KLR Line Reactors

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KLR Price List | Enclosure Price List

Drawings :

KLR UL Recognized: Open Units / Enclosed

KLR UL Listed:

• Open Units
• Type 1 Enclosed
• Type 3R Enclosed

Universal Mounting Footprint
For more information on the Universal Mounting footprint, see the following documents:

• Universal Mounting Frame Size Dimension Listing
• Universal Mounting "No Fit" List
• Press Release and Frame Size Mounting Bracket drawings

PRODUCT SPECIFICATIONS Lifetime Warranty Performance Guarantee UL Listed K-Rated, UL/CUL-Recognized; CSA-Certified 3 Phase, 690V Class l Gapped Iron Core Inductor All Copper Windings 40°C Ambient Temp. / 155°C Max. Operating Temp Available in UL Type 1 and UL Type 3R enclosures NEMA 1 enclosures available Available with Terminal Options Patented High quality Bobbin Construction, units 80A and below. Distributed GapTM Technology, units 110A and above. Can tolerate 200% rated I, for at least 3 minutes Din Rail Mountable (units 80A and below) Universal Mounting Footprint

Applications
TCI KLR series three phase AC line reactors are intended for use as input filters for adjustable speed DC drives and as input or output filters for AC-PWM variable frequency drives. Drive performance is significantly improved, the drives input rectifier is protected from failure or damage, and drive harmonic demands are tamed with the addition of a K-rated line reactor. KLR line reactors act as interface buffers between solid state power circuits and the line or the motor. (Not unlike the surge protector for your desk-top PC). All drives, in any application, will benefit when applied with KLR series line reactors.

Before KLR Line Reactors
Drives are susceptible to problems caused at their interface to the line or motor. Some of these issues include AC voltage waveform line notching or cross-talk, DC bus overvoltage trips, inverter overcurrent and overvoltage, and poor total power factor. Since all drives demand nonlinear current and voltage, drives demand currents rich in harmonics.

After KLR Line Reactors
KLR line reactors provide additional circuit inductance which slows rapid changes in current that are the heart of the problems listed above.

1. Voltage line notching, or commutation notching, is caused by SCR phase-controlled rectifiers. KLR line reactors provide a voltage-dividing impedance which reduces the depth and rounds the edges of the notches, thereby eliminating drive cross-talk, interference, and equipment damage.
2. Transient voltages on the AC power lines can cause inrush currents to an AC-PWM drive, resulting in an overvoltage condition of the DC bus.
   
   These transient voltage conditions are often caused by utility capacitor switching and will cause VFDs to shut down without warning. The addition of a KLR line reactor will Figure 1 - Voltage transient caused by switched capacitor.
   

KDR Optimized Drive Reactors

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Price List

Drawings :

KDR UL Recognized: 240V - 480V - 575V

KDR UL Listed:

• Open Units
• Type 1 Enclosed
• Type 3R Enclosed

Universal Mounting Footprint
For more information on the Universal Mounting footprint, see the following documents:

• Universal Mounting Frame Size Dimension Listing
• Universal Mounting "No Fit" List
• Press Release and Frame Size Mounting Bracket drawings

PRODUCT SPECIFICATIONS 3 Phase, 690V UL Listed UL and CUL Recognized CE Marked High Performance Compact Design Available in Low Impedance (Low Z) and High Impedance (High Z) Available in 240, 480, and 575 VAC Patented High Quality Bobbin Construction (Units 75 HP and below) Distributed GapTM Technology Available in UL Type 1 and UL Type 3R enclosures NEMA 1 enclosures available Input and Output Specified 40 Degrees C Ambient Temperature Minimum 95%L at 110% Load Minimum 80%L at 150% Load Tolerate 200% rated I for a minimum of 3 minutes Universal Mounting Footprint

Applications
The new KDR Optimized Drive Reactors have been designed to provide the same rugged reliability customers have come to expect from TCI products. These reactors are now available for both the input and the output of PWM drives. The KDR reactors for the input are available in two ratings versions, Low "Z" (low impedance) and High "Z" (high impedance). The Low "Z" units can be used in any application where traditionally either a 1.5% or 3% impedance reactor would be applied. The High "Z" units can be used in any application where traditionally a 5% impedance reactor would be applied. The output reactors have been selected based on the unit's ability to withstand the rigors of variable system characteristics. With TCI's same outstanding warranty and performance guarantee, the KDR Optimized Drive Reactors offer a superior design and performance solution.

