Harmonix™ Active Harmonic Cancellation System Installation Manual
(750-0055-001, Rev.5)
INTRODUCTION
Harmonix is a 3-phase 4-wire active harmonic filter.
Harmonix eliminates 100A rms of zero-sequence current harmonics from the three phases and neutral conductor of a 3-phase 4-wire distribution system with a high density of non-linear electronic loads.
Harmonix
Fig. 1: 21"H x 24"W x 13"D, Floor Mount Stackable INSTALLATION

THE FOLLOWING IS INTENDED FOR QUALIFIED ELECTRICAL PERSONNEL ONLY.

READ THE INSTALLATION INSTRUCTIONS COMPLETELY BEFORE BEGINNING INSTALLATION. PLEASE CONTACT THE MANUFACTURER, CURRENT TECHNOLOGY, WITH ANY QUESTIONS.

IT IS THE FINAL RESPONSIBILITY OF THE INSTALLING ELECTRICIAN TO ENSURE THAT ALL LOCAL CODES AND OTHER APPLICABLE SAFETY/ENVIRONMENTAL CONDITIONS ARE MET.

Enclosure/Environment: Current Technology’s Harmonix Active Harmonics Cancellation System is housed in a NEMA Type 1 enclosure. The unit should be installed in a safe, protected area with ambient temperature between 0°C to +50°C (32°F to +132°F). The relative humidity should be 5-95% non-condensing.

Verify Voltages: Ensure that ALL voltages are correct and verify the type of power distribution configuration used (i.e., 3 Phase 120/208 grounded WYE) before installing the Harmonix. See Table 1 below for nominal voltages.

Table 1
  Nominal Voltages
Model Voltage Configuration L-L L-N L-G N-G
HX3-100-120/208 120/208 Grounded Wye 208 120 120 -

Note: All voltages should be within ± 10% of rated nominal voltage.

WARRANTY VOID IF CONNECTED TO IMPROPER VOLTAGE. CHECK SOURCE VOLTAGES BEFORE CONTINUING. CHECK NEUTRAL BOND AT DISTRIBUTION TRANSFORMER PROVIDING POWER TO PROTECTED LOADS AND NEUTRAL BOND AT SERVICE ENTRANCE TO VERIFY Xo BOND CONNECTION INTEGRITY.

HARMONIX INSTALLATION

Location

  • Install Harmonix at the farthest downstream 3-phase panelboard location possible within the electrical distribution system.
  • Install Harmonix as close as possible to panelboards feeding nonlinear electronic loads.
  • Install Harmonix in a location that reduces electrical wire bends and wiring distances from the point of connection to minimize installed system impedance.
  • Keep conductor lengths as short as possible.

Mounting
Harmonix can either be bolted on the floor or it can be mounted on the wall (please see section on Mounting for details).

How to Connect the Harmonix Filter
Install Harmonix in parallel with the electrical distribution system. Connect Harmonix to the electrical distribution system via feed-through lugs in the panelboard or via a 3-pole, 60A (max), UL Listed, molded-case circuit breaker.

Safely perform the following power and control wire connections:

Power Connections

  • 5 power conductors will be utilized: 3 Phases, 1 Neutral, 1 Ground
  • Phase lugs: #14 – 2/0 AWG
  • Neutral lug: #4 – 500 MCM AWG
  • Ground lug: #14 – 2/0 AWG

Control Connections
Connect the two control wires provided by Current Technology from the neutral current monitoring transformer to Harmonix. Because Harmonix is a closed-loop control filter, it is critical to correctly install the neutral current monitoring transformer correctly in the panelboard (please see section on "Installation of Neutral Conductor CT" for details).

