Application Note Sine wave filter solutions for

motor drive applications

1
Note: This document is in Content
tended to support designers,
installers, and application
engineers with sine wave 1. Technical background 3
filter selection, installation,
application and maintenance 2. Motor drives output phenomena 4
in motor drives applications. 2.1 Excessive dv/dt 4
2.2. Peak- and overvoltage 5
In order to get the maximum 2.3 Additional losses in the motor 6
benefit out of the Schaffner 2.4 Cable shields and parasitic earth currents 6
filters, please also consult 2.5 HF electromagnetic noise in the motor cable 7
Basics in EMC and Power 2.6 Bearing currents 8
Quality, published in 2.7 Acoustic motor noise 9
the download section of
www.schaffner.com. 3. Output filter solutions for motor drives 10
These additional guidelines 3.1 dv/dt reactor 10
provide helpful hints for HF- 3.2 dv/dt filter 11
grounding, shielding, prop 3.3 Sine wave filter 12
er cable routing including a 3.3.1 Symmetrical sine wave filter 13
chapter Output solutions for 3.3.2 Sinus plus symmetrical and asymmetrical sine wave filter 14
motor drives.
4. Sine wave filter selection 16
Schaffner will not assume 4.1 Current and voltage rating 16
liability for any consequential 4.2 Frequency 17
downtimes or damages 4.3 Required drives settings 18
resulting from use or appli 4.4 Voltage drop considerations 20
cation of this document and/
or installation of Schaffners 5. Application examples 21
or any other sine wave filter. 5.1 Motor drive with long motor cable 21
5.2 Motor drive with multiple motors in parallel 21
5.3 Retrofit installations with motor drives 21
5.4 LV motor drive with MV-motor/ 22
step-down/step-up transformer application

6. Mounting and installation guidelines 22

6.1 Important safety considerations 22
6.2 General application notes 23
6.3 General installation notes 24
6.4 Mechanical mounting 25
6.5 Wiring and cabling 25

2
 1. Technical background

Whenever electricity is used to drive an equipment, in particular when a

motor drive is controlling the speed of an electric motor special attention
of the noises generated by the motor drives need to be taken into consid-
erations along the entire electric power line from the source to the load.

This guideline is intended to describe why and when to use which type of
motor drive output filter. Nevertheless, following overall view of the noise
potential around the motor drive, which can cause equipment to malfunc-
tion or be damaged, is shown as follow:

Overview of noise potential around a motor drive

For cancellation of the unwanted noises and fulfilment of the norms on

the line side, Schaffner offers a complete range of EMC filter and harmonic
filter solutions for any applications, enabling cost effective standard and
customized solutions to cancel or reduce the voltage and current noises
to the levels required.

For 3-Phase motor drive applications, following filter combinations are ap-
propriate to be considered:

In this application and selection guide the output filters and in particular
the sine wave filters will be described in detail.

3
 Motor drives (frequency inverters) are among the most widely used pieces
of equipment for AC motor control. Nowadays, they are found in virtually
every area of industry, in applications as diverse as pumps, air conditioning
systems, elevators and cranes, conveyors, machine tools, renewable elec-
tricity production and in a vast array of other industrial and domestic auto-
mation. In the quest for ultra-compact, efficient power conversion, motor
drive manufacturers employ high-speed semiconductor (IGBT ) switches
and pulse width modulation (PWM) techniques to generate fast rise time
voltage pulses of the appropriate duration and polarity. Unfortunately, this
creates a considerable number of problems for OEMs and system integra-
tors, from purely functional difficulties to very severe motor damage. Here
is a brief summary of the most significant problems and phenomena:

Motor drive input: Motor drive output:

EMC problems Excessive dv/dt
Harmonics Peak and overvoltage
Commutation notches Parasitic earth currents
Inrush & peak currents Eddy current losses in the motor
Low-frequency interference Displacement currents in the coils
Motor drive DC link: Bearing currents
DC link capacitor stress Additional inverter pulse loads
Harmonics Acoustic motor noise
Other interference problems EMC problems

Whole system:
Low efficiency/low power factor
Uncertain system immunity
Unacceptable interference emissions
Uncertain service security & reliability

2. Motor drives output phenomena/influence

Motor drives are known sources of interference and are therefore usually
equipped with an input filter. However, the problems generated on the
output side of the motor drives where the converter supplies the motor
with a modulated rectangular PWM signal (a switching frequency depen-
dent series of trapezoidal pulses with variable width) have to be taken into
additional consideration as described in following chapters.

2.1 Excessive dv/dt voltage

To keep the losses in the frequency converter low, the aim is to keep the
switching times of the power semiconductors as short as possible. The re-
sult of this is that with the newest generation of IGBTs, rise times of some-
times more than 12 kV/us can be measured, whereas depending on the
motor a dv/dt of around 1000 V/us is considered permissible. The IEC
60034-17 standard does define the voltage peak limits in relation to the rise

4
 time for general purpose 500 VAC motors when fed by motor drives and
IEC 60034-25 specifies the limits for motor drive rated 500 VAC and 690 VAC
motors. For US applications the NEMA MG1 standard shows the limit for
definite purpose motor drive fed motors.

dv
t t

dt

Definition of dv/dt: PWM-Signal and single pulse at the inverter output

In the case of short motor cables (up to about 20 m), these rise times ow-
ing to the small line impedance act fully on the insulation of the motor
windings. Depending on the structure of the motor coils, wires that carry
the full voltage are situated immediately in parallel and next to each other.
Since even very short parallel-laid wires have a capacitive action, the per-
manent potential jumps result in pole reversal losses across the winding
insulation. Now, if the enamel insulation is impure even to a very minor
extent, this results in hot-spots, and hence, sooner or later, to a destruction
of the winding insulation. In any case, this dv/dt stress leads to premature
aging and thus to a reduction in the life of the motor, in particular when an
older motor is fed by a motor drive.

2.2 Peak- and overvoltage

Voltage overshoots and voltage peaks can come with high dv/dt values
but are also a problem on their own. Due to the structure of the windings, a
motor acts like a capacitor in the equivalent circuit diagram owing to the
fast voltage pulses of the switching frequency and not as an inductance,
as is the case in normal 50 Hz applications. With every additional meter of
motor cable, more wire inductance is added to this structure. This induc-
tance acts like a choke according to the energy storage principle. If chokes
are subject to voltage pulses, voltage peaks occur every time switching
on or off takes place. The higher the energy content (inductance) of the
choke, the higher these voltage peaks become. In other words, the longer
the motor cable, the higher the maximum voltage amplitudes.

VInv.
t

VInv. VMot.
VMot.

Inverter Motor cable Motor

10m cable / 100m cable

Simplified equivalent circuit diagram of shielded cables (only 2 phases are

shown) and theoretical single pulse at 10 m and at 100 m motor cable length

5
 These amplitudes can, in turn, reach values that cause a stress situation in
the winding insulation of the connected motor. Owing to the cable im-
pedance, the dv/dt stress in the case of longer motor cables is reduced
to less problematical values. On the basis of the line theory, however, peak
values of 1600 V or more (depending on the DC link voltage) can occur due
to cable reflections, which can have very steep dv/dt values. According to
IEC 60034, peak values of around 1000 V are recommended. In cases the
resulting voltage peak and rise time exceed the standard limits an output
filter should be used for protecting the motor winding insulation. Despite
the reduced dv/dt owing to the cable impedance, there is no significant
stress relief for the motor, since now the increased voltage amplitudes rep-
resent the dominant stress factor.

