Schaffner Ecosine active sync User And Installation Manual

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User and Installation Manual

Ecosine active sync

Schaﬀner Group | Nordstrasse 11 | 4542 Luterbach | Switzerland

T +41 32 681 66 26 | F +4132 681 66 30

www.schaﬀner.com

www.myecosine.com

English version

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Revision: 1.7 (October 2019) The most current edition of these instructions (PDF format) can be obtained from your contact of the

Schaffner organization or online at myecosine.com

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

Document name: User and Installation Manual ecosine active sync Rev1.7.pdf

Valid for power module firmware version:

V03.02.03 or higher

(For firmware version, see parameter P010)

Meaning of firmware version number:

V XX.xx.xx – hardware release, downwards incompatible V xx.XX.xx – function version V xx.xx.XX – small compatible changes

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Copyright ©2019 Schaffner International Ltd. All Rights Reserved. All rights of this User and Installation Manual (“Manual”) including but not limited to the contents, information, and figures are solely owned and reserved by Schaffner International Ltd. (“Schaffner”). The Manual can only be applied to the operation or the use of ecosine active sync harmonic filter. Any disposition, duplication, dissemination, reproduction, modification, translation, extraction, or usage of this Manual in whole or in part is prohibited without the prior written permission of Schaffner. Given that Schaffner will continuously improve and develop the product, changes may be made to the information in this Manual at any time without obligation to notify any person of such revision or changes. Schaffner will make all possible efforts to secure the accuracy and the integrity of this Manual. Schaffner disclaims any kinds or forms of warranty, guarantee, or undertaking, either expressly or implicitly, including but not limited to the completeness, faultlessness, accuracy, non-infringement, merchantability or fitness for a particular purpose of the Manual.

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Content

1 Version History .................................................................................................... 7

2 Introduction .......................................................................................................... 8

Purpose ........................................................................................................................................ 8

Additional Resources ................................................................................................................. 8

Naming convention .................................................................................................................... 8

3 General Safety Notes and Installation Guidelines ............................................ 9

4 Environmental Conditions / Exclusion of warranty ........................................ 10

5 Ecosine Active Sync Product Line Overview .................................................. 13

Principle of operation ............................................................................................................... 13

Ecosine active sync system configuration ............................................................................ 14

5.2.1 Ecosine active sync power module FN3530 and FN3531 .................................................. 15

5.2.2 Ecosine active sync power module FN3540 and FN3541 .................................................. 16

5.2.3 Ecosine active sync Double Power Pack (DPP) FN3532 and FN3542 .............................. 17

5.2.4 Ecosine active sync cabinet version (cabinet + power modules) ........................................ 19

Ecosine active sync cabinet version type code information ............................................... 20

Technical specification ecosine active sync power module versions ................................ 24

Technical specification ecosine active sync cabinet versions ............................................ 25

Temperature derating of ecosine active sync power module .............................................. 27

Temperature derating of ecosine active sync cabinet version ............................................ 27

Sync Module SYNC300A .......................................................................................................... 28

5.8.1 Technical specification for Sync module SYNC300A .......................................................... 29

5.8.2 Mechanical dimensions of SYNC300A ................................................................................ 30

Ecosine active sync display module ...................................................................................... 31

5.9.1 RS485 communication ........................................................................................................ 32

5.9.2 AHF parameters and INI file ................................................................................................ 32

5.9.3 Event log and LOG file ........................................................................................................ 32

5.9.4 Load and save AHF parameter set ..................................................................................... 32

6 Mechanical Installation Guidelines .................................................................. 33

Pre-Installation Guidelines ...................................................................................................... 33

6.1.1 Receiving ecosine active sync ............................................................................................ 33

6.1.2 Transportation and unpacking of power modules ............................................................... 33

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6.1.3 Lifting ................................................................................................................................... 33

6.1.4 Important note for installation .............................................................................................. 34

Mechanical installation of ecosine active sync power module ........................................... 34

6.2.1 Dimensions of an ecosine active sync power module ......................................................... 34

6.2.2 Ecosine active sync power module mounting options ......................................................... 37

Mechanical installation of ecosine active sync DPP ............................................................ 38

6.3.1 Dimensions of ecosine active sync DPP ............................................................................. 38

6.3.2 Mounting options of ecosine active sync DPP .................................................................... 38

Mechanical installation inside customer cabinet .................................................................. 40

6.4.1 Customer cabinet requirements .......................................................................................... 40

6.4.2 Cooling requirements of customer cabinet .......................................................................... 40

Mechanical data of ecosine active sync cabinet version ..................................................... 42

6.5.1 Dimensions of ecosine active sync cabinet version ............................................................ 42

6.5.2 Cooling requirements of ecosine active sync cabinet versions ........................................... 44

7 Electrical Installation Guidelines ...................................................................... 45

Protection (Fuses, Breakers) ................................................................................................... 45

Installation with power factor correction (PFC) systems ..................................................... 45

Power Module electrical installation ....................................................................................... 45

7.3.1 Connecting terminal locations ............................................................................................. 45

7.3.2 Connection of AC Mains ...................................................................................................... 52

Sync Module electrical installation ......................................................................................... 53

7.4.1 Connecting terminal location ............................................................................................... 53

7.4.2 Interconnection between Sync Module and Power Modules .............................................. 55

Ecosine active sync cabinet version electrical installation ................................................. 56

7.5.1 Connecting terminal locations ............................................................................................. 56

7.5.2 Connection of AC Mains ...................................................................................................... 58

Connection of current transformers ....................................................................................... 59

7.6.1 Connection of 3-phase 3-wire devices CT secondary output 5A ........................................ 60

7.6.2 Connection of 3-phase 3-wire devices CT secondary output 1A ........................................ 61

7.6.3 Connection of 3-phase 4-wire devices CT secondary output 5A ........................................ 62

7.6.4 Connection of 3-phase 4-wire devices CT secondary output 1A ........................................ 63

Current transformers specifications and cable selection .................................................... 64

Current transformer specification for UL conformity ........................................................... 67

Connection and verification of current measurements ........................................................ 68

7.9.1 CT connection for operation of single ecosine active sync power module ......................... 68

7.9.2 CT connection for operation of double power pack (DPP) ecosine active sync ................. 72

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7.9.3 CT connection for operation of the sync module and multiple ecosine active sync power modules 76

7.9.4 CT connection for parallel operation of several ecosine active sync power modules without

sync module ....................................................................................................................................... 80

7.9.5 Grounding of the current transformers ................................................................................ 84

7.9.6 Checking current transformers rotating field ....................................................................... 85

7.9.7 Checking current transformers phase assignment .............................................................. 86

HS-Bus connection (master-slave configuration) ............................................................. 88

8 Comissioning and Programming ..................................................................... 91

Display module functions ........................................................................................................ 91

8.1.1 Boot window ........................................................................................................................ 92

8.1.2 Home window ...................................................................................................................... 92

8.1.3 Main menu ........................................................................................................................... 92

Ways of Software Commissioning .......................................................................................... 96

8.2.1 Commissioning via Ethernet ................................................................................................ 96

8.2.2 Commissioning via display module ..................................................................................... 96

Commissioning procedure ...................................................................................................... 96

8.3.1 Common steps for all configurations ................................................................................... 96

8.3.2 Single power module or asynchronous operation ............................................................... 97

8.3.3 Double Power Pack (DPP) operation .................................................................................. 99

8.3.4 Sync module operation (with SYNC300A installed) .......................................................... 100

Status message ...................................................................................................................... 103

Error message ......................................................................................................................... 105

9 Parameter List .................................................................................................. 106

Parameter list of power module ............................................................................................ 107

9.1.1 Power module parameter group P0XX, P1XX (read only) ................................................ 107

9.1.2 Power module parameter group P2XX and P3XX (Commissioning parameters) ............. 111

9.1.3 Power module parameter group P4XX (Compensation settings) ..................................... 115

9.1.4 Power module parameter group P6XX (Error message) .................................................. 119

Parameter list of sync module ............................................................................................... 121

9.2.1 Sync module parameter group P0XX, P1XX (read only) .................................................. 121

9.2.2 Sync module parameter group P2XX and P3XX (Commissioning parameters) ............... 125

9.2.3 Sync module parameter group P4XX ................................................................................ 133

9.2.4 Sync module parameter group P6XX and P7XX: Error message ..................................... 138

10 AHF Viewer Software .................................................................................... 141

Requirements and Setup .................................................................................................... 141

Connections......................................................................................................................... 142

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10.2.1 Connection via RS485 ....................................................................................................... 142

10.2.2 Connection via Ethernet .................................................................................................... 144

11 AHF Firmware Update Tool .......................................................................... 145

Usage .................................................................................................................................... 145

11.1.1 Select serial port ................................................................................................................ 146

11.1.2 Communication configuration ............................................................................................ 147

11.1.3 Load firmware packet ........................................................................................................ 148

11.1.4 Upload Firmware ............................................................................................................... 149

12 Maintenance .................................................................................................. 151

13 Abbreviation .................................................................................................. 152

14 Index of Figures ............................................................................................ 153

15 Index of Tables .............................................................................................. 156

16 Appendix A: References .............................................................................. 157

17 Appendix B .................................................................................................... 158

Commissioning after longer storage ................................................................................ 158

Type Plate of ecosine active sync ..................................................................................... 159

18 Appendix C: Calculation example ............................................................... 160

Commutation notches ........................................................................................................ 160

18.1.1 Commutation notches calculation example 1 .................................................................... 161

18.1.2 Commutation notches calculation example 2 .................................................................... 162

18.1.3 Commutation notches calculation example 2 .................................................................... 163

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1 Version History

Revision

Date

Description

1.0

February 2018

Initial version

1.1

March 2018

Added index of figures, index of tables Optimized chapters order and content Updated LED indication table and parameters list

1.2

May 2018

Added Figure 7 dimension of drill pattern for wall mount Revised Group P4XX

1.3

June 2018

Added Appendix 17.2 Type Plate of ecosine active sync. Corrected control response time from 300 µs (AHF Gen I) to 100 µs. Corrected height of cabinet in chapter 5.5 to: 2328mm (including top Fan

and socket).

