TCI HGA User Manual

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Active 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

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

T able of Contents

■ Section 1

HGA Quick Start Unit Software Setup.......................................................... 6

■ Section 2

Safety Instructions ...................................................................................... 11

Overview ............................................................................................................................................... 11

Warnings and Caution s ....................................................................................................................... 11

General Safety Instructions ................................................................................................................ 12

General Terminology ................................................................................... 13

■ Section 3

Introduction .................................................................................................. 14

Intended Audience ............................................................................................................................... 14

Additional Information ....................................................................................................................... 14

Installation Checklist ........................................................................................................................... 14

Receiving Inspection and Storage ............................................................. 15

Receiving Inspection ............................................................................................................................ 15

TCI Limited Warranty Policy ............................................................................................................ 15

Storage Instructions ............................................................................................................................. 15

Product Description .................................................................................... 16

Nameplate Data .................................................................................................................................... 18

Part Number Encoding ....................................................................................................................... 19

■ Section 4

Pre-installation Planning ............................................................................. 26

Verify the Application ......................................................................................................................... 26

Select a Suitable Location ................................................................................................................... 26

Mounting an Open Chassis Unit ......................................................................................................... 26

Cooling Diagrams ................................................................................................................................ 26

Installation Guidelines ................................................................................ 29

Mounting .............................................................................................................................................. 29

Wiring ................................................................................................................................................... 29

Current Transformer Installation ...................................................................................................... 31

HGA Filter Operation ......................................................................................................................... 45

Adjustments ......................................................................................................................................... 45

Start Up (Commissioning) ................................................................................................................... 45

General Operation ............................................................................................................................... 45

■ Section 5

Maintenance and Service ............................................................................ 46

HGA Reliability and Serv ic e Lif e ....................................................................................................... 46

Periodic Maintenance .......................................................................................................................... 46

Troubleshooting ................................................................................................................................... 51

■ Section 6

HMI Introduction .......................................................................................... 67

Overview ............................................................................................................................................... 67

Additional Information ....................................................................................................................... 68

Receiving Inspection ............................................................................................................................ 68

Installation Guidelines ................................................................................ 69

Checklist ............................................................................................................................................... 69

Location ................................................................................................................................................ 69

Mounting .............................................................................................................................................. 69

Wiring ................................................................................................................................................... 70

■ Section 7

Operation ...................................................................................................... 74

HMI Screen Elements .......................................................................................................................... 75

Initialization ......................................................................................................................................... 76

HMI Screens ......................................................................................................................................... 76

Network Interface ................................................................................................................................ 94

■ Section 8

Maintenance ................................................................................................. 96

Clock Battery Replacement ................................................................................................................ 97

Software Field Upgrades ..................................................................................................................... 97

Troubleshooting .......................................................................................... 97

HGA Filter Fault .................................................................................................................................. 98

Interface Module Problem .................................................................................................................. 98

Troubleshooting Notes ......................................................................................................................... 99

Troubleshooting Flow Chart ............................................................................................................... 99

■ Section 9

Appendix – Installation Diagram ................................................................ 99

Appendix – Part Numbering ..................................................................... 101

Appendix – Ethernet/IP Gateway Option ................................................. 101

Introduction ....................................................................................................................................... 101

Wiring ................................................................................................................................................. 101

Configuration ..................................................................................................................................... 102

Register Map ...................................................................................................................................... 103

Operation ............................................................................................................................................ 103

■ Section 1

HGA Quick Start Unit Software Setup

Warning

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

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the HarmonicGuard Active (HGA) filter.

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

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

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

The HGA filter may receive power from two or more sources. Three-phase power is connected to the main input terminals of the HGA filter. All of these sources of power must be disconnected before working on the HGA filter.

After switching off the power, always allow 5 minutes for the capacitors in the HGA filter and in the drive to di s charge before working on the HGA filter, the drive, the motor, or the connecting wiring. It is good practice 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.

Select language setting from the language setup

1) Verify unit external connections

• Phase A, B, C power connection,

with positive A-B-C phase rotation expected

• CT H1 Terminal is pointing toward the source

• CT feedback on phases A & C to TB-1

• Leave CT shorting bars in place o n TB-1

• With the HGA circuit breaker open,

energize the source to the HGA

• Close the HGA circuit breaker

• Fans and HMI should come on in < 5 seconds

• HMI will start on Home screen

• Load(s) have an integral 5% line reactance or

equivalent dc bus choke

Warning

Hazardous voltages are present when unit is ener gi zed

NOTE: Language Selection

• The active filter supports several languages

including English, French and S panish

• Press “Setup” to navigate to Setup screen and

press the “Language Setup” button.

•

pop-up screen.

2) Converter check - 1

• Press “Setup” to navigate to Setup screen

• Ensure that “Auto Start En,” “Harmonic

Correct En,” and “PWR Fact Correct En” buttons are off (blue color)

• If they are ON (green) press them to toggle to OFF

(blue)

• Press “Save Settings”

• Press “Status” to navigate to Status screen

• Press “Home” to navigate to Home screen

NOTE: Built In Sensor Wiring Error De tection

• The active filter has an automatic sensor wiring

error detection algorithm built in to the controls.

• If a sensor wiring error is detected please reference

the Sensor Error Auto Detection sectio n on page

93.

Warning

3) Home screen check

• Compare “Freq” to expected line frequency

• Compare “Supply Voltage” to expected

line voltage

• “Current” expected to be zero because unit is not

running and CT inputs ar e shorted

• If status indicates a Fault, press “Stop” button to

reset condition

4) Status screen check

• Press “Status” to navigate to Status screen

• Compare “Volts” to expected line voltage

• Compare “Freq” to expected line frequency

• “Current” expected to be zero if unit is not running

and CT inputs are shorted

5) Phase rotation check

• Press “Phase to Neutral Voltage Plot”

• Check that the current p eaks follow the follo wing

sequence from left to right: Phase A (green), Phase B (blue), Phase C (red)

• Equipment is phase rotation sensit ive, if phase

rotation is incorrect, power down unit and rewire to adjust pha s e rotation by swapping two inco ming phase connections

Improper operation will occur when input voltage phase rotation is incorrec t.

6) Converter check - 2

• Press “Setup” to navigate to Setup screen

• Ensure that “Auto Start En,” “Harmonic

Correct En,” and “PWR Fact Correct En” buttons are off (blue color)

• Press “Status” to navigate to Status screen

• Press “Run” to start unit operation

from CTs connected to TB-1

Warning

7) Remove CT shorting bars

• Press “Stop” to turn off unit

• Disconnect power from cabinet

o Turn off the built in door breaker A ND o Turn off the upstream feeder breaker

Lethal voltages may be present. Wait 5 minutes for DC bus voltage to drop to safe levels.

Warning

Check for vol t age in cabinet with a DMM before working inside cabinet.

• Open the cabinet door and remove shorting bars

8) Current polarity - 1

• Power up unit

• From Home screen press “Run” to turn on unit

• Press “Status” to navigate to Status screen

• Select “Vline/Iline” screen

• Note: Lightly loaded conditions (less than 20% CT

rating) wil l not have enough current to show up on Iline plot

• Check that Phase A to Neutral voltage peak lines

up with Phas e A current (use zoom if necessary)

• Check that Phase C to Neutral voltage peak lines

up with Phas e C current

• Power system down and check CT inst allation

location and orientation if Phase A plots differ significantly from Phase C plots

Warning

Improper operation and damage may occur if CTs are installed incor r e c tly.

9) Current Polarity – 2

• Navigate to Status screen

• Navigate to Line/Load status

• Verify that “Volts,” “Current,” “Power,” “I THD,"

and “V THD” match expected values for the power system

• If they do not, verify CTs are corr e c tly insta lle d

Warning

Improper operation and damage may occur if CTs are installed incor r e c tly.

Warning

• Let the unit come on automatically (about 30 s)

10) Final setup

• Press “Setup” to navigate to Setup screen

• Press “Harmonic Correct En” to enable

harmonic correction

• If unit is sized with sufficient cap a c ity to provide

power factor correction, press “PF Correct En”

• Press “Auto Start En” to enable Autostart

When Auto Start is enable d unit may operate without operator input.

• Press “Save Settings” to save settings

and restart converter

11) Final check

• Navigate to Status screen

• Navigate to Line/Load status

• Note the corrected voltage, current, power

and THD

■ Section 2

Safety Instructions

Overview

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

The HGA filter is intended to be connected to the bus or power cables where one or more loads are connected. Three-phase power is connected to the input terminals of the unit and corrective current is supplied to the system through the HGA filter in respo nse to the i nput signal being received from the CTs connect ed to the moni tored bus. T he instructio ns, and pa rticularly t he safety ins tructions, fo r 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 wit h war ni n g stat e men t s mar ked wit h the fo ll o wi ng s ymb o ls:

Warning

Dangerous Voltage Wa rning: warns of situations in whic h a high voltage can cause physical injury and/or damage equipment. The text ne xt to this symbol describes ways to avoid the danger.

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

Many electronic components located within the filter are sensitive to static electricity. Voltages imperceptible to human touch can reduce the life, and affect performance, or completely destroy sensitive electronic devices. Use proper electrostatic discharge (ESD) procedur es when servic ing the filter and its circuit boards.

Warning

Cautions

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

Caution

Warning

General Caution: Identifies situations that can lead to a malfunction and possible equipment damage. The text describes ways to avo id the situation.

General S afety Ins truct ions

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

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

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

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

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

Warning

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

General T erminology

Throughou t this manual, many d ifferent terms are used. A list of so me typical terms ca n be found below. These are provided in order to assist with the overall understanding of the manual. Please feel free to contact TCI directly if there are any questions regarding any portion of this manual.

HarmonicGuard Active Filter - TCI’s brand name for a real ti me filter that mitigates harmonic s while also maintaining near unity power factor. An Active Har monic Filter is any piece of equipment that actively moni to rs and chan ges the incoming AC line current.

HGA – The term commonly used in place of the entire brand name of HarmonicGuard Active filter. Active Harmonic Filter - An active harmonic filter is a piece of equipment that reads the incoming

voltage and curre nt and i nje cts curr ent wavefor ms tha t canc el di storti on. T his ter m is co mmonl y used in place of the entire brand name of HarmonicGuard Active filter.

Bus-Applied Filter – A shunt device connected in parallel to the load. This is an active filter designed to mitigate the harmonics associa ted with multiple load s. The filter is dir ectly co nnected to a main bus as can be found in a typical Motor Control Center. The filter is sized for the amount of corrective current needed to be injected to cancel the offending harmonics. A Digital Signal Processor (DSP) pulse width modulated controller is used for switching Insulated Gate Bip olar Transistor (IGBT) in order to cancel the harmonic s .

Power Converter - The power converter is the digital filter module of the HarmonicGuard Active filter. Non-Linear Load Input Line Inductor – The three phase line reactor connected at the input of an

adjustable frequency drive or other non-linear load. Converter Inductor – The three phase inductor maintains a unifor m air gap to give high ly consistent

and predictable inductance. These inductors are connected to the inverter which buffers the inverter output from the analog portion o f the filter , the source, and connected drives.

Current Transfor mer (CT) – The device that monitors t he incoming AC curre nt waveform typicall y sized to handle the total connected load.

■ Section 3

Introduction

Thank you fo r selecting TCI’s HarmonicGuard Active filter. TCI has produced this filter for use in variable speed drive and non-linear load applications that require input power line harmonic current reduction and power factor correction. This manual describes how to install, operate, and maintain the HarmonicGuard Active filter.

Intended Audience

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

Additiona l Infor mation

Caution

This manual pro vid es gene ra l i nfo r mati o n desc ri b i ng yo ur H GA filter. Be sure to carefully review the more specific information that is provided by the drawings shipped with the unit. Information provided by the drawings takes precedence over the information provided in this manual.

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

Installation Checklist

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

Make sure that the installation location will not be exposed to direct sunlight, excessive vibration, corrosive or combus tible airborne contaminants, excessive d ir t, or liquids.

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

Make sure that all wiring conforms to the requirements of the National Electric Code (NEC) and/or other applicable electrical codes.

