TCI KMG User Manual

MotorGuard

KMG High Performance

Output Sine Wave Filter

Installation, Operation, and Maintenance Manual

MotorGuard

™

KMG High Performance Output Sinewave Filter Installation, Operation, and Maintenance Manual

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022

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

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

T able of Contents

Safety Instructions ........................................................................................ 5

Overview ................................................................................................................................................. 5

Warnings and Cautions ......................................................................................................................... 5

General Safety Instructions .................................................................................................................. 6

Introduction .................................................................................................... 7

Intended Audience ................................................................................................................................. 7

Additional Information ......................................................................................................................... 7

Installation Checklist ............................................................................................................................. 7

Receiving Inspection and Storage ............................................................... 8

Receiving Inspection .............................................................................................................................. 8

Warranty Information .......................................................................................................................... 8

Storage Instructions ............................................................................................................................... 8

Product Description ...................................................................................... 9

MotorGuard Sine Wave Filter .............................................................................................................. 9

Nameplate Data .................................................................................................................................... 10

Model Number Encoding .................................................................................................................... 11

Standard Product Ratings and Dimension Tables ............................................................................ 12

Product Technical Specifications........................................................................................................ 17

Pre-installation Planning ............................................................................. 19

Verify the Application ......................................................................................................................... 19

Select a Suitable Location ................................................................................................................... 19

Power Wiring ....................................................................................................................................... 20

Control Wiring (for units with boards).............................................................................................. 20

Optional Features ................................................................................................................................ 20

Installation Guidelines ................................................................................ 21

Mounting .............................................................................................................................................. 21

Wiring ................................................................................................................................................... 21

MotorGuard Operation ................................................................................ 24

Adjustments ......................................................................................................................................... 24

Start Up (Commissioning) ................................................................................................................... 24

Operation .............................................................................................................................................. 24

Maintenance and Service ........................................................................... 25

MotorGuard Reliability and Service Life .......................................................................................... 25

Periodic Maintenance........................................................................................................................... 25

For Units with Boards:......................................................................................................................... 25

Troubleshooting .................................................................................................................................... 26

Replacement Parts ................................................................................................................................ 29

Factory Contacts and Tech Support ................................................................................................... 29

Drawings ...................................................................................................... 30

Typical Isometr i c Drawings and Schematic Diagrams ..................................................................... 30

Safety Instructions

Overview

This section provides the safet y instructions which must b e followed when installing, operating and servicing t he KMG MotorGuard Filter. If neglected, physical injury or death may follow, or damage may occur to the MotorGuard or equipment connected to the MotorGuard. The material in this chapter must be read and understood before attempting any work on, or with, the product.

The MotorGuard is intended to be connected to the output terminals of a variable frequency drive (VFD). An AC motor is connected to the output terminals of the MotorGuard and receives power from the VFD through the MotorGuard. The instructions, and particularly the safet y instructions, for the VFD, motor 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 caution readers about conditions, which can, if proper steps are not taken, lead to a serious

fault condition, physical injury, or death. Cautions are used to draw attention to instructions. Failure to properly follow such instr uctions may

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 which a high voltage can cause physical injury and/or equipment damage. The text next to this symbo l describes ways to avoid the danger.

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

Electrostatic Discharge Warning: warns of situations i n which an electrostatic discharge may damage equipment. The text next to this symbol desc ribes ways to avoid the d anger.

Cautions

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

Caution

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

General S afety Ins truct ions

torGuard for the cooling

urces of power have been disconnected

These safety instructions are intended for all work on the MotorGuard. Additional safety instructions are provided at appropriate points o n other sec tions of this manual.

Warning

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

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

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 MotorGuard.

The MotorGuard, VFD, motor, and other connected equipment must be properly grounded.

The MotorGuard receives power from two or more sources. Three-phase power from the output terminals of the VFD is c onnected to the main input terminals of

the MotorGuard. Power from a single-phase 120, 240 or 480 volt supply is connected to the Mo

fan and monitor board. The monitor board alarm contacts may be connected to a circuit that receives power from another

source. All of these sources of power must be disconnected before working on the MotorGuard.

