Danfoss OF7S1SM Liquid Cooled Sine Wave Filter User Guide

Installation Requirements
Only qualified personnel should perform the installation. Follow the guide and local regulations. Refer to the operating guide for additional safety information.

Installing the Filter into a Cabinet

Install the filter vertically or horizontally in the cabinet.
Attach the filter to the cabinet using the mounting holes on the frame.

Cooling Requirements

Dimensions of the Sine-wave Filter

FAQ

Q: What is the purpose of the sine-wave filter?
A: The sine-wave filter eliminates high-frequency components from the AC drive output voltage, reducing bearing currents, voltage reflections, and motor noise levels.

Q: Can anyone install the filter?
A: No, only qualified personnel should perform the installation to ensure safety and proper functioning.

Overview

Sine-wave Filter
The sine-wave filter is an LC low-pass filter, whose cut-off frequency is set to eliminate all the high-frequency components from the output voltage of the AC drive. The filter produces a near perfect sinusoidal voltage waveform.
The sine-wave filter reduces bearing currents and eliminates voltage reflections, and it also reduces the noise levels of the motor. There is 1 electrical size of the filter: SIN12L (800 A).

AuxBus temperature measurement board
Terminals

Cooling connectors

Contents of the Delivery

1 Sine-wave Filter	2	AuxBus cable, 3 m (9.8 ft)
3 AuxBus terminals, 2 pcs	4	AuxBus isolation board installation kit

Available options:

+ANN1 = Push-in cooling connectors

+ANNC = Threaded cooling connections, metric (default)
+AO20 = Coolant hoses (2.0 m)

Mechanical Installation

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.

Installation Requirements

The products described in this guide have the protection rating IP00/UL Open Type. Install the products in an enclosure that has a correct level of protection against the ambient conditions in the installation area. Make sure that the enclosure gives protection against water, humidity, dust, and other contaminations.
The enclosure must also be sufficiently strong for the weight of the filter components and other devices.
The protection rating of the enclosure must be at least IP21/UL Type 1. When preparing the installation, obey the local regulations.

Installing the Filter into a Cabinet

Install the filter into the cabinet in a vertical or horizontal position. See 2.4 Dimensions of the Sine-wave Filter.

Attach the filter from the mounting holes on the frame to the cabinet.
- For aluminum parts, use M6 grade 8.8 screws with a thread depth of 6–14 mm (0.24–0.55 in), and a tightening torque of 6– 8 Nm (53–71 in-lb).
- For sheet metal parts, use M5 (DIN 7500) screws with a maximum thread depth of 20 mm (0.79 in), and a tightening torque of 3–4 Nm (27–35 in-lb).

Mounting brackets
Mounting holes in aluminum parts

Mounting holes in aluminum parts

Dimensions of the Sine-wave Filter

A Center of gravity

B View from the top
C View from the bottom

Cooling Requirements

Safety in Liquid-cooling

WARNING

POISONOUS COOLANTS
Glycols and inhibitors are poisonous. If touched or consumed, they can cause injury.

Prevent the coolant from getting into the eyes. Do not drink the coolant.

CAUTION

HOT COOLANT
Hot coolant can cause burns.

Avoid contact with the hot coolant.

CAUTION

PRESSURIZED COOLING SYSTEM
Sudden release of pressure from the cooling system can cause injury.

Be careful when operating the cooling system.

NOTICE

INSUFFICIENT COOLING CAPACITY
Insufficient cooling can cause the product to become too hot and thus become damaged.

To make sure that the cooling capacity of the cooling system stays sufficient, make sure that the cooling system is vented and that the coolant circulates properly.

NOTICE

DAMAGE TO COOLING SYSTEM
If the coolant circulation is stopped too soon, high-temperature components can cause rapid local increase in the coolant temperature, which can damage the cooling system.

Do not stop the cooling system when stopping the drive. Keep the coolant circulation flowing for 2 minutes after the drive has been stopped.

General Information on Cooling

NOTICE

For more detailed information about the requirements for liquid-cooling, see the iC7 Series Liquid-cooled System Modules Design Guide.

The product is cooled with liquid. The liquid circulation of the drive is usually connected to a heat exchanger (liquid-to-liquid or liquid-to-air) that cools down the liquid circulating in the cooling elements. The cooling elements are made of aluminum.
If there is no risk of freezing, purified water can be used as coolant. Freezing water permanently damages the cooling system. Purified water is demineralized, deionized, or distilled water.
The allowed antifreeze coolants are the following ethylene glycols and propylene glycols.

Ethylene glycols: DOWCAL 100 or Clariant Antifrogen N
Propylene glycols: DOWCAL 200 or Clariant Antifrogen L
These glycols already include corrosion inhibitors. Do not add any other inhibitor. Do not mix different glycol qualities because there can be harmful chemical interactions.

