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Schaffner ECOsine Maintenance Manual

Fn3420-200-690-3 active harmonic filters
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April 2015
®
ECOsine
active Harmonic Filters
Maintenance Manual for FN3420-200-690-3

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Summary of Contents for Schaffner ECOsine

  • Page 1 April 2015 ® ECOsine active Harmonic Filters Maintenance Manual for FN3420-200-690-3...
  • Page 2 Revision: 01 (March 2016) 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...

  • Page 3: Table Of Contents

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Table of Contents General Safety Instructions Intended use Personnel qualification Environmental conditions / Exclusion of warranty Introduction Principle of operation About these instructions Type plate Type code Welcome About this manual...
  • Page 4 Table 1: Use of symbols, terms, and designations Table 2: Type code Table 3: Maintenance schedule 200-690-3 Table 4: Wear parts 200-690-3 Table 5: Wear parts 200-690-3 (UL) Index of Figures ® Fig. 1: Principle of operation of the ECOsine active filter...

  • Page 5: General Safety Instructions

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine General Safety Instructions...

  • Page 6: Intended Use

    Please note that there are additional manuals for some product variants. For the latest versions of these manuals go to www.schaffner.com It particularly applies to types FN3420-100/120-400-3-GL, please observe the special EMC-Filter Manual for these types (ECOsine EMC Filters for Applications with GL)

  • Page 7: Personnel Qualification

    Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Personnel qualification ® Installation of the ECOsine active 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.

  • Page 8: Environmental Conditions / Exclusion Of Warranty

    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 ®...
  • Page 9 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Storage environmental Climate conditions for storage class 1K3: specifications  Temperature range: -25°C to +55°C (IEC 60721-3-1, EN50178)  Relative humidity: < 95%, no condensation  Atmospheric pressure: 70KPa to 106KPa...

  • Page 10: Introduction

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Introduction...

  • Page 11: Principle Of Operation

    ECOsine Principle of operation ® The ac mains current, which is drawn by a non-linear load, is measured by ECOsine active either directly or indirectly via external current transformers. The harmonic content and reactive power components are detected and processed in a digital control structure. The...

  • Page 12: About These Instructions

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine About these instructions The following symbols, terms and designations are used in these operating and installation instructions: Description Notice NOTICE Follow these instructions to avoid damages to the unit. Caution Follow these instructions to avoid damages to the unit or injuries of personnel.

  • Page 13: Type Plate

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Type plate Type code Serial number WO 1234567 + S/N 00001 Part number Date of manufacture (year (yy) + calendar week (ww)) WO number...

  • Page 14: Type Code

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Type code ® The type designations of all ECOsine active have the following structure: FN34TT-AAA-VVV-W-CC Variable Description Type: 20 – 3-wire device 30 – 4-wire device Rated current Rated voltage...

  • Page 15: Welcome

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Welcome...

  • Page 16: About This Manual

    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 ®...

  • Page 17: 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.

  • Page 18: Personnel Qualification

    ECOsine 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 and Wear Parts Manual.

  • Page 19: Get Help

    ECOsine 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.

  • Page 20: Get Training

    Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 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.

  • Page 21: Contact Us

    ECOsine 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.

  • Page 22: Ahf 200-690-3

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine AHF 200-690-3...

  • Page 23: Maintenance Schedule

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Maintenance Schedule Year after start operation Maintenance job             Check operation of main fan, DC-bus fan and clean fan guards ...

  • Page 24: Wear Parts

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Wear parts 4.2.1 Wear parts - AHF 200-690-3 (Not UL) Required Description Part # Classification amount / filter DC-bus fan assembly (Set incl. 2 fans) 814878 Wear part DC-bus pre-charge fuse (Set incl. 2 fuses) 10A 690VAC / 14x51mm (Position F1 &...

  • Page 25: Wear Parts - Ahf 200-690-3 (Ul)

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4.2.2 Wear parts - AHF 200-690-3 (UL) Required Description Part # Classification amount / filter DC-bus fan assembly (Set incl. 2 fans) 814878 Wear part DC-bus pre-charge fuse (Set incl. 2 fuses) 10A 600VAC / 10x38mm (Position F1 &...

