KMG Manual

KMG® MotorGuard High Performance Output
Sine Wave Filter Installation, Operation, and Maintenance

Manual
Including information for:
TCI, LLC
W132 N10611 Grant Drive
Germantown, Wisconsin 53022
Phone: 414-357-4480
Fax: 414-357-4484
Helpline: 800-824-8282
Web Site: www.transcoil.com
© 2021 TCI, LLC All rights reserved
Product No: 24362
Effective: 06-01-2021
Version: 1.3
Revision Description Date
1.0 Release 05/17/2014
1.1 Updates to formatting and layout 02/23/2018
1.2 Addition of PQconnect 02/23/2020
Edits to PQconnect; addition of
1.3 06/01/2021
PQvision
Table of Contents
Table of Contents .......................................................................................................... 5
1.0 Safety ................................................................................................................... 1

Safety Instructions Overview ..................................................................................................................... 1
Warnings and Cautions .............................................................................................................................. 1
General Safety Instructions ....................................................................................................................... 2
2.0 General Information ............................................................................................ 3

Intended Audience ...................................................................................................................................... 3
Receiving Inspection .................................................................................................................................. 3
Storage Instructions ................................................................................................................................... 3
TCI Limited Warranty Policy ...................................................................................................................... 3
Product Description .................................................................................................................................... 5
Nameplate Data ........................................................................................................................................... 6
Model Number Encoding ............................................................................................................................ 7
Standard Product Ratings and Dimension Tables .................................................................................. 8
Product Technical Specifications ........................................................................................................... 14
3.0 Installation Guidelines ...................................................................................... 16

Pre-installation Planning .......................................................................................................................... 16
Select a Suitable Location........................................................................................................................ 16
Mounting .................................................................................................................................................... 17
Wiring ......................................................................................................................................................... 18
Fuses .......................................................................................................................................................... 21
Installation Checklist ................................................................................................................................ 22
4.0 Operation ........................................................................................................... 24

Variable Frequency Drive Settings .......................................................................................................... 24
Start Up (Commissioning) ........................................................................................................................ 24
Before Applying Power for the First Time .............................................................................................. 24
Before Operating the VFD for the First Time.......................................................................................... 24
Drawings .................................................................................................................................................... 24
5.0 PQconnect ......................................................................................................... 25

Product Description .................................................................................................................................. 25
Modbus RTU .............................................................................................................................................. 25
PQvision PC application Screen Elements ............................................................................................. 26
PQvision PC Home Screen Elements ...................................................................................................... 26
PQvision PC Settings Screen Elements.................................................................................................. 27
PQvision PC Status Detection History Elements ................................................................................... 30
Modbus RTU Connections........................................................................................................................ 31
Modbus Input and Output Register Maps ............................................................................................... 31
Waveform Data .......................................................................................................................................... 41
PQconnect Hardware ................................................................................................................................ 42
USPTL4 RS485 Converter Dip Switch settings ...................................................................................... 43
Example Setup Instructions to Read Data from the PQconnect Unit .................................................. 43
Example Setup Instructions to Write Data to the PQconnect Unit ....................................................... 44
PCB Connections ...................................................................................................................................... 45
Troubleshooting ........................................................................................................................................ 46
Receiving Inspection................................................................................................................................. 46
Connectivity Board Problem .................................................................................................................... 47
Communication Problems ........................................................................................................................ 48
PCB Calibration Process .......................................................................................................................... 49
Debug Status Conditions.......................................................................................................................... 50
Debug Fault conditions............................................................................................................................. 51
6.0 Maintenance and Service ................................................................................. 52

Evaluating MotorGuard Performance ...................................................................................................... 52
MotorGuard Reliability and Service Life ................................................................................................. 52
Periodic Maintenance................................................................................................................................ 52
Replacement Parts .................................................................................................................................... 52
Factory Contacts and Tech Support ....................................................................................................... 52
KMG IOM 1.0 Safety
1.0 Safety
Safety Instructions Overview
This section provides the safety instructions which must be followed when installing, operating
and servicing the KMG MotorGuard Filter. If neglected, physical injury or death may follow, or
damage may occur to the MotorGuard or equipment connected to the MotorGuard. The material
in this chapter must be read and understood before attempting any work on, or with, the product.
The MotorGuard 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 MotorGuard and receives power
from the VFD through the MotorGuard. 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 caution readers about conditions, which can, if proper steps are not taken, lead to a
serious fault condition, physical injury, or death.
Cautions are used to draw attention to instructions. Failure to properly follow such instructions
may 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 marked with the following symbols:
Warning Dangerous Voltage Warning: warns of situations in which

a high voltage can cause physical injury and/or
equipment damage. 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 equipment damage 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 may 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.
1
KMG IOM 1.0 Safety
General Safety Instructions
These safety instructions are intended for all work on the MotorGuard. 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 MotorGuard.
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 MotorGuard.
Warning
The MotorGuard, VFD, motor, and other connected equipment must be properly grounded.
Warning The MotorGuard receives power from two or more sources.

Three-phase power from the output terminals of the VFD is connected to the main input
terminals of the MotorGuard.
Power from a single-phase 120, 240 or 480 volt supply is connected to the MotorGuard
for the cooling fans and PQconnect. Do not connect fan circuit to the output of VFD,
separate line voltage needs to be wired to the filter. Damage to the filter will occur if
fans are left unpowered or connected to VFD output.
The PQconnect alarm contacts may be connected to a circuit that receives power from
another source.
All of these sources of power must be disconnected before working on the MotorGuard.
Warning After switching off the power, always allow 5 minutes for the capacitors in the MotorGuard
and in the VFD to discharge before working on the MotorGuard, the VFD, the motor, or
connecting wiring. It is 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.
Warning
The VFD output terminals and the motor cables are at a dangerously high voltage when
power is applied to the VFD regardless of motor operation.
2
KMG IOM 2.0 General Information
2.0 General Information

Thank you for selecting the KMG MotorGuard High Performance Output Filter. TCI has produced
this filter for use in many PWM variable frequency drive (VFD) applications that require low
distortion sine wave output power. This manual describes how to install, operate, and maintain
the MotorGuard filter.
Caution This manual provides general information describing your MotorGuard filter. More specific
information is provided by the drawings shipped with the unit. Be sure to carefully review the
! information provided by these drawings. Information provided by the drawings shipped with
the unit takes precedence over the information provided in this manual.
Intended Audience
This manual is intended for use by all personnel responsible for the installation, operation, and
maintenance of the MotorGuard. Such personnel are expected to have knowledge of electrical
wiring practices, electronic components, and electrical schematic symbols.
Receiving Inspection
The MotorGuard has been thoroughly inspected and functionally tested 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 unit you received is the same as the part number listed on your purchase order.
Storage Instructions
If the MotorGuard is to be stored before use, be sure that it is stored in a location that conforms to
published storage humidity and temperature specifications stated in this manual. 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, , KMG, not to exceed 18 months from the date of
MSD, V1K shipment.
PFGuard, HGP,
Three (3) years from the date of shipment.
HGL, HSD, KRF
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:
3
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.
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.
4
Product Description
The MotorGuard 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
MotorGuard is available for 460/480 volt and 575/600 volt systems.
The MotorGuard 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, L-R-C device 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
MotorGuard will also reduce the effects of stray high frequency harmonic currents, thereby
reducing VFD ground fault problems and noise interference in transducer signals.
The MotorGuard is available in two package configurations: Industrial and GP. The Industrial
filter is a stand-alone device that can be furnished in its own enclosure and mounted adjacent to
the VFD, and is also available on an open panel for mounting within an enclosure provided with
the VFD or other equipment. The GP filter is furnished in its own enclosure and mounted
adjacent to the VFD.
The MotorGuard is suitable for all lead lengths extending as far as 15,000 feet.
The MotorGuard consists of the following standard features and components:
• An R-L-C power filter circuit with:

o A TCI 3-phase reactor specifically designed for the MotorGuard
o Power resistors
o High-endurance, harmonic-rated capacitors
• Bleeder resistors to ensure safe capacitor discharge upon filter shutdown.
• Compression terminals for ease and integrity of all power wiring.
• Cooling fans to ensure adequate cooling and safe operating temperatures.
• PQconnect monitoring and communications (optional)
5
Nameplate Data
The figure below shows an example of a MotorGuard nameplate. The following information is
marked on the nameplate:
• Part number: encoded model number explained on the following page

• FLA: the rated continuous operating current (RMS amps)
• System Voltage: the maximum VFD output voltage (fundamental)
• Hz: the maximum VFD output frequency (fundamental)
• Phase: 3 – The MotorGuard is designed for use only with 3 phase motors.
• Drawing #: outline and mounting dimension of filter
• Schematic #: schematic diagram of filter
• Manufacturing #: for TCI internal use
• Enclosure Type: Industrial filters are open panel construction or UL Type 1 enclosed.
GP filters are NEMA 1 or NEMA 3R enclosed.
Figure 1: Example of MotorGuard Nameplate
6
Model Number Encoding
Figure 2 and Figure 3 identify the significance of each character in the MotorGuard model
number. The example model number, KMG130A01P designates an Industrial MotorGuard that is
rated 130 amps, 480 volts, UL Type 1 enclosure, with the PQconnect option.
Figure 2: MotorGuard Model Number Encoding – Industrial Version
Figure 3: MotorGuard Model Number Encoding – General Purpose Version (Legacy

Product)
7
The MotorGuard has a current rating rather than a horsepower rating. The rating and dimension
tables in the following section list the nominal horsepower ratings corresponding to the current
ratings of the standard models.
Standard Product Ratings and Dimension Tables

