rotation Expected 2 = ACB Rotation Expected

Source Utility Line Phase to Phase Voltage (AB)

Source Utility Line Phase to Phase Voltage (BC)

Source Utility Line Phase to Phase Voltage (CA)

V_LOAD_AB_RMS

Output

Filter Output Phase to Phase Voltage (A-B)

V_LOAD_BC_RMS

Output

Filter Output Phase to Phase Voltage (B-C)

V_LOAD_CA_RMS

Output

Filter Output Phase to Phase Voltage (C-A)

V_TRAP_A_RMS

Output

Filter Tuned Circuit Phase A Voltage

V_TRAP_B_RMS

Output

Filter Tuned Circuit Phase B Voltage

V_TRAP_C_RMS

Output

Filter Tuned Circuit Phase C Voltage

I_LINE_A_RMS

Output

Filter Input Current Phase A

I_LINE_B_RMS

Output

Filter Input Current Phase B

I_LINE_C_RMS

Output

Filter Input Current Phase C

I_LOAD_A_RMS

Output

Filter Output Current Phase A

I_LOAD_B_RMS

Output

Filter Output Current Phase B

I_LOAD_C_RMS

Output

Filter Output Current Phase C

I_TUNE_A_RMS

Output

Filter Tuned Circuit Current Phase A

I_TUNE_B_RMS

Output

Filter Tuned Circuit Current Phase B

I_TUNE_C_RMS

Output

Filter Tuned Circuit Current Phase C

I_LINE_A_THD

Output

Phase A THID for line current feedback

I_LINE_B_THD

Output

Phase B THID for line current feedback

I_LINE_C_THD

Output

Phase C THID for line current feedback

I_LOAD_A_THD

Output

Phase A THID for load current feedback

I_LOAD_B_THD

Output

Phase B THID for load current feedback

I_LOAD_C_THD

Output

Phase C THID for load current feedback

Read Parameters:

Table 21: Network Interface OUTPUT/Feedback Register Map

Parameter Name

DSP_SW_VER 12 Output

LINE_VOLTAGE 20 Output

LINE_FREQ 21 Output

LINE_ROT 22 Output

V_LINE_AB_RMS 30 Output

V_LINE_BC_RMS 31 Output

V_LINE_CA_RMS 32 Output

Address

Direction Data Values and Examples Description

Software revision code for processor.

Filter input voltage

Filter input frequency

Filter input phase orientation

Volts RMS 4800 = 480 Vrms Range: 0 to 1000 Vrms

Amps RMS 1,000 = 1,000 ARMS Range: 0 to 1000 Arms

% THID 50 = 5.0% THID

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

I_TUNE_A_THD

Output

Phase A THID for tuned circuit current feedback

I_TUNE_B_THD

Output

Phase B THID for tuned circuit current feedback

I_TUNE_C_THD

Output

Phase C THID for tuned circuit current feedback

V_LINE_AB_THD

Output

A-B Phase to Phase THVD

V_LINE_BC_THD

Output

B-C Phase to Phase THVD

V_LINE_CA_THD

Output

C-A Phase to Phase THVD

V_LOAD_AB_THD

Output

A-B Phase to Phase THVD

V_LOAD_BC_THD

Output

B-C Phase to Phase THVD

V_LOAD_CA_THD

Output

C-A Phase to Phase THVD

V_TRAP_A_THD

Output

Tuning circuit A Phase THVD

V_TRAP_B_THD

Output

Tuning circuit B Phase THVD

V_TRAP_C_THD

Output

Tuning circuit C Phase THVD

I_LINE_A_TDD

Output

Filter input total Demand Distortion Phase A iTDD

I_LINE_B_TDD

Output

Filter input total Demand Distortion Phase B iTDD

Filter input total Demand Distortion Phase C iTDD

0 = Power Off 1 = Power On

0 = Filter is operating

warning

0 = Nominal 1 = At Capacity

Indicates if the filter is running at its maximum current capacity

0,1 = Initialization

19 = Calibrate Check

Read Parameters:

