TCI HG7 User Manual

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HarmonicGuard

Series Drive-Applied Harmonic Filter

Installation, Operation, and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-TCI-8282

Web Site: http://www.transcoi l. c om

T able of Contents

Introduction .............................................................................................................................. 2

Receiving Inspection and Storage ............................................................................................ 4

Pre-installation Planning .......................................................................................................... 5

Installation Guidelines ............................................................................................................. 6

HG7 Harmonic Filter Operation .............................................................................................. 7

Installation ............................................................................................................................... 8

Maintenance and Service ......................................................................................................... 9

Product Description ............................................................................................................... 13

Drawings ................................................................................................................................ 16

Standard Filter (ST) ............................................................................................................... 21

Contactor Option (STC)......................................................................................................... 22

Power Monitor Package Option (XM) ................................................................................... 23

HG7 “XM” Option Operation................................................................................................ 27

The HG2TM Protection Monitor ............................................................................................. 28

Kit Package Option (KP) ....................................................................................................... 45

Installation ............................................................................................................................. 47

Component Package Option (CP) ........................................................................................ 49

Installation ............................................................................................................................. 51

HG7 I, O, & M Manual

INTRODUCTION

Introduction

Safety Instruc tions Over vie w

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

The HG7 harmonic filter is intended to be connected to the input terminals of one or more adjustable speed drives. Three-phase power is connected to the input terminals of the HG7 and po wer is supplied to the dri ve or drives t hrough the HG7 . The instruct ions, and p articularly the safety instruc t io ns, for the drives, motors and any other related equipment must be read, understood and followed when working on any of the equipment.

Warnings and Cautions

This manual provides two types of safety instructions. Warnings are used to call attention to instructions, which describe steps, which must be taken to avoid conditions, which can lead to a serious fault condition, physical injury or death.

Cautions are used to call attention to instructions that describe steps that must be taken to avoid conditions that can lead to a malfunction and possible equipment damage.

Warnings

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

Warning

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

General Warning: warns of situatio ns 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 W arning: warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger.

Cautions

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

Caution

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

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

General S afety Ins truct ions

These safety instructions are intended for all work on the HG7. Additional safety instructions are provided at appropriate points on other sections of this manual.

Warning

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

Only qualified electricians should carry out all electrical installation and maintenance work on the HG 7 harmonic fil ter.

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 HG7 filter.

The HG7 harmonic filter, drive, motor, and other connected equipment must be properly grounded.

After switching off the power, always allow 5 minutes for the capacitors in the HG7 filter and in the drive to discharge before working on the HG7, the d rive, 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.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Product Family

Warranty Period

KLR, KDR

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

One (1) year of useful service,

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.

Receiving Inspection and St orage

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

Receiving Inspection

The HG7 harmonic filter has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment. When you receive the unit, you should immediately inspect the shipping container and report any damage to the carrier that delivered the unit. Verify that the part number of the unit you received is the same as the part number listed on your purchase order.

TCI Limited Warranty Policy

TCI, LLC (“TCI”) warrants to the original purchaser only that its products will be free from defects in materials and workmanship under normal use and service for a period originating on the date of shipment from TCI and expiring at the end of the period described below:

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 defecti ve, 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 agen ts oral statements do not constitute warranties, shall not be relied upon by the Buyer, and are not part of any contract for sale. All warranties of TCI embodied in this writing and no other warranties are given beyond those set forth herein.

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

not to exceed 18 months from the date of shipment.

Storage Instructions

If the HG7 harmonic filter is to be stored before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in Table 2 (HG7 Harmonic Filter Technical Specifications). Store the unit in its original packaging.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Pre-installation Planning

Verify th e A pplicat ion

HG7 Ratings

Make sure that the HG7 harmonic filter is correct for the a pplication. The voltage ra tings of the filter must match t he input voltage rating o f the conne cted dr ive. T he horse power and current r atings of the filter must be adequate for the connected load.

Select a Suitable Locat ion

Environment

Locating the HG7 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 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 mounting an open panel uni t in your own encl osure, you must p rovide a n enclo sure that is adequately sized and ventilated sufficiently to prevent overheating. The rating and dimension tables for open panel units list the watts o f heat los s t hat is dissipated by the HG7 harmonic filter. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).

Power Wiring

When selecting a mounting loca tion for the HG7 filter, plan for the routing of the power wiring. Route the conduit and wiring from the power source to the filter and then to the variable speed drive. The HG7 is provided with internal fuses. Additional fuses may be required at the connecting point to

protect the tap conductors. Refer to the National Electrical Code (NEC) and/or any other applicable codes.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Installa tion Guidelines

Mounting

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

Wiring

Cable Entry Locations

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

Field Wiring Connection Terminals

Compression type terminals a re pr ovided for a ll field wirin g connection s. The co ntrol cir cuit terminals will accommodate 18 AWG to 10 AWG wire and should be tightened to 7 lbs. - in. torque . The wire size capacity ranges and tightening torque for the grounding and power terminals are listed in the drawings and other information shipped with the unit.

Grounding

The HG7 panel equipment-grounding lug must be connec ted to the ground of the wiri ng system. T he 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 condui t is not a suitable grounding conductor . The integrity of al l ground connections should be periodically checked.

Power Wiring

Caution

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

Connect the output terminals of the HG7 to the input power ter minals of the adjustable speed drive. 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 adjustable speed drive installation instructions for additional information.

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.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

HG7 Harmonic Filter Operation

Caution

Thoroughly check the installation befor e applying po wer and operating 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.

Operation

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

INTRODUCTION HG7 I, O, & M Manual

Installation

Make sure that the installation lo c a tion will not be exposed to direct sunlight, corr osive 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 HG7 equipment-grounding lug to the system ground of the premises wiring system.

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

Connect the output power terminals, of the HG7, T1, T2 & T3, to the input power terminals of

INTRODUCTION

Intended Audience

This manual is intended for use by all personnel responsible for the installation, operation and maintenance of the HG7 har mo nic filt ers. Such personnel are expected to have knowledge of electrical wiring practices, electronic components and electrical schematic symbols.

Additional Information

Caution

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.

This manual pro vid es gene ra l in fo r mati o n desc ri b i ng your H G7 har monic filt er . Be sure to carefully review the more specific information that is provided by the drawings shipped with the unit. Information provided by the drawings takes precedence over the information provided in this manual.

The ratings, dimensions and weights given in this manual are approximate and should not be used for any purpose requiring exact data. Contact the factory in situations where certified data is r e quired. All data is subject to change without notice.

combustible airborne contaminants, excessive dirt or liquids.

and/or other applicable electrical codes.

Use a properly sized grounding conductor.

the variable frequency drive.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Maintenance a nd Service

HG7 Harmonic Filter Reliability and Service Life

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

Periodic Maintenance

Warning

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

Check to make sure that the enclosure ventilation openings are clean and unobstructed. Clean the air filter in units that have filtered air inlets. Clean as often as necessar y to prevent dirt build-

up from impeding air flow.

Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 filter.

Disconnect all sources of power to the drive and HG7 before working on the equipment. Do not attempt any work on a powered HG7.

Check the o peration of the cooling fan. Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the

enclosure whenever excess dirt has accumulated. Check the integrity of all power and ground wiring connect ions.

All electrical connectio ns must be re-torqued annually.

Troubleshooting

Warning

Note: when disconnecting wires from components and terminations, mark the wires to correspond to their compone nt and terminal c onnection.

Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 harmonic filter.

Disconnect all sources of power to the drive and HG7 before working on the equipment. Do not attempt any work o n a powered HG7 harmonic filter.

The harmonic filter contains high voltages and capacitors. Wait at 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.

Reference Drawings

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

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

7.5

100

125

1.57

1.74

1.87

5.5

2.62

2.90

3.12

7.5

3.14

3.48

3.75

9.3

4.19

4.64

5.00

4.72

5.22

5.62

6.29

6.97

7.50

18.5

7.86

8.71

9.37

9.43

10.45

11.25

13.10

14.51

15.62

15.72

17.41

18.75

18.34

20.32

21.87

23.58

26.12

28.12

31.43

34.83

37.49

36.67

40.63

43.74

110

44.53

49.34

53.11

132

55.01

60.95

65.61

160

65.49

72.56

78.11

200

81.20

89.98

96.85

250

99.54

110.3

118.7

315

128.4

142.2

153.1

355

141.5

156.7

168.7

400

162.4

180.0

193.7

450

178.1

197.4

212.4

500

199.1

220.6

237.4

560

222.7

246.7

265.6

630

251.5

278.6

299.9

710

262

290

312

Fuse Specifications

Table 1a through 1d list the specifications for the LC filter power circuit fuses in the HG 7. Refer also to the drawings and other information shipped with the unit.

