TCi MFC A, Installation Instructions Manual

Page 1: ...lation Instructions TCI LLC W132 N10611 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 TCI 8282 Web Site http www transcoil com 2020 TCI LLC All rights reserved Effective 10 22 2020 Version G ...

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Page 3: ... 22 2020 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 ...

Page 4: ... with PQconnect 12 MFC P Filter Kit Part Number and Ratings 13 Variable Frequency Drive Settings 13 Filter Schematic 14 Capacitors 16 Capacitor Brackets 17 Recommendations for MFC Kit Usage 17 4 0 Installation 18 Installation Guidelines 18 Select a Suitable Location 18 Mounting the Filter Kit 19 Power Wiring 19 Line Reactor Wiring 19 Wire Sizing 20 5 0 PQconnect Option 26 Product Description 26 In...

Page 5: ...2 Replacement Parts 56 Factory Contacts and Tech Support 56 ...

Page 6: ...en to avoid conditions that can lead to a serious 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 possible equipment damage Warnings Readers are informed of situations that can result in serious physical injury and or serious damage to equipment with warning st...

Page 7: ...e 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 MFC Filter Kit Warning The MFC Filter Kit drive motor and other connected equipment must be properly grounded Warning After switching off the power always allow 5 minutes for the capacitors in the MFC Filter Kit ...

Page 8: ...tps transcoil com products kmg mfcdrawings htm Storage Instructions If the MFC Filter Kit is to be stored before use be sure that it is stored in a location that conforms to published storage humidity and temperature specifications in this manual and on the applicable technical drawings available at transcoil com Store the unit in its original packaging TCI Limited Warranty Policy TCI LLC TCI warr...

Page 9: ... 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 an...

Page 10: ...n from the output voltage waveform The use of this low pass filter will result in a nearly pure sine wave voltage profile This design will reduce the effects of the reflected wave phenomenon dV dt such as insulation damage or premature failure in motors transformers and VFD output cables The MFC Filter Kit will also reduce the effects of stray high frequency harmonic currents thereby reducing VFD ...

Page 11: ... 2 000 m derating required for operation above this level Operating Temp 30 C 22 F to 50 C 122 F Cooling provisions required for operation above this temperature Ambient Storage Temp 40 C 40 F to 50 C 122 F Maximum Humidity 95 non condensing Reference Technical Standards Voltage Drop 3 at nominal voltage frequency and rated current Capacitors High endurance design no PCBs Agency Approvals UL cULus...

Page 12: ...RMG or KLRUL series filter reactor o The 480 V 900 HP and larger units include two reactors that need to be wired in parallel High endurance PWM ripple current rated capacitors o Bleeder resistors to ensure safe capacitor discharge on filter shutdown located on capacitors Damping resistors o High power 3 phase damping resistors to reduce VFD control or load dynamic induced resonances Damping resis...

Page 13: ...0 362 MFC362AA 350 420 MFC420AA 400 480 MFC480AA 450 540 MFC540AA 500 600 MFC600AA 600 750 MFC750AA 700 850 MFC850AA 800 960 MFC960AA 900 1080 MFC1080AA 1000 1200 MFC1200AA 575 600 Volt MFC Kit HP Amp 575 600 Volt Model 5 8 MFC008CA 7 5 10 MFC010CA 10 12 MFC012CA 15 20 MFC020CA 20 25 MFC025CA 25 28 MFC028CA 30 35 MFC035CA 40 45 MFC045CA 50 55 MFC055CA 60 65 MFC065CA 75 80 MFC080CA 100 110 MFC110CA...

Page 14: ...t provided with capacitor brackets because these units utilize single phase capacitors that do not have mounting brackets available for them These small size single phase capacitors are typically mounted vertically due to the small size and reduced use of panel space Note There are no damping resistors included these kits are most suitable for VFD applications with low load and VFD dynamics MFC R ...

Page 15: ... reactor o The 480 V 900 HP and larger units include two reactors that need to be wired in parallel High endurance PWM ripple current rated capacitors o Bleeder resistors to ensure safe capacitor discharge on filter shutdown located on capacitors Capacitor mounting brackets o Capacitor mounting brackets are provided on kits rated 50 Amps and higher o Kits below 50 Amps are not provided with capaci...

