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Installation Guide for Danfoss models including: AN412930943622en-000201, 172F8128, iC7 Series Pre Charging Unit, iC7 Series, Pre Charging Unit, Charging Unit
iC7-Hybrid | Danfoss
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DocumentDocumentInstallation Guide iC7 Series Pre-charging Unit for AFE and GC Modules 1 Overview 1.1 Pre-charging Unit The pre-charging unit is used for pre-charging the system modules that are connected to the same DC bus. There are 3 electrical sizes, and an IEC and a UL variant of the unit. · Pre-charging unit 10, IEC/UL · Pre-charging unit 20, IEC/UL · Pre-charging unit 30, IEC/UL The pre-charging unit is available as an accessory. 5 e30bj917.11 1 Illustration 1: The Pre-charging Unit 1 Charging resistors 2 Fuse switch 3 Contactor 4 3 2 4 Terminal blocks 5 Rectifier and snubber capacitor Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 | 1 iC7 Series Pre-charging Unit Installation Guide Mechanical Installation 2 Mechanical Installation 2.1 Safety Information DANGER DISCHARGE TIME The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off. Failure to wait the specified time after power has been removed before performing service or repair work could result in death or serious injury. - Stop the motor. - Disconnect AC mains, permanent magnet type motors, and DC-link connections to other drives. - Wait for the capacitors to discharge fully before performing any service or repair work. The discharge time is 5 minutes. - Use a measuring device to make sure that there is no voltage, before opening the drive or performing any work on the ca- bles. WARNING SHOCK HAZARD FROM THE COMPONENTS The components of the drive are live when the drive is connected to mains. - Do not make changes in the AC drive when it is connected to mains. 2.2 Installation Requirements The products that are described in this guide have the protection rating IP00/UL Open Type. Install them in a cabinet or other enclosure that has a correct level of protection against the ambient conditions in the installation area. Make sure that the cabinet gives protection against water, humidity, dust, and other contaminations. The maximum temperature of the air inside the cabinet for the pre-charging unit is +60 °C (140 °F). The cabinet must also be sufficiently strong for the weight of the system module and other devices. The protection rating of the cabinet must be at least IP21/UL Type 1. When preparing the installation, obey the local regulations. 2.3 Installing the Pre-charging Unit into the Cabinet Install the pre-charging unit into the cabinet in a horizontal position. Procedure 1. Attach the pre-charging unit to the cabinet using the mounting holes. Use M5 screws. In industrial installations, use a minimum of 4 screws. In marine installations, use 8 screws. To make the installation secure, use the outermost mounting holes. 2 | Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 iC7 Series Pre-charging Unit Installation Guide 2121 1212 Mechanical Installation e30bk014.10 2121 1212 Illustration 2: Mounting Holes of the Pre-charging Unit 1 Preferred mounting holes 2 Alternative mounting holes 2.4 Cooling Requirements The maximum ambient temperature of the pre-charging unit is 60 °C (140 °F). The product is cooled with natural convection. Make sure that the installation position provides conditions for natural convection. A minimum of 50 mm (2 in) free