Amps Without HGA. Amps With HGA. Amps Without HSD Time (ms)

Transcription

1 Harmonic Solutions HarmonicGuard Active (HGA) Filter Save money and space: a single bus-applied HGA can correct harmonics for multiple loads Reduce current harmonic distortion to less than 5% allowing you to meet IEEE-519 specifi cations Easily monitor performance & remotely control the HGA with one of our communications options Patented Master - Master operation allows multiple fi lters to run in a more robust closed-loop mode Amps Without HGA Injection Current Amps With HGA HarmonicGuard Passive (HGP) Filter 3 2 Meets IEEE-519 requirements by limiting current harmonic distortion to less than 5% with background voltage distortion as high as 5% Internal fusing prevents capacitor damage 1kA SCCR simplifi es system acceptance Available with a wide range of options to suit any application Generator compatible Amps Without HGP Amps With HGP HarmonicShield (HSD) Filter 4 2 The HarmonicShield is TCI s newest addition to our passive harmonic fi lter line. 5% ithd Performance over a wide load range UL 58 Listed Available in UL Type 1 and Type 3R package 48V and 6V, up to 6 HP Optional contactor Available with or without lugs Amps Without HSD Amps With HSD KDR/KLR Line Reactor Extend your drive uptime by reducing the likelihood of the drive tripping Protect other equipment on the same bus from operational issues caused by voltage distortion Reduce overheating issues due to harmonic currents Visit Us At:

2 Power Factor Correction PF Guard TM Capacitor Bank Automatic Cap Bank prevents leading power factor and reduces apparant power drawn from the utility Returns power factor to near unity Includes a detuning reactor to mitigate resonance issues Motor Protection Solutions MotorShield TM Sinewave Output Filter (for cable leads up to approximately 15, ft.) Protect your motor and cable runs by reduction of vibration and heat to improve system performance Protects older and non inverter duty motors from the harmful effects of voltage spikes caused by VFDs Reduce audible motor noise Ideal for protecting lead insulation in downhole pumping applications Volts Without MotorShield Volts With MotorShield V1k dv/dt Output Filter (for cable leads up to approximately 1,5 ft.) Extend the life of your motor and cable by reduction of harmful voltage spikes due to dv/dt Protect cable runs and reduce motor heating, noise and vibration Prevent motor failure with protection against motor insulation breakdown Volts feet Without V1k Volts High Frequency Noise Solutions KRF EMC Filter With V1k 5 feet Filter EMI/RFI noise caused by power switching devices Prevent interference between automated lighting circuits, security cameras, and other critical electronics on your system TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #27865 Version 1.6 Copyright 216

3 Power Factor Correction The Power of PF Guard Avoid penalty fees and high utility bills with TCI s PF Guard. By providing reactive power to your system the PF Guard will improve your facility s power factor to near unity. This reduces the amount of costly apparent power the utility must provide. The PF Guard will reduce the demand on your electrical equipment, resulting in improved electrical system capacity and a more effective power supply. Powerful Features The PF Guard offers an automatic switching design, providing an optimized solution for your application. A detuned, anti-resonance reactor is built into the unit for an extra layer of protection from harmonics and to prevent equipment failure, reduce costs and increase the life of the system. What is Power Factor? All inductive loads require two types of power to function properly: Active power (kw) performs real work in loads such as motors Reactive power (kvar) is consumed by inductive loads such as AC motors and performs no productive work Power Factor is the ratio between the active power and the total power consumed (apparent power or kva) and is the standard measure of how effectively electrical power is being used by a system. Why Improve Power Factor? When the power factor is below 1. or unity, the electrical capacity of the system decreases, forcing the utility to supply more apparent power than necessary. Utilities can pass on the resulting costs to the industrial users as power factor penalties and high utility bills. Issues caused by low power factor may include: Poor system performance High energy costs Electric surcharges Harmful environmental impacts

4 Power Factor Correction Technical Characteristics Voltage Rating 48 VAC Phase 3-Phase Operating Frequency 6 Hz Fuse Interrupt Rating 2kA SCCR Rating 1kA: Terminal block, disconnect switch or fuse block option 5kA: Circuit breaker only, 65kA: With customer supplied fusing KVAR Rating(s) 15, 2, 25, 3, 4, 5, 6 Voltage Unbalance 1% maximum Continuous Overvoltage 11% Capacitor Tolerance ±5% Expected Life Over 13, operating hours Maximum Harmonic Voltage 5% Discharge Time Less than 1 minute Environmental Conditions Operating Temperature Enclosed: -1 C (14 F) to 4 C (14 F) Storage Temperature -3 C (-22 F) to 6 C (14 F) Relative Humidity 95% non-condensing Operating Altitude Up to 1,m without derating Cooling Method Forced Air Convection Reference Technical Standards Protection (Enclosure) UL Type 1 Agency Approvals UL 58A Part Numbering System Typical Applications Large Industrial Heavy Manufacturing Wood Processing Steel / Paper Mills Tire / Rubber Refi neries Mining TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #29745 Version 1.3 Copyright 215

