Schaffner ECOsine FN3416, ECOsine FN3418 User Manual

Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland
T [phone] F [phone] www.schaffner.com

energy efficiency and reliability

User Manual

ECOsine™ – Passive Harmonic Filters

FN3416 (50Hz) & FN3418 (60Hz) Economy Line

September 2012
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User Manual

ECOsine™ – Passive Harmonic Filters Economy Line
September 2012
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ECOsine™ – Passive Harmonic Filters
FN3416 (50Hz) & FN3418 (60Hz) Economy Line

Schaffner ECOsine™ harmonic filters represent an economical solution to the challenge of load-applied
harmonics mitigation in three-phase power systems. With a plug-and-play approach and more compact
dimensions than comparable products, they can be quickly installed and easily commissioned. They
increase the reliability and service life of electrical installations, help utilize electric system capacity
better, and are the key to meet Power Quality standards such EN61000-3-12. ECOsine™ filters help to
reduce the costly waste of electricity.

This user manual is intended to support designers, installers, and application engineers with filter
selection, installation, application and maintenance. For additional helpful tips for overcoming harmonics
mitigation challenges, please also consult the more detailed user manual of the ECOsine™ FN3410
(50Hz) and FN3412 (60Hz) full performance filters.

If you require additional support, please feel free to contact your local Schaffner partner.

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Important user notice

Schaffner ECOsine™ harmonic filters are designed for the operation on the input (grid) side of power
electronic equipment with six-pulse rectifier front-ends in balanced three-phase power systems, like
typically used in AC or DC motor drives and high power DC supplies. Filter suitability for a given
application must be determined by the user on a case by case basis. Schaffner will not assume liability

for any consequential downtimes or damages resulting from use or application of ECOsine™ filters

outside of their specifications. ECOsine™ filters are not designed for single-phase or split-phase
applications.

ECOsine™ filters with protection category IP20/NEMA1 must be mounted in a clean, dry location.
Contaminants such as oils, corrosive vapors and abrasive debris must be kept out of the enclosure.
These filter enclosures are intended for indoor use, primarily to provide a degree of protection against
contact with enclosed equipment. These enclosures offer no protection against airborne contaminants.

Important safety considerations

Note: Filter installation has to be carried out by a trained and certified electrician or technician, who is

familiar with installation and safety procedures in three-phase power systems.
Warning: High voltage potentials are involved in the operation of ECOsine™ filters. Always remove

power before handling energized parts of the filter, and let ample time elapse (> 1 minute) for the
capacitors to discharge to safe levels.

Warning: Follow the installation instructions closely. Ensure that fans and cooling slots are free from
obstructions that could inhibit efficient air circulation. Do not operate the filter in ambient conditions
outside of specifications.

Note: Do not operate ECOsine™ filters on unsymmetrical loads, on linear loads, or with single-phase
equipment.

Note: Always use an upstream disconnect or protection device as required by most national and
international electric codes.

Note: Always connect the filter to protective earth (PE) first, then continue with the wiring of the phase
connectors.

Note: Follow the Schaffner instructions closely when doing maintenance work. Use exclusively spare
parts recommended and approved by Schaffner.

Note: Always practice the safety instructions defined by your company when handling, installing,
operating, or maintaining ECOsine™ harmonic filters.

Note: In case of uncertainty and questions please contact your local Schaffner partner for assistance.

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Content

1. Part number coding ............................................................................................................................... 5

2. Filter description ................................................................................................................................... 6

2.1 General electrical specifications FN 3416 (50Hz filters) .................................................................... 6

2.2 General electrical specifications FN 3418 (60Hz filters) .................................................................... 7

2.3 Additional electrical specifications ..................................................................................................... 8

2.4 Mechanical specifications .................................................................................................................. 9

2.5 Performance characteristics ............................................................................................................ 11

2.6 Function diagram ............................................................................................................................. 14

2.7 External filter elements (Frank: new picture needed) ...................................................................... 15

2.8 Audible noise ................................................................................................................................... 16

3. Filter purpose and function ................................................................................................................ 17

4. Filter selection ..................................................................................................................................... 20

5. Filter application .................................................................................................................................. 23

6. Filter installation .................................................................................................................................. 24

7. Filter maintenance ............................................................................................................................... 29

8. Special considerations ....................................................................................................................... 31

8.1 Over-temperature contact and load disconnect ............................................................................... 31

9. Troubleshooting .................................................................................................................................. 32

10. FAQ – Frequently asked questions ................................................................................................. 33

11. Custom design input form ................................................................................................................ 36

Appendix I: International standards ...................................................................................................... 37

I. Engineering recommendation G5/4-1 ................................................................................................. 37

II. International standard EN 61000-3-12............................................................................................... 39

III. IEEE Std 519-1992 ........................................................................................................................... 42

Appendix II: Declaration of conformity ................................................................................................. 43

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1. Part number coding

FN 34xx xx -xxx -xx

Connection style
33 = safety terminal block 10mm2
34 = safety terminal block 25mm2
35 = safety terminal block 50mm2
40 = safety terminal block 95mm2
44 = safety terminal block 6mm2
99 = copper bus bars in different sizes

Rated, unfiltered load (drive input) current [A]

Blank = standard voltage rating

Filter family
3416 = filter for 50Hz, 380-500V grids
3418 = filter for 60Hz, 380-480V grids

Schaffner standard filter

Examples:
FN 3416-60-34: Filter for 50Hz, 380-500V grids, 60A drive input current, with 25mm2 terminals, for

diode or SCR (thyristor) rectifier front-end.
FN 3418-240-99: Filter for 60Hz, 380-480V grids, 240A drive input current, with copper bus bar,

for diode or SCR (thyristor) front-end.

