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Version B - TCI, LLC

1. 28 Puu 293u05 xhy EUU TEL 12 poo MIA E woog OPIS 5243 47 2 0414 008 9695 MITA 54000 yog SiS 59494 A 5 308 H 5842 07 1 uan _ B 22 4203 54000 ejqnog 3404 5 INH 60 99 ISSZON uraims aX 5905 _ 540001 yog 53340 4v a 4344379 300143 4ooq yagis Kay una 5 46 7 513035 Figure 5 12 200 Amp Type 3R Enclosed 65 pau 4M A MILA PIS 2007 2487 SEOL Wa usuy addy qN aansoju3 2 07 sq BOEBZE 2130 o4suen 8 4 0 43333 9 WOW 0 5 Gn punoug p 006 25949 aad 2012npuo2 yonp 5 Puwa 5 240d 558220 4 14 928 SE 3320 005701 5501 309H 1 830N 292000 52001 T 4oog 295 Kaug pagsang
2. uo Buipuaedap AoW jouonippy 8 ueiquo 2 404 4 S 5 55049 CZ aq o spaau 5 55095 Ss apis unuxow 40Ss9829u aq 10u Aow SUD 25841 UaU 4100 a41 30 Adualdigga 241 uo Bulpuadag Cr UL OST 5 CE bs 00 30 10404 Sapis 341 30 ZG 4840 294 Ul 5 JO 04 y pjnous Fo Ce sau2uj bs 001 40 9949 19401 xoaddo sopis 244 30 s4addn ui 5 30 do ayy U 418j41no 2340207 1S 4 0N u6no4au uly 1snuouxj Su 4 2 suv 4 5 Figure 41 Cooling Diagram for 39 45 78 90 and 100 amp units 28 uo Saydu U puo suo sueu ZI suo 0212245 a5244 21 3302U09 II Sunoo2 4adoud pjnous COT S88 g 53398 000 7 550 439 1040 6 uop o4n6 3u02 aJnso 2ua puo uaa uo Burpuadap papaau ou uolo ius jouolilppug 8 4ua quo 5 gy wos pa494 5 S sS59u2 CZ sp u 5155049 9 sau2u 2 s 8uj pods pom ap s wnwixow
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5. 4 98 Troubleshooting 99 Troubleshooting Flow Chart 4 4 eres ee 99 m Section 9 Appendix Installation Diagram ecce 99 Appendix Part Numbering 101 Appendix Ethernet IP Gateway Option 101 P 101 Roe 101 v Dt te stupite Voss oo rsson SSi ta 102 Resister M 103 Sc 103 Section 1 HGA Quick Start Unit Software Setup 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 All wiring must be in accordance with the National Electrical Code NEC and or any other codes that apply to the installation site Disconnect all power before working on the equipment Do not attempt any work on a powered HGA filter The HGA filter drive motor and
6. unysdozs 5316 ae 5 MILA 30013 Figure 5 14 300 amp Type 3R Enclosed 67 Section 6 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 Overview The Interface Module has three major components the Interface PCB the HMI Display and an option network Communications Gateway see Figure 6 1 The interface PCB contains a Chassis Communications Port that connects to the power converter of the HarmonicGuard Active filter The interface PCB translates status and commands data between the power converter controls and the HMI Display The interface PCB also contains the 24V Relay I O for basic status monitoring and run stop control of the HarmonicGuard Active filter The HMI Display is a 6 color Touchscreen display containing a series of status screens that provide the user with a convenient way to monitor the operation of the HarmonicGuard Active filter The HMI display also contains an integrated ModbusRTU network connection for remote monitoring of the HarmonicGuard Active filter The optional network Communications Gateway can be connected to the integrated ModbusRTU network connection in the HMI Display to translate
7. 5 aq 40U 2524 04 244 30 A2ua jjje eu uo Gujpuedag UI 2 8 432 5 UOJ CE sau2u bs 922 30 0401 Sapis 243 30 ZG 243 5 40 WOPTOG 24 Ul aq pjnous sayrsu bs 92 40 9949 10103 uii sapis aui 30 24 uo do aui u 18jino 281020 5 6 eunso auq aas ee 02 1 u6nouu snoyxg 8upoo5 no 5 aAanso 2u3 x OW pve Figure 4 2 Cooling Diagram for 200 amp units 29 Installation Guidelines Caution Mounting The HGA must be mounted vertically on a smooth solid surface free from heat dampness and condensation Wiring Cable Entry Locations The enclosed HarmonicGuard Active filters are not provided with enclosure wiring knockouts however a removable wire entry plate is provided A selection can be made at the time of installation Typical or recommended cable entry locations are shown in the drawings shipped with the unit Refer to circuit breaker section on page 50 Field Wiring Connection Terminals Compression type terminals are provided for all field wiring connections The wire size 75 C copper capacity ranges and tightening torque for the grounding and power terminals are lis
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9. 5 55942 54 Avjdsig IWH E 225 ou uaa p sano ayu WwO310g ui sucisuaulq 54000 anog E 93 N 225 ASIA MIA Figure 5 13 300 amp Type 1 Enclosed 66 5 2 uj suo suau q sak 483 98H 484 08H S SH 909 969 MITA doy sano 3ndur 4 04sowusaU a4nsoj2u3 puvog uo 3 o junuudo zal 29105 xny MOT 181 19 pro 4 PIS TS ISNY 5 13 ae ad IN 5 2693 6 Sq 9 992 8umvap 5 UBANI E86928 2043425 T 8692 2 4233234 auim 9 0 0Gz jonp s 6n Gav p 006 25949 4oi2npuo2 51 Pu U NLE 476 0 370M 000727 5501 038H ISSLON Ka4u3 MATA UlI0JJOg 52000 yog aw 50494 di 6ujoo5 52424 07 5 5 54000 yog 682 4293 2 5 3404 gt s0uG oq 0 9 IWH
10. Screen Brightness Button This option allows the user to change the brightness and gamma of the display The contrast control is not enabled in this display model 90 Close screen Contrast disabled Brightness Gamma This option lets the user view the status of and configure the Network Setu Button 2 integrated ModbusRTU network connection in the HMI display This button is password protected and used during technician setup and commissioning only Technician Setup The Technician Setup Screen is used by TCI qualified personnel Button to configure the System CT Ratio Autostart AutoReset Delay Time Unit Power Save Threshold System Metering Voltage Sensor Wiring Error Auto Detection Parameters and to initiate the built in Auto Calibration Procedure Language Setup Sets display language of HMI text This button will restore the user saved settings from non volatile persistent memory A confirmation screen will pop up asking Are you sure you want to load saved settings If Yes is chosen any temporary changes made to the working set point parameters will be lost and the user saved settings will be restored If No is pressed the user will be sent back at the Basic Setup screen Load Settings Button This button will save the current working settings to non volatile memory that persist when power is removed from the unit To save the current setti
11. 291 aaddo2 pajojnsu 2 GZ aq poys 1 81 8 Z 9 S v E 2 T gsgsgsgs a unos 1 830N W upas wo3 ag Uo j2auuo 225 1 225 480g JV asud E so ono uere 8 e cerle 58828 uon 2auuoj3 4H dojsuval 2 uon2es ad L aas 50007 j a2unos 930N 225 LT 119 LNAWADV1d 12 3015 600 volt Figure 4 4b Line Side or Load Side CT Placement 39 and 78 35 JARIO 244 03 PUY bajoisu 4ewojsno avo 5 1 anos 8 ssa AspoodoD AADO 403 10 ijnsuoo uo iez in 25329 gt sho iuaje nba a2u9420a4 aq a o4 S p90 CZ gt aq s4eu4045u944 9 jauuosuad Syoupuss Avopucdas 24 550129 a030 5 uj aui ui w sJewdJc4suo4 uad Aul S andog Gay 21 0 51 uos joujula gt ejsodsaJ S Aog2npuca Sru Sapo 1920 JAN 82u9pu4023230 uj uais s Bue sasj
12. 43 109 2 59 1499 29 737 6 2 157 5 38 965 5 7 144 8 0 22 56 KCTF2000B03 1 30 0 0 j I 5 4 3 109 2 59 1499 290737 620575 381965 57 144 8 022 56 29 1245 300 120 _ 43 1092 5 9 149 9 29 737 6 2 157 5 38 965 5 7 144 8 0 22 5 6 4 9 124 5 300 120 43 1092 59 1499 29037 620575 351965 57 1448 922 56 49 124 5 20005 200 080 43 1092 59 499 29137 620575 381965 57 144 8 0 22 5 6 49 124 5 2 2 55 9 KCTF1000C4 3 3 Figure 4 7 Current Transformer Diagram Solid Core 45 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 Electric Code NEC and or any other codes that apply to the installation site The ground connection must be made using a wire conductor Metallic conduit is not a suitable grounding conductor The integrity of all ground connections should be periodically checked HarmonicGuard Active Filter Operation Adjustments e The HGA has been factory calibrated and thoroughly tested There is no need to make any adjustments Start Up Commissioning Caution A first time Before Applying Power for the First Time Inspect the installation to make sure that all equipment has bee
13. Check the power semiconductors mounted to heat sink for cracked cases ruptures debris arcing and burning Check for any loose connections if no apparent damage is found to the power semiconductors Measure resistance of power semiconductors using a multimeter set on the diode check setting see Figure 5 2 Look for opens or dead short readings With the red lead of your meter connected to the far right negative terminal of the capacitor bank measure with the black lead of the meter to each of the three output terminals bus bars the reading should be approximately 0 35Q Reverse the meter leads and repeat measuring to each terminal This time a low reading will be present which will continue to increase this is an indication of a capacitor charging Next connect the black meter lead to the positive capacitor terminal and again measure to each of the output terminals with the other lead the reading should be approximately 0 35 2 Reverse the meter leads and repeat measuring to each terminal Again it will be a low reading which will continue to increase If the readings are as described in all likelihood the power semiconductors are good If any readings are opens or dead shorts it will be an indication that something is bad in the power section Do not reapply power if you are not sure the IGBT s are good Bus Bors lett Dual SCR 5 NL Dual SCR
14. 51 enbaoa 4 2 0 51 Buva 2 Hl 1 91 PuL 40123npuo2 Buisn 4snu sapo2 1020 puo JIN 82u9pJ40229 ul uass s y puno48 aui aq puno46 s ssouj Bujo ajoLidoaddo aug uaddod 5 uaySiy o 9 aq pjnous 830N 103430 19 90 uon2euuoj aas uon2euuoj aas cH TH 483 48 u02 483 48 u02 001 v 001 aaunos Figure 4 4d Line Side CT Placement 200 amp Type 3R 480 volt 37 WN 9 QFU enbuot ZL 01 OF 9216 SIM 5 pepddns a10 sJ4aud03Su0o44 48348 u07 C4 a4ou2 sng a25u942984 au yS 4 uo 5 007 c9 A8u403SU044 ZUBUUND UO 4a x4ou uo i2e4 p O3 4838 Jo312npuo2 puno4o PINOYS 5 3 1us44n2 4usudinba jauuosuad 5 Suwa eui 550429 yy ij nsa4 GujpulM Auvpuordas aui YIM s4auJo3sub4i iua44n2 Sup o4edp CE 4032npuo usn 8pou 514 uo 28uuo 5 1020 JAN YIM 82uv0p40229 ua3s s
15. Navigate to Status screen Navigate to Line Load status Note the corrected voltage current power and THD V THD THD Ref 10 Section 2 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 The HGA filter is intended to be connected to the bus or power cables where one or more loads are connected Three phase power is connected to the input terminals of the unit and corrective current is supplied to the system through the HGA filter in response to the input signal being received from the CTs connected to the monitored bus The instructions and particularly the safety instructions for the drives motors and any other related equipment must be read understood and followed when working on any of the equipment Warnings and Cautions This manual provides two types of safety instructions Warnings are used to call attention to instructions which describe steps which must be taken to avoid conditions which can lead to a serious fault condition physical injury or death Cautions are used to call attention to instructions that describe ste
16. SH Figure 5 5 39 and 78 amp Open Chassis Filter Open Transformer 58 SH 293 a4nsoj2ua awos 2944 ul pa4920 4 5 5 4 241 C SH 241 pa4920 4 5 5 4 au 66LLZ sissou2 uado 04 4233283 T iSOLON JaW us L amb 4004 sapis u3og 5243 auos 5 3 39044 225 dol s lejoq IouL10 SU I J 2500 panddns 51 IWH 4oop 403 MONY 1S840N apis 4043 O14 suv4 9 Woreq 225 SeA IA oAnoy SH Filter Type Transformer IS 5 6 39 and 78 amp Open Chass Figure 59 400 j JO 5 291 9 SH 94 30 5 4aujja uo gt J4auJ0jsuo44 241 om apis 52924 9 spun ajdijnu u2u 21 apis apis UPUH 48uJ0 5 30 320juns do 29 Ssau2u 21 o aq pjnous CH JO WOZZOG 291 48u4O0gsuo44 puo GH 29 sau2u 21 30 wnujuju aq 51 GH a43 4apun aq 40u UVI 4au403suoJ4 T 1 830
17. Yellow leads Phase A current Red e Phase A voltage Green and Phase A current Red are in phase and the same polarity Phase C voltage Blue and Phase C current Yellow in phase and the same polarity 82 Figure 7 8 VLine amp ILine Waveform Plot of a Properly Connected HarmonicGuard Active filter unit in stopped state Note The example VLine amp Line Waveform Plot screens apply to rectifier loads only For low power factor loads the VLine amp ILine waveform screen will appear different Table 7 8 shows what the VLine amp ILine Waveform Plot Sub Screen would look like with various connection errors present in the system Table 7 8 VLine amp ILine Waveform Plot Screen Examples when Typical Connections Errors Present in System VLine amp ILine Waveform Plot Sub Screen with Connection Connection Error Rectifier Load Error Resolution Description Phase rotation is To correct swap Incorrect Phase A and Phase C HarmonicGuard Phase A leads Active filter power Phase C instead connections AND of Phase C swap Phase A and leading Phase A Phase C system CT current feedback then recheck plot 83 Phase C system CT current feedback missing Phase C current is zero while Phase A current is present Phase A and Phase C CT current feedback swapped Phase A current red in phase with Phase C voltage blue instead of Phase A voltage green C
18. back to allow the system to continue correcting harmonics This option allows the Active Line Condition to be remotely turned on or off across a network connection If the stop button is Network Start Enable Button pressed locally on the HMI Display the Network Start Enable is automatically set to DISABLED and has to be re enabled manually via the HMI display Relay Start Enable This option allows the Active Line Condition to be remotely turned on or off via an external relay J2 on the interface requires a switch closure to stop the converter If the stop button is pressed Button locally on the HMI Display the Relay Start Enable is automatically set to DISABLED and has to be re enabled manually via the HMI display Factory Setup This button is password protected and used during the factory and Button technician setup only Set Date and Time Presents a sub screen which allows the user to change the date Button and time displayed on the screen The date and time are also used for time stamps in the fault history and historical trend plots Power Factor Correction Enable Button This option turns the Automatic Power Correction on or off This option is on by default If both harmonic correction and power factor correction are enabled and the HarmonicGuard Active filter is at its maximum capacity the power factor correction will automatically be phased back to allow the system to continue correcting harmonics
