mfc sinewave filter kit installation instructions€¦ · mfc kit instructions 2.0 receiving...

MFC Sinewave Filter Kit

Installation Instructions

TCI, LLC W132 N10611 Grant Drive Germantown, Wisconsin 53022 Phone: 414-357-4480 Fax: 414-357-4484 Helpline: 800-TCI-8282 Web Site: http://www.transcoil.com © 2019 TCI, LLC All rights reserved Effective: 01/09/2020 Version: E

Revision Description Date A Release 09/27/2016 B Update to drawings, heat loss 08/07/2018 C Update to drawings and cooling 12/13/2018

D Various text updates; added

Maintenance and Service section and PQconnect option

04/09/2019

E Updates to PQconnect section 01/09/2020

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of TCI, LLC. The information in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. TCI, LLC assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

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Table of Contents Introduction ............................................................................................................................................................ 2

Safety Instructions Overview ............................................................................................................. 2 Warnings and Cautions ..................................................................................................................... 2 General Safety Instructions ............................................................................................................... 3

Receiving Inspection and Storage ....................................................................................................................... 4 Receiving Inspection ......................................................................................................................... 4 Storage Instructions .......................................................................................................................... 4 TCI Limited Warranty Policy .............................................................................................................. 4

Pre-Installation Planning ...................................................................................................................................... 6 Intended Audience ............................................................................................................................ 6 Verify the Application......................................................................................................................... 6 Variable Frequency Drive Settings .................................................................................................. 10 Select a Suitable Location ............................................................................................................... 11 Mounting the Filter Kit ..................................................................................................................... 11 Power Wiring ................................................................................................................................... 11 Filter Schematic ............................................................................................................................... 11 Line Reactor Wiring ......................................................................................................................... 13 Capacitors ....................................................................................................................................... 14 Capacitor Brackets .......................................................................................................................... 15 Recommendations for MFC Kit Usage ............................................................................................ 16 Wire Sizing ...................................................................................................................................... 16 Installation Guidelines ..................................................................................................................... 21

PQconnect Connectivity Option ........................................................................................................................ 22 Product Description ......................................................................................................................... 22 Modbus RTU Connections .............................................................................................................. 23 Register Map ................................................................................................................................... 24 PQconnect Hardware ...................................................................................................................... 32 PCB Connections ............................................................................................................................ 35 Troubleshooting ............................................................................................................................... 37

Maintenance and Service ................................................................................................................................... 40

Periodic Maintenance.......................................................................................................................................... 40

Troubleshooting .................................................................................................................................................. 40

Evaluating MFC Sinewave Filter Performance ................................................................................................. 41

Replacement Parts .............................................................................................................................................. 41

Factory Contacts and Tech Support ................................................................................................................. 41

Product Description .............................................................................................................................................. 6 Part Number Encoding ...................................................................................................................... 7 MFC “A” Filter Kit – Sinewave Filter Kit with damping resistor ......................................................... 8 MFC “A” Filter Kit Part Number and Ratings ..................................................................................... 9 MFC “R” Filter Kit – Sinewave Filter Kit without damping resistor .................................................... 9 MFC “R” Filter Kit Part Number and Ratings................................................................................... 10

MFC Kit IOM 1.0 Introduction

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1.0 Introduction The information presented in this manual covers the MFC Sinewave Filter Kit (MFC Filter kit) only. Safety Instructions Overview

This section provides the safety instructions which must be followed when installing, operating, and servicing the MFC Filter Kit. If neglected, physical injury or death may follow, or damage may occur to the filter or equipment connected to the filter. The material in this chapter must be read and understood before attempting any work on, or with, the product.

The MFC Filter Kit is intended to be connected to the output terminals of a variable frequency drive (VFD). An AC motor is connected to the output terminals of the MFC Kit and receives power from the VFD through the MFC Filter Kit. The instructions, and particularly the safety instructions, for the VFD, motor 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 that describe steps that must be taken to avoid conditions that can lead to a serious fault condition, physical injury, or death.

Cautions are used to call attention to instructions that describe steps that must be taken to avoid conditions that can lead to a malfunction and possible equipment damage.

Warnings Readers are informed of situations that can result in serious physical injury and/or serious damage to equipment with warning statements highlighted by the following symbols:

Warning

Dangerous Voltage Warning: warns of situations where high voltage can cause physical injury and/or damage equipment. The text next to this symbol describes ways to avoid the danger.

Warning

General Warning: warns of situations that can cause physical injury and/or damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger.

Warning

Electrostatic Discharge Warning: warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger.

Cautions Readers are informed of situations that can lead to a malfunction and possible equipment damage with caution statements:

Caution

General Caution: identifies situations that can lead to a malfunction and possible equipment damage. The text describes ways to avoid the situation.

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MFC Kit IOM 1.0 Introduction

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General Safety Instructions These safety instructions are intended for all work on the MFC Filter Kit. Additional safety instructions are provided at appropriate points on other sections of this manual.

Warning

Be sure to read, understand, and follow all safety instructions.

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the MFC Filter Kit.

Warning

All wiring must be in accordance with the National Electrical Code (NEC) and/or any other codes that apply to the installation site.

Warning

Disconnect all power before working on the equipment. Do not attempt any work on a powered MFC Filter Kit.

Warning

The MFC Filter Kit, drive, motor, and other connected equipment must be properly grounded.

Warning

After switching off the power, always allow 5 minutes for the capacitors in the MFC Filter Kit and in the drive to discharge before working on the MFC Kit, the drive, the motor, or the connecting wiring. It is a 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.

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MFC Kit Instructions 2.0 Receiving Inspection and Storage

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2.0 Receiving Inspection and Storage Thank you for selecting the MFC Filter Kit. TCI has produced this filter for use in many variable frequency drive (VFD) applications that require output voltage filtering. This manual gives an overview of how to install, operate and maintain the MFC Filter Kit. Please contact TCI Technical Support or visit https://transcoil.com/Support for additional information

Receiving Inspection The MFC Filter Kit has been thoroughly inspected 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 components you received is the same as the part numbers listed on the engineering drawings for the kit which can be found at:

https://transcoil.com/products-kmg-mfcdrawings-htm/

Storage Instructions

If the MFC Filter Kit is to be stored before use, be sure that it is stored in a location that conforms to published storage humidity and temperature specifications in this manual and on the applicable technical drawings available at: transcoil.com. Store the unit in its original packaging.

TCI Limited Warranty Policy TCI, LLC (“TCI”) 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 at the end of the period described below:

Product Family Warranty Period

KLR, KDR For the life of the drive with which they are installed.

HGA, V1K, KLC One (1) year of useful service, not to exceed 18 months from the date of shipment.

MFC, HG7, KH, KRF Three (3) years from the date of shipment.

KCAP, KTR Five (5) years from the date of shipment.

All Other Products One (1) year of useful service, not to exceed 18 months from the date of shipment.

