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Installation Guide for Danfoss models including: OF7U1, iC7 Series Air Cooled dU dt Filter, iC7 Series, Air Cooled dU dt Filter, Cooled dU dt Filter, dU dt Filter, Filter
iC7-Automation | Danfoss
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DocumentDocumentInstallation Guide iC7 Series Air-cooled dU/dt Filter OF7U1 1 Overview 1.1 dU/dt Filter The dU/dt Filter is used to limit the voltage rise time and maximum voltage seen by the motor. This can be necessary to protect motor insulations and guarantee a long lifetime. The motor terminal phase-to-phase voltage remains pulse shaped, but the dU/dt and maximum values are reduced. There are 2 electrical sizes of the filter: 590 A and 880 A. 1.2 Contents of the Delivery e30bk584.10 1 2 5 9 10 6 11 12 3 13 4 7 8 14 Illustration 1: Items Included in the Delivery 1 dU/dt Filter inductor, 590 or 880 A 9 2 Power cables, 1.5 m (4.9 ft) at each side, assembled 10 3 AuxBus temperature measurement wire, 1.5 m 11 (4.9 ft), assembled 12 4 Thermal relay wire, 1.0 m (3.3 ft), assembled 13 5 Grommet M50, 6 pcs 14 6 Tubular cable lug 90° angle, 120 or 150 mm2, 6 pcs 15 7 dU/dt Filter capacitor assembly, 590 or 880 A 8 dU/dt Filter capacitor wire harness AuxBus temperature measurement board assembly Cable ties, 3 pcs M5x10 screws, 2 pcs Grommet, Ø25.3 mm (Ø1 in), 2 pcs AuxBus cable, 3 m (9.8 ft) AuxBus terminals, 2 pcs Heat shrinkable tubing, 32 mm (1.26 in), 1 m (3.3 ft), not shown in illustration Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 | 1 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Mechanical Installation 2 Mechanical Installation 2.1 Safety Information 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. CAUTION BURN HAZARD The filter is hot during operation. - Do not install the filter on a combustible surface. - Do not touch the filter when hot. Only qualified personnel are allowed to perform the installation described in this guide. Follow the instructions in this guide and relevant local regulations. Also read the instructions and safety information in the operating guide for the iC7 Series System Modules. 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 cabinet must also be sufficiently strong for the weight of the system modules 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 dU/dt Filter into the Cabinet See the installation dimension in 2.5 Dimensions of the dU/dt Filter. 1. Attach the dU/dt Filter inductor to the cabinet with 4 screws. Mount the inductor vertically, with the temperature measurement sensor at the top (assuming that the direction of the cooling air flow is upwards). In IP54 installations, mount the inductor in the IP54 section. 1 1 1 1 2 2 e30bk590.10 1 1 1 1 Illustration 2: Mounting Holes of the dU/dt Filter Inductor 1 Mounting holes 2 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 e30bk591.10 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Mechanical Installation 2 Temperature measurement wire 2. Attach the inductor from the mounting holes on the front support plate to an air channel or other cover plate. 2 2 2 2 1 1 1 1 2 2 2 2 Illustration 3: Mounting Holes on the Front Support Plate of the Inductor 1 Mounting holes on 590 A inductor 2 Mounting holes on 880 A inductor 3. Mount the dU/dt Filter capacitor assembly to the cabinet with 4 screws. In IP54 installations, mount the capacitor assembly outside the IP54 section. e30bk592.10 1 1 1 1 Illustration 4: Mounting Holes of the Capacitor Assembly 1 Mounting holes 4. Mount the assembly plate of the AuxBus temperature measurement board to the cabinet with 4 screws. In IP54 installations, mount the assembly plate outside the IP54 section. Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 | 3 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide 1 1 2 2 e30bk562.10 Mechanical Installation Illustration 5: Mounting Holes of the Assembly Plate 1 Mounting holes with keyholes, Ø5/3 mm (Ø0.20/0.12 in) 2 Mounting holes, Ø5.5 mm (Ø0.22 in) 2.4 Cooling Requirements The maximum ambient operating temperature of the dU/dt Filter is 40 °C (104 °F), with derating up to 55 °C (131 °F). The product requires forced air cooling. Make sure that the cooling air flow through the filter is sufficient. The minimum air flow is 3 m/s (10 ft/s). e30bk585.10 Illustration 6: Air Flow Through the Filter 2.5 Dimensions of the dU/dt Filter The dimensional drawings for the dU/dt Filters do not show the pre-installed cables. 