Table 22: Network Interface OUTPUT/Feedback Register Map

Parameter Name

I_LINE_C_TDD 44 Output

SYS_POWER_ON 201 Output

Address

Direction Data Values and Examples Description

% THID 50 = 5.0% THID

% THVD 50 = 5.0% THVD

% iTDD 50 = 5.0% iTDD

Indicates if the filter has input power available

SYS_STATUS_OK 202 Output

SYS_AT_CAPACITY 203 Output

SYS_STATE 256 Output

1 = Filter has indicated status

2 = Power on Delay 3 = Unit Self State Inhibit 4 = Reset 5 = Force Open Contactor 6 = Force Close Contactor 7 = Auto Load Open 8 = Auto Load Close 9 = Auto kVAR Close 10 = Auto kVAR Open 11 = External Open 12 = External Close 13 = No Contactor 14 = Contactor Closed Inhibited 15 = Calibrate offsets 16 = Calibrate Magnitude 17 = No Communication 18 = Communication configuration

Indicates filters status

Indicates the present state of the system state machine.

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HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Address Offset

Direction

Data Values and

Examples

100 = 100 kVA Range: 0 to 1000 kVA

100 = 100kW Range: 0 to 1000 kW

Total Filter output reactive power; Negative number

capacitive power

1,000 = 1.00 Unity PF

Range: -99 to 1000

I_LINE_A_HARM_1

140

Output

I_LINE_A_HARM_3

141

Output

I_LINE_A_HARM_5

142

Output

I_LINE_A_HARM_7

143

Output

I_LINE_A_HARM_11

144

Output

I_LINE_A_HARM_13

145

Output

I_LINE_A_HARM_17

146

Output

I_LINE_A_HARM_19

147

Output

I_LINE_A_HARM_23

148

Output

I_LINE_A_HARM_25

149

Output

I_LINE_B_HARM_1

160

Output

I_LINE_B_HARM_3

161

Output

I_LINE_B_HARM_5

162

Output

I_LINE_B_HARM_7

163

Output

I_LINE_B_HARM_11

164

Output

I_LINE_B_HARM_13

165

Output

I_LINE_B_HARM_17

166

Output

I_LINE_B_HARM_19

167

Output

I_LINE_B_HARM_23

168

Output

I_LINE_B_HARM_25

169

Output

I_LINE_C_HARM_1

180

Output

I_LINE_C_HARM_3

181

Output

I_LINE_C_HARM_5

182

Output

I_LINE_C_HARM_7

183

Output

I_LINE_C_HARM_11

184

Output

I_LINE_C_HARM_13

185

Output

I_LINE_C_HARM_17

186

Output

I_LINE_C_HARM_19

187

Output

I_LINE_C_HARM_23

188

Output

I_LINE_C_HARM_25

189

Output

Read Parameters:

Table 23: Network Interface OUTPUT/Feedback Register Map

Parameter Name

P_LOAD_APPARENT_TOTAL 120 Output

P_LOAD_REAL_TOTAL 121 Output

P_LOAD_REACTIVE_TOTAL 122 Output

P_LOAD_POWER_FACTOR 123 Output

100 = 100 kVAR Range: 0 to 1000 kVAR

-95 = 0.95 Lagging PF 95 = 0.95 Leading PF

Fundamental = 1000 = 100% Range: 0 to 100 %

Description

Total Filter output apparent power

Total Filter output real power

indicates inductive power. Positive number indicates

Filter output Displacement Power Factor - Negative values indicate lagging power factor

Filter input phase A spectrum data. Data points from the fundamental to the 25

harmonic. If the user would like the full spectrum data points up to the 50 harmonic; the user will have to run the full data capture command.

Fundamental = 1000 = 100% Range: 0 to 100 %

Filter input phase B spectrum data. Data points from the fundamental to the 25

harmonic. If the user would like the full spectrum data points up to the 50 harmonic; the user will have to run the full data capture command.

Filter input phase C spectrum data. Data points from the fundamental to the 25

harmonic. If the user would like the full spectrum data points up to the 50 harmonic; the user will have to run the full data capture command.

Page 41

HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Address Offset

Data Values and

Examples

0 = Contactor Closed 1 = Contactor Open

Indicates the status of the Filters tuned circuit contactor.

