TCi HarmonicGuard Series User manual

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 TCI, LLC All rights reserved

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

Performance Guarantee
Select and install the appropriate HarmonicGuard® Low Capacitance Harmonic
Filter in a variable torque, variable frequency AC drive application, within our
published technical specifications and we guarantee that the input current
distortion will be less than or equal to 5% THID for standard HGL Series filters
at full load. If a properly sized and installed filter fails to meet its specified THID
level, TCI will provide material for necessary modifications or replacement filter
at no charge.
HG filters can also provide similar performance in other drive applications such
as constant torque, DC drives and other phase controlled rectifiers, but actual
THID levels can vary by load and/or speed and therefore cannot be guaranteed.
Consult factory for assistance when applying HGL filters on these types of
equipment.
MINIMUM SYSTEM REQUIREMENTS:
The guaranteed performance levels of this filter will be achieved when
the following system conditions are met:
Frequency: 60Hz ± 0.75Hz
System Voltage: Nominal System Voltage (line to line) ±10%
Balanced Line Voltage: Within 0.5%
Background Voltage Distortion: < 0.5% THVD
The input VFD current waveform shall be consistent with that of a VFD
with 5% AC line reactance at full load and a 5% source impedance.
NOTE: The presence of background voltage distortion will cause motors and
other linear loads to draw harmonic currents.
Additional harmonic currents may flow into the HGL filter if there is harmonic
voltage distortion already on the system.

Revision
Description
Date
A Release 10/19/2017
B Added Additional Options
Updated Part Number
11/22/2017
C Updates to Watts loss table 12/12/2018

Table of Contents
Introduction................................................................................................................................ 1
Receiving Inspection and Storage ................................................................................3
Pre-installation Planning ............................................................................................... 5
Installation Guidelines................................................................................................... 6
HGL Filter Operation ..................................................................................................... 7
Installation .................................................................................................................................. 8
Maintenance and Service ............................................................................................. 8
Product Description ................................................................................................................13
Part Number Encoding................................................................................................14
Standard Option (S).................................................................................................................18
Product Description..................................................................................................... 18
Contactor Option (C) ............................................................................................................... 19
Product Description..................................................................................................... 19
Fuse Monitor without Contactor Option (G) .........................................................................20
Product Description..................................................................................................... 20
Filter and Fuse Monitor Operation......................................................................................... 21
Vibration Pad Option (V) .........................................................................................................23
Floor Stand Option (F).............................................................................................................23
Oilfield Duty Option (P) ...........................................................................................................23
Heater Option (H) .....................................................................................................................23

HarmonicGuard® Low Capacitance
Introduction
HGL IOM Manual - Rev. B
1
Introduction
Safety Instructions Overview
This section provides the safety instructions which must be followed when installing, operating, and
servicing the HarmonicGuard® Low Capacitance (HGL) filter. If neglected, physical injury or death may
follow, or damage may occur to the filter or equipment connected to the HGL filter. The material in this
chapter must be read and understood before attempting any work on, or with, the product.
The HGL filter is intended to be connected to the input terminals of one or more VFDs. Three-phase
power is connected to the input terminals of the HGL and power is supplied to the VFD or VFDs through
the HGL. The instructions, and particularly the safety instructions, for the VFDs, 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
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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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Introduction
General Safety Instructions
These safety instructions are intended for all work on the HGL. 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 HGL 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 HGL filter.
Warning The HGL 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 HGL filter and in the drive to discharge before
working on the HGL, 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.

HarmonicGuard® Low Capacitance
Introduction
HGL IOM Manual - Rev. B
3
Receiving Inspection and Storage
Thank you for selecting the HarmonicGuard® Low Capacitance (HGL) filter. TCI has produced this filter
for use in many variable frequency drive (VFD) applications that require input power line harmonic
current reduction. This manual describes how to install, operate and maintain the HGL filter.
Receiving Inspection
The HGL 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.
KLC, KLCUL,
KMG,
V1k
One (1) year of useful service,
not to exceed 18 months from the date of
shipment.
HGP, HGL, KH,
3H, KRF
Three (3) years from the date of shipment.
KCAP, KTR, KMP
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.

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Introduction
Storage Instructions
If the HGL filter is to be stored before use, be sure that it is in a location that conforms to published
storage humidity and temperature specifications stated in the HarmonicGuard® Low Capacitance Filter
Technical Specifications. Store the unit in its original packaging.

