TCi HarmonicGuard HGP, HarmonicGuard Series Installation, Operation And Maintenance Manual

Harmoni

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cGuard

®

Series Drive-Applied Harmonic Filter

Installation, Operation, and Maintenance Manual

rt of this publication may be repro duced, stored in a retrieval system, or transmitted in any form or

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No pa
by any means, mechanical, electr onic, photocopying, recording, or o therwise, without the prior written
permissio n of TCI, LLC. The infor mation in this manual is sub ject to change without notice. Every
precautio n has been taken in the preparation of this manual. TCI, LLC assumes no responsibility for errors
or omissions. Neither is any liab ility assumed for damages resulting from the use of the information
contained in this publication.

T able of Contents

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Introduction .............................................................................................................................. 5

Receiving Inspection and Storage ............................................................................................ 7

Pre-installation Planning .......................................................................................................... 8

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

HGP Filter Operation ............................................................................................................. 10

Installation ............................................................................................................................. 11

Maintenance and Service ....................................................................................................... 12

Product Description ............................................................................................................... 14

Standard Option (S) ............................................................................................................... 17

Contactor Option (C) ............................................................................................................. 18

Fuse Monitor with Contactor Option (F).............................................................................. 19

Fuse Monitor without Contactor Option (G) ....................................................................... 20

CP Kit Enclosure (8) with Option (0) .................................................................................... 21

Line Reactor Installation ........................................................................................................ 22

Typical Voltage Distortion Option (0) .................................................................................. 23

High Voltage Distortion Option (1) ....................................................................................... 24

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Introduction

an electrostatic discharge can damage equipment. The text next

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Safety Instruc tions Over vie w

This section provides the safety instructions which must b e followed when installing, oper ating, and
servicing t he HarmonicGuard Passive (HGP) filter. If negle cted, physical injur y or death may follo w,
or damage may occur to the filter or equipment connected to the HGP filter. The material in this
chapter must be read and understood before attempting any work on, or with, the product.

The HGP filter is intended to be connected to the input terminals o f one or more VFDs. Thr ee-phase
power is connected to the input terminals of the HGP and power is supplied to the VFD or VFDs
through the HGP. T he instr uctio ns, and particu larly t he saf ety inst ructio ns, for t he 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 step s 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 s ymbo ls:

Warning

Warning

Warning

Dangerous Voltage Warning: warns of situatio ns where high
voltage can cause physical injur y and/or damage equipment.
The text next to this symbol describes ways to avoid the
danger.

General Warning: warns of situations that can cause physical
injury and/ or damage equipment by means other than
electrical. The text next to this symbol describes ways to avoid
the danger.

Electrostatic Discharge Warning: warns of situations in which

to this symbol describes ways to avoid the danger.

Cautions

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

Caution

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

General S afety Ins truct ions

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

Warning

Warning

Warning

Warning

Warning

Warning

Be sure to read, understand, and follow all safety instructions.

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

The HGP filter, drive, motor, a nd other connected equipment
must be properly grounded.

After switching off the power, always allow 5 minutes for the
capacitors in the HGP filter and in the drive to discharge before
working on the HGP, the drive, the motor, or the connecting
wiring. It is a good idea to check with a voltmeter to make sure
that all sources of power have been disconnected and that all
capacitors have discharged before beginning work.

Receivi ng Inspection and Storage

Product Family

Warranty Period

KLR, KDR

For the life of the drive with which they are installed.

One (1) year of useful service,

HGP, HG7, KH, 3H, KRF

Three (3) years from the d ate of shipment.

KCAP, KTR, KMP

Five (5) years from the date of shipment.

One (1) year of useful service,

not to exceed 18 months from the date of shipment.

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Thank you fo r select ing the H armonicGuard Passive (HGP) filter. TCI has produced this filter for use
in many variable frequency drive (VFD) app lications that require input power line harmonic current
reduction. This manual describes how to install, operate and maintain the HGP filter.

