Eaton HCU2 Installation Manual Download

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Instruction Booklet IB156002EN

Effective February 2022
Supersedes November 2015

Eaton HCU2/HCUn active harmonic

filter installation manual

Summary of Contents for HCU2

Page 1: ...Instruction Booklet IB156002EN Effective February 2022 Supersedes November 2015 Eaton HCU2 HCUn active harmonic filter installation manual ...

Page 2: ...3 Line voltage 23 Power cable routing 23 Power and ground cable selection and connections 23 Power termination covers 24 60 A and 120 A models 25 200 A and 300 A models 26 Current transformers CTs 26 Electrical connection HCUn 27 Line voltage 27 Overcurrent protection device selection 27 Residual current device 29 Power and ground cable selection and connections 29 General CT information 31 Minimu...

Page 3: ...NJURY OR DEATH CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED CAN RESULT IN MINOR TO MODERATE INJURY OR SERIOUS DAMAGE TO THE PRODUCT THE SITUATION DESCRIBED IN THE CAUTION MAY IF NOT AVOIDED LEAD TO SERIOUS RESULTS IMPORTANT SAFETY MEASURES ARE DESCRIBED IN CAUTION AS WELL AS WARNING Warnings and cautions WARNING HAZARD OF PERSONAL INJURY USE PROPER LIFTING EQUIPMENT SUC...

Page 4: ... as described in this manual These products are both referred to as an active filter in this manual Harmonic correction unit Harmonic Correction Units HCU2 are static power electronic products that employ digital logic and IGBT semiconductors to synthesize a current waveform that is injected into the electrical network to cancel harmonic currents caused by nonlinear loads HCU2 employ current trans...

Page 5: ...e unit from potential damage Installation This section provides the information required to properly install the active filter and associated equipment for proper operation and performance Frequently commissioning difficulties are the result of incorrect wiring Every precaution must be taken to assure that the wiring is done as instructed Read and understand all instructions in this manual prior t...

Page 6: ...y of 95 noncondensing and a maximum dewpoint of 37 C The operating temperatures are maximum and minimum levels the unit is designed to operate within Operating above or below these levels will result in the unit either shutting down or reduced performance The upper or lower limit should not be used as ideal room temperature levels System reliability and product life expectancy will improve if temp...

Page 7: ...om 970 1200 89 560 1440 x 450 x 285 HCUN050Y4N1 60 UL Type 1 wall Bottom 1265 1500 89 560 1440 x 450 x 285 HCUN060Y4N1 ote N Mass information is approximate and subject to change without notice Table 4 HCUn physical description IP00 Amperage rating Mounting style Cable entry Typical heat load 415 V W Mass kg Air flow m3 h Exterior dimensions H x W x D mm Eaton HCUN model 20 IP00 chassis Bottom 530...

Page 8: ...stalled Figure 1 HCUn UL Type 1 wall mount dimensions Height 1440 mm Width 450 mm Depth 282 main unit Depth 264 expansion unit no HMI required Top and bottom clearance 200 mm Figure 2 HCUn UL Type 1 mounting hole location When installing the unit in locations that experience vibration or that require additional mounting holes it is recommended to use the chassis mounting hole Refer to Figure 5 for...

Page 9: ...ng features 960 mm Enclosure height 930 mm Width 440 mm Zero side clearance Top and bottom clearance 200 mm each Figure 4 HCUn bottom air intake Use M8 hardware to mount the unit in the enclosure Mounting hole layout is provided in Figure 6 Figure 5 HCUn mounting hold dimensions mm 350 175 M8 940 Figure 6 HCUn wall mount main and expansion electrical connections Service door Power cable cover ...

Page 10: ...IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com NEMA 1 wall mounted enclosures Figure 7 NEMA 1 60 A dimensions in inches mm 60 40 1534 0 13 70 348 0 16 80 426 0 ...

Page 11: ...uction Booklet IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 8 NEMA 1 120 A dimensions in inches mm 64 30 1634 0 15 10 384 0 16 80 426 0 ...

Page 12: ...uction Booklet IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 9 NEMA 1 200 A dimensions in inches mm 62 90 1598 0 17 20 437 0 22 90 581 0 ...

Page 13: ... Booklet IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 10 NEMA 1 300 A dimensions in inches mm 72 20 1835 0 17 20 438 0 22 90 581 0 Lift here ...

Page 14: ...fective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com NEMA 1 chassis mounted units Figure 11 Chassis mount 60 A dimensions in inches mm 51 20 1300 0 13 70 348 0 16 70 425 0 Lift here Lift here ...

Page 15: ... IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 12 Chassis mount 120 A dimensions in inches mm 55 10 1400 0 15 12 384 0 16 73 425 0 Lift here Lift here ...