STATUS_FILTER_A

210

Output

STATUS_FILTER_B

211

Output

STATUS_FILTER_A_ENABLE_RO

220

Output

STATUS_FILTER_B_ENABLE_RO

221

Output

STATUS_FILTER_A_RELAY_ACTION_RO

230

Output

STATUS_FILTER_B_RELAY_ACTION_RO

231

Output

STATUS_FILTER_A_CNT_ACTION_RO

240

Output

STATUS_FILTER_B_CNT_ACTION_RO

241

Output

STATUS_LINE

212

Output

STATUS_LINE_ENABLE_RO

222

Output

STATUS_LINE_RELAY_ACTION_RO

232

Output

STATUS_LINE_CNT_ACTION_RO

242

Output

STATUS_FILTER_LOAD

213

Output

STATUS_FILTER_LOAD_ENABLE_RO

223

Output

STATUS_FILTER_LOAD_RELAY_ACTION_R O

STATUS_FILTER_LOAD_CNT_ACTION_RO

243

Output

0 = Always Open

5 = No contactor

0 = Capture Done 1 = Start Capture

0 = Disabled 1 = Enabled

XXXX:5 where XXXX

Range 5 to 10000

Dual Turned Circuit Current

with two tuned circuits

Level of parameter access to

inputs

Read Parameters:

Table 24: Network Interface OUTPUT/Feedback Register Map

Parameter Name

CNT_CLOSED 200 Output

233 Output

Direction

0 = Disabled

To Enable desired status detections, enter bit mask from table by converting to decimal Range: 0 to 65535

Description

Reference Table 18 above for filter status detections.

Reference Table 19 above for line status detections.

Reference Table 20 above for load status detections.

SYS_CONTROL_MODE_RO 250 Output

TRACE_GO_DONE_RO 251 Output

SYS_AUTO_FAULT_RESET_RO 252 Output

CT_RATIO_RO 253 Output

PARAM_ACCESS_LEVEL_RO 254 Output

1 = Always Closed DEFAULT: 2= Auto load 3 = Auto kVAR 4 = External Control Input

is the primary turns count of the CT 1000 = 1000:5

0 = Base access 1 = Tech access

Contactor control; keep contactor always off/on, auto turn on/off based on desired load percentage or kVAR, external relay input.

Indicates waveform data

Displays auto contactor reset

Transformer (CT) ratios

Note: Only required for units

read and/or change parameter

Page 42

HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

0 = Contactor Closed 1 = Contactor Open

4800 = 480Vrms Range: 120 to 690 Vrms

50 = 50 Hz 60 = 60 Hz

DEFAULT: 30 = 30% Range: 10 to 100 %

Contactor close threshold based on the load *

DEFAULT: 5 = 5% Range: 2 to 50 %

Contactor will open when it reaches the hysteresis percentage

100 = 100 kVAR Range: 0 to 1000 kVAR

Contactor close threshold for kVAR control*

DEFAULT: 5 = 5 seconds Range: 1 to 3600 seconds

Displays set value of contactor closed delay time

DEFAULT: 5 = 5 seconds Range: 1 to 3600 seconds

Displays set value of contactor open delay time

DEFAULT: 300 = 300

seconds

DEFAULT: 0 = 0 seconds Range: 0 to 3600 seconds

Indicates contactors power on delay time

DEFAULT: 5 = 5 attempts Range 1 to 15

CNT_AUTO_RECLOSE_TIMESPAN_R O

Displays timespan of contactor to reclose

Displays count down time for contactor to reclose

Minimum time off for contactor reclosures

Displays count down time for contactor re-closures

960 = 9600 moderate

115200 baud rate

Read Parameters:

