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ecosine? july 2008 ecosine? advanced passive harmonic filters www.myecosine.com
ecosine? schaffner group schaffner is the international leader in the fields of electromagnetic compatibility and power quality, supplying components that support the efficient and reliable use of electric energy. customers benefit from the techno- logical know-how of the schaffner group in the development, manufacturing and marketing of high-performance products that offer optimized and fault-free operation and compliance with all major quality and performance standards. with its products and services, the schaffner group plays a key role in promoting technologies that support renewable energies, ensures the reliable functioning of electronic equipment and systems and meets the requirements for greater energy efficiency. a global one-stop shop emc filters C pcb filters C iec inlet filters C single-phase filters C three-phase filters C three-phase + neutral line filters C open frame filters rfi suppression chokes feedthrough filters and capacitors automotive components customized solutions power quality C line reactors C dv/dt reactors and filters C sine wave filters C harmonic filters C regen reactors and filters C transformers customized solutions
3 ecosine? ecosine? filters calm your harmonic waves. schaffner ecosine? filters can be applied to virtually any kind of power electronics with front-end six-pulse rectifiers, where harmonic current distortion needs to be reduced to defined limits. typical applications, where the above-mentioned non-sinusoidal consumers of power can account for a significant portion of the load, include: a better way to power quality 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 electric installations, help utilize electric system capacity better, and are the key to meet power quality standards such as ieee 59. schaffner ecosine? harmonic filters provide: efficient mitigation of harmonic currents. compliance with ieee 519 and other power quality standards. increased equipment service life and system reliability in mission-critical applications. more efficient utilization of electric system capacity (e.g. distribution transformers). long-term savings in system operation and maintenance cost. support energy savings. fast and simple plug-and-play operation. very compact and light-weight filter concept. seamless integration with previously installed dc chokes or emi filters. equipment with front-end six-pulse rectifier ac and dc motor drives factory automation equipment ups and three-phase power supplies water/wastewater treatment facilities oil and gas exploration heavy industry and machinery self-contained systems (e.g. ships) electronic welders battery chargers hvac installations mission-critical processes
ecosine? harmonics are a serious problem 4 power quality in times of blackouts and brownouts. power quality has become the buzzword of entire industries. while definitions diverge, nobody disputes its importance and the consequences of poor power quality. often, electric utilities end up in the line of fire of frustrated customers. however, many disturbances C like electromagnetic interferences or harmonics C are not attributable to the utility company, but to the user of the electric power supply and the nature of the connected loads. creation of harmonic currents and voltages. modern consumers of power, such as variable speed drives for motor controls, switch-mode power supplies in home electronics, or ballasts in fluorescent lamps, significantly contribute to energy saving and a more efficient use of electricity. however, the nature of their operation causes a non-sinusoidal current to be drawn from the grid. this non- sinusoidal current consists of the fundamental 50 or 60hz wave and its integer multiples, the harmonics. harmonic currents flow through system impedances, transformers, reactors etc., and cause harmonic voltages. as a result, the supply voltage of other consumers connected to the same branch of the grid is distorted, raising questions about equipment service life, function, and reliability. non-linear load (six-pulse recti?er) rl 1 rl 2 rl 3 ll3 ll1 ll 2 line impedance vl1 vl2 vl3 power source power line r load r es r c out voltage distortions: propagate throughout the system and affect sensitive loads current distortions: overload the electric infrastructure, affect power lines and equipment vo ltage (phase-neutral ) curren t
5 ecosine? harmonics are a serious problem
ecosine? harmonics have a serious impact. harmonics reduce system efficiency and waste precious energy. harmonic currents overload and overheat electric installations, distribution transformers, breakers, fuses, conductors etc. they cause premature system ageing or generate the requirement for an increase in electric system capacity. harmonics overload capacitor banks in var compensation equipment and cause malfunctions in electronic controls, disturbances in sensitive medical devices, or crashes in communication networks. financial consequences. unfortunately, harmonics mitigation is considered an expensive nuisance. very often it is not budgeted for in the planning phase of a project. however, the decision to ignore this issue can potentially lead to a much more substantial cost impact. the capacity of electric installations may have to be increased. equipment may fail prematurely. disturbances may cause production downtime. utility companies may even issue power quality violation penalties to the point where an entire factory has to be temporarily disconnected from the grid.