2.3 Additional losses in the motor

Apart from protecting the winding insulation against unacceptable voltage
peaks, the steep switching edges create another phenomenon of harmon-
ics of the output signal. By applying Fourier analysis, it can be mathemati-
cally proven that the harmonic spectrum of the motor currents becomes
wider with the steepness of the pulses which means that the harmonic
content increases. The current ripple (PWM and harmonics) results in ad-
ditional magnetic losses in the motor. The life of the motor is sensitively
shortened owing to the permanently increased operating temperature.

2.4 Cable shields and parasitic earth currents

From the standpoint of EMI suppression, shielded motor cables are re-
quired to avoid back-coupling of radiated interference to the mains cable
in the frequency range from about 1 to 30 MHz. This measure of the EMC
can, however, only be considered to be efficient if the ends of the cable
shield of the motor cable are put in contact with the ground of the motor
and the frequency converter if possible, at HF low impedance and over
as large an area as possible. This ensures that the interference currents can
mostly flow back to the source by the shortest route. Frequency convert-
ers normally work in grounded networks and do not have any potential
separation. The geometric expansion of the frequency converter, motor
and this shielded motor cable therefore form parasitic capacitances of the
electrically conducting components with respect to the ground potential.
If the available DC voltage is chopped in the frequency converter, then
during the potential jumps of the voltage, considerable pulse currents flow
across the parasitic capacitances to the earth. The level of the interference
currents on the cable shield depends on the dv/dt as well as the value
of the parasitic capacitances (I = C * dv/dt). With a motor cable length of
about 100 m, peak values of the pulse currents of 20 amperes and more are
not unusual, regardless of the power rating class of the drive.

The harmonic spectrum of these currents can reach a range of several

MHz. The shield of the motor cable, owing to the existing braiding, offers a
very large surface area and a sufficient cross-section to carry these currents.
As a result, the impedance of the shield across a broad frequency range is
of a very low-impedance nature. Losses due to the skin effect are limited
to a minimum because of the large surface area. Inadequate ground con-
nections of the cable shield (the so-called pigtails), on the other hand,
are highly resistive for the frequency range under consideration and often
nullify the desired shielding effect.

6
 If there are parallel-laid control cables or electronic components in the vi-
cinity of the motor cables, pulsed HF currents flow across their geometric
expansion and the resultant parasitic capacitances, which in turn could
have an impermissible influence on neighbouring equipment through ca-
pacitive coupling.

If neighbouring components are located in the immediate vicinity of the

motor cable, the conductor loops and the high di/dt values of the shield
currents also result in a magnetic coupling that can also lead to impermis-
sible influencing.

Parasitic capacitances in a drive system

The currents flowing across the shield must be supplied by the frequency
converter as well. They are not dependent on the rating of the drive but
only on the geometric expansion of the structure. With small power rat-
ings, the result of this, especially in case of long motor cables, can be that a
frequency converter of the next higher rating has to be used that is able to
supply both the currents required by the load and the parasitic currents
via the earthing. The operation of several motors connected in parallel on
one frequency converter is problematic. The parallel connection of several
shielded cables results in a relatively high total capacitance and thus cor-
respondingly high shield currents. The parallel connection of several drives,
however, is accompanied by even more issues to be solved. Parasitic cur-
rents across the motor and the installation can considerably affect the re
liability of the entire system.

>>> refer also application examples in chapter 5

2.5 HF electromagnetic noise in the motor cable

The high frequency noise is caused by the switching frequency of the
semiconductors. The source occurs due to the pulse voltage overshoot at
the motor terminal. With the use of a dv/dt filter the frequency of the ring-
ing oscillation is only reduced below 150 kHz compared with a sine wave
filter eliminating the pulse voltage overshoot completely by feeding the
motor with a sine wave phase-to-phase voltage.

7
 The noise coupling between the unshielded motor cable with the line ca-
ble or other sensitive cables (sensors, encoder etc.) can be reduced when
using sine wave filters in combination with EMC line filters.

Line conducted noise without (left) and with sine wave filter (right)

2.6 Bearing currents

A general distinction has to be made between two different physical oc-
currences:

The shaft voltage (or rotor voltage) is an inductive voltage that is induced
in the motor shaft owing to the differences in the flux densities of the
stator and rotor. Above all, it is influenced by the length of the motor. As
long as the lubricant film in the bearing is intact, the voltage builds up
until, finally, a compensating current flows towards the earth. In this case,
the path of least resistance is through the motor bearings. This bearing
current (I 1), over a long period of time, usually results in drying out the
bearings and thus create a mechanical motor failure, acoustic noise and
a possible break-down. It is possible to counter this phenomenon to a
certain degree through the use of ceramic bearings.
The bearing voltage is an asymmetric (common-mode) voltage that oc-
curs because of capacitive coupling between the motor housing, the
stator and the rotor (C 1, C 2, C 3) and results in dv/dt and electrostatic
discharge currents (I dv/dt and I EDM) across the bearing (C Bearing, U
Bearing). To be more accurate, this bearing voltage results in two differ-
ent currents: in the first minutes of operation, as long as the lubricant in
the bearing is cold, currents in the range of 5 to 200 mA (I dv/dt) flow
through C Bearing because of the dv/dt. These rather negligible currents
generally do not result in any bearing damage. After a little while, when
the lubricant film has heated up, peak currents of 5 to 10 A and more
can be measured (IEDM). These flashovers leave behind small pits on the
surface of the bearing. The running of the bearing becomes increasingly
rough because of the damaged surface and the life is thus considerably
shortened. Typically, the bearing voltage is between 10 and 30 V. But
since it is directly dependent on the mains supply voltage, bearing dam-
age increases over proportionally at higher supply voltages.

In the case of the use of unshielded motor cables, the cable capacitance
(C Cable) and hence the current (I Cable) is relatively small. The parasitic
capacitances on the inside of the motor dominate. Ideally, the parasitic cur-
rents flow through the motor housing to the ground (I C1).

8
 Motor cable IC1
Motor uninsulated coupling
Line Inv.
I1 C1
IBearing
C2 C3
CBearing
Idv/dt Load
Bearing UBear. IEDM
Rotor shaft
CCable

ICable Rotor

Copper coils

C1 Stator

Metal frame

IC1 Imp. IBearing

However, if the grounding of the motor is inadequate, an additional im-

pedance (Imp.) is limiting the current (I C1). As a result of the additional im-
pedance, the potentials at C 2, C 3 and C Bearing increase sharply. The val-
ues of the bearing currents also increase massively and flow fully through
the bearings to the earth (I Bearing); in that case, the life expectancy of the
ball bearings, and hence of the entire motor, is reduced to a few hours.

I e [A]
120

100

80

60

40

20

0
500 kW motor A 500 kW motor B 110 kW motor A 110 kW motor B

motor earth current with out filter

motor earth current with sine wave filter
motor bearing current with out filter
motor bearing current with sine wave filter

2.7 Acoustic motor noise

Compared to the previously described issues, the whistling noises of the
motor caused by the pulse width modulated (PWM) switching frequency
would appear to be negligible. However, in applications related to heating,
ventilation and airconditioning technology (HVAC), the noise is distributed
and may be amplified in the entire building through air ducts or heat-
ing pipes. For acoustic noise sensitive applications, often the motor drive
switching frequency is set to 16 kHz, since this audible frequency noise
level is less noticeable by humans. This generates higher IGBT switching
losses, higher heating, higher leakage currents and therefore a correspond-
ing derating of the motor drive need to be taken into consideration.
Three main acoustic noise sources are generated by motors:

Motor core magnetic noise, through magnetostriction

Motor bearing noise
Motor ventilation noise

9
 6 > Sine Wave Filter - Application and Selection

In order to eliminate or reduce unwanted acoustic noise levels, a sine-wave

filter can be used. This will filter the pulse shaped voltage from the frequen-
cy converter and provide a smooth sinusoidal phase-to-phase voltage at
the motor terminals.