The following tables list the ratings and dimensions of the standard MotorGuard models.
Table 1: Industrial 480 Volt Models on Open Panels
Current Heat
Model Nominal Weight Height Width Depth
Rating Loss
Number Horsepower (lbs.) (in.) (in.) (in.)
(amps) (Watts)
KMG8A00_ 5 8 300 60
KMG12A00_ 7.5 12 350 60
KMG16A00_ 10 16 400 70
KMG23A00_ 15 23 550 75
30.75 17.00 11.75
KMG30A00_ 20 30 650 85
KMG35A00_ 25 35 750 85
KMG45A00_ 30 45 850 100
KMG55A00_ 40 55 1000 115
KMG65A00_ 50 65 1100 160
KMG80A00_ 60 80 1550 175
KMG110A00_ 75 110 1700 195
56.00 17.00 11.75
KMG130A00_ 100 130 2050 200
KMG160A00_ 125 160 2450 250
KMG200A00_ 150 200 3300 255
KMG250A00_ 200 250 3700 445
KMG305A00_ 250 305 4700 460 60.00 32.00 14.75
KMG362A00_ 300 362 4650 475
KMG420A00_ 350 420 5400 580
KMG480A00_ 400 480 6050 635 60.00 32.00 16.38
KMG600A00_ 500 600 7350 645
KMG750A00_ 600 750 8800 760 60.00 32.00 17.75
8
Table 2: Industrial 480 Volt Models in UL Type 1 Enclosures
Current
Rating
(amps)
KMG8A01_ 5 8 110
KMG12A01_ 7.5 12 110
KMG16A01_ 10 16 120
KMG23A01_ 15 23 125 31.38
Wall 17.50 12.14
KMG30A01_ 20 30 140 Mounted
KMG35A01_ 25 35 140
KMG45A01_ 30 45 155
KMG55A01_ 40 55 170
KMG65A01_ 50 65 245
KMG80A01_ 60 80 260
KMG110A01_ 75 110 280 56.00
Wall 17.52 16.40
KMG130A01_ 100 130 300 Mounted
KMG160A01_ 125 160 340
KMG200A01_ 150 200 345
KMG250A01_ 200 250 770
KMG305A01_ 250 305 790
KMG362A01_ 300 362 800
76.50
KMG420A01_ 350 420 915 Free 36.00 24.00
Standing
KMG480A01_ 400 480 970
KMG600A01_ 500 600 975
KMG750A01_ 600 750 1085
9
Table 3: Industrial 600 Volt Models on Open Panels
Current Heat
Rating Loss
(Amps) (Watts)
KMG8C00_ 5 8 400 60
KMG10C00_ 7.5 10 400 65
KMG12C00_ 10 12 400 70
KMG20C00_ 15 20 550 75
30.75 17.00 11.75
KMG25C00_ 20 25 700 85
KMG28C00_ 25 28 750 90
KMG35C00_ 30 35 800 100
KMG45C00_ 40 45 950 115
KMG55C00_ 50 55 1200 160
KMG65C00_ 60 65 1600 175
KMG80C00_ 75 80 1650 195 56.00 17.00 11.75
KMG110C00_ 100 110 2250 225
KMG130C00_ 125 130 2300 250
KMG160C00_ 150 160 2500 260 56.00 17.00 14.78
KMG200C00_ 200 200 3500 450
KMG250C00_ 250 250 4500 460
KMG305C00_ 300 305 5100 475 60.00 32.00 14.75
KMG362C00_ 350 362 6100 580
KMG420C00_ 400 420 6900 635
KMG500C00_ 500 500 7900 645
60.00 32.00 16.00
KMG600C00_ 600 600 9000 750
10
Table 4: Industrial 600 Volt Models in UL Type 1 Enclosures
Current
Rating
(Amps)
KMG8C01_ 5 8 115
KMG10C01_ 7.5 10 115
KMG12C01_ 10 12 120
KMG20C01_ 15 20 135 31.38
Wall 17.50 12.14
KMG25C01_ 20 25 140 Mounted
KMG28C01_ 25 28 145
KMG35C01_ 30 35 155
KMG45C01_ 40 45 175
KMG55C01_ 50 55 260
KMG65C01_ 60 65 265
KMG80C01_ 75 80 265 56.00
Wall 17.52 16.40
KMG110C01_ 100 110 290 Mounted
KMG130C01_ 125 130 295
KMG160C01_ 150 160 340
KMG200C01_ 200 200 770
KMG250C01_ 250 250 775
KMG305C01_ 300 305 790
76.50
KMG362C01_ 350 362 975 Free 36.00 24.00
Standing
KMG420C01_ 400 420 975
KMG500C01_ 500 500 1015
KMG600C01_ 600 600 1015
11
Table 5: General Purpose 480 Volt Models in NEMA 1 Enclosures
Current
Rating
(Amps)
KMG55AG010000 40 55 209
KMG65AG010000 50 65 215
KMG80AG010000 60 80 235
KMG110AG010000 75 110 220 36.50 18.67 29.50
KMG130AG010000 100 130 225
KMG160AG010000 125 160 250
KMG200AG010000 150 200 260
KMG250AG010000 200 250 595
KMG305AG010000 250 305 625
KMG362AG010000 300 362 630
64.00 24.17 42.00
KMG420AG010000 350 420 635
KMG480AG010000 400 480 635
KMG600AG010000 500 600 755
Table 6: General Purpose 480 Volt Models in NEMA 3R Enclosures
Current
Rating
(Amps)
KMG55AG3R0000 40 55 209
KMG65AG3R0000 50 65 215
KMG80AG3R0000 60 80 235
KMG110AG3R0000 75 110 220 36.50 18.67 29.50
KMG130AG3R0000 100 130 225
KMG160AG3R0000 125 160 250
KMG200AG3R0000 150 200 260
KMG250AG3R0000 200 250 595
KMG305AG3R0000 250 305 625
KMG362AG3R0000 300 362 630
64.00 24.17 42.00
KMG420AG3R0000 350 420 635
KMG480AG3R0000 400 480 635
KMG600AG3R0000 500 600 755
12
Table 7: General Purpose 600 Volt Models in NEMA 1 Enclosures
Current
Rating
(Amps)
KMG45CG010000 40 45 209
KMG55CG010000 50 55 235
KMG65CG010000 60 65 235
KMG80CG010000 75 80 266 36.50 18.67 29.50
KMG110CG010000 100 110 275
KMG130CG010000 125 130 280
KMG160CG010000 150 160 290
KMG200CG010000 200 200 570
KMG250CG010000 250 250 615
KMG305CG010000 300 305 620
KMG362CG010000 350 362 650 64.00 24.17 42.00
KMG420CG010000 400 420 675
KMG500CG010000 500 500 810
KMG600CG010000 600 600 835
Table 8: General Purpose 600 Volt Models in NEMA 3R Enclosures

Current
Rating
(Amps)
KMG45CG3R0000 40 45 209
KMG55CG3R0000 50 55 235
KMG65CG3R0000 60 65 235
KMG80CG3R0000 75 80 266 36.50 18.67 29.50
KMG110CG3R0000 100 110 275
KMG130CG3R0000 125 130 280
KMG160CG3R0000 150 160 290
KMG200CG3R0000 200 200 570
KMG250CG3R0000 250 250 615
KMG305CG3R0000 300 305 620
KMG362CG3R0000 350 362 650 64.00 24.17 42.00
KMG420CG3R0000 400 420 675
KMG500CG3R0000 500 500 810
KMG600CG3R0000 600 600 835
13
Product Technical Specifications
Table 9 and Table 10 list the major technical specifications for the MotorGuard product line.
Table 9: MotorGuard Technical Specifications – Industrial

Continuous current: 8 to 750 amps. See Rating and Dimension
Current Ratings tables
Overload current: 150% for 1 minute out of every 60 minutes
VFD Output Voltage 460/480 and 575/600 V, 3 ph, at fundamental base frequency
VFD Output Frequency 0 to 80 Hz
VFD Carrier Frequency 2 kHz and 16 kHz; ideally a minimum of 4 kHz
Control Power Input For fan operation.
Maximum peak voltage of output waveform
– 480 V models: 815 V
– 600 V models: 1,018 V
Filter Performance
Maximum dV/dt of output waveform
– 480 V models: 5 V/μs
Up to 2,000m (6,600ft) without derating. Consult factory for higher
Maximum Elevation
elevations.
-30°C (-22°F) to 50°C (122°F) open panel
Operating Temperature
-30°C (-22°F) to 40°C (104°F) enclosed
Storage Temperature -40°C (-40°F) to 50°C (122°F)
Maximum Humidity 95%, non-condensing.
Open panel for mounting in an enclosure furnished by others
Enclosure Options
UL Type 1 enclosure
Free standing enclosures: ANSI 61 gray
Enclosure Finish
Wall mount enclosures: White Matte (beige) Munsel 5.8Y7.83/1
Agency Approvals or UL and cUL Listed to UL508A and CSA-C22.2 No. 14

Certifications
Insertion Impedance Approximately 6.5% at 60 Hz & full load current

Unit has internal fuse protection and a performance monitoring
Fusing and Protection:
circuit.
Capacitors Oil filled high endurance design (no PCBs)
14
Table 10: MotorGuard Technical Specifications – General Purpose

