TCI HGP User Manual

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HarmonicGuard

Series Drive-Applied Harmonic Filter

Installation, Operation, and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-TCI-8282 Web Site: http://www.transcoi l. c om

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

i HGP I, O, & M Manual

T able of Contents

Introduction .............................................................................................................................. 4

Receiving Inspection and Storage ............................................................................................ 6

Pre-installation Planning .......................................................................................................... 7

Installation Guidelines ............................................................................................................. 8

HGP Filter Operation ............................................................................................................... 9

Installation ............................................................................................................................. 10

Maintenance and Service ....................................................................................................... 11

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

Standard Option (S) ............................................................................................................... 16

Contactor Option (C) ............................................................................................................. 17

Fuse Monitor with Contactor Option (F).............................................................................. 18

Fuse Monitor without Contactor Option (G) ....................................................................... 19

Filter and Fuse Monitor Operation ....................................................................................... 20

CP Kit Enclosure (8) with Option (0) .................................................................................... 22

Line Reactor Installation ........................................................................................................ 23

Typical Voltage Distortion Option (0) .................................................................................. 25

High Voltage Distortion Option (1) ....................................................................................... 26

STANDARD OPTION (S)

Dangerous Voltage Warning: warns o f situation s where high

General Warning: warns of situations that can cause physical

Electrostatic Dischar ge Warning: warns of sit uations in which

General Caution: identifies situatio ns that can lead to a

Introduction

Safety Instruc tions Over vie w

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

The HGP filter is intended to be connected to the input terminals of one or more VFDs. Three -phase power is connected to the input terminals of the HGP and power is supplied to the VFD or VFDs through the HGP. T he instr uctio ns, and particu larly t he saf ety inst ructio ns, for t he VFDs, motors, and any other related equipment must be read, understood, and followed when working on any of the equipment.

Warnings and Cautions

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

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

Warnings

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

Warning

voltage can cause physical injury and/or damage equipment. The text next to this symbol describe s ways to avoid the danger.

injury and/ or damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger.

an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger.

Cautions

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

Caution

malfunction and possible equipment damage. The text describes ways to avoid the situation.

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

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

Only qualified electricians should carry out all electrical

All wiring must be in accordance with the National Electrical

Disconnect all power before working on the equipment.

The HGP filter, drive, motor, a nd other connected equipment

After switching off the power, always allow 5 minutes for the

capacitors have discharged before beginning work.

General S afety Ins truct ions

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

Warning

installation and maintenance work on the HGP filter.

Code (NEC) and/or any other codes that apply to the installation site.

Do not attempt any work on a powered HGP filter.

must be properly grounded.

capacitors in the HGP filter and in the drive to discharge before working on the HGP, the drive, the motor, or the connecting wiring. It is a good idea to check with a voltmeter to make sure that all sources of power have been disconnected and that all

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Product Family

Warranty Period

KLR, KDR

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

One (1) year of useful service,

HGP, HG7, KH, 3H, KRF

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

KCAP, KTR, KMP

Five (5) years from the date of shipment.

One (1) year of useful service,

not to exceed 18 months from the date of shipment.

Receivi ng Inspection and Storage

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

Receiving Inspection

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

TCI Limited Warranty Policy

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

KLC, KLCUL, KMG,

V1k

All Other Products

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

This warranty shall not apply if the product was:

a) Altered or repaired by anyone other than TCI; b) Applied or used for situations other than those originally specified; or c) Subjected to negligence, accident, or damage by circumstances beyond TCI’s control, including but not

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

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

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

The employees and sales agents of TCI are not authorized to make additional warranties about TCI’s products. TCI’s employees and sales agent’s oral statements do not constitute warranties; these shall not be relied upon by the Buyer, and are not part of any contract for sale. All warranties of TCI embodied in this writing and no other warranties are given beyond those set forth herein.

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

not to exceed 18 months from the date of shipment.

Storage Instructions

If the HGP filter is to be stored before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in Table 1 (HarmonicGuard Passive Filter Technical Specifications). Store the unit in its original packaging.