Page 16: ...130 MFC130CP 150 160 MFC160CP 200 200 MFC200CP 250 250 MFC250CP 300 305 MFC305CP 350 362 MFC362CP 400 420 MFC420CP 450 450 MFC450CP 500 500 MFC500CP 600 600 MFC600CP 750 750 MFC750CP Variable Frequency Drive Settings Make sure that the variable frequency drive will be set for operation modes and ranges that are compatible with the MFC Kit Maximum output frequency 80 Hz Constant PWM switching carri...

Page 17: ... REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT VFD For horsepower ratings 480 V 900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors as illustrated in the schematic below Figure 3 Typical MFC A Filter Kit Wiring for 480 V 900 HP and larger with two reactors DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERS...

Page 18: ...OT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT VFD For horsepower ratings 480 V 900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors as illustrated in the schematic below Figure 5 Typical MFC R Filter Kit Wiring for 480 V 900 HP and larger with two reactors DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVE...

Page 19: ...capacitors are supplied with the kit they are intended to be connected in parallel with each other Typically the capacitors are three terminal three phase capacitors with the internal capacitive elements connected in delta Each capacitor has a bleeder resistor connected across the three input terminals to ensure voltage discharges in the time required by UL Warning Do not connect capacitors to pow...

Page 20: ... bracket damaging the capacitor cans This hole does not firmly clamp the capacitors and is not intended to do so such a design would prevent the internal capacitor pressure disconnection means from operating This bracket prevents gross motion of the capacitors during shipping vibration which could fracture the mounting bracket or allow the capacitors to hit other components Recommendations for MFC...

Page 21: ... damage may result if capacitor circuit is attached directly to VFD three phase output Sine wave reactor terminations can be swapped to improve wiring due to physical orientation of components in a cabinet In this case all terminations must change to be consistent Connect VFD three phase output to terminals A2 B2 and C2 of KTRMG sine wave reactor Connect load to terminals A1 B1 and C1 of KTRMG sin...

Page 22: ...ure of the air around the MFC filter capacitors and line reactor should not exceed 50 C 122 F Consult the Technical Data tables within this manual as appropriate when planning enclosure ventilation Power Wiring When selecting a mounting location for the MFC Filter Kit plan for the routing of the power wiring Line Reactor Wiring Consult the reactor drawing for your line reactor to verify proper fil...

Page 23: ...uit current If the capacitor wiring is split into separate capacitor branches the current each branch carries is proportional to the value of capacitance in each branch Additional Cooling Considerations Reactors generate heat during operation due to harmonic currents in the coil wire and magnetic fields in the core Reactors constructed to Class R 220 C insulation system would be expected to have s...

Page 24: ...s directed through the ducts in a coil parallel to the core it will help cool the reactor Designers should be careful to avoid mounting reactors close to walls where there is no airflow Capacitors are more sensitive to high temperatures than reactors so filter capacitors should not be mounted within a four inches of reactor coils where radiation from the coil would heat the capacitor Capacitor sur...

Page 25: ...1 0 825 MFC055AA 40 55 10 5 1000 MFC065AA 50 65 16 0 1175 MFC080AA 60 80 20 0 1550 MFC110AA 75 110 28 0 1670 MFC130AA 100 130 32 0 1965 MFC160AA 125 160 40 0 2600 MFC200AA 150 200 49 0 3275 MFC250AA 200 250 61 0 3700 MFC305AA 250 305 75 0 4660 MFC362AA 300 362 89 0 4650 MFC420AA 350 420 102 0 5720 MFC480AA 400 480 117 0 6275 MFC540AA 450 540 132 0 7000 MFC600AA 500 600 146 0 7710 MFC750AA 600 750 ...

Page 26: ...475 MFC065AR 50 65 17 0 600 MFC080AR 60 80 21 0 775 MFC110AR 75 110 30 0 750 MFC130AR 100 130 34 0 825 MFC160AR 125 160 42 0 1000 MFC200AR 150 200 51 5 1050 MFC250AR 200 250 64 0 1500 MFC305AR 250 305 79 0 1650 MFC362AR 300 362 94 0 1500 MFC420AR 350 420 107 0 1800 MFC480AR 400 480 123 0 2100 MFC540AR 450 540 139 0 2350 MFC600AR 500 600 154 0 2500 MFC750AR 600 750 191 0 2700 MFC850AR 700 850 216 0...

