TCi HarmonicGuard HGL Series, Installation, Operation And Maintenance Manual

Page 1: ...and Maintenance Manual TCI LLC W132 N10611 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 824 8282 Web Site www transcoil com 2019 TCI LLC All rights reserved...

Page 2: ......

Page 3: ...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 a...

Page 4: ...led rectifiers but actual THID levels can vary by load and or speed and therefore cannot be guaranteed Consult factory for assistance when applying HGL filters on these types of equipment MINIMUM SYST...

Page 5: ...Description Date A Release 10 19 2017 B Added Additional Options Updated Part Number 11 22 2017 C Updates to Watts loss table 12 12 2018 D Addition of PQconnect 08 21 2019 E Addition of PQvision App 0...

Page 6: ...ct 15 PQvision PC application Screen Elements 15 Example Application Using Simply Modbus Master 8 1 0 18 USPTL4 RS485 Converter Dip Switch settings 19 Example Setup Instructions to Read Data from the...

Page 7: ...erious fault condition physical injury or death Cautions are used to call attention to instructions that describe steps that must be taken to avoid conditions that can lead to a malfunction and possib...

Page 8: ...National Electrical Code NEC and or any other codes that apply to the installation site Warning Disconnect all power before working on the equipment Do not attempt any work on a powered HGL filter War...

Page 9: ...imited Warranty Policy TCI LLC TCI 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 originatin...

Page 10: ...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 wi...

Page 11: ...the major harmonic currents demanded by the drive The filter is a stand alone device that can be furnished in its own enclosure and mounted adjacent to the drive It is also available on an open panel...

Page 12: ...of each character in the HGL part number The example part number HGL0150AW1S0000 designates an HGL filter that is rated 150 HP 480 volts 60 Hz It includes a line reactor tuning reactor and capacitors...

Page 13: ...ations UL and cUL Listed to UL508A Insertion Impedance 10 at full load current Fusing and protection All units have internal fuse protection for the capacitor branch circuit Performance Guarantee To m...

Page 14: ...ity of leading power factor interacting with other devices on the power system Contactor logic should also maintain the contactor closed in cases where the VFD is bypassed and the filter is not bypass...

Page 15: ...d Location as defined in article 500 of the National Electrical Code NEC The unit must be installed in an area where it will not be exposed to Direct sunlight Rain or dripping liquids unless filter is...

Page 16: ...ution 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 NEC and or other appli...

Page 17: ...s below Note that to achieve a 100kA SCCR the customer provided line fuse must be installed as per the requirements in Table 2 and sized following NEC National Electrical Code guidelines for the sourc...

Page 18: ...250 125 350 300 150 450 350 175 500 400 175 600 450 200 600 500 225 750 600 250 800 700 300 1000 800 350 1200 900 400 1300 Table 4 Fuse Table for HGL 600 Volt 60Hz Models HGL Rating HP Branch Circuit...

Page 19: ...239 242 242 40 447 54 454 50 518 525 525 60 608 617 617 75 560 569 569 100 760 771 771 125 871 884 884 150 1046 1062 1062 200 907 921 921 250 1217 1235 1235 300 1454 1476 1476 350 1411 1432 1432 400 1...

Page 20: ...93 297 297 40 341 346 346 50 511 519 519 60 600 609 609 75 734 745 745 100 736 747 747 125 920 934 934 150 1182 1200 1200 200 976 991 991 250 1306 1325 1325 300 1452 1474 1474 350 1766 1792 1792 400 1...

Page 21: ...coil com products HGL 5 passive harmonic filter Figure 2 HGL Filter with PQconnect Typical Connection Diagram PQvision PC application Screen Elements This section focuses on the operation of the PQvis...

Page 22: ...d current as a percentage Displays three phase real power P of the filter input output in kW Displays three phase reactive power Q of the filter input output in kVAR Displays three phase apparent powe...

Page 23: ...8252014 to enable In the PQvision settings a user can set their desired Modbus settings Note if changing Modbus settings one must restart the PQconnect by cycling power to the HarmonicGuard Low Capaci...

Page 24: ...as Relay input 1 J8 of the PCB is configured as Relay input 2 Select and save desired relay action if applicable If the user will be using the digital inputs they must select relay under contactor con...

Page 25: ...ng Figure 6 Dip Switch settings Example Setup Instructions to Read Data from the PQconnect Unit Connect the cable to the J5 communication header Connect USB end to the computer o Determine the assigne...

Page 26: ...e parameter keys o Navigate to the settings menu and then select force open or force close button o The contactor state box will indicate if the contactor is open or closed Next select the WRITE butto...

Page 27: ...Default Modbus settings of the application are below o Baud rate 115200 o Parity Even o Slave Address 10 o See PQconnect Display connections section for changing the default settings PQconnect Blueto...

Page 28: ...t PQconnect device Each PQconnect device in the app will be identified by their Device ID 3 A prompt to enter the Bluetooth pairing passkey will pop up automatically Enter the 6 digit serial number fo...

Page 29: ...ng prompt does not appear automatically o Wait up to 15 seconds for the prompt to appear o Close the app completely and reopen it Please report any issues to TCI tech support transcoil com PCB Connect...

Page 30: ...HGL Manual 5 0 PQconnect Connectivity 24 Figure 7 PQconnect Connections...