Table 1a – Fuse S peci fications for HG7 240 Volt Models

HG7 Rating

(HP)

kVar

Amps Type

Table 1b – Fuse Specifications for HG7 380 – 415 Volt Models

HG7

Rating

(kW)

380V kVar

400V

kVar

415V

kVar

Power Circuit

Fuse Ratings

Class CC Bussmann

type KTK-R

or equivalent

Class T

Bussmann

type JJS

or equivalent

Power Circuit

Fuse Ratings

Type

Class CC Bussmann

type KTK-R

or equivalent

Class T

Bussmann

type JJS

or equivalent

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

100

125

150

100

200

125

250

175

300

200

350

105

225

400

120

250

450

135

300

600

180

400

700

210

450

800

240

500

900

270

600

100

125

150

200

100

250

125

300

150

350

105

175

400

120

200

450

135

250

500

150

250

600

180

300

700

210

350

800

240

400

900

270

450

Table 1c – Fuse Spec ifications fo r HG7 48 0 Volt Mode ls

HG7 Rating

(HP)

kVar

Amps Type

Power Circuit Fuse Ratings

Class CC Bussmann

type KTK-R

or equivalent

Class T

Bussmann

type JJS

or equivalent

Table 1d – Fuse S pecific ations for HG7 600 V olt Models

HG7 Rating

(HP)

kVar

Amps Type

Power Circuit Fuse Ratings

Class CC Bussmann

type KTK-R

or equivalent

Class T

Bussmann

type JJS

or equivalent

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INTRODUCTION

Replacement Parts

If replacement parts are needed, please contact your TCI representative. To ensure that the HG7 harmonic filter continues to p erfor m to its original spec ificatio ns, replace ment parts s hould c onform 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" and have

your HG7 harmonic filter namepla te information available.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Product Description

HG7 Drive-A pp lied Ha rmon ic F ilter

The HG7 is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 is available for 240, 480, 600 (60 Hz) and 380 – 415 (50 Hz) volt systems. It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC drives.

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

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

♦ A KDR input series reactor to prevent system interaction and improve filter performance. ♦ An L-C harmonic filter circuit with:

A TCI 3-phase tuning reactor specifically designed for the HG7 filter High-endurance, harmonic-rated capacitors

♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown. ♦ Cooling fans (on select models) to ensure adequate cooling and safe operating

temperatures.

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

Nameplate Data

Figure 1 sho ws a typical HG7 harmonic filter na meplate. The follo wing information 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/50 Hz) ♦ Phase: 3 – The HG7 filter is designed for use o nly with 3-phase power. ♦ Drawing #: outline and mounting dimension drawing number ♦ Schematic #: schematic diagram drawing number ♦ Manufacturing #: for TCI i nt ernal use ♦ Enclosure Type: UL designation or "Open" panel construction

Figure 1 – Typical HG7 Harmonic Filter Nameplate

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

Part Number Encoding

Figure 2 identifies the significance of each character in the HG7 part number. The example part number, HG250AW00ST designates a HG7 filter that is rated 75 kVar, 480 volts, 60 Hz. It includes a standard 10% reacto r, is t u ned to the 5th har monic, i s an open panel and is designed for use with a 250 HP drive.

Figure 2 – HG7 Part Number Encoding

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INTRODUCTION

Product Technical Specifications

Table 2 lists the major technical specifications for the HG7 Harmonic Filter.

Table 2 – HG7 ST and STC Opti on Harmo nic Filte r Tec hnical S peci fications

Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz

380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.5 -900 Hp depending on voltage, 4–710kW

See Rating and Dimension tables. Current ratings The include d 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 r ating is 10kA.

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. Capacitors Oil filled high endurance design (no PCBs)

INTRODUCTION HG7 I, O, & M Manual

Drawings

INTRODUCTION

Typical Schematic Diagrams and Outline and Mounting Dimension Drawings

Typical HG7 drawings are provided on the following pages. These drawings provide general information describing your HG7 harmonic filter. More specific information is provided by the drawings shipped with the unit. Be sure to carefully review the information on the provided drawings. The information on the drawings provided with the filter takes precedence over the information provided in this manual.

Schematic Diagrams

The schematic diagram shows the details of the HG7 circuitry. The power circuit schematic shows the variations in input and output power connections.

Outline and Mounting Dimension Drawings

Outline and mountin g dimens ion drawin gs show the overal l enclos ure dimen sions, the c onduit ac cess areas and the wiring connection points. The major internal components are shown pictorially.

Additional Typical Drawings

Some additional typical drawings are available for downloading at http://www.transcoil.com.

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INTRODUCTION

Typical Drawings continued

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

HG7 ST Typical Schematic based on 480V

HG7 STC Typical Schematic based on 480V

When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Det ail ed note below.

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INTRODUCTION

HG7 XM Schematic: 7.5 – 60 HP based on 480V

When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Det ail ed note below.

HG7 XM Schematic: 200 – 400 HP based on 480V

When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Det ail ed note below.

INTRODUCTION HG7 I, O, & M Manual

INTRODUCTION

HG7 XM Schematic: 450 – 600 HP based on 480V

When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Det ail ed note below.

NOTE 1 Detail:

When possible, t he “Up t o Speed” Aux iliar y Contac ts s hould be use d inste ad of the “R un-S top” Aux iliar y Contac ts on the VFD.

Benefits of this setup:

1. Most electrical systems have generator back-up systems today. The filters will start-up with no capacitance in the circuit. On generator applications this allows the voltage regulator and the load to stabilize before the capaci tors are brought int o the circuit elim inating spiking and potent ial leading power factor condition.

2. This will potentially prevent a leading power f ac tor c on dit ion on the B us , es pecially when many VFDs with filters are on the sam e Bus. For ex ample, if the VFD at speed refer ence is programmed f or 45 hertz, the contactor is open at speeds less than 45Hz. The capacitors will be off-line when the frequency drops below this reference. The capacitors will be closed above the 45Hz programmed contact closure for normal harmonic mitigation.

On variable torque fan and pump loads the current drops dramatically below a 60 hertz operation and as a result there will be too many vars of capacitance in the system for the load applied. The result will lead to a high voltage condition at the input terminals of the VFD, potentially causing an “overvoltage” trip.

INTRODUCTION HG7 I, O, & M Manual

CONTACTOR & CPT OPTION

Standard Filter (ST)

The Standard Package has the suffix of “ST” in the part number and includes very high quality harmonic-grade capacitors and line reactors. This filter will meet the majority of application requirements found today. This cost effective product is available as an open panel version, in a UL Type 1 enclosure, or in an U L Type 3 R enclos ure. The open panel is perfect for inclusion in a MCC section or easy installation into industry standard enclosures. The UL Type 1 enclosed units maintai n 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

HG7 Standard Harmonic Filter

The HG7 harmonic filter is a d rive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 Standard harmonic filter is for 200/208, 230/240, 460/480 volt or 575/600 volt systems (60 Hz) or 380 – 415 Volt systems (50 Hz). It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC drives.

The HG7 harmonic filter is a passive filter connected in series with the input terminals of a variable speed drive or several drives that operate as a group. It is designed to provide a low impedance path for the major harmonic currents demanded by the drive. The filter is a stand-alone device that can be furnished i n its o wn enc losur e and moun ted ad jac ent to the drive. It is also available on an open panel for mounting within an enclosure with the drive or other equipment.

The HG7 Standard consists of the followin g standard featur es and components.

♦ A KDR input series reactor to prevent s ystem interaction and improve filter

performance.