5 Harmonics & Power Quality Poor power quality can be a result of variable frequency drives or other types of non-linear loads using a power conversion process that causes current and voltage distortion. This resulting distortion is known as harmonics. Issues caused by harmonics may include: Transformer and distribution equipment overheating Random breaker tripping Sensitive equipment failure Poor power factor HarmonicGuard Active Filter The HarmonicGuard Active (HGA) filter monitors the load current and reacts to changes almost instantaneously. A counter current is injected by the unit to cancel out harmonics and synchronize the current and voltage waveforms. True power factor will be returned to near unity if power factor correction is enabled on the filter. The HGA meets even the most stringent IEEE requirements with its advanced technology. A large, built-in, 65k color touchscreen HMI display with LED backlight is included, along with the communication options of Modbus RTU over RS485, Modbus TCP/IP, EtherNet/IP, DeviceNet and HGA-HMI. HGA Filters vs. Other Harmonic Solutions In comparison to 18-pulse drives, the HarmonicGuard Active filter is superior in many aspects and features including: The HGA is a bus-applied solution eliminating the need for harmonic correction at each drive which results in significant savings Can be installed in an MCC section Offers up to a 65% reduced footprint when coupled with a standard 6-pulse drive The HGA is a shunt-applied device: a failure will not shut down your processes Can be less expensive than multi-pulse and AFE (active front-end) variable frequency drives Optional add-ons: (contact factory for more details) Ready to assemble wall mount or floor stand Portable HMI unit (HGA-HMI) for 3R units Remote mountable HMI unit for open chassis and 3R units Advantages of the HarmonicGuard Active Filter The HGA s patented master-master operation provides unparalleled accuracy not found in other active filters Up to six HGA filters can be connected in parallel to increase correction capability Automatic harmonic cancellation Remaining capacity, after harmonic target is achieved, can be applied towards power factor correction Bus-Applied Configuration for MCC or Switchboard The HGA can be directly connected to the power bus in standard MCC and Switchboard configurations. Large, 65K Color HMI Typical Applications Wastewater Treatment Plants Mining Material Handling Oil & Gas HVAC Systems Chemical Processing Data Centers Renewable Energy Pulp & Paper

6 Technical Specifications Compensation Capacity (Parallel for High Capacity) Technical Characteristics Power Factor Correction Response Time Harmonic Cancellation Spectrum 48 V: 5A, 1A, 15A, 2A, 25A, 3A, 4A, 5A; 3-phase, 6 Hz 6 V: 39A, 78A, 11A, 15A, 185A, 22A, 37A; 3-phase; 6 Hz Up to.98 lagging Less than 8 ms to step load changes To the 5th harmonic - auto-selecting RMS Current Attenuation Less than 1:1 Parallel Configuration Up to six active filters can be connected in parallel* Display High quality 6 65k color touchscreen with LED backlight Communications Modbus RTU over RS485, Modbus TCP/IP, EtherNet/IP, DeviceNet, HGA-HMI Environmental Conditions Open Chassis: C (32 F) to 4 C (14 F) Derating above 4 C UL Type 1: C (32 F) to 4 C (14 F) Derating above 4 C Operating Temperature UL Type 12: C (32 F) to 4 C (14 F) Derating above 4 C UL Type 3R: -2 C (-4 F) to 4 C (14 F) Derating above 4 C Relative Humidity 95%, non-condensing Operating Altitude 1, m (3,3 ft), up to 3, m (9,9 ft) with derating Storage Temperature Open Chassis, UL Type 1 & UL Type 12: -2 C (-4 F) to 6 C (14 F) UL Type 3R: -4 C (-4 F) to 6 C (14 F) Reference Technical Standards Agency Approvals UL & cul Listed Protection (Enclosure) Open Chassis, UL Type 1, UL Type 12, UL Type 3R Over Current Protection Molded Case Circuit Breaker HMI Languages English, French, Spanish Surge Protection ANSI C62.42 Warranty One year of useful service, or 18 months from shipment *Consult factory for larger systems. Non-linear Load Waveform Resulting Line Current Waveform TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #28722 Version 1.7 Copyright 216

7 Harmonics & Power Quality TCI s HarmonicGuard Passive gives you options. Our HGP 5% harmonic filter is a performance product with the versatility to tackle tough application challenges. This field-proven passive fi lter has factory options available to meet your specifi c requirements, such as: Contactor - Can be used to disconnect capacitors to prevent leading power factor. Fuse Monitor - The fuse monitor will detect a fuse failure. Heater - Protects internal fi lter electronics from corrosion and condensation. Vibration Pads - Reduces audible noise. Floor Stand - 12 steel feet for Type 3R enclosures 125hp and below. Units 15 hp and above include provisions for fl oor mounting. Custom designs are available upon request. HarmonicGuard Passive Filter Limits current harmonic distortion to less than 5% over a wide load range Industry leading performance under high background voltage distortion True 1kA SCCR IEEE compliant Generator compatible Increases drive uptime Eliminates nuisance tripping ithd% vs. % Load % ithd % Load HGP Filters vs. Other Harmonic Solutions Today s marketplace has provided numerous products intended to address harmonics and power quality issues in industrial applications. TCI is focused on developing solutions that offer the lowest total cost of ownership for the end user. Compared to 18-pulse drives, the HGP: Is a more efficient and reliable solution at reduced loads Has a better ithd at reduced loads Saves money by reducing operation costs and energy loss Has a smaller footprint Compared to Active Front End, the HGP: Does not require input (LCL and EMI/RFI) filters as AFE does. Is a more cost effective solution. Produces no ground leakage current. Application The HGP filter is a drive applied 5% passive harmonic filter. High quality components and a robust design allow this passive filter to deliver best in class performance under the harshest conditions and in the most challenging applications. Typical Applications Oil & Gas Steel Industry Water/Wastewater HVAC Systems Machining Airports Commercial Buildings Hospitals Irrigation Fields, Farms Extruders Pulp & Paper

