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ECOsine Passive Harmonic Filters

1. Passive Harmonic Filters 5 energy efficiency and reliability May 2013 52 52 Appendix Il Declaration of conformity Declaration of Conformity A manufacturer Schaffner EMV AG Nordstrasse 11 CH 4542 Luterbach Switzerland declares under the sole responsibility that the following products ECOsine FN3410 range ECOsine FN3411 range ECOsine FN3412 range ECOsine FN3413 range options all are in conformity with the following directives and standards directives Low voltage directive 2006 95 EC EMC directive 2004 108 EC standards EN 50178 Electronic equipment for use in power installations EN 61000 6 2 EMC immunity for industrial environments ECOsine FN3410 to FN3413 filters are passive harmonic filters designed for the operation on the input grid side of power electronic equipment with 6 pulse diode FN3410 FN3412 or SCR FN3411 FN3413 rectifier front ends in balanced three phase power systems like typically used in AC or DC motor drives and high power DC supplies The installation instructions are integrated part of the product The product shall exclusively be used in the above mentioned applications according to the installation instruction The validity of this declaration expires if the products are modified or improperly applied We certify the compliance of the products and options with the mentioned directives and standards Luterbach 17 09 2009 Schaffner EMV AG AL pn Fabiar
2. 190 S Leer F KL Installation All filters from FN 341x 8 to 130 are wall mountable and have to be operated vertically The filters FN 341x 150 and higher are designed for floor mounting In order to allow for sufficient air flow all filters must be clear on top and bottom min 150mm Optional NEMA1 cover All filters can be optionally fitted with a NEMA1 cover Please find order codes on previous pages Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 PIISCHAFFNeL energy efficiency and reliability May 2013 11 52 Dimensions FN 3410 FN 3411 10 13 16 24 32 38 45 60 75 90 110 150 180 210 260 320 FN 3412 FN 3413 8 11 15 21 28 35 41 53 65 80 105 130 160 190 240 310 A 400 400 430 430 520 520 520 590 590 750 750 750 1000 1000 1000 1000 1000 B 170 170 210 210 250 250 250 300 300 320 320 320 500 500 500 500 500 c 190 190 210 210 280 280 280 300 300 300 300 300 450 450 450 450 450 E 380 380 410 410 495 495 495 565 565 725 725 725 240 240 240 240 240 F 130 130 170 170 200 200 200 250 250 270 270 270 338 338 338 338 338 G 7 7 9 9 11 11 11 11 11 11 11 11 14x30 14x30 14x30 14x30 14x30 J Me Me Me M M8 M8 M8 M8 M8 M10 M10 M10 M10 M10 M10 M10 M10 Vv 25 25 w 6 6 X 125 125 Y 40 40 Z 11 11 All dimensions in mm 1 inch 25 4mm Tolerances according ISO 2768 m EN 22768 m Filter connector cross sections 33
3. 34 35 40 44 Solid wire 16mm _ 35mm 50mm _ 95mm __ 10mm Flex wire 10mm 25mm somm 95mm _ mm AWG type wire AWG 6 AWG 2 AWG 1 0 AWG 4 0 AWG 8 Recommended torque 1 5 1 8Nm 4 0 4 5Nm 7 8Nm 17 20Nm 1 0 1 2Nm Please visit www schaffner com to find more details on filter connectors Schaffner EMV AG User Manual LIISCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 12 52 2 6 Mechanical specifications FN 3410HV Mechanical data FN 3410HV 10 to 110 aL G A UU J FN 3410HV 260 to 320 FN 3410HV 150 to 210 Filters with busbar terminals are shipped with a protective cover User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 13 52 A 430 430 520 520 590 590 590 750 750 750 750 830 830 830 1055 1055 B 210 210 250 250 300 300 300 320 320 320 320 450 450 450 500 500 L 210 210 280 280 300 300 300 300 300 300 300 320 320 320 360 360 E 410 410 495 495 565 565 565 725 725 725 725 800 800 800 1025 1025 F 170 170 200 200 250 250 250 270 270 270 270 350 350 350 400 400 G 9 9 D 1 D D u u u u u u u u 13 13 J M6 M6 M8 M8 MSs M8 MS MIO M10 M10 M10 M10 M10 M10 M10 M10 N 25 25 Ww 6 6 x 125 12 5 Y 50 50 Z u D All dimensions in mmy 1 inch 254mm Tolerances according to ISO 2768 m EN 22768 m Filter connector cross sections 33 34 35 40 4 53 Solid wire 16mm 35mm 5Om
4. 5 4 Sa 3 L Demand 200 A Demand 100 H 2 1 0 d 0 20 40 60 80 100 120 140 160 Load Demand 100 means that maximum demand at PCC is equal to 100 of maximum fundamental component of nonlinear load Demand 200 means that maximum demand at PCC is equal to 200 100 nonlinear load 100 additional linear load TDD vs load SCR rectifier front ends 6 Phase 0 Phase 20 Phase 40 TDD wo 0 20 40 60 80 100 120 Load In SCR rectifier applications filter performance greatly depends upon the firing angle of the thyristors User Manual S IISCHAFFNeF User Manual ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 16 52 Power factor vs load diode rectifier front ends 1 20 1 00 0 80 Zline 0 2 to 3 0 Si a Ei COS phi 0 20 40 60 80 100 120 140 160 Load Power factor vs load SCR rectifier front ends 1 20 1 00 0 80 Phase 0 Phase 20 Phase 40 0 60 COS phi 0 40 0 20 0 00 0 20 40 60 80 100 120 Load In SCR rectifier applications filter characteristics greatly depend upon the firing angle of the thyristors Gees IISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency an
5. Harmonic Order Harmonic h voltage h voltage h voltage 5 4 0 3 4 0 2 1 6 Z 4 0 9 1 2 4 1 0 11 3 0 15 0 3 6 0 5 13 2 5 21 0 2 8 0 4 17 1 6 gt 21 0 2 10 0 4 19 1 2 12 0 2 23 12 gt 12 0 2 25 0 7 gt 25 0 2 0 5 The Total Harmonic Distortion THD level is 5 G5 4 1 current harmonic limits for loads rated gt 16A per phase Table 7 Stage 1 Maximum Permissible Harmonic Current Emissions in Amperes RMS for Aggregate Loads and Equipment Rated gt 16A per phase Harmonic Emission order bh current I 41 E Lk RB These limits are based on a typical fault level of 10 MVA see Table 9 and Application Guide ETR 122 Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 48 52 LIISCHAFFNEL energy efficiency and reliability ll 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 Definitions Total harmonic distortion THD Ratio of the r m s value of the harmonics harmonic currents of the order n to the r m s value of the fundamental r THD JI 1 Partial weighted harmonic distortion PWHD Ratio of the r m s value
6. Over temperature switch and load disconnect sssssssessessiessissrississinstinttnnstnnntnnttnnntnnntnnnenn nnt 36 8 2 Trap Circuit CISCOMMECE ceeeceecceceeeeeceeeeeeeceeeeneeceeeesseceeeesaeaeeeeaaeaeeesaeeeeesnaeceeesnneaeceeseeaeeesnneeeeeaneaaes 37 9 Application example S si AEEA EAE REAA RASENS RNAAR NANNA EAKA RRRS 38 9 1 Harmonics mitigation on an individual motor drive eee cece ence eeeeeneeeeeeaaeeeeeeaaeeeeeeaaeeeseeaeeeeeeaaes 38 9 2 Harmonics mitigation in applications with multiple loads in parallel 39 10 Troubleshooting E 41 11 FAQ Frequently asked questions ccccseccsseeceseeeeeeeeeeeeseseaeensneeeeeeeeseaesaseeeenseeeseeesesnaesaseeneeeeaes 42 12 CUSTOM design Input form cece seeee seen eeeeeeeeee ee eaee ee neee ea eeee esas se saee ed neeeeeeeesaesaneeeenneeeeenesdsnaesaneeneneeaes 45 Appendix I International Standards cccssecceceseeeseseeneeeeeeenenseseeneeseseeneeseseeneesesesneeseseseeeseseenenseseeenens 46 I Engineering recommendation G5 4 1 ccccceccceceneeeeeeeeeeeeeceeeeeeaeeeeeeeseeeeeseaeeesaaesdeaeeseaeeeseaeeeeaeeeeneeees 46 Il International standard EN Gi 00021 48 I IEEE Std KE E 51 Appendix Il Declaration Of conformity 2 ceceeeeeeeeeeeee ee eeeeee ee eeneee se neseeeseseeeeeseseseeeseseeneeseseeneeseseenenees 52 Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 5 52 1 Part number coding FN 34xx x
7. of a selected group of higher order harmonics in this International Standard beginning from the fourteenth harmonic weighted with the harmonic order n to the r m s value of the fundamental n 40 I 2 PWHD Bint n 14 L Reference fundamental current l4 r m s value of the fundamental component of the rated line current legu of the equipment The reference fundamental current shall be either measured or calculated as follows I L equ 1 THD Total harmonic current THC The total r m s value of the harmonic current components of orders 2 to 40 40 THC X n 2 Point of common coupling PCC The point in the public system which is closest to the customer concerned and to which other customers are or may be connected Short circuit power Sse Value of the three phase short circuit power calculated from the nominal interphase system voltage Unomina and the line impedance Z of the system atthe PCC e y2 d where Z is the system impedance at the power frequency Rated apparent power of the equipment Sequ Value calculated from the rated line current legu of the piece of equipment stated by S 3 77 E equ i equ Short circuit ratio Rsce Characteristic value of a piece of equipment defined as follows Rce Sef S equ User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 49 52 EN 61000 3 12 curr
