TCI HGP User Manual

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

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