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TCi MFC A Installation Instructions Manual

Sine wave filter kit
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MFC Sine Wave Filter Kit
Installation Instructions
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.com
© 2020 TCI, LLC All rights reserved
Effective: 10/22/2020
Version: G

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  • Page 1 MFC Sine Wave Filter Kit Installation Instructions 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.com © 2020 TCI, LLC All rights reserved Effective: 10/22/2020 Version: G...
  • 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 .

  • Page 4: Table Of Contents

    General Safety Instructions ....................... 4 General Information ........................ 5 Intended Audience ..........................5 Receiving Inspection ......................... 5 Storage Instructions .......................... 5 TCI Limited Warranty Policy ......................5 Pre-Installation Planning ......................7 Verify the Application......................... 7 Product Description ........................... 7 Part Number Encoding ........................8 MFC “A”...
  • Page 5 Replacement Parts .......................... 56 Factory Contacts and Tech Support ....................56...

  • Page 6: Introduction

    MFC Kit IOM 1.0 Introduction Introduction The information presented in this manual covers the MFC Sine Wave Filter Kit only. Safety Instructions Overview This section provides the safety instructions which must be followed when installing, operating, and servicing the MFC Filter Kit. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the filter.

  • Page 7: General Safety Instructions

    MFC Kit IOM 1.0 Introduction General Safety Instructions These safety instructions are intended for all work on the MFC Filter Kit. 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 8: General Information

    2.0 General Information General Information Thank you for selecting the MFC Filter Kit. TCI has produced this filter for use in many VFD applications that require output voltage filtering. This manual gives an overview of how to install, operate and maintain the MFC Filter Kit. Please contact TCI Technical Support or visit https://transcoil.com/Support...
  • Page 9 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,...

  • Page 10: Pre-Installation Planning

    Product Description The MFC Filter kit 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 MFC Kit is available for 460/480 Volt and 575/600 Volt systems.

  • Page 11: Part Number Encoding

    MFC Kit Instructions 3.0 Pre-Installation Planning Table 1: MFC Sine Wave Filter Technical Specifications 480 V: 5 – 1200 Amps Current Ratings 600 V: 8 – 750 Amps Intermittent overload current of 150% for 1 minute / hour VFD Output Voltage 480 V and 600 V, 3-phase, at fundamental base frequency configured to Volts per Hz VFD Output Frequency...

  • Page 12: Mfc "A" Filter Kit - Sine Wave Filter Kit With Damping Resistor

    MFC “A” Filter Kit – Sine Wave Filter Kit with damping resistor The MFC Filter Kit is a sine wave filter component package designed and developed by TCI to allow qualified customers to build sine wave filters to for the output of VFDs. The filter components are designed to filter out PWM switching ripple when applied correctly and following the schematic connections used by TCI.

  • Page 13: Mfc "A" Filter Kit Part Number And Ratings

    MFC Kit Instructions 3.0 Pre-Installation Planning MFC “A” Filter Kit Part Number and Ratings 480 Volt Model 575/600 Volt Model MFC008AA MFC008CA MFC012AA MFC010CA MFC016AA MFC012CA MFC023AA MFC020CA MFC030AA MFC035AA MFC025CA MFC045AA MFC028CA MFC055AA MFC035CA MFC065AA MFC045CA MFC080AA MFC055CA MFC110AA MFC065CA MFC130AA MFC080CA...

  • Page 14: Mfc "R" Filter Kit - Sine Wave Filter Kit Without Damping Resistor

    MFC “R” Filter Kit – Sine Wave Filter Kit without damping resistor The MFC Filter Kit is a sine wave filter component package designed and developed by TCI to allow qualified customers to build sine wave filters to for the output of VFDs. The filter components are designed to filter out PWM switching ripple when applied correctly and following the schematic connections used by TCI.

