Eaton HCU2 Installation Manual
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Eaton HCU2 Installation Manual

Active harmonic filter
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Instruction Booklet IB156002EN
Eaton HCU2/HCUn active harmonic
filter installation manual
Effective February 2022
Supersedes November 2015

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Summary of Contents for Eaton HCU2

  • Page 1 Effective February 2022 Instruction Booklet IB156002EN Supersedes November 2015 Eaton HCU2/HCUn active harmonic filter installation manual...

  • Page 2: Table Of Contents

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Contents Description Page Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Definition of symbols .

  • Page 3: Important Information

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Important information Warnings and cautions Read these instructions carefully and look at the equipment to WARNING become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear HAZARD OF PERSONAL INJURY.

  • Page 4: Safety Precautions

    HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH. HCU2 also have the ability to correct for poor displacement power • APPLY APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) AND factor (DPF) and for mains current balancing. DPF correction can FOLLOW SAFE ELECTRICAL WORK PRACTICES.

  • Page 5: Receiving, Handling, And Storing

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Receiving, handling, and storing Installation This section provides the information required to properly install Receiving the active filter and associated equipment for proper operation and Inspect the active filter for any damage as soon as it is received.

  • Page 6: Installation

    This list indicates minimum requirements. Complete descriptions of the requirements are provided in the standards referenced in this list. Standard units physical description Table 2 . HCU2 physical description NEMA 2, NEMA 12, IP31, IP54 Active Cable Operating Exterior dimensions...
  • Page 7 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Table 3 . HCUn physical description UL Type 1 wall mount Typical Exterior Amperage Mounting Cable heat load Air flow dimensions Eaton rating style entry 208/415 V (W)

  • Page 8: Dimensional Drawings

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Dimensional drawings Refer to the drawings on the following pages for dimensions of the active filter to be installed. Figure 1 . HCUn UL Type 1 wall mount dimensions Figure 2 .
  • Page 9 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 3 . HCUn IP00 front view Figure 5 . HCUn mounting hold dimensions (mm) Total height including mounting features 960 mm • Enclosure height 930 mm •...
  • Page 10 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 NEMA 1 wall-mounted enclosures Figure 7 . NEMA 1, 60 A—dimensions in inches (mm) 60.40 (1534.0) 13.70 16.80 (348.0) (426.0) EATON www.eaton.com...
  • Page 11 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 8 . NEMA 1, 120 A—dimensions in inches (mm) 64.30 (1634.0) 15.10 16.80 (384.0) (426.0) EATON www.eaton.com...
  • Page 12 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 9 . NEMA 1, 200 A—dimensions in inches (mm) 17.20 22.90 (437.0) (581.0) 62.90 (1598.0) EATON www.eaton.com...
  • Page 13 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 10 . NEMA 1, 300 A—dimensions in inches (mm) 22.90 17.20 (581.0) (438.0) Lift here 72.20 (1835.0) EATON www.eaton.com...
  • Page 14 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 NEMA 1 chassis-mounted units Figure 11 . Chassis mount 60 A—dimensions in inches (mm) Lift here 51.20 (1300.0) Lift here 16.70 (425.0) 13.70 (348.0) EATON www.eaton.com...
  • Page 15 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 12 . Chassis mount 120 A—dimensions in inches (mm) Lift here 55.10 (1400.0) Lift here 16.73 (425.0) 15.12 (384.0) EATON www.eaton.com...
  • Page 16 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 13 . Chassis mount 200 A—dimensions in inches (mm) 17.20 22.90 (437.0) (581.0) Lift here 51.20 (1323.0) Lift here EATON www.eaton.com...
  • Page 17 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 14 . Chassis mount 300 A—dimensions in inches (mm) 17.20 22.90 (438.0) (581.0) Lift here 61.40 (1560.0) Lift here EATON www.eaton.com...
  • Page 18 Effective January 2022 Floor mount 60 A and 120 A drawings Figure 15 . HCU2 60 A and 120 A, 380–480 V, NEMA 2, NEMA 12, IP31 and IP54 units—dimensions in inches (mm) Lift here 82.24 (2089.0) 19.69...
  • Page 19 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 16 . HCU2 60 A and 120 A enclosure top and bottom dimensional drawing in inches (mm) 31.50 (800.0) 19.92 (506.0) Top view M10 mounting hardware 27.56...
  • Page 20 Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 200 A and 300 A drawings Figure 17 . HCU2 200 A and 300 A, 380–480 V, NEMA 2, NEMA 12, IP31 and IP54 units in inches (mm) Lift here 82.32 (2091.0) 23.62...
  • Page 21 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 18 . HCU2 200 A and 300 A enclosure top and bottom dimensional drawing in inches (mm) 35.43 (900.0) 3.74 (95.0) 6.89 (175.0) 18.64 (473.5) 23.82 (605.0)

  • Page 22: Attaching The Enclosure To The Floor

    5. Secure the unit to the floor using mounting hardware. 6. Replace the front access covers and torque the screws to Figure 19 . HCU2 floor attachment point locations 5.7 N•m (50.4 Ib-in). Figure 20 . HCU2 Plinth access covers Table 5 .

