Medium Voltage Drive Harmonic Filter and Power
Contents
1. Voltage erts 6 pulse 12 pulse Part Number 225 X X 80022 428 01 450 X X 80022 428 02 600 X X 80022 428 03 800 X X 80022 428 04 2400 V 1250 X X 80022 428 05 e 1300 2 X 80022 428 06 1750 X Seen 2250 X 80022 428 07 2500 X 8022 48 08 350 X X 8022 49 01 500 X X 80022 429 02 700 x X 80022 429 08 1000 X X 80022 429 04 3300 V 1250 X X 80022 429 05 ail 1300 2 A 80022 429 06 1750 X dnd 2500 X 80022 429 08 3000 X 80022 429 09 225 X X 80022 430 01 450 X X 80022 430 02 600 X X 80022 430 03 4160 V 900 X X 80022 430 04 60 Hz 1250 X X 80022 430 05 1750 X X 80022 430 06 2250 X 80022 430 07 2750 X 80022 430 08 3500 X 80022 430 10 Table 8 C Reactors 5th 7th amp 11 filters 12 pulse drives 1 of each required per unit Voltage Maximum Part Number Part Number Part Number Horsepower 5th Filter T Filter 11 Filter 900 80022 431 01 80022 434 01 80022 437 01 2400 V 1000 80022 431 02 80022 434 01 80022 437 02 60 Hz 1750 80022 431 02 80022 434 02 80022 437 02 2000 80022 431 03 80022 434 02 80022 437 03 2500 80022 431 03 80022 434 03 80022 437 03 900 80022 432 01 80022 435 01 80022 438 01 3300 V 1750 80022 432 02 80022 435 02 80022 438 02 50 Hz 2500 80022 432 03 80022 435 03 80022 438 03 3000 80022 432 04 80022 435 04 80022 438 04 900 80022 433 01 80022 436 01 80022 439 01 1000 80022 433 02 80022 436 01 80022 439 02 4160 V 1750 80022 433 02 80022 436 02 80022 439 02 60 Hz 20002. 62 Rockwell Automation Allen Bradley Medium Voltage Drive Harmonic Filter and Power User Man ual Factor Correction Units Bulletin 1519 2300 4160 volts 250 3500 hp Important User Information Read this document and the documents listed in the Additional Resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automatio
3. Renewal Parts The following control components are common to all variations of Harmonic Filters regardless of power ratings and options Select the appropriate part number based on your control voltage A customized detailed parts list was shipped with your unit and should be used as a primary reference Table 8 A Control Components Part Number Description gt Y e SC ei V 50 Hz Qty per 5 filter i ig Control on Cooling Fan 22610 101 02 22610 101 03 2 4 Strip Heater Assy 80160 695 52 80160 695 53 1 2 Thermostat Assy 80160 696 51 80160 696 51 1 2 SMP 3 O L Relay 193 C1F1 193 C1F1 10r2 3 Relay Adapter 193 BPM4 193 BPM4 10r2 3 Bul 592 O L Relay 592 BOV16 592 BOV16 1or20 3 Reset Relay 700 F220A1 700 F220A2 10r2 3 en 195 FA20 195 FA20 1012 3 Surge Suppressor 199 FSMA1 199 FSMA2 1or20 3 Reset Button Assy 800T A2D1 800T A2D1 1 1 ae 800T XD1 800T XD1 Not required 2 1 required for each set of 3 capacitors some 5 only filters have 6 capacitors 1519 IN050B EN P J une 2013 8 2 Renewal Parts Power Components The following power components must be chosen specifically for the voltage and horsepower ratings of the unit A customized detailed parts list was shipped with the unit and should be used as a primary reference Table 8 B Reactors 5 filter only 6 pulse drives or Power Factor Correction 6 or 12 pulse drives 1 required per unit
4. 80022 433 03 80022 436 02 80022 439 03 2750 80022 433 03 80022 436 03 80022 439 03 3000 80022 433 04 80022 436 03 80022 439 04 3500 80022 433 04 80022 436 04 80022 439 04 2 6K 2 BKAMG ko O Power Components cont Table 8 D Current Transformers 5 filter only 6 pulse drives or Power Factor Correction 6 or 12 pulse drives 3 required per unit unless noted otherwise Renewal Parts 8 3 Voltage eel 6 pulse 12 pulse Part Number 225 X X 80025 046 01 450 X X 80025 046 01 600 X X 80025 046 01 800 X X 80025 046 02 2400 V 1250 X X 80025 046 03 60 Hz 1500 X X 1750 X 80025 046 05 80025 046 03 3 2250 X 80025 046 02 3 2500 X 80025 046 03 6 350 X X 80025 046 01 500 X X 80025 046 01 700 X X 80025 046 01 1000 X X 80025 046 02 m 1250 x x 80025 046 02 1500 X X 80025 046 02 3 1750 X 80025 046 01 3 2500 X 80025 046 02 6 3000 X 80025 046 02 6 225 X X 80025 046 01 450 X X 80025 046 01 600 X X 80025 046 01 900 X X 80025 046 01 4160 V 1250 X X 80025 046 02 60 Hz 1750 X X 80025 046 02 80025 046 02 3 80025 046 01 3 2750 X 80025 046 02 6 3500 X 80025 046 02 6 Table 8 E Current Transformers 5t 7 amp 11 filters 12 pulse drives 3 of each required per unit Voltage Maximum Part Number Part Number Part N
5. MG ko O Component Identification and Functional Descriptions Chapter 2 Physical Layout and Component Identification Refer to Figures 2 1 and 2 2 to identify the functional components described in this section Note For illustrative purposes a 5 harmonic filter with six 6 capacitors is shown In a 5 7 and 11 configuration there will be two 2 cabinets as shown with the 7 and 11 filter legs in the right hand cabinet Customer load terminals and low voltage control components are always located in the 5 filter leg cabinet left hand side Filter Reactor A three phase iron core reactor with 5 taps on the inductance is wired in series with capacitors to create a specific tuned frequency for the filter Each winding has a normally closed thermal switch that opens when the temperature reaches an excessive level Filter Capacitor Single phase individually fused capacitors are used in combination with a reactor to tune the filter to a specific frequency The capacitors also serve the purpose of providing leading kvar to correct the power factor of the associated drive Current Transformer Window type current transformers are used around the conductors feeding each capacitor The 5A CT secondary drives a 592 thermal overload relay and an SMP 3 relay SMP 3 Overload Relay Only the phase loss function of this relay is used to detect a blown fuse on a capacitor A blown fuse on a capacitor generally indicates