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2. Filter description

2.1 General electrical specifications FN 3416 (50Hz filters)

Nominal operating voltage:

3x 380 to 500VAC

Voltage tolerance range:

3x 342 to 550VAC

Operating frequency:

50Hz ±1Hz

Network:

TN, TT, IT

Nominal motor drive input current rating: 1)

10 to 320A @ 45°C

Nominal filter input current rating: 1)

7A

rms

to 240A

rms

@ 45°C

Nominal motor drive input power rating:

4 to 200kW

Total harmonic current distortion THID: 2)

According to EN61000-3-12, table 3

<10% @ rated power (with Ldc)

<15% @ rated power (without Ldc)

Total demand distortion TDD: 2)

According to IEEE 519, table 10-3

Partially weighted harmonic distortion PWHID:

<22% @ rated power

Efficiency:

>98% @ nominal line voltage and power

Drive dc-link voltage behavior: 3)

No load: +10%

Full load: -5%

High potential test voltage: 4)

P  E 2500VAC (1min)

SCCR: 5)

100kA

Protection category:

IP20

Pollution degree:

1, 2 (according to EN 61800-5-1, EN 50178)

Cooling:

Natural convection cooling (4 to 7.5kW)

Internal forced cooling (11kW and above)

Overload capability:

1.6x rated current for 1 minute, once per hour

2x rated current for 10 seconds, once per hour

5x rated current for 1 second, once per hour

Capacitive current at low load:

<30% of rated input current, at 400VAC

<37% of rated input current, at 500VAC

Ambient temperature range:

-25°C to +45°C fully operational

+45°C to +55°C derated operation 6)

-25°C to +70°C transportation and storage

Flammability class:

UL 94V-2 or better

Insulation class of magnetic components:

H (180°C)

Design corresponding to:

UL 508, EN 61558-2-20, CE (LVD 2006/95/EC)

MTBF @ 45°C/500V (Mil-HB-217F):

200’000 hours

MTTR:

<15 minutes (capacitors and fans)

Lifetime (calculated):

Min. 15 years

Safety monitoring functions:

Over-temperature of magnetic components

Safety monitor output signal:

NO switch

1)

ECOsine™ filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor.

2)

System requirements: THVD <2%, line voltage unbalance <1%
Performance specification for six-pulse diode rectifiers. SCR rectifier front-ends produce different results, depending upon
the firing angle of the thyristors.

3)

Conditions: line impedance <5%

4)

Repetitive tests to be performed at max. 80% of above levels, for 2 seconds.

5)

External UL-rated fuses required.

6)

I

derated

= I

nominal

*(70°C-T

amb

)/25°C

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2.2 General electrical specifications FN 3418 (60Hz filters)

Nominal operating voltage:

3x 380 to 480VAC

Voltage tolerance range:

3x 342 to 528VAC

Operating frequency:

60Hz ±1Hz

Network:

TN, TT, IT

Nominal motor drive input current rating: 1)

8 to 310A @ 45°C

Nominal filter input current rating: 1)

5A

rms

to 250A

rms

@ 45°C

Nominal motor drive input power rating:

5 to 250HP

Total harmonic current distortion THID: 2)

According to EN61000-3-12, table 3

<10% @ rated power (with Ldc)

<15% @ rated power (without Ldc)

Total demand distortion TDD: 2)

According to IEEE 519, table 10-3

Partially weighted harmonic distortion PWHID:

<22% @ rated power

Efficiency:

>98% @ nominal line voltage and power

Drive dc-link voltage behavior: 3)

No load: +10%

Full load: -5%

High potential test voltage: 4)

P  E 2500VAC (1min)

SCCR: 5)

100kA

Protection category:

IP20

Pollution degree:

1, 2 (according to EN 61800-5-1, EN 50178)

Cooling:

Natural convection cooling (5 to 15HP)

Internal forced cooling (20HP and above)

Overload capability:

1.6x rated current for 1 minute, once per hour

2x rated current for 10 seconds, once per hour

5x rated current for 1 second, once per hour

Capacitive current at low load:

<30% of rated input current, at 460VAC

Ambient temperature range:

-25°C to +45°C fully operational

+45°C to +55°C derated operation 6)

-25°C to +70°C transportation and storage

Flammability class:

UL 94V-2 or better

Insulation class of magnetic components:

H (180°C)

Design corresponding to:

UL 508, EN 61558-2-20, CE (LVD 2006/95/EC)

MTBF @ 45°C/460V (Mil-HB-217F):

200’000 hours

MTTR:

<15 minutes (capacitors and fans)

Lifetime (calculated):

Min. 15 years

Safety monitoring functions:

Over-temperature of magnetic components

Safety monitor output signal:

NO switch

1)

ECOsine™ filters reduce RMS input and peak current by reducing harmonic currents and improving true power factor.

2)

System requirements: THVD <2%, line voltage unbalance <1%
Performance specification for six-pulse diode rectifiers. SCR rectifier front-ends produce different results, depending upon
the firing angle of the thyristors.

3)

Conditions: line impedance <5%

4)

Repetitive tests to be performed at max. 80% of above levels, for 2 seconds.

5)

External UL-rated fuses required.

6)

I

derated

= I

nominal

*(70°C-T

amb

)/25°C

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2.3 Additional electrical specifications

ECOsine™ passive general electrical specifications refer to operating altitudes up to 1000m a.s.l.
(3300ft). Operation between 1000m and 4000m (3300ft and 13123ft) requires a derating according to the
table below:

80

85

90

95

100

105

0 500 1000 1500 2000 2500 3000 3500 4000

Altitude a.s.l. [m]

Rated load power [%]

Note: do not use ECOsine™ passive harmonic filters in altitudes above 4000m without consulting

Schaffner first.
ECOsine™ passive filters have been designed and certified acc. UL508, resp. UL508C, so there is no

limitation in terms of altitude up to 4000m for clerance and creepage.