19. em Tar aD Er ED panog 205227044 daas serek Ayquassy J43343 u02 mam ETTE de serep Gn oer panog soseo p Wes g02 303 arput da3a2 u23 18 149 gt 4 2 A 2aays 4 4 SR 1 0 gt 3 jen n 1 41 18 my 91 i rn Janod indul my Parallel Figure 5 1c General Schematic Bus Applied 200 Amp Type 3R This drawing is for general reference only Use the drawings supplied with the unit for installation 50 Overload Over Current Protected The filter has factory set built in electronic overload and over current protection If the converter current exceeds the preset instantaneous peak the converter will shut down to prevent permanent damage to the converter and at which time it will indicate a fault Faults that do not automatically reset can be cleared by pressing the stop button on the HMI display An indication that the filter is going into overload will be observed by a gradual worsening of the total harmonic distortion THD or power factor as the load increases The HGA filter units can be paralleled to increase total corrective current cap
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22. state provincial and local requirements Install new battery and close battery cover Replacement Battery Type 3V Lithium CR2032 x Quantity 1 Figure 8 1 HMI Display Battery Location Software Field Upgrades In the event the HMI Display application software needs to be upgraded the USB host port on the back panel of the HMI Display see Figure 8 2ftware updates provided by can be used for field upgrades Software upgrade instructions will be sent with any software updates provided by TCI Back View of HMI Display USB Host Port for Software Upgrades Figure 8 2 HMI Display USB Host Location 97 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 screen To clear a fault press the Reset button from inside the Fault Screen or the Stop button from any screen Only qualified electricians should carry out all electrical installation amp maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered HGA Warning This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before attempting to service the conditioner Check for
23. CAUTION OPEN SPLIT CORE WITH A TWISTING MOTION ONLY 5 DIMENSIONS ARE IN INCHES MM Dimensions in Inches mm Catalog Current Ratio VA Rating ARDEN ee ee ee A 0200 04 2 5 6 1 2 165 1 KCTF0400B04 6 1 2 165 1 0500 04 1 1 4 31 8 1 1 2 38 1 KCTF1600B04 16005 15 06 4 1016 1 1 4 31 8 1 1 2 28 1 KCTF1600B06 16005 15 06 6 1524 1 1 4 31 8 1 1 2 38 1 KCTF1600B08 16005 15 06 8 203 2 1 1 4 31 8 1 1 2 38 1 10 5 266 7 KCT3F1600B04 16005 15 06 4 1016 1 1 4 31 8 1 1 2 38 1 6 1 2 165 1 43 Rectangular SPADE eee S 1200402 1005 50 02 23 4 699 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 KCTF1600A02 _ 16005 15 06 23 4 69 9 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 2000402 2000 5 2 3 4 69 9 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 KCTF3000A02 3000 5 2 3 4 69 9 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 5000 04 50005 45 18 4 1016 11 279 4 6 1 2 165 1 13 3 8 339 7 Figure 4 6 Current Transformer Diagram Rectangular __250 10 2 508 99 252 1 1 4 31 4 7 119 4 5 1 8 350 7140 2 508 99 25 2 1 1 4 318 4 7 119 4 53 4 146 1 6 1 2 165 1 0 28 7 1 300 9040 3 762 0 74 19 1 11 4 318 4 7 1194 53 4 146 1 6 1 2 165 1 0 28 7 1 150 100
24. Figure 4 4a It is important that both CTs are on the same side of the HGA The CTs should be centered around the conductor Optional Load Side CT placement is available for single units as shown in Figure 4 4a 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 amp 2 and the CT around conductor L3 should connect to TB 1 terminals 3 amp 4 The secondary wire of the CT identified as must connect to the X1 terminal of TB 1 for both CTs Failure to maintain the correct polarity and phasing will cause an over current fault If this should happen refer to the troubleshooting section The exact CT placement is dependent on the HGA s configuration and size Please refer to Figures 4 4a through 4 4i for the installation that applies Note Units with black TB 1 terminal blocks are shipped with two position shorting jumpers installed between positions 1 amp 2 and 3 amp 4 This is done for your safety and to prevent equipment damage The jumpers are installed in the center of the block and can be identified by the gray top After the load CTs are installed and wired these jumpers must be removed for correct unit operation They can be removed with a standard flat blade screw driver See Figure 5 3 Note CT operation can be verified viathe HMI touchscreen feedback waveform plot screens Reference the HMI V
25. Historical Trend screen menu is displayed see Figure 7 9 Converter Status Sub Screen The converter status sub screen shows the present status of the HarmonicGuard Active filter power converter module 79 rey Total one 73 RU Link voltage Heatsink Temp Filter 50 Current Used 7 10 0 EE E Figure 7 4 Converter Status Sub Screen Table 7 4 Converter Status Sub Screen Elements Screen Element Description Run Stop Button Runs and stops the HarmonicGuard Active filter Displays the present HarmonicGuard Active filter Display output corrective current in Amps RMS Displays the internal DC Link Bus voltage of the Link Voltage Display HarmonicGuard Active filter in Volts DC Displays the present HarmonicGuard Active filter power converter heat sink temperature in Degrees Celsius Heatsink Temp Display This gauge displays the current filter capacity as a percentage of total available capacity In normal operation the display will read Nominal If the unit output corrective current is above 95 of maximum capacity the indicator light will turn red and display At Capacity When the converter is at capacity the Relay 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 contac
26. Module 5 m Q3 Dua IGBT 9 CeE1 C1 Bb Dual IGBT Modules Bus Bars Ove Capacitors Positive Terminal Four Electrolytic Negative Terminal Capacitor Bank Bus Capacitors Capacitor Bank Figure 5 2 39 45 78 90 100 and 200 Amp Power Component Layout Jumpers LL Terminals Figure 5 3 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 A on a powered filter converter The HGA contains high voltages and capacitors Wait at least five minutes after disconnecting power from the converter before you attempt servicing Check for zero voltage between all terminals to the converter Be aware everything ahead of the circuit breaker will still be energized 55 Suspected System Failure YES NO Is active fitter powered with 480VAC at unit input breaker Is circuit breaker in active filter tripped Are the fans running in the active filter Is HMI display on unit operating Tap screeen to disable screen saver NO Contact TCI Customer Service Power off and inspect unit see Is branch circuit YES Sec
27. Open Chassis or UL Type 1 ALC 100 A 01 H 00 00 ALC Prefix Current Rating 50 100 200 Voltage Rating A 480 Filter Enclosure 00 Open Chassis 01 UL Type 1 Package Option H Interface Module Circuit Breaker 10 ABB 22kA 20 ABB 100kA 30 A B 25kA 40 A B 65kA 60 Eaton 65kA 70 Eaton 100kA 80 Square D 18 90 Square D 65kA 00 breaker 01 ABB 65kA Reserved for custom options to be defined as needed each position can use 0 thru 9 Default option is 00 Figure 3 3 HarmonicGuard Active filter part number encoding 19 Figure 3 4 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be H5100A03H4000 This designates an enclosed HarmonicGuard Active filter that is rated for 100 amps 480 volts and has an HMI Interface Module Package HGA Part Numbering System 480V 3R Temperature 40 C Current 50 100 200 300 Voltage 480 Enclosure UL Type 3R 5 100 A03 01 00 5 Prefix _______ Current Rating 050 100 200 300 Voltage Rating A 480 Filter Enclosure 03 UL Type 3R Package Option H Interface Module Circuit Breaker 10 ABB 22kA 20 ABB 100kA 30 25 40 65 60 Eaton 65kA 70 Eaton 100kA 80 Square D 18kA 90 Square D 65kA 00 No breaker 01 ABB 65kA Reserved for custom options to be defined as needed each position can use 0 thru 9 Default option is 00 Figur
28. Plot Scale Display located on the left side of the graph Indicates the magnitude of the samples of the trend plot The scale varies with each of the trend plots Right Timestamp Left Timestamp Indicates the date and time the right most sample displayed on the Screen was taken Indicates the date and time the left most sample displayed on the Screen was taken Scroll Bar Allows the user to scroll through all sample points available in the trend plot data buffer Trend Plot Display The historical graph of the value being sampled over time 86 Fault Screen This button takes the user to the Active Fault screen see Figure 7 11 which lists all of the active faults The faults will stay in this list until the Reset or Stop button is pressed or the fault self clears From here the user can also go to the Fault History screen Figure 7 11 Fault Screen Table 7 11 Fault Screen Elements Screen Element Description Stop Button Turns off the HarmonicGuard Active filter Reset Button This button will remove all faults from the list if the fault conditions have cleared Once cleared a fault will still be viewable in the fault history log Fault Trip Entry Display When a fault occurs the fault screen will display information about the fault including the from left to right across the screen e Fault bit mask number e Fault timestamp
29. e Fault code see Table 7 12 e Fault description History Button This button will take the user to the Fault History sub screen where previous faults can be reviewed 87 Table 7 12 Fault Codes Fault Critical or Auto or Manual Code Non critical Fault Reset Fault Description Critical Manual Desat IGBT Gate Driver Fault 10 Phase A Critical Manual Desat IGBT Gate Driver Fault 20 Phase B Critical Manual Desat IGBT Gate Driver Fault 30 Phase C 1000 Non critical Auto DC Bus Overvoltage 1250 Non critical Auto DC Bus Undervoltage 3000 Non critical Auto Overcurrent on Phase A 3010 Non critical Auto Overcurrent on Phase B 3020 Non critical Auto Overcurrent on Phase C 4000 Critical Power Cycle Overtemperature 4250 Non critical Auto Undertemperature 7000 Non critical Auto Calibration Fault 7010 Non critical Auto Communications Fault Non critical Auto Fault location indication Fault originated in Unit N where N is in the range 1 to 8 For factory configured parallel systems the Unit N Faulted unit numbers are sequential ordered from left to right when looking at the front of the system Unit 1 is the left most unit in the system Critical faults flagged with a manual reset require a HMI stop button or run stop switch stop command at the unit to clear Critical faults flagged with a power cycle reset require a manual on off power cycle
30. is detected the specific fault code will be shown See Table 7 19 for a description of specific fault codes Self Test Result When a sensor wiring error is detected one or more corrective actions will be Description displayed here See Table 7 19 for a list of suggested resolutions Acknowledge Pressing the Acknowledge Button will hide the Sensor Wiring Error Self Test Sub Button Screen so other the screens can be examined in order to trouble shoot the wiring error If a user attempts to operate the unit while a sensor wiring error is still present by pressing the Run or Stop buttons the screen will reappear 94 Table 7 18 Sensor Wiring Error Code Table Error Code Error Suggested Corrective Action 0 No Error No corrective action required No correction action required Typically the self test will 1 Self Test In Progress complete and auto clear in less than 10 seconds after power up Turn off unit and check 3 phase AC input voltage wiring for 5 missing phase connection or low line voltage 3 Input Over Voltage Turn off unit and check 3 phase AC input voltage wiring for high line voltage 4 Reverse Voltage Phase Turn off unit and check 3 phase AC input voltage wiring for Rotation A B C phase rotation or missing phase connection Turn off unit and check 3 phase AC input voltage wiring for Phase pate eer Voltage missing phase or low line voltage Turn off unit and c
31. light see Figure 7 1 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 the troubleshooting section at the end of this user manual for diagnosing common problems HMI Screens Home screen The Home screen displays a dashboard of overall filter status information and allows the user to run and stop the HarmonicGuard Active filter Figure 7 2 illustrates the functions Filter Status Stopped LinefLoad Status Filter Current Used Power Factor 50 Freq Supply Yoltage 4194 Current E Figure 7 2 Home Screen 76 Table 7 2 Home Screen Elements Screen Element Filter Status Display Description Indicates if a converter fault is active and preventing the HarmonicGuard Active filter from running If a fault occurs the indicator will flash red and display Fault Specific Fault codes can be viewed on the Fault Screen 96 Filter Current Used Display This gauge displays the current filter capacity as a percentage of total available capacity In normal operation the display will read Nominal If the unit output corrective current is above 9596 of maximum capacity the indicator light will turn red and display At Capacity When the converter is at capacity the Relay K4 J12 Connector and J11 Contacts used for a remote indicator will also be energized If the monitor continually displays At Ca
32. of the unit to clear Fault History Sub Screen The Fault History sub screen See Figure 7 12 contains up to 120 entries that mark the onset and clearing of system faults At the onset of a fault condition an entry will be generated in the fault history marked with on the left side of the fault entry When a fault clears an entry will be generated in the fault history marked with an on the left side of the fault entry The Fault History persists through power on off cycles In the event the fault history log exceeds the max number of 120 entries the oldest entry will be overwritten by new entries 88 13 19 10 02 2012 13 19 10 02 2012 13 20 10 02 2012 1000DC BUS OVER VOLTAG 13 20 10 02 2012 1000DC BUS OVER VOLTAG 13 20 10 02 2012 3000 OVER CURRENT PHAS 13 20 10 02 2012 3000 OVER CURRENT PHAS Figure 7 12 Fault History Sub Screen Table 7 13 Fault History Log Entry Format Column Format Description from left to right Onset Clear Marker O Fault Onset Marks the start and end of a fault in the X Fault Cleared fault history Timestamp HH MM MM DD YYYY Time and date the fault entry was logged Fault Code Four digit code Fault code see Table 7 12 Fault Description Text A short text description of the fault Setup Screen Note Some set up screens are password protected to prevent changes that could damage the filter When the user presses the Setup butt
33. on other sections of this manual Be sure to read understand and follow all safety instructions Only qualified electricians should carry out all electrical installation and maintenance work on the HOGA filter All wiring must be in accordance with the National Electrical Code NEC and or any other codes that apply to the installation site Disconnect all power before working on the equipment Do not attempt any work on a powered HGA filter The HGA filter drive motor and other connected equipment must be properly grounded The HGA filter may receive power from two or more sources Three phase power is connected to the main input terminals of the HGA filter All of these sources of power must be disconnected before working on the HGA filter After switching off the power always allow 5 minutes for the capacitors in the HGA filter and in the drive to discharge before working on the HGA filter the drive the motor or the connecting wiring It is good practice to check with a voltmeter to make sure that all sources of power have been disconnected and that all capacitors have discharged before beginning work 12 General Terminology Throughout this manual many different terms are used A list of some typical terms can be found below 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 Harmo
