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HG7 Series Filter Installation, Operation, & Maintenance Manual

1. HarmonicGuard Series Drive Applied Harmonic Filter Installation Operation and Maintenance Manual To Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Table of Contents uice Tai E M P 2 Receiving Inspection and 4 5 Installation Guidelines aad es ue 6 HG7 Harmonie Filter Operation eiie Ie iive e a 8 Installation ote e ee RE ud RATS 9 Maintenance and Service iste b n v na ee 10 Product Description oue 14 Dt ings siepe eR RE eH e eni EE 17 iSc Halli Bt 2p S 23 Contactor Option STO rrr rrr rnv n nnn nn nr 24 Power Monitor Package Option rennen enne nnne nnn 25 HG7 XM Option Operation cc dette REESE TEES ERE RESERVE NEUES 29 The HG2 Protection Monitor 2a rade db ed ee ut e dua DAG 30 Component Package Option 47 Installation 2 5 civic genic RR ERU IER HH UC HE IRURE 49 i HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Introduction Safety Instructions Overview This section provides the safety instructions which must be followed when installing operating and se
2. 888 723 4773 Web www clrwtr com Email info clrwtr com CONTACTOR amp CPT OPTION Standard Filter ST The Standard Package has the suffix of ST in the part number and includes everything necessary for an application to meet IEEE 519 standards From the highest quality harmonic grade capacitors on the market to the extraordinary reactors this filter will meet the majority of application requirements found today This cost effective product is available as either an open panel version or in a UL Type 1 enclosure The open panel is perfect for inclusion in a MCC section or easy installation into industry standard enclosures The UL Type 1 enclosed units maintain the same vertical profile as the open panel design This design is perfect for applications where floor space is at a premium Product Description HG7 Standard Harmonic Filter The HG7 harmonic filter is a drive applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives The HG7 Standard harmonic filter is for 200 208 230 240 460 480 volt and 575 600 volt systems 60 Hz and 400 Volt systems 50 Hz It is suitable for use with 3 phase diode bridge rectifier loads such as PWM AC drives and 3 phase controlled rectifier SCR or thyristor loads such as DC drives The HG7 harmonic filter is a passive filter connected in series with the input terminals of a variable speed drive or several drives tha
3. Ful a Fu2 a Fu3 a All setup maintenance and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Note when disconnecting wires from components and terminations mark the wires to correspond to their component and terminal connection Reference Drawings When troubleshooting refer to the drawings provided for the specific equipment Typical drawings are provided in this manual INTRODUCTION 10 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Fuse Specifications Table 1a through 1d list the specifications for the LC filter power circuit fuses in the HG7 Refer also to the drawings and other information shipped with the unit Table 1a Fuse Specifications for HG7 240 Volt Models HG7 Power Circuit Rating Fuse Ratings Var Amps Type 3 15 3 15 Class CC Bussmann 5 25 type KTK R or equivalent 6 25 8 35 10 45 15 60 Class T Bussmann 13 60 type JJS 20 80 or equivalent 25 100 30 125 Table 1b Fuse Specifications for HG7 400 Volt Models HG7 Power Circuit Rating Fuse Ratings kW Amps Type 4 5 5 6 7 5 7 9 3 9 Class CC Bussmann 11 12 type KTK R 15 15 or equivalent 18 5 25 22 25 30 30
4. Rain or dripping liquids unless filter is in a 3R enclosure Corrosive liquids or gasses Explosive or combustible gases or dust Excessive airborne dirt and dust 2 9 9 9 Excessive vibration 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 Panel Unit If you are mounting an open panel unit in your own enclosure you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating The rating and dimension tables for open panel units list the watts of heat loss that is dissipated by the HG7 harmonic filter The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50 C 122 F Power Wiring When selecting a mounting location for the HG7 filter plan for the routing of the power wiring Route the conduit and wiring from the power source to the filter and then to the variable speed drive The HG7 is provided with internal fuses Additional fuses may be required at the connecting point to protect the tap conductors Refer to the National Electrical Code NEC and or any other applicable codes IN
5. 1 Upon exiting this time the filter will re energize in the Calibration Mode Caution When in the Calibration Mode the HG2 board will not de energize the filter under fault conditions Follow the Calibration Procedure on page 42 The factory default setting for the Filter Current Low Trip parameter 7A is 80 of the filters nominal fundamental current rating as determined by the filter s kVar frequency and voltage ratings parameters 3A 4a amp 8A If the trip level is set below 80 the HG2 may not trip when a partial loss of capacitance has occurred If the trip level is set above 8096 the HG2 may trip unnecessarily It is recommended that the setting not be changed without consulting the technical support department at the factory POWER MONITOR OPTION 38 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY FAULT Troubleshooting Procedure Code F11 F13 Filter Current Low Trip Fault If the F11 F12 or F13 fault occurred after the unit had been operating normally for some after time after initial startup commissioning use this procedure If the fault occurred upon initial initial startup commissioning refer to the previous section normal service If the unit operated normally after setup and calibration the fault usually indicates a fuse cleared or a loss of capacitance occurred thus lowering the normal current F
6. HG7 Drive Applied Filter Drawing 102554DG Schematic 25077 Manufacturing 10126 Enclosure Type 1 INTRODUCTION Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 14 HG7 I O amp M Manual INTRODUCTION Part Number Encoding Figure 2 identifies the significance of each character in the HG7 part number The example part number HG250AWOOST designates a HG7 filter that is rated 75 kVar 480 volts 60 Hz It includes the standard 10 reactor is tuned to the 5th harmonic is an open panel and is designed for use with a 250 Hp drive Figure 2 HG7 Part Number Encoding Part Numbering System HG 250 A W00 ST Series Horsepower Voltage Rating 480v B 240v C 600v 60 Hz L 400v 50 Hz Enclosure W00 open W01 UL Type 1 WO3 UL 3R Package Option ST Standard Option Package XM Power Monitor Package STC Contactor Option Package CP Component Product Package Custom Custom Design based on standard options INTRODUCTION 15 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Product Technical Specifications Table 2 lists the major technical specifications for the HG7 Harmonic Filter Table 2 HG7 ST and STC Option Harmonic Filter Technical Specifications Voltage ratings 240 480 and 600 V 3 ph 60 Hz 400 V 3 ph 50 Hz kVar ratings 3 to 270 kVar depending on
7. J1 10 Trouble shoot by verifying continuity at the Protection Monitor between J1 8 amp J1 10 POWER MONITOR OPTION 37 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY FAULT Troubleshooting Procedure Code F11 F13 Filter Current Low Trip Fault If the F11 F12 or F13 fault occurred upon initial startup commissioning use this on procedure If the unit had been operating normally for some time after initial startup initial commissioning refer to the next section startup This fault indicates the filter current is lower than normal Fault F11 indicates low current through fuse Fu1 a F12 indicates low current through fuse Fu2 a and F13 indicates low current through fuse Fu3 a First check for any shipping damage Look for loose connections especially those associated with the HG2 board and fuses Fu1 a Fu2 a and Fu3 a Make sure that Fu1 a Fu2 a and Fu3 a are properly installed Check for proper balanced line to line voltages on L1 L2 and L3 If there are no obvious errors in the wiring and installation of the filter go to the Setup Procedure page 34 Verify that all the parameters are correct for this installation At this point leave the parameter 11A set to 0 exit the setup mode and allow the filter to reenergize If the F11 fault still appears return to the Setup Procedure and set parameter 11 to
8. POWER MONITOR OPTION 42 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Warning Line voltage is connected to terminals J2 J3 and J4 at the top edge of the HG2 board AN The board circuitry is also connected to 120 volts Calibration Procedure Perform the Setup Procedure on page 34 and verify that all settings are correct for the application Set parameter 11A to 1 Calibration Mode When you exit the Setup Mode the HG2 will be in the Calibration Mode The unit may then be calibrated using the following procedure 1 Press the UP key to select parameter C Filter Current 2 The Filter Current calibrations can be performed without the drive operating to avoid the difficulty of making adjustments with rapidly changing currents 3 Press the SELECT key to select 1 With an ammeter current probe on filter line L1 adjust potentiometer R43 to match the ammeter reading 4 Press the SELECT key to select L 2 With an ammeter current probe on filter line L2 adjust potentiometer R44 to match the ammeter reading 5 Press the SELECT key to select L 3 With an ammeter current probe on filter line L3 adjust potentiometer R45 to match the ammeter reading 6 Press the UP key to select parameter U Line Voltage 7 Press the SELECT key to select L 1 With a voltmeter connected between L1 and neutral adjust potentiomete