3. Output filter solutions for motor drives With Schaffner

reduction of hig
For reasons of cost, time and space, an attempt is generally
can be achieve
first made to overcome the motor drives issues without addi-
3. Output filter solutions for motor drives shaped genera
tional components. However, the subsequent costs that can
result from motor or system failures are often entirely out of It protects the m
proportion to cost,
the far lower destruction and
For reasons of time and initial
space, costs of preventive
an attempt output
is generally filter to
first made
measures. tric motors. dv/
overcome theIf motor
the decision is made
drives issues in favour
without of components
additional components. toHow-
increase
ever, the reliability,
the subsequent coststhe
thatoperational safety
can result from motor and the installa-
or system failures are
tor cables. The
tion lifetime the following types of passive output filter compo-
often entirely out of proportion to the far lower initial costs of preventive pends mainly o
nents have
output established
filter measures. If thethemselves to solve
decision is made the major
in favour applica- to
of components voltage. The va
tion requirements:
increase the reliability, the operational safety and the installation lifetime derating curve
the following types of passive output filter components have established
I dv/dt reactors (increase inductivity, signal smoothing)
themselves to solve the major application requirements:
I dv/dt filters (low inductance, hardly any reduction in the con-
trol dynamic)
dv/dt reactors (increase inductivity, signal smoothing)
dv/dt filters (low inductance, hardly any reduction in the control dynamic)
I Sinusoidal output filters (high L and C for optimizing the out-
Sinusoidal output filters (high L and C for optimizing the output signal,
put signal, but also not universally applicable)
but also not universally applicable)

Locations of filters around motor/power drives

Locations of filters around motor/power drives

3.1 dv/dt reactor

frequency dependi
Reactors can be used in various locations in a power drive system: as line
3.1 dv/dt
reactor, reactor
in the DC link between the rectifier and capacitor (DC link choke)
and at the drive output to the motor (dv/dt reactor). A reactor at each of
Reactors can be used in various locations in a power drive
these positions has specific effects that are by no means mutually exclu-
system: as line reactor, in the DC link between the rectifier and
sive.
capacitor (DC link choke) and at the drive output to the motor
(dv/dt reactor). A reactor at each of these positions has specif-
Generally, it would be unnecessary to have a reactor in both the power
ic effects that are by no means mutually exclusive.
input and the DC link, but the functions of the input line reactor are quite
Generally,
different it would
from bethe
a filter at unnecessary to and
drive output, have a reactor
it is in both
entirely reasonable to
the power
include bothinput and the DC link, but the functions of the input
of these.
line reactor are quite different from a filter at the drive output,
Aand
reactor
it is on the line
entirely side will dototwo
reasonable things:
include protect
both the drive electronics
of these.
from power disturbances and protect the power supply from disturbances
A reactor
created on the
by the line
drive. In side will do two
this document thethings: protect
line input side the drive
will not be cov-
electronics
ered in depth,from power
therefore disturbances
please consult forand protect
more the power
information the Basics in
supply
EMC andfrom disturbances
Power created
Quality, published by download
in the the drive. section
In this docu-
of
ment the line input side will not be covered in depth, therefore
www.schaffner.com
please consult for more information the Basics in EMC and
Power Quality, published in the download section of
10
www.schaffner.com
 With Schaffner dv/dt reactor types RWK305 a cost efficient reduction of
high output voltage dv/dt from IGBT motor drives can be achieved. The
voltage still being PWM pulse pattern shaped generates a lower output
current ripple.

It protects the motor coil insulation from premature aging and destruction
and increases significantly the service life of electric motors. dv/dt reactors
are limited when used with long motor cables. The maximum admissible
motor cable length depends mainly on the switching frequency and the
drive output voltage. The value for a given application can be found in the
derating curve below.

kHz
15
14
13
12
Switching frequency

11
400 VAC
10
9
8
480 VAC
7
6
7 > Sine
5 Wave Filter - Application and Selection
4
3
2
1 10 20 30 40 50 60 70 m
Cable length
Switching frequency depending cable length curves for RWK305 reactor
3.2 dv/dt filter
Motor
3.2 drives
dv/dt filterswitching frequencies of 16kHz or more can gen- Side effect of t
erate dv/dt
Motor drivesvalues of up
switching to 12 kV/us.
frequencies of 16Depending
kHz or moreoncan output dv/ pulse ringing v
thegenerate
dt values of up to 12 kV/us. Depending on the output voltage
voltage of the motor drive, the cable length and type as well of the
asmo-
tor Mainly for high
thedrive,
layoutthedo
cable length the
influence andvoltage
type as well
rise as the layout
time. do influence
High dv/dt levels the
voltage rise time. slightly reduce
can damage theHigh dv/dt
motor levels can
windings. damage the
According motor
to EN windings.
60034 volt- Ac-
cording to EN 60034 voltage rise times of 500 to 1000 V/us are permissible switching frequ
age rise times of 500 to 1000V/us are permissible depending
depending on motor types.
on motor types.

Thedv/dt
The dv/dtfilters
filters
areare
lowlow
passpass
filter filter builtinductors,
built with with inductors, capaci-
capacitors and pow-
tors
er and power
resistors. resistors.
The nominal The nominal
switching switching
frequency frequency
of the motor of be
drive shall
the motor
below drive cut
the typical shall
offbe below the
frequency typical
of the dv/dtcut
filteroff frequency
(typical of The
< 10 kHz).
the dv/dt
sine filterhave
wave filter (typical < 10
higher kHz).
L and The sine
C values, wave
therefore filterfilters
dv/dt haveare lower
higher
in L and
cost and C values,
smaller in size.therefore dv/dt
With a dv/dt filters
filter are lower
the output in cost
current ripple is
and smaller
lower but the in size. isWith
voltage a dv/dt
still PWM filter
pulse the output
pattern shaped.current ripple
is lower but the voltage is still PWM pulse pattern shaped.
11
 and smaller in size. With a dv/dt filter the output current ripple
is lower but the voltage is still PWM pulse pattern shaped.

Without dv/dt filter With dv/dt filter

Without dv/dt filter With dv/dt filter

The Filter FN510 from Schaffner reduces the high output volt-
The
ageFilter
dv/dtFN510 from Schaffner
from IGBT reduces
motor drives andthe highthe
limits output
peakvoltage
voltagedv/dt
from IGBT motor drives and limits the peak voltage to 1000 V. It protects
to 1000V. It protects the motor insulation windings from prem-
the motor insulation windings from premature aging and destruction and
ature aging and destruction and increases significantly the
increases significantly the service life of electric motors. In addition less
service life of electric motors. In addition less interference
interference propagation towards neighbouring equipment or lines are
propagation towards neighbouring equipment or lines are oc-
occurring. The typical cable length used is 80 m at a maximum switching
curring. The typical cable length used is 80m at a maximum
frequency of 16 kHz at 400 VAC.
switching frequency of 16kHz at 400VAC.

Side effect of the use of a dv/dt filter: the frequency of the pulse ringing
voltage oscillation is reduced below 150 kHz. Mainly for high power motors,
the motor bearing stress is slightly reduced, but dv/dt filters do not elimi-
nate the acoustic switching frequency noise from the motor.

