Schaffner ecosine FN3540 User manual

www.myecosine.com
English version
Maintenance Manual
Ecosine active sync
Schaffner Group |Nordstrasse 11 |4542 Luterbach |Switzerland
T [phone] |F [phone] |www.schaffner.com

2 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
© All rights reserved, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and
dissemination.
Revision: 01 (March 2018)
The most current edition of these instructions (PDF format) can be obtained from your contact
of the Schaffner service organization.
Other technical documentation of our products is also available in the download area of our
website www.schaffner.com
Document name:
Maintenance Manual for FN35xx Cabinet
Version history
Revision Date Description
01
March 2018
Initial version

3 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Table of Contents
1Introduction 4
1.1 Purpose 4
1.2 Additional Resources 4
2General Safety Notes and Installation Guidelines 5
3Environmental Conditions / Exclusion of warranty 6
4Welcome 8
4.1 About this manual 8
4.2 Who should read this guide 8
4.3 Personnel qualification 8
4.4 Get help 8
4.5 Get training 8
4.6 Contact us 9
5CABINET 380VAC-415/480VAC 3-/4-WIRE 10
5.1 Maintenance schedule 10
5.2 Wear parts 10
5.3 Maintenance instruction 11
5.3.1 Check operation, clean cabinet fans, fan guard of cabinet, filter pads,
internal fan, fan guard of internal fan and air path 11
5.3.2 Replace filter pads 19
5.3.3 Spare parts 19
5.3.4 Replace cabinet fans, fans 4 – 7 20
5.3.5 Replace internal fan, fan 8 26
5.3.6 Replace Main fuses 29
5.3.7 Replace Power Supply fuses 32
5.3.8 Remove Power Module from cabinet 34
5.3.9 Dismantling process 34

4 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
1 Introduction
1.1 Purpose
The ecosine active sync User and Installation Manual provide information for unpacking,
installation and commissioning of the filter and describe mechanical and electrical installation
of the filters. 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 need to be given to the general safety notes
and installation guidelines (cautions and warnings)! Keep these instructions available with
the filter(s) at all times.
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.
1.2 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 manual provides information on maintenance and
testing for field service technicians, as well as disassembly and assembly instructions for
wear parts.

5 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
2 General Safety Notes and Installation Guidelines

6 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
3 Environmental Conditions / Exclusion of warranty
This document classifies groups of environmental parameters and their severities to which
ecosine active 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 variants 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 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 AHF must be installed in a clean, dry location, e.g. in
sufficiently ventilated or air-conditioned 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 FN3540/41 series, 3/4-wire filters, models 60A
FN3545 series, 3/4-wire filters, models 60…300A
Overvoltage class
(EN50178)
Ecosine active sync are designed according to EN 50178
overvoltage class III
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

7 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Operation environmental
specifications
(IEC 60721-3-3, EN50178)
Climate conditions for operation class 3K3:
•Temperature range: 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
cm
3
/m
3
0.3
0.11
1.0
0.37
Hydrogen sulphide
ppm
cm
3
/m
3
0.1
0.071
0.5
0.36
Chlorine
ppm
cm
3
/m
3
0.1
0.034
0.3
0.1
Hydrogen chloride
ppm
cm
3
/m
3
0.1
0.066
0.5
0.33
Hydrogen fluoride
ppm
cm
3
/m
3
0.01
0.012
0.03
0.036
Ammonia
ppm
cm
3
/m
3
1.0
1.4
3.0
4.2
Ozone
ppm
cm
3
/m
3
0.05
0.025
0.1
0.05
Nitrogen oxides
ppm
cm
3
/m
3
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.
(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.

8 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
4 Welcome
4.1 About this manual
This manual is meant to provide comprehensive information on maintenance requirements of
Ecosine®active harmonic filters. The issues discussed in this guide cover the basic
maintenance schedule, necessary wear parts as well as practical aspects of working with
Ecosine®active harmonic filters. The guide will familiarize you with the required hardware
checks and settings to conduct various maintenance tasks.
4.2 Who should read this guide
The primary audience for this book is anyone interested in or responsible for maintenance of
Ecosine®active harmonic filters. To fully understand the guide, you should have a good
knowledge of electronic and electrical systems and at least some basic power quality habits.
Attending Schaffner International training courses is considered helpful.
4.3 Personnel qualification
Any maintenance actions on Ecosine®active harmonic filter has to be performed only by
skilled electricians who additionally must be familiar with the instructions in the Installation
and Operation Manual as well as this Maintenance Manual.
CAUTION
Caution
Maintenance tasks should only be performed by trained and skilled personnel to
avoid damages to the unit or injuries of personnel.
WARNING
Warning
Changing of wear parts may cause malfunction of device and can cause injuries
of
personnel if not properly performed.
4.4 Get help
Schaffner believes in the value of service and partnering. We do offer help with a lot of
topics. In order to provide the most successful help Schaffner does operate a service
organization and worldwide service centers. We do also closely collaborate with a growing
network of qualified and authorized service partners to maintain our high service quality on a
global approach.
4.5 Get training
Do you need training? Schaffner can offer a training course comprised of lecture and hands-
on workshops designed to introduce you to the fundamental concepts of power quality,
Ecosine®harmonic filters and filter maintenance.
We also offer customized training courses designed to meet your specific needs. Please
contact your local Schaffner service organization or Schaffner representative to discuss how
we can help you achieve success in your power quality efforts.