Receiving Inspection

The HGP filter has been thoroughly inspected and functionally tested at the factory and carefully
packaged for shipment. When you receive the unit, you should immediately inspect the shipping
container and report any damage to the carrier that delivered the unit. Verify that the part number of
the unit you received is the same as the part number listed on your purchase order.

TCI Limited Warranty Policy

TCI, LLC (“TCI”) warrants to the original purch aser only that its produ cts will be free from defects i n 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:

KLC, KLCUL, KMG,

V1k

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 EXC LUDES ANY AND ALL EXPRESS OR IMP LIED
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 b y anyone other than TCI;

b) applied or used for situations other than those originally specified; or
c) subjected to negligence, accident, or damage by circumstances beyond TCI’s control, including but not

limited to, improper storage, installation, operation, or maintenance.

If, within the warranty period, any product shall be found in TCI’s reasonable judgment to be defective, TCI’s
liability and the Buyer’s exclusive remedy under this warranty is expressly limited, at TCI’s option, to (i) repair or
replacement of that product, or (ii) return of the product and refund of the purchase price. Such remedy shall be
Buyer’s sole and exclusive remedy. TCI SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL
DAMAGES OR FOR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF
INCOME, LOSS OF TIME, LOST SALES, INJURY TO PERSONAL PROPERTY, LIABILITY BUYER
INCURS WITH RESPECT TO ANY OTHER PERSON, LOSS OF USE OF THE PRODUCT OR FOR ANY
OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMI C 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 sal es agents oral statement s do not constitute warrant ies, these shall not be relied upon by
the Buyer, and are no t 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 Retur n Aut h or i z a ti o n Pr oc e dur e .

not to exceed 18 months from the date of shipment.

Storage Instructions

If the HGP filter is to be stored before use, be sure that it is stored in a location that conforms to
published storage humidity a nd temperature specifications stated in Table 2 (HarmonicGuard Passive
Filter Technical Specifications). Store the unit in its original packaging.

Pre-installation Planning

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Verify th e A pplicat ion

HGP Ratings

Make sure that the HGP filter is correct for the application. The volta ge ratings of the filter must matc h
the input voltage rating of the connected drive. The horsepower and current ratings of the filter must be
appropriate for the connected load.

Select a Suitable Location

Environment

Locating the HGP in a suitable environment will help ensure proper performance and a normal
operating life. Refer to the environmental specifications listed in Table 2, marked on the unit's
nameplate, and/or noted on the drawings furnished with the unit.

Warning

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

♦ Direct sunlight
♦ Rain or dripping liquids (unless filter is in a Type 3R enclosure)
♦ Corrosive liquids or gasses
♦ Explosive or combustible gases or dust
♦ Excessive airborne dirt and dust
♦ Excessive vibration

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.

Working Space

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

Mounting an Open Panel Unit

If you are moun ting an open p anel unit in your own enclosure , you must provide an enclosure that is
adequately sized and ventilated sufficiently to pre vent overheating. The ratin g and dimension tables for
open panel units list the watts of heat loss dissipated by the HGP filter. The maximum temperature of
the air around the HGP filter capacitors, line reactor, and tuning reactor should not exceed 50°C
(122°F).

Power Wiring

When selecting a mounting location for the HGP f ilte r, plan for the routing of the po wer wiring.
Route the conduit and wiring from the power source to the filter and the n to the VFD.
The HGP is provided wit h i nternal fuses.

Installa tion Guidelines

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Mounting

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

Wiring

Cable Entry Locations

The enclosed HGP filters are not provided with enclosure wir ing kno c ko ut s. A lo ca tio n c a n b e se le ct ed
at the time of installation. Typical or recommended cable entry locations are shown in the drawings
section of t his manual.

Field Wiring Connection Terminals

Compression type terminals are provided for all field wiring connections. The wire size capacity
ranges and tightening torques for all field wiring connections are listed in the drawings and other
information shipped with the unit.

