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HarmonicGuard Series Bus-Applied Active Harmonic

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1. mente 88 ERU 88 M LC DL D Au EAD 66 Wiring 89 01 9 RN NU RT 93 93 IE RSS eue s EP 93 94 I 95 ERO 119 M LED TRE M M 119 Clock Battery __ ___________ 119 dr Upe rade 119 120 Active Filter gt ___ ___6___ _ 6__ _6____ ____ _ 120 I tertace Module PFO DICH ___ 6 6 _ _6__6____ __ ____6___ ___6 120 O UH a 121 Troubleshooting Flow 121 95545555 54 5 2 24528 2258528 2584628422285 25522288 8 2224528 2258 122 Appendix Installation 5 5 55 000 0 0000 122 Appendix E
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3. 18 Part Numbering System 480V Open amp Type 1 50 19 3 4 5 Comimunicattons Part 0061 20 3246 Pedestal Part UT 20 Standard Product Ratings and Dimension Tables eee eee eee eee ee eee eene eee e eese teet eee eese e esses esse 21 Bee Mh er 21 cc LI er MI n E 22 ASOV SO 23 0 144 24 Pre mnstallation Planning 24 1 CaO 0 S 24 Select Ao Ul eae toe ee 24 24 Mounting am Open Chassis 24 149141 ettet ete TC Ua PET TO een 24 EIS S M 29 MOUN eee See ne 29 MM 29 Current Franstormer asin eae eas eode ba 31 Current Transformer ius coded oo deli out
4. m z5 y E HGA 45 150 AMP PARALLEL CT PLACEMENT Figure 4 8 HGA 45A to 150A 480V Parallel Connection Drawing HGA IOM Manual 34 d Section 4 HGA IOM Manual 885 5007 QU sem 52007 Aaz am E sunu 50 1 T jons cx sm wT 1 eon g 2184 yy E mog ju E ERIS dee T 1 LNAWSAIV Id 12 15 OGI OL 57 Figure 4 9 HGA 45A to 150A 480V Master Slave Connection Drawing HGA IOM Manual 35 fa Section 4 IOM Manual Table 4 5 HGA 45 to 150 Amp Parallel Wiring Requirements Torque In lbs Nm Size 30 to 12 Awg torque 4 4 5 Nm 57 7 57 1 Wiring should be 75 or higher insulated copper with the appropriate voltage and current rating 2 Chassis ground must be connected to the ground of the premises wiring system in accordance with NEC and local codes Connection must be made using a wire conductor 3 Customer is responsible for branch circuit protection Terminal 1 125 wire range is 30 45 Awg tightening torque is 4 4 in lb 5 Nm 5 Operating current transformers with the secondary winding open can result in a high voltage across
5. a 32 HarmonicGuard Active Filter Operation 51 kc ME 51 Sart UP COMMISSIONS 51 AN OC AE OM cede una 51 2 52 52 Service elected 52 ER ces _ __ _ ____ 52 Troubleshoot Ojo oem E 58 Troubleshoot 60 C omponent cau aioe 61 Replacement Rue ME EE 63 Factory Contacts and Technical SUppott a 63 Outline and Mounting Dimension Drawings sssssccccssccsccccccssssssssssssssssssccscccccccccccsscccssssssssscsssescccccescssssssssees 64 E aa 86 A eS 86 Installation Guide ties Tode eges 220 Caio e aa Orso CUNEO aa 88 UB S E
6. gt Eorces ojo o OF 0 0 00 00 00 00 00 00 O O O o o o FP O O O O o o or Ff e O O O O O o HP O O o o Figure 9 18 Ladder Diagram Observing HMI Status HGA IOM Manual 140 HGA IOM Manual Section 9 Appendix Quick Start Unit Software Setup for HMI Revisions H and Earlier Be sure to read understand and follow all safety instructions Only qualified electricians should carry out all electrical installation and maintenance work on the HarmonicGuard Active HGA filter All wiring must be in accordance with the National Electrical Code NEC and or any other codes that apply to the installation site Disconnect all power before working on the equipment Do not attempt any work on a powered HGA filter The HGA filter drive motor and other connected equipment must be properly grounded The HGA filter may receive power from two or more sources Three phase power is connected to the main input terminals of the HGA filter All of these sources of power must be disconnected before working on the HGA filter After switching off the power always allow 5 minutes for the capacitors in the filter and in the drive to discharge before working on the HGA filter the drive the motor or the connecting wiring It is good practice to check with a voltmeter to make sure that all
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9. Connection Detail 23451617 8 Converter See Note 2 3 Phase AC Power Optional See Note 1 a See Note 4 See Note 4 Figure 4 5 Load Connection Diagram Note 1 Wiring should be 75 C or higher insulated copper with the appropriate voltage and current rating 2 Chassis ground must be connected to the ground of the premises wiring system in accordance with NEC and local codes Connection must be made using a wire conductor 3 Terminal 1 amp J25 wire range is 30 12 AWG tightening torque is 4 4 IN LB 0 5 NM 4 Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment Current Transformer Installation For accurate sensing of the load it is important that the load sensing current transformers are properly installed Warning All electrical installation and maintenance work on the HGA should be carried out by qualified electricians only Failure to follow standard safety procedures may result in death or serious injury Do not attempt any work on a powered HGA Disconnect all sources of power to the drive and HGA before working on the equipment Check for zero voltage between all phases of the input and output lines Operating current transformers with the secondary winding open can result
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12. 2 Transformer Converter See Gannection De tall _Seetion Figure 4 14 HGA 39 78 Amp 600V Volt Load Side Connection Drawing HGA IOM Manual 42 27 HGA IOM Manual Section 4 HGA 39 78 AMP GOOV MASTER SLAVE CT PLACEMENT memen Source Garr Loads al Pe Hote 72 _ fee Conmecdon Ital E Cenverter HF haster Filter Connec tlan Detall 1 Filter Connection 0 Figure 4 15 39 78 Amp 600V Master Slave Connection Drawing 43 Manual Section 4 IOM Manual Table 4 7 HGA 39 to 78 Amp 600 Volt Parallel Wiring Requirements Ground Lug Chassis Size Torque In lbs Nm Breaker IC Torque In Ibs Nm 39 to 78 Amp 14 2 0 AWG 180 20 3 14 2 0 AWG 180 20 3 39 to 78 Amp 14 2 0 AWG 70 7 9 22 kA 14 1 0 AWG 70 7 9 39 to 78 Amp 2 4 0 AWG 250 28 2 25 kA 2 4 0 AWG 250 28 2 39 to 78 4 AWG 350 250 28 2 65 kA 4 AWG 350 MCM 250 28 2 3910 78 6 350 274 31 100 kA 6 AWG 350 MCM 274 31 Control Wire Size 30 to 12 Awg torque 4 4 in lb 5 Nm Notes Wiring should be 75 C or higher insulated copper with the appropriate voltage and current rating 2 Chassis ground must be connected to the ground of the premises wiring
13. 2590 paddas S 50 Buprunay 105 pu er oM am Roms EC Sec t ee B 1914 fee HET 150 seq 29114 SAV Figure 5 15 600V 150 Amp Open Filter Open Transformer 70 HGA IOM Manual Section 5 HGA IOM Manual AJADI awos BUY pajuso en j3 upjnaus AGL 4 243 er j upjncus 4 Buono S5047 uada D Add Af T pee ET md GES 181114 aar BET ood mo rr emn HE E 195401 Bujgonoy dung 3l Bujanu annua 3500 papddrns EC SE SITE H 1 Tz aas ELDIE Suits BRIS 87 Figure 5 16 600V 150 Amp Type 1 Filter Type 1 Transformer HGA IOM Manual 71 HGA IOM Manual Section 5 ding 351 12 gt ood ero 481114 AADI awus ren FWA OWS UH HE E
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15. Fede File MO m Setup Screen DOUG Figure 9 5 Ladder Logic Diagram Data file MG 12 is a message file containing 2 elements 0 and 1 e The Message Structure settings are shown in Figure 9 6 write command and Figure 9 7 read command MSG MG12 0 1 Elements 3 General MultiHop send Data Receive Data This Controler Channel Ignore if timed out TO xe i timed out Communication Command Break Connection BK 0 Send Awaiting Execution EW 0 Size in Bytes Receive Send Error ER n Target Device Message done DM 1 Message Timeout Message Transmitting sti n Message Enabled EM Local Remote Extended Routing Info 1 EE Service Service Code hex Eror Class hex dec Instance hex dec Attribute hex dec Errar Description errors Figure 9 6 Message Structure Write Command Settings 7 127 Manual Section 9 HGA IOM Manual MSG MG12 1 1 Elements 45 This Controller Control Bits Channel if timed 0 Communication Command Generic AES Connection BK n Data Table Address Receive Awaiting Execution Ew 0 Size in Bytes Receive Se
16. 65 70 Eaton 100 00 No breaker 01 ABB 65 Line Load Control 0 Line Control Master Software Load Control Slave Software Default Option 0 Default Option Not available for Open Chassis units Only available for Open Chassis units Figure 3 3 HarmonicGuard Active Part Number Encoding Manual 16 HGA IOM Manual Section 3 HGA Part Numbering System 480V Type 12 amp 3R Temperature 40 C Current 50 100 150 200 300 Voltage 480 Enclosure UL Type 12 amp 3R Figure 3 4 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be 5150 12 0110 This designates an enclosed HarmonicGuard Active filter that is rated for 100 amps 480 volts and has an HMI Interface Module Package 5150 12 0110 H5 Prefix 2 Current Rating 50 100 150 200 300 Voltage Rating A 480 Filter Enclosure 12 UL 12 03 UL 3R 150 200 3R UL 3R 50 100A amp 300A Package Option H Interface Module no display if 3R Circuit Breaker 20 100 40 65kA 50 100 60 Eaton 65kA 70 Eaton 00 00 No breaker 01 ABB 65kA Line Load Control 0 Line Control Master Software Load Control Slave Software Default Option 0 Default Option Not available for UL Type 12 units Only available for Open Chas
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18. VE S 415 outuaa 12 O 9 aaq Figure 5 18 480V 45 50 90 and 100 Amp Open Chassis HGA IOM Manual 73 HGA IOM Manual Section 5 WS MOUIAW nap 49 AoW ayowau 04 2500 51 apog 195 204 421 4 16 21 753398 Qc2 G 550 024 19401 8 591 19 92 apop 195 5 4424 g amp pBg4 571 02062 24049425 SHUM DAT zur 980 88 dip 10320 ag dol OTE OTF v woad 21025 Y 19380 69 by 06 419 apis 48 277 EXP 172419 2euuo 9123 5 Oujda 13 sapis 4408 5301 511 Ma A 14044 Figure 5 19 480 150 Amp Open Chassis 74 HGA IOM Manual Section 5 HGA IOM Manual Buyjoos 404 saps 4104 254040912 u2u ytz 69 soy 34 15 3 18 3440j45u04 34444817 28282 0 45 82944834 ual2auuo Jau sn v ESGPpOZ amp 103 20 uno 99
19. save your settings 5 Takes user back to the Tech Setup screen HGA IOM Manual 112 Ta HarmonicGuard Active Section 7 Run Stop Control Setup Sub Screen Allows user to configure control settings NOTE If button is GREEN the option is ENABLED If button 15 BLUE option is DISABLED Control Setup Figure 7 18 Tech Setup Screen Table 7 17 Run Stop Control Setup Screen Elements Screen Element Auto Start Setup Takes user to Auto Start Setup sub screen Relay Start Enable Network Start Enable Power Saver Save Settings This option allows the Active Line Condition to be remotely turned on or off via an external relay J2 on the interface requires a switch closure to stop the converter If the stop button is pressed locally on the HMI Display the Relay Start Enable is automatically set to DISABLED and has to be re enabled manually via the HMI display This option allows the Active Line Condition to be remotely turned on or off across a network connection If the stop button is pressed locally on the HMI Display the Network Start Enable is automatically set to DISABLED and has to be re enabled manually via the HMI display This button opens the power save feature sub screen The power save feature allows the unit to turn off its internal power converter if the system line current drops below a set percentage threshold The Amp threshold depends on the system CTs installed with the
20. 5 6 5 3 2 4 E 220 25 2 6 Vm Note Some circuit breaker door handle kits may require additional internal clearance when mounting an open chassis unit inside an enclosure Consult the circuit breaker manufacturer for any door handle requirements Type 3R Transformer Table 3 7 Type 1 Filter Type 3R Transformer Type 1 Filter Filter Dimensions Inch Heat Transformer Dimensions Loss Inch cm watts HxWxD 60 15 1757 16 39 415 270 24 9 226 20 8 168 4 152 8 44 6 41 6 122 5 63 2 574 52 8 60 15 1757 16 39 640 270 24 9 226 20 8 152 8 44 6 41 6 122 5 632 574 52 8 64 2 31 76 1718 1950 400 30 0 28 26 19 26 150 7000 480 218 163 806 43 6 182 76 2 71 7 48 9 772 32 7 8 2 665 31 4 31 76 19 26 220 10500 722 327 5 196 0 83 46 2 1990 301 6 14 24 144 48 9 Add two inches for disconnect circuit breaker handle HGA IOM Manual Section 3 480V 50 C Table 3 8 Open Chassis i Filter Dimensions Inch cm watts 2676 167 75 8 56 142 2 14 18 36 6 3500 167 75 8 56 142 2 14 18 36 6 Note Some circuit breaker door handle kits may require additional internal clearance when mounting an open chassis unit inside an enclosure Consult the circuit breaker manufacturer for any door handle requirements Table 3 9 HarmonicGuard Active Filter Technical Specifi
21. Figure 8 1 HMI Display Battery Location Software Field Upgrades In the event the HMI Display application software needs to be upgraded the USB host port on the back panel of the HMI Display see Figure 8 2 can be used for field upgrades Software upgrade instructions will be sent with any software updates provided by TCI Back View of HMI Display USB Host Port for Software Upgrades Figure 8 2 HMI Display USB Host Location 119 Manual Section 8 HGA IOM Manual Troubleshooting HarmonicGuard Active Filter Fault If the display indicates a fault has occurred proceed to the fault screen by choosing the Fault menu screen button To see if this is a recurring fault hit the History button from inside the Fault screen To clear a fault press the Reset button from inside the Fault Screen or the Stop button from any screen Only qualified electricians should carry out all electrical installation amp maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered HGA This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before attempting to service the conditioner Check for zero voltage between all Warning terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenan
22. IOM Manual Table 4 8 HGA 150A 600V amp 200 Amp 480V Type 3R Parallel Wiring Requirements 2 Ground Lug Power Terminals Chassis Size Wire Size Torque In lbs Nm Breaker IC Wire Size Torque In los Nm 150 to 200 Amp 14 2 0 AWG 180 20 3 None 14 2 0 AWG 180 20 3 150 to 200 Amp 14 2 0 AWG 70 7 9 22 kA 14 1 0 AWG 70 7 9 Control Wire Size 30 to 12 Awg torque 4 4 in lb 5 Nm 1 Wiring should be 75 C or higher insulated copper with the appropriate voltage and current rating 2 Chassis ground must be connected to the ground of the premises wiring system in accordance with NEC and local codes Connection must be made using a wire conductor 3 Customer is responsible for branch circuit protection Terminal TB 1 and J25 wire range is 30 12 A wg tightening torque is 4 4 in Ib 5 Nm 5 Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment Current transformers should be centered around the conductor Load s have an integral 596 line reactance or equivalent dc bus choke HGA IOM Manual 46 Section 4 HGA IOM Manual 14919 Ayede Hre x00 H 0VOOFCH S42 08 7 TVIDads WALSVW 21 JT 18201 NIBH Sra p ung Ju 2107 12 841 sur 51745 505 4
23. PI le Displ Indicates the magnitude of the samples of the trend plot The scale varies with located on the left side ofthe gach of the trend plots graph Indicates the date and time the right most sample displayed on the screen was taken Right Timestamp Indicates the date and time the left most sample displayed on the screen was Left Timestamp i5 ke Allows the user to scroll through all sample points available in the trend plot data Scroll Bar dE Trend Plot TrendPlotDisplay The historical The historical graph of the value being sampled over time of the value being sampled over time 105 Manual Section 7 HarmonicGuard Active Fault Screen This button takes the user to the Active Fault screen see Figure 7 12 which lists all of the active faults The faults will stay in this list until the Reset or Stop button is pressed or the fault self clears From here the user can also go to the Fault History screen Fault 004 15 24 100008 BUS OVER VOLTAGE 023 15 24 Unit 7 Faulted Figure 7 12 Fault Screen Table 7 11 Fault Screen Elements Screen Element Stop Button Turns off the HarmonicGuard Active filter This button will remove all faults from the list if the fault conditions have cleared Once cleared a fault will still be viewable in the fault history log When a fault occurs the fault screen will display information
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26. 11014 4000 x00 HeoVOOESH S42 008 WALSVW 33 1 HIA Figure 4 17 Main Tie Main 480V 300 Amp HGA IOM Manual 47 Section 4 HGA IOM Manual ine 0 D le Ft 5 DIMENSIONS ARE IN INCHES MM NOTES FREQUENCY RANGE 50 400Hz VECTORS 2 THERMAL FACTOR 1 25 50 1 0 55 DEG 3 INSULATION 10 FULL WAVE 4 CAUTION OPEN SPLIT CORE WITH A TWISTING MOTION ONLY LEAD Dimensions in Inches mm 11 4 31 8 1 1 4 31 8 1 1 2 38 1 1 1 4 31 8 1 1 4 31 8 1 1 4 31 8 1 1 2 38 1 KCTF1600B04 16005 15 06 4 1016 11 4 318 KCTF1600B06 16005 15 06 6 1524 1 1 4 31 8 KCTF1600B08 16005 15 06 8 2032 11 4 31 8 1 1 2 38 1 10 5 266 7 1 1 4 31 8 1 1 4 31 8 KCT3F1600B04 16005 15 06 4 1016 1 1 4 31 8 1 1 2 38 1 6 1 2 165 1 Figure 4 18 Current Transformer Diagram Round Manual 48 27 HGA IOM Manual Section 4 Rectangular SPADE CONN KCTFO500A02 500 5 5 2 3 4 69 9 6 5 8 168 3 5 172 139 7 9 3 8 238 1 1 1 2 38 1 KCTF1000A02 1000 5 9 2 3 4 69 9 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 1 1 2 38 1 KCTF1200A02 1200 5 2 3 4 69 9 6 5 8 168 3 5 1 2 139 7 9 3 8 238 1 1 1 2 38 1 1600
27. 13 Figure 5 12 600V 220 Amp Open Chassis Filter Transformer HGA IOM Manual 67 fa HGA IOM Manual Section 5 1004 10 NOM J48uJ0jSuOoJ443 241 9 84 30 5 uo pa4020 045 9 4 241 apis Sau2ui 9 puo 5120 21 apis apis A9uJO 3 Su 043 243 30 405 903 24 Sau2u 21 o pjnous 94 JO 0 9 1 49uwJO0jSuoJ4 puo 2942 sau2u 21 JO unujuju aq a48u Oujjunou pa4020 aq I S940N 225 4 445941 opis Aq opis 3 2 5 seraq IOULOJSUPI L 19320 Suis unos apis 9203029440 IWH 4a xoaug s rejoq Figure 5 13 600V 39 and 78 Amp Type 1 Filter Type 3R Transformer 68 HGA IOM Manual Section 5 HGA IOM Manual 15950 2014 44 JPA 29 WUD 24 9 jn 221029 29 WIS AGW JS 24 CE 04 spun sunu gp anis epis m aui 10 204S 454
28. 2 97 22 K43u3 OOL BE d J 16 41 arte di 5 2975 uroH Q 14044 2541 Figure 5 23 480V 45 50 90 and 100 Amp 1 Enclosed 78 HGA IOM Manual Section 5 HGA IOM Manual 4034 a23uo4oay 420114 16721 751308 5501 3044 10101 B2or sq 1523 ON 199928 48 04540 83044814 68088 04062 1942420 iS La n a 290 88 034 88 90 01 v 19180 91014 npuog 434 3 44 8435 zu dol apis 14814 ee 4093308 DE 21925 v 90 69 ajpuoH i aman W4OH 5243 4 30434 4 Figure 5 24 480 150 Amp 1 Enclosed HGA IOM Manual 19 HGA IOM Manual WSIUDUIBW ajpuou 480840 LINDUID 404 ajqo2 aj0uaa 404 asoo panddns 5 ajnpoy 4010510 4 5440m 000 5501 1084 10101 Tore 591 5
29. Anybus Communicator Product Line Anybus Communicator AB7007 Table 9 5 Modbus TCP IP Communications Gateway Key Features NECEM MN Profile Support Modbus TCP class 0 class 1 and partially class 2 slave functionality 10 100 MBit twisted pair RJ45 Connection Galvanic Isolation Transformer isolated Ethernet interface TCP IP Settings Web Browser Based Configuration Baud Rate 10 100 MBit auto detect Fully compliant Modbus TCP IP gateway See HMS website Protocol Conformance www hms se for Conformance Test Results Note The optional network Communications Gateway part number and hardware is identical for the Ethernet IP interface and the Modbus TCP IP interface Verify you are referencing the appropriate Appendix section for the network protocol you have selected Wiring Connection of the HarmonicGuard Active filter Interface Module to the end user s upstream Modbus TCP IP network occurs at the RJ45 connection see Table 9 1 on the Communications Gateway The Communication Gateway 15 mounted on the back panel of the Interface Module see Figure 9 8 Back View EtherNet IP Communications Gateway RJ45 Connection to End User Network Figure 9 8 Modbus TCP IP Communications Gateway Location 129 Manual Section 9 HGA IOM Manual Table 9 6 Modbus TCP IP Connector Pinout Configuration To configure the IP address of the Modbus TCP IP communications gateway connect the gateway to the Ethernet
30. Fully compliant EtherNet IP gateway ODVA File Number E 090 Protocol Conformance 10070 See HMS website www hms se for Conformance Test Results Note The optional network Communications Gateway part number and hardware 15 identical for the Ethernet IP interface and the Modbus TCP IP interface Verify you are referencing the appropriate Appendix section for the network protocol you have selected Wiring Connection of the HarmonicGuard Active filter Interface Module to the end user s upstream EtherNet IP network occurs at the RJ45 connection see Table 9 1 on the Communications Gateway The Communication Gateway 15 mounted on the back panel of the Interface Module see Figure 9 2 Back View EtherNet IP Communications Gateway RJ45 Connection to End User Network Figure 9 2 EtherNet IP Communications Gateway Location 123 Manual Section 9 HGA IOM Manual Table 9 2 EtherNet IP Connector Pinout D D Li o1 T _ __2 1 _ 4 5 7 8 Configuration To configure the IP address of the EtherNet IP communications gateway connect the gateway to the Ethernet network then open a web browser window and type in the default IP address of the gateway see Table 9 3 and press enter The Communications Gateway configuration page should load see Figure 9 3 7 Configuration Mozilla Firefox BAR Configuration 192 168 12 253 2 3 E Configurat
