MFC Sinewave Filter Kit Installation Instructions - TCI, LLC

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MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Sinewave Filter Kit
Installation Instructions

                TCI, LLC
                W132 N10611 Grant Drive
                Germantown, Wisconsin 53022

                Phone: 414-357-4480
                Fax: 414-357-4484
                Helpline: 800-TCI-8282
                Web Site: http://www.transcoil.com
                © 2019 TCI, LLC All rights reserved
                Effective: 01/09/2020 Version: E
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
Revision                        Description                               Date
    A                               Release                           09/27/2016
    B                Update to drawings, heat loss                    08/07/2018
    C               Update to drawings and cooling                    12/13/2018
                    Various text updates; added
    D           Maintenance and Service section and                   04/09/2019
                         PQconnect option
    E                Updates to PQconnect section                     01/09/2020

 No part of this publication may be reproduced, stored in a retrieval system, or transmitted in
 any form or by any means, mechanical, electronic, photocopying, recording, or otherwise,
 without the prior written permission of TCI, LLC. The information in this manual is subject to
 change without notice. Every precaution has been taken in the preparation of this manual.
 TCI, LLC assumes no responsibility for errors or omissions. Neither is any liability assumed
 for damages resulting from the use of the information contained in this publication.
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
Table of Contents
 Introduction ............................................................................................................................................................ 2
              Safety Instructions Overview ............................................................................................................. 2
              Warnings and Cautions ..................................................................................................................... 2
              General Safety Instructions ............................................................................................................... 3

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

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

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

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

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

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

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

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

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

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

                                                                                   1
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Kit IOM                                                                                   1.0 Introduction

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

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

              The MFC Filter Kit is intended to be connected to the output terminals of a variable frequency drive
              (VFD). An AC motor is connected to the output terminals of the MFC Kit and receives power from
              the VFD through the MFC Filter Kit. The instructions, and particularly the safety instructions, for the
              VFD, motor and any other related equipment must be read, understood and followed when working
              on any of the equipment.

     Warnings and Cautions
              This manual provides two types of safety instructions. Warnings are used to call attention to
              instructions that describe steps that must be taken to avoid conditions that can lead to a serious
              fault condition, physical injury, or death.

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

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

                       Warning         Dangerous Voltage Warning: warns of situations where
                                       high voltage can cause physical injury and/or damage
                                       equipment. The text next to this symbol describes ways
                                       to avoid the danger.
                       Warning         General Warning: warns of situations that can cause
                                       physical injury and/or damage equipment by means
                           !           other than electrical. The text next to this symbol
                                       describes ways to avoid the danger.
                       Warning         Electrostatic Discharge Warning: warns of situations in
                                       which an electrostatic discharge can damage
                                       equipment. The text next to this symbol describes ways
                                       to avoid the danger.

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

                       Caution         General Caution: identifies situations that can lead to a

                           !
                                       malfunction and possible equipment damage. The text
                                       describes ways to avoid the situation.

                                                        2
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Kit IOM                                                                                   1.0 Introduction

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

                 Warning
                                Be sure to read, understand, and follow all safety

                      !         instructions.

                 Warning
                                Only qualified electricians should carry out all electrical

                      !         installation and maintenance work on the MFC Filter Kit.

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

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

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

                                After switching off the power, always allow 5 minutes for
                                the capacitors in the MFC Filter Kit and in the drive to
                 Warning        discharge before working on the MFC Kit, the drive, the
                                motor, or the connecting wiring. It is a good practice to
                                check with a voltmeter to make sure that all sources of
                                power have been disconnected and that all capacitors
                                have discharged before beginning work.

                                                     3
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Kit Instructions                                            2.0 Receiving Inspection and Storage

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

      Receiving Inspection
            The MFC Filter Kit has been thoroughly inspected at the factory and carefully packaged for
            shipment. When you receive the unit, you should immediately inspect the shipping container and
            report any damage to the carrier that delivered the unit. Verify that the part number of the
            components you received is the same as the part numbers listed on the engineering drawings for
            the kit which can be found at:

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

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

      TCI Limited Warranty Policy
            TCI, LLC (“TCI”) warrants to the original purchaser only that its products will be free from defects
            in materials and workmanship under normal use and service for a period originating on the date of
            shipment from TCI and expiring at the end of the period described below:
                  Product Family                          Warranty Period
                                        For the life of the drive with which they are
                    KLR, KDR
                                        installed.

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

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

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

                                        One (1) year of useful service,
                All Other Products      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.

                                                      4
MFC Sinewave Filter Kit Installation Instructions - TCI, LLC
MFC Kit Instructions                                           2.0 Receiving Inspection and Storage

            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.

                                                      5
MFC Kit Instructions                                                         3.0 Pre-Installation Planning

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

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

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

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

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

            The MFC Filter Kit consists of the following standard features and components:
              • A TCI 3-phase line reactor specifically designed for high PWM ripple current from the
                sinewave filter application
              • High-endurance, PWM current ripple rated capacitors
              • Damping resistors (optional)
              • Capacitor bleeder resistors to ensure safe capacitor discharge upon filter shutdown.
              • Brackets for mounting capacitors to a panel

                                                      6
MFC Kit Instructions                                                          3.0 Pre-Installation Planning

   Table 23 – MFC Sinewave Filter Technical Specifications
    Voltage Rating                   460/480 V and 575/600 V, 3-phase