♦ An L-C harmonic filter circuit with:

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

CONTACTOR & CPT OPTION HG7 I, O, & M Manual

CONTACTOR & CPT OPTION

Contactor Option (STC)

STC Option Models

This model is identified by the suffix “STC” in the part number. The STC version provides a contactor, control power transformer and connection terminals in the filter trap circuit which allows the VFD user to control the insertion of the HG7 filter’s trap circuit through the use of a relay contact in the drive. 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 and enables the user to perform trap circuit maintenance wi thout shutting down the entire drive system.

Product Description

HG7 STC Option Harmonic Filter

The HG7 harmonic filter is a d rive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 STC option harmonic filter is for 200/208, 230/240, 460/480 volt or 575/600 volt systems (60 Hz) or 380 – 415Volt systems (50 Hz). It i s suitable for use with 3-phase diode br idge rectifier loads such as PWM AC drives.

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

The HG7 STC Option consists of the following standard features and components.

♦ A KDR input series reactor to prevent system interaction and improve filter performance. ♦ An L-C harmonic filter circuit with:

A TCI 3-phase tuning reactor specifically designed for the HG7 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 transformer for fan and control voltage power. ♦ Compression terminals for ease a nd integrity of all power and control wiring. ♦ STCH Option has heater.

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Po wer Monitor Pac kage Option (XM)

This model is identified by the suffix “XM” in the part number. The "XM" Option HG7 filters are similar to the standard series HG7, but they have features and characteristics that are beyond the scope of the “Standard” series HG7. In the rating and dimension tables we list the sizes of the “XM” option units only to avoid confusion. T his manual is inte nded to b e used as a genera l guide to the installatio n, operation, and maintenance of “XM” Option filters.

Product Description

HG7 “XM” Option Harmonic Filter

The HG7 harmonic filter is a d rive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 “XM” option harmonic filter is for 200/208, 230/240, 460/480 volt, 575/600 volt systems (60 Hz) and 380 – 415 volt systems (50 Hz). It is suitable for use with 3-p hase diode bridge rectifier loads such as PWM AC drives and 3-phase controlled rectifier (SCR or thyristor) loads such as DC drives.

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

The HG7 “XM” Option consists of the following standard features and components.

♦ A KDR input series reactor to prevent system interaction and improve filter performance. ♦ An L-C harmonic filter circuit with:

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

♦ The HG2

standard in H G7 “XM” option filters rated over 20kVar to 120 kVar in capacitance. It includes:

♦ Filter Enabled and Blown Fuse indicating lights are included as standard in filters rated

20 kVar and under, or over 120 kVA in filter capacitance rating.

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

temperatures.

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

Protection Monitor and Harmonic Power Factor Meter is included as

Three-character LCD display

Filter Disabled and Filter Enabled status indic ating LEDs UP, DOWN, and SELECT keys Fault Alarm Relay with form C contact for customer use

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Product Technical Specifications

Table 3 lists the major technical specifications for the HG7 “XM” Option filter product:

Table 3 – HG7 “XM” Opti on Ha rmonic Fi lter Tech nical Spe cifica tions

Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz

380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 120 kVar, 140 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.5 - 400 HP, 500 - 900 Hp depending on voltage. See Rating and

Dimension tables. 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. Product must be equipped with

Maximum ambient operating temperature

Maximum ambient storage temperature

Maximum humi d it y, operating or storage

Enclosure options Standard: UL Type 1 enclosure Agency approvals or

certifications

Standard rating is 10kA.

special cooling provisions for o peration above this altitude.

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 and cUL Listed to UL508A and CSA-C2.2 No. 14

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

HG2 Protection Monitor is standard in units rated over 20 kVar. LCD display

(units with HG2 Monitor)

Status indication LEDs (units with HG2 Monitor)

Fault relay (units with HG2 Monitor)

Pilot lights (Units w/o HG2 monitor)

Capacitors Oil filled high endurance design (no PCBs)

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Operating Parameter values: kW, kVA, power factor, voltage,

current, harmonic voltage, current, and total harmonic distortion

Faults: low current trip, high curre nt trip, time delay over-current trip,

door interlock, over-temperature, multi-unit e xternal, and interlock

faults.

Setup Parameters: filter nameplate ratings, fault & re set delays, and

trip levels.

Green LED indicates: Filter Enabled

Red LED indicates: Filter Disabled

De-energized when a fault is detected.

Form C contact for customer use; rated 5 A at 120 VAC & 5 VDC.

Blown Fuse indica ting lights for 3-phase filter fuses

Filter Enabled pilot light

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Control Wiring

Control Power

An internal control power transformer is provided to supply 120 VAC single-phase power for the contactor, Protection Monitor, and cooling fan(s). Fuses are provided on both the primary and secondary sides of the control transformer.

Filter Enable Input

An auxiliary N.O. run contact from the drive should be connected to the Filter Enable input to enable the HG7 “XM” Option only when the drive is r unning.

Fault Alarm Relay

A Fault Alarm relay is included in the HG2 Protection Monitor which is furnished as standard in “XM” Option units rated over 20 kVar. The Fault Alarm relay is energized when control power is applied to the HG7 and the HG7 is operating properly. A set of form C contacts is provided for customer use.

Determine how the Fault Alarm contact will be used. It may be connected to the drive external fault input or to some supervisory control or alarm annunciation equipment. A HG7 fault alarm i ndicates that the HG7 filter has been disabled by the HG2 Protection Monitor. If the drive operates while the HG7 is disabled, increased harmonic distortion of the power source may have adverse effects on the power distribution system components and other equipment. To guard against the effects of increased harmonic distortion, consider connecting the HG7 to automatically shut down the drive if a fault occurs. T he best alternat ive to shuttin g down the dr ive is to provide an alarm to personnel who will promptly investigate the problem.

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Connection Diagram

Figure 3 shows the typical wiring connections between the HG7 and the drive. Refer to the drawings furnished with the HG7 for mor e sp e c ific in formation. Refer also to the instructions for the drive and other equipment to which t he Enable Input and the Fault Al arm contact are connected.

Figure 3 –

Typical Connection Dia gram

For HG7 Harmonic Filters with the “XM” Option: When connecting input power conductors directly to the input line reactors in the HG7 “XM”

Option units, the cond uc tor s must be passe d thr oug h the c urrent tra nsfo r mers t hat are prov ided for use by the HG2 Protection Monitor. Units below 75 kVar and above 120 kVar do not have

current transformers.

Control Wiring

Connect the HG7 “XM” Option Filter Enable input (terminals 1 and 2) to an auxiliary N.O. Run contact in the adjustable speed drive. Connecting a Drive Aux Run contact will automatically connect the HG7 whe never t he drive is running. If a jumper is connected between terminals 1 and 2, the HG7 will be connected whenever the drive branch circuit power disconnect device is closed. Connect the HG7 Fault Ala rm relay contacts to the app ropriate fault monitorin g circuit. It may be con nected to the drive or to some supervisory control or alarm annuncia tion equipment. T he fault contact is par t of the HG2 Protection Monitor, which is provided as standard in HG7 “XM” Option units lar ger than 20 kVar.

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HG7 “XM” Option Op erat ion

Adjustments

Protection Monitor Settings

♦ The Protection Monitor Setup Parameters and calibration adjustments are factory set and

should not be changed except as directed in the troubleshooting procedures.

♦ The protection monitor is described in detail in the following section of this manual.

Start Up (Commissioning)

Caution

Before Applying Power for the Fir st Time

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

Before Operating the Drive for the First Time

♦ For units equipped with the HG2 Protection Monitor, check to see that the HG2 operates

as described in the HG2 Power Up Sequence

♦ For units equipped with pilot lights, the Blown Fuse lights should be off. The Filter

Enabled light should be off unless the Enable Input has been jumpered rather than connected to a Drive Aux Run contact.

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

Thoroughly check the installation befor e applying po wer and operating the equipment for the first time.

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The HG2TM Protection Monitor

Introduction

Product Description

The HG2TM Protection Monito r is included as standard in HG7 “XM” Option models rated over 20 kVar. The HG2 monitors the HG7 operation, electronically protects the power circuits, displays performance information, and provides a control interface with the drive and/or supervisory control system. A three-character display is provided with UP, DOWN, and SELECT keys and two status- indicating LEDs.

The HG2 includes analog inputs for monitoring the line voltage and current and the current in the harmonic filter. Current transformers are included in HG7, “XM” Option harmonic filter units to provide the line current inp uts. Sense wind ings from in the t uning reactor p rovide the sour ce for the current measurements. Voltage is measured through direct input to the HG2.