Before KDR Optimized Drive Reactors
KDR Optimized Drive Reactors applied to the line side of a PWM drive will greatly improve the overall performance of the drive. The additional circuit inductance will reduce AC voltage waveform notching, DC bus overvoltage trips, inverter overvoltage, poor total power factor and cross-talk.

After KDR Optimized Drive Reactors

• Transient voltages, commonly caused by capacitor switching, or the switching of large load blocks, can result in an overvoltage condition of the DC bus. This overvoltage condition will cause the Drive to shut down in order to protect its components. These transients can sometimes be very severe and too quick for the Drive to shut down. The addition of a KDR Optimized Drive Reactor can prevent Drive shutdown and even protect components from possible damage.
• Input line distortion is caused by the non-linear characteristics of drives. The addition of a KDR Optimized Drive Reactor will limit the inrush current to the rectifier, rounding the waveform, reducing the peak currents and lowering the harmonic current distortion. High peak currents may cause distortion of the voltage waveform. KDR's reduction of those peak currents also reduces total harmonic voltage distortion at the point of common coupling.
• Drive input currents rich in harmonics result in a decrease in total input power factor to the drive. The addition of a KDR Optimized Drive Reactor will reduce RMS current through the reduction in harmonic content, thereby improving the total power factor.
  

DIN Rail Drive Reactors
Brochure | Din-Rail FAQ | 690V FAQ | Price List
KDR DIN Rail - Drawings
KLR DIN Rail - Drawings

Easy Installation, Superior Performance

• For smaller applications incorporate DIN Rail Drive Reactors to the input and output of PWM drives.
• Due to reactor sizes varying based on rated voltage and impedance, refer to the selection charts for available product sizes.
• Reduce your installation time and cost using our DIN Rail Drive Reactor compatible with any 35mm DIN Rail.
• Mounts to “Standard Steel High Profile” or “Heavy Duty Steel” DIN Rails.
• Reactor mounts horizontally on horizontal DIN Rail.
• Improve organization of reactors and their cabling.

PRODUCT SPECIFICATIONS 3% or 5% Impedance Protection based on fundamental current rating Tolerate 200% rated I for a minimum of 3 minutes 208/240 VAC, 480 VAC, 575/690 VAC system voltage Class H (180 C or better) Insulation System 115° C (average) Temperature Rise 40° C Ambient Temperature 1000 meters altitude (Derating necessary above 1000 meters) 50/60 hz Fundamental Frequency CE Marked, UL and CUL Recognized Minimum 95%L at 110% Load Minimum 80%L at 150% Load Available for either the line or load side of a PWM drive Patented Bobbin Design DIN Rail Reactors will reduce RMS current through the reduction in harmonic content, thereby improving the total power factor DIN Rail Reactors applied to the input of every drive will help balance the drive input line currents

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KLC-Series Motor Protection Filter
[ Brochure | FAQ | Drawings | Price List ]

PRODUCT SPECIFICATIONS High Performance Limit Peak Voltage Increase Voltage Rise Time • Reduce Filter Size Smaller Mechanical Layout Common Mode Current Reduction of at least 30% Reduce Bearing, Pitting, and Fluting Manufacturer’s Warranty V1000 Output Filters are warranted against Manufacturer’s defect for one year from the date of original purchase Performance Guarantee Specific Applications can reach 3000 feet (individual results may vary) UL and CUL Listed Single Motor or Multiple Motor Capable Efficiency is greater than 98%

TCI's V1000 KLC-Series Motor Protection Filters
Peak Voltages on a 460V system can reach 1200 to 1600 V, causing rapid breakdown of motor insulation, leading to motor failure. On 575 V systems, the peak voltages can easily reach 2100 V. If this is left uncontrolled, insulation failure may occur. The same peak voltages that damage the motor can also damage the cable. Since the V1000 filters are designed to be placed at the output of the Drive, these units will also protect the cable runs.

The added inductance of a V1000 filter will also help reduce motor heating, motor noise, and motor vibration by reducing the current harmonics in the system.

Manufacturer’s Warranty
V1000 Output Filters are warranted against Manufacturer’s defect for one year from the date of original purchase.

Performance Guarantee
The V1000 is guaranteed to limit motor terminal voltage to 150% of bus voltage (peak input voltage) when applied to the output of a VFD and ahead of a motor connected with up to 2000ft leads depending on carrier frequency and lead type and following the manufacturer’s guidelines. The V1K must be sized at no more than 110% of the drive output current rating. Additional restrictions apply for multiple motor applications, consult factory. The V1K must be sized to have regular line current loading of no less than 25% of its current rating. If the load has a potential for overhauling the drive must be equipped with braking resistors or other features limiting bus voltage to no more than the level of the peak line voltage. The V1K must be wired no more than 12 feet from the drive.