31. Manual Section 7 HarmonicGuard Active Table 7 23 Network Interface INPUT Register Map Reg Parameter Name Address Format Description Offset fo 2 7 Network Run Stop command to ls 0 The network Run Stop command allows remote network to send a run command to the HarmonicGuard Active filter The network command input will only be acknowledged if the Relay Run Stop Enable is set to ENABLED on the HMI Display setup screen Pressing stop locally via the HMI Display will set the enable for the Relay Run Stop Enable to DISABLED 9 118 HGA IOM Manual Section 8 Section 8 Maintenance Clock Battery Replacement The HMI Display Real Time Clock is maintained by a non rechargeable battery internal to the HMI Display Change the battery every ten years or as needed The system will continue to function as an active filter with a dead battery but HMI information fault logs and trend plots will not be maintained between power cycles To replace the battery open the battery cover on the back of the HMI Display see Figure 8 1 and remove the old battery Dispose or recycle the old battery in accordance with any applicable national state provincial and local requirements Install new battery and close battery cover Replacement Battery Type 3V Lithium CR2032 x Quantity 1 Back View of HMI Display Battery Cover
32. apis 91 404308 42191 4800 v 19390 054 pg eF UNT Tr Loc 7 Daud 2 97 22 K43u3 OOL BE d J 16 41 arte di 5 2975 uroH Q 14044 2541 4ooq Figure 5 20 480 45 50 90 and 100 Amp 1 Enclosed HGA IOM Manual 75 HGA IOM Manual Section 5 U NAG vI6 ZI 753308 550 1024 10301 10158094 81 90 a4nso 2u3 42811 4 By 50 5140 8 oS26e Assy o1s2pag 19 92 14844102 1 282828 ojdsiq 2a203421u 0 0624 2 4 94942 Vous 02451 T ed SI SUL Cp 40 4 puo sapis uo 2 aunsul 10401490 suv 291 sajou 24 Sau2ul 5 pnpuog doj jpaezey proa A ourn285 aq ISN 123114 M 0 59015 194 uly 14044 i 1045 45491 ADO
33. password protected Tech Setup button opens up application specific setup screens for advanced configuration of the active filter Access to this HMI screen is not need for basic system installation and commissioning If a specialized setup feature is required for your application an authorized filed service representative will provide instruction on those features 111 HGA IOM Manual Section 7 HarmonicGuard Active Harmonic PF Correction Setup Sub Screen Allows for selection of Harmonic and PF correction CT Ratio and system calibration NOTE If button is GREEN the option is ENABLED If button 15 BLUE option is DISABLED HarmoniciPF Correction Setup E Figure 7 17 Tech Setup Screen Table 7 16 Harmonic PF Correction Setup Screen Elements Screen Element Harmonic Correction Enable PF Correction Enable CT Ratio Calibrate System Enable Save Settings Description This option turns the Automatic Harmonic Correction on or off This option is on by default If both harmonic correction and power factor correction are enabled and the HarmonicGuard Active filter is at its maximum capacity the power factor correction will automatically be phased back to allow the system to continue correcting harmonics This option turns the Automatic Power Correction on or off This option is on by default If both harmonic correction and power factor correction are enabled and the HarmonicGuard Active filter is at its
34. 7 17 WAR a 1 Figure 7 16 Tech Setup Screen HGA IOM Manual 110 HarmonicGuard Active Section 7 Table 7 15 Tech Setup Sc reen Elements Screen Element Fault History Clear Clears the Fault History Harmonic PF Correction Setup Password Set This button is password protected Takes user to pop up screen where p passwords can be re configured Run Stop Control Setup Load Settings Save Settings Tech Setup Takes user to Harmonic PF Correction Setup sub screen Outline to follow Takes user to Run Stop Control Setup sub screen Outline to follow This button will restore the user saved settings from non volatile persistent memory A confirmation screen will pop up asking Are you sure you want to load saved settings If Yes is chosen any temporary changes made to the working set point parameters will be lost and the user saved settings will be restored No is pressed the user will be sent back at the Basic Setup screen Are vau sure you want to load saved settings EX This button will save the current working settings to non volatile memory that persist when power 15 removed from the unit To save the current settings choose Yes on the confirmation screen or choose to cancel and go back to the Basic Setup The settings will not be saved if No is chosen Are you sure you want to save your settings 5
35. Ensure that Auto Start En Harmonic Correct En and PWR Fact Correct buttons are off blue color Press Status to navigate to Status screen Press Run to start unit operation 143 Section 9 Filter Status Fun Stopped Line Load Status Filter Current Used Power Factor 0 00 50 Freq 60 0 5 108 Supply Voltage Current 404 Current 0 R ineLoa Power 0 00 Negative Current Plot Factor equals Lag Freq 60 Hz Converter Current P lot V LineALine About Total Current ARMS MIS CIS 734 RADE Heatsink Temp Filter Current Used HGA IOM Manual Section 9 HGA IOM Manual 7 Remove CT shorting bars Press Stop to turn off unit Disconnect power from cabinet o Turn off the built in door breaker AND o Turn off the upstream feeder breaker Warning Lethal voltages may be present Wait 5 minutes for DC bus voltage to drop to safe levels Warning Check for voltage in cabinet with a DMM before working inside cabinet Open the cabinet door and remove shorting bars from CTs connected to TB 1 8 Current polarity 1 e Power up unit From Home screen press Run to turn on unit Press Status to navigate to Status screen Select Vline Iline screen Note Lightly loaded conditions less than 200 CT rating will not have enough current to show up on Iline plot Check that Phase A to
36. HarmonicGuard Active filter The relay start command input will only be acknowledged if the Relay Run Stop Enable is set to Enabled on the HMI Display setup screen Pressing stop locally via the HMI Display will set the enable for the relay start command to DISABLED 120V VAC INPUT 1 8 we Ss an H5 RS485 105272 UER RE V NN 24VOC OPTIONAL Stagt START INPUT 2 1 4 From filter converter RELAY STATUS OUTPUTS Figure 6 3 Interface PCB connections Table Power 8 Communications Terminals Terminal tebe 1 HMI HMI Display For factory use 5485 5 connected 2 Input Power 120 VAC 1 24 VDC B HMI Power Supply 24 VDC m 24 VDC Start Command Start Contact Closure Note The power on back of the HMI display accepts 28 to 14 AWG stranded wire with tightening torque of 4 4 in Ib 0 5 Nm Manual 90 7 HGA IOM Manual Section 6 er 6 2 gm Contacts Terminal Description Tightening Torque EL Common 4 4 lbs in 0 5 Nm 28 14 Awg Normally Open Open 4 4 Ibs in 0 5 Nm 28 14 Awg Normally Open Normally Closed 44lbsin 0 5 Nm 28 14 Awg Normally Open Normally Closed Current Limit 4 4 lbs in 0 5 Nm 28 14 Awg Normally Open Note For
37. If status indicates a Fault press Stop button to reset condition Section 1 7 RuniStop Control Setup Aute Start Limit Setup Humber of faults allowed before auto start is disabled E valuation time freqeuncy of selected faults minutes Turn off Unit and check system CT feedback for feedback CT short or open Filter Status RUN Line Status Fiter Current Used power Factor Freq 60 voltage Current HGA IOM Manual Section 1 HarmonicGuard Active 4 Status screen check Stop F hase to Netral Press Status to navigate to Status screen Volts v 5 ae Volts to expected line voltage 244 Compare Freq to expected line frequency Power Ren rA Current expected to be zero if unit is not running and Factor 1 00 201 inputs are shorted Freq Hz Current lot Flat 5 Phase rotation check Press Phase to Neutral Voltage Plot button Check that the current peaks follow the following sequence from left to right Phase A Green Phase B Blue Phase C Red Equipment is phase rotation sensitive if phase rotation is incorrect power down unit and rewire to adjust phase rotation by swapping two incoming phase connections Warning Improper operation will occur if input voltage phase rotation is incorrect 6 Converter recheck Follow steps in 2 to once again ensure PF Corr
38. Neutral voltage peak lines up with Phase A current use zoom if necessary Check that Phase C to Neutral voltage peak lines up with Phase C current Power system down check installation location and orientation if Phase A plots differ B E significantly from Phase C plots Warning Improper operation and damage may occur if CTs are installed incorrectly 9 Current Polarity 2 Y Navigate to Status screen 480 2422 NES Navigate to Line Load status Gc ARMS Verify that Volts Current Power I THD Power K Watts and V THD match expected values for acus 210 2 power system Power Factor If they do not verify CTs are correctly installed THO 2 3 E Warning 37 1 Improper operation and damage may zal N occur if CTs are installed incorrectly Im ic Manual 144 7 HGA IOM Manual Section 9 10 Final setup Press Setup to navigate to Setup screen Press Harmonic Correct En to enable harmonic correction If unit 18 sized with sufficient capacity to provide power factor correction press PF Correct Press Auto Start En to enable Autostart Warning When Auto Start is enabled unit may operate without operator input e Press Save Settings to save settings and restart converter Let the unit come on automatically about
39. The is designed for use with only 3 wire systems with balanced 3 phase voltage source Drawing outline and mounting dimension drawing number Schematic schematic diagram drawing number Serial for unit tracking purposes Enclosure Type Open UL Type 1 UL Type 3R Germantown WI 53022 Phone 824 8282 one 800 824 828 4 m www transcoil com IND CONT EQ 5HAO Part Number 100 01 0100 Corrective Current 100A RMS Drawing 103382 System Voltage 480 Schematic 26463 01 Hz 60 Serial Number 10000 Phase 3 3 Wire Enclosure Type 1 HarmonicGuard Active Filter Figure 3 2 Typical HarmonicGuard Nameplate 15 HGA IOM Manual Section 3 HGA IOM Manual Part Number Encoding HGA Part Numbering System 480V Open and Type 1 Temperature 40 C Current 50 100 150 200 300 Voltage 480 Enclosure Open Chassis or UL Type 1 Figure 3 3 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be ALC100A01H0010 This designates an enclosed HarmonicGuard Active filter that is rated for 100 amps 480 volts and has an HMI Interface Module Package LC 100A01H 0010 ALC Prefix 1 Current Rating 50 100 150 200 300 Voltage Rating A 480 Filter Enclosure 00 Open Chassis 01 UL Package Option H Interface Module Circuit Breaker 20 ABB 100 40 A B 65kA 50 100 60
40. about the fault including the from left to right across the screen Fault bit mask number Fault timestamp Fault code Fault Trip Entry Display Fault description History Button This button will take the user to the Fault History sub screen where previous faults can be reviewed IOM Manual 106 HarmonicGuard Active Table 7 12 Fault Codes Section 7 2 Desat IGBT Gate Driver Fault Phase A Desat IGBT Gate Driver Fault Phase B Desat IGBT Gate Driver Fault Phase C Non critical Auto Unit N Faulted Fault location indication Fault originated in Unit N where N is in the range 1 to 8 For factory configured parallel systems the unit numbers are sequential ordered from left to right when looking at the front of the system Unit 1 is the left most unit in the system Critical faults flagged with a manual reset require a HMI stop button or run stop switch stop command at the unit to clear Critical faults flagged with a power cycle reset require a manual on off power cycle of the unit to clear 107 HGA IOM Manual Section 7 HarmonicGuard Active Fault History Sub Screen The Fault History sub screen See contains up to 120 entries that mark the onset and clearing of system faults At the onset of a fault condition an entry will be generated in the fault history marked with an O on the left side of the fault entry When a fault clears an entry will be generated in t
41. active filter For example a power save threshold set to 10 with 1000 5 CTs installed would result in the filter turning off if less than 100A of current is measured via the line load CTs The power save feature threshold has a five second on off delay and threshold hysteresis built in to prevent limit cycling of the active filter when the system current level is near the power save feature threshold This button will save the current working settings to non volatile memory that persist when power is removed from the unit To save the current settings choose Yes on the confirmation screen or choose No to cancel and go back to the Basic Setup The settings will not be saved if No is chosen Are YOU sure you want save your settings Takes user back to the Tech Setup screen 113 HGA IOM Manual Section 7 HarmonicGuard Active Auto Start Setup Sub Screen Allows user to configure the parameters necessary to use the Auto Start option NOTE If button is GREEN the option is ENABLED If button is BLUE option is DISABLED Auto 5tart Limit Setup Number of faults allowed Ly before auto start is disabled E waluation time freqeuncs Las of selected faults minutes Start Delay Fault Reset delay Figure 7 19 Auto Start Setup Screen Table 7 18 Auto Start Setup Screen Elements Screen Element Auto Start Enable This option will set the converter to start automatically
42. and 4X Buttons 4X Buttons Waveform zoom buttons will redraw the Waveform zoom buttons will redraw the present data at a different scale data at a different scale VLine amp Waveform Plot Sub Screen The VLine amp Waveform Plot Sub Screen is available to verify the proper installation of the HarmonicGuard Active filter power connections and system current CT feedbacks The waveform plot shows voltage and current feedback for both Phase A and the same plot When the HarmonicGuard Active filter 15 powered but in the stopped state this plot can be used to check for the following e Proper Line Voltage phase rotation e Proper Line Load Current phase rotation e Proper Line Voltage and Line Load Current relative polarity and phase Missing Open Circuit System Current CT Feedback In the event that the HarmonicGuard Active filter performance is degraded the VLine amp ILine waveform plot should be examined as a means to determine if any system connection errors are present Prior to examining the VLine amp Line waveform plot the HarmonicGuard Active filter should be put in the stopped state by pressing stop button in the upper right corner of the HMI screen Figure 7 9 shows the VLine amp Line waveform plot sub screen for a properly connected but non running HarmonicGuard Active filter when connected to a typical non linear rectifier load Note the following characteristics e Phase C voltage Blue
43. by TCI that all power to the HarmonicGuard Active filter be disconnected If you elect to service the HGA by using the circuit breaker to isolate the converter section please take special note of the following warnings Warning Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the and affect performance or destroy sensitive dy electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards Manual 58 HGA IOM Manual Section 5 Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Do Warning attempt any work on a powered HGA This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before you attempt to service the conditioner Check for zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenance and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker including the reactors will stil
44. can be used such as Ethernet IP to implement other protocols see Appendix The input output register maps of the data available from the network interface are available in Table 7 22 and Table 7 23 All input and output registers are two bytes in size and formatted as 16 bit signed integers For the base address of the input and output data sections please reference the connection sections in this manual specific to the configured protocol For the integrated ModbusRTU network interface reference the HMI Display Connection section If an option Communications Gateway is configured reference the appendix Table 7 22 Network Interface OUTPUT Register Map Reg Parameter Name Address Data Values and Description Offset Examples SYS RUNNING Output 0 Running Indicates if the HGA filter is currently running or 1 Idle in the idle state 0 Power Indicates if the filter has input power Not faul SYS FAULTED 2 Output Indicates if the filter is faulted 1 Faulted 0 Nominal Indicates if the HGA filter is running at its Volts RMS V LINE LL RMS 4 Output 480 480 VRMSLL Source Utility Line Phase to Phase Voltage e Range 0 to 1 000 Amps RMS Range 0 to 10 000 100 1 00 Unity PF 95 0 95 Lagging PF i PF Ct 111 Range 99 to 100 0 Network Run Disabled SYS NW START EN 1 Bun En bl d Network Run Stop command enable setpoint 117
45. components 15 available in Figure 6 2 When selecting a mounting location for the unit plan for the routing of commutation and power cable Keep the wiring away from power wires where electrical noise could be induced wiring should conform to the requirements of the National Electric Code NEC and or other applicable electrical codes The length of the communication cable between the Interface module chassis communication port and the HarmonicGuard Active filter power converter module should not exceed 25 feet 7 6 meters 120VAC Input Gateway Front Vlew See Note 4 To To Customer s Chassls Network Communication Port Uptional Display Interface RJ4S PC Board 3 I JS Network J19 e Connection Optional Gateway Current End View Fault Limit Start J22 Input Customer Relay Contacts Figure 6 2 Interface Module Connections 89 Manual Section 6 HGA IOM Manual Interface PCB Connections Most customer connections to the Interface module will be made on the Interface PCB Refer to connection diagrams in Figure 6 3 The details of the power and communications terminals are shown in Table 6 1 Form C relays are available on the Interface PCB these connections are shown in Table 6 2 Four outputs are available on the Interface PCB The relay start command input connection on J22 of the interface PCB allows a contact closure to send a run command to the
46. feedback for A B C phase rotation inverted CT polarity or CT short open Phase A CT Under Current Turn off unit and check system CT feedback for no feedback CT short or open CT Under Current Turn off unit and check system CT feedback for no feedback CT short or open Phase C CT Under Current Turn off unit and check system CT feedback for no feedback CT short or open Reverse CT Current Rotation Phase C Input Under Voltage Turn off unit and check 3 phase AC input voltage wiring for missing phase or low line voltage Manual 116 7 HarmonicGuard Active Section 7 Error Phase CT Polarity Turn off unit and check system CT phase A feedback for incorrect polarity or reverse phase rotation CT Polarity Turn off unit and check system CT phase A and C feedback for incorrect polarity or reverse phase rotation Phase C CT Polarity Turn off unit and check system CT feedback phase C for incorrect polarity or reverse phase rotation Phase Power imbalance Turn off unit and check CT feedback and 3 phase AC input voltage for incorrect polarity or reverse phase rotation Network Interface The network interface on the Interface Module allows basic Run Stop commands and internal status data and can be communicated to and from the HarmonicGuard Active filter The HMI display implements an integrated ModbusRTU slave device for the network interface see the HMI Display Connection section or an optional network communications gateway
