maintenance manual - schaffner · 2018-03-23 · 3 ecosine® active harmonic sync filters –...

2 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module © 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 Power Module Version history

Revision Date Description 01 March 2018 Initial version

http://www.schaffner.com/

3 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module

Table of Contents 1 Introduction 4 1.1 Purpose 4 1.2 Additional Resources 4 2 General Safety Notes and Installation Guidelines 5 3 Environmental Conditions / Exclusion of warranty 6 4 Welcome 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 5 POWER MODULE 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 fans, fan guard and air path 11 5.3.2 Replace fans 1 to 3 17 5.3.3 Replace PDB board fuses F100, F101 & F102 21 5.3.4 Replace PDC board fuses F701 & F705 24 5.3.5 Replace control board battery 27


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.


2 General Safety Notes and Installation Guidelines


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




Operation environmental specifications (IEC 60721-3-3, EN50178)

Climate conditions for operation class 3K3:

• Temperature range: 0°C to +40°C



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 cm3/m3

0.3 0.11

1.0 0.37

Hydrogen sulphide ppm cm3/m3

0.1 0.071

0.5 0.36

Chlorine ppm cm3/m3

0.1 0.034

0.3 0.1

Hydrogen chloride ppm cm3/m3

0.1 0.066

0.5 0.33

Hydrogen fluoride ppm cm3/m3

0.01 0.012

0.03 0.036

Ammonia ppm cm3/m3

1.0 1.4

3.0 4.2

Ozone ppm cm3/m3

0.05 0.025

0.1 0.05

Nitrogen oxides ppm cm3/m3

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.


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 Sync Filters – Maintenance Manual for FN35xx Power Module 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: [email protected] Service E-mail for EMEA: [email protected] Service E-mail for India: [email protected] Service E-mail for USA: [email protected]

http://www.schaffner.com/service/

mailto:[email protected]




5 POWER MODULE 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 fans, fan guards and air path

Replace fans 1 to 3

Replace PDB board fuses F100, F101 & F102

Replace PDC board fuses F701 & F705

Replace control board battery

Table 1: Maintenance schedule

5.2 Wear parts Required amount / filter

Description Part # Classification

1x AHF FAN SET GEN II SP (Set includes 3 fans) 818217 Wear part

1x AHF FUSE 6.3X32MM 1A 1000V GEN II SP (Set includes 2 fuses) 818208 Wear part

1x AHF FUSE5X20 3.15A 1000V GEN II SP (Set includes 3 fuses) 818210 Wear part

1x AHF COIN CELL BATTERY 3V GEN II SP 818213 Wear part

Table 2: Wear parts

11 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 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 fans, fan guard and air path 5.3.1.1 Tool List

CLEANING MATERIAL LIST

1. Gloves 2. Brush3. Cleaning paper4. Alcohol5. Compressed air6. Vacuum cleaner

MAINTENANCE TOOL LIST

1. Socket wrench set2. Torque wrench3. Screw driver set insulated4. Combination wrench set 5 mm – 19 mm5. Pliers set6. Multimeter with capacitance test (for example Fluke 175)7. Torx screw driver set insulated

5.3.1.2 Dismantling process

Disconnect the device from the grid and check it for loss of voltage


Remove all connections from the front side

Remove the 17 screws with a torx T20 screw driver and open the front plate

Disconnect the 3 fan cable plugs and remove the front plate


Remove the 15 screws with a torx T20 screw driver and remove the back plate

Remove the 7 screws with a torx T20 screw driver and remove the top cover

Remove the insulation foil


Clean the air path, depending on the pollution degree, with brush, cleaning towels, alcohol and/or compressed air and/or vacuum cleaner, from front side

and from back side

Clean all other areas with compressed air and/or vacuum cleaner

Attention!Do not go with the air gun closer than 30 cm

15 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.1.3 Reassembly process

Assemble the insulation foil

Mount the top cover and tighten the 7 screws with a torque wrench and a T20 torx bit, with 3.0 Nm