HarmonicGuard® Low Capacitance
Introduction
HGL IOM Manual - Rev. B
5
Pre-installation Planning
Verify the Application
HGL Ratings
Make sure that the HGL filter is correct for the application. The voltage rating of the filter must match
the input voltage rating of the connected drive. The horsepower and current ratings of the filter must be
appropriate for the connected load.
Select a Suitable Location
Environment
Locating the HGL in a suitable environment will help ensure proper performance and a normal operating
life. Refer to the environmental specifications listed in Table 2 and/or noted on the drawings furnished
with the unit.
The unit must be installed in an area where it will not be exposed to:
•Direct sunlight
•Rain or dripping liquids (unless filter is in a Type 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. Keep the widest or deepest portion of
the unit enclosure having ventilation openings a minimum of six inches from adjacent walls or other
equipment. The unit enclosure sides that do not have ventilation openings should be kept a minimum of
three inches from adjacent walls or other equipment.
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 dissipated by the HGL filter. The maximum temperature of
the air around the HGL filter capacitors, line reactor, and tuning reactor should not exceed 50°C (122°F).
Power Wiring
When selecting a mounting location for the HGL filter, plan for the routing of the power wiring.
Route the conduit and wiring from the power source to the filter and then to the VFD.
The HGL is provided with internal fuses.
Warning
Unless specifically labeled as approved for such use, this equipment is not
suitable for use in an explosive atmosphere or in a "Hazardous (Classified)
Location" as defined in article 500 of the National Electrical Code (NEC).

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Introduction
Installation Guidelines
Mounting
The HGL must be mounted vertically on a smooth, solid surface, free from heat, dampness, and
condensation.
Wiring
Cable Entry Locations
The enclosed HGL filters are not provided with enclosure wiring knockouts. A location can be selected
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 wire size capacity ranges
and tightening torques for all field wiring connections are listed in the drawings and other information
shipped with the unit.
Grounding
The HGL panel equipment-grounding lug must be connected to the ground of the wiring system. The
equipment-grounding connection must conform to the requirements of the National Electrical 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
Connect three-phase power of the appropriate voltage and current capacity to the circuit
protective device to the HGL 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 HGL to the input power terminals of the VFD.
Note: in large units, the output power conductors are connected directly to the output terminals
on the line reactors. Refer to the VFD installation instructions for additional information.
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 (NEC) 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.

HarmonicGuard® Low Capacitance
Introduction
HGL IOM Manual - Rev. B
7
HGL Filter Operation
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 soequipped.
•Check to make sure power connections are torqued to recommended torque value.
Operation
Since the HGL is a passive filter, it is always operating whenever the drive is operating.
Caution
Thoroughly check the installation before applying power and operating
the equipment for the first time.

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Installation
Installation
Intended Audience
This manual is intended for use by all personnel responsible for the installation, operation and maintenance of
the HGL filters. Such personnel are expected to have knowledge of electrical wiring practices, electronic
components and electrical schematic symbols.
Additional Information
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 Electrical Code
(NEC) and/or other applicable electrical codes.
Connect the HGL equipment-grounding lug to the system ground of the premises wiring system.
Use a properly sized grounding conductor.
Connect three-phase power to the input terminals of the HGL, L1, L2 &L3.
Connect the output power terminals, of the HGL, T1, T2 & T3, to the input power terminals of
the VFD.
Maintenance and Service
HGL Filter Reliability and Service Life
The HGL has been designed to provide a service life that equals or exceeds the life of the VFD. It
has been thoroughly tested at the factory to assure that it will perform reliably from the time it is
put into service. It is recommended that the following maintenance is performed once a year to
ensure that the HGL filter will always operate reliably and provide the expected service life.
Periodic Maintenance
Caution
This manual provides general information describing your HGL 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.
Warning Only qualified electricians should carry out all electrical installation and
maintenance work on the HGL filter.
Disconnect all sources of power to the drive and HGL before working on
the equipment. Do not attempt any work on a powered HGL.

HGL IOM Manual - Rev. B
9
HarmonicGuard® Low Capacitance
Installation
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.
Torque all power wire connections, loose connections can overheat and damage the filter.
All electrical connections must be re-torqued annually.
Troubleshooting
Note: when disconnecting wires from components and terminations, mark the wires to
correspond to their component and terminal connection.
Replacement Parts
If replacement parts are needed, please contact your TCI representative. To ensure that the HGL filter
continues to perform to its original specifications, replacement parts should conform to TCI specifications.
Warning
Only qualified electricians should carry out all electrical installation and
maintenance work on the HGL filter.
Disconnect all sources of power to the drive and HGL before working on
the equipment. Do not attempt any work on a powered HGL 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)–Fu3(a), and all input terminals L1, L2 and L3 of
the line reactor (KDR). All setup, maintenance, and troubleshooting must be
done by a qualified electrician. Failure to follow standard safety procedures
may result in death or serious injury.