The foregoing limited warranty is TCI’s sole warranty with respect to its products and TCI makes no other warranty, representation, or promise as to the quality or performance of TCI’s products. THIS EXPRESS LIMITED WARRANTY IS GIVEN IN LIEU OF AND EXCLUDES ANY AND ALL EXPRESS OR IMPLIED WARRANTIES INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty shall not apply if the product was:

a) Altered or repaired by anyone other than TCI; b) Applied or used for situations other than those originally specified; or c) Subjected to negligence, accident, or damage by circumstances beyond TCI’s control,

including but not limited to, improper storage, installation, operation, or maintenance.

https://transcoil.com/Support


http://www.transcoil.com/

MFC Kit Instructions 2.0 Receiving Inspection and Storage

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If, within the warranty period, any product shall be found in TCI’s reasonable judgment to be defective, TCI’s liability and the Buyer’s exclusive remedy under this warranty is expressly limited, at TCI’s option, to (i) repair or replacement of that product, or (ii) return of the product and refund of the purchase price. Such remedy shall be Buyer’s sole and exclusive remedy. TCI SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL DAMAGES OR FOR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF INCOME, LOSS OF TIME, LOST SALES, INJURY TO PERSONAL PROPERTY, LIABILITY BUYER INCURS WITH RESPECT TO ANY OTHER PERSON, LOSS OF USE OF THE PRODUCT OR FOR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS. The foregoing warranties do not cover reimbursement for removal, transportation, reinstallation, or any other expenses that may be incurred in connection with the repair or replacement of the TCI product. The employees and sales agents of TCI are not authorized to make additional warranties about TCI’s products. TCI’s employees and sales agent’s oral statements do not constitute warranties; these 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.

MFC Kit Instructions 3.0 Pre-Installation Planning

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3.0 Pre-Installation Planning Intended Audience

This manual is intended for use by all personnel responsible for the assembly, wiring installation, operation and maintenance of the MFC Filter Kit. Such personnel are expected to have knowledge of electrical wiring practices, electronic components and electrical schematic symbols. Panel design using a TCI MFC Filter Kit should be performed with appropriate engineering supervision so the design meets the requirements based on materials utilized in the construction of the panel, wiring practices followed by your shop, and the actual ambient conditions of the components for each application.

Product Description The MFC Filter kit is a low-pass sine wave filter designed and developed by TCI to deliver conditioned power to motor loads driven by PWM drives at a variety of lead lengths. The MFC Kit is available for 460/480 Volt and 575/600 Volt systems.

The MFC Filter kit is a passive filter connected in series with the output terminals of the variable frequency drive. It is designed to remove the carrier frequency distortion from the output voltage waveform. The use of this low-pass filter will result in a nearly pure sine wave voltage profile. This design will reduce the effects of the reflected wave phenomenon, (dV/dt), such as insulation damage or premature failure in motors, transformers, and VFD output cables. The MFC Filter Kit will also reduce the effects of stray high frequency harmonic currents, thereby reducing VFD ground fault problems and noise interference in transducer signals.

The MFC Filter Kit is suitable for all lead lengths extending as far as 15,000 feet.

The MFC Filter Kit is available in the following configurations: 1. MFC A - Sinewave Filter Kit with damping resistor 2. MFC R - Sinewave Filter Kit without damping resistor

The MFC Filter Kit consists of the following standard features and components: • A TCI 3-phase line reactor specifically designed for high PWM ripple current from the

sinewave filter application • High-endurance, PWM current ripple rated capacitors • Damping resistors (optional) • Capacitor bleeder resistors to ensure safe capacitor discharge upon filter shutdown. • Brackets for mounting capacitors to a panel


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Table 23 – MFC Sinewave Filter Technical Specifications Voltage Rating

460/480 V and 575/600 V, 3-phase

Fundamental Frequency Range 0 Hz to 80 Hz Max. Horsepower Ratings 5 HP – 1000 HP at 480 V

5 HP – 750 HP at 600 V Consult Factory for additional ratings See Rating table for current ratings

Overload Capability 150% of rated current for 1 minute every 60 minutes: VFD carrier frequency 2 kHz to 16 kHz, greater than 4 kHz preferred Maximum output 480 V models: 600 V models:

Peak Voltage: 1000 V 1500 V Peak dV/dt: 500 V/μs 1500 V/μs

Insertion impedance Approximately 6.5% at 60 Hz & rated current Capacitors Oil filled or dry high endurance design (no PCBs) Environmental Conditions Operating Temperature Kit component ambient: 50°C (122°F) Storage Temperature 60°C (140°F) Elevation Up to 2,000 m without derating Humidity 95% non-condensing Agency approvals or certifications

Capacitors UR and cUR Recognized

Reactors UR and cUR Recognized

Part Number Encoding Figure 12 identifies the significance of each character in the MFC part number. The example part number MFC130AR designates an MFC kit that is rated 130A, 480 Volts and does not include resistors.

Figure 12: MFC Kit Part Number Encoding

NOTE: Individual part drawings for each component included in the MFC Filter Kits are found at: https://transcoil.com/products-kmg-mfcdrawings-htm/




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MFC “A” Filter Kit – Sinewave Filter Kit with damping resistor The MFC Filter Kit is a harmonic filter component package designed and developed by TCI to allow qualified customers to build sinewave filters to for the output of VFDs. The filter components are designed to filter out PWM switching ripple when applied correctly and following the schematic connections used by TCI. The MFC Filter Kit is available for 480 Volt and 600 Volt systems. When properly designed, assembled, and installed, the completed product is intended to be suitable for use with 3-phase PWM AC VFDs. The MFC A Filter Kit component package consists of the following components:

• A KTRMG series filter reactor. o The 480 V/900 HP and larger units include two reactors that need to be wired in

parallel. • High-endurance, PWM ripple current rated capacitors.

o Bleeder resistors to ensure safe capacitor discharge on filter shutdown, located on capacitors.

• Damping resistors o High power 3-phase damping resistors to reduce BFD control or load dynamic

induced resonances. Damping resistors are recommended for applications which have dynamically changing loads like hoists, elevators, or servos.

• Capacitor mounting brackets o Capacitor mounting brackets are provided on 50 HP and higher rated kits o Kits from 5 through 40 HP are not provided with capacitor brackets because

these units utilize single phase capacitors that do not have mounting brackets available for them. These small size single phase capacitors are typically mounted vertically due to the small size and reduced use of panel space.


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MFC “A” Filter Kit Part Number and Ratings

480 Volt MFC

Kit

HP Amp 480 Volt Model 5 8 MFC008AA

7.5 12 MFC012AA 10 16 MFC016AA 15 23 MFC023AA 20 30 MFC030AA 25 35 MFC035AA 30 45 MFC045AA 40 55 MFC055AA 50 65 MFC065AA 60 80 MFC080AA 75 110 MFC110AA 100 130 MFC130AA 125 160 MFC160AA 150 200 MFC200AA 200 250 MFC250AA 250 305 MFC305AA 300 362 MFC362AA 350 420 MFC420AA 400 480 MFC480AA 450 540 MFC540AA 500 600 MFC600AA 600 750 MFC750AA 700 850 MFC850AA 800 960 MFC960AA 900 1080 MFC1080AA 1000 1200 MFC1200AA

575/600 Volt MFC

Kit

HP Amp 575/600 Volt Model 5 8 MFC008CA

7.5 10 MFC010CA 10 12 MFC012CA 15 20 MFC020CA 20 25 MFC025CA 25 28 MFC028CA 30 35 MFC035CA 40 45 MFC045CA 50 55 MFC055CA 60 65 MFC065CA 75 80 MFC080CA 100 110 MFC110CA 125 130 MFC130CA 150 160 MFC160CA 200 200 MFC200CA 250 250 MFC250CA 300 305 MFC305CA 350 362 MFC362CA 400 420 MFC420CA 450 450 MFC450CA 500 500 MFC500CA 600 600 MFC600CA 750 750 MFC750CA

MFC “R” Filter Kit – Sinewave Filter Kit without damping resistor The MFC Filter Kit is a harmonic filter component package designed and developed by TCI to allow qualified customers to build sinewave filters to for the output of VFDs. The filter components are designed to filter out PWM switching ripple when applied correctly and following the schematic connections used by TCI. The MFC Filter Kit is available for 480 Volt and 600 Volt systems. When properly designed, assembled, and installed, the completed product is intended to be suitable for use with 3-phase PWM AC VFDs.