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Unless specifically labeled as approved for such use, this equipment is not

Pre-installation Planning

Verify th e A pplicat ion

HGP Ratings

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

Select a Suitable Location

Environment

Locating the HGP in a suitable environment will help ensure proper performance and a normal operating life. Refer to the environmental sp ecifica tions li sted in Table marke d on t he u ni t' s na me p late, and/or noted on the drawings furni s hed with the unit.

Warning

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

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

suitable for use in an explosive atmosphere or in a "Hazardous (Classified) Location" as defined in article 500 of the National Electrical code.

Working Space

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

Mounting an Open Panel Unit

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

Power Wiring

When selecting a mounting location for the HGP filte r, plan for the routing of the power wiring. Route the conduit and wir ing from the power source to the filter and then to the VFD. The HGP is provided with internal fuses.

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Use copper wire that is appropriate for the voltage and current rating of the

rating of 75°C or higher.

Installa tion Guidelines

Mounting

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

Wiring

Cable Entry Locations

The enclosed HGP filters are not provided with enclosure wir ing kno c ko ut s. A loc at io n can be select ed at the time of installation. Typical or recommended cable entry locations are shown in the drawings section of this manua l .

Field Wiring Connection Terminals

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

Grounding

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

Power Wiring

Caution

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

Note: in large units, the input power conductors are connected directly to the input terminals on the line reactors.

Connect the output terminals o f the HGP to the input power terminals of the VFD. Note: in la rge unit s, the o utput power conductors are connected directly to the output terminals on the

line reactors. Refer to the VFD installation instructions for additional information.

equipment. The wire selection must conform to the requirements of the National Electrical Code and/or other applicable electrical codes. For units rated less than 100 amps, use wire with an insulation temperature rating of 60°C or higher. For units rated 100 amps or more, use wire with an insulation temperature

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Thoroughly check the installation before applying power and operating

HGP Filter Operation

Caution

the equipment for the first time.

Before Applying Power for the Fir st Time

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

♦ Check to see that the cooling fan(s) a re operating in units so equipped . ♦ Check to make sure power connections are torqued to recommended torque value.

Operation

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

Standard Option (S) HGP IOM Manual

Installation

This manual pro vid es gene ra l in fo r mati o n desc ri b i ng your HGP filter. Be sure to

notice.

Make sure that the installation lo c a tion will not be exposed to direct sunlight, corrosive or

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

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

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

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

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

≤ 40 HP

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

≥ 50 HP

Use Class J, T, CC, or L fuses appropriate for rating of conductor used to connect to source

STANDARD OPTION (S)

Intended Audience

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

Additiona l Infor mation

Caution

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 ar e approximate and should not be used for any purpose requiring exact data. Contact the factory in situations where certified data is r e quired. All data is subject to change wit hout

Installation Checklist

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

combustible airborne contaminants, excessive dirt or li quids.

and/or other applicable electrical codes.

Use a properly sized grounding conductor.

the VFD.

100 kA SCCR Fusing Requirements

Below is a table of line fusing requirements that must be supplied to comply with the 100kA SCCR rating.

Size Required Action(s)

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Only qualified electricians should carry out all electrical installatio n and

may result in death or ser ious injur y.

Maintenance a nd Service

HGP Filter Reliabil ity and Servic e Lif e

The HGP has been designed to provide a service life that equals or exceeds the life of the VFD. It has been thoroughly tested at the factor y to assure that it will perform reliabl y from the time it is put into service. It is recommended that the following maintenanc e be done once a year to ensure that the HGP filter will always perform reliably and provide the expected service life.

Periodic Maintenance

Warning

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

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

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

enclosure whenever excess dirt has accumulated. Torque all power wire connections, loose connections can overheat and damage the filter.

All electrical connections must be re-torqued annually.

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

Troubleshooting

Warning

maintenance work on the HGP filter. Disconnect all sources of power to the drive and HGP before working on the equipment. Do not attempt any work on a powered HGP filter. The harmonic filter contains high voltages and capacitors. Wait at least five minutes after disconnecting p ower from the filter before you attempt to service the harmonic filter. Check for zero voltage between all terminals on the capacitors. Also, check for zero voltage between all phases of the line side of the fuses, Fu1(a)–Fu2(a)–Fu3(a), and all input terminals L1, L2 and L3 of the line reactor (KDR). All set up, maintenance, and tro ubleshooti ng must be done by a qualified electrician. Failure to follow standard safety procedures

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

Replacement Parts

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

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

1.3

7.5 3 20

10 3 20

15 5 30

20 6 30

25 8 30

100

125

100

150

125

200

150

100

225

200

125

300

250

150

375

300

175

450

350

105

200

500

Fuse Specifications

Table 1a lists the specifications for the fuses in the HGP. Refer also to the drawings and other information shipped with the unit.