34. shows a typical HarmonicGuard Active filter nameplate The following information is marked on the nameplate Part number encoding is explained on the following page Corrective Current The maximum amount of RMS Corrective Current the unit can deliver System Voltage the rated 3 phase line voltage RMS volts Hz the rated frequency 60 Hz Phase 3 3 Wire The HGA is designed for use with only 3 wire systems with balanced 3 phase voltage source Drawing outline and mounting dimension drawing number Schematic schematic diagram drawing number Serial for unit tracking purposes Enclosure Type Open UL Type 1 UL Type 3R Milwaukee WI 53224 Phone 800 824 8282 www transcoil com t US LISTED Part Number ALC100A01H2000 Corrective Current 100A RMS Drawing 103382 System Voltage 480 Schematic 26463 01 Hz 60 Serial Number 10000 Phase 3 3 Wire Enclosure Type 1 HarmonicGuard Active Filter Figure 3 2 Typical HarmonicGuard Active filter Nameplate 18 Part Number Encoding Figure 3 3 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be ALC100A01H2000 This designates an enclosed HarmonicGuard Active filter that is rated for 100 amps 480 volts and has an HMI Interface Module Package HGA Part Numbering System 480V Open and Type 1 Temperature 40 C Current 50 100 200 Voltage 480 Enclosure
35. 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 expected service life Warning Warning A Periodic Maintenance The following checks should be conducted monthly or more frequently when installed in harsh or dusty environments Check to see that the installation environment remains free from excessive vibration exposure to excessive dirt moisture and contaminants Refer to the Pre installation Planning section of this manual Check to make sure that the enclosure ventilation openings are clean and unobstructed Clean the air filter in units that have filtered air inlets Clean as often as necessary to prevent dirt build up from impeding air flow Check for any dust or dirt build up on the fans and heat sink fins Check the operation of the cooling fan Inspect the interior of the enclosure for signs of overheated components Clean the interior of the enclosure whenever excess dirt has accumulated Check the integrity of all power ground and control wiring connections All electrical connections must be re torqued annually Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the life and affect performance or destroy sensitive electronic devices Use proper electrosta
36. to be stored before use be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in this manual Store the unit in its original packaging Long Term Storage In the case of long term storage defined as any period greater than eighteen 18 months TCI Technical Support must be contacted prior to applying power 15 Product Description HarmonicGuard Active filter The HarmonicGuard Active filter is an active harmonic filter designed and developed by TCI to relieve the power distribution system of the issues associated with harmonic currents that flow within the power distribution network caused by non linear loads The typical configuration can be found in Figure 3 1 The topology of the bus applied three phase three wire HGA consists of major components or modules Component 1 is made up of two current transformers CTs installed on phases A and C of the AC bus that is to be acted upon by the filter The purpose of the CTs are to supply information to the HGA regarding the integrity of the composite AC bus current with regard to the distortion non sinusoidal waveform and displacement power factor relative to the AC bus voltage These signals will result in the HGA injecting currents that will return the AC line current to near sinusoidal shape and at unity power factor Note that the CTs are located outside the HGA enclosure Component 2 is the HGA input circuit breake
37. 0V 3 phase 60 Hz three wire systems Phase Sequence Positive phase rotation A B C or L1 L2 L3 Load types 3 phase diode bridge rectifier loads such as PWM AC drives 3 phase controlled rectifier SCR or thyristor loads such as DC drives Current ratings Maximum elevation See Ratings in Standard Product Rating and Dimensions tables 1 000 meters 3 280 feet For every 100 meters 328 feet over 1 000 de rate by 1 Maximum elevation is 2 000 meters 6 560 feet Maximum Ambient operating temperature All units 40 C 104 F except 45 amp 90 amp open chassis units rated for 50 C 122 F surrounding air Product must be equipped with special cooling provisions for operation above this temperature Minimum Ambient operating temperature 09 32 F for open chassis and 1 enclosures 20 C 4 F for Type 3R enclosures Product must be equipped with special heating provisions for operation below this temperature Ambient storage temperature 20 C to 60 C for Open Chassis and UL Type 1 40 C to 60 Cfor UL Type 3R Maximum humidity operating or storage 95 non condensing Enclosure options Standard Open Chassis and UL Type 1 enclosed UL Type 3R enclosed Contact TCI Technical Support for other enclosure options Agency approvals or certifications Electronic overload over current protection US UL and cUL Listed Factory calibrated processor contr
38. 15402 uO 07 JARI az 4ido gt Jo sdu9s 3034 auj o48a2u savy puno4e PIMOUS S4aw4OsSUSUS iue44n2 9 ueudpba 40 jeuuos4ad sno4aSuop yya Sousa Avopuodas 343 550120 9 pinsau Bupu ui amp s4eu402su944 i4a44no qi 4 pr S anbuoz 2r 0 S Gar ujua 4cop42eicad i p24 p 42uv4q 404 ew sodssu 5 aeuoisn ce 4oz2npuos uo 2auu0 sapo2 1030 JAN 32u9 p4022 uj ua4s s Sasjuaud 24 punoJ6 aq peiseuuo2 jsru puno46 s sso45 Oujo iuaJ4n2 pus aui yya 1 24 2 peivjnsu 484014 40 2 GL eq pinous cT 1 83 0N 43334 3A i2v 5 040 531474405 su dang ye E ewe gu iili a2unos 4 919N 225 50001 lt 271 U TI 12 3AV IS 831SV A Figure 4 4i Master Slave CT Placement 200 amp 480 volt 42 WiNG NUT T e m YP 60 D 12 Ft SPADE CONNECTORS NOTES SECONDARY FREQUENCY RANGE 50 400 2 LEAD 2 THERMAL FACTOR 1 25 30 DEG C 1 0 55 pec 3 INSULATION IOKV FULL WAVE 4
39. Dimensions Inch cm watts kg HxWxD 39 2676 254 115 2 60 15 152 8 17 57 44 5 16 4 41 7 50 2676 254 115 2 60 15 152 8 17 57 44 5 16 4 41 7 78 3500 254 115 2 60 15 152 8 17 57 44 5 16 4 41 7 100 3500 254 115 2 60 15 152 8 17 57 44 5 16 4 41 7 200 7000 480 217 72 64 17 163 32 62 82 86 17 2 43 7 300 10500 1042 4 472 9 84 20 213 9 63 3 160 8 23 9 60 7 Add Two Inches for Disconnect Circuit Breaker Handle 24 Table 3 4 UL Type 3R Enclosed Amps HeatLoss Weight 155 Dimensions Inch cm watts kg HxWxD 39 Consult Factory 50 3176 371 168 3 80 00 203 2 32 00 81 3 25 00 63 5 78 Consult Factory 100 3500 371 168 3 80 00 203 2 32 00 81 3 25 00 63 5 200 7000 1040 472 80 00 203 2 57 00 144 78 25 00 63 5 300 Consult Factory Table 3 5 Transformer for 600V units Open and Type 3R Heat Loss Weight Dimensions Inch cm Amps Encl watts Ibs kg 39 345 180 81 7 16 00 40 7 19 50 49 6 12 20 31 78 Open 740 180 81 7 16 00 40 7 19 50 49 6 12 20 31 39 3R 345 270 122 5 24 90 63 3 24 40 62 20 80 52 9 78 3R 740 270 122 5 24 90 63 3 24 40 62 20 80 52 9 25 Table 3 6 HarmonicGuard Active filter Technical Specifications Voltage ratings 48
40. HARMONICGUARD ACTIVE 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 TCI 8282 Web Site http www transcoil com 2014 No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of TCI LLC The information in this manual is subject to change without notice Every precaution has been 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 Table of Contents Section 1 Safety Instructions aan 11 11 Warnings and OCTO COL CREER 11 General Safety LICINIUS M 12 General otn eu aura aa 13 Section 3 entm 14 Intended AUdience sssssssssrserssssrsersessrsessssssessessssessessssessessssessesessessesessessasessessasessessesessessesessesees 14 Additional Information PR 14 Installation Checklist sssccscssssscssessssssssscsssssssscsssses
41. Line amp ILine Waveform Plot Sub Screen in Section 6 for details Table 4 2 CT Range by Model Size Amps CT Min Ratio Notes 39 250 5 3000 5 50 250 5 3000 5 79 250 5 3000 5 Factory technician start up required to 100 250 5 3000 5 use CTs outside of the published range 200 750 5 3000 5 300 750 5 5000 5 32 Current Transformer Diagrams The following pages contain detailed diagrams on the placement of CTs in relation to the HGA Figure 4 4a Line Side or Load Side CT Placement for stand alone HGA filters rated at 45 to 100 amps 480V Figure 4 4b Line Side or Load Side CT Placement for stand alone HGA filters rated at 39 to 78 amps 600V Figure 4 4c Line Side or Load Side CT Placement for stand alone HGA filters rated at 200 amps Open or Type 1 480V Figure 4 4d Line Side CT Placement for stand alone HGA filters rated at 200 amps Type 3R 480V Figure 4 4e Line Side CT Placement for stand alone HGA filters rated at 300 amps 480V Figure 4 4f Master and Multiple Slave Parallel Units CT Placement for HGA filters rated at 45 to 100 amps 480V Figure 4 4g Master and Multiple Slave Parallel Units CT Placement for HGA filters rated at 39 to 78 amps 600V Figure 4 4h optional Multiple Slave Parallel Units CT Placement for HGA filters rated at 39 to 100 amps Figure 4 4i Master and Multiple Slave Parallel Units CT Placement for HGA filters rated at 200 amps The pages after th
42. M323U UAI SPUN 2 942425 O3 sad 4 aunsojaua auos puo sissou2 uado uo i1ueseJd aq ZOU jm suoj a4nsoj 2u3 33392403 2 aas Jer 34035 Youon dp un 1 Tie 34 Adsl ur qm q u0 dg 209 69 v 14 97942 IPON 220 212i I Ll 02 wug 1 PEE n D Ian 1 H EG 03 65 40y2npuT J3343 u03 quon 20 1 1 2 gt gn jin 5555454 5 5 ler 90 and 100 amp 45 78 5 General Schematic Bus Applied 39 Figure 5 1a This drawing is for general reference only Use the drawings supplied with the unit for installation 48 f Rane Qn 54 di s A A quassy Ayquassy anduy Figure 5 16 General Schematic Bus Applied 200 Amp Open and Type 1 Master Master This drawing is for general reference only Use the drawings supplied with the unit for installation 49 Eas AL AL 1 91 S 40u035n5 Aiquassy E U 6 66 46
43. N S 7 p 5830N 225 43uJ03usoJ4 5 Aq opts 8 epis 48 3294424u ajpuoH IWH TEMIA SPERA 12114 SH 1ourogsuer vauy Figure 5 7 39 and 78 amp Type 1 Filter Type Transformer 60 cv6 bb 006 dwy 007 01 06 00 LEL 6 9 90 dwy 05 01 Gt ung 5507 HEM 9715 WSIUDYDSW ajpuou ZINDUID paulnbau aq u4dap youonippy agon Gulzunow J04 2500 panddns s 5 d8348 u02 24 JAOD YIM uMOuS S UOJ 86 7 491 591 4463M 5 5 PUEUUND 664484 5 ejpow 5 20S2H 490403502 0 29 9 2049u8u2S 0071 1966 lt 0 wozz0q V 193 BUNCH 014 Su 1 6unooj3 v 10420 084 m a 29 vid Tr Ja xovaug 241n24l uOI 2auuo j sapis yog 015 6413311 SA ON 225 Puwa 13 Figure 5 8 45 50 90 100 amp Open Chassis 61 sapis 4109 ap s u2u 591 Ulam 1 33 0N au4oj4suo4 3ua44nh7 292924 apoy ojdsim a2934a43u
44. RMS current historical trend graph screen ILine ILoad Button This signal is sampled every seconds and historical data is maintained for 2 hours Opens the HarmonicGuard Active filter RMS current historical trend graph screen This signal is sampled every 3 seconds 2 Button hours of historical data is maintained Current THD Opens the line load Total Harmonic Distortion historical trend Button graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained 85 Historical Trend Plot Sub Screens The historical trend plot screens graph time stamped feedback data over an extended period of time Once the trend plot display data buffer is full the oldest data is overwritten Historical data can be viewed using the integrated scroll bars of the trend plot All trend plot data is maintained between power on off cycles of the HarmonicGuard Active filter See Figure 7 10 for an example of a typical trend graph trend plot example is for the HarmonicGuard Active filter power converter heatsink temperature measurement For data buffer sample times and size see Figure 7 10 Converter Heatsink Temperature 80 11 20 12 19 16 11 20 12 Dnm Figure 7 10 Example Historical Trend Plot Sub Screen Table 7 10 Trend Plot Screen Elements Screen Element Description Run Stop Button Runs and stops the HarmonicGuard Active filter
45. T F 20G2 uon2auuoj aauo4sn 0 9 92 2 0 8 425 1104 90 doy pis l EU a WOOT 42497 voog 7 10420 0 amp 4 7911 29 oa m a 0a4 oady Kapuz aam oor y aas sap s 430g 64337 9044 ZG T 100 usog paGujH ainpow B30 44a PUT TWH Figure 5 9 45 50 90 and 100 amp Type 1 Enclosed 62 WS IUDYDEW 3102412 pauinbau aq yadep jouolnlppg agod azyowau 403 asoo panddns 5 aynpow 0 510 U LUSAUOD JUL UMOYS S ZUOUY seq yaa iSOLON T9792 5 3us44n2 989 86unooj3 9 92 Avjdsiq adv0jue zu 45 9 0 982 214049425 5 06 e a 401304 do a 0a f 302413 SUGA a S2 0E ogag Guia unoy 20915 4 Su 4 54 4 7 4435 joulud4e 2 9 aes 52015 37 13291 Figure 5 10 200 amp Open Chassis 63 AAU sepis yoq
46. These points are explained in detail in the following sections o Make sure the installation location will not be exposed to direct sunlight excessive vibration corrosive or combustible airborne contaminants excessive dirt or liquids o Select a mounting area that will allow adequate cooling air o Make sure that all wiring conforms to the requirements of the National Electric Code NEC and or other applicable electrical codes o Ground the HMI display by using the grounding terminal Not only does this act as a safety but it also filters out electrical noise o Check all connections and components thoroughly before applying power to the equipment o Check the panel and the inside of the enclosure for any foreign objects dirt and or loose hardware Location Environment The location of the Interface Module should be a suitable environment to assure proper performance and a normal operating life Refer to the environmental specifications furnished in this manual and noted on the drawings with the Interface Module Warning Unless specifically labeled as approved for such use this equipment is not suitable for use in an explosive atmosphere or in a Hazardous Classified Location as defined in article 500 of the National Electrical Code NEC e Display front rated Type 1 amp 4X e Avoid direct sunlight Avoid corrosive liquids or gasses Avoid explosive or combustible gases or dust Avoid excessive airborne d