The MFC “R” Filter Kit component package consists of the following components:

• A KTRMG series filter reactor. o The 480 V/900 HP and larger units include two reactors that need to be wired in

parallel. • High-endurance, PWM ripple current rated capacitors.

o Bleeder resistors to ensure safe capacitor discharge on filter shutdown, located on capacitors.

• Capacitor mounting brackets o Capacitor mounting brackets are provided on 50 HP and higher rated kits o Kits from 5 through 40 HP are not provided with capacitor brackets because these

units utilize single phase capacitors that do not have mounting brackets available for them. These small size single phase capacitorss are typically mounted vertically due to the small size and reduced use of panel space.


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• Note: There are no damping resistors included, these kits are most suitable for VFD applications with low load and VFD dynamics

MFC “R” Filter Kit Part Number and Ratings

480 Volt MFC

Kit

HP Amp 480 Volt Model 5 8 MFC008AR

7.5 12 MFC012AR 10 16 MFC016AR 15 23 MFC023AR 20 30 MFC030AR 25 35 MFC035AR 30 45 MFC045AR 40 55 MFC055AR 50 65 MFC065AR 60 80 MFC080AR 75 110 MFC110AR 100 130 MFC130AR 125 160 MFC160AR 150 200 MFC200AR 200 250 MFC250AR 250 305 MFC305AR 300 362 MFC362AR 350 420 MFC420AR 400 480 MFC480AR 450 540 MFC540AR 500 600 MFC600AR 600 750 MFC750AR 700 850 MFC850AR 800 960 MFC960AR 900 1080 MFC1080AR 1000 1200 MFC1200AR

575/600 Volt MFC

Kit

HP Amp 575/600 Volt Model 5 8 MFC008CR

7.5 10 MFC010CR 10 12 MFC012CR 15 20 MFC020CR 20 25 MFC025CR 25 28 MFC028CR 30 35 MFC035CR 40 45 MFC045CR 50 55 MFC055CR 60 65 MFC065CR 75 80 MFC080CR 100 110 MFC110CR 125 130 MFC130CR 150 160 MFC160CR 200 200 MFC200CR 250 250 MFC250CR 300 305 MFC305CR 350 362 MFC362CR 400 420 MFC420CR 450 450 MFC450CR 500 500 MFC500CR 600 600 MFC600CR 750 750 MFC750CR

Verify the Application

MFC Filter Kit Rating Make sure that the MFC Filter Kit is correct for the application. The voltage rating of the filter kit must match the voltage and current rating of the connected drive. The horsepower and current rating of the filter kit must be appropriate for the connected load.

Variable Frequency Drive Settings Make sure that the variable frequency drive will be set for operation modes and ranges that are compatible with the MFC Kit:

• Maximum output frequency: 80 Hz • Constant PWM switching (carrier) frequency between 2 kHz and 12 kHz, ideally 4

kHz to 8 kHz • Mode of operation: speed control "scalar" or "V/Hz" without DC braking unless the drive

application has been confirmed by TCI Technical Support • Consult VFD manual for other drive specific recommendations for use with sinewave

filters, specific instructions may include but are not limited to: disabling any variable PWM switching frequency options such as features to reduce motor noise or control temperature and setting drive to continuous 3-phase modulation. Six-step operation is not compatible with sinewave filter technology.


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Select a Suitable Location Environment Locating the MFC Filter in a suitable environment will help ensure proper performance and a normal operating life. Refer to the environmental specifications listed on Table 5.

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.

The unit must be installed in an area where it will not be exposed to:

• Direct sunlight • Rain or dripping liquids (unless the filter kit is installed in a Type 3R enclosure) • Corrosive liquids or gases • Explosive or combustible gases or dust • Excessive airborne dirt and dust • Excessive vibration

Working Space Provide sufficient access and working space around the unit to permit ready and safe installation, operation and maintenance. Make sure that the installation conforms to all working space and clearance requirements of the National Electrical Code (NEC) and/or any other applicable codes. Provide sufficient unobstructed space to allow cooling air to flow through the unit.

Mounting the Filter Kit When mounting the filter kit in your own enclosure, you must provide an enclosure that is adequately sized and ventilated sufficiently to prevent overheating. Refer to the applicable kit drawings for rating and dimensions. The maximum temperature of the air around the MFC filter capacitors and line reactor should not exceed 50°C (122°F). Consult Technical Data tables 1, 2, 3, or 4 as appropriate when planning enclosure ventilation.

Power Wiring When selecting a mounting location for the MFC Filter Kit, plan for the routing of the power wiring.

Filter Schematic The schematic shown in Figure 1 is an illustration of a typical MFC filter wiring.

Figure 1 – Typical MFC “A” Filter Kit Wiring *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD)

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For horsepower ratings 480 V/ 900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors, as illustrated in the schematic below.

Figure 2 - Typical MFC “A” Filter Kit Wiring for 480 V/900 HP and larger with two reactors *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD)

The schematic shown in Figure 3 is an illustration of a typical resistor-less MFC (AR, CR) filter wiring.

Figure 3 – Typical MFC “R” Filter Kit Wiring *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD)


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For horsepower ratings 480 V/900 HP and larger the series line reactor is comprised of two parallel KTRMG reactors, as illustrated in the schematic below.

Figure 4 - Typical MFC “R” Filter Kit Wiring for 480 V/900 HP and larger with two reactors *DISCONNECT NOT REQUIRED BY UL IF FILTER SUPPLIED BY LOAD SIDE OF POWER CONVERSION EQUIPMENT (VFD)

Line Reactor Wiring

Consult the reactor drawing for your line reactor to verify proper filter wiring. All line reactor drawings are available on the parts web page:


The incoming line must be wired to the winding start noted as A1, B1, and C1 in the reactor drawing. The output to the motor load is connected to the winding end noted as A2, B2, and C2 in the reactor drawing.

In small line reactors with six position terminal blocks, the terminal block is wired A1, A2, B1, B2, C1, and C2 from left to right.



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Figure 5 – Six Position Terminal Block In line reactors where current exceeds the terminal block capability, copper flag terminations are used.

Figure 6 – Copper Flag Terminations

In larger line reactors, all the terminals extend from the front of the reactor and are constructed from copper bus bar terminals.

Figure 7 – Larger Reactors with Copper Flag Terminations

Wiring

TCI does not recommend running drive input and output wires in the same conduit. Capacitors

The high-endurance, PWM current ripple rated capacitors supplied in the MFC Filter kit are in shunt with the load. In the case of the MFC “A” Filter Kit, the capacitors are wired in series with the power resistors. If multiple capacitors are supplied with the kit, they are intended to be connected in parallel with each other. Typically, the capacitors are three-terminal, three-phase capacitors with the internal capacitive elements connected in delta. Each capacitor has a bleeder resistor connected across the three input terminals to ensure voltage discharges in the time required by UL.

Warning

Do not connect capacitors to power unless the bleeder resistors are connected, otherwise, hazardous voltages will remain across the capacitors after the power has been disconnected.

The small horsepower kits, 480 V/40 HP and below and 600 V/45 HP and below are supplied with single phase capacitors for each filter.


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These capacitors are connected in wye, and the bleeder resistors are connected across the terminals of each capacitor.