Table 1a – Fuse S peci fications for HGP 48 0 Volt Models

HG7 Rating

(HP)

kVar

Max Branch Circuit

Fuse

(J or T) (J, T or L)

Max Line Fusing

NOTE: Customers must provide line fusing to complete SCCR 100KA rating.

Factory Contacts and Tech Suppor t

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

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Product Descript ion

HGP Drive-Applied Filter

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

The HGP is a passive filter connected in series with the input terminals of a VFD or several VFDs that operate as a group. It is designed to provide a low impedance path for t he major harmonic currents demanded by the drive. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the drive. It is also available o n an ope n panel fo r mountin g within an enclo sure with the dri ve or other equipment.

The HGP filters consi st minimally of the following features and components:

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

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

♦ Multiple tuned circuits on 700 HP to 900 HP ♦ Bleeder resistors to ensure safe capacitor discharge upon filter shu t down ♦ Cooling fans (on select models) to ensure adequate cooling and safe operating

temperatures

♦ Compression terminals for ease and integrity of all power and control wiring ♦ Fuses, sized to protect the capacitor wiring

Nameplate Data

The following information is marked on the nameplate:

• Part number : encoding is explained on the following page

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

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

• Hz: the rated frequency (60 Hz)

• Phase: 3 – The HGP filter is designed for use onl y with 3-phase power.

• Drawing #: outline and mounting dimension drawing number

• Schematic #: schematic diagram drawing number

• Manufacturing #: for TCI internal use

• Enclosure Type: UL designation or "Open" panel construction

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

FGOption:

- St andard

Option:

- Typic al V ol tage Dis tort i on

Option:

- High Vol t age Di st ort i on

Option:

- St andard

Option:

- Fus e M oni t or with Cont act or

- Fus e M oni t or without Cont act or

- 60 Hz

Enclosure:

- Open

Frequency:

Horse P ower:

Vol t age Rat i ng:

A - 480 V

000

Series:

AW1SP150G

- Type 1

- Contac tor

- St andard

- Type 3R

Part Number Encoding

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

Figure 1 – HGP Part N umber Encod ing

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Voltage ratings

480V, 3 phase, 60 Hz

kVar ratings

1.3 to 270 kVar depending on voltage.

Load types

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

Load power range

5 -900 HP

The included series reactors can tolerate 200% of rated current for at least 3 minutes.

SCCR (short circuit current rating)

Maximum elevation

3,000 feet (1,000 meters) as standard.

operation above this temperature.

Maximum ambient storage temperature

Maximum humi d it y, operating or storage

UL Type 1 enclosure UL Type 3R enclosure

Insertion Impedance

+/- 10% at full load curre nt

Fusing and protection:

All units have internal fuse prote c tion for the harmonic filter circuit.

550 700

2900

675 800

3000

650 900

3300

100

750 200

1600

125

1000

250

1800

150

1200

Product Technical Specifications

Tables 1 & 2 list the major technical specifications for the HGP Filter.

Table 1 – HGP Technical Specifications

Current ratings

Standard rating is 100kA.

Maximum ambient operating temperature

Enclosure options

Agency approvals or certifications

Table 2 – HGP Watts loss

HP Heat Loss (w atts) HP Heat Loss (w atts)

5 140 200 1600

7.5 150 250 1800 10 175 300 2100 15 250 350 2200 20 275 400 2600 25 250 450 2800

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

60°C (140°F)

95%, non-condensing.

UL and cUL Listed to UL508A

30 300 500 3100 40 500 600 2700

Standard Option (S) HGP IOM Manual

STANDARD OPTION (S)

Standard Option (S)

The Standard Option includes hi gh q ualit y ha r monic-grade capacitors and line reactors. This filter will meet the majority of application requirements found today. This cost effective product is available as an open panel version, in a UL Type 1 enclosure, or in an UL Type 3R enclosure. The open panel is perfect for inclusion in a MCC section or easy installation into industry standard enclosures. The UL Type 1 enclosed units maintain the same vertical profile as the open panel design. This design is perfect for applications where floor space is at a premium. The UL Type 3R enclosure protects the filter from harsh conditions.

