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Schaffner Ecosine evo FN3452 User And Installation Manual

Passive harmonic filters
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USER AND INSTALLATION MANUAL
Ecosine evo Passive Harmonic Filters
Schaffner EMV AG
Nordstrasse 11e
|
4542 Luterbach
|
Switzerland
|
Main +41 32 681 66 26
|
schaffner.com

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  • Page 1 USER AND INSTALLATION MANUAL Ecosine evo Passive Harmonic Filters Schaffner EMV AG Nordstrasse 11e 4542 Luterbach Switzerland Main +41 32 681 66 26 schaffner.com...
  • Page 2 English version (original instructions) The most current edition of this document (PDF format) can be obtained from your contact of the Schaffner organization or at schaffner.com/downloads. Other technical documentation of our products is also available in the download area of our website schaffner.com.
  • Page 3 It provides helpful solutions to overcome harmonics mitigation challenges and answers frequently asked questions. If you require additional support, please feel free to contact your local Schaffner representative. ii. Performance Guarantee By selecting and installing the appropriate ecosine evo passive harmonic filter in a variable frequency...
  • Page 4 Line voltage unbalance: <1% Line voltage distortion: THVD <2% If a properly sized and installed filter fails to meet the 5% THDi level, Schaffner will provide the necessary application engineering support or filter replacement at no charge. iv. Important user notice...
  • Page 5 v. General Safety Notes and Installation Guidelines (Cautions and Warnings) User and installation manual Ecosine evo Passive Harmonic Filters 4/62...

  • Page 6: Table Of Contents

    Table of Contents 1 Ecosine evo passive harmonic filter designation ......8 Distinguishing between FN3440/FN3441, FN3450/FN3451, FN3442/FN3443 and FN3452/FN3453 ....................8 Explanation of ecosine evo designation ............8 1.2.1 Examples of ecosine evo filter designations ............... 10 2 Filter selection ................11 Filter selection table FN3440/FN3441 (50 Hz, 3×380 …...
  • Page 7 Thermal protection switch specifications ........... 32 Cooling requirement ..................33 Mechanical frame sizes ................. 34 3.10 Ecosine evo filter footprint ................ 36 3.11 Filter performance ..................38 3.12 Functional diagram ..................40 4 Modular Design: How to choose optional modules..... 41 5 Filter appearance and elements ............
  • Page 8 11 Troubleshooting ................61 12 Abbreviation ................61 7/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 9: Ecosine Evo Passive Harmonic Filter Designation

    1.2 Explanation of ecosine evo designation Ecosine evo is the new generation of Schaffner passive harmonic filter. They are introduced with a new designation system, which contains of 4 sections connected with ‘-’ as shown in Figure 1 Ecosine evo designation...
  • Page 10 The first part of the designation ‘FN34nn-xxx-yyy-_ _ _ _ _ _ _’ distinguishes between the six ecosine evo filter series. Table 1 filter application, operating frequency and nominal voltage per filter type FN3440 FN3441 FN3450 FN3451 FN3442 FN3443 FN3452 FN3453 For 6-pulse diode rectifier ✓...

  • Page 11: Examples Of Ecosine Evo Filter Designations

    Schaffner offers an online Product Configurator (myecosine.com) and the Schaffner Power Quality Simulator SchaffnerPQS3 (pqs.schaffner.com) to select and verify the most suitable ecosine evo filter for your application. 1.2.1 Examples of ecosine evo filter designations FN3440-22-115-E0XXJRX: Filter for 50 Hz, 380–415 V AC grid, motor drive power rating 22kW without...

  • Page 12: Filter Selection

    Ecosine evo passive harmonic filters need to be carefully selected and configured in order to enjoy maximum benefits. Besides the enclosed selection tables and the product datasheets included in the online configurator (myecosine.com), Schaffer advices to verify the selection by using the Schaffner Power Quality Simulator tool SchaffnerPQS3, available at pqs.schaffner.com.
  • Page 13 Step 4: Rectifier/Drive input power The individual filter must be selected with respect to the rectifier/motor drive input power in kW respec- tively in HP. It is important to match rated filter power as close as possible with the effective input power of the rectifier/drive.
  • Page 14 ➔ Recommended filter according to the filter selection table FN3452: Type FN3452-30-113 Oversizing of passive harmonic filters is not recommended because of the inherent lower harmonic mitigation performance at partial load as well as higher cost, size, and weight. Please refer to Table 2 - Table 9 to select suitable filters. 13/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 15: Filter Selection Table Fn3440/Fn3441 (50 Hz, 3×380

