TCi HarmonicShield Series User manual

HarmonicShield®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: www.transcoil.com
© 2017 TCI, LLC All rights reserved

Performance Guarantee
Select & install the appropriate HarmonicShield®Harmonic Filter in a variable
torque, variable frequency AC drive application, within our published technical
specifications & we guarantee that the input current distortion will be less than
or equal to 5% THID for standard HSD Series filters at full load, and less than
8% at 30% load. If a properly sized & installed filter fails to meet its specified
THID level, TCI will provide material for necessary modifications or replacement
filter at no charge.
HSD filters can also provide similar performance in other drive applications such
as constant torque, DC drives & other phase controlled rectifiers, but actual
THID levels can vary by load and/or speed & therefore cannot be guaranteed.
Consult factory for assistance when applying HSD 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%, No more
than 1.5% Source inductance
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 3% AC line reactance at full load.
NOTE: The presence of background voltage distortion will cause motors & other
linear loads to draw harmonic currents.
Additional harmonic currents may flow into the HSD filter if there is harmonic
voltage distortion already on the system.

Revision
Description
Date
A
Release
08/01/16
B
Added SCCR Statement
09/12/16
C
Updates to torques and specs
10/12/16
D
Update to Installation Instructions & Technical
Specifications
9/13/17
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written
permission of TCI, LLC. The information in this manual is subject to change without notice. Every
precaution has been taken in the preparation of this manual. TCI, LLC assumes no responsibility for errors
or omissions. Neither is any liability assumed for damages resulting from the use of the information
contained in this publication

Table of Contents
Introduction.............................................................................................................................. 1
Receiving Inspection and Storage .............................................................................. 3
Pre-installation Planning ............................................................................................. 5
Installation Guidelines................................................................................................. 6
Connections ................................................................................................................ 7
HSD Filter Operation................................................................................................... 8
Installation ................................................................................................................................ 9
Maintenance and Service ......................................................................................... 10
Product Description .............................................................................................................. 11
Standard Product Ratings and Dimension Tables.................................................... 15
Standard Option (S)............................................................................................................... 18
Product Description................................................................................................... 18
Contactor Option (C) ............................................................................................................. 19
Lugs Option (L) ...................................................................................................................... 20
Filter Operation ...................................................................................................................... 21

Introduction HarmonicShield®
HSD IOM Manual - Rev. D 1
Introduction
Safety Instructions Overview
This section provides the safety instructions which must be followed when installing, operating, and
servicing the HarmonicShield®(HSD) filter. If neglected, physical injury or death may follow, or damage
may occur to the filter or equipment connected to the HSD filter. The material in this chapter must be
read and understood before attempting any work on, or with, the product.
The HSD 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 HSD and power is supplied to the VFD or VFDs through
the HSD. 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:
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.
!
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.
!

HarmonicShield®Introduction
2 HSD IOM Manual - Rev. D
General Safety Instructions
These safety instructions are intended for all work on the HSD. 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 HSD 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
The HSD does not have any user serviceable parts. Please
return your filter to TCI for servicing or refer service to TCI
authorized service personnel. Failure to do so can void your
product warranty.
Warning
Disconnect all power before working on the equipment.
Do not attempt any work on a powered HSD filter.
Warning
The HSD 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 HSD filter and in the drive to discharge before
working on the HSD, 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.
!
!
!
!

Introduction HarmonicShield®
HSD IOM Manual - Rev. D 3
Receiving Inspection and Storage
Thank you for selecting the HarmonicShield®(HSD) 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 HSD filter.
Receiving Inspection
The HSD 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.
Storage Instructions
If the HSD 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 the HSD Technical Specifications. Store the
unit in its original packaging.

HarmonicShield®Introduction
4 HSD IOM Manual - Rev. D
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
KDR, KLR
For the life of the drive with which they are installed.
V1K, KMG
One (1) year of useful service, not to exceed 18 months from the date of shipment.
HGA
One (1) year of useful service, not to exceed 18 months from the date of shipment. The
warranty for active filters may be extended to 30 months of useful service and 42 months
from date of shipment with the purchase of an extended warranty and start-up service.
See active filter warranty policy for details.
PFG, HGP, HG7, KRF, MSD,
HSD
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.
TCI will not accept the return of any product without its prior written approval. All freight charges to return any product
shall be at purchaser’s expense. Please consult TCI Customer Service for instructions on the Return Authorization
Procedure.
The employees and sales agents of TCI are not authorized to make additional warranties about TCI’s products.
TCI’s employees and sales agents oral statements do not constitute warranties, shall not be relied upon by the
Buyer and are not part of any contract for sale. All warranties of TCI embodied in this writing and no other
warranties are given beyond those set forth herein.
Rev. 2/29/2016

