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TCi HGA HarmonicGuard Series Installation, Operation And Maintenance Manual

Bus-applied active harmonic filter
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HarmonicGuard
Installation, Operation, and Maintenance Manual
®
Active Harmonic Filter
Series Bus-Applied
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
2020 TCI, LLC All rights reserved
Product No: 26030
Effective: 06/12/20 Version: P

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  • Page 1 Active 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: 800-824-8282 Web Site: www.transcoil.com © 2020 TCI, LLC All rights reserved Product No: 26030 Effective: 06/12/20 Version: P...
  • Page 2 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. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

  • Page 3: Table Of Contents

    3.0 General Information ..................... 12 Intended Audience ............................12 General Terminology ..........................12 Receiving Inspection ..........................13 Storage Instructions ........................... 13 TCI Limited Warranty Policy ........................13 4.0 Pre-installation Planning..................15 Verify the Application ..........................15 Product Description ............................ 15 Nameplate Data ............................17 HGA Part Numbering System –...
  • Page 4 6.0 Filter Operation ..................... 48 Adjustments ..............................48 Start Up (Commissioning) .......................... 48 General Operation ............................48 Maintenance and Service ........................... 49 Outline and Mounting Dimension Drawings..................... 60 7.0 HMI Introduction ....................61 Overview ..............................61 Additional Information ..........................62 Receiving Inspection ..........................
  • Page 5 Register Map .............................. 109 Operation ..............................109 HMS Gateway to PLC Master Example ....................110 Required equipment ..........................110 Setup................................110 Programming ............................. 110 11.0 Appendix B: Modbus TCP/IP Gateway Option ..........113 Introduction ............................... 113 Wiring ................................. 113 Configuration ............................. 114 Register Map and Address Offsets ......................
  • Page 6 14.0 Appendix E: Operating the HGA in a 3R Enclosure ........132 Introduction ............................... 133 HGA-HMI Operation ........................... 134 15.0 Appendix F: BACnet Gateway Option............135 Introduction ............................... 135 Wiring ................................. 135 Configuration ............................. 136 Register Map .............................. 137 HMS Gateway Example ..........................137 16.0 Appendix G: HMI Modbus RTU COM Change Instructions ......
  • Page 7 Revision Description Date Release 10/29/13 03/03/14 Added 300A 09/10/14 Added 150A 480 V Added 150A 600 V Updated Quick Start Guide Rev. B Updated 300A Drawings 09/26/14 Added Floor Stand 11/5/14 Added 600 V 220A Added Legacy QS Guide as Appx. E Updated Watts Loss on Standard Product Ratings and Dimension Tables Updated Quick Start...

  • Page 8: Hga Quick Start Unit Software Setup For Hmi Revision I

    Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 1.0 HGA Quick Start Unit Software Setup for HMI Revision I 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 HarmonicGuard Active (HGA) filter.
  • Page 9 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 1) Verify unit external connections Note: If unit is configured for load side operation, reference the User Manual for Load Side CT Loads Placement diagram. Loads Phase A, B, C power connection, with positive •...
  • Page 10 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 2) Converter check – 1 Press “Password Setup” to navigate to Setup • screen Next, select “Tech Setup” and enter the • password: 08252014 Select the “Operation Modes” button •...
  • Page 11 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM • On this pop-up screen, ensure the “Auto Start Setup” button is OFF (Blue). If button is ON (Green), press to toggle off. Navigate back to “Tech Setup” screen •...
  • Page 12 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM Line Side Configured Unit 4) Status screen check Note: The Line/Load button and Line/Load Current Plot will say “Line” if a master/ line side unit or say “Load”...
  • Page 13 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 6) Running Converter Press “Setup” to navigate to the setup screen Select the “Tech Setup” button and enter the password: 08252014 • Select the “Next” button from the splash screen Select the “Operation Modes”...
  • Page 14 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 8) Current polarity #1 • Power up unit From Home screen, press “Run” to turn on unit • Press “Status” to navigate to Status screen • Select “VLine/ILine”...
  • Page 15 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 10) Final setup Press “Setup” to navigate to setup screen • • Select the “Tech Setup” button and enter the password: 08252014 • Select the next button from the splash screen Select the “Operation Modes”...
  • Page 16 Section 1.0 HGA Quick Start Unit Software Setup for HMI Revision I HGA IOM 11) Final check Note: If unit is configured for load side operation, reference the User Manual for Load Side CT Placement diagram. Navigate to the Status screen •...

  • Page 17: Safety

    Section 2.0 Safety HGA IOM 2.0 Safety Safety Instructions Overview This section provides the safety instructions, which must be followed when installing, operating, and servicing the HarmonicGuard Active (HGA) filter. If neglected, physical injury or death may ® follow, or damage may occur to the HGA filter or equipment connected to the HGA filter. The material in this chapter must be read and understood before attempting any work on or with the product.

  • Page 18: General Safety Instructions

    Section 2.0 Safety HGA IOM General Safety Instructions These safety instructions are intended for all work on the HGA 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. Warning Only qualified electricians should carry out all electrical installation and maintenance work on the HGA filter.

  • Page 19: General Information

    These are provided in order to assist with the overall understanding of the manual. Please feel free to contact TCI directly if there are any questions regarding any portion of this manual. Active Filter – TCI’s brand name for a real time filter that mitigates harmonics HarmonicGuard ®...

  • Page 20: Receiving Inspection

    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 21 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...