3.3 Sine wave filter

Sine wave filters are low pass frequency filters which convert the rectan-
gular PWM output signal of motor drives into a smooth sine wave voltage
with low residual ripple. Sine wave filters, also known as LC-filters or named
sinusoidal filters, are mainly used in combination with variable speed drives
to protect the motor against excessive voltage spikes and overheating. As
a result, insulation stress and losses in AC motors are reduced and prolon-
gate the motor life time.

12
 filters, also known as LC-filters or named sinusoidal filters, are
even with short
mainly used in combination with variable speed drives to pro-
tect the motor against excessive voltage spikes and overheat- I Motor drive ap
ing. As a result, insulation stress and losses in AC motors are
I LV motor drive
reduced and prolongate the motor life time. er
Voltages:
Voltages: drive output
drive outputw/o
w/o filter
filter sine wave
sine filter output
wave filter output
I Increase in the
system

For a large num

wave filters can
major motor dri
effective way.

Schaffners sine
ments of moder
long motor cabl
acoustic motor
bearing current
tor cable thus re
very useful for s
smooth sine wa

Currents: drive output w/o filter sine wave filter output

Currents: drive output w/o filter sine wave filter output

3.3.1
3.3.1Differential mode
Differential mode sinesine
wavewave
filter filter
There are basically two types of sine wave filters. For the majority of the
There are basically two types of sine wave filters. For the ma-
applications, the basic versions are the differential mode (also called sym-
jority of the applications, the basic versions are the differential
metric) sine wave filter types FN5020, FN5040, FN5040HV and FN5045 from
mode (also called symmetric) sine wave filter types FN5020,
Schaffner.
FN5040, FN5040HV and FN5045 from Schaffner.
Differentialmode
mode sine
sine wave Motor drive with diff
Differential waveoutput
outputfilters connected
filters directly
connected to thetomotor
directly
thedrive
motoroutput have, above all, the following advantages:
drive output have, above all, the following ad-
vantages:
Protect motor winding insulation against The residual rip
I Protect
dv/dtmotor
voltagewinding insulation
spikes and against dv/dt voltage spikes
overvoltage values of the L
and Rovervoltage
eduction of the additional magnetic losses reached at a rip
and eddy current losses in the motor
I Reduction of the additional magnetic losses and eddy current
Reduction of motor heating
losses
Reductionmotor
in the of the additional losses of the motor drives
Reduction
I Reduction ofofmotor
motorheating
bearing currents caused by circulating currents
Reduction of the acoustic noise of the motor
I Reduction ofofthe
Reduction additional losses
electromagnetic of the
emissions of motor drives
motor cables

I Reduction of motor bearing currents caused by circulating

For following applications differential mode sine wave filters are strongly
currents
recommended:
I Reduction of the acoustic noise of the motor
Applications with motor cable runs above 100 m long Differential mode L
I Reduction of electromagnetic emissions of motor cables
Applications with 600 VAC/60 Hz or 690 VAC/50 Hz motors,
even with short motor cables
Motor drive applications with multiple motors in parallel
LV motor drive feeding MV motor through step-up transformer
Increase in the reliability and operational safety of the overall system

13
olongate the motor life time. er
ive output w/o filter sine wave filter output
I Increase in the reliability and operational safety of the overall
system

For a large number of applications, differential mode sine

wave
For filters
a large can be
number of considered
applications, to be the ideal
differential modesolution.
sine waveThefilters can
major motor drives issues are solved efficiently and in a cost- are
be considered to be the ideal solution. The major motor drives issues
solved efficiently
effective way. and in a costeffective way.

Schaffners
Schaffners sine
sine wave
wave filter
filter areare matching
matching the the technical
technical require- of
requirements
ments of
modern modern
drive drive
systems and systems and are
are particularly usedparticularly used
for long motor for appli-
cable
long motor
cations. cable they
In addition applications.
calm down Inacoustic
additionmotor
they calm
noises,down
lower the HF-
acoustic
leakage motor reduce
currents, noises,bearing
lower the HF-leakage
currents currents,
and eliminate reduce
the pulse reflec-
bearing
tions currents
in the and eliminate
motor cable the the
thus reducing pulse reflections
motor in the
drive losses. mo-they
Finally
torvery
are cable thusfor
useful reducing themotor
special AC motor drive
drive losses. Finally
applications they
requiring are
a smooth
verywave
sine useful for special AC motor drive applications requiring a
voltage.
smooth sine wave voltage.

ive output w/o filter sine wave filter output

tial mode sine wave filter

ally two types of sine wave filters. For the ma-
ications, the basic versions are the differential
ed symmetric) sine wave filter types FN5020,
40HV and FN5045 from Schaffner.
Motor drive
Motor drive with
withdifferential
differentialmode
modesine wave
sine filter
wave filter
e sine wave output filters connected directly to
output have, above all, the following ad-
The residual ripple of the signal can be adjusted by using the values of the
LThe
and residual ripple cost-benefit
C. An optimum of the signal canis be
ratio adjusted
often reachedby
at ausing
ripplethe
voltage
winding insulation against dv/dt voltage spikes values
of 3% to of

the L and C. An optimum cost-benefit ratio is often
5%.
e reached at a ripple voltage of 3 % to 5 %.
U1 U2
he additional magnetic losses and eddy current
otor V1 V2
motor heating
W1 W2
he additional losses of the motor drives

motor bearing currents caused by circulating PE PE

he acoustic noise of the motor
lectromagnetic emissions of motor cables
Drive Motor
Differential mode LC sine wave filter
Differential mode LC sine wave filter
3.3.2 Sinus plus (differential and common mode) sine wave filter
In some cases, additional measures with motor drives applications are nec-
essary. To counter effects or requirements such as
Bearing damage caused by common mode currents (shaft currents)
 Parasitic earth currents
Avoid shielded motor cables (e.g. for retrofit installations)
Motors not having conform motor drives insulation
prerequisite (e.g. for retrofit installations)
Limited maximum possible motor cable length