Table 25: Network Interface OUTPUT/Feedback Register Map

Parameter Name

CNT_STATUS 257 Output

RATED_VOLTAGE_RO 260 Output

RATED_CURRENT_RO 261 Output

RATED_FREQUENCY 262 Output

CNT_CLOSE_LOAD_THRESHOLD_RO 270 Output

CNT_CLOSE_LOAD_HYSTERESIS_RO 271 Output

CNT_CLOSE_KVAR_THRESHOLD_RO 272 Output

CNT_CLOSE_KVAR_HYSTERESIS_RO 273 Output

CNT_CLOSE_DELAY_RO 274 Output

CNT_OPEN_DELAY_RO 275 Output

Address

Direction

Data Values and Examples

1000 = 100 A Range: 3 to 1500 Arms

DEFAULT: 10 = 10% Range: 5 to 100 %

Description

Contactor command status

Filter rated voltage

Filter rated current

Filter rated frequency

Contactor will open when it reaches the hysteresis percentage

CNT_AUTO_RECLOSE_DELAY_RO 280 Output

CNT_POWER_ON_DELAY_RO 281 Output

CNT_AUTO_RECLOSE_ATTEMPS_RO 282 Output

283 Output

CNT_AUTO_RECLOSE_TIMER_RO 284 Output

SYS_CNT_MIN_OFF_TIME_RO 285 Output

SYS_CNT_MIN_OFF_TIMER 286 Output

MB_SLAVE_ADDRESS_RO 300 Output

MB_BAUD_RATE_RO 301 Output

seconds Range: 120 to 3600

DEFAULT: 1800 = 1800 seconds Range: 300 to 3600 seconds

DEFAULT: 60 = 60 seconds Range: 30 to 300 seconds

DEFAULT: = 10 Range: 0 to 255

3840 = 38400 baud rate DEFAULT: 11520 =

Indicates contactor auto reclose delay time

Indicates set value of attempts

Modbus slave address

Modbus baud rate

Page 43

HGL Manual 5.0 PQconnect Connectivity

I/O Reg

Offset

0 = None

DEFAULT: 2 = Even

0 = Enabled

DEFAULT: 1 = Disabled

DEFAULT: 0 = Disabled

4 = External Control Input

DEFAULT: 0 = Disabled

4 = External Control Input

Parameter contains UUUU in

number format.

Parameter contains LLLL in the

format.

Parameter contains NN in the

format.

0 = Not calibrated 1 = Unit is calibrated

0 = Unit is not calibrating 1 = Unit is Calibrating

System null timer; indicates whether the unit is calibrating*

Processor background heartbeat. Internal

used to verify processor clock operation *

Read Parameters:

Table 26: Network Interface OUTPUT/Feedback Register Map

Parameter Name

MB_PARITY_RO 302 Output

RELAY_INPUT_STATUS 320 Output

RELAY_INPUT_1_CONFIG_RO 321 Output

RELAY_INPUT_2_CONFIG_RO 322 Output

SYS_SERIAL_NUM_2_RO 350 Output

SYS_SERIAL_NUM_1_RO 351 Output

Address

Direction Data Values and Examples Description

1 = Odd

1 = Tuning Reactor Thermal Switch Input 2 = Line Reactor Thermal Switch Input 3 = Reset Command

the UUUULLLL-NN serial

UUUULLLL-NN serial number

Modbus Parity

Digital relay status

Customer external control input 1

Customer external control input 2

Unit serial number section - upper 16 bits of 32-bit unit job number

Unit serial number section - lower 16 bits of 32-bit unit job number

SYS_SERIAL_NUM_0_RO 352 Output

SYS_NULL_STAT 400 Output

SYS_NULL_TMR 401 Output

SYS_INT_HB 402 Output Range: 0 to 65535

SYS_BG_HB 403 Output Range: 0 to 65535

UUUULLLL- NN serial number

Unit serial number section - two-digit unit number

System auto null status *

Processor internal heartbeat. Internal counter that counts and rolls over to zero used to verify processor clock operation. *

counter that counts and rolls over to zero

Page 44

HGL Manual 6.0 PQconnect Troubleshooting

Only qualified electricians should carry out all electrical installation & maintenance work on the HGL.

reactors, will still be energized.

6.0 PQconnect Troubleshooting

HarmonicGuard® Low Capacitance Filter Status Warning

If the desktop interface indicates a status warning, hover over the status detection for a brief description. Depending on the condition there are multiple ways to try and clear the status warnings.

Warning

Disconnect all sources of power to the HGL and connected equipment before working on the equipment. Do not attempt any work on a powered HGL. This HGL unit contains high voltages and capacitors. Wait at least five minutes after disconnecting power from the filter before attempting to service the conditioner. Check for zero voltage between all terminals on the capacitors. Also, check for zero voltage between all phases of the input and output lines. All maintenance and troubleshooting must be done by a qualified electrician. Failure to follow standard safety procedures may result in death or serious injury. Unless an external disconnect

means has been provided everything ahead of the filter circuit breaker, including the

Receiving Inspection

The connectivity board has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment. After receiving the unit, immediately inspect the shipping container and report any damage to the carrier that delivered the unit. Verify that the part number of the unit received is the same as the part number listed on the purchase order.