Connect the HGA filter equipment-grounding lug to the system ground of t he premises wiring system. Use a properly sized grounding conductor.

Connect three-phase power to the input terminals o f the HGA filter, L1, L2, & L3.

Ensure that the CTs are properly installed and connected to the proper terminals inside the HGA filter (see CT Installation section of IOM Manual).

Check ever ything thor oughly before appl yi ng power to t he equipment.

Check the panel and the inside of the enclosure for any foreign objects, dirt, or loose hardware.

Receivi ng Inspection and Storage

Receiving Inspection

The HarmonicGuard Active filter ha s been thoro ughly i nspecte d and fu nctiona lly te sted at the fac tory 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 after one (1) year of useful service, not to exceed eighteen (18) months from the date of shipment.

The foregoing limited warranty is TCI’s sole warranty with respect to its products and TCI makes no other warranty, representation or promise as to the quality or performance of TCI’s products. THIS EXPRESS LIMITED WARRANTY IS GIVEN IN LIEU OF AND EXCLUDES ANY AND ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

This warranty shall not apply if the product wa s : a) Altered or repaired by anyone other than TCI; b) Applied or used for situations other than those originally specified; or c) Subjected to negligence, accident, or damage by circumstances beyond TCI’s control,

including but not limited to, imprope r storage, installation, operation or maintenance.

If, within the warranty period, any product shall be found in TCI’s reasonable judgment to be defective, TCI’s liability and the Buyer’s exclusive remedy under this warranty is expressly limited, at TCI’s option, to (i) repair or replacement of that product, or (ii) return of the product and refund of the purchase price. Such remedy shall be Buyer’s sole and exclusive remedy. TCI SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL DAMAGES OR FOR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF INCOME, LOSS OF TIME, LOST SALES, INJURY TO PERSONAL PROPERTY, LIABILITY BUYER INCURS WIT H RESPECT TO ANY OTHER PERSON, LOSS OF USE OF THE PRODUCT OR FOR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS.

The foregoing warranties do not cover reimbursement for removal, transportation, reinstallation, or any other expenses that may be incurred in connection with the repair or replacement of the TCI product.

The employees and sales agents of TCI are not authorized to make additional warranties about TCI’s products. TCI’s employees and sales agents oral statements do not c onstitute 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 fo rth herein.

TCI will not accept the return of any prod uct without its prior written approval. Please co nsult TCI Customer Service for instructions on the Return Authorization Procedure.

Storage Instructions

If the HarmonicGuar d Active filter is to be stored before use , be sure that it is stored in a location that conforms to published s torage h umidity a nd temperat ure sp ecificatio ns stated in this manual. Sto re the unit in its original pac kaging.

Long-Term Storage

In the case of long-term storage, defined as any period greater than eighteen (18) months, TCI Technical Support must be contacted prior to applying power.

Product Descript ion

HarmonicGuard Active filter

The HarmonicGuard Active filter is an active harmonic filter designed and developed by TCI to relieve the power distribution system o f the issues associated with harmonic currents that flow within the power distribution network caused by non-linear loads. The typical configuration can be found in Figure 3.1.

The topology of the bus-applied (three phase, three wire) HGA consists of major components or modules:

Component 1 is mad e up of two current transformers (CTs) installed on phases A and C of the AC bus that is to be acted upon by the filter. The purpose of the CTs are to supply information to the HGA regarding t he integrity of the composite AC bus c urrent with rega rd to the distor tion (non-sinusoidal waveform) and displacement power factor relative to the AC bus voltage. These signals will result in the HGA inje cting currents th at will return the AC line current to near sinusoidal s hape and at unit y power factor. Note that the CTs are located outside the HGA enclosure.

Component 2 is the HGA input circuit breaker (optional) . This is provided to protect the HGA for destructi ve ove r cur rent c ond itio ns if a malfu nctio n oc curs withi n the HGA circ uitry. It also p rovides a convenient disconnect means and field wiring point for the installer of the filter equipment.

Components 3 and 4 are the high freq uency co nverter i nductors . These i nductors provid e the prop er inductance to the power converter.

Component 5 is the power electronic converter module. The Power converter module (PCM) is the heart of the HarmonicGuard Active filter and is what differentiates the HGA from other types of harmonic mitigation. The PCM provides several highly complex electronic functions controlled by the on board DSP controller. The PCM continuously senses the AC bus line voltage and currents, processes the information at “nearly real time” by means of the instructions resident within the DSP program code, properly controls the six IGBT’s to operate in a safe manner that injects current into the AC bus grid that ensures the AC bus current is sinusoidal and near unity power factor. Power converter contains a pre-charge circuit which consists of two SCRS and two pre-charging resistances which control the inrush current.

Filter Configuration

Figure 3.1 – Typi cal Configur ation of the HarmonicGuard Active filter

*This drawing is for gene ral reference only. Us e the drawings supplied with the unit for inst allation.

Nameplate Data

Figure 3.2 shows a typical HarmonicGuard Active filter nameplate. The following information is marked on the nameplate:

Part number : encoding is explaine d on the following page Corrective Current: The maximum amount of RMS Corrective Current the unit can deliver. System Voltage: the rated 3-phase line voltage (RMS volts) Hz: the rated frequency (60 Hz) Phase: 3, 3 Wire – The HGA is designed for use with only 3 wire systems with balanced 3-

phase voltage sour ce. Drawing #: outline and mounting dimension drawing number Schematic #: schematic diagra m drawing number Serial #: fo r unit tracking purposes Enclosure Type: Open, UL Type 1, UL Type 3R

Figure 3.2 – Typical HarmonicGuar d Ac tive filter Nameplate

ALC 100 A 01

H 00

ALC

Prefix

Current Rating

Voltage Rating

A= 480

Filter Enclosure

00 = Open Chassis

01 = UL Type 1

Package Option

Circuit Breaker

H = Interface Module

10=ABB 22kA

0=ABB 100kA 30=A-B 25kA 40=A-B 65kA 60=Eaton 65kA 7

0=Eaton 100kA 80=Square D 18kA 90=Square D 65kA 00=No breaker 01=ABB 65kA

Reserved for custom options to be defined as needed, each position can use 0 thru 9. Default option is 00.

50, 100, 200

Part Number Encoding

Figure 3.3 identifies the significance of each character in the HarmonicGuard Active filter part number. An example of a completed part number would be ALC100A01H2000. This designates an enclosed HarmonicGuard Active filter that i s rated for 100 amps, 480 volts, and has an HMI Interface Module Package.

HGA Part Numbering System – 480V Open and T ype 1

Temperature: 40° C Current: 50, 100, 200 Voltage: 480 Enclosure: Open Chass is or UL Type 1

Figure 3.3 – Harmoni cGuard A ctive filte r par t number encoding

Figure 3.4 identifies the significance of each character in the HarmonicGuard Active filter part number. An example of a completed part number would be H5100A03H4000. This designates an enclosed HarmonicGuard Active filter that is rated for 100 amps, 480 volts, and has an HMI Interface Module Package.

HGA Part Numbering System – 480V 3R

Temperature: 40° C Current: 50, 100, 200, 300 Voltage: 480 Enclosure: UL Type 3R

Figure 3.4 – Harmoni cGuard A ctive filte r Part number Encoding

Figure 3.5 identifies the significance of each character in the HarmonicGuard Active filter part number. An example of a completed part number would be H5300A00H1000. This designates an enclosed HarmonicGuard Active filter that i s rated for 300 amps, 480 volts, and has an HMI Interface Module Package.

HGA Part Numbering System – 480V 300A

Temperature: 40° C Current: 300 Voltage: 480 Enclosure: U L Type 1 or UL Type 3R

Figure 3.5 – Harmoni cGuard A ctive filte r Part number Encoding

Figure 3.6 identifies the significance of each character in the HarmonicGuard Active filter part number. An example of a completed part number would be H5039C033H0100. This desig nates an enclosed Har monicGuard Active filter that is rated for 39 amps, 600 volts, and has an H MI Interface Module Package.

HGA Part Numbering System – 600V

Temperature: 40° C Current: 39, 78 Voltage: 600 Enclosure: Open Chassis, UL Type 1 or UL Type 3R

Figure 3.6 – Harmoni cGua rd Active Part number Encoding

Figure 3.7 identifies the significance of each character in the HarmonicGuard Active filter part number. An example of a completed part number would be ALC45A01H10. This designates an enclosed HarmonicGuard Active filter that is rated for 45 amps, 480 volts, and has an HMI Interface Module Package.

HGA Part Numbering System – 480V Open & Type 1 (50° C)

Temperature: 50° C Current: 45, 90 Voltage: 480 Enclosure: Open Chass is or UL Type 1

Figure 3.7 – Harmoni cGuard A ctive filte r Part number Encoding

Communications

39, 45, 50, 78, 90, 100,

200, 300

Voltage rating of 480V

Voltage rating of 600V

Modbus RTU over RS485

Ethernet/IP

Dimensions Inch (cm)

2676

167 (75.8)

56 (142.2)

17 (43.2)

14.18 (36.6)

45 & 50

2676

167 (75.8)

56 (142.2)

17 (43.2)

14.18 (36.6)

3500

167 (75.8)

56 (142.2)

17 (43.2)

14.18 (36.6)

90 & 100

3500

167 (75.8)

56 (142.2)

17 (43.2)

14.18 (36.6)

200

7000

340 (154.22)

57.97 (147.25)

32 (81.28)

14.18 (36.6)

Dimensions Inch (cm)

2676

254 (115.2)

60.15 (152.8)

17.57 (44.5)

*16.4 (41.7)

2676

254 (115.2)

60.15 (152.8)

17.57 (44.5)

*16.4 (41.7)

3500

254 (115.2)

60.15 (152.8)

17.57 (44.5)

*16.4 (41.7)

100

3500

254 (115.2)

60.15 (152.8)

17.57 (44.5)

*16.4 (41.7)

200

7000

480 (217.72)

64.17 (163)

32.62 (82.86)

*17.2 (43.7)

300

10500

1042.4 (472.9)

84.20 (213.9)

63.3 (160.8)

*23.9 (60.7)

*Add Two Inches for Disconnect/Circuit Breaker Handle,

Communications Part Numbering

Table 3.1 bel ow shows the HGA part numbering with the communications part numbers. The base

communications unit is CM100A00 which has both the HMI and Modbus.

Table 3.1 – Communcation Part Numbering

Options Descriptions

Amp rating

A, C

00, 01

Standard Product Ratings and Dimension Tables

The following tables list the ratings and dimensions of the standard HarmonicGuard Active filter models. See drawing at the end of this manual.

• Table 3.2 – Open Chassis

• Table 3.3 – UL Type 1 Enclosed

• Table 3.4 – UL Type 3R Enclosed

• Table 3.5 – 600V Open and Type 3R

Table 3.2 – Open Chassis

Amps

Heat Loss

(watts)

Weight lbs.

(kg)

H x W x D

Table 3.3 – UL Type 1 Enclosed

Amps

Heat Loss

(watts)

Weight lbs.

(kg)

H x W x D

Dimensions Inch (cm)

Consult Factory

3176

371 (168.3)

80.00 (203.2)

32.00 (81.3)

25.00 (63.5)

Consult Factory

100

3500

371 (168.3)

80.00 (203.2)

32.00 (81.3)

25.00 (63.5)

200

7000

1040 (472)

80.00 (203.2)

57.00 (144.78)

25.00 (63.5)

300

Consult Factory

Heat Loss

(watts)

Weight

lbs. (kg)

Dimensions Inch (cm)

H x W x D

Open

345

180 (81.7)

16.00 (40.7)

19.50 (49.6)

12.20 (31)

Open

740

180 (81.7)

16.00 (40.7)

19.50 (49.6)

12.20 (31)

345

270 (122.5)

24.90 (63.3)

24.40 (62)

20.80 (52.9)

740

270 (122.5)

24.90 (63.3)

24.40 (62)

20.80 (52.9)

Table 3.4 – UL Type 3R Enclosed

Amps

HeatLoss

(watts)

Weight lbs.

(kg)

H x W x D

Table 3.5 – Transformer for 600V units – Open and Type 3 R

Amps Encl.

