Zener IP00 Series User manual

ZENER VARIDRIVE SOLUTIONS
ZENER 8000
High Performance Output Filter
IP00 Series
Instruction Manual
Document: IM00168
Printed: 18 March 2019

ZENER 8000
IM00168
All documentation for this product can be found on our product support link:
http://www.zener.com.au/support-zener.php
ZENER TECHNOLOGY AND QUALITY ASSURANCE
Since 1976 Zener Electric has supplied many thousands of drives to industry. These drives have been installed
into numerous applications resulting in a wealth of in house experience. The ZENER 8000 AC variable speed
controller is the culmination of this experience, modern technology and industrial application requirements.
The Zener Quality Assurance program ensures that every ZENER 8000 manufactured has proven to operate
correctly in the production test bay before dispatch.
SAFETY
Your ZENER 8000 must be applied, installed and operated in a safe manner. It is the responsibility of the user to
ensure compliance with all regulations and practices covering the installation and wiring of your ZENER 8000.
The instruction manual should be completely read and understood before attempting to connect or operate the
ZENER 8000. Only skilled personnel should install this equipment. This equipment contains a number of
components that are designated by their various manufacturers as “not for use in life support appliances,
devices or systems where malfunction of the components can reasonably be expected to result in personal
injury or death”. Customers using or selling Zener products for use in such applications do so at their own risk
and agree to indemnify Zener for any damage resulting from improper use or sale.
THE CONTENTS OF THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE
ZENER is a registered trademark of Zener Electric Pty Limited

ZENER 8000 High Performance Output Filter - IP00 Series
IM00168 i
Contents
Explanation of Symbols .............................................................................................................................................1
Receiving....................................................................................................................................................................1
Warnings....................................................................................................................................................................2
Performance..............................................................................................................................................................3
Mechanical Installation Information .........................................................................................................................4
Dimensions............................................................................................................................................................4
Installation Considerations........................................................................................................................................5
Operating Considerations..........................................................................................................................................5
Wiring Diagram..........................................................................................................................................................6
+B Terminal................................................................................................................................................................7
Fuse Data:..........................................................................................................................................................7
Specification ..............................................................................................................................................................8
Standards Compliance...........................................................................................................................................8
Current Ratings......................................................................................................................................................8

High Performance Output Filter –IP00 Series
IM00168
Explanation of Symbols
WARNING
Indicates a condition or practice that, if the warning is not strictly
observed, could result in personal injury or death.
CAUTION
Indicates a condition or practice, if the caution is not strictly
observed, could lead to damage or destruction of equipment or a
significant impairment of proper operation.
WARNING
This symbol is used to highlight an electrical hazard. Failure to
strictly observe the warning could result in electrocution.
i
This symbol is used to highlight additional information on the
product’s capabilities or a common error in installation,
commissioning or operation.
Receiving
Inspect the High Performance Output Filter for any shipping damage. If any damage is found, report it to the carrier
immediately. Access the inside of the filter and visually check for any damage.
Do not attempt to operate the High Performance Output Filter if any obvious damage exists.
After the initial inspection, the High Performance Output Filter can be repacked and stored in a clean, dry location
until it is required for use.
DO NOT store this equipment in an area where the ambient temperature will fall below -20°C or rise above 70°C. DO
NOT store this equipment in areas that are subject to condensation or corrosive atmosphere. Proper storage is
necessary to ensure satisfactory High Performance Output Filter start up and performance.

