TCi HarmonicGuard HSP User manual

HSP
Single – Phase Harmonic Filter
HarmonicGuard®Series Drive-Applied Harmonic Filter
Installation, Operation, and Maintenance Manual
TCI, LLC
W132 N10611 Grant Drive
Germantown, Wisconsin 53022
Phone: [phone]
Fax: [phone]
Helpline: 800-TCI-8282
Web Site: http://www.transcoil.com
© 2017
Revision A

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.

Revision
Description
Date
1.0
Release
6/16/11
A
Removed “No contactor option”, minor edits and
corrections
8/21/17

Table of Contents
Introduction ..............................................................................................................................1
Receiving Inspection and Storage .........................................................................................3
Pre-installation Planning .........................................................................................................4
Installation Guidelines.............................................................................................................5
HSP Harmonic Filter Operation ..............................................................................................7
Installation ................................................................................................................................8
Maintenance and Service ........................................................................................................9
Product Description...............................................................................................................11
Drawings .................................................................................................................................13
Standard (SC) .........................................................................................................................17
Component Package Option (CP) ........................................................................................18

Introduction HarmonicGuard® HSP
HSP IOM Manual - Rev. A 1
Introduction
Safety Instructions Overview
This section provides the safety instructions which must be followed when installing, operating, and
servicing the HSP single-phase harmonic filter. If neglected, physical injury or death may follow, or
damage may occur to the filter or equipment connected to the HSP single-phase harmonic filter. The
material in this chapter must be read and understood before attempting any work on, or with, the
product.
The HSP single-phase harmonic filter is intended to be connected to the input terminals of one or more
variable frequency drives. Single-phase power is connected to the input terminals of the HSP and
power is supplied to the drive or drives through the HSP. The instructions, and particularly the safety
instructions, for the drives, motors and any other related equipment must be read, understood and
followed when working on any of the equipment.
Warnings and Cautions
This manual provides two types of safety instructions. Warnings are used to call attention to
instructions, which describe steps, which must be taken to avoid conditions, which can lead to a
serious fault condition, physical injury or death.
Cautions are used to call attention to instructions that describe steps that must be taken to avoid
conditions that can lead to a malfunction and possible equipment damage.
Warnings
Readers are informed of situations that can result in serious physical injury and/or serious damage to
equipment with warning statements highlighted by the following symbols:
Warning Dangerous Voltage Warning: warns of situations in which a
high voltage can cause physical injury and/or damage
equipment. The text 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.
!

HarmonicGuard® HSP Introduction
2 HSP IOM Manual - Rev. A
General Safety Instructions
These safety instructions are intended for all work on the HSP. 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 HSP single-phase
harmonic filter.
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 HSP filter.
Warning
The HSP single-phase harmonic filter, 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 HSP filter and in the drive to discharge before
working on the HSP, the drive, the motor, or the connecting
wiring. It is a good idea to check with a voltmeter to make sure
that all sources of power have been disconnected and that all
capacitors have discharged before beginning work.
!
!
!

Receiving Inspection and Storage HarmonicGuard® HSP
HSP IOM Manual - Rev. A 3
Receiving Inspection and Storage
Thank you for selecting the HSP Single-Phase Harmonic Filter. TCI has produced this filter for use in
many variable frequency drive applications that require input power line harmonic current reduction.
This manual describes how to install, operate and maintain the HSP single-phase harmonic filter.
Receiving Inspection
The HSP single-phase harmonic filter has been thoroughly inspected and functionally tested at the
factory and carefully packaged for shipment. When you receive the unit, you should immediately
inspect the shipping container and report any damage to the carrier that delivered the unit. Verify that
the part number of the unit you received is the same as the part number listed on your purchase order.
TCI Limited Warranty Policy
TCI, LLC (“TCI”) warrants to the original purchaser 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, KMG,
MSD
One (1) year of useful service,
not to exceed 18 months from the date of shipment.
PF Guard, HGP, HSP, HG7,
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.
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.
Storage Instructions
If the HSP single-phase harmonic filter is to be stored before use, be sure that it is stored in a location
that conforms to published storage humidity and temperature specifications stated in Table 1 (HSP
Single-Phase Harmonic Filter Technical Specifications). Store the unit in its original packaging.