    Fundamental Frequency Range          0 Hz to 80 Hz Max.
    Horsepower Ratings                   5 HP – 1000 HP at 480 V
                                         5 HP – 750 HP at 600 V
                                         Consult Factory for additional ratings
                                         See Rating table for current ratings
    Overload Capability                  150% of rated current for 1 minute every 60 minutes:
    VFD carrier frequency                2 kHz to 16 kHz, greater than 4 kHz preferred
                                         Maximum output                      480 V models:    600 V models:
                                         Peak Voltage:                       1000 V             1500 V
                                            Peak dV/dt:                      500 V/μs           1500 V/μs
    Insertion impedance                  Approximately 6.5% at 60 Hz & rated current
    Capacitors                           Oil filled or dry high endurance design (no PCBs)
    Environmental Conditions
    Operating Temperature                Kit component ambient: 50°C (122°F)
    Storage Temperature                  60°C (140°F)
    Elevation                            Up to 2,000 m without derating
    Humidity                             95% non-condensing
    Agency approvals or certifications
    Capacitors                                        UR and cUR Recognized

    Reactors                                          UR and cUR Recognized

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

                                  Figure 12: MFC Kit Part Number Encoding

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

                                                        7
MFC Kit Instructions                                                      3.0 Pre-Installation Planning

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

                •   A KTRMG series filter reactor.
                    o The 480 V/900 HP and larger units include two reactors that need to be wired in
                       parallel.
                •   High-endurance, PWM ripple current rated capacitors.
                    o Bleeder resistors to ensure safe capacitor discharge on filter shutdown, located on
                        capacitors.
                •   Damping resistors
                    o High power 3-phase damping resistors to reduce BFD control or load dynamic
                       induced resonances. Damping resistors are recommended for applications which
                       have dynamically changing loads like hoists, elevators, or servos.
                •   Capacitor mounting brackets
                    o Capacitor mounting brackets are provided on 50 HP and higher rated kits
                    o Kits from 5 through 40 HP are not provided with capacitor brackets because
                       these units utilize single phase capacitors that do not have mounting brackets
                       available for them. These small size single phase capacitors are typically
                       mounted vertically due to the small size and reduced use of panel space.

                                                     8
MFC Kit Instructions                                                                     3.0 Pre-Installation Planning

      MFC “A” Filter Kit Part Number and Ratings
                                  HP    Amp    480 Volt Model                          HP    Amp   575/600 Volt Model
                                    5      8     MFC008AA                                5     8       MFC008CA
                                  7.5     12     MFC012AA
                                                                                       7.5    10       MFC010CA
                                   10     16     MFC016AA
                                   15     23     MFC023AA                               10    12       MFC012CA
                                   20     30     MFC030AA                               15    20       MFC020CA
                                   25     35     MFC035AA                               20    25       MFC025CA
                                   30     45     MFC045AA

                                                                575/600 Volt MFC Kit
                                                                                        25    28       MFC028CA
                                   40     55     MFC055AA                               30    35       MFC035CA
                                   50     65     MFC065AA
              480 Volt MFC Kit

                                                                                        40    45       MFC045CA
                                   60     80     MFC080AA
                                                                                        50    55       MFC055CA
                                   75    110     MFC110AA
                                  100    130     MFC130AA                               60    65       MFC065CA
                                  125    160     MFC160AA                               75    80       MFC080CA
                                  150    200     MFC200AA                              100   110       MFC110CA
                                  200    250     MFC250AA                              125   130       MFC130CA
                                  250    305     MFC305AA                              150   160       MFC160CA
                                  300    362     MFC362AA                              200   200       MFC200CA
                                  350    420     MFC420AA                              250   250       MFC250CA
                                  400    480     MFC480AA                              300   305       MFC305CA
                                  450    540     MFC540AA                              350   362       MFC362CA
                                  500    600     MFC600AA                              400   420       MFC420CA
                                  600    750     MFC750AA                              450   450       MFC450CA
                                  700    850     MFC850AA                              500   500       MFC500CA
                                  800    960     MFC960AA                              600   600       MFC600CA
                                  900   1080    MFC1080AA                              750   750       MFC750CA
                                 1000   1200    MFC1200AA
      MFC “R” Filter Kit – Sinewave Filter Kit without damping resistor
            The MFC Filter Kit is a harmonic filter component package designed and developed by TCI to allow
            qualified customers to build sinewave filters to for the output of VFDs. The filter components are
            designed to filter out PWM switching ripple when applied correctly and following the schematic
            connections used by TCI. The MFC Filter Kit is available for 480 Volt and 600 Volt systems. When
            properly designed, assembled, and installed, the completed product is intended to be suitable for use
            with 3-phase PWM AC VFDs.

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

              • A KTRMG series filter reactor.
                  o The 480 V/900 HP and larger units include two reactors that need to be wired in
                    parallel.
              • High-endurance, PWM ripple current rated capacitors.
                  o Bleeder resistors to ensure safe capacitor discharge on filter shutdown, located on
                    capacitors.
              • Capacitor mounting brackets
                 o Capacitor mounting brackets are provided on 50 HP and higher rated kits
                 o Kits from 5 through 40 HP are not provided with capacitor brackets because these
                   units utilize single phase capacitors that do not have mounting brackets available for
                   them. These small size single phase capacitorss are typically mounted vertically due
                   to the small size and reduced use of panel space.