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Installation
Fuse Specifications
Always refer to the drawings and other information shipped with your unit. Consult applicable wiring
codes, UL and NEC, for current limiting and disconnect requirements.
100 kA SCCR Fusing Requirements
See Table 1 for line fusing requirements that must be supplied to comply with the 100kA SCCR.
Table 1 – Customer Installed Line Fuse Requirements to comply with the 100kA SCCR
Voltage
Size
Customer Installed Line Fuse Requirements to Comply with the 100 kA SCCR
600
≤ 40
Use appropriately rated Class J, T, or L fuse less than or equal to 60 A
600
> 40
No requirement for SCCR
480
≤30
Use appropriately rated Class J, T, or L fuse less than or equal to 60 A
480
> 30
No requirement for SCCR
Provisional 480V Fuse Table
The fuse tables, provided below (Tables 2 and 3), show the fuse ratings of the included branch circuit
fuse internal to the HGL unit as a fuse replacement reference.
The fuse tables also show a typical line fuse or circuit breaker current rating for overcurrent protection,
given the unit’s nameplate power rating, if necessary, based on the installation. The line current fuses
listed below are typical values given the unit power rating, not required values. Line fusing ratings are
determined by the installer, based on input conductor sizing and protection required for downstream
equipment. Any drawings or documentation included with the unit literature kit take precedence over
the fuse tables below.
Note that to achieve a 100kA SCCR, the customer provided line fuse must be installed as per the
requirements in Table 1 and sized following NEC (National Electrical Code) guidelines for the source
conductors selected by the installer. The branch fuses are required to be installed at the shown ratings.

HGL IOM Manual - Rev. B
11
HarmonicGuard® Low Capacitance
Installation
Table 2 – Fuse Table for HGL 480 Volt, 60Hz Models
HGL Rating (HP) Branch Circuit Fuse
Current Rating (Included
Internal to HGL Unit)
Typical Line
Current Fuse
or Circuit
Breaker
Rating
(Customer
Supplied)
(J or T)
20
20
60
25
20
60
30
20
60
40
20
60
50
25
80
60
30
90
75
30
125
100
45
150
125
60
200
150
70
225
200
90
300
250
125
350
300
150
450
350
175
500
400
175
600
450
200
600
500
225
750
600
250
800
700
300
1000
800
350
1200
900
400
1300

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Installation
Table 3 – Fuse Table for HGL 600 Volt, 60Hz Models
HGL Rating (HP) Branch Circuit Fuse
Current Rating (Included
Internal to HGL Unit)
Typical Line
Current Fuse
or Circuit
Breaker
Rating
(Customer
Supplied)
(J or T)
20
20
30
25
20
60
30
20
60
40
20
60
50
20
70
60
30
80
75
40
100
100
40
125
125
50
175
150
60
200
200
70
250
250
90
300
300
110
350
350
125
400
400
150
450
450
175
500
500
175
550
600
200
650
700
250
750
800
300
900
900
300
1000
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 HGL filter
nameplate information available.

HGL IOM Manual - Rev. B
13
HarmonicGuard® Low Capacitance
Product Description
Product Description
HGL Drive-Applied Filter
The HGL is a drive-applied harmonic filter designed and developed by TCI to reduce the harmonic
currents drawn from the power source by VFDs. The published HGL voltage, Power (Hp or kW) and
current ratings apply to matching power (Hp or kW) rated standard VFDs with six-pulse diode bridge
rectifiers. The HGL may also be sized to filter other loads such as SCR six-step drives, SCR Direct
Current (DC) motor drives, thyristor furnaces, battery chargers, electroplating supplies or other types of
non linear loads. In many cases, the filter power rating (Hp or kW) will differ from load power rating
(Hp or kW). Please contact TCI Technical Support for additional information and support on sizing HGL
harmonic filters for your non six-pulse diode front end VFD applications.
The HGL is a passive filter connected in series with the input terminals of a VFD or several VFDs 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 HGL filters consist minimally of the following features and components:
•A KDR tuned series reactor to prevent system interaction and improve filter
performance
•An L-C-L filter circuit with:
•A TCI 3-phase tuning reactor specifically designed for the HGLfilter
•High-endurance, harmonic-rated capacitors
•Larger filters may have multiple tuned circuits. Consult fuse tables to determine if the
filter in question has “parallel” branches.
•Bleeder resistors to ensure safe capacitor discharge upon filter shutdown
•Cooling fans (on select models) to ensure adequate cooling and safe operating
temperatures
•Compression terminals for ease and integrity of all power and control wiring
•Fuses, sized to protect the capacitor wiring
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 3-phase line voltage (RMSvolts)
•Hz: the rated frequency
•Phase: 3 – The HGL filter is designed for use only with 3-phase power.
•Drawing #: outline and mounting dimension drawing number
•Schematic #: schematic diagram drawing number
•Manufacturing #: for TCI internal use
•Enclosure Type: UL designation or "Open" panel construction

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HGL IOM Manual - Rev. B
HarmonicGuard® Low Capacitance
Product Description
Part Number Encoding
Figure 1 identifies the significance of each character in the HGL part number. The example part number,
HGL0150AW1S0000 designates an HGL filter that is rated 150 HP, 480 volts, 60 Hz. It includes a line
reactor, tuning reactor, and capacitors in a UL Type 1 enclosure. It is designed for use with a 150 HP
drive.
Figure 1 – HGL Part Number Encoding