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Schaffner ECOsine FN3416 User Manual

Passive harmonic filters economy line
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Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland
T +41 32 681 66 26 F +41 32 681 66 30 www.schaffner.com
energy efficiency and reliability
User Manual
ECOsine™ – Passive Harmonic Filters
FN3416 (50Hz) & FN3418 (60Hz) Economy Line
September 2012
1/43

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  • Page 1 Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland T +41 32 681 66 26 F +41 32 681 66 30 www.schaffner.com energy efficiency and reliability User Manual ECOsine™ – Passive Harmonic Filters FN3416 (50Hz) & FN3418 (60Hz) Economy Line September 2012...
  • Page 2 For additional helpful tips for overcoming harmonics mitigation challenges, please also consult the more detailed user manual of the ECOsine™ FN3410 (50Hz) and FN3412 (60Hz) full performance filters. If you require additional support, please feel free to contact your local Schaffner partner.
  • Page 3 AC or DC motor drives and high power DC supplies. Filter suitability for a given application must be determined by the user on a case by case basis. Schaffner will not assume liability for any consequential downtimes or damages resulting from use or application of ECOsine™ filters outside of their specifications.
  • Page 4 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 4/43 Content 1. Part number coding ..........................5 2. Filter description ........................... 6 2.1 General electrical specifications FN 3416 (50Hz filters) ..............6 2.2 General electrical specifications FN 3418 (60Hz filters) ..............7 2.3 Additional electrical specifications .....................
  • Page 5 Blank = standard voltage rating Filter family 3416 = filter for 50Hz, 380-500V grids 3418 = filter for 60Hz, 380-480V grids Schaffner standard filter Examples: FN 3416-60-34: Filter for 50Hz, 380-500V grids, 60A drive input current, with 25mm terminals, for diode or SCR (thyristor) rectifier front-end.

  • Page 6: Filter Description

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 6/43 2. Filter description 2.1 General electrical specifications FN 3416 (50Hz filters) Nominal operating voltage: 3x 380 to 500VAC Voltage tolerance range: 3x 342 to 550VAC Operating frequency: 50Hz ±1Hz...

  • Page 7: General Electrical Specifications Fn 3418 (60Hz Filters)

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 7/43 2.2 General electrical specifications FN 3418 (60Hz filters) Nominal operating voltage: 3x 380 to 480VAC Voltage tolerance range: 3x 342 to 528VAC Operating frequency: 60Hz ±1Hz...

  • Page 8: Additional Electrical Specifications

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 8/43 2.3 Additional electrical specifications ECOsine™ passive general electrical specifications refer to operating altitudes up to 1000m a.s.l. (3300ft). Operation between 1000m and 4000m (3300ft and 13123ft) requires a derating according to the...

  • Page 9: Mechanical Specifications

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 9/43 2.4 Mechanical specifications...
  • Page 10 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 10/43...

  • Page 11: Performance Characteristics

    Note: the values of EMI-filter components present in the same non-linear load (e.g. motor drive) can influence the mitigation performance of passive harmonic filters. For Schaffner FN3418 (60Hz) filters the following boundary conditions exist for the smallest frame sizes:...
  • Page 12 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 12/43 Power factor vs. load (diode rectifier front-ends) Note: in SCR rectifier applications, filter characteristics greatly depend upon the firing angle of the thyristors.
  • Page 13 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 13/43 Drive dc-link voltage vs. load (diode rectifier front-ends) Note: in SCR rectifier applications, filter characteristics greatly depend upon the firing angle of the thyristors.