8 Technical Specifications Voltage / Frequency Rating 28, 24, 48 & 6 VAC- 6 Hz 4 VAC- 5 Hz Phase 3Ø Motor drive input power rating range 28, 24 VAC: 5-1 Hp 4 VAC: 4-1 KW 48, 6 VAC: Hp SCCR (Short Circuit Current Rating) 1 ka Immunity from Voltage Distortion Less than 5% ithd at full load with vthd as high as 5%* THID Less than 5% at full load Efficiency Greater than 99% Overload Capability 2% of current rating for 3 minutes Environmental Conditions Operating Temperature Open: 5 C (122 F), Enclosed: 4 C (14 F) Storage Temperature 6 C (14 F) Elevation Up to 1, m without derating. Consult factory for higher elevations. Humidity 95% non-condensing Protection Category Open Chassis, UL Type 1, UL Type 3R and Type 12 enclosure Cooling Method Natural or Forced Air Convection Reference Technical Standards Agency Approvals culus Part Numbering System H G P 1 5 L X 1 S Series: Rating (HP - 6Hz) ( kw - 5 Hz ): Voltage Rating: A - 48 V B - 24 V C - 6 V D - 28 V L - 4 V Frequency: W - 6 Hz (HP Rated) X - 5 Hz (kw Rated) Enclosure: - Open 3 - Type 3R 1 - Type Type 12 Option: S - Standard C - Contactor F - Contactor and Fuse Monitor G - Standard & Fuse Monitor Option: - Standard Option: - Standard F - Floor Stand (for 15 HP and below Type 3R & 2 HP and below Type 1) Option: - Typical Voltage Distortion 1 - High Voltage Distortion Option: - Standard H - Heater (only available on Type 3R Enclosures) P - Oilfield Version V - Vibration Pads P One-Line Diagram (System Bus/ Panel/ Source Transformer) LINE Current Distortion (ithd) vs. Background Voltage Distortion (vthd) % ithd LINE REACTOR FUSE % vthd (VFD) LOAD CONTACTOR(S) (Optional) TUNING REACTOR CAP(S). *When configured for High Background Voltage Distortion. See IOM for guidelines for distortion above 5%. TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #28559 Version 1.8

9 Harmonics & Power Quality TCI s HarmonicShield passive harmonic filter offers the best-in-class performance that you expect from TCI at a price that you don t. TCI s new HarmonicShield is a 5% passive harmonic fi lter designed for a wide variety of standard duty indoor and outdoor environments, wherever a VFD is used. Harmonics Power system harmonics are not new. However industrial equipment generate more harmonics than ever while simultaneously sensitive electronic equipment is becoming increasingly susceptible. Couple this with the transformer heating and nuisance breaker trips caused by harmonics as well as the utilities IEEE-519 mandate and managing harmonics is no longer optional. And while the problem is well known, the solution can at times be confusing. Multi-pulse drives, harmonic mitigating transformers, active front end drives, standard VFD with harmonic mitigating equipment; which one is right for you? HarmonicShield TCI s new HarmonicShield can make the decision easy. The HarmonicShield offers industry leading 5% ithd performance even at light loads and under the harshest of conditions. The optional contactor allows the tuning circuit to be disconnected at light loads to avoid leading power factor problems. Natural convection cooling means no moving parts. A lug kit option accommodates oversized cabling if needed. All this is backed up by TCI s 3 year warranty, which means you will have many years of hassle free operation. General Application and Maintenance Free The HarmonicShield (HSD) filter is built using the highest quality components and is suitable for general power quality applications and normal environmental conditions. The HSD filter is designed with simplicity in mind. This convection cooled, maintenance-free fi lter requires no adjustments once installed. Typical Applications Oil & Gas Equipment Metal Processing Equipment Water/Wastewater Pump Systems HVAC Compressors and Blowers Irrigation Pumps Extruders Pulp & Paper Mills ithd 12% 1% 8% 6% 4% 2% The Economics of Harmonics If you re like most, spending the least possible amount of your budget on harmonic mitigation is a goal. A 6-pulse drive with TCI s new HarmonicShield passive harmonic filter is the most cost effective method of meeting IEEE-519: 214 s tightest standards. When compared to an 18-pulse drive solution the HarmonicShield and 6-pulse drive combination can save you up to 46%. And when compared to an active front end drive that number shoots up to 59%. The HarmonicShield offers TCI s industry best performance in an economical package. Price Ratio ithd Price Ratio % 6-Pulse Drive 6-Pulse Drive + Line Reactor 6-Pulse Drive + HarmonicShield 18-Pulse Drive HSD vs. Other Harmonics Solutions Active Front End Drive.

10 Technical Specifications Voltage / Frequency Rating 48 & 6 VAC- 6 Hz Phase 3Ø Immunity from Voltage Distortion Less than 5% ithd at full load with vthd as high as 5% ithd Less than 5% at full load Efficiency Greater than 99% Overload Capability 2% of current rating for 3 minutes Environmental Conditions Operating Temperature 4 C (14 F) Storage Temperature 6 C (14 F) Elevation Up to 1, m without derating. Consult factory for higher elevations. Humidity 95% non-condensing Protection Category UL Type 1 and UL Type 3R Cooling Method Natural Convection Reference Technical Standards Agency Approvals UL & cul Listed (up to 6 Hp) NOTE: The HSD is classifi ed as an Auxiliary Device, not an industrial control panel. Under UL and NFPA NEC guidelines an SCCR rating or marking is not required. Part Numbering One-Line Diagram H S D 1 5 A W 3 Series: Horse Power: Voltage Rating: A - 48 V C - 6 V Frequency: W - 6 Hz Enclosure: 1 - UL Type UL Type 3R Option: - Standard, no contactor 1 - With contactor Option: - Standard, no lugs 1 - Lugs Option: - Standard Option: - Standard Line Line Reactor Load Contactor (opt.) Tuning Reactor Capacitor(s) Application Matrix TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #3253 Version 1.2 Copyright 216

11 HARMONIC FILTER DRIVE-APPLIED HARMONICGUARD HG7 Limits harmonic distortion and improves power factor Meets IEEE Protects drives and other sensitive equipment Improves energy efficiency Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filters