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2.4 Mechanical specifications

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2.5 Performance characteristics

THID vs. load (diode rectifier front-ends)

Note: shown above is the typical performance characteristic of FN3416/18 series in balanced diode
rectifier front-end applications, with and without DC-link choke. In SCR rectifier applications, filter
performance greatly depends upon the firing angle of the thyristors.

Note: the values of EMI-filter components present in the same non-linear load (e.g. motor drive) can
influence the mitigation performance of passive harmonic filters. For Schaffner FN3418 (60Hz) filters the
following boundary conditions exist for the smallest frame sizes:

Filter

Typical
drive dc-linke choke

Max. recommended
EMI-filter X-capacitor

Expected THID *

FN3418-8-44

8.4mH

≤ 1.0µF

~10%

-

≤ 2.2µF

~15%

FN3418-11-44

6.7mH

≤ 1.5µF

~10%

-

≤ 1.5µF

~13%

FN3418-15-44

4.2mH

≤ 3.3µF

~10%

-

≤ 3.3µF

~15%

* System requirements: THVD <2%, line voltage unbalance <1%

All other FN3416 and FN3418 filters are not subject to any such limitations.

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Power factor vs. load (diode rectifier front-ends)

Note: in SCR rectifier applications, filter characteristics greatly depend upon the firing angle of the
thyristors.

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Drive dc-link voltage vs. load (diode rectifier front-ends)

Note: in SCR rectifier applications, filter characteristics greatly depend upon the firing angle of the
thyristors.

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2.6 Function diagram

In-Out choke

Power capacitors

Trap choke

Power
supply

Fan

L1
L2
L3

L1'
L2'
L3'

Line Load

PE PE

NC
C

Filter terminals

Line

3 touch safe terminal blocks (busbar terminals >240A)

Load

3 touch safe terminal blocks (busbar terminals >240A)

Over-temperature

NC switch, 250VAC/2.5A, touch safe terminal 4mm2

contact

Open position indicates error

PE

Protective earth. Threaded studs with washer and nut

Function blocks

Chokes

Power magnetic components incl. over-temparature switch

Capacitors

Power capacitors incl. discharge resistors

Fan *

Field replaceable fan for choke cooling (some models)

Power supply *

Internally generated 24VDC for fan supply (some models)

* the followinging filters do not require forced cooling and therefore have no internal fan and power
supply: FN3416-10, -13, -16; FN3418-8, -11, -15.

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2.7 External filter elements

Line terminals (3) Over temperature contact (2) Load terminals (3)

PE terminals (2) Fan(s)

Line terminals (3) Over temperature contact (2) Load terminals (3)

PE terminals (2) Fans

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2.8 Audible noise

Tests have been performed at nominal filter load. Ambient noise level: 49dB[A]

Filter

FN 3416-13-44 (P=5.5kW)

60dB[A] @ 1m

FN 3416-210-40 (P=110kW)

70dB[A] @ 1m

Equipment used: Peak Tech Sound Level Meter 5055

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3. Filter purpose and function

ECOsine™ harmonic filters are based on passive LCR filtering technology. They are intended for the
operation on the input side of balanced three-phase six-pulse rectifiers, like commonly used in inverters
for motor drives.

ECOsine™ Motor drive Motor

Six-pulse rectifiers inherently draw current in a non-sinusoidal fashion from the grid, creating a current
wave form rich in harmonics. Harmonic currents flow through system impedances and create harmonic
voltages. Both harmonic currents and voltages give raise to serious issues, such as electric system
overload, reliability problems, and violations against international standards and utility codes.

ECOsine™ filters efficiently reduce the harmonic currents to negligible levels and ensure, that a sine­wave current is drawn from the grid. In the process, they also reduce peak currents and RMS input
current, allowing for lower wire cross sections in conductors, smaller fuses, breakers, and transformers.
In existing installations, more drives can be used on the same distribution transformer.

The examples on the next pages visualize typical performance test results with and without a Schaffner
ECOsine™ harmonic filter FN 3416-210-40 for the rated load power of 110kW.

M

3~

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Example 1: motor drive without built-in DC-link choke
Without ECOsine™ filter With ECOsine™ filter

Voltage and current waveforms

Voltage and current waveforms

Current harmonics THD = 76.9%

Current harmonics THD = 11.6%
Current harmonics THD, H5, H7, H11, H13, H17, H19, H23

Current harmonics THD, H5, H7, H11, H13, H17, H19, H23

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Example 2: motor drive with built-in DC-link choke
Without ECOsine™ filter With ECOsine™ filter

Voltage and current waveforms

Voltage and current waveforms

Current harmonics THD = 45.1%

Current Harmonics THD = 7.9%
Current harmonics THD, H5, H7, H11, H13, H17, H19, H23

Current harmonics THD, H5, H7, H11, H13, H17, H19, H23

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4. Filter selection

ECOsine™ harmonic filters need to be carefully selected in order to enjoy maximum benefits.

Step 1: supply frequency

Determine, whether the system in question will be operated in a 50Hz or 60Hz electricity grid, and select
the corresponding filter family according to the following table:

50Hz grid

Europe, Middle East, parts of Asia, parts of South America

FN 3416

60Hz grid

North and Central America, parts of Asia, parts of South America

FN 3418

Note: a 50Hz filter will not provide satisfying harmonics mitigation in a 60Hz grid, and vice versa.

