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ECOsine

®

active Harmonic Filters

– Maintenance Manual for FN3420-200-690-3

3.1

About this manual

This manual is meant to provide comprehensive information on maintenance requirements
of ECOsine

®

active harmonic filters. The issues discussed in this guide cover the basic

maintenance schedule, necessary wear parts as well as practical aspects of working with
ECOsine

®

active harmonic filters. The guide will familiarize you with the required hardware

checks and settings

to conduct various maintenance tasks.

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Summary of Contents for ECOsine

Page 1: ...April 2015 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3...

Page 2: ...ying transmission and dissemination Revision 01 March 2016 The most current edition of these instructions PDF format can be obtained from your contact of the Schaffner service organization Other techn...

Page 3: ...2 4 1 Maintenance Schedule 23 4 2 Wear parts 24 4 2 1 Wear parts AHF 200 690 3 No UL 24 4 2 2 Wear parts AHF 200 690 3 UL 25 4 3 Replacement Instruction 26 4 3 1 Check operation of main fan and DC Bus...

Page 4: ...Index of Tables Table 1 Use of symbols terms and designations 12 Table 2 Type code 14 Table 3 Maintenance schedule 200 690 3 23 Table 4 Wear parts 200 690 3 24 Table 5 Wear parts 200 690 3 UL 25 Inde...

Page 5: ...ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 5 1 General Safety Instructions...

Page 6: ...roperly The discharge time of the intermediate circuit after disconnecting from the mains can be more than 5 minutes All interventions involving opening the device cover or removing or installing the...

Page 7: ...3 7 1 2 Personnel qualification Installation of the ECOsine active filter inspections for proper operation and certain troubleshooting measures may only be performed by qualified personnel All other...

Page 8: ...PCB s according to IEC61721 3 3 Schaffner standard PCB construction complies with class 3C2 Please carefully read the provided information and check if your application fulfills the required specifica...

Page 9: ...locations with normal levels of contaminants experienced in urban areas with industrial activities Levels Environmental parameter Units 1 Class 3C2 2 Mean value Max value Sea salt Salt mist Sulphur d...

Page 10: ...10 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 2 Introduction...

Page 11: ...d and processed in a digital control structure The active filter continually generates a compensating current that offsets the harmonic content and reactive current in the load so the ac mains only ha...

Page 12: ...s of personnel WARNING Warning Follow these instructions to avoid situations which may cause severe or deadly injuries DANGER Danger Follow these instructions to avoid situations which may cause sever...

Page 13: ...COsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 13 Serial number WO 1234567 S N 00001 Date of manufacture year yy calendar week ww WO number Part number 2 3 Type plate Type code...

Page 14: ...de The type designations of all ECOsine active have the following structure FN34TT AAA VVV W CC Variable Description TT Type 20 3 wire device 30 4 wire device AAA Rated current VVV Rated voltage W Num...

Page 15: ...ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 15 3 Welcome...

Page 16: ...ion on maintenance requirements of ECOsine active harmonic filters The issues discussed in this guide cover the basic maintenance schedule necessary wear parts as well as practical aspects of working...

Page 17: ...ce for this book is anyone interested in or responsible for maintenance of ECOsine active harmonic filters To fully understand the guide you should have a good knowledge of electronic and electrical s...

Page 18: ...tionally must be familiar with the instructions in the Installation and Operation Manual as well as this Maintenance and Wear Parts Manual CAUTION Caution Maintenance tasks should only be performed by...

Page 19: ...and partnering We do offer help with a lot of topics In order to provide the most successful help Schaffner does operate a service organization and worldwide service centers We do also closely collabo...

Page 20: ...hands on workshops designed to introduce you to the fundamental concepts of power quality ECOsine harmonic filters and filter maintenance We also offer customized training courses designed to meet you...

Page 21: ...t support custom products and a worldwide customer service organization Our goal is to ensure that you obtain the level of support you actually need Toward this objective we invite you to contact your...

Page 22: ...22 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 4 AHF 200 690 3...

Page 23: ...ck of coolant level Check coolant pump for any signs of coolant leakage Replace inverter fan DC bus fan Replace pre charge fuses F1 F2 Replace 230V auxiliary power supply fuses F3 F4 Replace 24V power...

Page 24: ...14437 Wear part 1x 24V power supply fuse Set incl 2 fuses 1 25A 500V 6 3x32mm Position F45 F46 814442 Wear part 1x Cooling system power supply fuses Set incl 2 fuses 10A 500V 6 3x32mm Position F47 F48...

