Schaffner FN 3452, FN 3441, FN 3443, FN 3450, FN 3453 User And Installation Manual
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User and Installation Manual
Ecosine evo Passive Harmonic Filters
Ecosine evo FN 3440/FN 3441 (50 Hz) for 380–415 VAC
FN 3450/FN 3451 (50 Hz) for 440–500 VAC
FN 3442/FN 3443 (60 Hz) for 380–415 VAC
FN 3452/FN 3453 (60 Hz) for 440–480 VAC
Schaffner Group
User and Installation Manual
Ecosine
®
evo
October 2018
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© All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or
by any means without the prior written permission of Schaffner International Ltd. The information in this
manual is subject to change without notice. Every precaution has been taken in the preparation of this
manual. Schaffner assumes no responsibility for errors or omissions. Neither is any liability assumed for
damages resulting from the use of the information contained in this publication.
Revision: 05 (October 2018)
The most current edition of these instructions (PDF format) can be obtained from www.schaffner.com
or from
your local Schaffner sales representative.
Other technical documentation of our products is also available in the download area of www.schaffner.com
Document name:
User and Installation Manual ecosine evo Rev05.pdf
Version history
Revision
Date
Description
01
November 2016
Initial version
02
03
February 2017
July 2017
FN 3441/51/53 and IP 20 types added
SCCR
04
January 2018
Update filter selection table of FN3441/51/53 (min. required Lac, Ldc
included)
Add thread size and torque for finger guard
05
October 2018
Add new filter series FN 3 442 and FN 3443 (60 Hz, 380VAC)
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i. Ecosine evo passive harmonic filter
Ecosine evo product highlights
Schaffner ecosine evo passive harmonic filters are configurable products which provide a tailored solution to
each specific problem of current harmonics mitigation of 3-phase non-linear loads.
The eight product lines, FN 3440/FN 3441, FN 3450/FN 3451, FN 3442/FN 3443 and FN 3452/FN 3453 are
applicable for low voltage 50 Hz and 60 Hz systems and they are particularly suitable for AC and DC motor
drives, battery chargers and other power electronics applications with 6-pulse front-end rectifiers.
Ecosine evo passive harmonic filter technology represents an evolution of the previous generations of
passive harmonic filters and introduces following aspects of novelty:
| Ecosine evo is designed for the most demanding harmonic mitigation tasks. Ecosine evo filters
FN 3440, FN 3450, FN 3442 and FN 3452 are designed for three-phase diode and thyristor rectifier,
to achieve THID ≤5% even without DC-link choke included in the drive. If there is 8% DC link choke
present in the drive, ecosine evo filters FN 3441, FN 3451, FN 3443 and FN 3453 help to achieve 5%
THID @ rated power. The new generation ecosine evo filters guarantee compliance with the toughest
requirement of IEEE-519 and other stringent international power quality standards.
| Ecosine evo demonstrates superior partial load performance. The excellent performance of
ecosine evo filters not only reflects on mitigating harmonic current and bringing the THID down to 5%
(diode rectifiers @ rated power), but also introducing minimum reactive power, even at partial or no
load condition. The displacement power factor remains at cosφ >0.98 @ 50% load.
| The modular concept of ecosine evo offers optimal tailored solution. Ecosine evo are
configurable filters, optional modules includes fan with aux. power supply, fan without aux. power
supply, trap disconnect jumper and RC damper modules. Optimal solutions can be achieved by
merely plugging a new module according to different installation conditions and drive setups.
| Most compact design, robust, reliable and ready to use.
| The Schaffner ecosine evo product configurator (myecosine.com
) supports customers in evaluating
the best suited filter type.
| The upgraded version of the Schaffner power quality simulator SchaffnerPQS3 (pqs.schaffner.com)
provides the possibility to simulate ecosine evo passive harmonic filters within an electrical system. It
furthermore offers quick and accurate performance checks.
This user manual is intended to support designers, installers, and application engineers with filter selection,
installation, application, and maintenance. It provides helpful solutions to overcome harmonics mitigation
challenges and answers frequently asked questions.
If you require additional support, please feel free to contact your local Schaffner representative.
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ii. Performance Guarantee
Selecting and installing the appropriate ecosine evo passive harmonic filter in a variable frequency AC drive
application,variable speed drive application within our published technical specifications we guarantee that
the input current distortion will be less than or equal to 5% THID for standard ecosine evo series filters at
rated power. Ecosine evo filters can also provide similar performance in other drive applications such as
constant torque, DC drives or other phase controlled rectifiers, e.g. SCR drives, but actual THID levels can
vary by load and/or speed and/or firing angle of thyristors and therefore cannot be guaranteed. Consult your
local Schaffner representative for assistance when applying ecosine filters on these types of equipment.