Step 2: supply voltage and configuration

Verify, that the supply voltage and configuration is suitable for standard ECOsine™ harmonic filters
according to the following table:

50Hz grid

Nominal voltage 380-500VAC ±10%

TN, TT, IT configuration

60Hz grid

Nominal voltage 380-480VAC ±10%

TN, TT, IT configuration

Note: filters for 690V/50Hz or 600V/60Hz are available upon request.

Step 3: real rectifier/drive input power

The individual filter must be selected by the actual rectifier/drive input real power (kW, HP). It is
important to select the filter as close as possible to the effective input power of the rectifier/drive.

Note that FN 3416 (50Hz) filters show double ratings in the selection table. Depending upon the grid
voltage, the same filter is rated for two different rectifier/drive input real power values. For 380/400/415V
lines, the filters have a lower power rating than for 500V systems.

Note that if the rectifier/drive is being operated very close to its rated power, then the filter can be

selected by the motor drive’s nominal power rating. However, if the drive will be operated e.g. at only

66% of its rated power, then a smaller filter should be selected in order to get maximum harmonics
mitigation performance and the optimum in terms of filter cost, size, and weight.

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Please refer to the following examples:

Example 1:

Power line rating: 400V, 50Hz
Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A, diode rectifier
Planned rectifier/drive input real power: 15kW (100% of drive rating)

 Recommended filter according to the filter selection table FN 3416: Type FN 3416-32-33

Example 2:

Power line rating: 500V, 50Hz
Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A, diode rectifier
Planned rectifier/drive input real power: 15kW (100% of drive rating)

 Recommended filter according to the filter selection table FN 3416: Type FN 3416-24-33

Example 3:

Power line rating: 400V, 50Hz
Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A, diode rectifier
Planned rectifier/drive input real power: 10kW (66% of drive rating)

 Recommended filter according to the filter selection table FN 3416: Type FN 3416-24-33

Example 4:

Power line rating: 500V, 50Hz
Drive rating: 380-500V, 50-60Hz, 15kW, 22.5A, diode rectifier
Planned rectifier/drive input real power: 10kW (66% of drive rating)

 Recommended filter according to the filter selection table FN 3416: Type FN 3416-16-44

Overrating the filter does never make sense, because of the inherent lower harmonics mitigation
performance at light load, as well as higher price, size, and weight.

Please refer to the selection tables on the next page.

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Filter selection table FN 3416 (50Hz)

Filter selection table FN 3418 (60Hz)

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5. Filter application

ECOsine™ filters are designed as “load-applied” filters. In contrary to “bus-applied” filters, which are
being installed e.g. at the main power bus of a building, they are specifically designed to be used with
either an individual non-linear load, or with a group of non-linear loads.

One advantage of load-applied filtering is the fact that the upstream power (relative to the harmonic filter)
is clean. This can be of vital importance when the same power bus supplies both motor drives and
sensitive loads. One example could be the elevator drives or HVAC drives in a hospital, where power
must be very clean for all the sensitive medical devices. In such a case, it would not be sufficient to use
a central harmonic filter at the PCC for IEEE Std 519-1992 compliance purposes.

ECOsine™ filters are also suitable for paralleling lower power non-linear loads on a higher power
harmonic filter to improve overall system economy. In this case the total expected load power of all
connected drives must match the filter.

Mains

ECOsine

Non-linear load 1: 30kW/400VAC

Non-linear load 2: 75kW/400VAC

FN3416-210-40

(110kW/400VAC)

If the expected input power exceeds the rating of the largest available filter, and a custom solution is not
desired, then two or more filters can be wired in parallel. In this mode of operation, it is recommended to
use filters with equal power ratings to ensure proper current sharing.

Mains

ECOsine

ECOsine

Non-linear load: 300kW / 500VAC

2x FN3416-260-99

(2x 160kW/500VAC)

AC line reactors are not required when ECOsine™ filters are installed. For a new system, this helps to
offset a good portion of the harmonic filter cost. If a harmonic filter is added to a drive with an existing AC
line reactor, it is recommended to remove the reactor if possible.

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6. Filter installation

Please follow the few simple steps below to ensure a safe and satisfying filter function for many years.

Step 1: Visual inspection

All Schaffner ECOsine™ filters have undergone rigorous testing before they left our ISO 9001:2008
certified factory. They are packaged with great care in a sturdy container for international shipment.

However, carefully inspect the shipping container for damage that may have occurred in transit. Then
unpack the filter and carefully inspect for any signs of damage. Save the shipping container for future
transportation of the filter.

In the case of damage, please file a claim with the freight carrier involved immediately and contact your
local Schaffner partner for support. Under no circumstances install and energize a filter with visible
transportation damage.

If the filter is not going to be put in service upon receipt, store within the original container in a clean, dry
location, free of dust and chemicals.

Step 2: Mounting

ECOsine™ load-applied filters are best installed as close as possible to the non-linear load in question.
Ideally they are mounted next to the rectifier or motor drive inside the electrical cabinet or control room.

Unlike ECOsine™ full performance filters FN3410/11/12/13, all sizes of FN3416/18 come in designs for
vertical wall mounting.

Note: Filters for vertical wall mounting must not be installed horizontally. Horizontal installation will
negatively affect air flow and the life time of the filter.

Important:

In order to ensure sufficient air flow, keep a
clearance of min.150mm above and below the
filter to walls or other components. A 20mm
clearance on either side is recommended for the
possibility to comfortably open the cover in case
of field maintenance.

It must be ensured that the environmental
temperature is kept below 45°C with appropriate
thermal management (e.g. cabinet cooling). Filter
operation in warmer environments require
temperature derating.

