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.
Page 4
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.
Verify the Application ................................................................................................................................5
Nameplate Data ........................................................................................................................................5
Part Numbering System............................................................................................................................6
Power Wiring ......................................................................................................................................... 10
Replacement Parts ................................................................................................................................ 45
Factory Contacts and Tech Support ...................................................................................................... 45
Page 7
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.
1
Page 8
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
Warning
Warning
Warning
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
2
Page 9
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
not to exceed 18 months from the date of
3
Page 10
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.
4
Page 11
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
5
Page 12
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
6
Page 13
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.
7
Page 14
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.
8
Page 15
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
9
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.
10
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.
11
Page 18
HGL Manual 4.0 Installation Guidelines
(Included Internal to HGL Unit)
(J or T)
20
20
60
25
20
60
30
20
60
40
20
60
50
25
80
60
30
90
75
30
125
100
45
150
125
60
200
150
70
225
200
90
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)
20
20
30
25
20
60
30
20
60
40
20
60
50
20
70
60
30
80
75
40
100
100
40
125
125
50
175
150
60
200
200
70
250
250
90
300
300
110
350
350
125
400
400
150
450
450
175
500
500
175
550
600
200
650
700
250
750
800
300
900
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)
12
Page 19
HGL Manual 4.0 Installation Guidelines
HP
Open
Type 1
Type 3R
20
205
208
208
25
341
346
346
30
239
242
242
40
447
54
454
50
518
525
525
60
608
617
617
75
560
569
569
100
760
771
771
125
871
884
884
150
1046
1062
1062
200
907
921
921
250
1217
1235
1235
300
1454
1476
1476
350
1411
1432
1432
400
1548
1571
1571
450
1842
1869
1869
500
2053
2083
2083
600
1976
2005
2005
700
2225
2258
2258
800
2419
2455
2455
900
2577
2616
2616
Table 5: 480 V HGL Watts loss
13
Page 20
HGL Manual 4.0 Installation Guidelines
HP
Open
Type 1
Type 3R
20
338
343
343
25
304
309
309
30
293
297
297
40
341
346
346
50
511
519
519
60
600
609
609
75
734
745
745
100
736
747
747
125
920
934
934
150
1182
1200
1200
200
976
991
991
250
1306
1325
1325
300
1452
1474
1474
350
1766
1792
1792
400
1566
1589
1589
450
2079
2110
2110
500
1984
2014
2014
600
2034
2064
2064
700
2341
2376
2376
800
2726
2766
2766
900
3080
3126
3126
Table 6: 600 V HGL Watts loss
14
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
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
2.
3.
4.
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
Pin
Description
Label
Rating
1
Phase A
2
Phase B
3
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
1
Not Connected
2
B (non-inverting)
3
Ground
4
A (inverting)
5
Not connected
1
Input Power from control
power transformer
Neutral
2
Line
J14
1-14
Micro Programming
For factory use
N/A
Tightening
Torque
J7
1, 2
Multi-functional digital Input 1
Customer contacts
3.5 lb.-in (0.4 Nm)
28-12 AWG
J8
1, 2
Multi-functional digital Input 2
Customer contacts
3.5 lb.-in (0.4 Nm)
28-12 AWG
1
Normally Closed (NC)
2
Common (COM)
3
Normally Open (NO)
1
Normally Closed (NC)
2
Common (COM)
3
Normally Open (NO)
• DEFAULT: 0 = Disabled
• 2 = Line Reactor Thermal Switch Input
Table 10: Power & Communications Terminals
J1, J2, J3
J4
J5
J12
For factory use; Measurement
connection points
RS485
600VAC
N/A
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
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
1
No connect
- 2 B
RS-485 B (non-inverting)
3
GND
RS-485 SC/G
4 A RS-485 A (inverting)
5
No connect
-
Parameter
Default Value
Units
Baud Rate
115200
Bd
Data Bits
8
Bits
Stop Bits
1
Bits
Parity
Even
-
Slave ID
10
-
Modbus RTU
5
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 dataof 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.
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
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
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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
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HGL Manual 6.0 PQconnect Troubleshooting
LED
LED Color
Description
D1
Green
Tuned circuit contactor control 1
D2
Green
Optional 2nd Status LED/ tuned circuit contactor control 2
D5
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
1
Tune Phase B Loss
2
Tune Phase C Loss
3
Tune Balance Loss Phase A
4
Tune Balance Loss Phase B
5
Tune Balance Loss Phase C
6
Tune Undercurrent Phase A
7
Tune Undercurrent Phase B
8
Tune Undercurrent Phase C
9
Tune Overcurrent Phase A
10
Tune Overcurrent Phase B
11
Tune Overcurrent Phase C
12
Under Temperature
13
Over Temperature
14
CPU Error
15
Tune Reactor Thermal Switch
16
Reclose Limit
1
Line Reactor Thermal Switch
4
Filter Line Phase A Loss
1
Filter Line Phase B Loss
2
Filter Line Phase C Loss
3
Filter Line Overvoltage Phase A
4
Filter Line Overvoltage Phase B
5
Filter Line Overvoltage Phase C
6
Filter Line Frequency Mismatch
7
Filter Line High THVD
8
Filter Line Phase Rotation
9
Filter Load Phase A imbalance
1
Filter Load Phase B imbalance
2
Filter Load Phase C imbalance
3
Filter Load Phase A Overcurrent
4
Filter Load Phase B Overcurrent
5
Filter Load Phase C Overcurrent
6
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
2
3
4
5
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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
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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
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
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HGL Manual 6.0 PQconnect Troubleshooting
Code
Description
Resolution
1
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.
2
Contactor is open due to
mode.
The present contactor control mode (feedback parameter 250) is set to Force Open.
see setpoint parameter 510.
3
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.
4
Contactor is open due to
The present contactor control mode (feedback parameter 250) is set to Automatic
parameter can be adjusted via setpoint 572.
5
Contactor is open due to
The present contactor control mode (feedback parameter 250) is set to External
parameter 610.
6
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
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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
7
status detection.
8
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
9
to a unit power on
Contactor is open due
10
to a calibration inhibit.
Contactor is being
held open due to the
11
minimum reclose
timer.
Contactor is being
12
held open due to
close delay timer.
Contactor is being
13
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.
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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
14
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.
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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.
7.0Maintenance 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.
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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