12 HARMONIC FILTER DRIVE-APPLIED HARMONICGUARD HG7 Harmonic Current Distortion Without HG7 Amps Harmonic Current Distortion with HG7 applied Amps Typical Problems, Superior Solutions with HG Filters Power quality has degraded over time due to the increased use of non-linear loads. The IEEE-519 standard for harmonic distortion was developed to address this problem. An increasing number of utilities are now mandating that this standard be followed. Harmonics and Power Quality Variable frequency drives are beneficial for a wide range of applications, however VFDs contain a power conversion process that creates current and voltage distortion which can cause system-wide problems. If non-linear loads represent a significant portion of the entire installed load, this distortion begins to cause problems throughout the electrical system: Transformer and distribution equipment overheating Random breaker tripping Sensitive equipment may fail completely Poor power factor Reduced system efficiency The HG7 Passive Harmonic Filter The HG7 not only limits current distortion to less than 7% (5-6% typical), it also: Eliminates nuisance tripping Increases drive uptime dramatically Improves power factor Improves system efficiency & reliability Extends equipment life Meeting IEEE-519 Recommendations on Harmonics The HG7 passive filter provides a cost effective solution allowing the user to meet IEEE-519 requirements. Using our harmonic analysis software, TCI can help customers meet IEEE-519. Typical applications include: Wastewater treatment plants Commercial buildings Hospitals Airports HG7 Filters v. Other Harmonic Solutions The HG7 passive filter is built using the highest quality components. HG7 filters include capacitors designed to withstand harsh harmonic currents. The UL58A configuration includes built-in safety features like fusing and easy access inside the enclosure. Processes will not shut down if the filter goes off-line. When compared to multi-pulse solutions, HG7 filters: Save money Save space Reduce energy losses

13 Configure the HG7 to meet your performance and monitoring needs: ST - Part Numbering System High Quality Harmonic Filter HG 15 A W 3 STC Series HP Voltage Rating A = 48V, B = 24V, C = 6V, L = V Frequency X = 5 Hz, W = 6 Hz Enclosure = Open, 1 = UL Type 1, 3 = UL Type 3R Package Option ST = Base Option Package STC = Contactor & CPT Option Package STCH = Contactor & CPT Option Package with Heater XM = Power Monitor Package KP = Component Package Package Options STC - High Quality Harmonic Filter with contactor and control power transformer which allows users to remove the capacitors from circuit, eliminating the possibility of leading power factor Product Specifications 3-Phase Ratings: 48V/6Hz: HP 6V/6Hz: 15-9 HP 24V/6Hz: HP 4V/5Hz: 4-71 kw Harmonic Reduction: < 7% (Typically better TDD) at full load Efficiency (typical): Below 1 HP 98% 1-25 HP 98.8% Above 25 HP > 99% Capacitors: Components designed for harmonicrich environments Protection: All units have internal fusing protection for the capacitors and trap reactor Operating Temperature: Open: 5 C (122 F) Enclosed: 4 C (14 F) Maximum Altitude: 1, m (Derating necessary above 1, m) XM - Similar to STC version with the addition of a power monitor display to view filter performance One-Line Diagram Fundamental Frequency: 6 Hz (5Hz for 4V) Agency Approvals: cul, UL Enclosures: Open, UL Type 1, UL Type 3R HG7 HarmonicGuard Filters are warranted for three years from the date of original shipment (System Bus/ Panel/ Source Transformer) LINE LINE REACTOR FUSE (VFD) LOAD TUNING REACTOR CONTACTOR(S) (Optional) CAP(S). Performance Guarantee When properly applied and sized for the application, HG7 will typically provide 5-6% current distortion. TCI further guarantees that the HG7 will lower ITDD (as calculated using IEEE-519 guidelines) to no more than 8% at the filter input terminals. If a properly selected, installed, and loaded HG7 filter fails to meet the guaranteed performance levels, TCI will provide the necessary components or replacement filter at no additional charge. TCI does not take responsibility for additional installation or removal costs, to include, but not limited to, replacement of third party equipment. Please see TCI web site for minimum system requirements.

14 HG7 Typical Applications Oil and Gas Pumps Irrigation Fields, Farms Water, Wastewater HVAC Steel Industry Pulp/Paper Machining Extruders Additional Power Quality Solutions: HarmonicGuard Active (HGA) Filter Helps meet IEEE-519 Reduces current harmonic distortion to less than 5% at full load Actively monitors system current, improves power factor to near unity Built-in touchscreen display & Modbus RTU Copyright 215 Part Number: 2522 Version 1.5 KDR Line Reactor Prevents nuisance tripping Protects the source by lowering current distortion created by the drive MotorGuard TM Sinewave Output Filter Protects the motor by converting the PWM waveform into a near sinusoidal wave Prevents voltage overshoots that cause early degradation of insulation systems in motors, transformers, and cables Extends motor life by reducing operating temperature V1k Motor Protection Output Filter Protects the motor and cable from voltage spikes due to high dv/dt and excessive cable capacitance Helps stop motor insulation breakdown Protects cable runs (up to 3, feet) and reduces motor heating, noise and vibration KRF EMI/RFI Filter Filter EMI/RFI noise caused by power switching devices Meet FCC regulation 15, subpart J Prevents interference with automated lighting circuits, security cameras, and other critical electronics TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Please contact us about specific products and services. Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filters

15 Harmonics & Power Quality KDR Line Reactor Variable frequency drives (VFD) are beneficial to a wide range of applications, but contain a power conversion process that creates current and voltage distortion, known as harmonics. Issues caused by harmonics may include: Transformer and distribution equipment overheating Random breaker tripping Sensitive equipment failure Poor power factor KDR Line Reactor The KDR Line Reactor offers impedance against the flow of harmonics and other high frequencies that can cause tripping and equipment failure. Drives and other sensitive devices are protected by the KDR from electrical distortion on the line including harmonics. Harmonic Current Distortion Without KDR 3 2 Advantages of the KDR Line Reactor Extend the life of the motor on the output of the VFD Protect other equipment on the line from operational issues caused by voltage distortion Dramatically increase drive uptime by reducing the likelihood of the drive tripping Improve power factor Reduce motor heating and audible noise Increase system productivity Meet IEEE Typical Applications Pulp & Paper Machining Wastewater Treatment Plants Oil & Gas HVAC Systems Irrigation Fields, Farms Extruders Steel Industry Warranty Every TCI line reactor is manufactured in Wisconsin with high quality materials and is backed by a lifetime warranty.* Amps Transient Voltage Without KDR Harmonic Current Distortion With KDR Bus Volts Amps Transient Voltage With KDR Bus Volts Manufactured in Germantown, Wisconsin

