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.transcoil.
Table of Contents Introduction .............................................................................................................................. 2 Receiving Inspection and Storage............................................................................................ 4 Pre-installation Planning .......................................................................................................... 5 Installation Guidelines ..................................................................
INTRODUCTION Introduction Safety Instructions Overview This section provides the safety instructions which must be followed when installing, operating, and servicing the HG7 harmonic filter. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the HG7 harmonic filter. The material in this chapter must be read and understood before attempting any work on, or with, the product.
INTRODUCTION General Safety Instructions These safety instructions are intended for all work on the HG7. Additional safety instructions are provided at appropriate points on other sections of this manual. Warning Be sure to read, understand and follow all safety instructions. ! Warning Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 harmonic filter.
INTRODUCTION Receiving Inspection and Storage Thank you for selecting the HG7 Drive-Applied Harmonic Filter. TCI has produced this filter for use in many variable speed drive applications that require input power line harmonic current reduction. This manual describes how to install, operate and maintain the HG7 harmonic filter. Receiving Inspection The HG7 harmonic filter has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment.
INTRODUCTION Pre-installation Planning Verify the Application HG7 Ratings Make sure that the HG7 harmonic filter is correct for the application. The voltage ratings of the filter must match the input voltage rating of the connected drive. The horsepower and current ratings of the filter must be adequate for the connected load. Select a Suitable Location Environment Locating the HG7 in a suitable environment will help ensure proper performance and a normal operating life.
INTRODUCTION Installation Guidelines Mounting The HG7 must be mounted vertically on a smooth, solid surface, free from heat, dampness, and condensation. Wiring Cable Entry Locations The enclosed HG7 harmonic filters are not provided with enclosure wiring knockouts. A selection can be made at the time of installation. Typical or recommended cable entry locations are shown in the drawings section of this manual.
INTRODUCTION HG7 Harmonic Filter Operation Caution Thoroughly check the installation before applying power and operating the equipment for the first time. Before Applying Power for the First Time Inspect the installation to make sure that all equipment has been completely and correctly installed in accordance with the Installation Guidelines section of this manual. ♦ Check to see that the cooling fan(s) are operating in units so equipped.
INTRODUCTION Installation Intended Audience This manual is intended for use by all personnel responsible for the installation, operation and maintenance of the HG7 harmonic filters. Such personnel are expected to have knowledge of electrical wiring practices, electronic components and electrical schematic symbols. Additional Information Caution This manual provides general information describing your HG7 harmonic filter.
INTRODUCTION Maintenance and Service HG7 Harmonic Filter Reliability and Service Life The HG7 has been designed to provide a service life that equals or exceeds the life of the variable speed drive. It has been thoroughly tested at the factory to assure that it will perform reliably from the time it is put into service. The following periodic maintenance is recommended to assure that the HG7 filter will always perform reliably and provide the expected service life.
INTRODUCTION Fuse Specifications Table 1a through 1d list the specifications for the LC filter power circuit fuses in the HG7. Refer also to the drawings and other information shipped with the unit. Table 1a – Fuse Specifications for HG7 240 Volt Models HG7 Rating (HP) kVar 7.
INTRODUCTION Table 1c – Fuse Specifications for HG7 480 Volt Models HG7 Rating (HP) kVar 10 15 20 30 40 60 75 100 125 150 200 250 300 350 400 450 600 700 800 900 3 5 6 10 15 20 25 30 40 45 60 75 90 105 120 135 180 210 240 270 Power Circuit Fuse Ratings Amps 10 15 15 30 30 40 50 60 80 100 125 175 200 225 250 300 400 450 500 600 Type Class CC Bussmann type KTK-R or equivalent Class T Bussmann type JJS or equivalent Table 1d – Fuse Specifications for HG7 600 Volt Models HG7 Rating (HP) kVar 15 30 50 6
INTRODUCTION Replacement Parts If replacement parts are needed, please contact your TCI representative. To ensure that the HG7 harmonic filter continues to perform to its original specifications, replacement parts should conform to TCI specifications. Factory Contacts and Tech Support For technical support, contact your local TCI distributor or sales representative. You can contact TCI directly at 800-TCI-8282.
INTRODUCTION Product Description HG7 Drive-Applied Harmonic Filter The HG7 is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives. The HG7 is available for 240, 480, 600 (60 Hz) and 380 – 415 (50 Hz) volt systems. It is suitable for use with 3-phase diode bridge rectifier loads such as PWM AC drives.