9. Units rated 20 kVar and less have Blown Fuse and Filter Enabled pilot lights to indicate their operating status and are not equipped with the HG2 as standard Troubleshooting information for pilot light equipped units is provided in the following section under the heading Troubleshooting Units Equipped with Pilot Lights Normal Operation The normal operation of the HG2 protection monitor is described in detail in the HG2 Protection Monitor section of this manual Refer also to HG2 Protection Monitor Calibration including figures 5 6 and 7 Protection Monitor Display and Status Lights During Normal Operation the green Filter Enabled LED should be on the red Filter Disabled LED should be off and the display should show the selected Operating Parameter If the HG2 display is blank and no LEDs are illuminated the possible causes include Ifthe drive is also inoperable and lacking any Power On indications Three phase power has probably been disconnected either manually or by the operation of a protective device Check the main disconnect and fuses or circuit breaker If fuses have blown or a breaker has tripped a short circuit or severe overload condition has probably occurred in the HG7 filter drive motor or power wiring Check for evidence of damaged burned or overheated wiring or components Ifthe drive appears to be receiving power Check the primary and secondary control power transformer fuses in the HG7 filter If a fuse has
10. and improve filter performance An L C harmonic filter circuit with A TCI 3 phase tuning reactor specifically designed for the HG7 High endurance harmonic rated capacitors X Bleeder resistors to ensure safe capacitor discharge upon filter shutdown Filter enable disable contactor with protection and drive interlock provisions Cooling fans on select models to ensure adequate cooling and safe operating temperatures Control transformer for fan and control voltage power Compression terminals for ease and integrity of all power and control wiring CONTACTOR amp CPT OPTION 24 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Power Monitor Package Option XM This model is identified by the suffix XM in the part number The XM Option HG7 filters are similar to the standard series HG7 but they have features and characteristics that are beyond the scope of the Standard series HG7 In the rating and dimension tables we list the sizes of the XM option units only to avoid confusion This manual is intended to be used as a general guide to the installation operation and maintenance of XM Option filters Product Description HG7 XM Option Harmonic Filter The HG7 harmonic filter is a drive applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variabl
11. blown there is probably a short circuit ground fault or overload condition in the HG7 Check for evidence of damaged burned or overheated wiring or components Check the following items Control circuit wiring Control circuit transformer Cooling fan HG2 Protection Monitor If the fuses are good the HG2 may be defective If drive is operating but the HG2 display shows OFF the red Filter Disabled LED is on and the green Filter Enabled LED is off Check the Filter Enable input to the HG2 If the Filter Enable input is open the Drive Aux Run contact may be open or disconnected If the Filter Enable input is closed HG2 may be defective POWER MONITOR OPTION 36 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Protection Monitor Display Fault Codes If the Protection Monitor display shows a Fault Code F01 to F33 follow the troubleshooting procedure provided in Table 8 If a Fault Code is displayed the Filter Disabled LED will be illuminated and the Fault Alarm Relay will be de energized Table 8 Fault Code Troubleshooting Procedures FAULT Troubleshooting Procedure Code F01 External Fault This Fault Code indicates a fault in an HG7unit other than the one displaying the F01 Fault Code In a system that has multiple sections each monitored with an HG2 any HG2 may detect a fault and in turn disconnect all the harmoni
12. factory default setting for the Filter Current Low Trip parameter 7A is 80 of the filter s nominal fundamental current rating the as determined by the filter s kVar frequency and voltage ratings parameters 4a amp 8A If the trip level is set below 80 the HG2 may not trip when a partial loss of capacitance has occurred If the trip level is set above 8096 the HG2 may trip unnecessarily It is recommended that the setting not be changed without consulting the technical support department at the factory POWER MONITOR OPTION 39 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY FAULT Troubleshooting Procedure Code F21 23 Filter Over current Fast Trip The usual causes for this fault are Oversized drive for the capability of the filter Excessive harmonics present on the distribution system from other sources Partial loss of capacitance thus causing the filter circuit tuning point to shift at or above the designed frequency Line voltage is greater than 125 of the nominal rating Interaction with power factor capacitors on the distribution system resulting in system resonance conditions If F21 F23 faults occur repeatedly in the apparent absence of any of the above problems verify the actual filter current with a current probe suited for true RMS measurements in a harmonic rich circuit Note It may be necessary
13. feet 1 000 meters as standard Product must be equipped with special cooling provisions for operation above this altitude Maximum ambient operating 50 C 122 F Open Panel 40 C 104 F Enclosed Panel temperature Product must be equipped with special cooling provisions for operation above this temperature Maximum ambient storage 60 C 140 F temperature Maximum humidity 95 non condensing operating or storage Enclosure options Standard UL Type 1 enclosure Agency approvals or UL and cUL Listed to UL508A and CSA C2 2 No 14 certifications C US Insertion Impedance 10 at full load current Fusing and protection All units have internal fuse protection for the harmonic filter HG2 Protection Monitor is standard in units rated over 20 kVar LCD display Operating Parameter values kW kVA power factor voltage units with HG2 Monitor current harmonic voltage current and total harmonic distortion Faults low current trip high current trip time delay over current trip door interlock over temperature multi unit external and interlock faults Setup Parameters filter nameplate ratings fault amp reset delays and trip levels Status indication LEDs Green LED indicates Filter Enabled units with HG2 Monitor Red LED indicates Filter Disabled Fault relay De energized when a fault is detected units with HG2 Monitor Form C contact for customer
14. in the following sections of this manual Make sure that the installation location will not be exposed to direct sunlight corrosive or combustible airborne contaminants excessive dirt or liquids Select a mounting area that will allow adequate cooling air and maintenance access Make sure that all wiring conforms to the requirements of the National Electric Code NEC and or other applicable electrical codes Connect the HG7 equipment grounding lug to the system ground of the premises wiring system Use a properly sized grounding conductor Connect three phase power to the input terminals of the HG7 L1 L2 amp L3 L1 DL L1 L1 L1 EI Connect the output power terminals of the HG7 T1 T2 amp T3 to the input power terminals of the variable frequency drive INTRODUCTION 9 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Maintenance and Service HG7 Harmonic Filter Reliability and Service Life The HG7 has been designed to provide a service life that equals or exceeds the life of the variable speed drive It has been thoroughly tested at the factory to assure that it will perform reliably from the time it is put into service The following periodic maintenance is recommended to assure that the HG7 filter will always perform reliably and provide the expected service life Periodic Maintenance Warning Only qualified electricians should carry out all el
15. next to this symbol describes ways to avoid the danger Warning 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 an electrostatic discharge can damage equipment The text next Warning Electrostatic Discharge Warning warns of situations in which to this symbol describes ways to avoid the danger 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 The text describes ways to avoid the situation INTRODUCTION 2 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION General Safety Instructions These safety instructions are intended for all work on the HG7 Additional safety instructions are provided at appropriate points 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 HG7 harmonic 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 no
16. s reasonable judgment to be defective TCI s liability and the Buyer s exclusive remedy under this warranty is expressly limited at TCI 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 TCTs 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 HG7 harmonic f
17. the HG7 filter is connected to the power distribution system The power monitoring display selections include line voltage current real power kW apparent power kVA power factor and harmonic distortion parameters The harmonic distortion parameters include total harmonic distortion YoTHD of the line voltage and current as well as individual values of low order harmonics Filter current and harmonic values are also available Three phase average parameter values totals and individual phase values are available The HG2 calculates parameter values from the signals available at the analog inputs The HG2 includes contact closure inputs for Filter Enable control and for optional Over temperature and Door Interlock protection functions A serial interlock connection is provided for coordinating the protection functions of multiple HG2 Protection Monitors The HG2 Protection Monitor provides fault protection for the filter by disconnecting the capacitor banks when a fault is detected Protection functions include filter over and under current door interlock over temperature and others Note that the door interlock switch and the over temperature thermostatic switch are optional Fault Codes are generated on the display for ease of troubleshooting POWER MONITOR OPTION 30 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Filter Disabled HG2 M Pro