Continuous current: 55 to 600 amps. See Rating and Dimension
Current Ratings tables
Overload current: 150% for 1 minute out of every 60 minutes
VFD Output Voltage 460/480 and 575/600 V, 3 ph, at fundamental base frequency
VFD Output
0 to 80 Hz
Frequency
VFD Carrier
2 kHz and 16 kHz; ideally a minimum of 4 kHz
Frequency
Control Power Input For fan operation.
Maximum peak voltage of output waveform
– 480 V models: 815 V
– 600 V models: 1,018 V
Filter Performance
Maximum dV/dt of output waveform
Up to 2,000m (6,600ft) without derating. Consult factory for
Maximum Elevation
higher elevations.
Operating
Temperature -30°C (-22°F) to 40°C (104°F) enclosed
Storage Temperature -40°C (-40°F) to 50°C (122°F)
Maximum Humidity 95%, non-condensing.
General Purpose NEMA 1
Enclosure Options
General Purpose NEMA 3R
Insertion Impedance Approximately 6.5% at 60 Hz & full load current
Capacitors Oil filled high endurance design (no PCBs)
15
KMG IOM 3.0 Installation Guidelines
3.0 Installation Guidelines

Warning
Be sure to read, understand, and follow all safety instructions provided in this manual prior to
beginning work.
Warning
Dangerous Voltage is used in the operation of the MotorShield™. Only qualified electricians
should carry out all electrical installation and maintenance work on the MotorShield™.
Warning
All wiring must be performed in accordance with the National Electrical Code (NEC) and/or
any other codes that apply to the installation site.
Pre-installation Planning
Verify the Application
Make sure that the MotorGuard is correct for the application. The voltage and current ratings of
the MotorGuard must match the output voltage and current ratings of the connected variable
frequency drive as it is configured for use with the connected motor.
Select a Suitable Location

Locating the MotorGuard in a suitable environment will help ensure proper performance and a
normal operating life.
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:
• Corrosive liquids or gasses

• Explosive or combustible gases or dust
• Excessive airborne dirt and dust
• Excessive vibration
In addition to the above, products that are not in a 3R enclosure should not be exposed to:
• Direct sunlight
• Rain or excessive dripping liquids
Mounting Area
Select a mounting area that will allow sufficient cooling air to flow through the unit. Adequate
space should be provided to allow access for maintenance.
If you are mounting an open panel unit in your own enclosure, you must provide an enclosure
that is adequately sized and ventilated sufficiently to prevent overheating. The rating and
dimension tables for open panel units list the watts of heat loss that is dissipated by the
MotorGuard. The maximum temperature of the air around the MotorGuard's capacitors and
PQconnect should not exceed 50 °C (122 °F).
16
Power Wiring Considerations
The conduit and wiring from the output of the variable frequency drive to the motor must be
routed to the MotorGuard and then to the motor. When selecting a mounting location for the
MotorGuard, plan for the routing of the power wiring.
Control Wiring Considerations

The MotorGuard requires 120 VAC single-phase power for the PQconnect and cooling fans. The
control power source must be ensured to be energized whenever the variable frequency drive is
operating. A control power transformer is provided in the MotorGuard to allow control power to
be obtained from the three-phase source that provides input power to the VFD. Fuses are
provided on the control transformer, but the wires connecting control power to the MotorGuard
will need to be appropriately protected at the power source.
Refer to the drawings furnished with your MotorGuard to determine the control power VA
required.
Thermal Switch
A normally closed thermal switch is included on the sine wave reactor. The thermal switch
opens if the filter reactor overheats. Connect this switch to the VFD external fault input to
monitor the integrity of the filter. This is on the filter as a method of protecting the components in
the situation where the temperature begins to get above the acceptable levels of operation.
Optional Features
Additional wiring requirements may apply to MotorGuard units that are equipped with certain
optional features such as a space heater or 120 VAC control power supplied directly rather than
through a control power transformer. For instructions covering these additional requirements,
refer to drawings and/or other supplemental information furnished with the unit.
Mounting
The MotorGuard must be mounted vertically on a smooth, solid surface, free from heat,
dampness, and condensation. Provide 3” of clearance along the sides of an enclosed filter.
17
Wiring
Cable Entry Locations
Lifting eye is optional
Figure 4: Cable Entry Location for General Purpose units
Field Wiring Connection Terminals

Compression type terminals may be provided for all field wiring connections. The control circuit
terminals will accommodate 18 AWG to 10 AWG wire and should be tightened to 18 in.-lbs.
torque. The wire size capacity ranges and tightening torque for the grounding and power
terminals are listed in the following tables.
18
Table 11: Motor Power Terminal Wire Size Capacity Range and Tightening Torque (Cu or Al) - Industrial
Ground Lug Input and Output

KMG IND Motor Power
Model Numbers
Wire Size Torque Wire Size Torque
(in.-lb.) (in.-lb.)
KMG8A to KMG55A 14 - 1/0 AWG 200 22 - 16 AWG 25
KMG8C to KMG45C 14 - 6 AWG 30
4 - 2 AWG and 35
1 AWG (7 & 19 strand only)
KMG65A to KMG130A 6 - 2/0 AWG 120 6 - 2/0 AWG 120
KMG55C to KMG130C
KMG160A to KMG200A 6 AWG - 250 MCM 275 6 AWG - 250 MCM 275
KMG160C to KMG200C
KMG250A to KMG305A 4 AWG - 600 MCM or 500 4 AWG - 600 MCM or 500
KMG250C to KMG305C (2) 1/0 AWG - 250 MCM (2) 1/0 AWG - 250 MCM
KMG362A (2) 4 AWG - 350 MCM 275 (2) 4 AWG - 350 MCM 275
KMG362C to KMG420C
KMG420A to KMG600A (2) 2 AWG - 600 MCM 500 (2) 2 AWG - 600 MCM 500
KMG500C to KMG600C
Table 12: Motor Power Terminal Wire Size Capacity Range and Tightening Torque (Cu or Al) – General
Purpose
Ground Lug Input and Output

KMG GP Motor Power
Model Numbers
Wire Size Torque Wire Size Torque
(in.-lb.) (in.-lb.)
KMG55A 14 - 1/0 AWG 200 22 - 16 AWG 25
KMG45C 14 - 6 AWG 30
4 - 2 AWG and 35
1 AWG (7 & 19 strand only)
KMG65A to KMG130A 6 - 2/0 AWG 120 6 - 2/0 AWG 120
KMG55C to KMG130C
KMG160A to KMG200A 6 AWG - 250 MCM 275 6 AWG - 250 MCM 275
KMG160C to KMG200C
KMG250A to KMG305A 4 AWG - 600 MCM or 500 4 AWG - 600 MCM or 500
KMG250C to KMG305C (2) 1/0 AWG - 250 MCM (2) 1/0 AWG - 250 MCM
KMG362C to KMG420C
KMG420A to KMG600A (2) 2 AWG - 600 MCM 500 (2) 2 AWG - 600 MCM 500
KMG500C to KMG600C
19
Connection Diagram
Figure 5 shows the typical wiring connections between the MotorGuard and the VFD and motor.
Note that separate conduits may be required for the control power and fault contact wiring. Refer
to the instructions for the VFD or other equipment to which the fault contact is connected.
Ext Fault TS1 TS2 L1 L2

L1(R) Input (U)T1 U Control T1
Power T1
L2(S) (V)T2 V
T2 T2 Motor
L3(T) Variable (W)T3 W
Frequency T3
G Drive G G T3 G
MotorGuard
Ext Fault NC COM NO NC COM NO

L1 L2
L1(R) (U)T1 U J11 J12 Control T1
Input Output Output
Relay 1 Relay 2 Power T1
L2(S) (V)T2 V
PQconnect T2 T2 Motor
L3(T) Variable (W)T3 W
Frequency T3
G G G T3 G
Drive MotorGuard
Figure 5: Typical Connection Diagram
Grounding
The MotorGuard panel equipment grounding lug must be connected to the ground of the
premises wiring system. The equipment grounding connection must conform to the requirements
of the National Electric Code (NEC) and/or any other codes that apply to the installation site. The
ground connection must be made using a wire conductor. Metallic conduit is not a suitable
grounding conductor. The integrity of all ground connections should be periodically checked.
Power Wiring
Connect the output of the VFD, terminals T1(U), T2(V), & T3(W), to the input of the MotorGuard,
terminals U, V, & W. Connect the motor to the output of the MotorGuard, terminals T1, T2, & T3.
Use wire that is appropriate for the voltage and current rating of the motor.
Caution For units rated less than 100 amps, use copper or aluminum wire with an insulation
temperature rating of 60 °C or higher.
! For units rated 100 amps or more, use copper or aluminum wire with an insulation
temperature rating of 75 °C or higher.
The wire size and the voltage ratings must conform to the requirements of the National
Electrical Code and/or other applicable electrical codes.
Be sure to also follow the motor wiring instructions provided in the instruction manual for the
VFD.
Control Wiring
Connect control power to the MotorGuard. Be sure to provide fuses or other appropriate
protection for the control power wiring. Make sure that the voltage and VA capacity of the control
20
power source matches the MotorGuard's control power input ratings. Refer to the drawings
shipped with the unit.
Do not connect fan circuit to the output of VFD, separate line voltage needs to be wired to
the filter. Damage to the filter will occur if fans are left unpowered or connected to VFD
output.
For filters with PQconnect, connect the MotorGuard PQconnect fault output relay contacts to the
appropriate fault monitoring circuit. It may be connected to the VFD or to some supervisory
control or alarm annunciation equipment.
Thermal Switch
This option includes an over-temperature switch installed on the sine wave reactor. On the
reactor, over-temperature switches are wired to a terminal block separate from the power
terminals. The over-temperature switch opens if unpredicted heating occurs. An interlocking
circuit should be used with the over-temperature switch to turn off the VFD to prevent filter
damage in the event of filter overheating. The over-temperature switch contact is rated 6 amps at
120 VAC. The over-temperature switches are normally closed, open on temperature rise and
typically have the following trip points:
• On a Class R 220°C insulation reactor, the switch opens on rise above 200°C
• On a Class H 180°C insulation reactor, the switch opens on rise above 160°C
Wire the over-temperature switches according to the reactor schematic using T1 and T2
locations on the over-temperature switch terminal block.
Figure 6: Terminal Block
If the KMG MotorGuard is ordered with the PQconnect, the thermal switch feedback will be wired
to the PQconnect board, and the PQconnect will indicate whether there is an over-temperature
problem. The PQconnect fault relay (J10 header) can be used to be alerted when there is an
Over-temp issue as an additional measure. For further detail please refer to the pin out
references in the PCB connections section of this manual.
Fuses
The table below lists the specifications for the LC power circuit fuses in the MotorGuard.
21
Table 13: RC Power Circuit Fuses for Industrial Model
480 V Models 600 V Models
MotorGuard Power Circuit MotorGuard Power Circuit