Connectivity Board Problem

The HGL is comprised of five major components; the PQconnect connectivity board, the line reactor, the tuning reactor, the contactor and the capacitors. The PQconnect PCB contains diagnostic LEDs. The locations of the LEDs are shown in Figure 9 and their functions are listed in Table 27.

Figure 9: PQconnect LED Placements

Page 45

HGL Manual 6.0 PQconnect Troubleshooting

LED

LED Color

Description

Green

Tuned circuit contactor control 1

Green

Optional 2nd Status LED/ tuned circuit contactor control 2

Green

Status LED

D11

Green

RS485 Communication is active

D20

Green

24V LED

D21

Green

5V LED

Status Condition

Group (Slow blinks)

LED Specifier (Fast Blinks)

Tune Phase A Loss

Tune Phase B Loss

Tune Phase C Loss

Tune Balance Loss Phase A

Tune Balance Loss Phase B

Tune Balance Loss Phase C

Tune Undercurrent Phase A

Tune Undercurrent Phase B

Tune Undercurrent Phase C

Tune Overcurrent Phase A

Tune Overcurrent Phase B

Tune Overcurrent Phase C

Under Temperature

Over Temperature

CPU Error

Tune Reactor Thermal Switch

Reclose Limit

Line Reactor Thermal Switch

Filter Line Phase A Loss

Filter Line Phase B Loss

Filter Line Phase C Loss

Filter Line Overvoltage Phase A

Filter Line Overvoltage Phase B

Filter Line Overvoltage Phase C

Filter Line Frequency Mismatch

Filter Line High THVD

Filter Line Phase Rotation

Filter Load Phase A imbalance

Filter Load Phase B imbalance

Filter Load Phase C imbalance

Filter Load Phase A Overcurrent

Filter Load Phase B Overcurrent

Filter Load Phase C Overcurrent

Table 27: LED Functions

D6 Green Microprocessor Status LED

Note: Status LED’s will blink according to the filter status. The microprocessor status LED will blink 1hz if the filter is okay, however if there has been an alert the LED will blink according to the status detection. It will initially start with a slow blink (2 = filter lower, 3 = filter upper, 4 = filter input, 5 = filter load) then blink fast depending on the status code.

The table below shows the specified blinks for each status condition.

Table 28: Specified Blinks for Each Status Condition

Page 46

HGL Manual 6.0 PQconnect Troubleshooting

Communication Problems

• J5 Communication Header

o With the power de-energized from the filter, check wiring leading to J5 header

 If the user is using a different RS485 converter than the example above, please

follow the datasheet for the A & B signals and ground for proper setup

• Ensure the drivers of the RS485 to USB converter is installed to the computer. Simple way of checking while the RS485 converter connected is to go to the device manager and scroll down to ports. There will be a device connected to the ports. If your device is not listed, the user will need to install the correct drivers of the RS485 converter.

• PQvision App Load Defaults o With the RS485 Converter connected to the circuit

board

o Energize Filter o Open PQvision desktop interface o Go to Settings o Select Load Defaults o Select Apply o Default Modbus settings should be applied. Try

connecting to the COM port  If this doesn’t work de-energize power to the filter

and try flipping the A and B signal wires leading to the J5 header of the circuit board.

• Hard Reset Modbus settings (Worst Case) o To perform a hard reset of Modbus settings the user will need to remove jumper J20 with

the power de-energized from the filter. Once the jumper is removed connect the RS485 converter to J5 header and energize filter.

o Open PQvision o Confirm there is a COM port under Communication and try to connect

 Note if connecting to the COM port does not work, try flipping the A and B signal

wires leading to the J5 header of the circuit board

o Under Menu go to settings, Load defaults and Apply o Save settings and de-energize filter o Connect jumper to J20 o Energize filter o Try connecting to PCB

 All Modbus settings should be set to default settings at this point  If the board doesn’t connect after trying hard reset contact TCI Tech-Support

Page 47

HGL Manual 6.0 PQconnect Troubleshooting

Status Condition

Description

Debug/ Resolution

Check fuses of the tune circuit

properly connected

Check power connections of the tune circuit

properly connected

Make sure you have the right size filter selected for the application. Based on the

properly connected

Make sure you have the right size filter selected for the application. Based on the

properly connected

Filter ambient temperature

threshold

Filter ambient temperature

threshold

CPU Error

Processor Malfunction

Power cycle unit and if issue persists upgrade firmware and/or contact tech support

Check thermal switch connections to PCB and check if thermal switch is damaged.

switch.