Superior Solutions:
Reflective Wave Phenomenon
Variable Frequency Drives generate useful “fundamental” voltage and frequency using Pulse Width Modulation (PWM) for adjusting the speed of an AC motor. The Drive’s inverter circuit “switches” (transitions from the off state to the on state) rapidly, producing a carrier containing the fundamental voltage and frequency. Voltage wave reflection is a function of the voltage rise time (dV/dT) and the length of the motor cables. The impedance on either end of the cable run does not match, causing voltage pulses to be reflected back in the direction from which it arrived. As these reflected waves encounter other waves, their values add, causing higher peak voltage. As wire length or carrier frequency increases, the overshoot peak voltage also increases. The V1000 Motor Protecting Output Filters have been designed to limit peak voltage and increase voltage rise time. In specific applications, the V1000 has performed with cable runs of up to 3,000 feet.

Filtering increases Motor Life
The V1000 reduces common mode current by at least 30%. The V1000 substantially slows down the rate of change of the PWM switching as seen by the load. The slowing of the rate of change of the PWM switching increases the capacitive coupling impedance between bearings and bearing races. The increase in capacitive coupling, in turn, reduces the damaging Common Mode Currents and increases motor up-time. The V1000 reduces bearing, pitting, and fluting.

KLC Drive Output Filters Brochure (High Quality - 2MB!)
KLC - [ Drawings ]
KLCUL - [ Drawings ]
Price List

dV/dTGuard KLC Filter Motor-Protecting Output Filter

PRODUCT SPECIFICATIONS 3 Phase, 600V Class KLCUL is UL and CUL Listed Manufacturer's Warranty Performance Guarantee High Performance NEMA 1 enclosures available Inductor uses Distributed Gap Technology 40 degrees C ambient temperature 180 degrees C or 220 degrees C Inductor insulation rating Specific applications can reach 3000 feet Single motor or multiple motor capable

TCI's KLC & KLCUL dV/dTGuard Output Filters Provide Superior
Patented Protection for Motors
As the technology of Pulse Width Modulated (PWM) Drives are incorporated into various applications and processes, the increased energy savings and decreased maintenance on Drives can be offset by increases in Motor failures. The dV/dTGuard product family has been designed as an engineered solution for motor failures due to the reflected wave phenomenon. Designed to be installed at the output terminals of the Drive, dV/dTGuard Output Filters provide effortless installation, convenient accessibility and enhanced motor performance and durability. Available in a UL/CUL version or in our original version, these products provide the outstanding performance that our customers have come to expect from TCI.

Manufacturer's Warranty
KLC and KLCUL Output Filters are warranted against Manufacturer's defect for one year from the date of original purchase.

Performance Guarantee
Properly applied and sized for the application, a KLC or KLCUL output filter is guaranteed to limit the peak voltage and reduce electrical stress on the motor insulation. If a KLC or KLCUL fails to reduce peak voltages, TCI will take back the output filter and pay shipping both ways. (Offer valid for 60 days from purchase date.)

Typical Problems, Superior Solutions with KLC Products
The Reflective Wave Phenomenon
Variable Frequency Drives generate useful "fundamental" voltage and frequency using Pulse Width Modulation (PWM) for adjusting the speed of an AC motor. The Drive's inverter circuit "switches" (transitions from the off state to the on state) rapidly, producing a carrier containing the fundamental voltage and frequency. Voltage wave reflection is a function of the voltage rise time (dV/dT) and the length of the motor cables. The impedance on either end of the cable run does not match, causing voltage pulses to be reflected back in the direction from which it arrived. As these reflected waves encounter other waves, their values add, causing higher peak voltage. As wire length or carrier frequency increases, the overshoot peak voltage also increases. The dV/dT Motor Protecting Output Filters have been designed to limit peak voltage and increase voltage rise time. In specific applications, the KLC has performed with cable runs of up to 3,000 feet.

dV/dT and Reflective Wave unsuppressed causes Motor failures

• Peak Voltages on a 460V system can reach 1200 to 1600 V, causing rapid breakdown of motor insulation, leading to motor failure. On 575 V systems, the peak voltages can easily reach 2100 V. If this is left uncontrolled, insulation failure may occur. The same peak voltages that damage the motor can also damage the cable. Since the KLC and KLCUL filters are designed to be placed at the output of the Drive, these units will also protect the cable runs.

The added inductance of a KLC or KLCUL filter will also help reduce motor heating, motor noise, and motor vibration by reducing the current harmonics in the system.