Figure 8 –Bleeder Resistor Installation and Wiring for Single Phase

Capacitor Brackets

Figure 9 – Capacitors and Brackets

Capacitor brackets supplied with the MFC kits mount the three-phase capacitors cans (480 V, 50 HP and higher, 600 V, 50 HP and higher) from a right-angle bracket using the studs on the bottom of the capacitors. The bracket surrounding the capacitors is mounted near the top of the capacitor can. Rubber grommet material is placed around the large diameter holes to prevent the edges of the bracket damaging the capacitor cans. This hole does not firmly clamp the capacitors and is not intended to do so: such a design would prevent the internal capacitor pressure disconnection means from operating. This bracket prevents gross motion of the capacitors during shipping vibration which could fracture the mounting bracket or allow the capacitors to hit other components.


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Recommendations for MFC Kit Usage Panel design using a TCI MFC Filter Kit should be performed with appropriate engineering supervision, so the design meets the requirements based on materials utilized in the construction of the panel, wiring practices followed by your shop, and the actual ambient conditions of the components for each application.

Wire Sizing Wires need to be sized based on current to be carried, wire insulation temperature rating, panel temperature rating, bundling of wires, and appropriate codes and standards. Wire size between drive and filter reactor as well as the filter reactor and the load are based on line current. Wire size in the branch circuit is based on rated capacitor circuit current. If the capacitor wiring is split into separate capacitor branches, the current each branch carries is proportional to the value of capacitance in each branch.

Additional Cooling Considerations Reactors generate heat during operation due to harmonic currents in the coil wire and magnetic fields in the core. Reactors constructed to Class R 220°C insulation system would be expected to have surface temperatures as hot as 195°C. Cooling of reactors needs to be considered during enclosure packaging design, otherwise these hot temperatures will get out of control and result in filter failures due to overheated reactors.

Customers should use filter power dissipation values to ensure enclosure forced convection capacity is sufficient to maintain maximum enclosure temperatures to 50°C or less. Sinewave reactors with rated currents from small values up to 480 A have been successfully used with natural convection cooling in TCI’s MotorShield product line. Natural convection designs require significant open ventilation area underneath the reactor and large open exhaust vents above the reactor to ensure proper cooling. In the case of forced convection cooling, these reactors will work as long as sufficient air movement is present to prevent excessive ambient temperatures.

Larger sinewave filter kits with current ratings greater than 540 A should be cooled with forced convection, and care should be taken to direct cooling air flow across the reactor coils. Baffles may be required to ensure cooling air entering the enclosure does not short circuit directly to the exhaust and not cool the reactor. If cooling air is directed through the ducts in a coil parallel to the core, it will help cool the reactor. Designers should be careful to avoid mounting reactors close to walls where there is no airflow.

Capacitors are more sensitive to high temperatures than reactors, so filter capacitors should not be mounted within a four inches of reactor coils where radiation from the coil would heat the capacitor. Capacitor surface temperatures should remain less than 65°C under worst case operation conditions.

Operating a sinewave filter at a higher carrier frequency decreases ripple current in the sinewave reactor. This decreases reactor internal power dissipation which decreases reactor temperatures.

TCI recommends customers verify intended cooling systems with drive output full current testing to ensure cooling provided is sufficient for the sinewave filter kit components.


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Table 1 – Technical Data for MFC “A” 480 Volt Models

Model Number

Load Rating (HP)

Rated Line Current

(A)

Capacitor Circuit Current

(A)

Power Dissipation (W)

MFC008AA 5 8 2.0 260 MFC012AA 7.5 12 3.0 330 MFC016AA 10 16 4.0 370 MFC023AA 15 23 6.0 515 MFC030AA 20 30 7.5 650 MFC035AA 25 35 8.5 710 MFC045AA 30 45 11.0 825 MFC055AA 40 55 10.5 1000 MFC065AA 50 65 16.0 1175 MFC080AA 60 80 20.0 1550 MFC110AA 75 110 28.0 1670 MFC130AA 100 130 32.0 1965 MFC160AA 125 160 40.0 2600 MFC200AA 150 200 49.0 3275 MFC250AA 200 250 61.0 3700 MFC305AA 250 305 75.0 4660 MFC362AA 300 362 89.0 4650 MFC420AA 350 420 102.0 5720 MFC480AA 400 480 117.0 6275 MFC540AA 450 540 132.0 7000 MFC600AA 500 600 146.0 7710 MFC750AA 600 750 182.0 9320 MFC850AA 700 850 205.0 10400 MFC960AA 800 960 235.0 11100 MFC1080AA 900 1080 2x 132.0 2x 7000 MFC1200AA 1000 1200 2x 146.0 2x 7710


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Table 2 – Technical Data for MFC “R” 480 Volt Models Model

Number Load Rating

(HP) Rated

Line Current (A)


(A)


MFC008AR 5 8 2.1 195 MFC012AR 7.5 12 3.2 220 MFC016AR 10 16 4.2 250 MFC023AR 15 23 6.3 300 MFC030AR 20 30 7.9 400 MFC035AR 25 35 9.0 410 MFC045AR 30 45 11.6 450 MFC055AR 40 55 14.2 475 MFC065AR 50 65 17.0 600 MFC080AR 60 80 21.0 775 MFC110AR 75 110 30.0 750 MFC130AR 100 130 34.0 825 MFC160AR 125 160 42.0 1000 MFC200AR 150 200 51.5 1050 MFC250AR 200 250 64.0 1500 MFC305AR 250 305 79.0 1650 MFC362AR 300 362 94.0 1500 MFC420AR 350 420 107.0 1800 MFC480AR 400 480 123.0 2100 MFC540AR 450 540 139.0 2350 MFC600AR 500 600 154.0 2500 MFC750AR 600 750 191.0 2700 MFC850AR 700 850 216.0 2600 MFC960AR 800 960 247.0 2800 MFC1080AR 900 1080 2x 139.0 2x 2350 MFC1200AR 1000 1200 2x 154.0 2x 2500


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Table 3 – Technical Data for MFC “A” 600 Volt Models

Model Number

Load Rating (HP)

Rated Line Current

(A)


(A)


MFC008CA 5 8 2.0 355 MFC010CA 7.5 10 2.0 370 MFC012CA 10 12 2.5 365 MFC020CA 15 20 5.0 530 MFC025CA 20 25 6.0 685 MFC028CA 25 28 7.0 715 MFC035CA 30 35 9.0 875 MFC045CA 40 45 11.0 945 MFC055CA 50 55 14.0 1180 MFC065CA 60 65 16.0 1540 MFC080CA 75 80 21.0 1610 MFC110CA 100 110 27.0 2140 MFC130CA 125 130 33.0 2290 MFC160CA 150 160 37.0 2510 MFC200CA 200 200 49.0 3430 MFC250CA 250 250 61.0 4505 MFC305CA 300 305 74.0 5065 MFC362CA 350 362 89.0 6055 MFC420CA 400 420 104.0 6830 MFC450CA 450 450 113.0 7400 MFC500CA 500 500 121.0 7850 MFC600CA 600 600 146.0 8850 MFC750CA 750 750 182.0 10700


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Table 4 – Technical Data for MFC “R” 600 Volt Models

Model Number

Load Rating (HP)

Rated Line Current

(A)


(A)


MFC008CR 5 8 2.1 205 MFC010CR 7.5 10 2.1 220 MFC012CR 10 12 2.7 215 MFC020CR 15 20 5.3 320 MFC025CR 20 25 6.3 400 MFC028CR 25 28 7.2 400 MFC035CR 30 35 9.5 435 MFC045CR 40 45 11.6 450 MFC055CR 50 55 14.7 560 MFC065CR 60 65 17.0 725 MFC080CR 75 80 22.0 775 MFC110CR 100 110 28.5 900 MFC130CR 125 130 35.0 925 MFC160CR 150 160 39.0 950 MFC200CR 200 200 52.0 1275 MFC250CR 250 250 64.0 1500 MFC305CR 300 305 78.0 1750 MFC362CR 350 362 94.0 1725 MFC420CR 400 420 110.0 2100 MFC450CR 450 450 119.0 2175 MFC500CR 500 500 127.0 2200 MFC600CR 600 600 154.0 2400 MFC750CR 750 750 192.0 2550


21

Installation Guidelines Installation Checklist The following are the key points to be followed for a successful installation.