ecosine? international requirements. international power quality standards such as ieee 519- 1992, en 61000-3-12, en 50160, en 12015, g5/4 or as 2279 define C among many other things C distortion limits and recommend harmonics mitigation practices. ieee 519-1992 is probably the most widely accepted set of recommendations that defines maximum permissible current and voltage distortion percentages at the point of common coupling (pcc) under full load conditions. the applicable limit depends upon the system loading parameters, i.e. the relation between the maxi - mum short circuit current (i sc ) and the maximum demand load current (i l ) at the pcc. ieee 5 9- 992 current distortion limits [%] harmonic order (odd harmonics) i sc /i l tdd < h< h<23 23h<35 35h <20 5.0 4.0 2.0 1.5 0.6 0.3 20<50 8.0 7.0 3.5 2.5 1.0 0.5 50<100 12.0 10.0 4.5 4.0 1.5 0.7 100<1000 15.0 12.0 5.5 5.0 2.0 1.0 >1000 20.0 15.0 7.0 6.0 2.5 1.4 maximum harmonic current distortion in percent of i l (even harmonics are limited to 25% of the odd harmonic limits above). ieee 5 9- 992 voltage distortion limits [%] please consult the published standards or local utility codes for more details about your individual harmonics mitigation requirements. special applications (hospitals, airports) 3 general systems applications 5 dedicated systems (100% non-linear loads) 10
ecosine? ecosine? C getting a grip on harmonics reliable harmonics mitigation. the best place to eliminate harmonics is right at their source, i.e. at the individual non-linear load. only then can the propagation of harmonic currents and voltages throughout the system be avoided. schaffner ecosine? filters are uniquely able to master this challenge. they provide a low impedance path for harmonic currents required by the rectifier, thus significantly reducing the amount of harmonics flowing through the electric distribution system. as a result, the non-linear load virtually draws a sinusoidal current from the grid. in a typical motor drive system, the total harmonic current distortion (thid) is reduced to well below 8% at any load condition, and to <5% at full load. compliance with the toughest total demand distortion (tdd) levels according to table 10-3 of ieee 519 is therefore ensured. high performance C not only at full load. often manufacturers promote filter perfor - mance only at full load because light load conditions can be a challenge in terms of both harmonics mitigation and capacitive current. schaffner ecosine? filters not only guarantee the thid rating of 8% maximum over the entire load range, but also limit the amount of capacitive current in all conditions. an external capacitor disconnect switch can easily be installed, if capacitive current under light load conditions has to be suppressed. you can obtain more information on this subject from the schaffner ecosine? application note. load [%] z line = 0.2% z line = 3.0% 8 7 6 5 4 3 2 1 0 0 20 40 60 80 100 120 140 160 thid [% ] load [%] z line = 0.2 to 3.0% 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0 20 40 60 80 100 120 140 160 cos (phi)
9 ecosine? ecosine? C getting a grip on harmonics cost and energy savings. schaffner ecosine? filters reduce harmonics and ensure that a clean sinusoidal current is drawn from the grid. both true rms and peak current are reduced in the process, thus lowering the burden on the electric installation. transformers, conductors, fuses, breakers etc. experience less electric and ther - mal stress, and can therefore be downsized already in the planning phase. in an existing installation, the capacity of the distribution transformer can be utilized more efficiently, and more electric consumers (e.g. motor drives) can be operated without investments in electric system upgrades. current voltage (phase-neutral) voltage (phase-neutral) current without schaffner ecosine? with schaffner ecosine? current current i in a rms (for power 5.5kw) i in .5a rms (for power 5.5kw) thid 92 % (for r sce 50) thid 4.0 % pwhd 3 % pwhd 5.2 % individual harmonics 5th C 4 % individual harmonics 5th C 2.0 % th C 5 % th C 2.2 % th C 3 % th C 2.0 % 3th C 5 % 3th C .4 % voltage voltage u in 40v rms (phase-phase) u in 40v rms (phase-phase) thvd 4.4 % (for i sc /i l 50) thvd 0.2 % (for i sc /i l 50) example with 5.5kw drive linke seite conductor size with ecosine tm without ecosine tm amp rating of breaker s, fuse s, etc . n o. of drives on given transformer 65% 100% 65% 100% 150% 100% linke seite conductor size with ecosine tm without ecosine tm amp rating of breaker s, fuse s, etc . n o. of drives on given transformer 65% 100% 65% 100% 150% 100% linke seite conductor size with ecosine tm without ecosine tm amp rating of breaker s, fuse s, etc . n o. of drives on given transformer 65% 100% 65% 100% 150% 100% ecosine? 9