  • Page 22: Pre-Installation Planning

    The Voltage ratings of the HGA must match the input Voltage rating of the connected AC bus. Seismic Compliance TCI offers the seismic anchoring drawings for both wall and floor mounting Type 1 HGA filters to meet compliance of a seismic value (Sds) equal to or less than 1.00. If the project location has a higher seismic value, contact a representative at TCI for further assistance with new documentation.
  • Page 23 Section 4.0 Pre-installation Planning HGA IOM Filter Configuration Figure 1: Typical Configuration of the HarmonicGuard ® Active Filter *This drawing is for general reference only. Use the drawings supplied with the unit for installation.

  • Page 24: Nameplate Data

    Section 4.0 Pre-installation Planning HGA IOM Nameplate Data Figure 2 shows a typical HarmonicGuard Active filter nameplate. The following information is ® marked on the nameplate: Part number: Encoding is explained in following pages. • Corrective Current: The maximum amount of RMS Corrective Current the unit can •...
  • Page 25 Open Chassis, UL Type 1, UL Type 12, UL Type 3R Reference Technical Standards Agency Approvals UL & cUL Listed HMI Languages English, French, Spanish Surge Protection ANSI C62.42 *Please consult TCI regarding optimum filter performance when applied to DC drives...
  • Page 26 Section 4.0 Pre-installation Planning HGA IOM Figure 3: Altitude and Ambient Temperature Derating...

  • Page 27: Hga Part Numbering System - 480 V Open And Type 1

    Section 4.0 Pre-installation Planning HGA IOM HGA Part Numbering System – 480 V Open and Type 1 Temperature: 40° C Current: 50, 100, 150, 200, 250, 300, 350, 400, 500, 600, 700 Voltage: 480 V, 240 V, 208 V Enclosure: Open Chassis or UL Type 1 Figure 4 identifies the significance of each character in the HarmonicGuard Active filter part number.

  • Page 28: Hga Part Numbering System - 480 V Type 12 & 3R

    Section 4.0 Pre-installation Planning HGA IOM HGA Part Numbering System – 480 V Type 12 & 3R Temperature: 40° C Current: 50, 100, 150, 200, 250, 300, 350, 400, 500, 600, 700 Voltage: 480 V, 240 V, 208 V Enclosure: UL Type 12 & 3R Figure 5 identifies the significance of each character in the HarmonicGuard Active filter part ®...

  • Page 29: Hga Part Numbering System - 600 V

    Section 4.0 Pre-installation Planning HGA IOM HGA Part Numbering System – 600 V Temperature: 40° C Current: 39, 78, 110, 150, 185, 220, 370A Voltage: 600 Enclosure: Open Chassis, UL Type 1 or UL Type 3R Figure 6 identifies the significance of each character in the HarmonicGuard Active filter part ®...

  • Page 30: Communications Part Numbering

    Section 4.0 Pre-installation Planning HGA IOM Communications Part Numbering Figure 6 below shows the Communications Module part numbering system. The base/standard communications unit is the CMXXXX00, which has the HMI with a Modbus RTU over RS485 network interface. The CMXXXX01 (EtherNet/IP and Modbus TCP) and the CMXXXX02 (DeviceNet) options also include the HMI but supports an alternate network interface instead of Modbus RTU.

  • Page 31: Open Chassis Unit Cooling Notes

    • Dimensions in the cooling diagrams are approximate and in inches. Cooling Diagrams Please reference TCI’s website for a list of cooling diagram drawings for the HGA open chassis units. They are available for download at https://transcoil.com/products/hga-5-active-harmonic- filter/hga-drawings/. Paper copies of the cooling diagrams are in the literature kit that is included with all open chassis units.

  • Page 32: Installation Guidelines

    Section 5.0 Installation Guidelines HGA IOM 5.0 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 excessive vibration, corrosive or combustible airborne contaminants, excessive dirt, or liquids.
  • Page 33 Section 5.0 Installation Guidelines HGA IOM installation. Typical or recommended cable entry locations are shown in the drawings shipped with the unit. Circuit Breaker For HGA units provided with an internal circuit breaker, see tables below for field wiring terminal wire size and tightening torque information.
  • Page 34 Section 5.0 Installation Guidelines HGA IOM Table 5: 480 V - Power Terminal Wire Size Capacity Range and Tightening Torque for Active Filter Models with Rockwell Allen Bradley Circuit Breakers Filter Size Breaker IC CB Power Terminals 480 V 600 V Wire Size* Torque In-Lbs.
  • Page 35 Section 5.0 Installation Guidelines HGA IOM Table 9: Power Terminal Wire Size Capacity Range and Tightening Torque for Open Chassis Active Filter Models with Power Terminal Block (without Circuit Breaker) Filter Size Power Terminal Block 480 V Wire Size* Torque In-Lbs. (Nm) Wire Type 45A to 100A 14 - 2/0 AWG...
  • Page 36 Refer to the drawings furnished with the unit for more specific information. Connection diagrams in this section are representative. For the latest connection diagram, please see the TCI website for the 25027-1 208-480 V connection diagram, the 28425 600 V connection diagram, and the HMI and network connection diagram 28283-1.
  • Page 37 Section 5.0 Installation Guidelines HGA IOM The polarity of the CT is important; the “H1” marking on the CT must face the source. The secondary windings of the CT around conductor L1 should connect to TB-1 terminals 1 & 2 and the CT around conductor L3 should connect to TB-1 terminals 3 &...
  • Page 38 Section 5.0 Installation Guidelines HGA IOM LINE SIDE CT PLACEMENT Figure 9: HGA 480 V Single Unit Line Side / Bus Applied Connection Diagram...
  • Page 39 Section 5.0 Installation Guidelines HGA IOM Figure 10: HGA 480 V Single Unit Load Side / Drive Applied Connection Diagram...
  • Page 40 Section 5.0 Installation Guidelines HGA IOM Figure 11: HGA 480 V Two Unit Parallel Connection Diagram...

