Danfoss 176F3737, 176F3752 Installation Instructions Manual

1.1 Description

The 300 A and 500 A current sensor kits are designed for
D2h/D4h/D7h/D8hdrives in the power ranges shown in

Tab l e 1.1 and Tabl e 1.2 . To identify the power rating, see
chapter 1.1.1 Identifying the Power Rating.

Product group and series Voltage rating

(V)

Power rating [kW

(hp)]

VLT

®

HVAC Drive FC 102,

VLT

®

Refrigeration Drive FC 103,

VLT

®

AQUA Drive FC 202

(T4) 380–480 110–200

(150–300)

(T7) 525–690 75–315

(75–350)

VLT

®

AutomationDrive FC 302

(T5) 380–500 90–160

(125–200)

(T7) 525–690 55–250

(75–350)

Table 1.1 Applicable Power Ranges for 300 A Current Sensor Kit

Product group and series Voltage rating

[V]

Power rating [kW

(hp)]

VLT

®

HVAC Drive FC 102,

VLT

®

Refrigeration Drive FC 103,

VLT

®

AQUA Drive FC 202

(T4) 380–480 200–315

(300–450)

(T7) 525–690 200–400

(250–400)

VLT

®

AutomationDrive FC 302

(T5) 380–500 200–250

(300–350)

(T7) 525–690 160–315

(200–350)

Table 1.2 Applicable Power Ranges for 500 A Current Sensor Kit

1.1.1 Identifying the Power Rating

To

nd

the drive power rating, use the following steps:

1. Obtain the following information from the
nameplate, which is on the drive. Refer to
Illustration 1.1.

•

Product group and drive series
(characters 1–6)

•

Power rating (characters 7–10)

•

Voltage rating (phases and mains)
(characters 11–12)

2. Determine if the power rating is in Ta ble 1. 1 and
Tab l e 1.2 .

1 Product group and drive series

2Power rating

3 Voltage rating (phases and mains)

Illustration 1.1 Example Nameplate

1.1.2 Kit Ordering Numbers

Kit number Kit description

176F3752 300 A Current Sensor Conversion Kit

D2h/D4h/D7h/D8h

176F3737 500 A Current Sensor Conversion Kit

D2h/D4h/D7h/D8h

Table 1.3 Kit Numbers for 300 A and 500 A Current Sensor Kits

Installation Instructions

300 A/500 A Current Sensor Kit for
D2h/D4h/D7h/D8h Drives

VLT

®

FC Series FC 102, FC 103, FC 202, FC 302

Danfoss A/S © 07/2018 All rights reser ved. MI70V202

1.1.3 Items Supplied

Tabl e 1.4 provides a list of items included in the 300 A and 500
A current sensor kits for D2h/D4h/D7h/D8h drives. Refer also
to Illustration 1.4.

Description Quantity

R/S/T terminal label 1

M10x30 machine screw with captive washer 6

M10 nut 6

Mains input terminal block 1

M5x12 machine screw 12

U/V/W terminal label 1

Motor terminal block 1

Cable retaining clip 6

M10 nut with captive washer 4

Cable clamp adapter 2

Power terminal mounting plate (IP21/IP54) 1

Power terminal mounting plate (IP20/Chassis) 1

Mixing fan 1

Mixing fan housing 1

EMC shield 1

Plastic mounting button 3

Motor busbar (U) 1

Motor busbar (V) 1

Motor busbar (W) 1

Busbar insulator sleeve 1

M5x16 torx screw 3

M8x70 screw 3

Cylinder busbar 3

Nomex tube 3

300 A or 500 A current sensor 3

Wire harness (current sensor cables) 1

M4x10 thread-forming screw 6

M5 nut 2

Wire harness (current sensor cables) 1

Multiple wire guide, not shown 4

Wire routing clip, not shown 1

M5x11 thread-cutting screw, not shown 6

IGBT busbar (300 A kit only) 3

Table 1.4 Items Supplied in 300/500 A Current Sensor Kit

1.2 Safety Information

Only qualied, Danfoss-authorized personnel are allowed to
install the parts described in these installation instructions.
Handling of the drive and its parts must be done in
accordance with the corresponding operating guide.

WARNING

ELECTRICAL SHOCK HAZARD

VLT® FC series drives contain dangerous voltages when
connected to mains voltage. Improper installation, and
installing or servicing with power connected, can cause
death, serious injury, or equipment failure.