Product Description

HGP S Option Filter

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

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals of a VFD or several VFDs that operate as a group. It is designed to provide a low impedance path for the major harmonic currents demanded by the VFD. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting within an enclosure with the VFD or other equipment.

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

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

capacitors.

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

temperatures.

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

Standard Option (S) HGP IOM Manual

CONTACTOR OPTION (C)

Contactor Opti on (C)

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

Product Description

HGP C Option Filter

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

The HGP harmonic filter is a passive filter connected in series with the input termi nals of a VFD or several VFDs that operate as a group. It is designed to provide a low impedance path for the major harmonic currents demanded by the VFD. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the VFD. It is also available on an open panel for mounting within an enclosure with the VFD or other equipment.

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

capacitors.

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

temperatures.

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

Contactor Option (C) HGP IOM Manual

FUSE MONITOR WITH CONTACTOR OPTION (F)

Fuse Monitor with Contactor Option (F)

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

This option includes a contactor, control power transformer, and connection terminals in the filter circuit which allows the VF D user to control the insertion of t his circuit throu gh the use of a rel ay contact in the VFD. It is recommended that the drive contact be programmed to open the contactor below 33% motor power. For variable torque (fan) loads this will be approximately below 70% speed, so the at-speed contact may be used. This reduces the possibility of leading power factor interacting with other devices on the power syste m. Contactor logic should also mainta in the contactor closed in cases where the VFD is bypassed and the f ilte r is not bypassed.

Product Description

HGP F Option Filter

The HGP F Option consists of the follo wi ng standard features and compone nts:

capacitors.

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

temperatures.

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

Fuse Monitor with Contactor Option (F) HGP IOM Manual

FUSE MONITOR WITHOUT CONTACTOR OPTION (G)

Fuse Monitor wi thout Contactor Option ( G)

The Fuse Monitor without Contactor Option includes a voltage monitor module and relay that can be connected to a VFD or other device. The fuse monitor will indicate a fuse failure and communicate this condition through the relay to a connected device.

Product Description

HGP G Option Filter

The HGP harmonic filter is a passive filter connecte d in series with the input ter minals of a VFD or several VFDs that operate as a group. It is designed to provide a low impedance path for the major harmonic currents demanded by the VFD. The filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to the VFD. It is als o available on an open panel for mounting within an enclosure with the VFD or other equipment.

The HGP G Option consists of the following s t andard features and components:

capacitors.

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

temperatures.

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

Fuse Monitor without Contactor Option (G) HGP IOM Manual

FITLER AND FUSE MONITOR OPERATION

Filter and Fuse Monitor Operation

HGP Filter Overview

The Harmonic Guard Passive (HGP) Filter provides a low impedance path for the major harmonic currents demanded by Variable Frequency Drives (VFDs). This greatly reduces the amount of harmonic c urrents flowi ng through the e lectrical po wer distributi on system, bri nging those ha rmonic currents i n li ne wi th the I E EE -519 standard for harmonic distortion mandated by an increasing number of utilities.

The HGP Filter includes branch fuses on the harmonic trap circuit capacitors. These fuses are included in the desi gn to pre ve nt da ma ge to the c apa cito rs i n t he e vent of e xce ssi ve ha rmo nic tra p cur rent if the filter is misapplied.

HGP Fuse Monitor Overview

The HGP Fuse Monitor Optio n is used in conj unction with the HGP filter to mo nitor the status o f the HGP branch circuit capacitor fuses and optional contactor. If a blown fuse condition is detected the HGP Fuse Monitor Option will ener gize a SPDT relay contact. Additionally, the Fuse Monitor Option is used to indicate the state of the op tional contactor that allows users to re move the capacitors from the circuit, eliminating the possibility of leading power factor. Finally, the Fuse Monitor Option provides the additional benefit of detecting drive input voltage phase reversal and loss of phase.