Table 3.6 – HarmonicGuard Ac tive filter Technical Specifications

Voltage ratings 480V, 3 phase, 60 Hz, three wire systems

Phase Sequence Positive phase rotation: A-B-C (or L1-L2-L3)

Load types

Current ratings See Ratings in Standard Product Rating and Dimensi ons tables.

Maximum elevation

Maximum Amb ient

operating temperature

Minimum Amb ie n t

operating temperature

Ambient storage temperature

Maximum humi d it y,

operating or storage

Enclosure options

Agency approvals or

certifications

3-phase diode bridge rectifier loads such as PWM AC drives *3-phase controlled rectifier (SCR or thyristor) loads such as DC drives

1,000 meters (3,280 feet) For every 100 meters (328 feet) over 1,000, de-rate by 1%. Maximum elevation is 2,000 meters (6,560 feet).

All units 40°C (104°F) except 45 & 90 amp open chassis units rated for 50°C (122°F) surrounding air. Product must be equipped with special cooling provisions for operation above this temperature.

0°C (32°F) for open chassis and Type 1 enclosures.

-20°C (-4°F) for Type 3R enclosures. Product must be equipped with special heating provisions for operation

below this temperature.

-20°C to 60°C for Open Chassis and UL Type 1

-40°C to 60°Cfor UL Type 3R 95%, non-condensing Standard: Open Chassis and UL Type 1 enclosed, UL Type 3R enclosed

Contact TCI Technical Support for other enclosure options.

UL and cUL Listed

Electronic overload / over

current protection

Over current protection:

Status indication LEDs Numerous LED indicators on converter unit

P *Please consult TCI regarding optimum filter performance when applied to DC drives.

Factory calibrated processor controlled electronic over current fault, and over load.

All units have internal circuit bre a ker for protection of the converter section of the HGA. The customer must supply branch circuit protection.

■ Section 4

Pre-installation Planning

Verify th e A pplicat ion

HGA Ratings

Make sure that the HarmonicGuard Active filter is correct for the application and sized for load. The voltage ratings of the HGA m us t match the input voltage rating of t he connected AC bus.

Select a Suitable Location

Environment

Locating the HarmonicGuard Active filter in a suitable environment will help assure proper performance and a normal op erating life. Re fer to t he enviro nmental spec ifications listed in Table 3.6, marked on the unit's nameplate and/or noted on the drawings furnished with the unit.

Warning

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

UL Type 1 and open chassis units must be installed in an area where it will not be exposed:

• Direct sunlight

• Rain or dripping liquids

• Corrosive liquids or gasses

• Explosive or combustible gases or dust

• Excessive airborne dirt and dust (Pollution Degree 2, according to EN50178 and UL508)

• Excessive vibration [0.152 mm (0.006 in.) displacement, 1G peak]

Please note that custom enclosure options may vary available installation areas.

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 uno bstructed space to allow cooling air to flow through the unit.

Mounting an Open Chassis Unit

If you are mount in g an o pe n c has sis unit in your o wn enc los ure , yo u mu st p rovi de a n e ncl osur e tha t i s adequately sized and ventilated sufficiently to p revent o verheati ng. Re fer to Table 3.2 for dimensions and heat loss that is dissipated b y the HGA. The maximum ambient temperature should not exceed 40° C (104° F). The 45 and 90 amp open chassis units have an ambient surrounding air temperature of 50ºC (122ºF).

Cooling Diagrams

Please see Figures 4.1 and 4.2 for cooling diagrams of the HGA.

Figure 4.1 – Cooling Diagram for 39, 45, 78, 90 and 100 amp uni ts

Figure 4.2 – Co oling Dia gram for 200 amp units

Ground Lug

Power Terminals

(Nm)

39 & 78 Amp

14 AWG - 2/0

120 (13.6)

22 kA

14 - 1/0 AWG

70 (7.9)

39 & 78 Amp

14 AWG - 2/0

120 (13.6)

65 kA

4 AWG – 350 MCM

250 (28.2)

70 (7.9)

274 (31)

25 to

100 kA

Two 3/0 AWG – 250

MCM

274 (31)

45, 50, 100, 200

Amp

Installa tion Guidelines

Mounting

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

Wiring

Cable Entry Locations

The enclosed HarmonicGuard Active filters are not provided with enclosure wiring knockouts, however, a removable wire entry plate is provided. A selection can be made at the time of installation. Typical or recommended cable entry locations are shown in the drawings shipped with the unit.

Caution

Refer to circuit breaker section on page 50.

Field Wiring Connection Terminals

Compression type terminals are provided for all field wiring connections. The wire size (75° C copper) capacity ranges and tightening torque for the grounding and power terminals are listed in Table 4.1a and 4.1b. Refer also to the drawings and other information shipped with the unit. A disconnecting means is the responsibility of the customer.

Table 4.1a – Exa mple Power Termi nal Wire Size Ca pacity Ra nge and Tightenin g Torque for ABB Circuit Breakers

Filter Size

45 & 50 Amp 14 AWG - 2/0 120 (13.6) 22 kA 14 - 1/0 AWG 70 (7.9) 39 & 78 Amp 14 AWG - 2/0 120 (13.6) 25 kA 2 - 4/0 AWG 250 (28.2)

100 Amp 14 AWG - 2/0 120 (13.6) 25 kA 4 AWG – 300 MCM 200 (22.6)

Wire Size

Torque In-lbs

Breaker

Wire Size

Torque In-lbs

45 & 50 Amp 14 AWG - 2/0 120 (13.6) 65 kA 14 - 1/0 AWG

100 Amp 14 AWG – 2/0 120 (13.6) 65 kA 6 AWG – 350 MCM

39 to 100 Amp 14 AWG – 2/0 120 (13.6) 100 kA 6 AWG – 350 MCM

200 Amp Two 6 AWG – 250 MCM 275 (31.1) 300 Amp Consult Factory

39 & 78 Amp Control Terminals Wire Size 30 to 12 AW G Torque 4.4 in-lb. (.5 Nm)

Note: The values in this table are representative of ABB switch gear. For other manufacturer’s switch gear please contact TCI.

Control Terminals Wire Size 28 to 14 AWG Torque 4.4 in-lb. (.5 Nm)

Ground Lug

Power Terminals

Wire Size

Torque In-lbs (Nm)

Breaker IC

Wire Size

Torque In-lbs (Nm)

39 to 100 Amp

14 AWG – 2/0

120 (13.6)

25 to 100 kA

14 – 2/0 AWG

180 (20.3)

25 to 100 kA

None

Control Terminals Wire Size 28 to 14 AWG Torque 4.4 in-lb (0.5 Nm)

Table 4.1b – Power Termi nal Wire Size (wi thout brea ker) Ca pacity Range and Tightenin g Torque

Chassis Size

150 to 200 Amp 14 AWG – 2/0 120 (13.6) 150 to 200 Amp 14 AWG – 2/0 120 (13.6)

Caution

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

Use wire with an insulation temper ature rati ng of 75°C or higher.

Connection Diagram

Figure 4.3 sho ws the typical wiring connections between the models of the HGA and the load. Refer to the drawings furnished with the unit for more specific information.

• The input 3-p hase AC voltage source must be connected in a positive ABC phase rotation

from L1-L2-L3 for correct unit operation.

6 AWG – 350 MCM 274 (31) 6 AWG – 350 MCM 274 (31)

Figure 4.3 – Typical Load Connection Di agram

Notes:

1.) Wiring should be 75°C or higher insulated copper, with the appropriate voltage and current rating.

2.) Chassis ground must be connected to the ground of the premises wiring system, in accordance

with NEC and local codes. Connection must be made using a wire conductor.

3.) Terminal TB-I & J25 wire range is 30-12 AWG, tightening torque is 4.4 IN-LB (0.5 NM).

4.) Operating current transformers with the secondary winding open can result in a high voltage

across the secondary terminals which may be dangerous to personnel or equipment.

250:5

3000:5

250:5

3000:5

250:5

3000:5

100

250:5

3000:5

200

750:5

3000:5

300

750:5

5000:5

Current Transformer Installation

For accurate sensing of the load it is important that the load sensing current transformers are properly installed.

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the HGA. Failure to follow standard safety procedures may result in death or serious inj ury.

Disconnect all sources of power to the drive and HGA before working on the equipment. Do not attempt any work on a powered HGA. Also, check for zero voltage between all phases of the input and output lines.

Operating current transformers with the secondary winding open can r esult in a high volta ge across the secondary terminals which may be dangerous to personnel or equipment.

It is necessary for the HGA to moni tor the cur rent in P ha se “ A” ( L1) a nd P hase “C” ( L3). Stand-alone HGA filters are designed for Line Side current transformer (CT) placement as shown in Figure 4.4a. It is important that both CTs are on the same side of the HGA. The CTs sho uld be cente red around the conductor. Optional Load Side CT placement is available for sin gle units as shown in Figure 4.4a.

The polarity of the CT is important; the “H1” marking on the CT must face the source. The secondary windings o f the CT around conductor L1 should connect to TB-1 terminals 1 & 2 and the CT around conductor L3 should connect to TB-1 terminals 3 & 4. The secondary wire of the CT identified as “X1” must connect to the “X1” terminal of TB-1 for both CTs. Failure to maintain the correct polarity and phasing wi l l cause an over-current fa ult . If this shoul d happen refer to the troubleshoo ting section.

The exact CT placement is dependent on the HGA’s configuration and size. Please refer to Figures

4.4a through 4.4i for the installation that applies. Note: Units with black “TB-1” terminal blocks are shipped with two position shorting jumpers

installed between positions 1 & 2 and 3 & 4. This is done for your safety and to prevent equipment damage. The jumpers are installed in the center of the block and can be identi fied by the gray to p. After the load CTs are installed and wired, these jumpers must be removed for correct unit operation. They can be removed with a standard flat blade screw driver (See Figure 5.3).

Note: CT operation can be verified via the HMI touchscreen feedback waveform plot screens. Reference the HMI VLine & ILine Waveform Plot Sub Screen in Section 6 for details.

Table 4.2 – CT Range by Model Size

Amps CT Min Ratio

CT Max

Ratio

Notes

Factory technician start up required to

use CTs outside of the published range

Current Transformer Diagrams

The following pages contain de ta ile d diagrams on the placement of CTs in relation to the HGA. Figure 4.4a Line Side or Load Side CT Placement for stand-alone HGA filters rated at 45 to 100 amps, 480V. Figure 4.4b Line Side or Load Side CT Placement for stand-alone HGA filters rated at 39 to 78 amps, 600V. Figure 4.4c Line Side or Load Side CT Placement for stand-alone HGA filters rated at 200 amps, Open or Type 1, 480V.

Figure 4.4d Line Side CT Placement for stand-alone HGA filters rated at 200 amps, Type 3R, 480V. Figure 4.4e Line Side CT Placement for stand-alone HGA filters rated at 300 amps 480V. Figure 4.4f Master and M ultiple Slave Para llel Units CT Plac ement for HGA filters rated at 45 to 100

amps, 480V. Figure 4.4g Master and Multiple Slave Parallel Un its CT Placement for HGA filters rated at 3 9 to 78 amps, 600V. Figure 4.4h optional Multiple Slave Parallel Units CT P lacement for HGA filter s rated at 39 to 100 amps. Figure 4.4i Master and Multiple Slave Parallel Units CT Placement for HGA filters rated at 200 amps.

The pages after the CT Placement diagrams contain detailed diagrams on the current ratios and dimensions of TCI Current Transformers. Contact TCI for CTs not found in figures 4.5, 4.6, or 4.7.

Figure 4.5 is the diagr am for Round Current Transformers. Figure 4.6 is the diagram for Rectangular Current Transformers. Figure 4.7 is the diagram for Solid Core Current Transformers.