The glycol concentration of the coolant must be 25–55% by volume according to the specified ambient temperature. Higher concentration reduces cooling capacity. Lower concentration results in biological growth and inadequate amount of corrosion inhibitors. Antifreeze must be mixed with purified water.
To gain full performance of the product, the temperature of the coolant entering the system module must be a maximum of 45 °C (113 °F). Typically, 95% of the power losses are dissipated in the coolant. It is recommended to equip the cooling circulation with temperature supervision.

The minimum nominal flow rate of the coolant:

8.0 l/min (2.11 gal/min) with water
10.4 l/min (2.75 gal/min) with 30% glycol
12.0 l/min (3.17 gal/min) with 50% glycol

The liquid volume per element: 1.25 l (0.330 gal)

Cooling Circuit Connectors
The Sine-wave Filter OF7S1SM has cooling circuit connectors in the manifold plate. The internal thread size is G1/2. The depth of the threads is 13 mm (0.51 in). The maximum tightening torque is 30 Nm (265 in-lb). Push-in connectors are available as option +ANN1. The inlet and outlet connectors are at the bottom of the filter. An alternative outlet connector is available at the top of the filter. If the optional outlet connector at the top is used, the outlet connector at the bottom must be closed with a plug. Do not connect filters in series. Connecting in series requires high flow rates and high pressure because of the temperature rise of the coolant in the filters.
Table 1: Recommended Connectors

Connector	Tightening torque	Pipe	Pipe ferrule
Parker 69111621 MALE STUD 1/2″BSPP SS STEEL 31 6L D16 EPDM SEAL	20–30 Nm (177–265 in-lb)	PA 16/13 pipe	Parker 1827-16-13

Outlet connector
Inlet connector
Alternative outlet connector

Electrical Installation

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 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.

Installing the Sine-wave Filter
Install the sine-wave filter at the inverter output. If the inverter has parallel power units, install a separate sine-wave filter at the output of each power unit. See 4.10 Wiring Diagrams.

Cable Requirements
For information about recommended cable types and required cable sizes, see the iC7 Series Liquid-cooled System Modules Design Guide.

Grounding
Ground the filter in accordance with applicable standards and directives. Unless local wiring regulations state otherwise, the cross-sectional area of the protective grounding conductor must be at least 50% of the cross-sectional area of the phase conductor and made of the same material when the phase conductor cross-section is above

mm2 (AWG 2) according to IEC 60364-5-54; 543.1.
The connection must be fixed.

Installing the Cables

Connect the AC cables from the inverter module to terminals U’, V’, and W’. Use M10 screws and tightening torque 35–40 Nm (310–354 in-lb).

Connect the motor phase cables to terminals U, V, and W.
Use M10 screws and tightening torque 35–40 Nm (310–354 in-lb).
Connect the grounding cable to the PE terminal.
Use M8 screws and tightening torque 17–20 Nm (150–177 in-lb).

Terminals

Table 2: Sine-wave Filter Terminal Descriptions

Terminal	Description
U/T1	Connection point for motor output
V/T2
W/T3
U’/T1′	Connection point for inverter module to sine-wave filter
V’/T2′
W’/T3′
PE	Grounding terminal for filter frame

Installing the AuxBus Isolation Board
Install the AuxBus isolation board on the system module.

Release the cover of the AuxBus isolation board. Remove the M4x8 combi screw with a TX20 bit.

Install the PCB insulator.
- Mount the spacer screw on the front of the module. Use an 8 mm hex bit and tighten the screw to torque 0.4 Nm.
- Mount the PCB insulator on the spacer screw.

Mount the AuxBus isolation board with 2 size M4x8 combi screws. Use a TX20 bit and tighten the screws to torque 2.2 Nm.
Connect the AuxBus wire harness to terminal X78 on the AuxBus isolation board and to terminal X77 on the system module.
Mount the relief plate with a M4x8 screw. Use a TX20 bit and tighten the screw to torque 2.2 Nm.

Reinstall the cover of the AuxBus isolation board. Use the old M4x8 combi screw or the spare one provided in the delivery. Use a TX20 bit and tighten the screw to torque 2.2 Nm.

Preparing the AuxBus Cable

Cut the cable to the required length.

To reveal the wires, strip the cable at both ends.
At 1 end of the cable, remove approximately 15 mm (0.59 in) of the cable insulation.
Strip the wires 7 mm (0.28 in).

Connect the wires to the terminals included in the delivery. Use the tightening torque 0.22–0.25 Nm (1.9–2.2 in-lb).