Replaced P203 (not used) by P559 in chapter 8.4.

1.4a

September 2018

Corrected description of X11 connector (valid for FW V03.01.02 or higher)

1.5

March 2019

Added Sync Module (SYNC300A)

- Technical specification

- Electrical connection

Updated Firmware of power module information to V03.01.07 or higher

1.6

July 2019

- Updated Label and technical specification of power modules with UL.

- Updated parameters table of power modules for V03.02.03.

- Updated commissioning procedure with sync module.

- Changed description of P320 settings in chapter 8.2 (with new Firmware V03.02.03 and higher, P320: Total current parallel = 120A for master and slave modules)

1.7

October 2019

Introduction of the new firmware Update Tool software replacing the bootloader in chapter 11

Additional information regarding the usage of the sync module Update of terminal X11 desciption in Table 15 Update of the parameters lists for power module Addition of the parameters lists for sync module Additional details in the commissioning procedure Additional appendix with calculation examples Several minor corrections across the whole document

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2 Introduction

2.1 Purpose

The ecosine active sync User and Installation Manual provides information for unpacking, installation and commissioning of the active harmonic filter and describe mechanical and electrical installation of the filter power module and cabinet version. It contains basic information about parameters and communication as well as troubleshooting information.

The instructions are intended for use by qualified personnel. Reading and following these instructions is mandatory. Particular attention needs to be given to the general safety notes and installation guidelines (cautions and warnings)! always keep these instructions available with the filter(s).

Installation of the ecosine active sync 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.

2.2 Additional Resources

The Schaffner group does provide a number of additional resources available at schaffner.com to understand power quality in general and product in particular.

The ecosine active sync filter maintenance instruction provides information on maintenance and testing for field service technicians, as well as disassembly and assembly instructions for wear parts.

2.3 Naming convention

In this document the acronyme AHF, standing for Active Harmonic Filter, is often used in the text for easier reading. It refers to the ecosine active sync power module, Double Power Pack (DPP) or cabinet system.

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3 General Safety Notes and Installation Guidelines

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4 Environmental Conditions / Exclusion of warranty

This document classifies groups of environmental parameters and their severities to which ecosine active sync 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 factors 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 sync 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 sync harmonic filters are transported, stored, installed or operated outside their published specifications.

Important

Ecosine active sync 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 active harmonic filters (AHF) must be installed in a clean, dry location, e.g. in sufficiently ventilated or airconditioned 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 sync harmonic filters. Ensure that installation site of ecosine active sync is free of conductive dust.

Products

FN3530/31 series, 3-wire filters, 380-480VAC, models 60A FN3540/41 series, 4-wire filters, 380-415 VAC, models 60A FN3532 series, 3-wire filters, 380-480VAC, models 120A FN3542 series, 4-wire filters, 380-415VAC, models 120A FN3545 series, 3/4-wire filters, models 60…300A SYNC300A, optional sync module for ecosine active sync

Overvoltage class (EN50178)

Ecosine active sync are designed according to EN 50178 overvoltage class III

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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

• Vibrations according to IEC 60068-2-6

• Shocks according to IEC 60068-2-27

Operation environmental specifications

(IEC 60721-3-3, EN50178)

Climate conditions for operation class 3K3:

• Temperature range:

| Power module: 0°C to +50°C | Cabinet: 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.

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(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.

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5 Ecosine Active Sync Product Line Overview

5.1 Principle of operation

Ecosine active sync filters are used for harmonic current mitigation, reactive current compensation (both inductive and capacitive) and phase unbalance correction and optimization. The filter units can be integrated into systems and applications as a centrally installed filter unit to mitigate all application related harmonics or can be combined with frequency converters and motor drives to turn standard converters and motor drives into low harmonic solutions.

Ecosine active sync filters are connected in parallel to the load and do steadily monitor all 3-phase line currents (simplified schematic in Figure 1). Harmonic currents and reactive power components are reliably detected and processed in an ultra fast digital control structure. By generating and actively imposing currents in the opposite phase shift, unwanted harmonic and reactive currents are reliably mitigated. By using the latest generation of 3-level IGBT technology ultra fast (real time) feeding is possible with lower losses compared to older generation active harmonic filters. Build-in LCL-filter technology ensures that neither the switching frequency (16 kHz) nor DC components are imposed into the mains. Operation is possible independend of the source, thus the use of the filter in generator or transformer supply applications is feasible. Connected loads can be of various nature, e.g. individual non-linear loads or groups of non-linear loads.

Figure 1 Principle of operation of the ecosine active sync harmonic filter

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5.2 Ecosine active sync system configuration

With the below listed power module variants, optional kits and cabinet variants it is possible to build tailored ecosine active sync filters and systems. Schaffner offers power modules, optional kits and cabinets independently or ready to use filter systems integrated in cabinets.

In the following the designations of ecosine active sync systems and options are introduced.

Table 1 Ecosine active sync power modules versions and options

Designation

Description

FN3530

Power Module 380-480 VAC 3-wire

FN3531

Power Module 380-480 VAC 3-wire with CT Module

FN3540

Power Module 380-415 VAC 4-wire

FN3541

Power Module 380-415 VAC 4-wire with CT Module

FN3532

DPP Double Power Pack 120A 380-480 VAC 3-wire

FN3542

DPP Double Power Pack 120A 380-415 VAC 4-wire

CTM

Current Transformer Module

LCD

Display module

Patch Cable Set

Patch cable set sync module

KITIP21

Ecosine active sync IP21 cover KIT

SYNC300A

Sync module for ecosine active sync

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5.2.1 Ecosine active sync power module FN3530 and FN3531

FN3530 and FN3531 ecosine active sync power modules are 3-phase 3-wire power modules with 60A of mitigation current. FN3530 and FN3531 are applied to 3-phase network without neutral line. FN3530 power modules do not have the CT module included whereas FN3531 power modules come with the CT module included.

FN3530/31

Number of phases (system input)

3-phase 3-wire

Mains frequency

50/60 Hz ± 3 Hz

Mains voltage

380VAC ± 15% to 480VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

16 kHz

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive

compensation)

Mitigation current

60Arms

Dimensions of a single unit

440 mm × 420 mm × 222mm (w × d × h)

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5.2.2 Ecosine active sync power module FN3540 and FN3541

FN3540 and FN3541 ecosine active sync power modules are 3-phase 4-wire power modules with 60A of mitigation current. FN3540 and FN3541 are applied to 3-phase network with neutral line. FN3540 power modules do not have the CT module included whereas FN3541 power modules come with the CT module included.

FN3540/41

Number of phases (system input)

3-phase 4-wire

Mains frequency

50/60 Hz ± 3 Hz

Mains voltage

380VAC ± 15% to 415VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

16 kHz

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive

compensation)

Rated phase mitigation current

60Arms

Rated neutral conductor mitigation current

180Apk

Dimensions of a single unit

440 mm × 420 mm × 222mm (w × d × h)

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5.2.3 Ecosine active sync Double Power Pack (DPP) FN3532 and FN3542

FN3532 and FN3542 are so called Double Power Packs consisting of two ecosine active sync power modules. FN3532 is applied to 3-phase 3-wire networks without neutral wire. FN3542 is applied to 3phase 4-wire network with neutral wire. Both DPP packages will always include two power modules (3wire or 4-wire) and will work in master-slave architecture. That’s why only one CT module and only one display module is needed and will be included in the package. Communication between the modules is realized via a high-speed bus.

FN3532

Number of phases (system input)

3-phase 3-wire

Mains frequency

50/60 Hz ± 3 Hz

Mains voltage

380VAC ± 15% to 480VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

2x16kHz interleaved (32kHz effective)

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive

compensation)

Rated phase mitigation current

60Arms

Dimensions of a single unit

440 mm × 420 mm × 222mm (w × d × h)

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FN3542

Number of phases (system input)

3-phase 4-wire

Mains frequency

50/60 Hz ± 3 Hz

Mains voltage

380VAC ± 15% to 415VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

2x16kHz interleaved (32kHz effective)

Response time

100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive

compensation)

Mitigation current

120A

Rated neutral conductor mitigation current

180Apk

Dimensions of a single unit

440 mm × 420 mm × 222mm (w × d × h)

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5.2.4 Ecosine active sync cabinet version (cabinet + power modules)

The ecosine active sync power modules can be integrated into a cabinet and delivered as a system. The cabinet version can include up to 5 modules depending on the configuration and options defined in the typecode (see chapter 5.3). The cabinet version is designated as FN3545 + the typecode as shown later in Table 2. The main features are summarized below:

FN3545-_ _ _ _ _ _ _ _ _ _

Number of phases (system input)

3-phase 3-wire or 3-phase 4-wire

Mains frequency

50/60 Hz ± 3 Hz

Mains voltage 3-wire

380VAC ± 15% to 480VAC± 10%

Mains voltage 4-wire

380VAC ± 15% to 415VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

number of modules x 16kHz interleaved (up to 5x16kHz effective)

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive

compensation)

Mitigation current

60A, 120A, 180A, 240A, 300A

Dimensions

600 mm × 600 mm × 2265mm (w × d × h)

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5.3 Ecosine active sync cabinet version type code information

Schaffner ecosine active sync series offers a modular solution which enables users to build tailored systems with respect to application and installation needs. Ecosine active sync power modules and options are listed in Table 1, while cabinet versions are listed in Table 2 and Table 3.