ecosine? 0 equipment longevity, reliable production uptime. because of their unique design, ecosine? filters add impedance to the supply, thus providing all the benefits of traditional schaffner ac line reactors. in motor drive applications, for example, they eliminate nuisance tripping, and protect the rectifier and dc-link capacitors from mains transients. longer equipment service life and reliable operation of mission-critical applications reduce cost of ownership and help safeguard profits. simply plug-and-play. schaffner ecosine? filters are black boxes with three input and three output connectors. they can easily be incorporated into existing designs without requiring an in-depth system analysis or highly trained specialists. ecosine? filters do not attract harmonics from other parts of the system and do not cause system resonances. they have been designed to operate smoothly with dc-link chokes and emi filters installed in the same system. a superior inductor design and advanced thermal management result in the most compact filter package on the market today. where traditional harmonics mitiga - tion approaches require large standalone cabinets, the compact and light-weight design of ecosine? allows for filter integration right in the electric cabinet next to the motor drive. straightforward filter selection. schaffner ecosine? filters are available for 50hz (fn 3410 series) and 60hz (fn 3412 series) power grids. the ideal filter can easily be selected by determining the actual total power rating of the load (e.g. motor drive) to be connected to the filter. alternatively, the filter can also be selected by the total specified motor drive input current (arms) before filter ins tallation. it is important to avoid over-specification of the filter because it operates best close to full load.
ecosine? two or more filters can be paralleled in case the total input power of a given load exceeds the largest available product. please consult the schaffner ecosine? application note for more details about filter selection, installation, and application. mains ecosin e non-linear load 1: 30kw/400v ac non-linear load 2: 75kw/400v ac fn 3410-210-40 (110kw/400v ac ) main s ecosine ecosine non-linear load : 300kw/500v ac 2x fn 3410-260-99 (2x 160kw/500v ac ) mains ecosin e non-linear load 1: 30kw/400v ac non-linear load 2: 75kw/400v ac fn 3410-210-40 (110kw/400v ac ) main s ecosine ecosine non-linear load : 300kw/500v ac 2x fn 3410-260-99 (2x 160kw/500v ac ) ecosine? filters are designed to be installed at the individual non-linear load. however, they can also reduce harmonics for multiple loads in parallel. if multiple loads are connected to one filter, the filter needs to be matched to the total resulting input power.
ecosine? typical electrical schematic filter* rated load power rated load power filter efficiency input/output capacitor weight @ 400vac/50hz @ 500vac/50hz @ 25c/50hz connections disconnections [kw] [kw] [%] [kg] filter selection table fn 3410-10-44 4 5.5 98.5 C44 C44 13 fn 3410-13-44 5.5 7.5 98.5 C44 C44 14 fn 3410-16-44 7.5 11 98.5 C44 C44 21 fn 3410-24-33 11 15 98.5 C33 C44 27 fn 3410-32-33 15 18.5 98.5 C33 C44 31 fn 3410-38-33 18.5 22 98.6 C33 C44 35 fn 3410-45-34 22 30 98.7 C34 C33 45 fn 3410-60-34 30 37 98.8 C34 C33 54 fn 3410-75-35 37 45 98.9 C35 C34 65 fn 3410-90-35 45 55 99.0 C35 C34 77 fn 3410-110-35 55 75 99.1 C35 C34 86 fn 3410-150-40 75 90 99.2 C40 C35 118 fn 3410-180-40 90 110 99.3 C40 C35 136 fn 3410-210-40 110 132 99.3 C40 C35 154 fn 3410-260-99 132 160 99.4 C99 C35 201 * filter to be selected by system voltage and load (motor drive) power. note: the harmonic filter will reduce the rms input current. example: the rated rms input current