Minimum system Requirements
The guaranteed performance levels of this filter will be achieved when the following system conditions are
met:
| Type of load: Any 3-p hase equ ipment with front-end six-pulse diode rectifier, with
(FN 3441/43/51/53) or without DC-link choke (FN 3440/42/50/52).
| Type of source: 3-phase power line without neutral
| Line impedance: <3% (calculated for the rated filter power)
| Line frequency: 50 Hz ±1 Hz (FN 3440/41, FN 3450/51), 60 Hz ±1 Hz (FN 3442/43, FN 3452/53)
| Line voltage: Nominal line voltage ±10%
| Line voltage unbalance: <1%
| Line voltage distortion: THVD <2%
If a properly sized and installed filter fails to meet the 5% THID level, Schaffner will provide thenecessary
application engineering support or filter replacement at no charge.
iii. Important user notice
Schaffner ecosine evo 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 app licat io ns.
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iv. General Safety Notes and Installation Guidelines (Cautions and Warnings)
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Content
Version history .......................................................................................................................................... 2
i. Ecosine evo passive harmonic filter .................................................................................................. 3
Ecosine evo product highlights ........................................................................................................................ 3
ii. Performance Guarantee ...................................................................................................................... 4
Minimum system Requirements .............................................................................................................. 4
iii. Important user notice .......................................................................................................................... 4
iv. General Safety Notes and Installation Guidelines (Cautions and Warnings) ................................ 5
Content ....................................................................................................................................................... 6
1. Ecosine evo passive harmonic filter designation.............................................................................. 8
1.1 Distinguishing between FN 3440/FN 3441, FN 3450/FN 3451, FN 3442/FN 3443 and FN 3452/FN 3453
......................................................................................................................................................................... 8
1.2 Explanation of ecosine evo designation .................................................................................................... 8
2. Filter selection ..................................................................................................................................... 11
2.1 Filter selection table FN 3440/FN 3441 (50 Hz, 3×380 … 415 VAC) ...................................................... 13
2.2 Filter selection table FN 3450/FN 3451 (50 Hz, 3×440 … 500 VAC) ...................................................... 14
2.3 Filter selection table FN 3442/FN 3443 (60 Hz, 3×380 … 415 VAC) ...................................................... 15
2.4 Filter selection table FN 3452/FN 3453 (60 Hz, 3×440 … 480 VAC) ...................................................... 16
2.5 Filter configurations and designations if external air flow is available for cooling ................................... 17
2.6 Filter configurations and designation with embedded ventilation ............................................................ 18
2.7 Filter configurations and designation if external aux. power supply for the fan is available ................... 19
3. Filter description ................................................................................................................................. 20
3.1 General electrical specifications FN 3440/FN 3441 (50 Hz filters) .......................................................... 20
3.2 General electrical specifications FN 3450/FN 3451 (50 Hz filters) .......................................................... 21
3.3 General electrical specifications FN 3442/FN 3443 (60 Hz filters) .......................................................... 22
3.4 General electrical specifications FN 3452/FN 3453 (60 Hz filters) .......................................................... 23
3.5 Additional electrical spe cif ic ations ........................................................................................................... 24
3.6 Cooling requirement ................................................................................................................................ 24
3.7 Mechanical frame sizes ........................................................................................................................... 25
3.8 Ecosine evo filter footprint ....................................................................................................................... 27
3.9 Filter performance ................................................................................................................................... 28
3.10 Functional diagram ................................................................................................................................ 30
4. Modular Design: How to choose optional modules ........................................................................ 31
5. Filter appearance and elements ........................................................................................................ 33
5.1 IP 00 version, frame size A - F ................................................................................................................ 33
5.2 IP 00 version, frame size G - H ............................................................................................................... 34
5.3 IP 20 version ............................................................................................................................................ 35
6. Performance estimation using SchaffnerPQS ................................................................................. 36
7. Filter application.................................................................................................................................. 37
8. Filter installation.................................................................................................................................. 38
9. Filter maintenance .............................................................................................................................. 45
9.1 Maintenance schedule ............................................................................................................................. 45
9.2 Fan ........................................................................................................................................................... 46
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9.3 Power capacitors ..................................................................................................................................... 46
9.4 Electrical connections .............................................................................................................................. 46
10 Trap circuit disconnect ...................................................................................................................... 48
11. Troubleshooting ................................................................................................................................ 49
Disclaimer ................................................................................................................................................ 50
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1. Ecosine evo passive harmonic filter designation
1.1 Distinguishing between FN 3440/FN 3441, FN 3450/FN 3451, FN 3442/FN 3443 and FN 3452/FN 3453
Before going into the details of the designation, it is important to be aware of the difference between
FN 3440 and FN 3441, FN 3450 and FN 3451, FN 3442 and FN 3443, FN 3452 and FN 3453. FN 3440, FN
3450, FN 3442 and FN 3452 are used for motor drives without dc-link choke. They are similar to FN 3441, FN
3451, FN 3443 and FN 3453 except there is one choke less in FN 3441, FN 3451, FN 3443 and FN 3453
series as they are meant to be used for motor drives with dc-link choke (8%) included. In other w ords, there
are three chokes (line choke, trap choke and load choke) included in filter series FN 3440, FN 3450, FN 3442
and FN 3452, whereas there are only two chokes (line choke, trap choke) included in filter series FN 3441,
FN 3451 FN 3443 and FN 3453 series.