47. filter panel equipment grounding lug must be connected to the ground of the premises wiring system The equipment grounding connection must conform to the requirements of the National Electric Code NEC and or any other codes that apply to the installation site The ground connection must be made using a wire conductor Metallic conduit is not a suitable grounding conductor The integrity of all ground connections should be periodically checked Manual 50 7 HGA IOM Manual Section 4 HarmonicGuard Active Filter Operation Adjustments e The HGA has been factory calibrated and thoroughly tested There is no need to make any adjustments Start Up Commissioning Caution 1 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 in accordance with the Installation Guidelines section of this manual Ifitis a floor mount unit check to see that it is securely anchored to the floor e Check the panel and the inside of the enclosure for any foreign objects dirt metal filings wire whiskers and loose hardware Verify that any covers or guards that were removed during installation were reinstalled e Ensure that the unit is properly grounded e Check for properly tightened connections General Operation Please refer
48. in detail in the following sections e Make sure the installation location will not be exposed to direct sunlight excessive vibration corrosive or combustible airborne contaminants excessive dirt or liquids e Select a mounting area that will allow adequate cooling air e Make sure that all wiring conforms to the requirements of the National Electric Code NEC and or other applicable electrical codes e Ground the HMI display by using the grounding terminal Not only does this act as a safety but it also filters out electrical noise e Check all connections and components thoroughly before applying power to the equipment e Check the panel and the inside of the enclosure for any foreign objects dirt and or loose hardware Location Environment The location of the Interface Module should be a suitable environment to assure proper performance and a normal operating life Refer to the environmental specifications furnished in this manual and noted on the drawings with the Interface Module Warning Unless specifically labeled as approved for such use this equipment is not suitable for use in an explosive atmosphere or in a Hazardous Classified Location as defined in article 500 of the National Electrical Code NEC e Display front rated Type 1 amp 4X e Avoid direct sunlight e Avoid corrosive liquids or gasses e Avoid explosive or combustible gases or dust e Avoid excessive airborne dirt and dust Pollution Degr
49. power factor A value of 1 00 indicates Power Factor Display unity power factor A negative power factor indicates lagging power factor Frequency Display Displays the current utility line frequency in Hz Run Stop Button Runs and stops the HarmonicGuard Active filter Converter Button This button will take the user to the Converter Status Sub Screen see Figure 7 4 The Waveform screen buttons will take the user to one of the four real time waveform capture screens Phase to Neutral voltage Line Voltage Line Current Converter current or VLine ILine plot see Figures 7 7 and 7 8 Phase to Neutral Voltage Line Voltage Line Load Current Converter Current and VLine ILine When the user presses the Trend Plots button the Historical Trend Trend Plots Screen screen menu is displayed see Figure 7 9 IOM Manual 96 TQ HarmonicGuard Active Converter Status Sub Screen Section 7 The converter status sub screen shows the present status of the HarmonicGuard Active filter power converter module Link Voltage 749 Oc Heatsink Temp S Filter Current Used Figure 7 4 Converter Status Sub Screen Table 7 4 Converter Status Screen Elements Run Stop Button Runs and stops the HarmonicGuard Active filter Displays the present HarmonicGuard Active filter output corrective current in Amps RMS Displays the internal DC Link Bus voltage of the Ha
50. removable wire entry plate is provided selection can be made at the time of installation Typical or recommended cable entry locations are shown in the drawings shipped with the unit Caution Refer to circuit breaker section on page 52 Field Wiring Connection Terminals Compression type terminals are provided for all field wiring connections The wire size 75 C copper capacity ranges and tightening torque for the grounding and power terminals are listed in Table 4 1 Table 4 3 Refer also to the drawings and other information shipped with the unit A disconnecting means is the responsibility of the customer Table 4 1 480V Example Power Terminal Wire Size Capacity Range and Tightening Torque for ABB Circuit Breakers Ground Lug Power Terminals Torque In Ibs Nm 250 28 2 45 0100 6AWG 20 4560 25kA 00 4 40AWG 250 28 2 250 28 2 274 81 45 5 180 2 45 5 25 10 100 kA 274 3 Rockwell 274 31 274 31 274 31 274 31 274 31 375 42 4 375 42 4 550 62 Wire Size 28 10 14 AWG Torque 44 5 Nm Note The values in this table are representative of ABB switch gear unless otherwise specified For other manufacturer s switch gear please contact TCI 29 Manual Section 4 HGA IOM Manual Table 4 2 600V Example Power Terminal Wire Size Capacity Range and Tightening Torque for Circuit Breakers Ground GroundLug 00000 Power Terminals Torque In Torque In
51. to the ground of the premises wiring system accordance with NEC and local codes Connection must be made using a wire conductor 3 Customer is responsible for branch circuit protection Terminal 125 wire range is 30 15 Awg tightening torque is 4 4 in Ib 5 Nm 5 Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment 6 Current transformers should be centered around conductor 7 Load s have an integral 5 line reactance or equivalent dc bus choke to optimize Active Filter utilization consult TCI for Active filter capacity with less than 5 8 Source CT s are customer installed and external to the active filter Note TB 1 positions 9 10 11 amp 12 are for internal use HGA IOM Manual 40 HGA IOM Manual HGA 39 78 Amp 600 Volt Section 4 HGA 39 78 AMP 600 LINE SIDE CT PLACEMENT Section 2 Transtorner See 174 P n Converter mu letak Section 1 Filter Connection Detall Londs See Note 7 Loads Gee Mote 21 Figure 4 13 39 78 Amp 600V Volt Line Side Connection Drawing 41 HGA IOM Manual Section 4 HGA IOM Manual HGA 39 78 AMP GOOV LOAD SIDE CT PLACEMENT rt Loads See Note 7 d Pup
52. 28282 oi 48385 I 5311 1 Bun an HGA IOM Manual 85 HGA IOM Manual Section 6 Section 6 HMI Introduction The Interface Module provides the user with a convenient way to monitor the operation of TCI s HarmonicGuard Active filter and allows for the ability to adjust run time set points under password control This section describes how to install operate and maintain the Interface Module Overview The Interface Module has three major components the Interface PCB the HMI Display and an optional network Communications Gateway see Figure 6 1 The interface PCB contains a Chassis Communications Port that connects to the power converter of the HarmonicGuard Active filter The interface PCB translates status and commands data between the power converter controls and the HMI Display The interface PCB also contains the 24V Relay I O for basic status monitoring and run stop control of the HarmonicGuard Active filter The HMI Display is a 6 color Touchscreen display containing a series of status screens that provide the user with a convenient way to monitor the operation of the HarmonicGuard Active filter The HMI display also contains an integrated ModbusRTU network connection for remote monitoring of the HarmonicGuard Active filter The optional network Communications Gateway can be connected to the integrated ModbusRTU network connection in the HMI Display to translate the ModbusRTU
53. 30 s 11 Final check Volts VAC RMS Navigate to Status screen Current ARMS Navigate to Line Load status 212 Note corrected voltage current power pos d a KVA and THD ower Factor THD THD 96 37 1 E UG 145 HGA IOM Manual TCI LLC W132 N10611 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 TCI 8282 Web Site http www transcoil com 2014 TCI LLC Publication No 26030 Effective 11 26 14 Version E Printed in USA
54. 402 1 1 2 38 1 KCTF2000A02 5 1 2 139 7 1 1 2 38 1 KCTF3000A02 1 1 2 38 1 KCTF5000A04 13 3 8 339 7 1 1 2 38 1 Figure 4 19 Current Transformer Diagram Rectangular 49 Manual Section 4 HGA IOM Manual KCTFOSOOBO 250 10 2 508 99 25 2 4 7 119 4 5 3 4 146 1 6 1 2 165 1 0 28 7 1 KCTFO800B2 5 800 5 350 140 2 508 99 252 1 1 4 31 8 4 7 119 4 53 4 146 1 16 0 28 7 1 KCTF1600C4 3 1600 5 1 43 109 2 59 1499 290737 62 1575 38 96 5 57 1448 0 22 56 49 1245 2000803 2000 5 3 76 2 11 4 31 8 4 7 119 4 53 4 146 1 6 1 2 165 1 0 28 71 2500 4 3 73 7 5 7 144 8 0 22 5 6 9 E 9 Catalog Ome 2 508 99 25 2 ii 055 4 7 KCTF1200B03 1200 5 04 3 762 074 191 1174 318 47 1194 5 3 4 146 1 6 1 2 165 1 0 28 7 1 100 2 KCTF1000B03 0 55 3176 2 0 74 19 1 1 4 31 8 4 7 119 4 534 146 1 1 2 1651 0 28 7 1 00 2 2 9 4 3 800 5 30 0 4 3 109 2 5 9 149 9 2 9 73 7 6 2 157 5 3 8 96 5 5 7 144 8 0 22 5 6 4 9 124 5 KCTF1000C4 3 30 0 4 3 109 2 59 1499 2 9 73 7 3 8 96 5 5 7 144 8 0 22 5 6 80 9 73 7 5 7 144 8 KCTF2000C4 3 2000 5 43 10921 59 1499 2 Figure 4 20 Current Transformer Diagram Solid Core Grounding The HarmonicGuard Active
55. 81 HGA IOM Manual Section 5 TS ISNY MSU qn S4 541 0801 co 2 Luang ce d3 amp bPBzH 01 8 0 onp punog OMY p n 00 25040 aad S OWJ 262121 DODn B 15591 POSH Salou aaa SUOS LUANI Fr 1 un 5 19 19461490 Lai um nir MILA Sild FOP SOMA aWNSO IuWy unu anu d3lsU d sv za MJA UE t T esum 4 wee Hadas PT TSN d 379015 9002 431 74 JALIY 3904 S431400 47 SP 54294 pene dit 05 MATA 10014 54 487 51455 480 200 Amp 3R Enclosed Figure 5 27 5 82 HGA IOM Manual Section 5 HGA IOM Manual usiuou2au ajpuou 403 aq
56. AOD T 8 Cee 9 4 J lt 17519 204 443141 IWH 321 sapis 4308 apis dol 34043 Figure 5 21 480 amp 600V Filter with Pedestal 110 to 150 Amp 1 Enclosed 76 HGA IOM Manual Section 5 HGA IOM Manual 82866 SLLOM 00601 5501 4024 0101 9610 1945804 2 22 aA4nsoj2u3 421 1 Gy 591 3 6 IS262 Assy 48 045403 puan 1 28282 Avdsiq saz04uazuy 1 96 888 0628 1 9 1 5 SUL sapis uo 2 u2u aadoad aunsul 01 CE youondo sajou 4 242 sajou aul 5 cT Sa 0p T Y n Y M Y Y ANY 4 RARR R RTI D AN i M M 1 L Y Y
57. DeviceNet Communications Gateway DeviceNet Connection to End User Network Figure 9 14 DeviceNet TCP IP Communications Gateway Location Configuration To configure the DeviceNet gateway on the DeviceNet network a node ID needs to be configured on the DeviceNet The Node address can be assigned by setting the configuration switches on the anybus as shown in the image Figure 9 15 Anybus Configuration Switches The values of the switches represent are listed in the table below Figure 9 16 Anybus Switch Values After a node address has been assigned the gateway can be connected to the DeviceNet network by using RSNetworks for DeviceNet devices The EDS file for the DeviceNet Communications Gateway 15 available via TCI technical support direct dial 414 357 4541 email tech support transcoil com or from the TCI website http www transcoil com Support htm For advanced configuration options reference the HMS Anybus Communicator Serial DeviceNet Gateway User Manual available on the HMS website www hms se Operation The Communication Gateway has six LED indicators that show the current status of the Modbus TCP IP and sub network communications The meanings of the LED indicators are described in Figure 9 8 135 Manual Section 9 Table 9 9 DeviceNet TCP IP Gateway LED Diagram 1 Network Status 2 Module Status 3 Not used 4 Not used 5 Subnet Status 6 Device Status HM
58. HARMONICGUARD ACTIVE HarmonicGuard Series Bus Applied Active Harmonic Filter Installation Operation and Maintenance Manual TCI LLC W 132 N10611 Grant Drive Germantown Wisconsin 53022 Phone 414 357 4480 Fax 414 357 4484 Helpline 800 TCI 8282 Web Site http www transcoil com 2014 TCI LLC All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical electronic photocopying recording or otherwise without the prior written permission of TCI LLC The information in this manual is subject to change without notice Every precaution has been taken in the preparation of this manual TCI LLC assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained in this publication Table of Contents SO P 1 Quick Start Unit Software Setup HMI Revision I sccssssssssscccccccccccccccssssssssssscccsccccccccsccsssssessess 1 D 8 Safety e IIT I 8 8 arid PI
59. I 81 VES 34044 apis 3 4 Jounogsuei yO Buiyunou 4034 2500 5 5 alipaou 403 moy apis 148 3 0 14 2 lt gt 39149422 7S N E 12414 Figure 5 9 600V 39 and 78 Amp Open Chassis Filter Open Transformer 64 HGA IOM Manual Section 5 HGA IOM Manual 244 aansaj2ua 092150201 l up nous 49514 BA 944 mojeg 6584950 LUA MOS su 04zun4j ay 191 84002 555945 uada 04 1484 sun gll p En eo 193 90 Buguni Hun 25090 payddes 8 np aps a Se ENTE 2 om 1 EAI sad s rejaq 43 0158 uadp uadp yoda 42114 84424 008 HGA IOM Manual Figure 5 10 600V 220 Amp Open Chassis Filter Open Transformer 65 HGA IOM Manual Section 5 aut aunsopua ul 3 Up
60. Ibs mx toe EM lbs es 39 amp 78Amp 6 20 45 22 45 6 25 45 5 65 45 5 100 45 6 25 to 100 Rockwell 2510 100 Note The values in this table are representative of ABB switch gear unless 2 For other a S switch gear please contact TCI Table 4 3 Power Terminal Wire Size without breaker Capacity Range and Tightening Torque Ground Lug Power Terminals Chassis Size WireSize In Ibs Nm Breaker IC Torque In Ibs Nm 600V 39 to 100 Amp 6 AWG 2 0 4 2 00AWG 180 20 3 600V 150 200 Amp 4 AWG 2 0 50 5 7 3 0 350 MCM 274 31 480V 300 Amp 3 AWG 500 MOM 50 5 7 500 MCM 375 42 4 39 300 Amp Control Terminals Wire Size 28 to 14 AWG Torque 4 4 0 5 Nm Caution Use copper wire that is appropriate for the voltage and current rating of the equipment The wire selection must conform to the requirements of the National Electrical Code and or other N applicable electrical codes Use wire with an insulation temperature rating of 75 C or higher Connection Diagram Figure 3 1 shows the typical wiring connections between the models of the HGA and the load Refer to the drawings furnished with the unit for more specific information The input 3 phase AC voltage source must be connected in a positive ABC phase rotation from L1 L2 L3 for correct unit operation HGA IOM Manual 30 HGA IOM Manual Section 4
61. Protected The filter has factory set built in electronic overload and over current protection If the converter current exceeds the preset instantaneous peak the converter will shut down to prevent permanent damage to the converter and at which time it will indicate a fault Faults that do not automatically reset can be cleared by pressing the stop button on the HMI display An indication that the filter is going into overload will be observed by a gradual worsening of the total harmonic distortion THD or power factor as the load increases The HGA filter units can be paralleled to increase total corrective current capability if a unit is undersized for a particular application Call TCI sales support for options to expand the installed system current capability Circuit Breaker Protection Each converter section is protected by a thermo magnetic circuit breaker in the event the HGA experiences a catastrophic failure or a destructive over current condition should occur It also provides a convenient disconnect means to isolate the converter from the power source The size and type of circuit breaker must not be altered without consulting TCI engineering since the circuit breaker is an integral part of the UL file Notes e Open chassis units can be provided without circuit breakers The end user must protect the HGA with the following UL listed thermal magnetic common trip molded case circuit breaker e All circuit breakers referenced belo
62. S Gateway Example HMI slave connected through Anybus Gateway to a DeviceNet network The end node for this setup is a DeviceNet Scanner that is connected to a ML1500 PLC Hardware Requirements QU 21282848 228 M es Status _____ Unk OK On ine Connected Green flashing On line Not connected 77 Unk Faure Connection tmeou or Device Operational size bigger configured ped eave a Red flashing Minor Fault Power off Green flashing Running correctly but one or more trans action error s have occurred Running Red Transaction error timeout or subnet or or msg cour Ilf the Device Status LED is flashing in a sequence starting with one or more red flashes please note the sequence pattem and contact the HMS support department HMI display Anybus gateway assembly 1770 Allen Bradley KFD with respective serial cable 1769 DeviceNet Scanner Bus terminator cap MicroLogix 1500 PLC DeviceNet cables LED Network for Output display software Requirements RSLinx classics RSNetworx RSLogix 500 Micro HGA IOM Manual Anybus configuration manager 136 HGA IOM Manual HGA IOM Manual Section 9 Setup Connect Anybus gateway on the HMI assembly using a DeviceNet cable to the 1770 Allen Bradley KFD Connect the 1770 Allen Bradley KFD to the 1769 DeviceNet Scanner using
63. THER 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 TCT s employees and sales agents oral statements do not constitute warranties shall not be relied upon by the Buyer and are not part of any contract for sale All warranties of TCI embodied in this writing and no other warranties are given beyond those set forth herein TCI will not accept the return of any product without its prior written approval Please consult TCI Customer Service for instructions on the Return Authorization Procedure Storage Instructions If the HarmonicGuard Active filter 1s to be stored before use be sure that it 1s stored in a location that conforms to published storage humidity and temperature specifications stated in this manual Store the unit in its original packaging Long Term Storage In the case of long term storage defined as any period greater than eighteen 18 months TCI Technical Support must be contacted prior to applying power HGA IOM Manual 12 HGA IOM Manual Section 3 Product Description HarmonicGuard Active filter The HarmonicGuard Active filter 15 an active harmo
64. The HGA contains high voltages and capacitors Wait at least five minutes after disconnecting power from the converter before you attempt servicing Check for zero voltage between all terminals to the converter Be aware everything ahead of the circuit breaker will still be energized Replacement Parts If replacement parts are needed please contact your TCI representative To ensure that the HarmonicGuard Active filter continues to perform to its original specifications replacement parts should conform to TCI specifications Use of non TCI approved components will void all warranties Factory Contacts and Technical Support For technical support contact your local TCI distributor or sales representative You can contact TCI directly at 1 800 824 8282 Select Customer Service or Technical Support and have your HarmonicGuard Active filter nameplate information and any drawings available 63 Manual HGA IOM Manual Section 5 imension Drawings Outline and Mounting D the conduit access areas and the 2 Outline and mounting dimension drawings show the overall enclosure dimensions wiring connection points The major internal components are shown pictorially 241 AZIADD 5 29 ul 2920 1 60 0 00 45 8 04540 SH 24 i upj ouS 48 04540 661168 Gunoor 5155942 uado 949
65. U i LU UL Y A y Y 4 N M PR dl 86 94 pnpuog 2 cL 20 1 024 6t 1 do iprezeu suiddn 211 01 112 5 ISNUI 191114 ONTNDH V AA 96 184044 Sapis 4308 Spay uly 39141 19 5 3000 239 Goog 9 82044843u IWH 42391 Joof 4409 223221 3n E poop dol T6 344944 t e i T 480V amp 600V Filter with Pedestal 220 to 300 Amp Type 1 Enclosed Figure 5 22 HGA IOM Manual 77 7 HGA IOM Manual Section 5 Buyjoos 404 saps 4104 254040912 u2u ytz 69 soy 34 15 3 18 3440j45u04 34444817 28282 0 45 82944834 ual2auuo Jau sn v ESGPpOZ amp 103 20 uno 99 apis 91 404308 42191 4800 v 19390 054 pg eF UNT Tr Loc 7 Daud
66. after a programmed delay after power is applied or after a fault occurs This option is on by default Allows user to select number of faults allowed to occur before auto start option is Select number of faults disabled Allows user to select the time allowed between faults before auto start option is Select time frequency disabled Disable Auto Start Limit The disable auto start limit button will disable the frequency limit or the number of allowed unit auto starts after a fault is detected The start delay is the time in seconds the active filter will wait after a power up or Start Delay after a fault before auto starting the harmonic and or power factor correction if the auto start feature is enabled The fault reset delay is the time in seconds the active filter will wait after a fault is detected prior to attempting to auto clear the fault and restart harmonic and or power factor correction if the auto start feature is enabled Fault Reset Delay HGA IOM Manual Takes user back to the Tech Setup screen 114 7 HarmonicGuard Active Section 7 About Screen The About Screen see Figure 7 20 displays model number serial number and software firmware version information regarding the filter as well as the CT ratio Converter 100 System voltage y CT RATIO 1000 5 stopped Sofhaare 800 844 8252 Figure 7 20 About Screen Table 7 19 About Screen Elements Stop Bu