Rating Fuse Rating Rating Fuse Rating
(Amps) Amps Type (Amps) Amps Type
8 2 8 2
12 2.5 10 2
16 4 12 2.5
23 6 Class CC 20 5
30 8 Bussmann 25 6 Class CC
type KLD-R Bussmann
35 9 28 7
or equivalent type KLD-R
45 12 35 9 or equivalent
55 15 45 12
65 20 55 15
80 20 65 20
110 30 80 25
130 35 110 30
160 40 130 35
200 50 160 40
250 70 Class T 200 50
Bussmann Class T
305 80 250 70 Bussmann
type JJS
362 90 or equivalent 305 80 type JJS
420 110 362 90 or equivalent
480 125 420 110
600 150 500 125
750 200 600 150
Control Circuit Fuses

Refer to the drawings furnished with your MotorGuard for control circuit fuse specifications.
Installation Checklist
The following are the key points to be followed for a successful installation. These points are
explained in detail in the following sections of this manual.
• Make sure that the installation location will not be exposed to 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 MotorGuard equipment grounding lug to the system ground of the premises
wiring system. Use a properly sized grounding conductor.
• Wire the output power terminals of the VFD, T1(U), T2(V), & T3(W) to the input terminals
of the MotorGuard, U, V, & W.
• Wire the output power terminals, of the MotorGuard, T1, T2, & T3 to the motor.
• Connect control power to the MotorGuard as described in the section Control Wiring .
22
• For PQconnect option: Connect the MotorGuard fault relay contact to the appropriate fault
monitoring circuit.
• Connect product thermal switches to VFD external fault input relay. This will monitor filter
component temperatures, and shut down VFD and troubleshoot issues should cooling
power be lost, cooling equipment fails, or VFD output get outside of the filter design
limitations.
• Make sure that the VFD is set for operating modes and ranges that are compatible with
the MotorGuard sine wave filter.
• Check everything thoroughly before operating the equipment.
23
KMG IOM 4.0 Operation
4.0 Operation
Since the MotorGuard is a passive filter, it is always operating whenever the variable frequency
drive is operating. Whenever the VFD is operating, control power should be applied to the
MotorGuard so that the MotorGuard's cooling fan will operate and prevent it from overheating.
Control power is also required for the PQconnect.
Variable Frequency Drive Settings

Make sure that the variable frequency drive is set for operation modes and ranges that are
compatible with the MotorGuard:
• Maximum output frequency: 80 Hz

• PWM switching frequency between 2 kHz and 16 kHz; ideally a minimum of 4 kHz.
Since the MotorGuard removes most of the harmonic content from the output
waveform, quiet motor operation should be achieved with a switching frequency
setting within this range.
• Mode of operation: "scalar" or "V/Hz" without DC braking unless the drive
applications has been confirmed by TCI Technical Support
• Consult VFD manual for other drive specific recommendations for use with sine
wave 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.
Start Up (Commissioning)
Caution
Thoroughly check the installation before applying power and operating the equipment
! for the first time.
Caution
Never Operate the MotorGuard without a load connected to its output terminals.
!
Before Applying Power for the First Time
Inspect the installation to make sure that all equipment has been completely and correctly
installed in accordance with the Installation Guidelines section of this manual.
Before Operating the VFD for the First Time

Make sure that the variable frequency drive is set for operation modes and ranges that are
compatible with the MotorGuard as described above.
Drawings
Typical MotorGuard drawings are provided on the transcoil website. Please visit
https://transcoil.com/products/motorguard-sinewave-filter/motorguard-industrial-drawings/
These drawings provide general information describing your MotorGuard filter. More specific
information is provided by the drawings shipped with the unit. Be sure to carefully review the
information provided by these drawings. This information takes precedence over the information
provided in this manual
24
KMG IOM 5.0 PQconnect
5.0 PQconnect
Product Description
The PQconnect is an integrated controls option for TCI’s industry sine wave filter used for filtering
the output of variable frequency motor drives (VFDs). In the sine wave filter, the PQconnect
provides unit status detection, metering, voltage waveform 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
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.
4
Modbus RTU
3
Connections
2
Figure 7: PQconnect Modbus RTU Connection
25
PQvision PC application Screen Elements
This section focuses on the operation of the PQvision application. The PC application contains
several screens that allow the user to monitor the status of the KMG Sine Wave filter. Additionally,
the PQvision application can be used for basic setup of the KMG Sine Wave filter.
Enter password 08252014 to enable tech access.
Please ensure the latest version of PQvision is downloaded to your PC. The software is available
on the TCI KMG page located here:
https://transcoil.com/products/motorguard-sinewave-filter/
A standard RS485 to USB converter can be used with your sine wave filter with PQconnect. To run
the PQvision software the converter will need to be connected to terminal J5 on the PQconnect
PCB with pin orientation as described in Table 14, the USB connector will need to be run to laptop
or PC.
PQvision PC Home Screen Elements
Figure 8: PQvision Desktop Application
The tables and figures below describe navigation of the PQvision Application.
Table 14: PQvision PC Navigation

Designators Name Description
1 Filter Status Will determine the status of the filter and output of the filter
The PQconnect PC application supports capture and display of real
time of the filters Output Voltage.
Output Voltage
2 Phase A – Black
Waveform
Phase B – Red
Phase C – Blue
Communication Status and Communication Port
3 Communication To determine the COM port, go to Device Manager Ports (COM &
LPT) and finding “USB Serial Port”
26
Note: If Modbus settings differ from the default values above; Set
and save desired Modbus settings, then select Reset PQconnect
from the drop-down Menu.
Displays PQconnect Software revision
Displays the estimated carrier frequency of the VFD in Hz
Displays the fundamental frequency of the filter output voltage in Hz
Displays the board temperature in degrees Celsius
4 Summary Data
Displays line to line output voltage of the filter in Vrms
(THVD) Displays the Total Harmonic Voltage Distortion of the output
of the filter as a percentage
Displays percentage of Output Peak voltage to Output RMS voltage.
PQvision PC Settings Screen Elements

To access the settings page as seen in Figure 8, under the Menu toolbar select Tech Access and
Enter password 08252014 to enable the settings configurations. In the PQvision settings a user
can set their desired Modbus settings, however, this will require the PQconnect reset command.
The settings screen can also be used to enable and disable alert conditions that activate the
output relays and Modbus registers. The tables below describe the different settings menus.
PQconnect Reset command: if changing the Modbus settings, the user will be required to reset
the PCB after saving settings. This can be easily done through the menu by clicking menu and
Reset PQconnect. The reset command will only work if the PCB is communicating to the desktop
application or Modbus network. Note: resetting the board will de-energize the relay outputs if the
relay state is closed.
Figure 9: PQvision Settings Menu
27
Table 15: PQvision Settings Menu
Determines if the unit’s PCB is ready to run
“Run” – PCB is calibrated and ready

1 System State
If the system state is labeled as “Calibrate check” the user
must perform the calibration process. Follow calibration steps
in the debug section
This section can be used to enable and disable the status
detections conditions that drive the output relays. Upon power
up the relays energize, closing the normally open contacts.
This is the nominal status OK state. The output relays stay in
2 Alert Management
this state until one of the configured alerts is detected or the
board becomes unpowered.
After selecting desired relay outputs select save settings.

Allows the user to change Modbus settings of the App and
device.
When changing Modbus settings, the user will start with

selecting a new slave address/Baud rate/ and parity of the
Device. After selecting desired Modus settings of the device,
the user will select apply Modbus settings and save settings.
Afterwards the user will need to go to Menu and Reset

3 Modbus PQconnect. This will soft reboot the board.
Note: Changing Modbus settings of the device can only be

done through tech access
If the user would still like to use the PQvision application with
the updated Modbus settings, they would need to navigate to
the settings menu and apply the new Modbus settings for the
application.
By default, Input Relay 1 will be set to thermal switch and Input

Relay 2 is off. Relay 1 is intended to be used with the normally
closed thermal switch available on the filter reactor.
4 Relay Inputs
Note: Input Relay 1 is connected to J7 of the PCB and Input
Relay 2 is connected to J8.
Allows the user to change the filter rated voltage.