Mount the back plate and tighten the 15 screws with a torque wrench and a T20 torx bit, with 3.0 Nm


Mount the front plate and connect the 3 fan cable plugs

Attention!Ensure that the three fans are connected in the right sequence:

Right fan → Topmost cableMiddle fan → Middle cableLeft fan → Lowermost cable

Tighten the 17 screws with a torque wrench and a T20 torx bit, with 3.0 Nm

Connect all connections to the front side and fix the main connection cables with a torque wrench and the right bit with 4.2 Nm and the earth cable with a torque wrench and a 13 mm socket, with 9.5 Nm

17 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.2 Replace fans 1 to 3 5.3.2.1 Tool List



5.3.2.2 Spare parts

Spare part

818217 AHF FAN SET GEN II SP

Attention!Different cable length




Remove the 12 screws with a torx T20 screw driver and a 7 mm flat wrench and remove the fans and fan guards

5.3.2.4 Reassembly process

Assemble the 3 fans and tighten the 12 screws with a torque wrench, a T20 torx bit and a 7 mm flat wrench, with 1.2 Nm

Fix the cables with cable ties

21 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.3 Replace PDB board fuses F100, F101 & F102 5.3.3.1 Tool List



5.3.3.2 Spare parts

Spare part

818210 AHF FUSE5X20 3.15A 1000V GEN II SP





Remove the 5 screws with a torx T20 screw driver

Move the control board to the side


Replace the three PDB fuses


Mount the control board and tighten the 5 screws with a torque wrench and a T20 torx bit, with 3.0 Nm

Mount the cover and tighten the 13 screws with a torque wrench and a T20 torx bit, with 3.0 Nm

24 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.4 Replace PDC board fuses F701 & F705 5.3.4.1 Tool List



5.3.4.2 Spare parts

Spare part

818208 AHF FUSE 6.3X32MM 1A 1000V GEN II SP




Replace the two PDC fuses








5.3.5 Replace control board battery 5.3.5.1 Tool List



5.3.5.2 Spare parts

Spare part

818213 AHF COIN CELL BATTERY 3V GEN II SP

28 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.5.3 Dismantling process



Replace the control board battery

29 Ecosine® Active Harmonic Sync Filters – Maintenance Manual for FN35xx Power Module 5.3.5.4 Reassembly process

Mount the top cover and tighten the 13 screws with a torque wrench and a T20 torx bit, with 3.0 Nm


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 and understood. However, neither Schaffner nor its subsidiaries assume any liability whatsoever for any errors or inaccuracies of this document and the consequences thereof. Published specifications are subject to change without notice. Product suitability for any area of application must ultimately be determined by the customer. In all cases, products must never be operated outside their published specifications. Schaffner does not guarantee the availability of all published products. This disclaimer shall be governed by substantive Swiss law and resulting disputes shall be settled by the courts at the place of business of Schaffner Holding AG. Latest publications and a complete disclaimer can be downloaded from the Schaffner website. All trademarks recognized.

Schaffner Group Nordstrasse 11 4542 Luterbach Switzerland T +41 32 681 66 26 F +41 32 681 66 30 [email protected] www.schaffner.com

Schaffner Service Centers APAC Schaffner EMC Ltd. Shanghai T20-3, No 565 Chuangye Road Pudong New Area Shanghai 201201 China EMEA Schaffner EMC S.A.S. Rue du Luxembourg 16 68310 Wittelsheim France India Schaffner India Pvt. Ltd “ShriNivas” 26, 2nd Street, Kasthuri Nagar Extension, Ondipudur, Coimbatore - 641 016 Tamil Nadu India North America Schaffner EMC Inc. 52 Mayfield Avenue Edison New Jersey 08837 United State of America

maintenance manual - schaffner · 2018-03-23 · 3 ecosine® active harmonic sync filters –...

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