  • Page 23: Electrical Connection (Hcu2)

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Electrical connection (HCU2) NOTICE Line voltage RISK OF CONTAMINATION BY CONDUCTIVE MATERIAL OR DEBRIS. Refer to Table 7 to determine the line voltage that is compatible REMOVE CONDUIT ENTRY GLAND PLATES TO DRILL CABLE ENTRY with the voltage range of the active filter.

  • Page 24: Power Termination Covers

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Power termination covers Figure 21 . Power termination covers Top cable entry cover M4 hardware T20 driver 1.7 N•m (15.0 lb-in) Bottom cable entry cover Customer access cover T20 driver EATON www.eaton.com...

  • Page 25: 60 A And 120 A Models

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 60 A and 120 A models Figure 22 . 60 A and 120 A enclosure internal layout drawing M8 ground stud M8 busbar studs Top entry power...

  • Page 26: 200 A And 300 A Models

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 200 A and 300 A models Figure 23 . 200 A and 300 A enclosure internal layout drawing—dimensions in mm M12 busbar studs M8 ground stud Top entry power...

  • Page 27: Electrical Connection (Hcun)

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Electrical connection (HCUn) Figure 25 . 20 A unit 200% neutral distributed and 300% neutral distributed Line voltage Refer to Table 8 to determine the line voltage that is compatible...
  • Page 28 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 27 . 30 A unit 200% neutral distributed and Figure 29 . 50 A unit 200% neutral distributed and 300% neutral distributed 300% neutral distributed 200% neutral...

  • Page 29: Residual Current Device

    Direct current can be introduced in the protective ground conductor exceed 19 mm. Installation of parallel power cabling is not supported. of this Eaton HCUn active filter. If a residual current device Careful consideration must be given when sizing the neutral...
  • Page 30 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 32 . Wallmount main and expansion electrical connections Figure 34 . Line, neutral, and ground—torque Service door Ground Using a punch or similar, create a hole in the grommet just large...

  • Page 31: General Ct Information

    X1 and X2 OUT are used for parallel active filter systems. Minimum CT requirements The terminal block on the CT board for the HCU2 can accept wire The active filter uses a minimum of two external current sizes of up to 6 mm (10 AWG) wire and has a torque specification transformers (CTs) to measure load current waveforms.
  • Page 32 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 36 . Control board and CT board detail Control Board CT Board Table 10 . 5 A secondary maximum wire length with Table 12 . 5 A secondary maximum wire length with...
  • Page 33 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 37 . Source side CT position single main with neutral connected Source Load Protection Device Provided by others. See Over-current Protection Device Selection for details Active Filter...
  • Page 34 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 39 . Load side CT position single main with neutral connected Source Load X1 X2 Protection Device Provided by others. See Over-current Protection Device Shorting Selection for details...

  • Page 35: Parallel System

    The factory installed shorting jumpers must be installed. Parallel system Up to ten active filters can be installed in parallel for the HCU2 and up to twelve active filters can be installed for the HCUn. If more units in parallel are required, contact the local sales representative for assistance prior to installation.

  • Page 36: Wiring Diagrams

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Wiring diagrams Figure 42 . Source side CT position parallel units diagram EATON www.eaton.com...
  • Page 37 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 43 . CT wiring for three primaries EATON www.eaton.com...
  • Page 38 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 44 . CT wiring for two primaries and one secondary EATON www.eaton.com...
  • Page 39 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 45 . CT wiring for two primaries and three secondaries EATON www.eaton.com...

  • Page 40: Parallel Communication

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Parallel communication For parallel operation, the units communicate through the RJ-45 CAT5e cable with all 8 conductors terminated at the RJ-45 connectors labeled 1P and 2P on the Control Board. This is a connections is required for parallel communication.

  • Page 41: Control Wiring

    See the User Manual for setting the output contacts. Maximum voltage accepted is 250 Vac or 30 Vdc with a 1 A maximum current for the HCU2 and 0.5 A maximum current per dry contact for the HCUn.
  • Page 42 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 50 . Chassis to HMI/front panel connections Figure 51 . Control board and CT board detail LED light pipe socket (D404) HMI COM1 HMI 24 Vdc...

  • Page 43: Pre-Commissioning

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Pre-commissioning Pre-commissioning checklist Prior to commissioning the active filter system, the following items This section provides information for preparation of the active filter must be completed: for commissioning. Before applying power, read and understand this information thoroughly.

  • Page 44: Hrg, And Corner Grounded Systems (Hcu2)

    Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 IT, HRG, and corner grounded systems (HCU2) This section provides information on using the active filter with Isolated Terra (IT), High Resistance Ground (HRG), and corner grounded systems.
  • Page 45 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 When connecting the active filter to an IT, HRG, or corner grounded system, open the IT/BP switches as follows: 1. Remove the large main cover of the unit.
  • Page 46 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 2. Locate the IT/BP switches. Figure 54 . IT/BP switch locations on 60 A and 120 A units IT/BP switches EATON www.eaton.com...
  • Page 47 Instruction Booklet IB156002EN Eaton HCU2/HCUn active harmonic filter installation manual Effective January 2022 Figure 55 . IT/BP switch locations on 200 A and 300 A units IT/BP switches 3. Pull the plunger out. The switch is open when the plunger is completely out as shown in the figure below.

  • Page 48: Catalog Numbering System

    CONTAINED HEREIN . In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited...

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