5 Rated Voltage
Note: The user should only select the voltage the filter is rated
for. Range 240V to 600V
In the PQvision settings a user can set their desired Modbus settings, however this will require the
PQconnect reset command. The settings screen can also be used to enable and disable alert
conditions that activate the output relays and Modbus registers.
PQconnect Reset command: if changing the Modbus settings, the user will be required to reset
the PCB after saving settings. This can be easily done through the menu by clicking menu and
Reset PQconnect. The reset command will only work if the PCB is communicating to the desktop
application or Modbus network. Note: resetting the board will de-energize the relay outputs if the
relay state is closed.
28
Figure 10: PQvision Parameter List Menu
Table 16: PQvision Parameter List Menu

The setpoints toolbar will allow the user to adjust parameters
to their desired settings.
Feedbacks will allow the user to view the present values of the
filter.
1 Toolbar Menu
The Pinned tab will have any pinned parameters the user
selects. To pin parameters the user will select the pins box for
each desired parameter.
View parameter tables to determine what each value means.
Address is the spare ID for each parameter
Requested – If the user would like to adjust any values that

differ from the present value they will type in the new value in
the box.
Address/ Requested/
2
Value/ Read/ Write Value is the present value the parameter
Read/Write buttons: Pressing the Read button will display the

current value of the parameter. Pressing write will allow the
user to overwrite the present value.
29
PQvision PC Status Detection History Elements
Figure 11: Status Detection History
Table 17: PQvision Status Detection History Menu

Number of status conditions that occurred in the filter
Note: when reaching the 99 index any new status conditions

1 Index
will start to overwrite existing index’s starting with index 0. The
newest entry in the status history is always shown at the top of
the history list. The oldest entry will be at the bottom of the list.
The timestamp will indicate when a status condition was
detected.
The first 3 numbers represent the number of times the PCB

Timestamp power cycled when the event occurred.
2
(PC: Sec: Msec)
The middle 10 and last 3 digits represent the time in
seconds:milliseconds format since the last power on of the
PQconnect board since the status condition was detected
Status will indicate the status detection that occurred. The

3 Status status bit mask formatted as a hex value volowed by a list of
status conditions will be shown.
The status history will also record diagnostic values when the
status was detection
Values recorded: VTHD of A-B phase, VTHD of B-C Phase,

4 Values VTHD of C-A, Fundamental frequency in Hz, Carrier frequency
in Hz and the average filter output line to line RMS voltage
scaled in percent rated Volts. For example for a 480 V
sinewave filter a value of 100% would indicate average filter
output voltage was 480VRMSLL.
30
Modbus RTU Connections
The hardware pinout for the J5 communication header and default settings is shown below.
Table 18: 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 19: Modbus RTU Protocol Settings

Parameter Value Units
Baud Rate 38400 Bd
Data Bits 8 Bits
Stop Bits 1 Bits
Parity Even -
Slave ID 10 -
Table 20: 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+.
Modbus Input and Output Register Maps

The input and output registers from the KMG Sine Wave filter are mapped to the Modbus Analog
Output Holding Registers starting at address 40000. See Table 27 through Table 29 for definitions of
the input register maps and Table 21 through Table 25 for output register maps. All input and output
registers are two bytes in size and formatted as 16-bit signed integers.
Table 21: Network Interface OUTPUT/ Feedback Register Map

Note: For metering data including Output Voltage, THvD, Peak Voltage to RMS voltage ratio,
Fundamental Frequency, and Carrier Frequency, if data is not available, the PQconnect will
report a value of 63353 (or 0xFFFF in hex format) to indicate no data is available. The no data
available condition is usually triggered by the filter output voltage being below the minimum
fundamental frequency tracking voltage threshold (see parameter 680.)
I/O Reg
Parameter Name Address Direction Format and Examples Description
Offset
0 = Initialization
User state parameters
9 = Save current values to flash
USER_STATE 10 Input
150 = Load values from Flash
Read only value.
255 = Restore Defaults to Flas
Software revision code for
Two 8bit ASCII Characters
processor.
DSP_SW_VER 12 Output Example:
0x0141 = ASCII for "A1"
Read only value.
System Model Number
DSP_MODEL_NUM 13 Output Sinewave Filter
Read Only Value
Filter output RMS voltage
V_LOAD_AB_RMS 50 Output Volts RMS
phases A-B
31
4800 = 480.0 VRMSLL Read only value.
Range: 120 to 690 VRMSLL Filter output RMS voltage

phases B-C
V_LOAD_BC_RMS 51 Output
65535 (0xFFFF) = data not
available Read only value.
Filter output RMS voltage
phases C-A
V_LOAD_CA_RMS 52 Output
Read only value.
Filter output voltage THD
Output phases A-B
V_LOAD_AB_THD 53
Read only value.
% THVD
50 = 5.0% THVD Filter output voltage THD
Output phases B-C
V_LOAD_BC_THD 54
Filter output voltage THD
Output phases C-A
V_LOAD_CA_THD 55
Read only value.
Filter output peak voltage to
output RMS voltage ratio A-B
V_LOAD_AB_PEAK_RMS_RATIO 60 Output phase
Read only value.

% PEAK voltage /RMS voltage Filter output peak voltage to
1414 = 141.4% output RMS voltage ratio B-C
V_LOAD_BC_PEAK_RMS_RATIO 61 Output phase
Filter output peak voltage to
output RMS voltage ratio C-A
V_LOAD_CA_PEAK_RMS_RATIO 62 Output phase
Read only value.

Range 1 to 500 Hz Filter output fundamental
Output frequency
V_OUT_FUND_HZ 100
Filter input carrier frequency.
Note: due to widely variable
modulation schemes and
controls of industry VFDs,
Range 1 kHz to 16 kHz
this value may not always be
V_IN_CARRIER_HZ 101 Output accurate. This is intended as
an information estimate of
available
VFD switching frequency
only.
Read only value.

Filter output phase
0 = undetermined
Output orientation
V_OUT_ROT 102 1 = ABC Rotation
2 = ACB Rotation
Read only value
Filter internal ambient
Output temperature
T_PCB 103 400 = 40 C°
Read only value.
32
Table 22: Network Interface OUTPUT/ Feedback Register Map
I/O Reg
Direction Format and
Parameter Name Address Description
Examples
Offset
0 = Power on Determines if the PCB
Output unsuccessful was powered on
SYS_POWER_ON 201
1 = Power on
successful Read only value.
0 = Calibration in Determines the PCB’s
Output progress initial state of calibration.
SYS_INIT_COMPLETE 202
1 = Calibration
complete Read only value.
Filter warning
This value is a bit mask

0 = No warning where individual bits are
Output set to indicate a
CAP_DEGREDATION_WARNING 205
Non zero value = detection is active. For a
warning description of bit
positions see Table 15
Read only value.

Relay output 1 and 2
status bit mask
This value is a bit mask
where individual bits are
0 = Detection clear
Output set to indicate a
DETECTION_STATUS 210 Non zero value =
detection is active. For a
Detection active
description of bit
Read only value.

Output relay 1 status
detection enable
For each bit This value is a bit mask

position: where individual bits are
Output 0 = Detection set/cleared to
OUTPUT_RELAY_1_ENABLE_RO 230
disabled enable/disable a specific
1 = Detection status detection. For a
enabled description of bit
Read only value.

Output relay 2 status
detection enable
For each bit This value is a bit mask

position: where individual bits are
Output 0 = Detection set/cleared to
OUTPUT_RELAY_2_ENABLE_RO 240
disabled enable/disable a specific
1 = Detection status detection. For a
enabled description of bit
Read only value.

0 = Data capture
Capture waveform data
Output complete
TRACE_GO_DONE_RO 251
1 = Data capture
Read only value
in progress
Different access levels
0 = User access
PARAM_ACCESS_LEVEL_RO 254 Output available
1 = Tech access
33
2 = Factory Read only value.
access
0-11, 13-17 =
Indicates the present
parameter load,
state of the parameter
save, restore,
PARAM_STATE 255 Output state machine.
reboot in progress.
12 = parameter
Read only value.
load complete
0 = Initial state
1 = Parameter
load
Determines the current
2 = Calibration in
state of the PQconnect
SYS_STATE 256 Output Progress
3 = Calibration
Read only value.
check
4 = Run
Detections
4800 = 480.0Vrms Filter rated voltage

RATED_VOLTAGE_RO 260 Output Range = 1200 to
6900 Read only value.
Modbus slave address
Read only value. To

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

Modbus baud rate
960 = 9600 baud
rate Read only value. To
3840 = 38400 change this value,
MB_BAUD_RATE_RO 301 Output baud rate modify the corresponding
(DEFAULT) register in the setpoint
11520 = 115200 section below.
baud rate
Read only value.
34
Table 23: 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.
Relay input status.
1 = Thermal
RELAY_INPUT_STATUS 320 Output
switch opened
Read only value.
0 = Disabled
Input relay 1 configuration. View PCB
1 = Thermal
header J7
RELAY_INPUT_1_CONFIG_RO 321 Output Switch
(DEFAULT)
Read only value.
0 = Disabled Input relay 2 configuration. View PCB

(DEFAULT) header J8
RELAY_INPUT_2_CONFIG_RO 322 Output
1 = Thermal
Switch Read only value.
Parameter
contains UUUU
Unit serial number upper 16-bit value
in the
SYS_SERIAL_NUM_2_RO 350 Output
UUUULLLL-NN
Read only value.
serial number
format.
Parameter
contains LLLL
Unit serial number lower 16-bit value
in the
UUUULLLL-NN
Read only value.
serial number
format.
Parameter
contains NN in Unit serial number section - two-digit
the unit number.
UUUULLLL-
NN serial Read only value.
number format.
0 = Calibration
System calibration status
not active
SYS_NULL_STAT 400 Output
1 = Calibration
Read only value.
in progress
Calibration remaining time measured
Range 0 to in seconds
SYS_NULL_TMR 401 Output
3600 seconds
Read only value.
35
Table 24: Fault Codes
Bit Position Fault Descriptions