67. aj 21 40 m ag pinous 48414 3442y 944 uoj3o8 au ce 48114 Saou 10 unu 9 Ashu 414 au 6219291 iE az pp BH gr eg da GE E oe oe apis oed c TE 81825 quam 1 ad ggag 48114 009 Hogoita eaunn 600V 39 78 Amp 1 Filter Transformer Figure 5 14 69 HGA IOM Manual Section 5 apid SA LOY AADI eq 1 5 44 210454041 2415 49611357 944 do papoao LUPINOWUS 444 404544141 84 555042 o 4 LEH 11 4 a g oo ee LL Ee EE Bv m HT m HI z Ek n i 4 ils PT BE xus 4044 14 Baar oda s rejo q 49 015 61 1 008 OT 3 01 151114 Ft gan 994 98
68. and are read only Display fields will appear Numerical Displays flat Numerical displays are read only Numerical Entry fields Numerical Entry IF appear indented Selecting Fields 11 them will open a keypad for numerical entry The Navigation Bar allows 1l ay for easy navigation between Navigation Bar Status Faults Setup the five major HMI screens zi zi SL ____ The Navigation Bar appears on all HMI screens The Title Bar contains the current system time screen selection and a stop button to turn off the system The Navigation Bar appears on all HMI screens Title Bar 93 IOM Manual Section 7 HarmonicGuard Active ome Stop Title Bar HMI Display RUM Indicator Power LED Line Laoad Status di 3H d Power Facto 1 OD Display 480 Current ES Navigation Bar Figure 7 1 HMI Display Initialization When first powered the green LED Power on the HMI Display will light see Figure 7 1 After a five second boot up sequence the Home Screen will be displayed If the home screen 15 not displayed and power is available to the HMI Display see Section 8 Troubleshooting for diagnosing common problems 94 HGA IOM Manual HarmonicGuard Active Section 7 HMI Screens Home screen The Home screen displays a dashboard of overall filter status information and allows the user to run and stop the HarmonicGuard Act
69. 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 HGA filter 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 filter L1 L2 L3 Ensure that the CTs are properly installed and connected to the proper terminals inside the HGA filter see CT Installation section of IOM Manual Check everything thoroughly before applying power to the equipment Check the panel and the inside of the enclosure for any foreign objects dirt or loose hardware 11 HGA IOM Manual Section 3 HGA IOM Manual Receiving Inspection and Storage Receiving Inspection The HarmonicGuard Active 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 TCT warrants to the original purchaser only that its products will be free from defects in materials and workmanship under normal use and service for a period originating on the date of shipment from TCI and expiring afte
70. another DeviceNet cable Attach the 1769DeviceNet Scanner to the ML1500 PLC using the pin header present the scanner similarly attach the bus terminator cap to the other end of the scanner to finalize PLC assembly DeviceNet Cable Network 21 2 1769 DeviceNet scanner module and Bus terminator cap assembly EE TETE DeviceNet Network Programming Master Figure 9 17 DeviceNet Network Setup Establishing Correct Network Settings The baud rate and node address are two important aspects of DeviceNet network a mismatch in baud rate or a clash of node addresses will produce a red network status LED on the DeviceNet devices The baud rate and node address for the three network devices can be set as following 1 Anybus Gateway The gateway is equipped with 8 switches as described in the appendix DeviceNet network section These switches can be manipulated as descried to match network baud rate and provided the gateway with a distinct node address 2 1770 The network settings and node address for KFD are set in RSLinx The RSLinx software is used to obtain nodes in a network The KFD provides RSLinx the access to the DeviceNet network nodes 3 1769 DeviceNet Scanner The network and baud rate settings for the scanner are given on pg 40 of the DeviceNet Scanner Module http literature rockwellautomation com idc groups literat
71. armonicGuard Active filter and 15 what differentiates the HGA from other types of harmonic mitigation The PCM provides several highly complex electronic functions controlled by the on board DSP controller The PCM continuously senses the AC bus line voltage and currents processes the information at nearly real time by means of the instructions resident within the DSP program code properly controls the six IGBT s to operate in a safe manner that injects current into the AC bus grid that ensures the AC bus current is sinusoidal and near unity power factor Power converter contains a pre charge circuit which consists of two SCRS and two pre charging resistances which control the inrush current 13 Manual Section 3 HGA IOM Manual Filter Configuration Load Side CT Placement Com Com See Note 5 Figure 3 1 Typical Configuration of the HarmonicGuard Active Filter This drawing is for general reference only Use the drawings supplied with the unit for installation HGA IOM Manual 14 HGA IOM Manual Section 3 Nameplate Data Figure 3 2 shows a typical HarmonicGuard Active filter nameplate The following information is marked on the nameplate Part number encoding 15 explained on the following page Corrective Current The maximum amount of RMS Corrective Current the unit can deliver System Voltage the rated 3 phase line voltage RMS volts Hz the rated frequency 60 Hz Phase 3 3 Wire
72. ays the current and temperature levels for each individual converter that is present in the unit These values are summed and represented as Converter Current and Converter Temperature throughout the HMI Comerter CutTents Temps Total Current ARMS c 11 D aw 2 ARMS Me s Device ne MS 12 10 DUE Figure 7 6 Converter Current Temperature Screen Line Load Status Sub Screen The Line Load Status Sub Screen shows more specific information regarding the source and load voltage current power power factor and THD measurements VAC Current ARMS Power K Watts Apparent Power Power Factor THD 36 8 E v THD Its Figure 7 7 Line Load Status Sub Screen 7 99 Manual Section 7 Screen Element Volts Display Current Display Power Display Apparent Power Disp Power Factor Display THD Display V THD Display THD Ref Display Run Stop Button Back Button HGA IOM Manual HarmonicGuard Active Table 7 6 Line Load Status Screen Elements Displays the current utility phase to phase line voltage in Volts RMS Displays the current line load phase current in Amps RMS NOTE the displayed current is affected by the CT Ratio configuration on the Setup page The three phase real power P of the line load in kW lay The three phase apparent power S of
73. cations 480V 3 phase 60 Hz three wire systems 9 9 600V 3 phase 60 Hz three wire systems Phase Sequence Positive phase rotation A B C or L1 L2 L3 3 phase diode bridge rectifier loads such as PWM AC drives 3 phase controlled rectifier 5 or thyristor loads such as DC drives Current ratings See Ratings in Standard Product Rating and Dimensions tables 1 000 meters 3 280 feet For every 100 meters 328 feet over 1 000 de rate by 1 Maximum elevation is 2 000 meters 6 560 feet All units 40 C 104 F except 45 amp 90 amp open chassis units rated for 50 C 122 F surrounding air Product must be equipped with special cooling provisions for operation above this temperature Load types Maximum Ambient operating temperature 0 C 32 F for open chassis and 1 and Type 12 enclosures Minimum Ambient operating 20 C 4 F for Type 3R enclosures temperature Product must be equipped with special heating provisions for operation below this temperature 20 to 60 C for Open Chassis and UL 1 40 C to 60 C for UL 3R Maximum humidity operating or 95 non condensing storage Standard Open Chassis and UL 1 enclosed UL 3R and 12 enclosed Contact Technical Support for other enclosure options UL and cUL Listed Agency approvals or certifications US Electronic overload over Factory calibrated processo
74. cations that require input power line harmonic current reduction and power factor correction This manual describes how to install operate and maintain the HarmonicGuard Active filter Intended Audience This manual is intended for use by all personnel responsible for the installation operation and maintenance of the HarmonicGuard Active filter Such personnel are expected to have knowledge of electrical wiring practices electronic components and electrical schematic symbols Additional Information This manual provides general information describing your HGA filter Be sure to carefully review the more specific information that is provided by the drawings shipped with the unit Information provided by the drawings takes precedence over the information provided in this manual The ratings dimensions and weights given in this manual are approximate and should not be used for any purpose 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 in the following sections of this manual Make sure that the installation location will not be exposed to direct sunlight excessive vibration corrosive or combustible airborne contaminants excessive dirt or liquids Select a mounting area that will allow adequate cooling air
75. ce and troubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker including the reactors will still be energized Interface Module Problem The Interface Module is comprised of four major components the HMI display the Interface PCB the cabling and an optional Gateway The Interface PCB contains diagnostic LEDs The locations of the LEDs are shown in Figure 8 3 and their functions are listed in Table 8 1 LED PLACEMENT Dis m 014 Ds m De m E m E m Figure 8 3 Communications Board LED placement Table 8 1 LED Functions LED Color Description LED Color AUX 1 09 Green __ __ D4 __ Green Running Relay Energized 00000000 05 D 07 D1 D3 D4 D5 D7 D1 D1 D12 Green 7 85485 Communication is active from converter 000000 D 2 Manual 120 HGA IOM Manual Section 8 Warning Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the life affect performance and or destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards Fault Troubleshooting Notes To reboot the s
76. charging resistor will be cut off from the unit If for some reason this circuitry should malfunction class CC fuses are in the circuit to limit the max current as not to exceed the ratings of the components Note on the 50 100 200 amp units the fuses are located on the chassis on the 150 300 amp units the fuses are located on a separate circuit board above the chassis Over Temperature Protection The converter has a thermal fold back mechanism that will automatically reduce unit output current as the converter temperature approaches its shutdown threshold Additionally the converter has an internal heat sink over temperature protection which will shut down the converter if the threshold 1s exceeded The fans will continue to run and once the heat sink cools down the converter will automatically restart 57 IOM Manual Section 5 HGA IOM Manual There are secondary over temperature circuits which monitor the temperature of the power resistors and inductors located on the chassis of the HGA The sensors are snap action switches activated when the threshold is reached This over temp would be an indication that cooling fans have failed or something more serious with the operation of the converter For this reason this fault will latch and will remain latched until power 15 cycled The indicator light located on relay CR 2 will not be lit with this type of over temp fault Troubleshooting Current Transformer Orientation Troubleshoo
77. e Calibrate mode Power Save mode or Faulted When the HarmonicGuard Active filter is faulted it will shut down automatically System State Indicator located immediately below stop button Displays current line load power factor 1 00 indicates unity power factor A negative power factor indicates lagging power factor Line Frequency Display Displays the current utility line frequency in Hz Supply Voltage Displays the supply voltage coming into the HarmonicGuard Active filter Displays the current line load phase current in Amps RMS Line Load Current Display NOTE the displayed current is affected by the CT Ratio configuration on the Setup page Power Factor Display 7 95 Manual Section 7 HarmonicGuard Active Status Screen The Status screen shows more specific information on the performance of the system such as current and voltage waveforms Power Factor and information specific to the Line Load screen and Converter screen Figure 7 3 explains the main Status Screen stop 2 to Voltage F lot Line Load Current F lot Converter Current Plat wv LinenLine Flat Figure 7 3 Status Screen Table 7 3 Status Screen Elements Use this button to get to the Line Load Status Sub Screen see Figure 7 6 Displays the current utility phase to phase line voltage in Volts RMS Current Display Displays the current line load phase current in Amps RMS Displays current line load
78. e screen 15 only displayed if a wiring error 15 detected If no sensor wiring errors are detected the pop up screen will remain hidden If a Sensor Wiring Error 15 detected the HGA will be inhibited from running until system power is removed from the unit and the error 15 corrected The Sensor Wiring Error Detection feature 1s comprised of several independent detection algorithms The two main categories of algorithms are voltage based detections and current based detections The voltage based detection algorithms monitor the three phase line voltage input for proper ABC phase rotation polarity balance and nominal magnitude The current based detection algorithms monitor the system Current Transformer CT sensor feedback 115 IOM Manual Section 7 HarmonicGuard Active for proper phase rotation polarity balance and CT open or shorted conditions The current base detections are only engaged if a minimum level of load current is present during power up Both the voltage and current detection algorithms can be globally or individually configured by TCI qualified personnel via the password protected Technician level Setup Screen Self Test Indication Self Test Description Figure 7 21 Sensor Wiring Error Self Test Sub Screen Table 7 20 Sensor Wiring Error Self Test Sub Screen Elements Screen Element Self Test Result Displays the current Pass Fail In Progress State of the Sensor Wiring Error Auto Detection feature W
79. ect En ZW ASO Harmonic Correction En and Auto Start En buttons 242 B are OFF Blue If GREEN press to toggle OFF UM 1 00 Negative Current F lot Next select Status to navigate to Status screen Factor 1 inn Select Converter in top right corner Freq 7507 TE rm F lot Status bo Current A PMS Link Voltage v Dc Filter Once on Converter Status screen select Run to start unit operation Used Manual 4 7 HarmonicGuard Active Section 1 7 Remove CT shorting bars Press Stop to turn off unit Disconnect power from cabinet Turn off the built in door breaker AND Turn off the upstream feeder breaker Open the cabinet door and remove shorting bars from CTs connected to TB 1 Warning Lethal voltages may be present Wait 5 minutes for DC bus voltage to drop to safe levels Warning Check for voltage in cabinet with a DMM before working inside cabinet 8 Current polarity 1 Power up unit From Home screen press to turn on unit Press Status to navigate to Status screen Select Vline lline screen Note Lightly loaded conditions less than 2096 CT rating will not have enough current to show up on lline plot Check that Phase A to Neutral voltage peak lines up with Phase A current use zoom if necessary Check that Phase C to Neutral voltage peak lines up wi
80. ee 2 according to EN50178 and ULS08C e Avoid excessive vibration 0 152 mm 0 006 in displacement 1G peak Mounting Mounting requires at least a depth of 4 102 mm The Interface Module will mount in a panel with a thickness of 0 02 to 0 35 inch 0 5 9 0 mm with an opening 6 79 by 5 21 173 by 133 mm Fit the Interface Module assembly into the opening carefully pressing on all four corners Use the mounting hardware 4 sets to secure the assembly on the corners Warning to avoid damaging the case do not exceed tightening torque of 3 47 to 4 34 Ibs in 0 39 0 49 Nm Care should be taken not to mount the Interface Module too close to a heat source such as power resistors which could be located behind the Interface Module HGA IOM Manual 88 HGA IOM Manual Section 6 Caution The display panel is waterproof But care should be taken to prevent grease corrosive liquids and sharp objects from contacting the front panel Warning Many electronic components located within the Interface Module and HMI are sensitive to Static electricity Voltages imperceptible to human touch can reduce the life and affect performance or completely destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the Interface Module and HMI Wiring Note Some of the following sections only apply if the Interface Module is not factory installed A wiring block diagram of the Interface Module
81. ence Section 1 for the first time power up procedure Since the HGA is an active filter it is always operating whenever the power is applied Only qualified electricians should carry out all electrical installation and maintenance work on the HarmonicGuard Active filter Disconnect all sources of power to the drive and HGA before working on the equipment Do not attempt any work on a powered unit Be aware that everything ahead of the circuit breaker will still be energized It is important to note that the lack of lit LEDs does not necessarily mean that the is not receiving power from an external source 51 Manual Section 5 HGA IOM Manual g Section 5 Maintenance and Service Reliability and Service Life The has been designed and thoroughly tested at the factory to ensure that it will perform reliably from time it is put into service The following periodic maintenance 1s recommended to ensure that the HarmonicGuard Active filter will always perform reliably and provide the expected service life Periodic Maintenance The following checks should be conducted monthly or more frequently when installed in harsh or dusty environments Check to see that the installation environment remains free from excessive vibration exposure to excessive dirt moisture and contaminants Refer to the Section 4 of this manual Check to make sure that the enclosure ventilation openings are clean and u
82. eplace the HMI 1 controltransformer 1 display interface to interface Board control transformer service to the display the HMI interface Figure 8 4 Troubleshooting Flow Chart 121 Manual HGA IOM Manual Diagram ion Installat Section 9 Appendix Section 9 l amp uondo eseu jo asn 9 ainpow nod que sped 9 04 BE tt 01 op anboy ejdsip uj 2 uoi ejewpueu Guqunow asp GOL UBL 888 pajeJ g 94 JO e oqe si os ueo sejd Bugunoui ayy uo 7 229 x 6 9 eq pinoys Buruedo no no aU JO Bugs oj 9218 oj 1 eu 381 eu pejejeuaB einssaud pue Agjdsip jo uaewgeq aq A qm eur E eu uo amp eunsseJd m pey ue Ajquiesse sejd pue ejdsip pH 8140 eu Bugunow esn oj s
83. equipment Do not attempt any work on a powered HGA filter The HGA filter drive motor and other connected equipment must be properly grounded The HGA filter may receive power from two or more sources Three phase power is connected to the main input terminals of the HGA filter All of these sources of power must be disconnected before working on the HGA filter After switching off the power always allow 5 minutes for the capacitors in the HGA filter and in the drive to discharge before working on the HGA filter the drive the motor or the connecting wiring It is good practice to check with a voltmeter to make sure that all sources of power have been disconnected and that all capacitors have discharged before beginning work Section 1 1 Verify unit external connections Phase A B C power connection with positive A B C phase rotation expected Phase 11 CT 1 Terminal is pointing toward the source ne 1 CT feedback on phases A amp C to TB 1 Leave CT shorting bars in place on TB 1 With the circuit breaker open energize the source to the HGA Close the HGA circuit breaker Fans and HMI should come on in 5 seconds HMI will start on Home screen Load s have an integral 5 line reactance or equivalent dc bus choke Warning Hazardous voltages are present when unit is energized NOTE Language Selection The active filter supports several languages including English French and Spanish Press Setup t
