Schaffner Ecosine active sync Operating manual

User and Installation Manual
Ecosine active sync
Schaffner Group | Nordstrasse 11| 4542 Luterbach | Switzerland
T [phone] | F [phone] |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
1Version History....................................................................................................7
2Introduction..........................................................................................................8
Purpose........................................................................................................................................ 8
Additional Resources................................................................................................................. 8
Naming convention .................................................................................................................... 8
3General Safety Notes and Installation Guidelines............................................9
4Environmental Conditions / Exclusion of warranty........................................10
5Ecosine 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
5.9.4Load and save AHF parameter set ..................................................................................... 32
6Mechanical 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
7Electrical 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
8Comissioning 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
9Parameter 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 3-
phase 4-wire network with neutral wire. Both DPP packages will always include two power modules (3-
wire 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)