ECOsine™

Drive

>150mm
>150mm

>20mm

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2.1

Drilling pattern for wall mounted filters:

FN 3416

FN 3418

H W D

-10, -13, -16

-8, -11, -15

370

140

M8

-24, -32, -38, -45

-21, -28, -35, -41

435

200

M10

-60, -75

-53, -65

500

225

M10

-90, -110

-80, -105

555

225

M10

-150, -180, -210

-260, -320

-130, -160, -190

-240, -310

665

350

M12

All dimensions in mm; 1 inch = 25.4mm
Note: the numbers (e.g. -10) are in reference to the middle

part of the ECOsine part number coding (e.g. FN 3416-10-44)

H

W

D

2.2

Bolt selection: Schaffner recommends zinc coated hex ribbed

flange steel bolts. Respect filter weight for appropriate choice
of bolts! Head diameters must not exceed these dimensions:

M8: d ≤ 18.2mm, M10: d ≤ 21.2mm M12: d ≤ 25mm

2.3

Filter placement:

1. Set bolts loose into wall, leave 5mm distance from head to
wall.

2. Lift filter with appropriate hoist, using lifting eye bolt
(attached in package) – smallest types (up to 20kg) may be
lifted manually by two persons (no lifting eye bolt
applicable).

3. Place filter first onto lower bolts...

4. ...then position it through backplane head openings on upper

bolts.

5. Fix bolts with appropriate torque (depending upon the
material of the back plane and local standards).

d

3.

4.

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Step 3: Wiring

3.1

Verify safe disconnection of all line side power.

Consult your local safety instructions.

3.2

Safety cover for filters with bus-bar terminals.

The filters with bus-bar terminals (FN 3416-260/320-99,
FN 3418-240/310-99) are equipped with a terminal
cover for safety reasons.

Untighten the bolt on the front side to remove the
cover.

3.3

Connect protective earth (PE) wire to adequate
earth potential close to ECOsine™ filter.

Use a wire diameter of equal or bigger size as foreseen
for line/load side power cables – according to your local
codes and safety instructions.

3.4

Connect PE wire to min. one available PE bolt

with appropriate cable lug to threaded stud.

 max. torque M6: 4Nm
 max. torque M8: 10Nm
 max. torque M10: 18Nm



3.5

Connect ECOsine™ load side terminals L1’, L2’, L3’
to respective motor drive or rectifier inputs.

Last two digits of ECOsine™ part number, i.e.
FN 3418-65-34, indicate terminal type. See table to the
right for recommended wire size and torque.

Use stranded copper wire with a temperature rating of
75°C or higher.

Terminal

Wire

Torque

AWG

mm2

Nm

-44 8 6

1.0 - 1.2

-33 6 10

1.5 - 1.8

-34 2 25

4.0 - 4.5

-35

1/0

50

7.0 - 8.0

-40

4/0

95

17 - 20

-99

6/0

150

25 - 30

ECOsine™

Drive

>150mm

>150mm

>20mm

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3.6

Connect over-temperature contact

The over-temperature contact is a relay contact, which
is open in ALARM state. Its load rating is
250VAC/30VDC/2.5A. It may either be used to
remotely disconnect the drive’s load via respective
input of drive control (check drive manual) or as alarm
sensor for system control unit.

AN ENGAGED OVER­TEMPERATURE CONTACT MUST
LEAD TO IMMEDIATE LOAD
SHUTDOWN AND INVESTIGATION
OF THE PROBLEM.

3.7

Connect ECOsine™ line side terminals L1, L2, L3

to power input protection (current limiting fuses – see below).

3.8

Fuses

ECOsine™ filters need external over-current protection for compliance with UL/cUL standard.
Fuses and associated fuseholders must be UL listed and rated for 100kA SCCR supplies. The
subsequent list shows requested fuse current ratings for UL class J and, where UL compliance is
not mandatory, for IEC class gG. The fuse rating is independent of the supply voltage.

ECOsine™ type

Fuse class J

FN 3418

rated A

FN 3418-8-44

8

FN 3418-11-44

10

FN 3418-15-44

15

FN 3418-21-33

25

FN 3418-28-33

30

FN 3418-35-33

35

FN 3418-41-33

45

FN 3418-53-34

60

FN 3418-65-34

70

FN 3418-80-35

90

FN 3418-105-35

110

FN 3418-130-40

150

FN 3418-160-40

175

FN 3418-190-40

225

FN 3418-240-99

300

FN 3418-310-99

350

ECOsine™ type

Fuse class J

Fuse class gG

All FN 3416

rated A

rated A

FN 3416-10-44

10

10

FN 3416-13-44

15

10

FN 3416-16-44

20

16

FN 3416-24-33

25

20

FN 3416-32-33

35

35

FN 3416-38-33

40

35

FN 3416-45-33

50

50

FN 3416-60-34

75

63

FN 3416-75-34

80

80

FN 3416-90-35

100

100

FN 3416-110-35

150

125

FN 3416-150-40

175

160

FN 3416-180-40

200

200

FN 3416-210-40

250

224

FN 3416-260-99

300

250

FN 3416-320-99

350

300

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A system with multiple ECOsine™

filters paralleled for a high power load
need each a separate 3-phase line side
fuse block, corresponding to the
respective filter and according to above
table.

The drive’s application manual may

prescribe line-side fuse protection as
well, which in this case either
corresponds to the sum of the filter fuse
ratings or, if lower, would request
separate drive fuses at its input.

An application, having one ECOsine™

filtering harmonics of several drives,
requires in any case line side fuse
protection of the drives as well as the
correct filter protection according to
above table.

3.9

Safety cover for filters with bus-bar
terminals.

Once all filter terminals are properly
wired, replace the safety cover by
tightening the previously untightened
bolt.