18. to inhibit the board from de energizing the filter by operating in the calibrate mode However be aware that if excessive currents are indeed present the technician must be able to rapidly remove power from the filter to minimize damaging components or blowing the filter fuses The factory default setting for the Filter Over current Fast Trip parameter 5A is 18096 of the filter s nominal fundamental current rating as determined by the HG7 s kVar frequency and voltage ratings parameters 4a amp 8A If the trip level is set above 180 the life of the capacitors may be reduced or the fuses may blow If the trip level is set below 180 the filter may trip unnecessarily It is recommended that the setting not be changed without consulting the technical support department at the factory POWER MONITOR OPTION 40 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY FAULT Troubleshooting Procedure Code F31 F33 Filter Over current Delayed Trip The usual causes for a F31 displayed fault are Short term operation above rated line current during acceleration of the load or other normal utilization of the drive s short term overload capacity Operation above rated line current due to abnormal drive overload condition Excessive harmonics present on the distribution system from other sources Partial loss of capacitance thus causin
19. use rated 5 A at 120 VAC amp 5 VDC Pilot lights Blown Fuse indicating lights for 3 phase filter fuses Units w o HG2 monitor Filter Enabled pilot light Capacitors Oil filled high endurance design no PCBs POWER MONITOR OPTION 26 HG7 1 amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Control Wiring Control Power An internal control power transformer is provided to supply 120 VAC single phase power for the contactor Protection Monitor and cooling fan s Fuses are provided on both the primary and secondary sides of the control transformer Filter Enable Input An auxiliary N O run contact from the drive should be connected to the Filter Enable input to enable the HG7 Option only when the drive is running Fault Alarm Relay A Fault Alarm relay 1s included in the HG2 Protection Monitor which is furnished as standard in XM Option units rated over 20 kVar The Fault Alarm relay is energized when control power is applied to the HG7 and the HG7 is operating properly A set of form C contacts is provided for customer use Determine how the Fault Alarm contact will be used It may be connected to the drive external fault input or to some supervisory control or alarm annunciation equipment A HG7 fault alarm indicates that the HG7 filter has been disabled by the HG2 Protection Monitor If the drive operates while the HG7 is disabled in
20. voltage See Rating and Dimension tables Load types 3 phase diode bridge rectifier loads such as PWM AC drives Load power range 7 5 900 Hp depending on voltage See Rating and Dimension tables Current ratings The included series reactors can tolerate 200 of rated current for at least 3 minutes SCCR short circuit current Standard rating is 10 rating Maximum elevation 3 000 feet 1 000 meters as standard Maximum ambient operating 50 C 122 F Open Panel 40 C 104 F Enclosed Panel temperature Product must be equipped with special cooling provisions for operation above this temperature Maximum ambient storage 60 C 140 F temperature Maximum humidity 95 non condensing operating or storage Enclosure options UL Type 1 enclosure UL Type 3R enclosure Agency approvals or UL and cUL Listed to UL508A certifications C US Insertion Impedance 10 at full load current Fusing and protection All units have internal fuse protection for the harmonic filter circuit Capacitors Oil filled high endurance design no PCBs INTRODUCTION 16 HG7 1 amp Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Drawings Typical Schematic Diagrams and Outline and Mounting Dimension Drawings Typical HG7 drawings are provided on the following pages These drawings provide general information describing
21. your HG7 harmonic filter More specific information is provided by the drawings shipped with the unit Be sure to carefully review the information on the provided drawings The information on the drawings provided with the filter takes precedence over the information provided in this manual Schematic Diagrams The schematic diagram shows the details of the HG7 circuitry The power circuit schematic shows the variations in input and output power connections 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 Additional Typical Drawings Some additional typical drawings are available for downloading at Trans Coil website E INTRODUCTION 17 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Typical Drawings continued HG7 I O amp M Manual 18 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION INTRODUCTION HG7 ST Schematic CUSTOMER CONNECTIONS em BLEEDER RESISTORS HG7 STC Schematic CUSTOMER CONNECTIONS 480v FUSED DISCONNECT ki 60 HZ OR CIRCUIT BREAKER T2 LOAD LINE TB 100 HP AND ABOVE 100 AMPS USE MINIMUM 75 C COPPER WIRE m
22. 11 Harmonic 11 ve U13 Harmonie 13 fr wil ps das m pv Due d n nd LED will fight A Line Amps after he restart lockout time lit hos expired AH armine TH Al Harmonic 1 Tha puri will either read OFF or when no fault ists Xill show the A5 Harmonic 5 for the selected function ond line Switches or DOWN wil A7 Harmonic 7 display the selected dete function when pressed mamentariy Holding either down will seroll through the functions foward or backward re 11 Harmonic 11 spectively SELECT displays or scrolls through o selected line A13 Harmonic 13 Faults are displayed as FXX see the fault message table in the Opero UA Hong Manual and the red LED will light Press SELECT once to clear a PF Power Factor LA Average Refer to the Operations Manual for more information Lr Total Li Line 1 J6 J5 J1 Figure 5 HG2 Keypad View Dp J2 J3 J4 R68 R94 R43 R44 R45 R52 R53 R54 mimm Ji J6 Figure 6 HG2 Board Component View POWER MONITOR OPTION 45 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Line Voltage Inputs C1B1 A1 J2 J3 J4 INNNN 120 VAC Door Open e613 ome A Over temperoture CTS Filter Current Lon Enoble I
23. 25 A JUMPER 64 Je les J640 3140 NB 62 jes jer J6 5 Jes J57 S59 1540 Ul 480 V IHG MULTI FEATURE BOARD 12VOLT INTRODUCTION 20 75 HP AND BELOW USE MINIMUM 60 C COPPER WIRE ABOVE 75 HP USE MINIMUM 75 C COPPER WIRE CNT Tt L1 RB CAP TYP s a la fj 1 lu i OPTIONAL CUSTOMER CONNECTION TO BE SUPPLIED BY 5 AMP MAX FUSED DISCONNECT CT3 CURRENT TRANSFORMER INPUT cm Cnt 1 7 TB18 TB1 6 J54 J53 J52 N32 NA NA J13 NG J15 INTERNALLY PROVIDED FORM CONTACTS FOR CUSTOMERS USE ALARM SIGNAL ETC 5AMP 120 V HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION HG7 XM Schematic 450 600 HP based on 480V CUSTOMER CONNECTIONS CUSTOMER INTO HARMONIC FILTER CONNECTIONS CONTROL SCHEMATIC USE 75 C COPPER WIRE ONLY POWER SCHEMATIC CAP TYP NOTE 1 S BLEEDER RESISTORS FOR PROPER OPERATION CONNECT AUXILIARY N O RUN RELAY CONTACT 2 FROM DRIVE TRAP REACT SENSE COIL FOR CUSTOMERS ALARM SIGNAL TBa WINDINGS OR CONTROL CKT RESET CONTACTOR COILS typ TERMINAL BLOCK CONNECTIONS INTERNALLY PROVIDED FORM C CONTACTS FOR CUSTOMERS USE CABLE2 rerwnal ALARM SIGNALETC BLOCK 5AMP 120 V MAX OPTIONAL CUSTOMER CONNECTION TO BE SUPPLIED BY 5 AMP MAX FUSED DISCONNECT INTRODUCTION 21 HG7 I O amp M Manual Phone 800 894 0412 Fax
24. 37 35 45 45 55 60 75 80 90 90 110 110 132 150 160 150 Class T 200 200 peen ype JJS 250 250 or equivalent 315 300 355 350 400 400 450 450 500 500 560 600 630 600 INTRODUCTION 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email HG7 I O amp M Manual info clrwtr com INTRODUCTION Table 1c Fuse Specifications for HG7 480 Volt Models HG7 Power Circuit Rating Fuse Ratings kvar Amps Type 3 10 5 15 Class CC Bussmann 6 15 type KTK R 10 30 or equivalent 15 30 20 40 25 50 30 60 40 80 45 100 60 125 18 ES 90 200 type JJS 105 225 or equivalent 120 250 150 300 180 400 210 450 240 500 270 600 Table 1d Fuse Specifications for HG7 600 Volt Models HG7 Power Circuit Rating Fuse Ratings Yan Amps Type z Class CC Bussmann 10 2 type KTK R 12 20 or equivalent 20 35 25 40 30 50 40 70 45 80 60 100 75 125 Class T 90 150 Bussmann 105 175 type JJS 120 200 or equivalent 150 250 150 250 180 300 210 350 240 400 270 450 INTRODUCTION 12 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Replacement Parts If replacement parts are needed please contact your TCI representative To ensure that the HG7 harmonic
25. 460 480 volt 575 600 volt systems 60 Hz and 400 volt systems 50 Hz When properly designed assembled and installed the completed product is intended to be suitable for use with 3 phase diode bridge rectifier loads such as PWM AC drives SCR or thyristor loads such as DC drives would require a different filter configuration outside the scope of this product offering Please contact TCI Technical Support for additional information Product Description HG7 CP Option Harmonic Filter The HG7 CP Option filter components is a package of the primary passive filter components needed to build a harmonic filter and installed on the input terminals of a variable speed drive or drive system The filter component are tuned to provide a low impedance path for the major harmonic currents demanded by the drive when following the schematic connections used by TCI in the HG7 HarmonicGuard filter The HG7 CP Option filter component package consists of the following components AKDR input series reactor A TCI 3 phase tuning reactor specifically designed for the HG7 filter High endurance harmonic rated capacitors Bleeder resistors to ensure safe capacitor discharge upon filter shutdown Capacitor mounting brackets that allow for a neat and orderly mounting and connection of the cylindrical power capacitors COMPONENT PACKAGE OPTION 47 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clr