The HG2 Protection Monitor provides a local display for power monitoring at the point where the HG7 filter is connected to the power distrib ution system. The power monitoring displa y selections include line voltage, current, real power (kW), apparent power (kVA), power factor, and harmonic distortion parameters. The harmonic distortion parameters include total harmonic distortion (%THD) of the line voltage and current as well as indivi dual values of low ord er harmonics. Filter curr ent and harmo nic values are also available. Three-phase average parameter values, totals, and individual phase values are available. The HG2 calculates parameter values from the signals available at the analog inputs.

The HG2 inc ludes co ntact clo sure inp uts for F ilter Enable control and for optional Over-temperature and Door Interlock prote ction functions. A serial interlo ck connection is pr ovided for coo rdinating the protection functions of multiple HG2 Protection Monitors.

The HG2 Protection Monitor provides fault protection for the filter by disconnecting the capacitor banks when a fault is detected. Protection functions include filter over and under-current, door interlock, o ver-temperature, and others. Note that the doo r interlock switch a nd the over-temperature thermostatic switch are optional. Fault Codes are generated on the display for ease of troubleshooting.

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No.

Display

LCD

Displays “OFF” when filter is off. Displays Fault Code (Fnn) when a fault condition exists.

Filter Disabled

Red LED

Illuminated when filter is disabled by fault trip.

Filter Enabled

Green LED

Illuminated when filter is operating.

(Scroll)

scroll to desired parameter selection.

(Scroll)

SELECT

Key

Press and release quickly to display L #, L A, or L r, phase, desired selection.

Figure 4 – HG2 Protection Monitor Displ ay a nd Keypad

Display and Keypad

Figure 4 shows the HG2 Protection Monitor display and keypad. Table 4 lists the vario us component items and describes their functions.

Table 4 – HG2 Protec tion Monitor Displ ay and Key pad Features

Item

Name Description Function

Displays the value of the selected Operating Parameter.

Key Press and release quickly to display the name of the

selected parameter. Display automatically reverts to

DOWN

Key

parameter value display after 1 second. Press and hold to

average, or total value selection. Press and hold to scroll to

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General Operation

Power Up Sequence

♦ For the first 3 seconds after power is applied the display will show “888.” ♦ After the first 3 seconds and until the reset lockout time (parameter 1A, 30 sec. Default)

has expired, the display will show “OFF.”

♦ When the reset lockout time has expired:

If the Enable input is open and no fault exists:

The red Filter Disabled LED will be off. The green Filter Enabled LED will b e off. The display will show “OFF.”

If the Enable input is open and there is an external, over-temperature, or serial data fault:

The red Filter Disabled LED will be on. The Fault Alarm r elay will be energized. The green Filter Enabled LED will b e off. The display will show "F01," "F03," or "F04" for the respective faults.

If the Enable input is closed and no fault exists:

The red Filter Disabled LED will be off. The green Filter Enabled LED will be on. The contactor will pull in connecting t he filter. The display will show the value of the selected Operating Parameter.

If the Enable input is closed and a fault exists:

Initially, t he green Filter Enabled LED will be on and the contactor will pull in

connecting the filter until the fault is dete c te d.

Once the fault is detected:

The red Filter Disabled LED will be on. The Fault Alarm r elay will be energized. The green Filter Enabled LED will b e off. The display will show a Fault Code, F01 to F31.

Normal Operation

The filter should operate whenever the drive operates. When the drive starts, a Drive Aux Run contact should close the HG7’s Filter Enable input . After the reset lockout time has expired, the green Filter Enabled LED will turn on and the contactor in the HG7, “XM” Option will connect the filter. The display will show the value of the selected Operating Parameter.

When the d rive stops, a Drive Aux Run contact should open the filter’s Enable input. The gre en Filter Enabled LED will turn off and t he contactor in the HG7 will disco nnect the filter. The display will show "OFF."

Changing the Displayed Parameter

During operation, the HG2 displays the value of the selected Operating Parameter. The Operating Parameters are listed in Table 5. When the UP or DOWN key is pressed and immediately released, the

display shows the parameter name for approximately 1 second and then reverts to displaying the parameter value. To change to the next or previous parameter, press the UP or DOWN key and release the key as soon as the parameter name changes. Holding down the UP or DOWN keys will scroll through parameters forward or backward, respectively.

When the SELECT key is pressed and immediately released, the display shows "L 1," "L 2," "L 3," “L A,” or " L r," for approximately 1 second and then reverts to displaying the parameter value. "L A,"

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OFF

Not in run and no faults

Line Current (total RMS amps)

Filter current (total RMS amps)

A H

Line harmonic current distortio n

(% THD)

C H

Filter harmonic current distor tion

(% THD)

A 1

Line 1st harmonic current (fundamental RMS amps)

C 1

Filter 1st harmonic current

(fundamental RMS amps)

A 5

Line 5th harmonic current

(RMS amps)

C 5

Filter 5th harmonic current

(RMS amps)

A 7

Line 7th harmonic current

(RMS amps)

C11

Filter 11th harmonic current

(RMS amps)

A13

Line 13th harmonic current

(RMS amps)

C13

Filter 13th harmonic curre nt

(RMS amps)

Real Power (kW)

Line voltage L-N (total RMS volts)

volt system

U A

Apparent Power (kVA)

U H

Line harmonic voltage distortio n

(% THD)

Power Factor (%)

U 1

Line 1st harmonic voltage

(fundamental RMS volts)

*L A

Average value

(RMS volts)

U11

Line 11th harmonic voltage

(RMS volts)

*L 2

Line 2 value

U13

Line 13th harmonic voltage

(RMS volts)

*L 3

Line 3 value

indicates that the displayed value is the average of the individ ual phase val ues. "L 1," "L 2," & "L 3" indicate the display of individual phase values. "L r," indicates that the displa yed value is the total of the phase values. To change the "L *" selection, press and hold the SELECT key to scroll to the desired selection. The "L 1," "L 2," & "L 3" selections are available for all of the parameters. The “L A” selection is available for Filter Current “C,” Line Voltage “U,” Line Current “A” and Power Factor “PF.” The "L r” selection is available for Real Power “P” and Apparent Power “UA.”

Table 5 – Operating Parameter Display

Parameter

Name

Parameter Value

Parameter

Parameter Value

C 7 Filter 7th harmonic current

L-N approx. 277 for a 480 volt

system and approx. 139 for a 240

U 5 Line 5th harmonic voltage

U 7 Line 7th harmonic voltage

A11 Line 11th harmonic current

*L r Total value

*L 1 Line 1 value

* These functions are accessible by pressing the SELECT key.

Fault Detection

If a fault condition is d etected by the HG2, the red Filter Disabled LED will t urn on and the Fault Alarm relay will be energized. T he green Filter Enabled LED wil l turn off and t he contactor i n the

HG7 will disconnect the filter . The display will show a Fault Code, F001 to F31 as listed in Table 6. In order to minimize nuisance trips, time delays are applied to some fault conditions as indicated in the table.

When the fault condition has been corrected, press the UP and SELECT keys simu ltaneously t o clear the fault. When the fault reset clear time has expired, the red Filter Disabled LED will tur n off a nd t he Fault Alarm relay will be de-energized. The green Filter Enabled LED will turn on, the contacto r will connect the filter and the display to the selected Operating Parameter.

In a system wit h mul tip l e uni t s, an y u nit ma y d ete c t a fa ult a nd s hut d o wn the whole system. The other units in the system will displa y “F01,” External F ault, and turn off. The faul t may onl y be clea red by

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F01

External Fault (multiple boards in a series line)

F02

Door Open In Run Mode (no delay)

F03

Overtemp (6 sec. delay)

F04

Serial Data Fault (8 sec delay)

F11

Filter Current Low Trip Line 1 (20 sec. delay)

F12

Filter Current Low Trip Line 2 (20 sec. delay)

F13

Filter Current Low Trip Line 3 (20 sec. delay )

F21

Filter Overcurrent Fast Trip Line 1

F22

Filter Overcurrent Fast Trip Line 2

F23

Filter Overcurrent Fast Trip Line 3

F31

Filter Overcurrent Delayed Trip Line 1 (delay set by parameter 1A)

F32

Filter Overcurrent Delayed Trip Line 2 (delay set by para met er 1A)

F33

Filter Overcurrent Delayed Trip Line 3 (delay set by parameter 1A)

resetting the unit that detected the fault condition. The other units in the system will be clear automatically when the faulted unit i s r e set.

