Schaffner Maintenance Instruction For Power Module

Maintenance Manual
Ecosine active sync
www.myecosine.com
English version
Schaﬀner Group | Nordstrasse 11 | 4542 Luterbach | Switzerland

T +41 32 681 66 26 | F +4132 681 66 30 | www.schaﬀner.com
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
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 Ecosine active sync are designed according to EN 50178

overvoltage class III
(EN50178)
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
Transportation Climate conditions for transport class 2K3:

environmental
• Temperature range: -25°C to +70°C
specifications
(IEC 60721-3-2, EN50178)
Operation environmental Climate conditions for operation class 3K3:

specifications
• Temperature range: 0°C to +40°C
(IEC 60721-3-3, EN50178)
Degree of pollution Pollution conditions for operation class PD2

(IEC 61010, EN50178)
Corrosive levels Corrosive levels for storage, transport and operation Class
3C2(3):
(IEC 60721-3-3)
• 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
ppm 0.3 1.0
Sulphur dioxide
cm3/m3 0.11 0.37
ppm 0.1 0.5
Hydrogen sulphide
cm3/m3 0.071 0.36
ppm 0.1 0.3
Chlorine
cm3/m3 0.034 0.1
ppm 0.1 0.5
Hydrogen chloride
cm3/m3 0.066 0.33
ppm 0.01 0.03
Hydrogen fluoride
cm3/m3 0.012 0.036
ppm 1.0 3.0
Ammonia
cm3/m3 1.4 4.2
ppm 0.05 0.1
Ozone
cm3/m3 0.025 0.05
ppm 0.5 1.0
Nitrogen oxides
cm3/m3 0.26 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
Maintenance tasks should only be performed by trained and skilled personnel to
avoid damages to the unit or injuries of personnel.
CAUTION
Warning
Changing of wear parts may cause malfunction of device and can cause injuries
of personnel if not properly performed.
WARNING
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.
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: apac-pqservice@schaffner.com
Service E-mail for EMEA: emea-pqservice@schaffner.com
Service E-mail for India: india-pqservice@schaffner.com
Service E-mail for USA: usa-pqservice@schaffner.com
5 POWER MODULE 380VAC-415/480VAC 3-/4-WIRE

5.1 Maintenance schedule
Year after start
operation
1 2 3 4 5 6 7 8 9 10 11 12
Maintenance job
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 / Description Part # Classification
filter
AHF FAN SET GEN II SP

1x 818217 Wear part
(Set includes 3 fans)
AHF FUSE 6.3X32MM 1A 1000V GEN II SP

1x 818208 Wear part
(Set includes 2 fuses)
AHF FUSE5X20 3.15A 1000V GEN II SP

1x 818210 Wear part
(Set includes 3 fuses)
1x AHF COIN CELL BATTERY 3V GEN II SP 818213 Wear part
Table 2: Wear parts

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. 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
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

driver and remove the back plate

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
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 cable

Middle fan → Middle cable
Left 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
5.3.2 Replace fans 1 to 3

5.3.2.1 Tool List

2. Torque wrench
5. Pliers set
example Fluke 175)
5.3.2.2 Spare parts
Spare part
818217 AHF FAN SET GEN II SP
Attention!
Different cable length



the front plate

driver and a 7 mm flat wrench and remove the
fans and fan guards
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


cable plugs
Attention!
the right sequence:



socket, with 9.5 Nm
5.3.3 Replace PDB board fuses F100, F101 & F102

5.3.3.1 Tool List

2. Torque wrench
5. Pliers set
example Fluke 175)
5.3.3.2 Spare parts
Spare part
818210 AHF FUSE5X20 3.15A 1000V GEN II

SP



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

3.0 Nm
5.3.4 Replace PDC board fuses F701 & F705

5.3.4.1 Tool List

2. Torque wrench
5. Pliers set
example Fluke 175)
5.3.4.2 Spare parts
Spare part
818208 AHF FUSE 6.3X32MM 1A 1000V

GEN II SP



the front plate
Replace the two PDC fuses

cable plugs
Attention!
the right sequence:



socket, with 9.5 Nm
5.3.5 Replace control board battery

5.3.5.1 Tool List

2. Torque wrench
5. Pliers set
example Fluke 175)
5.3.5.2 Spare parts
Spare part
818213 AHF COIN CELL BATTERY 3V GEN

II SP


Replace the control board battery

Mount the top cover and tighten the 13 screws

3.0 Nm
Schaffner Group Schaffner Service Centers
Nordstrasse 11
4542 Luterbach
APAC
Switzerland Schaffner EMC Ltd. Shanghai
T20-3, No 565 Chuangye Road
T +41 32 681 66 26 Pudong New Area
F +41 32 681 66 30 Shanghai 201201
China
info@schaffner.com EMEA
www.schaffner.com 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
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.

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Maintenance Manual

Ecosine active sync

Schaﬀner Group | Nordstrasse 11 | 4542 Luterbach | Switzerland

Revision: 01 (March 2018)

Revision Date Description

1.2 Additional Resources

2 General Safety Notes and Installation Guidelines

3 Environmental Conditions / Exclusion of warranty

Products FN3540/41 series, 3/4-wire filters, models 60A

Overvoltage class Ecosine active sync are designed according to EN 50178

Storage environmental Climate conditions for storage class 1K3:

Transportation Climate conditions for transport class 2K3:

Operation environmental Climate conditions for operation class 3K3:

Degree of pollution Pollution conditions for operation class PD2

and not the entire device. The unprotected areas, such as

4.2 Who should read this guide

4.3 Personnel qualification

4.4 Get help

4.5 Get training

Service URL: www.schaffner.com/service/

5 POWER MODULE 380VAC-415/480VAC 3-/4-WIRE

Check operation, clean fans, fan

Replace PDB board fuses

Replace PDC board fuses

Replace control board battery  

Table 1: Maintenance schedule

5.2 Wear parts

AHF FAN SET GEN II SP

AHF FUSE 6.3X32MM 1A 1000V GEN II SP

AHF FUSE5X20 3.15A 1000V GEN II SP

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

Table 2: Wear parts

5.3 Maintenance instruction

CLEANING MATERIAL LIST

MAINTENANCE TOOL LIST

1. Socket wrench set

5.3.1.2 Dismantling process

Disconnect the device from the grid and check

Remove all connections from the front side

Remove the 17 screws with a torx T20 screw

Disconnect the 3 fan cable plugs and remove

Remove the 15 screws with a torx T20 screw

Remove the 7 screws with a torx T20 screw

Remove the insulation foil

Clean the air path, depending on the pollution

and from back side

Clean all other areas with compressed air

5.3.1.3 Reassembly process

Assemble the insulation foil

Mount the top cover and tighten the 7 screws

Mount the back plate and tighten the 15

Mount the front plate and connect the 3 fan

Right fan → Topmost cable

Tighten the 17 screws with a torque wrench

Connect all connections to the front side and

5.3.2 Replace fans 1 to 3

MAINTENANCE TOOL LIST

1. Socket wrench set

5.3.2.2 Spare parts

818217 AHF FAN SET GEN II SP

5.3.2.3 Dismantling process

Disconnect the device from the grid and check

Remove all connections from the front side