  • Page 41: Ct Wire Recommendations

    6. Load(s) have an integral 3% line reactance or equivalent DC bus choke to optimize Active Filter utilization, consult TCI for Active filter capacity with less than 3%. 7. Source CTs are customer installed and external to the active filter.
  • Page 42 Section 5.0 Installation Guidelines HGA IOM Figure 12: HGA 480 V Three Wide Parallel Unit Connection Diagram...
  • Page 43 Section 5.0 Installation Guidelines HGA IOM HGA Line Side CT Placement Figure 13: HGA 600 V Single Unit Line Side / Bus Applied Connection Diagram...
  • Page 44 Section 5.0 Installation Guidelines HGA IOM Load Side CT Placement Figure 14: HGA 600 V Single Unit Load Side Applied Connection Diagram...
  • Page 45 Section 5.0 Installation Guidelines HGA IOM HGA MASTER / SLAVE CT PLACEMENT Figure 15: HGA 600 V Two Unit Parallel Connection Diagram...
  • Page 46 Section 5.0 Installation Guidelines HGA IOM Notes: 1. Wiring should be 75° C or higher insulated copper, with the appropriate Voltage and current rating. 2. Chassis ground must be connected to the ground of the premises wiring system, in accordance with NEC and local codes.
  • Page 47 Section 5.0 Installation Guidelines HGA IOM Figure 16: HGA 480 V Main-Tie-Main Connection Diagram...
  • Page 48 Section 5.0 Installation Guidelines HGA IOM Figure 17: Current Transformer Diagram – Round...
  • Page 49 Section 5.0 Installation Guidelines HGA IOM Figure 18: Current Transformer Diagram – Rectangular...
  • Page 50 Section 5.0 Installation Guidelines HGA IOM Figure 19: Current Transformer Diagram – Solid Core Grounding The HarmonicGuard Active filter panel equipment-grounding lug must be connected to the ® ground of the premises wiring system. The equipment grounding connection must conform to the requirements of the National Electrical Code (NEC) and/or any other codes that apply to the installation site.
  • Page 51 Section 5.0 Installation Guidelines HGA IOM CM Module Serial Cable Connection for Open Chassis Units The HGA units the communications module (CM) is a separate assembly for the main HGA active filter chassis. The CM module assembly contains the HMI touchscreen, communications interface PCB, and any optional network interface communications gateway included with the unit.
  • Page 52 Section 5.0 Installation Guidelines HGA IOM 480 V - 50A / 100A 480 V - 150A 600 V - 39A / 78A 600 V - 220A 480 V - 300A / 350A 480 V - 200A / 250A 600 V - 150A / 185A / 370A Figure 21: HGA Power Converter Module with Serial Connector J25 Highlighted in Red...
  • Page 53 Section 5.0 Installation Guidelines HGA IOM Serial Cable Termination Setup Note: The serial cable termination configuration for the HGA units are setup during assembly and test of the unit. For new installations, the end user does not need to manually configure the serial cable termination DIP switches on the power converters.
  • Page 54 Section 5.0 Installation Guidelines HGA IOM Module Module Power Power Power Converter 1 Converter 1 Converter 2 SWITCH ON SWITCH OFF SWITCH ON 80 V: 50A, 100A, 150A, 200A, 250A, 300A, 350A 480 V: 400A, 500A 600A, 700A 600 V: 39A, 78A, 110A, 150A, 185 V 600 V: 220A, 370A Figure 23: HGA Serial Cable Connection Diagram and Serial Bus Termination Switch Configuration...

  • Page 55: Filter Operation

    Section 6.0 Filter Operation HGA IOM 6.0 Filter Operation Adjustments The HGA has been factory calibrated and thoroughly tested. There is no need to make any adjustments. Start Up (Commissioning) Caution Thoroughly check the installation before applying power and operating the equipment for the first time.