Make sure that the installation location will not be exposed to direct sunlight, corrosive or combustible airborne contaminants, excessive dirt or liquids.

Select a mounting area that will allow adequate cooling air and maintenance access.

Make sure that all wiring conforms to the requirements of the National Electric Code (NEC) and/or other applicable electrical codes.

Connect the MFC equipment-grounding lug to the system ground of the premises wiring system. Use a properly sized grounding conductor.

Connect VFD output three-phase output to the input terminals of the MFC: A1, B1, and C1 terminals of the KTRMG sinewave reactor

Connect MFC output terminals A2, B2, and C2 terminals of the KTRMG sinewave reactor to the load. Connect MFC output terminals A2, B2, and C2 to the optional damping resistor (supplied as part of an A kit) or to the filter capacitors.

MFC Kit Instructions 4.0 PQconnect Option

22

4.0 PQconnect Option Product Description

The PQconnect is an integrated controls option for TCI’s industry sinewave filter used for filtering the output of variable frequency motor drives (VFDs). In the sinewave filter, the PQconnect provides unit status detection, metering, waveforms and power quality data. The PQconnect data is made available via basic Modbus RTU over RS485 serial connection. The PQconnect is UL listed and intended for commercial and industrial applications.

Modbus RTU

Introduction

The PQconnect Modbus RTU network communication interface transmits and receives command and status data from the PQconnect Modbus master over a RS-485 serial link. Modbus RTU is a simple serial communications protocol originally developed by Modicon for use with Programmable Logic Controllers (PLCs) in control of industrial devices. Modbus RTU is commonly supported by most PLCs and is an open, royalty-free communications standard.

The PQconnect implements a Modbus RTU Master/Slave device, which supports two-wire RS-485 signal levels. The PQconnect communication port used for the Modbus RTU interface is connected directly to the PCB. The communication port is located on the side of the PQconnect board.

Figure 10 – PQconnect Modbus RTU Connection

5 4 3 2 1

Modbus RTU Connections


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Modbus RTU Connections The hardware pinout for the J5 communication header and default settings is shown below.

Table 5: Modbus Connector Pin Definitions J5 Header Pinout Signal Name Signal Type 1 No connect - 2 D- RS-485 B (non-inverting) 3 GND RS-485 SC/G 4 D+ RS-485 A (inverting) 5 No connect -

The default protocol settings for the RS-485 Modbus RTU interface are shown below.

Table 6: Modbus RTU Protocol Settings Parameter Default Value Units Baud Rate 38400 Bd Data Bits 8 Bits Stop Bits 1 Bits Parity Even - Slave ID 10 -

Table 7: Configuration Switches

SW1 Configure Modbus Connection on J5 Header

1 – Enable 560Ω bias resistor on D-. 2 – Enable 120Ω termination resistor.

3 - Enable 560Ω pull-up on D+. J20 Remove jumper to use default Modbus settings on next reboot.

The input registers from the Sinewave filter are mapped to Modbus register address 40000, see Tables 14-16 for definitions of the input register maps. The output registers are mapped to Modbus register address 40500, see Tables 8-12. All input and output registers are two bytes in size and formatted as 16-bit signed integers.


24

Register Map Read Parameters: Table 8 : Network Interface OUTPUT/ Feedback Register Map

Parameter Name I/O Reg Address Offset

Direction Format and Examples Description

SYS_STATE 11 Output

0,1 = Initialization 2 = Power on Delay 3 = Fault Inhibit 4 = Reset 5 = Nominal 6 = Fault Detected 7 = Calibrate offsets 8 = Calibrate Check

Indicates the present state of the system state machine.

DSP_SW_VER 12 Output Two 8bit ASCII Characters 0x0141 = ASCII for "A1" Software revision code for processor.

DSP_MODEL_NUM 13 Output 103 = 480 V System Model Number

V_OUT_A_RMS 30 Output Volts RMS 4800 = 480.0 VRMSLL Range: 120 to 690 VRMSLL

Filter output RMS voltage phase A

V_OUT_B_RMS 31 Output Filter output RMS voltage phase B

V_OUT_C_RMS 32 Output Filter output RMS voltage phase C

V_OUT_A_THD 45 Output

% THVD 50 = 5.0% THVD

Filter output Phase A THVD (Voltage Total Harmonic Distortion)

V_OUT_B_THD 46 Output Filter output Phase B THVD (Voltage Total Harmonic Distortion)

V_OUT_C_THD 47 Output Filter output Phase C THVD (Voltage Total Harmonic Distortion)

T_AMBIENT 48 Output 250 = 25.0 C° Filter internal ambient temperature

V_OUT_FUND_HZ 100 Output Range 1 to 500 Hz Filter output fundamental frequency

V_IN_CARRIER_HZ 101 Output Range 1kHz to 16 kHz Filter input carrier frequency

V_OUT_ROT 102 Output

1 = ABC Rotation Expected 2 = ACB Rotation Expected

Filter output phase orientation


25

Read Parameters: Table 9 : Network Interface OUTPUT/ Feedback Register Map



FAULT_A 200 Output

0 = Disabled To Enable desired fault detections, enter bit mask from table by converting to decimal Range: 0 to 65535

Example: Enabling all fault conditions is 1111 1111 1111 1111 in binary or 65535 decimal. Reference Fault codes Table

FAULT_B 201 Output

FAULT_A_ENABLE_RO 202 Output If a fault is active and the bit corresponding to that status in this mask is set, the relay will be activated. Reference Fault codes Table Read only values. To change these values, modify the corresponding register in the setpoint section below.

FAULT_B_ENABLE_RO 203 Output

FAULT_A_RELAY_ACTION_RO 204 Output

FAULT_B_RELAY_ACTION_RO 205 Output

SYS_POWER 250 Output 0 = Power Off 1 = Power On

Indicates if the filter has input power available

SYS_FAULTED 251 Output

0 = Filter is operating 1 = Filter has detected a fault condition

Indicates filters status

RATED_VOLTAGE_RO 260 Output 4800 = 480.0Vrms Range = 1200 to 6900

Filter rated voltage. Read only value.

RATED_CURRENT_RO 261 Output 1000 = 100.0 A Range = 3 to 1500 A

Filter rated current. Read only value.

RATED_FEQUENCY_RO 262 Output 60 = 60 Hz Filter rated frequency Read only value.

MB_SLAVE_ADDRESS_RO 300 Output Default = 10 Range 0 to 255

Modbus slave address Read only value. To change this value, modify the corresponding register in the setpoint section below.

MB_BAUD_RATE_RO 301 Output

960 = 9600 baud rate 3840 = 38400 baud rate (default) 11520 = 115200 baud rate

Modbus baud rate Read only value. To change this value, modify the corresponding register in the setpoint section below.