                                                            9
MFC Kit Instructions                                                                            3.0 Pre-Installation Planning

               • Note: There are no damping resistors included, these kits are most suitable for VFD
                 applications with low load and VFD dynamics
      MFC “R” Filter Kit Part Number and Ratings
                                 HP Amp 480 Volt Model                                   HP    Amp   575/600 Volt Model
                                   5    8 MFC008AR                                         5     8      MFC008CR
                                 7.5   12 MFC012AR                                       7.5    10      MFC010CR
                                  10   16 MFC016AR                                        10    12      MFC012CR
                                  15   23 MFC023AR                                        15    20      MFC020CR
                                  20   30 MFC030AR
                                                                                          20    25      MFC025CR
                                  25   35 MFC035AR
                                                                                          25    28      MFC028CR

                                                                  575/600 Volt MFC Kit
                                  30   45 MFC045AR
                                                                                          30    35      MFC035CR
                                  40   55 MFC055AR
             480 Volt MFC Kit

                                                                                          40    45      MFC045CR
                                  50   65 MFC065AR
                                  60   80 MFC080AR                                        50    55      MFC055CR
                                  75  110 MFC110AR                                        60    65      MFC065CR
                                 100 130  MFC130AR                                        75    80      MFC080CR
                                 125 160  MFC160AR                                       100   110      MFC110CR
                                 150 200  MFC200AR                                       125   130      MFC130CR
                                 200 250  MFC250AR                                       150   160      MFC160CR
                                 250 305  MFC305AR
                                                                                         200   200      MFC200CR
                                 300 362  MFC362AR
                                 350 420  MFC420AR                                       250   250      MFC250CR
                                 400 480  MFC480AR                                       300   305      MFC305CR
                                 450 540  MFC540AR                                       350   362      MFC362CR
                                 500 600  MFC600AR                                       400   420      MFC420CR
                                 600 750  MFC750AR                                       450   450      MFC450CR
                                 700 850  MFC850AR                                       500   500      MFC500CR
                                 800 960  MFC960AR
                                                                                         600   600      MFC600CR
                                 900 1080 MFC1080AR
                                                                                         750   750      MFC750CR
                                1000 1200 MFC1200AR

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

      Variable Frequency Drive Settings
            Make sure that the variable frequency drive will be set for operation modes and ranges that are
            compatible with the MFC Kit:
                           • Maximum output frequency: 80 Hz
                           • Constant PWM switching (carrier) frequency between 2 kHz and 12 kHz, ideally 4
                             kHz to 8 kHz
                           • Mode of operation: speed control "scalar" or "V/Hz" without DC braking unless the drive
                             application has been confirmed by TCI Technical Support
                           • Consult VFD manual for other drive specific recommendations for use with sinewave
                             filters, specific instructions may include but are not limited to: disabling any variable PWM
                             switching frequency options such as features to reduce motor noise or control
                             temperature and setting drive to continuous 3-phase modulation. Six-step operation is not
                             compatible with sinewave filter technology.

                                                             10
MFC Kit Instructions                                                        3.0 Pre-Installation Planning

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

                Warning               Unless specifically labeled as approved for such use, this equipment
                                      is not suitable for use in an explosive atmosphere or in a "Hazardous
                     !                (Classified) Location" as defined in article 500 of the National
                                      Electrical code.

            The unit must be installed in an area where it will not be exposed to:
                  • Direct sunlight
                  • Rain or dripping liquids (unless the filter kit is installed in a Type 3R enclosure)
                  • Corrosive liquids or gases
                  • Explosive or combustible gases or dust
                  • Excessive airborne dirt and dust
                  • Excessive vibration

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

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

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

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

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

                                                      11
MFC Kit Instructions                                                     3.0 Pre-Installation Planning

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

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

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

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

                                                    12
MFC Kit Instructions                                                          3.0 Pre-Installation Planning

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

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

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

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

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

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

                                                       13
MFC Kit Instructions                                                          3.0 Pre-Installation Planning

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

                                   Figure 6 – Copper Flag Terminations

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

                       Figure 7 – Larger Reactors with Copper Flag Terminations

      Wiring
            TCI does not recommend running drive input and output wires in the same conduit.
      Capacitors
            The high-endurance, PWM current ripple rated capacitors supplied in the MFC Filter kit are in
            shunt with the load. In the case of the MFC “A” Filter Kit, the capacitors are wired in series with
            the power resistors. If multiple capacitors are supplied with the kit, they are intended to be
            connected in parallel with each other. Typically, the capacitors are three-terminal, three-phase
            capacitors with the internal capacitive elements connected in delta. Each capacitor has a bleeder
            resistor connected across the three input terminals to ensure voltage discharges in the time
            required by UL.

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

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

                                                       14
MFC Kit Instructions                                                       3.0 Pre-Installation Planning

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

                           Figure 8 –Bleeder Resistor Installation and Wiring for Single Phase

      Capacitor Brackets

                                   Figure 9 – Capacitors and Brackets

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

                                                     15
MFC Kit Instructions                                                        3.0 Pre-Installation Planning

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

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

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

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

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

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

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

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

                                                      16
MFC Kit Instructions                                         3.0 Pre-Installation Planning

      Table 1 – Technical Data for MFC “A” 480 Volt Models
                                     Rated         Capacitor Circuit   Power Dissipation
          Model     Load Rating
                                  Line Current         Current               (W)
         Number        (HP)
                                         (A)             (A)
       MFC008AA           5              8               2.0                 260
       MFC012AA          7.5            12               3.0                 330
       MFC016AA          10             16               4.0                 370
       MFC023AA          15             23               6.0                 515
       MFC030AA          20             30               7.5                 650
       MFC035AA          25             35               8.5                 710
       MFC045AA          30             45              11.0                 825
       MFC055AA          40             55              10.5                 1000
       MFC065AA          50             65              16.0                 1175
       MFC080AA          60             80              20.0                 1550
       MFC110AA          75            110              28.0                 1670
       MFC130AA         100            130              32.0                 1965
       MFC160AA         125            160              40.0                 2600
       MFC200AA         150            200              49.0                 3275
       MFC250AA         200            250              61.0                 3700
       MFC305AA         250            305              75.0                 4660
       MFC362AA         300            362              89.0                 4650
       MFC420AA         350            420              102.0                5720
       MFC480AA         400            480              117.0                6275
       MFC540AA         450            540              132.0                7000
       MFC600AA         500            600              146.0                7710
       MFC750AA         600            750              182.0                9320
       MFC850AA         700            850              205.0               10400
       MFC960AA         800            960              235.0               11100
       MFC1080AA        900           1080             2x 132.0            2x 7000
       MFC1200AA       1000           1200             2x 146.0            2x 7710