Page 27: ...20 25 6 0 685 MFC028CA 25 28 7 0 715 MFC035CA 30 35 9 0 875 MFC045CA 40 45 11 0 945 MFC055CA 50 55 14 0 1180 MFC065CA 60 65 16 0 1540 MFC080CA 75 80 21 0 1610 MFC110CA 100 110 27 0 2140 MFC130CA 125 130 33 0 2290 MFC160CA 150 160 37 0 2510 MFC200CA 200 200 49 0 3430 MFC250CA 250 250 61 0 4505 MFC305CA 300 305 74 0 5065 MFC362CA 350 362 89 0 6055 MFC420CA 400 420 104 0 6830 MFC450CA 450 450 113 0 7...

Page 28: ... 7 2 400 MFC035CR 30 35 9 5 435 MFC045CR 40 45 11 6 450 MFC055CR 50 55 14 7 560 MFC065CR 60 65 17 0 725 MFC080CR 75 80 22 0 775 MFC110CR 100 110 28 5 900 MFC130CR 125 130 35 0 925 MFC160CR 150 160 39 0 950 MFC200CR 200 200 52 0 1275 MFC250CR 250 250 64 0 1500 MFC305CR 300 305 78 0 1750 MFC362CR 350 362 94 0 1725 MFC420CR 400 420 110 0 2100 MFC450CR 450 450 119 0 2175 MFC500CR 500 500 127 0 2200 MF...

Page 29: ... B2 and C2 terminals of the KTRMG sine wave reactor to the load Connect three phase power from the tuning reactor to the input terminals of the PQconnect board J1 and J2 as shown in Figure 12 and described in Table 7 VFD faults and component damage may result if capacitor circuit is attached directly to VFD three phase output Connect 120VAC Power customer supplied to the input power supply header ...

Page 30: ...5 0 PQconnect Option 27 Figure 12 Typical MFC P Filter Kit Wiring PCB Mounting Hardware Figure 13 below shows the standoffs and screws provided with the kits to mount the board on the bracket Figure 13 PCB mounting Hardware ...

Page 31: ... provided with the kit will need to installed onto the grounding pad of the board Figure 15 below indicates the location of the ground connection Wiring When selecting a mounting location for the PQconnect PCB plan for the routing of the power wiring Make sure all wiring conforms to the requirements of the NEC electrical codes and can handle the max current required PCB Connections Most customer c...

Page 32: ...nnections Phase A 600VAC 2 Phase B 3 Phase C J2 1 Tuning Reactor Connections Phase A Output of tuning reactor 2 Phase B Input of tuning reactor 3 Not connected J3 1 2 3 Not Connected N A J4 1 8 Not Connected N A J5 1 RS485 Not Connected N A 2 B non inverting 3 Ground 4 A inverting 5 Not connected J12 1 Input Power from control power transformer Neutral 120 VAC 2 Line J14 1 14 Micro Programming For...

Page 33: ...only supported by most PLCs and is an open royalty free communications standard The PQconnect implements a Modbus RTU Master Slave device which supports two wire RS 485 signal levels The PQconnect communication port used for the Modbus RTU interface is connected directly to the PCB The communication port is located on the side of the PQconnect board Figure 15 PQconnect Modbus RTU Connection Connec...

Page 34: ...he Sine wave filter are mapped to Modbus register address 40000 see Table 20 through Table 22 for definitions of the input register maps The output registers are mapped to Modbus register address 40500 see Table 20 through Table 22 All input and output registers are two bytes in size and formatted as 16 bit signed integers Note All parameters with an asterisk in the description will require the Te...

Page 35: ...s COM LPT and finding USB Serial Port Note If Modbus settings differ from the default values above Set and save desired Modbus settings then select Reset PQconnect from the drop down Menu 4 Summary Data Displays PQconnect Software revision Displays the estimated carrier frequency of the VFD in Hz Displays the fundamental frequency of the filter output voltage in Hz Displays the board temperature i...

Page 36: ... to the PCB Power will need to be energized to the PCB for the calibration process Step 1 Energize unit Step 2 Open PQvision desktop application Step 3 Connect to the device by selecting the appropriate COM port Step 4 Go to Menu and select Tech access Figure 17 PQvision Main Menu Step 5 Go to Menu and select Calibrate Figure 18 Calibration Screen Step 6 Select Default Non Cal Parameters Step 7 Se...

Page 37: ... the PCB after saving settings This can be easily done through the menu by clicking menu and Reset PQconnect The reset command will only work if the PCB is communicating to the desktop application or Modbus network Note resetting the board will de energize the relay outputs if the relay state is closed Figure 19 PQvision Settings Menu ...