INTRODUCTION Part Number Encoding Figure 2 identifies the significance of each character in the HG7 part number. The example part number, HG250AW00ST designates a HG7 filter that is rated 75 kVar, 480 volts, 60 Hz. It includes a standard 10% reactor, is tuned to the 5th harmonic, is an open panel and is designed for use with a 250 HP drive.
INTRODUCTION Product Technical Specifications Table 2 lists the major technical specifications for the HG7 Harmonic Filter. Table 2 – HG7 ST and STC Option Harmonic Filter Technical Specifications Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz 380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.5 -900 Hp depending on voltage, 4–710kW See Rating and Dimension tables.
INTRODUCTION Drawings Typical Schematic Diagrams and Outline and Mounting Dimension Drawings Typical HG7 drawings are provided on the following pages. These drawings provide general information describing your HG7 harmonic filter. More specific information is provided by the drawings shipped with the unit. Be sure to carefully review the information on the provided drawings. The information on the drawings provided with the filter takes precedence over the information provided in this manual.
INTRODUCTION Typical Drawings continued INTRODUCTION 17 HG7 I, O, & M Manual
INTRODUCTION HG7 ST Typical Schematic based on 480V HG7 STC Typical Schematic based on 480V When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Detailed note below.
INTRODUCTION HG7 XM Schematic: 7.5 – 60 HP based on 480V When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Detailed note below. HG7 XM Schematic: 200 – 400 HP based on 480V When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Detailed note below.
INTRODUCTION HG7 XM Schematic: 450 – 600 HP based on 480V When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Detailed note below. NOTE 1 Detail: When possible, the “Up to Speed” Auxiliary Contacts should be used instead of the “Run-Stop” Auxiliary Contacts on the VFD. Benefits of this setup: 1. Most electrical systems have generator back-up systems today. The filters will start-up with no capacitance in the circuit.
CONTACTOR & CPT OPTION Standard Filter (ST) The Standard Package has the suffix of “ST” in the part number and includes very high quality harmonic-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.
CONTACTOR & CPT OPTION Contactor Option (STC) STC Option Models This model is identified by the suffix “STC” in the part number. The STC version provides a contactor, control power transformer and connection terminals in the filter trap circuit which allows the VFD user to control the insertion of the HG7 filter’s trap circuit through the use of a relay contact in the drive. It is recommended that the drive contact be programmed to open the contactor below 33% motor power.
POWER MONITOR PACKAGE ONLY Power Monitor Package Option (XM) This model is identified by the suffix “XM” in the part number. The "XM" Option HG7 filters are similar to the standard series HG7, but they have features and characteristics that are beyond the scope of the “Standard” series HG7. In the rating and dimension tables we list the sizes of the “XM” option units only to avoid confusion.
POWER MONITOR PACKAGE ONLY Product Technical Specifications Table 3 lists the major technical specifications for the HG7 “XM” Option filter product: Table 3 – HG7 “XM” Option Harmonic Filter Technical Specifications Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz 380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 120 kVar, 140 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.5 - 400 HP, 500 - 900 Hp depending on voltage.
POWER MONITOR PACKAGE ONLY Control Wiring Control Power An internal control power transformer is provided to supply 120 VAC single-phase power for the contactor, Protection Monitor, and cooling fan(s). Fuses are provided on both the primary and secondary sides of the control transformer. Filter Enable Input An auxiliary N.O. run contact from the drive should be connected to the Filter Enable input to enable the HG7 “XM” Option only when the drive is running.
POWER MONITOR PACKAGE ONLY Connection Diagram Figure 3 shows the typical wiring connections between the HG7 and the drive. Refer to the drawings furnished with the HG7 for more specific information. Refer also to the instructions for the drive and other equipment to which the Enable Input and the Fault Alarm contact are connected.
POWER MONITOR PACKAGE ONLY HG7 “XM” Option Operation Adjustments Protection Monitor Settings ♦ The Protection Monitor Setup Parameters and calibration adjustments are factory set and should not be changed except as directed in the troubleshooting procedures. ♦ The protection monitor is described in detail in the following section of this manual. Start Up (Commissioning) Caution Thoroughly check the installation before applying power and operating the equipment for the first time.
POWER MONITOR PACKAGE ONLY The HG2TM Protection Monitor Introduction Product Description The HG2TM Protection Monitor is included as standard in HG7 “XM” Option models rated over 20 kVar. The HG2 monitors the HG7 operation, electronically protects the power circuits, displays performance information, and provides a control interface with the drive and/or supervisory control system. A three-character display is provided with UP, DOWN, and SELECT keys and two statusindicating LEDs.
