Maintenance Manual. Ecosine active sync. English version

Transcription

1 Maintenance Manual Ecosine active sync English version Schaffner Group Nordstrasse Luterbach Switzerland T F

2 2 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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 Document name: Maintenance Manual for FN35xx Cabinet Version history Revision Date Description 01 March 2018 Initial version

3 3 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Table of Contents 1 Introduction Purpose Additional Resources 4 2 General Safety Notes and Installation Guidelines 5 3 Environmental Conditions / Exclusion of warranty 6 4 Welcome About this manual Who should read this guide Personnel qualification Get help Get training Contact us 9 5 CABINET 380VAC-415/480VAC 3-/4-WIRE Maintenance schedule Wear parts Maintenance instruction Check operation, clean cabinet fans, fan guard of cabinet, filter pads, internal fan, fan guard of internal fan and air path Replace filter pads Spare parts Replace cabinet fans, fans Replace internal fan, fan Replace Main fuses Replace Power Supply fuses Remove Power Module from cabinet Dismantling process 34

4 4 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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.

5 5 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 2 General Safety Notes and Installation Guidelines

6 6 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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 IEC 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 Products Overvoltage class (EN50178) Storage environmental specifications (IEC , EN50178) Transportation environmental specifications (IEC , EN50178) 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. FN3540/41 series, 3/4-wire filters, models 60A FN3545 series, 3/4-wire filters, models A Ecosine active sync are designed according to EN overvoltage class III Climate conditions for storage class 1K3: Temperature range: -25 C to +55 C Relative humidity: < 95%, no condensation Atmospheric pressure: 70KPa to 106KPa Climate conditions for transport class 2K3: Temperature range: -25 C to +70 C Relative humidity: < 95%, no condensation Atmospheric pressure: 70KPa to 106KPa

7 7 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Operation environmental specifications (IEC , EN50178) Degree of pollution (IEC 61010, EN50178) Corrosive levels (IEC ) Climate conditions for operation class 3K3: Temperature range: 0 C to +40 C Relative humidity: < 95%, no condensation Atmospheric pressure: 70KPa to 106KPa Pollution conditions for operation class PD2 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 cm 3 /m Hydrogen sulphide ppm cm 3 /m Chlorine ppm cm 3 /m Hydrogen chloride ppm cm 3 /m Hydrogen fluoride ppm cm 3 /m Ammonia ppm cm 3 /m Ozone ppm cm 3 /m Nitrogen oxides ppm cm 3 /m (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 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.

8 8 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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 WARNING Caution Maintenance tasks should only be performed by trained and skilled personnel to avoid damages to the unit or injuries of personnel. 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 handson 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 9 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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 Service URL: Service for APAC: apac-pqservice@schaffner.com Service for EMEA: emea-pqservice@schaffner.com Service for India: india-pqservice@schaffner.com Service for USA: usa-pqservice@schaffner.com

10 10 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 5 CABINET 380VAC-415/480VAC 3-/4-WIRE 5.1 Maintenance schedule Maintenance job Year after start operation Check operation, clean cabinet fans, fan guard of cabinet, filter pads, internal fan, fan guard of internal fan and air path Replace filter pads Replace cabinet fans Fans 4-7 Replace internal fan Fan 8 Replace main fuses Replace Power Supply fuses F5-F7 Table 1: Maintenance schedule 5.2 Wear parts Required amount / filter Description Part # Classification 1x 1x 1x 3x (1) AHF EXHAUST FILTER PFA GEN II SP (Set includes 10 pcs.) AHF FAN 120 CABINET GEN II SP (Set includes 4 fans) AHF FAN 92 CABINET GEN II SP (Set includes 1 fan) AHF FUSE 100A 600V CABINET GEN II SP (1) 3 pcs. per installed Power Module are needed Wear part Wear part Wear part Wear part 1x AHF FUSE 10.3X38 8A 690V CABINET GEN II SP (Set includes 3 fuses) Wear part Table 2: Wear parts

11 11 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet 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 Check operation, clean cabinet fans, fan guard of cabinet, filter pads, internal fan, fan guard of internal fan and air path 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 8. Ladder Dismantling process Switch off the main switch and disconnect the device from the grid

12 12 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Open the front door Check the device for loss of voltage Remove the 2 screws on top with a torx T20 screw driver

13 13 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove the 2 screws on both sides with a torx T20 screw driver and remove the front cover Loose the two fixing screws and disconnect the cable from the main fan module Remove the 4 screws with a torx T20 screw driver and remove the main fan module

14 14 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Clean the fans Clean the air path Reassembly process Place the main fan module and tighten the 4 screws with a torque wrench and a T20 torx bit with 3.0 Nm

15 15 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Connect the cable to the main fan module and fix the two screws with 1.2 Nm Mount the front cover and tighten the 2 screws on both sides with a torque wrench and a T20 torx bit, with 3.0 Nm Tighten the 2 top screws with a torque wrench and a T20 torx bit, with 3.0 Nm

