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TCi HarmonicGuard HGL Series Installation, Operation And Maintenance Manual

Drive-applied harmonic filter
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HarmonicGuard
Series Drive-Applied
®
Harmonic Filter Installation, Operation,
and Maintenance Manual
Including information for:
TCI, LLC
W132 N10611 Grant Drive
Germantown, Wisconsin 53022
Phone: 414-357-4480
Fax: 414-357-4484
Helpline: 800-824-8282
Web Site: www.transcoil.com
©
2019 TCI, LLC All rights reserved
Product No: 30799
Effective: 09/25/19 Version: E

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Summary of Contents for TCi HarmonicGuard HGL Series

  • Page 1 Harmonic Filter Installation, Operation, and Maintenance Manual Including information for: TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022 Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-824-8282 Web Site: www.transcoil.com © 2019 TCI, LLC All rights reserved Product No: 30799 Effective: 09/25/19 Version: E...
  • Page 3 TCI, LLC. The information in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. TCI, LLC assumes no responsibility for errors or omissions.
  • Page 4 5% THID for standard HGL Series filters at full load. If a properly sized and installed filter fails to meet its specified THID level, TCI will provide material for necessary modifications or replacement filter at no charge.
  • Page 5 Revision Description Date Release 10/19/2017 Added Additional Options 11/22/2017 Updated Part Number Updates to Watts loss table 12/12/2018 Addition of PQconnect 08/21/2019 Addition of PQvision App 09/25/2019...

  • Page 6: Table Of Contents

    General Safety Instructions ........................2 2.0 General Information .........................3 Intended Audience ............................3 Receiving Inspection ..........................3 Storage Instructions ..........................3 TCI Limited Warranty Policy ........................3 3.0 Pre-Installation Planning .........................5 Verify the Application ..........................5 HGL Drive-Applied Filter ...........................5 Nameplate Data ............................5 Part Numbering System..........................6 HGL Filter Overview ..........................7...

  • Page 7: Safety

    HGL Manual 1.0 Safety 1.0 Safety Safety Instructions Overview This section provides the safety instructions which must be followed when installing, operating, and servicing the HarmonicGuard® Low Capacitance (HGL) filter. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the HGL filter. The material in this chapter must be read and understood before attempting any work on, or with, the product.

  • Page 8: General Safety Instructions

    HGL Manual 1.0 Safety General Safety Instructions These safety instructions are intended for all work on the HGL. 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.

  • Page 9: General Information

    Filter Technical Specifications. Store the filter in its original packaging. 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...
  • Page 10 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...

  • Page 11: Pre-Installation Planning

    HGL Drive-Applied Filter The HGL is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by VFDs. The published HGL voltage, Power (Hp or kW) and current ratings apply to matching power (Hp or kW) rated standard VFDs with six-pulse diode bridge rectifiers.

  • Page 12: Part Numbering System

    HGL Manual 3.0 Pre-Installation Planning Part Numbering System Figure 1 identifies the significance of each character in the HGL part number. The example part number, HGL0150AW1S0000 designates an HGL filter that is rated 150 HP, 480 volts, 60 Hz. It includes a line reactor, tuning reactor, and capacitors in a UL Type 1 enclosure.

  • Page 13: Hgl Filter Overview

    HGL Manual 3.0 Pre-Installation Planning Table 1: HGL Technical Specifications Electrical Characteristics 60 Hz, 3 Phase: 480 V/600 VAC Voltage ratings kVar rating 0.15 kVAR/HP Load types 3-phase diode bridge rectifier loads such as PWM AC drives 20-900HP for 480 V/600 V units. Power range varies Load power range depending on system voltage The included series reactors can tolerate 200% of rated...
  • Page 14 HGL Manual 3.0 Pre-Installation Planning No Contactor Option (S) The No Contactor (Standard) Option includes high quality harmonic-grade capacitors and line reactors. This filter will meet most application requirements found today. This cost-effective product is available as an open panel version, in a UL Type 1, UL Type 12, or in an UL Type 3R enclosure.

  • Page 15: Installation Guidelines

    HGL Manual 4.0 Installation Guidelines 4.0 Installation Guidelines 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 location will not be exposed to direct sunlight, corrosive or combustible airborne contaminants, excessive dirt or liquids.