Grounding

The HGP pane l equipme nt-groundi ng lug mu st be conne cted to the ground of the wir ing s ystem. The
equipment-grounding connection must conform to the requirements of the National Electric Code
(NEC) and/or any other codes that apply to the installation site. The ground connection must be made
using a wire conductor . Metallic conduit is not a suit able grounding cond uctor. The integrity of all
ground connections should be periodically checked.

Power Wiring

Caution

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

Use copper wire that is appropriate for the voltage and current rating of the
equipment. The wire selection must conform to the requirements of the
National Electrical Code and/or other applicable electrical codes.

For units rated less than 100 amps, use wire with an insulation temperature
rating of 60°C or higher.

For units rated 100 amps or more, use wire with an insulation temperature
rating of 75°C or higher.

Note: in large units, the output po wer conductors are co nnected dir ectly to the output ter minals on the
line reactors. Refer to the VFD installation instructions for additional information.

HGP Filt er Operation

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Caution

Thoroughly check the installation before ap plying power and oper ating
the equipment for the first time.

Before Applying Power for the Fir st 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) a re operating in units so equipped .
♦ Check to make sure power connections are torqued to recommended torque value.

Operation

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

Installation

filter. Be sure to

Make sure that the installation lo c a tion will not be exposed to direct sunligh t, c orrosive or

Select a mounting area that will allow adequate cooling air and maintenance access.

Make sure that all wiring conforms to the requirements of the National Electric Code (NEC)

Connect the HGP equipment-grounding lug to the syst em ground o f the premises wiring system.

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

Connect the output power terminals, of the HGP, T1, T2 & T3, to the input power terminals of

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Intended Audience

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

Additional Information

Caution

This manual pro vid es gene ra l in fo r mati o n desc ri b i ng your HGP
carefully review the more specific information that is provided by the drawings
shipped with the unit. Information provided by the drawings takes precedence
over the information provided in this manual.

The ratings, dimensions and weigh ts given in this manual ar e appro xi mate and
should not be used for any purpose requiring exact data. Contact the factory in
situations where certified data is r e quired. All data is subject to change wit ho ut
notice.

Installation Checklist

The following are the key points to be followed for a successful installation. These points are
explained in detail in the following sections of this manual.

combustible airborne contaminants, excessive dirt or liquids.

and/or other applicable electrical codes.

Use a properly sized grounding conductor.

the VFD.

Maintenance a nd Service

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HGP Filte r Re liabil ity and Servic e Life

The HGP 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 perfor m reliably from the time it is put into
service. It is recommended that the fo llowing maintena nce be done once a year to ensure t hat the
HGP filter will always perform reliably and provide the expected service life.

Periodic Maintenance

Warning

Check to see that the installation environment remains free from exposure to excessive dirt and
contamina nts. Refer to the Pre-installation P lanning section of this manual.

Check to make sure that the enclosure ventilation openings are clean and unobstructed.
Clean the air filter in units that have filtered a ir inlets. Clean as often as necessary to prevent d irt build-

up from impeding air flow.
Check the o peration of t he cooling fan.
Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the

enclosure whenever excess dirt has accumulated.

Only qualified electricians should carry out all electrical installatio n and
maintenance work on the HGP filter.

Disconnect all sources of power to the drive and HGP before working on the
equipment. Do not attempt any work on a powered HGP.

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

Troubleshooting

Warning

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

Only qualified electricians should carry out all electrical installatio n and
maintenance work on the HGP filter.

Disconnect all sources of power to the drive and HGP before working on the
equipment. Do not attempt any work on a powered HGP filter.

The harmonic filter contains high voltages and capacitors. Wait a t least five
minutes after disconnecting p ower 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 procedures
may result in death or serious injury.

Replacement Parts

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

Factory Contacts and Tech Suppor t

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" a nd ha ve

your HGP filter nameplate informatio n available.

Product Descript ion

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HGP Drive-Applied Filter

The HGP is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic
currents drawn from the power source by VFDs. It is suitable for use with 3-phase diode bridge
rectifier loads such as PWM AC drives. SCR or th yristor loads such as DC drives would require a
different filter configuration outside the scope of this product offering. Please contact TCI Technical
Support for additional information.

