Schaffner ECOsine FN3416 User manual

Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland
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energy efficiency and reliability
User Manual
ECOsine™ – Passive Harmonic Filters
FN3416 (50Hz) & FN3418 (60Hz) Economy Line
September 2012
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Schaffner Group
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 25mm2terminals, 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)
7Arms to 240Arms @ 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) Iderated = Inominal*(70°C-Tamb)/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)
5Arms to 250Arms @ 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) Iderated = Inominal*(70°C-Tamb)/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
0500 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 sine-
wave 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.