Page 31: ...m 28 14 AWG 2 Common COM 3 Normally Open NO Note Form C relay contacts are gold plated with a load rating of 5 0A 120VAC The filter is set to control the contactor pickup drop out at 30 of load curren...

Page 32: ...nector Pin Definitions J5 Header Pinout Signal Name Signal Type 1 No connect 2 B RS 485 B non inverting 3 GND RS 485 SC G 4 A RS 485 A inverting 5 No connect The default protocol settings for the RS 4...

Page 33: ...master device for the network interface see the PQvision application display connections Table 14 Configuration Switches SW1 Configure Modbus Connection on J5 Header 1 Enable 560 bias resistor on D 2...

Page 34: ...ss PARAM_KEY_B 504 Input Enter Key B CT_RATIO 505 Input XXXX 5 where XXXX is the primary turns count of the CT 1000 1000 5 Range 5 to 10000 Dual Tuned Circuit Current Transformer CT ratios Note Only r...

Page 35: ...relay will be activated Reference Table 19 below for line status detection bits STATUS_FILTER_LOAD_RELAY_ACTION 543 Input 0 Disabled DEFAULT 63 Range 0 to 65535 To Enable desired status detections ent...

Page 36: ...SPAN 583 Input DEFAULT 600 600 seconds Range 300 to 3600 seconds Maximum number of contactors auto re close attempts time span MB_SLAVE_ADDRESS 600 Input DEFAULT 10 Range 0 to 255 Modbus RTU Device Sl...

Page 37: ...VERCURRENT_B 11 TUNE_OVERCURRENT_C 12 UNDER_TEMP 13 OVER_TEMP 14 CPU_ERROR 15 TUNE_REACTOR_THERMAL_SW Register B 0 RECLOSE_LIMIT 3 LINE_REACTOR_THERMAL_SW Table 19 Filter Line Status References 16 bit...

Page 38: ...B C V_LOAD_CA_RMS 52 Output Filter Output Phase to Phase Voltage C A V_TRAP_A_RMS 70 Output Filter Tuned Circuit Phase A Voltage V_TRAP_B_RMS 71 Output Filter Tuned Circuit Phase B Voltage V_TRAP_C_RM...

Page 39: ...tput Tuning circuit C Phase THVD I_LINE_A_TDD 42 Output iTDD 50 5 0 iTDD Filter input total Demand Distortion Phase A iTDD I_LINE_B_TDD 43 Output Filter input total Demand Distortion Phase B iTDD I_LI...

Page 40: ..._A_HARM_5 142 Output I_LINE_A_HARM_7 143 Output I_LINE_A_HARM_11 144 Output I_LINE_A_HARM_13 145 Output I_LINE_A_HARM_17 146 Output I_LINE_A_HARM_19 147 Output I_LINE_A_HARM_23 148 Output I_LINE_A_HAR...

Page 41: ...BLE_RO 222 Output STATUS_LINE_RELAY_ACTION_RO 232 Output STATUS_LINE_CNT_ACTION_RO 242 Output STATUS_FILTER_LOAD 213 Output Reference Table 20 above for load status detections STATUS_FILTER_LOAD_ENABL...

Page 42: ...DELAY_RO 274 Output DEFAULT 5 5 seconds Range 1 to 3600 seconds Displays set value of contactor closed delay time CNT_OPEN_DELAY_RO 275 Output DEFAULT 5 5 seconds Range 1 to 3600 seconds Displays set...

Page 43: ...t Parameter contains UUUU in the UUUULLLL NN serial number format Unit serial number section upper 16 bits of 32 bit unit job number SYS_SERIAL_NUM_1_RO 351 Output Parameter contains LLLL in the UUUUL...

Page 44: ...ut 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 di...

Page 45: ...Status Condition Status Condition Group Slow blinks LED Specifier Fast Blinks Tune Phase A Loss 2 1 Tune Phase B Loss 2 Tune Phase C Loss 3 Tune Balance Loss Phase A 4 Tune Balance Loss Phase B 5 Tun...

Page 46: ...Load Defaults o Select Apply o Default Modbus settings should be applied Try connecting to the COM port If this doesn t work de energize power to the filter and try flipping the A and B signal wires...

Page 47: ...wer transformers leading to fans Make sure fans are operating CPU Error Processor Malfunction Power cycle unit and if issue persists upgrade firmware and or contact tech support Reactor Thermal Switch...

Page 48: ...its of percent rated nameplate filter current 4 Contactor is open due to an automatic kVAR control mode The present contactor control mode feedback parameter 250 is set to Automatic kVAR Control and c...

Page 49: ...r 281 The power on delay time can be adjusted via setpoint parameter 581 10 Contactor is open due to a calibration inhibit The contactor is open because the unit is presently undergoing an internal ca...

Page 50: ...top attempting to auto reclose To debug which status conditions caused the contactor open event the presently configured contactor open actions can be audited using feedback parameters 240 Filter A 24...

Page 51: ...onnections loose connections can overheat and damage the filter All electrical connections must be re torqued annually Troubleshooting Warning Only qualified electricians should carry out all electric...

Page 52: ...11 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 824 8282 Web Site http www transcoil com 2019 TCI LLC All rights reserved Publication No 30799 Effective 09 2...