26. Average value fundamental RMS volts U5 Line 5th harmonic voltage Lr Total value RMS volts U7 Line 7th harmonic voltage L 1 Line 1 value RMS volts U11 Line 11th harmonic voltage L2 Line 2 value RMS volts U13 Line 13th harmonic voltage L3 Line 3 value RMS volts These functions are accessible by pressing the SELECT key Fault Detection If a fault condition is detected by the HG2 the red Filter Disabled LED will turn on and the Fault Alarm relay will be energized The green Filter Enabled LED will turn off and the contactor in the HG7 will disconnect the filter The display will show a Fault Code F001 to F31 as listed in Table 6 In order to minimize nuisance trips time delays are applied to some fault conditions as indicated in the table When the fault condition has been corrected press the UP and SELECT keys simultaneously to clear the fault When the fault reset clear time has expired the red Filter Disabled LED will turn off and the Fault Alarm relay will be de energized The green Filter Enabled LED will turn on the contactor will connect the filter and the display to the selected Operating Parameter In a system with multiple units any unit may detect a fault and shut down the whole system The other units in the system will display F01 External Fault and turn off The fault may only be cleared by POWER MONITOR OPTION 33 HG7 1 amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwt
27. BLEEDER RESISTORS TERMINAL BLOCK ON PANEL Beebe cbs ololololololololo o TBa TBa 1 NOTE 1 Fan La FOR PROPER OPERATION 4 SEE NOTE 1 T CONNECT AUXILIARY RUN RELAY CONTACT FROM DRIVE TBa 2 CONTACTOR COIL Customer supplied connection INTRODUCTION 19 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION HG7 XM Schematic 7 5 60 HP based on 480V 480V Ti 60 HZ T2 LOAD LINE BLOWN FUSE LIGHT TYP 3 PLCS RED LIGHT ih Gu LT4 A SHOWN L1 DETAIL FutalOaD Fa2aLOAD Fela LOAD TBal I ji RIO WE Xi GRD m wag RI SOLDERED TO LEAD ANO COVERED WTH HEAT SHRINK TUBING Paue BLOWN FUSE LIGHTS FOR PROPER OPERATION CONNECT AUXILIARY N O L RUNRELAYCONTACT T TRAP ENABLED FROM DRIVE uw terval CONTACTOR memo COIL LT2 W TB14 GREEN LIGHT R2 TRAP ENABLED USE MINIMUM 60 C COPPER WIRE HG7 XM Schematic 200 400 HP based on 480V CUSTOMER CONNECTIONS INTO HARMONIC FILTER Disco bid T2 CUSTOMER LINE 9 FOR PROPER OPERATION CONNECT AUXILARY N O RUN RELAY CONTACT FROM DRIVE CUSTOMER SELECTED OPTIONS x TEE JUMPERED AT FACTORY pA om B1 1 B28 TB2 6 a IF USED NC AMBIENT ANA Do nur ezsa T8242 TR1a SENSE COILS sw sw Y T 6 T813 T814 T812 T
28. TRODUCTION 5 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Installation Guidelines Mounting The HG7 must be mounted vertically on a smooth solid surface free from heat dampness and condensation Wiring Cable Entry Locations The enclosed HG7 harmonic filters are not provided with enclosure wiring knockouts A selection can be made at the time of installation Typical or recommended cable entry locations are shown in the drawings section of this manual Field Wiring Connection Terminals Compression type terminals are provided for all field wiring connections The control circuit terminals will accommodate 18 AWG to 10 AWG wire and should be tightened to 7 Ibs in torque The wire size capacity ranges and tightening torque for the grounding and power terminals are listed in the drawings and other information shipped with the unit INTRODUCTION 6 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Grounding The HG7 panel equipment grounding lug must be connected to the ground of the 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 integ
29. an existing control cabinet drive cabinet motor control center or other large enclosure the reactor should be mounted in the lower half of the cabinet to prevent hot spots or pockets of heat Locating the reactor in the lower half of the cabinet typically allows better thermal dissipation and heat convection Reactors with ducts should be mounted vertically for proper cooling COMPONENT PACKAGE OPTION 49 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com COMPONENT PACKAGE OPTION CP Field Wiring Information Below is the typical wiring diagram for the 3 phase reactor applied to the front end of the Variable Frequency Drive VFD Single phase applications are acceptable however it is important to size the unit based on the single phase Full Load Amperage of the VFD The input and output connections should be on terminals A and C to ensure proper performance WIRING DIAGRAM LINE QVO LINE REACTOR PPLICATIONS USE FOR SINGLE PHASE COILS A AND C INSULATE TERMINALS BT AND B2 T gt COMPONENT PACKAGE OPTION 50 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com
30. ault F11 is associated with fuse Fu1 a F12 is associated with fuse Fu1 a and F13 is associated with fuse Fu3 a Check the fuses and replace any that have cleared with known good fuses of the same type and rating Check for signs of a short circuit Restart the filter and verify that the filter currents are at the proper levels Caution Troubleshooting with the filter energized means there are hazardous voltages present Only qualified personnel should do this service work If the fuses are good verify the integrity of the contactor The electrical contacts are consumable wear parts and may need service If the contactor is deemed in serviceable condition go to the Setup Procedure on page 34 Step through the parameters and set parameter 11A to 1 exit the setup mode and allow the filter to reenergize in the Calibration Mode Caution When in the Calibration Mode the filter will not automatically disconnect upon recognizing a fault condition Measure currents if lower than the percentage of nominal amount set in 7A an F11 fault will result It is usually an indication of loss of capacitance To locate the faulty capacitor s first verify the proper line to line voltage is present at the terminals of each capacitor If the voltage is correct then measure the current into each individual capacitor If any of the currents are lower than nameplate by greater than 1096 replace the defective capacitor s and verify proper operation The
31. c filters linked via the serial connection The unit detecting the fault will display the appropriate Fault Code while all others in the series will display F01 The fault may only be cleared from the harmonic filter section experiencing the fault Once the fault is cleared the other units will revert to Normal Operation In single board configurations there is a jumper wire installed in connector J1 8 amp J1 10 Troubleshoot by verifying continuity at the Protection Monitor between J1 8 amp J1 10 F02 Door Interlock Fault This Fault Code indicates the optional door interlock switch is open When this option is not supplied there is a jumper wire installed between TB2 7 amp TB2 8 Troubleshoot by verifying continuity between J6 1 amp J6 8 F03 Over temperature Fault This Fault Code indicates the optional over temperature switch open When this option is not supplied there is a jumper wire installed between TB2 5 amp TB2 6 Troubleshoot by verifying continuity at the Protection Monitor between J6 1 amp J6 6 F04 Serial Interlock Fault This fault indicates the serial link between multiple boards is open or wired incorrectly Verify that from board number one J1 8 is connected to board two J1 10 and board two J1 8 to board N J1 10 and board N J1 8 is connected to board one J1 10 thus completing the daisy chain serial loop In single board configurations there is a jumper wire installed in connector J1 8 amp
32. creased harmonic distortion of the power source may have adverse effects on the power distribution system components and other equipment To guard against the effects of increased harmonic distortion consider connecting the HG7 to automatically shut down the drive if a fault occurs The best alternative to shutting down the drive 1s to provide an alarm to personnel who will promptly investigate the problem POWER MONITOR OPTION 27 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Connection Diagram Figure 3 shows the typical wiring connections between the HG7 and the drive Refer to the drawings furnished with the HG7 for more specific information Refer also to the instructions for the drive and other equipment to which the Enable Input and the Fault Alarm contact are connected Figure 3 Typical Connection Diagram For HG7 Harmonic Filters with the Option When connecting input power conductors directly to the input line reactors in the HG7 Option units the conductors must be passed through the current transformers that are provided for use by the HG2 Protection Monitor Units below 75 kVar and above 120 kVar do not have current transformers Control Wiring Connect the HG7 XM Option Filter Enable input terminals 1 and 2 to an auxiliary N O Run contact in the adjustable speed drive Connecting a Drive Aux Run contact
33. cuit Simply use the drive relay run contact provided with the VFD to enable and disable the trap circuit This virtually eliminates the possibility of leading power factor interacting with other devices on the power system and enables the user to perform trap circuit maintenance without shutting down the entire drive system Product Description HG7 STC Option Harmonic Filter The HG7 harmonic filter 1s a drive applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives The HG7 STC option harmonic filter is for 200 208 230 240 460 480 volt and 575 600 volt systems 60 Hz and 400 Volt systems 50 Hz It is suitable for use with 3 phase diode bridge rectifier loads such as PWM AC drives and 3 phase controlled rectifier SCR or thyristor loads such as DC drives The HG7 harmonic filter is a passive filter connected in series with the input terminals of a variable speed drive or several drives that operate as a group It is designed to provide a low impedance path for the major harmonic currents demanded by the drive The filter 1s 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 for mounting within an enclosure with the drive or other equipment The HG7 STC Option consists of the following standard features and components AKDR input series reactor to prevent system interaction