Table 6 – Fault Code Dis play

Fault Code Fault Description

Setup Parameters

Introduction

The Setup Parameters are used to enter the nameplate data required for matching the HG2 to the HG7 harmonic filter ratings. Fault trip levels and delay times are also adjustable. A security code can be entered to prevent unauthorized access to the Setup Menu. The Calibration Mode is accessible through the Setup Menu (See HG2 Protection Monitor Calibration). Table 7 describes the Setup Parameters, indicates the adjustment ranges, and lists the factory default settings The Protection Monitor Setup Parameters a nd calibration adjustments are factory set and should not be changed except as directed in the troubleshooting procedures.

Setup Procedure

1. With the power off and no over-temperature fault condition, hold down all thre e keys (UP,

DOWN, and SELECT) while applying power. Hold for 5 seconds after power is applied.

2. Release all three keys. The display will show “000”.

3. If the security code has not been changed from the Factory Default of “000” go to step 5.

4. If the security code is not "000," press the DOWN key to enter the security code for digit one.

Press the UP key once to select digit two. Press the DOWN key to enter the code for digit two. Press the UP key once to select digit three. Press the DOWN key to enter the code for digit three.

5. P ress and release the SELECT key. The display will show “---” if the code is correct, or “OFF” if

the code is not correct. If the incorrect code has been entered, start over at step 1.

6. P ress and release the UP key. “1A” will be displayed.

7. P ress and release the SELECT key to display the parameter setting.

8. When the setting of a selected parameter is displayed, pressing the UP and DOWN keys will

increase and decrease the setting.

9. P ress and release the SELECT key to store the setting and return to the menu.

10. Press and release the UP key to display the next parameter on the Set up Menu.

11. To exit setup, use the UP key to ste p through the menu past paramete r "11A" to “---”, then press

the SELECT key.

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---

Enter/Exit Factory Setup Mode

1 A

Fault Delay Time

1-60 SEC

2 A

Restart Lockout Time

1-60 SEC

3 A

Filter KVAR Rating (Nameplate)

3.0-120 KVAR

(Nameplate)

4 A

Operating Frequency (Nameplate)

50 or 60 Hz

(Nameplate)

5 A

Fast Trip Overcurrent % Set

100%-199%

180

6 A

Slow Trip Overcurrent % Set

100%-199%

160

7 A

Low Trip Undercurrent % Set

1%-100%

8 A

Nominal Line to Line Voltage (Nameplate)

200 - 600 VOLTS

(Nameplate)

9 A

Line Current Rating (Nameplate)

0 or 5 - 480 AMPS

(Nameplate)

10A

Security Code

000 – 999

000

1 = Calibration Mode

NOTE:

If the code is changed and the new code is lost, you will no longer have

12. You can step thro ugh the menu only in the "UP" di rection. If you wish to return to a n item once

you have stepped past it, step past "---" without pressing the SELECT key to retur n to "1A."

Table 7 – Setup Menu

Parameter

Name

Description Range

Factory

Default Setting

11A

Calibration Mode

0 = Normal Operation

Changing the Security Code

The factory default security code is “000.” To change this code, enter the Setup Menu and proceed as follows:

13. Use the UP key to step to parameter “10A.”

14. P ress and release the SELECT key. The present security code will be displayed.

15. Use the DOWN key to change digit one to the first digit of t he new code.

16. Press the UP key once to select digit two.

17. Press the DOWN key to change digit two to the second digit of the new code.

18. Press the UP key once to select digit three.

19. Press the DOWN key to enter digit three to the third digit of the new code.

20. Press the UP key once and the original code will be disp layed.

21. Repeat the steps 3 to 7 to enter the new code a second time.

22. After completing step 7, press the SELECT key.

23. If the new code has been properly entered twice, the display will show “10A” and the new code

will be saved.

24. If the two entries of the new code did not agree, "err" will be displayed. Press any key and the

display will show “10A.” If you press and release the SELECT key, you can see that the code remains unchanged. You can start over at step 3.

access to the Setup Menu. The unit will have to be returned to the factory to be reprogrammed to the default security code.

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Troubleshooting Units Equipped with the HG2TM Protection M onitor

The HG2TM Protection Monitor and Harmonic Power Factor Meter is included as standard in HG7 “XM” option filters rated over 20 kVar. Units rated 20 kVar and less have Blown Fuse and Filter Enabled pilot lights to indicate their operating status and ar e not equipped with the HG2 as sta ndard. Troubleshooting information for pilot light equipped units is provided in the following section under the heading Troubleshooting Units Equipped with Pilot Lights.

Normal Operation

The normal operation of the HG2 protection monitor is described in detail in the HG2 Protection Monitor section of this manual. Refer also to HG2 Protection Monitor Calibration including figure s 5,

6 and 7.

Protection Monitor Display and Status L ights

During Normal Operation, the green Filter Enabled LED should be on, the red Filter Disabled LED should be off and the display should show the selected Operating Parameter.

If the HG2 display is blank and no LEDs are illuminated, the possible causes include:

♦ If the drive is also inoperable and lacking any "Power On" indications:

Three-phase power has probably been disconnected either manually or by the operation of a protective device. Check the main disconnect and fuses or circuit breaker. If fuses have blown or a breaker has tripped, a short circuit or severe overload condition has probably occurred in the HG7 filter, drive, motor, or power wiring. Check for evidence of damaged, b urned, or overheated wiring or components.

♦ If the drive appears to be receiving power:

Check the primary and secondary control power transformer fuses in the HG7 filter.

If a fuse has blown, there is probably a short circuit, ground fault, or overload condition in the HG7. Check for evidence of damaged, burned, or overheated wiring or components.

Check the following items:

Control circuit wiring Control circuit transformer Cooling fan HG2 Protection Monitor

If the fuses are good, the HG2 may be defective

If drive is operating but the HG2 display shows OFF, the red Filter Disabled LED is on and the green Filter Enabled LED is off:

♦ Check the Filter Enable input to the HG2.

If the Filter Enable input is open, the Drive Aux Run contact may be open or disconnected.

If the Filter Enable input is closed, the HG2 may be defective.

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F01

External Fault

J1-10.

F02

Door Interlock Fault

Troubleshoot by verifying conti nuity betw een J6-1 & J6-8.

F03

Over-temperature Fault

Troubleshoot by verifying continuity at the Protection Monitor between J6-1 & J6-6.

F04

Serial Interlock Fault

Protection Monitor between J1-8 & J1-10.

Protection Monitor Display Fault Codes

If the Protection Monitor display shows a Fault Code (F01 to F33), follow the troubleshooting procedure provided in Table 8. If a Fault Code is displayed, the Filter Disabled LED will be illuminated and the Fault Alarm R e lay will be de-energized.

Table 8 – Fault Code Trou bles hooting Pr ocedur es

FAULT

Code

This Fault Code indicates a fault in an HG7unit other than the one displaying the "F01" Fault Code.

In a system that has multiple sections, each monitored with an HG2, any HG2 may detect a fault and in turn disconnect all the harmonic filters linked via the serial connection. The unit detecting the fault will display the appropriate Fault Code while all others in the series will display “F01.” The fault may only be cleared from the harmonic filter section experiencing the fault. Once the fault is cleared the other units will revert to Normal Operation. In single board configurations, there is a jumper wire installed in connector J18 & J1-10. Troubleshoot by verifying continuity at the Protection Monitor between J1-8 &

This Fault Code indicates the optional door interlock switch is open. When this option is not supplied there is a jumper wire installed between TB2-7 &TB2-8.

Troubleshooting Procedure

This Fault Code indicates the optional over temperature swit ch open. When this option is not supplied there is a jumper wire installed between TB2-5 & TB2-6.