84. er operation NO YES Are the voltage current and harmonics correct and at acceptable levels Is the harmonic correction enabled on the HMI setup screen Complete Set autostart enable on HMI Setup screen and save settings Figure 5 5 HGA Troubleshooting Flow Chart HGA IOM Manual 60 7 Section 5 HGA IOM Manual Power Component Layout 503120997 0129905 youjwuay v3 N 7 9 5408 374 7 gt 1891 yong o 88 99 o SJO4 2odoj sng 4004 1323 0 0 r uvovg 203120007 5 a npow 1491 yong MOS eng Figure 5 6 600V 39 78 150 Amp amp 480V 45 90 100 150 200 Amp Power Component Layout HGA IOM Manual 61 Section 5 Outout Terminal Bus Bars Dual SCR Module Dual IGBT Module Bus Bars over Capacitors Electrolytic Bus Capacitors 6 Terminals HGA IOM Manual Dual SCR Module Dual IGBT Module Positive Terminal Capacitor Bank Negative Terminal Capacitor Bank gt Figure 5 8 TB 1 Terminal Block HGA IOM Manual 62 IOM Manual Section 5 Warning Only qualified personnel should operate the HarmonicGuard Active filter with the door open Failure to follow standard safety procedures may result in death or serious injury Do attempt any work on a powered filter converter
85. from drop down menu select Micrologix Keep slot as 1 Move now to the Input tab of the 1769 SDN scanner module window From here you can observe that the registers 0 65 are read only Manual 138 HGA IOM Manual Section 9 Therefore the Anybus data 15 saved the registers 66 73 each register being 16 bits Similarly in the output tab the first 2 registers are read only The 3rd register will say Anybus Communicator meaning that the anybus data 15 redirected and mapped to that register in the 1769 SDN Once set click on Apply and then click OK The 1769 DeviceNet Scanner is now also set for proper communication with Anybus Communicator RSLogix RSLogix is used to program the ML1500 PLC Once in RSLogix a new file 15 created and the PLC ML1500 revision C is selected in the list of compatible PLCs The Who Active option is used to connect the live PLC to the software In RSLogix the IOConfiguration option present on the left panel 15 selected A new window will open from the list of items present on the right panel select the 1769 DeviceNet Scanner Once selected the DeviceNet Scanner should move to spot 1 in the left panel of the window given that no other I O modules are attached to the PLC Click now on the ReadI O option The program will try to read IO profile of the DeviceNet scanner once found a message box confirming the same will appear In the IOConfiguration screen click on the Adv Config op
86. ftware Ethernet RJ45 cables 131 HGA IOM Manual Section 9 HGA IOM Manual Setup e Connect the RJ45 cable to the Ethernet Port on the Anybus gateway from a router LAN e Connect the PLC to the router LAN via RJ45 cable e The network setup is displayed in Figure 9 10 TCP IP Master Figure 9 10 Network Setup with PLC Example Programming e Once all connections are set the Modbus TCP master is set for communication In our example the Modbus TCP master is Simply Modbus see Figure 9 11 copy down register byte notes dear notes C 114551 press T ares TE rower 40503 0000 0 tine 40506 PF ir 4057 NN IEB S 01 00 00 00 96 OL 03 01 FS 00 OA hl lGbit INT 40509 11221121 5 EJ response time seconds Response 54 00 00 00 17 01 03 14 00 OO 00 01 00 00 00 00 01 DF 00 Fe AS 00 01 00 00 00 00 F High byte byte SXPected MI bytes eu GEN Low word Ctri H for context help Figure 9 11 Simply Modbus Screen HGA IOM Manual 132 TQ HGA IOM Manual Section 9 Read HMI Data Open Simply Modbus and type in the IP address set for the Modbus TCP IP gateway 1 Select mode as TCP and then hit CONNECT 2 Once connected a disconnect option will appear in place of NOT CONNECTED Se
87. he fault history marked with an X on the left side of the fault entry The Fault History persists through power on off cycles In the event the fault history log exceeds the max number of 120 entries the oldest entry will be overwritten by new entries 13 19 10 02 2012 4000 HE ATSINK OVER 13 19 10 02 2012 4000 HEATSINK OVER 13 20 10 02 2012 10000 BUS OVER VOLTAG 13 20 10 02 2012 1000DC BUS OVER VOLTAG 13 20 10 02 2012 3000 OVER CURRENT FHAS 13 20 10 02 2012 3000 OVER CURRENT PHAS 5 m Figure 7 13 Fault History Sub Screen Table 7 13 Fault History Log Entry Format Column Description from left to right Onset Clear Marker O Fault Onset Marks the start and end of a fault in the fault X Fault Cleared history HH MM HHMMMMDDYYYY Time and date the fault entry was logged 0 Code digit code Fault code see Table 7 12 Fault A short text description of the fault Manual 108 7 HarmonicGuard Active Section 7 Setup Screen Note Some set up screens are password protected to prevent changes that could damage the filter When the user presses the Setup button a screen will appear where the Date Time Language and Screen Brightness can be selected Figure 7 14 Setup screen Table 7 14 Setup Screen Elements Screen Element Description Presents a sub screen which allows the user to change the date and time displayed o
88. he running of the HarmonicGuard Active filter Comm and Enabled or F resent Source Disabled Command Local 5 gt ue Enabled Run Auto Start Fel ay Figure 7 5 Enable Summary Screen Table 7 5 Run Enable Summary Sub Screen Elements Run Stop Button Runs and stops the HarmonicGuard Active filter Local HMI Shows if the start or stop button is enabled Enabled Changes to blue if enabled or the left button is pressed and the Auto Start countdown timer to the right of the button will start When it reaches 0 the HarmonicGuard Active filter will start Changes to blue if enabled or the left button is pressed if enabled Remote Relay the HarmonicGuard Active filter can be remotely stopped with a contact closure When enabled and the option is active the field to the right will be green and read RUN Changes to blue if enabled or the left button is pressed if enabled the HarmonicGuard Active filter can be remotely stopped started with Remote Network a contact closure When the contact is closed the unit will run and when opened the unit will stop When enabled and the option is active the field to the right will be green and read RUN This button will take you back to the converter status screen Manual 98 7 HarmonicGuard Active Section 7 Converter Current Temperature Sub Screen The Converter Current Temperature screen displ
89. hen a sensor Indication wiring error is detected the specific fault code will be shown Self Test Result When a sensor wiring error is detected one or more corrective actions will be displayed here for a list of suggested Description resolutions Pressing the Acknowledge Button will hide the Sensor Wiring Error Self Test Sub Screen so other screens can be examined in order to trouble shoot the wiring error user attempts to operate the unit while a sensor wiring error is still present by pressing the Run or Stop buttons the screen will reappear Acknowledge Button Table 7 21 Sensor Wiring Error Code Table Error No corrective action required No correction action required Typically the self test will complete and auto clear in less than Self Test In Progress 10 seconds after power up Line Voltage Synch and check 3 phase AC input voltage wiring for missing phase connection low 3 Input Over Voltage Turn off unit and check 3 phase AC input voltage wiring for high line voltage Reverse Voltage Phase Turn off unit and check 3 phase AC input voltage wiring for A B C phase rotation or missing Rotation phase connection Phase A Input Under Voltage Turn off unit and check 3 phase AC input voltage wiring for missing phase or low line voltage Phase B Input Under Voltage Turn off unit and check 3 phase AC input voltage wiring for missing phase or low line voltage 4 Turn off unit and check system CT
90. i n onfiguration AnyBus S Ethernet 10 100 IP address 192 168 12 253 Subnet mask 255 255 0 0 Gateway address 192 168 10 20 DNS1 address 0 0 0 0 DNS2 address 0 0 0 0 Host name Domain name SMTP server SMTP user name SMTP password DHCP enabled STORE CONFIGURATION Figure 9 3 EtherNet IP Gateway Configuration Page Table 9 3 Gateway Default Settings setting Default Value IP Address 192 168 0 1 255 255 255 0 255 255 255 0 DHCP Off HGA IOM Manual 124 HGA IOM Manual Section 9 To update the IP address type in a new IP address on the configuration page then click on the STORE CONFIGURATION button After the new IP address 15 stored cycle power to the Communication Gateway to load the new IP address The EtherNet IP Communications Gateway supports implicit Ethernet IP I O and explicit Ethernet IP CIP Message commands For an example of communication with the Gateway using explicit CIP Message commands via a PLC please reference the following application note from HMS Reading writing data from Anybus S EtherNet IP using ControlLogix5000 MSG instruction The EDS file for the EtherNet IP Communications Gateway 15 available via TCI technical support direct dial 414 357 4541 email tech support transcoil com or from the TCI website http www transcoil com Support htm For advanced configuration options such as IP Access Control reference the HMS Anybus Com
91. ice on the network has a nodeaddress To write read data terminal node addresses needs to be programmed into the devices The DeviceNet network Communications Gateway translates command status data to from the HMI Display s integrated network interface from the ModbusRTU protocol to DeviceNet The DeviceNet Communications Gateway is implemented using a third party industry leading DeviceNet solution from HMS Anybus Communicator Product Line Anybus Communicator AB7007 Table 9 1 DeviceNet Communications Gateway Key Features Features Slave messaging Bit strobe Polling Cyclic COS Explicit Messaging Connection Multi drop to up to 31 nodes Galvanic Isolation Standard for both bus side and serial side Profile Support Application RS232 RS422 RS485 Intterface Baud Rate 125 250 500 kbit s Protocol CE UL amp cUL marked Conformance Wiring Pin Signal Description DeviceNet bus power negative supply voltage 2 ww mum o UNHbsEe DeviceNet bus power positive supply voltage Figure 9 13 DeviceNet TCP IP Connector Pinout Connection of the HarmonicGuard Active filter Interface Module to the end user s upstream DeviceNet network occurs at the DeviceNet connection see Table 9 1 on the Communications Gateway The Communication Gateway is mounted on the back panel of the Interface Module see Figure 9 14 HGA IOM Manual 134 HGA IOM Manual Section 9
92. ight 105 kg Inch cm 150 Consult Factory Add two inches for disconnect circuit breaker handle 16 40 41 6 16 40 41 6 21 Manual Section 3 600V 40 C Table 3 5 Open Filter Open Transformer HGA IOM Manual HGA IOM Manual 22 Open Filter Open Transformer Heat Transformer Dimensions Filter Dimensions Inch cm Loss HxWxD Loss Inch cm watts watts HxWxD 39 2676 167 56 0 17 0 14 18 345 180 16 0 12 2 11 1 75 8 142 2 43 2 36 6 81 6 40 6 30 9 28 2 78 3500 167 0 56 0 17 0 14 18 740 180 16 0 12 2 11 1 75 8 142 2 43 2 36 6 81 6 40 6 30 9 28 2 57 97 320 14 84 690 400 18 0 232 124 1009 340 154 1472 812 87 7 182 457 58 9 31 5 541 69 1 320 169 550 18 0 232 124 105001 245 4 175 5 81 2 43 1950 249 5 45 72 59 31 5 Note Some circuit breaker door handle kits may require additional internal clearance when mounting an open chassis unit inside an enclosure Consult the circuit breaker manufacturer for any door handle requirements Table 3 6 Open Filter Type 3R Transformer Open Filter Type 3R Transformer Heat Transformer Dimensions L Filter Dimensions Inch cm oss HxWxD Loss Inch cm watts watts HxWxD 56 14 18 415 270 24 9 22 6 20 8 5009 197 US 11499 36 6 122 5 63 2 57 4 52 8 56 31 76 14 4 19 26 48 9 758 14222
93. ilter powered with 480VAC tripped at unit input breaker YES NO Power off and YES Is branch circuit protection tripped inspect unit see Section 5 of user manual NO NO Check power between Did the unit pass the inspection branch breaker and active filter Close unit enclosure and apply power to active filter Check and repair load Drive Did the circuit NO breaker in active filter trip Follow the Quickstart Do not re energize Guide to configure the Contact TCI Customer Service unit see section 1 of user manual YES HGA IOM Manual NO Is HMI display on unit operating Tap screeen to disable screen saver Are the fans running in the active filter NO Contact TCI Customer Service YES YES Are any sensor wiring errors reported by the HMI display Is power present at the fans Replace fans Power off and correct wiring errors see section 5 of user manual Power off and check control power transformer fusing replace if bad Are any active faults reported by the HMI display Press the stop or Perform a power reset button on the on off cycle of HMI display the unit Are the fans running in the active filter Did the fault clear Contact TCI Customer Service Press the run button on the unit HMI display to start active filt
94. in a high voltage across the secondary terminals which may be dangerous to personnel or equipment It 15 necessary for the to monitor the current in Phase L1 and Phase L3 Stand alone HGA filters are designed for Line Side current transformer CT placement as shown in Figure 4 6 It is important that both CTs are on the same side of the HGA The CTs should be centered around the conductor Optional Load Side CT placement is available for single units as shown in Figure 4 7 The polarity of the CT is important the H1 marking on the CT must face the source The secondary windings of the CT around conductor L1 should connect to TB 1 terminals 1 amp 2 and the CT around conductor L3 should connect to TB 1 terminals 3 amp 4 The secondary wire of the CT identified as 1 must connect to the X1 terminal of TB 1 for both CTs Failure to maintain the correct polarity and phasing will cause an over current fault If this should happen refer to the troubleshooting section Note Units with black TB 1 terminal blocks are shipped with two position shorting jumpers installed between positions 1 amp 2 and 3 amp 4 This 1s done for your safety and to prevent equipment damage The jumpers are installed in the center of the block and can be identified by the gray top After the load CTs are installed and wired these jumpers must be removed for correct unit operation They can be removed with a standard flat blade sc
95. ive filter Stop Filter Status Line Load Status Filter Current Used Power aed 1 00 1 1818 Freq 60 480 1 1 Current m Figure 7 2 Home Screen Table 7 2 Home Screen Elements Indicates if a converter fault is active and preventing the HarmonicGuard Active Filter Status Display filter from running If a fault occurs the indicator will flash red and display Fault Specific Fault codes can be viewed on the Fault Screen This gauge displays the current filter capacity as a percentage of total available capacity In normal operation the display will read Nominal If the unit output corrective current is above 9596 of maximum capacity the indicator light will turn red and display At Capacity When the converter is at capacity the Relay K4 J12 Connector and J11 Contacts used for a remote indicator will also be energized If the monitor continually displays At Capacity a second filter may be required to handle the load Please contact TCI for assistance Run Stop Button Runs and stops the HarmonicGuard Active filter When the HarmonicGuard Active filter is in a stop mode the Status light will Filter Current Used Display turn red and display Stopped When the converter is running the status light will be green and will display Running The status light will also show if the HarmonicGuard Active filter is in Input line Sync mode Reset mode Precharge mod
96. ix LED indicators that show the current status of the Modbus TCP IP and sub network communications The meanings of the LED indicators are described in Table 9 8 Table 9 8 Modbus TCP IP Gateway LED Diagram Off Green Flashing Green Flashing Red Red Flashing Green Red Off Green Flashing Green No Power Normal Operation Configuration Missing Minor Fault Recoverable Major Fault Unrecoverable Self Test in Progress 1 Module Status No IP Address Online Connection s Established Online No Connection Established Hed Flashina Red Duplicate IP Address Connection s Timed Out Flashing Self Test in Progress Green Red 2 Network Status 3 Off No Link Link Green Connected to Ethernet Network No Ethernet Activity sis Green Receiving Transmitting Packets Flashing Green Running Transaction Error Detected Green Runnin Gateway Front View Status Red S ncs un error timeout lashi Invalid or Missin Flashing g Configuration Green Red Initializing Green Running Flashing Green Bootloader Mode Red Note the LED flash sequence and contact Flashing Red Customer support 6 Device Status HMS Gateway Example HMI slave connected through Anybus gateway to Simply Modus Master Required equipment Anybus gateway programmed with TCI Anybus configuration HMI display connected to Anybus gateway Local Area Network LAN routers Simply Modbus Master So
97. jnous 94 015004 2841 24 20 3 Upjnous 5 291 66 4 gt sissou2 42348 59 0 48u40 3450 4 SurnunoJA LT 6 325 do 5 391 19014015481 9390 702 Buizunow 404 asoo 99 51 acop 404 u3dao ap 3 34 44 4 2 sed IAA SH Figure 5 11 600V 39 and 78 Amp Open Chassis Filter Type 3R Transformer 66 HGA IOM Manual Section 5 HGA IOM Manual 24 44 Lil patada dall 4Su n 48111 8429 244 30 BADD 0 ac j upjnous 248 2104510211 Gupoup 555045 uado 01 rI A Ll surjunoJA J9ULloJSUEJ adA uadpg 9022 85429 009 ALAND fim il 151441 anus payddmrs s SUtj BHu 1ng 5 he pau 107 19 444 1
98. l be energized Required Equipment Note AC voltmeter and ammeter or multimeter designed for true RMS measurements in a harmonic rich circuit and suitable for the rated current and voltage marked on the nameplate The meter should have 1000 volt minimum isolation Clamp on current probe suitable for the rated current and voltage marked on the nameplate Clip on voltage probes suitable for the rated voltage marked on the nameplate Select probes that can be securely clipped on to the test points without shorting between points or falling off when disconnecting wires from components and terminations mark the wires to correspond to their component and terminal connection Extreme Care should be taken when removing the fast on terminals from the circuit board Excessive force will result in damaging the interface board and require the converter to be repaired by TCI authorized personnel only Converter Inspection Verify that power has been removed from converter and 5 minutes has passed before inspection Remove plastic cover from over converter section Visually check the circuit boards for debris contamination overheated traces burnt circuit board overheated cracked or broken components corrosion and poor solder joints Check all wires and terminals connected to the circuit boards Check the four electrolytic capacitors for bulges ruptures popped vent plugs discoloration or leakage Check the power semiconductors moun
99. leads Phase A voltage Green e Phase C current Yellow leads Phase A current Red Phase A voltage Green and Phase A current Red are in phase and the same polarity Phase C voltage Blue and Phase C current Yellow are in phase and the same polarity 101 Manual Section 7 HarmonicGuard Active FOO P FOO Figure 7 9 VLine amp ILine Waveform Plot of a Properly Connected HarmonicGuard Active filter unit in stopped state Note The example VLine amp Waveform Plot screens apply to rectifier loads only For low power factor loads VLine amp Line waveform screen will appear different Figure 7 8 shows what the VLine amp Line Waveform Plot Sub Screen would look like with various connection errors present in the system Table 7 8 VLine amp ILine Waveform Plot Screen Examples when Typical Connection Errors Present in System Phase rotation is To correct swap Phase Incorrect A and Phase C Phase A leads Phase HarmonicGuard Active C instead of Phase C filter power connections leading Phase A AND swap Phase A and Phase C system CT current feedback then recheck plot Manual 102 HarmonicGuard Active 103 FOO A FOO FOO A Phase C system CT current feedback missing Phase C current is zero while Phase A current is present Phase A and Phase C CT current feedback swap