  • Page 26: Replacement Instruction

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Replacement Instruction Attention! Before starting to work on the device, ensure that it is switched of, disconnected from the grid and capacitors are discharged 4.3.1 Check operation of main fan and DC-Bus fan and clean fan guards 1.
  • Page 27 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Check with parameter group P1XX Measured values / No. 183 Enclosure fan 4, Check the speed (rpm) of fan 3. In case rpm stays on “0” , then replace it according to the instruction <<Replace DC-...
  • Page 28 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Make sure that the control box is closed during the whole cleaning process Locating the position of main fan Remove the marked lifting bolts...
  • Page 29 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Remove the top cover and use vacuum cleaner / compressor to clean main fan and surrounding area. Remove the marked screws and take out the protection panel. Remove the marked screws and take out the...
  • Page 30 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Use the brush to clean the two inverter fans 3. Work instruction – Reassembly process Close the top cover Tighten the marked lifting bolts...
  • Page 31 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Mount the protection panel and tighten all marked screws with 5 Nm. Mount the second protection panel and tighten marked screws with 5Nm Close and lock the door...

  • Page 32: Check Of Coolant Level

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4.3.2 Check of coolant level 1. Tools List Tool list 1. Funnel with extended tube 2. Spare Parts Spare Parts 1x 814453 AHF Coolant mixed SP (10l) 3. Work instruction...
  • Page 33 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Check the position of level indicator Max level Min level Only fill in the coolant in case level indicator under “Min level “ Remove the cap of water tank and insert...

  • Page 34: Check Coolant Pump For Any Signs Of Coolant-Leakage

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Remove the funnel and close the cap of water tank. Close and lock the door 4.3.3 Check coolant pump for any signs of coolant- leakage 1. Tools List Tool list Visual inspection only 2.
  • Page 35 Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Locating the position of pump Visual checking left side area of pump & tubes Attention! Contact Schaffner Service Center in case any leakage points are detected Visual checking right side area of pump & tubes Attention!

  • Page 36: Replace Inverter Fan (Dc Bus Fan)

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine If no any leakage are found, close and lock the door 4.3.4 Replace inverter fan (DC bus fan) 1. Tools List TOOLS LIST 1. M6 Hex socket wrench 2. Philips screwdriver 3.
  • Page 37 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 3. Work instruction - Dismantling process Unlock the cabinet by key Remove the marked screws and take out the protection panel. Remove the marked screws and take out the protection panel...
  • Page 38 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Disconnect the fan cables of the two fan modules. Bend the clip on fan plate straight. Pull out the fans away from cover...
  • Page 39 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4. Work instruction – Reassembly process Insert the fans into the fan cover and reconnect the fan cables Bend the clip on fan plate back to block fix the Mount the protection panel and tighten all...

  • Page 40: Replace Pre-Charge Fuses F1 & F2

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Mount the second protection panel and tighten marked screws with 5Nm Close and lock the door 4.3.5 Replace pre-charge fuses F1 & F2 1. Tools List Tool list 1. Cabinet Key...
  • Page 41 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 2. Spare Parts Spare Parts 1x 814437 (For no UL-Version) AHF FUSE 10AMP 690VAC 14X51MM 690 1x 814438 (For UL-Version) AHF FUSE 10AMP 600VAC 14X38MM 690 3. Work instruction - Dismantling process...
  • Page 42 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Open the fuse holder F1 and F2 and take out the fuses 4. Work instruction – Reassembly process Insert the two new fuses into teh fuse holder Close the covers and take care that the...

  • Page 43: Replace 230V Auxiliary Power Supply

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Close and lock the door 4.3.6 Replace 230V auxiliary power supply 1. Tools List Tool list 1. Cabinet Key 2. Spare Parts Spare Parts 1x 814437 AHF FUSE 10AMP 600VAC 14X38MM 690...
  • Page 44 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 3. Work instruction - Dismantling process Unlock the cabinet by key Locating the position of pre-charging fuses F3 Open the fuse holder F3 and F4 and take out the fuses...
  • Page 45 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4. Work instruction – Reassembly process Insert the two new fuses into the fuse holder Close the covers and take care that the covers are closed complete Close and lock the door...