By distinguishing between FN 3440, (FN 3450, FN 3442, FN 3452) as well as FN 3441 (FN 3451, FN 3443,
FN 3453) Schaffner is able to provide optimized solutions for different drive types:
| If there is no DC-link choke present in the motor drive, FN 3440, FN 3450, FN 344 2, FN 3452 filter
series help to reduce THID to 5% @ rated power.
| If there is a minimum 8% DC-link choke present in the motor drive, FN 3441, FN 3451, FN 3443, FN
3453 filter series reduce THID to 5% @ rated power
In case you have difficulties to decide for the right filter, please contact your local Schaffner representative for
support.
1.2 Explanation of ecosine evo designation
Ecosine evo is the new generation of Schaffner passive harmonic filter. They are introduced w ith a new
designation system, which contains of 4 sections connected with ‘-’ as shown in
Figure 1 Ecosine evo designation
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| The first part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ distinguishes between the six
ecosine evo filter series.
FN 3440
FN 3441
FN 3450
FN 3451
FN3442
FN3443
FN 3452
FN 3453
For 6
-pulse diode rectifier
without DC-link choke
For 6
-pulse diode rectifier
with 8% DC-link choke
For SCR rectifier
Operating
frequency 50 Hz 50 Hz 60 Hz 60 Hz
Nominal operating voltage
3x 380 to 415 VAC 3x 440 to 500 VAC
3x 380 to 415
VAC
3x 440 to 480
VAC
| The second part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ indicates the motor drive power
rating, in kW for 50 Hz filters and in HP for 60 Hz filters. Please note that ecosine evo filters are not
using current rating in the designation anymore.
| The third part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ indicates the power terminal type.
For more information please see Table 1.
| The fourth part of the designation ‘FN 34nn-xxx-yyy- _ _ _ _ _ _ _’ contains seven slots, the first two
slots reveal the protection category of the filter, e.g. E0 and E2 represent IP 00 and IP 20 enclosure,
while N1 and N3 respresent NEMA type1 and NEMA type 3R, respectively. The following five slots
represent the presence (F,A,R,J,P) or absence (X) of optional modules in the filter, as shown in
Figure 1. Please find more information in section 2.4, 2.5 and 2.6.
Schaffner offers an online Product Configurator (myecosine.com
) and the Schaffner Power Quality
Simulator SchaffnerPQS3 (pqs.schaffner.com) to select and verify the most suitable ecosine evo filter for
your application.
Examples of ecosine evo filter designations:
FN 3440-22-115-E0XXJRX: Filter for 50 Hz, 380–415 V AC grid, motor drive power rating 22kW without DC-
link choke present, with 20 m m
2
terminals, open frame (IP 00), filter contains trap disconnect jumper module
and RC damper module.
FN 3441-22-115-E2FAXXX: Filter for 50 Hz, 380–415 V AC grid, motor drive power rating 22kW with 8% DC-
link choke present, with 20 m m
2
terminals, IP 20 enclosure, filter contains Fan module and auxiliary power
supply module.
FN 3452-150-116-E0XXXXX: Filter for 60 H z, 440–480 V AC grid, motor drive power rating 150HP with no
DC-link choke present, with 24mm
2
terminals, open frame (IP 00), filter contains no optional modules.
FN 3452-150-116-N1XXJRX: Filter for 60 H z, 440 –480 V AC grid, motor drive power rating 150HP with no
DC-link choke present, with 24mm
2
terminals, NEMA type 1 enclosure, filter contains trap disconnect jumper
module and RC damper module.
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Table 1 Ecosine evo filter power terminals designation
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2. Filter selection
Ecosine evo passive harmonic filters need to be carefully selected and configured in order to enjoy maximum
benefits. Besides the enclosed selection tables and the product datasheets included in the online configurator
(myecosine.com
), Schaffer advices to verify the selection by using the Schaffner Power Quality Simulator tool
SchaffnerPQS3, avai lab le at pqs.schaffner.com.