Voltage Rise Time
While peak voltages can reach 1600V or more, it is important to note that these same spikes can have a rise time, dV/dT, in excess of 7500V/ms. Such high rise times can cause significant damage to the motor windings and the insulation system, resulting in premature motor failure. The life of the motor can be greatly extended by limiting both the magnitude of the voltage spikes to levels below 1000V and the dV/dT at the motor terminals to levels less than 1000V/ms on 480V systems.

Considerations when Specifying and Selecting KLC/KLCUL Filters
KLC and KLCUL filters may be used in single Drive and Motor applications as well as a single Drive controlling multiple motors. In each case, there are some application guidelines that need to be followed in order to insure the optimum performance of your KLC or KLCUL Filter. Filters are sized based on the full load amps of the motor or motors.

Single Drive, Single Motor

• Provide sufficient ventilation. Unit loss characteristics can be found on the selection charts on the previous pages.
• Mount the unit within ten (wire) feet from the drive
• Insure the Drive's carrier frequency is set to 8kHz or below and the operating frequency is set to 60 Hz or below. A carrier frequency of 4 kHz is recommended.
• Connect the drive output leads to the A1, B1, and C1 terminations of the KLC or KLCUL unit. A2, B2, and C2 service the wire to the motor.
• If system requirements are outside of the above recommendations, please contact the factory.

Single Drive, Multiple Motors

• Provide sufficient ventilation. Unit loss characteristics can be found on the selection charts on the previous pages.
• Mount the unit within ten (wire) feet from the drive
• Insure the Drive's carrier frequency is set to 4 kHz or below and the operating frequency is set to 60 Hz or below.
• Connect the drive output leads to the A1, B1, and C1 terminations of the KLC or KLCUL unit. A2, B2, and C2 service the wire to the motor.
• The length of each motor lead should be less than 500 feet and the sum total of all the leads should be less than 1500 feet
• Total number of motors should be 10 or below

Do not operate the Drive/KLC configuration into unterminated long leads as the gross impedance mismatch will cause excessive heating in the unit's damping resistors.

It is recommended that the unit not be mounted above the Drive, as this may affect the ambient temperature of the filter.

Upon system start up, observe the KLC or KLCUL unit for a minimum of 30 minutes. Under normal operating conditions, the filter components will be too hot to touch (in excess of 100 degrees C). However, if there is any noticeable component discoloration , remove the filter from the system and consult the factory.

HarmonicGuard Harmonic Trap Filters

HarmonicGuard K-Series Drive Applied Harmonic Filters - [ Brochure | Drawings | Price List ]

PRODUCT SPECIFICATIONS UL-Listed (Industrial Control Panel) 3 Year Warranty Standard kVar: 3 through 300 Standard Voltages: 208/240/480/ 575/600V Standard Frequencies: 50/60Hz Many enclosure options available HG2 TM Protection Monitor/ Harmonic-Power Factor meter standard (above 20 kVar) Fuse lights (units 20kVar and below) Wall mountable (50kVar and below) Vertical aspect ratio (MCC Style) (120 kVar/below) 5% KLR Series Line Reactor included as standard!

Applications
HarmonicGuard drive-applied harmonic filters are used where drives are or will be installed, and harmonic reduction is necessary. Prime candidates for filtering are installations of variable frequency drives or adjustable speed devices in facilities where those drives represent a significant portion of the load, or when specifications call for limited harmonics (like IEEE 519, 1992). Filtering would also benefit any application that utilizes sensitive electronic equipment that may be susceptible to harmonic distortion, such as capacitors, control devices, motors, etc. Some industrial examples include printers, extruders, machining and pulp and paper. Commercial applications include waste water treatment, pumping and cooling, and HVAC.

Before HarmonicGuard
When nonlinear loads like drives are present in electrical systems in significant percentages, harmonic currents will exist. Harmonic currents flowing through system impedances (i.e. transformers, wires, etc.) cause voltage distortion. In addition, harmonic currents will cause a poor total power factor. Problems such as utility penalties, transformer overheating, distribution equipment overheating, system interaction, sensitive equipment failure, power factor capacitor or fuse failure, motor cogging or overheating, and random breaker tripping may occur. Harmonic mitigation is necessary. HarmonicGuard drive applied filters have been proven the most effective harmonic distortion mitigation technique available for drives.