  • Page 56: Maintenance And Service

    Section 6.0 Filter Operation HGA IOM Maintenance and Service HGA Reliability and Service Life The HGA has been designed and thoroughly tested at the factory to ensure that it will perform reliably from the time it is put into service. The following periodic maintenance is recommended to ensure that the HarmonicGuard Active filter will always perform reliably and provide the ®...
  • Page 57 An adhesive coating can be applied to the washable air filters used in the HGA Type 3R enclosures to increase the effectiveness of the filter. If the adhesive coating is used, the air filters should be periodically inspected and re-coated. To order the Air Filter Adhesive Spray Coating, contact TCI Technical Support and order TCI part number 29636.
  • Page 58 Section 6.0 Filter Operation HGA IOM Notes: Open chassis units can be provided without circuit breakers. The end user must • protect the HGA with the following UL listed molded case circuit breaker. • All circuit breakers referenced below are 480 V circuit breakers and the trip levels specified are at 480 V.
  • Page 59 Section 6.0 Filter Operation HGA IOM Table 15: Active Filter 100kAIC Circuit Breaker Manufacturer Part Number and Trip Ratings. HGA Unit Rating* ABB - Option 2000 Allen Bradley - Option 5000 Eaton - Option 7000 LSIS - 0300 480VAC 600VAC*** Amps** MFG P/N Amps**...
  • Page 60 Section 6.0 Filter Operation HGA IOM Warning If the system breaker has been tripped, do not attempt to re-energize the HGA unit until the cause of the trip has been determined. Pre-Charge Circuit Over Current Protection The Pre-Charge circuitry is used to limit the in-rush current to a safe level upon powerup. When started, the Pre-Charge circuitry will be switched out of circuit.
  • Page 61 TB-1 positions 1 & 2 with the two wires in positions 3 & 4. Apply power for proper power-up; if it doesn’t repeat steps 2 and 3. 5. If the HGA doesn’t indicate a run status after completion of steps 1 through 4, contact TCI technical support for further assistance.
  • Page 62 Section 6.0 Filter Operation HGA IOM Converter Inspection Verify that power has been removed from converter and 5 minutes has passed • before inspection. Remove plastic cover from over converter section. • Visually check the circuit boards for debris, contamination, overheated traces, burnt •...
  • Page 63 Section 6.0 Filter Operation HGA IOM Troubleshooting Flow Chart Figure 24: HGA System Troubleshooting Flowchart...
  • Page 64 Section 6.0 Filter Operation HGA IOM Power Component Layout Figure 25: (600 V) 39, 78 Amp & (480 V) 45, 90, 100 Amp Power Component Layout...
  • Page 65 Section 6.0 Filter Operation HGA IOM Output Terminal Bus Bars Dual SCR Module Dual SCR Module Dual IGBT Module Dual IGBT Module Positive Terminal Capacitor Bank Bus Bars over Capacitors Negative Electrolytic Bus Terminal Capacitors (6) Capacitor Bank Figure 26: (480 V) 150, 300 Amp & (600 V) 110, 220 Amp Power Component Layout Figure 27: (480 V) 200, 250, 500 Amp &...
  • Page 66 Section 6.0 Filter Operation HGA IOM Figure 28: (480 V) 300N, 350, 600, 700 Amp Power Component Layout Figure 29: TB-1 Terminal Block Warning Only qualified personnel should operate the HarmonicGuard Active filter with the door ® open. Failure to follow standard safety procedures may result in death or serious injury. Do not attempt any work on a powered filter converter.

  • Page 67: Outline And Mounting Dimension Drawings

    Section 6.0 Filter Operation HGA IOM Replacement Parts If replacement parts are needed, please contact your TCI representative. To ensure that the HarmonicGuard Active filter continues to perform to its original specifications, replacement parts ® should conform to TCI specifications. Use of non-TCI approved components will void all warranties.

  • Page 68: Hmi Introduction

    Section 7.0 HMI Introduction HGA IOM 7.0 HMI Introduction The Interface Module provides the user with a convenient way to monitor the operation of TCI’s HarmonicGuard Active filter and allows for the ability to adjust run-time set-points under ® password control. This section describes how to install, operate, and maintain the Interface Module.

  • Page 69: Additional Information

    Section 7.0 HMI Introduction HGA IOM Additional Information This section provides general information describing the Interface Module. Be sure to Caution carefully review the more specific information provided by the drawings shipped with the module. Information from by the drawings takes precedence over the information provided in this section.

  • Page 70: Mounting

    Section 7.0 HMI Introduction HGA IOM Mounting Mounting requires at least a depth of 4” (102 mm). The Interface Module will mount in a panel with a thickness of 0.02 to 0.35 inch (0.5-9.0 mm) with an opening 6.79” by 5.21” (173 by 133 mm).

  • Page 71: Interface Pcb Connections

    Section 7.0 HMI Introduction HGA IOM Interface PCB Connections Most customer connections to the Interface module will be made on the Interface PCB. Refer to connection diagrams in Figure 30. The details of the power and communications terminals are shown in Table 17. Form C relays are available on the Interface PCB, these connections are shown in Table 18.

  • Page 72: Hmi Display Connections

    Section 7.0 HMI Introduction HGA IOM Table 17: Power & Communications Terminals Terminal Description Label Rating HMI Display For factory use Not Connected RS485 Ground Not connected Neutral Input Power 120 VAC Line Micro Programming 1-14 For factory use 24 VDC HMI Power Supply 24 VDC Common...
  • Page 73 Section 7.0 HMI Introduction HGA IOM ModbusRTU Connection Figure 33: HMI ModbusRTU Connection Table 19: Modbus Connector Pin Definitions COM2/3 Signal Name Signal Type DB9 Pin no connect no connect no connect RS-485 B (non-inverting) RS-485 SC/G no connect no connect no connect RS-485 A (inverting) Table 20: ModbusRTU Protocol Settings...
  • Page 74 Section 7.0 HMI Introduction HGA IOM Table 21: General HMI Screen Elements HMI Graphic Element Example Description Buttons will appear raised or depressed, depending on set Buttons point and command conditions. Indicator status fields will Indicators appear flat and are read only.

  • Page 75: Initialization

    Section 7.0 HMI Introduction HGA IOM Initialization Title Bar Indicator HMI Display Power LED Numerical Display Navigation Figure 34: HMI Display When first powered, the green LED (Power) on the HMI Display will light (see Figure 33). After a five second boot up sequence, the Home Screen will be displayed. If the home screen is not displayed and power is available to the HMI Display, see Section 8.0 Troubleshooting for diagnosing common problems.

  • Page 76: Hmi Installation Diagram

    Section 7.0 HMI Introduction HGA IOM HMI Installation Diagram...