HarmonicGuard® HSP Pre-Installation Planning
4 HSP IOM Manual - Rev. A
Pre-installation Planning
Verify the Application
HSP Ratings
Make sure that the HSP single-phase harmonic filter is correct for the application. The voltage ratings
of the filter must match the input voltage rating of the connected drive. The horsepower and current
ratings of the filter must be adequate for the connected load.
Select a Suitable Location
Environment
Locating the HSP in a suitable environment will help assure proper performance and a normal
operating life. Refer to the environmental specifications listed in Table 3, marked on the unit's
nameplate and/or noted on the drawings furnished with the unit.
Warning Unless specifically labeled as approved for such use, this equipment is not
suitable for use in an explosive atmosphere or in a "Hazardous (Classified)
Location" as defined in article 500 of the National Electrical code.
The unit must be installed in an area where it will not be exposed to:
♦Precipitation or dripping liquids (unless in a 3R enclosure)
♦Corrosive liquids or gasses
♦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 an Open Panel Unit
If you are mounting an open panel unit in your own enclosure, you must provide an enclosure that is
adequately sized and ventilated sufficiently to prevent overheating. The rating and dimension tables for
open panel units list the watts of heat loss that is dissipated by the HSP single-phase harmonic filter.
The maximum temperature of the air around the HSP filter internal components should not exceed
50°C (122°F).
Power Wiring
When selecting a mounting location for the HSP filter, plan for the routing of the power wiring.
For standard units with a line reactor included in the HSP: route the conduit and wiring from the power
source to the filter and then to the variable frequency drive.
The HSP is provided with internal fuses. Additional fuses may be required at the connecting point to
protect the tap conductors. Refer to the National Electrical Code (NEC) and/or any other applicable
codes.

Installation Guidelines HarmonicGuard® HSP
HSP IOM Manual - Rev. A 5
Installation Guidelines
Mounting
The HSP must be mounted vertically on a smooth, solid surface, free from heat, dampness, and
condensation.
Wiring
Cable Entry Locations
The enclosed HSP single-phase harmonic filters are not provided with enclosure wiring knockouts. A
selection can be made at the time of installation. Typical or recommended cable entry locations are
shown in the drawings section of this manual.
Field Wiring Connection Terminals
Compression type terminals are provided for all field wiring connections. The control circuit terminals
will accommodate 18 AWG to 10 AWG wire and should be tightened to 18 in.-lbs. torque. The wire
size capacity ranges and tightening torque for the grounding and power terminals are listed in Table 1.
Refer also to the drawings and other information shipped with the unit.
Table 1: Power Terminal Wire Size Capacity Range and Tightening Torque for Standard Units
HarmonicGuard
Current Ratings
Ground Lug
Input and Output Power
Wire Size Torque
(in.-lb.)
Wire Size Torque
(in.-lb.)
14 to 45 Amps
14 - 1/0 AWG
200
18 AWG - 4 AWG
20
55 to 80 Amps
14 - 1/0 AWG
200
22 - 16 AWG or
14 - 6 AWG or
4 - 2 AWG or
1 AWG (7 & 19 strand only)
25
30
35
110 Amps
6 AWG - 250 MCM
275
6 AWG - 2/0 AWG
120
130 Amps
6 AWG - 250 MCM
275
Input: 6 AWG - 350 MCM
Output: 6 AWG - 2/0 AWG
275
120
160 to 200 Amps
6 AWG - 250 MCM
275
Input: 6 AWG - 250 MCM
Output: 6 AWG - 350 MCM
275
275
250 Amps
6 AWG - 250 MCM
275
4 AWG - 600 MCM or
(2) 1/0 AWG - 250 MCM
500
300 Amps
4 AWG - 600 MCM or
(2) 1/0 AWG - 250 MCM
375
4 AWG - 600 MCM or
(2) 1/0 AWG - 250 MCM
500
360 to 480 Amps
4 AWG - 600 MCM or
(2) 1/0 AWG - 250 MCM
375
(2) 4 AWG - 350 MCM
375

HarmonicGuard® HSP Installation Guidelines
6 HSP IOM Manual - Rev. A
Grounding
The HSP panel equipment-grounding lug must be connected to the ground of the premises wiring
system. The equipment grounding connection must conform to the requirements of the National
Electric Code (NEC) and/or any other codes that apply to the installation site. The ground connection
must be made using a wire conductor. Metallic conduit is not a suitable grounding conductor. The
integrity of all ground connections should be periodically checked.
Power Wiring
Caution Use copper wire that is appropriate for the voltage and current rating of the
equipment. The wire selection must conform to the requirements of the
National Electrical Code and/or other applicable electrical codes.
For units rated less than 100 amps, use wire with an insulation temperature
rating of 60°C or higher.
For units rated 100 amps or more, use wire with an insulation temperature
rating of 75°C or higher.
Connect single-phase power of the appropriate voltage and current capacity to the branch circuit
protective device then to the HSP input power terminals. Note: in large units, the input power
conductors are connected directly to the input terminals on the line reactors.
Connect the output terminals of the HSP to the input power terminals of the variable frequency drive.
Note: in large units, the output power conductors are connected directly to the output terminals on the
line reactors. Refer to the variable frequency drive installation instructions for additional information.