6. Parts to determine the appropriate replacement part See page 1 for parts supply contacts Generally all components are easily accessible and simply require removal of cables and mounting hardware Make sure to label wire and cable terminations before disconnecting and properly torque power connections when reassembling per page 5 1 The following are some specific details to note regarding certain components ATTENTION Damaged components must be replaced with those bearing the same part number or equivalent Failure to use N correct replacement parts or to follow the specified replacement guidelines may result in equipment damage or poor equipment performance locked out before replacing any components Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in electric shock causing severe burns injury or death ATTENTION Ensure main power has been disconnected and Current Transformers The orientation is important for proper current sensing Make sure the replaced unit is physically oriented the same way as the others in the grouping as indicated by the position of the control wire terminals You will need to disconnect the power cable associated with the particular current transformer at one end as well as the control wires from the Bul 592 overload relay in order to remove the unit being replaced Component Replacement Instructions cont Troubleshooting and Repair 7 3 Filter Rea
7. additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how
8. ee ER EO P rx areca 2 2 COONS Fassin Eh bread decre eis Ree sinla 2 2 Strip Heater and Thermostat sss 2 2 Component Identification Figure 311 2 3 Control Components Figure 2 2 essere 2 4 Overall Dimensions Figure 2 3 sss 2 5 Chapter 3 Performance Specifications and Design Assumptions 3 1 Chapter 4 Handling m 4 1 Power and Control Wing ane 4 Routing siooni aeaea ener nnn enn nnne ener innen 4 1 Cable Terminal Access use einerseits 4 2 Ground BUS eter eie Ea een erg eed e e REP DER 4 2 Auxiliary Components sse ene eene 4 2 1519 IN050B EN P J une 2013 ii Table of Contents Medium Voltage Drive Harmonic Filter and Power Factor Correction Units User Manual Commissioning Annual Inspection Troubleshooting and Repair Renewal Parts 2 CK 2 BMG KH O Chapter 5 Pre st rt u p INSPECUOM s vies oie tet eri eee eto EUN M ERI Rte EE Are 5 MISMO TU UICE 5 2 Chapter 6 Physical specu OM T 6 1 BONS uccisi E DE eegen 6 1 signi 6 1 Cable MY 6 1 OTI 6 2 de ee 6 2 Foreisn Maltetl al iecore cente estre ett n eeu vets 6 2 Chapter 7 Tro bleshoOoftlBg ecc i o Gr reete n tere are Feeds 7 1 Harmonie Filter Fault ie eiie repere tete ts 7 1 SMP 3 Relay nanan ne EE rin 7 1 592 Thermal Overload Relax 7 2 Component Replacement Instructions eese 7 2 Current Transformers 4o detener e eet ned ed
9. for the reactor insulation The three switches are wired out individually to a terminal strip on the top of the reactor where the switches are then connected in series These contacts are typically configured to open a dedicated harmonic filter contactor and or shut down an associated drive Reactor Capacitor Overload An Allen Bradley Bulletin 592 Thermal Overload relay is driven by window type current transformers which are installed on each of the phases feeding each set of three capacitors The heater elements are factory selected to protect the filter reactors and capacitors from an overload condition If there is one capacitor per phase in a particular harmonic filter then the heater elements are selected on the basis of the root mean square rms current rating of the reactor in the filter This heater element sizing also allows protecting the capacitors against overload If there are two identical capacitors per phase in the harmonic filter then the heater elements are chosen based on half of the rms current rating of the associated reactor A contact from the 592 overload relay is wired to either open a dedicated harmonic filter contactor and or shut down the associated drive 1519 INO50B EN P J une 2013 1 4 Introduction Protective Features cont 2 GK 2 BK MG ko O Short circuit Protection for Capacitors Short circuit protection for harmonic filter capacitors is addressed by individual fusing of each capacitor The
10. to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1519 INOSOB EN P June 2013 Supersedes Publication 1519 5 0 May 1998 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada
11. 025 834 02 6 80025 834 04 6 2500 80025 834 02 6 80025 834 02 6 80025 834 04 6 900 80025 834 01 3 80025 834 01 3 80025 834 02 3 3300 V 1750 80025 834 02 3 80025 834 02 3 80025 834 03 3 50 Hz 2500 80025 834 03 3 80025 834 02 3 80025 834 05 3 3000 80025 834 03 3 80025 834 03 3 80025 834 06 3 900 80025 834 01 3 80025 834 01 3 80025 834 02 3 1000 80025 834 02 3 80025 834 01 3 80025 834 03 3 4160 V 1750 80025 834 02 3 80025 834 02 3 80025 834 03 3 60 Hz 2000 80025 834 02 3 80025 834 02 3 80025 834 05 3 2750 80025 834 02 3 80025 834 02 3 80025 834 05 3 3000 80025 834 03 3 80025 834 02 3 80025 834 06 3 3500 80025 834 03 3 80025 834 03 3 80025 834 06 3 1519 IN050B EN P J une 2013 8 6 Renewal Parts 2 GK 2 BKAMG ko O Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an