  • Page 16: Power Wiring

    HGL Manual 4.0 Installation Guidelines Power Wiring When selecting a mounting location for the HGL filter, plan for the routing of the power wiring. Route the conduit and wiring from the power source to the filter and then to the VFD. The HGL is provided with internal fuses.

  • Page 17: Fuse Specifications

    HGL Manual 4.0 Installation Guidelines Since the HGL is a passive filter, it is always operating whenever the drive is operating. Only qualified electricians should carry out all electrical installation and maintenance work on the HGL filter. Disconnect all sources of power to the drive and HGL before working on the equipment. Do not attempt any work on a powered HGL filter.
  • Page 18 HGL Manual 4.0 Installation Guidelines Table 3: Fuse Table for HGL 480 Volt, 60Hz Models Branch Circuit Fuse Current Rating Typical Line Current Fuse Rating (Included Internal to HGL Unit) or Circuit Breaker Rating (HP) (Customer Supplied) (J or T) 1000 1200 1300...
  • Page 19 HGL Manual 4.0 Installation Guidelines Table 5: 480 V HGL Watts loss Open Type 1 Type 3R 1046 1062 1062 1217 1235 1235 1454 1476 1476 1411 1432 1432 1548 1571 1571 1842 1869 1869 2053 2083 2083 1976 2005 2005 2225 2258...
  • Page 20 HGL Manual 4.0 Installation Guidelines Table 6: 600 V HGL Watts loss Open Type 1 Type 3R 1182 1200 1200 1306 1325 1325 1452 1474 1474 1766 1792 1792 1566 1589 1589 2079 2110 2110 1984 2014 2014 2034 2064 2064 2341 2376...

  • Page 21: Pqconnect Connectivity

    5.0 PQconnect Connectivity HGL Drive-Applied Filter with PQconnect The PQconnect is an integrated controls option for TCI’s industry leading passive harmonic filters used for filtering the input of variable frequency motor drives (VFDs). In a passive harmonic filter, the PQconnect provides basic tuned circuit contactor control and provides unit status detection, metering, waveforms and power quality data.
  • Page 22 Menu: Save settings, about screen, software update, tech access Settings – Modbus, contactor control, kVAR settings, alert management view Figure 4. Help – Direct links to the TCI Home page and tech support contact information. (THVD) Displays the Total Harmonic Distortion of the utility Line/Load voltage as a...
  • Page 23 HGL Manual 5.0 PQconnect Connectivity To access the settings page as seen in Figure 4, under the Menu toolbar select Tech Access and Enter password 08252014 to enable. In the PQvision settings a user can set their desired Modbus settings. (Note: if changing Modbus settings, one must restart the PQconnect by cycling power to the HarmonicGuard®...

  • Page 24: Example Application Using "Simply Modbus Master 8.1.0

    HGL Manual 5.0 PQconnect Connectivity Table 8: Settings Menu Designators Name Description Allows the user to change Modbus settings of the App and device. When changing Modbus settings of the device the user will select apply and Modbus save settings. Afterwards the user will need to de-energize power to the filter and re-energize the filter.

  • Page 25: Usptl4 Rs485 Converter Dip Switch Settings

    HGL Manual 5.0 PQconnect Connectivity Figure 5: B&B SmartWorx, Inc Model: USPTL4 model RS-422/485 converter With the example converter above, the user can make proper connections from the RS485 converter to the PQconnect J5 communication header. The table below indicates the positions where the RS485 connections lead to.

  • Page 26: Example Setup Instructions To Write Data To The Pqconnect Unit

    HGL Manual 5.0 PQconnect Connectivity Example Setup Instructions to Write Data to the PQconnect Unit: To control the contactor in the unit, first the user will need tech access by writing the • parameter keys Navigate to the settings menu and then select force open or force close button. The contactor state box will indicate if the contactor is open or closed.

  • Page 27: Pqconnect Quick Start Unit Software Setup

    HGL Manual 5.0 PQconnect Connectivity PQconnect Quick Start Unit Software Setup • Verify connections to the PCB via ModbusRTU over RS485 before filter is energized Download PQvision software found on our website: https://transcoil.com/wp- • content/uploads/2018/11/PQvision-Setup-v1.zip Enter password: 08252014 to access software package •...
  • Page 28 HGL Manual 5.0 PQconnect Connectivity Pairing Instructions 1. Once installed, open the PQvision mobile app. (You must allow PQconnect to use Bluetooth.) Any Bluetooth capable PQconnect devices in range will be automatically displayed on the connection screen. 2. Tap CONNECT next to your target PQconnect device.

