Schaffner ECOsine evo FN 3441 User And Installation Manual Download

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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

User and Installation Manual

Ecosine evo Passive Harmonic Filters

Ecosine evo

FN 3440/FN 3441 (50 Hz) for 380–415 VAC
FN 3450/FN 3451 (50 Hz) for 440–500 VAC

FN 3442/FN 3443 (60 Hz) for 380–415 VAC

FN 3452/FN 3453 (60 Hz) for 440–480 VAC

Summary of Contents for ECOsine evo FN 3441

Page 1: ...66 26 F 41 32 681 66 30 www schaffner com User and Installation Manual Ecosine evo Passive Harmonic Filters Ecosine evo FN 3440 FN 3441 50 Hz for 380 415 VAC FN 3450 FN 3451 50 Hz for 440 500 VAC FN 3442 FN 3443 60 Hz for 380 415 VAC FN 3452 FN 3453 60 Hz for 440 480 VAC ...

Page 2: ...of the information contained in this publication Revision 05 October 2018 The most current edition of these instructions PDF format can be obtained from www schaffner com or from your local Schaffner sales representative Other technical documentation of our products is also available in the download area of www schaffner com Document name User and Installation Manual ecosine evo Rev05 pdf Version ...

Page 3: ...al power quality standards Ecosine evo demonstrates superior partial load performance The excellent performance of ecosine evo filters not only reflects on mitigating harmonic current and bringing the THID down to 5 diode rectifiers rated power but also introducing minimum reactive power even at partial or no load condition The displacement power factor remains at cosφ 0 98 50 load The modular con...

Page 4: ...phase equipment with front end six pulse diode rectifier with FN 3441 43 51 53 or without DC link choke FN 3440 42 50 52 Type of source 3 phase power line without neutral Line impedance 3 calculated for the rated filter power Line frequency 50 Hz 1 Hz FN 3440 41 FN 3450 51 60 Hz 1 Hz FN 3442 43 FN 3452 53 Line voltage Nominal line voltage 10 Line voltage unbalance 1 Line voltage distortion THVD 2 ...

Page 5: ...Schaffner Group User and Installation Manual Ecosine evo October 2018 5 50 iv General Safety Notes and Installation Guidelines Cautions and Warnings ...

Page 6: ...ations if external air flow is available for cooling 17 2 6 Filter configurations and designation with embedded ventilation 18 2 7 Filter configurations and designation if external aux power supply for the fan is available 19 3 Filter description 20 3 1 General electrical specifications FN 3440 FN 3441 50 Hz filters 20 3 2 General electrical specifications FN 3450 FN 3451 50 Hz filters 21 3 3 Gene...

Page 7: ...Schaffner Group User and Installation Manual Ecosine evo October 2018 7 50 9 3 Power capacitors 46 9 4 Electrical connections 46 10 Trap circuit disconnect 48 11 Troubleshooting 49 Disclaimer 50 ...

Page 8: ...es FN 3440 FN 3450 FN 3442 and FN 3452 whereas there are only two chokes line choke trap choke included in filter series FN 3441 FN 3451 FN 3443 and FN 3453 series By distinguishing between FN 3440 FN 3450 FN 3442 FN 3452 as well as FN 3441 FN 3451 FN 3443 FN 3453 Schaffner is able to provide optimized solutions for different drive types If there is no DC link choke present in the motor drive FN 3...

Page 9: ...type1 and NEMA type 3R respectively The following five slots represent the presence F A R J P or absence X of optional modules in the filter as shown in Figure 1 Please find more information in section 2 4 2 5 and 2 6 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...

Page 10: ...Schaffner Group User and Installation Manual Ecosine evo October 2018 10 50 Table 1 Ecosine evo filter power terminals designation ...

Page 11: ...Nominal voltage 380 415 V AC TN TT IT configuration 50 Hz grid Nominal voltage 440 500 V AC TN TT IT configuration 60 Hz grid Nominal voltage 380 415 V AC TN TT IT configuration 60 Hz grid Nominal voltage 440 480 V AC TN TT IT configuration Step 3 Rectifier type presence of DC link choke in drive FN 3440 FN 3441 FN 3450 FN 3451 FN3442 FN3443 FN 3452 FN 3453 For 6 pulse diode rectifier without DC l...

Page 12: ...r drive input real power 15 kW 100 of drive rating Recommended filter according to the filter selection table FN 3450 Type FN 3450 15 113 Example 4 Power line rating 500 V 50 Hz Drive rating 380 500 V 50 60 Hz 15 kW 18 A B6 thyristor rectifier Planned rectifier drive input real power 15 kW 100 of drive rating Recommended filter according to the filter selection table FN 3450 Type FN 3450 15 113 Ex...