100. lect the first register as 40500 Modbus Read Write registers 4 Set the register size as 16 bits 3 Leave the minus offset at 40001 Click SEND The HMI data will appear on the table to the right 5 To receive data continuously decrease the pause between sends to 0 0 6 and check send continuously 7 rej d mm gt Close Window Fest Values to Write em 11 Dere ters Values to Write register bytes ta Tv 2 Loo 99 T High byte Low byte High Low word 01 00 00 00 06 01 06 01 FS 00 00 response time seconde 2 0 20 Figure 9 12 Simply Write Modbus Screen Write To HMI Reference Figure 9 11 and click the write command in the Simply Modbus main window Select the first register value as 40563 1 this address reference to the Master network enable Enabling the Master network enable runs the filter from the network Master in this case Simply Modbus Select the data type as 16 bit INT 2 Write the value as 1 in register number 40563 3 and hit SEND 4 The unit will begin to run sending 0 in the same command will stop the unit The changes can be observed in the main window see Figure 9 12 133 HGA IOM Manual HGA IOM Manual Section 9 Appendix D DeviceNet Gateway Option Introduction DeviceNet is a node priority based communication protocol Each dev
101. m C relay contacts are gold plated with a load rating of 0 6A 125VAC general use 0 2A 250VAC 0 6A 125VAC 2A 30VDC resistive The minimum permissible load rating is 10uA 10mVDC HMI Display Connections Note The following section describes the default ModbusRTU network connection available on the base model If an optional advanced network Communications Gateway is included in the Interface Module see the appendix for the specific Communications Gateway configuration The HMI display implements a ModbusRTU slave device over RS 485 This network connection is available on the 2 3 DB9 connector on the back of the HMI Display see Figure 6 4 The output registers from the HarmonicGuard Active filter are mapped to Modbus register address 40500 The input registers to the HarmonicGuard Active filter are mapped to Modbus register address 40564 For definitions of the input and output data available via the network connection see Table 6 3 and Table 6 4 If the optional network Communications Gateway is present the integrated ModbusRTU interface on the HMI Display will not be available When configured the Communications Gateway will occupy the ModbusRTU 2 3 DB9 connector on the back of the HMI Display 91 Manual Section 6 Connection HGA IOM Manual Figure 6 4 HMI ModbusRTU Connection Table 6 3 Modbus Connector Pin Definitions COM2 3 089 Pin Signal Name Signal Type 2 moconnec
102. maximum capacity the power factor correction will automatically be phased back to allow the system to continue correcting harmonics The CT ratio button opens a pop up sub screen that allows selection of the turns ratio of the system line or load current transducers CTs The CT ratio is expected to be in terms of primary current to 5A of secondary current For example a 1000 5 CT means that for 1000A of primary current there are 5A of current in the CT secondary winding connected to the active filter See user manual Table 4 4 for the allowable CT range for a particular active filter unit type This button initiates the active filter sensor calibration procedure There is no need to calibrate the unit unless instructed by authorized field service personnel The active filter ships from the factory with all sensors fully calibrated so calibration is not required at the time of unit startup This button is available for recalibration of the unit during field service trips The calibration process will only run if the unit is in the nominal stopped state Calibration should be done when the system bus 15 at no load This button will save the current working settings to non volatile memory that persist when power is removed from the unit To save the current settings choose Yes on the confirmation screen or choose No to cancel and go back to the Basic Setup The settings will not be saved if No is chosen Are YOU sure you want
103. mponents located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the life and affect performance or completely destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards 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 N damage The text describes ways to avoid the situation Manual 8 7 HGA IOM Manual Section 2 General Safety Instructions These safety instructions are intended for all work on the HGA filter 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 HGA filter All wiring must be in accordance with the National Electrical Code NEC and or any other codes that apply to the installation site Disconnect all power before working on the equipment Do not attempt any work a powered HGA filter The HGA filter drive motor and other connected equipment must be properly grounded The HGA filter may receive power from two or more sources Three phase power is connected to
104. municator Serial EtherNet IP Gateway User Manual available on the HMS website www hms se Register Map For a description of the input and output data available over the network interface reference Section 7 in this user manual Operation The Communication Gateway has six LED indicators that show the current status of the EtherNet IP and sub network communications The meanings of the LED indicators are described in Table 9 4 LED Number No Power Green Normal Operation 1 Flashing Green Configuration Missing Module Status Flashing Red Minor Fault Recoverable Red Major Fault Unrecoverable Flashing Green Red Self Test in Progress Off No IP Address Green Online Connection s Established 2 Flashing Green Online No Connection Established Network Status Red Duplicate IP Address Flashing Red Connection s Timed Out Flashing Green Red Self Test in Progress 3 No Link Link Green Connected to Ethernet Network 4 Off No Ethernet Activity Activity Flashing Green Receiving Transmitting Packets Flashing Green Running Transaction Error Detected Green Running Red Transaction error timeout Gateway Front View Off Power Off Subnet Status Flashing Green Red Invalid or Missing Configuration 6 Green Initializing Running Device Status Flashing Green Bootloader Mode Red Note the LED flash sequence and Flashing Red contact customer support 125 Manual Section 9 HGA IOM Manual HMS Gatewa
105. n drop down menu Once the PLC is found it can be used in RSLogix to program the DeviceNet scanner and establish a ladder diagram for the LED status display Similar to the PLC RSNetworx uses the 1770KFD network to changes properties on the Devices found on the DeviceNet network RSNetworx In RSNetworx the first step is to open tools and follow the EDS wizard option The EDS wizard is used to load the EDS file for the Anybus Gateway on the RSNetworx database The EDS file will be provided in the Anybus Gateway CD Next go to the network option and select online In the window that will appear select the DeviceNet network setup in RSLinx The software will populate the devices online on the graph window of RSNetworx Once all devices are on the network without errors and the network is online right click on the 1769 SDN Then go to properties A new window will appear go to the scanlist tab Move the Anybus Communicator from the Available Devices to the Scanlist Then click on the Anybus Communicator under the scanlist section Once the Anybus option is highlighted click on Edit I O Parameters button in the same window A new window will appear check the Polled option Put the input size as 16 Bytes and the Output Sizes 2 bytes The bytes sizes are as defined in the Anybus Configuration manager Hit Ok and click yes on the next two windows that appear Click now on the Module tab of the 1769 SDN scanner Module window In the plat
106. n the screen The date and time are also used for time stamps in the fault history and historical trend plots Language Setup Allows user to select Language English Spanish French This option allows the user to change the brightness and gamma of the display The contrast control is not enabled in this display model Close screen Set Date and Time Contrast disabled Screen Brightness Briahtness 3amma NOTE Screen is designed to be viewed at chest level If viewing from below and screen appears light in color adjust Gamma to the left Adjust to right if screen appears too dark 7 109 Manual Section 7 HarmonicGuard Active Tech Setup Screen To continue to the Tech Setup page select the Tech Setup button and enter the Tech Password 08252014 Next a splash screen will appear saying The Filter is about to stop see Figure 7 15 Choosing Next will stop the filter and take the user to the Tech Setup screen see Figure 7 17 Pressing the Back button returns the user to the screen and does not turn off the filter If the filter is off this splash screen will not appear Figure 7 15 Setup Transition Sub Screen The Tech Setup Screen see Figure 7 17 allows basic configuration of the HarmonicGuard Active filter operation Note It is recommended that the new settings are saved when changes are made See the description of the Save Settings button in Figure
107. n to the controls If a sensor wiring error 1s detected please reference the Sensor Error Auto Detection section on page 93 HGA IOM Manual 142 HGA IOM Manual Turn off unit and check 3 phase AC input voltage wiring for A B C phase rotation or missing phase connection Loads See Note 9 Warning HGA IOM Manual 3 Home screen check Compare Freq to expected line frequency Compare Supply Voltage to expected line voltage Current expected to be zero because unit is not running and CT inputs are shorted If status indicates a Fault press Stop button to reset condition 4 Status screen check Press Status to navigate to Status screen Compare Volts to expected line voltage Compare Freq to expected line frequency Current expected to be zero if unit is not running and CT inputs are shorted 5 Phase rotation check Press Phase to Neutral Voltage Plot Check that the current peaks follow the following sequence from left to right Phase A green Phase B blue Phase C red Equipment 15 phase rotation sensitive if phase rotation 15 incorrect power down unit and rewire to adjust phase rotation by swapping two incoming phase connections Improper operation will occur when input voltage phase rotation 15 incorrect 6 Converter check 2 Press Setup to navigate to Setup screen
108. nd Error 5 Target Device Message done DM Message Timeout Message Transmitting ST 0 Message Enabled EM 0 Local Remote Extended Routing Into EITOT Service Service Code hex Fifer Code Hex 0 Class hex dec Instance hex 100 Attribute hex dec Error Description Figure 9 7 Message Structure Read Command Settings Data files RIX 19 and RIX9 hold the message read and write information respectively The Anybus gateway configuration is programmed for 16 bit I O registers PLC word 2 bytes 1 Anybus 16 bit I O register As there are 8 registers in total the Size in Bytes Receive will equal 16 2 bytes for each PLC word e The above steps set the PLC settings to successfully communicate and exchange data with Anybus gateway The program can now be downloaded on to the PLC and set to run HGA IOM Manual 128 HGA IOM Manual Section 9 Appendix C Modbus TCP IP Gateway Option Introduction The Modbus TCP IP network Communications Gateway translates command status data to from the HMI Display s integrated network interface from the Modbus RTU protocol to Modbus TCP IP Modbus TCP IP also Modbus TCP is simply the Modbus RTU protocol with a TCP interface that runs on Ethernet The Modbus TCP IP Communications Gateway is implemented using a third party industry leading Modbus TCP IP solution from HMS
109. network then open a web browser window and type in the default IP address of the gateway see Table 9 6 and press enter The Communications Gateway configuration page should load see Figure 9 9 7 Configuration Mozilla Firefox Configuration FL 192 168 12 253 7 Configuration onfiguratic AnyBus S Ethernet 10 100 IP address 192 168 12 253 Subnet mask 255 255 0 0 Gateway address 192 168 10 20 DNS1 address 0 0 0 0 DNS2 address 0 0 0 0 Host name Domain name SMTP server SMTP user name SMTP password DHCP enabled STORE CONFIGURATION Figure 9 9 Modbus TCP IP Gateway Configuration Page Table 9 7 Gateway Default Settings Default Value IP Address 192 168 0 1 Gateway 255 255 255 0 255 255 255 0 DHCP Off To update the IP address type in a new IP address on the configuration page then click on the STORE CONFIGURATION button After the new IP address is stored cycle power to the Communication Gateway to load the new IP address HGA IOM Manual 130 7 HGA IOM Manual Section 9 For advanced configuration options such as IP Access Control reference the HMS Anybus Communicator Serial Modbus TCP IP Gateway User Manual available on the HMS website www hms se Register Map For a description of the input and output data available over the network interface reference Section 7 in this user manual Operation The Communication Gateway has s
110. nic filter designed and developed by TCI to relieve the power distribution system of the issues associated with harmonic currents that flow within the power distribution network caused by non linear loads The typical configuration can be found in Figure 3 1 The topology of the bus applied three phase three wire HGA consists of major components or modules Component 1 is made up of two current transformers CTs installed on phases A and C of the AC bus that is to be acted upon by the filter The purpose of the CTs are to supply information to the HGA regarding the integrity of the composite AC bus current with regard to the distortion non sinusoidal waveform and displacement power factor relative to the AC bus voltage These signals will result in the HGA injecting currents that will return the AC line current to near sinusoidal shape and at unity power factor Note that the CTs are located outside the HGA enclosure Component 2 is the HGA input circuit breaker optional This is provided to protect the HGA for destructive over current conditions if a malfunction occurs within HGA circuitry It also provides a convenient disconnect means and field wiring point for the installer of the filter equipment Components 3 and 4 are the high frequency converter inductors These inductors provide the proper inductance to the power converter Component 5 is the power electronic converter module The Power converter module PCM 15 the heart of the H
111. nobstructed Clean air filter in units that have filtered air inlets Clean as often as necessary to prevent dirt build up from impeding air flow Check for any dust or dirt build up on the fans and heat sink fins Check the operation of the cooling fan Inspect the interior of the enclosure for signs of overheated components Clean the interior of the enclosure whenever excess dirt has accumulated Check the integrity of all power ground and control wiring connections electrical connections must be re torqued annually Warning Many electronic components located within the filter are sensitive to static electricity Voltages imperceptible to human touch can reduce the and affect performance or A destroy sensitive electronic devices Use proper electrostatic discharge ESD procedures when servicing the filter and its circuit boards Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Disconnect all sources of power to the drive and HGA before working on the equipment Warning Do not attempt any work on a powered HGA This HGA unit contains high voltages and capacitors Wait at least five minutes after disconnecting power from the filter before you attempt to service the conditioner Check for zero voltage between all terminals on the capacitors Also check for zero voltage between all phases of the input and output lines All maintenance and t
112. o difficult proceed to step 2 2 There is a possibility that the CTs markings are different from the diagrams provided in Section 4 This could affect the polarity to verify this try reversing the two leads on TB 1 positions 1 amp 2 do the same with wires in positions 3 amp 4 Apply power for proper power up if it doesn t proceed to 3 3 Reverse just one set of CT leads at a time first 1 amp 2 verify power up If it doesn t work put wires 1 amp 2 back and now try the same with wires 3 amp 4 Apply power for proper power up 1f it doesn t replace all wiring to its original positions and proceed to 4 4 There is a possibility that the phasing of the CT L1 and L3 are incorrect To test this theory swap the two wires on TB 1 positions 1 amp 2 with the two wires in positions 3 amp 4 Apply power for proper power up if it doesn t repeat steps 2 and 3 5 Ifthe HGA doesn t indicate a run status after completion of steps 1 through 4 contact TCI technical support for further assistance System Failure The Digital Signal Processor is continually monitoring the performance and fault status of the filter It will shut down the converter section if the processor should sense a fault The filter is also equipped with a circuit breaker providing a second layer of over current protecting for the converter section The circuit breaker can also serve as a means of electrical isolation from the system power grid It is recommended
113. o navigate to Setup screen and press the Language Setup button Select language setting from the language setup pop up screen 2 Converter check 1 Press Setup to navigate to Setup screen Next select Tech Setup and enter the password 08252014 Select the Next button from the splash screen First select Harmonic PF Correction Setup On this pop up screen ensure PF Correct En and Harmonic Correction En buttons are OFF Blue If buttons are GREEN press them to toggle off Select the Next button from the pop up screen HGA IOM Manual 2 HarmonicGuard Active Line Side CT Placement L1 HarmonicGuard Active Next select Run Stop Control Setup on Tech Setup screen Select Auto Start Setup On this pop up screen ensure the Auto Start En button is OFF Blue If button is ON Green press to toggle off Navigate back to Tech Setup screen Now select Save Settings Press Status to navigate to Status screen Press Home to navigate to Home screen Built In Sensor Wiring Error Detection The active filter has an automatic sensor wiring error detection algorithm built into the controls If a sensor wiring error is detected please reference the Sensor Error Auto Detection section 3 Home screen check Compare Freq to expected line frequency Compare Voltage to expected line voltage Current expected to be zero because unit is not running and CT inputs are shorted
114. ollution Degree 2 according to EN50178 and UL508 e Excessive vibration 0 152 mm 0 006 in displacement 1G peak Please note that custom enclosure options may vary by available installation areas Working Space Provide sufficient access and working space around the unit to permit ready and safe installation operation and maintenance Make sure that the installation conforms to all working space and clearance requirements of the National Electrical Code NEC and or any other applicable codes Provide sufficient unobstructed space to allow cooling air to flow through the unit Mounting an Open Chassis Unit If you are mounting an open chassis unit in your own enclosure you must provide an enclosure that 15 adequately sized and ventilated sufficiently to prevent overheating Refer to Table 3 1 for dimensions and heat loss that 15 dissipated by the HGA The maximum ambient temperature should not exceed 40 C 104 F The 45 and 90 amp open chassis units have an ambient surrounding air temperature of 50 C 122 F Cooling Diagrams Please see Figure 4 1 through Figure 4 4 for cooling diagrams of the HGA HGA IOM Manual 24 Section 4 HGA IOM Manual 81671 9 VOS cv6 0056 0010106 LEL 6 06 0 GP qua soem 95 SSUDU puo a40uixoaddo suoisuaul T TI 5401 0231 J12ads 95943 OY IJL 39914093 OI uedoud 0 09 uj