                                           17
MFC Kit Instructions                                        3.0 Pre-Installation Planning

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

                                           18
MFC Kit Instructions                                         3.0 Pre-Installation Planning

      Table 3 – Technical Data for MFC “A” 600 Volt Models
                                     Rated         Capacitor Circuit   Power Dissipation
          Model     Load Rating
                                  Line Current         Current               (W)
         Number        (HP)
                                        (A)               (A)
       MFC008CA          5              8                 2.0                 355
       MFC010CA        7.5             10                 2.0                 370
       MFC012CA         10             12                 2.5                 365
       MFC020CA         15             20                 5.0                 530
       MFC025CA         20             25                 6.0                 685
       MFC028CA         25             28                 7.0                 715
       MFC035CA         30             35                 9.0                 875
       MFC045CA         40             45                11.0                 945
       MFC055CA         50             55                14.0                1180
       MFC065CA         60             65                16.0                1540
       MFC080CA         75             80                21.0                1610
       MFC110CA        100            110                27.0                2140
       MFC130CA        125            130                33.0                2290
       MFC160CA        150            160                37.0                2510
       MFC200CA        200            200                49.0                3430
       MFC250CA        250            250                61.0                4505
       MFC305CA        300            305                74.0                5065
       MFC362CA        350            362                89.0                6055
       MFC420CA        400            420               104.0                6830
       MFC450CA        450            450               113.0                7400
       MFC500CA        500            500               121.0                7850
       MFC600CA        600            600               146.0                8850
       MFC750CA        750            750               182.0               10700

                                           19
MFC Kit Instructions                                             3.0 Pre-Installation Planning

   Table 4 – Technical Data for MFC “R” 600 Volt Models
                                  Rated            Capacitor Circuit    Power Dissipation
       Model    Load Rating
                               Line Current            Current                (W)
      Number       (HP)
                                     (A)                  (A)
     MFC008CR            5           8                    2.1                  205
     MFC010CR          7.5          10                    2.1                  220
     MFC012CR           10          12                    2.7                  215
     MFC020CR           15          20                    5.3                  320
     MFC025CR           20          25                    6.3                  400
     MFC028CR           25          28                    7.2                  400
     MFC035CR           30          35                    9.5                  435
     MFC045CR           40          45                   11.6                  450
     MFC055CR           50          55                   14.7                  560
     MFC065CR           60          65                   17.0                  725
     MFC080CR           75          80                   22.0                  775
     MFC110CR          100         110                   28.5                  900
     MFC130CR          125         130                   35.0                  925
     MFC160CR          150         160                   39.0                  950
     MFC200CR          200         200                   52.0                 1275
     MFC250CR          250         250                   64.0                 1500
     MFC305CR          300         305                   78.0                 1750
     MFC362CR          350         362                   94.0                 1725
     MFC420CR          400         420                  110.0                 2100
     MFC450CR          450         450                  119.0                 2175
     MFC500CR          500         500                  127.0                 2200
     MFC600CR          600         600                  154.0                 2400
     MFC750CR          750         750                  192.0                 2550

                                              20
MFC Kit Instructions                                                       3.0 Pre-Installation Planning

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

                        Make sure that the installation location will not be exposed to direct sunlight, corrosive
                        or combustible airborne contaminants, excessive dirt or liquids.
                        Select a mounting area that will allow adequate cooling air and maintenance access.

                        Make sure that all wiring conforms to the requirements of the National Electric Code
                        (NEC) and/or other applicable electrical codes.
                        Connect the MFC equipment-grounding lug to the system ground of the premises
                        wiring system. Use a properly sized grounding conductor.
                        Connect VFD output three-phase output to the input terminals of the MFC: A1, B1, and
                        C1 terminals of the KTRMG sinewave reactor
                        Connect MFC output terminals A2, B2, and C2 terminals of the KTRMG sinewave
                        reactor to the load.
                        Connect MFC output terminals A2, B2, and C2 to the optional damping resistor
                        (supplied as part of an A kit) or to the filter capacitors.

                                                     21
MFC Kit Instructions                                                             4.0 PQconnect Option

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

            Modbus RTU

            Introduction

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

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

                                                                                          5
                                                                                          4
                                                                                          3   Modbus RTU
                                                                                          2   Connections
                                                                                          1

                           Figure 10 – PQconnect Modbus RTU Connection

                                                    22
MFC Kit Instructions                                                                         4.0 PQconnect Option

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

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

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

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

                Table 7: Configuration Switches
                                                               1 – Enable 560Ω bias resistor on D-.
                            Configure Modbus Connection        2 – Enable 120Ω termination resistor.
                 SW1
                            on J5 Header
                                                               3 - Enable 560Ω pull-up on D+.
                 J20        Remove jumper to use default Modbus settings on next reboot.