16 bit register with bit position 0 to 15
0 Overvoltage Phase A
1
Overvoltage Phase B
2
Overvoltage Phase C
3 High THVD Phase A
4 High THVD Phase B
5 High THVD Phase C
6 Reactor Thermal Switch 1
7 Reactor Thermal Switch 2
8 PCB Under Temperature
9 PCB Over Temperature
10 Phase Loss (Phase A)
11 Phase Loss (Phase B)
12 Phase Loss (Phase C)
13 Unused
14 Unused
15 CPU Error
36
Table 25: Network Interface INPUT/Setpoint Register Map
I/O Reg
Format and
Examples
Offset
0 = Initialization
9 = Save current
Note that defaulting the flash
values to flash
will clear all calibration data
USER_STATE_REQ 500 Input 150 = Load values
and require that the calibration
from Flash
procedure be re-run..
255 = Restore
Defaults to Flash
Input 0 = Capture Done Update trace data points for

TRACE_GO_DONE 501
1 = Start Capture waveforms
PARAM_KEY_A 502 Input Enter Key A

Read/write parameters under
Input Tech Access
PARAM_KEY_B 503 Enter Key B
Output Relay
Minimum status
detection active time Minimum time output relay will
RELAY_MIN_ON_TIME 505 Input in seconds indicate an active status
Range 1 to 3600 detection.
seconds. Default 10
seconds
Waveform time base
resolution range hysteresis.
Fundamental period The higher the number the
TRACE_RESOLUTION_RANGE_HY Input
508 steps of 30uS, Range less the waveform will adjust
ST
0 to 500, Default 5. its time scale based on the
fundamental frequency of the
filter output.
4800 = 480 Vrms
Input Filter rated voltage in Volts
RATED_VOLTAGE 521 Range = 120 to 690
RMS Line to Line
Vrms, Default of 4800
For each bit position:
0 = Detection
disabled This value is a bit mask where
1 = Detection enabled individual bits are set to
Default = 32888 ( indicate a detection is active.
High THVD Phase A, For a description of bit
B, C, Thermal SW1, positions see Table 15
Input and CPU error
OUTPUT_RELAY_1_ENABLE 540
enabled). Example: Enabling all fault
conditions is 1111 1111 1111
To Enable desired 1111 in binary or 65535
fault detections, enter decimal. *
bit mask from table by
converting to decimal Reference Fault codes
Range: 0 to 65535
For each bit position:

This value is a bit mask where
0 = Detection
individual bits are set to
disabled
indicate a detection is active.
1 = Detection enabled
For a description of bit
Default = 64 (Theral
OUTPUT_RELAY_2_ENABLE 550 Input SW1 enabled)
Example: Enabling all fault
conditions is 1111 1111 1111
To Enable desired
1111 in binary or 65535
fault detections, enter
decimal. *
bit mask from table by
converting to decimal
Reference status conditions
Range: 0 to 65535
37
Input DEAFAULT = 10 Modbus RTU Device Slave

MB_SLAVE_ADDRESS 600
Range 0 to 255 Address *
11520 = 115200 baud
rate
Input Modbus RTU Device Baud
MB_BAUD_RATE 601 DEFAULT: 3840 =
Rate*
38400 baud rate
960 = 9600 baud rate
0 = None
MB_PARITY 602 Input 1 = Odd Modbus Parity*
2 = Even (DEFAULT)
Table 26: Network Interface INPUT Register Map

I/O Reg
Format and
Examples
Offset
0 = Disabled
RELAY_INPUT_1_CONFIG Input Input relay configuration
610 DEFAULT: 1 =
reference J7 header*
Thermal Switch
DEFAULT: 0 =
RELAY_INPUT_2_CONFIG Input Input relay configuration
611 Disabled
reference J8 header*
1 = Thermal Switch
Set desired filter output
STATUS_OVERVOLTAGE_ONSET Input DEFAULT: =130%
620 voltage peak overvoltage
Range 100 to 500
onset threshold*
Set desired filter output
STATUS_OVERVOLTAGE_CLEAR Input DEFAULT: = 125%
621 voltage peak overvoltage
Range 100 to 500
clear threshold*
Status detection delay time
DEFAULT: = 6 in seconds.
STATUS_OVERVOLTAGE_DELAY Input seconds.
622
Range 1 to 3600 Set desired filter output
seconds voltage high THD delay
threshold*
DEFAULT: = 16 = Set desired filter output
STATUS_HIGH_THD_ONSET 630 Input 16% voltage high THD onset
Range 1 to 100 threshold*
DEFAULT: = 15 = Set desired filter output
STATUS_ HIGH_THD_CLEAR 631 Input 15% voltage peak overvoltage
Range 1 to 100 clear threshold*
DEFAULT: = 6 in seconds.
Input seconds.
STATUS_ HIGH_THD_DELAY 632
Range 1 to 3600 Set desired filter output
seconds voltage peak overvoltage
delay threshold*
DEFAULT: = 6
in seconds.
STATUS_REACTOR_SWITCH_DELA Input seconds.
635
Y Range 1 to 3600
Reactor thermal switch time
seconds
delay*
Status detection measure in
DEFAULT: = -400 = - degrees Celsius
STATUS_T_AMBIENT_UT_ONSET 640 Input 40C
Range -50C to 0C PCB under temperature
onset threshold*
Input DEFAULT: = -350 = - Status detection measure in

STATUS_T_AMBIENT_UT_CLEAR 641
35C degrees Celsius
38
Range -50C to 0C
PCB under temperature
clear threshold*
DEFAULT: = 6
in seconds.
Input seconds.
STATUS_T_AMBIENT_UT_DELAY 642
Range 1 to 3600
PCB under temperature
seconds
delay threshold*
Status detection measure in
DEFAULT: = 750 = degrees Celsius.
STATUS_T_AMBIENT_OT_ONSET 645 Input 75C
Range 10C to 85C PCB over temperature
onset threshold*
DEFAULT: = 700 =
Input PCB over temperature clear
STATUS_T_AMBIENT_OT_CLEAR 646 70C
threshold*
Range 10C to 80C
DEFAULT: = 6
in seconds.
Input seconds.
STATUS_T_AMBIENT_OT_DELAY 647
Range 1 to 3600
PCB over temperature
seconds
delay threshold*
DEFAULT: = 60 = 60
Input Filter output voltage phase
STATUS_PHASE_LOSS_ONSET 650 %
loss onset threshold*
Range 1 to 100
DEFAULT: = 65 =
Input Filter output voltage phase
STATUS_PHASE_LOSS_CLEAR 651 65%
loss clear threshold*
Range 1 to 100
DEFAULT: = 6
in seconds.
Input seconds.
STATUS_PHASE_LOSS_DELAY 652
Range 1 to 3600
Filter output voltage phase
seconds
loss delay threshold*
DEFAULT: = 6
in seconds.
Input seconds.
STATUS_CPU_ERROR_DELAY 655
Range 1 to 3600
PCB processor CPU error
seconds
delay*
DEFAULT: = 12 = 12
STATUS_HIGH_THD_WARNING_ON Input Filter output voltage high
660 %
SET THD onset threshold*
Range 1 to 100
DEFAULT: = 11 =
STATUS_HIGH_THD_WARNING_CL Input Filter output voltage high
661 11%
EAR THD clear threshold*
Range 1 to 100
Status detection delay
time in seconds.
STATUS_HIGH_THD_WARNING_DE Input DEFAULT: = 6 Filter output voltage high
662
LAY seconds. THD delay threshold*
Range 1 to 3600
seconds
DEFAULT: = 5 = 5%
STATUS_MIN_DETECTION_VOLTA Input Minimum voltage to enable
670 of rated voltage
GE status detection*
Range 1 to 100
Minimum voltage to enable
output voltage tracking. If
the filter output voltage is
DEAULT: = 5 = 5% of
Input below this threshold the
FUND_MIN_TRACKING_VOLTAGE 680 rated voltage
waveform data will be
Range 1 to 100
zeroed out and the
metering data will report a
value 65535 (or 0xFFFF
39
hex) to indicate data not
available.*
Fundamental frequency
tracking mode. This
DEFAULT: = 0
parameter determines if the
Range 0 to 4
fundamental frequency
0=AC Coupling
tracking algorithm uses an
Input 1=DC and AC
FUND_TRACKING_MODE 681 AC coupled signal (dynamic
Coupling
DC nulling), a DC reference
2=DC Coupling
signal, a combination of
3=Fund Freq Tracking
both (DC first then AC) or
Disabled.
does not track fundamental
frequency
Fundamental frequency
filter gain. This parameter
DEFAULT: = 13 sets how heavily the
Input (~4Hz reference fundamental frequency
FUND_TRACKING_FILTER_GAIN 682
voltage filtering) reference voltage is filtered.
Range 1 to 16 A higher value is more
filtering (lower frequency
reference filter).
DEFAULT: = 9639
Input Adjusts filter output voltage
V_OUT_SCALAR_A 703 Range -32768 to
scaling fir phase A-B*
32767
DEFAULT: = 9639
V_OUT_SCALAR_B 704 Range -32768 to
scaling fir phase B-C*
32767
DEFAULT: = 9639
V_OUT_SCALAR_C 705 Range -32768 to
scaling fir phase A-C*
32767
Input DEFAULT: = 2048 Adjusts filter output voltage
V_OUT_A_OFFSET 708
Range 0 to 4096 offset for phase A-B*