space at top and bottom is necessary for sufficient cooling air flow. CAUTION BURN HAZARD The pre-charging resistor will be very hot during the pre-charging sequence and the following cooling down period. - Do not install the pre-charging unit on a combustible surface. - Do not touch when hot. 2.5 UL 98 Requirements Minimum distances are required from the fuse switch of the pre-charging unit to the enclosure walls. · 165 mm (6.50 in) from the top and bottom of the fuse switch terminals · 13 mm (0.52 in) from the left side of the fuse switch These distance requirements are for the size of the enclosure, not for electrical spacings. Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 | 3 iC7 Series Pre-charging Unit Installation Guide 13 (0.52) 165 97.5 (6.50) (3.84) e30bk550.10 Mechanical Installation e30bj821.11 165 81.5 (6.50) (3.21) Illustration 3: Keep-out-area Around the Pre-charge Unit 1030 UL Types, UL 98 2.6 Dimensions of the Pre-charging Unit, IEC 15 (0.59) 30 (1.18) 60 (2.36) 292 (11.5) 240 (9.45) Ø6 (0.24) 60 (2.36) 239 (9.41) 118 (4.64) 240 (9.45) 263 (10.35) 18 (0.71) 230 (9.05) Illustration 4: Dimensions of the Pre-charging Unit in mm (in), IEC 4 | Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 iC7 Series Pre-charging Unit Installation Guide 2.7 Dimensions of the Pre-charging Unit, UL 15 (0.59) 30 (1.18) 60 (2.36) 292 (11.5) 240 (9.45) Ø6 (0.24) 60 (2.36) 112 (4.41) 240 (9.45) 263 (10.35) 115 (4.53) 156 (6.14) Illustration 5: Dimensions of the Pre-charging Unit in mm (in), UL Mechanical Installation 239 (9.41) e30bj822.11 Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 | 5 iC7 Series Pre-charging Unit Installation Guide Electrical Installation 3 Electrical Installation 3.1 Electrical Installation Safety WARNING OVERHEATED CABLES Overheated cables are a fire hazard. - Because of several possible cable installations and environmental conditions, it is important to consider local regulations and IEC/EN standards. Route the main circuit and control circuit wires away from sharp edges, screw threads, burrs, fins, moving parts, drawers, and similar parts, which can abrade the wire insulation. For the main circuit, use double insulated wires or protect the wires with, for example, a protective sleeve or wrap to minimize the risk of short circuit. Maintain separation between the main and control circuit wires. 3.2 Cable Requirements Table 1: Mains Terminals Line 1, Line 3, Line 5 Item Value Terminal type Screw terminal Tool Wire size (Cu) Flat head 410 mm2 (108 AWG), solid or stranded, with minimum insulation temperature rating of 75 °C. Strip length 12 mm (0.47 in) Torque per wire size 46 mm2: 3 Nm 10 mm2: 4 Nm 10 AWG: 30 in-lb 8 AWG: 35 in-lb Table 2: DC Terminals DC+, DC- Item Value Terminal type Wire size (Cu) Spring terminal 410 mm2 (108 AWG), solid or stranded, with minimum insulation temperature rating of 75 °C. Strip length 15 mm (0.59 in) Table 3: Control Terminals A1, A2 Item Terminal type Tool Wire size Strip length Torque Value Screw terminal Pozidriv 2 or flat head 5.5 mm (0.22 in) 12.5 mm2 (1814 AWG) 10 mm (0.39 in) 1.2 Nm (11 in-lb) A PE conductor is required if the pre-charging unit is not fixed to a grounded conductive structural part of the drive enclosure. 