Contactor Reclose is at its limit

The contactor will close for many reasons if you are experiencing any issues with the contactor view Table 30 for further details.

Filter Line Phase Loss A, B, or C

Check fused disconnect or circuit breaker upstream of the filter. Check input power connections to the filter

Check input power connections to filter

expecting a certain input voltage.

Filter Frequency Mismatch

Line Frequency does not match program setpoint

During the user calibration the filter frequency is set based on the model number entered. Verify the frequency

Check fuses leading to filter capacitors

Check power connections of the unit

Phase rotation differs from default setting. Status condition can be turned off or switched to ACB

Check power connections of the line side of the filter

properly connected

Make sure you have the right size filter selected for the application. Based on the

properly connected

Debug Status Conditions

Based on the status condition there are various ways a status can appear. Some status conditions are not critical are used as warnings. Before investigating the filter internally, disengage supply voltage to the filter. If problems persist after initial checks, please contact TCI Tech-Support.

Table 29

Filter Tune Phase Loss A, B, or C

Filter Tune balance Loss Phase A, B, or C

Filter Tune Undercurrent Phase A, B, or C

Filter Tune Overcurrent Phase A, B, or C

Under Temperature

Over Temperature

Reactor Thermal Switches

Reclose Limit

: Status Conditions

Phase loss in one of the phases of the filter tune circuit

Filter tune imbalance on one of the phases.

Filter tune current is seeing less current than expected

Filter tune current is seeing more current than expected

is operating below

is operating above

Reactor Thermal Switch is open

Check power connections of the tune circuit Check voltage sense wires leading to the board and reactor, make sure they are

Check voltage sense wires leading to the board and reactor, make sure they are

model number the filter will expect a certain amount of current in the tune circuit. Check voltage sense wires leading to the board and reactor, make sure they are

Check fuses of control power transformers leading to the heater.

Check fuses of control power transformers leading to fans. Make sure fans are operating

J7 typically has the line reactor thermal switch and J8 has the tuning reactor thermal

Filter line phase loss

Filter Line Overvoltage Phase A, B, or C

Filter Line High THVD

Filter Line Rotation Filter phase rotation

Filter Load Phase Imbalance A, B, or C

Filter load Overcurrent Phase A, B, or C

Filter overvoltage on one of the phases.

High voltage Total Harmonic Distortion

Phase imbalance between the phases

Filter output current is more than expected

Check voltage setpoint, based on the filter model number entered the filter is

If fuses are not blown, measure Capacitance of the capacitors

Check voltage sense wires leading to the board and reactor, make sure they are

model number the filter will expect a certain amount of current in the tune circuit. Check voltage sense wires leading to the board and reactor, make sure they are

Page 48

HGL Manual 6.0 PQconnect Troubleshooting

Code

Description

Resolution

Contactor is already

The PQconnect is presently commanding the tuned circuit contactor to be closed. If

to the tuned circuit contactor and 120VAC control power transformer.

Contactor is open due to

mode.

The present contactor control mode (feedback parameter 250) is set to Force Open.

see setpoint parameter 510.

Contactor is open due to

The present contactor control mode (feedback parameter 250) is set to Automatic

is scaled in units of percent rated nameplate filter current.

Contactor is open due to

The present contactor control mode (feedback parameter 250) is set to Automatic

parameter can be adjusted via setpoint 572.

Contactor is open due to

The present contactor control mode (feedback parameter 250) is set to External

parameter 610.

Contactor is open

The present contactor control mode (feedback parameter 250) is set to No Contactor

support.

Contactor Problem

Parameter 257 Contactor Status can be used to determine why the PQconnect board is not closing the tuned circuit contactor. The following tables define what a specific contactor status code value means and list potential resolutions to allow the contactor to close.

Note that some setpoint parameters require tech level parameter access to be viewable over the serial connection or via the PQvision software. The tech level parameter access key is available above.

