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TCi HGP HarmonicGuard Series Installation, Operation And Maintenance Manual

Drive applied harmonic filter kit with pq connect
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Drive Applied Harmonic Filter Kit
Installation, Operation, and Maintenance Manual
HarmonicGuard
Series
®
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
© 2019 TCI, LLC All rights reserved
Product No: 29289
Effective: 01/06/2020 Version: N

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  • Page 1 Drive Applied Harmonic Filter Kit 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.com © 2019 TCI, LLC All rights reserved Product No: 29289 Effective: 01/06/2020 Version: N...
  • Page 2 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 3 No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of TCI, LLC. The information in this manual is subject to change without notice. Every precaution has been...
  • Page 4 TCI, LLC assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication. Performance Guarantee Select and install the appropriate HarmonicGuard ®...

  • Page 5: Table Of Contents

    General Safety Instructions ........................3 2.0 General Information ..........................4 Intended Audience ............................4 Receiving Inspection ..........................4 Storage Instructions ..........................4 TCI Limited Warranty Policy ........................4 3.0 Pre-Installation Planning........................6 Verify the Application ..........................6 Recommendations Kit Usage ........................6 HGP Kit Part Numbering System ......................6 Technical Specifications ...........................7...

  • Page 6: Safety

    HGP Kit Manual 1.0 Safety Safety The information presented in this manual covers the HGP filter kits only. For the full HGP manual please visit: https://transcoil.com/Products/HGP-Passive-Harmonic-Filter.htm Safety Instructions Overview This section provides the safety instructions which must be followed when installing, operating, and servicing the HGP Filter kit.

  • Page 7: General Safety Instructions

    HGP Kit Manual 1.0 Safety General Safety Instructions These safety instructions are intended for all work on the HGP filter. 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 HGP filter kit. TCI has produced this filter for use in many variable frequency drive (VFD) applications that require input power line harmonic current reduction. This manual gives an overview of how to install, operate and maintain the HGP PQconnect Filter kit.
  • 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

    Pre-Installation Planning Verify the Application The HGP 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 HGP 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 11: Technical Specifications

    • • The input VFD current waveform shall be consistent with that of a VFD with 3% AC line reactance at full load Please consult TCI regarding optimum filter performance when applied to DC drives. Installation Installation Guidelines Installation Checklist The following are the key points to be followed for a successful installation.

  • Page 12: Select A Suitable Location

    HGP Kit Manual 4.0 Installation Make sure that all wiring conforms to the requirements of the National Electrical Code (NEC) and/or other applicable electrical codes. Ground the filter components using properly sized grounding conductor. Connect three-phase power to the input terminals of the HGP, L1, L2, and L3. Connect the output power terminals of the HGP line reactor, T1, T2, and T3, to the input power terminals of the VFD.

  • Page 13: Sccr Ratings

    5 kA for contactors, pay attention to component selection and circuit fusing. Contactors need to be protected by line or branch tuned circuit fusing based on their published SCCR. TCI HGP Kit include reactors that are not required to have a short circuit current rating per UL 508A SB4.2.1 Exception 1.
  • Page 14 > 7.5 No requirement for SCCR *Please review UL 508A SB4.1 in context of the final filter design (any deviation from the TCI HGP filter of similar rating) and Table 2 – Customer Installed Line Fuse Requirements to Comply with 100kA SCCR to confirm applicable SCCR.

  • Page 15: Filter Wire Sizing

    HGP Kit Manual 4.0 Installation Filter Wire Sizing 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. Wire size between the power source and the filter line reactor, as well as the line reactor and the drive input, are based rated filter line current.
  • Page 16 HGP Kit Manual 4.0 Installation Table 5 – 480 V, 60Hz, HGP HGP Rating (HP) Watts Loss Tuned Circuit Current (A) Line Current (A) 10.3 13.7 17.1 25.7 25.7 34.2 42.8 51.3 68.4 1075 77.0 1325 1475 1875 1725 1775 2000 2300 1975...
  • Page 17 HGP Kit Manual 4.0 Installation Table 6 – 380-415 V, 50Hz, HGP HGP Rating (HP) Tuned Circuit Current (A) Line Current (A) 10.3 13.7 25.7 25.7 25.7 42.8 51.3 68.4 77.0 1120 1200 1280 1440 1520...

