Schaffner FN5420 User And Installation Manual
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Schaffner FN5420 User And Installation Manual

Output filter
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User and installation manual
Output filter FN5420 and RWK5420
www.schaffner.com
English version (original instructions)
Schaffner Group
|
Nordstrasse 11e
T +41 32 681 66 26
|
info@schaffner.com
|
4542 Luterbach
|
Switzerland
|
www.schaffner.com

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  • Page 1 User and installation manual Output filter FN5420 and RWK5420 www.schaffner.com English version (original instructions) Schaffner Group Nordstrasse 11e 4542 Luterbach Switzerland T +41 32 681 66 26 info@schaffner.com www.schaffner.com...
  • Page 2 Manual at any time without obli- gation to notify any person of such revision or changes. Schaffner will make all possible efforts to se- cure the accuracy and the integrity of this Manual. Schaffner disclaims any kinds or forms of warranty,...
  • Page 3 Other technical documentation of our products is also available in the download area of our website schaffner.com/downloads Document name: User and Installation Manual output filter FN5420 and RWK5420 Rev01.pdf Valid for: sine wave filter FN5420 (all versions) dv/dt filter RWK5420 (all versions)
  • Page 4 Schaffner sine wave filters help to avoid problems that can result in purely functional difficulties to very severe motor damage. Sine wave filters FN5420 series offer state of the art motor protection for the most demanding applica- tions. By installing a sine wave filter between your drive and motor: The filter converts the rectangular PWM output voltage of the drive into a smooth sinusoidal wave form signal with low residual ripple and without any voltage peaks between phases.
  • Page 5 AC or DC motor drives. 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 dam- ages resulting from use or application of Schaffner sine wave filters beyond their specifications.
  • Page 6 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 General Safety Notes and Installation Guidelines (Cautions and Warnings) 5/52 schaffner.com...

  • Page 7: Table Of Contents

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Content Sine wave filter FN5420 designation ..............8 Sine wave filter designation ...................... 8 1.1.1 Example of sine wave filter designations ................8 Dv/dt reactor designation ......................9 1.2.1 Example of sine wave filter designations ................
  • Page 8 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 3.8.1 Dimensions FN5420 IP00....................26 3.8.2 Dimensions FN5420 IP20....................31 3.8.3 Dimensions RWK5420 ......................32 Functional diagram ........................37 Filter appearance and elements ............... 38 Filter installation ....................43 Step 1: Visual inspection ......................

  • Page 9: Sine Wave Filter Fn5420 Designation

    For more details, please consult the datasheet and section 3.1 below. The fourth part of the designation ‘FN5420-xxx-yy-E_ _ _ _’ contains 4 slots, the first is the IP degree of protection, second, the presence of active ventilation (fan), third the presence of a power supply for the fan (if present) and the last one indicates the presence or not of a tem- perature switch.

  • Page 10: Dv/Dt Reactor Designation

    50Hz, with terminal type 99 (bus bar), rated IP00, without fan nor power supply and with temperature switch. 1.3 Additional Resources The Schaffner group does provide a number of additional resources available at schaffner.com to un- derstand power quality in general and product in particular. 1.4 Naming convention...

  • Page 11: Filter Selection

    Schaffner output filters need to be selected according to the applications specifications and needs. Step 1: motor frequency Sine wave filter FN5420 series and dv/dt reactor RKW5420 series work at rated current up to a motor frequency of 60Hz and with a derating up to 200Hz, see derating in section 2.4.2.
  • Page 12 Dv/dt reactor RWK5420 series doesn’t have any minimum fPWM but is still limited to the same maxi- mum fPWM than sine wave filter FN5420 series. The maximum switching frequency must be reduced according to the cable length or the cable length must be limited for a given switching frequency.
  • Page 13 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 fPWM at 400V fPWM at 480V Cable length [m] Figure 4 RWK5420 limitation in switching frequency and cable length Step 4: motor protection and acoustic noise Output filters are mean to filter the signal coming out of the drive feeding the motor. Filter type dv/dt reactor, like RWK5420 series, allow to reduce the voltage rise (dv/dt) visible by the motor.