Figure 4.4a – Line Side or Load Side CT Placement – 45, 50, 90 and 100 am p, 480 volt

Figure 4.4b – Line Side or Load Side CT Pl aceme nt – 39 and 78 amp, 600 volt

Figure 4.4c – Line Side or Load Side CT Place ment – 200 amp, Open or Type 1, 480 volt

Figure 4.4d – Line Side CT Placement – 200 amp, Type 3R, 480 volt

Figure 4.4e – Line Side CT Placement – 300 amp, 480 volt

Figure 4.4f – Master and Multiple Parallel Units CT Placement – 45, 50, 90 and 100 amp, 480 volt

Figure 4.4g – Master and Multiple Slave Parallel Units CT Placement – 39 and 78 amp, 600 volt

Figure 4.4h – Optional Multipl e Sla ve Parallel Units CT Placement – 39, 45, 78, 90 and 100 amp, 480 volt

Figure 4.4i – Master/Slave CT Placement – 200 amp, 480 volt

Figure 4.5 – Current Transformer Diagram – Round

Figure 4.6 – Current Transformer Diagram – Rectangular

Figure 4.7 – Current Transformer Diagram – Solid Core

is not receiving power from an

Grounding

The HarmonicGuard Active filter p anel equip ment-grounding lug must be connected to the ground of the premises wiring system. The equipment grounding connection must conform to the requirements of the National Electric Code (NEC) and/or any other codes that ap ply to the installation site . T he gro und connection must be made using a wire conductor. Metallic conduit is not a suitable grounding conductor . The integrity of all ground connec tions should be periodically checked.

HarmonicGuard Active Filter Operation

Adjustments

• The HGA has been factory calibrated and thoroughly tested. There is no need to make

any adjustments.

Start Up (Commissioning)

Caution

Warning

Thoroughly check the i nstallation before applying power and operating the equipment for the first time.

Before Applying Power for the First Time

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

• If it is a floor mount unit, check to see that it is securely anchored to the floor.

• Check the panel and the inside of the enclosure for any foreign objects, dirt, metal filings,

wire whiskers, and loose hardware.

• Verify that any covers or guards that were removed during installation were reinstalled.

• Ensure that the unit is properly grounded.

• Check for properly tightened co nnections.

General Operation

Please reference the Quick Start Guide in Section 1 for the first time power up procedure.

Since the HGA is an active filter, it is always operating whenever the power is applied.

Warning

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

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

Warning

Be aware everything ahead of the circuit breaker will still be energized. It is important to note that the lack of lit LEDs does not necessarily mean that the HGA external source.

Warning

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

■ Section 5

Maintenance and Service

HGA Reliability and Service L ife

The HGA has been designed and thoroughly tested at the facto ry to ensure tha t it will per form reliabl y from the time it is put into service. The following periodic maintenance is recommended to ensure that the HarmonicGuard Active filter will always perform reliably and provide the expected service life.

Periodic Maintenance

The following checks should be conducted monthly or more frequently when installed in harsh or dusty environments.

• Check to see that the installation environment remains free from excessive vibration, exposure

to excessive dirt, moisture, and contaminants. Refer to the Pre-installation Planning section of this manual.

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

• Clean the air filter in units that have filter ed air inlets. Clean as often as necessary to prevent

dirt build-up from impeding air flow.

• Check for any dust or dirt build-up on the fans and heat s ink fins.

• Check the o peration o f t he cooling fan.

• Inspect the interior of the enclosure for signs of overheated components. Clean the interior of

the enclosure whenever excess dirt has accumulated.

• Check the integrity of all power , ground, and control wiring connec t ions.

• All electrical connections must be re-torqued annually.

Many electronic components located within the filter are sensitive to static electricity. Voltages imperceptible to human touch can reduce the life, and affect performance, or destroy sensitive electronic devices. Use proper electrostatic discharge (ESD) procedures when se rvicing the filter and its circuit boards.

Warning

HGA. Disconnect all sources of power to the drive and HGA before working on the e quipment. Do not

attempt any work on a powered HGA. This HGA unit contains high voltages and c a pacitors. Wait at least five minutes after

disconnecting power from the filter before you attempt to service the conditioner. Check for zero voltage between all terminals on the capacitors. Also, check for zero voltage between all phases of the input and output lines. All maintenance and troubleshooting must be done by a qualified electrician. Failure to follow standard safety procedures may result in death or serious injury. Unless an external disconnect means has been provided everything ahead of the filter circuit breaker will still be energized.

Reference Drawings

Typical HGA configurations are illustrated in Figures 5.1a, 5.1b, and 5.1c. There could be slight differences between your unit and the configurations shown below. It is recommended that you refer to the drawings provided with your specific equipment when conducting troubleshooting operations.

Figure 5.1a – General Schematic Bus Applied 39, 45, 78, 90 and 100 amp

*This drawing is for general reference only. Use the drawings supplied with the unit for installat ion.

Figure 5.1b – General Schematic Bus Applied 200 Amp, Open and Type 1, Master/Master

*This drawing is for gene ral reference only. Us e the drawings supplied with the unit for inst allation.

Figure 5.1c – General Schematic Bus Applied 200 Amp, Type 3R, Parallel

*This drawing is for general reference only. Use the drawings supplied with the unit for installatio n.

Overload / Over Current Protected

The filter has factory set built-in electronic overload and over current protection. If the converter current exceeds the preset instantaneous peak, the converter will shut do wn to prevent p ermanent damage to the converter, and at which time it will indicate a fault. Faults that do not automaticall y reset can be cleared by pressing the stop button on the HMI display.

An indicati on that the filter is going into overload will be observed by a gradual worsening of the total harmonic distortion (THD), o r power factor, as the load increases. The HGA filter units can be paralleled to increase total corrective current capability if a unit is undersized for a particular application. Call TCI sales support for options to expand the installe d system current capabilit y.

Circuit Breaker Protection

Each converter section is protected by a thermo magnetic circuit breaker; in the event the HGA experiences a catastrophic failure, or a destructive over current condition should occur. It also provides a convenient disconnect means to isolate the converter from the power source. The size and type of circuit breaker must not be altered without consulting TCI engineering since the circuit breaker is an integral part of the UL file.

Notes:

• Open chassis units can be provided without circuit breakers. The end user must protect the

HGA with the following UL listed thermal magnetic common trip molded case circuit breaker.

Warning

• 39, 45, 78 & 50 Amp: A max peak let-through current of 26 kA in correspondence with a

short circuit of 100 kA at 480 volt, and a trip current of 100 amps.

• 90 to 100 Amp: A max peak let-through current of 26 kA in correspondence with a short

circuit of 100 kA at 480 volt, and a trip current of 125 amps .

• 200 Amp: A max peak let-t hro ugh c urr ent o f 35 kA in correspondence with a short circuit

of 100 kA at 480 volt, and a trip current of 225 amps.

If the system breaker has been tripped, do not attempt to re-energize the HGA unit. Until the cause of the trip has been determined.

Pre-Charge Circuit Over Current Protec tion

SCR’s are used to limit the converter power up in-rush current to a safe level once the converter DC voltage has reached the threshold, SCRS will be turne d on and the charging resisto r will be cut off from the unit. If fo r so me reas on thi s circ uitr y shoul d mal func tion, c lass CC f uses ar e

in the circuit to limit the max current as not to exceed the ratin gs of the components. Note: on the 50 to 100 amp units the fuses are located on the chassis; on the 175 and 225 amp unit s the fuses are located on the interface/mother printed circuit board.

Over Temperature Protection

The converter has a thermal fold back mechanism that will automatically reduce unit output current as the converter temperature approaches its shutdown threshold. Additionally, the converter ha s an i nt er nal he a t sin k o ver temperatur e p r ot ec tio n whic h will sh ut d o wn t he c o nver te r if the threshold is exceeded. The fans will continue to run and o nce the hea t sink co ols do wn the converter will automatically restart.

There are secondary over temperature circuits which monitor the temperature of the power resistors and inductors locate d on the chassis of the HGA. The sensors are snap action switches activated when the threshold is reached. This over temp would be an indication that cooling fans

have failed or something more serious with the operation of the converter. For this reason this fault will latch and will remain latched until po wer is cycled. The indicator light located on relay CR-2 will not be lit with this type of over temp fault.

Troubleshooting

Current Transformer Orientation Troubleshoo ting

Failure to maintain the correct p olarity and phasing of the current trans formers (CTs) will cause an over current fault on power up. The converter will never attempt to run; it will stay in a stopped condition. Possibly the CTs are installed backwards or the secondary wiring is incorrect, if this is suspected refer to the steps below to isolate the error.

Note: CT operation can be verified via the HMI touchscreen feedback waveform plot screens. Reference the HMI VLine & ILine Waveform Plot Sub Screen in Section 6 for details.

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the HGA. Failure to follow standard safety procedures may result in death or serious injury.

Disconnect all sources of power to the drive and HGA befo re working on the equipment. Do not attempt any work on a powered HGA. Also, check for zero voltage between all phases of the input and output lines .

Operating current transformers with the secondary winding open can r esult in a high voltage across the secondary terminals which may be dangerous to personnel or equipment.

1.) If the CTs and wiring is easily accessible double check the CT orientation for proper direction, and

trace the secondary wiring against Figure 4.3 for polarity, phasing and connection to terminal TB-

1. Correct any errors and apply power for proper power-up, if it doesn’t clear the fault or if accessibility is too difficult pro c e e d to step #2.

2.) There is a possibility that the CTs markings are different from Figure 4.3. This could a ffect the

polarity, to verify this try reversing the two leads on TB-1 positions 1 &2, do the same with wires in positions 3 & 4. Apply power for proper power-up; if it doesn’t proceed to #3.

3.) Reverse just one set of CT leads at a time, first # 1 & 2; verify power-up. If it doesn’t work put

wires 1 & 2 back and now try the same with wires 3 & 4. Apply power for proper power-up; if it doesn’t replace all wiring to its original positions, and proceed to #4.

4.) There is a possibility that the phasi ng of the CT L1 and L3 are incorrect. To test this theory swap

the two wires o n TB-1 positions 1 & 2 with the two wires in positions 3 & 4. Apply power for proper power-up; if it doesn’t repeat steps 2 and 3.

5.) If the HGA doesn’t indicate a run status after completion of steps 1 through 4 contact TCI

technical support for further assistance.

Warning

System Failure

The Digital Signal Processor is continually mo nitoring the perfor mance and fault statu s of the filter. It will shut do wn the converte r section if the p rocessor should sense a fault. The filter is also equipped with a circuit breaker providing a second layer of over current protecting for the converter section. The circuit breaker can also serve as a means of electrical isolation from the system power grid. It is recommended by TCI that all power to the HarmonicGuard Ac tive filter be disconnected. If you elect to service the HGA by using the circuit breaker to isolate the converter section, please take special note of the following warnings:

Many electronic components located within the filter are sensitive to static electricity. Voltages imperceptible to human touch can reduce the life, and affect performance, or destroy sensitive electronic devices. Use proper electrostatic discharge (ESD) procedures when se rvicing the filter and its circuit boards.

Warning

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

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

This HGA unit contains high voltages and c a pacitors. Wait at least five minutes after disconnecting power from the filter before you attempt to service the conditioner. Check for zero voltage between all terminals on the capacitors. Also, check for zero voltage between all phases of the input and output lines. All maintenance and troubleshooting must be done by a qualified ele c trician. Failure to follow standard safety procedures may result in death or serious injury. Unless an external disconnect means

has been provided everything ahead of the filter circuit breaker, including the reactors, will still be energized.

Required Equipment

• AC voltmeter and ammeter or multimeter designed for true RMS measurements in a

harmonic rich circuit and suitab le for the r a te d current and voltage marked on the nameplate. The meter should have 1000 volt minimum isolation.

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

nameplate.

• Clip-on voltage probes suitable for the rated voltage marked on the nameplate Select

probes that can be securely clipped on to the test points without shorting between points or falling off.

Note: when disconnecting wires from components and terminations, mark the wires to correspond to their component and terminal connection. Extr eme Care should be ta ken when removing the fast-on terminals from the circuit board. Excessive force will result in damaging the interface board and require the converter to be repaired by TCI authorized personnel only.

Converter Inspection

• Verify that power has been removed from converter, and 5 minutes has passed before

inspection.

• Remove plastic cover from over converter section.

• Visually check the circuit boards for debris; contamination; overheated traces; burnt

circuit board; overheated, cracked, or broken components; corrosion; and poor solder joints.