Table 3: Wiring of the AuxBus Terminals

Pin	Wire color	Signal
1	White	+24 V
2	Brown	GND

Pin	Wire color	Signal
3	Green	CAN_H
4	Yellow	CAN_L
5	Grey	+24 V

Terminals

Wires
Shield removed

AuxBus Connection

NOTICE
For the drive to be able to protect the filters, the AuxBus must be connected.

For more information about AuxBus, see the iC7 Series Liquid-cooled System Modules Design Guide.

To access the AuxBus temperature measurement board, remove the cover.
1. AuxBus temperature measurement board
2. Cover
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.
- Connect the end of the AuxBus cable where the insulation was removed to terminal X79 on the power unit.
- Connect the other end of the AuxBus cable to terminal X86 on the AuxBus temperature measurement board.
- X206 Temperature measurement input
- X85 AuxBus in
- X86 AuxBus out
Route the cable so that there is no risk of getting in touch with bare busbars or terminals.

Ground each AuxBus cable at 1 end at the X79 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. Stripping length, 15 mm (0.59 in)
  2. Strain relief
  3. Grounding
At the terminal X86 end of the cable, place the cable in a cable clamp for strain relief.

Wiring Diagrams

DC fuses, loose option
Inverter module

Sine-wave filter

Maintenance

Preventive Maintenance Recommendations
Generally, all technical equipment needs a minimum level of preventive maintenance. Regular maintenance is recommended to ensure trouble-free operation and long life of the product. It is also recommended, as a good service practice, to record a maintenance log with counter values, date, and time describing the maintenance and service actions.
Danfoss recommends the following inspections and service intervals for the product.

NOTICE
The service schedule for part replacements can vary depending on operating conditions. Under specific conditions, the combination of stressful operation and environmental conditions work together to reduce the lifetime of the components significantly. These conditions can include, for example, extreme temperature, dust, high humidity, hours of use, corrosive environment, and loading.

For operation in stressful conditions, Danfoss offers the DrivePro® Preventive Maintenance service. DrivePro® services extend the lifetime and increase the performance of the product with scheduled maintenance including customized part replacements. DrivePro® services are tailored to your application and operating conditions.
Table 4: Maintenance Schedule for Liquid-cooled Filters

Component	Inspection interval⁽¹⁾	Service schedule⁽²⁾	Preventive maintenance actions
Installation
Visual inspection	1 year	–	Check for the unusual, for example, for signs of overheating, aging, corrosion, and for dusty and damaged components.

Component	Inspection interval⁽¹⁾	Service schedule⁽²⁾	Preventive maintenance actions
Cable routing	1 year	–	Check for parallel routing of motor cables, mains wiring, and signal wiring. Avoid parallel routing. Avoid routing cables through free air without support. Check for aging and wearing of the cable insulation.
Power cabling	1 year	–	Check for loose connections, aging, insulation condition, and proper torque to the drive connections. Check for proper rating of fuses and continuity check. Observe if there are any signs of operation in a demanding environment. For example, discoloration of the fuse housing can be a sign of condensation or high temperatures.
Control wiring	1 year	–	Check for tightness, damaged or crimped wires, or ribbon wires. Terminate the connections correctly with solid crimped ends. The use of shielded cables and grounded EMC plate, or a twisted pair is recommended.
EMC consideration	1 year	–	Inspect the installation wiring regarding the electromagnetic capability and the separation distance between control wiring and power cables.
Grounding	1 year	–	The drive system requires a dedicated ground wire connecting the drive, the output filter, and the motor to the building ground. Check that the ground connections are tight and free of paint or oxidation. Daisy-chain connections are not allowed. If applicable, braided straps are recommended.
Proper clearances	1 year	–	Check that the required external clearances for proper airflow for cooling are followed according to the type of the drive. For clearances, refer to the local design regulations.
Corrosive environ- ments	1 year	–	Conductive dust and aggressive gases, such as sulphide, chloride, and salt mist, can damage the electrical and mechanical compo- nents. Air filters do not remove airborne corrosive chemicals. Act based on findings.
Filter components
Capacitors	1 year	12–15 years	The expected life time of the capacitor is determined based on load and the temperature of the environment. Replace parts ac- cording to the service schedule. For applications with heavy loads or demanding environments, replace the capacitors every 12 years. In a typical environment, within the specifications of the fil- ter, replace every 15 years. Only trained service personnel are al- lowed to perform this action.
PCB	1 year	10–12 years	Visually inspect the printed circuit boards for signs of damage or degrading due to aging, corrosive environments, dust, or environments with high temperatures. Only trained service personnel are allowed to perform the inspection and service action.
Insulators	1 year	10–15 years	Inspect the insulators for signs of degradation due to high temperature and aging. Replacement is based on findings. Only trained service personnel are allowed to perform this action.