26

Read Parameters: Table 10 : Network Interface OUTPUT / Feedback Register Map



MB_PARITY_RO 302 Output

0 = None 1 = Odd 2 = Even (default)

Modbus Parity Read only value. To change this value, modify the corresponding register in the setpoint section below.

CNT_CLOSE_DELAY_RO 320 Output

Relay close delay time in milliseconds Range 0 to 60 seconds

Delay time on fault relay being energized when any enabled fault condition is detected. This delay is in addition to any configured delay for a specific fault condition. Read only value. To change this value, modify the corresponding register in the setpoint section below.

CNT_OPEN_DELAY_RO 321 Output

Relay open delay time in milliseconds Range 0 to 60 seconds

Delay time on fault relay being unenergized when all enabled fault detection conditions have cleared. Read only value. To change this value, modify the corresponding register in the setpoint section below.

OVERVOLTAGE_FAULT_ONSET_RO 322 Output

Default 125% Range 100 to 200

Overvoltage onset threshold in percent rated voltage Read only value. To change this value, modify the corresponding register in the setpoint section below.

OVERVOLTAGE_FAULT_CLEAR_RO 323 Output

Overvoltage fault clear threshold Read only value. To change this value, modify the corresponding register in the setpoint section below.

OVERVOLTAGE_FAULT_DELAY_RO 324 Output

Fault detection delay time in milliseconds. Default of 6 seconds. Range 0.02 to 60 seconds

Overvoltage fault delay time. Read only value. To change this value, modify the corresponding register in the setpoint section below.

HIGH_FREQUENCY_FAULT_ONSET_RO 325 Output

Default 125% Range 100 to 200

Filter output high frequency fault onset threshold Read only value. To change this value, modify the corresponding register in the setpoint section below.

HIGH_FREQUENCY_FAULT_CLEAR_RO 326 Output

High frequency fault clear threshold Read only value. To change this value, modify the corresponding register in the setpoint section below.

HIGH_FREQUENCY_FAULT_DELAY_RO 327 Output


High frequency fault delay time. Read only value. To change this value, modify the corresponding register in the setpoint section below.


27

Read Parameters: Table 11 : Network Interface OUTPUT Register Map

Read Parameters:



PHASE_LOSS_FAULT_ONSET_RO 328 Output Default = 60 = 60% Range 1 to 100

Phase loss fault onset threshold (average of the three filter output voltages) Read only value. To change this value, modify the corresponding register in the setpoint section below.

PHASE_LOSS_FAULT_CLEAR_RO 329 Output Default = 55 = 55% Range 1 to 100

Phase loss fault clear threshold (average of the three filter output voltages) Read only value. To change this value, modify the corresponding register in the setpoint section below.

PHASE_LOSS_FAULT_DELAY_RO 330 Output


Phase loss fault delay time. Read only value. To change this value, modify the corresponding register in the setpoint section below.

THD_FAULT_ONSET_RO 331 Output

Default of 120 = 12.0% THD Range 2 to 100

Filter output high THVD fault onset threshold. Read only value. To change this value, modify the corresponding register in the setpoint section below.

THD_FAULT_CLEAR_RO 332 Output

THVD fault clear threshold Read only value. To change this value, modify the corresponding register in the setpoint section below.

THD_FAULT_DELAY_RO 333 Output


Voltage Total Harmonic Distortion (THVD) fault delay time. Read only value. To change this value, modify the corresponding register in the setpoint section below.

T_AMBIENT_OT_ONSET_RO 334 Output

Default = 20 = 20% Range 2 to 100

Filter Ambient overtemperature onset threshold. Read only value. To change this value, modify the corresponding register in the setpoint section below.

T_AMBIENT_OT_CLEAR_RO 335 Output

Filter Ambient overtemperature clear threshold. Read only value. To change this value, modify the corresponding register in the setpoint section below.

T_AMBIENT_OT_DELAY_RO 336 Output


Filter Ambient overtemperature fault delay. Read only value. To change this value, modify the corresponding register in the setpoint section below.


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Table 12 : Network Interface OUTPUT Register Map



REACTOR_OT_DELAY_RO 337 Output


Tuning reactor overtemperature fault delay. Read only value. To change this value, modify the corresponding register in the setpoint section below.

SYS_SERIAL_NUM_2_RO 350 Output

Parameter contains UUUU in the UUUULLLL-NN serial number format.

Unit serial number section - upper 16 bits of 32-bit unit job number Read only value.


Parameter contains LLLL in the UUUULLLL-NN serial number format.

Unit serial number section - lower 16 bits of 32-bit unit job number Read only value.


Parameter contains NN in the UUUULLLL- NN serial number format.

Unit serial number section - two-digit unit number. Read only value.

SYS_NULL_STAT 400 Output 0 = Not calibrated 1 = Unit is calibrated System auto null status

SYS_NULL_TMR 401 Output 0 = Unit is not calibrating 1 = Unit is Calibrating

System null timer; indicates whether the unit is calibrating

SYS_INT_HB 402 Output Range 0 to 65535

Processor internal heartbeat. Internal counter that counts up and rolls over to zero used to verify processor clock operation.

SYS_BG_HB 403 Output Range 0 to 65535

Processor background heartbeat. Internal counter that counts up and rolls over to zero used to verify processor clock operation


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Table 13 : Fault Codes

Bits Fault Descriptions

Register A

0 No fault detected / enabled

1 Overvoltage Phase A

2 Overvoltage Phase B

3 Overvoltage Phase C

4 High Frequency Phase A-B

5 High Frequency Phase B-C

6 High Frequency Phase C-A

7 Phase Loss (Phase A)

8 Phase Loss (Phase B)

9 Phase Loss (Phase C)

10 High THVD Phase A

11 High THVD Phase B

12 High THVD Phase C

13 Under Temperature

14 Over Temperature

15 CPU Error

Register B

0 Reactor Switch


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Write Parameters: Table 14 : Network Interface INPUT/Setpoint Register Map

Write Parameters:



USER_STATE_REQ 500 Input

0 = Initialization 9 = Save current values to flash 150 = Load values from Flash 255 = Restore Defaults to Flash

Note that defaulting the flash will clear all calibration data and require that the calibration procedure be re-run with no voltage applied to the PQconnect board.

TRACE_GO_DONE 501 Input 0 = Capture Done 1 = Start Capture

Update trace data points for waveforms

CNT_CLOSE_DELAY 505 Input

Relay close delay time in milliseconds Range 0 to 60 seconds

Delay time on fault relay being energized when any enabled fault condition is detected. This delay is in addition to any configured delay for a specific fault condition.

CNT_OPEN_DELAY 506 Input

Relay open delay time in milliseconds Range 0 to 60 seconds

Delay time on fault relay being unenergized when all enabled fault detection conditions have cleared.

POWER_ON_DELAY 507 Input

Default 20 = 20 milliseconds Range 0.02 to 60 Seconds.