  • Page 77: Hmi Set-Up Instructions

    Section 7.0 HMI Introduction HGA IOM HMI Set-Up Instructions 2) Verify unit external connections Note: If unit is configured for load side operation, reference the User Manual for Load Side CT Loads Placement diagram. Loads Phase A, B, C power connection, with positive •...
  • Page 78 Section 7.0 HMI Introduction HGA IOM 2) Converter check – 1 Press “Password Setup” to navigate to Setup • screen Next, select “Tech Setup” and enter the • password: 08252014 Select the “Operation Modes” button • On the “Operation Mode Setup” screen, •...
  • Page 79 Section 7.0 HMI Introduction HGA IOM • On this pop-up screen, ensure the “Auto Start Setup” button is OFF (Blue). If button is ON (Green), press to toggle off. Navigate back to “Tech Setup” screen • • Now select “Save Settings” Press “Home”...
  • Page 80 Section 7.0 HMI Introduction HGA IOM Line Side Configured Unit 4) Status screen check Note: The Line/Load button and Line/Load Current Plot will say “Line” if a master/ line side unit or say “Load” if it is a slave/load side unit. Press “Status”...
  • Page 81 Section 7.0 HMI Introduction HGA IOM 6) Running Converter Press “Setup” to navigate to the setup screen Select the “Tech Setup” button and enter the password: 08252014 • Select the “Next” button from the splash screen Select the “Operation Modes” button •...
  • Page 82 Section 7.0 HMI Introduction HGA IOM 8) Current polarity #1 • Power up unit From Home screen, press “Run” to turn on unit • Press “Status” to navigate to Status screen • Select “VLine/ILine” screen • Note: Lightly loaded conditions (less than 20% CT rating) •...
  • Page 83 Section 7.0 HMI Introduction HGA IOM 10) Final setup Press “Setup” to navigate to setup screen • • Select the “Tech Setup” button and enter the password: 08252014 • Select the next button from the splash screen Select the “Operation Modes” button •...
  • Page 84 Section 7.0 HMI Introduction HGA IOM 11) Final check Note: If unit is configured for load side operation, reference the User Manual for Load Side CT Placement diagram. Navigate to the Status screen • Navigate to Line/Load status • Note the corrected Voltage, current, power •...

  • Page 85: Hmi Screens

    K4 (J12 Connector), and J11 Contacts used for a remote indicator will also be energized. If the monitor continually displays “At Capacity”, a second filter may be required to handle the load. Please contact TCI for assistance. Run/Stop Button Runs and stops the HarmonicGuard ®...
  • Page 86 Section 7.0 HMI Introduction HGA IOM Status Screen The Status screen shows more specific information on the performance of the system, such as current and Voltage waveforms, Power Factor and information specific to the Line/Load screen and Converter screen. Note: The Status Screen will indicate if unit is Line Side/Load Side. The “Line/Load” button and the “Line/Load Current Plot”...
  • Page 87 Connector), and J11 Contacts used for a remote indicator will also be energized. If the monitor continually displays “At Capacity”, a second filter may be required to handle the load. Please contact TCI for assistance. Displays the current state of all enables that affect the running of the HarmonicGuard ®...
  • Page 88 Section 7.0 HMI Introduction HGA IOM Run Enable Summary Sub-Screen The Run Enable Summary sub screen shows state of all the enables that affect the running of the HarmonicGuard Active filter. ® Figure 38: Run Enable Summary Screen (RUN) When the HMI Stop button is pressed locally on the HMI, the unit enters a Run Inhibit state and will show a “Run Inhibit Active”...
  • Page 89 Section 7.0 HMI Introduction HGA IOM Table 25: Run Enable Summary Sub Screen Elements Screen Element Description Run/Stop Button Runs and stops the HarmonicGuard ® Active filter. This option is always enabled. The “Present Command” field will be green and say RUN, if the local HMI run button has been pressed Local HMI and the unit is operational.
  • Page 90 Section 7.0 HMI Introduction HGA IOM Line/Load Status Sub-Screen The Line/Load Status Sub Screen shows more specific information regarding the source or Load Voltage, Current, Power, Power Factor and THD measurements. Figure 41: Line Status Sub Screen Figure 42: Load Status Sub Screen...
  • Page 91 Section 7.0 HMI Introduction HGA IOM Table 26: Line/Load Status Screen Elements Screen Element Description Volts Display Displays the current utility phase to phase line Voltage in Volts RMS. Displays the current line/load phase current in Amps RMS. Current Display Note: The displayed current is affected by the CT Ratio configuration on the “Setup”...
  • Page 92 Section 7.0 HMI Introduction HGA IOM Figure 43: Example Waveform Plot Screens (Converter Corrective Current) Table 27: Waveform Plot Sub Screen Elements Screen Element Description The “Refresh” button will reload the data from the HarmonicGuard ® Active filter Refresh Button power converter controller and redraw the waveform plot.
  • Page 93 Section 7.0 HMI Introduction HGA IOM • Phase C Voltage (Blue) and Phase C current (Yellow) are in phase and the same polarity. Figure 44: VLine & ILine Waveform Plot of a Properly Connected HarmonicGuard Active filter (unit in stopped state) ®...
  • Page 94 Section 7.0 HMI Introduction HGA IOM Phase C system CT Check Phase C CT for current feedback missing: open circuit or loose Phase C current is zero connection. while Phase A current is present. Phase A and Phase C CT To correct, swap Phase current feedback swapped: A and Phase C system...
  • Page 95 Section 7.0 HMI Introduction HGA IOM Figure 45: Historical Trend Plot Menu Sub Screen Table 29: Historical Trend Plot Menu Sub Screen Elements Screen Element Description Opens the HarmonicGuard ® Active filter heatsink temperature historical trend Converter Temp Button graph screen. This signal is sampled every 15 seconds and historical data is maintained for 10 hours.
  • Page 96 Section 7.0 HMI Introduction HGA IOM Figure 46: Example Historical Trend Plot Sub Screen Table 30: Trend Plot Screen Elements Screen Element Description Run/Stop Button Runs and stops the HarmonicGuard Active filter. ® Plot Scale Display Indicates the magnitude of the samples of the trend plot. The scale varies with (located on the left side of the each of the trend plots.
  • Page 97 Section 7.0 HMI Introduction HGA IOM Figure 47: Fault Screen Table 31: Fault Screen Elements Screen Element Description Stop Button Turns off the HarmonicGuard Active filter. ® This button will remove all faults from the list, if the fault conditions have cleared. Once Reset Button cleared, a fault will still be viewable in the fault history log.
  • Page 98 Section 7.0 HMI Introduction HGA IOM Table 32: Fault Codes Fault Critical or Auto or Fault Description Code Non-critical Fault Manual Reset Critical Manual* Desaturation - Hardware Phase A Critical Manual* Desaturation - Hardware Phase B Critical Manual* Desaturation - Hardware Phase C Non-critical Auto Internal CPU Fault 1...
  • Page 99 Section 7.0 HMI Introduction HGA IOM Figure 48: Fault History Sub Screen Table 33: Fault History Column Format Description (from left to right) O = Fault Onset Marks the start and end of a fault in the fault Onset/Clear Marker X = Fault Cleared history.
  • Page 100 Note: Screen is designed to be viewed at chest level. This button is password protected. Takes user to “Tech Setup” screen. Outline to Tech Setup follow. This button is password protected and used during the factory and TCI technician Factory Setup setup only. Tech Setup Screen To continue to the Tech Setup page, select the “Tech Setup”...
  • Page 101 Tech Setup + not needed for basic system installation and commissioning. If a specialized setup feature is required for your application, an authorized TCI field service representative will provide instruction on those features. This button allows user to enter in the system full load amps rating and is used to calculate the ITDD display shown on the “Line Status”...
  • Page 102 This button initiates the active filter sensor calibration procedure. There is no need to calibrate the unit unless instructed by authorized TCI field service personnel. The active filter ships from the factory with all sensors fully calibrated so calibration is not required at Calibrate System Enable the time of unit startup.
  • Page 103 Section 7.0 HMI Introduction HGA IOM Run/Stop Control Setup Sub-Screen Allows user to configure control settings. Note: If button is GREEN, the option is ENABLED. If button is BLUE, option is DISABLED. Figure 53: Tech Setup Screen Table 37: Run/Stop Control Setup Screen Elements Screen Element Description Auto-Start Setup...
  • Page 104 Section 7.0 HMI Introduction HGA IOM Auto Start Setup Sub-Screen Allows user to configure the parameters necessary to use the Auto-Start option. Note: If button is GREEN, the option is ENABLED. If button is BLUE, option is DISABLED. Figure 54: Auto Start Setup Screen Table 38: Auto-Start Setup Screen Elements Screen Element Description...
  • Page 105 Section 7.0 HMI Introduction HGA IOM About Screen The About Screen displays model number, serial number, and software/firmware version information regarding the filter, as well as the CT ratio. Figure 55: About Screen Table 39: About Screen Elements Screen Element Description Stop Button Turns off the HarmonicGuard...
  • Page 106 Both the Voltage and current detection algorithms can be globally or individually configured by TCI qualified personnel via the password protected Technician level Setup Screen.

