TCI MotorShield Users Manual

MotorShield™ Section 1

Warning

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

Warning

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

Caution

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

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■ Section 1

1.1 Safety Instructions

1.1.1 Overview

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

The MotorShield 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 MotorShield and receives power from the VFD through the
MotorShield. The instructions, and particularly the safety instructions, for the VFD, motor and any other related
equipment must be read, understood and followed when working on any of the equipment.

1.1.2 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 instructions 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 with
warning statements marked with the following symbols:

Cautions

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

1 MSD IOM Manual

Section 1 MotorShield

Warning

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

Warning

Dangerous Voltage is used in the operation of the MotorShield. Only qualified electricians
should carry out all electrical installation and maintenance work on the MotorShield.

Warning

Do not attempt any work on a powered MotorShield.
All sources of power must be disconnected before working on the MotorShield.

Warning

After removing power, always allow 5 minutes for the capacitors in the MotorShield and in
the drive to discharge before working on the MotorShield, the drive, the motor, or connecting
wiring. Verify with a voltmeter to make sure that all sources of power have been
disconnected and that all capacitors have discharged before beginning work.

Caution

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

Warning

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

Caution

Visually inspect and secure all loose electrical connections before applying power to the
filter. Failure to do so may result in filter damage or diminished filter performance.

Warning

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

Warning

Prior to operation, confirm the drive operation mode is set to Volts per Hertz mode prior to
operation. Consult the drive manufacturer for proper configuration parameters. Failure to
properly configure the drive could result in drive failure or filter component failure.

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1.1.3 General Safety Instructions

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

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MSD IOM Manual 2

MotorShield™ Section 2

Caution

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

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

 Make sure that the installation location is appropriate for the enclosure type selected.

 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 MotorShield equipment grounding lug to the system ground of the premises wiring

system. Use a properly sized grounding conductor.

 Wire the output power terminals of the VFD, T1(U), T2(V), & T3(W) to the input terminals of

the MotorShield, U, V, & W.

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

 Connect reactor and capacitor temperature switches to the appropriate fault monitoring circuit.

 Check the MotorShield nameplate to ensure rated voltage is appropriate for the power, drive and

motor voltage.

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

MotorShield.

 Confirm the drive operation mode is set to Volts per Hertz mode prior to operation. Consult the

drive manufacturer for compatibility settings for use with sine wave filters.

 Check the installation thoroughly before operating the equipment.

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2 ■ Section 2

2.1 Introduction

Thank you for selecting the MotorShield™ High Performance Sine wave Filter. TCI has produced this filter for use in
many PWM variable frequency drive (VFD) applications that require low-distortion sine wave output power. This
manual describes how to install, operate, and maintain the MotorShield filter.

2.1.1 Intended Audience

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

2.1.2 Additional Information

2.1.3 Installation Checklist

Adhere to the following installation checklist for a successful installation. These points are explained in detail in the
subsequent sections of this manual.

3 MSD IOM Manual

Section 2 MotorShield

2.2 Receiving Inspection and Storage

2.2.1 Receiving Inspection

The MotorShield™ has been thoroughly inspected, 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.

2.2.2 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 was:

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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 agents oral statements do not constitute warranties, shall not be relied upon by the Buyer

and are not part of any contract for sale. All warranties of TCI embodied in this writing and no other warranties are
given beyond those set forth herein.

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

2.2.3 Storage Instructions

If the MotorShield 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 this manual. Store the unit in its original packaging.

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.

MSD IOM Manual 4

MotorShield™ Section 2

2.3 Product Description

MotorShield™ Sine Wave Filter

The MotorShield is a low-pass sine wave filter designed and developed by TCI to deliver conditioned power to
motor loads driven by PWM drives with switching frequencies from 2kHz to 16kHz. This filter is suitable for VFD
drives configured to Volts per Hz modes only. Available for three phase voltage systems up to 460/480 Volts, the
MotorShield is a passive LC filter connected in series with the output terminals of the variable frequency drive. This
design removes the carrier frequency distortion from the output voltage waveform resulting in a nearly pure sine
wave voltage profile.

The MotorShield sine wave filter reduces the effects of the reflected wave phenomenon (dV/dt), which can cause
motor heating, insulation damage, and excessive audible noise. The reduction of high frequency VFD output
currents extends the life of motors and transformers, and eliminates the need for special motor cables. The
MotorShield reduces VFD ground fault problems and noise interference in transducer signals caused by stray high
frequency harmonic currents.

The MotorShield is available in a NEMA 1 / 3R enclosure which can be mounted adjacent to the VFD.

The MotorShield consists of the following standard features and components:

 An L-C power filter circuit with:

o A TCI 3-phase reactor
o High-endurance, harmonic-rated capacitors
o Compression terminals for ease and integrity of all power wiring
o Suitable for all lead lengths extending up to 15,000 feet

5 MSD IOM Manual

Section 2 MotorShield

2.3.1 Filter Configuration

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Typical Configuration* for MSD 480V 9A to 45A

Typical Configuration* for MSD 480V 55A to 305A

Figure 2.1: Typical Configurations for the MotorShield™ Filter

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

MSD IOM Manual 6

MotorShield™ Section 2

MotorS hie ld™ Output F ilter

MSD0110A000

105798DG

130

105798DG

80 MAX

MotorShield

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110

1 / 3R

2.4 Nameplate Data

Figure 2.2 shows an example of a MotorShield nameplate. The following information is marked on the nameplate:
Part number: encoded model number explained on the following page
FLA: the rated continuous operating current (RMS amps)
System Voltage: the maximum VFD output voltage (fundamental)
Hz: the maximum VFD output frequency (fundamental)
Phase: 3 – The MotorShield is designed for use only with 3 phase loads.
Drawing and Schematic #: outline and mounting dimension of filter with schematic diagram
Manufacturing #: for TCI internal use
Enclosure Type: NEMA 1 / 3R

Figure 2.2 – Example of MotorShield™ Nameplate

7 MSD IOM Manual