Table 30: Contactor Codes

commanded closed.

a Force Open control

an automatic load control mode and insufficient load Amps to close the contactor.

an automatic kVAR control mode.

an external contactor open command.

because the PQconnect has been configured without a contactor.

the contactor is not closing check the wiring from the PCB J11 control relay header

This control mode will always keep the contactor open. To change the control mode,

Load Control and the measured filter load Amps are below the configured close threshold (feedback parameter 270). The contactor will be closed when the filter load Amps exceed the close threshold. The contactor close filter load current threshold can be adjusted via setpoint parameter 570. The contactor close threshold parameter

kVAR Control and closing the contactor would exceed the max allowable kVAR flowing to the source to be exceeded (feedback parameter 272). The contactor will be closed when the inductive load kVAR minus the capacitive tuned circuit kVAR of the passive filter is below the max kVAR setpoint parameter. The max kVAR setpoint

Control and the external command is set to open the contactor. The external contactor control command is wired to the PQconnect PCB header J7 where shorting pins 1 and 2 of that header equal a close command.

The internal state of the external control command can be audited via feedback parameter 320 in bit position 0. If an external contactor close command is correctly being input to the PQconnect board then confirm the J7 header input is configured as the external control command by verifying feedback parameter 321 is set to a value of 2=external command input. If the input configuration parameter 321 is not set to 2=external command input the input configuration can be changed via setpoint

Mode. No Contactor mode is typically reserved for HGL units that do not include a tuned circuit control contactor. If your HGL unit does include a tuned circuit contactor but the PQconnect is configured to not support a contactor, please call TCI technical

Page 49

HGL Manual 6.0 PQconnect Troubleshooting

Code

Description

Resolution

The contactor is open due to a filter, filter line, or filter load status detection being detected that is

611.

Contactor is open due

condition.

The contactor is open because the PQconnect is still loading stored parameters in flash memory.

persists power cycle the unit and call TCI technical support if the condition does not clear.

Contactor is open due

delay.

The contactor is open because the PQconnect is waiting for the configured power on delay time

281. The power on delay time can be adjusted via setpoint parameter 581.

The contactor is open because the unit is presently undergoing an internal calibration procedure,

persists power cycle the unit and call TCI technical support if the condition does not clear.

An internal contactor close event is pending but the contactor is being held open because it was

viewed on feedback parameter 286.

An internal contactor close event is pending but the contactor is being held open because the

parameter 574

An internal contactor automatic reclose event is pending but the contactor is being held open

Table 31: Contactor codes

configured to open the tuned circuit contactor when detected. The PQconnect continuously monitors the internal conditions of the HGL filter and the external conditions of the filter line and load currents and voltages. Some status conditions, such as tuned circuit overcurrent, are configured to open the tuned circuit contactor when detected as a self-protection feature.

The presently configured contactor open actions can be audited using feedback parameters 240Filter A, 241-Filter B 242-Filter Line and 243 Filter Load. The set or clear status of these contactor open status detections can be viewed via feedback parameters 210-Filter A, 211-Filter B 212Filter Line and 213 Filter Load. Also, the present value of all status detections and wither they are

Contactor is open due

status detection.

to a parameter inhibit

configured to open the tune circuit contactor when detected can be viewed via the PQvision software settings menu screen.

To reset all status conditions and attempt to re-close the contactor the unit can be power cycled, a serial command can be sent over the network interface via setpoint parameter 502, or an external wired reset command can be input to the PQconnect PCB at header J8 where shorting pins 1 and 2 of that header equal a close command. The internal state of the external wired reset command can be audited via feedback parameter 320 in bit position 1. If an external reset command is correctly being input to the PQconnect board then confirm the J8 header input is configured as the external reset command by verifying feedback parameter 322 is set to a value of 1=external reset command input. If the input configuration parameter 322 is not set to 1=external reset command input the input configuration can be changed via setpoint parameter

This condition should clear shortly after the unit is powered up. If this contactor status condition

to a unit power on

Contactor is open due

to a calibration inhibit.

Contactor is being held open due to the

minimum reclose timer.

Contactor is being

held open due to close delay timer.

Contactor is being

held open due to the auto reclose delay

to expire. The power on delay time in units of seconds can be viewed via feedback parameter

or no calibration data has been stored to the unit’s flash memory. If this contactor status condition

recently closed, and the minimum reclose time has not been yet achieved. The minimum contactor re-close time in units of seconds is viewable via feedback parameter 285. This time out period allows any residual stored charge in the tune circuit capacitors to be dissipated by bleeder resistors before the tune circuit is re-energized.