115. pe 1 Figure 3 6 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be ALC45A00H0000 This designates an enclosed HarmonicGuard Active filter that is rated for 45 amps 480 volts and has an HMI Interface Module Package ALC Prefix Current Rating 45 90 Voltage Rating A 480 Filter Enclosure 00 Open Chassis 01 UL Type Package Option H Interface Module Circuit Breaker 20 ABB 100 40 A B 65kA 50 100 60 Eaton 65kA 70 Eaton 00 No breaker 01 ABB 65kA Reserved for custom options to be defined as needed each position can use 0 thru 9 Default option is 00 Only available for Open Chassis units Figure 3 6 HarmonicGuard Active Part Number Encoding 19 Manual Section 3 IOM Manual Communications Part Numbering Figure 3 7 below shows the Communications Module part numbering system The base communications unit is CM200A01 which has both the HMI and Modbus Current Rating 00 Voltage Rating A 480 C 600 Communication Options 00 Modbus RTU over RS485 01 EtherNet IP and Modbus TCP IP 02 DeviceNet Figure 3 7 Communcation Part Number Encoding Pedestal Part Numbering Figure 3 8 below shows the Floor Stand part numbering system The floor stand is currently only available for use with Type 1 enclosures Floor Stand Part N
116. ped Phase A current red in phase with Phase C voltage blue instead of Phase A voltage green Phase A current red 15 opposite polarity of Phase A voltage green and Phase C current yellow is opposite polarity of Phase C voltage blue Section 7 Check Phase C CT for open circuit or loose connection To correct swap Phase A and Phase C system CT current feedback and recheck plot To correct re install both Phase A and Phase C system CTs with polarity arrow in opposite direction OR swap positive and negative connections of each CT at HGA filter terminal block then recheck plot HGA Manual Section 7 HarmonicGuard Active Historical Trend Plot Menu Sub Screen From the historical trend plot menu sub screen you can view trend graphs of various HarmonicGuard Active filter system signals see Figure 7 10 Figure 7 10 Historical Trend Plot Menu Sub Screen Table 7 9 Historical Trend Plot Menu Sub Screen Elements Converter Temp Button Converter VLink Button Converter Current Button Current THD Button HGA IOM Manual Opens the HarmonicGuard Active filter heatsink temperature historical trend graph screen This signal is sampled every 15 seconds and historical data is maintained for 10 hours Opens the HarmonicGuard Active filter DC Link Voltage historical trend graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained Opens the
117. protocol to an alternate Fieldbus or Industrial Ethernet protocol such as Ethernet IP Back Vlew Side View Front View Network Gateway Interface PCB HMI Display Figure 6 1 Interface Module Components HGA IOM Manual 86 HGA IOM Manual Section 6 Additional Information Caution This section provides general information describing the Interface Module Be sure to carefully review the more specific information provided by the drawings shipped with the module Information from by the drawings takes precedence over the information provided in this section The information and ratings given in this manual are approximate and should not be used for any purpose requiring exact data Contact the factory in situations where certified data is required All data is subject to change without notice Receiving Inspection The Interface Module has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment After receiving the unit immediately inspect the shipping container and report any damage to the carrier that delivered the unit Verify that the part number of the unit received 15 the same as the part number listed on the purchase order See appendix for part numbering details 87 Manual Section 6 HGA IOM Manual Installation Guidelines Checklist The following are the key points to be followed for a successful installation These points are explained
118. r controlled electronic over current fault and over current protection load Over current protection All units have internal circuit breaker for protection of the converter section of the HGA The customer must supply branch circuit protection Please consult TCI regarding optimum filter performance when applied to DC drives 23 HGA IOM Manual Section 4 HGA IOM Manual Section 4 Pre installation Planning Verify the Application HGA Ratings Make sure that the HarmonicGuard Active filter 15 correct for the application and sized for load The voltage ratings of the HGA must match the input voltage rating of the connected AC bus Select a Suitable Location Environment Locating the HarmonicGuard Active filter in a suitable environment will help assure proper performance and a normal operating life Refer to the environmental specifications listed in Figure 3 2 marked on the unit s nameplate and or noted on the drawings furnished with the unit Warning Unless specifically labeled as approved for such use this equipment is not suitable for use in an explosive atmosphere or in a Hazardous Classified Location as defined in article 500 of the National Electrical Code NEC UL Type 1 and open chassis units must be installed in an area where it will not be exposed to e Direct sunlight e Rain or dripping liquids e Corrosive liquids or gasses e Explosive or combustible gases or dust Excessive airborne dirt and dust P
119. r more loads are connected Three phase power is connected to the input terminals of the unit and corrective current 15 supplied to the system through the HGA filter in response to the input signal being received from the CTs connected to the monitored bus The instructions and particularly the safety instructions for the drives motors and any other related equipment must be read understood and followed when working on any of the equipment Warnings and Cautions This manual provides two types of safety instructions Warnings are used to call attention to instructions which describe steps which must be taken to avoid conditions which can lead to a serious fault condition physical injury or death Cautions are used to call attention to instructions that describe 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 marked with the following symbols Dangerous Voltage Warning warns of situations in which a high voltage can cause physical injury and or damage equipment The text next to this symbol describes ways to avoid the danger General Warning warns of situations that can cause physical injury and or damage equipment by means other than electrical The text next to this symbol describes ways to avoid the danger Many electronic co
120. r one 1 year of useful service not to exceed eighteen 18 months from the date of shipment The foregoing limited warranty is TCI s sole warranty with respect to its products and TCI makes no other warranty representation or promise as to the quality or performance of TCT s products THIS EXPRESS LIMITED WARRANTY IS GIVEN IN LIEU OF AND EXCLUDES ANY AND ALL EXPRESSED OR IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE This warranty shall not apply if the product was a Altered or repaired by anyone other than TCT 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 TCT s reasonable judgment to be defective TCT s liability and the Buyer s exclusive remedy under this warranty is expressly limited at TCI s option to 1 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 O
121. rew driver Note CT operation can be verified via the HMI touchscreen feedback waveform plot screens Reference the HMI VLine amp ILine Waveform Plot Sub Screen in Section 7 for details 31 HGA IOM Manual Section 4 HGA IOM Manual Table 4 4 CT Range by Model Size 39 600V 250 5 3000 5 00 2 45 C open 250 5 3000 5 250 5 3000 5 78 600 250 5 3000 5 3000 5 Current Transformer Placement The exact CT placement is dependent on the HGA s configuration and size Please refer to the following current transformer diagrams for the installation that applies to your configuration HGA 45 to 150 Amp HGA 45 150 AMP LINE SIDE PLACEMENT Londs See Mote 2 Chee Hate 73 fog Hote L Conngctian Load CTS ETL Active Filter Figure 4 6 HGA 45A to 150A 480V Line Side Connection Drawing Manual 32 HGA IOM Manual Section 4 HGA 49 TO 150 AMP LOAD SIDE CT PLACEMENT Li See Hote 71 E 13 Loads pee Hote 7 3 Pose 1 rae ea Figure 4 7 45A to 150A 480 Load Side Connection Drawing HGA IOM Manual TO 33 Section 4 HGA IOM Manual Loads Chee Hote 7 filter __ Hebr 14 3 3 4 1 2 2 Ts Cam Hote 3 Unit 14
122. rmonicGuard Active filter in Volts DC Displays the present HarmonicGuard Active filter power converter emp ebay heat sink temperature in Degrees Celsius Filter Current Used Display Run Enable Summary This gauge displays the current filter capacity as a percentage of total available capacity In normal operation the display will read Nominal If the unit output corrective current is above 95 of maximum capacity the indicator light will turn red and display At Capacity When the converter is at capacity the Relay K4 J12 Connector and J11 Contacts used for a remote indicator will also be energized If the monitor continually displays Capacity a second filter may be required to handle the load Please contact TCI for assistance Displays the current state of all enables that affect the running of the HarmonicGuard Active filter If a button is red that option is disabled and if it is green that option is enabled If the Auto Start is enabled a countdown timer will run to the right of the button when the count reaches 0 the converter will start See Figure 7 5 Conv Curr Temp Button Displays current and temperature levels for each individual converter in the unit Back Button Returns user to the main status screen 97 HGA IOM Manual Section 7 HarmonicGuard Active Run Enable Summary Sub Screen The Run Enable Summary sub screen shows state of all the enables that affect t
123. roubleshooting must be done by a qualified electrician Failure to follow standard safety procedures may result in death or serious injury Unless an external disconnect means has been provided everything ahead of the filter circuit breaker will still be energized HGA IOM Manual 52 HGA IOM Manual Section 5 Reference Drawings Typical HGA configurations are illustrated in Figure 5 1 Figure 5 4 There could be slight differences between your unit and the configurations shown below It is recommended that you refer to the drawings provided with your specific equipment when conducting troubleshooting operations La L1 Load Ganverter CT Connection ip tional 696906 i X3 Connection L1 Heatsink Over Tenp Sensor Optional Converter Induc tar 55 to Converter Ineuctor 208 Saul 20 to 4DuF Hode Choke L3 BRKT 1 Converter Assembly Input Power Le Li OS O S 9 437 1 A a EL a AD Display Interface Board Cus toner Relay Contacts 26463 04 Has values 12 Enclosure fans will not be present on open chassis and some enclosure types 2 2 Refer to schematic 28283 on units with network gateways Motes Figure 5 1 General Schematic Bus Applied 600V 39 78 150 Amp amp 480V 45 90 100 and 150 Amp This drawing 15 for general reference only Use the drawings supplied with the unit for ins
124. sis units Figure 3 4 HarmonicGuard Active Part Number Encoding 17 Manual Section 3 HGA IOM Manual HGA Part Numbering System 600V Temperature 40 C Current 39 78 150 220A Voltage 600 Enclosure Open Chassis UL Type 1 or UL Type 3R Figure 3 5 identifies the significance of each character in the HarmonicGuard Active filter part number An example of a completed part number would be 5039 033 0110 This designates an enclosed HarmonicGuard Active filter that is rated for 39 amps 600 volts and has an HMI Interface Module Package 5 039 10 Current Rating 039 078 150 220 Voltage Rating C 600 Filter Enclosure 00 Open Chassis Ol UL Type 03 UL Type 3R Transformer Enclosure 0 Open Chassis 3 UL Type 3R Package Option H Interface Module no display if 3R Circuit Breaker 20 ABB 100 40 A B 65kA 50 100 60 Eaton 65kA 70 Eaton 00 No 01 ABB 65kA Line Load Control Line Control Master Software Load Control Slave Software Line Load Control Default Option 0 Default Option Only available for Open Chassis units Figure 3 5 HarmonicGuard Active Part Number Encoding Manual 18 HGA IOM Manual Section 3 HGA Part Numbering System 480V Open amp Type 1 50 C Temperature 50 C Current 45 90 Voltage 480 Enclosure Open Chassis or UL Ty
125. soococeeceeecscessssscoocosccesecessessssssoooosccescessssssssssoocsseecesssssssssssso 134 522 00008 134 ME 134 2 2 135 pec 135 Establishing Correct Network Sel E 137 BI cie mu 137 caia a A E 138 a re 139 Appendix E HGA Quick Start Unit Software Setup for HMI Revisions and Earlier 141 Revision Description 2 C Added 300A 09 10 14 Added 150A 480V Added 150A 600V Updated Quick Start Guide Rev B Updated 300A Drawings 09 26 14 Added Floor Stand 11 5 14 Added 600V 220A Added Legacy QS Guide as Appx E Updated Watts Loss on Standard Product Ratings and Dimension Tables HarmonicGuard Active Section 1 Section 1 HGA Quick Start Unit Software Setup for HMI Revision HGA IOM 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 HarmonicGuard Active HGA filter All wiring must be in accordance with the National Electrical Code NEC and or any other codes that apply to the installation site Disconnect all power before working on the
126. sources of power have been disconnected and that all capacitors have discharged before beginning work 141 HGA IOM Manual Section 9 1 Verify unit external connections Phase A B C power connection with positive A B C phase rotation expected CT HI Terminal is pointing toward the source CT feedback on phases A amp C to TB 1 Leave CT shorting bars place on TB 1 With the HGA circuit breaker open energize the source to the HGA Close the HGA circuit breaker Fans and HMI should come on in 5 seconds HMI will start on Home screen Load s have an integral 5 line reactance or equivalent dc bus choke Warning Hazardous voltages are present when unit 18 energized Language Selection The active filter supports several languages including English French and Spanish Press Setup to navigate to Setup screen and press the Language Setup button Select language setting from the language setup pop up screen 2 Converter check 1 Press Setup to navigate to Setup screen Ensure that Auto Start En Harmonic Correct and PWR Fact Correct buttons are off blue color If they are ON green press them to toggle to OFF blue Press Save Settings Press Status to navigate to Status screen Press Home to navigate to Home screen NOTE Built In Sensor Wiring Error Detection The active filter has an automatic sensor wiring error detection algorithm built i
127. system in accordance with NEC and local codes Connection must be made using a wire conductor 3 Customer is responsible for branch circuit protection Terminal TB 1 and J25 wire range is 30 12 Awg tightening torque is 4 4 in Ib 5 Nm 5 Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment 6 Current transformers should be centered around conductor 7 Load s have an integral 5 line reactance or equivalent dc bus choke IOM Manual 44 7 CJ HGA IOM Manual Section 4 HGA 600V amp 200A 480V TYPE 3R CT PLACEMENT Lt E aad Lz Caf Hl SOURCE FILER Loads a here Hote 72 CH 110 8 Converter NE WIRE Connection Connection Detail Detail HB 2453 4584 qus qun F iter Connectiar 4 516 510 See ee ae Pun Faut nt Pomer n Detail SS eee E 456 LT TNT ERMAL Cerne Mote E 8 Connection d d Prose A Power mm Note 1 het d Figure 4 16 HGA 150A 600V amp 200A 480V Type 3R Connection Drawing d 45 HGA IOM Manual Section 4
128. t J 00000 38 0001 0000 4 D _________ 85 485 noninverting RS 485SC G 4 gt GND RS 485 SC G no connect 7 no connect 8 00 00 D 1 RS 485 inverting Table 6 4 ModbusRTU Protocol Settings Default Value Baud Rate 19200 Data Bits 8 its 00 bits Even Slave ID Communications Gateway Connections Optional If an optional advanced network Communications Gateway is included in the Interface Module see Appendix A for the specific Communications Gateway wiring details If the optional network Communications Gateway 15 present the integrated ModbusRTU interface on the HMI Display will not be available When configured the Communications Gateway will occupy the ModbusRTU 2 3 DB9 connector on the back of the HMI Display HGA IOM Manual 92 HarmonicGuard Active Section 7 Section 7 Operation HMI Screen Elements This section focuses on the operation of the HMI Display The HMI Display contains several screens that allow the user to monitor the status of the line load and the HarmonicGuard Active filter Additionally the HMI display can be used for local run stop control and basic setup of the HarmonicGuard Active filter Table 7 1 General HMI Screen Elements HMI Graphic Element Description Buttons will appear raised or depressed depending on set point and command conditions Buttons Indicator status fields will Indicators appear flat
129. tallation 1767 53 Manual IOM Manual Section 5 ey dass 4 1 41111114114111 Lil Lulu m Lui ung Aas Sy 0 8 69 69 66 Sol FE I Figure 5 2 General Schematic Bus Applied 480V 200 Amp amp 600V 150A Open and Type 1 Master Master drawing is for general reference only Use the drawings supplied with the unit for installation 54 HGA IOM Manual HGA IOM Manual Section 5 16 wire 2920 Customer s 1 8 7 TB 1 Corver er Power 4 Au Rd Ua Figure 5 3 General Schematic Bus Applied 480V 200A amp 600V 150A Type 3R Parallel drawing is for general reference only Use the drawings supplied with the unit for installation LQ 55 IOM Manual Section 5 HGA IOM Manual BRE Conver ter Assenbly THe TE QU A 1 Input Power Ree a hit gt HE LE ea gt 4 eT Refer to schematic 28283 on units with network gateways Note Figure 5 4 General Schematic Bus Applied 480V 300 Amp Master Master This drawing is for general reference only Use the drawings supplied with the unit for installation HGA IOM Manual 56 TO HGA IOM Manual Section 5 Overload Over Current
130. ted to heat sink for cracked cases ruptures debris arcing and burning Check for any loose connections 1 no apparent damage 15 found to the power semiconductors Measure resistance of power semiconductors using a multi meter set on the diode check setting see Figure 5 6 Look for opens or dead short readings With the red lead of your meter connected to the far right negative terminal of the capacitor bank measure with the black lead of the meter to each of the three output terminals bus bars the reading should be approximately 0 350 Reverse the meter leads and repeat measuring to each terminal This time a low reading will be present which will continue to increase this 1s an indication of a capacitor charging Next connect the black meter lead to the positive capacitor terminal and again measure to each of the output terminals with the other lead the reading should be approximately 0 350 Reverse the meter leads and repeat measuring to each terminal Again it will be a low reading which will continue to increase If the readings are as described in all likelihood the power semiconductors are good If any readings are opens or dead shorts it will be an indication that something is bad in the power section Do not reapply power if you are not sure the IGBT s are good 50 HGA IOM Manual Section 5 Troubleshooting Flow charts Suspected System Failure Is circuit breaker NO Is active filter in active f
131. th Phase C current Power system down and check CT installation location and orientation if Phase A plots differ significantly from Phase C plots Stop 00 Open circuit CT outputs can result in high voltages and damage to equipment Warning Wiring the CT incorrectly can lead to improper operation which includes unit operating in limit and or contributing to rather than correcting harmonics olts 470 MZ Current 5 amp PMS 9 Current polarity 2 Power EERE K watts Navigate to Status screen Apparent Power gt 3 KYA Navigate to Line Load status Verify that Volts Current Power I THD and V THD match expected values for the power system THO 35 If they do not verify CTs are correctly installed 211 THD 1767 5 Manual Section 1 10 Final setup Press Setup to navigate to Setup screen e Next select Tech Setup and enter your password 08252014 Select the Next button from the pop up screen e First select Harmonic PF Correction Setup e Onthis pop up screen select Harmonic Correction En button and ensure the button is ON Green NOTE If unit is sized with sufficient capacity to provide power factor correction press PF Correct En and ensure the button is ON green e Next select Run Stop Control Setup from Tech Setup screen e Then select Auto Start Setup e On
132. the secondary terminals which may be dangerous to personnel or equipment 6 Current transformers should be centered around conductor 7 Load s have an integral 5 line reactance or equivalent dc bus choke to optimize Active Filter utilization consult TCI for Active filter capacity with less than 5 8 Source CT s are customer installed and external to the active filter Manual 36 IOM Manual Section 4 HGA 200 to 300 Amp HGA 200 500 480V amp 50 600V LINE SIDE CT PLACEMENT L1 E M S LJ Loads E ae See Nate 7 vee Note 3 x Loads Hate 7 m 385 Figure 4 10 HGA 200A to 300A 480V amp 150A 600V Line Side Connection Drawing 37 Manual Section 4 HGA IOM Manual 200 500 480V amp 150 600V LOAD SIDE CT PLACEMENT 11 E Lands a Note 7 m ate Mate 3 Loads Hote 72 edie Prisma cet eer Figure 4 11 HGA 200A to 300A 480V amp 150A 600V Load Side Connection Drawing HGA IOM Manual 38 Section 4 HGA IOM Manual Fer fe L T 221121 m 8 5 25 Javi uu CEP 58 LB 55 Is 19 IS UU E sing E 2 auri E H