12. 60 01 pod 1500 X X 80025 959 01 3 1750 X 80025 958 01 3 80025 960 01 3 2500 n 80025 959 01 3 3000 X 80025 960 01 6 225 X X 80025 927 02 450 X X 80025 957 02 600 X X 80025 926 02 900 X X 80025 958 02 4160 V 1250 x X 80025 959 02 60 Hz 1750 x X 80025 960 02 80025 959 02 3 2250 X 80025 958 02 3 2750 X 80025 959 02 6 3500 X 80025 960 02 6 Table 8 G Capacitors 5t 7th amp 11 filters 12 pulse drives 3 of each required per unit Voltage Maximum Part Number Part Number Part Number Horsepower 5th Filter 7 Filter 11 Filter 900 80025 927 02 80025 927 02 80025 957 02 2400 V 1000 80025 957 02 80025 927 02 80025 958 02 60 Hz 1750 80025 957 02 80025 957 02 80025 958 02 2000 80025 926 02 80025 957 02 80025 959 02 2500 80025 926 02 80025 926 02 80025 959 02 900 80025 927 01 80025 927 01 80025 957 01 3300 V 1750 80025 957 01 80025 957 01 80025 958 01 50 Hz 2500 80025 926 01 80025 926 01 80025 959 01 3000 80025 958 01 80025 958 01 80025 960 01 900 80025 927 02 80025 927 02 80025 957 02 1000 80025 957 02 80025 927 02 80025 958 02 4160 V 1750 80025 957 02 80025 957 02 80025 958 02 60 Hz 2000 80025 926 02 80025 957 02 80025 959 02 2750 80025 926 02 80025 926 02 80025 959 02 3000 80025 958 02 80025 926 02 80025 960 02 3500 80025 958 02 80025 958 02 80025 960 02 2 GK 2 BKAMG ko O Renewal Parts 8 5 Table 8 H Capacitor Fuses 5t filter only 6 puls
13. ar proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Introduction Physical Layout and Component Identification Performance Specifications and Design Assumptions Installation Table Of Contents Chapter 1 Functional DesGCriptioRi casscsd sezeseicazovecesvescd c ie ee eic dee Nee 1 1 Theory of Operation ii be 1 1 Application Consideratons sess 1 2 Protective POatUtes ose estie tet sue e Hv e ER IRR ehe E er ee 1 3 Reactor Overtemp erature ete eer hee dee NEE geen 1 3 Reactor Capacitor Overload itii eres 1 3 Short Circuit Protection for Capacitors esse 1 4 Blown Capacitor Fuse Detection sss 1 4 Schematic Diagrams Typical Schematic 5th Filter Fed from Drive Input Contactor Figure ND P 1 5 Chapter 2 Component I D and Functional Descermtons e 2 1 Filter Re ttor u isses ha oiaaar ease de 2 1 Filter Capacitor insect egt t e dee Do REC b etis 2 1 Current Transformer ecce teens rete epo a seeds gea ten 2 1 SMP 3 Overload Relay e du d ER ene EUER 2 592 Overload Relay sese 2 2 Reset Relav Dusbbutton sess 2 2 SUtge SUPPLESSOL ar
14. armonic filter fault will vary depending on the particular drive harmonic filter system Ifthe drive input starter is used as the harmonic filter switching device then a harmonic filter fault will have the effect of creating an external fault described as HF FAULT for Harmonic Filter Fault on the associated drive Any fault on the drive results in opening of the associated input starter which de energizes the filter This Harmonic Filter Fault will be annunciated on the Panelview operator terminal under ALARMS Harmonic Filter Fault The contacts for reactor overtemperature SMP 3 blown capacitor fuse detection and Bulletin 592 thermal overload are generally wired in series and any one of these conditions can create a Harmonic Filter Fault If a Harmonic Filter Fault occurs then the SMP 3 relay s and 592 overloads should be checked to see if they are in the tripped condition Both the SMP 3 and the 592 are manually reset relays SMP 3 Relay If an SMP 3 relay has tripped this generally indicates that one or more capacitors in the harmonic filter have failed in a short circuit condition Reset the SMP 3 relay by pressing its reset push button For your safety wait five minutes before accessing the capacitors to allow them to discharge Verify with a hot stick and meter that the capacitors are voltage free The fuses mounted on top of each of the capacitors associated with the tripped SMP 3 relay should be checked with an ohmmete
15. ation Theory of Operation Operating the rectifier of any drive will create harmonic currents that flow back towards the power source and to other plant loads These harmonics result from the non linearity of the rectifier which draws a non sinusoidal current from a sinusoidal voltage source The magnitude of the harmonic currents generated by the rectifier is primarily related to the pulse number of the rectifier 1519 IN050B EN P J une 2013 1 2 Introduction Theory of Operation cont Application Considerations 2 GK 2 BKAMG ko O These harmonic currents can result in distortion of the voltage waveform In rare instances excessive voltage distortion on the power system can have ill effects on the system These effects can include overheating of motors or transformers capacitor failure misoperation of relays computer system disruption and telephone system interference The purpose of a harmonic filter is to shunt certain harmonic currents that are produced by the rectifier away from the power system The result is a reduction in distortion of the voltage waveform on the power system and a reduction in the likelihood of harmonics affecting plant or utility system components Switching with Drive Input Contactor versus Dedicated Harmonic Filter Contactor To simplify the system and reduce capital cost a harmonic filter can be switched using the same contactor or breaker that feeds the input power to the associated driv