POWER MONITOR PACKAGE ONLY Figure 4 – HG2 Protection Monitor Display and Keypad Display and Keypad Figure 4 shows the HG2 Protection Monitor display and keypad. Table 4 lists the various component items and describes their functions. Table 4 – HG2 Protection Monitor Display and Keypad Features Item No. Name Description Function 1 Display LCD 2 3 4 Filter Disabled Filter Enabled UP (Scroll) DOWN (Scroll) SELECT Red LED Green LED Key Displays “OFF” when filter is off.
POWER MONITOR PACKAGE ONLY General Operation Power Up Sequence ♦ For the first 3 seconds after power is applied the display will show “888.” ♦ After the first 3 seconds and until the reset lockout time (parameter 1A, 30 sec. Default) has expired, the display will show “OFF.” ♦ When the reset lockout time has expired: If the Enable input is open and no fault exists: The red Filter Disabled LED will be off. The green Filter Enabled LED will be off. The display will show “OFF.
POWER MONITOR PACKAGE ONLY indicates that the displayed value is the average of the individual phase values. "L 1," "L 2," & "L 3" indicate the display of individual phase values. "L r," indicates that the displayed value is the total of the phase values. To change the "L *" selection, press and hold the SELECT key to scroll to the desired selection. The "L 1," "L 2," & "L 3" selections are available for all of the parameters.
POWER MONITOR PACKAGE ONLY resetting the unit that detected the fault condition. The other units in the system will be clear automatically when the faulted unit is reset. Table 6 – Fault Code Display Fault Code F01 F02 F03 F04 F11 F12 F13 F21 F22 F23 F31 F32 F33 Fault Description External Fault (multiple boards in a series line) Door Open In Run Mode (no delay) Overtemp (6 sec. delay) Serial Data Fault (8 sec delay) Filter Current Low Trip Line 1 (20 sec. delay) Filter Current Low Trip Line 2 (20 sec.
POWER MONITOR PACKAGE ONLY 12. You can step through the menu only in the "UP" direction. If you wish to return to an item once you have stepped past it, step past "---" without pressing the SELECT key to return to "1A.
POWER MONITOR PACKAGE ONLY Troubleshooting Units Equipped with the HG2TM Protection Monitor The HG2TM Protection Monitor and Harmonic Power Factor Meter is included as standard in HG7 “XM” option filters rated over 20 kVar. Units rated 20 kVar and less have Blown Fuse and Filter Enabled pilot lights to indicate their operating status and are not equipped with the HG2 as standard.
POWER MONITOR PACKAGE ONLY Protection Monitor Display Fault Codes If the Protection Monitor display shows a Fault Code (F01 to F33), follow the troubleshooting procedure provided in Table 8. If a Fault Code is displayed, the Filter Disabled LED will be illuminated and the Fault Alarm Relay will be de-energized.
POWER MONITOR PACKAGE ONLY FAULT Code Troubleshooting Procedure F11-F13 Fault on initial startup Filter Current Low Trip If the F11, F12 or F13 fault occurred upon initial startup (commissioning), use this procedure. If the unit had been operating normally for some time after initial startup (commissioning), refer to the next section. This fault indicates the filter current is lower than normal.
POWER MONITOR PACKAGE ONLY FAULT Code Troubleshooting Procedure F11-F13 Fault after initial normal service Filter Current Low Trip If the F11, F12, or F13, fault occurred after the unit had been operating normally for some time after initial startup (commissioning), use this procedure. If the fault occurred upon initial startup (commissioning), refer to the previous section.
POWER MONITOR PACKAGE ONLY Troubleshooting Procedure FAULT Code F31-F33 Filter Over-current Delayed Trip The usual causes for a F31 displayed fault are: Short-term operation above rated line current during acceleration of the load or other normal utilization of the drive's short-term overload capacity. Operation above rated line current due to abnormal drive overload condition. Excessive harmonics present on the distribution system from other sources.
POWER MONITOR PACKAGE ONLY HG2 Protection Monitor Calibration Introduction The HG2 has calibration adjustments, which can be used to calibrate the unit's filter current, line voltage, and line current Operating Parameter displays. The HG2 should not be re-calibrated unless re-calibration is indicated by the troubleshooting procedure or the installation of replacement parts makes re-calibration necessary.