  • Page 14: Filter Selection Table Fn5420 Ip00

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 2.1 Filter selection table FN5420 IP00 Table 4 FN5420 IP00 selection table Filter [kW] [kW] [mH] [µF] [kHz] [kg] FN5420-2.3-88-E0XXT 0.75 0.90 19.2 3x0.47 1.20 FN5420-3.1-88-E0XXT 14.2 3x0.68 1.55 FN5420-5.9-88-E0XXT...

  • Page 15: Filter Selection Table Fn5420 Ip20

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 2.2 Filter selection table FN5420 IP20 Table 5 FN5420 IP20 selection table Filter [kW] [kW] [mH] [µF] [kHz] [kg] FN5420-2.3-44-E2XXT 0.75 0.90 19.2 3x0.47 FN5420-3.1-44-E2XXT 14.2 3x0.68 FN5420-5.9-44-E2XXT 7.48 3x1.5...

  • Page 16: Filter Selection Table Rwk5420

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 2.3 Filter selection table RWK5420 Table 6 RWK5420 selection table Filter [kW] [kW] [mH] [kg] RWK5420-2.3-88-E0XXT 0.75 0.90 19.2 1.05 RWK5420-3.1-88-E0XXT 14.2 1.40 RWK5420-5.9-88-E0XXT 7.48 RWK5420-10-88-E0XXT 10.2 4.32 RWK5420-13-89-E0XXT 13.2...

  • Page 17: Derating

    2.4.1 Temperature derating All sine wave filter FN5420 series and dv/dt reactor RWK5420 series are able to operate at rated cur- rent up to an ambiante temperature of 45°C (measured next to the device, i.e. inside a cabinet). It is possible to use the filter and reactor above this limit, but a derating must be applied on the maximum current going through the filter.

  • Page 18: Motor Frequency Derating

    Output filter FN5420 and RWK5420 2.4.2 Motor frequency derating All sine wave filter FN5420 series and dv/dt reactor RWK5420 series can operate at rated current for a motor frequency up to 60Hz. They can also operate in case of increased motor speed with motor frequency up to 200Hz by applying a derating on the maximum current allowed in the filter or reactor.

  • Page 19: Filter Description

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 3 Filter description 3.1 General electrical specifications FN5420 Nominal operating voltage: 3x 480 V AC Rated operating voltage: 3x 530 V AC Operating frequency: Up to 60 Hz (up to 200Hz with derating)

  • Page 20: General Electrical Specifications Rwk5420

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 3.2 General electrical specifications RWK5420 Nominal operating voltage: 3x 480 V AC Rated operating voltage: 3x 530 V AC Operating frequency: Up to 60 Hz (up to 200Hz with derating)

  • Page 21: Power Losses

    Figure 6 power loss calculation chart 3.3.1 Power loss calculation example For a system using a sine wave filter type FN5420-45-92-E0XXT you take the typical power loss given in Table 4, 272W. This typical power loss is for 400/500V 50Hz at nominal current of 45A.

  • Page 22: Additional Electrical Specifications

    Output filter FN5420 and RWK5420 3.4 Additional electrical specifications Schaffner output filter type sine wave filter FN5420 and dv/dt reactor type RWK5420 general electrical specifications refer to operating altitudes up to 2000m a.s.l. (6600ft). Operation between 2000m and 4000m (6600ft and 13123ft) requires a derating on clearance accord- ing to IEC 60664-1 (table A.2), hereafter enclosed:...

  • Page 23: Screw Size, Torque And Cable Cross-Section Requirement

    In many applications a shielded motor cable may not be required when a sine wave filter is applied with a motor drive. Anyhow, due to other possible influences of common mode disturbances Schaffner does recommend using shielded motor cables. This is to avoid back-coupling of radiated interferences to the mains cable at the frequency range from 1–30 MHz.
  • Page 24 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Table 8 FN5420 IP00 and RWK5420 power terminals designation Type M8 / M10 / Ring cable shoe M3.5 Fork cable shoe width max. 6.4mm width max. 8.0mm Flex wire [AWG]...