The HGP 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 t he major harmonic currents
demanded by the drive. The filter is a stand-alone device tha t can be f urnis hed in its own enclosure and
mounted adjacent to the drive. It is also availabl e on an o pen pane l for mount ing wit hin an e nclosure
with the dri ve or other e quipment.

The HGP filters consi st 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 HGP filter
High-endurance, harmonic-rated capacitors

♦ Bleeder resistors to ensure safe capacitor discharge upon filter shu tdown
♦ 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 informati on is marked on the nameplate:

• Part number: encoding is explained on the following page

• FLA: the rate d continuous operating current (RMS amps)

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

• Hz: the rated frequency (60 Hz)

• Phase: 3 – The HGP 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

F

G

Option:

0

- St andard

0

- St andard

Option:

0

- Typic al V ol tage Dist ort i on

Option:

1

- High Vol t age Di st ort i on

0

0

Option:

0

- St andard

Option:

- Fus e M oni t or with Cont act or

- Fus e M oni t or without Cont act or

W

- 60 Hz

Enclosure:

0

- Open

Frequency:

Horse P ower:

Vol t age Rat i ng:

A - 480 V

000

Series:

AW1SP150G

H

1

- Type 1

C

- Contac tor

S

- St andard

3

- Type 3R

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Part Number Encoding

Figure identifies the significance of each character in the HGP part number. The example part number,
HGP0150AW1S0000 designates an HGP filter that is rated 150 HP, 480 volts, 6 0 Hz . I t incl ud e s a line
reactor, tuni ng reac tor, and capacitors in a UL Type 1 enclosure. It is designed for use with a 150 HP
drive.

Figure 1 – HGP Par t Number Enc oding

Product Technical Specifications

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Table 1 lists the major technical sp0ecifications for the HGP Filter.

Table 1 – HGP Technical Specifications

Voltage ratings 480V, 3 phase, 60 Hz
kVar ratings 1.3 to 270 kVar depending on voltage.
Load types 3-phase diode bridge rectifier loads such as PWM AC drives
Load power range 5 -900 HP
Current ratings The included series reactors can tolerate 200% of rated current for at

least 3 minutes.

SCCR (short circuit current
rating)

Maximum elevation 3,000 feet (1,000 meters) as standard.
Maximum ambient operating

temperature

Maximum ambient storage
temperature

Maximum humi d it y,
operating or storage

Enclosure options UL Type 1 enclosure

Agency approvals or
certifications

Standard rating is 100kA.

50°C (122°F) – Open Panel; 40°C (104°F) – Enclosed Panel.
Product must be equipped with special cooling provisions for

operation above this temperature.
60°C (140°F)

95%, non-condensing.

UL Type 3R enclosure

UL and cUL Listed to UL508A

Insertion Impedance +/- 10% at full load current
Fusing and protection: All units have internal fuse prote c tion for the harmonic filter circuit.

Standard Option (S)

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The Standard Option includes ve r y hi g h qua li t y harmonic-grade capacitors and line reactors. This filter
will meet the major ity of ap plica tion req uire ments found to day. T his cos t e ffective p rod uct is a vailab le
as an open panel version, in a UL Type 1 enclosure, 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.

Product Description

HGP S Option Filter

The HGP harmonic filter is a drive-applied harmonic filter designed and developed by TCI to reduce
the harmonic curr ents dra wn fr om the po wer sour ce b y VFDs. T he HGP har monic filter is for 480 volt
systems (60 Hz). It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC
VFDs.

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals 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 VFD. The filter is a stand-alone device that can be furnished in its
own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting
within an enclosure with the VFD or other equipment.

The HGP Standard Option consists of the following standard features and components:

♦ A KDR tuned series reactor.
♦ A TCI 3-phase tuning reactor specifically designed for the HGP filter.
♦ High-endurance, harmonic-rated capacitors.
♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

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

temperatures.