  • Page 107: Network Interface

    Section 7.0 HMI Introduction HGA IOM Error Error Suggested Corrective Action Code Phase C CT Under Current Turn off unit and check system CT feedback for no feedback (CT short or open). Turn off unit and check system CT phase A feedback for incorrect polarity or reverse phase Phase A CT Polarity rotation.
  • Page 108 Section 7.0 HMI Introduction HGA IOM Parameter Name I/O Reg Direction Data Values and Examples Description Address Offset 0,1 = Initialization 2 = Fault inhibit 3 = Input inhibit 4 = Fault reset 5 = Stop 6,7 = Pre-Charge SYS_STATE Output Present control state of power converter 8 = Run...
  • Page 109 Section 7.0 HMI Introduction HGA IOM Parameter Name I/O Reg Direction Data Values and Examples Description Address Offset Two 8bit ASCCI Characters Software revision code for HMI ID_HMI_SW_VER Output 0x3144 = ASCCI for "D1" touchscreen processor. 8,9,16=Line Side Control Active filter Line or Load controls SYS_MODEL_NUM Output 12,13,18=Load Side Control...
  • Page 110 Section 7.0 HMI Introduction HGA IOM Table 43: Network Interface INPUT Register Map I/O Reg Parameter Name Address Direction Format Description Offset 0 = Network Command Stop Remote Network Run/Stop command to SYS_NW_START_IN Input 1 = Network Command Run the HGA Enter in desired leading/lagging kVAR output Note: Software bounds to be unit...

  • Page 111: Maintenance

    In the event the HMI Display application software needs to be upgraded, the USB host port on the back panel of the HMI Display can be used for field upgrades. Software upgrade instructions will be sent with any software updates provided by TCI. Back View of HMI Display...

  • Page 112: Troubleshooting

    Section 9.0 HMI Troubleshooting HGA IOM 9.0 HMI Troubleshooting HarmonicGuard Active Filter Fault ® If the display indicates a fault has occurred, proceed to the fault screen by choosing the “Fault” menu screen button. To see if this is a recurring fault, hit the “History” button from inside the “Fault”...

  • Page 113: Fault Troubleshooting Notes

    Communications Fault in the fault screen, check the serial cable between Interface PCB J2 and the HarmonicGuard Active filter power converter module J25 (100A/50A units) or J7 ® (200A units). • For technical support, contact TCI directly at 1-800-824-8282. Select "Customer Service" or "Technical Support".