16 Technical Specifications Environmental Conditions Operating Temperature Operating Altitude Reference Technical Standards Agency Approvals Fundamental Frequency Impedance Protetion System Voltage Short Term Overload Rating Inductance Characteristics Input and Output Protection (enclosure) DIN Rail version available Open: 5 C (122 F) Enclosed: 4 C (14 F) 2, m (6, ft) Derating necessary above 2, m cul, UL; UL Recognized, CE Marked 5/6 Hz Low Z and High Z 28/24 VAC, 48 VAC, 575/6 VAC, 69 VAC Tolerate 2% rated I for a minimum of 3 minutes Minimum 95% L at 11% Load Minimum 8% L at 15% Load Available for either the line or load side of a VFD Open, UL Type 1, UL Type 3R See website for details Impedance Options KDR Line Reactors have been designed to provide the best protection for both your drive and your application. KDR Optimized Drive Reactors are available in two ratings versions, Low Z (low impedance) and High Z (high impedance). Input impedance can significantly improve drive performance. Select impedance based on the guidelines below: Use KDR Low Z Units For: Any application where either a 1.5% or 3% reactor would be applied. Reduction of nuisance tripping caused by: Transient voltages caused by capacitor switching Line notching DC bus overvoltage tripping Inverter overcurrent and overvoltage Additional benefits include: Lowering injected percentage of harmonic current Improving true power factor Reducing cross-talk between drives Adding impedance to drives with DC link chokes/ reactors when more impedance is desired due to a relatively stiff source Performance Guarantee Properly sized for the application, a KDR reactor is guaranteed to eliminate any AC drive overvoltage tripping problems. If a KDR reactor is installed and the tripping problem remains, TCI will take back the reactor and pay shipping both ways. (Offer valid for 6 days from date of shipment.) Use KDR High Z Units For: Any application where a 5% reactor would be applied. KDR High Z offers the same superior benefits as Low Z plus additional benefits which include: Helping prevent drive component damage Providing maximum harmonic mitigation without adding capacitance Part Numbering System KDR Series UL Listed (Blank if UL Recognized) Design Frame Sequence Code Impedance Rating L = Low Impedance H = High Impedance P = Output Reactor Enclosure E1 = UL Type 1 E3R = UL Type 3R KDR UL A 55 H E3R *For the life of the drive TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #2332 Version 1.5 Copyright 215

17 HIGH PERFORMANCE SINEWAVE OUTPUT FILTER MotorGuardTM Eliminate harmful dv/dt to result in sinewave output Allows Nema MG1 Part 3 motors to be used where Part 31 motors would otherwise be required Greatly extend motor and cable life by reduction of motor noise, vibration, and heat Specific applications can reach 15, feet Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filters

18 HIGH PERFORMANCE SINEWAVE OUTPUT FILTER MotorGuard Typical Problems, Superior Solutions with MotorGuard As Pulse Width Modulated (PWM) Drives are incorporated into various applications and processes, the increased energy savings and decreased maintenance on Drives can be offset by increases in Motor failures. Voltage Without MotorGuard The MotorGuard product family has been designed as an engineered solution for motor failures due to the reflected wave phenomenon. Reflective Wave Phenomenon Voltage wave reflection is a function of the voltage rise time (dv/dt) and the length of the motor cables. Volts The impedance on either end of the cable run does not match, causing voltage pulses to be reflected back in the direction from which it arrived. As these reflected waves encounter other waves, their values add, causing higher peak voltage. As wire length or carrier frequency increases, the overshoot peak voltage also increases. Voltage With MotorGuard Volts Peak Voltages on a 46V system can reach 12 to 16V, causing rapid breakdown of motor insulation, leading to motor failure. On 575V systems, the peak voltages can easily reach 21V. If this is left uncontrolled, insulation failure may occur. Eliminate Reflective Wave The MotorGuard filter converts the PWM wave form to a near sinusoidal wave form by eliminating the carrier frequency, allowing sensitive applications to take advantage of the efficiencies and savings that PWM output power supplies and drives offer. MotorGuard filters: Eliminate Torque Ripple Eliminate Voltage Wave Reflection Can reach 15, feet for specific applications Reduce Motor Noise, Vibration, and Heat Increase Motor Life May be used with virtually all AC induction motors, lead lengths and lead types Can be used with a wide range of carrier frequencies from 2 khz to 12 khz and beyond.