After HarmonicGuard
HarmonicGuard drive applied harmonic filters (series LC passive filters), when applied at the load, provide a low impedance path for the major harmonic currents demanded by the drive. This greatly reduces the amount of harmonic current flowing through the distribution system and results in improved power factor, lower RMS currents, lower harmonic current distortion, lower harmonic voltage distortion, and increased system capacity. In a typical industrial facility, where one-half or more of the load may be drives, voltage distortion may cause sensitive equipment to fail. In commercial/municipal buildings, IEEE-519, 1992 is often a critical requirement of drive systems. HarmonicGuard drive applied harmonic filters allow you to accomplish both!

Estimating Distortion Reduction
HarmonicGuard drive applied filters are commonly used in industrial applications where there are concerns about distortion effecting system integrity. In addition, they are often applied in commercial or municipal buildings where the electrical system must meet specified harmonic limits - like those in IEEE-519, 1992. To know whether your drive installation might require HarmonicGuard filters, and what the impact of filters will be, consider estimating the total harmonic distortion of your system using TCI's ANALYZER software. Once you have determined that filters are necessary, consider the following application notes: K-Series filters represent a significant optimization of TCI's HarmonicGuard line up. K-series filters are smaller, lighter, and feature-packed. They are designed with a vertical profile, making installation in tight spaces easier. K-Series filters are the first to include the HG2 Protection Monitor/Harmonic-Power Factor meter as standard (over 20kVar). Sizing HarmonicGuard filters are applied in increments of kVar. A diode front-end VFD (AC drive) will require 30% of the horsepower in kVar, and an SCR drive (DC drive) will require 40% of its rated horsepower in kVar.

Options

• HarmonicGuard "Classic" Series - includes ANSI #61 grey industrial NEMA 1 enclosure and forced-air ventilation, is available. Units over 120 kVar come standard in this configuration. See TCI publication HGCAT, revision date: 9/96, for more information.
• "+" Option - HarmonicGuard + filters provide additional distortion reduction, with an additional 1.5% KLR reactor, placed in series, between the primary filter and the drive that it services. TCI's ANALYZER software demonstrates the added benefit of "+" option filters.
  
• Performance Monitoring HarmonicGuard filters above 20 kVar come standard with TCI's exclusive HG2 TM Protection Monitor/Harmonic-Power Factor meter. HG2 displays operating information such as ITHD, VTHD, total filter Amps, true power factor, and a series of fault and protection codes including overcurrent, overvoltage and phase imbalance. It is also a programmable safety monitor, capable of bringing the filter off-line in a fault condition, or when the drive trips.
• Manufacturers Warranty - HarmonicGuard is warranted for 3 years from date of purchase.
• HarmonicGuard comes standard with KLR series 5% line reactors. Input series impedance improves filter performance, and eliminates system interaction common to de-tuned power factor banks. If a line reactor or drive isolation transformer exists on-site already, option type "N" filters (without an integral reactor) are available.
• Filters come standard in NEMA 1 and are available in NEMA 3R, and in ventilated NEMA 12 enclosures. Open panel units can be designed for your cabinet or MCC. (Contact factory with your special dimensional requirements.)
• HarmonicGuard T filters may be supplied in "kit" form. Kits include all primary filtering, control and safety components, and special mounting hardware and provisions. Kits do not include panels, enclosures, heating or cooling devices, wire or lugs.
• HarmonicGuard T filters can be designed with remote or internal switching of fractional sections of kVar. This may be appropriate when sizing filters to service more that one drive, operating independently. Please consult the factory on switched applications.

Ratings
HarmonicGuard is available in voltages from 208 to 600V, for AC or DC drives, from 3 to 2000 kVar. (300kVar maximum, as standard.) Consult TCI for part number and dimensions for non-standard configurations.

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HarmonicGuard® Series Drive-Applied Filter

[ Brochure (High Quality - 1.7 MB)]

[ I,O,&M Manual | HG7 Price List | Drawings ]

PRODUCT SPECIFICATIONS Limited to 7% Distortion Typical results of 5 - 6% TDD Superior Performance at 100% and 50% Load THD levels are consistently held low 100 HP at 100% = 5.8% TDD; 50% = 7.6% High Quality Capacitors Designed, built and tested specifically for use in harmonically rich environments Easy Installation Fits easily into motor control centers Ships ready to install Uninterrupted Operation The drive continues to operate in the event of an HG7 shut-down Flexible Options Power Monitor Option Component Package Option

Superior Solutions:

Where Drives are a Significant Portion of the Load
Prime candidates for filtering are installations of variable frequency drives or adjustable speed devices in facilities where those drives represent a significant portion of the load, or when specifications call for limited harmonics (like IEEE 519, 1992). Filtering would also benefit any application that utilizes sensitive electronic equipment that may be susceptible to harmonic distortion, such as capacitors, control devices, motors, etc. Some industrial examples include printing presses, extruders, machining and pulp and paper. Commercial applications include waste water treatment, pumping and cooling, and HVAC.