14
 I The shield mu
I Avoid shielded motor cables (e.g. for retrofit installations)
I Motors not having conform motor drives insulation prerequi- I The shield
housings muh
(e.g.
Isite
Motors
(e.g. not
for having conform motor drives insulation prerequi-
retrofit installations) housings (e.g. h
I All shield conn
site (e.g. for retrofit installations) Ipedance,
All shieldi.e.
conn
I Limited maximum possible motor cable length so
I Limited maximum possible motor cable length pedance, i.e. so
Sinus plus is a highly developed modular sine wave filter con-
Sinus plus is a highly developed modular sine wave filter concept from
Sinus plusSchaffner
cept from is a highlythatdeveloped
is uniquemodular sine wave
in the market filter
today. con-
Con- Feedback to th
Schaffner that is unique in the market today. Consisting of a traditional
cept from
sisting of aSchaffner
traditionalthat is unique(symmetric)
differential in the market andtoday. Con-
an additional Feedback to th
differential (symmetric) and an additional common mode (asymmetric) If only one conn
sisting of a traditional differential (symmetric) and
common mode (asymmetric) sine wave filter module, it can be an additional
sine wave filter module, it can be customized exactly to any requirement. If only
er ("+" one conn
or "-") th
common mode
customized (asymmetric)
exactly sine wave Through
to any requirement. filter module, it can be
innovative
Through innovative circuits and an additional connection to the DC link, er ("+" or "-")
(identified by th"D
customized
circuits and an exactly to anyconnection
additional requirement. Through
to the innovative
the additional module is capable of sending theDC link,
common the
mode addi-
interfer- (identified by
the "+" or "-" inv "D
circuits
tional and
module an isadditional
capable connection
of sending to
the the
commonDC link, the
mode addi-
inter-
ences directly to the very place they originated. thea"+"
or pureor block
"-" inv
tional module
ferences is capable
directly of sending
to the very the originated.
place they common mode inter-
or a pure
verter being swblock
ferences directly to the very place they originated. verter being sw
or "earth conne
or "earth conne
FN 530 combin
FN 530 combin
bination, this so
bination,
vantages:this so
vantages:
I Complete elim
I Complete elim
I The possibility
I The possibility
reductions in im
reductions in im
Drive with differential mode and add-on common mode filter modules I Practically no
Drive with differential mode and add-on common mode filter modules
I Practically
cable lengthno
Drive with differential mode and add-on common mode filter modules
cable length
I Almost comple
I Almost comple
I No interferenc
Iment
No interferenc
ment
I Elimination of
I Elimination of
I Reduction in t
Ifrequency
Reductionconv in t
frequency
works, conv
every m
Drive with
Drive with differential-
differential- and
andcommon mode
common all-in-one
mode sine wave
all-in-one filter filter
sine wave works, every mo
the behaviour
Drive with differential- and common mode all-in-one sine wave filter the
any behaviour
pulsed inteo
This procedure is in keeping with the basic principle of interfer-
This
Thisprocedure
procedure is is
in in
keeping with
keeping thethe
with basic principle
basic of interference
principle of interfer- sup- any
Pluspulsed
is used, inte
th
ence suppression techniques: take the necessary measures at Plus is used, th
pression techniques:techniques:
take the necessary can be reduced
encesource
the suppression
of the noise, not at the themeasures
takedrain. necessary at the source of
Sinus Plusmeasures
can be at
the
noise, not at the drain. Sinus Plus can be considered as a modular system
can be reduced
the source of
considered asthe noise, not
a modular at theindrain.
system whichSinus Plus can be
the differential filter
in which the differential filter part (FN5020, FN5040 and FN5045) can be
considered
part (FN 5020, as aFN5040
modularand system
FN5045)in whichcan the differentialauton-
be connected filter
connected autonomously and the common mode part (FN5030) may be For further tech
part (FN 5020, FN5040 and FN5045)
omously and the common mode part (FN5030) may be addedcan be connected auton- For
sult further
the datashetech
added or as an all-in-one type sine wave filter (FN530).
omously
or and the common
as an all-in-one mode
type sine wavepart (FN5030)
filter (FN530).may be added sult the datashe
the download s
or as an all-in-one type sine wave filter (FN530). the download s
Shielding
Shielding of certain conductors is necessary to prevent interference en-
ergy radiation into the environment.

Cable must be shielded between the inverter output and filter input (U,
V, W ), connect the cable present directly to the inverter
Motor cable between the filter output (U1, V1, W1) and the motor itself
does not have to be screened (unless special installation requirements
apply)
The shield must be solidly connected at both ends to the housings (e.g.
housing of filter and motor)
All shield connections must exhibit the largest possible impedance, i.e.
solid, large area connections

15
 Feedback to the dc link
If only one connection to the dc link is brought out of the inverter (+ or
) then the dc link cable connections from the filter (identified by DC+
and DC-) must be connected together to the + or inverter connection.
A lower switching frequency or a pure block modulation is unsuitable and
results in the inverter being switched off with the error message overcur-
rent or earth connection.

FN530 combines both solutions in one box. Operated in combination, this

solution results in the following additional advantages:

Complete elimination of bearing damage

The possibility of using unshielded motor cables without any reductions
in immunity
Practically no more limitations with regard to the maximum cable length
Almost complete elimination of the pulse currents to earth
No interference influence of neighbouring cables and equipment
Elimination of the additional losses in the frequency converter
Reduction in the suppression efforts on the input side. Since frequency
converters are operated in ground-referred networks, every measure
taken on the output side also influences the behaviour on the input side
(and vice versa). Since hardly any pulsed interference currents flow to
the earth when Sinus Plus is used, the asymmetric part of the EMC mains
input filter can be reduced, resulting in total cost savings.

For further technical specification and information please consult the data-
sheets of the corresponding products published in the download section of
www.schaffner.com

4. Sine wave filter selection

4.1 Current and voltage rating

Schaffners standard sine wave filters are designed to be applied with most
commonly used standard motor drives and motors available on the global
market. For dedicated and special requirements Schaffner does design cus-
tomized sine wave filters adapted to the specific needs.

In principle the nominal motor current and the duty cycle is defining the
size of the output filter. Schaffner filters are rated for 150% overload for
1 minute, ones per hour. Above 150% rated current the saturation of the
inductance can be reached and destroy the capacitors.

It is recommended that the rated current of the sine wave filter shall be
equal to or greater than the nominal motor current and should correspond
and be compatible with the ratings and duty cycle capability of the motor
drive.

For motor drives feeding isolation transformers select a sine wave filter with
a current rating equal or greater than that of the transformer primary current.

16
 With regard to the voltage, Schaffner offers sine wave filter for 400 VAC, 500
VAC, 600 VAC and 690 VAC applications. Even for short cable installations, at
voltages > 500 VAC sine wave filter are recommended, to protect the motor
winding insulation against high voltage peaks.

In cases the motor drive selection has been made prior to the sine wave filter
selection, the usual way is to size the sine wave filter to the corresponding mo-
tor drive. Nevertheless, the proper power selection depends on one side upon
the drives related specifications, e.g. rated current, voltage, line frequency, mo-
tor drives switching frequency, motor frequency, the ambient conditions (tem-
perature, altitude) and on the other side on the motor and application perfor-
mance requirements. In addition the motor cable length, cable type, motor
type, and some particular application requirements needs to be considered.

max. current [%]

110

100

90

80

70

60

50

40

30

20
20 40 60 80 100 120 140 160 180 200 220
Motor frequency [Hz]

max. current

Derating curve: maximum current vs. motor frequency for FN5040

4.2 Frequency
The frequency is an important factor when selecting output filter. Depend-
ing on the type of filter, three different frequencies are relevant.

Supply frequency. The frequency of the AC mains supply network, typi-

cally 50 or 60 Hz. The operating frequency of the filter is determined by
the behaviour of the capacitors. Depending on the voltage/frequency
characteristic of the capacitor, it might be possible to operate a filter at a
higher frequency but with a reduced input voltage.
Switching frequency. The frequency used to switch the IGBTs in the out-
put stage of a frequency converter. This frequency has a direct relation to
the power loss in the converter and to the output components.

Higher switching frequencies have following effects:

increasing the switching losses of the semiconductors
-> temperature rise of motor drive -> derating to be considered
reducing the audible noise level
increasing the leakage currents
reducing the harmonic motor current and motor temperature

17
 Generally speaking, lower frequencies result in lower motor drive losses
and lower leakage currents.

For an output filter, it is also necessary to consider the relation between the
motor drive switching frequency and the resonance frequency of the sine
wave filter. The Schaffner sine wave filters are always designed in such a
way that the resonance frequency is at least 2.5 times lower than the lowest
switching frequency. It is important that the minimum switching frequency
adjusted in the motor drive is respected according to the specified minimum
switching frequency of the sine wave filter (refer the product datasheet).

M
 otor frequency. The simulated supply frequency of the frequency con-
verter. This frequency determines the rotational speed of the motor. Most
applications operate at 50/60 Hz motor fields, but applications with high-
er rotational speeds also exist (high-speed spindle drives up to 2000 Hz).