8. standards directly from IEEE IEC and other organizations L Engineering recommendation G5 4 1 Definitions Non linear load or equipment A load or equipment that draws a non sinusoidal current when energized by a sinusoidal voltage Aggregate load Non linear load equal to the sum of the individual non linear equipment ratings Fault level A value expressed in MVA of the symmetrical short circuit power at a point in the supply system It is defined as the product of the symmetrical short circuit current I and the nominal system voltage Uph ph OF Uph n F L U ipn v3 e U phn e Harmonic current lh The RMS value of a harmonic current of order h expressed in amperes Harmonic distortion The cyclic departure of a waveform from the sinusoidal shape This can be described by the addition of one or more harmonics to the fundamental Point of common coupling The point in the public supply system electrically nearest to a PCC customer s installation at which other customers loads are or may be connected Total harmonic voltage distortion THD User Manual LP IISCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 47 52 G5 4 1 planning levels for harmonic voltages Table 2 Planning Levels for Harmonic Voltages in 400V Systems Odd harmonics Odd harmonics even harmonies Non multiple of 3 Multiple of 3 Order Harmonic Order
9. the corresponding filter family according to the following table 50Hz grid Europe Middle East parts of Asia parts of South America FN 3410 HV FN 3411 60Hz grid North and Central America parts of Asia parts of South America FN 3412 FN 3413 Note a 50Hz filter will not provide satisfying harmonics mitigation in a 60Hz grid and vice versa Step 3 grid configuration Verify that the grid configuration is suitable for standard ECOsine harmonic filters according to the following table 50Hz grid Nominal voltage 380 500VAC 10 TN TT IT configuration 50Hz grid Nominal voltage 690VAC 10 TN TT IT configuration 60Hz grid Nominal voltage 380 480VAC 10 TN TT IT configuration Note filters for 600V 60HZz as well as single phase filters are available upon request Step 4 real rectifier drive input power The individual filter must be selected by the actual rectifier drive input real power KW HP It is important to select the filter as close as possible to the effective input power of the rectifier drive Note that FN 3410 and FN 3411 50Hz filters show double ratings in the selection table Depending upon the grid voltage the same filter is rated for two different rectifier drive input real power values For 380 400 415V lines the filters have a lower power rating than for 500V systems Note that if the rectifier drive is being operated very close to its rated power then the filter can be selected by
10. the motor drive s nominal power rating However if the drive will be operated e g at only 66 of its rated power then a smaller filter should be selected in order to get maximum harmonics mitigation performance and the optimum in terms of cost size and weight User Manual IISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 24 52 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 gt Recommended filter according to the filter selection table FN 3410 Type FN 3410 32 33 Example 2 Power line rating 500V 50Hz Drive rating 380 500V 50 60Hz 15kW 22 5A diode rectifier Planned rectifier drive input real power 15kW 100 of drive rating gt Recommended filter according to the filter selection table FN 3410 Type FN 3410 24 33 Example 3 Power line rating 400V 50Hz Drive rating 380 500V 50 60Hz 15kW 22 5A diode rectifier Planned rectifier drive input real power 10kW 66 of drive rating gt Recommended filter according to the filter selection table FN 3410 Type FN 3410 24 33 Example 4 Power line rating 500V 50Hz Drive rating 380 500V 50 60Hz 15kW 22 5A diode rectifier Planned rectifier drive input real power 10kW 66 of drive rating gt Recommended filter according to t
11. 5 External UL rated fuses required derated nominal V 85 C Tamb 35 C UL compliant design for 600V operating voltage NOOO FW ECOsine filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor System requirements THVD lt 2 line voltage unbalance lt 1 2 dc link choke for filters 245kW Performance specification for six pulse diode rectifiers SCR rectifier front ends produce different results depending upon Repetitive tests to be performed at max 80 of above levels for 2 seconds Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 8 52 IISCHAFFNeL energy efficiency and reliability 2 3 General electrical specifications FN 3412 and FN 3413 60Hz filters Nominal operating voltage 3x 380 to 480VAC Voltage tolerance range 3x 342 to 528VAC Operating frequency 60Hz 1Hz Network TN TT IT Nominal motor drive input current rating W 8 to 310A 50 C Nominal filter input current rating 1 5Arms to 250Ams 50 C Nominal motor drive input power rating 5 to 250HP Total harmonic current distortion THID lt 5 rated power Total demand distortion TDD 2 According to IEEE 519 table 10 3 Partially weighted harmonic distortion PWHID lt 22 rated power Efficiency gt 98 5 nominal line voltage and power Drive dc link voltage behavior 3 No l
12. Beck VP Research amp Development Alexander Hagemann CEO
13. Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland P 41 32 681 66 26 F 41 32 681 66 30 www schaffner com IISCHAFFNeF energy efficiency and reliability User Manual ECOsine Passive Harmonic Filters Field guide to harmonics mitigation and energy efficiency Latest edition incl 690V 50Hz filters May 2013 1 52 User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 2 52 ECOsine Passive Harmonic Filters The field guide to harmonics mitigation and energy efficiency Stefan Melly Head of Product Management Norbert Haberle Head of Innovation Center Andrzej Pietkiewicz Ph D Project Manager Innovation Center Schaffner ECOsine harmonic filters represent an economical solution to the challenge of load applied harmonics mitigation in three phase power systems With a plug and play approach and more compact dimensions than comparable products they can be quickly installed and easily commissioned They increase the reliability and service life of electric installations help utilize electric system capacity better and are the key to meet Power Quality standards such as IEEE Std 519 1992 ECOsine filters help to reduce the costly waste of electric power This user manual is intended to support designers installers and application engineers with filter selection installation application and maintenance It provides helpful tips
14. ained as described in this document In the unlikely event of a problem please contact your local Schaffner partner for assistance Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 42 52 11 FAQ Frequently asked questions Q Why are ECOsine harmonic filters CE marked but Schaffner EMI filters are not A EMI filters and other passive components must not be CE marked according to the low voltage directive because they are not sold to the public as an individual device with an independent function They are usually part of an equipment which in turn has to be CE marked as a whole This is different with e g a transformer or a harmonic filter ECOsine can be sold as an individual aftermarket product that will not necessarily be built into another CE conform piece of equipment As a stand alone unit it must be CE marked in order to be distributed throughout Europe Q Can ECOsine filters be used for a single phase load or just be connected to two phases A 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 Q How are ECOsine harmonic filters co
15. c filters are installed In such cases it may not be necessary to install trap circuit disconnect functions Recommended settings Schaffner recommends to engage and disengage the trap circuit disconnect at following load levels Trap circuit status Proposed load level Dis connect When load level drops under 10 15 Connect When load level rises above 20 25 User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 38 52 9 Application examples 9 1 Harmonics mitigation on an individual motor drive Problem A D DKW motor drive with diode rectifier is used in the well head control system of a small scale oil exploration site The drive is controlling the motor of a submersible pump down in the well It is designed to run close to full load for the most part The well head control unit has to meet IEEE Std 519 1992 The existing harmonic spectrum is significantly above acceptable limits eel eae Motor LA Tm Mains J Motor drive 5 5kW 480VAC Measurements without filter el No filter lin 11Ams for power 5 5kW THID 92 Rsce 150 PWHD 37 Voltage Uin 480V ims phase phase THVD 4 4 for kl 150 Ims 5th 7th 11th 13th Voltage phase neutral Current Solution ECOsine FN 3410 10 44 is the appropriate harmonic filter to match both the s