  • Page 14: Function Diagram

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 14/43 2.6 Function diagram Power capacitors Trap choke Line Load In-Out choke Power supply Filter terminals Line 3 touch safe terminal blocks (busbar terminals >240A) Load 3 touch safe terminal blocks (busbar terminals >240A) Over-temperature NC switch, 250VAC/2.5A, touch safe terminal 4mm...
  • Page 15 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 15/43 2.7 External filter elements Line terminals (3) Over temperature contact (2) Load terminals (3) PE terminals (2) Fan(s) Line terminals (3) Over temperature contact (2) Load terminals (3)

  • Page 16: Audible Noise

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 16/43 2.8 Audible noise Tests have been performed at nominal filter load. Ambient noise level: 49dB[A] Filter FN 3416-13-44 (P=5.5kW) 60dB[A] @ 1m FN 3416-210-40 (P=110kW) 70dB[A] @ 1m...

  • Page 17: Filter Purpose And Function

    In existing installations, more drives can be used on the same distribution transformer. The examples on the next pages visualize typical performance test results with and without a Schaffner ECOsine™ harmonic filter FN 3416-210-40 for the rated load power of 110kW.
  • Page 18 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 18/43 Example 1: motor drive without built-in DC-link choke Without ECOsine™ filter With ECOsine™ filter Voltage and current waveforms Voltage and current waveforms Current harmonics THD = 76.9% Current harmonics THD = 11.6%...
  • Page 19 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 19/43 Example 2: motor drive with built-in DC-link choke Without ECOsine™ filter With ECOsine™ filter Voltage and current waveforms Voltage and current waveforms Current harmonics THD = 45.1% Current Harmonics THD = 7.9%...

  • Page 20: Filter Selection

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 20/43 4. Filter selection ECOsine™ harmonic filters need to be carefully selected in order to enjoy maximum benefits. Step 1: supply frequency Determine, whether the system in question will be operated in a 50Hz or 60Hz electricity grid, and select...
  • Page 21 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 21/43 Please refer to the following examples: Example 1: Power line rating: 400V, 50Hz Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A, diode rectifier Planned rectifier/drive input real power: 15kW (100% of drive rating) ...
  • Page 22 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 22/43 Filter selection table FN 3416 (50Hz) Filter selection table FN 3418 (60Hz)

  • Page 23: Filter Application

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 23/43 5. Filter application ECOsine™ filters are designed as “load-applied” filters. In contrary to “bus-applied” filters, which are being installed e.g. at the main power bus of a building, they are specifically designed to be used with either an individual non-linear load, or with a group of non-linear loads.

  • Page 24: Filter Installation

    In the case of damage, please file a claim with the freight carrier involved immediately and contact your local Schaffner partner for support. Under no circumstances install and energize a filter with visible transportation damage. If the filter is not going to be put in service upon receipt, store within the original container in a clean, dry location, free of dust and chemicals.
  • Page 25 Note: the numbers (e.g. -10) are in reference to the middle part of the ECOsine part number coding (e.g. FN 3416-10-44) Bolt selection: Schaffner recommends zinc coated hex ribbed flange steel bolts. Respect filter weight for appropriate choice of bolts! Head diameters must not exceed these dimensions: M8: d ≤...
  • Page 26 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 26/43 Step 3: Wiring Verify safe disconnection of all line side power. Consult your local safety instructions. Safety cover for filters with bus-bar terminals. The filters with bus-bar terminals (FN 3416-260/320-99, FN 3418-240/310-99) are equipped with a terminal cover for safety reasons.
  • Page 27 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 27/43 Connect over-temperature contact The over-temperature contact is a relay contact, which AN ENGAGED OVER- is open in ALARM state. Its load rating is TEMPERATURE CONTACT MUST 250VAC/30VDC/2.5A.
  • Page 28 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 28/43 A system with multiple ECOsine™ filters paralleled for a high power load need each a separate 3-phase line side FUSE ECOsine™ 1 fuse block, corresponding to the respective filter and according to above table.