Warning

After switching off the power, always allow 5 minutes for the capacitors in the MotorGuard and in the VFD to discharge before working on the MotorGuard, the VFD, the motor, or connecting wiring. It is good practice to check with a voltmeter to make sure that all so and that all capacitors have discharged before beginning work.

The VFD output terminals and the motor cables are at a dangerously high voltage when power is applied to the VFD regardless of motor operation.

Introduction

Caution

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 MotorGuard equipment grounding lug to the system ground of the premises wiring

Wire the output power terminals, of the MotorGuard, T1, T2, & T3 to the motor.

Connect control power to the MotorGuard.

For monitor board option: Connect the MotorGuard fault relay contact to the appropriate fault

Make sure that the VFD is set for operating modes and ranges that are compatible with the

Thank you for se lec ti n g t he KMG MotorGuard High Performa nce O utput Filter. TCI has p rod uced this filter for use in many PWM variable frequency drive (VF D) applications that require low distortion sine wave o utput po wer. This manual de scribes how to i nstall, operate, and maintain the MotorGuard filter.

Intended Audience

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

Additiona l Infor mation

This manual provides general information describing your MotorGuard filter. More specific information is provided by the drawings shipped with the unit. Be s ure to carefully review t he information provided by these drawings. Information provided by the drawings shipped with the unit takes precedence over the information provided in this manual.

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 lo c a tion will not be exposed to direc t sunlight, c orrosive or combustible airborne contaminants, excessive dirt, or liquids.

and/or other applicable electrical codes.

system. Use a properly sized grounding conductor. Wire the output power termina ls o f the V FD, T1(U), T2(V), & T3(W) to the input terminals of

the MotorGuard, U, V, & W.

monitoring c ircuit. Check the MotorGuard configuration settings to ensure proper voltage is selected.

MotorGuard. Check ever ything thor oughly be fore operating the equipment.

Receivi ng Inspection and Storage

Receiving Inspection

The MotorGuard has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment.

When you receive the unit, you should immediately inspect the shipping container and report any damage to the carrier that delivered the unit.

Verify that the part number of the unit you received is the same as the part number listed on your purchase order.

Warranty Info rmatio n

TCI, LLC (“TCI”) warrants to the original purchaser only that MotorGuard 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 One (1) year of useful service, not to exceed 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 EXPRESS OR IMPLIED WARRANTIES INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FIT NESS 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 stor a ge, 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 replace ment 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 CONSEQUENT IAL 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 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 forth here in.

TCI will not accept the return of any product witho ut its prior written approval. Please consult TCI Customer Service for instructions on the Ret urn Authori zation Pr ocedure.

Storage Instructions

If the MotorGuard is to be stored before use, be sure that it is stored in a location that conforms to published storage humidit y and temperature specifications stated in this manual. Store the unit i n its original packaging.

Product Descript ion

MotorGuard Sine Wave Filter

The MotorGuard is a low-pass sine wave filter designed and developed by TCI to deliver conditioned power to motor loads driven by PWM drives at a variety of lead lengths. The MotorGuard is available for 460/480 volt and 575/600 volt systems.

The MotorGuard is a passive filter connected in series with the output terminals of the variable frequency drive. It is designed to remove the carrier frequency distortion from the output voltage waveform. The use of this low-pass, L-R-C device will result in a nearly pure sine wave voltage profile. This design will reduce the effects of the reflected wave phenomenon, (dv/dt), such as insulation damage or premature failure in motors, transformers and VFD output cables. The MotorGuard will also reduce the effects of stray high fre quency harmo nic current s, thereby red ucing VFD ground fault prob l ems and noise interference in transducer signals.

The MotorGuard is available in t wo package configuration s: Industrial and GP. The Industrial filter is a stand-alone device that can be furnis hed in it s o wn enclo sure a nd mo unted a dja cent to the VFD, and is also avai lable on an op en panel for mo unting withi n an enclosure p rovided with t he VFD or othe r equipment. The GP filter is furnished in its own enclosure and mounted adja c e nt to the VFD.