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

                                                         23
MFC Kit Instructions                                                                    4.0 PQconnect Option

      Register Map
    Read Parameters:
    Table 8 : Network Interface OUTPUT/ Feedback Register Map
                       I/O Reg
      Parameter Name   Address   Direction    Format and Examples                       Description
                        Offset
                                             0,1 = Initialization
                                             2 = Power on Delay
                                             3 = Fault Inhibit
                                             4 = Reset                   Indicates the present state of the system
     SYS_STATE           11       Output
                                             5 = Nominal                 state machine.
                                             6 = Fault Detected
                                             7 = Calibrate offsets
                                             8 = Calibrate Check

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

     DSP_MODEL_NUM       13       Output     103 = 480 V                 System Model Number
     V_OUT_A_RMS         30       Output     Volts RMS                   Filter output RMS voltage phase A
                                             4800 = 480.0 VRMSLL
     V_OUT_B_RMS         31       Output                                 Filter output RMS voltage phase B
                                             Range: 120 to 690
     V_OUT_C_RMS         32       Output     VRMSLL                      Filter output RMS voltage phase C
                                                                         Filter output Phase A THVD (Voltage
     V_OUT_A_THD         45       Output
                                                                         Total Harmonic Distortion)
                                             % THVD
                                                                         Filter output Phase B THVD (Voltage
     V_OUT_B_THD         46       Output     50 = 5.0% THVD
                                                                         Total Harmonic Distortion)
                                                                         Filter output Phase C THVD (Voltage
     V_OUT_C_THD         47       Output
                                                                         Total Harmonic Distortion)
     T_AMBIENT           48       Output     250 = 25.0 C°               Filter internal ambient temperature
     V_OUT_FUND_HZ       100      Output     Range 1 to 500 Hz           Filter output fundamental frequency
     V_IN_CARRIER_HZ     101      Output     Range 1kHz to 16 kHz        Filter input carrier frequency
                                             1 = ABC Rotation
                                             Expected
     V_OUT_ROT           102      Output                                 Filter output phase orientation
                                             2 = ACB Rotation
                                             Expected

                                                     24
MFC Kit Instructions                                                                    4.0 PQconnect Option

  Read Parameters:
  Table 9 : Network Interface OUTPUT/ Feedback Register Map
                             I/O Reg
                                                             Format and
        Parameter Name       Address   Direction                                               Description
                                                              Examples
                              Offset
   FAULT_A                     200      Output                                    Example: Enabling all fault
                                                                                  conditions is 1111 1111 1111 1111
                                                                                  in binary or 65535 decimal.
   FAULT_B                     201      Output
                                                        0 = Disabled              Reference Fault codes Table
   FAULT_A_ENABLE_RO           202      Output                                    If a fault is active and the bit
                                                        To Enable desired         corresponding to that status in this
   FAULT_B_ENABLE_RO           203      Output          fault detections, enter   mask is set, the relay will be
                                                        bit mask from table by    activated.
                                                        converting to decimal
   FAULT_A_RELAY_ACTION_RO     204      Output          Range: 0 to 65535         Reference Fault codes Table

                                                                                  Read only values. To change these
   FAULT_B_RELAY_ACTION_RO     205      Output                                    values, modify the corresponding
                                                                                  register in the setpoint section
                                                                                  below.
                                                        0 = Power Off             Indicates if the filter has input power
   SYS_POWER                   250      Output
                                                        1 = Power On              available
                                                        0 = Filter is operating
                                                        1 = Filter has
   SYS_FAULTED                 251      Output                                    Indicates filters status
                                                        detected a fault
                                                        condition

                                                        4800 = 480.0Vrms          Filter rated voltage.
   RATED_VOLTAGE_RO            260      Output          Range = 1200 to
                                                        6900                      Read only value.

                                                                                  Filter rated current.
                                                        1000 = 100.0 A
   RATED_CURRENT_RO            261      Output
                                                        Range = 3 to 1500 A
                                                                                  Read only value.

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

                                                                                  Modbus slave address

                                                        Default = 10              Read only value. To change this
   MB_SLAVE_ADDRESS_RO         300      Output
                                                        Range 0 to 255            value, modify the corresponding
                                                                                  register in the setpoint section
                                                                                  below.

                                                                                  Modbus baud rate
                                                        960 = 9600 baud rate
                                                        3840 = 38400 baud
                                                                                  Read only value. To change this
   MB_BAUD_RATE_RO             301      Output          rate (default)
                                                                                  value, modify the corresponding
                                                        11520 = 115200 baud
                                                                                  register in the setpoint section
                                                        rate
                                                                                  below.

                                                   25
MFC Kit Instructions                                                              4.0 PQconnect Option

   Read Parameters:
   Table 10 : Network Interface OUTPUT / Feedback Register Map
                                   I/O Reg
                                                          Format and
           Parameter Name          Address   Direction                                  Description
                                                           Examples
                                    Offset
                                                                           Modbus Parity
                                                         0 = None
                                                         1 = Odd
   MB_PARITY_RO                      302      Output                       Read only value. To change this
                                                         2 = Even
                                                                           value, modify the corresponding
                                                         (default)
                                                                           register in the setpoint section below.
                                                                           Delay time on fault relay being
                                                                           energized when any enabled fault
                                                         Relay close       condition is detected. This delay is in
                                                         delay time in     addition to any configured delay for a
   CNT_CLOSE_DELAY_RO                320      Output     milliseconds      specific fault condition.
                                                         Range 0 to 60
                                                         seconds           Read only value. To change this
                                                                           value, modify the corresponding
                                                                           register in the setpoint section below.
                                                                           Delay time on fault relay being
                                                         Relay open        unenergized when all enabled fault
                                                         delay time in     detection conditions have cleared.
   CNT_OPEN_DELAY_RO                 321      Output     milliseconds
                                                         Range 0 to 60     Read only value. To change this
                                                         seconds           value, modify the corresponding
                                                                           register in the setpoint section below.
                                                                           Overvoltage onset threshold in
                                                                           percent rated voltage
   OVERVOLTAGE_FAULT_ONSET_RO        322      Output
                                                                           Read only value. To change this
                                                         Default 125%      value, modify the corresponding
                                                         Range 100 to      register in the setpoint section below.
                                                         200               Overvoltage fault clear threshold