HSP Harmonic Filter Operation HarmonicGuard® HSP
HSP IOM Manual - Rev. A 7
HSP Harmonic Filter Operation
Caution Thoroughly check the installation before applying power and operating
the equipment for the first time.
Before Applying Power for the First Time
Inspect the installation to make sure that all equipment has been completely and correctly installed in
accordance with the Installation Guidelines section of this manual.
♦Check to see that the cooling fan(s) are operating in units so equipped.

HarmonicGuard® HSP Installation
8 HSP IOM Manual - Rev. A
Installation
Intended Audience
This manual is intended for use by all personnel responsible for the installation, operation and
maintenance of the HSP single-phase harmonic filters. Such personnel are expected to have knowledge
of electrical wiring practices, electronic components and electrical schematic symbols.
Additional Information
Caution This manual provides general information describing your HSP single-phase
harmonic filter. Be sure to carefully review the more specific information that is
provided by the drawings shipped with the unit. Information provided by the
drawings takes precedence over the information provided in this manual.
The ratings, dimensions and weights given in this manual are approximate and
should not be used for any purpose requiring exact data. Contact the factory in
situations where certified data is required. All data is subject to change without
notice.
Installation Checklist
The following are the key points to be followed for a successful installation. These points are
explained in detail in the following sections of this manual.
Make sure that the installation location will not be exposed to direct sunlight, 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 HSP equipment-grounding lug to the system ground of the premises wiring system.
Use a properly sized grounding conductor.
Connect single-phase power to the input terminals of the HSP: L1 & L2.
Connect the output power terminals, of the HSP: T1 & T2, to the input power terminals of the
variable frequency drive.

Maintenance and Service HarmonicGuard® HSP
HSP IOM Manual - Rev. A 9
Maintenance and Service
HSP Single-Phase Harmonic Filter Reliability and Service Life
The HSP has been designed to provide a service life that equals or exceeds the life of the variable
frequency drive. It has been thoroughly tested at the factory to assure that it will perform reliably from
the time it is put into service. The following periodic maintenance is recommended to assure that the
HSP filter will always 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 HSP filter.
Disconnect all sources of power to the drive and HSP before working on the
equipment. Do not attempt any work on a powered HSP.
Check to see that the installation environment remains free from exposure to excessive dirt and
contaminants. Refer to the Pre-installation Planning section of this manual.
Check to make sure that the enclosure ventilation openings are clean and unobstructed.
Clean the air filter in units that have filtered air inlets. Clean as often as necessary to prevent dirt build-
up from impeding air flow.
Check the operation of the cooling fan.
Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the
enclosure whenever excess dirt has accumulated.
Check the integrity of all power and ground wiring connections.
All electrical connections must be verified and re-torqued annually.
Troubleshooting
Warning Only qualified electricians should carry out all electrical installation and
maintenance work on the HSP single-phase harmonic filter.
Disconnect all sources of power to the drive and HSP before working on the
equipment. Do not attempt any work on a powered HSP single-phase
harmonic filter.
The harmonic filter contains high voltages and capacitors. Wait at least five
minutes after disconnecting power from the filter before you attempt to
service the harmonic filter. Check for zero voltage between all terminals on
the capacitors. Also, check for zero voltage between all phases of the line side
of the fuses, Fu1(a)–Fu2(a). All setup, maintenance, and troubleshooting must
be done by a qualified electrician. Failure to follo
w standard safety procedures
may result in death or serious injury.
Note: when disconnecting wires from components and terminations, mark the wires to correspond to
their component and terminal connection.

HarmonicGuard® HSP Maintenance and Service
10 HSP IOM Manual - Rev. A
Reference Drawings
When troubleshooting, refer to the drawings provided for the specific equipment. Typical drawings are
provided in this manual.
Fuse Specifications
Table 2 lists the specifications for the L-R-C filter power circuit fuses in the HSP 480 volt models.
Refer also to the drawings and other information shipped with the unit.
Table 2 – Fuse Specifications for HSP 480 Volt Models*
HSP
Rating
(HP)
Power Circuit
Fuse Ratings
Amps
Type
5
15
Bussmann
JKS
or equivalent
7.5
15
10
20
15
20
20
30
25
40
30
45
40
60
50
70
60
80
75
100
100
150
* contact factory for additional information
Table 3 – Fuse Specifications for HSP 240 Volt Models
HSP
Rating
Power Circuit Fuse Ratings
(HP)
Amps
Type
5
20
7.5
25
10
30
15
40
20
50
25
70
Class T, Fast Acting
30
80
40
110
50
125
60
175
75
200
100
300
Replacement Parts
If replacement parts are needed, please contact your TCI representative. To assure that the HSP single-
phase harmonic filter continues to perform to its original specifications, replacement parts should
conform to TCI specifications.
Factory Contacts and Tech Support
For technical support, contact your local TCI distributor or sales representative.
You can contact TCI directly at 800-TCI-8282. Select "Customer Service" or "Tech Support" and have
your HSP single-phase harmonic filter nameplate information available.