HG7 Drive-Applied Harmonic Filters have been proven to be the most effective harmonic distortion mitigation technique available for drives.

Reduce Harmonic Distortion
HG7 Drive-Applied Harmonic Filters (series LC passive filters), when applied at the drive, provide a low impedance path for the major harmonic currents demanded by the drive. This greatly reduces the amount of harmonic current flowing through the distribution system and results in improved power factor, lower RMS currents, lower harmonic current distortion, lower harmonic voltage distortion, and increased system capacity. In a typical industrial facility, where one-half or more of the load may be non-linear loads, resulting distortion may cause sensitive equipment to fail. In commercial/municipal buildings, meeting IEEE-519, 1992 is often a critical requirement of power distribution systems.

KTR Reactors - [ Brochure | Price List ]

CAPGuard KTR Three Phase Tuning Reactor

PRODUCT SPECIFICATIONS 3 Phase, 600V Class Gapped Iron Core Inductor Copper Windings 40°C Ambient Temperature / 155°C Maximum Operating Temperature Available in NEMA 1 Enclosure Current Sense Windings for External Monitoring of Power Factor Bank. 5 year Warranty.

Applications
CAPGuard KTR tuning reactors are designed to be used in conjunction with power factor correction capacitors whenever nonlinear loads are present. Tuning reactors can be installed with existing power factor correction banks or as part of a new installation. Typical applications include any facility that applies power factor correction capacitors to avoid penalty or to allow for more efficient energy consumption.

Before CAPGuard KTR
Since all distribution systems contain some amount of parasitic inductance, the addition of power factor correction capacitors creates a parallel resonant tank circuit. The frequency of resonance is a function of the amount of inductance and capacitance in that system. When nonlinear loads are present, the harmonic frequencies generated by these loads may force the tank circuit into uncontrolled resonance. (Resonance occurs when the system resonant frequency is too close to one of the nonlinear load harmonic frequencies.) This can cause failure of either capacitor protection fuses, of the capacitors themselves, or of both.

After CAPGuard KTR
CAPGuard KTR tuning reactors prevent uncontrolled system resonance by force tuning the capacitors to a harmless resonant frequency. In an application where a high percentage of the connected load is three phase adjustable speed drives, high amounts of the 5th, 7th, 11th, and 13th harmonics will be present. CAPGuard KTR tuning reactors are designed to offer an inductance which will tune existing capacitors well below these frequencies, preventing resonance and, therefore, fuse or capacitor failure.

Application Notes and Codes
KTR tuning reactors are applied in increments of kVar. Other parameters are voltage, fundamental frequency and tuning frequency. Products listed are suitable for installations requiring 4th harmonic tuning of a 480V, 60Hz system. For other voltages and frequencies, consult TCI.

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[ Brochure | Drawings : 480V 600V | I,O,&M Manual | FAQ | Press Release | Price List ]

Sine Wave Filter

KMG High Performance Output Filter

PRODUCT SPECIFICATIONS Available in 480V and 600V designs UL-Listed (Industrial Control Panel) KMG Output Filters are warranted against Manufacturer’s defect for one year of useful service, not to exceed 18 months from the date of shipment. Available in Standard 5 through 600 HP NEMA 1 enclosures available Protection Monitor Board Specific applications can reach 15,000 feet Voltage Distortion at 5% (Typical) Performance Guarantee

Applications
In the continuing search to improve energy efficiency, many commercial and industrial power systems are turning to the technology of PWM (pulse width modulated) output power supplies. The ability to convert standard utility power into variable-frequency, variable-voltage electrical power has led to more efficient and economical installations. One of the drawbacks of the use of equipment such as adjustable frequency drives
and variable frequency/voltage power supplies is that the output of such PWM devices is a square wave form. Many applications require a more sinusoidal output, thus ruling out these economical and efficient solutions.

The MotorGuard High Performance Output Filter has been designed to be installed at the output terminals of PWM devices. The KMG filter converts the PWM wave form to a near sinusoidal wave form, allowing sensitive applications to take advantage of the efficiencies and savings that PWM output power supplies offer.

Manufacturer's Warranty
KMG Output Filters are warranted against Manufacturer's defect for one year of useful service, not to exceed 18 months from the date of shipment.

Performance Guarantee
Properly applied and sized for the application, the addition of a KMG Output Filter is guaranteed to bring the application into compliance with NEMA Standards Publications No. MG-1. If the system fails to meet MG-1 standards, with the addition of a KMG filter, TCI will take back the output filter and pay shipping both ways. (Offer valid for 60 days from purchase date.)