   OVERVOLTAGE_FAULT_CLEAR_RO        323      Output                       Read only value. To change this
                                                                           value, modify the corresponding
                                                                           register in the setpoint section below.
                                                         Fault detection
                                                         delay time in     Overvoltage fault delay time.
                                                         milliseconds.
   OVERVOLTAGE_FAULT_DELAY_RO        324      Output     Default of 6      Read only value. To change this
                                                         seconds.          value, modify the corresponding
                                                         Range 0.02 to     register in the setpoint section below.
                                                         60 seconds
                                                                           Filter output high frequency fault
                                                                           onset threshold
   HIGH_FREQUENCY_FAULT_ONSET_RO     325      Output
                                                                           Read only value. To change this
                                                         Default 125%      value, modify the corresponding
                                                         Range 100 to      register in the setpoint section below.
                                                         200               High frequency fault clear threshold

   HIGH_FREQUENCY_FAULT_CLEAR_RO     326      Output                       Read only value. To change this
                                                                           value, modify the corresponding
                                                                           register in the setpoint section below.
                                                         Fault detection
                                                         delay time in     High frequency fault delay time.
                                                         milliseconds.
   HIGH_FREQUENCY_FAULT_DELAY_RO     327      Output     Default of 6      Read only value. To change this
                                                         seconds.          value, modify the corresponding
                                                         Range 0.02 to     register in the setpoint section below.
                                                         60 seconds

                                                26
MFC Kit Instructions                                                                     4.0 PQconnect Option

   Read Parameters:
   Table 11 : Network Interface OUTPUT Register Map
                              I/O Reg
                                                          Format and
        Parameter Name        Address   Direction                                           Description
                                                           Examples
                               Offset
                                                                           Phase loss fault onset threshold (average of
                                                                           the three filter output voltages)
                                                         Default = 60 =
  PHASE_LOSS_FAULT_ONSET_RO     328      Output          60%
                                                                           Read only value. To change this value, modify
                                                         Range 1 to 100
                                                                           the corresponding register in the setpoint
                                                                           section below.
                                                                           Phase loss fault clear threshold (average of
                                                                           the three filter output voltages)
                                                         Default = 55 =
  PHASE_LOSS_FAULT_CLEAR_RO     329      Output          55%
                                                                           Read only value. To change this value, modify
                                                         Range 1 to 100
                                                                           the corresponding register in the setpoint
                                                                           section below.
                                                         Fault detection
                                                         delay time in     Phase loss fault delay time.
                                                         milliseconds.
  PHASE_LOSS_FAULT_DELAY_RO     330      Output          Default of 12     Read only value. To change this value, modify
                                                         seconds.          the corresponding register in the setpoint
                                                         Range 0.02 to     section below.
                                                         60 seconds
                                                                           Filter output high THVD fault onset threshold.

  THD_FAULT_ONSET_RO            331      Output                            Read only value. To change this value, modify
                                                                           the corresponding register in the setpoint
                                                         Default of 120    section below.
                                                         = 12.0% THD
                                                         Range 2 to 100    THVD fault clear threshold

  THD_FAULT_CLEAR_RO            332      Output                            Read only value. To change this value, modify
                                                                           the corresponding register in the setpoint
                                                                           section below.
                                                         Fault detection
                                                                           Voltage Total Harmonic Distortion (THVD)
                                                         delay time in
                                                                           fault delay time.
                                                         milliseconds.
  THD_FAULT_DELAY_RO            333      Output          Default of 12
                                                                           Read only value. To change this value, modify
                                                         seconds.
                                                                           the corresponding register in the setpoint
                                                         Range 0.02 to
                                                                           section below.
                                                         60 seconds
                                                                           Filter Ambient overtemperature onset
                                                                           threshold.
  T_AMBIENT_OT_ONSET_RO         334      Output
                                                                           Read only value. To change this value, modify
                                                                           the corresponding register in the setpoint
                                                         Default = 20 =    section below.
                                                         20%
                                                         Range 2 to 100    Filter Ambient overtemperature clear
                                                                           threshold.
  T_AMBIENT_OT_CLEAR_RO         335      Output
                                                                           Read only value. To change this value, modify
                                                                           the corresponding register in the setpoint
                                                                           section below.
                                                         Fault detection
                                                         delay time in     Filter Ambient overtemperature fault delay.
                                                         milliseconds.
  T_AMBIENT_OT_DELAY_RO         336      Output          Default of 12     Read only value. To change this value, modify
                                                         seconds.          the corresponding register in the setpoint
                                                         Range 0.02 to     section below.
                                                         60 seconds

   Read Parameters:

                                                    27
MFC Kit Instructions                                                                  4.0 PQconnect Option

   Table 12 : Network Interface OUTPUT Register Map
                           I/O Reg
                                                      Format and
        Parameter Name     Address   Direction                                           Description
                                                       Examples
                            Offset

                                                 Fault detection delay     Tuning reactor overtemperature fault
                                                 time in milliseconds.     delay.
                                                 Default of 12
    REACTOR_OT_DELAY_RO      337      Output
                                                 seconds.                  Read only value. To change this value,
                                                 Range 0.02 to 60          modify the corresponding register in the
                                                 seconds                   setpoint section below.