34. cuit and suitable for the rated current and voltage marked on the nameplate of the HG7 filter Clamp on current probe suitable for the rated current and voltage marked on the nameplate of the HG7 filter Clip on voltage probes suitable for the rated voltage marked on nameplate of the HG7 filter Select probes that can be securely clipped on to the test points without shorting between points or falling off Measuring Voltages and Currents To locate the line current filter current and line voltage measurement points refer to the schematic diagram and outline and mounting dimension drawing for the specific unit that will be calibrated Some typical drawings are included at the end of this manual Warning The safest procedure is to attach and remove the voltage and current probes only when power is disconnected from the equipment Capacitors in the HG7 harmonic filter are equipped with bleeder resistors to automatically discharge them to 50 volts or less within 1 minute after power 1s disconnected but the equipment should be considered to be live for at least 5 minutes Calibration Potentiometer Locations The calibration potentiometers are located behind the right edge of the HG2 board as viewed from the keypad side of the HG2 Refer to Figure 5 HG2 Keypad View When viewing the component side of the HG2 board the calibration potentiometers are on the left edge of the board Refer to Figure 6 HG2 Board Component View
35. e speed drives The HG7 XM option harmonic filter is for 200 208 230 240 460 480 volt 575 600 volt systems 60 Hz and 400 volt systems 50 Hz It is suitable for use with 3 phase diode bridge rectifier loads such as PWM AC drives and 3 phase controlled rectifier SCR or thyristor loads such as DC drives The HG7 harmonic filter is a passive filter connected in series with the input terminals of a variable speed drive or several drives that operate as a group It is designed to provide a low impedance path for the major harmonic currents demanded by the drive The filter 1s 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 for mounting within an enclosure with the drive or other equipment The HG7 XM Option consists of the following standard features and components AKDR input series reactor to prevent system interaction and improve filter performance An L C harmonic filter circuit with A TCI 3 phase tuning reactor specifically designed for the HG7 High endurance harmonic rated capacitors Bleeder resistors to ensure safe capacitor discharge upon filter shutdown Filter enable disable contactor with protection and drive interlock provisions The HG2 Protection Monitor and Harmonic Power Factor Meter is included as standard in HG7 XM option filters rated over 20kVar to 120 kVar in capacitance It includes Three characte
36. ection Monitor Setup Parameters and calibration adjustments are factory set and should not be changed except as directed in the troubleshooting procedures Setup Procedure 1 With the power off and no over temperature fault condition hold down all three keys UP DOWN and SELECT while applying power Hold for 5 seconds after power is applied 2 Release all three keys The display will show 000 3 Ifthe security code has not been changed from the Factory Default of 000 go to step 5 4 Ifthe security code is not 000 press the DOWN key to enter the security code for digit one Press the UP key once to select digit two Press the DOWN key to enter the code for digit two Press the UP key once to select digit three Press the DOWN key to enter the code for digit three 5 Press and release the SELECT key The display will show if the code is correct or OFF if the code is not correct If the incorrect code has been entered start over at step 1 6 Press and release the UP key 1A will be displayed 7 Press and release the SELECT key to display the parameter setting 8 When the setting of a selected parameter is displayed pressing the UP and DOWN keys will increase and decrease the setting 9 Press and release the SELECT key to store the setting and return to the menu 10 Press and release the UP key to display the next parameter on the Setup Menu 11 To exit setup use the UP key to step through
37. ectrical installation and maintenance work on the HG7 filter Disconnect all sources of power to the drive and HG7 before working on the equipment Do not attempt any work on a powered HG7 Check to see that the installation environment remains free from exposure to excessive dirt 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 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 and ground wiring connections Troubleshooting Warning Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 harmonic filter Disconnect all sources of power to the drive and HG7 before working on the equipment Do not attempt any work on a powered HG7 harmonic filter The harmonic filter contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before you attempt to service the harmonic filter Check for zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the line side of the fuses
38. er 1A 30 sec Default has expired the display will show OFF When the reset lockout time has expired If the Enable input is open and no fault exists The red Filter Disabled LED will be off The green Filter Enabled LED will be off The display will show OFF If the Enable input is open and there is an external over temperature or serial data fault The red Filter Disabled LED will be on The Fault Alarm relay will be energized The green Filter Enabled LED will be off The display will show F01 F03 or F04 for the respective faults If the Enable input is closed and no fault exists The red Filter Disabled LED will be off The green Filter Enabled LED will be on The contactor will pull in connecting the filter The display will show the value of the selected Operating Parameter If the Enable input is closed and a fault exists Initially the green Filter Enabled LED will be on and the contactor will pull in connecting the filter until the fault is detected Once the fault is detected The red Filter Disabled LED will be on The Fault Alarm relay will be energized The green Filter Enabled LED will be off The display will show a Fault Code F01 to F31 Normal Operation The filter should operate whenever the drive operates When the drive starts a Drive Aux Run contact should close the HG7 s Filter Enable input After the reset lockout time has expired the green Filter Enabled LED will turn on and the contact
39. filter continues to perform to its original specifications replacement parts should conform to TCI specifications Factory Contacts and Tech Support For technical support contact your local TCI distributor or sales representative You can contact TCI directly at 800 TCI 8282 Select Customer Service or Tech Support and have your HG7 harmonic filter nameplate information available INTRODUCTION 13 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Product Description HG7 Drive Applied Harmonic Filter The HG7 is a drive applied harmonic filter designed and developed by TCI to reduce the harmonic currents drawn from the power source by variable speed drives The HG7 is available for 240 480 600 60 Hz and 400 50 Hz volt systems It is suitable for use with 3 phase diode bridge rectifier loads such as PWM AC drives The HG7 is a passive filter connected in series with the input terminals of a variable speed drive or several drives that operate as a group It is designed to provide a low impedance path for 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 for mounting within an enclosure with the drive or other equipment The HG7 filters consist minimally of the following features and components AKDR i
40. g the filter circuit tuning point to shift to or above the designed frequency Line voltages greater than 12596 of the nominal rating Interaction with power factor capacitors on the distribution system resulting in system resonance conditions however not to the level that would cause a fast trip as indicated by the display of F2x fault If the problem is caused by short term 60 seconds operation above rated line current due to normal utilization of the drive s short term overload capacity increasing the time to fault setup parameter 1A may alleviate the problem If F31 F33 faults occur repeatedly in the apparent absence of any of the above problems verify the actual filter current with a current probe suited for true RMS measurements in a harmonic rich circuit Note It may be necessary to inhibit the board from de energizing the HG7 by operating in the calibrate mode However be aware that if excessive currents are indeed present the technician must be able to rapidly remove power from the filter to minimize damaging components or operating the filter fuses If the actual measured currents are within the acceptable levels for the rating of the filter but there are short periods 60 seconds that exceed the trip threshold increasing the time to fault setup parameter 1A may alleviate the problem The factory default setting for the Filter Over current Delayed Trip parameter 6A is 16096 of the filter s nominal fundamental cur
41. ilter is 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 Table 2 HG7 Harmonic Filter Technical Specifications Store the unit in its original packaging INTRODUCTION 4 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Pre installation Planning Verify the Application HG7 Ratings Make sure that the HG7 harmonic filter is correct for the application The voltage ratings of the filter must match the input voltage rating of the connected drive The horsepower and current ratings of the filter must be adequate for the connected load The kVar rating of the HG7 filter should be 3095 of the horsepower rating for 3 phase diode bridge rectifier loads such as PWM AC drives Select a Suitable Location Environment Locating the HG7 in a suitable environment will help assure proper performance and a normal operating life Refer to the environmental specifications listed in Table 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 The unit must be installed in an area where it will not be exposed to Direct sunlight