16. d A Mains FN 3410 210 40 7 e 110kW 400VAC Non linear load 1 30kW 400VAC e KEE KA A L Non linear load 2 75kW 400VAC If the expected input power exceeds the rating of the largest available filter and a custom solution is not desired then two or more filters can be wired in parallel In this mode of operation it is recommended to use filters with equal power ratings to ensure proper current sharing 3 La AAA T Non linear load 300kW 500VAC D SH L D D d Mains 2x FN 3410 260 99 2x 160kW 500VAC AC line reactors and or dc link chokes are not required when ECOsine filters are installed For a new system this situation helps to offset a good portion of the harmonic filter cost If a harmonic filter is added to a drive with an existing AC line reactor it is recommended to remove the reactor if possible Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 28 52 6 Filter installation Please follow the few simple steps below to ensure a safe and satisfying filter function for many years Step 1 Visual inspection All Schaffner ECOsine filters have undergone rigorous testing before they left our ISO 9001 2008 certified factory They are packaged with great care in a sturdy container for international shipment However carefully inspect the shipping container for damage that may have occu
17. d reliability May 2013 17 52 Drive dc link voltage vs load diode rectifier front ends 110 105 100 x Vdc Z line 0 2 3 Vdc Z line 3 95 90 Kee ror SS EE EE E E ELE EL REES E 0 20 40 60 80 100 120 140 Load Drive dc link voltage vs load SCR rectifier front ends 110 105 100 95 Vdc a 0 90 Vdc a 20 Vde a 40 Vde 85 80 75 70 T T T T T T T T T T T T T T T T T T T T I T T T T T Load In SCR rectifier applications filter characteristics greatly depend upon the firing angle of the thyristors Schaffner EMV AG User Manual IISCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 18 52 2 8 Function diagram Disconnect Power capacitors Al glrap choke B1 Gl A2 B2 C2 jie L1 Load L2 In Out choke L2 L3 0 L3 Power supply Fan Control No Monitor C error cooling power on PE 8 red yellow green LED Filter terminals Line 3 touch safe terminal blocks busbar terminals gt 240A Load 3 touch safe terminal blocks busbar terminals gt 240A Monitor NO switch 250VAC 3A touch safe terminal 4mm Open position indicates error PE Protective earth Threaded stud with washer and nut Trap disconnect Touch safe terminals Upon delivery wire bridges are install
18. dB A 1m 60dB A 1m FN 3410 75 35 P 37kW 66dB A 1m 70dB A 1m FN 3410 320 99 P 160kW tbd tbd Equipment used Peak Tech Sound Level Meter 5055 User Manual LP IISCHAFFNeL User Manual ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 21 52 3 Filter purpose and function ECOsine harmonic filters are based on passive LCR filtering technology They are intended for the operation on the input side of balanced three phase six pulse rectifiers like commonly used in inverters for motor drives ECOsine Motor drive Motor Six pulse rectifiers inherently draw current in a non sinusoidal fashion from the grid creating a current wave form rich in harmonics Harmonic currents flow through system impedances and create harmonic voltages Both harmonic currents and voltages give raise to serious issues such as electric system overload reliability problems and violations against international standards and utility codes e k EEN a E WB VL3 G KA RL1 Le Cont i e E Et R RL2 CE a 2 SE load Ll2 e A i A Rest Power source Line impedance Power line Voltage distortions propagate throughout the system and affect sensitive loads Current distortions overload the electric infrastructure affect power lines and equipment Voltage phase neutral Current ECOsine filters efficiently reduce the har
19. e above considerations a 2 year inspection interval is advisable An inspection should as well be performed after extreme overvoltage situations Field replacement of power capacitors is possible but must be executed by trained Schaffner personnel Indications for required capacitor replacement performance loss THID out of spec visible capacitor damage User Manual I SCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 35 52 Fan specifications Supply voltage 24VDC Power max 7W Size 1 92x92x25mm fixation holes 82 5x82 5mm 4 3mm Size 2 120x120x25mm fixation holes 105x105mm 4 3mm Air flow size 1 min 7OCFM cubic feet per minute 1 CFM 1 7m h Air flow size 2 min 110CFM Connection min 150mm cable length TYCO MTA 100 plug 2 poles pin 1 24VDC Recommended types SUNON PE92252V1 0000 A99 Size 1 NMB MAT 3610KL 05W B50 Recommended types SUNON PMD2412PTB3 A Size 2 NMB MAT 4710KL O5W B50 Size 1 FN 341x 10 44 FN 341x 13 44 FN 341x 8 44 FN 341x 11 44 Size 2 all other filters Fan replacement instructions 1 Disconnect line side power Consult your local safety instructions Unscrew fan plate on bottom side of filter Pull out fan connector plug Disassemble fan from plate 4 bolts oa A W bh Mount a new fan with appropriate plug isolation tube and plug of old fan may b
20. e significant negative effects such as Transformers Increased audible noise Increase in copper losses due to current harmonics Increase in iron losses due to voltage harmonics Power installation with capacitive power factor compensators Risk of resonance and resulting damage of capacitor banks Power cables Increased heating Risk of insulation failure if involved in system resonance Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 43 52 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 Very high slip in induction motors crawling Potential of mechanical oscillations in a turbine generator or motor load systems Pulsating or reduced torques Capacitors Increased heating and voltage stress Reduced capacitors life Electronic Equipment Wrong operation of equipment dependent upon accurate determination of the line voltage wave shape e g zero crossing Problems caused by transmission of ac supply harmonics via power supply or magnetic coupling into equipment components Erratic Sometimes subtle malfunctions of computers programmable controllers medical instruments etc in some cases having very serious consequences Metering watt hour meters Possible erroneous operation with both positi
21. e used again appropriate tool for IDC connection needed Pay attention to the polarity of the plug 6 Connect fan to plug socket re assemble fan plate Steps 4 5 Gees IISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 36 52 8 Special considerations 8 1 Over temperature switch and load disconnect ECOsine harmonic filters provide advanced safety monitoring two temperature detection levels for each inductive component fan activation level over temperature indication level monitoring of temperature sensor impedance too low short and too high open impedance trigger monitor switch fan operation monitoring too low fan current or fan supply voltage are recognized and trigger monitor switch All these alarm indications request adequate reaction in order to prevent possible system damage i e cable or cabinet overheating Either the cabinet safety monitoring unit will make use of the alarm switch or the switch can directly control a stop function of a connected motor drive refer to drive manual for applicability Technical data of monitor switch Error status Switch open Switching power max 3A 250VAC or 30VDC min 10mA 5V Technology Mechanical switch relay potential free Safety UL 508 Note The described applications of the monitor switch are proposals Please respect local and national safety prescriptions Note Open
22. echanical designs Please use the following table to gather essential technical information prior to contacting your local Schaffner partner Application incl power system Types of non linear loads Types of rectifiers involved System block schematic Current harmonic spectrum Required harmonics reduction THID TDD standard Expected total load real power kW HP Expected total input current A System voltage VAC System frequency Hz Efficiency K l Overload capability K Max capacitive current A Ambient temperature C Expected life time h Mechanical requirements Terminals Safety approvals Monitoring functionality Other special requirements Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 46 52 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 Therefore national and international standards for harmonic distortions and other Power Quality problems are needed In the following a brief overview of some important international standards recommendations are provided For full details please obtain the required