  • Page 18: Kdr Line Reactor Installation Instructions

    Refer to NEC (National Electrical Code) wiring practices for appropriate wire sizes for your application. TCI recommends that these reactors be wired and located as close to the front end of the VFD as possible to have the greatest success in both protecting the VFD as well as mitigating line harmonics.
  • Page 19 HGP Kit Manual 4.0 Installation reviewing specific requirements on heat limitations. Line reactor heat loss information is available on the web at https://transcoil.com/products/kits-page/hgp-kits. These reactors are designed to be floor-mounted or wall-mounted. Large open-style devices should be panel mounted by incorporating a bracket that would act as a shelf to support the reactor and/or enclosure.
  • Page 20 HGP Kit Manual 4.0 Installation • In small line reactors with six position terminal blocks, the terminal block is wired A1, A2, B1, B2, C1, and C2 from left to right. The tap lugs AT, BT, and CT extend out from the front face of the coil.

  • Page 21: Tuning Reactor

    HGP Kit Manual 4.0 Installation Figure 6 – Copper Flag Terminations • In the largest line reactors, the tap connection is off a winding that projects out from the front of the reactor. Figure 7 – In-Line Tap Termination Tuning Reactor The standard schematics above illustrate the normal configuration where the tuned circuit is connected to the line reactor tap.
  • Page 22 HGP Kit Manual 4.0 Installation power unless the bleeder resistors are connected, hazardous voltages will remain across the capacitors after the power has been disconnected. As a check, the total kVAR of capacitors connected to the tuned reactor should match the part number of the reactor.

  • Page 23: Capacitor Brackets

    HGP Kit Manual 4.0 Installation Capacitor Brackets Figure 9 – Capacitors and Brackets Capacitor brackets supplied with the HGP CP kits mount the capacitors from a right angle bracket using the studs on the bottom of the capacitors. The bracket surrounding the capacitors is mounted near the top of the capacitor can.

  • Page 24: Pqconnect

    PQconnect Product Description The PQconnect is an integrated controls option for TCI’s industry leading passive harmonic filter used for filtering the input of variable frequency motor drives (VFDs). In the passive harmonic filter, the PQconnect provides basic tuned circuit contactor control and provides unit status detection, metering, waveforms and power quality data.

  • Page 25: Installation

    PCB Connect RS 485 to USB serial converter to the Modbus RTU header J5. Use PQvision software from TCI website to calibrate PQconnect PCB. Ensure all component connections are torqued before energizing filter. NOTE: PQvision software is required to calibrate the PQconnect PCB...
  • Page 26 HGP Kit Manual 5.0 PQconnect Figure 11 : Typical HGP Filter Wiring with PQconnect PCB Mounting Hardware Figure 13 below shows the standoffs and screws provided with the kits to mount the board on the bracket. Figure 12 : Typical HGP Filter Wiring with PQconnect PCB...

  • Page 27: Wiring

    HGP Kit Manual 5.0 PQconnect Reference Drawing PKPQ5 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 28 HGP Kit Manual 5.0 PQconnect Figure 13: PQconnect Connection Terminals...
  • Page 29 Note: Voltage sense wire terminals J1, J2 & 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 or for reactor termination.

  • Page 30: Pqconnect Pcb Calibration

    HGP Kit Manual 5.0 PQconnect Table 10: Form C Relay Contacts/ Customer Inputs/Outputs Terminal Description Label Tightening Torque Wire Range Multi-functional Customer contact, 1, 2 3.5 lb-in (0.4 Nm) 28-12 AWG digital Input 1 normally open Multi- Customer contact, 1, 2 functional 3.5 lb-in (0.4 Nm) 28-12 AWG...
  • Page 31 HGP Kit Manual 5.0 PQconnect If desktop interface does not show the com port, disengage power from filter and check wiring to the RS485 converter. Figure 14: Communication Port (COM port) Step 4: Select Menu and Settings (Tech level access is required) as shown in Figure 15: SettingsError! Reference source not found..
  • Page 32 HGP Kit Manual 5.0 PQconnect Step 5: Ensure that Force Closed is selected as shown below. Figure 16: Settings Menu Step 6: Select Menu and Calibrate Figure 17: Calibration...
  • Page 33 HGP Kit Manual 5.0 PQconnect Step 7: Follow through the calibration screen shown in Figure 19 Figure 18: Calibration Mode • Enter Calibration Mode Note: If there is a problem with the board it will not enter calibration mode Contact Tech-Support if board does not enter the calibration state. •...