POWER MONITOR PACKAGE ONLY Warning Line voltage is connected to terminals J2, J3, and J4 at the top edge of the HG2 board. The board circuitry is also connected to 120 volts. Calibration Procedure Perform the Setup Procedure on page 32 and verify that all settings are correct for the application. Set parameter 11A to 1, Calibration Mode. When you exit the Setup Mode, the HG2 will be in the Calibration Mode. The unit may then be calibrated using the following procedure. 1.
POWER MONITOR PACKAGE ONLY Troubleshooting Calibration Problems If, during the Calibration Procedure, a parameter is missing or non-responsive, check for proper analog voltage levels at the points indicated in Figure 7 – HG2 Connection Details – Board Component View. Care must be taken not to short circuit between the board test points. Warning! Line voltage potentials are present on the board. If the analog voltage levels are normal and the board cannot be calibrated, the board is probably defective.
POWER MONITOR PACKAGE ONLY J4 J3 J2 R68 R94 R43 R44 R45 R52 R53 R54 J6 J5 J1 Figure 5 – HG2 Keypad View J2 J3 J4 R68 R94 R43 T1 R44 R45 R52 R53 R54 K2 K1 F1 10 1 10 J1 1 10 J5 1 J6 Figure 6 – HG2 Board Component View POWER MONITOR OPTION 42 HG7 I, O, & M Manual
POWER MONITOR PACKAGE ONLY Figure 7 – HG2 Connection Details – Board Component View Replacement Parts If replacement parts are needed, please contact your TCI representative. To ensure that the HG7 harmonic filter continues to perform to its original specifications, replacement parts should conform to TCI specifications. Factory Contacts and Tech Support For technical support, contact your local TCI distributor or sales representative. You can contact TCI directly at 800-TCI-8282.
KIT PACKAGE OPTION (KP) Kit Package Option (KP) “KP” Option Models The HG7 “KP” 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 variable speed drives. The HG7 “KP” Option is available for 200/208, 230/240, 460/480 volt, 575/600 volt systems (60 Hz) and 380 – 415 volt systems (50 Hz).
KIT PACKAGE OPTION (KP) Product Technical Specifications Table 9 lists the major technical specifications and intended environments for the HG7 Harmonic Filter components. Table 9 – HG7 “KP” Option Harmonic Filter Components Technical Specifications Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz 380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.
KIT PACKAGE OPTION (KP) Installation Review all Pre-Installation and Installation instructions at the beginning of this manual. If you are assembling a KP unit in your own enclosure, you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).
KIT PACKAGE OPTION (KP) Field Wiring Information Below is the typical wiring diagram for the 3-phase reactor applied to the front end of the Variable Frequency Drive (VFD). Single-phase applications are acceptable, however, it is important to size the unit based on the single phase Full Load Amperage of the VFD. The input and output connections should be on terminals A and C to ensure proper performance.
COMPONENT PACKAGE OPTION (CP) Component Package Option (CP) “CP” Option Models The HG7 “CP” 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 variable speed drives. The HG7 “CP” Option is available for 200/208, 230/240, 460/480 volt, 575/600 volt systems (60 Hz) and 380 – 415 volt systems (50 Hz).
COMPONENT PACKAGE OPTION (CP) Product Technical Specifications Table 11 lists the major technical specifications and intended environments for the HG7 Harmonic Filter components. Table 11 – HG7 “CP” Option Harmonic Filter Components Technical Specifications Voltage ratings 240, 480 and 600 V, 3 ph, 60 Hz 380 – 415 V, 3 ph, 50 Hz kVar ratings 3 to 270 kVar depending on voltage. Load types 3-phase diode bridge rectifier loads such as PWM AC drives Load power range 7.
COMPONENT PACKAGE OPTION (CP) Installation Review all Pre-Installation and Installation instructions at the beginning of this manual. If you are assembling a CP unit in your own enclosure, you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating. The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50°C (122°F).
COMPONENT PACKAGE OPTION (CP) Field Wiring Information Below is the typical wiring diagram for the 3-phase reactor applied to the front end of the Variable Frequency Drive (VFD). Single-phase applications are acceptable, however, it is important to size the unit based on the single phase Full Load Amperage of the VFD. The input and output connections should be on terminals A and C to ensure proper performance.
TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022 Phone: 800-824-8282 Fax: 414-357-4484 Web Site: http://www.transcoil.com ©2014 TCI, LLC Printed in USA Publication No: 25165 Effective: 05/17/2014 Version: 2.