Introduction HarmonicShield®
HSD IOM Manual - Rev. D 5
Pre-installation Planning
Verify the Application
HSD Ratings
Make sure that the HSD 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
appropriate for the connected load.
Select a Suitable Location
Environment
Locating the HSD in a suitable environment will help ensure proper performance and a normal operating
life. Refer to the environmental specifications listed in Table 5 and/or noted on the drawings furnished
with the unit.
Warning Unless specifically labelled 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).
Make sure that the installation location will not be exposed to corrosive or combustible airborne contaminants,
excessive dirt or liquids. The unit is to be installed in an environment where it will not be exposed to:
•Corrosive liquids or gasses
•Explosive or combustible gases or dust
•Excessive airborne dirt and dust
•Excessive vibration [0.152 mm (0.006 in) displacement, 1G peak]
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.
The widest or deepest portion of the unit enclosure having ventilation openings must be a minimum of
six inches from adjacent walls or other equipment. Any enclosure sides that do not have ventilation
openings should be a minimum of three inches from adjacent walls or other equipment.
Power Wiring
When selecting a mounting location for the HSD 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.
!

HarmonicShield®Introduction
6 HSD IOM Manual - Rev. D
Installation Guidelines
Mounting
Select a mounting area that will allow adequate cooling air flow and maintenance access.
Wiring
Cable Entry Locations
The enclosed HSD 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 (Lug Options) are available for 480V HSD filters 75HP and above and 600V
HSD filters 100HP and above. The wire size capacity ranges and tightening torques for all field wiring
connections are listed in Table 1.
Grounding
The HSD 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
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.
Use copper wire with an insulation temperature rating of 90°C or higher.
Connect three-phase power of the appropriate voltage and current capacity to the circuit
protective device to the HSD input power terminals. Use copper wire with an insulation
temperature rating of 90°C or higher.
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 HSD 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.
!

Introduction HarmonicShield®
HSD IOM Manual - Rev. D 7
Connections
Before Connecting
Always consult the drive manufacturer’s safety, installation and operation instructions prior to connecting the HarmonicShield®
to the drive.
Warning
Avoid contact with line voltage when checking for power.
Failure to follow the safety instructions set forth in this manual can result in serious injury or
death.
Warning
Exercise caution when connecting the filter to the drive. Internal filter components may carry
dangerous voltage which can cause death or serious injury upon contact.
Table 1 – Motor Power Terminal Wire Size Capacity Range and Tightening Torque (Cu)
Unit
Line/Load Connections
Ground Connection
Hp
Std. Lug Kit
P/N
Wire Range**
Torque in-lbs (N-m)
Wire Range**
Torque in-lbs (N-m)
3 to 30 at 480 Volt
N.A.*
18 AWG - 4 AWG
30 in-lbs (3.4 N-m)
Two 14 AWG to 2/0
45 in-lbs (5.1 N-m)
3 to 50 at 600 Volt
N.A.*
18 AWG - 4 AWG
30 in-lbs (3.4 N-m)
Two 14 AWG to 2/0
45 in-lbs (5.1 N-m)
40 to 60 at 480 Volt
N.A.*
18 AWG - 4 AWG
35 in-lbs (4 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
60 & 75 at 600 Volt
N.A.*
18 AWG - 4 AWG
35 in-lbs (4 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
75 at 480 Volt
LK00
2/0 - 14 AWG
50 in-lbs (5.6 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
100 at 480 Volt
LK01
2/0 - 14 AWG
50 in-lbs (5.6 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
100 at 600 Volt
LK00
2/0 - 14 AWG
50 in-lbs (5.6 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
125 at 480 Volt & 150 at
600 Volt
LK02
250kcmil - 6 AWG
375 in-lbs (42 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
125 at 600 Volt
LK01
2/0 - 14 AWG
50 in-lbs (5.6 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
150 to 250 at 480 Volt
LK03
600kcmil - 4 AWG
500 in-lbs (56 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
200 to 300 at 600 Volt
LK03
600kcmil - 4 AWG
500 in-lbs (56 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
300 to 400 at 480 Volt
LK04
Two 350kcmil - 6 AWG
375 in-lbs (42 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
350 to 500 at 600 Volt
LK04
Two 350kcmil - 6 AWG
375 in-lbs (42 N-m)
Two 14 AWG to 2/0
50 in-lbs (5.6 N-m)
450 & 500 at 480 Volt
LK05
Two 600kcmil - 4 AWG
500 in-lbs (56 N-m)
Two 350MCM - 6 AWG
375 in-lbs (42 N-m)
600 at 480 & 600 Volt
LK06
Three 600kcmil - 2AWG
375 in-lbs (42 N-m)
Two 350MCM - 6 AWG
375 in-lbs (42 N-m)
*For HSD units 60Hp and under no lug kit is available. Instead field connections are made to the reactor mounted standard option terminal block.
**Wire range specified is lug wire range. Follow NEC guidelines to determine minimum acceptable wire ampacity required for application.
Table 2 – Optional Contactor
Unit
Contactor Control Connection (optional)
HP
Wire Range
Torque in-lbs (N-m)
All Units
22AWG - 12 AWG
5 in-lbs (0.56 N-m)
!
!