23. ed 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 cooling Power supply Internally generated 24VDC for fan supply Control Temperature monitoring Monitor switch triggering LED readout User Manual LIN SCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 19 52 2 9 External filter elements Line terminals 3 Cap disconnect terminals 6 LEDs 3 Load terminals 3 PE terminal 1 Fan Monitor switch 2 2 10 Monitoring status Monitor switch Filter state Power off eo nr Power on internal temperature does not require fan Power on active fan cooling B e Power on over temperature or fan error erg Power on sensor short or monitor error Fan or sensor disconnection is recognized User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 20 52 2 11 Audible noise Tests have been performed with nominal load and with without fan running Ambient noise level 47dB A Filter Fans OFF Fans ON FN 3410 13 44 P 5 5kW 50dB A 1m 57dB A 1m FN 3410 32 33 P 15kW 57
24. ed load power User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 26 52 Filter selection table FN 3412 and FN 3413 60Hz Filter selection table Filter Rated load power Power loss Input Output Capacitor Weight NEMA1 460VAC 60Hz 460V connections disconnections covers HP Iw dh i di kg Order code FN 341x 8 44 5 56 44 44 12 803565 FN 341x 1 1 44 75 84 44 44 13 803565 FN 341x 15 44 10 112 44 44 17 803566 FN 341x 21 44 15 168 44 44 21 803566 FN 341x 28 33 20 209 33 44 28 803567 FN 341x 35 33 25 261 33 44 32 803567 FN 341x 41 33 30 291 33 33 35 803567 FN 341x 53 34 40 328 34 33 48 803568 FN 341x 65 34 50 373 34 34 52 803568 FN 341x 80 35 60 403 35 34 69 803569 FN 341x 105 35 75 447 35 34 77 803569 FN 341x 130 35 100 522 35 35 87 803569 FN 341x 160 40 125 559 40 35 124 803570 FN 341x 190 40 150 671 40 35 132 803570 EN 341x 240 99 200 746 99 35 185 803570 FN 341x 310 99 250 932 99 35 202 803570 To compile a complete part number please replace the x with a 2 for diode or 3 for SCR rectifiers Filter to be selected by system voltage and load motor drive power Note the harmonic filter will reduce the RMS input current Example the rated RMS input current of an unfiltered 460V 20HP 28A drive will be reduced to approximately 20A Therefore filter selection by current rating as it is common for EMC EMI filters is not suitable Calcu
25. eholders must be UL listed and rated for 100kA SCCR supplies The subsequent list shows requested fuse current ratings for UL class J and where UL compliance is not mandatory for IEC class gG The fuse rating is independent of the supply voltage ECOsine type Fuse class J ECOsine type Fuse class J Fuse class gG FN 3412 13 rated A All FN 3410 HV 11 rated A rated A FN 341x 8 44 8 FN 341x 10 44 10 10 FN 341x 11 44 10 FN 341x 13 44 15 10 _FN 341x 15 44 15 FN 341x 16 44 20 16 FN 341x 21 44 25 FN 341x 24 33 25 20 EN 341x 28 33 30 FN 341x 32 33 35 35 FN 341x 35 33 35 FN 341x 38 33 40 35 FN 341x 41 33 45 FN 341x 45 34 50 50 EN 341x 53 34 60 FN 341x 60 34 75 63 FN 341x 65 34 70 FN 341x 75 35 80 80 FN 341x 80 35 90 FN 341x 90 35 100 100 FN 341x 105 35 110 FN 341x 110 35 150 125 FN 341x 130 35 150 FN 341x 150 40 175 160 FN 341x 160 40 175 FN 341x 180 40 200 200 EN 341x 190 40 225 FN 341x 210 40 250 224 FN 341x 240 99 300 FN 341x 260 99 300 250 FN 341x 310 99 400 FN 341x 320 99 350 300 Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 33 52 A system with multiple ECOsine 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 corre
26. ent harmonic limits Table 3 Current emission limits for balanced three phase equipment Minimal Rsce Admissible individual Admissible harmonic harmonic current J J current distortion factors NOTE 1 The relative values of even harmonics up to order 12 must not exceed 16 n Even harmonics above order 12 are taken into account in THD and PWHD in the same way as odd order harmonics NOTE 2 Linear interpolation between successive Rce values is permitted See also Annex B a J reference fundamental current J harmonic current component Table 4 Current emission limits for balanced three phase equipment under specified conditions Admissible individual Admissible harmonic Minimal Rsce harmonic current J J 4 current distortion factors NOTE 1 The relative values of even harmonics up to order 12 must not exceed 16 n Even harmonics above order 12 are taken into account in THD and PWHD in the same way as odd order harmonics NOTE 2 Linear interpolation between successive Rsce values is permitted See also Annex B a J reference fundamental current J harmonic current component 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 to 150 Note This condition is normally fulfilled by equipment with an uncontrolled rectifier bridge and capacitive fi
27. er Consult your local safety instructions 3 2 IP20 cover for filters with bus bar terminals The filters with bus bar terminals FN 3410 FN 3411 260 99 FN 3412 FN 3413 240 99 and larger are equipped with an IP20 rated cover for safety reasons Remove bolts on both sides of the cover untighten the bolt on the front side to remove the cover IP20 cover Wires can be comfortably routed from the back side of bolt to untighten the filter in between the filter legs to the terminals refer to the picture to the right bolts to remove 3 3 Carefully connect protective earth PE wire to adequate earth potential close to ECOsine filter Use a wire diameter of equal or bigger size as foreseen for line load side power cables according to your local codes and safety instructions 3 4 Connect PE wire on lower left side of ECOsine with appropriate cable lug to threaded stud max torqueM6 4Nm max torque M8 10Nm max torque M10 18Nm 3 5 Connect ECOsine load side terminals L1 L2 L3 to respective motor drive or rectifier inputs Terminal Wire Torque Last two digits of ECOsine part number i e FN 3412 65 34 indicate terminal type See table to the right for recommended wire size and torque Use stranded copper wire with a temperature rating of 75 C or higher 3 6 Use wired trap circuit default or install external capacitive current control Con
28. ete part number please replace the x with a 0 for diode or 1 for SCR rectifiers Filter to be selected by system voltage and load motor drive power Note the harmonic filter will reduce the RMS input current Example the rated RMS input current of an unfiltered 400V 1S5kW 32A drive will be reduced to approximately 23A Therefore filter selection by current rating as it is common for EMC EMI filters is not suitable Calculated power loss at rated load power Please contact your local Schaffner partner to order the optional NEMA1 covers with the order code in the table above Filter selection table FN 3410HV 50Hz Filter selection table FN3410HV 10 44 7 5 150 44 44 20 FN3410HV 13 44 u 209 44 44 21 FN3410HV 16 33 15 270 23 44 29 FN3410HV 24 33 18 5 333 33 44 33 FN3410HV 32 53 22 374 53 33 H FN3410HV 38 53 30 480 53 33 48 FN3410HV 45 53 37 555 53 733 56 FN3410HV 60 35 45 610 35 34 58 FN3410HV 75 35 55 690 35 34 62 FN3410HV 90 35 75 860 35 34 77 FN3410HV 110 35 90 960 35 34 91 FN3410HV 150 40 110 1145 40 35 131 FN3410HV 180 40 132 1275 40 35 147 FN3410HV 210 40 160 1600 40 35 169 FN3410HV 260 99 200 1940 99 35 230 FN3410HV 320 99 250 2500 99 35 233 Fiter to be selected by system voltage and load motor drive power Note the harmonic filter will reduce RMS input current Therefore filter selection by current rating as it is common for EMC EMI filters is not suitable Calculated power loss at rat
29. filter 22701708 15 32 38 266U SOHZ3GWYE EN50160 UAN CURSOR VOLTAGE HOLD LIL L3 amp zZz00M RUN Voltage and current waveforms Harmonics 3 THD 4 0 F SK 1 2 I LU EEE ET del 1 5 9 13 17 21 25 29 33 37 41 45 49 22701708 16 09 33 2660 50Hz38 WYE EN50160 L1 L2 L3 Keng HOLD DOE ege ES he orr Sms Current Harmonics THD 4 0 scale 0 10 FULL 0 00 27 LI L L3 1 97 1 98 1 98 1 97 1 98 1 99 LI L L3 Arms 230 3 231 4 peu 50Hz 38 WYE ENERGY TREND Vrms 230 1 22 01 08 16 10 51 VOLTAGE a ENS0160 Power PF Cosq Current User Manual LP IISCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 23 52 4 Filter selection ECOsine harmonic filters need to be carefully selected in order to enjoy maximum benefits Step 1 rectifier topology of the non linear load Determine whether the non linear load in question e g motor drive has a diode or thyristor rectifier front end and select the proper filter family according to the following table For six pulse diode rectifiers 6 diodes FN 3410 HV FN 3412 For six pulse mixed rectifiers 3 diodes 3 thyristors FN 3410 HV FN 3412 For six pulse SCR rectifiers 6 thyristors FN 3411 FN 3413 for soft starting purposes in AC drives only Step 2 grid frequency Determine whether the system in question will be operated in a 50Hz or 60Hz electricity grid and select