Page 16: ... IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 13 Chassis mount 200 A dimensions in inches mm 51 20 1323 0 17 20 437 0 22 90 581 0 Lift here Lift here ...

Page 17: ... IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Figure 14 Chassis mount 300 A dimensions in inches mm 61 40 1560 0 17 20 438 0 22 90 581 0 Lift here Lift here ...

Page 18: ...HCU2 HCUn active harmonic filter installation manual EATON www eaton com Floor mount 60 A and 120 A drawings Figure 15 HCU2 60 A and 120 A 380 480 V NEMA 2 NEMA 12 IP31 and IP54 units dimensions in inches mm 82 24 2089 0 19 69 500 0 31 50 800 0 2 17 55 0 Lift here ...

Page 19: ...TON www eaton com Figure 16 HCU2 60 A and 120 A enclosure top and bottom dimensional drawing in inches mm 5 85 148 5 17 72 450 0 1 97 50 0 17 32 440 0 4 92 125 0 14 31 363 5 1 97 50 0 27 56 700 0 31 50 800 0 19 92 506 0 Ø 90 AC line entry top and bottom Top view M10 mounting hardware Customer connections top and bottom ...

Page 20: ...2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com 200 A and 300 A drawings Figure 17 HCU2 200 A and 300 A 380 480 V NEMA 2 NEMA 12 IP31 and IP54 units in inches mm 82 32 2091 0 23 62 600 0 Lift here 35 43 900 0 2 09 53 0 ...

Page 21: ...manual EATON www eaton com Figure 18 HCU2 200 A and 300 A enclosure top and bottom dimensional drawing in inches mm 35 43 900 0 1 97 50 0 1 97 50 0 3 74 95 0 6 89 175 0 18 64 473 5 23 82 605 0 5 91 150 0 2 56 65 0 AC line entry top and bottom Top view Customer connections top and bottom Bottom view 5 91 150 0 ...

Page 22: ... mm Ampere rating D W BD BE 60 A 120 A 19 69 500 0 31 50 800 0 17 32 440 0 27 56 700 0 200 A 300 A 23 62 600 0 35 43 900 0 21 26 540 0 31 50 800 0 Refer to Figure 19 and Table 5 for the dimensions and attachment locations for the enclosure you are installing and follow these steps 1 Ensure that the location is large enough for the enclosure Refer to the dimensions D and W for the enclosure you are...

Page 23: ...ted directly from the conduit entry plate to the terminations on power terminals and the earth grounding terminal without loops Instrumentation and CT wiring has to be routed in a separate grounded metal conduit or shielded encapsulated cable A dedicated ground conductor must be used when installing the active filter When used as a harmonic current compensation device the active filter produces cu...

Page 24: ...aton HCU2 HCUn active harmonic filter installation manual EATON www eaton com Power termination covers Figure 21 Power termination covers Customer access cover T20 driver Top cable entry cover M4 hardware T20 driver 1 7 N m 15 0 lb in Bottom cable entry cover ...

Page 25: ...filter installation manual EATON www eaton com 60 A and 120 A models Figure 22 60 A and 120 A enclosure internal layout drawing Top entry power connection location Bottom entry power connection location CT and control wiring termination location M8 ground stud M8 ground stud M8 busbar studs ...

Page 26: ...s Ground equipment using the ground connecting point provided before turning on any power supplying this device Turn off all power supplying this device and the equipment in which it is installed before working on the device or equipment After removing power wait for 15 minutes to allow the capacitors to discharge prior to opening the doors or removing covers Always use a properly rated voltage se...

Page 27: ... L3 N Neutral not distributed 100 neutral PEN L1 L2 L3 N PEN 3p3d 3p3d L1 L2 L3 N L1 L2 L3 N 3p3d 3p3d L1 L2 L3 N L1 L2 L3 N 3p3d 4p3d L1 L2 L3 N L1 L2 L3 N 3p3d 4p4d IT 20 A 20 A 25 A 25 A 20 A 20 A 25 A 25 A 20 A 20 A 25 A 25 A 20 A 20 A 25 A 25 A Figure 25 20 A unit 200 neutral distributed and 300 neutral distributed 200 neutral 300 neutral L1 L2 L3 N PEN 3p3d 3p3d 20 A Neutral must be sized fo...

Page 28: ...50 A 63 A L1 L2 L3 N 50 A 63 A L1 L2 L3 N 4p3d 50 A 63 A L1 L2 L3 N 3p3d 50 A 63 A L1 L2 L3 N 4p4d 50 A 63 A L1 L2 L3 N 3p3d 50 A 63 A L1 L2 L3 N 3p3d 50 A 63 A 50 A Figure 29 50 A unit 200 neutral distributed and 300 neutral distributed 50A Neutral must be sized for 100 A 63 A L1 L2 L3 N PEN 3p3d 200 neutral 300 neutral L1 L2 L3 N PEN 3p3d 3p3d 50 A Neutral must be sized for 150 A 63 A L1 L2 L3 N...

Page 29: ...esponse delay High frequency currents must be filtered Choose a suitable model integrating High frequency current filtering A time delay that helps to prevent a triggering of the upstream device caused by the load from stray capacitance on power on The time delay is not available for 30 mA device in this case choose devices with immunity against nuisance triggering Due to high leakage current in s...

Page 30: ...ow the line ground and neutral if required wires to pass through the grommet Pass one cable through each of the grommets Connect an appropriate one hole crimp lug on the end of each wire for an 8 mm stud Reinstall the power cable cover using the T25 hardware Ensure that the grommets are properly seated Figure 35 UL Type 1 main and expansion electrical connection Line connection Ground connection N...

Page 31: ...RE TO FOLLOW THIS INSTRUCTION CAN RESULT IN A REDUCTION IN PERFORMANCE CT wiring must be routed directly from the conduit entry plate to the terminal block of the CT board CT must be selected for 5 A secondary 100 to 10 000 primary rating 50 60 Hz or 400 Hz rated Type 1 accuracy The CT shall be metering class primary rating as required 5 A secondary rating The minimum Burden designation is B 0 5 a...

Page 32: ...urden capacity with 1 A secondary Maximum wire length from active filter to CT in meters feet 4 mm2 12 AWG 6 mm2 10 AWG 5 VA 373 1223 623 2043 15 VA 1135 3724 1895 6215 25 VA 1897 6223 3167 10 387 30 VA 2278 7473 3804 12 477 35 VA 2660 7412 4440 14 563 45 VA 3422 11 224 5712 18 735 Table 12 5 A secondary maximum wire length with 2 5 mm2 14 AWG diameter wire CTs burden capacity with 5 A secondary M...

Page 33: ...rent Protection Device Selection for details Shorting Terminal Block Provided by others N N Figure 38 Source side CT position single main without neutral connected X1 Active Filter Source Load X1 X1 L1 L2 L3 L2 L3 L1 X2 X1 X2 X1 CH1 X2 X1 OUT X2 X1 X2 X1 CH2 X2 X1 IN OUT X2 X1 X2 X1 CH3 X2 X1 IN OUT IN X1 X1 X2 X2 X2 X1 Optional 3rd CT Required if there are Line to Neutral connected Loads downstre...

Page 34: ...otection Device Provided by others See Over current Protection Device Selection for details Figure 40 Load side CT position single main without neutral connected X1 Active Filter Source Load X1 X1 L1 L2 L3 L2 L3 L1 X2 X1 X2 X1 CH1 X2 X1 OUT X2 X1 X2 X1 CH2 X2 X1 IN OUT X2 X1 X2 X1 CH3 X2 X1 IN OUT IN X1 X1 X2 X2 Optional 3rd CT Required if there are Line to Neutral connected Loads downstream of th...

Page 35: ...e local sales representative for assistance prior to installation CT installation parallel units WARNING HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH THE FACTORY PROVIDED SHORTING JUMPERS MUST BE INSTALLED AT THE OUT OF THE CT BOARD OF THE LAST UNIT WITH CT SECONDARY WIRING CONNECTED FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN DEATH OR SERIOUS INJURY The active filters can be set up to ...

Page 36: ...3 L2 L3 L1 X2 X1 X2 X1 CH1 X2 X1 OUT X2 X1 X2 X1 CH2 X2 X1 IN OUT X2 X1 X2 X1 CH3 X2 X1 IN OUT IN Active Filter X2 X1 X2 X1 CH1 X2 X1 OUT X2 X1 X2 X1 CH2 X2 X1 IN OUT X2 X1 X2 X1 CH3 X2 X1 IN OUT IN Optional 3 rd CT Required if there are Line to Neutral connected Loads downstream of the CTs L2 L3 L1 Factory Installed shorting jumpers MASTER MASTER 3 phase Protection Device Customer supplied X1 X2 ...

Page 37: ...L1 X2 X1 CH1 IN X2 X1 X2 X1 OUT X2 X1 CH2 IN X2 X1 X2 X1 OUT X2 X1 CH3 IN X2 X1 X2 X1 OUT Active Filter L2 L3 L1 X2 X1 CH1 IN X2 X1 X2 X1 OUT X2 X1 CH2 IN X2 X1 X2 X1 OUT X2 X1 CH3 IN X2 X1 X2 X1 OUT X1 X1 X1 Source L1 L2 L3 Load MASTER MASTER MASTER Factory Installed shorting jumpers Optional 3 rd CT Required if there are Line to Neutral connected Loads downstream of the CTs 3 phase Protection De...

Page 38: ...r L2 L3 L1 X2 X1 CH1 IN X2 X1 X2 X1 OUT X2 X1 CH2 IN X2 X1 X2 X1 OUT X2 X1 CH3 IN X2 X1 X2 X1 OUT Active Filter L2 L3 L1 X2 X1 CH1 IN X2 X1 X2 X1 OUT X2 X1 CH2 IN X2 X1 X2 X1 OUT X2 X1 CH3 IN X2 X1 X2 X1 OUT X1 X1 X1 Source L1 L2 L3 Load MASTER MASTER Slave Optional 3 rd CT Required if there are Line to Neutral connected Loads downstream of the CTs 3 phase Protection Device Customer supplied 3 pha...

Page 39: ... X1 CH3 IN X2 X1 X2 X1 OUT Active Filter L2 L3 L1 X2 X1 CH1 IN X2 X1 X2 X1 OUT X2 X1 CH2 IN X2 X1 X2 X1 OUT X2 X1 CH3 IN X2 X1 X2 X1 OUT Active Filter L2 L3 L1 X1 X1 X1 Source L1 L2 L3 Load MASTER MASTER SLAVE Factory Installed shorting jumpers Active Filter L2 L3 L1 SLAVE Active Filter L2 L3 L1 SLAVE Optional 3 rd CT Required if there are Line to Neutral connected Loads downstream of the CTs 3 ph...

Page 40: ... the factory NOTICE EXCESSIVE NOISE IN THE COMMUNICATION CIRCUIT WHEN THE UNIT IS SET TO OPERATE IN PARALLEL MODE THE TERMINATION PLUG MUST BE INSTALLED IN ANY RJ 45 JACKS THAT ARE NOT USED FOR PARALLEL COMMUNICATION WIRING SEE THE WIRING DIAGRAMS IN THIS SECTION FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN COMMUNICATION ERRORS CAT5e cable with all 8 conductors terminated at the RJ 45 connecti...

Page 41: ...set to either normally open or normally closed See the User Manual for setting the output contacts Maximum voltage accepted is 250 Vac or 30 Vdc with a 1 A maximum current for the HCU2 and 0 5 A maximum current per dry contact for the HCUn Digital input control Four input controls are available at J2 of the Control Board See Figure 36 on page 32 One Ground and four inputs labeled I1 to I4 The inpu...

Page 42: ...nel connections LED light pipe socket D404 HMI COM1 connection RJ45 J9 HMI 24 Vdc power connection J12 USB to front To control board J9 To power supply board J12 To customer s Ethernet for Modbus TCP IP Figure 51 Control board and CT board detail J2 Figure 52 Control board J2 detail Control Board Com Q1 Q2 Q3 Q4 GND I1 I2 I3 I4 Dry Contact Output Digital Input Control ...

Page 43: ...ed prior to start up Pre commissioning checklist Prior to commissioning the active filter system the following items must be completed Electrical connections have been made in accordance with local codes Main CTs are installed to measure the current of the system to be corrected The secondary wiring of the main CTs have been connected to the CT board of the active filter If it is a parallel active...

Page 44: ...GROUND EQUIPMENT USING THE GROUND CONNECTING POINT PROVIDED BEFORE TURNING ON ANY POWER SUPPLYING THIS DEVICE TURN OFF ALL POWER SUPPLYING THIS DEVICE AND THE EQUIPMENT IN WHICH IT IS INSTALLED BEFORE WORKING ON THE DEVICE OR EQUIPMENT AFTER REMOVING POWER WAIT FOR 15 MINUTES TO ALLOW THE CAPACITORS TO DISCHARGE PRIOR TO OPENING THE DOORS OR REMOVING COVERS ALWAYS USE A PROPERLY RATED VOLTAGE SENS...

Page 45: ... Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com When connecting the active filter to an IT HRG or corner grounded system open the IT BP switches as follows 1 Remove the large main cover of the unit Figure 53 Main cover removal ...

Page 46: ...oklet IB156002EN Effective January 2022 Eaton HCU2 HCUn active harmonic filter installation manual EATON www eaton com 2 Locate the IT BP switches Figure 54 IT BP switch locations on 60 A and 120 A units IT BP switches ...

Page 47: ...tive harmonic filter installation manual EATON www eaton com Figure 55 IT BP switch locations on 200 A and 300 A units IT BP switches 3 Pull the plunger out The switch is open when the plunger is completely out as shown in the figure below Figure 56 Plunger out switch is open ...

Page 48: ...g defects Disclaimer of warranties and limitations of liability This instruction manual is published solely for information purposes and should not be considered all inclusive If further information is required you should consult an authorized Eaton sales representative The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling pol...

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