16. ayout and Component Identification 2 5 Figure 2 3 Overall Dimensions 7 54 137 T l SES io E 4 i 36 914 e 44 1118 5 Z o P D oo oo 4 6 117 e H z D 5 lt 394 001 5 mE Holes 4 102 5 127 1519 IN050B EN P J une 2013 2 6 Physical Layout and Component Identification 2 GK 2 BKAMG ko O Chapter 3 Performance Specifications and Design Assumptions These harmonic filters are designed to limit rms currents to fall within the reactor rms current ratings assuming that the associated drive is operated within its ratings and other harmonic producing loads do not exceed the levels listed below In addition filters are designed to allow the capacitors to operate within their published voltage and current ratings as follows rms capacitor voltage limit 125 of nameplate voltage peak capacitor voltage limit 135 of peak nameplate voltage e rms capacitor current limit 180 of rated 60 Hz current For variable torque loads the reactors and capacitors have been selected on the basis that other harmonic producing loads up to 5096 of the drive rating may exist on the user or utility power systems For constant torque loads it is assumed that there are no other significant harmonic produc
17. ctors The mounting provision for the reactors is variable in the left to right direction There are sliding nuts under the mounting slots that may move while the reactor is being removed When the new reactor is placed in position simply slide the nuts into position with a screwdriver and reinstall the mounting bolts Make sure there is a minimum of 3 in of clearance between reactors and between any reactor and the cabinet There are lifting channels on top of each reactor suitable for forklifts that will accommodate a single fork for smaller reactors and two forks for larger reactors Make sure the capacity of the forklift is sufficient before lifting reactors the reactor weight is specified on the nameplate Cooling Fans When replacing cooling fans make sure they are oriented in the proper direction The airflow direction is indicated by an arrow on the outside surface of the fan housing and should be pointing outward out through the door Also make sure the leads are not reversed as this will reverse the fan rotation Capacitors and Capacitor Fuses Before beginning any disassembly to replace capacitors take note of the jumper configuration and cable termination locations i e wye or delta configuration When torquing connections on a capacitor terminal or on the top of a fuse remember to use only 10 ft lb 13 5 N m 1519 IN050B EN P J une 2013 7 4 Troubleshooting and Repair 12 CK 2 BKMG ko O Control Components
18. e Structure Check the cabinet and internal structure for any damage dents holes etc which could reduce electrical clearances or allow direct access to live parts from outside the cabinet Repair the damage or order replacement parts as required Cable Check for cut or worn insulation or damaged lugs due to electromechanical stress or improper routing cables will move when subjected to high current Replace any damaged cables and re position any cables that may have moved from their proper position Make sure cables do not contact any sharp edges 1519 IN050B EN P J une 2013 6 2 Annual Inspection Physical Inspection cont 2 GK 2 BKAMG ko O Components Check all components for any signs of damage or overheating Any components displaying physical damage or severe discoloration should be replaced see Chapter 8 In particular check the capacitors for ruptures and make sure there is no leaking dielectric fluid Interlocks Check for proper functioning of all door interlocks clip type and key type They must prevent medium voltage doors from being opened if there is power applied to the filter Foreign Material Check for dust dirt iron filings etc that may have entered the structure and vacuum clean if necessary In particular check the cooling fans and vents to make sure they are unobstructed Troubleshooting Chapter Troubleshooting and Repair Annunciation and action in the event of a h
19. e In this configuration the harmonic filter is energized as long as the drive input contactor is closed The input contactor is usually configured to close when the Emergency Stop string is completed The contactor would then stay closed regardless of whether the drive is running or stopped If the system is configured as described above the user should consider whether the leading kilovolt ampere rating kvar provided by the filter when the drive is not running and thus not drawing any lagging kvar result in an acceptable system power factor In this configuration it is necessary to shut down the drive in the event of a harmonic filter fault condition since the drive input contactor is the only means by which the filter can be taken off line Ifa harmonic filter fault were to occur and it was necessary to operate the drive without the filter it would be necessary to physically disconnect and isolate power cables from the harmonic filter while the drive system is shut off It is necessary to prevent reclosure of the drive input contactor within approximately five minutes of opening to prevent energizing a harmonic filter capacitor which may still have a DC charge on it Alternatively a harmonic filter can be switched with a dedicated vacuum contactor In general the vacuum contactor would be configured to energize the filter when the associated drive receives a start command The vacuum contactor would be configured to de energize the filter whe