Page 38: ...g Modbus settings the user will start with selecting a new slave address Baud rate and parity of the Device After selecting desired Modus settings of the device the user will select apply Modbus settings and save settings Afterwards the user will need to go to Menu and Reset PQconnect This will soft reboot the board Note Changing Modbus settings of the device can only be done through tech access I...

Page 39: ...eters the user selects To pin parameters the user will select the pins box for each desired parameter View parameter tables to determine what each value means 2 Address Requested Value Read Write Address is the spare ID for each parameter Requested If the user would like to adjust any values that differ from the present value they will type in the new value in the box Value is the present value th...

Page 40: ...e number of times the PCB power cycled when the event occurred The middle 10 and last 3 digits represent the time in seconds milliseconds format since the last power on of the PQconnect board since the status condition was detected 3 Status Status will indicate the status detection that occurred The status bit mask formatted as a hex value volowed by a list of status conditions will be shown 4 Val...

Page 41: ...ead only value DSP_SW_VER 12 Output Two 8bit ASCII Characters Example 0x0141 ASCII for A1 Software revision code for processor Read only value DSP_MODEL_NUM 13 Output 301 Sinewave Filter System Model Number Read only value V_LOAD_AB_RMS 50 Output Volts RMS 4800 480 0 VRMSLL Range 120 to 690 VRMSLL 65535 0xFFFF data not available Filter output RMS voltage phase A B Read only value V_LOAD_BC_RMS 51 ...

Page 42: ... Filter output fundamental frequency Read only value V_IN_CARRIER_HZ 101 Output Range 1kHz to 16 kHz 65535 0xFFFF data not available Filter input carrier frequency Note due to widely variable modulation schemes and controls of industry VFDs this value may not always be accurate This is intended as an information estimate of VFD switching frequency only Read only value V_OUT_ROT 102 Output 0 undete...

Page 43: ...This value is a bit mask where individual bits are set to indicate a detection is active For a description of bit positions see Table 15 Read only value OUTPUT_RELAY_1_ENABLE_RO 230 Output For each bit position 0 Detection disabled 1 Detection enabled Output relay 1 status detection enable This value is a bit mask where individual bits are set cleared to enable disable a specific status detection ...

Page 44: ...nt state of the PQconnect Read only value RATED_VOLTAGE_RO 260 Output 4800 480 0Vrms Range 1200 to 6900 Filter rated voltage Read only value MB_SLAVE_ADDRESS_RO 300 Output Default 10 Range 0 to 255 Modbus slave address Read only value To change this value modify the corresponding register in the setpoint section below Read only value MB_BAUD_RATE_RO 301 Output 960 9600 baud rate 3840 38400 baud ra...

Page 45: ...ONFIG_RO 322 Output 0 Disabled DEFAULT 1 Thermal Switch Input relay 2 configuration View PCB header J8 Read only value SYS_SERIAL_NUM_2_RO 350 Output Parameter contains UUUU in the UUUULLLL NN serial number format Unit serial number upper 16 bit value Read only value SYS_SERIAL_NUM_1_RO 351 Output Parameter contains LLLL in the UUUULLLL NN serial number format Unit serial number lower 16 bit value...

Page 46: ...0 to 15 0 Overvoltage Phase A 1 Overvoltage Phase B 2 Overvoltage Phase C 3 High THVD Phase A 4 High THVD Phase B 5 High THVD Phase C 6 Reactor Thermal Switch 1 7 Reactor Thermal Switch 2 8 PCB Under Temperature 9 PCB Over Temperature 10 Phase Loss Phase A 11 Phase Loss Phase B 12 Phase Loss Phase C 13 Unused 14 Unused 15 CPU Error ...

Page 47: ...the fundamental frequency of the filter output RATED_VOLTAGE 521 Input 4800 480 Vrms Range 120 to 690 Vrms Default of 4800 Filter rated voltage in Volts RMS Line to Line OUTPUT_RELAY_1_ENABLE 540 Input For each bit position 0 Detection disabled 1 Detection enabled Default 32888 High THVD Phase A B C Thermal SW1 and CPU error enabled To Enable desired fault detections enter bit mask from table by c...