  • Page 34: Pqvision Software

    HGP Kit Manual 5.0 PQconnect Step 8: Final connections Disengage power from the filter after the calibration steps are complete, proceed with • connecting the load side connections of the filter. If a PLC is being used make sure to make these connections to the Modbus header of the PCB Re-energize filter PQvision Software...
  • Page 35 Settings – Modbus, contactor control, kVAR settings, alert management view Figure 21 - Figure 23 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 percentage...
  • Page 36 HGP Kit Manual 5.0 PQconnect To access the settings page as seen in , 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, however this will require the PQconnect reset command. As well as controlling the contactor and enabling/ disabling alerts.
  • Page 37 HGP Kit Manual 5.0 PQconnect Figure 22: Relay and Status Settings Menu Table 13: Relay and Status Settings Menu Designators Name Description Enable and Disable status detections. Depending on which status conditions the user would like to view The column labeled Relay & LED will show the LED pattern of the status detection and send a warning.
  • Page 38 HGP Kit Manual 5.0 PQconnect Figure 23: Connectivity Settings Menu Table 14: Connectivity 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 Modbus and save settings.
  • Page 39 HGP Kit Manual 5.0 PQconnect PQconnect Bluetooth App Setup ® Android OS 5.0 or higher System Requirements: Bluetooth 4.2 Installation Instructions 1. Download the app using your mobile device. 2. Extract the contents of the downloaded zip folder. 3. Tap on the APK file to install. Note: The Android system may require permission to install apps from sources other than the Play Store.
  • Page 40 HGP Kit Manual 5.0 PQconnect 4. Once the passkey is successfully entered, all filter data will be presented. Changing Settings 1. Once connected to a PQconnect device, scroll to the bottom of the Summary page, and tap Settings to open the Settings screen 2.
  • Page 41 Verify that the PQconnect is powered on and that the CPU LED is blinking. Restart the app. 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...

  • Page 42: Modbus Rtu

    HGP Kit Manual 5.0 PQconnect Modbus RTU Introduction 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. Modbus RTU is a simple serial communications protocol originally developed by Modicon for use with Programmable Logic Controllers (PLCs) in control of industrial devices.
  • Page 43 HGP Kit Manual 5.0 PQconnect Table 15: Modbus Connector Pin Definitions J5 Header Signal Name Signal Type Pinout No connect RS-485 B (non-inverting) RS-485 SC/G RS-485 A (inverting) No connect The default protocol settings for the RS-485 Modbus RTU interface are shown below. Table 16: Modbus RTU Protocol Settings Parameter Default Value...
  • Page 44 HGP Kit Manual 5.0 PQconnect Register Map Write Parameters: : Network Interface INPUT/Setpoint Register Map Table 18 I/O Reg Signal Parameter Name Address Direction Data Values and Examples Description Offset to Filter 9 = Save Current Values to Flash 21 = Set User Access 25 = Set Access to Tech Access (access key needs to be set to PARAM_USER_CMD_REQ...
  • Page 45 HGP Kit Manual 5.0 PQconnect Write Parameters: Table 19: Network Interface INPUT/Setpoint Register Map I/O Reg Signal Data Values and Parameter Name Address Direction Description Examples Offset to Filter 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...
  • Page 46 HGP Kit Manual 5.0 PQconnect Write Parameters: Table 20: Network Interface INPUT/Setpoint Register Map I/O Reg Signal Parameter Name Address Direction Data Values and Examples Description Offset to Filter DEFAULT: 5 = 5 kVAR Steps Desired filter kVAR for contactor to SYS_PF_STEP_1_KVAR Input Range: 1 to 200 kVAR...
  • Page 47 HGP Kit Manual 5.0 PQconnect Write Parameters: Table 21: Network Interface INPUT/Setpoint Register Map I/O Reg Signal Data Values and Parameter Name Address Direction Description Examples Offset to Filter Input current measured on B phase of the filter* SYS_I_LINE_CAL_B Input Note: For calibration setup Input current measured on C phase of the filter*...
  • Page 48 HGP Kit Manual 5.0 PQconnect Table 22: Filter Status References 16-bit values Register B 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 A RECLOSE_LIMIT NCP_FAULT_A NCP_FAULT_B LINE_REACTOR_THERMAL_SW Table 23: Filter Line Status References 16-bit values Status Detection PHASE_LOSS_A...
  • Page 49 HGP Kit Manual 5.0 PQconnect Read Parameters: Table 25: Network Interface OUTPUT/Feedback Register Map I/O Reg Signal Data Values and Parameter Name Address Direction Description Examples Offset from Filter Two 8bit ASCII DSP_SW_VER Output Characters Software revision code for processor. 0x0141 = ASCII for "A1"...
  • Page 50 HGP Kit Manual 5.0 PQconnect Read Parameters: Table 26: Network Interface OUTPUT/Feedback Register Map Signal I/O Reg Address Parameter Name Direction Data Values and Examples Description Offset from Filter Phase A THID for tuned circuit current I_TUNE_A_THD Output feedback % THID Phase B THID for tuned circuit current I_TUNE_B_THD Output...
  • Page 51 HGP Kit Manual 5.0 PQconnect Read Parameters: Table 27: Network Interface OUTPUT/Feedback Register Map I/O Reg Signal Data Values and Parameter Name Address Direction Description Examples Offset from Filter 100 = 100 kVA P_LOAD_APPARENT_TOTAL 120 Output Total Filter output apparent power Range: 0 to 1000 kVA 100 = 100kW P_LOAD_REAL_TOTAL...
  • Page 52 HGP Kit Manual 5.0 PQconnect I_LINE_C_HARM_25 Output Read Parameters: Table 28: Network Interface OUTPUT/Feedback Register Map Signal I/O Reg Direction Data Values and Parameter Name Address Description from Examples Offset Filter Board will give a status condition of overtempt if it exceeds 75C or BOARD_TEMP Output Range -40C to 75C...
  • Page 53 HGP Kit Manual 5.0 PQconnect Read Parameters: Table 29: Network Interface OUTPUT/Feedback Register Map Signal I/O Reg Direction Data Values and Parameter Name Address Description from Examples Offset Filter 0 = Contactor Closed CNT_STATUS Output Contactor command status 1 = Contactor Open 4800 = 480Vrms RATED_VOLTAGE_RO Output...
  • Page 54 HGP Kit Manual 5.0 PQconnect Read Parameters: Table 30: Network Interface OUTPUT/Feedback Register Map Signal I/O Reg Direction Parameter Name Address Data Values and Examples Description from Offset Filter 0 = None MB_PARITY_RO Output 1 = Odd Modbus Parity DEFAULT: 2 = Even 0 = Enabled RELAY_INPUT_STATUS Output...