Page 25: ...ar part 1x 24V power supply fuse Set incl 2 fuses 1 25A 500V 6 3x32mm Position F45 F46 814442 Wear part 1x Cooling system power supply fuses Set incl 2 fuses 10A 500V 6 3x32mm Position F47 F48 814440...

Page 26: ...f main fan and DC Bus fan and clean fan guards 1 Tools List TOOLS LIST 1 Glove 2 Brush 3 Mask 4 Cleaning paper 5 Alcohol 6 Water Tips Prefer to have vacuum cleaner 2 Work Instruction Dismantling proce...

Page 27: ...the speed rpm of fan 3 In case rpm stays on 0 then replace it according to the instruction Replace DC LINK fan Tips for main fan only do physically check if you feel some moving air Switch off the dev...

Page 28: ...ne active Harmonic Filters Maintenance Manual for FN3420 200 690 3 Make sure that the control box is closed during the whole cleaning process Locating the position of main fan Remove the marked liftin...

Page 29: ...Manual for FN3420 200 690 3 29 Remove the top cover and use vacuum cleaner compressor to clean main fan and surrounding area Remove the marked screws and take out the protection panel Remove the mark...

Page 30: ...Osine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 Use the brush to clean the two inverter fans 3 Work instruction Reassembly process Close the top cover Tighten the marked lifting...

Page 31: ...rmonic Filters Maintenance Manual for FN3420 200 690 3 31 Mount the protection panel and tighten all marked screws with 5 Nm Mount the second protection panel and tighten marked screws with 5Nm Close...

Page 32: ...ters Maintenance Manual for FN3420 200 690 3 4 3 2 Check of coolant level 1 Tools List Tool list 1 Funnel with extended tube 2 Spare Parts Spare Parts 1x 814453 AHF Coolant mixed SP 10l 3 Work instruc...

Page 33: ...heck the position of level indicator Max level Min level Only fill in the coolant in case level indicator under Min level Remove the cap of water tank and insert funnel into water tank Fill in coolant...

Page 34: ...ual for FN3420 200 690 3 Remove the funnel and close the cap of water tank Close and lock the door 4 3 3 Check coolant pump for any signs of coolant leakage 1 Tools List Tool list 1 Visual inspection...

Page 35: ...ng the position of pump Visual checking left side area of pump tubes Attention Contact Schaffner Service Center in case any leakage points are detected Visual checking right side area of pump tubes At...

Page 36: ...3420 200 690 3 If no any leakage are found close and lock the door 4 3 4 Replace inverter fan DC bus fan 1 Tools List TOOLS LIST 1 M6 Hex socket wrench 2 Philips screwdriver 3 Pliers 4 Cabinet key 2 S...

Page 37: ...rs Maintenance Manual for FN3420 200 690 3 37 3 Work instruction Dismantling process Unlock the cabinet by key Remove the marked screws and take out the protection panel Remove the marked screws and t...

Page 38: ...38 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 Disconnect the fan cables of the two fan modules Bend the clip on fan plate straight Pull out the fans away from cover...

Page 39: ...al for FN3420 200 690 3 39 4 Work instruction Reassembly process Insert the fans into the fan cover and reconnect the fan cables Bend the clip on fan plate back to block fix the fan Mount the protecti...

Page 40: ...monic Filters Maintenance Manual for FN3420 200 690 3 Mount the second protection panel and tighten marked screws with 5Nm Close and lock the door 4 3 5 Replace pre charge fuses F1 F2 1 Tools List Too...

Page 41: ...41 2 Spare Parts Spare Parts 1x 814437 For no UL Version AHF FUSE 10AMP 690VAC 14X51MM 690 SP 1x 814438 For UL Version AHF FUSE 10AMP 600VAC 14X38MM 690 SP 3 Work instruction Dismantling process Unlo...

Page 42: ...enance Manual for FN3420 200 690 3 Open the fuse holder F1 and F2 and take out the fuses 4 Work instruction Reassembly process Insert the two new fuses into teh fuse holder Close the covers and take c...

Page 43: ...al for FN3420 200 690 3 43 Close and lock the door 4 3 6 Replace 230V auxiliary power supply 1 Tools List Tool list 1 Cabinet Key 2 Spare Parts Spare Parts 1x 814437 AHF FUSE 10AMP 600VAC 14X38MM 690...

Page 44: ...onic Filters Maintenance Manual for FN3420 200 690 3 3 Work instruction Dismantling process Unlock the cabinet by key Locating the position of pre charging fuses F3 F4 Open the fuse holder F3 and F4 a...

Page 45: ...ilters Maintenance Manual for FN3420 200 690 3 45 4 Work instruction Reassembly process Insert the two new fuses into the fuse holder Close the covers and take care that the covers are closed complete...