    2.1 Filter selection table FN3440/FN3441 (50 Hz, 3×380 … 415 VAC) Table 2 FN3440 filter selection table Filter Rated Motor Rated Weight Typical Terminal Frame load drive filter losses size power input input @400 current current V/50 Hz [kW] [Arms]*** [Arms] [kg] [W]****...
  • Page 16 Table 3 FN3441 filter selection table Rated Motor Rated Min. Min. Weight Typical Terminal Frame Filter load drive filter required required losses size power input input @400 current current V/50 [kW] [Arms]*** [Arms] [mH]***** [mH]***** [kg] [W]**** FN3441-1-110-E0_____* 1.62 37.41 FN3441-2-110-E0_____* 3.23 18.71...

  • Page 17: Filter Selection Table Fn3450/Fn3451 (50 Hz, 3×440

    2.2 Filter selection table FN3450/FN3451 (50 Hz, 3×440 … 500 VAC) Table 4 FN3450 filter selection table Filter Rated load Motor Rated Weight Typical Terminal Frame power @480 drive filter input losses size V/50 Hz input current current [kW] [Arms]*** [Arms] [kg] [W]****...
  • Page 18 Table 5 FN3451 filter selection table Rated Motor Rated Min. Min. Weight Typical Terminal Frame Filter load drive filter required required losses size power input input @480 current current V/50 Hz [kW] [Arms]*** [Arms] [mH]***** [mH]***** [kg] [W]**** FN3451-1-110-E0_____* 53.9 16.7 FN3451-2-110-E0_____* 26.9...

  • Page 19: Filter Selection Table Fn3442/Fn3443 (60 Hz, 3×380

    2.3 Filter selection table FN3442/FN3443 (60 Hz, 3×380 … 415 VAC) Table 6 FN3442 filter selection table Filter Rated load Motor Rated Weight Typical Terminal Frame power @380 drive filter losses size V/60 Hz input input current current [kW] [HP] [Arms]*** [Arms] [kg]...
  • Page 20 Table 7 FN3443 filter selection table Filter Rated load Motor Rated Min. Min. Weight Typical Terminal Frame power @380 drive filter required required losses size V/60 Hz input input current current [kW] [HP] [Arms]*** [Arms] [mH]***** [mH]***** [kg] [lbs] [W]**** FN3443-1-110-E0_____* 1.37 21.5...

  • Page 21: Filter Selection Table Fn3452/Fn3453 (60 Hz, 3×440

    2.4 Filter selection table FN3452/FN3453 (60 Hz, 3×440 … 480 VAC) Table 8 FN3452 filter selection table Filter Rated load Motor Rated Weight Typical Terminal Frame power drive filter losses size @480 V/60 input input current current [kW] [HP] [Arms]*** [Arms] [kg] [lbs]...
  • Page 22 Table 9 FN3453 filter selection table Filter Rated load Motor Rated Min. Min. Weight Typical Terminal Frame power @480 drive filter required required losses size V/60 Hz input input current current [kW] [HP] [Arms]*** [Arms] [mH]***** [mH]***** [kg] [lbs] [W]**** FN3453-1-110-E0_____* 1.44 1.37...

  • Page 23: Filter Configurations And Designations If External Air Flow Is Available For Cooling

    2.5 Filter configurations and designations if external air flow is available for cooling If there is external air flow available for cooling in the installation, then the filters do not contain fan and do not contain aux. power supply. The filter configurations are shown in Table 10 and Table 11, if external air flow is available for cooling, Table 10 FN3440, FN3450, FN3452 filter configurations if external air flow available for cooling Table 11 FN3441, FN3451, FN3453 filter configurations if external air flow available for cooling User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 24: Filter Configurations And Designation With Embedded Ventilation

    2.7 Filter configurations and designation with embedded ventilation If external air flow for cooling is not available, then the filters contain embedded ventilation, which means the filters contain fan and aux. power supply. The open frame filter configurations are shown in Table 12 and Table 13, if external air flow is not available and embedded ventilation is equipped.