V_OUT_B_OFFSET 709
Range 0 to 4096 offset for phase B-C*

V_OUT_C_OFFSET 710
Range 0 to 4096 offset for phase A-C*
DEFAULT: = 12000
T_PCB_SCALAR 741 Input Range -32768 to PCB temperature scalar*
32767
Input DEFAULT: = 683
T_PCB_OFFSET 745 PCB temperature offset*
Range -8192 to 8192
DEFAULT: = 437
Input Filter output RMS voltage
V_LOAD_RMS_SCALAR 751 Range -32768 to
scalar*
32767
DEFAULT: = 16384
Input Filter output voltage THD
V_THD_SCALAR 802 Range -32768 to
scalar*
32767
DEFAULT: = 0
Input Filter output voltage THD
V_THD_OFFSET 804 Range -32768 to
offset*
32767
40
Table 27: Network Interface INPUT Register Map
System auto null calibration
Input 0 = Disabled enable. This value auto
SYS_NULL_EN 700
1 = Enabled clears to 0 when calibration
complete.
Unit serial number section -
Input 1301 = Sinewave
SYS_SERIAL_NUM_2 810 upper 16 bits of 32-bit unit
Filter
job number
Parameter contains
Unit serial number section -
Input LLLL in the
SYS_SERIAL_NUM_1 811 lower 16 bits of 32-bit unit
UUUULLLL-NN serial
job number
number format.
Parameter contains
Input NN in the UUUULLLL- Unit serial number section -
SYS_SERIAL_NUM_0 812
NN serial number two-digit unit number
format.
Waveform Data
The waveform data displayed by the PQconnect is available in the Modbus Read Analog Input
Register data space (function code 4) in the following addresses:
Table 28: Waveform Data

Waveform Phase Waveform Start Address Waveform Length
Phase A 0 512
Phase B 512 512
Phase C 1024 512
The waveform data is scaled in units of tenths of Volts. For example 6787 would equal 678.7
Volts.
Status Detection History Data

The Status Detection History data displayed by the PQconnect is available in the Modbus Read
Analog Input Register data space (function code 4) at the following addresses:
Table 29: Status Detection History Data

Waveform Phase History Record Start Address History Record Length
History Record 0 1536 16
… … …
The history record is circular buffer of 100 records from index 0 to 99. When the history buffer fills
up the oldest record is overwritten. The newest entry in the history record is at index 0 and the
oldest entry is at index 99.
A history record is logged each time the status detection parameter 210 value changes. Each
history record is a collection of 16 bytes with the following format:
Table 30: History Records

Byte Value Format
0 Timestamp Seconds (4 bytes) Seconds value of timestamp.
1 Timstamp seconds:milliseconds
2 value is the time since power on
3 of the event.
41
4 Timestamp Power Cycle Count Range 0 to 255. Indicates the
number times the PQconnect
has been reset / power cycled.
5 Timestamp Milliseconds Millisecond value of timestamp in
units of 10s of milliseconds.
6 Detection Status For format see Parameter 210
7 Detection Status
8 Filter Output THVD Phase A Filter Output Voltage THD at the
9 Filter Output THVD Phase B time of the event in units of
10 Filter Output THVD Phase C percent THD (100 = 100%)
11 Filter Output Average RMS Filter output average RMS
Voltage voltage in units of percent rated
voltage (100=100% or nominal
voltage).
12 Filter Output Voltage Fundamental Frequency divided
Fundamental by 2 in Hz. For example a value
of 30 would equate to 30 x 2 =
60Hz Fundamental Frequency.
The factor of two is used to
compress the 0 to 500Hz
fundamental frequency value to
fit in an 8 bit value.
13 Estimated Carrier Frequency VFD Carrier frequency in units of
100Hz. For example a value of
20 would equate to a carrier
frequency of 20x100 = 2000Hz.
The factor 100 is used to
compress the data to fit in an 8 bit
value.
14 16 Bit, Two’s Compliment History Record Checksum.
15 Checksum When this 16 bit value is added
together with the reset of the
history records as 16 bit values
the result should be zero if no
data errors exist in the packet.
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 “B&B SmartWorx, Inc
Model: USPTL4” RS-485 to USB converter. As another alternative RS-485 converter there is
WINGONEER USB 2.0 to RS485 Serial Converter Adapter CP2104.
Figure 12: B&B SmartWorx, Inc Model: USPTL4 model RS-422/485 converter
42
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 31: USPTL4 to J5 Header Connections

J5 Header B&B Converter
Signal Name Signal Type
Pinout USPTL4Pin Out
1 - No connect -
2 TDB(+) D+ RS-485 B (non-inverting)
3 GND GND RS-485 SC/G
4 TDA(-) D- RS-485 A (inverting)
5 - No connect -
USPTL4 RS485 Converter Dip Switch settings

All four switches of the B&B converter from the factory should be set to the ON position and should
look like the following.
Figure 13: Dip Switch settings
Example Setup Instructions to Read Data from the PQconnect Unit:

• Connect the cable to the communication header on the side of the board
• Connect USB end to the computer
o Determine the assigned COM port number for the RS-485 to USB converter
using the computer device manager control panel.
o The converter used in this example typically enumerates between the range
of COM5 to COM20 on a standard laptop computer running the Microsoft
windows operating system
• Open the Simply Modbus Master software
o Can be downloaded from the link below:
o http://www.simplymodbus.ca/manual.htm
o The trial version of the software is free and fully functional for this task hence
no License key is necessary
• Next, configure the fields in the screen as shown below. These are again the default
settings of the PQconnect COM port.
o Note: The “notes” section of the display data registers are filled in manually
43
Example Setup Instructions to Write Data to the PQconnect Unit:
• To change the voltage rating of the unit, first gain tech access by writing the
parameter keys.
• Select the “WRITE” button on the screen shown above.
• The screen below will be shown. Configure the fields as shown in the picture.
o Select 4800 in the field “Values to Write” to change the voltage rating of
the unit to 480 Vrms.
44
PCB Connections
Most customer connections to PQconnect will be made on the PCB. Refer to connection diagram
below and to drawing 24281-1PQ for the wiring schematic. The details of the power and
communications terminals are shown in the table below. Form C relays are available on the PCB,
these connections are shown in Table 32. Two relay outputs are available on the PCB.
Figure 14: PQconnect Connections
Table 32: Form C Relay Contacts

Terminal Pin Description Label Tightening Torque Wire Range
Reactor
J7 1, 2 Thermal Customer contacts 3.5 lb-in (0.4 Nm) 28-12 AWG
Switch
Optional Customer contacts 3.5 lb-in (0.4 Nm) 28-12 AWG
Reactor
J8 1, 2
Thermal
Switch
1 Normally Closed
J11 2 Output Relay 1 Common 4.4 lb-in (0.5 Nm) 28-14 AWG
3 Normally Open
1 Normally Closed
J10 2 Output Relay 2 Common 4.4 lb-in (0.5 Nm) 28-14 AWG
3 Normally Open
Note: Form-C relay contacts are gold plated with a load rating of 5.0A @ 120VAC
45
Table 33: Power & Communication Terminals
Terminal Pin Description Label Rating
1 Phase A
Tuning Reactor Output
J1 2 Phase B
Connections
3 Phase C 600VAC
1 Phase A (Output of Tuning reactor)
Tuning Reactor
J2 2 Phase B (Input of Tuning Reactor)
Connections
3 Not connected
J3 1,2,3 Not Connected
N/A
J4 1-8 Not Connected N/A
1 Not Connected
2 B (non-inverting)
J5 3 RS485 Ground N/A
4 A (inverting)
5 Not connected
1 Input Power from control Neutral
J12 120 VAC
2 power transformer Line
J14 1-14 Micro Programming For factory use N/A
Note: The power terminals on the PQconnect accepts 28 to 14 AWG stranded wire, with a
tightening torque of 4.4 in-lb (0.5 Nm).
Note: The PQconnect board needs to be earth grounded via the plated metal mounting hole on
the corner of the board near J16. The board mounting standoff used on this mounting hole must
be metal and connected to unit chassis earth ground. The PQconnect board must be grounded
via the ground stud whenever the KMG filter with PQconnect is energized.
Troubleshooting
Only qualified electricians should carry out all electrical installation & maintenance work
on the Sine wave filter.
Disconnect all sources of power to the KMG and connected equipment before working
on the equipment. Do not attempt any work on a powered KMG.
Warning The KMG unit contains high voltage and capacitors. Wait at least five minutes after
disconnecting power from the filter before attempting to service the conditioner. Check
for zero voltage between all terminals on the capacitors. Also, check for zero voltage
between all phases of the input and output lines. All maintenance and troubleshooting
must be done by a qualified electrician. Failure to follow standard safety procedures
may result in death or serious injury. Unless an external disconnect means has
been provided everything ahead of the filter circuit breaker, including the
reactors, will still be energized.
Receiving Inspection
The connectivity board has been thoroughly inspected and functionally tested at the factory and
carefully packaged for shipment. After receiving the unit, immediately inspect the shipping
container and report any damage to the carrier that delivered the unit. Verify that the part number
of the unit received is the same as the part number listed on the purchase order.
46
Connectivity Board Problem
The KMG is comprised of three major components; the PQconnect connectivity board, the tuning
reactor, and the capacitors. The PQconnect PCB contains diagnostic LEDs. The locations of the
LEDs are shown Figure 14 and their functions are listed in Table 34.
Figure 15: PQconnect LED Placements
Table 34: LED Functions

LED LED Color Description
D1 Green Output Relay 1
D2 Green Output Relay 2
D5 Green Detection Status LED
D6 Green Microprocessor Status LED
D11 Green RS485 Communication is active
D20 Green 24V LED
D21 Green 5V LED
Note: Status LED’s will blink according to the filter status. The microprocessor status LED will
blink 1hz if the filter is okay, however if there has been an alert the LED will blink according to the
status detection. It will initially start with slow blinks (3 = Filter Status Detections), then blink fast
depending on the fault. The table below summarizes the LED blinks based on the fault condition.
Table 35: D6 LED Codes Microprocessor Status LED)