  • Page 29: Filter Maintenance

    Maintenance considerations: Schaffner harmonics filters are equipped with long life components that ensure a satisfactory function for many years under normal operating conditions. Any operation under extreme conditions such as over- temperatures, overvoltage situations, polluted environments etc. reduces the life expectancy.
  • Page 30 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 30/43 Fan specifications: Supply voltage: 24VDC Power: max. 7W Size: 120x120x25mm, fixation holes 105x105mm, Ø4.3mm Air flow: min. 110CFM Connection: min. 150mm cable length, TYCO MTA-100 plug, 2 poles (pin 1 = +24VDC)

  • Page 31: Special Considerations

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 31/43 8. Special considerations 8.1 Over-temperature contact and load disconnect ECOsine™ harmonic filters provide basic safety monitoring:  temperature detection level for each inductive component (over-temperature contact) This alarm indication requires adequate reaction in order to prevent possible system damage (i.e.

  • Page 32: Troubleshooting

    Every unit runs through a 100% test in our ISO 9001:2008 factories. There are no troubles to be expected if the filter is installed, operated, and maintained as described in this document and within published specifications. In the unlikely event of a problem, please contact your local Schaffner partner for assistance.

  • Page 33: Faq – Frequently Asked Questions

    This mode of operation is not possible. ECOsine™ filters are optimized for balanced three-phase power systems with six-pulse rectifier front ends and their performance depends upon voltage distortion and phase unbalance. Schaffner is experienced in custom harmonic filter design and can potentially come up with a single-phase solution to your requirement.
  • Page 34 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 34/43 Motors and Generators  Increased heating due to iron and cooper losses at the harmonic frequencies (performance reduced to 90%)  Higher audible noise  Refusal to start smoothly (cogging) ...
  • Page 35 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 35/43 How much cooling air capacity should be planned for the integration of ECOsine™ filters into a cabinet? This value, defined as CFM (cubic feet per minute; 1CFM = 1.7m /h) depends upon filter model and power rating.

  • Page 36: Custom Design Input Form

    36/43 11. Custom design input form There may be occasions where ECOsine™ standard filters are not suitable for the job at hand. Schaffner is very experienced in the design and manufacture of custom filters based on the existing modular ECOsine™ platform and can potentially come up with an alternative design proposal for you.

  • Page 37: Appendix I: International Standards

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 37/43 Appendix I: International standards The use of non-linear loads with six-pulse rectifiers has grown rapidly in recent years, to the point where this type of load represents more than 50% of western world power system load. Harmonic currents and the resulting voltage distortions can have devastating effects on power distribution systems and connected equipment.
  • Page 38 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 38/43 G5/4-1 planning levels for harmonic voltages: G5/4-1 current harmonic limits for loads rated >16A per phase:...

  • Page 39: Ii. International Standard En 61000-3-12

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 39/43 II. International standard EN 61000-3-12 This standard applies to equipment intended to be connected to low-voltage systems interfacing with the public supply at the low-voltage level. It does not apply to equipment intended to be connected only to private low-voltage systems interfacing with the public supply only at the medium- or high-voltage level.
  • Page 40 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 40/43 EN 61000-3-12 current harmonic limits: Conditions to use Table 4: 1. The phase angle of the 5th harmonic current related to the fundamental phase voltage is in the range of 90°...
  • Page 41 Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 41/43 Interpolation of current harmonic limits: Product documentation according to EN 61000-3-12: For equipment complying with the harmonic current emission limits corresponding to R = 33, the manufacturer shall state in his instruction manual or literature: ”Equipment complying with IEC 61000-3-12”...

  • Page 42: Iii. Ieee Std 519-1992

    However, because of different/relaxed limits, simpler filters may be sufficient for the job. Schaffner has already designed many engineered harmonic filters for relaxed requirements and may be able to quickly offer you a custom product that perfectly matches the requirements of an...

  • Page 43: Appendix Ii: Declaration Of Conformity

    Schaffner Group User Manual ECOsine™ – Passive Harmonic Filters Economy Line September 2012 43/43 Appendix II: Declaration of conformity...

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