16 16 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Dismantling process Loose the two screws of the enclosure fan module plug with a long PZ screw driver and disconnect it Loose the 2 screws and remove the enclosure fan module Clean the fan and the fan guard

17 17 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Reassembly process Mount the enclosure fan module and tighten the screws Connect the plug to the enclosure fan module and fix it with a long PZ screw driver with 2.0 Nm Dismantling process Open the covers of the filter pads

18 18 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove the filter pads and clean them all with compressed air Reassembly process Place the filter pads to the covers and close them Attention! The mounting direction must be according to the guidline inside of the spare part packing

19 19 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Replace filter pads Spare parts AHF EXHAUST FILTER PFA GEN II SP Dismantling process Open the covers of the filter pads Remove the filter pads

20 20 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Reassembly process Place the filter pads to the covers and close them Attention! The mounting direction must be according to the guidline inside of the spare part packing Replace cabinet fans, fans Tool list 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 8. Ladder Spare parts AHF FAN 120 CABINET GEN II SP

21 21 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Dismantling process Switch off the main switch and disconnect the device from the grid Open the front door Check the device for loss of voltage

22 22 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove the 2 screws on top with a torx T20 screw driver Remove the 2 screws on both sides with a torx T20 screw driver and remove the front cover Loose the two fixing screws and disconnect the cable from the main fan module

23 23 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove the 4 screws with a torx T20 screw driver and remove the main fan module Remove the terminals from the rail Remove the 16 screws with a torx screw driver T20

24 24 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Reassembly process Replace the fans one by one, with connecting the cables to the terminals as before Tighten the screws with a torque wrench and a torx T20 bit, with 3.0 Nm Fix the terminals to the rail

25 25 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Place the main fan module and tighten the 4 screws with a torque wrench and a T20 torx bit with 3.0 Nm Connect the cable to the main fan module and fix the two screws with 1.2 Nm Mount the front cover and tighten the 2 screws on both sides with a torque wrench and a T20 torx bit, with 3.0 Nm

26 26 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Tighten the 2 top screws with a torque wrench and a T20 torx bit, with 3.0 Nm Replace internal fan, fan Tool List 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 8. Ladder Spare parts AHF FAN 92 CABINET GEN II SP

27 27 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Dismantling process Switch off the main switch and disconnect the device from the grid Open the front door Check the device for loss of voltage

28 28 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Loose the two screws of the enclosure fan module plug with a long PZ screw driver and disconnect it Loose the 2 screws and remove the enclosure fan module Remove the 4 screws and replace the fan

29 29 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Reassembly process Mount the enclosure fan module and tighten the screws Connect the plug to the enclosure fan module and fix it with a long PZ screw driver with 2.0 Nm Replace Main fuses Spare parts AHF FUSE 100A 600V CABINET GEN II SP

30 30 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Dismantling process Switch off the main switch and disconnect the device from the grid Open the front door Check the device for loss of voltage

31 31 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Open all fuse holder and remove them Replace the fuses Reassembly process Assemble the fuse holder carefully to all 4 guidances each side

32 32 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Close the fuse holder Replace Power Supply fuses Spare parts AHF FUSE 10.3X38 8A 690V CABINET GEN II SP Dismantling process Switch off the main switch and disconnect the device from the grid

33 33 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Open the front door Open the fuse holder and replace the 3 fuses Reassembly process Close the fuse holder

34 34 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove Power Module from cabinet Tool list 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 SPECIAL TOOL LIST 1. Load lifter Schaffner order number Dismantling process Switch off the main switch and disconnect the device from the grid

35 35 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Open the front door Check the device for loss of voltage Remove all connections from the front side

36 36 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Remove the 8 power module fixing screws with a socket wrench and a 10 mm nut Place the load lifter under the power module you want to remove Move the power module out of the cabinet, put it on a table and start the maintenance according to the maintenance instruction for the power module

37 37 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Reassembly process Put the power module on the load lifter, place it in front of the cabinet and adjust the hight Slide the power module into the cabinet Fix the power module with the 8 fixing screws and tighten it with a socket wrench and a 10 mm nut with 4.2 Nm

38 38 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Connect all connections to the power module, tighten 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 Continue with the next power module until all assembled power modules are maintained

39 39 Ecosine active Harmonic Filters Maintenance Manual for FN35xx Cabinet Schaffner Group Nordstrasse Luterbach Switzerland T F Schaffner Service Centers APAC Schaffner EMC Ltd. Shanghai T20-3, No 565 Chuangye Road Pudong New Area Shanghai China info@schaffner.com EMEA Schaffner EMC S.A.S. Rue du Luxembourg Wittelsheim France India Schaffner India Pvt. Ltd ShriNivas 26, 2nd Street, Kasthuri Nagar Extension, Ondipudur, Coimbatore Tamil Nadu India North America Schaffner EMC Inc. 52 Mayfield Avenue Edison New Jersey United State of America To find your local partner within Schaffner s global network, please go to 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.