of an unfiltered 400v/15kw/32a drive will be reduced to approximately 23a. therefore, filter selection by current rating, as it is common for emi filters, is not suitable. technical specifications nominal operating voltage: 3x 380 to 500vac voltage tolerance range: 3x 342 to 550vac operating frequency: 50hz 1hz nominal motor drive input current rating*: 10 to 260a @ 50c nominal motor drive input power rating: 4 to 160kw total harmonic current distortion thid**: <5% @ rated power total demand distortion tdd: according to ieee-519, table 10-3 efficiency: >98.5% @ nominal line voltage and power high potential test voltage: p C> e 2500vac (1min) protection category: ip20 / nema1 cooling: internal fan cooling overload capability: 1.6x rated current for 1 minute, once per hour ambient temperature range: C25c to +50c fully operational +50c to +70c derated operation*** C25c to +85c transport and storage flammability corresponding to: ul 94v-2 or better design corresponding to: ul 508, en 61558-2-20, ce (lvd 2006/95/ec) mtbf @ 50c/500v (mil-hb-217f): 200,000 hours * ecosine filters reduce rms input and peak current by reducing harmonic currents and improving true power factor. ** system requirements: thvd < 2%, line voltage unbalance < 1% *** i derated = i nominal * (85c-t amb )/35c 2 ecosine? fn 34 0 C filters for 50hz systems line power capacitors tr ap choke in-out choke power supply fa n control error red pe l3 l2 l1 l3' nc c l2' l1' a1 b1 c1 a2 b2 c2 yellow green led coolin g p ower on disconnect load monitor eut emi eut emi equipment under test emi receiver gp ground plane height variable 1 - 4m gp direct wave ground reflected wave
ecosine? 3 typical electrical schematic nominal operating voltage: 3x 440 to 480vac voltage tolerance range: 3x 396 to 528vac operating frequency: 60hz 1hz nominal motor drive input current rating*: 8 to 310a @ 50c nominal motor drive input power rating: 5 to 250hp total harmonic current distortion thid**: <5 % @ rated power total demand distortion tdd: according to ieee-519, table 10-3 efficiency: >98.5 % @ nominal line voltage and power high potential test voltage: p C> e 2500vac (1min) protection category: nema1 / ip20 cooling: internal fan cooling overload capability: 1.6x rated current for 1 minute, once per hour ambient temperature range: C25c to +50c fully operational +50c to +70c derated operation*** C25c to +85c transport and storage flammability corresponding to: ul 94v-2 or better design corresponding to: ul 508, en 61558-2-20, ce (lvd 2006/95/ec) mtbf @ 50c/460v (mil-hb-217f): 200,000 hours * ecosine filters reduce rms input and peak current by reducing harmonic currents and improving true power factor. ** system requirements: thvd < 2%, line voltage unbalance < 1% *** i derated = i nominal * (85c-t amb )/35c ecosine? fn 34 2 C filters for 0hz systems technical specifications filter* rated load power filter efficiency input/output capacitor weight @ 4 0vac/0hz @ 25c/0hz connections disconnections [hp] [%] [kg] filter selection table fn 3412-8-44 5 98.5 C44 C44 12 fn 3412-11-44 7.5 98.5 C44 C44 13 fn 3412-15-44 10 98.5 C44 C44 17 fn 3412-21-44 15 98.5 C44 C44 21 fn 3412-28-33 20 98.6 C33 C44 28 fn 3412-35-33 25 98.6 C33 C44 32 fn 3412-41-33 30 98.7 C33 C44 35 fn 3412-53-34 40 98.9 C34 C33 48 fn 3412-65-34 50 99.0 C34 C33 52 fn 3412-80-35 60 99.1 C35 C34 69 fn 3412-105-35 75 99.2 C35 C34 77 fn 3412-130-35 100 99.3 C35 C34 87 fn 3412-160-40 125 99.4 C40 C35 124 fn 3412-190-40 150 99.4 C40 C35 132 fn 3412-240-99 200 99.5 C99 C35 185 fn 3412-310-99 250 99.5 C99 -35 202 * filter to be selected by system voltage and load (motor drive) power. note: the harmonic filter will reduce the rms input current. example: the rated rms input current of an unfiltered 460v/20hp/28a drive will be reduced to approximately 20a. therefore, filter selection by current rating, as it is common for emi filters, is not suitable. line power capacitors tr ap choke in-out choke power supply fa n control error red pe l3 l2 l1 l3' nc c l2' l1' a1 b1 c1 a2 b2 c2 yellow green led coolin g p ower on disconnect load monitor eut emi eut emi equipment under test emi receiver gp ground plane height variable 1 - 4m gp direct wave ground reflected wave