Table 2: Recommended Single Unit Wire Size

Conductor Wire Phase Lug Size Minimum Recommended Wire Size
Phase Wires ABC #14–2/0 #6 AWG 75oC Class THHW or THWN Insulation OR #8 AWG 90oC Class THHN Insulation
Neutral Conductor #4–500 MCM #1 AWG 75oC Class THHW or THWN Insulation OR #2 AWG 90oC Class THHN Insulation
Ground Conductor #14–2/0 #8 AWG 75oC Class THHW or THWN


Table 3: Recommended Wire Size for Two Units in Parallel

Conductor Wire Phase Lug Size Minimum Recommended Wire Size
Phase Wires ABC #14–2/0 #1 AWG 75oC Class THHW or THWN Insulation OR #2 AWG 90oC Class THHN Insulation
Neutral Conductor #4–500 MCM 300 MCM 75oC Class THHW or THWN Insulation OR 250 MCM 90oC Class THHN Insulation
Ground Conductor #14 –2/0 #8 AWG 75oC Class THHW or THWN


Conduit Hole Location
Figures 2–4 show the three possible conduit entry locations. Select the location yielding the shortest possible conductor lengths. Punch the conduit hole for the conduit connector (maximum conduit diameter = 3.00") in the shaded areas shown in Figures 2–4. These locations ensure that external wiring will not interfere with internal components or require sharp bends. Do not use the hole provided in the top for conduit entry. This hole is reserved for stacking multiple Harmonix units in parallel.

Maximum Conduit Hole Size: 3" Diameter
Fig. 2: Side View (Left) Harmonix Filter


Fig. 3: Side View (Right), Harmonix Filter


Fig. 2: Top View, Harmonix Filter Electrical Connection
Install Harmonix in parallel with the electrical power distribution system via feed through lugs or a 3-pole, 60A (max), UL listed molded-case circuit breaker. After selecting the conduit entry location for Harmonix, establish an opening through the metal cabinet and run required length of the phase, neutral and ground wires through the conduit. NOTE: Also run the neutral current monitoring transformer wires through the conduit. Connect phases A, B, and C conductors to the phase terminal block, then connect the neutral conductor to the neutral terminal block mounted on the inner back wall of the filter (Figures 6–7) before connecting the ground wire to the equipment ground terminal. Connect the black wire of the neutral current monitoring transformer to the control terminal block, pin 7 and the white wire to pin 9 of the control terminal block (Figure 8 and Table 4).

Remote Monitor Contacts Option

  • All Harmonix models include two sets of form "C" monitor dry contacts that may be connected to the building management system or remote annunciation alarm panels.
  • When dry contacts wiring is routed in the same conduit as the phase wiring and the neutral wiring, use NEC Class 1 wiring method.
  • Dry contact ratings must not exceed the Class 2 limit.
  • Figure 8 shows the control terminal block and the form "C" remote monitoring contact output. Each set of contacts may be wired independently.
  • Each set of form "C" remote monitoring contacts include common (C), normally open (NO) and normally closed (NC) contacts. For normally open operation under energized conditions, connect the normally open terminals and common terminal to the monitoring input. For normally closed operation during energized conditions, connect the normally closed terminal and common terminal to the monitoring input. The contacts change to the Alarm State during malfunction of Harmonix or loss of power.


Fig. 6: Internal View - Harmonix Filter
Conduit and Wire Entry from Left side of the Enclosure


Fig. 7: Internal View - Harmonix Filter
Conduit Entry from Right or Back Side of the Filter


Fig. 8: Control Terminal Block, Harmonix Filter

Table 4

Terminal Block Number Terminal Block Connection Application
1 NO1 2 Form C Dry Contacts
2 C1 2 Form C Dry Contacts
3 NC1 2 Form C Dry Contacts
4 NO2 2 Form C Dry Contacts
5 C2 2 Form C Dry Contacts
6 NC2 2 Form C Dry Contacts
7 Neutral Current Black Wire
(from Current Transformer)
8 Neutral Current White Wire
(from Current Transformer)
9 Load Share Current For 2nd Unit in Parallel
(see Multiple Unit section)
10 Load Share Current For 2nd Unit in Parallel
(see Multiple Unit section)
11 Filter Current Pre-connected by Factory
(Black Wire)
12 Filter Current Pre-connected by Factory
(White Wire)