Page 13: ...er Group User and Installation Manual Ecosine evo October 2018 13 50 2 1 Filter selection table FN 3440 FN 3441 50 Hz 3 380 415 VAC Table 2 FN 3440 filter selection table Table 3 FN 3441 filter selection table ...

Page 14: ...er Group User and Installation Manual Ecosine evo October 2018 14 50 2 2 Filter selection table FN 3450 FN 3451 50 Hz 3 440 500 VAC Table 4 FN 3450 filter selection table Table 5 FN 3451 filter selection table ...

Page 15: ...er Group User and Installation Manual Ecosine evo October 2018 15 50 2 3 Filter selection table FN 3442 FN 3443 60 Hz 3 380 415 VAC Table 6 FN 3442 filter selection table Table 7 FN 3443 filter selection table ...

Page 16: ...er Group User and Installation Manual Ecosine evo October 2018 16 50 2 4 Filter selection table FN 3452 FN 3453 60 Hz 3 440 480 VAC Table 8 FN 3452 filter selection table Table 9 FN 3453 filter selection table ...

Page 17: ...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 FN 3440 FN 3450 FN 3452 filter configurations if external air flow available for cooling Table 11 FN 3441 FN 3451 FN 3453 filter configurations if external air flow available for c...

Page 18: ... 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 Table 12 FN 3440 FN 3450 FN 3452 filter configurations with embedded ventilation Table 13 FN 3441 FN 3451 FN 3453 filter configurations with embedded ventilation Remark Frame sizes A B C do not require air flow ...

Page 19: ... 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 Table 14 FN 3440 FN 3450 FN 3452 filter configurations if external auxiliary power supply for the fan is available Table 15 FN 3441 FN 3451 FN 3453 filter configurations if external auxiliary power supply for the fan is available Remark Frame sizes A...

Page 20: ...no load 20 of rated input current at 400 V AC Ambient temperature range 25 C to 45 C fully operational 45 C to 70 C derated operation 7 25 C to 85 C transportation and storage Flammability class UL 94V 2 Insulation class of magnetic components N 200 C H 180 C Design corresponding to Filter UL 61800 5 1 EN 61800 5 1 Chokes EN 61558 2 20 or EN 60076 6 MTBF 45 C 415 V Mil HB 217F 200 000 hours MTTR 1...

Page 21: ...d 20 of rated input current at 480 V AC Ambient temperature range 25 C to 45 C fully operational 45 C to 70 C derated operation 7 25 C to 85 C transportation and storage Flammability class UL 94V 2 Insulation class of magnetic components N 200 C H 180 C Design corresponding to Filter UL 61800 5 1 EN 61800 5 1 Chokes EN 61558 2 20 or EN 60076 6 MTBF 45 C 415 V Mil HB 217F 200 000 hours MTTR 15 minu...

Page 22: ...oad 20 of rated input current at 480 V AC Ambient temperature range 25 C to 45 C fully operational 45 C to 70 C derated operation 7 25 C to 85 C transportation and storage Flammability class UL 94V 2 Insulation class of magnetic components N 200 C H 180 C Design corresponding to Filter UL 61800 5 1 EN 61800 5 1 Chokes EN 61558 2 20 or EN 60076 6 MTBF 45 C 415 V Mil HB 217F 200 000 hours MTTR 15 mi...

Page 23: ...load 20 of rated input current at 480 V AC Ambient temperature range 25 C to 45 C fully operational 45 C to 70 C derated operation 7 25 C to 85 C transportation and storage Flammability class UL 94V 2 Insulation class of magnetic components N 200 C H 180 C Design corresponding to Filter UL 61800 5 1 EN 61800 5 1 Chokes EN 61558 2 20 or EN 60076 6 MTBF 45 C 415 V Mil HB 217F 200 000 hours MTTR 15 m...

Page 24: ...ark Do not use ecosine evo passive harmonic filters in altitudes above 4000m without consulting Schaffner first 3 6 Cooling requirement Inlet air flow requirements for each frame size are listed in Table 17 Please notice that the filters with frame size A B and C do not require air cooling For frame sizes D to H the required inlet air flow should be fulfilled either by including the optional Fan m...