HarmonicShield®Introduction
8 HSD IOM Manual - Rev. D
HSD 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 make sure power and ground connections are torqued to recommended
torque value.
•Check to make sure the enclosure openings on the bottom and the top of the unit are
not blocked or partially obstructed.
•If the HSD unit includes the optional tuned circuit control contactor, confirm the
contactor relay coil is wired to 110VAC control power.
Operation
Since the HSD is a passive filter, the HSD is always energized and operating whenever the input to the
drive is energized.
!

Introduction HarmonicShield®
HSD IOM Manual - Rev. D 9
Installation
Intended Audience
This manual is intended for use by all personnel responsible for the installation, operation and
maintenance of the HSD 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 HSD 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 corrosive or combustible airborne
contaminants, excessive dirt or liquids. The unit must be installed in an environment where it
will not be exposed to:
•Corrosive liquids or gasses
•Explosive or combustible gasses or dust
•Excessive airborne dirt and dust
•Excessive vibration [0.152 mm (0.006 in) displacement, 1G peak]
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 HSD equipment-grounding lug to the system ground of the premises wiring system.
Use a properly sized grounding conductor. Ground lug is optional and will not be present if the
lugs option is not selected.
Connect three-phase power to the input terminals of the HSD L1, L2 & L3.
Connect the output power terminals of the HSD T1, T2 & T3 to the input power terminals of the
VFD.
!

HarmonicShield®Introduction
10 HSD IOM Manual - Rev. D
Maintenance and Service
HSD Filter Reliability and Service Life
The HSD 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 ensure 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 HSD filter will always operate reliably and provide the expected service life.
Periodic Maintenance
Warning Only qualified electricians should carry out all electrical installation and
maintenance work on the HSD filter.
Disconnect all sources of power to the drive and HSD before working on the
equipment. Do not attempt any work on a powered HSD.
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.
All electrical connections must be re-torqued annually.
Troubleshooting
Warning
Only qualified electricians should carry out all electrical installation and
maintenance work on the HSD filter.
Disconnect all sources of power to the drive and HSD before working on the
equipment. Do not attempt any work on a powered HSD filter.
The harmonic filter contains high voltages and capacitors. Wait at least five
minutes after disconnecting power from the filter before you attempt to connect
or disconnect the harmonic filter. Check for zero voltage between all terminals.
All work on the HSD must be performed by a qualified electrician. Failure to
follow standard safety procedures may result in death or serious injury.
Note: when disconnecting wires from terminations, mark the wires to correspond to their terminal
connection.
Service
Your HSD has no user serviceable parts. If your HSD requires service, it must be returned to TCI or taken to
an authorized TCI service technician.
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 HSD filter
nameplate information available.

Product Description HarmonicShield®
HSD IOM Manual - Rev. D 11
Product Description
HSD Drive-Applied Filter
The HSD 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 HSD 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 HSD 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 HSD
harmonic filters for your non six-pulse diode front end VFD applications.
The HSD 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 is furnished in its own enclosure and
mounted adjacent to the drive.
The HSD 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:
oA TCI 3-phase tuning reactor specifically designed for the HSD filter
oHigh-endurance, harmonic-rated capacitors
oBleeder resistors to ensure safe capacitor discharge upon filter shutdown
Filter Configuration
Figure 1: HSD Connection Diagram 3HP to 10HP

HarmonicShield®Product Description
12 HSD IOM Manual - Rev. D
Figure 2: HSD Connection Diagram 15HP and Above

Product Description HarmonicShield®
HSD IOM Manual - Rev. D 13
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 (RMS volts)
•Hz: the rated frequency (60 Hz)
•Phase: 3 – The HSD 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
Figure 3: HarmonicShield® Nameplate

HarmonicShield®Product Description
14 HSD IOM Manual - Rev. D
Part Number Encoding
Figure 4 identifies the significance of each character in the HSD part number. The example part number,
HSD0150AW30000 designates an HSD filter that is rated 150 HP, 480 volts, 60 Hz. It includes a line
reactor, tuning reactor, and capacitors in a UL Type 3R enclosure. It is designed for use with a 150 HP
drive.
Figure 4 – HSD Part Number Encoding