Connection to the Distribution Panel Board

  • Ensure that the breaker supplying power to the panelboard is de-energized.
  • Turn Harmonix breaker to the OFF position
  • Turn Harmonix filter control panel switch to the OFF position
  • Harmonix is connected in parallel with the 3-phase 4-wire distribution system as shown in Figures 11–12. Figure 11 depicts the installation of the Harmonix filter via feed-through lugs. Figure 12 shows the connection of the filter to the system using a 3-pole, 60A, UL listed molded-case circuit breaker. Before connecting Harmonix, ensure that the panelboard is completely de-energized. Insert the neutral current monitoring current sensor in the incoming neutral wire in the proper direction as shown in Figure 9 and 10 and discussed in the next two sections.

Installation of Neutral Conductor Monitoring Transformer (Standard CT)

  • Ensure that the breaker supplying power to the panelboard is de-energized.
  • Unscrew the incoming neutral conductor of the panelboard and insert the neutral current monitoring (CT) into the neutral conductor with "HI", "XI" and "500:5" pointing to the line-side or towards the service entrance. Return the neutral conductor back to its normal position (please see Figure 9).
  • Secure the secondary wiring of the CT away from all phase and neutral conductor components. Ensure that this wiring is not in contact with any sharp edges of the panelboard.
  • Route the secondary wiring of the CT in the same conduit as the phase, neutral and ground conductors.

Installation of Neutral conductor Monitoring Transformer (Split-Core CT)

  • Ensure that the breaker supplying power to the panelboard is de-energized
  • Unscrew the split-core neutral current monitoring transformer and wrap it around the incoming neutral conductor of the panelboard with arrow pointing to the line-side or towards the service entrance (please see Figure 10).
  • Secure the secondary wiring of the CT away from all phase and neutral conductor components. Ensure that this wiring is not in contact with any sharp edges of the panelboard.
  • Route the secondary wiring of the CT in the same conduit as the phase, neutral and ground conductors.

Standard CT
Fig. 9: Installation of Neutral Current Monitoring
Current Transformer (Standard CT)



Fig. 10: Installation of Neutral Current Monitoring
Current Transformer (Split-Core CT)


Fig. 11: Installation of Harmonix Filter using Fed-Through Lugs


Fig. 12: Installation of Harmonix Filter using 60A UL Listed Breaker

Harmonix – Control Panel
Figure 12 depicts the Harmonix control panel, while Table 5 describes various features of the control panel.

Table 5
Control Panel Function Normal Operation
Filter On Filter is Operational ON
Imax Filter operating at > 100A OFF
Alarm Disabled Audible Alarm is disabled OFF
Fault Indicates filter malfunction OFF
Thermal Overload Inverter is overheated due to Fan malfunction OFF
Low-battery Indicates low back-up battery OFF
ON /OFF Operational / Non-operational ON
I – Harmonics /I – Total Measures harmonics Current
  • Measures total Current
    •      		I – Harmonics
    Alarm (ON/OFF) ON : Alarm enabled
    OFF : Alarm disabled    		 Enabled
    Mode Test Test monitor circuits Normal


    Harmonix Control Panel Indicators


    Facility Neutral Current
    This feature monitors total rms or harmonic current in the neutral conductor of a facility. When the METER switch is in the I-Harmonic or upward position, the neutral current meter displays total harmonic current in the neutral conductor. When the METER switch is in the I-Total or downward position, the meter displays the total rms current of the neutral conductor.

    Harmonic Cancellation Current
    This feature monitors Harmonix total rms and harmonic current injected. When the METER switch is in the I-Harmonic or upward position, the Harmonix meter displays the total harmonic current injected by the filter. When the METER switch is in the I-Total or downward position, the meter displays the total current (including fundamental) injected by Harmonix.