ZENER 8000
IM00168
Warnings
This manual should be read in conjunction with the ZENER 8000 Installation Manual (IM00124).
Read all operating instructions before installing, wiring, operating, servicing or inspecting the
High Performance Output Filter. Ensure that the instruction manual is made available to the final
user of the product as well as all personnel involved in any aspect of installation, adjustment or
maintenance. Your High Performance Output Filter must be applied and installed by a suitably
qualified and experienced electrical tradesperson in accordance with this manual, good
engineering practice and all local rules and regulations
There are hazardous voltages inside the High Performance Output Filter whenever it is connected
to an electrical supply and for some time after it is disconnected. Before touching anything inside
the High Performance Output Filter enclosure or other equipment connected to the High
Performance Output Filter terminals, disconnect all sources of electrical power, wait at least 11
minutes for capacitors within the High Performance Output Filter to discharge to less than 50VDC
and then ensure, by measurement, that there is no hazardous AC or DC voltage present at any
terminal.
The High Performance Output Filter contains high energy circuits that may be hazardous. Do not operate the High
Performance Output Filter with the door open or any part of the enclosure removed.
Do not touch the terminals of the High Performance Output Filter or any associated motor and wiring when it is
energised, even if the High Performance Output Filter and motor are stopped. Electric shock may result.
Do not modify this equipment electrically, mechanically or otherwise. Modification may create safety hazards.
The High Performance Output Filter is designed to operate in series with an appropriately rated and otherwise
suitable 3 phase induction motor. It is not suitable for single phase motors or other types of motor or non-motor
load. Use with inappropriate load types may create a safety hazard.
Where the High Performance Output Filter is used as a component part of another product, it is the purchaser’s
responsibility to ensure that the final product meets all of the necessary safety, EMC, regulatory, operational and
other requirements for that product. Requirements for the purchaser’s final product may be substantially different to
the requirements for stand-alone filters.
The High Performance Output Filter is intended for use only in fixed wiring applications. It is not intended for use on a
flexible supply cable.
Mount the High Performance Output Filter on a vertical, incombustible surface such as metal or masonry.
Do not place combustible or flammable material near the High Performance Output Filter. Failure to observe these
precautions may create a fire hazard.
The High Performance Output Filter is manufactured under strict quality control arrangements, however additional
and independent safety equipment must be installed if the application is such that failure of the product may result in
personal injury or property damage.
Ensure that electrical noise generated by the product and any associated equipment does not adversely affect the
proper operation of other equipment or systems, particularly those that have a safety function.
Do not install this equipment in locations where mechanical damage to the enclosure is possible. In particular,
consider vehicles, vandalism and attack by insects or animals. Severe equipment damage and safety hazards may
result.

High Performance Output Filter –IP00 Series
IM00168
Performance
The following benefits can be realised with the High Performance Output Filter when connected between the ZENER
8000 inverter and a motor:
Significant reduction of RF voltages and currents achieving 40dB to 45dB attenuation.
Complies with AS61800.3 (Adjustable speed electrical power drive systems, Part 3: EMC requirements and
specific test methods) category C3 limits, category C2 limits and category
C1 limits (0.2 to 30MHz) (see below for definitions) in a typical installation with 100m of either unscreened or
screened motor cable.
Ideal solution for eliminating AM radio frequency interference
Maximum reduction of potential RF voltages and currents achieving 45dB to 50dB attenuation with screened
motor cable.
High efficiency, greater than 99%
Eliminate the need for installing screened motor cables.
The permissible cable length
1
between filter and motor is 500m.
Categories as defined in AS61800.3 are:
C1 limits apply to equipment in a domestic environment that does not require installation and commissioning
by a professional.
C2 limits apply to equipment in a domestic environment that does require installation and commissioning by
a professional.
•C3 limits apply to equipment in a non-domestic environment.
•C4 limits apply to equipment with currents above 400A and special cases.
Maximum rate of change of voltage (dv/dt) = 150V/μs
Maximum peak motor voltage with 100m of cable typically 120% of bus voltage
1
Cable resistive voltage drop should be taken into consideration when long cable runs are used.
Vertical: 200V / div, Horizontal: 5μs / div.
Figure 1
High Performance Output Filter voltage.
Vertical: 200V / div, Horizontal: 5μs / div.
Figure 2
Motor terminal voltage with 100m of
unscreened cable.

ZENER 8000
IM00168
Mechanical Installation Information
Dimensions
Model
Dimensions (A x B X C)
Weight
Mounting holes
AHP0070
200 x 280 x 150
10 kg
AHP2200
650 x 335 x 410
14mm Diameter
600mm x 250mm centres
AHP3150
AHP3900
AHP4900
130 kg
C
A
B
Allow sufficient
clearance for all cable
terminations.
Mounting Holes
(inside channel)
Models AHP2200 - AHP490A (AHP4900 model shown)

High Performance Output Filter –IP00 Series
IM00168
Installation Considerations
CAUTION
The High Performance Output Filter must be mounted on a vibration free surface, away from heat radiating
sources. Do not mount the High Performance Output Filter in direct sunlight or on a hot surface.
In selecting an enclosure for the High Performance Output Filter and any associated equipment, the total
heat dissipation and resulting temperature rise in the enclosure must be considered.
Attention is drawn to the potential for condensation in vulnerable environments. Additional precautions may
be required for all enclosure types.
The installation location and environment should provide for safe access and working conditions for service
personnel. Do not mount the High Performance Output Filter in “confined spaces”
2
Do not drill holes in the High Performance Output Filter.
Do not allow metal shavings or any other conductive material to enter the enclosure or damage may result.
Operating Considerations
Zener recommends that the associated ZENER 8000 inverter be set for an audible switching frequency of
2kHz.
2
Confined spaces are generally defined in Workplace Health and Safety (WH&S) regulations to mean spaces where
special precautions are necessary to ensure a safe breathing atmosphere, or there is limited access for escape/rescue
in case of emergency.