  • Page 25: Filter Configurations And Designation If External Aux. Power Supply For The Fan Is Available

    2.9 Filter configurations and designation if external aux. power supply for the fan is available If there is an external 24 V DC power supply available to the fan, then the filters contain fan but do not contain auxiliary power supply, user should provide aux. power supply to the fan. The open frame filter configurations are shown in Table 14 and Table 15, if external air flow is not available but external auxiliary power supply for the fan is available.
  • Page 26 2.10 Frame size Filter configuration (FN3440/41-250-119, FN3450/51-315-119) 25/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 27: Filter Description

    3 Filter description 3.1 General electrical specifications FN3440/FN3441 (50 Hz filters) Nominal operating voltage: 3x 380 to 415 V AC Voltage tolerance range: 3x 342 to 457 V AC Operating frequency: 50 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 1.1 to 250kW Total harmonic current distortion THDi: <5% @ rated power...

  • Page 28: General Electrical Specifications Fn3450/Fn3451 (50 Hz Filters)

    3.2 General electrical specifications FN3450/FN3451 (50 Hz filters) Nominal operating voltage: 3x 440 to 500 V AC Voltage tolerance range: 3x 396 to 550 V AC Operating frequency: 50 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 1.1 to 315kW Total harmonic current distortion THDi: <5% @ rated power...

  • Page 29: General Electrical Specifications Fn3442/Fn3443 (60 Hz Filters)

    3.3 General electrical specifications FN3442/FN3443 (60 Hz filters) Nominal operating voltage: 3x 380 to 415 V AC Voltage tolerance range: 3x 342 to 456 V AC Operating frequency: 60 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 1 to 240 HP (0.9 to 177) Total harmonic current distortion THDi: <5% @ rated power...

  • Page 30: General Electrical Specifications Fn3452/Fn3453 (60 Hz Filters)

    3.4 General electrical specifications FN3452/FN3453 (60 Hz filters) Nominal operating voltage: 3x 440 to 480 V AC Voltage tolerance range: 3x 396 to 528 V AC Operating frequency: 60 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 1.5 to 300 HP (1.1 to 224) Total harmonic current distortion THDi: <5% @ rated power...

  • Page 31: Additional Electrical Specifications

    100A can only be used up to 91.87A. Remark: Do not use ecosine evo passive harmonic filters in altitudes above 4000m without consulting Schaffner first. 3.6 Screw size, torque and cable cross-section requirement 3.6.1 Power terminals The cable cross-section must be selected according the rated filter input current, the maximum current, the environment and other special requirement of the application.

  • Page 32: Trap Disconnect Jumper Terminals

    Table 17 Ecosine evo filter power terminals designation Terminal Screw Flex wire Flex wire Screw Max width Frame size designation thread torque value cable lug* [Nm] [mm] 14-22 0.4-2.5 10-22 0.4-6 B, C 6-18 0.75-16 1/0-8 10.50 E, F 3/0-8 10-95 3/0-500 kcmil 95-240...

  • Page 33: Auxiliary Signal And Earth Terminals

    3.6.3 Auxiliary signal and earth terminals The auxiliary signal and earth terminals screw size and torque is given in Table 19. Table 19 Ecosine evo filter signal and earth terminals Terminal type Screw thread Screw torque value Frame size [Nm] Signal Earth (PE) Earth (PE)

  • Page 34: Cooling Requirement

    3.8 Cooling requirement Inlet air flow requirements for each frame size are listed in Table 21. Please notice that the filters with frame size A, B and C do not require air cooling. For frame sizes D to J, the required inlet air flow should be fulfilled, either by including the optional fan module or by providing sufficient external air flow.