The Typecode is defined as a combination of FN3545 (indicating a cabinet version) plus an extension containing information about configuration and options.

Figure 2 Typecode description of ecosine active sync cabinet version

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Table 2 Ecosine active sync cabinet versions without sync module

Designation

Voltage

Sync

Module

Mitigation

Current

3-wire /

4-wire

setup

Power

Module

Display Module

Protection

(Main

Switch)

FN3545-X0603WXXP

380-480 VAC

60A

3-wire

1 x FN3531

Yes

FN3545-X0603WLXP

380-480 VAC

60A

3-wire

1 x FN3531

Yes

FN3545-X0604WXXP

380-415 VAC

60A

4-wire

1 x FN3541

Yes

FN3545-X0604WLXP

380-415 VAC

60A

4-wire

1 x FN3541

Yes

FN3545-X1203WXXP

380-480 VAC

120A

3-wire

2x FN3531

Yes

FN3545-X1203WLXP

380-480 VAC

120A

3-wire

2x FN3531

Yes

FN3545-X1204WXXP

380-415 VAC

120A

4-wire

2x FN3541

Yes

FN3545-X1204WLXP

380-415 VAC

120A

4-wire

2x FN3541

Yes

FN3545-X1803WXXP

380-480 VAC

180A

3-wire

3x FN3531

Yes

FN3545-X1803WLXP

380-480 VAC

180A

3-wire

3x FN3531

Yes

FN3545-X1804WXXP

380-415 VAC

180A

4-wire

3x FN3541

Yes

FN3545-X1804WLXP

380-415 VAC

180A

4-wire

3x FN3541

Yes

FN3545-X2403WXXP

380-480 VAC

240A

3-wire

4x FN3531

Yes

FN3545-X2403WLXP

380-480 VAC

240A

3-wire

4x FN3531

Yes

FN3545-X2404WXXP

380-415 VAC

240A

4-wire

4x FN3541

Yes

FN3545-X2404WLXP

380-415 VAC

240A

4-wire

4x FN3541

Yes

FN3545-X3003WXXP

380-480 VAC

300A

3-wire

5x FN3531

Yes

FN3545-X3003WLXP

380-480 VAC

300A

3-wire

5x FN3531

Yes

FN3545-X3004WXXP

380-415 VAC

300A

4-wire

5x FN3541

Yes

FN3545-X3004WLXP

380-415 VAC

300A

4-wire

5x FN3541

Yes

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Table 3 Ecosine active sync cabinet versions with sync module

Designation

Voltage

Sync

Module

Mitigation

Current

3-wire /

4-wire

setup

Power

Module

Display Module

Protection

(Main

Switch)

FN3545-S0603WXXP

380-480 VAC

Yes

60A

3-wire

1 x FN3530

Yes

FN3545-S0603WLXP

380-480 VAC

Yes

60A

3-wire

1 x FN3530

Yes

FN3545-S0604WXXP

380-415 VAC

Yes

60A

4-wire

1 x FN3540

Yes

FN3545-S0604WLXP

380-415 VAC

Yes

60A

4-wire

1 x FN3540

Yes

FN3545-S1203WXXP

380-480 VAC

Yes

120A

3-wire

2x FN3530

Yes

FN3545-S1203WLXP

380-480 VAC

Yes

120A

3-wire

2x FN3530

Yes

FN3545-S1204WXXP

380-415 VAC

Yes

120A

4-wire

2x FN3540

Yes

FN3545-S1204WLXP

380-415 VAC

Yes

120A

4-wire

2x FN3540

Yes

FN3545-S1803WXXP

380-480 VAC

Yes

180A

3-wire

3x FN3530

Yes

FN3545-S1803WLXP

380-480 VAC

Yes

180A

3-wire

3x FN3530

Yes

FN3545-S1804WXXP

380-415 VAC

Yes

180A

4-wire

3x FN3540

Yes

FN3545-S1804WLXP

380-415 VAC

Yes

180A

4-wire

3x FN3540

Yes

FN3545-S2403WXXP

380-480 VAC

Yes

240A

3-wire

4x FN3530

Yes

FN3545-S2403WLXP

380-480 VAC

Yes

240A

3-wire

4x FN3530

Yes

FN3545-S2404WXXP

380-415 VAC

Yes

240A

4-wire

4x FN3540

Yes

FN3545-S2404WLXP

380-415 VAC

Yes

240A

4-wire

4x FN3540

Yes

FN3545-S3003WXXP

380-480 VAC

Yes

300A

3-wire

5x FN3530

Yes

FN3545-S3003WLXP

380-480 VAC

Yes

300A

3-wire

5x FN3530

Yes

FN3545-S3004WXXP

380-415 VAC

Yes

300A

4-wire

5x FN3540

Yes

FN3545-S3004WLXP

380-415 VAC

Yes

300A

4-wire

5x FN3540

Yes

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Table 4 Ecosine active sync cabinet only versions and cabinet accessoiries

Designation

Description

Cabinet 380-480V IP54 3W

IP54 Cabinet 600x600x2328 3-wire (w/o modules) 480V

Cabinet 380-415V IP54 4W

IP54 Cabinet 600x600x2328 4-wire (w/o modules) 415V

Plinth panel 100

Cabinet plinth panel 100mm

Plinth panel 200

Cabinet plinth panel 200mm

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5.4 Technical specification ecosine active sync power module versions

Number of phases (system input)

3-phase 3-wire or 3-phase 4-wire

Mains frequency

50/60Hz ± 3 Hz

Mains voltage

3-wire: 380VAC ± 15% - 480VAC± 10% 4-wire: 380VAC ± 15% - 415VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

16 kHz

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cos φ = -0.7 … 1 … 0.7 (inductive and capacitive compensation)

Dimensions of a single unit

440 mm × 420 mm × 222mm (w × d × h)

Rated phase mitigation current

60Arms

Rated neutral conductor mitigation current

180Apk

Overload capability (Amp for 10 ms)

150A

Current transformer placement

Mains side or load side

Current transformer ratio

50…50000:5A or 50…50000:1A

Mounting

Wall-mounting (book or flat mounting)

Weight of a single unit

44 kg

Cooling type

Air cooling

Communication interface

Ethernet TCP/IP, Modbus RTU RS485

Digital I/O

2 DIO + 2 DO

Ambient temperature of power modules

0 …50°C full performance, up to 55°C with derating of 3% per Kelvini

Power Losses

<1100W under full mitigation performance (< 2.6%) <970W in typical operation (< 2.3%)

Protection class

IP 20 / IP 21

Noise level

< 56 to 63 dB A (depending on load situation)

Self-protection

Yes

Overheat protection

Yes

See chapter 5.6

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Overvoltage and undervoltage protection

Yes

Recommended fuse protection

100A, type gL or gG

Earthing system

TT, TN-C, TN-S, TN-C-S, IT, corner grounded delta

Altitude

<1000m without derating; Up to 4000m with derating 1% / 100m

Ambient conditions

Pollution degree 2 Relative humidity < 95% non-condensing, 3K3 Temperature: Storage 55°C, 1K3, 1K4, Transportation -25°C to 75°C,

2K3

Approval

CE, RoHS, cUL

Design standards

IEC 61000-4-2, 4-4, 4-5, 4-6 EN 61000-3-11, 3-12 EN 61000-6-2 EN 55011 EN 62477-1 EN 61800-3

5.5 Technical specification ecosine active sync cabinet versions

Number of phases (system input)

3-phase 3-wire or 3-phase 4-wire

Mains frequency

50/60Hz ± 3 Hz

Mains voltage

3-wire: 380VAC ± 15% - 480VAC± 10% 4-wire: 380VAC ± 15% - 415VAC± 10%

Inverter topology

3-level NPC topology, IGBT

Switching frequency

16 kHz

Response time

<100 µs

Harmonic mitigation performance

Up to the 50th harmonic

Total harmonic current distortion THDi

< 5%

Power factor correction

cosφ = -0.7 … 1 … 0.7 (inductive and capacitive compensation)

Dimensions cabinet

600 mm × 600 mm × 2328mm (w × d × h)

Number of Modules

0 i 1 2 3 4 5 Rated phase mitigation current

0 A

60A

120A

180A

240A

300A

Rated neutral conductor mitigation current

0 A

180A

360A

540A

720A

900A

Overload capability (for 10 ms)

0 A

150A

300A

450A

600A

750A

Weight

180kg

224kg

268kg

312kg

356kg

400kg

Power Losses full mitigation performance

200W

< 1300W

<2400W

<3500W

<4600W

<5700W

Power Losses typical operation

200W

< 1170W

<2100W

<3100W

<4000W

<5000W

Current transformer placement

Mains side or load side

Current transformer ratio

50…50000:5A or 50…50000:1A

Mounting

Floor mounting

Parameters of cabinet only configuration

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Cooling type

Air cooling

Communication interface

Ethernet TCP/IP, Modbus RTU RS485

Digital I/O

2 DIO + 2 DO

Ambient temperature

0 …40°C full performance, up to 50°C with derating of 3% per Kelvini

Protection class

IP 54

Noise level

< 75 dB A (depending on load situation)

Self-protection

Yes

Overheat protection

Yes

Overvoltage and undervoltage protection

Yes

Earthing system

TT, TN-C, TN-S, TN-C-S, IT, corner grounded delta

Altitude

<1000m without derating; Up to 4000m with derating 1% / 100m

Ambient conditions

Pollution degree 2 Relative humidity < 95% non-condensing, 3K3 Temperature: Storage 55°C, 1K3, 1K4, Transportation -25°C to 75°C,

2K3

Approval

CE, RoHS, UL (pending)

Design standards

IEC 61000-4-2, 4-4, 4-5, 4-6 EN 61000-3-11, 3-12 EN 61000-6-2 EN 55011 EN 62477-1 EN 61800-3

See chapter 5.7

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5.6 Temperature derating of ecosine active sync power module

The rated current of ecosine active sync power module is 60A when the ambient temperature is between 0°C and 50°C. Derated operation is necessary if the ambient temperature is above 50°C, the rated current reduced 3% per kelvin, and the maximum ambient temperature for derated operation is 55°C. The derating curve of ecosine active sync power module is shown below in Figure 3.