ecosine? mechanical data fn 3410 - 10 to - 1 10 fn 3412-8 to - 130 b f g c e a j fn 3410 - 150 to -210 fn 3412 - 160 and - 190 fn 3410-260 fn 3412-240 and -310 installation. all filters from fn 341x-8 to -130 are wall mountable and have to be operated vertically. the filters fn 341x-150 and higher are designed for floor mounting. in order to allow for sufficient air flow all filters must be clear on top and bottom min. 150mm. b g f e c a j w z v x y ecosine? j a f e g b c 4
ecosine? 5 all dimensions in mm; 1 inch = 25.4mm tolerances according: iso 2768-m / en 22768-m fn 340-... 0 3 24 32 3 45 0 5 90 0 50 0 20 20 fn 342-... 5 2 2 35 4 53 5 0 05 30 0 90 240 30 dimensions a 400 400 430 430 520 520 520 590 590 750 750 750 1000 1000 1000 1000 1000 b 170 170 210 210 250 250 250 300 300 320 320 320 500 500 500 500 500 c 190 190 210 210 280 280 280 300 300 300 300 300 500 500 500 500 500 e 380 380 410 410 495 495 495 565 565 725 725 725 240 240 240 240 240 f 130 130 170 170 200 200 200 240 240 270 270 270 336 336 336 336 336 g 7 7 9 9 11 11 11 11 11 11 11 11 14x30 14x30 14x30 14x30 14x30 j m6 m6 m6 m6 m8 m8 m8 m8 m8 m10 m10 m10 m10 m10 m10 m10 m10 v 25 25 w 6 6 x 12.5 12.5 y 40 40 z 11 11 C33 C34 C35 C40 C44 filter connector cross sections solid wire 16mm 2 35mm 2 50mm 2 95mm 2 10mm 2 flex wire 10mm 2 25mm 2 50mm 2 95mm 2 6mm 2 awg type wire awg 6 awg 2 awg 1/0 awg 4/0 awg 8 recommended torque 1.5 C 1.8nm 4.0 C 4.5nm 7 C 8nm 17 C 20nm 1.0 C 1.2nm please visit www.schaffner.com to find more details on filter connectors. schaffner C more than just filters. schaffner ecosine? standard filters are available for different supply networks throughout the world. they are ul approved, ce marked, and fulfill the requirements of the low voltage directive. a large selec - tion of power, current, voltage and frequency ratings leaves the choice of filter up to the user. however, there are always occasions where different electric or mechanical requirements exist, or where more than just products are needed for the job at hand. schaffner is in the unique position of being able to support the user with problem analysis, engineering advice, testing and measurement support, custom products, and a worldwide customer service organisation. our goal is to ensure that you obtain the level of harmonics mitigation you actually need C guaranteed. please contact your local schaffner partner for comprehensive support. more information can also be obtained from the schaffner ecosine? application note.
headquarters schaffner emv ag 4542 luterbach switzerland t +41 32 681 66 26 f +41 32 681 66 41 sales@schaffner.com www.schaffner.com china schaffner emc ltd. shanghai t +86 21 6813 9855 cschina@schaffner.com finland schaffner oy t +358 19 357 271 fnlandsales@schaffner.com france schaffner emc s.a.s. t +33 1 34 34 30 60 francesales@schaffner.com germany schaffner emv gmbh t +49 721 56910 germanysales@schaffner.com schaffner jacke gmbh t +49 2951 6001 0 buerensales@schaffner.com italy schaffner emc s.r.l. t +39 02 66 04 30 45 italysales@schaffner.com japan schaffner emc k.k. t +81 3 5456 0180 japansales@schaffner.com singapore schaffner emc pte ltd. t +65 6377 3283 singaporesales@schaffner.com sweden schaffner emc ab t +46 8 5792 1121 swedensales@schaffner.com switzerland schaffner emv ag t +41 32 681 66 26 sales@schaffner.ch taiwan schaffner emv ltd. t +886 2 87525050 taiwansales@schaffner.com thailand schaffner emc co. ltd. t +66 53 58 11 04 thailandsales@schaffner.com uk schaffner ltd. t +44 118 9770070 uksales@schaffner.com usa schaffner emc inc. t +1 732 225 9533 toll free 1 800 367 5566 usasales@schaffner.com to fnd your local partner within schaffner's global network, please go to www.schaffner.com 690-888b druckerei ag suhr july 2008 ? 2008 schaffner emc. specifcations are subject to change without notice. the latest version of the data sheets can be obtained from the website. all trademarks recognized. schaffner is an iso-registered company. its products are designed and manufac- tured under the strict quality and environ- mental requirements of the iso 9001 and iso 14001 standards. this document has been carefully checked. however, schaffner does not assume any liability for errors or inaccuracies.

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