42. ing 15 Remove power to the unit to exit the Calibration Mode 16 Restart the filter in the normal operating mode and verify proper operation POWER MONITOR OPTION 43 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Troubleshooting Calibration Problems If during the Calibration Procedure a parameter is missing or non responsive check for proper analog voltage levels at the points indicated in Figure 7 HG2 Connection Details Board Component View Care must be taken not to short circuit between the board test points Warning Line voltage potentials are present on the board If the analog voltage levels are normal and the board cannot be calibrated the board is probably defective Replace the board and perform the Setup and Calibration procedures POWER MONITOR OPTION 44 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY J4 J3 J2 1 HG2 Protection Monitor MESSAGES O OFF Filter inactive C Filter 1 Amps Filter Filter i CH He THD Disabled Enabled c1 Harmonie 1 C5 Harmonic 5 UP DOWN SELECT C7 Harmonic 7 C11 Harmonic 11 C13 Harmonic 13 U Line V Volts UH Harmonie THD U1 Harmonic 1 US Harmonic 5 U7 Harmonic 7 BASIC OPERATION gt 5 7 Le U
43. ipment has been completely and correctly installed in accordance with the Installation Guidelines section of this manual Check to see that the cooling fan s are operating in units so equipped Operation Since the HG7 is a passive filter it is always operating whenever the drive is operating INTRODUCTION 8 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Installation Intended Audience This manual is intended for use by all personnel responsible for the installation operation and maintenance of the HG7 harmonic filters Such personnel are expected to have knowledge of electrical wiring practices electronic components and electrical schematic symbols Additional Information Caution This manual provides general information describing your HG7 harmonic filter Be sure to carefully review the more specific information that 1s 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 requiring 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
44. lt by a qualified UL certified facility Insertion Impedance of the series line reactor 10 at full load current Capacitors Oil filled high endurance design no PCBs COMPONENT PACKAGE OPTION Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 48 HG7 I O amp M Manual COMPONENT PACKAGE OPTION CP Installation Review all Pre Installation and Installation instructions at the beginning of this manual If you are assembling a CP unit in your own enclosure you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating The maximum temperature of the air around the HG7 filter capacitors and Protection Monitor should not exceed 50 C 122 F KLR KDR Line Reactor Installation Instruction Recommendations and Considerations When installing the KLR KDR Line Reactors on the INPUT side of the Variable Frequency Drive VFD please use the following guidelines when wiring the unit The KLR KDR Line Reactor is a 3 phase device and should be wired in series and positioned on the input side of the VFD All Terminal Block connectors will be marked Al B1 and C1 are the input terminals where the 3 phases of incoming power are to be wired As a result A2 B2 and C2 are the output terminals Units with copper bus or ring lug terminals are not marked In these cases either the upper terminals or the lower terminals can be used as the inpu
45. ly 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 at the end of the period described below Product Family Warranty Period KLR KDR For the life of the drive with which they are installed KLC KLCUL KMG One 1 year of useful service Vik not to exceed 18 months from the date of shipment HG7 KH 3H KRF Three 3 years from the date of shipment KCAP KTR KMP Five 5 years from the date of shipment Other Products One 1 year of useful service not to exceed 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 EXPRESS 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 TCT s control including but not limited to improper storage installation operation or maintenance If within the warranty period any product shall be found in TCI
46. mp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY HG2 Protection Monitor Calibration Introduction The HG2 has calibration adjustments which can be used to calibrate the unit s filter current line voltage and line current Operating Parameter displays The HG2 should not be re calibrated unless re calibration is indicated by the troubleshooting procedure or the installation of replacement parts makes re calibration necessary The Calibration Mode is the same as the normal running mode except that the HG2 does not trip in response to fault conditions HG2 Protection Monitor Calibration Procedure Warning Only qualified electricians should carry out all electrical installation and maintenance work on the HG7 Harmonic filter safely working on powered equipment To calibrate the HG2 it is Personnel performing the calibration procedure must be capable of necessary to operate the drive and HG7 filter while measuring actual operating currents and voltages inside the unit When in calibrate mode the filter will not automatically disconnect upon recognizing a fault condition If a fault occurs during calibration the technician must be able to rapidly remove power from the filter to minimize damaging components or blowing the filter fuses Required Equipment AC voltmeter and ammeter or multi meter designed for true RMS measurements in a harmonic rich cir
47. nput Current transformer Sense Coils P connections CN Filter Contactor A 3 37 4 72 VAC N ot nameplate FLA Fault Alarm Contacts Serial connection for coordinating fault trips of several HG2 units ABC N 419 VACA B C 725 VAC Jumpered when not used 5 0 at rated fundamental filter current __ X 1000 Rated Line V X 1 732 Figure 7 HG2 Connection Details Board Component View Replacement Parts If replacement parts are needed please contact your TCI representative To ensure that the HG7 harmonic filter continues to perform to its original specifications replacement parts should conform to TCI specifications Factory Contacts and Tech Support For technical support contact your local TCI distributor or sales representative You can contact TCI directly at 800 TC1 8282 Select Customer Service or Tech Support and have your HG7 harmonic filter nameplate information available POWER MONITOR OPTION 46 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com COMPONENT PACKAGE OPTION CP Component Package Option CP CP Option Models The HG7 CP Option is a harmonic filter component package designed and developed by TCI to allow qualified customers to build harmonic filters to reduce the harmonic currents drawn from the power source by variable speed drives The HG7 CP Option is available for 200 208 230 240
48. nput series reactor to prevent system interaction and improve filter performance An L C harmonic filter circuit with A TCI 3 phase tuning reactor specifically designed for the HG7 filter High endurance harmonic rated capacitors Bleeder resistors to ensure safe capacitor discharge upon filter shutdown Cooling fans on select models to ensure adequate cooling and safe operating temperatures Compression terminals for ease and integrity of all power and control wiring Fuses to protect caps from over current Nameplate Data Figure 1 shows a typical HG7 harmonic filter nameplate The following information is marked on the nameplate X Part number encoding is explained on the following page the rated continuous operating current RMS amps System Voltage the rated 3 phase line voltage RMS volts Hz the rated frequency 60 Hz 50 Hz Phase 3 The HG7 filter is designed for use only with 3 phase power Drawing outline and mounting dimension drawing number Schematic schematic diagram drawing number Manufacturing for TCI internal use Enclosure Type UL designation or Open panel construction Figure 1 Typical HG7 Harmonic Filter Nameplate Milwaukee WI Part Number HG15AWO1ST FLA 21 System Voltage 480 Hz 60 Phase 3 The Leader in Power Quality Solutions and Support HarmonicGuard Series Short Circuit Current 10kA rms symmetrical 480V maximum
49. or in the HG7 XM Option will connect the filter The display will show the value of the selected Operating Parameter When the drive stops a Drive Aux Run contact should open the filter s Enable input The green Filter Enabled LED will turn off and the contactor in the HG7 will disconnect the filter The display will show OFF Changing the Displayed Parameter During operation the HG2 displays the value of the selected Operating Parameter The Operating Parameters are listed in Table 5 When the UP or DOWN key is pressed and immediately released the display shows the parameter name for approximately 1 second and then reverts to displaying the parameter value To change to the next or previous parameter press the UP or DOWN key and release the key as soon as the parameter name changes Holding down the UP or DOWN keys will scroll through parameters forward or backward respectively When the SELECT key is pressed and immediately released the display shows L 1 L 2 L 3 L A or Lr for approximately 1 second and then reverts to displaying the parameter value L A POWER MONITOR OPTION 32 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY indicates that the displayed value is the average of the individual phase values L 1 L 2 amp L 3 indicate the display of individual phase values L r indicates that the displayed value i
50. r LCD display Filter Disabled and Filter Enabled status indicating LEDs UP DOWN and SELECT keys Fault Alarm Relay with form C contact for customer use Filter Enabled and Blown Fuse indicating lights are included as standard in filters rated 20 kVar and under or over 120 kVA in filter capacitance rating Cooling fans on select models to ensure adequate cooling and safe operating temperatures Control transformer for fan and control voltage power Compression terminals for ease and integrity of all power and control wiring POWER MONITOR OPTION 25 HG7 1 amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Product Technical Specifications Table 3 lists the major technical specifications for the HG7 XM Option filter product Table 3 HG7 XM Option Harmonic Filter Technical Specifications Voltage ratings 240 480 and 600 V 3 ph 60 Hz 400 V 3 ph 50 Hz kVar ratings 3 to 120 kVar 140 to 270 kVar depending on voltage See Rating and Dimension tables Load types 3 phase diode bridge rectifier loads such as PWM AC drives Load power range 7 5 400 HP 500 900 Hp depending on voltage See Rating and Dimension tables Current ratings The included series reactors can tolerate 200 of rated current for at least 3 minutes SCCR short circuit current Standard rating is 10 rating Maximum elevation 3 000