To avoid death, serious injury, or equipment failure:

•

Only use

qualied

electricians for the installation.

•

Disconnect the drive from all power sources before
installation or service.

•

Treat the drive as live whenever the mains voltage
is connected.

•

Follow the guidelines in these instructions and local
electrical safety codes.

WARNING

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 LED indicator lights
are

o.

Failure to wait the

specied

time after power has
been removed before performing service or repair work can
result in death or serious injury.

•

Stop the motor.

•

Disconnect AC mains and remote DC-link power
supplies, including battery back-ups, UPS, and DC­link connections to other drives.

•

Disconnect or lock PM motor.

•

Wait for the capacitors to discharge fully. The
minimum waiting time is 20 minutes.

•

Before performing any service or repair work, use
an appropriate voltage measuring device to make
sure that the capacitors are fully discharged.

NOTICE

ELECTROSTATIC DISCHARGE

Follow proper ESD precautions to prevent damage to
sensitive components.

Installation Instructions

300 A/500 A Current Sensor Kit for D2h/D4h/D7h/D8h Drives
VLT

®

FC Series FC 102, FC 103, FC 202, FC 302

2

Danfoss A/S © 07/2018 All rights reser ved. MI70V202

1.3 Disassembly Guidelines

NOTICE

To make the disassembly/reassembly process easier, use
these general guidelines:

1. Follow the disassembly instructions for each
component.

2. Place the component together with the removed
fasteners.

3. Replace old component with the new component
provided in the kit.

4. If any fasteners are stripped or lost, replace with
similar fastener from the kit.

5. Follow the assembly instructions to replace and
secure each component.

1.3.1 General Torque Tightening Values

Use a torque wrench to ensure that correct torque is applied.
Incorrect torque can cause electrical connection problems. For
fastening hardware described in this instruction, use the values
listed in Tab le 1.5 to Tabl e 1.7 except where noted in the
procedures.

Shaft

size

Tor x /h ex

drives size

Class A

Nm (in-lb)

Class B

Nm (in-lb)

M4 T20/7 mm 1.2 (10) 0.8 (7)

M5 T25/8 mm 2.3 (20) 1.2 (10)

M6 T30/10 mm 3.9 (35) 2.3 (20)

M8 T40/13 mm 9.6 (85) 3.9 (35)

M10 T50/17 mm 19.1 (169) 9.6 (85)

M12 –/18 mm or

19 mm

37.9 (335) –

Table 1.5 Torque Values Standard Thread

Shaft

size

Tor x dri ve s

size

Class A

Nm (in-lb)

Class B

Nm (in-lb)

M4.8 T25 5.7 (50) 3.1 (27)

M5 T25 1.7 (15) 1.7 (15)

Table 1.6 Torque Values for Thread Cutting into Metal

Shaft

size

Tor x d riv es

size

Class A

Nm (in-lb)

Class B

Nm (in-lb)

M4 T20 2.8 (24) 2.8 (24)

M5 T25 5.1 (45) 4.0 (35)

Table 1.7 Torque Values for Thread Forming into Plastic

Class A: Clamping metal

Class B: Clamping PCA or plastic

1.3.2 Removing AC Input Busbars

To remove the AC input busbars, use the following steps. The
AC input busbars can look

dierent

when the drive includes
extra input options, such as RFI lter or mains fuses.
Illustration 1.2 shows the AC input busbars congured to
include mains fuses.

1. Remove the air bae by removing 4 screws (T25)
and 2 nuts (13 mm).

2. Disconnect the customer input power wiring.

3. The next step

diers

based on the input options
present in the drive. Select the appropriate procedure
for the drive:

•

No options

•

Mains fuses only

•

RFI lter only

•

Mains fuses and RFI

lter

1 Top nut (13 mm) 6 Power terminal mounting plate

2 AC input busbar 7 Brake busbar (optional)

3 Bottom nut (13 mm) 8 U motor busbar

4 Fuse spacer 9 Brake terminal (optional)

5 Mains input terminal 10 Motor terminal block

Illustration 1.2 AC Input Busbars with Mains Fuse Conguration

(Shown with Fuses Removed)

Installation Instructions

300 A/500 A Current Sensor Kit for D2h/D4h/D7h/D8h Drives
VLT

®

FC Series FC 102, FC 103, FC 202, FC 302

MI70V202 Danfoss A/S © 07/2018 All rights reser ved.

3