  • Page 29: Pcb Connections

    3. If the pairing prompt does not appear automatically: Wait up to 15 seconds for the prompt to appear. Close the app completely and reopen it. Please report any issues to TCI: tech-support@transcoil.com PCB Connections Most customer connections to PQconnect will be made on the PCB. Refer to connection diagrams in Figure 7.
  • Page 30 HGL Manual 5.0 PQconnect Connectivity Figure 7: PQconnect Connections...

  • Page 31: Modbus Rtu

    HGL Manual 5.0 PQconnect Connectivity Table 10: Power & Communications Terminals Terminal Description Label Rating Phase A For factory use; Measurement J1, J2, J3 Phase B 600VAC connection points Phase C 1,2,3,4 Not Connected Current transformer For factory use; Only used for 5,6,7,8 connections filters with dual tuned circuits...

  • Page 32: Pqvision Display Connections

    HGL Manual 5.0 PQconnect Connectivity Modbus RTU Connection Figure 8: PQconnect Modbus RTU Connection PQvision Display Connections The hardware pinout for the J5 communication header and default settings is shown below. : Modbus Connector Pin Definitions Table 12 J5 Header Pinout Signal Name Signal Type No connect...
  • Page 33 HGL Manual 5.0 PQconnect Connectivity The default settings can be modified via the PQconnect system menu. A Tech level access password is required to change these parameters. Ensure the board communicates to the desktop app and then First go to Menu  Settings  Device settings  Change to desired Modbus parameters ...

  • Page 34: Register Map

    HGL Manual 5.0 PQconnect Connectivity Register Map Write Parameters: Table 15: Network Interface INPUT/Setpoint Register Map I/O Reg Parameter Name Address Direction Data Values and Examples Description Offset 9 = Save Current Values to Flash 21 = Set User Access 25 = Set Access to Tech Access PARAM_USER_CMD_REQ Input...
  • Page 35 HGL Manual 5.0 PQconnect Connectivity Write Parameters: Table 16: Network Interface INPUT/Setpoint Register Map I/O Reg Data Values and Parameter Name Address Direction Description Examples Offset 0 = Disabled To Enable desired status detections, enter STATUS_FILTER_A_RELAY_ACTION Input DEFAULT: 9 bit mask from table by converting to Range 0 to 65535 decimal.
  • Page 36 HGL Manual 5.0 PQconnect Connectivity Write Parameters: Table 17: Network Interface INPUT/Setpoint Register Map I/O Reg Parameter Name Address Direction Data Values and Examples Description Offset DEFAULT: 5 = 5 kVAR Steps Desired filter kVAR for contactor to SYS_PF_STEP_1_KVAR Input Range: 1 to 200 kVAR enable* Filter Second Tuned Circuit kVAR...
  • Page 37 HGL Manual 5.0 PQconnect Connectivity Table 18: Filter Status References 16-bit values Register A Status Detection TUNE_PHASE_LOSS_A TUNE_PHASE_LOSS_B TUNE_PHASE_LOSS_C TUNE_BALANCE_LOSS_A TUNE_BALANCE_LOSS_B TUNE_BALANCE_LOSS_C TUNE_UNDERCURRENT_A TUNE_UNDERCURRENT_B TUNE_UNDERCURRENT_C TUNE_OVERCURRENT_A TUNE_OVERCURRENT_B TUNE_OVERCURRENT_C UNDER_TEMP OVER_TEMP CPU_ERROR TUNE_REACTOR_THERMAL_SW Register B RECLOSE_LIMIT LINE_REACTOR_THERMAL_SW Table 19: Filter Line Status References 16-bit values Status Detection PHASE_LOSS_A...
  • Page 38 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 21: Network Interface OUTPUT/Feedback Register Map I/O Reg Parameter Name Address Direction Data Values and Examples Description Offset Two 8bit ASCII Characters DSP_SW_VER Output Software revision code for processor. 0x0141 = ASCII for "A1" DSP_MODEL_NUM_RO Output 102 = HGL...
  • Page 39 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 22: Network Interface OUTPUT/Feedback Register Map I/O Reg Parameter Name Address Direction Data Values and Examples Description Offset I_TUNE_A_THD Output Phase A THID for tuned circuit current feedback % THID I_TUNE_B_THD Output Phase B THID for tuned circuit current feedback 50 = 5.0% THID I_TUNE_C_THD...
  • Page 40 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 23: Network Interface OUTPUT/Feedback Register Map I/O Reg Data Values and Parameter Name Direction Description Address Offset Examples 100 = 100 kVA P_LOAD_APPARENT_TOTAL Output Total Filter output apparent power Range: 0 to 1000 kVA 100 = 100kW P_LOAD_REAL_TOTAL Output...
  • Page 41 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 24: Network Interface OUTPUT/Feedback Register Map I/O Reg Data Values and Parameter Name Direction Description Address Offset Examples 0 = Contactor Closed Indicates the status of the CNT_CLOSED Output 1 = Contactor Open Filters tuned circuit contactor.
  • Page 42 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 25: Network Interface OUTPUT/Feedback Register Map I/O Reg Data Values and Parameter Name Address Direction Description Examples Offset 0 = Contactor Closed CNT_STATUS Output Contactor command status 1 = Contactor Open 4800 = 480Vrms RATED_VOLTAGE_RO Output Filter rated voltage...
  • Page 43 HGL Manual 5.0 PQconnect Connectivity Read Parameters: Table 26: Network Interface OUTPUT/Feedback Register Map I/O Reg Parameter Name Address Direction Data Values and Examples Description Offset 0 = None MB_PARITY_RO Output 1 = Odd Modbus Parity DEFAULT: 2 = Even 0 = Enabled RELAY_INPUT_STATUS Output...

