Schaffner Ecosine FS42842 Series Operating manual

Schaffner Group |Nordstrasse 11e |4542 Luterbach |Switzerland
T [phone] |[email protected]m | www.schaffner.com
User and installation
manual
Passive Harmonic Filters
ecosine® FS42842

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ecosine® FS42842 (50Hz)
Rev01
March 2021
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 installation 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® evo
FN3440 user manual.
If you require additional support, please feel free to contact your local Schaffnerpartner.

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i. 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 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 airbornecontaminants.
ii. 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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Contents
1Part number coding............................................................................................................................................ 6
2Filter description................................................................................................................................................. 7
3Additional electrical specifications .................................................................................................................. 8
4Mechanical specifications ................................................................................................................................. 9
5Performance characteristics FS42842 ........................................................................................................... 12
6Power factor vs. load (diode rectifier front-ends) ......................................................................................... 13
7Drive dc-link voltage vs. load (diode rectifierfront-ends)............................................................................ 14
8Function diagram.............................................................................................................................................. 15
9External filter elements.................................................................................................................................... 16
10 Audible noise .............................................................................................................................................. 17
11 Filter purpose and function ....................................................................................................................... 18
12 Example 1: motor drive without built-in DC-link choke.......................................................................... 19
13 Example 2: motor drive with built-in DC-link choke................................................................................ 20
14 Filter selection............................................................................................................................................. 21
14.1 Filter selection table FS42842 (50Hz) .......................................................................................................... 22
15 Filter application......................................................................................................................................... 23
16 Filter installation......................................................................................................................................... 24
16.1 Drilling pattern for wall mounted filters: ........................................................................................................ 25
2.1 Bolt selection ................................................................................................................................................ 25
16.2 Filter placement ............................................................................................................................................ 25
16.3 Safety cover for filters with bus-bar terminals............................................................................................... 26
16.4 Connect protective earth (PE) wire to adequate earth potential close to ecosine® filter............................. 26
16.5 Connect PE wire to min. one available PE bolt............................................................................................ 26
16.6 Connect ecosine® load side terminals L1’, L2’, L3’...................................................................................... 26
16.7 Connect over-temperature contact............................................................................................................... 26
16.8 Connect ecosine® line side terminals L1, L2, L3 ......................................................................................... 27
3.2 Connect ecosine® trap terminals A1, B1, C1, A2, B2, C2 ........................................................................... 27
16.9 Safety cover for filters with bus-bar terminals............................................................................................... 27
16.10 Fuses........................................................................................................................................................ 28
16.11 Safety cover for filters with bus-bar terminals........................................................................................... 28
17 Filter maintenance...................................................................................................................................... 29

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17.1 Maintenance considerations:........................................................................................................................ 29
18 Fan specifications: ..................................................................................................................................... 30
19 Special considerations............................................................................................................................... 31
20 Technical data of over-temperature contact:........................................................................................... 32
21 Troubleshooting ......................................................................................................................................... 33
22 FAQ –Frequently asked questions........................................................................................................... 34
22.1 Motors and Generators................................................................................................................................. 35
22.2 Capacitors..................................................................................................................................................... 35
22.3 Electronic Equipment.................................................................................................................................... 35
22.4 Metering (watt-hour meters) ......................................................................................................................... 35
22.5 Switchgear and Relaying.............................................................................................................................. 35
22.6 Communication Equipment........................................................................................................................... 35
23 Appendix I: International standards ......................................................................................................... 37
23.1 Engineering recommendation G5/4-1 Definitions:........................................................................................ 37
23.2 G5/4-1 planning levels for harmonic voltages:.............................................................................................. 37
23.3 G5/4-1 current harmonic limits for loads rated >16A per phase:.................................................................. 38
23.4 Definitions..................................................................................................................................................... 39
23.5 EN 61000-3-12 current harmonic limits: ....................................................................................................... 40
23.6 Interpolation of current harmonic limits:........................................................................................................ 41
23.7 IEEE Std 519 ................................................................................................................................................ 41
23.8 Other standards:........................................................................................................................................... 42
24 Appendix II: Declaration of conformity..................................................................................................... 43

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1 Part number coding
Examples:
FS42842-60-34: Filter for 50Hz, 380-500V grids, 60A drive input current, with 25mm2 terminals, for
diode or SCR (thyristor) rectifier front-end.
FS42842-240-99: Filter for 60Hz, 200-240V grids, 240A drive input current, with copper busbar,
for diode or SCR (thyristor) front-end.
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]
Filter family
42842 = Siemens custom filter for 50Hz, 380-500V
grids
FN = Schaffner standard filter
FS = Schaffner custom filter
FS42842-xxx-xx

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2 Filter description
General electrical specifications FS42842 (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
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 thethyristors.
3) Conditions: line impedance <3%
4) Repetitive tests to be performed at max. 80% of above levels, for 2 seconds.
5) External UL-rated fuses required.
6) I
derated =I nominal*(70°C-T amb)/25°C

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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:
105
100
95
90
85
80
0 500 1000 1500 2000 2500 3000 3500 4000
Altitude a.s.l. [m]
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.
Rated
load
power
[%]

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4 Mechanical specifications

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5 Performance characteristics FS42842
THID vs. load (diode rectifier front-ends)
Note: shown above is the typical performance characteristic of FS42842 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.

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6 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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7 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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8 Function diagram
Filter terminals
Line
3 touch safe terminal blocks (busbar terminals >240A)
Load
3 touch safe terminal blocks (busbar terminals >240A)
Disconnect
TDJ terminal 6 touch safe terminal blocks
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-temperatureswitch
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 following filters do not require forced cooling and therefore have no internal fan and power supply: FS42842 -
10, -13, -16

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9 External filter elements
Line terminals (3) TDJ terminals (6) Over temperature contact (2) Load terminals (3)
PE terminals (2) Fan(s)
Line terminals (3) TDJ terminals (6) Over temperature contact (2) Load terminals (3)
PE terminals (2) Fans

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10 Audible noise
Tests have been performed at nominal filter load. Ambient noise level:49dB[A]
Filter
FS42842-13-44 (P=5.5kW)
60dB[A] @ 1m
FS42842-210-40 (P=110kW)
70dB[A] @ 1m
Equipment used: Peak Tech Sound Level Meter 5055

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11 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.
3~
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 utilitycodes.
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 FS42842-210-40 for the rated load power of 110kW.

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12 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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13 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