This fault indicates the serial link between multiple boards is open or wired incorrectly. Verify that from board number one J1-8 is connected to board two J1-10 and board two

J1-8 to board “N” J1-10 and board “N” J1-8 is connected to boar d one J1-10 thus completing the daisy chain serial loop. In single board configurations, there is a jumper wire installed in connector J1-8 & J1-10. Trouble shoot by verifying continuity at the

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F11-F13

Filter Current Low Trip

changed without consulting the technical support department at the factory.

FAULT

Code

Fault

initial

startup

Troubleshooting Procedure

If the F11, F12 or F13 fault occurred upon initial startup (commissioning), use this procedure. If the unit had been operating normally for some time after initial startup (commissioning), refer to the next section.

This fault indicates the filter current is lower than normal. Fault F11 indicates low current through fuse Fu1(a), F12 indicates low curren t through f us e Fu2(a) and F 13 indi cat es low current through fuse Fu3(a).

First check for any shipping damage. Look for loose connections, especially those associated with the HG2 board and fuses Fu1(a), Fu2(a) and Fu3(a). Make sure that Fu1(a), Fu2(a), and Fu3(a) are properly installed. Check for proper balanced line-to-line voltages on L1, L2, and L3.

If there are no obvious errors in the wiring and installation of the filter go to the Setup Procedure page 32. Verify that all the parameters are correct for this installation. At this point leave the parameter 11A set to (0), exit the setup mode, and allow the filter to reenergize.

If the F11 fault still appears, return to the Setup Procedure and set parameter 11A to (1). Upon exiting this time, the filter will re-energize in the Calibration Mode. Caution! When

in the Calibration Mode, the HG2 board will not de-energize the filter under fault conditions. Follow the Calibration Procedure on page 39.

The factory default setting for the Filter Current Low Trip (parameter 7A) is 80% of the filter's nominal fundamental current rating as determined by the filter’s kVar, frequency, and voltage ratings (parameters 3A, 4a & 8A). If the trip level is set below 80%, the HG2 may not trip when a partial loss of capacitance has occurred. If the trip level is set above 80%, the HG2 may trip unnecessarily. It is recommended t hat the setting not be

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F11-F13

Filter Current Low Trip

factory.

F21-23

Filter Over-current Fast Trip

not be changed without consulting the technical support department at the factory.

FAULT

Code

Fault

after

initial normal service

Troubleshooting Procedure

If the F11, F12, or F13, fault occurred after the unit had been operating normally for some time after initial startup (commissioning), u se thi s proced ure. If the fault occurred upon initial startup (commissioning), refer to the previous section.

If the unit operated nor mal ly after setup and cal ibra tion, the fault usually indicates a fuse cleared or a loss of capacitance occurred, thus lowering the normal current. Fault F11 is associated with fuse Fu1(a), F12 is associated with fuse Fu1(a), and F13 is associated with fuse Fu3(a). Check the fuses and replace any that have cleared with known good fuses of the same type and rating. Check for signs of a short circuit.

Restart the filter and verify that the filter currents are at the proper levels. Caution!

Troubleshooting with the filter energized means there are hazardous voltages present. Only qualified personnel should do this service work.

If the fuses are good, verify the integrity of the contactor. The electrical contacts are consumable wear parts and may need service.

If the contactor is deemed in serviceable condition go to the Setup Procedure on page 32. Step through the parameters and set parameter 11A to (1), exit the setup mode, and allow the filter to reenergize in the Calibration Mode. Caution! When in the Calibration

Mode, the filter will not automatically disconnect upon recognizing a fault condition. Measure currents; i f lower than the perc enta ge of nomi nal am ount set in 7A,

an F11 fault will result. It is usually an indication of loss of capacitance. To locate the faulty capacitor(s), first verify the proper line-to-line voltage is present at the terminals of each capacitor. If the voltage is correct, then measure the current into each individual capacitor. If any of the currents are lower than nameplate by greater than 10%, replace the defective capacitor(s), and verify proper operat io n.

The factory default setting for the Filter Current Low Trip (parameter 7A) is 80% of the filter’s nominal fundament al cu rr ent rat ing the as deter min ed by the filter’s kVar, frequency, and voltage ratings (parameters 3A, 4a & 8A). If the trip level is set below 80%, the HG2 may not trip when a partial loss of capacitance has occurred. If the trip level is set above 80%, the HG2 may trip unnecessarily. It is recommended that the

setting not be changed without consulting the technical support department at the

The usual causes for this fault are:

Oversized drive for the capability of the filter. Excessive harmonics present on the distribution system from other sources. Partial loss of capacitance (thus causing the filter circuit tuning point to shift at or

above the designed frequency). Line voltage is greater than 125% of the nomina l rating. Interaction with power factor capacitors on the distribution system resulting in system

resonance conditions.

If F21-F23 faults occur repeatedly in the apparent absence of any of the above problems, verify the actual filter current with a current probe suited for true RMS meas urements in a harmonic rich circuit. Note: It may be necessary to inhibit the board from de-energizing the filter by operating in the calibrate mode. However, be aware that if excessive currents are indeed present, the technician must be able to rapidly remove power from the filter to minimize damaging components or blow ing the filter fuses.

The factory default setting for the Filter Over-current Fast Trip (parameter 5A) is 180% of the filter’s nominal fundamental current rating as determined by the HG7’s kVar, frequency, and voltage ratings (parameters 3A, 4a & 8A). If the trip level is set above 180%, the life of the capacitors may be reduced or the fuses may blow. If the trip level is set below 180%, the filter may trip unnecessarily. It is recommended that the setting

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F31-F33

Filter Over-current Delayed Trip

the technical support department at the factory if this becomes necessary.

FAULT

Code

Troubleshooting Procedure

The usual causes for a F31 displayed fault are:

Short-term operation above rated line current during acceleration of the load or other normal utilization of the drive's short-term overload capacity.

Operation above rated line current due to abnormal drive overload condition. Excessive harmonics present on the distribution system from other sources. Partial loss of capacitance (thus causing the filter circuit tuning point to shift to or

above the designed frequency). Line voltages greater than 125% of the nominal rating. Interaction with power factor capacitors on the distribution system resulting in system

resonance conditions; however, not to the level that would cause a fast trip as indicated by the display of F2x fault.

If the problem is caused by short-term (<60 seconds) operation above rated line current due to normal utilization of the drive's short-term overload capacity, increasing the time to fault setup parameter (1A) may alleviate the problem.

If F31-F33 faults occur repeatedly in the apparent absence of any of the above problems, verify the actual filter current with a current probe suited for true RMS meas urements in a harmonic rich circuit. Note: It may be necessary to inhibit the board from de-energizing the HG7 by operating in the calibrate mode. However, be aware that if excessive currents are indeed present, the technician must be able to rapidly remove power from the filter to minimize damaging components or opera tin g the filter fuses.

If the actual measured currents are within the acceptable levels for the rating of the filter, but there are short periods (<60 seconds) that exceed the trip threshold, increasing the time to fault setup parameter (1A) may alleviate the problem.

The factory default setting for the Filter Over-current Delayed Trip (parameter 6A) is 160% of the filter’s nominal fundamental current rating as determined by the filter’s kVar, frequency, and voltage ratings (parameters 3A, 4a & 8A). It may be acceptable to increase the slow trip parameter setup 6A. However, it is recommended that you consult

Troubleshooting Units Equipped with Pilot L ights

Units rated 20 kVar and less, or over 120 kVar, have Blown Fuse and Filter Enable d pilot light s to indicate their operating status and are not equipped with the HG2 Protection Monitor as standard. Troubleshooting information for units equipped with the HG2 Protection Monitor is provided in the previous sec tion under the heading Troubleshooting Units Equipped with the HG2 Protection Monitor.

Filter Enabled Pilot Light

The Filter Enabled pilot light indicates that the Filter Enable input is clo sed.

Blown Fuse Indicating Pilot Lights

If a Blown Fuse Indicating pilot light is illuminated, the corresponding fuse, Fu1(a), Fu2(a), or Fu3(a) has blown. These fuses protect the three-phase HG7 filter power circuitry. Check for damaged components or wiring in the filter power circuit. Check for discolored or burned components and deformed or leaking capacitors. Damaged components can be caused by overheating. Check to see that the ambient temperature is not excessive and make sure that the unit is receiving an adequate flow of cooling air. Check the fan i f the unit has one.