51. r R68 to match the voltmeter reading If the neutral is not accessible then connect between L1 and L2 and calculate the line to neutral voltage 8 Press the SELECT key to select L 3 With a voltmeter connected between L3 and neutral adjust potentiometer R94 to match the voltmeter reading If the neutral is not accessible then connect between L1 and L3 and calculate the line to neutral voltage 9 Press the SELECT key to select L 1 Recheck the L 1 setting and readjust if necessary Recheck the L 3 setting readjust if necessary since there is some interaction between R68 and R94 There is no adjustment for L 2 10 Press the UP key to select parameter A Line Current 11 The drive should be running while performing the Line Current calibrations For optimum accuracy the actual current as measured with an ammeter should be more than half the unit s rated current Due to the low resolution of the A D converters the display readings are not intended to be used for certification purposes 12 Press the SELECT key to select L 1 With an ammeter current probe on source line L1 adjust potentiometer R52 to match the ammeter reading 13 Press the SELECT key to select L 2 With an ammeter current probe on source line L2 adjust potentiometer R53 to match the ammeter reading 14 Press the SELECT key to select L 3 With an ammeter current probe on source line L3 adjust potentiometer R54 to match the ammeter read
52. r com Email info clrwtr com POWER MONITOR PACKAGE ONLY resetting the unit that detected the fault condition The other units in the system will be clear automatically when the faulted unit is reset Table 6 Fault Code Display Fault Code Fault Description F01 External Fault multiple boards in a series line F02 Door Open In Run Mode no delay F03 Overtemp 6 sec delay F04 Serial Data Fault 8 sec delay F11 Filter Current Low Trip Line 1 20 sec delay F12 Filter Current Low Trip Line 2 20 sec delay F13 Filter Current Low Trip Line 3 20 sec delay F21 Filter Overcurrent Fast Trip Line 1 F22 Filter Overcurrent Fast Trip Line 2 F23 Filter Overcurrent Fast Trip Line 3 F31 Filter Overcurrent Delayed Trip Line 1 delay set by parameter 1A F32 Filter Overcurrent Delayed Trip Line 2 delay set by parameter 1A F33 Filter Overcurrent Delayed Trip Line 3 delay set by parameter 1A Setup Parameters Introduction The Setup Parameters are used to enter the nameplate data required for matching the HG2 to the HG7 harmonic filter ratings Fault trip levels and delay times are also adjustable A security code can be entered to prevent unauthorized access to the Setup Menu The Calibration Mode is accessible through the Setup Menu See HG2 Protection Monitor Calibration Table 7 describes the Setup Parameters indicates the adjustment ranges and lists the factory default settings The Prot
53. rent rating as determined by the filter s kVar frequency and voltage ratings parameters 3A 4a amp 8A It may be acceptable to increase the slow trip parameter setup 6A However it is recommended that you consult the technical support department at the factory if this becomes necessary Troubleshooting Units Equipped with Pilot Lights Units rated 20 kVar and less or over 120 kVar have Blown Fuse and Filter Enabled pilot lights to indicate their operating status and are not equipped with the HG2 Protection Monitor as standard Troubleshooting information for units equipped with the HG2 Protection Monitor is provided in the previous section under the heading Troubleshooting Units Equipped with the HG2 Protection Monitor Filter Enabled Pilot Light The Filter Enabled pilot light indicates that the Filter Enable input is closed Blown Fuse Indicating Pilot Lights If a Blown Fuse Indicating pilot light is illuminated the corresponding fuse Ful a Fu2 a or Fu3 a has blown These fuses protect the three phase HG7 filter power circuitry Check for damaged components or wiring in the filter power circuit Check for discolored or burned components and deformed or leaking capacitors Damaged components can be caused by overheating Check to see that the ambient temperature is not excessive and make sure that the unit is receiving an adequate flow of cooling air Check the fan if the unit has one POWER MONITOR OPTION 41 HG7 I O a
54. rity of all ground connections should be periodically checked Power Wiring 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 For units rated less than 100 amps use wire with an insulation temperature rating of 60 C or higher For units rated 100 amps or more use wire with an insulation temperature rating of 75 C or higher Connect three phase power of the appropriate voltage and current capacity to the branch circuit protective device to the HG7 input power terminals Note in large units the input power conductors are connected directly to the input terminals on the line reactors Connect the output terminals of the HG7 to the input power terminals of the adjustable speed drive Note in large units the output power conductors are connected directly to the output terminals on the line reactors Refer to the adjustable speed drive installation instructions for additional information INTRODUCTION 7 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION HG7 Harmonic Filter Operation Caution Thoroughly check the installation before applying power and operating the equipment for the first time Before Applying Power for the First Time Inspect the installation to make sure that all equ
55. rvicing the HG7 harmonic filter If neglected physical injury or death may follow or damage may occur to the filter or equipment connected to the HG7 harmonic filter The material in this chapter must be read and understood before attempting any work on or with the product The HG7 harmonic filter is intended to be connected to the input terminals of one or more adjustable speed drives Three phase power is connected to the input terminals of the HG7 and power is supplied to the drive or drives through the HG7 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 ofthe 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 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 statements highlighted by the following symbols Warning Dangerous Voltage Warning warns of situations in which a high voltage can cause physical injury and or damage equipment The text
56. s the total of the phase values To change the L selection press and hold the SELECT key to scroll to the desired selection The L 1 L 2 amp L 3 selections are available for all of the parameters The L A selection is available for Filter Current C Line Voltage U Line Current A and Power Factor PF The L r selection is available for Real Power P and Apparent Power UA Table 5 Operating Parameter Display er eg Parameter Value Parameter Value ame ID OFF Not in run and no faults A Line Current total RMS amps C Filter current total RMS amps AH Line harmonic current distortion 9o THD CH Filter harmonic current distortion A 1 Line 1st harmonic current 96 THD fundamental RMS amps C 1 Filter 1st harmonic current A5 Line 5th harmonic current fundamental RMS amps RMS amps C5 Filter 5th harmonic current AT Line 7th harmonic current RMS amps RMS amps C7 Filter 7th harmonic current A11 Line 11th harmonic current RMS amps RMS amps C11 Filter 11th harmonic current A13 Line 13th harmonic current RMS amps RMS amps C13 Filter 13th harmonic current P Real Power kW RMS amps U Line voltage L N total RMS volts UA Apparent Power kVA L N approx 277 for a 480 volt System and approx 139 for a 240 volt system UH Line harmonic voltage distortion PF Power Factor THD U1 Line 1st harmonic voltage LA
57. t attempt any work on a powered HG7 filter The HG7 harmonic filter drive motor and other connected equipment must be properly grounded After switching off the power always allow 5 minutes for the capacitors in the HG7 filter and in the drive to discharge before working on the HG7 the drive the motor or the connecting wiring It is a good idea 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 INTRODUCTION 3 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INTRODUCTION Receiving Inspection and Storage Thank you for selecting the HG7 Drive Applied Harmonic Filter TCI has produced this filter for use in many variable speed drive applications that require input power line harmonic current reduction This manual describes how to install operate and maintain the HG7 harmonic filter Receiving Inspection The HG7 harmonic filter has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment 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 TCI warrants to the original purchaser on
58. t operate as a group It is designed to provide a low impedance path for the major harmonic currents demanded by the drive The filter 1s 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 for mounting within an enclosure with the drive or other equipment The HG7 Standard consists of the following standard features and components KDR input series reactor to prevent system interaction and improve filter performance An L C harmonic filter circuit with A TCI 3 phase tuning reactor specifically designed for the HG7 High endurance harmonic rated capacitors Bleeder resistors to ensure safe capacitor discharge upon filter shutdown Cooling fans on select models to ensure adequate cooling and safe operating temperatures Control Power transformer on enclosed units requiring auxiliary cooling fans Compression terminals for ease and integrity of all power and control wiring Fuses CONTACTOR amp CPT OPTION 23 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONTACTOR amp CPT OPTION Contactor Option STC STC Option Models This model is identified by the suffix STC in the part number The STC version provides a contactor control power transformer and connection terminals in the filter trap circuit which allows the VFD user to control the use of the HG7 filter s trap cir