19 58A Industrial Enclosure UL Listed Part Numbering System Series Current Rating Voltage Rating A = 48V C = 6V Enclosure = Open Panel 1 = Type 1 A = Standard NEMA General Purpose Part Numbering System KMG 13 A 1 A KMG 13 A G1 Series Current Rating Voltage Rating A = 48V C = 6V Enclosure G1 = GP Indoor G3R = GP NEMA 3R Options L = Lugs, = No Lugs B = Monitor Board, = No Monitor Board S = Thermal Switch, = No Thermal Switch H = Space Heater, = No Space Heater Product Specifications Carrier frequencies from 2 khz to 12 khz Short Term Overload Rating: Tolerance 2% rated I for a minimum of 3 minutes System Voltage: 48 VAC, 6 VAC Insulation System: Class H (18 C) or Class R (22 C) Temperature Rise: 115 C or 155 C Ambient Temperature: Open Panel 5 C (122 F) Enclosed Panel 4 C (14 F) Distance: up to 15, feet Voltage Distortion: < 5% (typical) Agency Approvals: Industrial - cul, UL Enclosures: Industrial Version: UL Open, UL Type 1 General Purpose: NEMA 1 and 3R Low Voltage PWM Power Supply to Medium Voltage Motor DRIVE DRIVE Motor Guard STEP-UP XFMR Block Diagram Test Stand Motor Guard Multiple Motor Applications DRIVE MOTOR PERFORMANCE GUARANTEE Properly sized and applied, the addition of a MotorGuard Output Filter is guaranteed to bring the application into compliance with NEMA Standards Publication No. MG-1. If the system fails to meet MG-1 standards with the addition of a MotorGuard filter, TCI will take back the output filter and pay shipping both ways. This offer is valid for 6 days from the installation date. DRIVE Motor Guard MOTOR MOTOR MOTOR Extreme Long Lead Applications DRIVE Motor Guard MOTOR

20 MOTORGUARD TYPICAL APPLICATIONS Extreme long motor lead lengths. Applications can reach 15, feet Low voltage PWM power supply to medium voltage motor Multiple motor applications such as conveyors, blowers, pumps, and fans Test floor and test stand applications Shore to ship power for non-6 Hz systems HVAC systems to reduce audible noise Additional Power Quality Solutions: HarmonicGuard Active (HGA) Filter Helps meet IEEE-519 Reduces current harmonic distortion to less than 5% at full load Actively monitors system current, improves power factor to near unity Built-in touchscreen display & Modbus RTU Copyright 215 Part Number: Version 1.5 HarmonicGuard Passive (HGP) and HarmonicGuard HG7 Filters Helps meet IEEE-519 Improves power factor The HGP limits current harmonic distortion to less than 5% over a wide load range The HG7 reduces current harmonic distortion to less than 7% at full load KDR Line Reactor Prevents nuisance tripping Protects the source by lowering current distortion created by the drive V1k Motor Protection Output Filter Protects the motor and cable from voltage spikes due to high dv/dt and excessive cable capacitance Helps stop motor insulation breakdown Protects cable runs (up to 3, feet) and reduces motor heating, noise and vibration KRF EMI/RFI Filter Filter EMI/RFI noise caused by power switching devices Meet FCC regulation 15, subpart J Prevents interference with automated lighting circuits, security cameras, and other critical electronics TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Please contact us about specific products and services. Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filters

21 Motor Protection MotorShield Sinewave Output Filter As Pulse Width Modulated (PWM) Drives are incorporated into various applications and processes, the increased energy savings and decreased maintenance on drives can be offset by increases in motor failures. High voltage spikes caused by a phenomenon known as reflected wave (dv/dt) occur when there are long cable runs between the drive and the motor. The impedance on either end of the cable run does not match, causing voltage pulses to be reflected back in the direction from which it arrived. As these reflected waves encounter other waves, their values add, causing higher peak voltage. Peak voltages on a 48V system can reach 1,6V. These high peak voltages will cause a rapid breakdown of motor insulation, leading to motor failure. Industry Application: Fans & Pumps The MotorShield is designed to extend motor life in variable torque applications such as fans and pumps with lead lengths up to 15, feet. Motors on these systems typically produce a large amount of heat as they run. The MotorShield is the perfect solution to prevent overheating and motor failure. Typical Applications Wastewater Treatment Plants Mining Material Handling Oil & Gas HVAC Systems Chemical Processing Power Plants Data Centers Renewable Energy Pulp & Paper Motor Input Waveform Without MotorShield 15 TCI s MotorShield TM improves system performance by protecting the motor from the harmful effects of reflected waves and preventing motor failure associated with insulation failure, overheating, and noise. Volts Motor Input Waveform With MotorShield Volts

22 Technical Specifications Current Ratings VFD Output Voltage VFD Output Frequency VFD Carrier Frequency Filter Performance 48V: 9 to 18 amps 6V: 8 to 5 amps Intermittent current: 15% for 1 minute out of every 6 minutes Up to 48 V, 3-phase, at fundamental base frequency configured to Volts per Hz Up to 8 Hz 2 khz to 16 khz Maximum peak voltage of output waveform - 48 V: 1V Maximum dv/dt of output waveform - 48 V: 5V/μs Environmental Conditions Maximum Elevation 3,3 ft (1, m), derating required for operation above this level Ambient Operating Temperature Range -3 C (32 F) to 4 C (14 F) Cooling provisions required for operation above this temperature Ambient Storage Temperature Range -4 C (-4 F) to 5 C (122 F) Maximum Humidity, Operating or Storage 95%, non-condensing Reference Technical Standards Enclosure Options NEMA 1/3R enclosure Insertion Impedance 6.5% nominally at 6 Hz & full load current Capacitors High endurance design (no PCBs) Agency Approvals UL & cul Listed (up to 48 amps) Part Numbering System Series: UL Rating: MSD - UL 58 MSN - Non-UL Current Rating: Voltage Rating: A - 48 V C - 6 V Enclosure: 3 - Type 1 / 3R Option: - Default MS D 1 6 A 3 Extreme Long Lead Applications MOTOR VFD Multiple Motor Applications MOTOR MOTOR MOTOR VFD Low Voltage PWM Power Supply to Medium Voltage Motor VFD STEP-UP XFMR MOTOR Performance Guarantee Properly sized and applied, the addition of a MotorGuard Sinewave Output Filter is guaranteed to bring the application into compliance with NEMA Standards Publication No. MG-1. If the system fails to meet MG-1 standards with the addition of a MotorGuard filter, TCI will take back the output filter and pay shipping both ways. This offer is valid for 6 days from the installation date. TCI, LLC transcoil.com W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #2944 Version 1.4 Copyright 215