47. ability if a unit is undersized for a particular application Call TCI sales support for options to expand the installed system current capability Circuit Breaker Protection Each converter section is protected by a thermo magnetic circuit breaker in the event the HGA experiences a catastrophic failure or a destructive over current condition should occur It also provides a convenient disconnect means to isolate the converter from the power source The size and type of circuit breaker must not be altered without consulting TCI engineering since the circuit breaker is an integral part of the UL file Notes e Open chassis units be provided without circuit breakers The end user must protect the HGA with the following UL listed thermal magnetic common trip molded case circuit breaker e 39 45 78 amp 50 Amp A max peak let through current of 26 kA in correspondence with a short circuit of 100 kA at 480 volt and a trip current of 100 amps e 90 to 100 Amp A max peak let through current of 26 kA in correspondence with a short circuit of 100 kA at 480 volt and a trip current of 125 amps e 200 Amp A max peak let through current of 35 kA in correspondence with a short circuit of 100 kA at 480 volt and a trip current of 225 amps Warnin g 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 SCR s ar
48. able judgment to be defective TCT s liability and the Buyer s exclusive remedy under this warranty is expressly limited at TCT s option to i repair or replacement of that product or ii return of the product and refund of the purchase price Such remedy shall be Buyer s sole and exclusive remedy TCI SHALL NOT IN ANY EVENT BE LIABLE FOR INCIDENTAL DAMAGES OR FOR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF INCOME LOSS OF TIME LOST SALES INJURY TO PERSONAL PROPERTY LIABILITY BUYER INCURS WITH RESPECT TO ANY OTHER PERSON LOSS OF USE OF THE PRODUCT OR FOR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS The foregoing warranties do not cover reimbursement for removal transportation reinstallation or any other expenses that may be incurred in connection with the repair or replacement of the TCI product The employees and sales agents of TCI are not authorized to make additional warranties about TCI s products TCI s employees and sales agents oral statements do not constitute warranties shall not be relied upon by the 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 Customer Service for instructions on the Return Authorization Procedure Storage Instructions If the HarmonicGuard Active filter is
49. airborne dirt and dust Pollution Degree 2 according to EN50178 01 508 e Excessive vibration 0 152 mm 0 006 in displacement 1G peak Please note that custom enclosure options may vary available installation areas Working Space Provide sufficient access and working space around the unit to permit ready and safe installation operation and maintenance Make sure that the installation conforms to all working space and clearance requirements of the National Electrical Code NEC and or any other applicable codes Provide sufficient unobstructed space to allow cooling air to flow through the unit Mounting an Open Chassis Unit If you are mounting an open chassis unit in your own enclosure you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating Refer to Table 3 2 for dimensions and heat loss that is dissipated by the HGA The maximum ambient temperature should not exceed 40 C 104 F The 45 and 90 amp open chassis units have an ambient surrounding air temperature of 50 122 F Cooling Diagrams Please see Figures 4 1 and 4 2 for cooling diagrams of the HGA 27 aoe OO LISLE msz duy Os cst um sigma Sau2u uj puo TI Suon 0214I2ads 85843 OY IJL 4294409 COT Bunoo2 a20 jd ul pjnous S543409 6 uon oan8ijuo 2
50. assis UL Type 1 or UL Type 3R 033H 01 00 5 Prefix Current Rating 039 078 Voltage Rating 600 Filter Enclosure 00 Open Chassis 01 UL Type 1 03 UL Type Transformer Enclosure 0 Open Chassis 3 UL Type 3R Pa e Option H Interface Module no display if 3R Circuit Breaker 10 ABB 22kA 20 ABB 100kA 30 25kA 40 A B 65kA 60 Eaton 65kA 70 Eaton 100kA 80 Square D 18kA 90 Square D 65kA 00 No breaker 01 ABB 65kA Reserved for custom options to be defined as needed each position can use 0 thru 9 Default option is 00 Figure 3 6 HarmonicGuard Active Part number Encoding 22 Figure 3 7 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be ALC45A01H10 This designates an enclosed HarmonicGuard Active filter that is rated for 45 amps 480 volts and has an HMI Interface Module Package HGA Part Numbering System 480V Open amp Type 1 50 C Temperature 50 C Current 45 90 Voltage 480 Enclosure Open Chassis or UL Type 1 ALC 45 00 0000 Current Rating 45 90 Voltage Rating A 480 Filter Enclosure 00 Open Chassis 01 1 e Option H Interface Module Circuit Breaker 10 ABB 22kA 20 ABB 100kA 30 A B 25kA 40 A B 65kA 60 Eaton 65kA 70 Eaton 100kA 80 Square D 18kA 90 Square D 65kA 00 No breaker 01 ABB 65kA Reserved for custom options to be defin
51. available in Figure 6 2 When selecting a mounting location for the unit plan for the routing of commutation and power cable Keep the wiring away from power wires where electrical noise could be induced All wiring should conform to the requirements of the National Electric Code NEC and or other applicable electrical codes The length of the communication cable between the Interface module chassis communication port and the HarmonicGuard Active filter power converter module should not exceed 25 feet 7 6 meters 120VAC Input Gateway To Front Vlew See Note 4 i e Customer s Optional Chassis Network Status Communica tion Display Interface 8 45 Board zd Network Connection Optional Gateway Start Jee Power Current End View Input Run On Fault Limit I v 1 ji v le Seb O Sl 82325 2 3 46 47 J12 JS Customer Relay Contacts Figure 6 2 Interface Module Connections 71 Interface PCB Connections Most customer connections to the Interface module will be made on the Interface PCB Refer to connection diagrams in Figure 6 3 The details of the power and communications terminals are shown in Table 6 1 form C relays are available on the Interface PCB These connections are shown in Table 6 2 Four outputs are available on the Interface PCB The relay start command input connection on J22 of th
52. ce see the HMI Display Connection section or an optional network communications gateway can be used such as Ethernet IP to implement other protocols see Appendix The input output register maps of the data available from the network interface are available in Table 7 18 and Table 7 19 All input and output registers are two bytes in size For the base address of the input and output data sections please reference the connection sections in this manual specific to the configured protocol For the integrated ModbusRTU network interface reference the HMI Display Connection section If an option Communications Gateway is configured reference the appendix Table 7 19 Network Interface OUTPUT Register Map Re Parameter Name Direction Format Description Offset SYS RUNNING 0 Output 0 Running Indicates if the HGA filter is currently 1 Idle running or in the idle state SYS POWER ON 1 Output 0 Power Off Indicates if the HGA filter has input 1 Power On power available SYS FAULTED 2 Cute es ee Indicates if the HGA filter is faulted SYS IN I LIMIT 3 Output 0 Nominal Indicates if the HGA filter is running at 1 At Capacity its maximum capacity V LINE LL RMS 4 Output Volts RMS ee Pine Penasco Erase LINE RMS 5 Output Amps RMS Line Load Phase Current 1000 1 0 Unity PF Lue pr 6 ouput 2250 0 25 Lagging PF ty 950 Leading PF
53. e 3 4 HarmonicGuard Active filter Part number Encoding 20 Figure 3 5 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be H5300A00H1000 This designates an enclosed HarmonicGuard Active filter that is rated for 300 amps 480 volts and has an HMI Interface Module Package HGA Part Numbering System 480V 300A Temperature 40 C Current 300 Voltage 480 Enclosure UL Type 1 or UL Type 3R 5 300 A03 H 01 00 H5 Prefix ______ Current Rating 300 Voltage Rating A 480 Filter Enclosure 01 UL Type 1 03 UL Package Option H Interface Module no display if 3R Circuit Breaker 10 ABB 22kA 20 100 30 25 40 65 60 Eaton 65 70 Eaton 100kA 80 Square 18 90 Square D 65kA 00 No breaker 01 ABB 65kA Reserved for custom options to be defined as needed each position can use 0 thru 9 Default option is 00 Figure 3 5 HarmonicGuard Active filter Part number Encoding 21 Figure 3 6 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be 5039 033 0100 This designates enclosed HarmonicGuard Active filter that is rated for 39 amps 600 volts and has an HMI Interface Module Package HGA Part Numbering System 600V Temperature 40 C Current 39 78 Voltage 600 Enclosure Open Ch
54. e CT Placement diagrams contain detailed diagrams on the current ratios and dimensions of TCI Current Transformers Contact TCI for CTs not found in figures 4 5 4 6 or 4 7 Figure 4 5 is the diagram for Round Current Transformers Figure 4 6 is the diagram for Rectangular Current Transformers Figure 4 7 is the diagram for Solid Core Current Transformers 33 SH 03 PUD pajoisu sawogsn2 6 12 ANOS 8 AG Ssa 3100000 403 121 ZINSUOD GH azjudo sna 4o aun Gazu uo S p00 4042npuo2 pjnous saauJojsuoJ 9 jauuosaad uou 5 uopuo2as 55020 yy 5 uo2 uado 5 JUJ 5 5 3uaJ4n2 a u p p 5 Gay 21 0 51 au Ger 1 91 Puwa Cy 403 ejqisodsau 51 5 40423npuo2 Snu sapo2 1030 23 32u9pJ0229 uj 5 5 5 a44 snw 5155047 2 Bu puan uaddo gt
55. e and 1 46 Reliability and Service Life cccssccssscsssccscscsssssccescesescsssssescsecssecsecsssessessscsssesssesssssssseees 46 Periodic Maintenance ccscssscssscssscesccscscscssecssecsscssscssscssssssssesssessssecsncesecesecssccssesssesssesssessssessseees 46 51 Section 6 HMI IntrodUcliOh uenit tdi i Ce ba F3 ein d ed EC eR aa de buds 67 OVETVICW frc 67 Additional Information PR 68 Receiving Ins Peli Oni ee M 68 Installation Guidelines ii 2 69 Che CHS e 69 LOCATION EE E E O E E I E EO EE EA 69 unire RR 69 MEI te eee sa beh eae eh eeu eus 70 PEE 74 HMI Screen D SU TOT RD 75 estes esses sess 76 76 Network dE ELEM 94 Section 8 Maintenance 96 Clock Battery Replacements doses 97 Software Field 97 TrOUBIESNOOURG n Rada 97 HGA Filter Fault negem 98 Interface Module Problem
56. e interface PCB allows a contact closure to send a run command to the HarmonicGuard Active filter The relay start command input will only be acknowledge if the Relay Run Stop Enable is set to Enabled on the HMI Display setup screen See Figure 7 14 for details Pressing stop locally via the HMI Display will set the enable for the relay start command to DISABLED 120V VAC INPUT OPTIONAL START INPUT TOR AUR H5 85485 105272 VER TEU E E A eem RELAY SES Su WERON From filter B js E STATUS converter 2 9 OUTPUT 4 9L S 1 JN 8 48 03 Nr LEDS POWER ON FAULT E Aux 1 Aux 2 g S Ne COn No __ CON NO Wo NE Lint NG NC CON NO RELAY STATUS OUTPUTS Figure 6 3 Interface PCB connections Table 6 1 Power amp Communications Terminals Terminal Pin Description Label Rating J1 1 HMI Display For factory use N A 1 Not Connected 2 B J2 3 RS485 Ground N A 4 A 5 Not connected 1 Neutral 2 Input Power Line 120 VAC 1 Micro Programming For factory use N A 1 24 VDC J19 2 HMI Power Supply Common 24 VDC 3 Not Connected 1 24 VDC J22 2 Start Command Start Contact Closure Note The
57. e main Status Screen 78 urrent Kew ower Negative Cl P Beta 0 00 ac O Hz Line Load Current equals Lag Converter Current P lot VLinedLine Figure 7 3 Status Screen Table 7 3 Status Screen Elements Screen Element Description Line Load Button Use this button to get to the Line Load Status Sub Screen see Figure 7 6 Volts Display Displays the current utility phase to phase line voltage in Volts RMS Current Display Displays the current line load phase current in Amps RMS Power Factor Display Displays current line load power factor A value of 1 00 indicates unity power factor A negative power factor indicates lagging power factor Frequency Display Displays the current utility line frequency in Hz Run Stop Button Runs and stops the HarmonicGuard Active filter Converter Button This button will take the user to the Converter Status Sub Screen see Figure 7 4 Phase to Neutral voltage Line Voltage Line Load Current and Converter Current and Vline lline Waveform Screens The Waveform screen buttons will take the user to one of the four real time waveform capture screens Phase to Neutral voltage Line Voltage Line Current Converter current or VLine ILine plot see Figures 7 7 and 7 8 Trend Menu Screen When the user presses the Trend button the
58. e used to limit the converter power up in rush current to a safe level once the converter DC voltage has reached the threshold SCRS will be turned on and the charging resistor will be cut off from the unit If for some reason this circuitry should malfunction class CC fuses are in the circuit to limit the max current as not to exceed the ratings of the components Note on the 50 to 100 amp units the fuses are located on the chassis on the 175 and 225 amp units the fuses are located on the interface mother printed circuit board Over Temperature Protection The converter has a thermal fold back mechanism that will automatically reduce unit output current as the converter temperature approaches its shutdown threshold Additionally the converter has an internal heat sink over temperature protection which will shut down the converter if the threshold is exceeded The fans will continue to run and once the heat sink cools down the converter will automatically restart There are secondary over temperature circuits which monitor the temperature of the power resistors and inductors located on the chassis of the HGA The sensors are snap action switches activated when the threshold is reached This over temp would be an indication that cooling fans 51 Warning A Warning have failed something more serious with the operation of the converter For this reason this fault will latch and will remain latched until power is cycled The
59. ector Pinout Pin Number Description 1 TD 2 TD 6 RD 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 see Table 9 2 and press enter The Communications Gateway configuration page should load see Figure 9 3 2 Configuration Mozilla Firefox Configuration 192 168 12 253 elg 4 AnyBus S Ethernet 10 100 IP address 192 168 12 253 Subnet mask 255 255 0 0 Gateway address 192 168 10 20 DNS1 address 0 0 0 0 DNS2 address 0 0 0 0 Host name Domain name server SMTP user name SMTP password DHCP enabled STORE CONFIGURATION Figure 9 3 EtherNet IP Gateway Configuration Page Table 9 3 Gateway Default Settings Setting Default Value IP Address 192 168 0 1 Gateway 255 255 255 0 Subnet 255 255 255 0 DHCP Off 103 To update the IP address type in a new IP address on the configuration page then click on the STORE CONFIGURATION button After the new IP address is stored cycle power to the Communication Gateway to load the new IP address The EtherNet IP Communications Gateway supports implicit Ethernet IP I O and explicit Ethernet IP CIP Message commands For an example of communication with the Gate