Sine wave filters usually have a better performance compared to dv/dt

chokes or dv/dt filters. The resonance frequency of the sine wave filter must
be at least 2.53 times lower than the motor drive switching frequency.

4.3 Required drives settings

The nominal switching frequency of the motor drive can vary or be ad-
justed and therefore need to be considered from the beginning for the
sine wave filter selection.

The motor drive must be suitable to be operated with sine wave filter
and therefore shall be adjusted with a constant switching frequency. The
mode of operation must be scalar (V/Hz) with a fixed switching frequency.
Check the drives manufacturer manual whether special settings are neces-
sary. In any doubt contact the drives manufacturer.

Ensure the drives switching frequency is set to the required minimum switch-
ing frequency (refer filter selection table of corresponding product datasheet).

Following are the product specific rating selection guidelines with regard
to the maximum permissible cable length in relation with the minimum
PWM switching frequency:
Motor cable length [m]
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0
4.5 8 1017 2462 75260 410660 7501200
Type current [A]

max. length for min. PWM x 2 max. length for min. PWM

Selection curve for 500 VAC sine wave filter FN5040 and FN5045 series

18
 2500

2000

1500

1000

500

0
1345 75260 3001320
Filter current rating (A)
max. length for min. PWM max. length for min. PWM x 2

Selection curve for 690 VAC sine wave filter FN5040 HV series

*In case a step-up transformer is used, then the length is meant to be be-
tween the filter and transformer.

Sine wave filters, unlike dV/dt filters, can be applied for higher switching
frequencies (some types up to 16 kHz) than the nominal switching frequen-
cy, but lower switching frequencies close to the resonance frequency of
the sine wave filter will damage the capacitors. Ensure that the switching
frequency of the motor drive is always higher than the minimum allowed
switching frequency as shown in following table.

Schaffners sine wave filters support lower minimum switching frequencies,

therefore a derating of the motor drive is not necessary and does reduce
the overall system cost. The minimum switching frequency is compatible
with typical motor drives on the market. With reduced motor cable length
max. switching frequency up to 16 kHz are allowed.

Filter Version Typival motor Minimum

Voltage Version & Current Range power switching
frequency fPWM
400 V/4.5 to 48 A 1.1 to 22 kW 4 kHz
400 V/62 to 480 A 30 to 250 kW 3 kHz
400 V/660 to 1200 A 315 to 630 kW 2 kHz
690 V/13 to 300 A 7.5 to 2560 kW 2 kHz
690 V/430 to 1320 A 355 to 1200 kW 1.5 kHz

19
 Following special motor drive considerations need to be taken into ac-
count in combination with sine wave filters:

Motor drives operating at reduced switching frequency or using block

pulsing at particular operation points (e.g. at low motor speed or high
load conditions) must not be used or the feature be disabled
Sine wave output filter may not be used with servo drives, because they
normally are current controlled devices
Check the recommended motor drive output frequency levels and ad-
justments when non-regenerative/regenerative drives with or without
brake choppers are used
Automatic frequency adaptation modes need to be disabled within the
motor drive
Protective functions and features of the motor drive, such as overcurrent,
short circuit, motor phase loss or imbalance may be impaired in combi-
nation with sine wave filter and/or long motor cables

CAUTION: If the motor drives settings are not correct the filter may be
damaged.

4.4 Voltage drop considerations

The voltage drop across the sine wave filter must be taken into account
when dimensioning the motor and the drive.

At constant motor power level the current will increase above the rated
current. For constant operation at this level, which means above the field
weakening point or at high overload conditions are limiting or reducing
the motor torque performance. It is recommended to consider the voltage
drop impact when dimensioning the motor and the motor drive.

The voltage drop at full load can not be neglected and therefore the motor
will not receive the full voltage at nominal speed.

The additional voltage drop of long motor cables does also influence the
selection and dimensioning of the motor and the drive.

Schaffners sine wave filters have an impedance of 810% at nominal volt-

age, frequency and rated current. They are designed for motor frequency
operation up to 70 Hz (up to 200 Hz with derating according graph on
page 17).

Voltage drops need to be considered when the motor drives protective

functions, such as overcurrent, short circuit, motor phase imbalance, motor
phase loss or predictive monitoring features need to be set accordingly.
Please refer to the corresponding motor drive manual or application guide.

Due to the charging action of the sine wave filter capacitors through DC
currents coming from the motor drive (DC braking, DC injection for mo-
tor parameter/characteristics measurements) a short circuit trip within the
motor drive could be provoked or the measurement values could be im-
paired. For those cases some parameters within the motor drive need to
be programmed and set accordingly. Contact your motor drives manual
or supplier.

20
 5. Application examples

Typical applications requiring sine wave filters:

Motor drive with long motor cable

Motor drive with multiple motors in parallel
Retrofit installations with motor drives
Step-up transformer applications for LV-drives control of MV-motors

5.1 Motor drive with long motor cable

For motor drives controlling a motor over a long distance with a shielded
motor cable can lead to the effect of high parasitic capacitive currents flow-
ing across the shield. Those unwanted currents must as well be supplied
by the frequency converter or motor drive. The result of this can be that a
motor drive of the next higher rating has to be used that is able to supply
both the currents required by the load and the parasitic currents via the
earthing.

When using a sine wave filter the maximum motor cable length does de-
pend on the motor drive switching frequency.

>>> refer to chapter 4.3 Required drive settings

5.2 Motor drive with multiple motors in parallel

The operation of several motors connected in parallel to one frequency
converter is problematic. The parallel connection of several shielded cables
results in a relatively high total capacitance and thus correspondingly high
shield currents. The parallel connection of several drives, however, is ac-
companied by even more problems. Parasitic currents across the motor
and the entire system can considerably affect the reliability of the whole
system.

For such configurations it is recommended to use a sine wave filter cov-

ering the symmetrical and asymmetrical aspects as described in chapter
3.3.2 Sinus Plus symmetrical and asymmetrical sine wave output filter.

5.3 Retrofit installations with motor drives

For existing installation where long motor cables and old motors want to
be kept and be modernized with a variable speed motor drive equipment
following issues would need to be considered before making a final instal-
lation choice.

The cable layout should be checked and all the insulations on the cable
and the motor shall be measured against each other phase and to ground/
chassis and PE and still be conform to the newest installation norms.

In any case, even a shielded cable is installed, then it is recommended to

use a sine wave filter covering the differential (symmetrical) and common
mode (asymmetrical) aspects as described in chapter 3.3.2 Sinus Plus dif-
ferential and common mode sine wave output filter.

21
 5.4 LV motor drive with MV-motor or step-down/step-up
transformer application
With a step-up isolation transformer* a cost effective LV motor drive can
control a MV motor. This application requires a sine wave filter to ensure
that the step-up transformer is fed by a sine wave voltage. Otherwise the
transformer power losses would be high and overheat the transformer. In
addition the voltage spikes would overstress the winding isolation and sig-
nificantly reduce the life time of the transformer. The additional advantage
of this system is, that there is no limitation (other than cable voltage drop
and losses) of the cable length between the step-up transformer and the
MV-motor.

T1 U1 F1 T2 M1
0.39 kV 0.69 kV
6 kV B1 6 kV
Frequency
Inverter

Diagram is showing a step-up motor drive system consisting the step-

down transformer T1, the LV-circuit breaker B1, the motor drive U1, the sine
wave filter F1, step-up transformer T2 and the MV-motor M1.