• Check all wires and terminals connected to the circuit boards.

• Check the four electrolytic cap acitors for bulges, ruptures, pop ped vent plugs,

discoloration, or leakage.

• Check the p ower semiconductors mounted to heat-sink for cracked cases, ruptures,

debris, arcing, and burning.

• Check for any loose connections if no apparent damage is found to the power

semiconductors.

• Measure resistance of power semiconductors using a multimeter set on the diode check

setting, see Figure 5.2. Look for opens, ∞, your meter connected to the far right negative terminal of the capacitor bank, measure with the black lead of the meter to each of the three output terminals (bus bars), the

reading should be approximately 0.35Ω. Reverse the meter leads and repeat measuring to

each terminal. This time a low reading will be present which will continue to increase; this is an indication of a capacitor charging. Next connect the black meter lead to the “positive capacitor terminal” and again measure to each of the output terminals with the

other lead; the reading should be approximately 0.35Ω repeat measuring to each terminal. Again it will be a low reading which will continue to increase. If the readings are as described, in all likelihood the power semiconductors are good. If any readings are opens or dead shorts it will be an indication that something is bad in the power section. Do not reapply power if you are not sure the IGBT’s are good.

or dead short readings. With the red lead of

. Reverse the meter leads and

Figure 5.2 – 39, 45, 78, 90, 100, and 200 Amp Power Component Layout

Warning

Figure 5.3 – TB-1 Terminal Block

Only qualified personnel should operate the HarmonicGuard Active filter with the door open. Failure to follow standard safety procedures may result in death or serious injury. Do not attempt any work on a powered filter converter.

The HGA contains high voltages and capacitors. Wait a t le ast five min utes after disconnecting po wer from the converter before you attempt servicing. Check for zero voltage between all terminals to the converter. Be aware everything ahead of the circuit breaker will still be energized.

Figure 5.4 – Troubleshooting Flow Chart

Replacement Parts

If replacement parts are needed, please contact your TCI representative. To ensure that the HarmonicGuard Active filter continues to perform to its original specifica tions, replacement parts should conform to TCI specifications. Use of non-TCI approved components will void all warranties.

Factory Contacts and Techni cal S upport

For technical suppor t, contact your local T CI distributor or sales representative. You can contact TCI directly at 1-800-824-8282. Select "Customer Service" or "Technical Support" and have your HarmonicGuard Active filter nameplate information available and any drawings.

Outline and Mounting Dimension Drawings

Outline and mounting dimension drawings show the overall enclosure dimensions, the conduit access areas and the wiring connection points. The major internal components are shown pictorially.

Figure 5.5 – 39 and 78 amp Open Chassis Filter, Open Transformer

Figure 5.6

– 39 and 78 amp Open Chassis Filter, Type 3R Transformer

Figure 5.7

– 39 and 78 amp Type 1 Filter, Type 3R Transformer

Figure 5.8 – 45, 50, 90 and 100 amp Open Chassis

Figure 5.9 – 45, 50, 90 and 100 amp Type 1 Enclosed

Figure 5.10 – 200 amp Open Chassis

Figure 5.11 – 200 Amp Type 1 Enclosed

Figure 5.12 – 200 Amp Type 3R Enclosed

Figure 5.13 – 300 amp Type 1 Enclosed

Figure 5.14 – 300 amp Type 3R Enclosed

■ Section 6

HMI Introduction

The Interface Module provides the user with a convenient way to monitor the operation of TCI’s HarmonicGuard Active filter and allows for the ability to adjust run-time set-points under password control. This section describes how to insta ll, operate, and maintain the Interface Module.

Overview

The Interface Module has three major components; the Interface PCB, the HMI Display and an option network Communications Gateway (see Figure 6.1).

The interface PCB contains a Chassis Communications Port that connects to the power converter of the HarmonicGuard Active filter. The interface PCB translates status and commands data between the power converter controls and the HMI Display. The interface PCB also contains the 24V Relay I/O for basic status monitoring and run/stop control of the HarmonicGuard Active filter.

The HMI Display is a 6” color Touchscreen display containing a series of status screens that provide the user with a convenient way to monitor the operation of the HarmonicGuard Active filter. The HMI display also contains an integrated ModbusRTU network connection for remote monitoring of the HarmonicGuard Active filter.

The optional network Communications Gateway can be connected to the integrated ModbusRTU network connection in the HMI Di s play to translate the ModbusRTU protocol to an alternate Field bus or Industrial Ethernet protocol such as Ethernet/I P.

Figure 6.1 – Interface Module Components

Caution

review the more specific information provided by the drawings shipped with the module. Information

Additiona l Infor mation

This section provides general information describing the Interface Module. Be sure to carefully

from by the drawings takes precedence over the information provided in this section. The information and rat ings given in this manual are approximate and should not be used for any

purpose requiring exact data. Contact the factory in situations where certified data is required. All data is subject to change without notice.

Receiving Inspection

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

o Make sure the installation location will not be exposed to direct sunli ght, excessive o Select a mounting area that will allow adequate cooling air.

o Make sure that all wiring conforms to the requirements of the National Electric Code

o Ground the HM I display by using the grounding terminal. Not only does this act as a

o Check all connections and components thoroughly before applying power to the

o Check the panel and the inside of the enclosure for any foreign objects, dirt

Installa tion Guidelines

Checklist

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

vibration, corrosive or combus tible airborne contaminants, excessive d ir t or liquids.

(NEC) and/or other applicable electrical codes.

safety, but it also filters out electrical noise.

equipment.

and/or loose hardware.

Location

Environment

The location of the Interface Module should be a suitable environment to assure proper performance and a normal operating life. Refer to the environmental speci fi cations furnished i n this manual, and noted on the drawings with the Interface Module.

Warning

• Display front rated Type 1 & 4X

• Avoid direct sunlight

• Avoid corrosive liquids or gasses

• Avoid explosive or combustible gases or dust

• Avoid excessive airborne dirt and dust (Pollution Degree 2, according to EN50178 and UL508C)

• Avoid excessive vibration (0.152 mm (0.006 in.) displacement, 1G peak)

Mounting

Mounting requires at least a depth of 4” (102 mm). The Interface Module will mount in a panel with a thickness of 0.02 to 0.35 inch (0.5-9.0 mm) with an opening 6.79” by 5.21” (173 by 133 mm). Fit the Interface Module assembly into the opening carefully pressing on all four corners. Use the mounting hardware (4 sets) to secure the assembly on the corners.

Warning: to avoid damaging the case, do not exceed a tightening torque of 3.47 to 4.34 lbs-in (0.39-0.49 Nm). Care s hould be taken not to mount the Interface Module too close to a heat source (such as power resistors) which could be located behind the Interface Module.

Caution

The display panel is waterproof. But care should be taken to prevent grease, corrosive liquids and sharp

objects from contacting the front panel.

Warning

Many electronic components located within the Interface Module and HMI are sensitive to static electricity. Voltages imperceptible to human touch can reduce the life, and affect performance, or completely destroy sensitive electronic devices. Use proper electrostatic discharge (ESD) procedures when servicing the Interface Module and HMI.

Wiring

Note: Some of the following sectio ns only apply if the Interface Module is not factory installed. A wiring block diagram of the Interface Module components is available in Figure 6.2. When selecting a mounting loca tion for the unit, plan for the routing of commutation and power cable. Kee p

the wiring away from power wire s where electrical noise could be ind uced. All wiring should conform to the requirements of the National Electric Code (NEC) and/or other applicable electrical codes. The length of the communication cable between the Interface module chassis communication port and the HarmonicGuard Active filter power converter module should not exceed 25 feet (7.6 meters).

Figure 6.2 – Interface Module Connections

Terminal

Description

Label

Rating

J1 1 HMI Display

For factory use

N/A

Not Connected

2 B 3

Ground

Not connected

Neutral

Line

Micro Programming

For factory use

N/A

24 VDC

Common

Not Connected

24 VDC

Start

Interface PCB Connections

Most customer connections to the Interface module will be made on the Interface PCB. Refer to connection diagrams in Figure 6.3. The details of the power and communications terminals are shown in Table 6.1, form C relays are available on the Interface PCB. These connections are shown in Table 6.2. Four outputs a re available on the Interface PCB.

The relay start command input connection on J22 of the interface PCB allows a contact closure to send a r un command to the HarmonicGuard Active filter. The relay start command input will only be acknowledge if the Relay Run/Stop Enable is set to Enabled on the HMI Display setup screen. See Figure 7.14 for details. Pressing stop locally via the HMI D isp lay will set the enable for the rela y start command to DISABLED.

Figure 6.3 – Interface PCB connections

Table 6.1 – Power & Communications Terminals

RS485

Input Power

N/A

120 VAC

J19

J22

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

HMI Power Supply

Start Command

24 VDC

Contact Closure

Tightening

Torque

Wire

Range

Normally Closed

Common

Normally Open

Normally Closed

Common

Normally Open

Normally Closed

Common

Normally Open

Normally Closed

Common

Normally Open

Table 6.2 – Form C Relay Contacts

Terminal Pin Description Label

J12

Note: Form-C relay contacts are gold plated with a load rating of 0.6A @ 125VAC general use; 0.2A @ 250VAC, 0.6A @ 125VAC, 2A @ 30VDC resistive. The minimum permissible load rating is 10uA, 10mVDC.

Run

Power On

Fault

Current

Limit

4.4 lbs-in (0.5 Nm) 28-14 Awg

HMI Display Connections

Note: The following section describes the d e fault ModbusRTU network connection available on the base model. If an optional advanced network Communications Gateway is included in the Interface Module see the appendix for the specific Communications Gateway configuration.

The HMI display implements a ModbusRTU slave device over RS-485. This network connection is available on the COM2/3 DB9 connector on the back of the HMI Display (see Figure 6.4).

The output r egisters fro m the HarmonicGuard Active filter are mapped to Modbus register address 40500. The input re gisters to the Har monicGuard Active filter are mapped to Modbus register address 40564. For definitions of the input and output data available via the network connection see the Network Interface section below.

If the optional network Communications Gateway is present the integrated ModbusRTU interface on the HMI Display will not be available. When configured, the Communications Gateway will occupy t he ModbusR TU COM2/3 DB9 connector on the back of the HMI Display.

COM2/3 DB9 Pin

no connect

D+

RS-485 B (non-inverting)

GND

RS-485 SC/G

no connect

D-

RS-485 A (inverting)

Parameter

Default Value

Units

Baud Rate

19200

bps

Data Bits 8 bits

Stop Bits 1 bits

Parity

Even

Slave ID

113

ModbusRTU

Connection

Figure 6.4 – HMI ModbusRTU Connection

Table 6.4 – Modbus Connector Pin Definitions

Signal Name Signal Type

Table 6.5 – ModbusRTU Protocol Settings

Communications Gateway Connections ( Optional)

If an optional advanced network Communications Gateway is included in the Interface Module see the appendix for the specific Communications Gateway wiring details.

If the optional network Communications Gateway is present, the integra te d ModbusRTU interface on the HMI Display will not be available. When configured, the Communications Gateway will occupy the ModbusRTU COM2/3 DB9 connector on the back of the HMI Display.

HMI Graphic Element

Example

Description

Buttons will appear raised or and command conditions.

Indicator status fields will appear Display fields will appear flat.

Numerical Entry fields appear

The Navigation Bar allows for easy

The Title Bar contains the current

■ Section 7

Operation

HMI Screen Elements

This section focuses on the operation of the HMI Display. The HMI Display contains several screens that allow the user to monitor the status of the line/load and the HarmonicGuard Active filter. Additionally the HMI display can be used for local run/stop control and basic setup of the HarmonicGuard Active filter.

Table 7.1 – General HMI Screen Elements

Buttons

Indicators

Numerical Displays

Numerical Entry Fields

Navigation Bar

Title Bar

depressed, depending on set point

flat and are read only.

Numerical displays are read only.

indented. Selecting them will open a keypad for numerical entry.

navigation between the five major HMI screens. The Navigation Bar appears on all HMI screens.

system time, screen selection, and a stop button to turn off the system. The Navigation Bar appears on all HMI screens.