60. ed as needed each position can use 0 thru 9 Default option is 00 Figure 3 7 HarmonicGuard Active filter Part number Encoding 23 Communications Part Numbering Table 3 1 below shows the HGA part numbering with the communications part numbers The base communications unit is CM100A00 which has both the HMI and Modbus Table 3 1 Communcation Part Numbering Options Descriptions CM Communications 39 45 50 78 90 100 Amp rating 200 300 AC A Voltage rating of 480V i Voltage rating of 600V 00 01 00 Modbus RTU over RS485 01 Ethernet IP Standard Product Ratings and Dimension Tables The following tables list the ratings and dimensions of the standard HarmonicGuard Active filter models See drawing at the end of this manual e Table 3 2 Open Chassis Table 3 3 UL Type 1 Enclosed Table 3 4 UL Type 3R Enclosed e Table 3 5 600V Open and Type 3R Table 3 2 Open Chassis Amps Heat Loss Weight Ibs Dimensions Inch cm watts kg HxWxD 39 2676 167 75 8 56 142 2 17 43 2 14 18 36 6 45 amp 50 2676 167 75 8 56 142 2 17 43 2 14 18 36 6 78 3500 167 75 8 56 142 2 17 43 2 14 18 36 6 90 amp 100 3500 167 75 8 56 142 2 17 43 2 14 18 36 6 200 7000 340 154 22 57 97 147 25 32 81 28 14 18 36 6 Table 3 3 UL 1 Enclosed Amps Heat Loss Weight 155
61. egister address 40564 For definitions of the input and output data available via the network connection see the Network Interface section below If the optional network Communications Gateway is present the integrated ModbusRTU interface on the HMI Display will not be available When configured the Communications Gateway will occupy the ModbusRTU 2 3 DB9 connector on the back of the HMI Display 73 Communications Gateway Connections Optional If an optional advanced network Communications Gateway is included in the Interface Module see the ModbusRTU Connection Figure 6 4 HMI ModbusRTU Connection Table 6 4 Modbus Connector Pin Definitions Signal Name Signal Type 1 no connect 2 no connect 3 no connect 4 D RS 485 B non inverting 5 GND RS 485 SC G 6 no connect 7 connect 8 9 D RS 485 A inverting Table 6 5 ModbusRTU Protocol Settings Parameter Default Value Units Baud Rate 19200 bps Data Bits 8 bits Stop Bits 1 bits Parity Even Slave ID 113 appendix for the specific Communications Gateway wiring details If the optional network Communications Gateway is present the integrated ModbusRTU interface on the HMI Display will not be available When configured the Communications Gateway will occupy the ModbusRTU COM2 3 DB9 connector on the back of the HMI Display 74 Section 7 Operatio
62. erve as a means of electrical isolation from the system power grid It is recommended by TCI that all power to the HarmonicGuard Active filter be disconnected If you elect to service the HGA by using the circuit breaker to isolate the converter section please take special note of the following warnings Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the life and affect performance or destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards 52 Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Do not Warning attempt any work on a powered HGA This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before you attempt to service the conditioner Check for zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenance and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker including the reacto
63. f no sensor wiring errors are detected the pop up screen will remain hidden If a Sensor Wiring Error is detected the HGA will be inhibited from running until system power is removed from the unit and the error is corrected The Sensor Wiring Error Detection feature is comprised of several independent detection algorithms The two main categories of algorithms are voltage based detections and current based detections The voltage based detection algorithms monitor the three phase line voltage input for proper ABC phase rotation polarity balance and nominal magnitude The current based detection algorithms monitor the system Current Transformer CT sensor feedback for proper phase rotation polarity balance and CT open or shorted conditions The current base detections are only engaged if a minimum level of load current is present during power up 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 Self Test Result Indication ge and current feedback Self Test Result Indication Em gm About Figure 7 17 Sensor Wiring Error Self Test Sub Screen Table 7 17 Sensor Wiring Error Self Test Sub Screen Elements Screen Element Description Self Test Result Displays the current Pass Fail In Progress State of the Sensor Wiring Error Auto Indication Detection feature When a sensor wiring error
64. f the HarmonicGuard Active filter Protocol Settings Displays the Modbus RTU protocol settings Display This option allows the HGA to be remotely turned on or off across Network Sian a network connection If the stop button is pressed locally on the Enable Button HMI Display the Network Start Enable is automatically set to DISABLED and has to be re enabled manually via the HMI display Displays the current network Run Stop command being received Remote Start by the HMI Display Note the HarmonicGuard Active filter will only Display acknowledge the network run command if the Network Start Enable is set to ENABLED and there is no active fault Warning the values of the HMI Settings are changed from what the A network administrator has set for the filter the ability to connect to the filter 92 remotely will be lost TCI will not be responsible for the loss of communication due to this change About Screen The About Screen see Figure 7 16 displays model number serial number and software firmware version information regarding the filter z Total Output Current Converter 100 E System voltage V Software sions HMI Master 100A ITEM AYR Revision HMI Revision D Home Status Setup About Screen Element Figure 7 16 About Screen Table 7 16 About Screen Elements Description Stop Button Turns off the Harm
65. gging p 0 Network Run SYS NW START E 7 Disabled Network Run Stop command enable N 1 Network Run setpoint Enabled Table 7 20 Network Interface INPUT Register Map Reg Parameter Name Address Direction Format Description Offset SYS NW START 0 Input 0 Network Command Stop Remote Network Run Stop N 1 Network Command Run command to the unused 1 Input unused 2 Input unused 3 Input unused 4 Input unused 5 Input unused 6 Input unused 7 Input The network Run Stop command allows a remote network to send a run command to the HarmonicGuard Active filter The network command input will only be acknowledged if the Relay Run Stop Enable is set to ENABLED on the HMI Display setup screen Pressing stop locally via the HMI Display will set the enable for the Relay Run Stop Enable to DISABLED 96 Section 8 Maintenance Clock Battery Replacement The HMI Display Real Time Clock is maintained by a non rechargeable battery internal to the HMI Display Change the battery every ten years or as needed The system will continue to function as an active filter with a dead battery but HMI information fault logs and trend plots will not be maintained between power cycles To replace the battery open the battery cover on the back of the HMI Display see Figure 8 1 and remove the old battery Dispose or recycle the old battery in accordance with any applicable national
66. he waveform plot 1X 2X and 4X Waveform zoom buttons will redraw the present data at a different Buttons scale VLine amp Waveform Plot Sub Screen The VLine amp ILine Waveform Plot Sub Screen is available to verify the proper installation of the HarmonicGuard Active filter power connections and system current CT feedbacks The waveform plot shows voltage and current feedback for both Phase A and C on the same plot When the HarmonicGuard Active filter is powered but in the stopped state this plot can be used to check for the following e Proper Line Voltage phase rotation e Proper Line Load Current phase rotation e Proper Line Voltage and Line Load Current relative polarity and phase e Missing Open Circuit System Current CT Feedback In the event that the HarmonicGuard Active filter performance is degraded the VLine amp ILine waveform plot should be examined as a means to determine if any system connection errors are present Prior to examining the VLine amp ILine waveform plot the HarmonicGuard Active filter should be put in the stopped state by pressing the stop button in the upper left corner of the HMI screen Figure 7 8 shows the VLine amp ILine waveform plot sub screen for a properly connected but non running HarmonicGuard Active filter when connected to a typical non linear rectifier load Note the following characteristics e Phase C voltage Blue leads Phase A voltage Green e Phase current
67. heck 3 phase AC input voltage wiring for 9 Phase missing phase or low line voltage Turn off unit and check 3 phase AC input voltage wiring for Input Under Wollage missing phase or low line voltage Turn off unit and check system CT feedback for A B C 2 phase rotation inverted CT polarity or CT short open Turn off unit and check system CT feedback for no 9 Phase A CT Under Current feedback CT short or open Turn off unit and check system CT feedback for no 19 ST Magar Curren feedback CT short or open Turn off unit and check system CT feedback for no 11 Phase C CT Under Current feedback CT short or open Turn off unit and check system CT phase A feedback for f Phase A CT Polarity incorrect polarity or reverse phase rotation Turn off unit and check system CT phase 13 feedback for incorrect polarity or reverse phase rotation Turn off unit and check system CT feedback phase C for m Phase e GT pola incorrect polarity or reverse phase rotation Turn off unit and check CT feedback and 3 phase AC 15 Phase Power Imbalance input voltage for incorrect polarity or reverse phase rotation 95 Network Interface The network interface on the Interface Module allows basic Run Stop commands and internal status data and can be communicated to and from the HarmonicGuard Active filter The HMI display implements an integrated ModbusRTU slave device for the network interfa
68. heck Phase C CT for open circuit or loose connection To correct swap Phase A and Phase C system CT current feedback and recheck plot Phase A current red is opposite polarity of Phase A voltage green and Phase C current yellow is opposite polarity of Phase C voltage blue To correct re install both Phase A and Phase C system CTs with polarity arrow in opposite direction OR swap positive and negative connections of each CT at HGA filter terminal block then recheck plot 84 Historical Trend Plot Menu Sub Screen From the historical trend plot menu sub screen you can view trend graphs of various HarmonicGuard Active filter system signals see Figure 7 10 Figure 7 9 Historical Trend Plot Menu Sub Screen Table 7 9 Historical Trend Plot Menu Sub Screen Elements Screen Element Description Opens the HarmonicGuard Active filter heatsink temperature historical trend graph screen This signal is sampled every 15 seconds and historical data is maintained for 10 hours Converter VLink Opens the HarmonicGuard Active filter DC Link Voltage historical Button trend graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained Opens the utility input RMS voltage historical trend graph screen VLine Button This signal is sampled every 3 seconds and 2 hours of historical data is maintained Opens the line load
69. how up plot e Check that Phase A to Neutral voltage peak lines up with Phase A current use zoom if necessary e Check that Phase C to Neutral voltage peak lines up with Phase C current e Power system down and check CT installation location and orientation if Phase A plots differ significantly from Phase C plots Warning Improper operation and damage may occur if CTs are installed incorrectly 9 Current Polarity 2 e Navigate to Status screen e Navigate to Line Load status e Verify that Volts Current Power I THD and V THD match expected values for the power system e If they do not verify CTs are correctly installed Warning Improper operation and damage may occur if CTs are installed incorrectly 480 BHL Stopped Current ARMS Power K Watts Power Factor ey 37 1 EZ v THD 37 1 LE Emm 10 Final setup Press Setup to navigate to Setup screen Press Harmonic Correct to enable harmonic correction If unit is sized with sufficient capacity to provide power factor correction press PF Correct En Press Auto Start En to enable Autostart Warning When Auto Start is enabled unit may operate without operator input Press Save Settings to save settings and restart converter Let the unit come on automatically about 30 s 11 Final check
70. icGuard 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 Factory Contacts and Technical Support For technical support contact your local TCI distributor or sales representative You can contact TCI directly at 1 800 824 8282 Select Customer Service or Technical Support and have your HarmonicGuard Active filter nameplate information available and any drawings Outline and Mounting Dimension Drawings Outline and mounting dimension drawings show the overall enclosure dimensions the conduit access areas and the wiring connection points The major internal components are shown pictorially 57 GH 244 5 auos aui ul gt 0 7 UP NOYS 5 241 SH 241 20 5 4auJ403Suo44 2941 CZ 6611 2 8unoo2 sissou2 uado o4 1 93 0N SununoJA apis 016 0l youjwaay de WO330g OF UOJ RMR d m Wm um Sud Jouojsuely 10390 up unow uigunou a430u84 403 2500 penddns 5 IWH ong 1S93 0N apis 3 44043 O14 Su 8unoo3 9 119391 29 i Ud Th SeA 19914
71. indicator light located on relay CR 2 will not be lit with this type of over temp fault Troubleshooting Current Transformer Orientation Troubleshooting Failure to maintain the correct polarity and phasing of the current transformers CTs will cause an over current fault on power up The converter will never attempt to run it will stay in a stopped condition Possibly the CTs are installed backwards or the secondary wiring is incorrect if this is suspected refer to the steps below to isolate the error Note CT operation can be verified via the HMI touchscreen feedback waveform plot screens Reference the HMI VLine amp ILine Waveform Plot Sub Screen in Section 6 for details Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Failure to follow standard safety procedures may result in death or serious injury Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered HGA Also check for zero voltage between all phases of the input and output lines Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment 1 Ifthe CTs and wiring is easily accessible double check the CT orientation for proper direction and trace the secondary wiring against Figure 4 3 for polarity phasing and connection to terminal TB 1 C
72. irt and dust Pollution Degree 2 according to EN50178 UL508C Avoid excessive vibration 0 152 mm 0 006 in displacement 1G peak 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 Fit the Interface Module assembly into the opening carefully pressing on all four corners Use the mounting hardware 4 sets to secure the assembly on the corners Warning to avoid damaging the case do not exceed a tightening torque of 3 47 to 4 34 bs in 0 39 0 49 Nm Care should be taken not to mount the Interface Module too close to a heat source such as power resistors which could be located behind the Interface Module 70 Caution The display panel is waterproof But care should be taken to prevent grease corrosive liquids and sharp objects from contacting the front panel Warning Many electronic components located within the Interface Module and HMI are sensitive to static electricity Voltages imperceptible to human touch can reduce the life and affect performance or completely destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the Interface Module and HMI Wiring Note Some of the following sections only apply if the Interface Module is not factory installed A wiring block diagram of the Interface Module components is