Status LED Specifier
No fault detected/ enabled LED Blinking at 1Hz
PCB Not Calibrated LED Solid On
Status Detection Active LED Solid Off
47
Table 36: D6 LED Codes (Detection Status LED)

LED Specifier
Detection (On/Off or Slow - Fast
Blink Sequence)
No fault detected/ enabled LED Solid Off
PCB Not Calibrated LED Solid On
Overvoltage Phase A 3–1
Overvoltage Phase B 3–2
Overvoltage Phase C 3–3
High THVD Phase A 3–4
High THVD Phase B 3-5
High THVD Phase C 3-6
Thermal Switch 1 3-7
Thermal Switch 2 3-8
PCB Under Temperature 3-9
PCB Over Temperature 3 - 10
Phase Loss A 3 - 11
Phase Loss B 3 – 12
Phase Loss C 3 – 13
CPU Error 3 – 16
Communication Problems
• J5 Communication Header
o With the power de-energized from the filter, check wiring leading to J5 header
 If the user is using a different RS485 converter than the example above, please follow
the datasheet for the A & B signals and ground for proper setup
• Ensure the drivers of the RS485 to USB converter is installed to the computer. Simple way
of checking while the RS485 converter connected is to go to the device manager and scroll
down to ports. There will be a device connected to the ports. If your device is not listed, the
user will need to install the correct drivers of the RS485 converter.
48
Figure 16: RS-485 Port In Device Manager
• PQvision App Load Defaults

o With the RS485 Converter connected to the circuit board
o Energize Filter
o Open PQvision desktop interface
o Go to Settings
o Select Load Defaults
o Select Apply
o Default Modbus settings should be applied. Try
connecting to the COM port
 If this doesn’t work de-energize power to the filter
and try flipping the A and B signal wires leading to
the J5 header of the circuit board.
• Hard Reset Modbus settings (Worst Case)
o To perform a hard reset of Modbus settings the user will need to remove jumper J20 with
the power de-energized from the filter. Once the jumper is removed connect the RS485
converter to J5 header and energize filter.
o Open PQvision
o Confirm there is a COM port under Communication and try to connect
 Note if connecting to the COM port does not work, try flipping the A and B signal
wires leading to the J5 header of the circuit board
o Load defaults and apply
o Save settings and de-energize filter
o Connect jumper to J20
o Energize filter
o Try connecting to PCB
 All Modbus settings should be set to default settings at this point
 If the board doesn’t connect after trying hard reset contact TCI Tech-Support
PCB Calibration Process

If the user needs to calibrate the PCB than they will need to follow the steps below. Note: an
RS485 to USB converter, a windows computer, and PQvision will be needed for the
calibration. Before energizing the filter, the user should connect the RS485 to USB converter
to the PCB.
49
Power will need to be energized to the PCB for the calibration process.
• Step 1. Energize unit

• Step 2: Open PQvision desktop application
• Step 3: Connect to the device by selecting the appropriate “COM port”
• Step 4. Go to “Menu” and select “Tech access”
Figure 17: PQvision Main Menu
• Step 5: Go to “Menu” and select “Calibrate”
Figure 18: Calibration Screen
• Step 6: Select “Default Non-Cal Parameters”

• Step 7: Select “Start Calibration”
o Note: Calibration will take about 1-2 minutes
• Step 8: After the calibration is complete, select “Save Parameters”
Debug Status Conditions

Based on the fault condition there are various ways a fault can appear. Before investigating the
sine wave filter internally, disengage supply voltage to the filter.
50
Debug Fault conditions
Based on the fault condition there are various ways a fault can appear. Before investigating the
sine wave filter internally, disengage supply voltage to the filter.
Table 37: Fault conditions

Fault Condition Description Debug
Filter has detected
Overvoltage
overvoltage on a Check input power connections to the filter.
Phase A, B, or C
phase(s)
Check fused disconnect or circuit breaker
Phase Loss
Filter phase loss upstream of the filter.
Phase A, B, or C
Check input power connections to the filter
Check fuses leading to filter capacitors
If fuses are not blown, measure Capacitance of
High THVD High voltage Total
the capacitors
Phase A, B, or C Harmonic Distortion
Check power connections of the unit, reference
drawing 24281-1PQ
Filter ambient
PCB Under temperature is Check fuses of control power transformers
Temperature operating below leading to the heater.
threshold
Filter ambient
Check fuses of control power transformers
PCB Over temperature is
leading to fans.
Temperature operating above
Make sure fans are operating
threshold
Processor Power cycle unit and if issue persists contact
CPU Error
malfunction tech support
Check thermal switch connections to PCB;
Reactor Thermal
Reactor Switch Reactor switch is a normally closed switch that
Switch open
opens if reactor overheats.
51
KMG IOM 6.0 Maintenance and Service
6.0 Maintenance and Service

Evaluating MotorGuard Performance
The MotorGuard performance can be evaluated by checking the output voltage waveform with
an oscilloscope.
Warning Only qualified electricians should carry out all electrical installation and maintenance
work on the MotorGuard.
Exercise caution when checking waveforms with an oscilloscope.
Use a dual probe, differential input set-up, or other means of isolating the scope
chassis from the motor voltage.
Disconnect power when attaching and removing the probes.
MotorGuard Reliability and Service Life

The MotorGuard has been designed to provide a service life that equals or exceeds the life of the
variable frequency drive. It has been thoroughly tested at the factory to ensure that it will perform
reliably from the moment it is put into service. The following periodic maintenance is
recommended to ensure that the MotorGuard will always perform reliably and provide the
expected service life.
Periodic Maintenance
Warning Only qualified electricians should carry out all electrical installation and maintenance
work on the MotorGuard.
Disconnect all sources of power to the VFD and MotorGuard before working on the
equipment. Do not attempt any work on a powered MotorGuard.
Check to see that the installation environment remains free from exposure to excessive dirt and
contaminants. Refer to the Pre-installation Planning section of this manual.
Check to make sure that the enclosure ventilation openings are clean and unobstructed.
Clean the air filter in units that have filtered air inlets. Clean as often as necessary to prevent dirt
build-up from impeding air flow.
Inspect the interior of the enclosure for signs of overheated components. Clean the interior of the
enclosure whenever excess dirt has accumulated.
Check the integrity of all power, ground, and control wiring connections.
All electrical connections must be re-torqued annually.
Replacement Parts
If replacement parts are needed, please contact your TCI representative. To ensure that the
MotorGuard continues to perform to its original specifications, replacement parts should conform
to TCI specifications.
Factory Contacts and Tech Support

For technical support, contact your local TCI distributor or sales representative.
You can contact TCI directly at 800-824-8282. Select "Customer Service" or "Technical Support"
and have your MotorGuard nameplate information available.
52
TCI, LLC
W132 N10611 Grant Drive
Germantown, Wisconsin 53022
Phone: 414-357-4480
Fax: 414-357-4484
Helpline: 800-824-8282
Web Site: www.transcoil.com
© 2020 TCI, LLC All rights reserved
Product No: 24362
Effective: 06-01-2021 Version: 1.3

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KMG® MotorGuard High Performance Output

Sine Wave Filter Installation, Operation, and Maintenance

Including information for:

1.0 Safety ................................................................................................................... 1

2.0 General Information ............................................................................................ 3

3.0 Installation Guidelines ...................................................................................... 16

4.0 Operation ........................................................................................................... 24

5.0 PQconnect ......................................................................................................... 25

6.0 Maintenance and Service ................................................................................. 52

Warnings and Cautions

Warning Dangerous Voltage Warning: warns of situations in which

! malfunction and possible equipment damage. The text

Warning The MotorGuard receives power from two or more sources.

2.0 General Information

TCI Limited Warranty Policy

Product Family Warranty Period

This warranty shall not apply if the product was:

The MotorGuard consists of the following standard features and components:

• An R-L-C power filter circuit with:

• Part number: encoded model number explained on the following page

Figure 1: Example of MotorGuard Nameplate

Figure 2: MotorGuard Model Number Encoding – Industrial Version

Figure 3: MotorGuard Model Number Encoding – General Purpose Version (Legacy

Standard Product Ratings and Dimension Tables

Table 1: Industrial 480 Volt Models on Open Panels

Table 6: General Purpose 480 Volt Models in NEMA 3R Enclosures

Table 8: General Purpose 600 Volt Models in NEMA 3R Enclosures

Table 9: MotorGuard Technical Specifications – Industrial

Agency Approvals or UL and cUL Listed to UL508A and CSA-C22.2 No. 14

Insertion Impedance Approximately 6.5% at 60 Hz & full load current

Table 10: MotorGuard Technical Specifications – General Purpose

3.0 Installation Guidelines

Select a Suitable Location

• Corrosive liquids or gasses

Control Wiring Considerations

Lifting eye is optional

Figure 4: Cable Entry Location for General Purpose units

Field Wiring Connection Terminals

Ground Lug Input and Output

Ground Lug Input and Output

Ext Fault TS1 TS2 L1 L2

Ext Fault NC COM NO NC COM NO

Figure 5: Typical Connection Diagram

Figure 6: Terminal Block

MotorGuard Power Circuit MotorGuard Power Circuit

Control Circuit Fuses

Variable Frequency Drive Settings

• Maximum output frequency: 80 Hz

! for the first time.

Before Operating the VFD for the First Time

Figure 7: PQconnect Modbus RTU Connection

Enter password 08252014 to enable tech access.

PQvision PC Home Screen Elements

Figure 8: PQvision Desktop Application

Table 14: PQvision PC Navigation

PQvision PC Settings Screen Elements

Figure 9: PQvision Settings Menu

“Run” – PCB is calibrated and ready

After selecting desired relay outputs select save settings.