  • Page 114: Appendix A: Ethernet/Ip Gateway Option

    Section 10.0 Appendix A: Ethernet/IP Gateway Option HGA IOM 10.0 Appendix A: Ethernet/IP Gateway Option Introduction The Ethernet/IP network Communications Gateway translates command/status data to/from the HMI Display’s integrated network interface from the ModbusRTU protocol to Ethernet/IP. The Ethernet/IP Communications Gateway is implemented using a third party, industry leading Ethernet/IP solution from HMS Anybus Communicator Product Line (Anybus Communicator AB7007).

  • Page 115: Configuration

    Section 10.0 Appendix A: Ethernet/IP Gateway Option HGA IOM Table 46: EtherNet/IP Connector Pinout Pin Number Description 4, 5, 7, 8 Termination Configuration To configure the IP address of the Ethernet/IP communications gateway, connect the gateway to the Ethernet network then open a web browser window and type in the default IP address of the gateway and press enter.

  • Page 116: Register Map

    CIP Message commands via a PLC, please reference the following application note from HMS: Reading/writing data from Anybus-S Ethernet/IP using ControlLogix5000 MSG instruction. The EDS file for the Ethernet/IP Communications Gateway is available via TCI technical support (direct dial: 414-357-4541, email tech-support@transcoil.com) or from the TCI website (http://www.transcoil.com/Support.htm)

  • Page 117: Hms Gateway To Plc Master Example

    Section 10.0 Appendix A: Ethernet/IP Gateway Option HGA IOM HMS Gateway to PLC Master Example HMI slave connected through Anybus gateway to PLC Master: Required equipment Anybus gateway programmed with TCI Anybus configuration • HMI display connected to Anybus gateway • •...
  • Page 118 Section 10.0 Appendix A: Ethernet/IP Gateway Option HGA IOM Figure 64: Ladder Logic Diagram Data file MG 12 is a message file containing 2 elements 0 and 1. • The Message Structure settings are shown in Figure 63 (write command) and Figure 64 (read •...
  • Page 119 Section 10.0 Appendix A: Ethernet/IP Gateway Option HGA IOM Figure 66: Message Structure (Read Command) Settings Data files RIX19 and RIX9 hold the message read and write information respectively. • The Anybus gateway configuration is programmed for 16 bit I/O registers. •...

  • Page 120: Appendix B: Modbus Tcp/Ip Gateway Option

    Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM 11.0 Appendix B: Modbus TCP/IP Gateway Option Introduction The Modbus TCP/IP network Communications Gateway translates command/status data to/from the HMI Display’s integrated network interface from the Modbus RTU protocol to Modbus TCP/IP. Modbus TCP/IP (also Modbus-TCP) is simply the Modbus-RTU protocol with a TCP interface that runs on Ethernet.

  • Page 121: Configuration

    Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM Table 50: Modbus TCP/IP Connector Pinout Pin Number Description 4, 5, 7, 8 Termination Configuration To configure the IP address of the Modbus TCP/IP communications gateway, there are two options. The preferred method is to use the IPConfig tool provided by HMS. This can be downloaded for free from their website www.anybus.com.

  • Page 122: Register Map And Address Offsets

    Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM Figure 68: Modbus TCP/IP Gateway Configuration Page Table 51: Gateway Default Settings Setting Default Value IP Address 192.168.0.1 Gateway 255.255.255.0 Subnet 255.255.255.0 DHCP To update the IP address, type in a new IP address on the configuration page, then click on the STORE CONFIGURATION button.

  • Page 123: Operation

    Flashing Red customer support HMS Gateway Example HMI slave connected through Anybus gateway to Simply Modus Master: Required equipment Anybus gateway programmed with TCI Anybus configuration • HMI display connected to Anybus gateway • Local Area Network (LAN) routers •...

  • Page 124: Setup

    Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM Setup Connect the RJ45 cable to the Ethernet Port on the Anybus gateway from a router (LAN). • Connect the PC to the router (LAN) via RJ45 Ethernet cable. • The network setup is displayed below.
  • Page 125 Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM • Read HMI Data • Open Simply Modbus and type in the IP address set for the Modbus TCP/IP gateway (1). Select mode as TCP and then hit CONNECT (2). Once connected, a disconnect option will •...

  • Page 126: Write To Hmi

    Section 11.0 Appendix B: Modbus TCP/IP Gateway Option HGA IOM Write To HMI Reference figure above and click the write command in the Simply Modbus main window. • Select the first register value as “0” (1). • Select the data type as 16-bit INT (2). •...

  • Page 127: Appendix C: Modbusrtu Master

    Section 12.0 Appendix C: ModbusRTU Master HGA IOM 12.0 Appendix C: ModbusRTU Master Introduction The HGA Modbus RTU network communication interface transmits and receives command and status data from the HGA HMI display to a connected Modbus master over a RS-485 serial link. ModbusRTU is a simple serial communications protocol originally developed by Modicon for use with Programmable Logic Controllers (PLCs) in control of industrial devices.
  • Page 128 Section 12.0 Appendix C: ModbusRTU Master HGA IOM Example Application Using “Simply Modbus Master 7.2.1” The ModbusRTU network interface COM3 port is configured for RS-485 signal levels. The following example uses an RS-485 to USB converter to connect the HGA HMI to a laptop PC running the ModbusRTU master application. The picture below shows an example “B&B SmartWorx, Inc”...
  • Page 129 Section 12.0 Appendix C: ModbusRTU Master HGA IOM Select the “SEND” button and the data available on the network will be displayed. • Start and stop the unit using the HMI to see the changes in the fields. Example Setup Instructions to Write Data to the HGA Unit: In order to start/stop the unit, first the “Network Start Enable”...
  • Page 130 Section 12.0 Appendix C: ModbusRTU Master HGA IOM Select “1” in the field “Values to Write” to turn the unit ON or “0” to turn the unit OFF. • • Verify via the HMI that the unit is receiving commands by going to the screen shown below.
  • Page 131 Section 12.0 Appendix C: ModbusRTU Master HGA IOM Network Run Command Status Figure 74: HGA with Remote Network Enabled This can be accomplished by selecting the “Status” page on the bottom of the screen, choosing • the blue “Converter” button, and selecting “Run Enable Summary”. The figure above displays the unit with the Remote Network enabled and the converter in the Off •...