  • Page 44: Pqconnect Troubleshooting

    HGL Manual 6.0 PQconnect Troubleshooting 6.0 PQconnect Troubleshooting HarmonicGuard Low Capacitance Filter Status Warning ® If the desktop interface indicates a status warning, hover over the status detection for a brief description. Depending on the condition there are multiple ways to try and clear the status warnings. Only qualified electricians should carry out all electrical installation &...
  • Page 45 HGL Manual 6.0 PQconnect Troubleshooting : LED Functions Table 27 LED Color Description Green Tuned circuit contactor control 1 Green Optional 2 Status LED/ tuned circuit contactor control 2 Green Status LED Green Microprocessor Status LED Green RS485 Communication is active Green 24V LED Green...

  • Page 46: Communication Problems

    Save settings and de-energize filter Connect jumper to J20 Energize filter Try connecting to PCB All Modbus settings should be set to default settings at this point  If the board doesn’t connect after trying hard reset contact TCI Tech-Support ...

  • Page 47: Debug Status Conditions

    Based on the status condition there are various ways a status can appear. Some status conditions are not critical are used as warnings. Before investigating the filter internally, disengage supply voltage to the filter. If problems persist after initial checks, please contact TCI Tech-Support. : Status Conditions...

  • Page 48: Contactor Problem

    Mode. No Contactor mode is typically reserved for HGL units that do not include a has been configured tuned circuit control contactor. If your HGL unit does include a tuned circuit contactor without a contactor. but the PQconnect is configured to not support a contactor, please call TCI technical support.
  • Page 49 This condition should clear shortly after the unit is powered up. If this contactor status condition condition. persists power cycle the unit and call TCI technical support if the condition does not clear. Contactor is open due The contactor is open because the PQconnect is waiting for the configured power on delay time to a unit power on to expire.
  • Page 50 HGL Manual 6.0 PQconnect Troubleshooting Table 32: Contactor codes Code Description Resolution An internal contactor automatic reclose event is pending but the contactor is being held open because the number of re-close attempts in a set time has been exceeded. The PQconnect continuously monitors the internal conditions of the HGL filter and the external conditions of the filter line and load currents and voltages.

  • Page 51: Maintenance And Service

    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 HGL filter continues to perform to its original specifications, replacement parts should conform to TCI specifications.
  • Page 52 TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022 Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-824-8282 Web Site: http://www.transcoil.com © 2019 TCI, LLC All rights reserved Publication No: 30799 Effective: 09/25/2019 Version: E...

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