  • Page 55: Rs485 To Usb Serial Converter

    RS485 connections lead to. Please ensure the correct dip switch settings are applied before installing. Table 31: USPTL4 to J5 Header Connections USPTL4 Wire Harness J5 Header Pinout Pin Out (TCI PN: 31617) No connect TDA (-) A (Pin 4) GND (Pin 3) Black TDB(+)
  • Page 56 HGP Kit Manual 5.0 PQconnect Example Setup Instructions to Read Data from the PQconnect Unit: Connect the cable to the communication header “J5” • Connect USB end to the computer • Determine the assigned COM port number for the RS-485 to USB converter using the computer device manager control panel.
  • Page 57 HGP Kit Manual 5.0 PQconnect Example Setup Instructions to Write Data to the PQconnect Unit: Figure 27: Example Setup Instructions In order 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.

  • Page 58: Troubleshooting

    HGP Kit Manual 6.0 Troubleshooting Troubleshooting ® HarmonicGuard Passive 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.
  • Page 59 HGP Kit Manual 6.0 Troubleshooting Figure 29: PQconnect LED Placements Table 32: LED Functions 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...
  • Page 60 HGP Kit Manual 6.0 Troubleshooting The table below shows the specified blinks for each status condition. Table 33: Specified Blinks for Each Status Condition Status Condition Group (Slow blinks) LED Specifier (Fast Blinks) Tune Phase A Loss Tune Phase B Loss Tune Phase C Loss Tune Balance Loss Phase A Tune Balance Loss Phase B...
  • Page 61 HGP Kit Manual 6.0 Troubleshooting Communication Problems J5 Communication Header • With the power de-energized from the filter, check wiring leading to J5 header If the user is using a different RS485 converter than the example above  please follow the datasheet for the A & B signals and ground for proper setup •...
  • Page 62 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.
  • Page 63 HGP Kit Manual 6.0 Troubleshooting Table 34: Status Conditions Status Condition Description Debug/ Resolution Check fuses of the tune circuit Phase loss in one of the Filter Tune Phase Check power connections of the tune circuit phases of the filter tune Loss A, B, or C Check voltage sense wires leading to the board and reactor, circuit...
  • Page 64 This condition should clear shortly after the unit is powered up. If this contactor status condition persists power cycle the unit and call TCI technical support if the condition does not clear. Contactor is open due to a The contactor is open because the PQconnect is waiting for the configured power on delay time to unit power on delay.
  • Page 65 HGP Kit Manual 6.0 Troubleshooting any residual stored charge in the tune circuit capacitors to be dissipated by bleeder resistors before the tune circuit is re-energized. If a minimum time is not enforced between repeated contactor close events the contactor may re- close and apply line voltage out of phase with the residual voltage on the tuned circuit capacitors.
  • Page 67 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 © 2019 TCI, LLC All rights reserved Part No: 29289 Effective: 01/06/2020 Version: N...

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