  • Page 15: Mfc "P" Filter Kit - Sine Wave Filter Kit With Pqconnect

    PWM switching ripple when applied correctly and following the schematic connections used by TCI. The MFC Filter Kit is available for 480 Volt and 600 Volt systems. When properly designed, assembled, and installed, the completed product is intended to be suitable for use with 3-phase PWM AC VFDs.

  • Page 16: Mfc "P" Filter Kit Part Number And Ratings

    8 kHz • Mode of operation: speed control "scalar" or "V/Hz" without DC braking unless the drive application has been confirmed by TCI Technical Support • Consult VFD manual for other drive specific recommendations for use with sine wave...

  • Page 17: Filter Schematic

    MFC Kit Instructions 3.0 Pre-Installation Planning Filter Schematic The schematic shown in the figure below is an illustration of a typical MFC filter wiring. Figure 2: Typical MFC “A” Filter Kit Wiring *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD) For horsepower ratings 480 V/ 900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors, as illustrated in the schematic below.
  • Page 18 MFC Kit Instructions 3.0 Pre-Installation Planning The schematic shown in the figure below is an illustration of a typical resistor-less MFC (AR, CR) filter wiring. Figure 4: Typical MFC “R” Filter Kit Wiring *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD) For horsepower ratings 480 V/900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors, as illustrated in the schematic below.

  • Page 19: Capacitors

    MFC Kit Instructions 3.0 Pre-Installation Planning The schematic shown in the figure below is an illustration of a typical MFC kit with PQconnect (AP, CP) filter wiring. Figure 6: Typical MFC “P” Filter Kit Wiring *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD) Capacitors The high-endurance, PWM current ripple rated capacitors supplied in the MFC Filter kit are in...

  • Page 20: Capacitor Brackets

    Recommendations for MFC Kit Usage Panel design using a TCI MFC Filter Kit should be performed with appropriate engineering supervision, so the design meets the requirements based on materials utilized in the construction of the panel, wiring practices followed by your shop, and the actual ambient conditions of the...

  • Page 21: Installation

    MFC Kit Instructions 4.0 Installation Installation Installation Guidelines Installation Checklist The following are the key points to be followed for a successful installation. Make sure that the installation location will not be exposed to direct sunlight, corrosive or combustible airborne contaminants, excessive dirt or liquids. Select a mounting area that will allow adequate cooling air and maintenance access.

  • Page 22: Mounting The Filter Kit

    MFC Kit Instructions 4.0 Installation 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.

  • Page 23: Wire Sizing

    Figure 11: Larger Reactors with Copper Flag Terminations Wiring TCI does not recommend running drive input and output wires in the same conduit. Wire Sizing Wires need to be sized based on current to be carried, wire insulation temperature rating, panel temperature rating, bundling of wires, and appropriate codes and standards.
  • Page 24 Operating a sine wave filter at a higher carrier frequency decreases ripple current in the sine wave reactor. This decreases reactor internal power dissipation which decreases reactor temperatures. TCI recommends customers verify intended cooling systems with drive output full current testing to ensure cooling provided is sufficient for the sine wave filter kit components.
  • Page 25 MFC Kit Instructions 4.0 Installation Table 2: Technical Data for MFC “A” 480 Volt Models Rated Capacitor Circuit Power Dissipation Model Load Rating Line Current Current Number (HP) MFC008AA MFC012AA MFC016AA MFC023AA MFC030AA MFC035AA MFC045AA 11.0 MFC055AA 10.5 1000 MFC065AA 16.0 1175 MFC080AA...
  • Page 26 MFC Kit Instructions 4.0 Installation Table 3: Technical Data for MFC “R” 480 Volt Models Rated Capacitor Circuit Power Dissipation Model Load Rating Line Current Current Number (HP) MFC008AR MFC012AR MFC016AR MFC023AR MFC030AR MFC035AR MFC045AR 11.6 MFC055AR 14.2 MFC065AR 17.0 MFC080AR 21.0 MFC110AR...
  • Page 27 MFC Kit Instructions 4.0 Installation Table 4: Technical Data for MFC “A” 600 Volt Models Rated Capacitor Circuit Power Dissipation Model Load Rating Line Current Current Number (HP) MFC008CA MFC010CA MFC012CA MFC020CA MFC025CA MFC028CA MFC035CA MFC045CA 11.0 MFC055CA 14.0 1180 MFC065CA 16.0 1540...
  • Page 28 MFC Kit Instructions 4.0 Installation Table 5: Technical Data for MFC “R” 600 Volt Models Rated Capacitor Circuit Power Dissipation Model Load Rating Line Current Current Number (HP) MFC008CR MFC010CR MFC012CR MFC020CR MFC025CR MFC028CR MFC035CR MFC045CR 11.6 MFC055CR 14.7 MFC065CR 17.0 MFC080CR 22.0...