                                                 Parameter contains        Unit serial number section - upper 16
                                                 UUUU in the               bits of 32-bit unit job number
    SYS_SERIAL_NUM_2_RO      350      Output
                                                 UUUULLLL-NN serial
                                                 number format.            Read only value.
                                                 Parameter contains        Unit serial number section - lower 16
                                                 LLLL in the               bits of 32-bit unit job number
    SYS_SERIAL_NUM_1_RO      351      Output
                                                 UUUULLLL-NN serial
                                                 number format.            Read only value.
                                                 Parameter contains        Unit serial number section - two-digit
                                                 NN in the                 unit number.
    SYS_SERIAL_NUM_0_RO      352      Output
                                                 UUUULLLL- NN
                                                 serial number format.     Read only value.
                                                 0 = Not calibrated
    SYS_NULL_STAT            400      Output                               System auto null status
                                                 1 = Unit is calibrated

                                                 0 = Unit is not
                                                                           System null timer; indicates whether the
    SYS_NULL_TMR             401      Output     calibrating
                                                                           unit is calibrating
                                                 1 = Unit is Calibrating

                                                                           Processor internal heartbeat. Internal
                                                                           counter that counts up and rolls over to
    SYS_INT_HB               402      Output     Range 0 to 65535
                                                                           zero used to verify processor clock
                                                                           operation.
                                                                           Processor background heartbeat.
                                                                           Internal counter that counts up and rolls
    SYS_BG_HB                403      Output     Range 0 to 65535
                                                                           over to zero used to verify processor
                                                                           clock operation

                                                 28
MFC Kit Instructions                                              4.0 PQconnect Option

      Table 13 : Fault Codes
                 Bits                       Fault Descriptions
                               Register A
       0                            No fault detected / enabled
       1                            Overvoltage Phase A
       2                            Overvoltage Phase B
       3                            Overvoltage Phase C
       4                            High Frequency Phase A-B
       5                            High Frequency Phase B-C
       6                            High Frequency Phase C-A
       7                            Phase Loss (Phase A)
       8                            Phase Loss (Phase B)
       9                            Phase Loss (Phase C)
       10                           High THVD Phase A
       11                           High THVD Phase B
       12                           High THVD Phase C
       13                           Under Temperature
       14                           Over Temperature
       15                           CPU Error
                               Register B

       0                            Reactor Switch

                                                        29
MFC Kit Instructions                                                              4.0 PQconnect Option

   Write Parameters:
   Table 14 : Network Interface INPUT/Setpoint Register Map
                                 I/O Reg
                                                            Format and
           Parameter Name        Address   Direction                                       Description
                                                             Examples
                                  Offset
                                                       0 = Initialization
                                                                                 Note that defaulting the flash
                                                       9 = Save current
                                                                                 will clear all calibration data
                                                       values to flash
                                                                                 and require that the calibration
    USER_STATE_REQ                 500       Input     150 = Load values
                                                                                 procedure be re-run with no
                                                       from Flash
                                                                                 voltage applied to the
                                                       255 = Restore
                                                                                 PQconnect board.
                                                       Defaults to Flash
                                                       0 = Capture Done          Update trace data points for
    TRACE_GO_DONE                  501       Input
                                                       1 = Start Capture         waveforms
                                                                                 Delay time on fault relay being
                                                       Relay close delay         energized when any enabled
                                                       time in milliseconds      fault condition is detected. This
    CNT_CLOSE_DELAY                505       Input
                                                       Range 0 to 60             delay is in addition to any
                                                       seconds                   configured delay for a specific
                                                                                 fault condition.
                                                       Relay open delay          Delay time on fault relay being
                                                       time in milliseconds      unenergized when all enabled
    CNT_OPEN_DELAY                 506       Input
                                                       Range 0 to 60             fault detection conditions have
                                                       seconds                   cleared.
                                                       Default 20 = 20
                                                       milliseconds
    POWER_ON_DELAY                 507       Input                               System power on delay
                                                       Range 0.02 to 60
                                                       Seconds.
                                                       1000 = 100 A
    RATED_CURRENT                  520       Input                               Filter rated current
                                                       Range = 3A to 1500A
                                                       4800 = 480 Vrms
    RATED_VOLTAGE                  521       Input     Range = 120 to 690        Filter rated voltage
                                                       Vrms
                                                       50 = 50 Hz
    RATED_FREQUENCY                522       Input                               Filter rated frequency
                                                       60 = 60 Hz
    FAULT_A_ENABLE                 540       Input                               Example: Enabling all fault
                                                                                 conditions is 1111 1111 1111
                                                       0 = Disabled              1111 in binary or 65535
    FAULT_B_ENABLE                 541       Input                               decimal.
                                                       To Enable desired
                                                       fault detections, enter   Reference Fault codes Table 3
    FAULT_A_RELAY_ACTION           542       Input     bit mask from table by    If a fault is active and the bit
                                                       converting to decimal     corresponding to that status in
                                                       Range: 0 to 65535         this mask is set, the relay will
    FAULT_B_RELAY_ACTION           543       Input                               be activated.