♦ Control Power transformer on enclosed units requiring auxiliary cooling fans.
♦ Compression terminals for ease a nd integrity of all power and control wiring.
♦ Fuses

Contactor Opti on (C)

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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 through the use of a r elay
contact in the VFD. It is recommended that t he 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. Contacto r logic should also maintain the conta ctor closed in
cases where the VFD is bypassed and the filter is not bypassed.

Product Description

HGP C Option Filter

The HGP harmonic filter is a drive-applied harmonic filter designed and developed by TCI to reduce
the harmonic curr ents dra wn fr om the po wer sour ce b y VFDs. T he HGP har monic filter is for 480 volt
systems (60 Hz). It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC
VFDs.

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals 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 VFD. The filter is a stand-alone device that can be furnished in its
own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting
within an enclosure with the VFD or other equipment.

The HGP Contactor Option consists of the following standard features and components:

♦ A KDR tuned series reactor.
♦ A TCI 3-phase tuning reactor specifically designed for the HGP filter.
♦ High-endurance, harmonic-rated capacitors.
♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

♦ Filter enable/disable contactor with protection and drive interlock provisions.
♦ Cooling fans (on select models) to ensure adequate cooling and safe operating

temperatures.

♦ Control power transformer
♦ Compression terminals for ease a nd integrity of all power and control wiring.
♦ Fuses
♦ Contactor

Fuse Monitor with Contactor Option (F)

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The Fuse Monitor with Contactor Option includes a voltage monitor module and relay that can be
connected to a VFD or other device. The fuse monitor will indicate a fuse failure and communicate this
condition through the relay to a connected device.

This 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 thr ough the use of a relay
contact in the VFD. It is recommended that the drive 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 conta ctor closed in
cases where the VFD is bypassed and the filter is not bypassed.

Product Description

HGP F Option Filter

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

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals 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 VFD. The filter is a stand-alone device that can be furnished in its
own enclos ure and mounted adjacent to the VFD. It is also available on an open panel for mounting
within an enclosure with the VFD or other equipment.

The HGP F Option consists of the foll owing sta ndard features and components:

♦ A KDR tuned series reactor.
♦ A TCI 3-phase tuning reactor specifically designed for the HGP filter.
♦ High-endurance, harmonic-rated capacitors.
♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

♦ Filter enable/disable contactor with protection and drive interlock provisions.
♦ Cooling fans (on select models) to ensure adequate cooling and safe operating

temperatures.

♦ Control power transformer
♦ Compression terminals for ease a nd integrity of all power and control wiring.
♦ Fuses
♦ Contactor
♦ Voltage monitor module to report status of fuses to control

Fuse Monitor wi thout Contactor Option ( G)

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The Fuse Monitor witho ut Contactor Option includes a voltage monitor module and relay that can be
connected to a VFD or other device. The fuse monitor will indicate a fuse failure and communicate this
condition through the relay to a connected device.

Product Description

HGP G Option Filter

The HGP harmonic filter is a d rive-applied harmonic filter designed and developed by TCI to reduce
the harmonic curr ents dra wn fr om the po wer sour ce b y VFDs. T he HGP har monic filter is for 480 volt
systems (60 Hz). It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC
VFDs.

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals 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 VFD. The filter is a stand-alone device that can be furnished in its
own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting
within an enclosure with the VFD or other equipment.

The HGP G Option consis t s of the following standard features and components:

♦ A KDR tuned series reactor.
♦ A TCI 3-phase tuning reactor specifically designed for the HGP filter.
♦ High-endurance, harmonic-rated capacitors.
♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

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

temperatures.

♦ Control Power transformer on enclosed units requiring auxiliary cooling fans.
♦ Compression terminals for ease and integrity of all power and control wiring.
♦ Fuses
♦ Voltage monitor module to report status of fuses to control

CP Kit Enclosure (8) with Option (0)

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The HGP CP Kit Option is a harmonic filter component package designed and developed by TCI to
allow qualified customers to build harmonic filters to reduce the harmonic currents drawn from the
power source by VFDs. The HGP CP Option is available f or 480 volt systems (60 Hz). When properly
designed, assembled, and installed, the completed product is intended to be suitable for use with
3-phase diode bridge rectifier loads such as PWM AC VFDs. SCR or thyristor lo ad s suc h a s DC d rives
would require a different filter configuration outside the scope of this product offering. Please contact
TCI Technical Support for additional information.