  • Page 25: Auxiliary Signal And Earth Terminals

    3.5.2 Auxiliary signal and earth terminals The auxiliary signal from temperature sensor and earth terminals screw size and torque are given in Table 10, Table 11 and Table 12. Table 10 Auxiliary signal terminals on FN5420 IP00 and RWK5420 Type 2.3A & 3.1A 5.9A to 18A...

  • Page 26: Thermal Protection Switch Specifications

    1.8A cosϕ = 0.4-0.5 3.7 Cooling requirement Sine wave filter FN5420 IP20 come with embedded ventilation when needed. Thus, it is important to install the filter in a way that the air channels are not blocked and within an ambient temperature ac- cording to the specifications from section 2.2.

  • Page 27: Mechanical Data

    3.8 Mechanical data 3.8.1 Dimensions FN5420 IP00 The drawings of each design is presented below. Dimensions are given in Table 14. Figure 9 drawings FN5420 IP00 sizes 2.3A to 3.1A Figure 10 drawings FN5420 IP00 sizes 5.9A to 18A schaffner.com...
  • Page 28 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 11 drawings FN5420 IP00 sizes 26A to 60A Figure 12 drawings FN5420 IP00 sizes 75A to 110A 27/52 schaffner.com...
  • Page 29 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 13 drawings FN5420 IP00 sizes 145A to 400A Figure 14 drawings FN5420 IP00 sizes 480A to 800A schaffner.com 28/52...
  • Page 30 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 15 drawings FN5420 IP00 size 1000A 29/52 schaffner.com...
  • Page 31 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Table 14 dimensions FN5420 IP00 Rating B±5 max. C H±5 L±5 M±5 N±5 6.5x5.5 47.2 6.5x5.5 45.3 8x5.5 10.2 71.5 12x9 13.2 71.5 12x9 57.5 12x9 77.5 12x9 ø6.5 84.5...

  • Page 32: Dimensions Fn5420 Ip20

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 3.8.2 Dimensions FN5420 IP20 The drawings of each design is presented below. Dimensions are given in Table 15. Figure 16 FN5420 IP20 sizes 2.3A to 38A 31/52 schaffner.com...

  • Page 33: Dimensions Rwk5420

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 17 FN5420 IP20 sizes 45A to 110A Table 15 dimensions FN5420 IP20 Frame Drill pattern Base Box size Type R +2/0 X ±2 Z ±2 Dimensions in mm For Dimensions without Tolerances: ISO2768-m/EN22768-m applies 3.8.3 Dimensions RWK5420...
  • Page 34 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Table 16. Figure 18 RWK5420 sizes 2.3A to 3.1A Figure 19 RWK5420 sizes 5.9A to 18A 33/52 schaffner.com...
  • Page 35 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 20 RWK5420 sizes 26A to 60A Figure 21 RWK5420 sizes 75A to 110A schaffner.com 34/52...
  • Page 36 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 22 RWK5420 sizes 145A to 1000A 35/52 schaffner.com...
  • Page 37 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Table 16 dimensions RWK5420 B±5 C±5 L±5 M±5 N±5 Rating 6.5x5.5 47.2 6.5x5.5 45.3 8x5.5 10.2 71.5 12x9 13.2 71.5 12x9 84.5 57.5 12x9 77.5 12x9 ø6.5 84.5 12x9 ø6.4...

  • Page 38: Functional Diagram

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 3.9 Functional diagram Figure 23 Functional sine wave filter FN5420 Figure 24 Functional diagram dv/dt reactor RWK5420 Filter terminals Drive U1/V1/W1 3 terminal blocks Motor U2/V2/W2 3 terminal blocks Signal TS Connecting terminals to thermal switch NC 180°C (UL-...