  • Page 132: Appendix D: Devicenet Gateway Option

    Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM 13.0 Appendix D: DeviceNet Gateway Option Introduction DeviceNet is a node priority-based communication protocol. Each device on the network has a node address. To write/read data, terminal node addresses needs to be programmed into the devices.

  • Page 133: Configuration

    After a node address has been assigned, the gateway can be connected to the DeviceNet network by using RSNetworks for DeviceNet devices. The EDS file for the DeviceNet Communications Gateway is available via TCI technical support (direct dial: 414-357-4541, email tech-support@transcoil.com) or from the TCI website (http://www.transcoil.com/Support.htm)

  • Page 134: Hms Gateway Example

    Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM Table 56: DeviceNet TCP/IP Gateway LED Diagram Number State Status Not powered / not online 1- Network Green Link OK, online, connected Status Green, flashing Online, not connected Critical link failure Red, flashing Connection timeout No power to device...

  • Page 135: Setup

    Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM Setup Connect Anybus gateway on the HMI assembly using a DeviceNet cable to the 1770 Allen • Bradley KFD. • Connect the 1770 Allen Bradley KFD to the 1769 DeviceNet Scanner using another DeviceNet cable.

  • Page 136: Rslinx Classics Settings

    Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM RSLinx Classics Settings In RSLinx a new network is defined by click on the communications and then the configure • drives option. From the menu that appears, select the 1770KFD DeviceNet option to view all devices on the •...

  • Page 137: Rslogix

    Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM • Click on the Module tab of the 1769 SDN scanner Module window. • In the platform drop down menu, select MicroLogix. Keep slot as 1. • Proceed to the Input tab of the 1769 SDN scanner module window. •...
  • Page 138 Section 13.0 Appendix D: DeviceNet Gateway Option HGA IOM Figure 80: Ladder Diagram Observing HMI Status...

  • Page 139: Appendix E: Operating The Hga In A 3R Enclosure

    Section 14.0 Appendix E: Operating the HGA in a 3R Enclosure HGA IOM 14.0 Appendix E: Operating the HGA in a 3R Enclosure 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 HarmonicGuard Active (HGA) filter.

  • Page 140: Introduction

    Section 14.0 Appendix E: Operating the HGA in a 3R Enclosure HGA IOM Introduction The HGA is available in a rugged 3R enclosure that makes it suitable for use in demanding environmental conditions. Standard status indicator lights have been placed on the exterior of the enclosure to accommodate the physical characteristics and requirements of a 3R enclosure.

  • Page 141: Hga-Hmi Operation

    Section 14.0 Appendix E: Operating the HGA in a 3R Enclosure HGA IOM HGA-HMI Operation Connect the HGA-HMI connection port to the HMI diagnostic port using the 9-pin serial cable provided. When the HGA-HMI unit boots up follow the Quick Start guide appropriate for your HGA model.

  • Page 142: Appendix F: Bacnet Gateway Option

    Section 16.0 Appendix G: HMI Modbus RTU COM Change Instructions HGA IOM 15.0 Appendix F: BACnet Gateway Option Introduction The BACnet-to-Modbus Communication Gateway translates command/status data to/from the HMI Display’s integrated network interface from the Modbus RTU protocol to BACnet. The BACnet Communication Gateway is implemented using a third party, industry leading BACnet solution from HMS Anybus Communicator Product Line (Anybus Communicator 024090-B).

  • Page 143: Configuration

    Section 16.0 Appendix G: HMI Modbus RTU COM Change Instructions HGA IOM Configuration To configure the IP address of the BACnet communications gateway, connect gateway to the BACnet network. Then, open a web browser window and type in the default IP address of the gateway and press enter.

  • Page 144: Register Map

    HMS Gateway Example HMS Gateway to BACnet Master Example HMI slave connected through Anybus gateway to BACnet Master: Required Equipment: Anybus gateway programmed with TCI Anybus configuration • HMI display connected to Anybus gateway • Ethernet RJ45 cable •...
  • Page 145 Section 16.0 Appendix G: HMI Modbus RTU COM Change Instructions HGA IOM Note: HGA unit will only respond to network run command if the network run command enable is enabled via the HGA unit’s HMI setup screen. See setup screen documentation in HMI Set-...
  • Page 146 Section 16.0 Appendix G: HMI Modbus RTU COM Change Instructions HGA IOM Up Instructions on page 70 for information on how to enable the network run command. The network run command enable can only be enabled via the HMI on the HGA unit.

  • Page 147: Appendix G: Hmi Modbus Rtu Com Change Instructions

    On the ‘Network’ page (Setup -> Tech Setup -> Tech Setup+ -> Network Setup) you can see the current settings of the port. When selecting ‘HMI Settings’ and attempting to change these, you will be prompted to call TCI. This document is intended to explain the process for changing those settings once TCI has been contacted.
  • Page 148 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 Publication No: 26030 Effective: 06/12/2020 Version: P...

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