30. he filter selection table FN 3410 Type FN 3410 16 44 Overrating the filter does never make sense because of the inherent lower harmonics mitigation performance at light load as well as higher price size and weight Please refer to the selection tables on the next page User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 25 52 Filter selection table FN 3410 and FN 3411 50Hz Filter selection table Filter Rated load power Rated load power Power loss Input Output Capacitor Weight NEMA1 e 400VAC 50Hz e 500VAC 50Hz 400V 500V connections disconnections covers Ikw ikw w dhg E ub kg Order code FN 341x 10 44 4 5 5 60 83 44 44 13 803565 FN 341x 13 44 55 75 83 113 44 44 14 803565 FN 341x 16 44 75 u 113 165 44 44 21 803566 FN 341x 24 33 II 15 165 225 33 44 27 803567 FN 341x 32 33 15 18 5 225 278 33 44 31 803567 FN 341x 38 33 18 5 22 259 308 33 44 35 803567 FN 341x 45 34 22 30 286 390 34 33 45 803568 FN 341x 60 34 30 37 360 444 34 33 54 803568 EN 341x 75 35 37 45 407 495 35 34 65 803569 FN 341x 90 35 45 55 450 550 35 34 77 803569 EN 341x 110 35 55 75 495 675 35 34 86 803569 EN 341x 150 40 75 90 600 720 40 35 118 803570 FN 341x 180 40 90 110 630 770 40 35 136 803570 EN 341x 210 40 110 132 770 924 40 35 154 803570 FN 341x 260 99 132 160 792 960 99 35 201 803570 FN 341x 320 99 160 200 960 1200 99 35 201 803570 To compile a compl
31. ian or technician who is familiar with installation and safety procedures in three phase power systems Warning High voltage potentials are involved in the operation of ECOsine filters Always remove power before handling energized parts of the filter and let ample time elapse gt 1 minute for the capacitors to discharge to safe levels Warning Follow the installation instructions closely Ensure that fans and cooling slots are free from obstructions that could inhibit efficient air circulation Do not operate the filter in ambient conditions outside of specifications Note Do not operate ECOsine filters on unsymmetrical loads on linear loads or with single phase equipment Note Always use an upstream disconnect or protection device as required by most national and international electric codes Note Always connect the filter to protective earth PE first then continue with the wiring of the trap disconnect if needed and phase connectors Note Follow the Schaffner instructions closely when doing maintenance work Use exclusively spare parts recommended and approved by Schaffner Note Always practice the safety instructions defined by your company when handling installing operating or maintaining ECOsine harmonic filters Note In case of uncertainty and questions please contact your local Schaffner partner for assistance User Manual LIISCHAFFNEL ECOsine Passive Harmonic Filters 5 energy efficie
32. imits may be exceeded by 50 Table 10 3 current distortion limits for general distribution systems 120V through 69000V Maximum Harmonic Current Distortion in Percent of J Individual Harmonic Order Odd Harmonics IIL ll 11 lt h lt 17 17 lt h lt 23 23 lt h lt 35 35 lt h TDD lt 20 4 0 2 0 1 5 0 6 0 3 5 0 20 lt 50 7 0 3 5 2 5 1 0 0 5 8 0 50 lt 100 10 0 4 5 4 0 1 5 0 7 12 0 100 lt 1000 12 0 5 5 5 0 2 0 1 0 15 0 gt 1000 15 0 7 0 6 0 2 5 1 4 20 0 Even harmonics are limited to 25 of the odd harmonic limits above Current distortions that result in a de offset e g half wave converters are not allowed All power generation equipment is limited to these values of current distortion regardless of actual LAN where maximum short circuit current at PCC J maximum demand load current fundamental frequency component at PCC Other standards ECOsine harmonic filters are perfectly suitable to fulfill the most stringent requirements of IEEE Std 519 1992 or EN 61000 3 12 They also fulfill the requirements of other standards like e g EN 12015 for elevators and escalators 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 application User Manual LIHSCHaAFFNer ECOsine
33. lated power loss at rated load power Please contact your local Schaffner partner to order the optional NEMA1 covers with the order code in the table above User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 27 52 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 One advantage of load applied filtering is the fact that the upstream power relative to the harmonic filter is clean This can be of vital importance when the same power bus supplies both motor drives and sensitive loads One example could be the elevator drives or HVAC drives in a hospital where power must be very clean for all the sensitive medical devices In such a case it would not be sufficient to use a central harmonic filter at the PCC for IEEE Std 519 1992 compliance purposes ECOsine 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 all connected drives must match the filter KK o e E i ES homes 2 ECOsine e bech o 2 A A A
34. lter including a 3 AC or 4 DC reactor 2 The design of the equipment is such that the phase angle of the 5th harmonic current has no preferential value over time and can take any value in the whole interval 0 360 Note This condition is normally fulfilled by converters with fully controlled thyristor bridges 3 The 5th and 7th harmonic currents are each less than 5 of the reference fundamental current User Manual IISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 50 52 Interpolation of current harmonic limits Figure A 1 Limits of the 5th harmonic current as functions of Ryo Product documentation according to EN 61000 3 12 For equipment complying with the harmonic current emission limits corresponding to Rsce 33 the manufacturer shall state in his instruction manual or literature Equipment complying with IEC 61000 3 12 For equipment not complying with the harmonic currents emission limits corresponding to Rsce 33 the manufacturer shall determine the minimum value of Rsce for which the limits given in Table 3 or 4 are not exceeded declare the value of the short circuit power Sse corresponding to this minimal value of Rsce in the equipment instruction manual and instruct the user to determine in consultation with the distribution network operator that the equipment is connected only to a supply of that S value or more For that
35. m 95mm 10mm 25mm Flex wire 10mm 25mm 50mm 95mm 6mm 16mm AWG wire AWG6 AWG 2 AWG 1 0 AWG 4 0 AWGS AWG4 Recommended 1 5 1 8Nm 40 45Nm 7 8Nm 17 20Nm 1 0 1 2Nm 2 0 23Nm Please visit www schaffner com to find more details on filter connectors User Manual LP IISCHAFFNeL User Manual ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 14 52 2 7 Performance characteristics THID vs load diode rectifier front ends 8 7 6 Z line 0 2 Zline 3 0 THID A 0 20 40 60 80 100 120 140 160 Load Note shown above is the typical behaviour of FN3410 12 up to 200kW and FN3410HV up to 37kW with diode rectifiers front ends FN3410HV from 45kW and up achieve this performance only with drives with a built in dc link choke Without full load THID performance will be roughly 8 10 THID vs load SCR rectifier front ends 12 10 Phase 0 Phase 20 Phase 40 THID D 0 20 40 60 80 100 120 Load Tod In SCR rectifier applications filter performance greatly depends upon the firing angle of the thyristors User Manual LP IISCHAFFNeF User Manual ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 15 52 TDD vs load diode rectifier front ends
36. monic currents to negligible levels and ensure that a sine wave current is drawn from the grid In the process they also reduce peak currents and RMS input current allowing for lower wire cross sections in conductors smaller fuses breakers and transformers In existing installations more drives can be used on the same distribution transformer The example on the next page visualizes typical performance test results with and without a Schaffner ECOsine harmonic filter FN 3410 13 44 for the same real load power of 6kW Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 22 52 Without ECOsine filter 266U SOHZ3GWYE EN50160 CURSOR ZOOM HOLD ON OFF Roar RUN 22701708 14 31 48 UAH Li L2 13 BACK Voltage and current waveforms Harmonics 3 THDIG4 3 F 05K 75 0 THODC ue Ze Li L2 13 VAU N ALL BU I ih all DI J e LA Lal Sg 45 49 1 21 25 29 33 3 41 266U 50H2Z36 WYE METER 1 HARM ONI OFF EN50160 HOLD RUN Current harmonics THD 164 3 scale 0 100 Pouer amp Energy FULL LI KU 1 68 kVA 3 59 VUm 3 17 PF 0 47 Cosi 0 98 Arms 15 7 LI 228 7 Vrms 22 01 08 14 36 53 VOLTAGE 0 00 52 L2 L3 1 75 2 43 3 76 4 67 3 32 3 99 0 47 0 52 0 96 1 00 16 4 20 3 Le L3 229 4 230 0 266U 50Hz38 WYE ENERGY Power PF Coso Current TREND EN50160 LP IISCHAFFNeL energy efficiency and reliability With ECOsine