ECOsine™

DRIVE 1

DRIVE 2

DRIVE 3

FUSE

FUSE

FUSE

FUSE

M M M

DRIVE M ECOsine™ 1

ECOsine™ 2

ECOsine™ 3

FUSE

FUSE

FUSE

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7. Filter maintenance

Schaffner ECOsine™ filters are reliable low maintenance products. Many products like power supplies,

inverters, or motor drives utilize fans for forced cooling to minimize the size and weight. ECOsine™

filters are designed with a similar temperature management concept and therefore, fans may have to be
maintained and replaced in certain intervals to sustain the function and value of the product. Fans are
100% field replaceable without the need to uninstall and disconnect the filter.

LINE SIDE POWER MUST BE SWITCHED OFF PRIOR TO REPLACEMENT OF FAN.

Warning:

Power electronic devices like motor drives contain large capacitors which may retain perilous charges for
a period of time. Before opening the cabinet or device, disconnect the supply power and let ample time
elapse (> 1 minute) for the capacitors to discharge to safe levels. Use a meter to check terminal voltages
before touching or handling!

Maintenance considerations:

Schaffner harmonics filters are equipped with long life components that ensure a satisfactory function for
many years under normal operating conditions. Any operation under extreme conditions such as over­temperatures, overvoltage situations, polluted environments etc. reduces the life expectancy.

Under normal operating conditions (ambient temp at 45°C) and with the filter permanently at full load, the
fan(s) run at 100% duty cycle. This translates roughly to a 10 year maintenance-free life time.

Nevertheless, it is recommended to check the functionality at least in a 2 year interval, when a ‘normal
100% load’ situation is given. More severe operating conditions may require shorter service intervals.

Indications for required fan replacement: - increased audible noise coming from the fan

- after 50,000 hours.

Power capacitor damage may be caused by severe abnormal supply voltage peaks (i.e. lightning –
depending upon system protection), but may only be recognizable through the measurement of line side
harmonics distortion. This may be indicated with a modern energy meter or by regular checkup with a
distortion analyzer. According to the above considerations, a 2 year inspection interval is advisable. An
inspection should as well be performed after extreme overvoltage situations.

Field replacement of power capacitors is possible, but must be executed by trained Schaffner personnel.

Indications for required capacitor replacement: - performance loss (THID out of spec)

- visible capacitor damage

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Fan specifications:

Supply voltage:

24VDC

Power:

max. 7W

Size:

120x120x25mm, fixation holes 105x105mm, Ø4.3mm

Air flow:

min. 110CFM

Connection:

min. 150mm cable length, TYCO MTA-100 plug, 2 poles (pin 1 = +24VDC)

Recommended types:

SUNON PMD2412PTB3-A
NMB-MAT 4710KL-05W-B50

Fan replacement instructions:

1

Disconnect line side power.

Let ample time elapse (> 1 minute) for the capacitors to discharge to safe levels.
Check with voltage meter before proceeding. Consult your local safety instructions.

2

Untighten bolts (5x) of fan plate at bottom side of filter.

3

Pull out fan connector plug (1x).

4

Disassemble fan from plate (4 bolts).

5

Mount a new fan with appropriate plug (isolation tube and plug of old fan may be used again;
appropriate tool for IDC connection needed). Pay attention to the polarity of the plug.

6

Connect fan to plug socket, re-assemble fan plate.

Step 2

Step 3

Steps 4, 5

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8. Special considerations

8.1 Over-temperature contact and load disconnect

ECOsine™ harmonic filters provide basic safety monitoring:

 temperature detection level for each inductive component (over-temperature contact)

This alarm indication requires adequate reaction in order to prevent possible system damage (i.e. cable
or cabinet overheating). Either the cabinet safety monitoring unit must make use of the alarm contact, or
the contact must directly control a stop function of a connected motor drive (refer to motor drive user
manual for applicability).

Important:

Connection and use of the over-temperature contact is required for safe operation. An engaged (open)
over-temperature contact must lead to immediate load shutdown and investigation of the problem.

Technical data of over-temperature contact:

Error status:

Switch open

Switching power:

max. 2.5A/250VAC or 30VDC

Technology:

Bi-metal switch (potential-free)

Safety:

UL 2111

Note: The described applications of the monitor contact are proposals. Please respect local and national
safety directives.

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9. Troubleshooting

Schaffner ECOsine™ harmonic filters are high quality products and have undergone rigorous testing and

qualification procedures. Every unit runs through a 100% test in our ISO 9001:2008 factories. There are
no troubles to be expected if the filter is installed, operated, and maintained as described in this
document and within published specifications.

In the unlikely event of a problem, please contact your local Schaffner partner for assistance.

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10. FAQ – Frequently asked questions

Q:

Why are ECOsine™ harmonic filters CE-marked, but Schaffner EMI filters are not?

A:

EMI filters and other passive components must not be CE-marked according to the low-voltage
directive because they are not sold to the public as an individual device with an independent
function. They are usually part of equipment, which in turn has to be CE-marked as a whole. This
is different with e.g. a transformer or a harmonic filter. ECOsine™ can be sold as an individual
aftermarket product that will not necessarily be built into another CE-conform piece of equipment.
As a “stand-alone unit”, it must be CE-marked in order to be distributed throughout Europe.

Q.

Can ECOsine™ filters be used for a single-phase load or just be connected to two phases?

A:

This mode of operation is not possible. ECOsine™ filters are optimized for balanced three-phase
power systems with six-pulse rectifier front ends and their performance depends upon voltage
distortion and phase unbalance. Schaffner is experienced in custom harmonic filter design and can
potentially come up with a single-phase solution to your requirement.

Q:

How are ECOsine™ harmonic filters contributing to financial savings? Are they reducing my
electricity bill?