The MotorGuard is suitable for all lead lengths extending as far as 15,000 feet. The MotorGuard consists of the following standard features and components:

♦ An R-L-C power filter circuit with:

A TCI 3-phase reactor specifically designed for the MotorGuard Power resistors High-endurance, harmonic-rated capacitors

♦ Bleeder resistors to ensure safe capacitor discharge upon filter shutdown. ♦ Compression terminals for ease and integrity of all power wiring. ♦ Cooling fans to ensure adequate cooling and safe operating temperatures.

Optional Monitor Board is available:

♦ A filter performance monitor and alarm circuit with:

Monitor board with relay and status indica ting lights Control transformer for control voltage power Compression terminal blocks for all control wiring

Nameplate Data

Figure 1 sho ws an example of a MotorGuard na meplate. The following i nformation is marked on the nameplate:

♦ Part number: encoded model number explained on the following page ♦ FLA: the rated continuous ope rating current (RMS amps) ♦ System Voltage: the maximum VFD output voltage (fundamental) ♦ Hz: the maximum VFD output frequency (fundamental) ♦ Phase: 3 – The MotorGuard is designed for use only with 3 phase motors. ♦ Drawing #: outline and mounting dimension of filter ♦ Schematic #: schematic diagram of filter ♦ Manufacturing #: for TCI internal use ♦ Enclosure Type: Industrial filters are open panel construction or NEMA 1 enclosed. GP filters

are NEMA 1 or NEMA 3R enclosed.

Figure 1 – Example of MotorGuard Nameplate

Model Number Enc oding

H = Space Heater

0 = No Thermal Switch

Monitor Board

B = Monitor Board

0 = No Monitor Board

Thermal Switch

L = Lugs

C = 600V

Voltage rating:

0 = No Space Heater

Space Heater

0 = No Lugs

S = Thermal Switch

Lugs

Options:

Enclosure:

Current Rating (amps)

A = 480V

K- Series

MotorGuard Product Line

0100A0G

G01 = General Purpose Indoor (gray)

G3R = General Purpose NEMA 3R (white)

MG3

Figures 2a and 2b identify the significance of each character in the MotorGuard model number. The example model number, KMG130A01A designate s an Industrial MotorGuard that is rated 130 amps, 480 volts, and is furnished in a NEMA 1 enclosure.

Figure 2a – MotorGuard Model Number Encodi ng – Industrial V ersion

Figure 2b – MotorGuard Model Number Encoding – General Purpose Version

The MotorGuard has a current rating rather than a horsepower rating. The rating and dimension tables in the following section list the nominal horsepo wer ratings corr esponding to the current ratings of the standard models.

Standard Product Ratings and Dimension Tables

The following tables list the ratings and dimensions of the standard MotorGuard models:

♦ Table 1 lists 480 Volt models on open panels. ♦ Table 2 lists 480 Volt models in NEMA 1 enclosures. ♦ Table 3 lists 600 Volt models on open panels. ♦ Table 4 lists 600 Volt models in NEMA 1 enclosures. ♦ Table 5 lists 480 Volt models in NEMA 1 enclosures. ♦ Table 6 lists 480 Volt models in NEMA 3R enclosures. ♦ Table 7 lists 600 Volt models in NEMA 1 enclosures. ♦ Table 8 lists 600 Vo lt models in NEMA 3R enclosures.