Indicator

Navigation

HMI Display Power LED

Title Bar

Button

Numerical Display

Figure 7.1 – HMI Display

Bar

Initialization

When first powered, the green LED (Power) on the HMI Display will light (see Figure 7.1). After a five second boot up sequence the Home Screen will be displayed. If the home screen is not displayed

and power is available to the HMI Display see the troubleshooting section at the end of this user manual for diagnosing common problems.

HMI Screens

Home screen

The Home screen displays a dashboard of overall filter status information and allows the user to run and stop the HarmonicGuard Active filter. Figure 7.2 illustrates the func ti o ns.

Figure 7.2 – Home Screen

Screen Element

Description

Indicates if a converter fault is active and preventing the

This gauge displays the current filter capacity as a percentage

Run/Stop Button

Runs and stops the HarmonicGuard Active filter.

When the HarmonicGuard Active filter is in a stop mode the

Displays current line/load power factor. 1.00 indicates unity

Line Frequency

Displays the supply voltage coming into the HarmonicGuard

Displays the current line/load phase current in Amps RMS.

Filter Status Display

% Filter Current Used

Display

System State

Indicator (located

immediately below

stop button)

Table 7.2 – Home Screen Elem ent s

HarmonicGuard Active filter from running. If a fault occurs the indicator will flash red and display “Fault”. Specific Fault codes can be viewed on the “Fault” Screen.

of total available capacity. In normal operation the display will read “Nominal”. If the unit output corrective current is above 95% of maximum capacity the indicator light will turn red and display “At Capacity”. When the converter is at capacity the Relay K4 (J12 Connector), and J11 Contacts used for a remote indicator will also be energized. If the monitor continually displays “At Capacity” a second filter may be required to handle the load. Please contact TCI for assistance.

“Status” light will turn red and display “Stopped”. When the converter is running the status light will be green and will display “Running”. The status light will also show if the HarmonicGuard Active filter is in Input line Sync mode, Reset mode, Precharge mode, Calibrate mode, Power Save mode or Faulted. When the HarmonicGuard Active filter is fault ed it wil l shut down automatically

Power Factor Display

Display

Supply Voltage

Line/Load Current

Display

power factor. A negative power factor indicates lagging power factor.

Displays the current utility line frequency in Hz.

Active filter.

NOTE: the displayed current is affected by the CT Ratio configuration on the “Setup” page.

Screen Element

Description

Use this button to get to the “Line/Load Status”

Displays the current utility phase to phase line

Displays the current line/load phase current in

Displays current line/load power factor. A value of

Frequency Display

Displays the current utility line frequency in Hz.

Run/Stop Button

Runs and stops the HarmonicGuard Active filter.

This button will take the user to the “Converter

Phase to Neutral voltage,

The “Waveform” screen buttons will take the user When the user presses the “Trend” button the

“Historical Trend screen menu is displayed

Status Screen

The Status screen shows more specific information on the performance of the system such as current and voltage waveforms, Power Factor and information specific to the Line/Load screen and Converter screen. Figure 7.3 explains the main “Status” Screen.

Figure 7.3 – Status Screen

Table 7.3 – Status Screen Elements

Line/Load Button

Volts Display

Current Display

Power Factor Display

Converter Button

Line Voltage, Line/Load Current, and Converter

Current, and Vline/Iline

Waveform Screens

Sub Screen (see Figure 7.6).

voltage in Volts RMS.

Amps RMS.

1.00 indicates unity power factor. A negative power factor indicates lagging power factor.

Status” Sub Screen (see Figure 7.4).

to one of the four real-time waveform capture screens: Phase to Neutral voltage, Line Voltage, Line Current, Converter current, or VLine/ILine plot (see Figures 7.7 and 7.8).

Trend Menu Screen

(see Figure 7.9).

Screen Element

Description

Run/Stop Button

Runs and stops the HarmonicGuard Active filter.

Displays the present HarmonicGuard Active filter

Displays the internal DC Link Bus voltage of the

Displays the present HarmonicGuard Active filter

This gauge displays the current filter capacity as a

Displays the current state of all enables that affect the

Back Button

Returns to the main status screen.

Converter Status Sub Screen

The converter status sub screen shows the present status of the HarmonicGuard Active filter power converter module.

Figure 7.4 – Converter Status Sub Screen

Table 7.4 – Converter Status Sub Screen Elements

Current Display

Link Voltage Display

Heatsink Temp

Display

% Filter Current Used

Display

Run Enable Summary

output corrective current in Amps RMS.

HarmonicGuard Active filter in Volts DC.

power converter heat sink temperature in Degrees Celsius.

percentage of total available capacity. In normal operation the display will read “Nominal”. If the unit output corrective current is above 95% of maximum capacity the indicator light will turn red and display “At Capacity”. When the converter is at capacity the Relay K4 (J12 Connector), and J11 Contacts used for a remote indicator will also be energized. If the monitor continually displays “At Capacity” a second filter may be required to handle the load. Please contact TCI for assistance.

running of the HarmonicGuard Active filter. If a button is red that option is disabled and if it is green that option is enabled. If the “Auto Start” is enabled a countdown timer will run to the right of the button, when the count reaches 0 the converter will start (See Figure 7.5).

Screen Element

Description

Run/Stop Button

Runs and stops the HarmonicGuard Active filter.

Shows if the start or stop button is enabled.

Changes to blue if enabled or the left button is pressed,

will start.

Changes to blue if enabled or the left button is pressed, if

green and read “RUN”.

Changes to blue if enabled or the left button is pressed, if

This button will take you back to the converter status

Run Enable Summary Sub Screen

The Run Enable Summary sub screen shows state of all the enables that affect the running of the HarmonicGuard Active filter.

Figure 7.5 – Run Enable Summary Sub Screen

Table 7.5 – Run Enable Summary Sub Screen Elements

Auto Start

Remote Relay

Remote Network

Back

and the countdown timer (to the right of the button) will start. When it reaches 0 the HarmonicGuard Active filter

enabled the HarmonicGuard Active filter can be remotely stopped with a contact closure. When enabled and the option is active the field to the right will be

enabled the HarmonicGuard Active filter can be remotely stopped/started with a contact closure. When the contact is closed the unit will run and when opened the uni t will stop. When enabled and the option is active the field to the right will be green and read “RUN”.

screen.

Volts Display

Displays the current utility phase to phase line voltage in Volts RMS.

Displays the current line/load phase current in Amps RMS.

Power Display

The three phase real power (P) of the line/load in kW.

Apparent Power

The three phase apparent power (S) of the line/load in kVA.

Power Factor

Displays current line/load power factor. 1.00 indicates unity power Displays the Total Harmonic Distortion of the utility Line/Load

current as a percentage.

Displays the Total Harmonic Distortion of the utility line Voltage as a percentage.

Displays the reference Total Harmonic Distortion of the utility

Run/Stop Button

Runs and stops the HarmonicGuard Active filter.

Back Button

Returns to the main Status Screen

Line/Load Status Sub Screen

The Line/Load Status Sub Screen shows more specific information regarding the source and load voltage, current, power, power factor and THD measurements.

Figure 7.6 – Line/Load Status Sub Screen

Table 7.6 – Line/Load Status Sub Screen Elements

Screen Element Description

Current Display

Display

I THD Display

V THD Display

I THD Ref Display

NOTE: the displayed current is affected by the CT Ratio configuration on the “Setup” page.

factor. A negative power factor indicates lagging power factor.

Line/Load current in percent. This THD display is the uncorrected THD of the Line/Load taken when the HarmonicGuard Active filter was not running.

Screen Element

Description

The “Refresh” button will reload the data from the HarmonicGuard

1X, 2X and 4X

Waveform zoom buttons will redraw the present data at a different

Waveform Plot Sub Screens

The HMI display supports capture and display of real time system voltage and current data. Three phase waveform data can be viewed for Line Voltage, Line/Load Current, and Converter Corrective Current.

The waveform screens contain a zoom feature which supports three magnitude scales: 1 X, 2 X and 4X (see Figure 7.7). The Refresh button on the waveform screens will update the plot with new data from the HarmonicGuard Active filter converter.

Figure 7.7 – Example Waveform Plot Sub Screens (Converter Corrective Current)

Table 7.7 – Waveform Plot Sub Screen Elements

Refresh Button

Buttons

Active filter power converter controller and redraw the waveform plot.

scale.

VLine & ILine Waveform Plot Sub Screen

The VLine & ILine Wavefor m Plot Sub Screen is a vailable to verify the proper installation of the HarmonicGuard Active filter power connections and system current CT feedbacks. The waveform plot shows voltage and current feedback for both Phase A and C o n the same pl ot. When the HarmonicGuard Active filter is powered, but in the stopped state this plot can be used to check for the following:

• Proper Line Voltage phase rotation

• Proper Line/Load Current phase rotation

• Proper Line Voltage and Line/Load Current relative polarity and phase.

• Missing/Open Circuit System Current CT Feedback

In the event that the HarmonicGuard Active filter performance is degraded the VLine & ILine waveform plot should be examined as a means to determine if any system connection errors are present. Prior to examining the VLine & ILine waveform plot, the HarmonicGuard Active filter should be put in the stopped state by pressing the stop button in the upper left corner of the HMI screen. Figure 7.8 shows the VLine & ILine waveform plot sub screen for a properly connected, but non-running HarmonicGuard Active filter when connected to a typical non-linear, rectifier load. Note the following characteristics:

• Phase C voltage (Blue) leads Phase A voltage (Green).

• Phase C current (Yellow) leads Phase A current (Red).

• Phase A voltage (Green) and Phase A current (Red) are in phase and the same polarity.

• Phase C voltage (Blue) and Phase C current (Yellow) are in phase and the same polarity

Figure 7.8 – VLine & ILine Waveform Plot of a Properly Connected

VLine & ILine Waveform Plot Sub Screen with

Connection

Connection Error

Phase rotation is

To correct swap

HarmonicGuard Active filter (unit in stopped state)

Note: The example VLine & ILine Waveform Plot screens apply to rectif ie r loads only. For low power factor loads the VLine & ILine wa veform screen will appear different.

Table 7.8 sho ws what the VLine & ILine Waveform Plot Sub Sc reen would look like with various connection errors present in the system.

Rectifier Load

Table 7.8 – VLine & ILine Waveform Plot Screen Examples when

Typical Connections Errors Present in System

Error Description

Incorrect: Phase A leads

Phase C instead of Phase C leading Phase A.

Resolution

Phase A and Phase C HarmonicGuard Active filter power connections AND swap Phase A and Phase C system CT current feedback then recheck plot.

Phase C system

Check Phase C CT

Phase A and

To correct swap

Phase A current

To correct, re-install

CT current feedback missing:

Phase C current is zero while Phase A current is present.

Phase C CT current feedback swapped:

Phase A current (red) in phase with Phase C voltage (blue) instead of Phase A voltage (green).

for open circuit or loose connection.

Phase A and Phase C system CT current feedback and recheck plot.

(red) is opposite polarity of Phase A voltage (green) and Phase C current (yellow) is opposite polarity of Phase C voltage (blue).

both Phase A and Phase C system CTs with polarity arrow in opposite direction OR swap positive and negative connections of each CT at HGA filter terminal block then recheck plot.

Screen Element

Description

Opens the HarmonicGuard Active filter heatsink temperature

Opens the HarmonicGuard Active filter DC Link Voltage historical

Opens the utility input RMS voltage historical trend graph screen.

Opens the line/load RMS current historical trend graph screen.

Opens the HarmonicGuard Active filter RMS current historical

Opens the line/load Total Harmonic Distortion historical trend

Historical Trend Plot Menu Sub S creen

From the historical trend plot menu sub scree n you can view trend gr aphs of various HarmonicGuard Active filter system signals (see Figure 7.10).

Figure 7.9 – Historical Trend Plot Menu Sub Screen

Table 7.9 – Historical Trend Plot Menu Sub Screen Elements

Converter Temp

Button

Converter VLink

Button

VLine Button

ILine/ILoad Button

Converter Current

Button

historical trend graph screen. This signal is sampled every 15 seconds and historical data is maintained for 10 hours.

trend graph screen. This signal is sampled every 3 seconds and 2 hours of historical data is maintained.