Page 48: ...ltage clear threshold STATUS_OVERVOLTAGE_DELAY 622 Input DEFAULT 6 seconds Range 1 to 3600 seconds Status detection delay time in seconds Set desired filter output voltage high THD delay threshold STATUS_HIGH_THD_ONSET 630 Input DEFAULT 16 16 Range 1 to 100 Set desired filter output voltage high THD onset threshold STATUS_ HIGH_THD_CLEAR 631 Input DEFAULT 15 15 Range 1 to 100 Set desired filter ou...

Page 49: ...LAY 652 Input DEFAULT 6 seconds Range 1 to 3600 seconds Status detection delay time in seconds Filter output voltage phase loss delay threshold STATUS_CPU_ERROR_DELAY 655 Input DEFAULT 6 seconds Range 1 to 3600 seconds Status detection delay time in seconds PCB processor CPU error delay STATUS_HIGH_THD_WARNING_ONS ET 660 Input DEFAULT 12 12 Range 1 to 100 Filter output voltage high THD onset thres...

Page 50: ...ts filter output voltage scaling fir phase A B V_OUT_SCALAR_B 704 Input DEFAULT 9639 Range 32768 to 32767 Adjusts filter output voltage scaling fir phase B C V_OUT_SCALAR_C 705 Input DEFAULT 9639 Range 32768 to 32767 Adjusts filter output voltage scaling fir phase A C V_OUT_A_OFFSET 708 Input DEFAULT 2048 Range 0 to 4096 Adjusts filter output voltage offset for phase A B V_OUT_B_OFFSET 709 Input D...

Page 51: ...rd 2 1668 16 History Record 99 3136 16 The history record is circular buffer of 100 records from index 0 to 99 When the history buffer fills up the oldest record is overwritten The newest entry in the history record is at index 0 and the oldest entry is at index 99 A history record is logged each time the status detection parameter 210 value changes Each history record is a collection of 16 bytes ...

Page 52: ...lue 13 Estimated Carrier Frequency VFD Carrier frequency in units of 100Hz For example a value of 20 would equate to a carrier frequency of 20x100 2000Hz The factor 100 is used to compress the data to fit in an 8 bit value 14 16 Bit Two s Compliment Checksum History Record Checksum When this 16 bit value is added together with the reset of the history records as 16 bit values the result should be ...

Page 53: ... the side of the board Connect USB end to the computer o Determine the assigned COM port number for the RS 485 to USB converter using the computer device manager control panel o The converter used in this example typically enumerates between the range of COM5 to COM20 on a standard laptop computer running the Microsoft windows operating system Open the Simply Modbus Master software o Can be downlo...

Page 54: ...ing the parameter keys Next select the WRITE button on the screen shown above The screen below will be shown Configure the fields as shown in the picture Select 4800 in the field Values to Write to change the voltage to 480V E x a m p l e S u p I n s t r u c t i o n s t o W r i t e D a t a t o t h e P Q c o n n e c t U n i t ...

Page 55: ...etween 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 The connectivity board has been thoroughly in...

Page 56: ...en blink fast depending on the fault The tables below summarize the LED blinks based on the fault condition Table 28 D6 LED Codes Microprocessor Status LED Status LED Specifier No fault detected enabled LED Blinking at 1Hz PCB Not Calibrated LED Solid On Status Detection Active LED Solid Off Table 29 D6 LED Codes Detection Status LED Detection LED Specifier On Off or Slow Fast Blink Sequence No fa...

Page 57: ...tings o Select 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 leading to the J5 header of the circuit board Hard Reset Modbus settings Worst Case o To perform a hard reset of Modbus settings the user will need to remove jumper J20 with the power de...

Page 58: ...rical connections must be re torqued annually Status detection Description Debug Overvoltage Phase A B or C Filter has detected overvoltage on a phase s Check input power connections to the filter Check system voltage setpoint Phase Loss Phase A B or C Filter phase loss Check fused disconnect or circuit breaker upstream of the filter Check input power connections to the filter High THVD Phase A B ...

Page 59: ...ponents Warning Only qualified electricians should carry out all electrical installation and maintenance work on the MFC sine wave filter Exercise caution when checking waveforms with an oscilloscope Use a dual probe differential input set up or other means of isolating the scope chassis from the VFD output or filter output Disconnect power when attaching and removing the probes Replacement Parts ...

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Page 61: ...10611 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 TCI 8282 Web Site http www transcoil com 2020 TCI LLC All rights reserved Part Number 30335 Effective 10 22 2020 Version G ...