Step 1: Grid frequency
Determine, whether the system in consideration will be operated in a 50 Hz or 60 Hz electricity grid, and
select the corresponding filter series according to the following table:
50
Hz grid Europe, Middle East, parts of Asia, parts of South America
FN 3440/FN 3441
FN 3450/FN 3451
60
Hz grid North and Central America, parts of Asia, parts of South America FN 3442/FN 3443
FN 3452/FN 3453
Note: a 50 Hz filter will not provide satisfying harmonics mitigation in a 60 Hz grid, and vice versa.
Step 2: Grid voltage
Verify that the grid configuration is suitable for standard ecosine evo passive harmonic filters according to the
following table:
50 Hz grid
Nominal voltage 380–415 V AC
TN, TT, IT configuration
50 Hz grid
Nominal voltage 440–500 V AC
TN, TT, IT configuration
60 Hz grid
Nominal voltage 380–415 V AC
TN, TT, IT configuration
60 Hz grid
Nominal voltage 440–480 V AC
TN, TT, IT configuration
Step 3: Rectifier type, presence of DC-link choke in drive
FN 3440
FN 3441
FN 3450
FN 3451
FN3442
FN3443
FN 3452
FN 3453
For 6
-pulse diode rectifier
without DC-link choke
For 6
-pulse diode rectifier
with 8% DC-link choke
For SCR rectifier
Note: For 6-pulse diode rectifier with DC-link choke smaller than 8%, it is recommended to choose
FN 3440, FN 3450, FN 3442 or FN 3452 if 5% THID is required.
Step 4: Rectifier/Drive input power
The individual filter must be selected with respect to the rectifier/motor drive input power in kW respectively in
HP. It is important to match rated filter power as close as possible with the effective input power of the
rectifier/drive.
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 cost, size, and weight. In that case the customer is responsible to ensure that
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ecosine passive harmonic filter will be operated within specification. This is particular important in terms of
overload.
Please refer to the following examples:
Example 1:
Power line rating: 400 V, 50 Hz
Drive rating: 380–500 V, 50–60 Hz, 15 kW, 22.5 A, B6-diode rectifier without DC-link choke
Planned rectifier/drive input real power: 15kW (100% of drive rating)
Recommended filter according to the filter selection table FN 3440: Type FN 3440-15-113
Example 2:
Power line rating: 400 V, 50 Hz
Drive rating: 380–500 V, 50–60 Hz, 15 kW, 22.5 A, B6-diode rectifier with an 8% DC-link choke
Planned rectifier/drive input real power: 15 kW (100% of drive rating)
Recommended filter according to the filter selection table FN 3441: Type FN 3441-15-113
Example 3:
Power line rating: 500 V, 50 Hz
Drive rating: 380–500 V, 50–60 Hz, 15 kW, 18 A, B6-diode rectifier without DC-link choke
Planned rectifier/drive input real power: 15 kW (100% of drive rating)
Recommended filter according to the filter selection table FN 3450: Type FN 3450-15-113
Example 4:
Power line rating: 500 V, 50 Hz
Drive rating: 380–500 V, 50–60 Hz, 15 kW, 18 A, B6-thyristor rectifier
Planned rectifier/drive input real power: 15 kW (100% of drive rating)
Recommended filter according to the filter selection table FN 3450: Type FN 3450-15-113
Example 5:
Power line rating: 400 V, 50 Hz
Drive rating: 380–500 V, 50–60 Hz, 15 kW, 22.5 A, diode rectifier
Planned rectifier/drive input real power: 10 kW (66% of drive rating)
Recommended filter according to the filter selection table FN 3440: Type FN 3440-11-113
Example 6:
Power line rating: 480 V, 60 Hz
Drive rating: 380–500 V, 50–60 Hz, 30 H P, 41 A, diode rectifier
Planned rectifier/drive input real power: 30 HP (100% of drive rating)
Recommended filter according to the filter selection table FN 3452: Type FN 3452-30-113
Oversizing of passive har m onic filters is not recommended because of the inherent lower harmonic mitigation
performance at partial load as well as higher cost, size, and weight.
Please refer to Table 2 - Table 9 to select suitable filters.
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2.1 Filter selection table FN 3440/FN 3441 (50 Hz, 3×380 … 415 VAC)
Table 2 FN 3440 filter selection table
Table 3 FN 3441 filter selection table
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2.2 Filter selection table FN 3450/FN 3451 (50 Hz, 3×440 … 500 VAC)
Table 4 FN 3450 filter selection table
Table 5 FN 3451 filter selection table
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2.3 Filter selection table FN 3442/FN 3443 (60 Hz, 3×380 … 415 VAC)
Table 6 FN 3442 filter selection table
Table 7 FN 3443 filter selection table
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