20. e drives or Power Factor Correction 6 or 12 pulse drives Power Components cont Quantities as noted Voltage Beie 6 pulse 12 pulse Part Number 225 X X 80025 834 01 6 450 X X 80025 834 02 6 600 X X 80025 834 02 6 800 X X 80025 834 03 6 2400 V 1250 X X 80025 834 04 6 60 Hz 1500 X X 1750 X 80025 834 06 6 80025 834 04 6 2250 80025 834 03 6 2500 X 80025 834 04 12 350 X X 80025 834 02 3 500 X X 80025 834 03 3 700 X X 80025 834 03 3 1000 X X 80025 834 05 3 3300 V 1250 X X 80025 834 06 3 50 Hz 1500 X X 80025 834 05 3 1750 X 80025 834 03 3 80025 834 06 3 2500 2 80025 834 05 3 3000 x 80025 834 06 6 225 X X 80025 834 01 3 450 X X 80025 834 02 3 600 X X 80025 834 02 3 900 X X 80025 834 03 3 4160 V 1250 X X 80025 834 04 3 60 Hz 1750 X X 80025 834 06 3 80025 834 04 3 a 80025 834 03 3 2750 X 80025 834 04 6 3500 X 80025 834 06 6 Table 8 J Capacitor Fuses 5t 7 amp 11 filters 12 pulse drives Quantities as noted Voltage Maximum Part Number Part Number Part Number Horsepower 5th Filter 7 Filter 11 Filter 900 80025 834 01 6 80025 834 01 6 80025 834 02 6 2400 V 1000 80025 834 02 6 80025 834 01 6 80025 834 03 6 60 Hz 1750 80025 834 02 6 80025 834 02 6 80025 834 03 6 2000 80025 834 02 6 80
21. e iN EORR NR 7 2 Filter Reactots iore iir ote ener nerd esc e ees 7 3 COOUNS Fans E 7 3 Capacitors and Capacitor FUSES sse 7 3 Chapter 8 Control Components stereo en etit e IRE get ORE a ee Meet e 8 1 Power Components presse anreisen 8 2 Reactors 5 filter only 6 pulse drives e Table 8 B 8 2 Reactors 5 7 amp 11 filters 12 pulse drives Table 8 C 8 2 Current Transformers 5 filter only 6 pulse drives s Tables D ass rte etrae e etit es irte fetten nias 8 3 Current Transformers 5 7 amp 11 filters 12 pulse drives ICH H H 8 3 Capacitors 5 filter only 6 pulse drives Table 8 F 8 4 Capacitors 5 7 amp 11 filters 12 pulse drives Table 8 G 8 4 Capacitor Fuses 5 filter only 6 pulse drives Table 8 H 8 5 Capacitor Fuses 5 7 amp 11 filters 12 pulse drives Table 8 J 8 5 Chapter 1 Introduction Functional Description A harmonic filter consists of one or more tuned inductor capacitor circuits A three phase iron core reactor is wired in series with three single phase individually fused capacitors These harmonic filters are designed for use with Bulletin 1557 Medium Voltage Drives There are two basic types of standard harmonic filters Filter Type 1 consists of an inductor capacitor combination tuned to the 5 harmonic 5 times the fundamental power system fr
22. equency which is designed to reduce harmonics and provide power factor correction when used in conjunction with a drive with a 6 pulse rectifier These Type 1 filters may also be used in conjunction with drives that have 12 pulse rectifiers When a 5 harmonic filter is applied with a 12 pulse drive it will primarily provide power factor correction and may provide some degree of harmonic reduction Type 2 harmonic filters consist of series inductor capacitor combinations tuned for approximately the 5 7 and 11 harmonics and are designed specifically for use with 12 pulse drives Drives with 12 pulse rectifiers do not produce significant amounts of 5 or 7 harmonic current however the 5 and 7 filters are designed to prevent a potentially detrimental resonance condition from occurring Type 2 filters provide harmonic reduction as well as power factor correction Harmonic filters of Type 1 or Type 2 are designed to correct the power factor to between 0 95 lagging and 0 95 leading over the 50 6096 to 10096 speed range for a typical variable torque load A particular harmonic filter may or may not allow compliance with the harmonic current limits specified in IEEE Std 519 1992 IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems Calculations need to be carried out which take into account specific power system data in order to assess compliance with IEEE 519 harmonic limits for a particular drive applic
23. es and lugs for any signs of damage from assembly or shipping Contact Rockwell Automation immediately if any damage is discovered see page 1 for phone numbers Check for proper functioning of all door interlocks clip type and key type They must prevent medium voltage doors from being opened if there is power applied to the filter Contact Rockwell Automation immediately if any malfunction is discovered see inside cover page for phone numbers ATTENTION Ensure the mechanical interlocking mechanisms are in place and functioning properly before energizing the equipment Improper interlocking could expose personnel to energized components causing severe burns injury or death 1519 IN050B EN P J une 2013 5 2 Commissioning Pre start up Inspection cont For future reference record component data on the table below Table 5 A Component Specifications Fifth Filter Seventh Filter Eleventh Filter Capacitor KVAR 3 Capacitor Farads 3 Reactor Amps Reactor mH Reactor Tap Connection CT Ratio 3 O L Elements SMP 3 Setting FLC Settings The SMP 3 relay s are factory set to allow detection of a blown capacitor fuse phase loss detection No adjustment should be required on the SMP 3 relay s The overload elements are factory selected and installed to provide proper overload protection No adjustment should be required on the heater elements The reactor s are factory set on the nom