Typical Problems, Superior Solutions with KMG Filters
Voltage wave reflection, a function of voltage rise time (dV/dT), occurs due to the impedance mismatch between the output of the PWM power supply and the load. This mismatch causes some portion of the high frequency leading edge to be reflected back in the direction from which it arrived. These reflected waves meet other incoming wave forms, causing higher and higher voltage overshoots. This high voltage can cause early degradation of insulation systems, not only for motors, but also transformers and cables.

The KMG filter is designed to attenuate the carrier components present in the output waveform of typical PWM output power supplies. The general filter topology is an L-C-R low pass circuit. The circuit input is a three phase reactor of sufficient impedance to control the capacitor charging below the inverter peak current fault point. The filter cutoff frequency is set approximately ten times the max allowed fundamental frequency of the inverter to minimize the fundamental KVAR absorbed by the filter while attenuating the carrier components at the rate of 40db per decade. This allows carriers greater than 2KHz to effectively be eliminated from the output of the filter. The purpose of the damping resistor is to control the over voltage excursion at the cutoff frequency to a reasonable level and keep the peak capacitor currents within design limits. An added benefit of the low pass configuration is the capacitive reactance at the load will provide motor power factor improvement thereby improving the overall filter insertion loss to that of the resistor and inductor thermal levels, typically about 2-3% of the inverter full load level.

Typical Applications

• Extreme long motor lead lengths. Specific applications can reach 15,000 feet.
• Low voltage PWM power supply to medium voltage motor.
• Multiple motor applications such as conveyors, blowers, pumps, and fans.
• Test floor and test stand applications.
• Shore to ship power for non-60 Hz systems.
• HVAC systems to include air distribution ducts and fans.

Application Benefits

• Reduced common mode current
  • Reduction in bearing currents
  • Reduction in instrumentation reference to ground
• Reduced motor noise, vibration, and heat
  • Increase in motor life
• Elimination of torque ripple
• Elimination of voltage wave reflection
• Enables systems to meet NEMA MG-1, Part 31 specification

KRF-Series RFI Filters - [ Brochure | Drawings : 480V - 600V ] [ Press Release | Price List ]

KRF Series 3-Phase RFI Power Line Filters

PRODUCT SPECIFICATIONS Available in 480V and 600V designs Recognized to UL 1283 480 V design is CE approved 3 Year Warranty Available in sizes from 8 - 600 Amps Advanced 2-stage filtering Lightweight and compact Common mode attenuation within critical 150KHz to 30MHz frequency range 100% tested for Hipot, Leakage Current, Ground Continuity and Component Value Ambient temperature range: 0° C to 40°C (operating @ rated I) Humidity range: 0 - 95% R.H.

Applications
AC Drives rely upon three phase RFI power line filters from TCI, because they provide effective EMC solutions up to 600A. RFI filters are integral components in power systems utilizing drives where high frequency noise should be held to a minimum. RFI Filtering would also benefit any application that utilizes sensitive electronic equipment that may be susceptible to interference, such as radios, computers, control devices, radar, sonar, etc. RFI filters will assist in system CE compliance. Some examples include airports, hospitals, factories with sophisticated automation equipment, pump stations, and commercial buildings.

Before K-Series RFI Filters
Recent developments in power conversion devices like AC drives include increases in switching frequencies. The ultra-fast switching devices now used in drives enable greater efficiency, greater motor control and cost effective packaging. As switching frequencies increase so increase the effective edge frequencies produced and delivered to the line and load. Control of the emission of these frequencies is often a critical factor in a quality drive application. Manufacturers, integrators, sellers or users of drives may be required to comply with electromagnetic immunity standards such as the FCC 15 - Sub-part J, CE (CISPR 11) EMC directive and IEC 801-X. Conducted noise output (db uV).

After K-Series RFI Filters
KRF Series 3 Phase RFI Power Line Filters assist with cost effective compliance to EMC directives, in a compact, efficient and lightweight design. High common mode reduction in the critical 150kHz to 30MHz frequency range assures that the potential for interference from AC drives is reduced or eliminated.

Application Notes and Codes
RFI filters are current rated devices. Therefore, in order to apply one, you simply need to know the voltage and the full load amps of the drive with which it will be used (See NEC Table 430-150 for HP/Current calculations). No de-rating or re-rating is necessary when applying a KRF Series filter to a voltage that is equal to or less than its rated voltage.

