Schaffner ECOsine Maintenance Manual

April 2015

ECOsine® active Harmonic Filters

Maintenance Manual for FN3420-200-690-3

2 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

© All rights reserved, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission
and dissemination.

Revision: 01 (March 2016)

The most current edition of these instructions (PDF format) can be obtained from your
contact of the Schaffner service organization.

Other technical documentation of our products is also available in the download area of our
website www.schaffner.com

Document name:
Maintenance Manual for FN3420-200-690-3

Version history

Revision

Date

Description

01

April 2016

Initial version

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 3

Table of Contents

1 General Safety Instructions 5

1.1 Intended use 6

1.2 Personnel qualification 7

1.3 Environmental conditions / Exclusion of warranty 8

2 Introduction 10

2.1 Principle of operation 11

2.2 About these instructions 12

2.3 Type plate 13

2.4 Type code 14

3 Welcome 15

3.1 About this manual 16

3.2 Who should read this guide 17

3.3 Personnel qualification 18

3.4 Get help 19

3.5 Get training 20

3.6 Contact us 21

4 AHF 200-690-3 22

4.1 Maintenance Schedule 23

4.2 Wear parts 24

4.2.1 Wear parts - AHF 200-690-3 (No UL) 24

4.2.2 Wear parts - AHF 200-690-3 (UL) 25

4.3 Replacement Instruction 26

4.3.1 Check operation of main fan and DC-Bus fan and clean fan guards 26

4.3.2 Check of coolant level 32

4.3.3 Check coolant pump for any signs of coolant-leakage 34

4.3.4 Replace inverter fan (DC bus fan) 36

4.3.5 Replace pre-charge fuses F1 & F2 40

4.3.6 Replace 230V auxiliary power supply 43

4.3.7 Replace 24V power supply fuses F45 & F46 46

4.3.8 Replace cooling system power supply fuses F47 & F48 48

4.3.9 Replace cooling system control unit fuses F1-F3 51

4.3.10 Replace air-conditioning fuses F11 53

4.3.11 Change cooling liquid 56

4.3.12 Replace main fan 59

4 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

Index of Tables

Table 1: Use of symbols, terms, and designations 12
Table 2: Type code 14
Table 3: Maintenance schedule 200-690-3 23
Table 4: Wear parts 200-690-3 24
Table 5: Wear parts 200-690-3 (UL) 25

Index of Figures

Fig. 1: Principle of operation of the ECOsine® active filter 11

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 5

1 General Safety Instructions

6 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

1.1 Intended use

The ECOsine® active harmonic filter is used for active compensation of reactive power and
harmonic content and for load balancing.
Please ensure that no compensation systems, which are not detuned, are connected to the
same grid. Otherwise interactions between ECOsine® active and these compensation
systems may occur.

DANGER

Dangerous voltage

Risk of death due to short circuits and electric shock if the
active filter is opened improperly. The discharge time of
the intermediate circuit after disconnecting from the
mains can be more than 5 minutes.

All interventions involving opening the device cover or
removing or installing the connection cable may only be
performed by qualified personnel.

WARNING

High-frequency interferences

In a residential environment, high-frequency interferences
could occur, which necessitate interference suppression.

Note

Please note that there are additional manuals for some product variants. For the latest
versions of these manuals go to www.schaffner.com
It particularly applies to types FN3420-100/120-400-3-GL, please observe the special
EMC-Filter Manual for these types (ECOsine EMC Filters for Applications with GL)

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 7

1.2 Personnel qualification

Installation of the ECOsine® active filter, inspections for proper operation, and certain
troubleshooting measures may only be performed by qualified personnel. All other
measures may be performed by people who have read these instructions.