24. g storage and installation site preparation These units are certified for seismic zone 4 conditions however this is only in effect if the unit is properly anchored with V5 in anchor bolts to a concrete pad at floor level Any other mounting situation that requires seismic certification must be analyzed and approved separately ATTENTION Ensure main power has been disconnected and locked out before starting the power and control wiring procedure N Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in electrical shock causing severe burns injury or death Routing See Figure 2 3 for locations of access holes in the top and bottom of the cabinet for incoming power cables and control wiring Also shown is the location of the customer power terminals The customer terminals are always located in the 5 filter cabinet i e the left cabinet in a 5 7 and 11 configuration Cabling to the 7 and 11 filter legs is done internal to the cabinets The maximum recommended cable size entering the unit is 1 500 or 2 250 MCM per phase at the factory You must use in bolts for connecting the lugs to the terminals The bolts must be torqued to 48 ft Ib 65 N m for proper contact pressure Phase 1 is located closest to the front of the cabinet ATTENTION Ensure bolts are tightened to specified torque Failure to correctly torque the bolts on the incoming cable lugs may result in overheating of
25. inal inductance tap The reactor s have 5 taps to allow increasing or decreasing the inductance and thus changing the tuned frequency of the filter In general Rockwell Automation should be consulted when considering a change to a reactor tap setting SMP 3 setting or 592 heater elements 2 GK 2 BKOMG ko O Physical Inspection Chapter 6 Annual Inspection unit Failure to perform inspections may result in poor equipment i ATTENTION Ensure annual inspections are performed on the performance possible damage and or injury to personnel On an annual basis harmonic filter units should be physically inspected for any signs of damage component breakdown misadjustment stress electrical mechanical or thermal or foreign material Specifically check the following ATTENTION Ensure main power has been disconnected and locked out before starting the inspection Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in electric shock causing severe burns injury or death Bolts Check tightness of all bolted power connections with a torque wrench Set the wrench to the nominal torque as specified on page 5 1 and apply the set torque to the connection Do not tighten beyond the set torque For inspecting connections to capacitor terminals a reduced torque of 10 ft Ib 13 5 N m must be used Visually inspect all component mounting bolts and tighten any which are obviously loos
26. ing loads If power factor correction capacitors are present on the plant or utility power system consideration should be given to resonant frequencies and potential harmonic amplification that could occur These harmonic filters are NEMA type 1 construction rated for ambient temperatures between 0 and 40 C 32 and 104 F They are available with 110 120 V or 220 V control Standard units are available to compliment the following drive power ratings Power Factor Harmonic Filter Correction Controller e 6 pulse drives 5 filter only 2400V 60 Hz 200 1500 hp 2400V 250 2500 hp 3300V 50 Hz 200 1500 hp 3300V 350 3000 hp 4160V 60 Hz 200 1750 hp 4160V 250 3500 hp e 2 pulse drives 5 7 and 11 filters 2400V 60 Hz 500 2500 hp 3300V 50 Hz 500 3000 hp 4160V 60 Hz 500 3500 hp See Chapter 8 Renewal Parts for specific horsepower breakdowns for each voltage level 1519 IN050B EN P J une 2013 3 2 Performance Specifications and Design Assumptions 12 CK 2 BKMG ko O Handling Power and Control Wiring Chapter 4 Installation ATTENTION Installation of industrial control equipment must only be performed by qualified personnel Failure to do so may result in damage to equipment injury to personnel and or delays in commissioning the equipment Please refer to the handling publication received with your shipment for details regarding receiving unpacking initial inspection handlin
27. intent of the capacitor fusing is to clear a short circuit type fault condition on a failed capacitor The fuses are chosen to prevent a capacitor from rupturing The fuses are not designed to prevent the capacitor from failing These fuses are generally chosen at 17596 to 200 of the capacitor rms current rating The thermal overload described above prevents operation of the fuse in the overload region Blown Capacitor Fuse Detection Blown capacitor fuse detection is performed by an Allen Bradley SMP 3 relay This relay is also fed by window type current transformers which are used on each phase for every capacitor The phase loss function of this relay is used to detect a blown capacitor fuse Ifa capacitor fuse has blown then there will be no current flow in that particular phase It is undesirable for a harmonic filter to continue to operate with a blown fuse on one or more capacitors since this significantly alters the tuned frequency of the filter A contact from the SMP 3 relay is wired to open a dedicated harmonic filter contactor and or shut down the associated drive Note that the SMP 3 relay is not used as an overload relay in this application since it is designed for a sinusoidal waveform It determines the rms value of a current waveform by repetitively sampling to find the peak of the waveform It then assumes that the rms current is the peak value divided by the square root of two This relationship between peak and rms current is not co
28. n Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death We