Page 25: ...to Frame H from the lowest to the highest rating Dimensions and footprint are provided in section 3 7 In particular frame sizes A to C do not require air flow while frame sizes D to H need embedded fan or external ventilation details are provided in filter selection tables Table 2 to Table 9 The overview of all frame sizes in IP 00 and IP 20 are shown in Figure 2 and Figure 3 Figure 2 Overview of ...

Page 26: ...Schaffner Group User and Installation Manual Ecosine evo October 2018 26 50 Figure 3 Overview of all IP 20 frame size versions ...

Page 27: ...2 11 9 6 3 7 3 B 405 120 7 425 370 180 206 15 9 4 7 0 3 16 7 14 6 7 1 8 1 C 460 150 7 483 430 210 221 18 1 5 9 0 3 19 0 16 9 8 3 8 7 D 540 180 11 560 491 260 252 21 3 7 1 0 4 22 0 19 3 10 2 9 9 E 680 220 11 705 635 290 318 26 8 8 7 0 4 27 8 25 0 11 4 12 5 F 730 250 11 752 684 340 343 28 7 9 8 0 4 29 6 26 9 13 4 13 5 G 920 280 11 960 863 353 396 36 2 11 0 0 4 37 8 34 0 13 9 15 6 H 1115 390 11 1150 ...

Page 28: ... 5 µF 2 2 kW 2 2 µF 4 11kW 3 3 µF 15 to 45 kW 4 7 µF 55 to 200 250 kW 10 µF Table 19 Typical expected EMI filter capacitance phase to star point for FN 3442 FN 3443 and FN 3452 FN 3453 1 5 HP 1 5 µF 3 HP 2 2 µF 5 20HP 3 3 µF 25 to 60 HP 4 7 µF 75 to 300 HP 10 µF Note 132 200 kW of FN 3440 FN 3441 series 160 250 kW of FN 3450 FN 3451 series 200 240HP of FN 3442 FN 3443 series and 250 300HP of FN 34...

Page 29: ...r and Installation Manual Ecosine evo October 2018 29 50 THID vs load diode rectifier front ends Power factor vs load diode rectifier front ends Drive dc link voltage vs load diode rectifier front ends with FN 3440 series ...

Page 30: ...ples of terminals For optional configurations with TDJ wire bridges are installed for immediate operation of the filter They allow for the connection of an external contactor for load dependent disconnection of the trap circuit if needed Function blocks Chokes Power magnetic components incl temperature sensors Capacitors Power capacitors incl discharge resistors Fan Field replaceable fan for choke...

Page 31: ... The base module of FN 3440 FN 3450 FN 3442 and FN 3452 series contains line choke load choke trap choke and trap capacitor which helps reduce THID to 5 for motor drives without DC link choke present The base module schematic is shown in Figure 7 Figure 7 Base module of FN 3440 FN 3450 FN 3442 and FN 3452 filter series General working principle of ecosine evo filter base modules is shown in Figure...

Page 32: ...ion Manual Ecosine evo October 2018 32 50 Figure 9 shows a summary of optional modules in use with ecosine evo passive harmonic filters Figure 9 Optional modules for ecosine evo filter and according to your requirement and installation ...

Page 33: ...sections 5 1 IP 00 version frame size A F The general design of the ecosine evo passive harmonic filter IP 00 versions with fan module aux power supply module TDJ module and RC damper module E0FAJRX is shown in Figure 10 There are load choke Lo trap capacitor Ct trap disconnect jumper power terminal and fan module visible on the upper stage The design and construction of the lower stage is shown i...

Page 34: ...t trap disconnect jumper power terminal visible on the upper stage The fan module is visible between the upper and lower stage The design and construction of the lower stage is shown in Figure 13 The line choke Li trap choke Lt load chock Lo RC damper module are constructed on the base plate which contains screw holes for wall mounting Figure 12 Design of ecosine evo filter Type E0FAJRX frame size...

Page 35: ...cover and finger guard on top of the IP 00 version filters Figure 14 Design of IP 20 version ecosine evo filter with frame size D left and frame size H right Parameters of IP 20 enclosure finger guard are shown in Table 20 Table 20 Parameters of finger guard of IP 20 enclosure Frame size Finger guard cross section width diameter mm Material A 11 Plastic B 11 Plastic C 11 Plastic D 12 Plastic E 14 ...

Page 36: ...By using SchaffnerPQS users can easily simulate and estimate system performance taking into account the most important design requirements and system s boundary conditions Furthermore an online product configurator myecoine com helps and guides users to select the best filter topology and choose the appropriate configurable functional options Simulate and estimate the performance of your selected ...