Figure 3 Temperature derating curve of ecosine active sync power module

5.7 Temperature derating of ecosine active sync cabinet version

The rated current of ecosine active sync cabinet version is n*60A (with n = number of installed power modules in operation) when the ambient temperature is between 0°C and 40°C. Derated operation is necessary if the ambient temperature is above 40°C, the rated current reduced 3% per kelvin, and the maximum ambient temperature for derated operation is 50°C. The derating curve of ecosine active sync power module is shown below in Figure 4.

Figure 4 Temperature derating curve of ecosine active sync cabinet versions referred to the rating of one module

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5.8 Sync Module SYNC300A

The Sync Module SYNC300A is a master communication module with following features and advantages:

| Intelligent load and energy management | Redundancy management | Flexible installation with current transformers on mains or load side; one simple CT connection

point for all modules

| Recommended for more than two power modules in parallel operation | Simple and modular installation (wall-mount or rack-mount) | Available as part of the ecosine active sync cabinet FN 3545 or as an option for later upgrade

in wall-mounting or custom cabinet configurations

| Easy filter scalability and extension of mitigation current beyond 300 A;

one sync module can connect and coordinate up to 5 power modules (5x60A) in parallel; interconnection of up to 4 sync modules for a total compensation current up to 1200A

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5.8.1 Technical specification for Sync module SYNC300A

Input voltage

22,0 … 27,0 VDC

Nominal current

< 1 A

Dimensions

440 mm × 200 mm × 87 mm (w × d × h)

Weight

3.0 kg

Protection class

IP20 (option IP21)

Digital I/O

3 DI, 2 DO, 4 DI/O (programmable) 2 relays NO/NC - 2 relays NO with common COM (250 VAC/3A)

24VDC GND

Ambient conditions

Pollution degree 2 Relative humidity < 95% non-condensing, 3K3 Temperature: Storage 55°C, 1K3, 1K4, Transportation -25°C to 75°C, 2K3

Approval

CE, RoHS

The sync module does not contain live parts and has no risk of shock and fire. Due to the low-voltage level of nominal 24 Volts and design as load (in point of limited current consumption), the sync module does not require UL approval.

It is applicable for use in industrial control equipment (i.e. for listed components of category NMTR or NITW).

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5.8.2 Mechanical dimensions of SYNC300A

Table 5 Sync module dimensions

[mm]

[in]

440 17.32

200 7.88

87 3.43

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5.9 Ecosine active sync display module

Ecosine active sync harmonic filters can be commissioned via the display module. It furthermore can be used to change and monitor all filter parameters and measured values of the three-phase network. One display module fit for all power modules and can be used in any of the system setups, whether it is single power module, Double Power Pack or cabinet version.

Function

Display module and keypad

Mounting types

The display module is used to monitor the measured values of the three-phase network and to change the filter parameters. More details can be found in chapter 8.

For DPP configuration, one display module is used and mounted on the master power module as shown in section 5.2.3.

For cabinet version, the display module is mounted on the front door of the cabinet as shown on the cover picture.

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5.9.1 RS485 communication

The display module is connected to the AHF through a RS485 bus and the communication protocol used is Modbus. In addition, the display module acts like a master and the AHF acts like a slave.

The display module can address only one slave device connected on a RS485 multi-slave bus and the target slave device is defined by the Modbus address.

During the normal working conditions, the display module polls almost continuously the AHF slave device to get the required information. In case the communication is missing, an exclamation mark is shown on the top-right corner of the window in order to make the user aware of the situation.

5.9.2 AHF parameters and INI file

The display module can access all parameters of the AHF and, for the purpose of supporting them dynamically, the display module is also able to manage the INI file. Exactly like for AHF-viewer, the INI file is the format used to get all the data regarding parameters and folder structure from the AHF.

Since the downloading and parsing of the INI file is a time-consuming operation, the display module saves it on the serial flash memory in order to avoid this operation at every start up.

At the beginning, the display module compares the software version of the current AHF with the software version of the saved INI file. In case of match, the display module loads the INI file from the serial flash memory and, after a couple of seconds, is already able to launch the application. In case of mismatch, the display module must download the INI file from the AHF, do the parsing and overwrite the old one in the serial flash memory.

This process could take more than one minute and depends strictly on the baudrate of the RS485 communication and on the number of parameters.

5.9.3 Event log and LOG file

With the display module it is possible to see the latest record of the event log, just like AHF-viewer does. The number of visible events is not fixed, it depends on how long the description strings associated to every event are, but it can be considered between 250 to 350 events.

5.9.4 Load and save AHF parameter set

The display module is able to save up to 10 different parameters sets on the serial flash memory. Every set is made up by all the “read/write” parameters of the AHF, the “read only” parameters are not taken into consideration. In addition, the display module is also able to load a complete parameter set to the AHF.

In order to guarantee the compatibility between parameter sets and AHF devices, the software version of the AHF and the software version the parameter set to be loaded must be the same.

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6 Mechanical Installation Guidelines

6.1 Pre-Installation Guidelines

6.1.1 Receiving ecosine active sync

Every single ecosine active sync power module is packed in a wooden box, additionally there are two sets of handlebars (wall-mount and rack-mount), a screw-set as well as the User and Installation manual.

The pre-attached handlebars are necessary for lifting the ecosine active sync base modules from the pallet using a crane or other appropriate lifting equipments. The handlebars might be removed from the power modules after lifting depending on the way of installation of the modules.

Every ecosine active sync cabinet version is packed in a wooden box. Please carefully inspect the shipping container and the product prior to the installation. In case of visual

damage, don’t install the filter and file a claim with the freight carrier involved.

6.1.2 Transportation and unpacking of power modules

Please note that transportation of ecosine active sync power modules must always be realized with the original packaging. Any other than that might lead to damages and will void warranty.

After receiving of ecosine active sync power modules please follow carefully the upacking instructions. Please refer to the document “Unpacking Instruction ecosine active sync filters (module or cabinet)”, which is attached to the transportation package.

6.1.3 Lifting

Figure 5 Instruction for lifting power module

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6.1.4 Important note for installation

All other installation positions than the ones described in the following chapters of this manual are prohibited and might result in improper air-cooling capabilities or unsafe operation.

Additionally, in case of wall mounted modules, the customer or installer is fully responsible to ensure proper mounting on a suitable wall using appropriate and compatible fixation material.

Schaffner is not responsible for any damage on the ecosine active sync device or any other device due to improper usage. Failing to respect the requirement will void the guarantee.

6.2 Mechanical installation of ecosine active sync power module

6.2.1 Dimensions of an ecosine active sync power module

Figure 6 mechanical drawing of ecosine active sync power module (see dimensions in Table 6 and Table 7 below)

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Figure 7 Dimensions [mm] drill-pattern for wall-mount (book and flat mounting)

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Dimensions of ecosine active sync power module and minimum required clearance are shown in the following tables.

Table 6 Ecosine active sync power module dimensions

[mm]

[in]

440 17.32

420 16.54

219.5i

8.64

463.5

18.25

56 2.20

112 4.41

23.5

0.93

2.36

0.12

3.15

Table 7 Ecosine active sync power module (internal dimensions)

[mm]

[in]

90 3.54

12 0.47

11.5 0.45

20 0.79

95 3.74

105 4.13

65 2.56

82.5 3.25

49 1.93

Table 8 Ecosine active sync power module clearance distances

Side

Minimum required

clearance [mm]

[in]

Front (air intel)

200 7.85

Back (air outlet)

200 7.85

Lateral 50 1.97

Module height: ~ 5 rack units

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6.2.2 Ecosine active sync power module mounting options

Ecosine active sync power module is designed for wall-mounting installation, there are flat mounting and book mounting options. The mounting rackets are mounted on the power module differently for flat mounting and book mounting, the details are presented in the following.

6.2.2.1 Flat mounting

For flat mounting, please mount the four mounting rackets as shown in Figure 8.

Figure 8 Instruction of power module flat mounting

6.2.2.2 Book mounting

For book mounting please mount the four mounting brackets as shown in Figure 9

Figure 9 Instruction of power module book mounting

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Important: In order to ensure sufficient air flow, make

sure a clearance of minimum 200mm, above and below the filter to walls or other components, is available.

6.3 Mechanical installation of ecosine active sync DPP

6.3.1 Dimensions of ecosine active sync DPP

A double power pack DPP filter is composed of two single ecosine active sync power module. The dimensions as in 6.2.1 apply.

6.3.2 Mounting options of ecosine active sync DPP

For Double Power Pack mounting, please install the modules next to each other horizontally, and keep the clearance distance above and below the filter as mentioned above. This principle also applies when more than two power modules are installed on the wall.

(a) Book mounting (b) Flat mounting

Figure 10 Double Power Pack installation variants It is not recommended to install power modules vertically close to each other, as shown in Figure 11;

because the warm exhaust air of the lower module heats up the upper module and therefore the air cooling for the upper module may not be sufficient.