73. is active the field to the right will be green and read RUN Changes to blue if enabled or the left button is pressed if Remote Network the right will be green and read RUN This button will take you back to the converter status screen Back enabled the HarmonicGuard Active filter can be remotely stopped started with a contact closure When the contact is closed the unit will run and when opened the unit will stop When enabled and the option is active the field to Line Load Status Sub Screen The Line Load Status Sub Screen shows more specific information regarding the source and load voltage current power power factor and THD measurements Volts VAC RMS Current ARMS Power K Watts Apparent Power 5 Power Factor 3 5 EJ THD Ref 2 0 2 v THD x Figure 7 6 Line Load Status Sub Screen Table 7 6 Line Load Status Sub 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 Power Display The three phase real power P of the line load in kW Apparent Power The three phase apparent power S of the line load in kVA Power Factor Displays current line load power factor 1 00 indicates
74. itive if phase rotation is incorrect power down unit and rewire to adjust phase rotation by swapping two incoming phase connections Improper operation will occur when input voltage phase rotation is incorrect 6 Converter check 2 Press Setup to navigate to Setup screen Ensure that Auto Start En Harmonic Correct and PWR Fact Correct buttons are off blue color Press Status to navigate to Status screen Press to start unit operation Filter Status Filter Current Used 50 0 10 v Current gr A HE Total Current ARMS Link Volt Heatsink Filter 50 7 Remove CT shorting bars e Press Stop to turn off unit e Disconnect power from cabinet o Turn off the built in door breaker AND o Turn off the upstream feeder breaker Warning Lethal voltages may be present Wait 5 minutes for DC bus voltage to drop to safe levels Warning Check for voltage in cabinet with a DMM before working inside cabinet e Open the cabinet door and remove shorting bars from CTs connected to TB 1 8 Current polarity 1 e 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 will not have enough current to s
75. ld 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 Connection must be made using a wire conductor 3 Terminal TB I amp J25 wire range is 30 12 AWG tightening torque is 4 4 IN LB 0 5 NM 4 Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment 31 Current Transformer Installation For accurate sensing of the load it is important that the load sensing current transformers are properly installed Warning Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Failure to follow standard safety procedures may result in death or serious injury Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered HGA Also check for zero voltage between all phases of the input and output lines Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment It is necessary for the HGA to monitor the current in Phase L1 and Phase L3 Stand alone HGA filters are designed for Line Side current transformer CT placement as shown in
76. n HMI Screen Elements This section focuses on the operation of the HMI Display The HMI Display contains several screens that allow the user to monitor the status of the line load and the HarmonicGuard Active filter Additionally the HMI display can be used for local run stop control and basic setup of the HarmonicGuard Active filter Table 7 1 General HMI Screen Elements HMI Graphic Element Example Description Buttons will appear raised or Buttons depressed depending on set point and command conditions Indicator status fields will appear Indicators flat and are read only Numerical Displays Display fields will appear flat Numerical displays are read only Numerical Entry Fields Navigation Bar Numerical Entry fields appear indented Selecting them will open a keypad for numerical entry The Navigation Bar allows for easy navigation between the five major HMI screens The Navigation Bar appears on all HMI screens Title Bar The Title Bar contains the current system time screen selection and a stop button to turn off the system The Navigation Bar appears on all HMI screens 75 C Title Bar HMI Display Filter status Power LED Indicator 96 Filter Current Used Button 479 M dim Numerical Current Display Navigation Bar Figure 7 1 HMI Display Initialization When first powered the green LED Power on the HMI Display will
77. n 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 Table 9 1 EtherNet IP Communications Gateway Key Features Feature Description EtherNet IP level 2 I O Server CIP ControlNet amp DeviceNet EtherNet IP Adapter Class Device Profile Support Connection 10 100 MBit twisted pair RJ45 Connection Galvanic Isolation Transformer isolated Ethernet interface TCP IP Settings Web Browser Based Configuration Baud Rate 10 100 MBit auto detect Fully compliant EtherNet IP gateway ODVA File Number E 090 10070 See HMS website www hms se for Conformance Test Results Protocol Conformance Wiring Connection of the HarmonicGuard Active filter Interface Module to the end user s upstream EtherNet IP network occurs at the RJ45 connection see Table 9 1 on the Communications Gateway The Communication Gateway is mounted on the back panel of the Interface Module see Figure 9 2 EtherNet IP Communications Gateway Back Vlew RJ45 Connection to End User Network Figure 9 2 EtherNet IP Communications Gateway Location 102 Table 9 2 EtherNet IP Conn
78. n completely and correctly installed on accordance with the Installation Guidelines section of this manual Thoroughly check the installation before applying power and operating the equipment for the e If itis a floor mount unit check to see that it is securely anchored to the floor e Check the panel and the inside of the enclosure for any foreign objects dirt metal filings wire whiskers and loose hardware e Verify that any covers or guards that were removed during installation were reinstalled e Ensure that the unit is properly grounded Check for properly tightened connections General Operation Please reference the Quick Start Guide in Section 1 for the first time power up procedure Warning Since the HGA is an active filter it is always operating whenever the power is applied Only qualified electricians should carry out all electrical installation and maintenance work on the HarmonicGuard Active filter Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered unit Warning TM TE T Be aware everything ahead of the circuit breaker will still be energized It is important to note that the lack of lit LEDs does not necessarily mean that the HGA is not receiving power from an external source 46 Section 5 Maintenance and Service HGA Reliability and Service Life The HGA has been designed and thoroughly tested at the factory to ensure
79. ngs choose Yes on the confirmation screen or choose No to cancel and go back to the Basic The settings will not be saved if No is chosen Save Settings Button Network Setup Sub Screen The network setup sub screen see Figure 7 15 allows the user to view and configure the network interface options available internally to the HMI Display For details on the integrated Modbus RTU interface connections see the HMI Display Connections section If an optional advanced network Communications Gateway is configured please reference the appropriate Gateway section in the Appendix This screen also displays the default Modbus network protocol settings and the current state of the network run stop enable and network run stop command Protocol MODBUS RTU Settings Interface Data Bits 8 Parity Even Stop Bits 1 HMI Station 113 Baud Rate 19200 Figure 7 15 Network Setup Sub Screen Table 7 15 Network Setup Sub Screen Elements Screen Element Description Run Stop Buttons Turns on or off the HarmonicGuard Active filter This button will take the user into the HMI display settings which HMI Settings allow the protocol settings of the Modbus RTU slave device to be Buttons changed baud rate parity slave ID etc A password is required to enter this screen Call TCI at 1 800 824 8282 to receive a password and configuration document if needed Stop Button Turns of
80. nicGuard Active Filter TCI s brand name for a real time filter that mitigates harmonics while also maintaining near unity power factor An Active Harmonic Filter is any piece of equipment that actively monitors and changes the incoming AC line current HGA The term commonly used in place of the entire brand name of HarmonicGuard Active filter Active Harmonic Filter An active harmonic filter is a piece of equipment that reads the incoming voltage and current and injects current waveforms that cancel distortion This term is commonly used in place of the entire brand name of HarmonicGuard Active filter Bus Applied Filter A shunt device connected in parallel to the load This is an active filter designed to mitigate the harmonics associated with multiple loads The filter is directly connected to a main bus as can be found in a typical Motor Control Center The filter is sized for the amount of corrective current needed to be injected to cancel the offending harmonics A Digital Signal Processor DSP pulse width modulated controller is used for switching Insulated Gate Bipolar Transistor IGBT in order to cancel the harmonics Power Converter The power converter is the digital filter module of the HarmonicGuard Active filter Non Linear Load Input Line Inductor The three phase line reactor connected at the input of an adjustable frequency drive or other non linear load Converter Inductor The three phase inductor maintains a
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82. olled electronic over current fault and over load Over current protection All units have internal circuit breaker for protection of the converter section of the HGA The customer must supply branch circuit protection Status indication LEDs Numerous LED indicators on converter unit Please consult TCI regarding optimum filter performance when applied to DC drives 26 Section 4 Pre installation Planning Warning Verify the Application HGA Ratings Make sure that the HarmonicGuard Active filter is correct for the application and sized for load The voltage ratings of the HGA must match the input voltage rating of the connected AC bus Select a Suitable Location Environment Locating the HarmonicGuard Active filter in a suitable environment will help assure proper performance and a normal operating life Refer to the environmental specifications listed in Table 3 6 marked on the unit s nameplate and or noted on the drawings furnished with the unit Unless specifically labeled as approved for such use this equipment is not suitable for use in an explosive atmosphere or in a Hazardous Classified Location as defined in article 500 of the National Electrical Code NEC UL Type 1 and open chassis units must be installed in an area where it will not be exposed Direct sunlight Rain or dripping liquids Corrosive liquids or gasses e Explosive or combustible gases or dust Excessive
83. on a splash screen will appear saying The Filter is about to stop see Figure 7 13 Choosing Next will stop the filter and take the user to the Setup screen see Figure 7 14 Pressing the Back button returns the user to the Home screen and does not turn off the filter If the filter is off this splash screen will not appear Figure 7 13 Setup Transition Sub Screen The Setup Screen see Figure 7 14 allows basic configuration of the HarmonicGuard Active filter operation When a feature is enabled via a button press the corresponding button will be highlighted in GREEN When a feature is disabled the corresponding button will turn BLUE Note It is recommended that the new settings are saved when changes are made See the description of the Save Settings button in Table 7 14 89 Figure 7 14 Setup Screen Table 7 14 Setup Screen Elements Screen Element Description Auto Start Enable This option will set the converter to start automatically after a programmed delay after power is applied or after a fault occurs Button This option is on by default This option turns the Automatic Harmonic Correction on or off H This option is on by default armonic Correction Enable If both harmonic correction and power factor correction are Button enabled and the HarmonicGuard Active filter is at its maximum capacity the power factor correction will automatically be phased
84. onicGuard Active filter Serial Display Displays the pre programmed factory serial number of the HarmonicGuard Active filter Total Output Current Display System Voltage Displays the total corrective current capacity in Amps RMS of the HarmonicGuard Active filter Displays the line voltage the HarmonicGuard Active filter is set to work on DSP Type Display Displays the Digital Signal Processor type used in the HarmonicGuard Active filter power converter controller Displays the software revision of the installed Digital Signal DSP Revision Processor used in the HarmonicGuard Active filter power Display converter controller AVR Revision Displays the software revision of the installed microcontroller in Display the Interface PCB HMI Revision Displays the software revision of the HMI Display application Display code Sensor Wiring Error Auto Detection Sub Screen Some HarmonicGuard Active filter models are equipped with voltage and current feedback sensor wiring error detection algorithms The detection algorithms run briefly on unit power up and check the unit sensors for signatures of common wiring errors such as incorrect ACB phase rotation instead of the required ABC rotation and inverted system CT polarity The Sensor Wiring Error Sub Screen is a pop up screen which is not accessible from any of the main navigation screens The screen is only displayed if a wiring error is detected I
85. op up screen 2 Converter check 1 Press Setup to navigate to Setup screen Ensure that Auto Start En Harmonic Correct En and PWR Fact Correct En buttons are off blue color If they are ON green press them to toggle to OFF blue Press Save Settings Press Status to navigate to Status screen Press Home to navigate to Home screen Built In Sensor Wiring Error Detection The active filter has an automatic sensor wiring error detection algorithm built in to the controls If a sensor wiring error is detected please reference the Sensor Error Auto Detection section on page 93 3 Home screen check Compare Freq to expected line frequency Compare Supply Voltage to expected line voltage Current expected to be zero because unit is not running and CT inputs are shorted If status indicates a Fault press Stop button to reset condition 4 Status screen check Press Status to navigate to Status screen Compare Volts to expected line voltage Compare Freq to expected line frequency Current expected to be zero if unit is not running and CT inputs are shorted 5 Phase rotation check Warning Press Phase to Neutral Voltage Plot Check that the current peaks follow the following sequence from left to right Phase A green Phase B blue Phase C red Equipment is phase rotation sens