If a minimum time is not enforced between repeated contactor close events the contactor may reclose and apply line voltage out of phase with the residual voltage on the tuned circuit capacitors. This could cause high currents to flow through the tuned circuit contactor and potentially blow the contactor protective fuses. The remaining time on the minimum contactor re-close timer can be

configured contactor close delay time out period has not yet been achieved. The automatic contactor control modes (load current control and line kVAR control) are configured with contactor close and open delay timers to avoid changing the contactor state due to short transient conditions. The presently configured contactor close delay time in units of seconds is viewable via feedback parameter 274. The contactor close delay time can be adjusted via setpoint

because the configured automatic re-close time has not been achieved yet.

The PQconnect continuously monitors the internal conditions of the HGL filter and the external conditions of the filter line and load currents and voltages. Some status conditions are configured to open the tuned circuit contactor when detected as a self-protection feature. An optional feature can be enabled (feedback parameter 252) to attempt to re-close the tuned circuit contactor after a status condition has been detected. The auto reclose enable setpoint parameter is parameter 511 and the auto reclose delay time setpoint parameter is parameter 580.

Page 50

HGL Manual 6.0 PQconnect Troubleshooting

Code

Description

Resolution

An internal contactor automatic reclose event is pending but the contactor is

filter and the external conditions of the filter line and load currents and

To debug which status conditions caused the contactor open event the

and 213 Filter Load. Also, the present value of all status detections and

is required to clear the condition and allow the contactor to re-close.

Many electronic components located within the filter are sensitive to static electricity.

duce the life, affect performance and/or

destroy sensitive electronic devices. Use proper electrostatic discharge (ESD)

Table 32: Contactor codes

being held open because the number of re-close attempts in a set time has been exceeded.

The PQconnect continuously monitors the internal conditions of the HGL

voltages. Some status conditions are configured to open the tuned circuit contactor when detected as a self-protection feature. An optional feature can be enabled (feedback parameter 252) to attempt to re-close the tuned circuit

Contactor is being held open due to auto reclose limit being reached.

contactor after a status condition has been detected. However, if too many re-close attempts (parameter 282) are made within a set time (parameter

283) the unit will stop attempting to auto reclose.

presently configured contactor open actions can be audited using feedback parameters 240-Filter A, 241-Filter B 242-Filter Line and 243 Filter Load. The set or clear status of these contactor open status detections can be viewed via feedback parameters 210-Filter A, 211-Filter B 212-Filter Line

wither they are configured to open the tune circuit contactor when detected can be viewed via the PQvision software settings menu screen.

When the auto re-close limit has been reached a power cycle of the filter unit

Warning

Voltages imperceptible to human touch can re

procedures when servicing the filter and its circuit boards.

Page 51

HGL Manual 7.0 Maintenance and Service

Warning

equipment. Do not attempt any work on a powered HGL.

procedures may result in death or serious injury.

7.0 Maintenance and Service

HGL Filter Reliability and Service Life

The HGL has been designed to provide a service life that equals or exceeds the life of the VFD. It has been thoroughly tested at the factory to assure that it will perform reliably from the time it is put into service. It is recommended that the following maintenance is performed once a year to ensure that the HGL filter will always operate reliably and provide the expected service life.

Periodic Maintenance

Only qualified electricians should carry out all electrical installation and maintenance

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.

work on the HGL filter. Disconnect all sources of power to the drive and HGL before working on the

 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 build- up 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.

 Torque all power wire connections, loose connections can overheat and damage the filter.

All electrical connections must be re-torqued annually.

Troubleshooting

Only qualified electricians should carry out all electrical installation and maintenance work on the HGL filter. Disconnect all sources of power to the drive and HGL before

Warning

Note: when disconnecting wires from components and terminations, mark the wires to

correspond to their component and terminal connection.

working on the equipment. Do not attempt any work on a powered HGL 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), and all input terminals L1, L2 and L3 of the line reactor (KDR). All setup, maintenance, and troubleshooting must be done by a qualified electrician. Failure to follow standard safety

Replacement Parts

If replacement parts are needed, please contact your TCI representative. To ensure that the HGL 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 HGL filter nameplate information available.

Page 52

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022 Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-824-8282 Web Site: http://www.transcoil.com

Publication No: 30799

Effective: 09/25/2019

Version: E