  • Page 29: Pqconnect Option

    PQconnect Option Product Description The PQconnect is an integrated controls option for TCI’s industry sine wave filter used for filtering the output of VFDs. In the sine wave filter, the PQconnect provides unit status detection, metering, waveforms and power quality data. The PQconnect data is made available via basic Modbus RTU over RS485 serial connection.
  • Page 30 MFC Kit Instructions 5.0 PQconnect Option Figure 12: Typical MFC “P” Filter Kit Wiring PCB Mounting Hardware Figure 13 below shows the standoffs and screws provided with the kits to mount the board on the bracket. Figure 13: PCB mounting Hardware...

  • Page 31: Wiring

    MFC Kit Instructions 5.0 PQconnect Option Reference Drawing PKPQ10 for complete board mounting with the bracket. When mounting the bracket into the enclosure there are three guidelines to follow. 1. Determine best location where there is adequate ventilation, depth for components, and cables;...
  • Page 32 MFC Kit Instructions 5.0 PQconnect Option Table 6: Form C Relay Contacts Terminal Description Label Tightening Torque Wire Range Reactor 1, 2 Thermal Customer contacts 3.5 lb-in (0.4 Nm) 28-12 AWG Switch Optional Reactor 1, 2 Customer contacts 3.5 lb-in (0.4 Nm) 28-12 AWG Thermal Switch...

  • Page 33: Modbus Rtu

    Note: Voltage sense wire terminals J1 & J3 accept wire gauges of 16-28 AWG with a tightening torque of 4.4 in-lb (0.5 Nm). Alternate/Equivalent tabs and ring lugs may be used for terminations. Please consult with TCI Tech-support if there are any questions for alternate parts. Modbus RTU The PQconnect Modbus RTU network communication interface transmits and receives command and status data from the PQconnect Modbus master over a RS-485 serial link.

  • Page 34: Pqvision Pc Application Screen Elements

    PQvision application can be used for basic setup of the MFC Sine Wave filter. Enter password 08252014 to enable tech access. Please ensure the latest version of PQvision is downloaded to your PC. The software is available on the TCI MFC Kit page located here: https://transcoil.com/products-kmg-mfcdrawings-htm/...
  • Page 35 MFC Kit Instructions 5.0 PQconnect Option A standard RS485 to USB converter can be used with your Sinewave Filter with PQconnect. To run the PQvision software the converter will need to be connected to terminal J5 on the PQconnect PCB with pin orientation as described in the table, the USB connector will need to be run to laptop or PC.