                                                                                 Reference Fault codes Table 3
                                                       DEFAULT = 10
    MB_SLAVE_ADDRESS               560       Input                               Modbus slave address
                                                       Range 0 to 255
                                                       960 = 9600 baud rate
                                                       3840 = 38400 baud
    MB_BAUD_RATE                   561       Input     rate (DEFAULT)            Modbus baud rate
                                                       11520 = 115200 baud
                                                       rate
                                                       0 = None
    MB_PARITY                      562       Input     1 = Odd                   Modbus Parity
                                                       2 = Even (DEFAULT)

   Write Parameters:

                                                30
MFC Kit Instructions                                                            4.0 PQconnect Option

   Table 15 : Network Interface INPUT Register Map
                                 I/O Reg
                                                            Format and
           Parameter Name        Address   Direction                                    Description
                                                             Examples
                                  Offset
                                                                                Set desired Overvoltage
    OVERVOLTAGE_FAULT_ONSET        600       Input                              onset threshold in percent
                                                       DEFAULT = 125%           rated voltage
                                                       Range 100 to 200
                                                                                Overvoltage fault clear
    OVERVOLTAGE_FAULT_CLEAR        601       Input
                                                                                threshold
                                                       Fault detection delay
                                                       time in milliseconds.
    OVERVOLTAGE_FAULT_DELAY        602       Input     Default of 12 seconds.   Overvoltage fault delay time
                                                       Range 0.02 to 60
                                                       seconds
                                                       Default 125%             Set desired High frequency
    HIGH_FREQUENCY_FAULT_ONSET     603       Input
                                                       Range 100 to 200         fault onset threshold
                                                       Default 125%             Set desired High frequency
    HIGH_FREQUENCY_FAULT_CLEAR     604       Input
                                                       Range 100 to 200         fault clear threshold
                                                       Fault detection delay
                                                       time in milliseconds.
                                                                                High frequency fault delay
    HIGH_FREQUENCY_FAULT_DELAY     605       Input     Default of 6 seconds.
                                                                                time
                                                       Range 0.02 to 60
                                                       seconds
                                                                                Phase loss fault onset
                                                       Default = 60 = 60%
    PHASE_LOSS_FAULT_ONSET         606       Input                              threshold (average of the
                                                       Range 1 to 100
                                                                                three filter output voltages)
                                                                                Phase loss fault clear
                                                       Default = 55 = 55%
    PHASE_LOSS_FAULT_CLEAR         607       Input                              threshold (average of the
                                                       Range 1 to 100
                                                                                three filter output voltages)
                                                       Fault detection delay
                                                       time in milliseconds.
    PHASE_LOSS_FAULT_DELAY         608       Input     Default of 12 seconds.   Phase loss fault delay time
                                                       Range 0.02 to 60
                                                       seconds
                                                       Default = 20 = 20%       Set desired THVD fault
    THD_FAULT_ONSET                609       Input
                                                       Range 2 to 100           onset threshold
                                                       Default = 20 = 20%       Set desired THVD fault
    THD_FAULT_CLEAR                610       Input
                                                       Range 2 to 100           clear threshold
                                                       Fault detection delay
                                                       time in milliseconds.    Voltage Total Harmonic
    THD_FAULT_DELAY                611       Input     Default of 6 seconds.    Distortion (THVD) fault
                                                       Range 0.02 to 60         delay time
                                                       seconds
                                                                                Filter Ambient
                                                       Default = 20 = 20%
    T_AMBIENT_OT_ONSET             612       Input                              overtemperature onset
                                                       Range 2 to 100
                                                                                threshold
                                                                                Filter Ambient
                                                       Default = 20 = 20%
    T_AMBIENT_OT_CLEAR             613       Input                              overtemperature clear
                                                       Range 2 to 100
                                                                                threshold
                                                       Fault detection delay    Filter Ambient
    T_AMBIENT_OT_DELAY             614       Input
                                                       time in milliseconds.    overtemperature fault delay
                                                       Default of 12 seconds.
                                                       Range 0.02 to 60         Tuning reactor
    REACTOR_OT_DELAY               615       Input
                                                       seconds                  overtemperature fault delay

                                              31
MFC Kit Instructions                                                             4.0 PQconnect Option

   Write Parameters:
   Table 16 : Network Interface INPUT Register Map
                                                                                 System auto null calibration
                                                           0 = Disabled          enable. This value auto
    SYS_NULL_EN                      700         Input
                                                           1 = Enabled           clears to 0 when calibration
                                                                                 complete.
                                                           Parameter contains
                                                                                 Unit serial number section -
                                                           UUUU in the
    SYS_SERIAL_NUM_2                 810         Input                           upper 16 bits of 32-bit unit
                                                           UUUULLLL-NN serial
                                                                                 job number
                                                           number format.
                                                           Parameter contains
                                                                                 Unit serial number section -
                                                           LLLL in the
    SYS_SERIAL_NUM_1                 811         Input                           lower 16 bits of 32-bit unit
                                                           UUUULLLL-NN serial
                                                                                 job number
                                                           number format.
                                                           Parameter contains
                                                           NN in the UUUULLLL-   Unit serial number section -
    SYS_SERIAL_NUM_0                 812         Input
                                                           NN serial number      two-digit unit number
                                                           format.

      PQconnect Hardware
         Example Application Using “Simply Modbus Master 8.1.0”
             The Modbus RTU network interface port is configured for RS-485 signal levels. The following
             example uses an RS-485 to USB converter to connect the PQconnect to a laptop PC running the
             Modbus RTU master application. The picture below shows an example “US Converters Model:
             XS890” model RS-485 to USB converter. As another alternative RS-485 converter there is
             WINGONEER USB 2.0 to RS485 Serial Converter Adapter CP2104.

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

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

                                                  32
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