The HGP Fuse Monitor can be connected to a programmable digital input available on most modern VFDs and/or Programmable Logic Controllers (PLCs). Once the status of the HGP Fuse Monitor is routed to a programmable digital input the status of the Fuse Monitor can be relayed on the VFDs or PLCs integrated communications field bus or Industrial Ethernet network interface.

Figure 2 – HGP Filter and Fuse Monitor Option Block Diagram

Filter and Fuse Monitor Operation HGP IOM Manual

FITLER AND FUSE MONITOR OPERATION

No Input Line Voltage

Not Present

Closed

Open

Input Line Volta ge has Missing Phase

Input Line Volta ge has Phase Reversal

Phase Reversal

HGP Filter has Blown Trap Fu se

Blown Trap Fu se

Blown

Fuse

HGP Filter Contactor is Open

Contactor Open

Contactor Closed

Relay Contact

Location

Contact Rating

10A Resistive @ 240V AC 1/3HP @ 120/240V AC

10A Resistive @ 240V AC 1/6HP @ 120/240V AC

Fuse Monitor Operation and Relay Specifications

The fuse monitor relay contac t is a s ingle p ole, doub le thro w (SPD T ) dr y type contact. T er minal Blo ck connection TBa-7 is the common connection, TBa-6 is the Normally Closed (NC) connection, and TBa-8 is the Normally Open (NO) Connection.

Table 2 – Fuse Monitor Operation Modes and Output Table

Operating State

HGP Fuse Monitor has Blown Fuse

Nominal Nominal

*X = don’t care condition

Table 3 – HGP Fi lter Fus e Monitor Rela y Con tact Speci fication s

Normally Open Contact (TBa-7 TBa-8)

Normally Closed Contact (TBa-6 TBa-7)

Input Voltage

Phase Loss X* Closed Open

Nominal

HGP Filter

X* Closed Open

Monitor

N.C. Relay Contact (TBa-6 TBa-7)

Closed Open

Open Closed

N.O. Relay Contact (TBa-7 TBa-8)

Figure 3 – HGP Filter Fuse Monitor Typic al Conne ction Cir cuit Di agram

Filter and Fuse Monitor Operation HGP IOM Manual

CP KIT OPTION (0)

CP Kit Encl osure (8) with Option (0)

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

Product Description

HGP CP Kit Option Filter

The HGP CP Kit Op tion is a package of the primary passive filter components needed to build and install a harmonic filter on a VFD or VFD system. The filter components are tuned to pro vide a low impedance path for the major harmonic currents demanded by the VFD when fol lowi ng the sc hemat ic connections used by TCI in the HGP filter.

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

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

capacitors.

♦ Fasten terminals for wirin g si ngle-phase capacitors (select models

CP KIT OPTION (0) HGP IOM Manual

CP KIT OPTION (0)

Line Rea ctor Installation

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

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

KDR Line Re actor In stalla tion Ins tructio n

Recommendations and Considerations: When instal ling t he KD R Li ne Reactors on the INPUT side of the VFD, please use the follo wing guidelines

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

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

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

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

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

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

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

Recommendations for CP Kit Usage to Achiev e 100kA SCCR

Panel design using a TCI HGP kit should be performed with appropriate engineering supervision so the design meets the requirements based on materials you utilize in the construction of your panel, the wiring practices your shop utilizes, and the actual ambient conditions the components will see in your application.

Wire Sizing

Appropriate wire sizing can be calculated using the information in the fuse specification table (repeated from Pg. 12 for convenience). Wires need to be sized based on current to be carried, wire insulation temperature rating, panel temperature rating, bundling of wires, and appropriate codes and standards. Wire size between the power source and the filter line reactor as well as the line reactor and the drive input are based rated filter line current. Wire size in the trap circuit is based on rated trap current. If the capacitor wiring is split into separate capacitor branches, the current each branch carries is proportional to the value of capacitance in each branch.

CP KIT OPTION (0) HGP IOM Manual

CP KIT OPTION (0)

1.3

7.5 3 20

10 3 20

15 5 30

20 6 30

25 8 30

100

125

100

150

125

200

150

100

225

200

125

300

250

150

375

300

175

450

350

105

200

500

Table 1a – Fuse Specifications for HGP 48 0 Volt Models

HG7 Rating

(HP)

kVar

Max Branch Circuit

Fuse

(J or T) (J, T or L)

Max Line Fusing

NOTE: Customers must provide line fusing to complete SCCR 100KA rating.