This signal is sampled every 3 seconds and 2 hours of historical data is maintained.

This signal is sampled every 3 seconds and historical data is maintained for 2 hours.

trend graph screen. This signal is sampled every 3 seconds and 2 hours of historical data is maintained.

Current THD

Button

graph screen. This signal is sampled every 3 seconds and 2 hours of historical data is maintained.

Screen Element

Description

Run/Stop Button

Runs and stops the H armonicGuard Active filter.

Plot Scale Display

Indicates the date and time the left-most sample displayed on the

Allows the user to scroll through all sample points available in the

Trend Plot Display

The historical graph of the value being sampled over time.

Historical Trend Plot Sub Screens

The historical trend plot screens gra ph time-stamped feedback data over an extended period of time. Once the trend plot display data buffer is full the o ldest data is overwritten. Historical data can be viewed using the integrated scroll bars of the tre nd plot. All trend plot data is maintained between power on/off cycles of the HarmonicGuard Active filter. See Figure 7.10 for an example of a typical trend graph (trend plot example is for the HarmonicGuard Active filter power converter heatsink temperature measurement). For data buffer sample times and size see Figure 7.10.

(located on the left side

of the graph)

Right Timestamp

Left Timestamp

Scroll Bar

Figure 7.10 – Example Historical Trend Plot Sub Screen

Table 7.10 – Trend Plot Screen Elements

Indicates the magnitude of the samples of the trend plot. The scale varies with each of the trend plots.

Indicates the date and time the right-most sample displayed on the screen was taken.

screen was taken.

trend plot data buffer.

Screen Element

Description

This button will remove all faults from the list if the fault conditions fault history log.

When a fault occurs the fault screen will display information about

• Fault description

This button will take the user to the “Fault History” sub screen where previous faults can be reviewed.

Fault Screen

This button takes the user to the “Active Fault” screen (see Figure 7.11) which lists all of the active faults. The faults will stay in this list until the “ Rese t” , or “Stop” button is pressed or the fault self clears. From here the user can also go to the “Fault History” screen.

Figure 7.11 – Fault Screen

Table 7.11 – Fault Screen Elements

Stop Button Turns off the HarmonicGuard Active filter.

Reset Button

Fault Trip Entry

Display

History Button

have cleared. Once cleared, a fault will still be viewable in the

the fault including the (from left to right across the screen):

• Fault bit mask number

• Fault timestamp

• Fault code (see Table 7.12)

Fault

Critical or

Auto or Manual

Critical

Manual*

Desat (IGBT Gate Driver) Fault Phase A

Critical

Manual*

Desat (IGBT Gate Driver) Fault Phase B

Critical

Manual*

Desat (IGBT Gate Driver) Fault Phase C

1000

Non-critical

Auto

DC Bus Overvoltage

1250

Non-critical

Auto

DC Bus Undervoltage

3000

Non-critical

Auto

Overcurrent on Phase A

3010

Non-critical

Auto

Overcurrent on Phase B

3020

Non-critical

Auto

Overcurrent on Phase C

4000

Critical

Power Cycle**

Overtemperature

4250

Non-critical

Auto

Undertemperature

7000

Non-critical

Auto

Calibration Fault

7010

Non-critical

Auto

Communications Fault

Non-critical

Auto

Fault location indication. Fault

unit in the system.

Table 7.12 – Fault Codes

Code

10 20 30

Unit N

Faulted

Non-critical Fault

Reset Fault Description

originated in Unit N where N is in the range 1 to 8. For factory configured parallel systems the unit numbers are sequential ordered from left to right when looking at the front of the system. Unit 1 is the left most

*Critical faults flagged with a manual r e set r e quire a HMI stop button or run/stop switch stop command at the unit to clear.

**Critical faults flagged with a power cycle reset require a manual on/off power cycle of the unit to clear.

Fault History Sub Screen

The “Fault History” sub screen (See Figure 7.12) contains up to 120 entries that mark the onset and clearing of system faults. At the onset of a fault condition an entry will be generated in the fault history marked with an “O” on the left side of the fault entry. When a fault clears an entry will be gener a te d in the fault history marked with an “X” on the left side o f the fau lt e ntry.

The Fault History persists through power on/off cycle s. In the event the fault history log exceeds the max number of 120 entries the oldest entry will be overwritten by new entries.

Column

Onset/Clear Marker

O = Fault Onset X = Fault Cleared

Marks the start and end of a fault in the fault history.

Timestamp

HH:MM MM/DD/YYYY

Time and date the fault entry was logged.

Fault Code

Four digit code

Fault code (see Table 7.12)

Fault Description

Text

A short text description of the fault

Figure 7.12 – Fault History Sub Screen

Table 7.13 – Fault History Log Entry Format

(from left to right)

Format Description

Setup Screen

Note: Some set-up screens are password protected to prevent changes that could damage the filter. When the user presses the “Setup” button a splash screen will appear saying “The Filter is about to stop” (see

Figure 7.13). Choosing “Next” will stop the filter and take the user to the “Setup” screen (see Figure 7.14). Pressing the “Back” button returns the user to the “Home” screen and does not turn off the filter. If the filter is off this splash screen will not appear.

The Setup Screen (see Figure 7.14) allows basic configuration of the HarmonicGuard Active filter operation. When a feature is enabled via a butt on, press the corresponding button will be hi ghlighted in GREEN. When a feature is disabled the corresponding button will turn BLUE.

Note: It is recommended that the new settings are saved when changes are made. See the description of the “Save Setti ngs” button in Table 7.14.

Figure 7.13 – Setup Transition Sub Screen

Screen Element

Description

This option will set the converter to start automatically after a This option is on by default.

This option turns the Automatic Harmonic Correction on or off.

back to allow the system to continue correcting harmonics.

This option allows the Active Line Condition to be remotely turned

manually via the HMI display.

This option allows the Active Line Condition to be remotely turned

display.

Factory Setup

Button

This button is password protected and used dur i ng the f ac tory and technician setup only.

Presents a sub screen which allows the user to change the date used for time stamps in the fault history and historical trend plots.

This option turns the Automatic Power Correction on or off. This

This option allows the user to change the brightness and gamma

Figure 7.14 – Setup Screen

Table 7.14 – Setup Screen Elements

Auto Start Enable

Button

Harmonic

Correction Enable

Button

Network Start

Enable Button

Relay Start Enable

Button

Set Date and Time

Button

programmed delay after power is applied or after a fault occurs.

This option is on by default. If both harmonic correction and power factor correction are enabled and the HarmonicGuard Active filter is at its maximum capacity the power factor correction will automatically be phased

on or off across a network connection. If the stop button is pressed locally on the HMI Displa y the Netw ork Start Enable is automatically set to DISABLED and has to be re-enabled

on or off via an external relay. J2 on the interface requires a switch closure to stop the converter. If the stop button is pressed locally on the HMI Display the Relay Start Enable is automatically set to DISABLED and has to be re-enabled manually via the HMI

and time displayed on the screen. The date and time are also

option is on by default.

Power Factor

Correction Enable

Button

Screen Brightness

Button

If both harmonic correction and power factor correction are enabled and the HarmonicGuard Active filter is at its maximum capacity, the power factor correction will automatically be phased back to allow the system to continue correcting harmonics.

of the display. The contrast control is not enabled in this display model.

This option lets the user view the status of and configure the

This button is password protected and used during technician

built in Auto Calibration Procedure.

This button will restore the user saved settings from non-volatile

This button will save the current working settings to non-volatile

Contrast (disabled)

Brightness

Gamma

Close screen

Network Setup

Button

Technician Setup

Button

Language Setup Sets display language of HMI text

Load Settings

Button

integrated ModbusRTU network connection in the HMI display

setup and commissioning only. The Technician Setup Screen is used by TCI qualified personnel

to configure the System CT Ratio, Autostart/AutoReset Delay Time, Unit Power Save Threshold, System Metering Voltage, Sensor Wiring Error Auto Detection Parameters and to initiate the

persistent memory. A confirmation screen will pop up asking “Are you sure you want to load saved settings”. If “Yes” is chosen any temporary changes made to the working set point parameters will be lost and the user saved settings will be restored. If “No” is pressed the user will be sent back at the “Basic Setup” screen.

memory that persist when power is removed from the unit. To save the current settings choose “Yes” on the confirmation screen, or choose “No” to cancel and go back to the “Basic Setup”. The settings will not be saved if “No” is chosen.

Save Settings

Button

Screen Element

Description

Run/Stop Buttons

Turns on or off the HarmonicGuard Active filter.

This button will take the user into the HMI display settings which

Stop Button

Turns off the HarmonicGuard Active filter.

Protocol Settings

Displays the Modbus RTU protocol settings.

This option allows the HGA to be remotely turned on or off across Displays the current network Run/Stop command being received

Network Setup Sub Screen

The network setup sub screen (see Figure 7.15) allows the user to view and configure the network interface options available internally to the HM I Display. For details on the integra te d Modbus RTU interface connections see the HMI Displa y Connections section. If an optional advanced network Communications Gateway is configured please reference the appropriate Gateway section in the Appendix. This screen also displays the default Modbus network protocol settings and the current state of the network run/stop enable and network run/stop command.

Table 7.15 – Network Setup Sub Screen Elements

HMI Settings

Buttons

Display

Network Start

Enable Button

Remote Start

Display

Figure 7.15 – Network Setup Sub Screen

allow the protocol settings of the Modbus RTU slave device to be changed (baud rate, parity, slave ID, etc…). A password is required to enter this screen. Call TCI at 1-800-824-8282 to receive a password and configuration document if needed.

a network connection. If the stop button is pressed locally on the HMI Display, the Network Start Enable is automatically set to DISABLED and has to be re-enabled manually via the HMI display.

by the HMI Display. Note: the HarmonicGuard Active filter will only acknowledge the network run command if the Network Start Enable is set to ENABLED and there is no active fault.

Warning: If the values of the “HMI Settings” are changed from what the network administrator has set for the filter, the ability to connect to the filter

Screen Element

Description

Turns off the HarmonicGuard Active filter.

Displays the pre-programmed factory serial number of the

Displays the total corrective current capacity in Amps RMS of

Displays the line voltage the HarmonicGuard Active filter is set

Displays the Digital Signal Processor type used in the

Displays the software revision of the installed Digital Signal Displays the software revision of the installed microcontroller in

Displays the software revision of the HMI Display application

remotely will be lost. TCI will not be responsible for the loss of communication due to this change.

About Screen

The About Screen (see Figure 7.16) displays model number, serial number, and software/firmware version information regarding the filter.

Stop Button

Serial # Display

Total Output Current

Display

System Voltage

DSP Type Display

DSP Revision

Display

Figure 7.16 – About Screen

Table 7.16 – About Screen Elements

HarmonicGuard Active filter.

the HarmonicGuard Ac t i ve filter.

to work on.

HarmonicGuard Active filter power converter controller.

Processor used in the HarmonicGuard Active filter power converter controller.

AVR Revision

Display

HMI Revision

Display

the Interface PCB.

code.

Screen Element

Description

Self Test Result

Displays the current Pass/Fail/In-Progress State of the Sensor Wiring Error Auto Self Test Result

When a sensor wiring error is detected one or more corrective actions will be

Acknowledge

Pressing the Acknowledge Button will hide the Sensor Wiring Error Self Test Sub

Self Test Result Indication

Sensor Wiring Error Auto Detection Sub Screen

Some HarmonicGuard Active filter models are equipped with voltage and current feedback sensor wiring error detection algorithms. The detection algorithms run briefly on unit p ower up and check the unit sensors fo r signature s of common wiring errors, such as incorrect ACB phase rotation (instead of the required ABC rotation) and inverted system CT polarity. The Sensor Wiring Error Sub Screen is a pop up screen which is not accessible from any of the main navigation screens. The

screen is only displayed if a wiring error is detected. If no sensor wiring errors are detected the pop up screen will remain hidden.