86. orrect any errors and apply power for proper power up if it doesn t clear the fault or if accessibility is too difficult proceed to step 2 2 There is a possibility that the CTs markings are different from Figure 4 3 This could affect the polarity to verify this try reversing the two leads on TB 1 positions 1 amp 2 do the same with wires in positions 3 amp 4 Apply power for proper power up if it doesn t proceed to 3 3 Reverse just one set of CT leads at a time first 1 2 verify power up If it doesn t work put wires amp 2 back and now try the same with wires 3 amp 4 Apply power for proper power up if it doesn t replace all wiring to its original positions and proceed to 4 4 There is a possibility that the phasing of the CT L1 and L3 are incorrect To test this theory swap the two wires on 1 positions 1 amp 2 with the two wires in positions 3 amp 4 Apply power for proper power up if it doesn t repeat steps 2 and 3 5 Ifthe HGA doesn t indicate a run status after completion of steps 1 through 4 contact TCI technical support for further assistance System Failure The Digital Signal Processor is continually monitoring the performance and fault status of the filter It will shut down the converter section if the processor should sense a fault The filter is also equipped with a circuit breaker providing a second layer of over current protecting for the converter section The circuit breaker can also s
87. other connected equipment must be properly grounded The HGA filter may receive power from two or more sources Three phase power is connected to the main input terminals of the HGA filter All of these sources of power must be disconnected before working on the HGA filter After switching off the power always allow 5 minutes for the capacitors in the HGA filter and in the drive to discharge before working on the HGA filter the drive the motor or the connecting wiring It is good practice to check with a voltmeter to make sure that all sources of power have been disconnected and that all capacitors have discharged before beginning work 1 Verify unit external connections Phase A B C power connection with positive A B C phase rotation expected CT Terminal is pointing toward the source CT feedback on phases A amp C to TB 1 Leave CT shorting bars in place on 1 With the HGA circuit breaker open energize the source to the HGA Close the HGA circuit breaker Fans and HMI should come on in lt 5 seconds HMI will start on Home screen Load s have an integral 5 line reactance or equivalent dc bus choke Warning Hazardous voltages are present when unit is energized Language Selection The active filter supports several languages including English French and Spanish Press Setup to navigate to Setup screen and press the Language Setup button Select language setting from the language setup p
88. pacity a second filter may be required to handle the load Please contact TCI for assistance Run Stop Button System State Indicator located immediately below stop button Runs and stops the HarmonicGuard Active filter When the HarmonicGuard Active filter is in a stop mode the Status light will turn red and display Stopped When the converter is running the status light will be green and will display Running The status light will also show if the HarmonicGuard Active filter is in Input line Sync mode Reset mode Precharge mode Calibrate mode Power Save mode or Faulted When the HarmonicGuard Active filter is faulted it will shut down automatically Power Factor Display Displays current line load power factor 1 00 indicates unity power factor A negative power factor indicates lagging power factor Line Frequency Display Supply Voltage Displays the current utility line frequency in Hz Displays the supply voltage coming into the HarmonicGuard Active filter Line Load Current Display Displays the current line load phase current in Amps RMS NOTE the displayed current is affected by the CT Ratio configuration on the Setup page 77 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 Figure 7 3 explains th
89. pment When you receive the unit you should immediately inspect the shipping container and report any damage to the carrier that delivered the unit Verify that the part number of the unit you received is the same as the part number listed on your purchase order TCI Limited Warranty Policy TCI LLC warrants to the original purchaser only that its products will be free from defects in materials and workmanship under normal use and service for a period originating on the date of shipment from TCI and expiring after one 1 year of useful service not to exceed eighteen 18 months from the date of shipment The foregoing limited warranty is TCI s sole warranty with respect to its products and TCI makes no other warranty representation or promise as to the quality or performance of TCI s products THIS EXPRESS LIMITED WARRANTY IS GIVEN IN LIEU OF AND EXCLUDES ANY AND ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty shall not apply if the product was a Altered or repaired by anyone other than TCI b Applied or used for situations other than those originally specified or c Subjected to negligence accident or damage by circumstances beyond TCI s control including but not limited to improper storage installation operation or maintenance If within the warranty period any product shall be found in TCT s reason
90. power terminal on the back of the HMI display accepts 28 to 14 AWG stranded wire with a tightening torque of 4 4 in lb 0 5 Nm 72 Table 6 2 Form Relay Contacts Tightening Wire Terminal Pin Description Label Torque Range Normally Closed Run Common 4 4 lbs in 0 5 Nm 28 14 Awg Normally Open Normally Closed Power On Common 4 4 lbs in 0 5 Nm 28 14 Awg Normally Open Normally Closed Fault Common 4 4 lbs in 0 5 Nm 28 14 Awg Normally Open Normally Closed Limit Common 4 4 Ibs in 0 5 Nm 28 14 Awg Normally Open Note Form C relay contacts are gold plated with a load rating of 0 6A 125VAC general use 0 2A 250VAC 0 6A 125VAC 2A 30VDC resistive The minimum permissible load rating is 10uA 10mVDC HMI Display Connections Note The following section describes the default ModbusRTU network connection available on the base model If an optional advanced network Communications Gateway is included in the Interface Module see the appendix for the specific Communications Gateway configuration The HMI display implements a ModbusRTU slave device over RS 485 This network connection is available on the COM2 3 DB9 connector on the back of the HMI Display see Figure 6 4 The output registers from the HarmonicGuard Active filter are mapped to Modbus register address 40500 The input registers to the HarmonicGuard Active filter are mapped to Modbus r
91. ps that must be taken to avoid conditions that can lead to a malfunction and possible equipment damage Warnings Readers are informed of situations that can result in serious physical injury and or serious damage to equipment with warning statements marked with the following symbols Dangerous Voltage Warning warns of situations in which a high voltage can cause physical injury and or damage equipment The text next to this symbol describes ways to avoid the danger General Warning warns of situations that can cause physical injury and or damage equipment by means other than electrical The text next to this symbol describes ways to avoid the danger Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the life and affect performance or completely destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards 11 Cautions Readers are informed of situations that can lead to a malfunction and possible equipment damage with caution statements Caution General Caution Identifies situations that can lead to a malfunction and possible equipment damage A The text describes ways to avoid the situation General Safety Instructions These safety instructions are intended for all work on the HGA filter Additional safety instructions are provided at appropriate points
92. r optional This is provided to protect the HGA for destructive over current conditions if a malfunction occurs within the HGA circuitry It also provides a convenient disconnect means and field wiring point for the installer of the filter equipment Components 3 and 4 are the high frequency converter inductors These inductors provide the proper inductance to the power converter Component 5 is the power electronic converter module The Power converter module PCM is the heart of the HarmonicGuard Active filter and is what differentiates the HGA from other types of harmonic mitigation The PCM provides several highly complex electronic functions controlled by the on board DSP controller The PCM continuously senses the AC bus line voltage and currents processes the information at nearly real time by means of the instructions resident within the DSP program code properly controls the six IGBT s to operate in a safe manner that injects current into the AC bus grid that ensures the AC bus current is sinusoidal and near unity power factor Power converter contains a pre charge circuit which consists of two SCRS and two pre charging resistances which control the inrush current 16 Filter Configuration Line Side CT Placement Figure 3 1 Typical Configuration of the HarmonicGuard Active filter This drawing is for general reference only Use the drawings supplied with the unit for installation 17 Nameplate Data Figure 3 2
93. rs will still be energized Required Equipment e AC voltmeter and ammeter or multimeter designed for true RMS measurements in a harmonic rich circuit and suitable for the rated current and voltage marked on the nameplate The meter should have 1000 volt minimum isolation e Clamp on current probe suitable for the rated current and voltage marked on the nameplate e Clip on voltage probes suitable for the rated voltage marked on the nameplate Select probes that can be securely clipped on to the test points without shorting between points or falling off Note when disconnecting wires from components and terminations mark the wires to correspond to their component and terminal connection Extreme Care should be taken when removing the fast on terminals from the circuit board Excessive force will result in damaging the interface board and require the converter to be repaired by TCI authorized personnel only 53 Converter Inspection 54 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 circuit board overheated cracked or broken components corrosion and poor solder joints Check all wires and terminals connected to the circuit boards Check the four electrolytic capacitors for bulges ruptures popped vent plugs discoloration or leakage
94. shing Red Connection s Timed Out Flashing Green Red Self Test in Progress 3 Off No Link Link Green Connected to Ethernet Network 4 Off No Ethernet Activity Activity Flashing Green Receiving Transmitting Packets 5 Flashing Green Running Transaction Error Detected Green Running Subnet Status Red Transaction error timeout Off Power Off Flashing Green Red Invalid or Missing Configuration Gateway Front 8 Initializing View Yr Running Device Status Res Green Bootloader Mode Note the LED flash sequence and contact customer Flashing Red support 104 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 2014 TCI LLC Publication No 26030 Effective 3 3 14 Version B Printed in USA 105
95. ssssesccssescosssssnsssssnessessessosssssnsssssnessessessossessoss 14 Receiving Inspection and Storage 15 Receiving SPECIOSA 15 TCI Limited Warranty Policy 15 Storage 15 Product ias noon ise enini cnin cw 16 DALSTON 18 Part Number Encoding 20 1 11 aeta eee 19 Section 4 Pre iristallation 2 2 26 Verify the Application ME 26 Select a Suitable Location cehaleta heehee 26 Mounting an Open Chassis 26 Cooling 26 IO e A OTIN E 29 WEIN RERE A T OAA ETR 29 Current Transformer Installation sseseosoeseosossesoessescosoesessossesoessesoesossessossessossesoesseseesossessossessssssse 31 HGA Filter 2 eren eee eene tnnt enata 45 45 Start Up Commissioning ccscssscssscscccecssscssecsscssscssscssscssssessscsssssecsnecsscsseessecssessscsssesssessssessseees 45 Gener l Oper ati OM aica enrol 45 m Section 5 Maintenanc
96. t 15 their 24VDC on the P E 2 Ne lt power connector on gt Yes Age E f 1s the display in Sleep the HMI 4 lt Is their 120VAC on the x mode touch screen 71 Yes Control Transformer _ Yes N No Y Replace the power Ri eplace the power cable from the Send the HMI Back 5 to the factory fro Replace the HMI sane som Replace Anp control transformer x display interface to interface Board control transformer service the HMI to the display interface BD Figure 8 4 Troubleshooting Flow Chart 99 Section 9 Appendix Installation Diagram Plate Detail 1 2 Scale 679 HMI __ Mounting Plate Assy C Chassis Communica tlon Front View Cable 0 DES Aux Relay Contacts See Note 6 20188 4 Pls 24 1 Input Assembly Sequence 10 Determine best location where there is adequate ventilation depth for components and cables away from any heat source 2 The Inside surface of the enclosure must be free of protrusions or obstructions In the area where the HMI mounting plate will rest Keep In mind that the plate can ke positioned so the components are above below the HMI display see note sectlon 2 3 If it is inconvenient to use the mo
97. t TCI for assistance Filter Current Used Display Displays the current state of all enables that affect the running of the HarmonicGuard Active filter If a button is red that option is disabled and if it is green that Run Enable Summary option is enabled If the Auto Start is enabled countdown timer will run to the right of the button when the count reaches 0 the converter will start See Figure 7 5 Back Button Returns to the main status screen 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 80 Command Enabled or Present Source Disabled Command Local Spee om Enableq Run Auto Start 1 Sec Stopped vork Home Ea E Figure 7 5 Run Enable Summary Sub Screen Table 7 5 Run Enable Summary Sub Screen Elements Screen Element Description Run Stop Button Runs and stops the HarmonicGuard Active filter Local HMI Enabled Shows if the start or stop button is enabled Changes to blue if enabled or the left button is pressed and the countdown timer to the right of the button will AUG tant start When it reaches 0 the HarmonicGuard Active filter will start Changes to blue if enabled or the left button is pressed if enabled the HarmonicGuard Active filter can be Remote Relay remotely stopped with a contact closure When enabled and the option