Table 1 – Industrial 4 80 Volt Models on Ope n Pane ls

KMG8A00A

5 8 300

KMG12A00A

7.5

350

KMG16A00A

400

KMG23A00A

550

KMG30A00A

650

KMG35A00A

750

KMG45A00A

850

100

KMG55A00A

1000

115

KMG65A00A

1100

160

KMG80A00A

1550

175

KMG110A00A

110

1700

195

KMG130A00A

100

130

2050

200

KMG160A00A

125

160

2450

250

KMG200A00A

150

200

3300

255

KMG250A00A

200

250

3700

445

KMG305A00A

250

305

4700

460

KMG362A00A

300

362

4650

475

KMG420A00A

350

420

5400

580

KMG480A00A

400

480

6050

635

KMG600A00A

500

600

7350

645

KMG750A00A

600

750

8800

760

60.00

32.00

17.75

(amps)

KMG8A01A

5 8 110

KMG12A01A

7.5

110

KMG16A01A

120

KMG23A01A

125

KMG30A01A

140

KMG35A01A

140

KMG45A01A

155

KMG55A01A

170

KMG65A01A

245

KMG80A01A

260

KMG110A01A

110

280

KMG130A01A

100

130

300

KMG160A01A

125

160

340

KMG200A01A

150

200

345

KMG250A01A

200

250

770

KMG305A01A

250

305

790

KMG362A01A

300

362

800

KMG420A01A

350

420

915

KMG480A01A

400

480

970

KMG600A01A

500

600

975

KMG750A01A

600

750

1085

Model

Number

Nominal

Horspower

Current

Rating

(amps)

Heat

Loss

(Watts)

Weight

(lbs.)

Height

(in.)

30.75 17.00 11.75

56.00 17.00 11.75

60.00 32.00 14.75

60.00 32.00 16.38

Width

(in.)

Depth

(in.)

Table 2 – Industrial 480 Volt Models in NEMA 1 Enclosures

Model

Number

Nominal

Horspower

Current

Rating

Weight

(lbs.)

Height

(in.)

31.38 Wall

Mounted

56.00 Wall

Mounted

76.50

Free

Standing

Width

(in.)

17.50 12.14

17.52 16.40

36.00 24.00

Depth

(in.)

Table 3 – Industrial 6 00 Volt Models on Ope n Pane ls

KMG8C00A

5 8 400

KMG10C00A

7.5

400

KMG12C00A

400

KMG20C00A

550

KMG25C00A

700

KMG28C00A

750

KMG35C00A

800

100

KMG45C00A

950

115

KMG55C00A

1200

160

KMG65C00A

1600

175

KMG80C00A

1650

195

KMG110C00A

100

110

2250

225

KMG130C00A

125

130

2300

250

KMG160C00A

150

160

2500

260

56.00

17.00

14.78

KMG200C00A

200

3500

450

KMG250C00A

250

4500

460

KMG305C00A

300

305

5100

475

KMG362C00A

350

362

6100

580

KMG420C00A

400

420

6900

635

KMG500C00A

500

7900

645

KMG600C00A

600

9000

750

KMG8C01A

5 8 115

KMG10C01A

7.5

115

KMG12C01A

120

KMG20C01A

135

KMG25C01A

140

KMG28C01A

145

KMG35C01A

155

KMG45C01A

175

KMG55C01A

260

KMG65C01A

265

KMG80C01A

265

KMG110C01A

100

110

290

KMG130C01A

125

130

295

KMG160C01A

150

160

340

KMG200C01A

200

770

KMG250C01A

250

775

KMG305C01A

300

305

790

KMG362C01A

350

362

975

KMG420C01A

400

420

975

KMG500C01A

500

1015

KMG600C01A

600

1015

Model

Number

Nominal

Horspower

Current

Rating

(Amps)

Heat

Loss

(Watts)

Weight

(lbs.)

Height

(in.)

30.75 17.00 11.75

56.00 17.00 11.75

60.00 32.00 14.75

60.00 32.00 16.00

Width

(in.)

Depth

(in.)

Table 4 – Industrial 600 Volt Models in NEMA 1 Enclosures

Model

Number

Nominal

Horspower

Current

Rating

(Amps)

Weight

(lbs.)

Height

(in.)

31.38 Wall

Mounted

56.00 Wall

Mounted

76.50

Free

Standing

Width

(in.)

17.50 12.14

17.52 16.40

36.00 24.00

Depth

(in.)

+ 30 hidden pages