8 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

1.3 Environmental conditions / Exclusion
of warranty

This document classifies groups of environmental parameters and their severities to which
ECOsine® active harmonic filters are subjected when mounted for stationary use at weather
protected locations under use conditions, including periods of erection work, down time,
maintenance and repair. The lifetime of electronic equipment is depending on the
environmental conditions they are exposed to. Especially in harsh environments lifetime is
reduced due to the corrosiveness of the atmospheric environment. Generally corrosion in
micro or power electronics depends on several variants such as the package type, materials
involved, assembly processes, moisture, inorganic and organic contaminants, atmospheric
pollutants, temperature, thermal stress and electrical bias. To increase the lifetime
Schaffner provides all ECOsine® active filters with the ability to work within pollution degree
2 (PD2) and does use coated PCB’s according to IEC61721-3-3. Schaffner standard PCB
construction complies with class 3C2. Please carefully read the provided information and
check if your application fulfills the required specifications as Schaffner expressly points

out that the manufacturer's warranty shall lapse with immediate effect if ECOsine®
active harmonic filters are transported, stored, installed or operated outside their
published specifications.

Important

ECOsine® active harmonic filters (AHF) listed below are IP20 or IP54
devices to be installed in an environment in compliance with the
requirements named in this document.

All AHF must be installed in a clean, dry location, e.g. in sufficiently
ventilated or air conditioned electric cabinets or closed electric rooms.
Contaminants such as oils, liquids, corrosive vapors, abrasive debris,
dust and aggressive gases must be kept out of the filter enclosure.

WARNING: Conductive dust may cause damage to ECOsine®
active harmonic filters. Ensure that installation site of ECOsine®
active is free of conductive dust.

Products

FN3420 series, 3-wire filters, models 30…300A
FN3430 series, 4-wire filters, models 30…300A

Overvoltage class
(EN50178)

ECOsine® active are designed according to EN 50178 overvoltage
class III

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 9

Storage environmental
specifications

(IEC 60721-3-1, EN50178)

Climate conditions for storage class 1K3:

 Temperature range: -25°C to +55°C
 Relative humidity: < 95%, no condensation
 Atmospheric pressure: 70KPa to 106KPa

Transportation
environmental
specifications

(IEC 60721-3-2, EN50178)

Climate conditions for transport class 2K3:

 Temperature range: -25°C to +70°C
 Relative humidity: < 95%, no condensation
 Atmospheric pressure: 70KPa to 106KPa

Operation environmental
specifications

(IEC 60721-3-3, EN50178)

Climate conditions for operation class 3K3:

 Temperature range: 0°C to +40°C
 Relative humidity: < 95%, no condensation
 Atmospheric pressure: 70KPa to 106KPa

Degree of pollution
(IEC 61010, EN50178)

Pollution conditions for operation class PD2

Corrosive levels
(IEC 60721-3-3)

Corrosive levels for storage, transport and operation Class 3C2

(3)

:

 Applies to locations with normal levels of contaminants,

experienced in urban areas with industrial activities

 Levels:

Environmental parameter

Units

(1)

Class 3C2

(2)

Mean value

Max value

Sea salt Salt mist

Sulphur dioxide

ppm

cm3/m3

0.3

0.11

1.0

0.37

Hydrogen sulphide

ppm

cm3/m3

0.1

0.071

0.5

0.36

Chlorine

ppm

cm3/m3

0.1

0.034

0.3

0.1

Hydrogen chloride

ppm

cm3/m3

0.1

0.066

0.5

0.33

Hydrogen fluoride

ppm

cm3/m3

0.01

0.012

0.03

0.036

Ammonia

ppm

cm3/m3

1.0

1.4

3.0

4.2

Ozone

ppm

cm3/m3

0.05

0.025

0.1

0.05

Nitrogen oxides

ppm

cm3/m3

0.5

0.26

1.0

0.52

(1)

The values given in cm3/m3 have been calculated from the values given in mg/m3
and refer to a temperature of 20 °C and a pressure of 101,3 kPa. The table uses
rounded values.

(2)

Mean values are expected long-term values. Maximum values are limit or peak
values, occurring over a period of time of not more than 30 min per day.

(3)

IEC 60721-3-3 is only applied to the coated PCB covered areas and not the entire device.
The unprotected areas, such as connections, terminations and exposed magnetics, may not
survive these exposure levels over time.