Page 37: ...eam power relative to the harmonic filter is clean i e unloaded by the harmonics This can be of vital importance when the same power bus supplies both motor drives and sensitive loads Ecosine evo passive harmonic filters are also suitable for paralleling lower power non linear loads on a higher power harmonic filter to improve overall system economy In this case the total expected load power of al...

Page 38: ...ed 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 Step 2 Mounting Ecosine evo passive...

Page 39: ...ommends 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 Filter placement 1 Set screws loose into wall leave 5mm distance from head to wall 2 Lift filter with appropriate crane smallest types up to 25kg may be lifted manually by two persons 3 Place filter first onto lower ...

Page 40: ...f 75 C or higher Remarks regarding IP 20 enclosure 1 To connect ecosine evo line and load side terminals the fingure guard has to be removed as a first step and be installed again when the line and load side terminals are connected The screw thread and torque value for all the frame sizes are Screw thread M5 Screw torque value 4Nm 2 The metal finger guard for frame sizes E F and G are equipped wit...

Page 41: ...is constituted by a thermal switch NC 180 C UL approved to detect overload of chokes It may either be used to remotely disconnect the drive s load via respective input of drive control check drive manual or as alarm sensor for system control unit AN ENGAGED MONITOR SWITCH MUST LEAD TO IMMEDIATE LOAD SHUTDOWN AND INVESTIGATION OF THE PROBLEM III 7 Connect ecosine line side terminals L1 L2 L3 to pow...

Page 42: ...e evo filters paralleled for a high power load need each a separate 3 phase line side fuse block corresponding to the respective filter and according to above table The drive s application manual may prescribe line side fuse protection as well which in this case either corresponds to the sum of the filter fuse ratings or if lower would request separate drive fuses at its input An application havin...

Page 43: ... 25 20 FN 3440 15 113 FN 3441 15 113 FN 3450 19 113 FN 3451 19 113 35 35 FN 3440 19 113 FN 3441 19 113 FN 3450 22 113 FN 3451 22 113 40 35 FN 3440 22 113 FN 3441 22 113 FN 3450 30 115 FN 3451 30 115 50 50 FN 3440 30 115 FN 3441 30 115 FN 3450 37 115 FN 3451 37 115 75 63 FN 3440 37 115 FN 3441 37 115 FN 3450 45 115 FN 3451 45 115 80 80 FN 3440 45 115 FN 3441 45 115 FN 3450 55 115 FN 3451 55 115 100...

Page 44: ...442 16 113 FN3443 16 113 FN 3452 20 113 FN 3453 20 113 30 FN3442 20 113 FN3443 20 113 FN 3452 25 113 FN 3453 25 113 35 FN3442 24 113 FN3443 24 113 FN 3452 30 113 FN 3453 30 113 40 FN3442 32 115 FN3443 32 115 FN 3452 40 115 FN 3453 40 115 50 FN3442 40 115 FN3443 40 115 FN 3452 50 115 FN 3453 50 115 60 FN3442 48 115 FN3443 48 115 FN 3452 60 115 FN 3453 60 115 80 FN3442 60 115 FN3443 60 115 FN 3452 7...

Page 45: ...ime Warnings High voltage potentials are involved in the operation of this product Always remove line side power before attempting to perform maintenance and let ample time elapse for the capacitors to discharge to safe levels 42 V Residual voltages are to be measured both line to line and line to earth Line side power must be disconnected prior to replacement of any part 9 1 Maintenance schedule ...

Page 46: ...lyzer According to the above considerations a 2 year inspection interval is advisable Note an inspection should as well be performed after extreme overvoltage situations in the system Note Storage of capacitors Up to 3 years long storage electrolitic capacitors can be operated without any restriction and the nominal voltage can be applied without any preliminary preparation System reliability and ...

Page 47: ...Schaffner Group User and Installation Manual Ecosine evo October 2018 47 50 Check of internal connections within the filters is not needed or should be conducted by a Schaffner service representative ...

Page 48: ...tomated capacitive current control Motor load power factor monitoring device Capacitor contactor A reduced load system status may be available as system controller output signal In this case only adequate driving of capacitor contactor has to be assured Note It is necessary to take into account overall concept of power factor correction A system PFC correction unit with large capacitor banks may b...

Page 49: ... have undergone rigorous testing and qualification procedures 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 ...

Page 50: ...pecifications are subject to change without notice Product suitability for an area of application must ultimately be determined by the customer In all cases products must never be operated outside their published specifications Schaffner does not guarantee the availability of all published products Latest publications and a complete disclaimer can be downloaded from the Schaffner website All trade...

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