4 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide 220 (8.66) 192 (7.56) 454 430 (17.87) (16.93) 85.8 (3.38) 85.6 (3.37) Ø4.5 (0.18) Ø9x14 (0.35x0.55) 220.5 (8.68) Illustration 7: Dimensions of the dU/dt Filter 590 A Inductor in mm (in) Mechanical Installation e30bk586.10 Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 | 5 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide 24 (0.95) 228.5 (9.00) 192 (7.56) Ø9x14 (0.35x0.55) 454 430 336.5 (17.87) (16.93) (13.25) 85.8 (3.38) 24 (0.95) 85.6 (3.37) 196 (7.72) Ø4.5 (0.18) Ø4.5 (0.18) 247 (9.72) 30.5 (1.20) Mechanical Installation e30bk587.10 e30bk588.10 Illustration 8: Dimensions of the dU/dt Filter 880 A Inductor in mm (in) Ø3 (0.12) Ø5 (0.20) Ø5.5 (0.22) 84 (3.31) 120.5 (4.74) 76.8 (3.02) 164.4 (6.47) 37 (1.46) Illustration 9: Dimensions of the AuxBus Temperature Measurement Board Assembly in mm (in) 6 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide 130 (5.12) 116 (4.57) 53 (2.09) Ø5.5 (0.22) 30 (1.18) 60 (2.36) Illustration 10: Dimensions of the dU/dt Filter Capacitor Assembly in mm (in) e30bk589.10 Mechanical Installation Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 | 7 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation 3 Electrical Installation 3.1 Installing the Filter Install the dU/dt Filter at the inverter output. If the inverter has parallel power units, install a separate dU/dt Filter at the output of each power unit. The dU/dt Filter can be installed as the only output filter, or it can be used with a Common-mode Filter. If a Common-mode Filter is installed, install the dU/dt Filter between the inverter output and the Common-mode Filter. See 3.5 Wiring Diagrams. 3.2 Installing the Cables 1. Prepare the power cables of the dU/dt Filter. - a. If necessary, cut the cables to the correct length. The length of the cables is 1.5 m (4.9 ft) at both sides of the filter. Use hot cutting for the mesh type mechanical protection sleeve to avoid fraying. The copper cable ends have tapes to keep the strands together. If possible, also use tape around the cutting point to avoid fraying. In general, keep the length between the drive output and the filter input as short as possible. The recommended maximum value is 3 m (9.8 ft). - b. If the filter is installed in a separate IP54 section, route the cables through the M50 grommets included in the delivery. Cut the grommets tight to the cable and use the provided heat shrink tube to seal the grommet to the cable. - c. Attach the provided cable lugs to the ends of the cables. Remove the possible tapes from the cable ends. Do not place the silicone sleeve and mesh type mechanical protection sleeve on top of the cable lug. Use the provided heat shrink tube to seal the connection. The recommended tube length is 70 mm (2.8 in). 2. Connect the power cables from the dU/dt Filter to the busbars. Use M12 bolts with plain washers and spring washers. 3. Use the provided dU/dt Filter capacitor wire harness to connect the capacitor assembly to the busbars. - a. Connect the connector on the wire harness to the connector of the capacitor assembly. - b. Connect the harness wires to the busbars on the motor side of the inductor. Use M4 bolts with plain washers and spring washers. Do not extend the capacitor wire harness. 4. Connect the temperature measurement wire from the filter inductor to terminal X206 on the AuxBus temperature measurement board. - a. If necessary, the wire can be cut shorter. The length of the wire is 1.5 m (4.9 ft). - b. If the filter inductor is installed in a separate IP54 section, route the wire through the grommet included in the delivery. - c. Attach the wire to the assembly plate with a cable tie. 5. If AuxBus is not available, connect the thermal relay wire to the I/O terminal of a temperature monitoring device. - a. If necessary, the wire can be cut shorter. The length of the wire is 1.0 m (3.3 ft). - b. If the filter inductor is installed in a separate IP54 section, route the wire through the grommet included in the delivery. 