10 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

2 Introduction

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 11

2.1 Principle of operation

The ac mains current, which is drawn by a non-linear load, is measured by ECOsine® active
either directly or indirectly via external current transformers. The harmonic content and
reactive power components are detected and processed in a digital control structure. The
active filter continually generates a compensating current that offsets the harmonic content
and reactive current in the load, so the ac mains only has to provide the minimum
fundamental in phase current.

Compensating current

Mains supply

Load

Neutral

Fig. 1: Principle of operation of the ECOsine® active filter

The active filter instantly adapts to all changes in the load and the systems harmonic
content spectrum, in order to be able to optimally respond at any time.

12 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

2.2 About these instructions

The following symbols, terms and designations are used in these operating and installation
instructions:

Description

NOTICE

Notice

Follow these instructions to avoid damages to the unit.

CAUTION

Caution

Follow these instructions to avoid damages to the unit or injuries of personnel.

WARNING

Warning

Follow these instructions to avoid situations which may cause severe or deadly
injuries.

DANGER

Danger

Follow these instructions to avoid situations which may cause severe or deadly
injuries.

DANGER

Dangerous voltage

Follow these instructions to avoid situations which cause severe or deadly
injuries due to dangerous electrical voltage.

NOTE

Note text

Note

Please observe these notes..

➩

1.

2.

Operation steps

Complete the operation described (multiple steps are numbered, arrow indicates
a single step).

Table 1: Use of symbols, terms, and designations

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 13

Serial number

WO 1234567 + S/N 00001

Date of manufacture (year (yy) + calendar week (ww))

WO number

Part number

2.3 Type plate

Type code

14 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

2.4 Type code

The type designations of all ECOsine® active have the following structure:
FN34TT-AAA-VVV-W-CC

Variable

Description

TT

Type:
20 – 3-wire device
30 – 4-wire device

AAA

Rated current

VVV

Rated voltage

W

Number of compensated conductors

CC

Certificates and variants (optional)

Table 2: Type code

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 15

3 Welcome

16 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

3.1 About this manual

This manual is meant to provide comprehensive information on maintenance requirements
of ECOsine® active harmonic filters. The issues discussed in this guide cover the basic
maintenance schedule, necessary wear parts as well as practical aspects of working with
ECOsine® active harmonic filters. The guide will familiarize you with the required hardware
checks and settings to conduct various maintenance tasks.

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 17

3.2 Who should read this guide

The primary audience for this book is anyone interested in or responsible for maintenance
of ECOsine® active harmonic filters. To fully understand the guide, you should have a good
knowledge of electronic and electrical systems and at least some basic power quality
habits. Attending Schaffner International training courses is considered helpful.

18 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

3.3 Personnel qualification

Any maintenance actions on ECOsine® active harmonic filter has to be performed only by
skilled electricians who additionally must be familiar with the instructions in the Installation

and Operation Manual as well as this Maintenance and Wear Parts Manual.

CAUTION

Caution

Maintenance tasks should only be performed by trained and skilled personnel to
avoid damages to the unit or injuries of personnel.

WARNING

Warning

Changing of wear parts may cause malfunction of device and can cause injuries
of personnel if not properly performed.

ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 19

3.4 Get help

Schaffner believes in the value of service and partnering. We do offer help with a lot of
topics. In order to provide the most successful help Schaffner does operate a service
organization and worldwide service centers. We do also closely collaborate with a growing
network of qualified and authorized service partners to maintain our high service quality on
a global approach.

20 ECOsine® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3

3.5 Get training

Do you need training? Schaffner can offer a training course comprised of lecture and
hands-on workshops designed to introduce you to the fundamental concepts of power
quality, ECOsine® harmonic filters and filter maintenance.
We also offer customized training courses designed to meet your specific needs. Please
contact your local Schaffner sales organization or Schaffner representative to discuss how
we can help you achieve success in your power quality efforts.