37. ncy and reliability May 2013 4 52 Content UN Gg number COGING EE 5 2 Finer description E 6 2 1 General electrical specifications FN 3410 and FN 3411 50Hz filters 0 02 ceeeeeeeeeeeeeeeeeeeteeeeeeees 6 2 2 General electrical specifications FN 3410HV 50Hz tere 7 2 3 General electrical specifications FN 3412 and FN 3413 60HZ filters 0 eeceeeeeeeeeeeeseeeeeeeeeeeees 8 2 4 Additional electrical SpeCIfICATIONS 2 22 eeecccceeeenceeeeeeeceeetneeceeeeneceeeeaeaeeeeaaeeeeesnseeeeesnneaeeeenneeeeeennnaes 9 2 5 Mechanical specifications FN3410 11 12 13 ooo eee ee eene ee ee eae ee teenie ee ee eaae eset eaeeeeeeaeeeeeeaeeeeeeea 10 2 6 Mechanical specifications FN 341 OHV A 12 2 7 Performance CharacteristiCs seccina ieina a E a aaaea 14 28 Funcion dagana EE 18 2 9 External filter elementa 0 0 cceceecccceeeecceeeeeeeeeeeeeeeceeeeeaeeaeesaaeeaeesaaeaaaesaaeaaaesaaeeaeeeaaeaeesseeeaaeseeeeaeeteaes 19 2 10 Monitorning Stat Soannen sheeted iacceces acantessanehees E AANE 19 ER Melu ET 20 3 Filter purpose and FUNCTION WW ceceeeee ee eeeeee ee eeeeee seen seen sees eeee se neneeesesenneeseseeeeesaseeeeesaseeeeeseseenenseseeenens 21 A Fiker Selectioun scscceieiise ee 23 5 Filter application eege ci cc ceccteieceeedcccccceste a 27 6 Filter Ipnstallaten 2 SeseeESeE TEE cs eccecetececetids ccececeecenced ed scueetdetenceded sceceeeesenced si scueesbseueuieyseecestvaeecetas 28 T du Mmaintenan CO EE 34 8 Special E E E 36 8 1
38. ntributing to financial savings Are they reducing my electricity bill A ECOsine harmonic filters help to save long term system operating cost and help to avoid expensive system production downtime There are two different aspects to answer this question 1 Most likely the installation of ECOsine filters will not result in a lower electricity bill ECOsine harmonic filters substantially reduce reactive current and thus reactive power in the system However most utility companies invoice only the consumption of real power which will not be changed with the installation of ECOsine Some utilities may issue penalties for consumers with low power factor usually lt 0 9 Low power factor can be caused by phase shift of the fundamental current low cos phi and or by harmonics of the current high THID as it is described by the following formula cosg V1 THD For nonlinear loads like six pulse rectifiers value of cos phi is high close to 1 and the main reason for a reduced power factor is a high value of THID The installation of ECOsine filters would increase the power factor and help to avoid utility penalties i e get into a less expensive rate class These penalty schemes are different from country to country and from utility company to utility company PN 2 Electric systems with significant non linear loads have high levels of harmonic current distortion and consequently also bad voltage quality Both can hav
39. o 320A 50 C Nominal filter input current rating 1 7Ams to 240Aims 50 C Nominal motor drive input power rating 4 to 200kW Total harmonic current distortion THID lt 5 rated power Total demand distortion TDD According to IEEE 519 table 10 3 Partially weighted harmonic distortion PWHID lt 22 rated power Efficiency gt 98 5 nominal line voltage and power Drive dc link voltage behavior 3 No load 10 Full load 5 High potential test voltage P gt E 2500VAC 1min SCCR 100kA Protection category IP20 Pollution degree 1 2 according to EN 61800 5 1 EN 50178 Cooling Internal forced cooling Overload capability 1 6x rated current for 1 minute once per hour 2x rated current for 10 seconds once per hour 5x rated current for 1 second once per hour Capacitive current at low load lt 30 of rated input current at 400VAC lt 37 of rated input current at 500VAC Ambient temperature range 25 C to 50 C fully operational 50 C to 70 C derated operation 25 C to 85 C transportation and storage Flammability class UL 94V 2 or better Insulation class of magnetic components H 180 C Design corresponding to UL 508 EN 61558 2 20 CE LVD 2006 95 EC MTBF 50 C 500V Mil HB 217F gt 200 000 hours MTTR lt 15 minutes capacitors and fan
40. oad 10 Full load 5 High potential test voltage 7 P gt E 2500VAC 1min SCCR 100kA Protection category IP20 Pollution degree 1 2 according to EN 61800 5 1 EN 50178 Cooling Internal forced cooling Overload capability 1 6x rated current for 1 minute once per hour 2x rated current for 10 seconds once per hour 5x rated current for 1 second once per hour Capacitive current at low load lt 30 of rated input current at 460VAC Ambient temperature range 25 C to 50 C fully operational 50 C to 70 C derated operation 25 C to 85 C transportation and storage Flammability class UL 94V 2 or better Insulation class of magnetic components H 180 C Design corresponding to UL 508 EN 61558 2 20 CE LVD 2006 95 EC MTBF 50 C 460V Mil HB 217F 200 000 hours MTTR lt 15 minutes capacitors and fans Lifetime calculated Min 15 years Safety monitoring functions Over temperature of magnetic components Safety monitor output signal NO switch 1 2 ECOsine filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor System requirements THVD lt 2 line voltage unbalance lt 1 Performance specification for six pulse diode rectifiers SCR rectifier front ends produce different results depending upon the firing angle of the thyristors
41. onents A 20mm clearance on either side is recommended for the possibility to open the cover in case of maintenance requirements gt 20mm It must be ensured that the environmental temperature is kept below 50 C with appropriate thermal management e g cabinet cooling Filter operation in warmer environments require gt 150mm temperature derating Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 29 52 2 1 Screw hole positions for wall mounted filters FN 3410 FN 3411 FN 3412 FN 3413 H Ww D 10 13 8 11 380 130 M6 16 15 21 410 170 M8 24 32 38 28 35 41 495 200 Mi 45 60 53 65 565 250 M10 75 90 110 80 105 130 725 270 M10 FN 3410HV high power versions 150 180 210 800 350 Mi 260 320 1025 400 M12 All dimensions in mm 1 inch 25 4mm Note the numbers e g 70 are in reference to the middle part of the ECOsine part number coding e g FN 3410 70 44 IISCHAFFNeEL energy efficiency and reliability 2 2 Screw selection Schaffner recommends zinc coated hex ribbed flange steel bolts Respect filter weight for appropriate choice of screws Head diameters must not exceed these dimensions M6 d lt 14 2mm M8 d lt 18 2mm M10 ds 21 2mm M12 d lt 25mm 2 3 Filter placement 1 Set screws loose into wall leave 5mm distance from head to wall 2 Lift filter with appropriate crane u
42. ording to IEEE 519 table 10 3 Partially weighted harmonic distortion PWHID lt 22 rated power Efficiency gt 98 nominal line voltage and power Drive dc link voltage behavior 7 No load 10 Full load 5 High potential test voltage P gt E 2500VAC 1min SCCR 100kA Protection category IP20 Pollution degree 1 2 according to EN 61800 5 1 EN 50178 Cooling Internal forced cooling Overload capability 1 6x rated current for 1 minute once per hour 2x rated current for 10 seconds once per hour 5x rated current for 1 second once per hour Capacitive current at low load lt 38 filters lt 37kW lt 30 filters gt 45kW of rated input current at 690VAC Ambient temperature range 25 C to 50 C fully operational 50 C to 70 C derated operation 25 C to 85 C transportation and storage Flammability class UL 94V 2 or better Insulation class of magnetic components H 180 C Design corresponding to 9 UL 508 EN 61558 2 20 CE LVD 2006 95 EC MTBF 50 C 690V Mil HB 217F gt 200 000 hours MTTR lt 15 minutes capacitors and fans Lifetime calculated Min 15 years Safety monitoring functions Over temperature of magnetic components Safety monitor output signal NO switch 1 2 the firing angle of the thyristors Conditions line impedance lt
43. otential solution 1 The first attempt of the project manager is the installation of 1 ECOsine harmonic filter type FN 3410 180 40 400V 50Hz 90kW upstream of the 100kW drive loaded with 85 Public grid FN3410 100kW 400VAC 50Hz Building supply 180 40 Drive PCC e e 30kW Drive SE 18 5kW Drive OOC Group of sensitive IT equipment Trying to utilize the harmonic filter at the biggest non linear load is a good idea but not sufficient in this case The TDD at the PCC after the installation of FN 3410 180 40 is 24 3 System loading parameters ask for a TDD of max 8 according to IEEE Std 519 1992 Potential solution 2 In order to overcome the problem above additional filters upstream of the lower power drives can be installed A good choice is FN 3410 60 34 400V 50Hz 30kW for the 30kW drive and FN 3410 32 33 400V 50Hz 15kW for the 18 5kW drive both loaded 85 Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 40 52 Public grid 400VAC 50Hz Building supply IISCHAFFNeEF energy efficiency and reliability FN3410 100kW 180 40 Drive FN3410 30kW 60 34 Drive FN3410 18 5kW 32 33 Drive OOC Group of sensitive IT equipment Adding these harmonic filters result