98. ted in Table 41 and 4 1b Refer also to the drawings and other information shipped with the unit A disconnecting means is the responsibility of the customer Table 4 1a Example Power Terminal Wire Size Capacity Range and Tightening Torque for ABB Circuit Breakers Ground Lug Power Terminals Filter Size Torque In Ibs Breaker Torque In Ibs Wire Size Nm IC Wire Size Nm 39 amp 78 Amp 14 AWG 2 0 120 13 6 22 kA 14 1 0 AWG 70 7 9 45 amp 50 Amp 14 AWG 2 0 120 13 6 22 kA 14 1 0 AWG 70 7 9 39 amp 78 Amp 14 AWG 2 0 120 13 6 25 kA 2 4 0 AWG 250 28 2 100 Amp 14 AWG 2 0 120 13 6 25 4AWG 300 200 22 6 39 amp 78 Amp 14 AWG 2 0 120 13 6 65 4 AWG 350 250 28 2 45 8 50 Amp 14 AWG 2 0 120 13 6 65 kA 14 1 0 AWG 70 7 9 100 Amp 14 AWG 2 0 120 13 6 65 6AWG 350 274 81 39 to 100 Amp 14 AWG 2 0 120 13 6 100 6 AWG 350 274 81 25 to Two 3 0 AWG 250 200 Amp Two 6 AWG 250 MOM 275 31 1 100 kA MCM 274 31 300 Amp Consult Factory 39 amp 78 Amp Control Terminals Wire Size 30 to 12 AWG Torque 4 4 in Ib 5 Nm pi rt 208 Control Terminals Wire Size 28 to 14 AWG Torque 4 4 in Ib 5 Nm Note The values in this table are representative of ABB switch gear For other manufacturer s switch gear please contact TCI 30 Table 4 1b Power Terminal Wire Size wi
99. the ModbusRTU protocol to an alternate Fieldbus or Industrial Ethernet protocol such as Ethernet IP Side View Front View Network Gateway Interface PCB pese ems n Uu wo A A Aux Relay Contacts HMI Display Figure 6 1 Interface Module Components 68 Additional Information Caution This section provides general information describing the Interface Module Be sure to 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 The information and ratings given in this manual are approximate and should not be used for any purpose requiring exact data Contact the factory in situations where certified data is required All data is subject to change without notice Receiving Inspection The Interface Module has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment After receiving the unit immediately inspect the shipping container and report any damage to the carrier that delivered the unit Verify that the part number of the unit received is the same as the part number listed on the purchase order See appendix for part numbering details 69 Installation Guidelines Checklist The following are the key points to be followed for a successful installation
100. thout breaker Capacity Range and Tightening Torque Chassis Size Ground Lug Power Terminals Wire Size Torque In Ibs Nm Breaker IC Wire Size Torque In Ibs Nm 39 to 100 Amp 14 AWG 2 0 120 13 6 25 to 100 kA 14 2 0 AWG 180 20 3 15010 200 Amp 14 2 0 120 13 6 2510 100 KA 6 AWG 350 274 31 150to 200 14 2 0 120 13 6 None 6 AWG 350 274 31 Control Terminals Wire Size 28 to 14 AWG Torque 4 4 in Ib 0 5 Nm Caution Use copper wire that is appropriate for the voltage and current rating of the equipment The wire selection must conform to the requirements of the National Electrical Code and or other applicable electrical codes Use wire with an insulation temperature rating of 75 C or higher Connection Diagram Figure 4 3 shows the typical wiring connections between the models of the HGA and the load Refer to the drawings furnished with the unit for more specific information e The input 3 phase AC voltage source must be connected in a positive ABC phase rotation from L1 L2 L3 for correct unit operation IHGA Connection E 2 3 4 5 6 7 8 bad 2 7 RE535 T M Communications E Converter CT See Note 2 Ed e Connection 3 Phase AC Power 5 9 Optional See Note 1 2 See Note 4 See Note 4 Figure 4 3 Typical Load Connection Diagram Notes 1 Wiring shou
101. tic discharge ESD procedures when servicing the filter and its circuit boards Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered HGA This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before you attempt to service the conditioner Check for zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenance and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker will still be energized 47 Reference Drawings Typical HGA configurations are illustrated in Figures 5 1 5 1b and 5 1 There could be slight differences between your unit and the configurations shown below It is recommended that you refer to the drawings provided with your specific equipment when conducting troubleshooting operations 18190999600 Ayquassy E dong dua 2 42 1 9er cif Cie ds 6 09 6 eer psvog cer ow 2 s owag 086 x40
102. tion 5 of protection tripped user manual YES Is power present at the fans Are any sensor wiring errors reported by the HMI display Replace Power off and correct fans wiring errors see section 7 of user manual Power off and check control power Are any active transformer fusing faults reported by replace if bad the HMI display Check power between branch breaker and active filter Did the unit pass the inspection Press the stop or Perform a power reset button on the on off cycle of HMI display the unit Are the fans running in the active fitter Close unit enclosure and apply power to active fitter Check and repair load Drive Did the fault clear Contact TCI Did the circuit Customer Service breaker in active filter trip Press the run button on the unit HMI display to start active filter operation Follow the Quickstart NO Guide to configure the Do not re energize YES Contact TCI Customer Service Is the harmonic correction enabled on the HMI setup screen Are the voltage current and harmonics correct and at acceptable levels unit see section 1 of user manual Complete Set autostart enable on HMI Setup screen and save settings Figure 5 4 Troubleshooting Flow Chart 56 Replacement Parts If replacement parts are needed please contact your TCI representative To ensure that the Harmon
103. uch can reduce the life affect performance and or destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards Troubleshooting Notes To reboot the system remove power to the filter and Interface Module wait a few minutes then reapply If this does not work check all the cable and connections and try again If the problem is still not resolved replace the Interface Module assembly e buttons are pressed for 5 minutes the screen will turn off To reactivate touch anywhere on the screen e HMI Display shows 1 Station 1 Communication Error across the bottom of the screen check the serial cable between HMI Display COMI and Interface PCB J1 e Ifthe HMI Display shows a NO COM indication on the system state indicator or a 7010 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 e For technical support contact TCI directly at 1 800 824 8282 Select Customer Service or Technical Support Troubleshooting Flow Chart Suspected Problem with HMI Yes 15 the HMI Power LED On ne N Pi P 5 Yes A Are their lights on the No geniy interface N there 120VAC J3 lt N SS the display interface v Pa UN N g
104. uiring exact data Contact the factory in situations where certified data is required All data is subject to change without notice 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 O Make sure that the installation location will not be exposed to direct sunlight excessive vibration corrosive or combustible airborne contaminants excessive dirt or liquids O Select a mounting area that will allow adequate cooling air and maintenance access O Make sure that all wiring conforms to the requirements of the National Electric Code NEC and or other applicable electrical codes O Connect the HGA filter equipment grounding lug to the system ground of the premises wiring system Use a properly sized grounding conductor O Connect three phase power to the input terminals of the HGA filter L1 L2 amp L3 O Ensure that the CTs are properly installed and connected to the proper terminals inside the HGA filter see CT Installation section of IOM Manual Check everything thoroughly before applying power to the equipment Check the panel and the inside of the enclosure for any foreign objects dirt or loose hardware 14 Receiving Inspection and Storage Receiving Inspection The HarmonicGuard Active filter has been thoroughly inspected and functionally tested at the factory and carefully packaged for shi
105. uniform air gap to give highly consistent and predictable inductance These inductors are connected to the inverter which buffers the inverter output from the analog portion of the filter the source and connected drives Current Transformer CT The device that monitors the incoming AC current waveform typically sized to handle the total connected load 13 Section Introduction Caution Thank you for selecting TCI s HarmonicGuard Active filter TCI has produced this filter for use in variable speed drive and non linear load applications that require input power line harmonic current reduction and power factor correction This manual describes how to install operate and maintain the HarmonicGuard Active filter Intended Audience This manual is intended for use by all personnel responsible for the installation operation and maintenance of the HarmonicGuard Active filter Such personnel are expected to have knowledge of electrical wiring practices electronic components and electrical schematic symbols Additional Information This manual provides general information describing your HGA filter Be sure to carefully review the more specific information that is provided by the drawings shipped with the unit Information provided by the drawings takes precedence over the information provided in this manual The ratings dimensions and weights given in this manual are approximate and should not be used for any purpose req
106. unity power Display factor A negative power factor indicates lagging power factor THD Display Displays the Total Harmonic Distortion of the utility Line Load current as a percentage V THD Display Displays the Total Harmonic Distortion of the utility line Voltage as a percentage Displays the reference Total Harmonic Distortion of the utility Line Load current in percent This THD display is the uncorrected THD of the Line Load taken when the HarmonicGuard Active filter was not running THD Ref Display Run Stop Button Runs and stops the HarmonicGuard Active filter 81 Back Button Returns to the main Status Screen Waveform Plot Sub Screens The HMI display supports capture and display of real time system voltage and current data Three phase waveform data can be viewed for Line Voltage Line Load Current and Converter Corrective Current The waveform screens contain a zoom feature which supports three magnitude scales 1 X 2 X and 4X see Figure 7 7 The Refresh button on the waveform screens will update the plot with new data from the HarmonicGuard Active filter converter 104 a SSeS Ferre FEE Figure 7 7 Example Waveform Plot Sub Screens Converter Corrective Current Table 7 7 Waveform Plot Sub Screen Elements Screen Element Description The Refresh button will reload the data from the HarmonicGuard Refresh Button Active filter power converter controller and redraw t
107. unting holes at the corners of the mounting plate The HMI display and mounting plate assembly can be held in place by the four pressure clamps on the display The enclosure will be sandwiched between the back of the display and the mounting plate via the pressure generated from the clamps It will be very important that the enclosure hole is cut to size to avoid ng of the display The mounting cut out opening should be 6 79 x inches 172 5 x 138 6mm Depending on the application the mounting plate n ke rotated so circuit board is above or kelow the HMI display 3 Minimum customer wire spacing from power s is 4 inches increose spocing to S inches for wires rated less thon 105 C 42 Use mounting hardware which come with display Torque to 3 5 to 44 lbs in to 49 Nm 5 These parts are present when you have a gateway module 6 Use of these mounting holes are optional Figure 9 1 Installation Diagram 100 Appendix Part Numbering Part numbering Here is an example the interface module part number CM100A00 CM Communications 100 amp rating of 100 amps A voltage rating of 480V 00 Modbus RTU over RS485 A suffix of 00 Modbus RTU over RS485 A suffix of 01 Ethernet IP Here would be the part number possibilities available as of this revision CM45A00 50 00 CM90A00 CM100A00 CM200A00 CM45A01 CM50A01 90 01 CM100A01 CM200A01 101 Appendix EthernetiP Gateway Option Introductio
108. wadd 243 2 peisauuco 5 555 43 64304 udan 00030 ays ao 2 c eq Pinoys Bua 129504 OMY QC i 4 9 610021 OZ OMY FL 002 01 05 WOW OSE __ eno _ duly ooz 01051 WN enbio ang 4 225 CL 830N 225 5 a2unos a 4nos gt zs NN 1 n ceci H uU 12 2015 QVO 12 3015 3 1 Line Side or Load Side CT Placement 200 amp Open or 1 480 volt 4 4c 36 Figure 225 2 2 EX a ka JV 95944 2 2 12 48i42 u03 ie aa TNA INI EN e e leder pea Aypodop snos nivis 9390 39 UOo z DOUUON 4 S20N eas 50007 4 225 Spoo sno 4uajo mba 32u9012984 aun YE 0146au uo anvoy S poo 9 paua ua PINOYS iuaJ44nj 1ueudpnba 40 jauuosuad 5 aq s oulw4a4 aui 550429 yy u Uado AUvpuodas aui UPM 5 3uas44n2 Bulrouadg G O U
109. way using explicit 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 For advanced configuration options such as IP Access Control reference the HMS Anybus Communicator Serial EtherNet IP Gateway User Manual available on the HMS website www hms se Register Map For a description of the input and output data available over the network interface reference the Network Interface section in this user manual Operation The Communication Gateway has six LED indicators that show the current status of the EtherNet IP and sub network communications The meanings of the LED indicators are described in Table 8 1 Table 9 4 EtherNet IP Gateway LED Diagram LED Number Indication Meaning ET 7 Off No Power Normal Operation ore 1 Flashing Green Configuration Missing E EN Module Status Flashing Red Minor Fault Recoverable o Red Major Fault Unrecoverable Flashing Green Red Self Test in Progress Off No IP Address Green Online Connection s Established 2 Flashing Green Online No Connection Established Network Status Red Duplicate IP Address Fla
110. zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenance and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker including the reactors will still be energized Interface Module Problem The Interface Module is comprised of four major components the HMI display the Interface PCB the cabling and an optional Gateway The Interface PCB contains diagnostic LEDs The locations of the LEDs are shown in Figure 8 3 and their functions are listed in Table 8 1 LED PLAGEMENT D13 m E Dia m E Dsm D4 m ES Dem EN 07 E D m ES mu Figure 8 3 Communications Board LED placement Table 8 1 LED Functions LED LED Color Description LED Color D1 Green AUX 1 D3 Green AUX 2 D4 Green Running Relay Energized D5 Green Power On Relay Energized D6 Green Fault Relay Energized D7 Green Current Limit Relay Energized D12 Green RS485 Communication is active from converter D13 Orange RS485 Communication is active to converter 014 Green Input Run Command Present 98 Warning Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human to

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