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Figure 11 Wrong ways to install DPP

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6.4 Mechanical installation inside customer cabinet

6.4.1 Customer cabinet requirements

Ecosine active sync power module up to five modules in total can also be installed in a cabinet provided by customer. To ensure the normal operation of ecosine active sync modules the cabinet must fulfill the cooling requirements mentioned below in chapters 6.4.2 and 6.5.2; the power modules must be connected according to the power module electrical installation as described later in chapter 7.

Table 9 Technical data for one ecosine active sync power module

Parameter

Value

Comments

Recommended fuse protection

100A

e.g. gL or gG

Cross-section of power cables (cable from distribution to power module)

| 3 Phase and PE: 1 x 25mm2 | Neutral: 2 x 25 mm2

System input (number of phases)

50/60Hz ± 3Hz 3-wire or 4-wire

Input voltage

| For 3-wire module: 380VAC ±

15% … 480VAC ± 10%

| For 4-wire module: 380VAC ±

15% … 415VAC ± 10%

Rated current

Phase: 60 A Neutral: 180A

CT cable cross section

2.5 mm2

If input is 1A signal, the cross section can be reduced to 1.5 mm2.

6.4.2 Cooling requirements of customer cabinet

If recommended components are used, it is important to seal the air channel as good as possible. The following points should be double checked to ensure the normal operation conditions for ecosine active sync modules.

1. The minimum required cross-section and length for air channel must be fulfilled.

2. Air channels between modules and air outlet must be sealed (metal sheets must be overlapped;

foam or gaskets should be used).

3. There is no air flow shortage. Attention should be paid at the holes on the cabinet frame.

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Parameter

Value

Comments

Power losses per module

Typical 1200 W Max. 1450 W

At maximum load current of 60 Arms

Air flow per module

270 m3/h

Depending on the position and pressure it can deviate

Max. air flow per cabinet

Max. 1400 m3/h

Including the cooling for fuse section

Area – air inlet per module

Min. 450 cm2

Placement in front of fans on each power module

Max. length of air guide channel behind power module

Max. 1200 mm

Min. space in air guide channel behind modules

Min. 70 mm

Top view of a cabinet.

Area – air guide channel in the roof

Min. 900 cm2

Front view of a cabinet

Max. length of air guide channel in the roof

Max. 800 mm

Distance air inlet filter to the front of power module

Min. 45 mm

Placement in front of fans on each power module (not interfered by cable connections)

Note: the aboved conditions are valid only when the channel is completely sealed. A small opening can cause shortages in air flow. In consequence, the module temperature increase is unbalanced among modules and the module operation can change to derating mode.

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6.5 Mechanical data of ecosine active sync cabinet version

6.5.1 Dimensions of ecosine active sync cabinet version

Figure 12 mechanical drawing of ecosine active sync cabinet (see Table 10 below)

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The ecosine active sync cabinet has protection degree IP54. The default color of the cabinet is RAL

7035. The cabinet dimensions are as shown in Table 10. Table 10 Ecosine active sync cabinet dimensions

Table 11 Ecosine active sync cabinet clearance distance

Side

Minimum required

clearance [mm]

[in]

Front (air inlet)

900 mm (to open the

door)

35.43

Back -

Lateral -

There are no clearance requirements for back and lateral installation of ecosine active sync cabinet version.

[mm]

[in]

2057 81

100 3.94

171.2

6.74

458.3

18.04

606.7

23.9

608 23.9

642.5

25.3

653.7

25.7

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6.5.2 Cooling requirements of ecosine active sync cabinet versions

Cooling air inlet is in the front door and outlet is in the top front of the cabinet cover.

Table 12 Air cooling requirement for ecosine active sync cabinet version

Parameter

Values

Side view into cabinet with

direction of air flow

Protection category

IP54

Default color

RAL 7035

Required air flow per module

270 m3/h

Maximum air flow per cabinet

1400 m3/h

Air flow through fuse section

100 m3/h

Area - air inlet per module

Min. 450 cm2

Area - air duct channel behind power modules

Min. 370 cm2

Max. length of air duct channel behind power modules

Max. 1200 mm

Min. space in air duct channel behind modules

Min. 70mm

Area - air duct channel in the roof

Min. 900cm2

Max. length of air duct channel in the roof

Max. 800mm

Distance between air inlet filter and front of power module

Min. 45mm

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7 Electrical Installation Guidelines

7.1 Protection (Fuses, Breakers)

Ecosine active sync filters must always be protected on the mains side of the filter with suitable fuses or circuit breakers. Depending on the operation mode, alternation of the load and the harmonic spectrum of ecosine active sync output current, fuses will be stressed differently. Recommended fuse protection type can be found in the technical specification in section 5.4.

Each power module must have own fuse protection of 100A e.g. type gL or gG.

7.2 Installation with power factor correction (PFC) systems

In case of installation of the ecosine active sync in combination with a PFC system, the following requirement are mandatory.

| The use of pure capacitive PFC system is not allowed, a reactor must be installed | The PFC system must be de-tuned to avoid overloading the capacitors

Table 13: Example of typical detuning order for 50Hz and 60Hz networks

Tuning order

Relative impedance [%]

Tuning frequency [Hz] @50Hz

Tuning frequency [Hz] @60Hz

2.7

135

162

3.8 7 190

228

7.3 Power Module electrical installation

7.3.1 Connecting terminal locations

| X1: Mains power input

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Terminal X1 - Mains Power Input

The three phase conducter and neutral line connection. Details of connecting ecosine active sync to the mains see section 7.5.2.

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Terminal X2 – Current transformer input (CT Module)

Switch S1 – Switch on/off

To switch on or switch off ecosine active sync module, when the parameter P202 is set to

“Switch S1”.

LEDs – Indication LEDs

To show the status of ecosine active sync module, the color of each LED is relevant. The indications of the LEDs are listed in

Table 14.

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Table 14 Indication of LED

Color

LED# / name

Meaning

•

LED1 Error

Blinking = Error ON = Fatal Error / Restart blocked

•

LED2 Ready/Operation

Blinking = ready to operate ON= operating

•

LED3 Alarm/Warning

ON= warning (HSB link not o.k.)

•

LED4 Status/Notice

Blinking 0.5sec = overload condition Blinking 1sec = Standby

Terminal 11 - Customer IOs: Digital Inputs and Outputs

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Table 15 Terminal 11 - customer Digital IOs (see chapter 9.1.2 for more detail)

PinNo.

Signal

Description

GND (potential-free)

Ground 0V (Reference for digital outputs)

IN1 / OUT4

Digital input/output (24V, 20mA)

| Set P262 as “Input” for using X11.2 as digital input or “Output”

for using X11.2 as digital output.

| Set P261 to select the polarity of the Input/Output X11.2, “low

active” or “high active”.

| Select the function of X11.2 from the list of functions in P260

IN2 / OUT3

Digital input/output (24V, 20mA)

| Set P265 as “Input” for using X11.3 as digital input or “Output”

for using X11.3 as digital output.

| Set P264 to select the polarity of the Input/Output X11.3, “low

active” or “high active”.

| Select the function of X11.3 from the list of functions in P263

OUT1

Relay output (230V, 3A)

| Select the function of X11.4 relay output from the list in P266

| Set P267 to select the polarity of the relay X11.4, “normal

open” or “normal closed”.

OUT2

Relay output (230V, 3A)

| Select the function of X11.5 relay output from the list in P268

| Set P269 to select the polarity of the relay X11.5, “normal

open” or “normal closed”.

COM

Relay input (common) for both relay outputs

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Figure 13: Logic schematic of the digital input/output

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Out4

+24V

In1

+24V

Gnd

+24V

X11.2

P262=1

P262=0

Figure 14: Functional connection of digital input/output

Terminal X12 - HS-Bus Port

HSB is used to realize data exchange and synchronization of interconnected sync module and power modules, more details refer to section

7.10.

Terminal X13 – Service port RS485

This port is mainly used for firmware updates. For further information refer to ecosine active sync service manual, available on www.schaffner.com.

Terminal X14 – Ethernet / Modbus TCP

HSB is used to realize data exchange and synchronization of interconnected sync module and power modules, for more details refer to section 7.10. Alternatively, this interface could be used to connect AHF with a device on LAN network, i.e. a PC with the AHF Viewer operating program.

Terminal X15 – ModBus Daisy Chain RS485

For DPP version and sync module, only one display module is used to display the information of multiple modules by connecting the X15 terminal of the power modules and sync module.

Terminal X16 – Display Port

Display port provides a Modbus connection including 24V powering the display module.

Warning: 24V power supply must be switched off before connecting other than original Schaffner display module (P255=OFF). There is

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a risk that external interface adapters will be damaged.

Terminal X-PE – Protective Earth Connection

Ecosine active sync power module must be grounded by connecting the protective earth at terminal X-PE.

7.3.2 Connection of AC Mains

The device must be grounded (connect the protective earth at terminal X-PE of the power module). The AC mains connection cross sections and the tightening torque are presented inTable 16:

Table 16 Connection cross sections and tightening torque mains connection

Device

Min. value cable cross section

Max. value cable cross section

Connecting bolt and tightening torque

Ecosine active sync single 60A Power Module

1 x 25 mm2 per phase and PE

2 x 25 mm2 (N)

1 x 25 mm2 per phase and PE

2 x 25 mm2 (N)

Terminal L1, L2, L3, N

| 4.2 Nm (0.47 lbf in)

PE bolt:

| M8 | 9.5 Nm (1.07 lbf in)

Always use the correct cable cross sections in consideration of cable type and type of cable mounting. To ensure UL conformity, use UL listed cable (90°C, AWG4 or larger) and suitable UL listed wire-lugs.