  • Page 36: Pcb Calibration Process

    MFC Kit Instructions 5.0 PQconnect Option PCB Calibration Process If the user needs to calibrate the PCB than they will need to follow the steps below. Note: an RS485 to USB converter, a windows computer, and PQvision will be needed for the calibration. Before energizing the filter, the user should connect the RS485 to USB converter to the PCB.
  • Page 37 MFC Kit Instructions 5.0 PQconnect Option PQconnect Reset command: if changing the Modbus settings, the user will be required to reset the PCB after saving settings. This can be easily done through the menu by clicking menu and Reset PQconnect. The reset command will only work if the PCB is communicating to the desktop application or Modbus network.
  • Page 38 MFC Kit Instructions 5.0 PQconnect Option Table 13: PQvision Settings Menu Designators Name Description Determines if the unit’s PCB is ready to run “Run” – PCB is calibrated and ready System State If the system state is labeled as “Calibrate check” the user must perform the calibration process.
  • Page 39 MFC Kit Instructions 5.0 PQconnect Option Figure 20: PQvision Parameter List Menu Table 14: PQvision Parameter List Menu Designators Name Description The setpoints toolbar will allow the user to adjust parameters to their desired settings. Feedbacks will allow the user to view the present values of the filter.
  • Page 40 MFC Kit Instructions 5.0 PQconnect Option Figure 21: Status Detection History Table 15: PQvision Status Detection History Menu Designators Name Description Number of status conditions that occurred in the filter Note: when reaching the 99 index any new status conditions Index will start to overwrite existing index’s starting with index 0.

  • Page 41: Register Map

    MFC Kit Instructions 5.0 PQconnect Option Register Map Read Parameters: Table 16 : Network Interface OUTPUT/ Feedback Register Map Note for metering data including Output Voltage, THVD, Peak Voltage to RMS voltage ratio, Fundamental Frequency, and Carrier Frequency if data is not available the PQconnect will report a value of 63353 (or 0xFFFF in hex format) to indicate no data is available.
  • Page 42 MFC Kit Instructions 5.0 PQconnect Option available. Filter output Peak Voltage to output RMS voltage ratio B-C V_LOAD_BC_PEAK_RMS_RATIO Output phase Read only value. Filter output Peak Voltage to output RMS voltage ratio C-A V_LOAD_CA_PEAK_RMS_RATIO Output phase Read only value. Range 1 to 500 Filter output fundamental frequency V_OUT_FUND_HZ...
  • Page 43 MFC Kit Instructions 5.0 PQconnect Option Read Parameters: Table 17 : Network Interface OUTPUT/ Feedback Register Map I/O Reg Format and Parameter Name Address Direction Description Examples Offset 0 = Power on Determines if the PCB was unsuccessful powered on SYS_POWER_ON Output 1 = Power on...
  • Page 44 MFC Kit Instructions 5.0 PQconnect Option 0-11, 13-17 = Indicates the present state of the parameter load, save, parameter state machine. PARAM_STATE Output restore, reboot in progress. Read only value. 12 = parameter load complete 0 = Initial state 1 = Parameter load Determines the current state of the 2 = Calibration In PQconnect...
  • Page 45 MFC Kit Instructions 5.0 PQconnect Option Read Parameters: Table 18: Network Interface OUTPUT / Feedback Register Map I/O Reg Parameter Name Address Direction Format and Examples Description Offset Modbus Parity 0 = None Read only value. To MB_PARITY_RO Output 1 = Odd change this value, modify 2 = Even (DEFAULT) the corresponding register...
  • Page 46 MFC Kit Instructions 5.0 PQconnect Option Table 19: Fault Codes Bit Position Fault Descriptions 16 bit register with bit position 0 to 15 Overvoltage Phase A Overvoltage Phase B Overvoltage Phase C High THVD Phase A High THVD Phase B High THVD Phase C Reactor Thermal Switch 1 Reactor Thermal Switch 2...
  • Page 47 MFC Kit Instructions 5.0 PQconnect Option Write Parameters: Table 20: Network Interface INPUT/Setpoint Register Map I/O Reg Format and Parameter Name Address Direction Description Examples Offset 0 = Initialization 9 = Save current Note that defaulting the flash values to flash will clear all calibration data USER_STATE_REQ Input...
  • Page 48 MFC Kit Instructions 5.0 PQconnect Option 11520 = 115200 baud rate Modbus RTU Device Baud MB_BAUD_RATE Input DEFAULT: 3840 = Rate* 38400 baud rate 960 = 9600 baud rate 0 = None MB_PARITY Input 1 = Odd Modbus Parity* 2 = Even (DEFAULT) Write Parameters: Table 21: Network Interface INPUT Register Map I/O Reg...
  • Page 49 MFC Kit Instructions 5.0 PQconnect Option PCB under temperature clear threshold* Status detection delay time DEFAULT: = 6 in seconds. seconds. STATUS_T_AMBIENT_UT_DELAY Input Range 1 to 3600 PCB under temperature seconds delay threshold* Status detection measure in DEFAULT: = 750 = degrees Celsius.
  • Page 50 MFC Kit Instructions 5.0 PQconnect Option hex) to indicate data not available.* Fundamental frequency tracking mode. This DEFAULT: = 0 parameter determines if the Range 0 to 4 fundamental frequency 0=AC Coupling tracking algorithm uses an 1=DC and AC FUND_TRACKING_MODE Input AC coupled signal (dynamic Coupling...
  • Page 51 MFC Kit Instructions 5.0 PQconnect Option Write Parameters: Table 22: Network Interface INPUT Register Map System auto null calibration 0 = Disabled enable. This value auto SYS_NULL_EN Input 1 = Enabled clears to 0 when calibration complete. 1301 = Sinewave DSP_MODEL_NUM Input Filter model number...