Page 46: ...anual for FN3420 200 690 3 4 3 7 Replace 24V power supply fuses F45 F46 1 Tools List Tool list 1 Cabinet Key 2 Spare Parts Spare Parts 1x 814442 AHF FUSE 1 25AMP 500VAC 6 3X32 690 SP 3 Work instructio...

Page 47: ...rmonic Filters Maintenance Manual for FN3420 200 690 3 47 Locating the position of GCS module PCB Take out the fuse of position F45 F46 4 Work instruction Reassembly process Insert the two new fuses i...

Page 48: ...s Maintenance Manual for FN3420 200 690 3 Close and lock the door 4 3 8 Replace cooling system power supply fuses F47 F48 1 Tools List Tool list 1 Cabinet Key 2 Spare Parts Spare Parts 1x 814440 AHF F...

Page 49: ...ctive Harmonic Filters Maintenance Manual for FN3420 200 690 3 49 3 Work instruction Dismantling process Unlock the cabinet by key Locating the position of GCS module PCB Take out the fuse of position...

Page 50: ...50 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 4 Work instruction Reassembly process Insert the two new fuses into the fuse clip Close and lock the door...

Page 51: ...ace cooling system control unit fuses F1 F3 1 Tools List Tool list 1 Cabinet Key 2 Spare Parts Spare Parts F1 F2 1x 811403 AHF FUSE 4A 500VAC 63X32 300A SP Spare Parts F3 1x 811405 AHF FUSE 2A 250VAC...

Page 52: ...quid cooling control box can vary depends on version Lift up the fuse holder open the cover and take out the fuses Repeat the same procedure for F2 and F3 4 Work instruction Reassembly process Insert...

Page 53: ...rs Maintenance Manual for FN3420 200 690 3 53 Close the cover of liquid cooling control box with Key Close and lock the door 4 3 10 Replace air conditioning fuses F11 1 Tools List TOOLS LIST Slotted s...

Page 54: ...monic Filters Maintenance Manual for FN3420 200 690 3 2 Spare Parts Spare Parts 1x 811403 AHF FUSE 4A 500VAC 63X32 300A SP 3 Work instruction Dismantling process Unlock the cabinet by key Remove the f...

Page 55: ...ctive Harmonic Filters Maintenance Manual for FN3420 200 690 3 55 Take out fuse from fuse holder 4 Work instruction Reassembly process Insert the fuse into the fuse holder Insert the fuse into the pos...

Page 56: ...rmonic Filters Maintenance Manual for FN3420 200 690 3 Close and lock the door 4 3 11 Change cooling liquid 1 Tools List Tool list 1 Funnel with extended tube 2 Spare Parts Spare Parts 1x 814453 AHF C...

Page 57: ...ance Manual for FN3420 200 690 3 57 3 Work instruction Dismantling process Unlock the cabinet by key Open the coiled silicon tube and guide this into a vessel Open the shut off cock and drain the whol...

Page 58: ...Manual for FN3420 200 690 3 4 Work instruction Reassembly process Close the shut off cock Remove the cap of water tank and insert funnel into water tank Fill in coolant into water tank till the level...

Page 59: ...3 59 Remove the funnel and close the cap of water tank Close and lock the door 4 3 12 Replace main fan 1 Tools List Tool list 1 Cabinet Key 2 M13 socket wrench with extension 3 Slotted screw driver 2...

Page 60: ...60 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 3 Work instruction Dismantling process Locating the position of main fan Remove the marked lifting bolts Remove the top cover...

Page 61: ...ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 61 Remove the marked screws with socket wrench Loosen the two cable glands Unlock the cabinet by key...

Page 62: ...id cooling control box with Key Remark The position of liquid cooling control box can vary depends on version Loosen the conection of the two fan cables with slotted screw driver Remark Take a picture...

Page 63: ...armonic Filters Maintenance Manual for FN3420 200 690 3 63 Take out the main fan from top cover 4 Work instruction Reassembly process Insert the new main fan Insert the two fan cables into the cable g...

Page 64: ...64 ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 Tighten the marked screws with 13 6Nm Close the top cover Tighten the marked lifting bolts...

Page 65: ...ECOsine active Harmonic Filters Maintenance Manual for FN3420 200 690 3 65 Rewiring all removed fan cables Close the cover of liquid cooling control box with Key Close and lock the door...

Page 66: ...ocument has been carefully checked and understood However neither Schaffner nor its subsidiaries assume any liability whatsoever for any errors or inaccuracies of this document and the consequences th...

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