Most electrical noise generated by AC drives is common mode noise. Hence, for peak filter performance, a low impedance, high frequency ground is essential. To obtain this type of grounding, a conductor wire composed of a high quantity of very fine strands must be used. Conductor wires of this nature include battery braid wire, ultra flexible welding cable, or Litz wire. Also, as high frequency electrical noise can radiate, input and output filter leads should be routed separately.

K-Series RFI Filters are available with convenient termination options. The last 2 letters of the part number determine the termination type. They are: QD=Quick disconnect, TB=Terminal block, PT=Pressure terminal, FL = Flying lead. See part number table for standard assignments.

KCAP Capacitors - [ Brochure | Price List ]

KCAP High Endurance Capacitors For Use in Electrical Environments High in Harmonics

PRODUCT SPECIFICATIONS UL-C VDE Listed Standard Voltages: 208/240/480/575V Standard Frequencies: 50/60Hz Standard KVAR: 2.5-20 Standard open can, with panel mounting brackets optional. (1X,2X and 4X) Over-pressure tear-off fuse, self-healing >100,000 operating hours. Polypropylene film, zinc metallized. Natural oil impregnant, non PCB, biodegradable 5 year Warranty

Applications
TCI High Endurance Capacitors are intended for use in electrical environments that are rich in harmonic content due to non-linear loads. Some applications include factories and plants with a large numbers of variable frequency drives and/or DC drives, waste water treatment plants, pumping stations, facilities that co-generate power, and power consumers that are incurring penalties for poor power factor.

Before High Endurance Caps
The reactive power demanded by motors, transformers and higher KVA RMS demanded by harmonic currents contribute to poor power factor in industrial and commercial buildings. Simply put, poor power factor means that energy is not being efficiently delivered or consumed. Power factor correction capacitors relieve the reactive power burden on supply generators, transformers and facility wiring. However, capacitors cannot be safely applied in buildings with a high content of harmonically-rich non-linear load, as their addition may induce plant resonance, a dangerous and costly situation. Force tuning (or de-tuning) capacitor banks may correct for the potential for resonance. However, standard capacitor cells, with service factor ratings designed for linear loads, still may not be suitable in non-linear environments. Testing shows that capacitors will need to tolerate at least 150% over-current and higher than intended temperatures in those environments.

After High Endurance Caps
TCI High Endurance capacitors are designed, built and tested specifically for use in harmonically rich environments. They are suitable for use in de-tuned central power factor correction banks, and in drive-applied and load-applied harmonic filters. They are capable of handling 190% of rated current continuously in a 65 degree C ambient temperature. Properly applied, they offer a robust and cost effective solution to inefficient power delivery and consumption.

Application Notes and Codes
TCI High Endurance Capacitors are metallized polypropylene film, with self-healing properties. Three winding elements are encapsulated and connected to form a 3-phase capacitor element. Overpressure tear-off fuses prevent failure at the end of service life. The impregant is natural oil (fire point >300 degree C). Capacitors are delivered with discharge resistors. One, two or four can mounting brackets are available. Brackets are pre-drilled to accept capacitors 12m mounting/grounding stud. Products listed in the following tables are suitable for 208/240/480/575V 60Hz installations. For other frequencies, consult TCI. The information contained in this brochure is subject to change without notice.

H5® Active Line Conditioner

Brochure (High Quality - 3.3 MB)
Product Profile
Sizing Request Form (xls)

PRODUCT SPECIFICATIONS TDD Reduction to 5% or better (full load) Power Factor Correction to .98 lagging (programmable) Response time of less than 8 ms to step load changes Additional filters can be added in parallel to increase correction capability Units can be paralleled withour any calibration Self-Commissioning Installation - Plug & Play Modular design Harmonic Cancellation to the 50th harmonic

Superior Solution:

Harmonics and Power Quality

Variable frequency drives and other types of non-linear loads draw significant harmonic current from the utility with resulting distortion in both line voltage and line current waveforms. If non-linear load represents a significant portion of the entire installed load, this distortion begins to cause problems throughout the electrical system. These problems range from transformer and distribution equipment overheating to random breaker tripping. Harmonics may even cause sensitive equipment to fail completely.

The H5 Active Line Conditioner

By actively monitoring the line or load current, H5 determines the nature and quantity of harmonic currents in the system and cancels the same by injecting equal amounts of harmonic currents opposite in phase. A state-of-the-art high speed DSP controller and a pulse width modulated (PWM) IGBT based power converter help to provide virtual real time compensation of non-linear load demanded by VFDs and other applications. H5 also inherently tries to synchronize the line current with its voltage resulting in near unity displacement power factor. Thus, H5 provides solutions for both reactive current and harmonic current compensation.