Product Description HarmonicGuard® HSP
HSP IOM Manual - Rev. A 11
Product Description
HSP Drive-Applied Harmonic Filter
The HSP is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic
currents drawn from the power source by variable frequency drives. The HSP is available for 240 and
480 volt systems. It is suitable for use with 1-phase diode bridge rectifier loads and 3-phase diode
rectifier loads operated from only 2 lines (single phase) such as PWM AC drives.
The HSP is a passive filter connected in series with the input terminals of a variable frequency drive or
several drives that operate as a group. It is designed to provide a low impedance path for the major
harmonic currents demanded by the drive. The filter is a stand-alone device that can be furnished in its
own enclosure and mounted adjacent to the drive. It is also available on an open panel for mounting
within an enclosure with the drive or other equipment.
The HSP filters consist of the following features and components.
♦A KDS input series reactor to prevent system interaction and improve filter performance.
♦An L-R-C harmonic filter circuit with:
A TCI 1-phase tuning reactor specifically designed for the HSP filter
High-endurance, harmonic-rated capacitors
♦Bleeder resistors to ensure safe capacitor discharge upon filter shutdown.
♦Cooling fans (on select models) to ensure adequate cooling and safe operating
temperatures.
♦Compression terminals for ease and integrity of all power and control wiring.
♦Resistor to dampen voltage rise.
Nameplate Data
The following information is marked on the nameplate:
♦Part number: encoding is explained on the following page
♦FLA: the rated continuous operating current (RMS amps)
♦System Voltage: the rated 1-phase line voltage (RMS volts)
♦Hz: the rated frequency (60 Hz)
♦Phase: 1 – The HSP filter is designed for use only with 1-phase power.
♦Drawing #: outline and mounting dimension drawing number
♦Schematic #: schematic diagram drawing number
♦Manufacturing #: for TCI internal use
♦Enclosure Type: 3R

HarmonicGuard® HSP Product Description
12 HSP IOM Manual - Rev. A
Part Number Encoding
Figure 1 identifies the significance of each character in the HSP part number. The example part
number, HSP055AG3SC designates a HSP filter that is rated 55 amps, 480 volts, 60 Hz. It includes the
standard 5% reactor, is tuned to the 5th harmonic, is furnished in General Purpose NEMA 3R
enclosure and is designed for use with a 25 Hp drive.
Figure 1: HSP Part Number Encoding
Product Technical Specifications
Table 3 lists the major technical specifications for the HSP single-phase Harmonic Filter.
Table 4 – HSP Single-Phase Harmonic Filter Technical Specifications
Voltage Ratings
240, 480 V, 1 phase, 60 Hz
Amp Ratings
240V: 28 – 432 amps; 480V: 14 – 216 amps
Harmonic Reduction
≤12% THID
Enclosure Options
Open Chassis; NEMA 3R
Storage Temperature
-40° to +60° C
Operating Temperature
Open: -40° to +50° C
Enclosed: -40° to +40° C
Maximum Humidity
95%, non-condensing
Elevation
2,000m (6,600 ft) without derating

Drawings HarmonicGuard® HSP
HSP IOM Manual - Rev. A 13
Drawings
Typical Outline Drawings and Schematic Diagrams
Typical HSP drawings are provided on the following pages. These drawings provide general
information describing your HSP single-phase harmonic filter. More specific information is provided
by the drawings shipped with the unit. Be sure to carefully review the information on the provided
drawings. The information on the drawings provided with the filter takes precedence over the
information provided in this manual.
Outline Drawing
The Outline drawing shows the overall enclosure dimensions. The major internal components are
shown pictorially.
Schematic Diagrams
The Schematic Diagrams show the details of the HSP circuitry. The power circuit schematic shows
the variations in input and output power connections.

HarmonicGuard® HSP Drawings
14 HSP IOM Manual - Rev. A
Typical Outline Drawing
Figure 2: Typical HSP Outline Drawing
(This drawing is not representative of all units; specific drawings are shipped with products)