  • Page 46: Replace 24V Power Supply Fuses F45 & F46

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4.3.7 Replace 24V power supply fuses F45 & F46 1. Tools List Tool list 1. Cabinet Key 2. Spare Parts Spare Parts 1x 814442 AHF FUSE 1.25AMP 500VAC 6.3X32 690 SP 3.
  • Page 47 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Locating the position of GCS module PCB Take out the fuse of position F45 F46 4. Work instruction – Reassembly process Insert the two new fuses into the fuse clip...

  • Page 48: Replace Cooling System Power Supply Fuses

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Close and lock the door 4.3.8 Replace cooling system power supply fuses F47 & F48 1. Tools List Tool list 1. Cabinet Key 2. Spare Parts Spare Parts 1x 814440...
  • Page 49 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 3. Work instruction - Dismantling process Unlock the cabinet by key Locating the position of GCS module PCB Take out the fuse of position F47 F48...
  • Page 50 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4. Work instruction – Reassembly process Insert the two new fuses into the fuse clip Close and lock the door...

  • Page 51: Replace Cooling System Control Unit Fuses

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4.3.9 Replace cooling system control unit fuses F1- 1. Tools List Tool list 1. Cabinet Key 2. Spare Parts Spare Parts F1 & F2 1x 811403 F1 F2 AHF FUSE 4A 500VAC 63X32 300A SP...
  • Page 52 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Open the cover of liquid cooling control box with Key Remark: The position of liquid cooling control box can vary, depends on version. Lift up the fuse holder, open the cover and take out the fuses.

  • Page 53: Replace Air-Conditioning Fuses F11

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Close the cover of liquid cooling control box with Key Close and lock the door 4.3.10 Replace air-conditioning fuses F11 1. Tools List TOOLS LIST - Slotted screwdriver - Rittal cabinet key...
  • Page 54 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 2. Spare Parts Spare Parts 1x 811403 AHF FUSE 4A 500VAC 63X32 300A SP 3. Work instruction - Dismantling process Unlock the cabinet by key Remove the fuse holder cover F11...
  • Page 55 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Take out fuse from fuse holder 4. Work instruction – Reassembly process Insert the fuse into the fuse holder Insert the fuse into the position F11...

  • Page 56: Change Cooling Liquid

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Close and lock the door 4.3.11 Change cooling liquid 1. Tools List Tool list 1. Funnel with extended tube 2. Spare Parts Spare Parts 1x 814453 AHF Coolant mixed SP (10l)
  • Page 57 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 3. Work instruction – Dismantling process Unlock the cabinet by key Open the coiled silicon tube and guide this into a vessel. Open the shut-off cock and drain the whole...
  • Page 58 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 4. Work instruction – Reassembly process Close the shut-off cock. Remove the cap of water tank and insert funnel into water tank Fill in coolant into water tank till the level of...

  • Page 59: Replace Main Fan

    ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Remove the funnel and close the cap of water tank. Close and lock the door 4.3.12 Replace main fan 1. Tools List Tool list 1. Cabinet Key 2. M13 socket wrench with extension 3.
  • Page 60 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine 3. Work instruction - Dismantling process Locating the position of main fan Remove the marked lifting bolts Remove the top cover...
  • Page 61 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Remove the marked screws with socket wrench Loosen the two cable glands Unlock the cabinet by key...
  • Page 62 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Open the cover of liquid cooling control box with Key Remark: The position of liquid cooling control box can vary, depends on version. Loosen the conection of the two fan cables...
  • Page 63 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Take out the main fan from top cover 4. Work instruction – Reassembly process Insert the new main fan Insert the two fan cables into the cable glands and fix it...
  • Page 64 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Tighten the marked screws with 13.6Nm Close the top cover Tighten the marked lifting bolts...
  • Page 65 ® active Harmonic Filters – Maintenance Manual for FN3420-200-690-3 ECOsine Rewiring all removed fan cables Close the cover of liquid cooling control box with Key Close and lock the door...
  • Page 66 United States - Edison Schaffner EMC Inc. 52 Mayfield Avenue Edison New Jersey 08837 To find your local partner within Schaffner‘s global network, please go to www.schaffner.com ® 2014 Schaffner Group The content of this document has been carefully checked understood.

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