Selection of Contactors

As an option, you can incl ude contactors to remove the tra p circuit from the filter under no load o r light load conditions. Review the impedance of t he line reactor, this isolates the trap cir cuit capacitors from line transients, removing the need for special capacitor rated contactors in this application. Contactors in the trap circuit can be selected based on the rated trap circuit current using the UL general purpose rating of your intended contactors.

Options

TCI fuses the trap circuit to isolate the trap circuit in the case of component damage. Some failures could leave an unbalanced load on the trap, which can damage additional parts. A fuse in the trap circuit can be selected based on trap circuit rated current.

SCCR Issues

If you need a n SCCR rating gre ater than the default values of compo nents: For example 1 0 kA for terminal blocks or 5 kA for contactors, pay attention to component selection and circuit fusing. Contactors need to be protected by line or trap fusing based on their published SCCR ratings. For trap circuits less than or equal to 40 HP , the inco ming line cir cuit p rote ction of Class J or Class T r ated less than or equal to 60 A will result in 10 kA being supplied to the panel, allowing any type of filter capacitors to be used. Larger filter kits are provided with dry capacitors, which are exempt f rom S C CR calculations.

CP KIT OPTION (0) HGP IOM Manual

VOLTAGE DISTORTION OPTION (0)

Typical V oltage Distortion Option (0 )

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

Typical Voltage Distortion Option (0) HGP IOM Manual

HIGH VOLTAGE DISTORTION OPTION (1)

High V oltage Distortion Option (1)

The High Voltage Distortion Option, intended for applications with levels of background voltage distortion of 2% or higher, is a configuration that e nables the HGP filter to achieve lower levels of current harmonic distortion in ap plications with high background voltage d istortion.

This performance option is availa ble in all of the package options.

High Voltage Distortion Option (1) HGP IOM 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.transcoil.com

Printed in USA

TCI HGP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Installation, Operation, and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

T able of Contents

Introduction

Safety Instruc tions Over vie w

Warnings and Cautions

Warnings

Cautions

General S afety Ins truct ions

Receivi ng Inspection and Storage

Receiving Inspection

TCI Limited Warranty Policy

Storage Instructions

Pre-installation Planning

Verify th e A pplicat ion

HGP Ratings

Select a Suitable Location

Environment

Working Space

Mounting an Open Panel Unit

Power Wiring

Installa tion Guidelines

Mounting

Wiring

Cable Entry Locations

Field Wiring Connection Terminals

Grounding

Power Wiring

HGP Filter Operation

Before Applying Power for the Fir st Time

Operation

Installation

Intended Audience

Additiona l Infor mation

Installation Checklist

100 kA SCCR Fusing Requirements

Maintenance a nd Service

HGP Filter Reliabil ity and Servic e Lif e

Periodic Maintenance

Troubleshooting

Replacement Parts

Fuse Specifications

Table 1a – Fuse S peci fications for HGP 48 0 Volt Models

Factory Contacts and Tech Suppor t

Product Descript ion

HGP Drive-Applied Filter

Part Number Encoding

Figure 1 – HGP Part N umber Encod ing

Product Technical Specifications

Table 1 – HGP Technical Specifications

STANDARD OPTION (S)

HGP S Option Filter

CONTACTOR OPTION (C)

HGP C Option Filter

FUSE MONITOR WITH CONTACTOR OPTION (F)

HGP F Option Filter

FUSE MONITOR WITHOUT CONTACTOR OPTION (G)

HGP G Option Filter

Filter and Fuse Monitor Operation

HGP Filter Overview

HGP Fuse Monitor Overview

Fuse Monitor Operation and Relay Specifications

CP Kit Encl osure (8) with Option (0)

HGP CP Kit Option Filter

Line Rea ctor Installation

KDR Line Re actor In stalla tion Ins tructio n

Recommendations for CP Kit Usage to Achiev e 100kA SCCR

Wire Sizing

Table 1a – Fuse Specifications for HGP 48 0 Volt Models

Selection of Contactors

Options

SCCR Issues

Typical V oltage Distortion Option (0 )

HIGH VOLTAGE DISTORTION OPTION (1)