8 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation 6. Bundle up the unused temperature measurement or thermal relay wire and attach it safely close to the inductor. Example IP54 IP00 U VW e30bk604.10 1.5 m 11 2 4 8 1.5 m 1 5 7 9 1.0 m 6 7 3 4 1.5 m 13 14 0.2 m 15 10 12 Illustration 11: dU/dt Filter Cable Connections 1 Inductor 2 Power cables, drive side, 1.5 m (4.9 ft) 3 Power cables, motor side, 1.5 m (4.9 ft) 4 M50 grommets, IP54 only 5 AuxBus temperature measurement wire, 1.5 m (4.9 ft) 6 Thermal relay wire, 1.0 m (3.3 ft) 7 Grommet, Ø25.3 mm (Ø1 in), IP54 only 8 dU/dt Filter capacitor assembly U VW 9 Connector of dU/dt Filter capacitor wire harness 10 dU/dt Filter capacitor wire harness connection to busbars, motor side 11 Power cable connections to busbars, drive side 12 Power cable connections to busbars, motor side 13 AuxBus temperature measurement assembly 14 Cable tie 15 Terminal X206 Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 | 9 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation 3.3 Preparing the AuxBus Cable 1. Cut the cable to the required length. 2. To reveal the wires, strip the cable at both ends. 3. At 1 end of the cable, remove approximately 15 mm (0.59 in) of the insulation of the cable. 4. Strip the wires 7 mm (0.28 in). 5. Connect the wires to the terminals included in the delivery. Use the tightening torque 0.220.25 Nm (1.92.2 in-lb). Table 1: Wiring of the AuxBus Terminals Pin Wire color Signal 1 White +24 V 2 Brown GND 3 Green CAN_H 4 Yellow CAN_L 5 Grey +24 V e30bk577.10 21 12 3 Illustration 12: The Ready AuxBus Cable 1 Terminals 2 Wires 3 Shield removed 3.4 AuxBus Connections NOTICE For the drive to be able to protect the filters, AuxBus must be connected. For more information about AuxBus, see the iC7 Series System Module operating guides. 1. Connect the AuxBus cable between the filter and the power unit. If there are several power units and filters, connect each filter to the power units individually. - a. Connect the end of the AuxBus cable where the insulation was removed to terminal X25 on the power unit. - 10 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 e30bk560.10 e30bk559.10 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation b. Connect the other end of the AuxBus cable to terminal X86 on the AuxBus temperature measurement board. X201 X202 X86 X203 X204 X205 X85 X206 Illustration 13: Terminals on the AuxBus Temperature Measurement Board X20_ X85 Temperature measurement input AuxBus in X86 AuxBus out Control unit Optical fiber cable Power unit X25 AuxBus Cable X86 Filter Control unit Optical fiber cable Star coupler board Optical fiber cable Optical fiber cable Optical fiber cable Power unit 1 X25 AuxBus cable X86 Filter 1 Power unit 2 X25 AuxBus cable X86 Filter 2 Power unit N X25 AuxBus cable X86 Filter N Illustration 14: AuxBus Topology 2. Route the cable so that there is no risk of getting in touch with bare busbars or terminals. 3. Ground each AuxBus cable at 1 end, at the X25 terminal. To make the grounding connection, attach the shield of the cable to the frame with a cable clamp. The lower part of the cable clamp fixes the cable to the plate and provides strain relief. The upper part provides ~360° grounding for the cable shield. 1 e30bj147.10 2 3 Illustration 15: Using the Cable Clamps 1 Stripping length, 15 mm (0.59 in) 2 Strain relief Danfoss A/S © 2023.08 3 Grounding AN440742625342en-000101 / 172K0614 | 11 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation e30bg725.11 4. At the terminal X86 end of the cable, place the cable in a cable clamp for strain relief. 3.5 Wiring Diagrams 1 2 3 4 U U' U DC+ DC+ V V' V DC- DCW W' W U/T1 V/T2 W/T3 PE 5 U1 V1 M W1 3~ PE Illustration 16: Wiring Diagram for Inverter and dU/dt Filter e30bg726.11 1 DC fuses 2 Inverter module 3 dU/dt Filter DC+ DC- 1 2 U DC+ V DC- W 4 Common-mode Filter (optional) 5 Motor 3 U' U V' V W' W 4 U/T1 V/T2 W/T3 U DC+ V DC- W U' U V' V W' W U/T1 V/T2 W/T3 5 U1 V1 M W1 3~ PE U DC+ V DC- W U' U V' V W' W DC+ DC- Illustration 17: Wiring Diagram for Inverter with Parallel Power Units and dU/dt Filters U/T1 V/T2 W/T3 PE 1 DC fuses 2 Inverter modules 3 dU/dt Filters 4 Common-mode Filters (optional) 5 Motor 12 | Danfoss A/S © 2023.08 AN440742625342en-000101 / 172K0614 iC7 Series Air-cooled dU/dt Filter OF7U1 Installation Guide Electrical Installation 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. Danfoss A/S © 2023.08 *172K0614A* AN440742625342en-000101 / 172K0614 | 13