ZENER 8000
IM00168
Wiring Diagram
Over temperature Protection:
N/C thermal switches are included. This must be
connected into the enable circuit or external trip
input of the ZENER 8000.
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* If the High Performance Output Filter is not mounted adjacent to the inverter on the
same mounting panel, inside a metal enclosure, screened power cable may be required
between the inverter and filter. If using screened cable, refer to ZENER 8000 Installation
Manual for EMC Installation practices.
ZENER 8000
INVERTER

High Performance Output Filter –IP00 Series
IM00168
+B Terminal
The ZENER 8000 +B/BR+ terminals are supplied as a factory fitted option. The following table lists the part numbers
corresponding to ZENER 8000 inverters from 15A to 490A.
Fuse Data:
The fuse is a fast acting type, rated 30A 600VDC with a cartridge size 38.1 x 10.31mm. Do not substitute other types.
Description
Zener Part Number
Replacement Fuse, 30A 600VDC
AP18080
NOTE: THE IP00 HIGH PERFORMANCE OUTPUT FILTER requires connection to the ZENER 8000 (+) DC bus. The factory
fitted option provides a fused terminal in the ZENER 8000 for this purpose.
Cable Size:
The minimum cable size used for the filter +B should be no less than the size required for the protective earth
conductor in the inverter installation (Chassis A & B models) or 30A for models (Chassis C & D) fitted with a fused
terminal. For supply protection, cable size and electrical isolation information, refer to the ZENER 8000 Installation
Manual.
Chassis C and D:
Chassis C & D include a 30Amp fuse on the +B terminal. This allows a smaller cable size to be used. The recommended
minimum cable size is 6mm2 (for UL508C compliance) or according to applicable wiring codes.
The fuse is intended provide thermal protection for the B+ wire in the event of a cable or filter fault condition.
Description
Part Number
Internal Fuse
ZENER 8000 DC Bus Terminal Kit for Chassis A - fitted
n/a
n/a
ZENER 8000 DC Bus Terminal Kit for Chassis B - fitted
AF03101
n/a
ZENER 8000 DC Bus (+ only) Terminal Kit for ChC with Fuse - fitted
AF08107
30A
ZENER 8000 DC Bus (+ only) Terminal Kit for ChD with Fuse - fitted
AF08108
30A

ZENER 8000
IM00168
Specification
Standards Compliance
When used with ZENER 8000 inverter
Complies with the Australian EMC
framework requirements
Adjustable speed electrical power drive
systems Part 3: EMC requirements and
specific test methods
IEC 61800.3
AS 61800.3
Current Ratings
Model
Current Rating
Heat Dissipation
@2KHz Audible frequency
Continuous
@ 40°C
Intermittent
60s
AHO0070
7.0A
9.0A
AHP2200
220A
242A
AHP3150
315A
347A
AHP3900
390A
429A
AHP4900
490A
539A
630W
Operation at higher Audible Frequency or at speeds >50Hz may require derating. The filter is matched to the ZENER
8000 to allow for operation at temperatures above 40°C.
Voltage Rating
380 to 480Vac, -15% +10%, 3 phase, 0-200Hz
Maximum rate of change of voltage dv/dt
150V/μs
Peak motor terminal voltage with 100m of
motor cable
Typically 120% of peak mains voltage
Enclosure
Open chassis –IP00
Storage temperature
-20°C to 70°C
Operating environment temperature
0°C to 50°C as per drive rating / temperature
(Consult Zener for higher ratings)
Relative Humidity
5 to 95% non-condensing
Altitude
0 to 1000m

ZENER ELECTRIC PTY LIMITED
ACN 001 595 428
366 Horsley Rd
Milperra NSW 2214
Australia
PO Box 347
Milperra NSW 2144
Australia
T: [phone]
E: [email protected]et
http://www.zener.com.au
© Zener Electric Pty Limited 2019
IM00168
15th February 2019