  • Page 52: Example Application Using "Simply Modbus Master 8.1.0

    MFC Kit Instructions 5.0 PQconnect Option Table 25: History Record Formatting Byte Value Format Seconds value of timestamp. Timestamp Timestamp Seconds (4 bytes) seconds:milliseconds value is the time since power on of the event. Range 0 to 255. Indicates the number times the PQconnect Timestamp Power Cycle Count has been reset / power cycled.

  • Page 53: Usptl4 Rs485 Converter Dip Switch Settings

    MFC Kit Instructions 5.0 PQconnect Option Table 26: USPTL4 to J5 Header Connections J5 Header B&B Converter Signal Name Signal Type Pinout USPTL4Pin Out No connect TDB(+) RS-485 B (non-inverting) RS-485 SC/G TDA(-) RS-485 A (inverting) No connect USPTL4 RS485 Converter Dip Switch settings All four switches of the B&B converter from the factory should be set to the ON position and should look like the following.
  • Page 54 MFC Kit Instructions 5.0 PQconnect Option • In order to the voltage in the unit, first the user will need tech access by writing the parameter keys • Next, select the “WRITE” button on the screen shown above. • The screen below will be shown. Configure the fields as shown in the picture. •...

  • Page 55: Troubleshooting

    MFC Kit Instructions 6.0 Troubleshooting Troubleshooting MFC sine wave filter components have been designed to provide a service life that equals or exceeds the life of the variable frequency drive. The following periodic maintenance is recommended to ensure that the MFC sine wave filter kit will perform reliably and provide the expected service life.
  • Page 56 MFC Kit Instructions 6.0 Troubleshooting Table 27: LED Functions LED Color Description Green Output Relay 1 Green Output Relay 2 Green Detection Status LED Green Microprocessor Status LED Green RS485 Communication is active Green 24V LED Green 5V LED Note: Status LED’s will blink according to the filter status. The microprocessor status LED will blink 1hz if the filter is okay, however if there has been an alert the LED will blink according to the status detection.

  • Page 57: 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 58: Debug Status Conditions

    MFC Kit Instructions 6.0 Troubleshooting Debug Status Conditions Based on the fault condition there are various ways a fault can appear. Before investigating the sine wave filter internally, disengage supply voltage to the filter. Table 30: Fault conditions Status detection Description Debug Filter has detected...

  • Page 59: Evaluating Mfc Sine Wave Filter Performance

    Replacement Parts If replacement parts are needed, please contact your TCI representative. To ensure that the MFC sine wave filter continues to perform to its original specifications, replacement parts should conform to TCI specifications.
  • Page 61 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.com © 2020 TCI, LLC All rights reserved Part Number #30335 Effective: 10/22/2020 Version: G...

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