23 Motor Protection dv/dt Output Filter The benefits of installing a Pulse Width Modulated (PWM) Drive, including increased energy savings and decreased maintenance, may make it seem like the perfect solution. But, these benefits can be offset by increases in motor failures. Voltage wave reflection is a function of the voltage rise time (dv/dt) and the length of the motor cables. The impedance on either end of the cable run does not match, causing voltage pulses to be reflected back in the direction from which it arrived. As these reflected waves encounter other waves, their values add, causing higher peak voltage. As wire length or carrier frequency increases, the overshoot peak voltage also increases. Peak voltages on a 48V system can reach 1,6V and 2,1V on a 6V system. These high peak voltages can cause a rapid breakdown of motor insulation, leading to motor failure. Superior Design, Proven Results By combining a patented dampening circuit with a low pass filter, V1k filters increase the voltage rise time (dt out of dv/dt) thereby preventing voltage spikes from exceeding 1, V, and protecting motor and cable insulation. With thousands of successful applications worldwide, the V1k is a proven reliable solution with its industry leading performance and benefits: Extend the life of your motor & cable by reduction of harmful voltage spikes due to dv/dt. Protect cable runs and reduce motor heating, noise and vibration. Prevent motor failure with protection against motor insulation breakdown. Reduce Common Mode by a minimum of 3%. Improve system productivity and increase bearing life and up-time. Protect long lead lengths up to 3, feet (depending on cable and VFD size). Typical Applications Oil and Gas Pumps Irrigation Field, Farms Wa s t ew a t e r Tre a t m e n t P l a n t s HVAC Pulp, Paper

24 Technical Specifications Technical Characteristics Ratings 2-75 amps; 24 V - 6 V Carrier Frequency 1-12 khz Insulation Rating 6 V Class Insulation Class Class H (18 C) or Class R (22 C) Efficiency 98% Lead Length Specific applications can reach 3, feet (consult factory for applications above 1,5 feet) Fundamental Frequency -6 Hz (consult factory for applications over 8 khz and/or 6-12 Hz fundamental if the cable lengths exceed 4 feet) Environmental Conditions Operating Temperature Enclosed: 4 C (14 F) Operating Altitude 2, m (6, ft) Derating necessary above 2, m Reference Technical Standards Agency Approvals UL & cul Protection (enclosure) Open, UL Type 1, UL Type 3R Warranty One year of useful service, not to exceed 18 months from date of shipment. Operation possible up to 12 Hz output drive frequency with derating (contact factory for details). Voltage Without V1k 15 Common Mode Without V1k 1 Volts feet Voltage With V1k 15 Per Unit Current Common Mode With V1k 1 Volts feet Per Unit Current Multiple Motor Applications MOTOR MOTOR MOTOR VFD Please see web site for configuration guidelines. Performance Guarantee Properly sized and applied, TCI guarantees that the V1k will limit motor terminal peak input voltage to 15% of the bus voltage with a wire lead length of 1, feet and a carrier frequency of 4 khz. Maximum lead length and carrier frequency can vary depending on wire lead type. If a properly selected, installed and loaded V1k filter fails to meet the guaranteed performance levels, TCI will provide the necessary components or replacement filter at no additional charge. TCI does not take responsibility for additional installation or removal costs to include, but not limited to, replacement of third party equipment. Please see TCI s website for minimum requirements. TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #25383 Version 1.6 Copyright 215

25 Harmonics & Power Quality KDR Line Reactor Variable frequency drives (VFD) are beneficial to a wide range of applications, but contain a power conversion process that creates current and voltage distortion, known as harmonics. Issues caused by harmonics may include: Transformer and distribution equipment overheating Random breaker tripping Sensitive equipment failure Poor power factor KDR Line Reactor The KDR Line Reactor offers impedance against the flow of harmonics and other high frequencies that can cause tripping and equipment failure. Drives and other sensitive devices are protected by the KDR from electrical distortion on the line including harmonics. Harmonic Current Distortion Without KDR 3 2 Advantages of the KDR Line Reactor Extend the life of the motor on the output of the VFD Protect other equipment on the line from operational issues caused by voltage distortion Dramatically increase drive uptime by reducing the likelihood of the drive tripping Improve power factor Reduce motor heating and audible noise Increase system productivity Meet IEEE Typical Applications Pulp & Paper Machining Wastewater Treatment Plants Oil & Gas HVAC Systems Irrigation Fields, Farms Extruders Steel Industry Warranty Every TCI line reactor is manufactured in Wisconsin with high quality materials and is backed by a lifetime warranty.* Amps Transient Voltage Without KDR Harmonic Current Distortion With KDR Bus Volts Amps Transient Voltage With KDR Bus Volts Manufactured in Germantown, Wisconsin