DANGER

Ensure correct grounding

Insufficient grounding of ecosine active sync filter may cause malfunction of the device and its destruction.

Each power module must have its own fuse protection of 100A e.g., type gL or gG (see section 7.1).

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7.4 Sync Module electrical installation

7.4.1 Connecting terminal location

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Terminal X110 – Current transformer input (CT Module)

When Sync module is installed, the CT connections are only done to the CT Module of SYNC300A.

No need to wire through the power modules.

With SYNC300A, the connection of the current transformers is done at one single point to the X110 CTM-interface of the sync module.

The sync module transmits the current measurements over the HSB to the installed power modules.

Switch S1 – Switch on/off

To switch on or switch off the sync module, when the parameter P202 is set to “Switch

S1”.

LEDs – Indication LEDs

To show the status of ecosine active sync power module and/or sync module, the color of each LED is relevant. The indications of the LEDs are listed in

Table 14.

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7.4.2 Interconnection between Sync Module and Power Modules

The connection between the Sync Module (designated as SM) and the power modules (designated as PM) is done via HSB-link on terminal X112 and X114 of the sync module and terminal X12 and X14 of the power modules using with RJ45 cables.

The sync module connection needs to be done exact in the way seen on Figure 15, otherwise the sync module is not able to read the power modules correctly. In Schaffner’s ecosine active sync cabinet, the power modules 1 to 5 are installed from bottom to top.

Figure 15 HSB connection between sync module and power modules

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7.5 Ecosine active sync cabinet version electrical installation

7.5.1 Connecting terminal locations

See detailed drawing of the lower part of the cabinet in the following pages.

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Terminal

Description

XC1

Terminal for connection of mains input cable

XC2

Terminal for connection of current transformers

XC-N

Terminal for connection of neutral conductors

XC-PE

Terminal for connection of protective earth conductors

Terminal XC1 – connection of mains 3-phase input cables L1, L2 and L3 (phase A, phase B and phase C)

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Terminal XC2 – connections of external Current Transformers (CT)

Note: The cabinet is assembled per default for 5A

CT secondary output. For CTs with 1A secondary output, the

terminations must be re-wired during electrical installation (same as indicated in Figure 21).

7.5.2 Connection of AC Mains

The device must be grounded (connect the protective earth at terminal XC-PE at the bottom left of the cabinet). The AC mains connection cross sections and the tightening torque are presented in Table 17:

Table 17 Connection cross sections and tightening torque mains connection

Device

Min. value cable cross section

Max. value cable cross section

Connecting bolt and tightening torque

Ecosine active sync max. 300A cabinet version

1 x 185 mm2 per phase and PE 2 x 240 mm2 (N)

2 x 120 mm2 or 1 x 240 mm2 per phase and PE 2x 240 mm2 (N)

| M10 | 19Nm (168.0 lbf in)

DANGER

Ensure correct grounding

Insufficient grounding of ecosine active sync filter may cause malfunction of the device and its destruction.

Each power module has its own fuse protection of 100A e.g., type gL or gG (see section 7.1) installed. Customer must ensure that protection fuses according to local regulations are installed for the mains input cables.

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7.6 Connection of current transformers

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

De-energize the active harmonic filter before carrying out this procedure. Failure to follow these instructions will result in death or serious injury.

CAUTION RISK OF INCORRECT MOUNTING

Respect and check the phase order and polarity of the current sensors. Failure to follow these instructions can result in injury or equipment

damage.

Dangerous Voltage Risk of death due to short circuits and electric shock if the current transformers are connected incorrectly

BEFORE installing current transformers on the primary conductor short circuit CTs on secondary side with separable short-circuit jumpers (not in the scope of delivery)

Keep the current transformers short circuited until

│ the ecosine active sync devices are connected with these

separable connecting terminals

│ the correct wiring of the secondary circuit has been confirmed

(5A or 1A)

BEFORE disconnecting current transformers from ecosine active sync devices always short-circuit them with separable short-circuit plugs.

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7.6.1 Connection of 3-phase 3-wire devices CT secondary output 5A

Figure 16 Connection of 3-phase 3-wire device CT secondary output 5A

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7.6.2 Connection of 3-phase 3-wire devices CT secondary output 1A

Figure 17 Connection of 3-phase 3-wire device CT secondary output 1A

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7.6.3 Connection of 3-phase 4-wire devices CT secondary output 5A

Figure 18 Connection of 3-phase 4-wire devices CT secondary output 5A

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7.6.4 Connection of 3-phase 4-wire devices CT secondary output 1A

Figure 19 Connection of 3-phase 4-wire devices CT secondary output 1A

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7.7 Current transformers specifications and cable selection

For correct ecosine active sync operation, three external current transformers (CT) must be connected. This applies regardless of whether ecosine active sync is used as 3 phase 3-wire or 3 phase 4-wire filter,

Please observe the following instructions when installing external current transformers:

For operation of one ecosine active sync power module FN3531 or FN3541, the CTs can be

installed on the mains or load side of the filter.

For Double Power Pack FN3532 and FN3542, current transformers can be installed either on

the mains or load side.

For use of more than two power modules in parallel, the use of the sync module SYNC300A

offers the optimal and more flexible solution. In this configuration, the CTs can be installed either on the mains or load side. Moreover, the PWM switching patterns of all power modules are synchronized leading to lowest switching harmonic content.

For use with more than two power modules in parallel without the sync module, the CTs must

be installed on the load side only. For installations with main side CTs special summation CTs are needed (for more information please refer to the document “Knowledge base information No. 002”).

Separate transformer circuits are mandatory for proper operation of ecosine active sync.

Dedicated current transformers must be used. Current transformer secondary circuits must not be looped through additional loads (i.e., the CT cable should not be routed through the CT loop itself or other burden that could influence the signal).

A current transformer terminal-block with separable short-circuit plugs must be installed

between the external current transformers and the connecting terminal of CT module interface of the ecosine active sync device (CTM terminal strip X2 for power module, X110 for sync module). This is necessary to be able to short-circuit the current transformers before disconnecting the CTM terminal strip on the ecosine active sync device during any kind of service work.

The power dissipation of the current transformer wiring must be considered when selecting the

current transformer power. See Table 18 and Table 19.

Grounding of CT secondary cicuit should be avoided. The wires of the secondary side of the current transformers must be separated from the power

cables of the ecosine active sync. The usage of twisted pair cables is recommended in case of high risk of perturbation but not mandatory in most cases.

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Characteristic

Value

Rated secondary current

1 A or 5 A

Primary current

For current signals with high crest factor, the primary current must be selected according to the peak value of the current signal.

Nominal CT current > I

peak

/ √2

Accuracy class

1.0 (or better) The total accuracy calculated from CT primary current and CT class

should not exceed 10% of the AHF nominal current. example 1: CT 1000:5A (class 1.0), AHF 120A

accuracy 10A (1% of 1000A) ≤ 12A (10% of 120A) ➩ ok example 2: CT 2000:5A (class 1.0), AHF 60A accuracy 20A (1% of 2000A) ≥ 6A (10% of 60A) ➩ not ok example 3: CT 2000:5A (class 0.5), AHF 120A

accuracy 10A (0.5% of 2000 A) ≤ 12 A (10% of 120 A) ➩ ok

Output power1

At least 1.5 VA (1 ecosine active sync) At least 3.0 VA (2 ecosine active sync in parallel operation) At least 4.5 VA (3 ecosine active sync in parallel operation) At least 6.0 VA (4 ecosine active sync in parallel operation) At least 7.5 VA (5 ecosine active sync in parallel operation)

The output power is defined for CT with 5A secondary output. For CTs with 1A secondary output, the CT output

power should be lower (i.e. around 0.25 VA pro power module).

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Table 18 Power consumption of the CT lines valid for copper wires and CT with secondary output 5A

Cross section

AWG

Distance between current transformer and ecosine active sync vs. CT 5A secondary burden in VA (Twin Wire)

(Consider forward and return lines!)

1 m

2 m

4 m

8 m

10m

1.0 mm2

18 - - - - - -

1.5 mm2

0.58

1.15

2.31

3.46

4.62

5.77

2.5 mm2

0.36

0.71

1.43

2.14

2.86

3.57

4.0 mm2

0.22

0.45

0.89

1.34

1.79

2.24

6.0 mm2

0.15

0.30

0.60

0.89

1.19

1.49

10.0 mm2

0.09

0.18

0.36

0.54

0.71

0.89

Example: With 4 meters between current transformer and ecosine active sync, the line length in the CT circuit is 8 meters. If 2.5mm² cables are used, the CT output power need to be at least 2.86VA.

Table 19 Power consumption of the CT lines valid for copper wires and CT with secondary output 1A

Cross section

AWG

Distance between current transformer and ecosine active sync vs. CT 1A secondary burden in VA (Twin Wire)

(Consider forward and return lines!)

10 m

20 m

40 m

60m

80 m

100m

1.0 mm2

0.35

0.71

1.43

2.14

2.85

3.57

1.5 mm2

0.23

0.46

0.92

1.39

1.85

2.31

2.5 mm2

0.14

0.29

0.57

0.86

1.14

1.43

4.0 mm2

0.09

0.18

0.36

0.54

0.71

0.89

6.0 mm2

0.06

0.12

0.24

0.36

0.48

0.60

10.0 mm2

0.04

0.07

0.14

0.21

0.29

0.36

Example: With 20 meters between current transformer and ecosine active sync, the line length in the transformer circuit is 40 meters. If 1.5mm² cables are used, the CT output power need to be at least

1.85VA.