System power on delay

RATED_CURRENT 520 Input 1000 = 100 A Range = 3A to 1500A Filter rated current

RATED_VOLTAGE 521 Input 4800 = 480 Vrms Range = 120 to 690 Vrms

Filter rated voltage

RATED_FREQUENCY 522 Input 50 = 50 Hz 60 = 60 Hz Filter rated frequency

FAULT_A_ENABLE 540 Input

0 = Disabled To Enable desired fault detections, enter bit mask from table by converting to decimal Range: 0 to 65535

Example: Enabling all fault conditions is 1111 1111 1111 1111 in binary or 65535 decimal. Reference Fault codes Table 3

FAULT_B_ENABLE 541 Input

FAULT_A_RELAY_ACTION 542 Input If a fault is active and the bit corresponding to that status in this mask is set, the relay will be activated. Reference Fault codes Table 3

FAULT_B_RELAY_ACTION 543 Input

MB_SLAVE_ADDRESS 560 Input DEFAULT = 10 Range 0 to 255 Modbus slave address

MB_BAUD_RATE 561 Input

960 = 9600 baud rate 3840 = 38400 baud rate (DEFAULT) 11520 = 115200 baud rate

Modbus baud rate

MB_PARITY 562 Input 0 = None 1 = Odd 2 = Even (DEFAULT)

Modbus Parity


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Table 15 : Network Interface INPUT Register Map



OVERVOLTAGE_FAULT_ONSET 600 Input DEFAULT = 125% Range 100 to 200

Set desired Overvoltage onset threshold in percent rated voltage

OVERVOLTAGE_FAULT_CLEAR 601 Input Overvoltage fault clear threshold

OVERVOLTAGE_FAULT_DELAY 602 Input


Overvoltage fault delay time

HIGH_FREQUENCY_FAULT_ONSET 603 Input Default 125% Range 100 to 200

Set desired High frequency fault onset threshold

HIGH_FREQUENCY_FAULT_CLEAR 604 Input Default 125% Range 100 to 200

Set desired High frequency fault clear threshold

HIGH_FREQUENCY_FAULT_DELAY 605 Input


High frequency fault delay time

PHASE_LOSS_FAULT_ONSET 606 Input Default = 60 = 60% Range 1 to 100

Phase loss fault onset threshold (average of the three filter output voltages)

PHASE_LOSS_FAULT_CLEAR 607 Input Default = 55 = 55% Range 1 to 100

Phase loss fault clear threshold (average of the three filter output voltages)

PHASE_LOSS_FAULT_DELAY 608 Input


Phase loss fault delay time

THD_FAULT_ONSET 609 Input Default = 20 = 20% Range 2 to 100

Set desired THVD fault onset threshold

THD_FAULT_CLEAR 610 Input Default = 20 = 20% Range 2 to 100

Set desired THVD fault clear threshold

THD_FAULT_DELAY 611 Input


Voltage Total Harmonic Distortion (THVD) fault delay time

T_AMBIENT_OT_ONSET 612 Input Default = 20 = 20% Range 2 to 100

Filter Ambient overtemperature onset threshold

T_AMBIENT_OT_CLEAR 613 Input Default = 20 = 20% Range 2 to 100

Filter Ambient overtemperature clear threshold

T_AMBIENT_OT_DELAY 614 Input Fault detection delay time in milliseconds. Default of 12 seconds. Range 0.02 to 60 seconds

Filter Ambient overtemperature fault delay

REACTOR_OT_DELAY 615 Input Tuning reactor overtemperature fault delay


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Write Parameters: Table 16 : Network Interface INPUT Register Map

PQconnect Hardware Example Application Using “Simply Modbus Master 8.1.0”

The Modbus RTU network interface port is configured for RS-485 signal levels. The following example uses an RS-485 to USB converter to connect the PQconnect to a laptop PC running the Modbus RTU master application. The picture below shows an example “US Converters Model: XS890” model RS-485 to USB converter. As another alternative RS-485 converter there is WINGONEER USB 2.0 to RS485 Serial Converter Adapter CP2104.

Figure 11: B&B SmartWorx, Inc Model: USPTL4 model RS-422/485 converter With the example converter above, the user can make proper connections from the RS485 converter to the PQconnect J5 communication header. The table below indicates the positions where the RS485 connections lead to. Please ensure the correct dip switch settings are applied before installing.

Table 17: USPTL4 to J5 Header Connections USPTL4 Pin Out J5 Header Pinout - No connect TDA (-) A (Pin 2) GND GND (Pin 3) TDB(+) B (Pin 4) - No connect

SYS_NULL_EN 700 Input 0 = Disabled 1 = Enabled

System auto null calibration enable. This value auto clears to 0 when calibration complete.

SYS_SERIAL_NUM_2 810 Input

Parameter contains UUUU in the UUUULLLL-NN serial number format.

Unit serial number section - upper 16 bits of 32-bit unit job number

SYS_SERIAL_NUM_1 811 Input Parameter contains LLLL in the UUUULLLL-NN serial number format.

Unit serial number section - lower 16 bits of 32-bit unit job number

SYS_SERIAL_NUM_0 812 Input

Parameter contains NN in the UUUULLLL- NN serial number format.

Unit serial number section - two-digit unit number


33

USPTL4 RS485 Converter Dip Switch settings All four switches of the B&B converter from the factory should be set to the ON position and should look like the following.

Figure 12: Dip Switch settings

Example Setup Instructions to Read Data from the PQconnect Unit: • Connect the cable to the communication header on the side of the board • Connect USB end to the computer

o Determine the assigned COM port number for the RS-485 to USB converter using the computer device manager control panel.

o The converter used in this example typically enumerates between the range of COM5 to COM20 on a standard laptop computer running the Microsoft windows operating system

• Open the Simply Modbus Master software o Can be downloaded from the link below: o http://www.simplymodbus.ca/manual.htm o The trial version of the software is free and fully functional for this task hence

no License key is necessary • Next, configure the fields in the screen as shown below. These are again the default

settings of the PQconnect COM port. o Note: The “notes” section of the display data registers are filled in manually

Example Setup Instructions to Write Data to the PQconnect Unit:

http://www.simplymodbus.ca/manual.htm


34

• In order to control the contactor in the unit, first the user will need tech access by writing the parameter keys

o Navigate to the settings menu and then select force open or force close button.

o The contactor state box will indicate if the contactor is open or closed.

• Next, select the “WRITE” button on the screen shown above.

• The screen below will be shown. Configure the fields as shown in the picture.

• Select “0” in the field “Values to Write” to close the contactor or “1” to open the contactor.


35

PCB Connections Most customer connections to PQconnect will be made on the PCB. Refer to connection diagram in Figure 9 and to drawing 24281-1PQ for the wiring schematic. The details of the power and communications terminals are shown in Table 18. Form C relays are available on the PCB, these connections are shown in Table 17. Two relay outputs are available on the PCB.

Figure 13: PQconnect Connections

Table 18: Form C Relay Contacts

Terminal Pin Description Label Tightening Torque Wire Range

J7 1, 2 Reactor Thermal Switch

Customer contacts 3.5 lb-in (0.4 Nm) 28-12 AWG

J8 N/A N/A N/A N/A N/A

J11 1

Fault Relay 1 Normally Closed

4.4 lb-in (0.5 Nm) 28-14 AWG 2 Common 3 Normally Open

J10 N/A N/A N/A N/A N/A

Note: Form-C relay contacts are gold plated with a load rating of 5.0A @ 120VAC


36

Table 19: Power & Communication Terminals Terminal Pin Description Label Rating

J1 1

Line Reactor Output Connections

Phase A

600VAC

2 Phase B 3 Phase C

J2 1

Line Reactor Connections

Phase A (Output of Line reactor) 2 Phase B (Input of Line Reactor) 3 Not connected

J3 1,2,3 Not Connected N/A

J4 1-8 Not Connected N/A

J5

1

RS485

Not Connected

N/A 2 B (non-inverting) 3 Ground 4 A (inverting) 5 Not connected

J12 1 Input Power from control

power transformer Neutral

120 VAC 2 Line

J14 1-14 Micro Programming For factory use N/A

Note: The power terminals on the PQconnect accepts 28 to 14 AWG stranded wire, with a tightening torque of 4.4 in-lb (0.5 Nm).