A:

ECOsine™ harmonic filters help to save long term system operating cost and help to avoid
expensive system/production downtime. There are two different aspects to answer this question:

1. Most likely, the installation of ECOsine™ filters will not result in a lower electricity bill.
ECOsine™ harmonic filters substantially reduce reactive current and thus reactive power
in the system. However, most utility companies invoice only the consumption of real
power, which will not be changed with the installation of ECOsine™. Some utilities may
issue penalties for consumers with low power factor (usually <0.9). Low power factor can
be caused by phase shift of the fundamental current (low cos phi) and/or by harmonics of
the current (high THID) as it is described by the following formula:

For nonlinear loads (like six-pulse rectifiers) value of cos phi is high (close to 1) and the
main reason for a reduced power factor is a high value of THID. The installation of
ECOsine™ filters would increase the power factor and help to avoid utility penalties, i.e.
get into a less expensive rate class. These penalty schemes are different from country to
country and from utility company to utility company.

2. Electric systems with significant non-linear loads have high levels of harmonic current
distortion and consequently also bad voltage quality. Both can have significant negative
effects, such as:

Transformers

 Increased audible noise
 Increase in copper losses (due to current harmonics)
 Increase in iron losses (due to voltage harmonics)

Power installation with capacitive power factor compensators

 Risk of resonance and resulting damage of capacitor banks

Power cables

 Increased heating
 Risk of insulation failure if involved in system resonance

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Motors and Generators
 Increased heating due to iron and cooper losses at the harmonic frequencies

(performance reduced to 90%)

 Higher audible noise
 Refusal to start smoothly (cogging)
 Very high slip in induction motors (crawling)
 Potential of mechanical oscillations in a turbine-generator or motor-load systems
 Pulsating or reduced torques

Capacitors

 Increased heating and voltage stress
 Reduced capacitors life

Electronic Equipment

 Wrong operation of equipment dependent upon accurate determination of the line

voltage wave shape (e.g. zero crossing)

 Problems caused by transmission of ac supply harmonics (via power supply or

magnetic coupling) into equipment components

 Erratic (sometimes subtle) malfunctions of computers, programmable controllers,

medical instruments etc. (in some cases, having very serious consequences)

Metering (watt-hour meters)
 Possible erroneous operation with both positive and negative errors (distortion must be

severe >20%)

Switchgear and Relaying

 Increased heating and thus reduced steady-state current carrying capability
 Fuses suffer derating
 Complete definition of relay response impossible
 Older circuit breakers (responding to peak currents) may cause nuisance tripping

Communication Equipment

 Telephone interferences (audible harmonic frequencies)

ECOsine™ harmonic filters substantially reduce harmonic currents and therefore basically convert
a non-linear load into a linear load. This eliminates the risk for most of the above problems. Lower
harmonic currents help to relieve the entire electrical installation from excessive loading and
heating, allow more consumers to be powered by the same (existing) installation, and help to
postpone expensive electrical system upgrades when retrofitting additional non-linear consumers.
ECOsine™ filters also reduce the risk of harmonics-related system downtimes which can have
tremendous financial consequences e.g. in a semiconductor manufacturing line or a banking
center. Last but not least, lower harmonic currents cause less harmonic voltages when flowing
through system impedances, so other sensitive consumers (e.g. medical devices) connected to the
same branch of the electrical system are not compromised in their functionality.

 So in essence, the annual savings enabled by ECOsine™ harmonic filters are first and foremost
the avoided potential expenses thanks to lack of harmonics.

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Q:

How much cooling air capacity should be planned for the integration of ECOsine™ filters into a
cabinet?

A:

This value, defined as CFM (cubic feet per minute; 1CFM = 1.7m3/h) depends upon filter model and
power rating. Please refer to the following table:

FN 3416
(400-500V/50Hz)

FN 3418
(480V/60Hz)

Air capacity
needed

-10, -13, -16

-8, -11, -15

No fan

-24, -32, -38, -45

-60, -75

-90, -110

-21

-28, -35, -41

-53, -65

-80, -105

110CFM

-150, -180, -210

-130, -160, -190

220CFM

-260, -320

-240, -310

330CFM

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11. Custom design input form

There may be occasions where ECOsine™ standard filters are not suitable for the job at hand. Schaffner
is very experienced in the design and manufacture of custom filters based on the existing modular
ECOsine™ platform and can potentially come up with an alternative design proposal for you.

Custom harmonic filters include (but are not limited to) solutions for higher power ratings, higher voltage
ratings, different performance levels, or special mechanical designs.

Please use the following table to gather essential technical information prior to contacting your local
Schaffner partner.

Application incl. power system:

Types of non-linear loads:

Types of rectifiers involved:

System block schematic:

Current harmonic spectrum:

Required harmonics reduction
(THID, TDD, standard):

Expected total load real power:

[kW], [HP]

Expected total input current:

[A]

System voltage:

[VAC]

System frequency:

[Hz]

Efficiency:

[%]

Overload capability:

[%]

Max. capacitive current:

[%], [A]

Ambient temperature:

[°C]

Expected life time:

[h]

Mechanical requirements:

Terminals:

Safety approvals:

Monitoring functionality:

Other special requirements:

Please also consider FN3410/11/12/13 ECOsine™ full performance filters (THID <5%) for your
application!

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Appendix I: International standards

The use of non-linear loads with six-pulse rectifiers has grown rapidly in recent years, to the point where
this type of load represents more than 50% of western world power system load. Harmonic currents and
the resulting voltage distortions can have devastating effects on power distribution systems and
connected equipment. Therefore, national and international standards for harmonic distortions (and other
Power Quality problems) are needed.

In the following, a brief overview of some important international standards/recommendations are
provided. For full details, please obtain the required standards directly from IEEE, IEC, and other
organizations.

I. Engineering recommendation G5/4-1
Definitions:

Non-linear load or equipment

A load or equipment that draws a non-sinusoidal current when
energized by a sinusoidal voltage.