  • Page 35: Mechanical Frame Sizes

    3.9 Mechanical frame sizes Ecosine evo passive harmonic filters are implemented on a base plate or base frame featuring 9 different frame sizes, Frame A to Frame J, from the lowest to the highest rating. Dimensions and footprint are provided in section 3.10. In particular, frame sizes A to C do not require air flow, while frame sizes D to J need embedded fan or external ventilation, details are provided in filter selection tables, Table 2 to Table 9.
  • Page 36 Figure 3 Overview of all IP 20 frame size versions 35/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 37: Ecosine Evo Filter Footprint

    3.10 Ecosine evo filter footprint Figure 4 Mechanical Data of FN3440, FN3450, FN3442 and FN3452 User and installation manual Ecosine evo Passive Harmonic Filters 36/62...
  • Page 38 Table 22 Dimensions of all frame sizes Dimensions in [mm] Dimensions in [in] Frame Drill pattern Base Volume Drill pattern Base Volume Max. Z Max. Z 13.4 14.2 11.9 15.9 16.7 14.6 18.1 19.0 16.9 21.3 22.0 19.3 10.2 26.8 27.8 25.0 11.4...

  • Page 39: Filter Performance

    3.11 Filter performance Ecosine evo passive harmonic filters achieve 5% THDi with 6-pulse diode rectifiers under the following condition. Filter is applied to rated voltage and power THVD <2%, line voltage unbalance <1% RC damper module is required to be included in the filter if there is EMI filter present in the drive. Typical expected EMI filter capacitance (phase to star point) are shown in Table 23 and Table 24.
  • Page 40 Figure 5 THDi vs. load (diode rectifier front-ends) Figure 6 Power factor vs. load (diode rectifier front-ends) Figure 7 Drive dc-link voltage vs. load (diode rectifier front-ends, with FN3440 series) 39/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 41: Functional Diagram

    3.12 Functional diagram Filter terminals Line L1/L2/L3 3 terminal blocks Load L1’/L2’/L3’ 3 terminal blocks Signal Connecting terminals to thermal switch NC 180°C (UL- approved) to detect overload in chokes Protective earth. Threaded stud with washer and nut Trap disconnect 3 couples of terminals.

  • Page 42: Modular Design: How To Choose Optional Modules

    4 Modular Design: How to choose optional modules Ecosine evo passive harmonic filters provide optimized solution for your application by merely plugging a new module. The base module of FN3441, FN3451, FN3443 and FN3453 series contains line choke, trap choke and trap capacitor, which helps reduce THDi to 5% for motor drives with an 8% DC-link choke present.
  • Page 43 Figure 11 Optional modules for ecosine evo filter and according to your requirement and installation User and installation manual Ecosine evo Passive Harmonic Filters 42/62...

  • Page 44: Filter Appearance And Elements

    5 Filter appearance and elements The very compact and neat design of ecosine evo passive harmonic filters is realized by a two-stage construction. The filter constructions of all frame sizes are identical, except the position of the load choke. The load choke is built on the upper-stage of the filter for frame size A- F, and on the lower-stage of the filter for frame sizes G –...

  • Page 45: Ip 00 Version, Frame Size G - H

    5.2 IP 00 version, frame size G - H The design of the ecosine evo filter IP 00 versions with fan module, aux. power supply module, TDJ module and RC damper module (E0FAJRX) is shown in Figure 14. There are trap capacitor C , trap disconnect jumper, power terminal visible on the upper-stage.

  • Page 46: Ip 20 Version

    Figure 16 Design of ecosine evo frame J, E0XXSXX: Upper-stage Figure 17 Design of ecosine evo frame J, E0XXSXX: Lower-stage Switch module, namely a circuit breaker, is required for frame size J for safety reasons. The short circuit current of FN3440/41-250-119 and FN3450/51-315-119 (constructed with frame J) can go beyond 10’000A, however the capacitors are only protected with failure current of max.
  • Page 47 filters. IP20 version of frame size J contains fan module, aux. power supply module and switch module (E2FASXX) is shown in Figure 19. Figure 18 Design of IP 20 version ecosine evo filter with frame size D (left) and frame size H (right) Figure 19 Design of IP 20 version ecosine evo filter with frame size J Parameters of IP 20 enclosure finger guard are shown in Table 25.
  • Page 48 Plastic Plastic Plastic Plastic Metal Metal 18.5 Metal Metal Metal 47/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 49: Performance Estimation Using Schaffnerpqs

    6 Performance estimation using SchaffnerPQS Ecosine max passive harmonic filters are included and can be simulated with the Schaffner Power Quality Simulator SchaffnerPQS pqs.schaffner.com. By using SchaffnerPQS, users can easily simulate and estimate system performance taking into account the most important design requirements and system’s boundary conditions.