29. n the drive has stopped In this way the leading kvar from the filter is only present when the drive is operating and power factor correction is required NOTE Re energization of the harmonic filter should be delayed until the filter has had adequate time to discharge typically 5 minutes Introduction 1 3 Application Considerations cont In this scheme energizing the filter can be a permissive to allow starting the Protective Features drive or the drive can be configured to operate independently of the harmonic filter Similarly a harmonic filter fault can be configured to shut down the drive or it can be configured to create an alarm only and allow the drive to continue to operate The isolation switch associated with the harmonic filter contactor can be opened to allow servicing of the filter without necessarily affecting operation of the associated drive There are a number of protective features that are incorporated in each tuned circuit of the harmonic filter to cover the following functions reactor overtemperature reactor capacitor overload short circuit protection for capacitors blown capacitor fuse detection Reactor Overtemperature Reactor overtemperature is implemented in the form of a normally closed thermal switch one of which is embedded in each of the three windings of a particular harmonic filter reactor The thermal switches operate at a temperature somewhat below the maximum allowable temperature
30. r for continuity If a very high resistance is seen on one or more fuses this indicates that the fuse has blown It is also likely that the associated capacitor has failed To check a capacitor an ohmmeter can be connected to the capacitor terminals Ifa gradual change in resistance is seen on the meter then the capacitor is good If a very low resistance and no gradual change in resistance is seen this indicates that the capacitor has shorted internally and must be replaced 1519 IN050B EN P J une 2013 7 2 Troubleshooting and Repair Troubleshooting cont Component Replacement Instructions 2 CK 2 BMG ko O 592 Thermal Overload Relay Ifa 592 thermal overload relay has tripped this indicates that an excessive current has occurred in the harmonic filter An overload condition means that the reactor and or the capacitors in the filter have been subjected to a current higher than they were designed for Some investigation should be carried out to determine why the overload occurred An overload could occur if excessive harmonic currents are present due to non linear loads other than the drive it was designed for The heater element sizing should be confirmed with Rockwell Automation to make sure that it coincides with the reactor current Nuisance tripping could result if the heater elements are undersized for the particular filter If any damaged components are discovered check your customized parts list or see Chapter 8 Renewal
31. rrect when there is significant harmonic content in the waveform For this reason the DIP switches for overload protection are set substantially above the current ratings of the filter components to prevent nuisance tripping due to overload and allow phase loss detection to reliably take place Introduction 1 5 Schematic Diagrams Figure 1 1 Typical schematic 5 Filter fed from drive input contactor 2400V 3 60Hz FROM VFD INPUT CONTACTOR UNIT yy xYS REACTOR SMP 3 SOLID STATE PHASE LOSS RELAY 592 komm Reser OVERLOAD O CH DI u ad 2 L2 T2 C1 e BH ele els ele 3 3A 3 T en ere ere g PE Bry LA ei eh gt SMP 3 SWITCH SETTINGS AUTO LIPIPIPIPTES rt cH a cae GFJAM TEST FOR FLC SETTING H H m CAPACITOR FUSES SEE DIMENSION DRAWING c2 2 Ses CAPACITORS L C1 Pd I LS 5th HARMONIC FILTER 13 13A a D182 TO VFD CUSTOMER TERMINAL BLOCKS DCTB 14p123 ON VFD DRAWING SHT 4 m EEACTOR BUTER RESET 9 018 CONTROL POWER FROM VFD INPUT CONTACTOR UNIT 15 Np 05A I 15815 gt 015p SHFPR Typ m 4 5HFPR 5th FILTER SHFPR 16 a TRIPPED SMP 3 i un 250 D i ss 13A FAN 14 550 CFM ON FAN 13A ON cm 1519 IN050B EN P J une 2013 1 6 Introduction 12 CK 2 BK
32. that the associated capacitor has failed in a short circuit condition The overload setting on this relay is intentionally set high since the overload function is not used The SMP 3 relay is a manually reset device 1519 IN050B EN P J une 2013 2 2 Physical Layout and Component Identification Component Identification and Functional Descriptions cont 2 CK 2 BKAMG ko O 592 Overload Relay A Bulletin 592 thermal overload relay is used to prevent an excessive current condition in the reactor and capacitors This is a manually reset eutectic alloy type device The ratchet stud assembly is heated by current flowing through the heater element Relay operation occurs when the temperature of the ratchet stud reaches the melting point of the eutectic alloy freeing the ratchet wheel and opening the normally closed contact Reset Relay Pushbutton The reset relay is used to latch in a fault that occurs on the harmonic filter The reactor thermal switches 592 overload contact and SMP 3 relay contact for a filter leg are wired in series with the reset relay When one of these devices operates the reset relay latches open until the individual device s are reset and the reset pushbutton associated with the reset relay 1s depressed Surge Suppressor Acts to reduce voltage transients associated with de energization of a reset relay coil Cooling fan Each cabinet has two continuously running cooling fans each with a 550 CFM capaci