6 | Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 iC7 Series Pre-charging Unit Installation Guide Electrical Installation Table 4: Grounding Terminal PE Item Terminal type Wire size (Cu) Value Ring or fork terminal, size M8 Reference terminal type (UL): · P8-38R-Q (AWG 8, Panduit) · P10-38R-L (AWG 10, Panduit) 410 mm2 (108 AWG) 3.3 Fuses Use only these fuse types in the fuse switch of the pre-charge unit. Table 5: Standard Fuse In [A] Fuse Un [V AC] Fuse type IEC 40 690 NH gG size 000 UL 40 600 Class J, Time-delay, 23/8 x 11/16 in (60x27 mm) Part number, Mersen Part number, Eaton H000GG69V40 40NHG000B-690 AJT40 LPJ-40SP 3.4 Terminals A1 A2 A1 A2 e30bj902.11 LINE 1 LINE 3 LINE 5 PE DC+ DC- Illustration 6: Terminals of the Pre-charging Unit Left Right Pre-charging unit 10/20 Pre-charging unit 30 Table 6: Pre-charging Unit Terminal Descriptions Terminal Description Line 1 Line 3 Line 5 AC-supply connection point for pre-charging circuit DC+ Pre-charging circuit, DC terminal connection point LINE 1 LINE 3 LINE 5 PE DC+ DC- Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 | 7 iC7 Series Pre-charging Unit Installation Guide Electrical Installation Terminal DC- A1 A2 PE Description Pre-charging circuit, contactor coil terminal. Coil voltage range 100250 V AC, 50/60 Hz. Grounding terminal for the pre-charging circuit See the wiring diagrams in 3.6 Pre-charging Unit Wiring Diagram and 3.7 Control Wiring Diagram. 3.5 Installing the Power Cables Procedure 1. Attach the mains cable to the mains terminals Line 1, Line 3, and Line 5 of the pre-charging unit. - a. Attach the grounding conductor of the mains cable to the PE terminal of the pre-charging unit. See the cable requirements in 3.2 Cable Requirements. See the location of the mains terminals in 3.4 Terminals. 2. Attach the DC cable to the DC terminals DC+ and DC- of the pre-charging unit. See the cable requirements in 3.2 Cable Requirements. See the location of the DC terminals in 3.4 Terminals. 3.6 Pre-charging Unit Wiring Diagram 8 | Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 iC7 Series Pre-charging Unit Installation Guide L1 L1 L1 L1 L1 L1 L2 L2 L2 L2 L2 L2 L3 L3 L3 L3 L3 L3 1 1 -QB6 LINE 1 LINE 3 LINE 5 2 4 6 1 3 5 1 3 5 -QA6 2 4 6 -TB6 3 + -CA6 - -QB6 LINE 1 LINE 3 LINE 5 2 4 6 1 3 5 1 3 5 -QA6 2 4 6 -TB6 3 + -CA6 - Electrical Installation e30bj903.11 L1 L1 L1 L2 L2 L2 L3 L3 L3 1 -QB6 LINE 1 LINE 3 LINE 5 2 4 6 1 3 5 1 3 5 -QA6 2 4 6 -TB6 3 + -CA6 - -XD6 1 + 3- -RA6.1 -RA6.2 -XD6 2 + 4- -XD6 1 + 3- -RA6.1 -RA6.3 -RA6.2 -RA6.4 -XD6 2 + 4- -XD6 2 + 1+ 5- 6- -RA6.3 -RA6.1 -RA6.5 -RA6.2 -RA6.6 -RA6.4 -XD6 4 + 3+ 7- 8- 1 1 1 DC+ DC- DC+ DC- DC+ DC- DC+ DC- DC+ DC- DC+ DC+ DC+ DC- DC- 10 20 30 Illustration 7: Main Circuits of the Pre-charging Units 1 Double-insulated cable 10 Pre-charging unit 10, IEC/UL 20 Pre-charging unit 20, IEC/UL 30 Pre-charging unit 30, IEC/UL DC+ DC- DC- Danfoss A/S © 2023.02 AN412930943622en-000201 / 172F8128 | 9 iC7 Series Pre-charging Unit Installation Guide 3.7 Control Wiring Diagram 1 115... 230 VAC -SF11 23 24 2 3 A1 -QA6 A2 A1 -QA3 A2 N 4 123 COM NO NC X1 456 COM NO NC X2 78 COM NO X3 71 72 TI+ TI- X51 Electrical Installation e30bi270.11 Illustration 8: Pre-charging Control Wiring Diagram 1 Short-circuit protected 2 Pre-charging contactor control 3 Main input device control 4 Basic I/O of the control unit of the AFE module Vacon Ltd, Member of the Danfoss Group Runsorintie 7 FIN-65380 Vaasa www.danfoss.com Danfoss can accept no responsibility for possible errors in catalogs, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved. 10 | Danfoss A/S © 2023.02 *172F8128B* AN412930943622en-000201 / 172F8128