The cable length between the sine wave filter F1 and the step-up trans-
former T2 can be treated in the same way as recommended by Schaffner
for the LV-motor cable length. For the cable between the transformer T2
and the MV-motor for EMC considerations unshielded cable can be used,
but need to be chosen to fit the application requirements.

The motor drives protective functions and predictive monitoring features

need to be considered with regard to the sine wave filter, the step-up
transformer and cable length impact.

In particular the earth/ground fault protection of the motor drives does

not protect the secondary side of the step-up transformer. For this another
protective device needs to be installed.

For the transformer dimensioning the starting torque/current of the MV-

motor, the cable length and the voltage drop over the sine wave filter need
to be considered.

* Note: an autotransformer is not allowed.

6. Mounting and installation guidelines

6.1 Important safety considerations

Note: Ensure that all protective earth and ground connections are made at
the lowest possible impedance. Remove paint or other isolation materials
to achieve good electrical contact. To keep common mode/high frequen-
cy effects low a proper large surface connection is required.

Note: For safety reasons, open style or IP00 LC sine wave filters must be
installed in cabinets or rooms, to prevent access of non-qualified persons
to the filters.

22
 Warning: Do not operate the filter outside of specifications.

Note: LC sine wave filters must be mounted in a clean, dry location which
protects the product from any liquids, corrosive vapours, dust, abrasive de-
bris and aggressive gases.

6.2 General application notes

NOTICE
Filter suitability for a given application must ultimately be determined by
the user (the party that is putting the filter into operation) on a case by case
basis. Schaffner will not assume liability for any consequential downtimes
or damages resulting from use of filters outside their specifications.

NOTICE
Output filters must be mounted in a clean, dry location (enclosures, cabi-
nets, closed rooms). Contaminants such as oils, liquids, corrosive vapours,
abrasive debris, dust and aggressive gases must be kept away of the filter
and enclosure.

Standard products
Standard catalogue filters must be used for the published applications and
operated within the published technical specifications.

Custom products
Custom filters must be used for the bespoke application and operated
within the provided and mutually agreed technical specifications.

NOTICE
Output filters are design-in products by definition. Their functionality and
suitability must be determined with a proper design-in process, involving
electrical, mechanical and thermal verification within the final equipment.

Filter installation, start-up, operation and maintenance (if any)

have to be carried out by a trained, certified and authorized
electrician or technician, who is familiar with the safety proce-
dures in electrical systems, if needed in accordance with NEC
and all local electrical codes and regulations and in particular of
three-phase power systems.

High voltage potentials are involved in the operation of this

product. Always remove power before touching energized and
electrical conductive parts of the filter, and let ample time elapse
for the capacitors to discharge to safe levels (< 42 V ). Residual
voltages are to be measured both line to line and line to earth.

Always connect the filter to protective earth (PE) first, and then
continue with the wiring of phase terminals. When decommis-
sioning the filter, remove the PE connection at the end. The sine
wave filter must not be operating without connected motor.

23
 Follow the general installation notes closely. Ensure that cooling
slots (if any) are free from obstructions that could inhibit effi-
cient air circulation. Operate the filter within its electrical, me-
15 > Sine Wave Filter - Application and S
chanical, thermal and ambient specifications at all times.

Special attention should be paid to cable dimensioning, fuses,

grounding, shutdown, disconnection, and overcurrent protec-
tion.

6.3 General installation notes

Output filters are lossy electrical components. Filter surfaces
and terminals may get hot under full load operating conditions
I Please read and follow the safety and ap
and can exceed surface temperature > 80 C.
above.

I Carefully
Always practice the safety procedures defined by yourinspect the shipping container a
company
to the installation. In case of visual damag
and by applicable national electric codes when handling, install-
filter and file a claim with the freight carrier
ing, operating or maintaining electrical equipment.
I Filters may be heavy. Follow the instructi
In case of uncertainty and questions please equipment
contactdefined by your company.
your local
Schaffner partner for assistance. I Mount the filter to a conductive surface fr
Use an appropriately sized threaded bolt f
6.3 General installation notes hole/slot provided by the filter flange. The
bolt must be determined by the installer, d
Please read and follow the safety and application notes above.
weight and the material of the mounting su
Carefully inspect the shipping container and the product prior to the
installation. In case of visual damage, dont install the I Connect the
filter and filter
file to the protective earth (
a claim
with the freight carrier involved. Remove all line side power, then connect
(s) and capacitor bank (if separate) to the
Filters may be heavy. Follow the instructions for lifting heavy equipment
nals of the filter. The output filter label indi
defined by your company.
sides (inverter or motor side).
Mount the filter to a conductive surface free of paint/lacquer. Use an ap-
propriately sized threaded bolt for every mounting I For the electrical
hole/slot providedconnection of the filter t
torques recommended on the filter label a
by the filter flange. The strength class of the bolt must be determined
lished filter datasheets.
by the installer, depending upon filter weight and the material of the
mounting surface. I Cable or busbar cross sections have to b
ance with national and international electri
Connect the filter to the protective earth (PE) terminal(s). Remove all line
cable product standards governing the equ
side power, then connect the phase terminal(s) and capacitor bank (if
incorporate the filter.
separate) to the designated terminals of the filter. The output filter label
indicates the connection sides (inverter or motor side).I Some filters provide additional terminals,
temperature monitoring. These features ha
For the electrical connection of the filter terminals, apply the torques rec-
used before energizing the filter. If uncerta
ommended on the filter label and/or in the published filter datasheets.
your local Schaffner representative.
Cable or busbar cross sections have to be chosen in accordance with
national and international electric codes and
applicableproduct standards governing the
equipment that will incorporate the filter.
Some filters provide additional terminals, e.g.
for overtemperature monitoring. These fea-
tures have to be properly used before energiz-
ing the filter. If uncertain, please consult your
local Schaffner representative.

24
stallation notes 6.4 Mechanical mounting
stallation notes 6.4 Mechanical mounting
Lift the filter with appropriate crane using lifting eye bolts (if
d follow the safety and application notes Lift the filter
available) with appropriate
smaller types maycrane using
be lifted lifting eye
manually bybolts (if
two per-
d follow the safety and application notes available) smaller
sons (no lifting types
eye bolt may be lifted manually by two per-
applicable).
sons (no lifting eye bolt applicable).
t the shipping container and the product prior 6.4 Mechanical mounting
.t In
thecase
shipping
of visualcontainer
damage, anddont
the product prior
install the Lift the filter with appropriate crane using lifting eye bolts (if available)
. In with
aim casethe of visual
freightdamage, dont install the
carrier involved. smaller types may be lifted manually by two persons (no lifting eye bolt
aim with the freight carrier involved. applicable).
eavy. Follow the instructions for lifting heavy
eavy.
d Follow
by your the instructions for lifting heavy
company.
d by your company.
to a conductive surface free of paint/lacquer.
to
tely a conductive
sized threaded surface
bolt free of paint/lacquer.
for every mounting
dtely sized
by the threaded
filter flange. boltThefor every mounting
strength class of the
drmined
by the by filter
theflange. Thedepending
installer, strength classuponoffilter
the
For units 75A the separate capacitor banks can be mounted
rminedofbythe
aterial themounting
installer, surface.
depending upon filter
For units
aside the 75A the separate
inductance capacitorair
with a minimum banks can be
distance of mounted
150mm.
aterial of the mounting surface.
er to the protective earth (PE) terminal(s). aside
Due the
to the
For units inductance
75 heat with
dissipation
A the a minimum air
of the inductance
separate capacitor distance not150mm.
of
it ismounted
banks can be recom-
aside the
eride topower,
the protective
then connectearth (PE) terminal(s).
the phase terminal Due
mendedto the
inductance heat
towith adissipation
mount minimum airofdistance
the capacitor the inductance
bank above
of orit on
150 mm. is
Duenottorecom-
top of
thethe
heat dis-
ide
bank power, then connect
(if separate) to the the phase terminal
designated termi- mended
sipation oftothe
inductance. mount the capacitor
inductance bank above or
it is not recommended to on top the
mount of the
capacitor
Thebank (if separate)
output filter label to the designated
indicates termi-
the connection inductance.
bank above or on top of the inductance.
Permitted mounting positions: FN 5045 up to 115 A:
Themotor output
side). filter label indicates the connection
Permitted mounting positions:
Permitted mounting positions: FN 5045up
FN5045 uptoto115115
A: A:
motor side).
al connection of the filter terminals, apply the
150 mm
al
endedconnection
on the of thelabel
filter filterand/or
terminals,in theapply
pub-the 50 mm