If a Sensor Wiring Error is detected the HGA will be in hib ited from running until system power is removed from the unit and the error is corrected.

The Sensor Wiring Error Detection feature is comprised of several independent detection algorithms. The two main categories of algorithms are voltage based detections and current based detections. The voltage based detection algorithms monitor the three phase line voltage input for proper ABC phase rotation, polarity, balance and nominal magnitude. The current based detection algorithms monitor the system Current Transformer (CT) sensor feedback for proper phase rotation, polarity, balance, and CT open or shorted conditions. The current base detections are only engaged if a minimum level of load current is present during power up. Both the voltage and current detection algorithms can be globally or individually configured by TCI qualified personnel via the password protected Technician level Setup Screen.

Table 7.17 – Sensor Wiring Error Self Test Sub Screen Elements

Indication

Description

Figure 7.17 – Sensor Wiring Error Self Test Sub Screen

Detection feature. When a sensor wiring error is detected the specific fault code will be shown. See Table 7.19 for a description of specific fault codes.

displayed here. See Table 7.19 for a list of suggeste d r es olutions .

Button

Screen so other the screens can be examined in order to trouble shoot the wiring error.

If a user attempts to operate the unit while a sensor wiring error is still present by pressing the Run or Stop buttons the screen will reappear.

Error Code

Error

Suggested Corrective Action

No Error

No corrective action required.

No correction action required. Typically the self test will Turn off unit and check 3 phase AC input voltage wiring for

Turn off unit and check 3 phase AC input voltage wiring for

Reverse Voltage Phase

Turn off unit and check 3 phase AC input voltage wiring for

Turn off unit and check system CT feedback for A,B,C

Turn off unit and check system CT feedback for no

Turn off unit and check system CT phase A feedback for

Turn off unit and check system CT phase A and C

Turn off unit and check system CT feedback phase C for

Turn off unit and check CT feedback and 3 phase AC

Table 7.18 – Sensor Wiring Error Code Table

1 Self Test In Progress

2 Line Voltage Synch

3 Input Over Voltage

5 Phase A Input Under Voltage

6 Phase B Input Under Voltage

7 Phase C Input Under Voltage

8 Reverse CT Current Rotation

9 Phase A CT Under Current

Rotation

complete and auto clear in less than 10 seconds after power up.

missing phase connection or low line voltage

high line voltage

A,B,C phase rotation or missing phase connection

missing phase or low line voltage

phase rotation, inverted CT polarity, or CT short/open

feedback (CT short or open)

10 CT Under Current

11 Phase C CT Under Current

12 Phase A CT Polarity

13 CT Polarity

14 Phase C CT Polarity

15 Phase Power Imbalance

feedback (CT short or open)

incorrect polarity or reverse phase rotation

feedback for incorrect polarity or reverse phase rotation

incorrect polarity or reverse phase rotation

input voltage for incorrect polarity or reverse phase rotation

I/O Reg

Offset

0 = Running 1 = Idle

Indicates if the HGA filter is currently running or in the idle state

0 = Power Off 1 = Power On

Indicates if the HGA filter has input power available

0 = Not faulted 1 = Faulted

0 = Nominal 1 = At Capacity

Indicates if the HGA filter is running at its maximum capacity

Source Utility Line Phase to Phase Voltage

I_LINE_RMS

Output

Amps RMS

Line/Load Phase Current

1000 = 1.0 Unity PF 950 = Leading PF

0 = Network Run

Enabled

I/O Reg

SYS_NW_START_I N

Input

0 = Network Command Stop 1 = Network Command Run

Remote Network Run/Stop command to the HGA

unused

Input

- - unused

Input

- - unused

Input

- - unused

Input

- - unused

Input

- - unused

Input

- - unused

Input

Network Inte rface

The network interface on the Interface Module allows basic Run/Stop commands and internal status data and can be communicated to and from the HarmonicGuard Active filter. The HMI display implements an integrated ModbusRTU slave device for the network interface (see the HMI Display Connection section) or an optional network communications gateway can be used such as Ether net/I P to implement other protoco ls (see Appendix).

The input/output register maps of the data available from the network interface are available in Table 7.18 and Table 7.19. All input and output registers are two bytes in size. For the base address of the input and output data sections please reference the connection sections in this manual specific to the configured protocol. For the integrated ModbusRTU network interface reference the HMI Display Connection section. If an option Communications Gateway is configured reference the appendix.

Table 7.19 – Network Interface OUTPUT Register Map

Parameter Name

SYS_RUNNING 0 Output SYS_POWER_ON 1 Output SYS_FAULTED 2 Output SYS_IN_I_LIMIT 3 Output V_LINE_LL_RMS 4 Output Volts RMS

I_LINE_PF 6 Output

SYS_NW_START_E N

Address

7 Output

Direction Format Description

-950 = 0.95 Lagging PF

Disabled 1 = Network Run

Table 7.20 – Network Interface INPUT Register Map

Parameter Name

Address

Offset

Direction Format Description

Indicates if the HGA filter is faulted

Line/Load Power Factor - Negative values indicate lagging power factor

Network Run/Stop command enable setpoint

The network Run/Stop command allows a remote network t o send a run command to the HarmonicGuard Active filter. The network command input will only be acknowledged if the Relay Run/Stop Enable is set to ENABLED on the HMI Display setup screen. Pressing stop locally via the HMI Display will set the enable for the Relay Run/Stop Enable to D I SABLED.

Back View of HMI Display

Battery

Back View of HMI Display

USB Host

■ Section 8

Maintenance

Clock Battery Replacement

The HMI Display Real Time Clock is maintained by a non-rechargeable battery internal to the HMI Display. Change the battery every ten years or as needed. The system will continue to function as an active filter with a dead battery but HMI information (fault logs and trend plots) will not be maintained between power cycles.

To replace the battery, open the battery cover on the back of the HMI Display (see Figure 8.1) and remove the old battery. Dispose or recycle the old battery in accordance with any applicable national, state/provincial, and local requirements. Install new battery and close battery cover.

Replacement Battery Type: 3V Lithium CR2032 x Quantity 1

Cover

Figure 8.1 – HMI Display Battery L o cation

Software Field Upgrades

In the event the HMI Display application software needs to be upgraded, the USB host port on the back panel of the HMI Display (see Figure 8.2ftware updates provided by TCI.) can be used for field upgrades. Software upgrade instructions will be sent with any software updates provided by TCI.

Port for Software Upgrades

Figure 8.2 – HMI Display USB Host Location

LED

LED Color

Description (LED Color)

Green

AUX 1

Green

AUX 2

Green

Running Relay Energized

Green

Power-On Relay Energized

Green

Fault Relay Energized

Green

Current Limit Relay Energized

D12

Green

RS485 Communication is active from converter

D13

Orange

RS485 Communication is active to converter

D14

Green

Input Run Command Present

Troubleshooting

HarmonicGuard A ctive Filter Fault

If the display indicates a fault has occurred proceed to the fault screen by choosing the “Fault” menu screen button. To see if this is a recurring fault hit the “History” button from inside the “Fault” screen. To clear a fault press the “Reset” button from inside the “Fault” Screen or the “Stop” button from any screen.

Warning

Only qualified electricians should carry out all electrical installation & maintenance work on t he HGA. Disconnect all sources of power to the drive and HGA before working on the e quipment. Do not

attempt any work on a powered HGA. This HGA unit contains high voltages and c a pacitors. Wait at least five minutes after disconnecting

power from the filter before attempting to service the conditioner. Check for zero voltage between all terminals on the capacitors. Also, check for zero voltage between all phases of the input and output lines. All maintenance and troubleshooting must be done by a qualified ele c trician. Failure to follow standard safety procedures may result in death or serious injury. Unless an external disconnect

means has been provided everything ahead of the filter circuit breaker, including the reactors, will still be energized.

Interface Module Problem

The Interface Module is comprised of four major components; the HMI display, the Interface PCB, the cabling and an optional Gateway. The Interface PCB contains diagnostic LEDs. The locations of the LEDs are shown in Figure 8.3, and their functions are listed in Table 8.1.

Figure 8.3 – Communications Board LED placement

Table 8.1 – LED Functions

Warning

Many electronic components located within the filter are sensitive to static electricity. Voltages imperceptible to human touch can reduce the life, affect performance and/or destroy sensitive electronic devices. Use proper electrostatic discharge (ESD) procedures when se rvicing the filter and its circuit boards.

Troubleshooting Notes

• To reboot the system, remove power to the filter and Interface Module, wait a few minutes then

reapply. If this does not work check all the cable and connections, and try again. If the problem is still not resolved replace the Interface Module assembly.

• If no buttons are pressed for 5 minutes the screen will turn off. To reactivate touch anywhere on the

screen.

• If the HMI Display shows a “COM 1 Station 1: Communication Error” across the bottom of the

screen check the serial cable between HMI Display COM1 and Interface PCB J1.

• If the HMI Display sho ws a “NO COM” indication on the system state indicator or a 7010

Communications Fault in the fault screen check the serial cable between Interface PCB J2 and the HarmonicGuard Active filter power converter module J25 (100A/50A units) or J7 (200A units).

• For technical support contact TCI directly at 1-800-824-8282. Select "Customer Service" or

"Technical Support".

Troubleshooting Flow Chart

Figure 8.4 – Troubleshooting Flow Chart

■ Section 9

Appendix – Installation Diagram

Figure 9.1 – Installation Diagram

100

TCI HGA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Installation, Operation, and Maintenance Manual

T able of Contents

HGA Quick Start Unit Software Setup

Safety Instructions

Overview

Warnings and Cautions

Warnings

Cautions

General S afety Ins truct ions

General T erminology

■ Section 3

Intended Audience

Additiona l Infor mation

Installation Checklist

Receivi ng Inspection and Storage

Receiving Inspection

TCI Limited Warranty Policy

Storage Instructions

Long-Term Storage

Product Descript ion

Nameplate Data

Figure 3.2 – Typical HarmonicGuar d Ac tive filter Nameplate

Part Number Encoding

HGA Part Numbering System – 480V Open and T ype 1

Figure 3.3 – Harmoni cGuard A ctive filte r par t number encoding

HGA Part Numbering System – 480V 3R

Temperature: 40° C Current: 50, 100, 200, 300 Voltage: 480 Enclosure: UL Type 3R

Figure 3.4 – Harmoni cGuard A ctive filte r Part number Encoding

HGA Part Numbering System – 480V 300A

Figure 3.5 – Harmoni cGuard A ctive filte r Part number Encoding

HGA Part Numbering System – 600V

Figure 3.6 – Harmoni cGua rd Active Part number Encoding

Temperature: 50° C Current: 45, 90 Voltage: 480 Enclosure: Open Chass is or UL Type 1

Figure 3.7 – Harmoni cGuard A ctive filte r Part number Encoding

Standard Product Ratings and Dimension Tables

Table 3.6 – HarmonicGuard Ac tive filter Technical Specifications

■ Section 4

Pre-installation Planning

Verify th e A pplicat ion

HGA Ratings

Select a Suitable Location

Environment

Working Space

Mounting an Open Chassis Unit

Cooling Diagrams

Installa tion Guidelines

Mounting

Wiring

Cable Entry Locations

Field Wiring Connection Terminals

Table 4.1a – Exa mple Power Termi nal Wire Size Ca pacity Ra nge and Tightenin g Torque for ABB Circuit Breakers

Table 4.1b – Power Termi nal Wire Size (wi thout brea ker) Ca pacity Range and Tightenin g Torque

Connection Diagram

Current Transformer Installation

Grounding

HarmonicGuard Active Filter Operation

Adjustments

Start Up (Commissioning)

Before Applying Power for the First Time

General Operation

Please reference the Quick Start Guide in Section 1 for the first time power up procedure.

■ Section 5

Maintenance and Service

HGA Reliability and Service L ife

Periodic Maintenance

Reference Drawings

Overload / Over Current Protected

Circuit Breaker Protection

Pre-Charge Circuit Over Current Protec tion

Over Temperature Protection

Troubleshooting

Current Transformer Orientation Troubleshoo ting

System Failure

Required Equipment

Converter Inspection

Outline and Mounting Dimension Drawings