33. the connections and damage to the equipment 1519 IN050B EN P J une 2013 4 2 Installation Power and Control Wiring cont 2 CK 2 BKOMG ko O Cable Terminal Access Cable terminals are accessible from the front of the unit with the medium voltage doors open If more working space is required for connecting incoming cables swing out the low voltage compartment by removing the top medium voltage door and then removing the self tapping screws which connect the vertical channel to the structure In order to remove the medium voltage door the control wires for the fans must be disconnected and temporarily removed from the inside surface of the door Remember to re install the self tapping screws and the fan control wires shipped before re energizing equipment Failure to do so may i ATTENTION Replace all components and hardware as result in electrical shock causing severe burns injury or death Ground Bus The ground bus is accessible through openings on either side at the rear of the cabinet Itis the responsibility of the installer to ensure the filter unit is properly grounded in accordance with the Canadian Electrical Code CEC or the National Electrical Code NEC and any local codes Failure to do so may result in electrical shock causing severe ATTENTION Ensure that the filter unit is properly grounded burns injury or death Auxiliary Components A low voltage 115 V or 230 V as specified power s
34. ty They are supplied either 110 120 V or 220 V depending on the control voltage available The fans are oriented to blow air out of the top forward facing vent Strip Heater and Thermostat Optional Strip heaters are located in each cabinet for preventing condensation which may occur if the cabinet temperature is lower than the ambient temperature They are available for either a 110 120 V or 220 V separate source Physical Layout and Component Identification 2 3 Figure 2 1 Component Identification top side and bottom door removed Current Transformers Capacitor Fuses A A SOON SON N an Thermostat Capacitors Cooling Fans Strip Heater Customer Terminals Assembly Vi 1 OW 1l T 7 dE E IR oy 3 ch Low Voltage Wire Duct NK Reactor 1519 IN050B EN P J une 2013 2 4 Physical Layout and Component Identification Figure 2 2 Control Components Reset Relays Shorting Blocks Optional SMP 3 Overload Relays Bul 592 Overload Relays Terminal Blocks 12 CK 2 BKMG ko O Note Dimensions are in inches mm 4 25 x 9 108 x 229 Power Cable Opening 3 x 6 76 x 152 Control Wire Opening Customer Terminals 3 x 3 76 x 76 Control Wire Opening 4 25 x 9 108 x 229 Power Cable Opening Physical L
35. umber Horsepower 5th Filter 7 Filter 11 Filter 900 80025 046 01 80025 046 01 80025 046 01 2400 V 1000 80025 046 01 80025 046 01 80025 046 02 60 Hz 1750 80025 046 01 80025 046 01 80025 046 02 2000 80025 046 01 80025 046 01 80025 046 03 2500 80025 046 01 80025 046 01 80025 046 03 900 80025 046 01 80025 046 01 80025 046 01 3300 V 1750 80025 046 01 80025 046 01 80025 046 01 50 Hz 2500 80025 046 01 80025 046 01 80025 046 02 3000 80025 046 01 80025 046 01 80025 046 02 900 80025 046 01 80025 046 01 80025 046 01 1000 80025 046 01 80025 046 01 80025 046 01 4160 V 1750 80025 046 01 80025 046 01 80025 046 01 60 Hz 2000 80025 046 01 80025 046 01 80025 046 02 2750 80025 046 01 80025 046 01 80025 046 02 3000 80025 046 01 80025 046 01 80025 046 02 3500 80025 046 01 80025 046 01 80025 046 02 1519 IN050B EN P J une 2013 8 4 Renewal Parts Power Components cont Table 8 F Capacitors 5th filter only 6 pulse drives or Power Factor Correction 6 or 12 pulse drives 3 required per unit unless noted otherwise Maximum Voltage Horsepower 6 pulse 12 pulse Part Number 225 X X 80025 927 02 450 X X 80025 957 02 600 x X 80025 926 02 800 X X 80025 958 02 2400 V 1250 X X 80025 959 02 60 Hz 1500 X X a S 80025 960 02 80025 959 02 3 2250 X 80025 958 02 3 2500 X 80025 959 02 6 350 X X 80025 957 01 500 X X 80025 926 01 700 X X 80025 958 01 1000 X X 80025 959 01 1250 X X 80025 9
36. upply is required for auxiliary components Terminal blocks are accessible when the low voltage door is opened Low voltage wiring may enter the cabinet through the designated openings in the top or bottom of the cabinet see Figure 2 3 When entering through the bottom use the wire duct provided to route wires into the low voltage compartment Pre start up Inspection Chapter 5 Commissioning ATTENTION Ensure main power has been disconnected and locked out before commissioning the unit Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in electric shock causing severe burns injury or death Visually inspect all bolted power connections to ensure they are secure Do not apply a wrench to any connection unless it is obvious that the connection has not been tightened over torquing will cause damage to bolts as well as components If a bolt must be tightened the following torques must be used Y in hardware 6 ft lb 8 N m 5 16 in hardware 12 ft lb 16 N m 3 8 in hardware 20 ft lb 27 N m 5 in hardware 48 ft lb 65 N m Important If torquing a cable connection to the top of a capacitor fuse or directly to a capacitor terminal a reduced torque of 10 ft lb 13 5 N m must be used to avoid over stressing the capacitor In addition if torquing connection at the top of a capacitor fuse hold the lower nut in place while tightening the upper nut Visually inspect all power wir
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