Product Description

HGP CP Kit Option Filter

The HGP CP Kit O ption is a package of the primary passive filter components needed to build and
install a harmonic filter on a VFD or VFD system. The filter components are tuned to p rovide a low
impedance path for the major harmonic currents demanded by the VFD when follo wing the sche matic
connectio ns used by TCI in the HGP filter.

The HGP CP Option filter component package consists of the following components:

♦ A KDR tuned serie s reactor.
♦ A TCI 3-phase tuning reactor specifically designed for the HGP filter.
♦ High-endurance, harmonic-rated capacitors.
♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

♦ Faston terminals for wiring single -phase capacitors (select models).

Line Rea ctor Installation

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Review all Pre-Installation and Installation instructions at the beginning of this manual.
If you are assembling a CP unit i n your own enc losure, you must provide a n enclosure tha t is adequate ly

sized and ventilated sufficiently to prevent overheating. The maximum temperature of the air around the
HGP filter capacitors should not exceed 50°C (122°F).

KDR Line Re actor In stalla tion Ins tructio n

Recommendations and Considerations:
When installing the KDR Line Reactors on the INPUT side of the VFD, please use the following guidelines

when wiring the unit:
The KDR Line Reactor is a 3-phase device and should be wired in series and positioned on the input side of

the VFD.
All Terminal Block connectors will be marked. A1, B1, and C1 are the input terminals where the 3 phases of

incoming power are to be wired. The tap for the filter co nnection will be marked AT, BT, and CT. Output
terminals will be marked A2, B2, and C2. Do not swap input and output terminals. Units with copper bus or
ring lug terminals are not marked. Wiring from the output terminals sho ul d connect to the input of the VFD.

Refer to NEC wiring practices for appropriate wire sizes for your application.
TCI recommends that these reactors be wired and located as close to the front end of the VFD as possible to

have the greatest success in both protecting the VFD as well as mitigating line harmonics. We reco mmend
this be 10 feet of cable or less.

Reactors generate a lot of heat in normal operations, and their surfaces get very hot. In standard 40°C
ambient or less installations, a clearance of 3 inches on all sides of the reactors and its enclosure is
recommended for assisting in heat dissipation. This is a general guideline for typical applications. If the
reactor is being installed ne xt to a heat sensitive instrument or control device, we recommend reviewing
specific requirements or heat limitations. Line reactor heat loss information is available in the standard TCI
product literature or on the web.

eactors are designed to be floor-mounted, or wall-mounted. Large open-style devices should be pane l

These r
mounted by incorporating a bracket that would act as a shelf to support the reactor and/or enclosure. When
installing an open style device in an existing contro l cabinet, drive cabinet, motor control center, or other
large enclosure, the reactor should be mounted in the lower half of the cabinet to prevent hot spots or
pockets of heat. Locating the reactor in the lower half of the cabinet typically allows better thermal
dissipation and heat convection. Reactors with ducts should be mounted vertically for proper cooling.

Typical Voltage Distortion Option (0 )

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The Typical Voltage D istortion Option, intended for applications with levels of background voltage
distortion less than 2%, i s a co nfiguratio n that e nable s the H GP filter to a chieve lower levels of current
harmonic distortion in applications with lo w backgro und volta ge distor tion. T his per formance op tion is
available in all of the package options.

High V oltage Distortion Option (1)

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The High Voltage Distortion Option, intended for applications with levels of background voltage
distortion of 2% or higher, is a c onfiguration that enables the HGP filter to achieve lower le vels of
current har monic disto rtio n in a pplic ations wit h high b ackgr ound volta ge di storti on. T his p erfor mance
option is available in all of the pa c kage o ptions.