26 Technical Specifications Environmental Conditions Operating Temperature Operating Altitude Reference Technical Standards Agency Approvals Fundamental Frequency Impedance Protetion System Voltage Short Term Overload Rating Inductance Characteristics Input and Output Protection (enclosure) DIN Rail version available Open: 5 C (122 F) Enclosed: 4 C (14 F) 2, m (6, ft) Derating necessary above 2, m cul, UL; UL Recognized, CE Marked 5/6 Hz Low Z and High Z 28/24 VAC, 48 VAC, 575/6 VAC, 69 VAC Tolerate 2% rated I for a minimum of 3 minutes Minimum 95% L at 11% Load Minimum 8% L at 15% Load Available for either the line or load side of a VFD Open, UL Type 1, UL Type 3R See website for details Impedance Options KDR Line Reactors have been designed to provide the best protection for both your drive and your application. KDR Optimized Drive Reactors are available in two ratings versions, Low Z (low impedance) and High Z (high impedance). Input impedance can significantly improve drive performance. Select impedance based on the guidelines below: Use KDR Low Z Units For: Any application where either a 1.5% or 3% reactor would be applied. Reduction of nuisance tripping caused by: Transient voltages caused by capacitor switching Line notching DC bus overvoltage tripping Inverter overcurrent and overvoltage Additional benefits include: Lowering injected percentage of harmonic current Improving true power factor Reducing cross-talk between drives Adding impedance to drives with DC link chokes/ reactors when more impedance is desired due to a relatively stiff source Performance Guarantee Properly sized for the application, a KDR reactor is guaranteed to eliminate any AC drive overvoltage tripping problems. If a KDR reactor is installed and the tripping problem remains, TCI will take back the reactor and pay shipping both ways. (Offer valid for 6 days from date of shipment.) Use KDR High Z Units For: Any application where a 5% reactor would be applied. KDR High Z offers the same superior benefits as Low Z plus additional benefits which include: Helping prevent drive component damage Providing maximum harmonic mitigation without adding capacitance Part Numbering System KDR Series UL Listed (Blank if UL Recognized) Design Frame Sequence Code Impedance Rating L = Low Impedance H = High Impedance P = Output Reactor Enclosure E1 = UL Type 1 E3R = UL Type 3R KDR UL A 55 H E3R *For the life of the drive TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Part #2332 Version 1.5 Copyright 215

27 3-PHASE EMC POWER LINE FILTER KRF Limits high frequency noise Reduces interference Protects sensitive equipment Eliminates drive cross-talk Meet FCC Regulation 15, Subpart J Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filters

28 3-PHASE EMC POWER LINE FILTER KRF Before KRF Non-Linear Loads can draw harmonic current from the source, resulting in harmful high frequency noise There are many pieces of equipment that can generate EMI (electro magnetic interference), variable frequency drives included. In the case of variable frequency drive, the electrical noise produced is primarily contained in the switching edges of the PWM controller. Increases in switching frequencies also increase the effective edge frequencies produced, thereby increasing the amount of electrical noise. Reduce High Frequency Distortion KRF filters use a combination of high frequency inductors and capacitors to reduce noise in the critical 15 khz to 3 MHz frequency range. The inductors act as open circuits and the capacitors act as short circuits at high frequencies while allowing the lower power line frequencies to pass untouched. KRF filters assist with cost effective compliance to EMC directives, in a compact, efficient, light-weight design. The high common mode and differential mode reduction in the critical 15 khz to 3 MHz frequency range ensures that potential interference from AC drives is reduced or eliminated. After KRF EMI (Electro Magnetic Interference) RFI (Radio Frequency Interference) The terms EMI and RFI are often used interchangeably. EMI is actually any frequency of electrical noise, whereas RFI is a specific subset of electrical noise on the EMI spectrum. Conducted EMI is unwanted high frequencies that ride on the utility AC wave form. Incorrect Interconnection Layout Correct Interconnection Layout KRF Filter KRF Filter To Line Ground VFD To Line and Load Note: Connect ground to main ground bus VFD To Load

29 Part Numbering System K RF 18 A CB K-Series 3 - Phase EMI/RFI Filter Max Current (amps) Voltage Rating A = 48V V = 69V Termination TB = Termination Block CB = Copper Bus Equipment Interference and Failure The power line noise emissions associated with variable frequency drives can cause disturbances in nearby equipment. Typical disturbances include: Dimmer and ballast instability Lighting disturbances such as flashing Poor radio reception Instability of control systems Flow metering fluctuation Computer system failures Remote I/O glitches Encoder feedback errors Nuisance faults PLC Analog meter bouncing Thermostat control problems Product Specifications 3-Phase System Voltage: 48 VAC (applied to 24 VAC - 52 VAC) 69 VAC (applied to 6 VAC - 76 VAC) Amp Ratings: 48V (8-25) 69V (25-25) Fundamental Frequency: 5/6 Hz Units to accommodate up to 2,5 amps Filtering: Advanced two-stage filtering design Warranty: 1 year Ambient Temperature: -25 to 1 C Maximum Altitude: 1, meters (3, feet) Derating necessary above 1, meters Short Term Overload Rating: 15% rated I for 3 minutes or 25% for 3 seconds Tested Value: 1% tested for Hipot, ground continuity, input-output continuity and insertion loss characteristic Agency Approvals: ENEC, UR & cur Typical Circuit Diagram

30 KRF Typical Applications Motor drives Elevators Commercial Buildings Wind farms Photovoltaics UPS Power supplies Additional Power Quality Solutions: HarmonicGuard Active (HGA) Filter Helps meet IEEE-519 Reduces current harmonic distortion to less than 5% at full load Actively monitors system current, improves power factor to near unity Built-in touchscreen display & Modbus RTU Copyright 215 Part Number: Version 1.5 HarmonicGuard Passive (HGP) and HarmonicGuard HG7 Filters Helps meet IEEE-519 Improves power factor The HGP limits current harmonic distortion to less than 5% over a wide load range The HG7 reduces current harmonic distortion to less than 7% at full load KDR Line Reactor Prevents nuisance tripping Protects the source by lowering current distortion created by the drive MotorGuard TM and MotorShield TM Sinewave Output Filters Protects the motor by converting the PWM waveform into a near sinusoidal wave Prevents voltage overshoots that cause early degradation of insulation systems in motors, transformers, and cables Extends motor life by reducing operating temperature V1k Motor Protection Output Filter Protects the motor from voltage spikes due to dv/dt Helps stop motor insulation breakdown Protects cable runs (up to 3, feet) and reduces motor heating, noise and vibration TCI, LLC W132 N1611 Grant Drive Germantown, WI 5322 USA Toll Free: P: F: Please contact us about specific products and services. Line Reactors Harmonic Filters EMC Filters dv/dt Filters Sinewave Filter