59. t terminals as long as the selection is consistent For example if an upper terminal is selected as the input all upper terminals must be input terminals Wiring from the output terminals should connect to the input of the VFD Refer to NEC wiring practices for appropriate wire sizes for your application Power Wiring Only use 75 C copper conductors unless the wire connector 1s marked for AI Cu then the use of aluminum wire is permitted TCI recommends that these reactors be wired and located as close to the front end of the VFD as possible to have the greatest success in both protecting the VFD as well as mitigating line harmonics We recommend this be 10 feet of cable or less In standard 40 C ambient or less installations a clearance of 3 inches on all sides of the reactors and its enclosure is recommended for assisting in heat dissipation and ample wire bending space This is a general guideline for typical applications If the reactor is being installed next to a heat sensitive instrument or control device we recommend reviewing specific requirements or heat limitations Line reactor heat loss information is available in the standard TCI product literature or on the web at Trans Coil website These reactors are designed to be floor mounted or wall mounted Large open style devices should be panel mounted by incorporating a bracket that would act as a shelf to support the reactor and or enclosure When installing an open style device in
60. tection Monitor Patent Pending Doo J KP e Filter Enabled Figure 4 HG2 Protection Monitor Display and Keypad Display and Keypad Figure 4 shows the HG2 Protection Monitor display and keypad Table 4 lists the various component items and describes their functions Table 4 HG2 Protection Monitor Display and Keypad Features x Name Description Function 1 Display LCD Displays OFF when filter is off Displays the value of the selected Operating Parameter Displays Fault Code Fnn when a fault condition exists 2 Filter Disabled Red LED Illuminated when filter is disabled by fault trip 3 Filter Enabled Green LED Illuminated when filter is operating 4 UP Key Press and release quickly to display the name of the Scroll selected parameter Display automatically reverts to 5 DOWN Key parameter value display after 1 second Press and hold to Scroll scroll to desired parameter selection 6 SELECT Key Press and release quickly to display L L A or phase average or total value selection Press and hold to scroll to desired selection POWER MONITOR OPTION 31 HG7 1 amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY General Operation Power Up Sequence For the first 3 seconds after power is applied the display will show 888 After the first 3 seconds and until the reset lockout time paramet
61. the menu past parameter 11 to then press the SELECT key POWER MONITOR OPTION 34 HG7 1 amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com P 12 OWER MONITOR PACKAGE ONLY Youcan step through the menu only in the UP direction If you wish to return to an item once you have stepped past it step past without pressing the SELECT key to return to 1A Table 7 Setup Menu Factor ricis Description Range Default Setting Enter Exit Factory Setup Mode 1A Fault Delay Time 1 60 SEC 30 2A Restart Lockout Time 1 60 SEC 30 3A Filter KVAR Rating Nameplate 3 0 120 KVAR Nameplate 4A Operating Frequency Nameplate 50 or 60 Hz Nameplate 5A Fast Trip Overcurrent Set 100 199 180 6A Slow Trip Overcurrent Set 100 199 160 TA Low Trip Undercurrent Set 1 100 80 8A Nominal Line to Line Voltage Nameplate 200 600 VOLTS Nameplate 9A Line Current Rating Nameplate 0 or 5 480 AMPS Nameplate 10A Security Code 000 999 000 11A Calibration Mode 0 Normal Operation 0 1 Calibration Mode Changing the Security Code The factory default security code is 000 To change this code enter the Setup Menu and proceed as follows 13 14 15 16 17 18 19 20 21 22 23 24 Use the UP key to step to parameter 10A Press and release the SELECT key The present securi
62. tion Monitor check to see that the HG2 operates as described in the HG2 Power Up Sequence For units equipped with pilot lights the Blown Fuse lights should be off The Filter Enabled light should be off unless the Enable Input has been jumpered rather than connected to a Drive Aux Run contact Check to see that the cooling fan s are operating in units so equipped POWER MONITOR OPTION 29 HG7 I O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY The HG2 Protection Monitor Introduction Product Description The HG2 Protection Monitor is included as standard in HG7 XM Option models rated over 20 kVar The HG2 monitors the HG7 operation electronically protects the power circuits displays performance information and provides a control interface with the drive and or supervisory control system A three character display is provided with UP DOWN and SELECT keys and two status indicating LEDs The HG2 includes analog inputs for monitoring the line voltage and current and the current in the harmonic filter Current transformers are included in HG7 XM Option harmonic filter units to provide the line current inputs Sense windings from in the tuning reactor provide the source for the current measurements Voltage is measured through direct input to the HG2 The HG2 Protection Monitor provides a local display for power monitoring at the point where
63. ty code will be displayed Use the DOWN key to change digit one to the first digit of the new code Press the UP key once to select digit two Press the DOWN key to change digit two to the second digit of the new code Press the UP key once to select digit three Press the DOWN key to enter digit three to the third digit of the new code Press the UP key once and the original code will be displayed Repeat the steps 3 to 7 to enter the new code a second time After completing step 7 press the SELECT key If the new code has been properly entered twice the display will show 10A and the new code will be saved If the two entries of the new code did not agree err will be displayed Press any key and the display will show 10A If you press and release the SELECT key you can see that the code remains unchanged You can start over at step 3 NOTE If the code is changed and the new code is lost you will no longer have access to the Setup Menu The unit will have to be returned to the factory to be reprogrammed to the default security code POWER MONITOR OPTION 35 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY Troubleshooting Units Equipped with the HG2 Protection Monitor The HG2 Protection Monitor and Harmonic Power Factor Meter is included as standard in HG7 XM option filters rated over 20 kVar
64. will automatically connect the HG7 whenever the drive is running If a jumper is connected between terminals 1 and 2 the HG7 will be connected whenever the drive branch circuit power disconnect device is closed Connect the HG7 Fault Alarm relay contacts to the appropriate fault monitoring circuit It may be connected to the drive or to some supervisory control or alarm annunciation equipment The fault contact is part of the HG2 Protection Monitor which is provided as standard in HG7 XM Option units larger than 20 kVar POWER MONITOR OPTION 28 HG7 O amp M Manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com POWER MONITOR PACKAGE ONLY HG7 XM Option Operation Adjustments Protection Monitor Settings The Protection Monitor Setup Parameters and calibration adjustments are factory set and should not be changed except as directed in the troubleshooting procedures The protection monitor is described in detail in the following section of this manual Start Up Commissioning Caution Thoroughly check the installation before applying power and operating the equipment for the first time Before Applying Power for the First Time Inspect the installation to make sure that all equipment has been completely and correctly installed on accordance with the Installation Guidelines section of this manual Before Operating the Drive for the First Time For units equipped with the HG2 Protec
65. wtr com COMPONENT PACKAGE OPTION CP Product Technical Specifications Table 9 lists the major technical specifications and intended environments for the HG7 Harmonic Filter components Table 9 HG7 CP Option Harmonic Filter Components Technical Specifications Voltage ratings 240 480 and 600 V 3 ph 60 Hz 400 V 3 ph 50 Hz kVar ratings 3 to 270 kVar depending on voltage See Rating table Load types 3 phase diode bridge rectifier loads such as PWM AC drives Load power range 7 5 900 Hp depending on voltage Series Reactor Current ratings The included series reactors can tolerate 200 of rated current for at least 3 minutes SCCR short circuit current rating Standard rating is 10kA Maximum elevation for all components 3 000 feet 1 000 meters as standard Product must be equipped with special cooling provisions for operation above this altitude Maximum ambient operating temperature 50 C 122 F Open Panel 40 C 104 F Enclosed Panel Product must be equipped with special cooling provisions for operation above this temperature Maximum ambient storage temperature 60 C 140 F Maximum humidity operating or storage 95 non condensing Agency approvals or certifications on components All components are UL component recognized and can be used to develop a cUL Listed to UL508A and CSA C2 2 No 14 system when designed and bui

HG7 Series Filter Installation, Operation, & Maintenance Manual

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HG7 Series Filter Installation, Operation, &amp; Maintenance Manual

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HG7 Series Filter Installation, Operation, & Maintenance Manual