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7.8 Current transformer specification for UL conformity

To ensure UL conformity, UL-compliant external current transformers must be used. Table 20 Example of a current transformer with UL conformity

Manufacturer

Current transformer type

Flex Core

FCL series

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7.9 Connection and verification of current measurements

7.9.1 CT connection for operation of single ecosine active sync power module

To ensure that currents are correctly detected, observe the specified direction of the current flow from the transformers and the correct phase assignment. The CT wiring for operation of single power module is shown below in Figure 20 for secondary output 5A, resp. Figure 21 for secondary output 1A.

Figure 20 CT (5A) wiring for single power module

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Figure 21 CT (1A) wiring for single power module

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Figure 22 CT installation on load side for operation of one power module

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Figure 23 CT installation on mains side for operation of one power module

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7.9.2 CT connection for operation of double power pack (DPP) ecosine active sync

Configuration with double power pack (DPP) need to have the CTs connected to one power module only. For DDP, the current transformer can be installed on the mains or the load side like for operation with one single power module.

Figure 24 CT (5A) wiring for DPP, CTs connected to one module only

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Figure 25 CT (1A) wiring for DPP, CTs connected to one module only

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Figure 26 CT installation on load side for operation of DPP

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Figure 27 CT installation on mains side for operation of DPP

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7.9.3 CT connection for operation of the sync module and multiple ecosine active sync power modules

Configuration using the sync module need only to have the CT connect to the sync module. To ensure that currents are correctly detected, observe the specified direction of the current flow from

the transformers and the correct phase assignment. The CT wiring for operation of single power module is shown below in Figure 20 for secondary output 5A, resp. Figure 21 for secondary output 1A.

Figure 28 CT (5A) wiring for the sync module

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Figure 29 CT (1A) wiring for the sync module

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Figure 30 CT installation on load side for operation of the sync module and multiple power modules

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Figure 31 CT installation on mains side for operation of the sync module and multiple power modules

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7.9.4 CT connection for parallel operation of several ecosine active sync power modules without sync module

The available compensation current can be increased through parallel operation of several ecosine active sync devices. In doing so, the current signal from the external current transformers is looped through all the ecosine active sync devices in accordance with the following schematic.

For more than 2 ecosine active sync power module in parallel connection, the current transformers must be installed on load side. For installation on mains side, the usage of the sync module is mandatory.

Figure 32 CT (5A) wiring for parallel operation up to five power modules, no sync module

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Figure 33 CT (1A) wiring for parallel operation up to five ecosine active sync power modules

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Figure 34 CT installation on load side for parallel operation of several (>2) ecosine active sync modules FN3531 or FN3541 without sync module

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Note

A maximum of five ecosine active sync devices may be operated on one current transformer set due to the maximum power output of the external current transformers. Usage of the sync module or additional current transformers must be installed if more than five devices are to be operated in parallel.

For parallel operation of more than one ecosine active sync without sync module (except for DPP), the current transformers must be installed on load side of the filter. Operation using the sync module allow to have the current transformers either on load or mains side.

P320 must be set to the sum of the entire rated compensation currents connected in parallel (See section 9.1.2).

Note

For additional CT installations, as well as additional information regarding sizing and connection of CTs two knowledge base articles are available:

Knowledge base information No. 002 – Current transformer special applications Knowledge base information No. 011 – Current transformer installation

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7.9.5 Grounding of the current transformers

According to DIN VDE 0100 one-side grounding of the current transformers is compulsory only starting from 3 kV rated voltage, it helps to prevent risk for the operating personnel in case of an insulation fault. For voltages below 3 kV, grounding of the current transformers is not required, unless it is necessary for a correct measurement. If it is necessary to ground the current transformers, then grounding should be performed in the following way:

Note

Grounding must be performed only once for each current transformer circuit!

Figure 35 Grounding of the current transformers (optional)

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7.9.6 Checking current transformers rotating field

Start a single measurement using the AHF Viewer and display the following parameters:

I Voltage values

| Instantaneous voltage value in phase 1 (P113) | Instantaneous voltage value in phase 2 (P114) | Instantaneous voltage value in phase 3 (P115)

I Current values depending on the installation of the current transformers

Current transformers on the load side:

| Load current phase 1 (P133) | Load current phase 2 (P134) | Load current phase 3 (P135)

Current transformers on the mains side:

| Mains current phase 1 (P123) | Mains current phase 2 (P124) | Mains current phase 3 (P125)

If the current transformers are connected correctly, then the rotating field of the voltage and current is identical. If the rotating field is revolving in the opposite direction, two current transformers are reversed in the phases.

Correct

Wrong

Figure 36 Checking rotating field of current and voltage

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7.9.7 Checking current transformers phase assignment

If the rotating field is correct, the same measured values can be used to check the phase location of current and voltage.

Example 1:

Phase location of current and voltage match.

Correct

Figure 37 Phase of current and voltage is correct

Example 2:

Phase location of current and voltage is shifted through 180°. Here both connections (S1 and S2) of the current transformer are interchanged or the current transformer is installed incorrectly. It becomes evident in 2 different ways. On the one hand, it becomes apparent, as shown in Figure 38, in form of the opposite current with respect to the voltage curve of the same phase. Just as it is apparent in Figure 39 when displaying all 3 currents, on the basis of incomplete current pattern which does not have a negative current curve for each positive current curve.

Wrong

Figure 38 Phase of current and voltage is shifted through 180°

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Wrong

Figure 39 Current transformer 1 phase-is shifted through 180°.

Example 3:

Current transformers of individual phases are interchanged, it becomes apparent already during the rotating field check. The comparison of current and voltage shows that the phase shifting of current and voltage exceeds 90°. See Figure 40.

Wrong

Figure 40 Current transformers of phase 1 and 3 are interchanged

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7.10 HS-Bus connection (master-slave configuration)

Double Power Pack is realized by connecting two ecosine active sync power module in parallel via HSBus. HS-Bus enables the communication between the modules and the workload is distributed equally between the two modules.

HSB communication link implements a MASTER-SLAVE point to point protocol. The MASTER device measures the external current (mains side or load side) needed by the current controllers and generates the base PWM modulation and control loop frequency used by MASTER and SLAVE devices.

HS-Bus configuration steps

Step 1: Master-slave device assignment

Figure 41 Master slave device assignment

Step 2: Connect the modules in parallel to the grid

Step 3: Connect the modules via Terminal X12

Build HSB between the master and slave module by connecting Terminal X12 of both modules with a twisted pair Ethernet CAT5 cable with RJ45 connectors not longer than 10m.

CT can be installed on the mains or the load side of the filters, see Figure 27 and Figure 26.

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Figure 42 Location of Terminal X12 on ecosine active sync module

Software step up: Software settings must be independently configured, this means that two different AHF viewer

sessions will be needed to set both MASTER and SLAVE devices up.

Step 4: Check firmware version

To read the firmware version of the ecosine active sync filter module, connect the target device with AHF viewer; under Device Parameters | 0 device specifications, the parameter with ID10 shows the present firmware version.

Figure 43 Ecosine active sync device Firmware version in AHF viewer.

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Step 5: Master-Slave configuration

In AHF Viewer ecosine active sync, under Device Parameters | 2..5 commissioning | base settings double click on parameter with ID205 (Operation Mode).

Figure 44 Ecosine active sync DPP operation Master/Slave configuration.

Operation mode, parameter P205

Value

Description

Asynchronous

Single or asynchronous operation mode.

Synchronous Master

HSB Master configuration. With this configuration, the AHF device must have a CT module connected.

In this mode (DDP), each power module will compensate 50% of the grid distortion.

Synchronous Slave

HSB Slave configuration. This power module will act as SLAVE and does not need a CT module. The

load current values, PWM modulation and base control frequency will follow the MASTER device.

In DPP configuration, the power module will compensate 50% of the grid distortion.

With sync module as MASTER, each power module is set automatically by the sync module to compensate 1/n (where n is the total number of installed power module in operation) of the total compensation current.

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8 Comissioning and Programming

Ecosine active sync harmonic filters can be commissioned via the display module and its keypad.

8.1 Display module functions

Figure 45 Display module and keypad The keys have the following functions:

Key

Function



| Go down one menu level



| Back to the higher menu level, exit menu | Scroll inside information screen



| Go up one line | Change information screen



| Go down one line | Change information screen

| Change parameters | Save value

| Go down one menu level

ESC

| Discard selection or new value | Back to home window

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8.1.1 Boot window

The boot window automatically appears at every start up for some seconds and simply represents the “Schaffner” logo.

8.1.2 Home window

The home window shows some basic information of the AHF. Here are the descriptions of the fields:

| product code: it’s a string defining the device type | AHF state: it represents the current status of the AHF, and it corresponds to the parameter

P020

| grid voltage: is the rms value of the line voltage U12, it corresponds to the parameter P110 | load current: this is the line current and it corresponds to the parameter P120 | device load %: this is the percentage value of the output current of the AHF, it corresponds to

the parameter P104

8.1.3 Main menu

The main menu is where the user can select the available functionalities, it is made up by the following five entries:

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8.1.3.1 Ecosine active sync (AHF) parameters

In the following section as in the whole document AHF designates the ecosine active sync filter. Table 21 AHF parameter menu on the display module

Level 1

Level 2

Level 3

AHF Parameters

0 Device Specifications

1 Measurements

2…5 Commissioning

6 Alarms

0 Device specifications

002 Rated current

003 Overload current

…

1 Measurements

100 Mains frequency

102 Cos phi

…

2 ... 5 Commissioning

2 Basic settings

3 Current transformer s

4 Compensation settings

5 Experts settings

2 Basic settings

200 Language

202 Switch on mode

…

3 Current transformer

settings

300 CT placement

310 CT primary value

…

4 Compensation settings

400 Reactive power

401 Cosphi lower limit

…

6 Alarms

600 Phase L3 IGBT4

615 Overcurrent L1

…

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8.1.3.2 Event log

When entering the event log, the display module downloads from the AHF the last record of events. By pushing the up and down arrow it is possible to scroll the event log and move through the event list.