Aggregate load

Non-linear load equal to the sum of the individual non-linear equipment
ratings.

Fault level

A value expressed in MVA of the symmetrical short-circuit power at a
point in the supply system. It is defined as the product of the
symmetrical short-circuit current (Isc) and the nominal system voltage
(U

ph-ph

or U

ph-n

):

Harmonic current (Ih)

The RMS value of a harmonic current, of order h, expressed in
amperes.

Harmonic distortion

The cyclic departure of a waveform from the sinusoidal shape. This can
be described by the addition of one or more harmonics to the
fundamental.

Point of common coupling
(PCC)

The point in the public supply system, electrically nearest to a
customer’s installation, at which other customers’ loads are, or may be,
connected.

Total harmonic voltage
distortion (THD)

33 

 nphscphphsc

UIUIF

2

1

50

2

2

V

V

THD

h

h

h









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G5/4-1 planning levels for harmonic voltages:

G5/4-1 current harmonic limits for loads rated >16A per phase:

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II. International standard EN 61000-3-12

This standard applies to equipment intended to be connected to low-voltage systems interfacing with the
public supply at the low-voltage level. It does not apply to equipment intended to be connected only to
private low-voltage systems interfacing with the public supply only at the medium- or high-voltage level.

Definitions:

Total harmonic distortion
(THD)

Ratio of the r.m.s. value of the harmonics (harmonic currents In of the
order n) to the r.m.s. value of the fundamental:

Partial weighted harmonic
distortion (PWHD)

Ratio of the r.m.s. value of a selected group of higher order harmonics
(in this International Standard beginning from the fourteenth harmonic),
weighted with the harmonic order n, to the r.m.s. value of the
fundamental:

Reference fundamental
current (I1)

r.m.s. value of the fundamental component of the rated line current I

equ

of the equipment. The reference fundamental current I1, shall be either
measured, or calculated as follows:

Total harmonic current
(THC)

The total r.m.s. value of the harmonic current components of orders 2 to
40:

Point of common coupling
(PCC)

The point in the public system which is closest to the customer
concerned, and to which other customers are, or may be, connected.

Short circuit power (Ssc)

Value of the three-phase short-circuit power calculated from the nominal
interphase system voltage U

nominal

and the line impedance Z of the

system at the PCC:
where Z is the system impedance at the power frequency.

Rated apparent power of the
equipment (S

equ

)

Value calculated from the rated line current I

equ

of the piece of

equipment stated by:

Short circuit ratio (R

sce

)

Characteristic value of a piece of equipment defined as follows:

I

I

n

n

THD

1

40

2

2





























40

14

2

1

n

n

n

I

I

nPWHD

2

1

1 THD

I

I

equ











40

22n

n

ITHC

ZUS

nomsc

2



equiequ

IUS  3

equscsce

SSR 

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EN 61000-3-12 current harmonic limits:

Conditions to use Table 4:

1. The phase angle of the 5th harmonic current related to the fundamental phase voltage is in the
range of 90° to 150°.
Note: This condition is normally fulfilled by equipment with an uncontrolled rectifier bridge and
capacitive filter, including a 3% AC or 4% DC reactor.

2. The design of the equipment is such that the phase angle of the 5th harmonic current has no
preferential value over time and can take any value in the whole interval (0°…360°).
Note: This condition is normally fulfilled by converters with fully controlled thyristor bridges.

3. The 5th and 7th harmonic currents are each less than 5% of the reference fundamental current.

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Interpolation of current harmonic limits:

Product documentation according to EN 61000-3-12:

For equipment complying with the harmonic current emission limits corresponding to R

sce

= 33, the

manufacturer shall state in his instruction manual or literature:

”Equipment complying with IEC 61000-3-12”

For equipment not complying with the harmonic currents emission limits corresponding to R

sce

= 33, the

manufacturer shall:

 determine the minimum value of R

sce

for which the limits given in Table 3 or 4 are not exceeded,

 declare the value of the short-circuit power Ssc corresponding to this minimal value of R

sce

in the

equipment instruction manual

 and instruct the user to determine, in consultation with the distribution network operator, that the

equipment is connected only to a supply of that Ssc value or more. For that purpose, the statement
in the instruction manual shall be:

"This equipment complies with IEC 61000-3-12 provided that the short-circuit
power Ssc is greater than or equal to xx at the interface point between the user's
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power Ssc greater than or equal to xx."

Where xx is the value of Ssc corresponding to the minimum value of R

sce

for which the limits given in

Table 3 or 4 are not exceeded.

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III. IEEE Std 519-1992

Table 10-3 lists the harmonic current limits based on the size of the load with respect to the size of the
power system to which the load is connected. The ratio Isc/IL is the ratio of the short-circuit available at
the point of common coupling (PCC), to the maximum fundamental load current.

IEEE Std 519-1992 also introduces the total demand distortion (TDD), the harmonic current distortion in
% of maximum demand load current (15 or 30min demand).

The limits listed in Tables 10-3, should be used as system design values for the worst case for normal
operation (conditions lasting longer than one hour). For shorter periods, during start-ups or unusual
conditions, the limits may be exceeded by 50%.

Table 10-3: current distortion limits for general distribution systems (120V through 69000V):

Other standards:

ECOsine™ harmonic filters are suitable to help fulfill the most stringent requirements of IEEE Std 519­1992 or EN 61000-3-12. They also fulfill the requirements of other standards, like e.g. EN 12015 for
elevators and escalators. However, because of different/relaxed limits, simpler filters may be sufficient
for the job. Schaffner has already designed many engineered harmonic filters for relaxed requirements
and may be able to quickly offer you a custom product that perfectly matches the requirements of an
application.

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Appendix II: Declaration of conformity