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only when power is disconnected from the equipment. Capacitors in the HG7

HG2 Prote ction Mon itor Cal ibrat ion

Introduction

The HG2 has calibration adjustments, which can be used to calibrate the unit's filter current, line voltage, and line current Operating Parameter displays. The HG2 should not be re-calibrated unless re-calibration is indicated by the troubleshooting procedure or the installation of replacement parts makes re -calibration necessary. The Calibration Mode is the same as t he nor mal run ning mod e exc ept that the HG2 does not trip in response to fault conditions.

HG2 Protection Monitor Calibration Procedure

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 Harmonic filter.

Personnel performing the calibration procedure must be capable of safely working on pow e red equipment. To calibrate the HG2, it is

necessary to operate the drive and HG7 filter while measuring actual operating currents and voltages in sid e the unit.

When in calibrate mode, the filter will not automatically disconnect upon recognizing a fault condition. If a fault occurs during calibration, the technician must be able to rapidly remove power from the filter to minimize damaging components or blowing the filter fuses.

Required Equipment

♦ AC voltmeter and ammeter or multi-meter designed for true RMS measurements in a

harmonic rich circuit and suitable for the rated current and voltage marked on the nameplate of the HG7 filter.

♦ Clamp-on current probe suitable for the rated current and voltage marked on the

nameplate of the HG7 filter.

♦ Clip-on voltage probes suitable for the rated voltage marked on the nameplate of the HG7

filter. Select probes that can be secure ly clipped on to the test points without shorting be tween points or falling off.

Measuring Voltages and Currents

To locate the line current, filter current, and line voltage measurement points, refer to the schematic diagram and outline and mounting dimension drawing for the specific unit that will be calibrated. Some typical drawings are included at the end of this manual.

Warning

The safest procedure is to attach and remove the voltage and current probes

harmonic filter are equipped with bleeder resistors to automatically discharge them to 50 volts or less within 1 minute afte r power is disconnected, but the equipment should be considered to be "live" for at least 5 minutes.

Calibration Potentiometer Locations

The calibration potentiometers are located behind the right edge of the HG2 board as viewed from the keypad side of the HG2. Refer to Figure 5 – HG2 Keypad View. When vie win g the co mpo nent sid e o f the HG2 board, the calibration potentiometers are on the left edge of the board. Refer to Figure 6 – HG2 Board Component View.

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Warning

Line voltage is connected to terminals J2, J3, and J4 at the top edge of the HG2 board.

The board circuitry is also connected to 120 volts.

Calibration Procedure

Perform the Setup Procedure on pa ge 32 and verify that all settings are correct for the application. Set parameter 11A to 1, Calibration Mode. When you exit the Setup Mode, the HG2 will be in the Calibration Mode. The unit may then be ca librated using the following procedure.

1. P ress the UP key to select parameter “C”, Filter Current.

2. The Filter Current calibrations can be performed without the drive operating to avoid the

difficulty of making adjustments with rapidly changing currents.

3. P ress the SELECT key to select “L 1.” With an ammeter current probe on filter line, L1, adjust

potentiometer R43 to match the ammeter reading.

4. Press the SELECT key to sel ect "L 2.” With an ammeter current probe on filter line, L2, adjust

potentiometer R44 to match the ammeter reading.

5. Press the SELECT key to sel ect "L 3.” With an ammeter current probe on filter line, L3, adjust

potentiometer R45 to match the ammeter reading.

6. P ress the UP key to select parameter “U,” Line Voltage.

7. Press the SELECT key to sel ect "L 1.” With a voltmeter connected between L1 and neutral, adjust

potentiometer R68 to match the voltmeter reading. If the neutral is not accessible, then connect between L1 and L2 and calculate the line to neutral voltage.

8. Press the SELECT key to sel ect "L 3.” With a voltmeter connected between L3 and neutral, adjust

potentiometer R94 to match the voltmeter reading. If the neutral is not accessible, then connect between L1 and L3 and calculate the line to neutral voltage.

9. Press the SELECT key to sel ect "L 1.” Recheck the "L 1” setting and readjust if necessary.

Recheck the "L 3” setting, readjust if necessary since there is some interaction between R68 and R94. There is no adjustment for "L 2”.

10. P ress the UP key to select parameter “A,” Line Cu rrent.

11. T he drive should be running while performing the Line Current calibrations. For optimum

accuracy, the actual current as measured with an ammeter, shoul d be more than half the unit's rated current. Due to the low resolution of the A/D converters, the display readings are not intended to be used for certification purposes.

12. Press the SELECT key to sel ect "L 1.” With an ammeter current probe on source line, L1, adjust

potentiometer R52 to match the ammeter reading.

13. Press the SELECT key to sel ect "L 2.” With an ammeter current probe on source line, L2, adjust

potentiometer R53 to match the ammeter reading.

14. Press the SELECT key to select "L 3.” W ith an ammeter current probe on source line, L3, adjust

potentiometer R54 to match the ammeter reading.

15. Remove power to the unit to exit the Calibration Mode.

16. Restart the filter in the normal operating mode, and verify proper operation.

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Troubleshooting Calibration Problems

If, during the Calibration Procedure, a parameter is missing or non-responsive, check for proper analog voltage levels at the points indicated in Figure 7 – HG2 C onne ct ion De tail s – Board Component View. Care must be taken not to short circuit between the board test points. Warning! Line voltage potentia ls ar e

present on the board.

If the analog voltage levels are normal and the board cannot be calibrated, the board is probably defective. Replace the board and perform the Setup and Calibration procedures.

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R68 R94 R43 R44 R45 R52 R53 R54

J1J5

J4 J3 J2

R68 R94 R43 R44 R45 R52 R53 R54

K2 K1

J1 J5

J3 J4

Figure 5 – HG2 Keypad View

Figure 6 – HG2 Board Component View

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Figure 7 – HG2 Connection Details – Board Component View

Replacement Parts

Factory Contacts and Tech Support

For technical support, contact your local TCI distributor or sales representative. You can contact TCI directly at 800-TCI-8282. Select "Customer Service" or "Tech Support" and have

your HG7 harmonic filter namepla te information available.

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KIT PACKAGE OPTION (KP)

Kit Package Option (KP)

“KP” Option Models

The HG7 “KP” 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 variable speed drives. The HG7 “KP” Option is available for 200/208, 230/240, 460/480 volt, 575/600 volt systems (60 Hz) and 380 – 415 volt systems (50 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 drives. SCR or thyristor loads such as DC drives would require a different filte r configuration outside the scope of this product offering. Please contact TCI Technical Support for additional information.

Product Description

HG7 KP Option Harmonic Filter

The HG7 “KP” Option filter components is a package of the primary passive filter components needed to build a harmonic filter and installe d on the inp ut ter minal s of a varia ble sp eed drive o r dr ive syste m. The filter components are tuned to provide a low impedance path for the major harmonic currents demanded by the drive when following the schematic connections used by TCI in the HG7 HarmonicGuard filter.

The HG7 “KP” Option filter component package consists of the following components:

♦ A KDR input series reactor. ♦ A TCI 3-phase tuning reactor specifically designed for the HG7 filter. ♦ KPC panelized, high-endurance, harmonic-rated capacitors. ♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

KIT PACKAGE OPTION HG7 I, O, & M Manual

KIT PACKAGE OPTION (KP)

Product Technical Specifications

Table 9 lists the major technical sp e c ifications and intended environments for the HG7 Harmonic Filter components.

Table 9 – HG7 “KP” Option Ha rmonic Fi lter C omponents Technica l Spec ifica tions

Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz

ratings Maximum elevation for all

components Maximum ambient operating

temperature

Maximum ambient storage temperature

Maximum humi d it y, operating or storage

Agency approvals or certifications on components

Insertion Impedance of the series line reactor

The included series reactors can tolerate 200% of rated current for at

least 3 minutes.

3,000 feet (1,000 meters) as standard. Product must be equipped with

special cooling provisions for o peration above this altitude.

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.

All components are UL component recognized and can be used to

develop a cUL Listed to UL508A system when designed and built by

a qualified UL certified facility. Components can also be developed

for CSA-C2.2 No. 14 when authorized by CSA.