9 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
4.6 Contact us
Schaffner – More than just filters. Schaffner is in the unique position of being able to support
the user with problem analyses, engineering advice, testing and measurement support,
custom products, and a worldwide customer service organization. Our goal is to ensure that
you obtain the level of support you actually need. Toward this objective, we invite you to
contact your local Schaffner representative at any time that we may be of service to you. You
can find out more about us and your local contact on our corporate website or you may
contact us via email:
Service URL: www.schaffner.com/service/
Service E-mail for APAC: [e-mail]
Service E-mail for EMEA: [e-mail]
Service E-mail for India: india-pqs[email protected]
Service E-mail for USA: [e-mail]

10 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5 CABINET 380VAC-415/480VAC 3-/4-WIRE
5.1 Maintenance schedule
Year after start
operation
Maintenance job 1 2 3 4 5 6 7 8 9 10 11 12
Check operation, clean cabinet
fans, fan guard of cabinet, filter
pads, internal fan, fan guard of
internal fan and air path

Replace filter pads 
Replace cabinet fans
Fans 4-7 
Replace internal fan
Fan 8 
Replace main fuses 
Replace Power Supply fuses
F5-F7 
Table 1: Maintenance schedule
5.2 Wear parts
Required
amount /
filter
Description Part # Classification
1x
AHF EXHAUST FILTER PFA GEN II SP
(Set includes 10 pcs.) 819135 Wear part
1x
AHF FAN 120 CABINET GEN II SP
(Set includes 4 fans) 819130 Wear part
1x
AHF FAN 92 CABINET GEN II SP
(Set includes 1 fan) 819132 Wear part
3x (1)
AHF FUSE 100A 600V CABINET GEN II SP
(1) 3 pcs. per installed Power Module are needed 819127 Wear part
1x
AHF FUSE 10.3X38 8A 690V CABINET GEN II SP
(Set includes 3 fuses) 819131 Wear part
Table 2: Wear parts

11 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5.3 Maintenance instruction
Attention!
Before starting to work on the device, ensure that it is switched off,
disconnected from the grid and capacitors are discharged
5.3.1 Check operation, clean cabinet fans, fan guard of cabinet, filter pads,
internal fan, fan guard of internal fan and air path
5.3.1.1 Tool list
CLEANING MATERIAL LIST
1. Gloves
2. Brush
3. Cleaning paper
4. Alcohol
5. Compressed air
6. Vacuum cleaner
MAINTENANCE TOOL LIST
1. Socket wrench set
2. Torque wrench
3. Screw driver set insulated
4. Combination wrench set 5 mm – 19 mm
5. Pliers set
6. Multimeter with capacitance test (for
example Fluke 175)
7. Torx screw driver set insulated
8. Ladder
5.3.1.2 Dismantling process
Switch off the main switch and disconnect the
device from the grid

12 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Open the front door
Check the device for loss of voltage
Remove the 2 screws on top with a torx T20
screw driver

13 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Remove the 2 screws on both sides with a
torx T20 screw driver and remove the front
cover
Loose the two fixing screws and disconnect
the cable from the main fan module
Remove the 4 screws with a torx T20 screw
driver and remove the main fan module

14 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Clean the fans
Clean the air path
5.3.1.3 Reassembly process
Place the main fan module and tighten the 4
screws with a torque wrench and a T20 torx
bit with 3.0 Nm

15 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Connect the cable to the main fan module and
fix the two screws with 1.2 Nm
Mount the front cover and tighten the 2 screws
on both sides with a torque wrench and a T20
torx bit, with 3.0 Nm
Tighten the 2 top screws with a torque wrench
and a T20 torx bit, with 3.0 Nm

16 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5.3.1.4 Dismantling process
Loose the two screws of the enclosure fan
module plug with a long PZ screw driver and
disconnect it
Loose the 2 screws and remove the enclosure
fan module
Clean the fan and the fan guard

17 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5.3.1.5 Reassembly process
Mount the enclosure fan module and tighten
the screws
Connect the plug to the enclosure fan module
and fix it with a long PZ screw driver with 2.0
Nm
5.3.1.6 Dismantling process
Open the covers of the filter pads

18 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
Remove the filter pads and clean them all with
compressed air
5.3.1.7 Reassembly process
Place the filter pads to the covers and close
them
Attention!
The mounting direction must be according to
the guidline inside of the spare part packing

19 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5.3.2 Replace filter pads
5.3.3 Spare parts
819135 AHF EXHAUST FILTER PFA GEN II
SP
5.3.3.1 Dismantling process
Open the covers of the filter pads
Remove the filter pads

20 Ecosine®active Harmonic Filters – Maintenance Manual for FN35xx Cabinet
5.3.3.2 Reassembly process
Place the filter pads to the covers and close
them
Attention!
The mounting direction must be according to
the guidline inside of the spare part packing
5.3.4 Replace cabinet fans, fans 4 – 7
5.3.4.1 Tool list
MAINTENANCE TOOL LIST
1. Socket wrench set
2. Torque wrench
3. Screw driver set insulated
4. Combination wrench set 5 mm – 19 mm
5. Pliers set
6. Multimeter with capacitance test (for
example Fluke 175)
7. Torx screw driver set insulated
8. Ladder
5.3.4.2 Spare parts
819130 AHF FAN 120 CABINET GEN II SP