44. purpose the statement in the instruction manual shall be This equipment complies with IEC 61000 3 12 provided that the short circuit power S is greater than or equal to xx at the interface point between the user s supply and the public system It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power S greater than or equal to xx Where xx is the value of S corresponding to the minimum value of Rsce for which the limits given in Table 3 or 4 are not exceeded User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 51 52 lll IEEE Std 519 1992 Table 10 3 lists the harmonic current limits based on the size of the load with respect to the size of the power system to which the load is connected The ratio is the ratio of the short circuit available at the point of common coupling PCC to the maximum fundamental load current IEEE Std 519 1992 also introduces the total demand distortion TDD the harmonic current distortion in of maximum demand load current 15 or 30min demand The limits listed in Tables 10 3 should be used as system design values for the worst case for normal operation conditions lasting longer than one hour For shorter periods during start ups or unusual conditions the l
45. r a period of time Before opening the cabinet or device disconnect the supply power and let ample time elapse gt 1 minute for the capacitors to discharge to safe levels Use a meter to check terminal voltages before touching or handling 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 Under normal operating conditions ambient temp at 25 C and with the filter permanently charged at full load the fan s will typically have 50 duty cycle This translates roughly to a 10 year maintenance free life time Nevertheless it is recommended to check the functionality at least in a 2 year interval when a normal 100 load situation is given More severe operating conditions may require shorter service intervals Indications for required fan replacement increased audible noise coming from the fan after 50 000 hours fan ON state Power capacitor damage may be caused by severe abnormal supply voltage peaks i e lightning depending upon system protection but may only be recognizable through the measurement of line side harmonics distortion This may be indicated with a modern energy meter or by regular checkup with a distortion analyzer According to th
46. rred in transit Then unpack the filter and carefully inspect for any signs of damage Save the shipping container for future transportation of the filter 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 Step 2 Mounting ECOsine load applied filters are best installed as close as possible to the non linear load in question Ideally they are mounted next to the rectifier or motor drive inside the electrical cabinet or control room ECOsine comes in two different installation designs FN 3410 FN 3411 Filters from 4 to 55kW For vertical wall mounting FN 3410 FN 3411 Filters from 75 to 160kW For upright floor mounting FN 3412 FN 3413 Filters from 5 to 1OOHP For vertical wall mounting FN 3412 FN 3413 Filters from 125 to 250HP For upright floor mounting FN 3410HV All sizes For vertical wall mounting Note Filters for vertical wall mounting must not be installed horizontally Horizontal installation will negatively affect air flow and the life time of the filter Important In order to ensure sufficient air flow keep a clearance of min 150mm above and below the filter to walls or other comp
47. rst and foremost the avoided potential expenses thanks to lack of harmonics Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 44 52 Q How much cooling air capacity should be planned for the integration of ECOsine filters into a cabinet A This value defined as CFM cubic feet per minute 1CFM 1 7m h depends upon filter model and power rating Please refer to the following table FN 3410 FN 3411 FN 3412 FN 3413 FN 3410HV Air capacity 400 500V 50Hz 480V 60Hz 690V 50Hz needed 10 13 8 11 70CFM 16 15 21 10 13 110CFM 24 32 38 28 35 41 16 24 45 60 53 65 32 38 45 75 90 110 80 105 130 60 75 90 110 150 180 210 160 190 150 180 210 220CFM 260 320 330CFM 260 320 240 310 440CFM Gees INISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 45 52 12 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 manufacturing of custom filters based on the existing modular ECOsine platform and can potentially come up with an alternative design proposal for you Custom harmonic filters include but are not limited to solutions for higher power ratings higher voltage ratings different performance levels or special m
48. s Lifetime calculated Min 15 years Safety monitoring functions Over temperature of magnetic components Safety monitor output signal NO switch 1 2 the firing angle of the thyristors Conditions line impedance lt 5 ao fw External UL rated fuses required Iderated Inominai V 85 C Tamb 35 C ECOsine filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor System requirements THVD lt 2 line voltage unbalance lt 1 Performance specification for six pulse diode rectifiers SCR rectifier front ends produce different results depending upon Repetitive tests to be performed at max 80 of above levels for 2 seconds Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 7 52 IISCHAFFNeL energy efficiency and reliability 2 2 General electrical specifications FN 3410HV 50Hz filters Nominal operating voltage 3x 690VAC Voltage tolerance range 3x 586 to 760VAC Operating frequency 50Hz 1Hz Network TN TT IT Nominal motor drive input current rating W 10 to 320A 50 C Nominal filter input current rating 1 7Ams to ZA n 50 C Nominal motor drive input power rating 7 5 to 250kW Total harmonic current distortion THID lt 5 rated power filters lt 37kW 5 rated power with Lac filters 245kW Total demand distortion TDD 2 Acc
49. s in 4 8 TDD at the PCC and thus IEEE Std 519 1992 is fulfilled However adding a total of 3 filters to the system may not be the most economic solution so the project manager considers yet another option Potential solution 3 Instead of adding a filter to each drive 1 higher power ECOsine harmonic filter with the following ratings is added FN 3410 260 99 400V 50Hz 132kW The total load real power of the 3 drives running in parallel at 85 is 126kW Public grid 400VAC 50Hz PCC e Building supply FN3410 260 99 100kW Drive 30kW Drive 18 5kW Drive OOC Group of sensitive IT equipment The measured result at the PCC after the implementation of above measures in now a TDD of 5 1 and thus the building is still well within the IEEE Std 519 1992 requirements An economic and technical analysis including filter price and installation time results in the conclusion that solution number 3 will be chosen for this particular case User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 41 52 10 Troubleshooting Schaffner ECOsine harmonic filters are high quality products and have undergone rigorous testing and qualification procedures Every unit runs through a 100 test in our ISO 9001 2000 factories There are no troubles to be expected if the filter is installed operated and maint
50. sing lifting eye bolt attached in package smallest types up to 20kg may be lifted manually by two persons no lifting eye bolt applicable 3 Place filter first onto lower screws 4 then position it through backplane head openings on upper screws 5 Fix screws with appropriate torque depending upon the material of the back plane and local standards E E E E a 2 4 Filter types FN 3410 FN 3411 150 FN 3412 FN 3413 160 and above are floor mounting upright designs non HV types only It is recommended to bolt them permanently to the floor with four screws Screw hole positions FN 3410 FN 3411 FN 3412 FN 3413 A B D 150 180 210 160 190 336 240 M12 260 320 240 310 All dimensions in mm 1 inch 25 4mm User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 30 52 2 5 Important Handling of floor mounting designs Use lifting eye bolts which can be fixed on both sides of the filter Caution has to be taken because of high product weight Never attempt to handle the filter with a forklift once it is unpacked by placing the fork between filter legs This procedure can tip over the filter and or damage the base of the filter Gees IISCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 31 52 Step 3 Wiring 3 1 Verify safe disconnection of all line side pow
51. sponds to the sum of the filter fuse ratings or if lower would request separate drive fuses at its input LIISCHaFFNer energy efficiency and reliability An application having one ECOsine filtering harmonics of several drives requires in any case line side fuse protection of the drives as well as the correct filter protection according to above table 3 10 IP20 safety cover for filters with bus bar terminals Once all filter terminals are properly wired replace the safety cover by tightening the previously removed untightened bolts IP20 cover bolt to untighten bolts to remove User Manual IISCHAFFNeF ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 34 52 7 Filter maintenance Schaffner ECOsine filters are reliable low maintenance products Many products like power supplies inverters or motor drives utilize fans for forced cooling to minimize the size and weight ECOsine filters are designed with a similar temperature management concept and therefore fans may have to be maintained and replaced in certain intervals to sustain the function and value of the product Fans are 100 field replaceable without the need to uninstall and disconnect the filter LINE SIDE POWER MUST BE SWITCHED OFF PRIOR TO REPLACEMENT OF FAN AN Warning Power electronic devices like motor drives contain large capacitors which may retain perilous charges fo