    FINAL INSTRUCTIONS

    • Before switching the breaker ON, check all electrical connections, both field and factory installed, for solid electrical connection.
    • Ensure that the harmonic control panel switch is in OFF position before turning breaker ON.
    • Turn the breaker ON.
    • The unit will energize but functionally remain in the OFF state.
    • The top meter will display the neutral current in the facility.
    • The bottom meter should display the current injected by the filter (0.00 A at this time).
    • Turn the filter switch ON.
    • The top meter (indicating the facility neutral current) must show a reduced current, to validate that the filter is installed correctly.
    • If the facility neutral current increases, please turn the filter OFF quickly and contact Current Technology.
    • If the filter is installed correctly, the meters will indicate the harmonic content of the neutral conductor and the current injected by the filter.

    WARNINGS

    • The phase and neutral terminals of Harmonix are energized even if the filter breaker is in the OFF position. The filter is completely de-energized only after the panelboard breaker (if fed from a breaker) is de-energized or after the main-breaker (if fed from fed-through lugs) is de-energized.
    • For safe operation of the filter, only replace fuses with those bearing the same type and rating originally installed in the unit.

    Table 6

    Mounting Recommended
    Hole Size         		Recommended Hardware
    Wall-Mount ½" diameter x 1 ½ deep 3/8 x 16 x 1 ½" LG Grade 8 bolt MacMaster #: 91257A6283/8 x 16 Expanding Plugs
    MacMaster #: 97083A310
    Floor-Mount   Masonry Screw ¼" x 1 ¼" LG



    Fig. 14: Harmonix Filter Floor-Mount Installation
    Fig. 15: Harmonix Filter Wall-Mount Installation Multiple Units in Parallel

    • Turn off the first filter and shut down the power to the filter by switching breaker to OFF position
    • Ensure that the breaker supplying power to the panel board is de-energized (If the panel is fed from the main lugs instead of the breaker, ensure that the breaker supplying power to the panelboard is de-energized).
    • Place the second 100A Harmonix unit on the top of the first unit (See Figure 16).
    • Remove the metal plug from the top of the first unit and the bottom of the second unit. Run Phase, Neutral and Ground Wires from the first unit to the second one through the hole provided on the top of the first unit and the bottom of the second unit.
    • Run the multiple unit cable (provided by Current Technology) from the control terminal block of the first unit to the control terminal block of the second unit (please see Figures 17 and 18 and Tables 6 and 7).
    • Update the jumper position on the first filter from the single-unit to the multiple-unit position (please leave the second filter jumper to the single-unit position).


    • Fig. 16: Multiple Units in Parallel


    Fig. 17: Control Terminal Block Connections of the First Unit

    Table 6

    Terminal Block Number Terminal Block Connection Application
    1 NO1 2 Form C Dry Contacts
    2 C1 2 Form C Dry Contacts
    3 NC1 2 Form C Dry Contacts
    4 NO2 2 Form C Dry Contacts
    5 C2 2 Form C Dry Contacts
    6 NC2 2 Form C Dry Contacts
    7 Neutral Current Black Wire
    (from Current Transformer)
    8 Neutral Current White Wire
    (from Current Transformer)
    9 Multiple-unit Current Signal Block Wire
    ( Multiple-unit Control Cable)
    10 Multiple-unit Current Signal White Wire
    ( Multiple-unit Control Cable)
    11 Filter Current Pre-connected by Factory
    (Black Wire)
    12 Filter Current Pre-connected by Factory
    (White Wire)




    Table 7

    Terminal Block Number Terminal Block Connection Application
    1 NO1 2 Form C Dry Contacts
    2 C1 2 Form C Dry Contacts
    3 NC1 2 Form C Dry Contacts
    4 NO2 2 Form C Dry Contacts
    5 C2 2 Form C Dry Contacts
    6 NC2 2 Form C Dry Contacts
    7 Neutral Current Black Wire
    (from Multiple-unit Cable)
    8 Neutral Current White Wire
    (from Multiple-unit Cable)
    9 Multiple-unit Current Signal No - Connection
    10 Multiple-unit Current Signal No -Connection
    11 Filter Current Pre-connected by Factory
    (Black Wire)
    12 Filter Current Pre-connected by Factory
    (White Wire)