  • Page 39: Filter Appearance And Elements

    Some selected examples of design will be detailed in this chapter to help the user locate the important parts of the product. Example of design of sine wave filter FN5420 and RWK5420 are shown in Figure 25 to Figure 33 with relevant elements indicated on the drawing.
  • Page 40 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 27 Design of FN5420 IP00 75A (apply for 75A to 110A) Figure 28 Design of FN5420 IP00 400A (apply for 145A to 1000A) 39/52 schaffner.com...
  • Page 41 User and Installation Manual Output filter FN5420 and RWK5420 Figure 29 Design of FN5420 IP20 frame B (apply for frame A and B, 2.3A to 10A) Figure 30 Design of FN5420 IP20 frame C (apply for frame C 13A to 38A) schaffner.com...
  • Page 42 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 31 Design of FN5420 IP20 frame D (apply for frame D and E, 45A to 110A) Figure 32 Design of RWK5420 60A (apply for 26A to 60A) 41/52...
  • Page 43 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 33 Design of RWK5420 75A (apply for 75A to 1000A) schaffner.com 42/52...

  • Page 44: Filter Installation

    Please do also always follow the general safety and installation guidelines provided within this docu- ment as well as relevant local, national or international standards that are applicable. Please note that the following installation steps are applicable for sine wave filter FN5420 series IP00 and IP20 as well as dv/dt reator RWK5420 series.
  • Page 45 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Figure 36 Mandatory mounting positions FN5420 IP20 Figure 37 Prohibited mounting positions The pictures above show permitted and prohibited mounting positions. The mounting on a vertical plate (see picture for permitted mouting positions) is limited to IP00 products with a maximum weight of 25 kg or for IP20 products.
  • Page 46 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 appropriate thermal management (e.g. cabi- >150mm net cooling). Filter operation in environ- >100mm ments with higher temperatures require a temperature derating (see section 2.4.1). >100mm >150mm Figure 39 Minimum distance for wall mounted devices 45/52 schaffner.com...

  • Page 47: Prepare The Fixation

    For sine wave filters FN5420 IP00 series refer to the dimensions E,D and F from the matchin drawing and table in section 3.8.1 For sine wave filters FN5420 IP20 series refer to the dimensions...
  • Page 48 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 5.2.3.2 For FN5420 IP20 Set screws loose into wall, leave 5mm distance from head to wall. Lift filter with appropriate crane, smallest types (up to 25kg) may be lifted manually by two persons.

  • Page 49: Step 3: Wiring

    Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 5.3 Step 3: Wiring 5.3.1 Verify safe disconnection of all line side power Consult your local safety instructions. >150mm 5.3.2 Carefully connect protective earth (PE) wire >100mm to adequate earth potential close to the device Use a wire diameter of equal or bigger size as fore- >100mm...

  • Page 50: Connect Shielding For Shielded Cables

    Connect the device on drive side terminals U, V, W to respective motor drive or rectifier outputs. The third part of the output filter/reactor designation is a number contains two digits, i.e. FN5420-10-88- E0XXT, which indicates power terminal type. See section 3.5.1 for the recommended wire size and torque.

  • Page 51: Filter Maintenance

    Schaffner output filters are reliable low maintenance products. Many products like power supplies, in- verters or motor drives utilize fans for forced cooling to minimize size and weight. Schaffner output fil- ters are designed with a similar temperature management concept and therefore, fans, when present, may have to be maintained and replaced in certain intervals to sustain the function and value of the product.

  • Page 52: Power Capacitors

    Therefore, Schaffner recommends checking and tighten all electrical connections on the occasion of a regular scheduled maintenance of the entire device that incorporates the filter. Check of internal connections within the filters is not needed or should be conducted by a Schaffner service representative.

  • Page 53: Troubleshooting

    Every unit runs through suitable tests in our ISO 9001:2000 factories. Due to this reason no major issues need to be expected if the filter is installed, operated, and maintained as described in this document. In the unlikely event of a problem, please contact your local Schaffner partner for assistance. schaffner.com 52/52...
  • Page 54 Schaffner Group User and Installation Manual Output filter FN5420 and RWK5420 Schaffner Group Nordstrasse 11e 4542 Luterbach Switzerland www.schaffner.com T +41 32 681 66 26 info@schaffner.com...

This manual is also suitable for:

Rwk5420

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