Depending on the size of the line reactor, you have the option of different terminations based on the reactor. Table 18 provides examples of the terminations used for the voltage sense wires from the PQconnect to the line reactor. All recommendations are used with 18 AWG stranded wire.

Table 20: Voltage sense wire termination

Note: Voltage sense wire terminals J1 & J3 accept wire gauges of 16-28 AWG with a tightening torque of 4.4 in-lb (0.5 Nm). Alternate/Equivalent tabs and ring lugs may be used for terminations. Please consult with TCI Tech-support if there are any questions for alternate parts.

Connector Termination

Manufacturer Part Number Manufacturer Description Reactor Size

Metal tab 43178-4002 Molex, LLC Blade Contact 18-20 AWG Crimp Male Blade

Small line reactors with six position terminal blocks.

3/8” Ring Lug 2-320573-4 TE Connectivity Amp Connectors

Large line reactors with copper bus bar terminals 1/4” Ring Lug 2-31894-2 TE Connectivity

Amp Connectors Ring Terminal Connector

1/2” Ring Lug 61863-2 Tyco Electronics


37

Troubleshooting

Warning

Only qualified electricians should carry out all electrical installation & maintenance work on the Sinewave filter. Disconnect all sources of power to the MFC and connected equipment before working on the equipment. Do not attempt any work on a powered MFC. The MFC unit contains high voltage 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 terminals on the capacitors. Also, check for zero voltage between all phases of the input and output lines. All maintenance and troubleshooting must be done by a qualified electrician. Failure to follow standard safety procedures may result in death or serious injury. Unless an external disconnect means has been provided everything ahead of the filter circuit breaker, including the reactors, will still be energized.

Receiving Inspection The connectivity board has been thoroughly inspected and functionally tested at the factory and carefully packaged for shipment. After receiving the unit, immediately inspect the shipping container and report any damage to the carrier that delivered the unit. Verify that the part number of the unit received is the same as the part number listed on the purchase order.

Connectivity Board Problem The MFC is comprised of five major components; the PQconnect connectivity board, the line reactor, the tuning reactor, the contactor and the capacitors. The PQconnect PCB contains diagnostic LEDs. The locations of the LEDs are shown in Figure 11 and their functions are listed in Table 20.

Figure 11: PQconnect LED Placements


38

Table 21: LED Functions LED LED Color Description D1 Green Fault Relay 1

D2 Green Fault Relay 2

D5 Green Status LED

D6 Green Microprocessor Status LED

D11 Green RS485 Communication is active

D20 Green 24V LED

D21 Green 5V LED

Note: Status LED’s will blink according to the filter status. The microprocessor status LED will blink 1hz if the filter is okay, however if there has been an alert the LED will blink according to the status detection. It will initially start with slow blinks (2 = Register A faults, 3 = Register B faults), then blink fast depending on the fault. Table 21 summarizes the LED blinks based on the fault condition.

Table 22: LED Codes Fault Group (Slow blinks) LED Specifier

(Fast Blinks) No fault detected/ enabled

2

1

Overvoltage Phase A 2

Overvoltage Phase B 3

Overvoltage Phase C 4

High frequency Phase A 5

High frequency Phase B 6

High frequency Phase C 7

Phase Loss (Phase A) 8

Phase Loss (Phase B) 9

Phase Loss (Phase C) 10

High THVD Phase A 11

High THVD Phase B 12

High THVD Phase C 13

Under Temperature 14

Over Temperature 15

CPU Error 16

Reactor Switch 3 1

Debug Fault conditions Based on the fault condition there are various ways a fault can appear. Before investigating the sinewave filter internally, disengage supply voltage to the filter.


39

Table 23: Fault conditions Fault Condition Description Debug

Overvoltage Phase A, B, or C

Filter has detected overvoltage on a phase(s)

Check input power connections to the filter.

High Frequency Phase A, B, or C

High Frequency detection on phase voltage(s)

Check fuses leading to filter capacitors If fuses are not blown, measure Capacitance of the capacitors Check power connections of the unit, reference drawing 24281-1PQ

Phase Loss Phase A, B, or C Filter phase loss

Check fused disconnect or circuit breaker upstream of the filter. Check input power connections to the filter

High THVD Phase A, B, or C

High voltage Total Harmonic Distortion

Check fuses leading to filter capacitors If fuses are not blown, measure Capacitance of the capacitors Check power connections of the unit, reference drawing 24281-1PQ

Under Temperature

Filter ambient temperature is operating below threshold

Check fuses of control power transformers leading to the heater.

Over Temperature

Filter ambient temperature is operating above threshold

Check fuses of control power transformers leading to fans. Make sure fans are operating

CPU Error Processor malfunction

Power cycle unit and if issue persists upgrade firmware and/or contact tech support

Reactor Switch Reactor Thermal Switch open Check thermal switch connections to PCB

MFC Kit Instructions 5.0 Maintenance and Service

40

5.0 Maintenance and Service MFC sinewave filter components have been designed to provide a service life that equals or exceeds the life of the variable frequency drive. The following periodic maintenance is recommended to ensure that the MFC sinewave filter kit will perform reliably and provide the expected service life.

Periodic Maintenance

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the MFC sinewave filter. Disconnect all sources of power to the VFD and MFC sinewave filter before working on the equipment. Do not attempt any work on a powered MFC sinewave filter.

• Check to see that the installation environment remains free from exposure to excessive dirt and contaminants. Refer to the Pre-installation Planning section of this manual.

• Check to make sure that the enclosure ventilation openings are clean and unobstructed.

• Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the enclosure whenever excess dirt has accumulated.

• Check the integrity of all power and ground connections.

• All electrical connections must be re-torqued annually.

Troubleshooting

Warning

Only qualified electricians should carry out all electrical installation and maintenance work on the MFC sinewave filter. Disconnect all sources of power to the VFD and MFC sinewave filter before working on the equipment. Do not attempt any work on a powered MFC sinewave filter.

Check to make sure current, drive switching frequency, and drive output fundamental frequency meet product specifications. Check to make sure ventilation openings are open and not blocked or clogged. Ensure reactor is not covered with a thick layer of dirt and dust. Measure filter capacitance with the filter disconnected from load. Perform line to ground DC insulation test of reactor with all parts disconnected from the reactor. Submit test values to tech support with part number for evaluation if continuous recordings have not been tracked.

MFC Kit Instructions 5.0 Maintenance and Service

41

Evaluating MFC Sinewave Filter Performance The MFC sinewave filter performance can be evaluated by checking the output voltage waveform with an oscilloscope.

Figure 10: Waveform at Input to MFC Sinewave Filter This waveform illustrates typical drive output and filter input voltages when measured from line to line.

Figure 11: Waveform at MFC Sinewave Filter Output This waveform illustrates typical filter output voltage waveform when measured from line to line. If the measured waveform does not resemble a sine wave like this illustration, and looks more like the filter input waveform, troubleshoot filter wiring and components.

Warning

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

Replacement Parts If replacement parts are needed, please contact your TCI representative. To ensure that the MFC sinewave filter continues to perform to its original specifications, replacement parts should conform to TCI specifications.

Factory Contacts and Tech Support For technical support, contact your local TCI distributor or sales representative. You can contact TCI directly at 800-824-8282. Select "Customer Service" or "Technical Support" and have your product information available.

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 © 2019 TCI, LLC All rights reserved Part Number #30335 Effective: 01/09/2020 Version: E

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