52. switch state is identical to non powered state thus safety monitoring unit must override monitoring signal during power on or restart User Manual LINSCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 37 52 8 2 Trap circuit disconnect The trap circuit disconnect feature is built in for the purpose of reducing the capacitive current during low load operation if needed With permanently connected trap circuit cos phi vs load shows following characteristics 1 20 1 00 o Ei EN Ke a E Zline 0 2 to 3 0 COS phi E D E o iy pad Ei E 0 20 40 60 80 100 120 140 160 Load When the trap circuit is disconnected cos phi returns to 0 98 At the same time the THID will increase This may be negligible since absolute values are low due to reduced load power Required external components not part of ECOsine filter or system functions for fully automated 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 become obsolete or massively reduced when harmoni
53. tactor performance estimate Terminals A1 A2 B1 B2 and C1 C2 are delivered with installed jumpers When interconnected via an external Example EN S412 B504 capacitor contactor not supplied by Schaffner they Divide rated load current by 2 allow for load dependent disconnection of the trap multiply with nominal 3 phase circuit if needed Thus capacitive current can be voltage i e 460VAC minimized for low load operation Estimation of required contactor size see box to the right USE ONLY CAPACITOR CONTACTORS FOR MINIMIZATION OF INRUSH CURRENT OTHERWISE CAPACITOR LIFETIME MAY BE REDUCED 65 2 460 15KVAR Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 32 52 3 7 Connect monitor switch I IISCHAFFNeEL energy efficiency and reliability The monitor switch is a relay contact which is open in OFF and ALARM state Its load rating is 250VAC 30VDC 3A 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 3 8 Connect ECOsine line side terminals L1 L2 L3 to power input protection current limiting fuses see below 3 9 Fuses ECOsine filters need external over current protection for compliance with UL cUL standard Fuses and associated fus
54. to overcome harmonics mitigation challenges and answers frequently asked questions If you require additional support please feel free to contact your local Schaffner partner EE Gees INSCHAFFNeEL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 3 52 Important user notice Schaffner ECOsine harmonic filters are designed for the operation on the input grid side of power electronic equipment with six pulse rectifier front ends in balanced three phase power systems like typically used in 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 ECOsine filters are not designed for single phase or split phase applications ECOsine filters with protection category IP20 NEMA1 must be mounted in a clean dry location Contaminants such as oils corrosive vapors and abrasive debris must be kept out of the enclosure These filter enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment These enclosures offer no protection against airborne contaminants Important safety considerations Note Filter installation has to be carried out by a trained and certified electric
55. ve and negative errors distortion must be severe gt 20 Switchgear and Relaying Increased heating and thus reduced steady state current carrying capability Fuses suffer derating Complete definition of relay response impossible Older circuit breakers responding to peak currents may cause nuisance tripping Communication Equipment Telephone interferences audible harmonic frequencies ECOsine harmonic filters substantially reduce harmonic currents to THID lt 5 at any load condition and therefore basically convert a non linear load into a linear load This fact eliminates the risk for most of the above problems Lower harmonic currents help to relieve the entire electrical installation from excessive loading and heating allow more consumers to be powered by the same existing installation and help to postpone expensive electrical system upgrades when retrofitting additional non linear consumers ECOsine filters also reduce the risk of harmonics related system downtimes which can have tremendous financial consequences e g ina semiconductor manufacturing line or a banking center Last but not least lower harmonic currents cause less harmonic voltages when flowing through system impedances so other sensitive consumers e g medical devices connected to the same branch of the electrical system are not compromised in their functionality gt So in essence the annual savings enabled by ECOsine harmonic filters are fi
56. w Conditions line impedance lt 5 a A External UL rated fuses required lderated nominal V 85 C Tamb 35 C D Repetitive tests to be performed at max 80 of above levels for 2 seconds User Manual L IISCHAFFNeF ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 9 52 2 4 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 table below 105 100 x 95 be Q kl S gt 90 S D 85 80 0 500 1000 1500 2000 2500 3000 3500 4000 Altitude a s l m Note do not use ECOsine passive harmonic filters in altitudes above 4000m without consulting Schaffner first ECOsine passive filters have been designed and certified acc UL508 resp UL508C so there is no limitation in terms of altitude up to 4000m for clerance and creepage Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 10 52 2 5 Mechanical specifications FN3410 11 12 13 Mechanical data FN 3410 FN 3411 10 to 110 FN 3412 FN 3413 8 to 130 FN 3410 FN 3411 260 and 320 FN 3412 FN 3413 240 and 310 LP IISCHAFFNeL energy efficiency and reliability FN 3410 FN 3411 150 to 210 FN 3412 FN 3413 160 and
57. x XXX XX i Examples LIISCHaFFNer energy efficiency and reliability Connection style 33 safety terminal block 10mm 34 safety terminal block 25mm 35 safety terminal block 50mm 40 safety terminal block 95mm 44 safety terminal block 6mm 53 safety terminal block 16mm 99 copper bus bars in different sizes Rated unfiltered load drive input current A Blank standard voltage rating HV 690V 50Hz rating FN3410HV Filter family 3410 filter for 50Hz 380 500V grids diode rectifiers 3411 filter for 50Hz 380 500V grids SCR rectifiers 3412 filter for 60Hz 380 480V grids diode rectifiers 3413 filter for 60Hz 380 480V grids SCR rectifiers Schaffner standard filter FN 3410 60 34 Filter for 50Hz 380 500V grids 60A drive input current with 25mm terminals for diode rectifier front end FN 3413 240 99 Filter for 60Hz 380 480V grids 240A drive input current with copper bus bars for SCR thyristor front end Schaffner EMV AG User Manual ECOsine Passive Harmonic Filters 5 May 2013 6 52 2 Filter description IIISCHAFFNeL energy efficiency and reliability 2 1 General electrical specifications FN 3410 and FN 3411 50Hz filters Nominal operating voltage 3x 380 to 500VAC Voltage tolerance range 3x 342 to 550VAC Operating frequency 50Hz 1Hz Network TN TT IT Nominal motor drive input current rating 1 10 t
58. ystem specifications and the load rating Ideally the filter is installed close to the motor drive potentially next to it on the back wall of the cabinet La zl 5 ECOsine gt Motor o ru Mam el FN3410 10 44 Motor drive 5 5kW 480VAC Measurements with filter 96 100 Current No filter mi Filter lin 7 5Arms for power 5 5kW THID 4 0 Rsce 150 PWHD 5 2 Voltage Uin 480Vims phase phase THVD 0 12 for kal 150 Ims 5th 7th 11th 13th wen VOltage phase neutral CUrrent User Manual IISCHAFFNeL ECOsine Passive Harmonic Filters 5 energy efficiency and reliability May 2013 39 52 9 2 Harmonics mitigation in applications with multiple loads in parallel Problem An office building is operating 3 HVAC systems in parallel involving drives with diode rectifiers and motors of different power rating On average the drives are running at 85 of rated power The resulting harmonic distortion is causing crashes of the in house IT infrastructure In addition the entire factory does not meet the IEEE Std 519 1992 requirements at the point of common coupling PCC TDD 102 5 The use of an active harmonic filter at the main building bus has already been evaluated but it is out of the question for cost reasons The project manager has to determine the best yet affordable solution P

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