133. the line load in kVA Displays current line load power factor 1 00 indicates unity power factor A negative power factor indicates lagging power factor Displays the Total Harmonic Distortion of the utility Line Load current as a percentage Displays the Total Harmonic Distortion of the utility line Voltage as a percentage Displays the reference Total Harmonic Distortion of the utility Line Load current in percent This THD display is the uncorrected THD of the Line Load taken when the HarmonicGuard Active filter was not running Runs and stops the HarmonicGuard Active filter Returns user to the main Status Screen 100 To HarmonicGuard Active Section 7 Waveform Plot Sub Screens The HMI display supports capture and display of real time system voltage and current data Three phase waveform data can be viewed for Line Voltage Line Load Current and Converter Corrective Current The waveform screens contain a zoom feature which supports three magnitude scales 2X and see Figure 7 8 The Refresh button on the waveform screens will update the plot with new data from the HarmonicGuard Active filter converter 100 A Figure 7 8 Example Waveform Plot Screens Converter Corrective Current Table 7 7 Waveform Plot Sub Screen Elements The Refresh button will reload the data from the HarmonicGuard Active filter Refresh Button mu M M Mr converter controller and redraw the waveform plot 1X 2X 1 2X
134. the main input terminals of the HGA filter All of these sources of power must be disconnected before working on the HGA filter After switching off the power always allow 5 minutes for the capacitors in the HGA filter and in the drive to discharge before working on the HGA filter the drive the motor or the connecting wiring It is good practice to check with a voltmeter to make sure that all sources of power have been disconnected and that all capacitors have discharged before beginning work 9 HGA IOM Manual Section 2 HGA IOM Manual General Terminology Throughout this manual many different terms are used A list of some typical terms can be found below These are provided in order to assist with the overall understanding of the manual Please feel free to contact TCI directly if there are any questions regarding any portion of this manual HarmonicGuard Active Filter TCI s brand name for a real time filter that mitigates harmonics while also maintaining near unity power factor An Active Harmonic Filter is any piece of equipment that actively monitors and changes the incoming AC line current HGA The term commonly used in place of the entire brand name of HarmonicGuard Active filter Active Harmonic Filter An active harmonic filter 15 a piece of equipment that reads the incoming voltage and current and injects current waveforms that cancel distortion This term 15 commonly used in place of the entire brand name of HarmonicG
135. thernet IP Gateway and Modbus TCP IP 123 HOTEL 123 bisher EE 123 Con UFAUOT o ________________ ELE 124 125 125 HMS Gateway to PLO Master obese in bap liu use 126 equi DEDE DIL E o ties 126 c M 126 DEOSPABAITHBO 126 Appendix C Modbus TCP IP Gateway Option cccccsssssssssssscccsssssscssssssssssscsscccsccccssssssssssssssssccesscssssssesees 129 DO tr Ore E eee Net A tat MEM E 129 b MI n 129 m TE 130 131 re en En 131 HMS Gateway EAI lc ti a te 131 Iseguited 131 M M M 132 al eet 132 a TL cL ELT METER A ace HE 133 Appendix D DeviceNet Gateway Option scssscessssssssss
136. this pop up screen select the Auto Start En button and ensure the button is ON Green Warning When Auto Start is enabled unit may operate without operator input e Navigate to Tech Setup screen Press Save Settings to save settings and restart converter e X Allow the unit turn on automatically about 30s HGA IOM Manual HarmonicGuard Active Ti 1 RuniStop Control Humber of faults allowed before Suto stan is disabled E valuation time freqeuncy of selected faults minutes HarmonicGuard Active Section 1 11 Final check Volts Current ARMS e Navigate to the Status screen mum e Navigate to Line Load status Power Watts e Note the corrected voltage current power THD Apparent Power KVA Power Factor on THO Pet 37 1 1 2 F aults Se 7 7 Manual Section 2 HGA IOM Manual Section 2 Safety Instructions Overview This section provides the safety instructions which must be followed when installing operating and servicing the HarmonicGuard Active HGA filter If neglected physical injury or death may follow or damage may occur to the HGA filter or equipment connected to the HGA filter The material in this chapter must be read and understood before attempting any work on or with the product The HGA filter is intended to be connected to the bus or power cables where one o
137. ting Failure to maintain the correct polarity and phasing of the current transformers CTs will cause an over current fault on power up The converter will never attempt to run it will stay in a stopped condition Possibly the CTs are installed backwards or the secondary wiring 15 incorrect if this is suspected refer to the steps below to isolate the error Note CT operation can be verified via the HMI touchscreen feedback waveform plot screens Reference the HMI VLine amp Line Waveform Plot Sub Screen in Section 6 for details Only qualified electricians should carry out all electrical installation and maintenance work on the HGA Failure to follow standard safety procedures may result in death or serious injury Disconnect all sources of power to the drive and HGA before working on the equipment Do A not attempt any work on a powered HGA Also check for zero voltage between all phases of Warning the input and output lines Operating current transformers with the secondary winding open can result in a high voltage across the secondary terminals which may be dangerous to personnel or equipment 1 Ifthe CTs and wiring is easily accessible double check the CT orientation for proper direction and trace the secondary wiring against the applicable diagrams in Section 4 for polarity phasing and connection to terminal TB 1 Correct any errors and apply power for proper power up 1f it doesn t clear the fault or if accessibility is to
138. tion present on the bottom left In this option the Input and Output words can be selected for the Scanner Select 73 Input words and 3 Output words The first 65 input words are reserved the words 66 73 are used to store the HMI data coming in from the Anybus Gateway Simiarly the first 2 ouput words are reserved leaving 1 word for HMI data The Input and Output data files present on the left panel of the RSLogix software hold the DeviceNet Scanner register values The reserved word definitions can be looked at in the scanner manual they serve as status bits The Ouput bit O 1 0 is the run bit for the scanner and can be toggled in the output data file Once the data files are understood the PLC is put into run mode and the data from the HMI can be seen in the IO data files Based on this information the below ladder diagram was built to observe the HMI status and report it though the DeviceNet network on a LED status setup 139 HGA IOM Manual Section 9 HGA IOM Manual Bul 1764 MicroLogix 1500 Bul 1764 MicroLogix 1500 Bul 1764 MicroLogix 1500 01 1764 MicroLogix 1500 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner 1769 SDN DeviceNetScanner DE Radix Binary Radix Binary Desc o
139. tton Turns off the HarmonicGuard Active filter Serial Display Displays the pre programmed factory serial number of the HarmonicGuard Active filter nore 1 Displays the total corrective current capacity in Amps RMS of the HarmonicGuard Active filter Displays the line voltage the HarmonicGuard Active filter is set to run on Displays the Digital Signal Processor type used in the HarmonicGuard Active filter power converter DSP Type Display 9 9 DSP Revision Displays the software revision of the installed Digital Signal Processor used in the HarmonicGuard Active filter power converter controller AVR Revision Display Displays the software revision of the installed microcontroller in the Interface PCB HMI Revision Display Displays the software revision of the HMI Display application code Sensor Wiring Error Auto Detection Sub Screen Some HarmonicGuard Active filter models are equipped with voltage and current feedback sensor wiring error detection algorithms The detection algorithms run briefly on unit power up and check the unit sensors for signatures of common wiring errors such as incorrect ACB phase rotation instead of the required ABC rotation and inverted system CT polarity CT Ratio Display Displays the CT ratio the HarmonicGuard Active filter is set to run on The Sensor Wiring Error Sub Screen is a pop up screen which is not accessible from any of the main navigation screens Th
140. ua uo CB 5 Bap gp 404 51 5155949 CL 2 PS LUNOW 5 sissouj C9 5 2 5 apis aq SUDY uon u iuaA ayy 40 2ual20 y4g8 uo Bulpuadag UT 2 W43 081 5 aad unulul CE 5au2u bs 40 1940414 sapis 241 40 Ul aunso 2ua 4 404 ul gpjnous 14914 sau2ui bs 082 40 0840 0101 09 40 ui eaAnsojua jo do Ul 840207 CI SALON 4404 9 ec 091 JW p Suv 4 SON Sun 4 epis 5 2 XOW x OW ia 0 do u6noau 19Sno0ux3 Diagram for 480V 300A and 600V 300A units ing Cooli Figure 4 4 7 7 28 HGA IOM Manual Section 4 Installation Guidelines Mounting The HGA must be mounted vertically on a smooth solid surface free from heat dampness and condensation Wiring Cable Entry Locations The enclosed HarmonicGuard Active filters are not provided with enclosure wiring knockouts however a
141. uard Active filter Bus Applied Filter A shunt device connected in parallel to the load This is an active filter designed to mitigate the harmonics associated with multiple loads The filter 15 directly connected to a main bus as can be found in a typical Motor Control Center The filter is sized for the amount of corrective current needed to be injected to cancel the offending harmonics A Digital Signal Processor DSP pulse width modulated controller is used for switching Insulated Gate Bipolar Transistor IGBT in order to cancel the harmonics Power Converter The power converter is the digital filter module of the HarmonicGuard Active filter Non Linear Load Input Line Inductor The three phase line reactor connected at the input of an adjustable frequency drive or other non linear load Converter Inductor The three phase inductor maintains a uniform air gap to give highly consistent and predictable inductance These inductors are connected to the inverter which buffers the inverter output from the analog portion of the filter the source and connected drives Current Transformer CT The device that monitors the incoming AC current waveform typically sized to handle the total connected load Manual 10 HGA IOM Manual Section 3 Section 3 Introduction Thank you for selecting TCI s HarmonicGuard Active filter TCI has produced this filter for use in variable speed drive and non linear load appli
142. umbering System FOL HGA F Product Type HGA Floor Stand Enclosure Type Type 01 Frame Size Frame El 480V 150A and 600V Frame E2 480V 300A and 600V 220A Figure 3 8 Pedestal Part Number Encoding Manual 20 HGA IOM Manual Section 3 Standard Product Ratings and Dimension Tables 480V 40 C Table 3 1 Open Chassis Heat Loss Dimensions Inch cm 3500 167 75 8 56 142 2 14 38 37 1 5250 267 121 1 69 10 175 5 17 43 2 14 5 36 8 7000 340 154 22 57 97 147 25 32 81 28 14 38 37 1 10500 541 245 4 69 1 175 5 32 81 2 16 9 43 Note Some circuit breaker door handle kits may require additional internal clearance when mounting an open chassis unit inside an enclosure Consult the circuit breaker manufacturer for any door handle requirements Table 3 2 UL Type 1 Enclosed Heat Loss Dimensions Inch cm Add two inches for disconnect circuit breaker handle Table 3 3 UL Type 3R Enclosed Heat Loss watts Weight Ibs kg Inch 3176 371 168 3 80 00 203 2 32 00 81 3 25 00 63 5 4000 371 168 3 80 00 203 2 32 00 81 3 25 00 63 5 6250 720 326 6 88 00 223 5 32 00 81 3 25 00 63 5 8000 1040 472 80 00 203 2 57 00 144 78 25 00 63 5 11 080 1330 603 3 94 00 238 8 57 00 144 9 28 2 71 6 Add two inches for disconnect circuit breaker handle Table 3 4 UL Type 12 Enclosed Heat Loss watts We
143. ure documents um 1769 um009 en p pdf Once the corrected baud rate and individual node addresses are assigned for the devices on the network the network and module LEDs on each device should be green RSLinx Classics Settings In RSLinx a new network is defined by click on the communications and then the configure drives option From the menu that appears select the 1770KFD DeviceNet option to view all devices on the DeviceNet network Once selected a window will appear with the Serial port and DeviceNet port settings drop down menus 137 Manual Section 9 IOM Manual Select the Serial port as listed in Device Manager in the windows control panel The data rate for the Serial port can be specified to 19200 For DeviceNet node address pick an address not assigned to the Anybus Gateway or the DeviceNet scanner to avoid address conflict The data rate 15 selected to 250K for this example The same data rate 15 set in the Anybus Gateway through the switches present on the Gateway and in the Scanner through the ML1500 PLC Once OK is hit the KFD will access the network once connected a box will appear to name the network This means the connection is successful By clicking on the network in the RSLinx main window it can be seen that the software automatically populates the right window panel with active devices on the network Similarly for the ML1500 PLC the RS232 option is selected in the Configure Drivers scree
144. utility input RMS voltage historical trend graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained Opens the line load RMS current historical trend graph screen This signal is sampled every 3 seconds and historical data is maintained for 2 hours Opens the HarmonicGuard Active filter RMS current historical trend graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained Opens the line load Total Harmonic Distortion historical trend graph screen This signal is sampled every 3 seconds and 2 hours of historical data is maintained 104 Ta HarmonicGuard Active Section 7 Historical Trend Plot Sub Screens The historical trend plot screens graph time stamped feedback data over an extended period of time Once the trend plot display data buffer 15 full the oldest data 15 overwritten Historical data can be viewed using the integrated scroll bars of the trend plot trend plot data is maintained between power on off cycles of the HarmonicGuard Active filter See Figure 7 11 for an example of a typical trend graph trend plot example 15 for the HarmonicGuard Active filter power converter heatsink temperature measurement Converter Heatsink Temperature 11 20 12 Figure 7 11 Example Historical Trend Plot Sub Screen Table 7 10 Trend Plot Screen Elements Screen Element Run Stop Button Runs and stops the HarmonicGuard Active filter
145. w are 480V circuit breakers and the trip levels specified are at 480V For 600V units that consist of a 600V 480V K Rated autotransformer paired with a 480V active filter the unit circuit breaker 15 located in the 480Vactive filter connected to the 480V secondary of the autotransformer 45Amp to 100Amp 480V 39A to 78A 600V A max peak let through current of 26 kA in correspondence with a short circuit of 100 kA at 480 volt The trip current for the 45A and 50A active filters must be 100 Amps and the 100A active filters must be 125 Amps 150Amp 480V A max peak let through current of 35 kA in correspondence with a short circuit of 100 kA at 480 volt The trip current for the 150A active filter must be 175Amps 200Amp 480V 150A 600V A max peak let through current of 35 kA in correspondence with a short circuit of 100 kA at 480 volt The trip current for the 200A active filter must be 225 Amps 300Amp 480V 220A 600V A max peak let through current of 55 kA in correspondence with a short circuit of 100 kA at 480 volt The trip current for the 300A active filter must be 350 Amps Warning If the system breaker has been tripped do not attempt to re energize the HGA unit until the cause of the trip has been determined Pre Charge Circuit Over Current Protection SCR s are used to limit the converter power up in rush current to a safe level once the converter DC voltage has reached the threshold SCRS will be turned on and the
146. y JI cd d uonoes eyou ees ejdsip IWH E EI JO aroge au os eq ue syed 181 desy 39 i iH eui au JO suoisnujoJd jo eq euynsopue jo 7 aounos Aue saged pue 204 dep eyenbepe si eeu eeuw uogeao 329 aouenbes jquessy S8b Su je3sur uonoeuuo TWH Installation Diagram 122 Figure 9 1 HGA IOM Manual HGA IOM Manual Section 9 Appendix Ethernet IP Gateway and Modbus TCP IP Option Introduction The EtherNet IP network Communications Gateway translates command status data to from the HMI Display s integrated network interface from the ModbusRTU protocol to EtherNet IP The EtherNet IP Communications Gateway is implemented using a third party industry leading EtherNet IP solution from Anybus Communicator Product Line Anybus Communicator AB7007 Table 9 1 EtherNet IP Communications Gateway Key Features EtherNet IP level 2 I O Server CIP EtherNet IP Adapter Class Profile Support Device 10 100 MBit twisted pair RJ45 Connection Galvanic Isolation Transformer isolated Ethernet interface TCP IP Settings Web Browser Based Configuration Baud Rate 10 100 MBit auto detect
147. y to PLC Master Example HMI slave connected through Anybus gateway to PLC Master Required equipment Anybus gateway programmed with TCI Anybus configuration e HMI display connected to Anybus gateway e Local Area Network LAN routers Rockwell ML1100 PLC e LED Network for output display e Ethernet RS45 cables Setup e Connect the RJ45 cable to the Ethernet Port on the Anybus gateway from a router LAN e Connect the PLC to the router LAN via RJ45 cable The network setup is displayed in Figure 9 4 Figure 9 4 Anybus Gateway Network Setup with PLC Example Programming e Once all the connections are set the PLC is programmed with the required configuration e The PLC and the Anybus are first established on the RSLinx network e The Ethernet Driver option is selected in RSLinx to find the PLC and the Gateway by typing the IP addresses for the respective devices in the Ethernet Driver configuration the Devices found by RSLinx RSLogix Micro is opened to program the PLC e There is no need to change PLC channel configuration settings e As example a ladder logic diagram has been presented see Figure 9 5 e Data files N7 integer and N18 integer are created with 8 words and 1 word respectively HGA IOM Manual 126 HGA IOM Manual Section 9 SG 1 Write gt _ MGIDO ksm
148. ystem remove power to the filter and Interface Module wait a few minutes then reapply If this does not work check all the cable and connections and try again If the problem is still not resolved replace the Interface Module assembly fno buttons are pressed for 5 minutes the screen will turn off To reactivate touch anywhere on the screen Ifthe HMI Display shows 1 Station 1 Communication Error across the bottom of the screen check the serial cable between HMI Display COMI and Interface PCB Ifthe HMI Display shows COM indication on the system state indicator or a 7010 Communications Fault in the fault screen check the serial cable between Interface PCB J2 and the HarmonicGuard Active filter power converter module 125 100A 504 units J7 200A units e For technical support contact TCI directly at 1 800 824 8282 Select Customer Service or Technical Support Fault Troubleshooting Flow Chart Suspected Problem with HMI IS the HMI Power LED On Aretheir lights on the display interface BD Isthere 120VAC on J3 on the display interface 15 their 24VDC on the power connector on the HMI Yes N Yes Replace the power cable from the 15 their 120VAC on the Control Transformer Isthe display in Sleep mode touch screen No Yes i y Send the HMI Back No Yes Replace the power Done to the factory fro R

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