ended
heets. on the filter label and/or in the pub-

FN 4045
heets.
cross sections have to be chosen in accord- 150 mm

alcross sections have

and international to be codes
electric chosenand in accord-
appli-
alndards
and international electric codes
governing the equipment that will and appli- Prohibited mounting
Prohibited mounting positions:
positions:
ndards
ter. governing the equipment that will Prohibited mounting positions:
ter.
vide additional terminals, e.g. for over-
vide
itoring.additional terminals,
These features havee.g.toforbeover-
properly
itoring.the
gizing These
filter.features have please
If uncertain, to be properly
consult
gizing
ner the filter. If uncertain, please consult
representative.
ner representative. The pictures above show permitted and prohibited mounting
The pictures above show permitted and prohibited mounting positions.
The pictures
positions. Theabove showon
mounting permitted
a verticaland prohibited
plate (top left mounting
picture) is
The mounting on a vertical plate (top left picture) is limited to IP00 prod-
positions. The mounting on a vertical plate
limited to IP00 products with a maximum weight of 25 (top left picture)
kg or is
for
ucts with a maximum weight of 25 kg or for IP20 products of FN5045 series
limited
IP20 to IP00 of
products products with a maximum weight of 25 kg or for
(far right picture) up to 115 A. Use all available mounting holes and select
IP20 products of
FN 5045 series
the correct screws(far
and right picture)
washers uptotoensure
in order 115 A. Use allmounting
a reliable availableand
FN
to do5045
mounting series
justice
holes (far
to the
and right
weight picture)
of
select these
the up toscrews
115Apply
products.
correct A. and
Use all available
torques appropriate
washers in
for the
mounting strength class
holes a
order to ensure and of the screws
selectmounting
reliable and
the correctwashers
andscrewsyou are using.
and washers
to do justice Specifica-
to the in
tions can be
order toofensureobtained from the
a reliable Applysupplier
mounting of the
and toscrews and washers.
do justice for to the
weight these products. torques appropriate the
weight
strength class of the screws and washers you are using.the
of these products. Apply torques appropriate for Spec-
6.5 Wiring and cabling
strength class
ifications can be of obtained
the screws andthe
from washers
supplieryou are screws
of the using. Spec-
and
The filter rating has to be compatible with the drives to which it is con-
ifications
washers. can be obtained from the supplier of the screws and
nected. All drives manufacturer installation and safety instructions must be
washers.
fulfilled. The installation and wiring must be in accordance and be conform
with the local standards and applicable codes (e.g. NEC).

25
 ble length ne
instructions must be fulfilled. The installation and wiring must
be in accordance and be conform with the local standards and Connect spa
applicable codes (e.g. NEC). adding a sup
The typical block schematic below is shown for a motor load Filters with s
but the
Theload can
typical beschematic
block multiplebelow
motors or a transformer
is shown instead.
for a motor load but the load
lows:
can be multiple motors or a transformer instead. Drives and load cable se-
Drives and load cable selection/placement should be in ac-
lection/placement should be in accordance with all local electrical stan-
cordance with all local electrical standards and regulations. Caution:
dards and regulations.
U1, V1, W1

U2, V2, W2

Filter may b

In many applications
In many applicationsaashielded cablemay
shielded cable may notnot be required
be required when a sine
whenwave
a sine
filterwave filter
is applied is aapplied
with withAnyhow,
motor drive. a motor drive.
due Anyhow,
to other existing in-
terference influences of common mode disturbances
due to other existing interference influences of common mode Schaffner does rec-
ommend to use shielded motor cables to avoid back-coupling of radiated
disturbances Schaffner does recommend to use shielded mo-
interferences to the mains cable at the frequency range from 130 MHz.
tor cables to avoid back-coupling of radiated interferences to
the mains
Becausecable at the frequency
of interference range
reasons, ensure that from 1-30MHz.
the motor cable is installed and
arranged separate or with enough distance to other cables or wires. In any
Because of interference reasons, ensure that the motor cable
case avoid parallel cable layout. In case this is not possible, e.g. encoder- or
is installed and arranged separate or with enough distance to
tachometer cable, then a metal separation shield or tube is recommended.
other cables or wires. In any case avoid parallel cable layout.
In case this is the
If possible, notsine
possible, e.g.encoder-
wave filter and the motor or drive
tachometer
should becable,
mounted
then on
a metal separation
the same conductiveshield
mounting or tube is least
plate. At recommended.
the motor drive and the
sine wave filter shall be connected with a flat copper ribbon. Because of
If possible, the and
EMI reasons sinevoltage
wavespikes
filter atand
the the
filtermotor drive should
input terminals becon-
the cable
mounted
nectiononbetween
the same conductive
the motor drive and mounting
sine wave plate. At least
filter needs theshort
to be as
motor as drive and
possible the23
(max. sine
m). wave filter shall be
For electromagnetic connected
emission reasonswith a
the shield
shall be ribbon.
flat copper connected EMC conform
Because of EMI on all ends onand
reasons a solid large connection
voltage spikes
area with the smallest possible impedance.
at the filter input terminals the cable connection between the
motor drive and sine wave filter needs to be as short as possi-
This EMC measure can only be considered to be efficient, if the ends of the
ble (max. 2-3m).
cable shield areFor electromagnetic
put in proper HF low-impedance emission reasons
contact thechassis
with the
shieldof shall be connected
the motor, the filter and EMC conform
the frequency on all ends on a solid
converter.
large connection area with the smallest possible impedance.
In case sine wave filters are installed in cabinets, the shield of the motor In order to g
This cable
EMCneeds
measure can only at
to be connected bethe
considered
cabinet entrytopoint.
be efficient, if application
the ends of the cable shield are put in proper HF low- EMC and P
impedance contact
To minimize with thecapacity
the coupling chassis ofinductivity
and the motor, the filter
reserve cableand
length of www.sch
the frequency converter.
need to be avoided.
These addit
Connect spare wires in the cable on both sides to ground for adding a
grounding,
supplementary shielding effect.

26
 Filters with separate capacitor bank must be connected as follows:

Caution:
U1, V1, W1 cable connection towards drive
U2, V2, W2 cable connection toward motor
Filter may be damaged when cables are swapped!

U1 U2

V1 V2

W1 W2

PE PE

Drive Motor

In order to get the maximum benefit out of your output filter applica-
tion and installation, please also consult Basics in EMC and Power Qual-
ity, published in the download section of www.schaffner.com.

These additional guidelines provide helpful hints for HF-grounding,

shielding, proper cable routing etc.
27
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This document has been carefully

06/2013 EN

checked. However, Schaffner does not

assume any liability for errors or
inaccuracies.

28