+/- 10% at full load current

Table 10 lists the major technical specifications and intended environments for the KPC Panelized Capacitors. Please see separate KPC IOM Manual (27908) for more detail.

Table 10 – KPC Panelized Capacitors Technical Specifications

Voltage ratings 3-phase; 240, 380-415, 480, 600 Volt kVar ratings 3 to 270 kVar depending on voltage. Agency app rovals UL Listed ; File E -116124 Capacitors Oil filled high endurance design (no PCBs)

KIT PACKAGE OPTION HG7 I, O, & M Manual

Installation

Review all Pre-Installation and Installation instructions at the beginning of thi s manual. If you are assembling a KP unit in your own enclosure, you must provide an enclosure that is adequately

sized and ventilated sufficien tly to prevent overheating. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).

KLR/KDR Lin e React or Ins tallat ion Inst ruction

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

guideline s when wiring the unit: The KLR/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. As a result, A2, B2, and C2 are the output terminals. Units with copper bus or ring lug terminals are not marked. In these cases, either the upper terminals or the lower ter minals can be used as the input terminals, as long as the selection is consistent. For example, if an upper terminal is selected as the input, all up per terminals must be input ter minals. Wiring from the outp ut terminals should connect to the input of the VFD.

KIT PACKAGE OPTION (KP)

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.

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 next 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 o r on the web at www.transcoil.com.

These reactors are designed to be floor-mounted, or wall-mounted. Large open-style devices should be panel mounted b y incor porati ng a bra cket that would a ct as a shelf to sup port 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.

KIT PACKAGE OPTION HG7 I, O, & M Manual

KIT PACKAGE OPTION (KP)

Field Wirin g Infor mation

Below is the typical wiring diagram for the 3-phase reactor applied to the front end of the Variable Frequency D rive (VFD). Si ngle-phase applications are acceptable, however, it is important to size the unit based on the single pha se Full Load Ampe rage o f the VFD. The inp ut and outp ut connections should be on terminals A and C to ensure proper performance.

KIT PACKAGE OPTION HG7 I, O, & M Manual

COMPONENT PACKAGE OPTION (CP)

Component P ackage Option (CP)

“CP” Option Models

The HG7 “CP” 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 variable speed drives. The HG7 “CP” Option is available for 200/208, 230/240, 460/480 volt, 575/600 volt systems (60 Hz) and 380 – 415 volt systems (50 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 drives. SCR or thyristor 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.

Product Description

HG7 CP Option Harmonic Filter

The HG7 “CP” Option filter components is a package of the p r i mary passive filter components needed to build a harmonic filter and installe d on the inp ut ter minal s of a varia ble sp eed drive o r d ri ve s ys te m. The filter components are tuned to provide a low impedance path for the major harmonic currents demanded by the drive when following the schematic connections used by TCI in the HG7 HarmonicGuard filter.

The HG7 “CP” Option filter component package consists of the following components.

♦ A KDR input series reactor. ♦ A TCI 3-phase tuning reactor specifically designed for the HG7 filter. ♦ High-endurance, harmonic-rated capacitors. ♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown, located on

capacitors.

♦ Capacitor mounting brackets that allow for a neat and orderly mounting and connection

of the cylindrical power capacitors.

COMPONENT PACKAGE OPTION HG7 I, O, & M Manual

COMPONENT PACKAGE OPTION (CP)

Product Technical Specifications

Table 11 lists the major technical specifications and intended environments for the HG7 Harmonic Filter components.

Table 11 – HG7 “CP” Option Harmonic Filter Components Technical Speci ficati ons

Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz

ratings Maximum elevation for all

components Maximum ambient operating

temperature

Maximum ambient storage temperature

Maximum humi d it y, operating or storage

Agency approvals or certifications on components

Insertion Impedance of the series line reactor

Capacitors Oil filled high endurance design (no PCBs)

The included series reactors can tolerate 200% of rated current for at

least 3 minutes.

3,000 feet (1,000 meters) as standard. Product must be equipped with

special cooling provisions for o peration above this altitude.

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.

All components are UL component recognized and can be used to

develop a cUL Listed to UL508A system when designed and built by

a qualified UL certified facility. Components can also be developed

for CSA-C2.2 No. 14 when authorized by CSA.

+/- 10% at full load current

COMPONENT PACKAGE OPTION HG7 I, O, & M Manual

Installation

Review all Pre-Installation and Installation instructions at the beginning of this manual. If you are assembling a CP unit in your own enclosure , you must p rovide an enclo sure that is ad equately

sized and ventilated sufficiently to prevent overheating. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).

KLR/KDR Lin e React or Ins tallat ion Inst ruction

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

guideline s when wiring the unit: The KLR/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. As a result, A2, B2, and C2 are the output terminals. Units with copper bus or ring lug t er mina ls a re not mar ked. In these cases, either the upper terminals or the lower ter minals can be used as the input terminals, as long as the selection is consistent. For example, if an upper terminal is selected as the input, all up per terminals must be input ter minals. Wiring from t he output te rminals sho uld connect to the input of the VFD.

COMPONENT PACKAGE OPTION (CP)

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.

These reactors are designed to be floor-mounted, or wall-mounted. Large open-style devices should be panel mounted b y incor porati ng 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 convectio n. Reactors with ducts should be mounted vertically for proper cooling.

COMPONENT PACKAGE OPTION HG7 I, O, & M Manual

COMPONENT PACKAGE OPTION (CP)

Field Wiring In format ion

Below is the typical wiring diagram for the 3-phase reactor applied to the front end of the Variable Frequency D rive (VFD). Si ngle-phase applications are acceptable, however, it is important to size the unit based on the single pha se Full Load Amperage of the VFD. The input and output connections should be on terminals A and C to ensure proper performance.

COMPONENT PACKAGE OPTION HG7 I, O, & M Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

Phone: 800-824-8282 Fax: 414-357-4484

Web Site: http://www.transcoil.com

Printed in USA

TCI HG7 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Installation, Operation, and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

T able of Contents

INTRODUCTION

Safety Instruc tions Over vie w

Warnings and Cautions

Warnings

Cautions

General S afety Ins truct ions

Receiving Inspection and St orage

Receiving Inspection

TCI Limited Warranty Policy

Storage Instructions

Pre-installation Planning

Verify th e A pplicat ion

HG7 Ratings

Select a Suitable Locat ion

Environment

Working Space

Mounting an Open Panel Unit

Power Wiring

Installa tion Guidelines

Mounting

Wiring

Cable Entry Locations

Field Wiring Connection Terminals

Grounding

Power Wiring

HG7 Harmonic Filter Operation

Before Applying Power for the Fir st Time

Operation

Installation

Intended Audience

Additional Information

Installation Checklist

Maintenance a nd Service

HG7 Harmonic Filter Reliability and Service Life

Periodic Maintenance

Troubleshooting

Reference Drawings

Fuse Specifications

Table 1a – Fuse S peci fications for HG7 240 Volt Models

Table 1b – Fuse Specifications for HG7 380 – 415 Volt Models

Table 1c – Fuse Spec ifications fo r HG7 48 0 Volt Mode ls

Table 1d – Fuse S pecific ations for HG7 600 V olt Models

Replacement Parts

Factory Contacts and Tech Suppor t

Product Description

HG7 Drive-A pp lied Ha rmon ic F ilter

Nameplate Data

Figure 1 – Typical HG7 Harmonic Filter Nameplate

Part Number Encoding

Figure 2 – HG7 Part Number Encoding

Product Technical Specifications

Table 2 – HG7 ST and STC Opti on Harmo nic Filte r Tec hnical S peci fications

Drawings

Typical Schematic Diagrams and Outline and Mounting Dimension Drawings

Schematic Diagrams

Outline and Mounting Dimension Drawings

Additional Typical Drawings

Standard Filter (ST)

HG7 Standard Harmonic Filter

Contactor Option (STC)

STC Option Models

HG7 STC Option Harmonic Filter

Po wer Monitor Pac kage Option (XM)

HG7 “XM” Option Harmonic Filter

Product Technical Specifications

Table 3 – HG7 “XM” Opti on Ha rmonic Fi lter Tech nical Spe cifica tions

Control Wiring

Control Power

Filter Enable Input

Fault Alarm Relay

Control Wiring

HG7 “XM” Option Op erat ion

Adjustments