Component	Inspection interval⁽¹⁾	Service schedule⁽²⁾	Preventive maintenance actions
Coolant
Log	Commissioning/start up, or at time of replacing liquid coolant	–	Record the water quality specification values to create a baseline for future reference before and after adding inhibitor and glycol. Also record the system pressure, coolant flow rate, temperature range, and create a baseline for future reference.
Glycols	1 year	Based on findings	Measure and record the level of glycol in the cooling system. The minimum concentration level is always 75/25% demineralized water/glycol.
Corrosive inhibitors	1 year	Based on findings	Measure and record the level of corrosive inhibitor (Cortec VpCI-649) in the liquid coolant (see specification). Measure the level of the inhibitor every year. If the inhibitor level is below the recommended level of 1%, add more inhibitor. Before adding more inhibitor, practice caution not to exceed the level of elecrical conductivity. Use the corrosive inhibitor recommended by Danfoss.
Pre-mixed glycol and inhibitor coolant	1 year	Based on findings	The pre-mixed coolants contain specific percentages of glycol and inhibitor for antifreeze and corrosion protection. The advantage of using a pre-mixed coolant is that the chemical composition is within Danfoss specifications, and there is no need for analyzing the coolant.
Demineralized water	1 year	Based on findings	Only use demineralized or deionized water in the coolant solution. Record and compare the chemical composition values when replacing or adding coolant.
Liquid cooling system
Pipes, hoses, and connections	1 year	1 year	Check for external signs of moisture, corrosion, and coolant leaks. Check the tightness of the cooling pipe connections. Check the heat sinks and host pipes in the cooling system.
Leak detector	1 year	10 years	Test the functioning of the leak detector.
Power unit heat sinks	1 year	6 years	Check that the heat sink temperature across all cooling circuits or power phases is balanced. Imbalanced temperature of the cooling circuits is a possible sign of a restriction. Under normal conditions, clean or acid-wash the heat sinks every 6 years with cleaning products recommended by Danfoss. Refill the coolant system and log the new coolant specification values.
Auxiliary equipment	1 year	According to manufacturer recommendations	Check that the sensors, gauges, and indicators are functioning correctly. Act based on findings.
System cooling capacity	1 year	Based on findings	Test the cooling capacity and the thermal transfer of the system. Record the coolant system flow, pressure, and input and output temperature, and compare to the previous measurements. Act based on findings.

Recommended Disposal
When the product reaches the end of its service life, its primary components can be recycled. Before the materials can be removed, the product must be disassembled. Product parts and materials can be dismantled and separated. Generally, all metals, such as steel, aluminum, copper and its alloys, and precious metals can be recycled as material. Plastics, rubber, and cardboard can be used in energy recovery. Printed circuit boards and large electrolytic capacitors with a diameter of under 2.5 cm (1 in) need further treatment according to IEC 62635 guidelines. To ease recycling, plastic parts are marked with an appropriate identification code. Contact your local Danfoss office for further information on environmental aspects and recycling instructions for professional recyclers. End-of-life treatment must follow international and local regulations.All products are designed and manufactured in accordance with Danfoss company guidelines on prohibited and restricted substances. A list of these substances is available at www.danfoss.com.

This symbol on the product indicates that it must not be disposed of as household waste. Do not dispose of equipment containing electrical components together with domestic waste.
It must be handed over to the applicable take-back scheme for the recycling of electrical and electronic equipment.

Dispose of the product through channels provided for this purpose.
Comply with all local and currently applicable laws and regulations.

Danfoss Drives Oy Runsorintie 7 FIN-65380 Vaasa drives.danfoss.com

Any information, including, but not limited to information on selection of product, its application or use, product design, weight, dimensions, capacity or any other technical data in product manuals, catalog descriptions, advertisements, etc. and whether made available in writing, orally, electronically, online or via download, shall be considered informative, and is only binding if and to the extent, explicit reference is made in a quotation or order confirmation. Danfoss cannot accept any responsibility for possible errors in catalogs, brochures, videos and other material. Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to form, fit or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies. Danfoss and the Danfoss logo are trademarks of Danfoss A/S. All rights reserved.

Documents / Resources

Danfoss OF7S1SM Liquid Cooled Sine Wave Filter [pdf] User Guide
OF7S1SM Liquid Cooled Sine Wave Filter, OF7S1SM, Liquid Cooled Sine Wave Filter, Cooled Sine Wave Filter, Sine Wave Filter, Wave Filter, Filter

References

User Manual

Danfoss OF7S1SM Liquid Cooled Sine Wave Filter

Product Usage Instructions

Overview

Mechanical Installation

Cooling Requirements

Electrical Installation

Maintenance

Documents / Resources

References

Leave a comment

Cancel reply