  • Page 50: Filter Application

    7 Filter application Ecosine evo passive harmonic filters are designed to mitigate harmonic current of non-linear loads, particularly of three-phase diode-type rectifiers. Contrary to “bus-applied or PCC (Point of Common Coupling)” filters, which are being installed e.g. at the main feeder, they are specifically designed to be used with either an individual non-linear load, or with a group of non-linear loads.

  • Page 51: Filter Installation

    In the case of damage, please file a claim with the freight forwarder 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 and with respect to named temperature limits, see section 3.2.
  • Page 52 1348 All dimensions in mm; 1 inch = 25.4mm II.2 Screw selection: Schaffner recommends zinc coated hex ribbed flange steel bolts. Respect filters weight for appropriate choice of screws! Head diameters must not exceed these dimensions: M6: d ≤14.2mm, M10: d ≤21.2mm II.3...

  • Page 53: Step 3: Wiring

    8.3 Step 3: Wiring III.1 Verify safe disconnection of all line side power. Consult your local safety instructions. III.2 Carefully connect protective earth (PE) wire to >150mm adequate earth potential close to ecosine filter. >100mm Use a wire diameter of equal or bigger size as foreseen >100mm for line/load side power cables –...
  • Page 54 Note: In case the cables on the power terminals are installed without cable lug, it is recommended to follow the maintenance manual closely. Maintenance manual is available on your request per Schaffner contact. III.5 Use wired...
  • Page 55 IP 20 enclosure cable wiring please refer to the remarks for the load side cable wiring (III.4). Note: For IP 20 filter versions the IP 20 finger guard must be installed in order to achieve IP 20 protection. When the finger guard is not installed, Schaffner do not guarantee IP 20 protection.
  • Page 56 Table 27 Requested fuse current rating for UL class J and for IEC class gG ecosine ecosine ecosine evo ecosine Fuse Fuse all FN3440 all FN3441 all FN3450 all FN3451 class J class gG rated A rated A FN3450-1-110 FN3451-1-110 FN3440-1-110 FN3441-1-110 FN3450-2-110...
  • Page 57 Table 28 Requested fuse current rating for UL class J ecosine type ecosine type ecosine type ecosine evo type Fuse class J all FN3442 all FN3443 all FN3452 all FN3453 rated A FN3442-1-110 FN3443-1-110 FN3452-1-110 FN3453-1-110 FN3442-2-110 FN3443-2-110 FN3452-3-110 FN3453-3-110 FN3442-4-112 FN3443-4-112 FN3452-5-112...

  • Page 58: Filter Maintenance

    9 Filter maintenance Ecosine evo passive harmonic filters described in this manual 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 59: Fan

    Fans are 100% field replaceable without the need to uninstall and disconnect the filter. Forced cooling devices are needed for the operation of Schaffner ecosine evo passive harmonic filters up to their nominal rating. Such cooling devices must be checked and cleaned regularly (if installed) to ensure sufficient air flow at all times.

  • Page 60: Electrical Connections

    Therefore, Schaffner recommends checking and tighten all electrical connections on the occasion of a regular scheduled maintenance entire device that incorporates filter. Check of internal connections within the filters is not needed or should be conducted by a Schaffner service representative. 59/62 User and installation manual Ecosine evo Passive Harmonic Filters...

  • Page 61: Trap Circuit Disconnect

    In such cases it may not be necessary to install trap circuit disconnect functions. Recommended settings: Schaffner recommends engaging and disengaging the trap circuit disconnect at following load levels: Trap circuit status Proposed load level Disconnect When load level drops under 10–15%...
  • Page 62 In the unlikely event of a problem, please contact your local Schaffner partner for assistance. 12 Abbreviation PHF:...
  • Page 63 Schaffner group companies (“Schaffner”) and do not constitute an offer for purchase or sale or a recommendation or advice. The content of this document has been carefully prepared and reviewed and all reasonable efforts have been made to ensure the accuracy of the information.
  • Page 64 Schaffner EMV AG Nordstrasse 11e 4542 Luterbach Switzerland Main +41 32 681 66 26 schaffner.com...

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