For each event the following information is recorded:

8.1.3.3 Save parameter set

By entering this menu, the user has access to the 10 spots available for saving a parameter set. If a spot is already used, the relative SW version of the parameter set is shown aside of the set number. If a spot is empty, nothing is shown aside the set number.

By pressing right arrow button or ok button, the user can start a saving procedure on the selected spot.

8.1.3.4 Load parameter set

By entering this menu, the user can check all the available parameter sets that have been previously saved. Like before, next to the set number lies the SW version of the parameter set.

By pressing right arrow button or ok button, the user can start a loading procedure of the selected set to the AHF. The SW version of the AHF and the SW version of the parameter set must match, otherwise the load procedure does not start, and an info message is shown to the user.

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8.1.3.5 Settings

This sub-menu “Settings” contains all the features related to the display module itself; it has the following items:

item

Description

Modbus

Here the user can configure the Modbus features (address, baudrate and frame type) of the display module itself. The Modbus configuration of the AHF has to be done separately through the proper parameters, not in this sub-menu.

Beware that the Modbus configuration of the display module and AHF must match, otherwise the communication between the two devices doesn’t work.

Password

Access to change the expert parameters password. The password is only needed for accessing expert parameters and can be used only by Schaffner service team or selected partners. First enter the old password then enter the new one twice. After pressing OK, the display module confirms if the operation was successful or not.

Screen saver

Access to set the timeout of the screen saver. Press the right arrow or OK button to modify the numerical value of the timeout before showing the screen saver.

Information

Information about the firmware. Page 1 is the firmware of the sync module or power module currently selected. Page 2 (press down arrow to access) display the display module firmware information.

FW update

Access to update the firmware of the display module. Note: Updating the firmware of the sync or power module cannot be

done from the display. Please refer to chapter 11 for more information.

Reload INI file

Access to force the loading of the INI file if necessary.

Restart

Select to restart the display module.

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8.2 Ways of Software Commissioning

8.2.1 Commissioning via Ethernet

Comissioning via Ethernet interface or RS485 can be used by connecting a PC with the AHF Viewer operating program (see section 10.2.2).

8.2.2 Commissioning via display module

Commisioning ecosine active sync via display module please refer to section 8.1 and Table 21.

8.3 Commissioning procedure

Note for Commissioning with AHF-Viewer (PC commissioning tool) It is always recommended to use the newest version of AHF-Viewer. The software can be

downloaded at www.schaffner.com in Downloads/Software.

8.3.1 Common steps for all configurations

1. Check the ambient conditions

| Ambient temperature < 40°C (cabinet) or 50°C (power module), with higher temperature values

of up to max. 55°C, the device switches to derating mode.

| Altitude < 1000 m, for higher altitudes the output power needs to be derated by setting the output

current limit in parameter P510.

𝑃510 = 100 −

(

𝐴𝑙𝑡𝑖𝑡𝑢𝑑𝑒 − 1000𝑚

)

100

| Check the ventilation of the room or control cabinet to find out whether sufficient cooling air is

available.

| Make sure that the ambient conditions from section 4 (environmental condition) are complied

with and no conductive dust can enter the ecosine active sync.

| The line voltage must be within 480V ±10% rms, corresponding to a maximum peak voltage of

746Vpk

| The commutation notches, if present, must be acceptable based on calculation according to

IEEE 519 (see appendix 18.1 for detail and examples).

2. Make sure that the electrical connection has been done correctly. The following prerequisites must be met.

| External fuse protection is installed, see section 7.1. | Make sure that the grounding has been performed correctly, check the conductor cross-section. | Mains phases L1, L2 and L3 are connected correctly (see section 7.5.2). | Check the conductor cross-section of the external conductors | Check the conductor cross-section of the neutral conductor (for 4-wire devices) | Check the tightening torque of the conductors

3. Check the current transformers

| External current transformers for all three mains phases are correctly connected, installation

site, current flow direction and phase assignment are ok (see section 7.6).

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| Check if the power of the current transformers is suitable for the application, see section 7.7. | Check, if the current transformers are connected correctly to the current transformers input

terminals of the device (5A or 1A input). NOTICE! Incorrect connection of the current transformers can result in damage to the CT module!

4. Check the installation clearances and conditions (power module and cabinet)

| Minimum installation clearance for wall mounting see section 6.1.4. | Minimum installation clearance for Schaffner cabinet version see section 6.5. | Minimum installation clearance for customized cabinets.

5. Before the first switching-on

| Check, if formation of the DC-link capacitor is necessary in case manufacturing date is over one

year. (see section 17.1)

| Disconnect the short circuit jumpers of the external current transformers | Switch ecosine active sync control off: Terminal X11.2 = open (neither 0V nor +24V shall be

connected to X11.2)

6. Switch on the mains voltage and wait until green LED2 is blinking (see Table 14) and the ecosine active sync is showing state OFF.

| Set all Modbus addresses of the interconnected modules to different values | We recommend using the same address for Service (P230) and Display Modbus (P250) | We recommend using the number according to the module number | Make sure all RS-485 connections between the ecosine active sync power modules and sync

modules (if installed) are correctly connected

| Now a normal operation and parametrization is possible

In the following paragraphs the commissioning procedure differs depending on the configuration of your active harmonic filter.

Application parameters P300, P310 and P312 must be set in each power module (single and Double Power Pack) with the correct application values independently of filter’s configuration. If the sync module is installed in the AHF system, the parameters shall be set only into the sync module.

8.3.2 Single power module or asynchronous operation

1. Check whether the DC-link has been charged correctly and the mains voltage and frequency have been determined correctly. (Note: A short-term charging current is flowing in the DC-link.)

P100 = 50 Hz (60 Hz) mains frequency

P110, P111, P112 = 342… 528 V mains voltages

P109: Check the rotating field to be the same at all power modules

2. Set the factory settings

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P210 = load default values

P220 = set date and time

3. Set ecosine active sync parameters for the application accordingly (for exact meaning of the parameters refer to section 9):

P300: Positioning of the external current transformers (mains side, load side)

P310: Primary current value of the external current transformers

P312: Secondary current value of the external current transformers P300, P310 and P312 must be set in each power module with the correct application values independently of filter configuration.

Following parameters must be set as shown below:

P205: Parallel Operation Mode = Asynchronous

P320: Sum of the rated compensating currents of the overall ecosine active sync power modules connected to one current transformer set (maximum 5 devices).

If more than 5 devices are operated at the same time, the power of the current transformers must be increased, or additional current transformers must be installed.

4. Check whether the displayed values are plausible. For motor load, the values must be positive and approximately the same:

| P102 = cosφ has a plausible value | Check active power value per phase:

o P105 = + … kW? – power L1 o P106 = + … kW? – power L2 o P107 = + … kW? – power L3

| P105 ≈ P106 ≈ P107? Are all values positive? | Check the phase voltages and currents by measuring them using the AHF Viewer oscilloscope

function to determine whether they are in phase (see sections 7.9.6 and 7.9.7).

| Otherwise, the current transformers wiring and parameter settings must be checked, except for

generator load.

5. Check whether the compensation has been deactivated (these parameters are set OFF by default when loading default factory settings in point 2. above):

| P403: Reactive power control = OFF | P405: Load balancing = OFF | P410: Harmonic current compensation = OFF

6. Switch on ecosine active sync control:

P202 = Terminal strip

Terminal X11.2 = 0 V or open => OFF-command

Terminal X11.2 = +24 V => ON-command (e.g. from external PLC)

P202 = Switch S1, use the control switch S1 on the front plate of the device

P202 = Direct ON (filter is always on)

7. Activate the required type of compensation:

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| P407: Priority at full load | P410: Harmonic current compensation

8. Set degrees of compensation P421 and Pxyz (xyz = 421+(3*n), with n = 1, 2, …,23)

9. If necessary, adjust the standby limit (P406)

10. Check if the compensation result on the mains side is correct by using a suitable measuring instrument

8.3.3 Double Power Pack (DPP) operation

1. Check in both power modules whether the DC-link has been charged correctly and the mains voltage and frequency have been determined correctly. (Note: A short-term charging current is flowing in the DC-link.)

P100 = 50 Hz (60 Hz) mains frequency

P110, P111, P112 = 342… 528 V mains voltages

P109: Check the rotating field to be the same at both power modules

P010 "FPGA Firmware Version" needs to be the same at all power modules

P026 "Mains connection" needs to be the same at all power modules

P230 "Service - MB address" needs to be different at all power modules and the sync module

P250 "Display - MB adress" needs to be different at all power moules and the sync module

2. Set the factory settings at both power modules

P210 = load default values

P220 = set date and time

3. Set ecosine active sync parameters at both power modules for the application accordingly (for exact meaning of the parameters refer to section 9):

P300: Positioning of the external current transformers (mains side, load side)

P310: Primary current value of the external current transformers

P312: Secondary current value of the external current transformers P300, P310 and P312 must be set in each power module with the correct application values independently of filter configuration.

Following parameters must be set as shown below: a. Master power module (FN3531/FN3541 with CT module):

P205: Parallel Operation Mode = Synchronous Master

P320: Total current parallel = 120A

b. Slave power module (FN3530/FN3540):

P205: Parallel Operation Mode = Synchronous Slave

P320: Total current parallel = 120A

4. Check whether the displayed values are plausible. For motor load, the values must be positive and approximately the same.

| P102 = cosφ has a plausible value | Check active power value per phase: