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TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC...

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Page 1: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors
Page 2: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide SuperiorPatented Protection for MotorsAs the technology of Pulse Width Modulated (PWM)Drives are incorporated into various applications andprocesses, the increased energy savings and decreasedmaintenance on Drives can be offset by increases inMotor failures.The dV/dTGuard product family has been designedas an engineered solution for motor failures due tothe reflected wave phenomenon. Designed to beinstalled at the output terminals of the Drive,dV/dTGuard Output Filters provide effortlessinstallation, convenient accessibility and enhancedmotor performance and durability. Available in aUL/CUL version or in our original version, theseproducts provide the outstanding performance thatour customers have come to expect from TCI.

Manufacturer’s WarrantyKLC and KLCUL Output Filters are warranted againstManufacturer’s defect for one year from the date oforiginal purchase.

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

Drawings/SpecificationsAutocad compatible *.dxf drawings and Acrobat Reader compatible *.pdf drawings of all KLCand KLCUL dV/dTGuard Output Filters are available at www.transcoil.com or by contacting TCIat (800) 824-8282.

Typical Problems, Superior Solutions with KLC ProductsThe Reflective Wave PhenomenonVariable Frequency Drives generate useful “fundamental” voltage and frequency using Pulse WidthModulation (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 fundamentalvoltage and frequency. Voltage wave reflection is a function of the voltage rise time (dV/dT) andthe 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 reflectedwaves encounter other waves, their values add, causing higher peak voltage. As wire length orcarrier frequency increases, the overshoot peak voltage also increases. The dV/dT Motor ProtectingOutput Filters have been designed to limit peak voltage and increase voltage rise time. In specificapplications, the KLC has peformed 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 motorinsulation, leading to motor failure. On 575 V systems, the peak voltages can easily reach 2100V. 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 andKLCUL filters are designed to be placed at the output of the Drive, these units will also protectthe 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.

UTILIT

Y

KDR DRIVE MOTORKLC

Page 3: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

0

-500

-1500

0

-500

-1500

70 Feet of Cable 500 Feet of Cable

70 Feet of Cable 500 Feet of Cable

VO

LTAG

E

1500

500

0

-500

-1500

-5 0 5 10 20

TIME BASE (micro seconds from trigger)

0

-500

-1500

0

-500

-1500V

OLTA

GE

1500

500

0

-500

-1500

-5 0 5 10 20

TIME BASE (micro seconds from trigger)

0

-500

-1500

0

-500

-1500

VO

LTAG

E

1500

500

0

-500

-1500

-5 0 5 10 20

TIME BASE (micro seconds from trigger)

0

-500

-1500

0

-500

-1500

VO

LTAG

E

1500

500

0

-500

-1500

-5 0 5 10 20

TIME BASE (micro seconds from trigger)

Carrier Frequency 2.5KHZCarrier Frequency 2.5KHZ

Carrier Frequency 8KHZCarrier Frequency 8KHZ

10001000

1000 1000

Page 4: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

PARTNUMBER

RATEDCURRENT

WATTSLOSSS

tandard

Open

dV

/dT

Moto

r Pro

tecting Filter

HEIGHT WIDTH DEPTHMTG

AMTG

B

WEIGHTDIMENSIONS (inches)

KLC2BKLC4BKLC6BKLC8BKLC12BKLC16BKLC25BKLC35BKLC45BKLC55BKLC80BKLC110B*KLC130B*KLC160B*KLC200B*KLC250B*KLC300B*KLC360B*KLC420B*KLC480B*KLC600B*KLC750B

246812162535455580110130160200250300360420480600750

757580909595110130135145255245270260265290325300450475515770

TBTBTBTBTBTBTBTBTBTBRLCBCBCBCBCBCBCBCBCBCBCB

6.56.56.56.56.56.57.57.57.57.591616161616191919191913

88888810101010121515151515202020202015

666666777781313131313161616161615

2.012.012.012.012.012.013.013.013.013.012.2614.7414.6814.7414.6814.7419.7419.7419.7419.7419.74Special

Mount Dims.

3.53.53.53.53.53.53.53.53.53.55.2513.513.513.513.4513.518.5118.5118.5118.5118.51Special

Mount Dims.

7777779999

10.56666688888

SpecialMount Dims.

77799111415161730808892107108110129150155162165

STANDARDTERMS MTG

CMTG

DIAGRAMAAAAAAAAAAABBBBBBBBBB

SpecialMount Dims.

PARTNUMBER

RATEDCURRENT

WATTSLOSS

Standard Enclosed dV

/dTM

otor Protecting Filter

HEIGHT WIDTH DEPTHMTG

AMTG

B

WEIGHTDIMENSIONS (inches)

KLC2BEKLC4BEKLC6BEKLC8BEKLC12BEKLC16BEKLC25BEKLC35BEKLC45BEKLC55BEKLC80BEKLC110BE*KLC130BE*KLC160BE*KLC200BE*KLC250BE*KLC300BE*KLC360BE*KLC420BE*KLC480BE*KLC600BE*KLC750BE

246812162535455580110130160200250300360420480600750

757580909595110130135145255245270260265290325300450475515770

TBTBTBTBTBTBTBTBTBTBRLCBCBCBCBCBCBCBCBCBCBCB

6.56.56.56.56.56.57.57.57.57.591616161616191919191936

88888810101010121515151515202020202028

6666667777813131313131616161616

30.19

2.012.012.012.012.012.013.013.013.013.012.2614.7514.6814.7414.6814.7419.7419.7419.7419.7419.74

28

3.53.53.53.53.53.53.53.53.53.55.2513.513.513.513.4513.518.5118.5118.5118.5118.51

26

7777779999

10.5666668888824

99911111316171819328896100115116130141162167174225

STANDARDTERMS MTG

CMTG

DIAGRAMAAAAAAAAAAABBBBBBBBBBB

The watts loss shown above are based on the effects of a sine-triangle modulated waveform at full load current, 60Hz fundamental,with a carrier frequency setting of 4 kHz and a lead length of 500 (wire) feet using THHN cable. It is important to note thatas system specifics vary, so shall the watts loss.* Denotes the change from a wall mount unit to a floor mount unit and a change in the mounting diagram.

VOLTAGE RISE TIMEVOLTAGE RISE TIME Carrier Frequency 8KHZ; 500 Feet of CableRate of voltage rise at motor terminals

VO

LTAG

E

1550

1100

700

450

0

-50.0 -25.0 0 25.0 50.0 -50.0 -25.0 0 25.0 50.0 -50.0 -25.0 0 25.0 50.0

DTDTDT

1550

1100

700

450

0

1550

1100

700

450

0

Page 5: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

PARTNUMBER

RATEDCURRENT

WATTSLOSSUL Listed

Open

dV

/dT

Moto

r Pro

tecting Filter

HEIGHT WIDTH DEPTHMTG

AMTG

B

WEIGHTDIMENSIONS (inches)

KLCUL2AKLCUL3AKLCUL4AKLCUL6AKLCUL8AKLCUL12AKLCUL16AKLCUL18AKLCUL21AKLCUL25AKLCUL27AKLCUL35AKLCUL45AKLCUL55AKLCUL80A

KLCUL110A*KLCUL130A*KLCUL160A*KLCUL200A*KLCUL250A*KLCUL300A*KLCUL360A*KLCUL420A*KLCUL480A*KLCUL600A*

2346812161821252735455580110130160200250300360420480600

75757580909595110110110110130135145255245270260265290325300450475515

TBTBTBTBTBTBTBTBTBTBTBTBTBTBTBCBCBCBCBCBCBCBCBCBCB

6.56.56.56.56.56.56.57.57.57.57.57.57.57.5916161616161919191919

8888888101010101010101215151515152020202020

66666667777777813131313131616161616

2.012.012.012.012.012.012.012.012.012.012.012.012.012.012.2614.7414.7414.7414.7414.7419.7419.7419.7419.7419.74

3.53.53.53.53.53.53.53.53.53.53.53.53.53.55.2513.513.513.513.4513.518.5118.5118.5118.5118.51

77777777777777

10.56666688888

991010101014202020202222313845526668688394114119125

STANDARDTERMS MTG

CMTG

DIAGRAMAAAAAAAAAAAAAAABBBBBBBBBB

PARTNUMBER

RATEDCURRENT

WATTSLOSS

UL Listed

Enclosed

dV

/dT

Moto

r Pro

tecting Filter

HEIGHT WIDTH DEPTHMTG

AMTG

B

WEIGHTDIMENSIONS (inches)

KLCUL2A1KLCUL3A1KLCUL4A1KLCUL6A1KLCUL8A1KLCUL12A1KLCUL16A1KLCUL18A1KLCUL21A1KLCUL25A1KLCUL27A1KLCUL35A1KLCUL45A1KLCUL55A1KLCUL80A2*KLCUL110A2*KLCUL130A2*KLCUL160A2*KLCUL200A3*KLCUL250A3*KLCUL300A3*KLCUL360A3*KLCUL420A3*KLCUL480A3*KLCUL600A3*

2346812161821252735455580110130160200250300360420480600

75757580909595110110110110130135145255245270260265290325300450475515

TBTBTBTBTBTBTBTBTBTBTBTBTBTBTBCBCBCBCBCBCBCBCBCBCB

12.2512.2512.2512.2512.2512.2512.2512.2512.2512.2512.2512.2512.2512.2519.1319.1319.1319.1322.1322.1322.1322.1322.1322.1322.13

12.512.512.512.512.512.512.512.512.512.512.512.512.512.515.515.515.515.520.520.520.520.520.520.520.5

6.756.756.756.756.756.756.756.756.756.756.756.756.756.7515.515.515.515.524.3724.3724.3724.3724.3724.3724.37

2.242.242.242.242.242.242.242.242.242.242.242.242.242.2415.2215.2215.2215.2220.2120.2120.2120.2120.2120.2120.21

7.757.757.757.757.757.757.757.757.757.757.757.757.757.7513.7213.7213.7213.7218.7118.7118.7118.7118.7118.7118.71

8.58.58.58.58.58.58.58.58.58.58.58.58.58.510101010

17.517.517.517.517.517.517.5

181819191919232626262627273664647488118119125136156161167

STANDARDTERMS MTG

CMTG

DIAGRAMAAAAAAAAAAAAAABBBBBBBBBBB

Please note that although an open style KLC can be changed in the field to an enclosed version, the same is nottrue for the KLCUL style filters. The enclosed version of the KLCUL filters uses an entirely different style of enclosure.* Denotes the change from a wall mount unit to a floor mount unit and a change in the mounting diagram.

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/µs. Such high rise times can cause significant damage to the motor windings and theinsulation system, resulting in premature motor failure. The life of the motor can be greatly extended by limitingboth the magnitude of the voltage spikes to levels below 1000V and the dV/dT at the motor terminals to levels lessthan 1000V/µs on 480V systems.

VOLTAGE RISE TIMEVOLTAGE RISE TIME

Page 6: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for 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.

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

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

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

DRIVE MOTORKLC

MOTOR

DRIVE KLC

MOTOR MOTOR

Do not operate the Drive/KLC configuration into unterminated long leads as the gross impedance mismatch willcause 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 ofthe filter.

Page 7: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

KLC / KLCUL OPEN & KLC ENCLOSED

KLCUL ENCLOSED

MOUNTING DIAGRAMS

Page 8: TCI’s KLC & KLCUL dV/dTGuard Output Filters …grfehr.com/PDF/TCI/KLC Brochure.pdf · TCI’s KLC & KLCUL dV/dTGuard Output Filters Provide Superior Patented Protection for Motors

• 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

TRANS-COIL, INC.7878 North 86th Street, Milwaukee, WI 53224PHONE 1-800-824-8282 FAX (414) 357-4484

WEB www.transcoil.com

REV.01-02-02


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