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 qualied, 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
qualied
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
specied
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
dierent
when the drive includes
extra input options, such as RFI lter or mains fuses.
Illustration 1.2 shows the AC input busbars congured to
include mains fuses.
1. Remove the air bae by removing 4 screws (T25)
and 2 nuts (13 mm).
2. Disconnect the customer input power wiring.
3. The next step
diers
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 Conguration
(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
No options
1. Remove 3 nuts (13 mm), 1 from the top of each AC
input busbar.
2. Remove 3 nuts (13 mm), 1 from the bottom of each
AC input busbar.
3. Remove the AC input busbars from the drive.
Mains fuses only
1. Remove 3 AC fuses by removing 6 nuts (13 mm), 1
from each end of the fuses.
2. Remove 3 nuts (13 mm), 1 from the top of each AC
input busbar.
3. Remove the AC input busbars from the drive.
RFI lter only
1. Remove 3 nuts (13 mm) at the top of the RFI lter, 1
per phase.
2. Remove 6 nuts (13 mm) at the bottom of the RFI
lter, 2 per phase.
3. Remove 4 thread-cutting screws (T20), which connect
the RFI lter to the side channels of the drive.
4. Unplug the RFI cable from the MK100 connector on
the RFI printed circuit card.
5. Lift the RFI lter from the drive.
Mains fuses and RFI lter
1. Remove 3 AC fuses by removing 6 nuts (13 mm), 1
from each end of the fuses.
2. Remove 3 nuts (13 mm) from the top of the RFI lter,
1 per phase.
3. Remove 4 thread-cutting screws (T20), which connect
the RFI lter to the side channels of the drive.
4. Unplug the RFI cable from the MK100 connector on
the RFI printed circuit card.
5. Lift the RFI lter from the drive.
1.3.3 Removing Mains Input Terminal Block
To remove the mains input terminal block, use the following
steps. Refer to Illustration 1.4.
1. Remove 2 screws (T25) at the bottom of the mains
input terminal block.
2. Release the current sensor wiring from the cable
retaining clips.
3. Slide the mains input terminal block downward to
disengage it from the 2 metal clips holding it in
place.
1.3.4 Removing Brake Terminals (Optional)
Drives can be congured with optional brake terminals. To
remove the brake terminals, if any, use the following steps.
1. Disconnect the customer brake wiring, if present.
2. Remove the R (+) terminal:
2a Unfasten 1 thread-forming screw (T25) at
the terminal block.
2b Unfasten 1 additional screw (T40).
3. Remove the R (-) terminal:
3a Unfasten 1 thread-forming screw (T25) at
the terminal block.
3b Unfasten 1 additional nut (13 mm).
4. Remove 2 nuts (13 mm) and lift the brake terminal
block from the drive.
1.3.5 Removing Motor Terminal Block
To remove the motor terminal block, use the following steps.
Refer to Illustration 1.4.
1. Disconnect wiring to the motor and remove the
U/V/W terminal label.
2. Remove the EMC shield by removing 1 screw (T25).
3. Remove the U motor busbar:
3a Remove 1 thread-forming screw (T25) from
the middle of the U busbar.
3b Unfasten 1 bolt (T40) from the U busbar.
4. Remove the V motor busbar:
4a Remove 1 thread-forming screw (T25) from
the middle of the V busbar.
4b Unfasten 1 bolt (T40) from the V busbar.
5. Remove the W motor busbar:
5a Remove 1 thread-forming screw (T25) from
the middle of the W busbar.
5b Unfasten 1 bolt (T40) from the W busbar.
6. Remove 3 current sensor cylinder busbars.
7. Remove 2 screws (T25) from the bottom of the
motor terminal block.
8. Remove the motor terminal block by sliding it down
to disengage it from the 2 metal retaining clips.
1.3.6 Removing Power Terminal Mounting
Plate
To remove the power terminal mounting plate, use the
following steps. Refer to Illustration 1.3.
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
4
Danfoss A/S © 07/2018 All rights reser ved. MI70V202
1 Power terminal mounting plate 4 Screw (T25)
2 Nut (8 mm) 5 Mixing fan slot
3 Mixing fan cable 6 Mixing fan and housing
Illustration 1.3 Power Terminal Mounting Plate
1. Remove 5 thread-cutting screws (T25) from the top
of the plate. The fan screw can remain in place, if
present.
2. Remove 2 nuts (8 mm).
3. Release the current sensor cables from the current
sensors.
4. Unplug the wire harness from the power card, and
discard it.
5. Lift the power terminal mounting plate and unplug
the mixing fan cable that is located under the plate.
6. Remove the power terminal mounting plate with the
old current sensors attached and discard it.
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.
5
1.4 Assembly Guidelines
1 R/S/T terminal label 12 Mixing fan 23 Nomex tube
2 M10x30 machine screw 13 Mixing fan housing 24 Current sensor
3 M10 nut 14 EMC shield 25 M4x10 thread-forming screw
4 Mains input terminal block 15 Plastic mounting button 26 M5 nut
5 M5x12 machine screw 16 Busbar insulator sleeve 27 Wire harness (current sensor cables)
6 U/V/W terminal label 17 Motor busbar, U – Not shown: multiple wire guide, wire
routing clip, M5x11 thread-cutting screw,
power terminal mounting plate (IP20/
Chassis), and IGBT busbars (in 300 A
current sensor kit only).
7 Motor terminal block 18 Motor busbar, V
8 Cable retaining clip 19 Motor busbar, W
9 M10 nut with captive washer 20 M5x16 torx screw
10 Cable clamp adapter 21 M8x70 screw
11 Power terminal mounting plate (IP21/IP54) 22 Cylinder busbar
Illustration 1.4 Exploded View of 500 A Current Sensor Kit
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
6
Danfoss A/S © 07/2018 All rights reser ved. MI70V202
1.4.1 Installing Current Sensors
NOTICE
MOUNTING PLATE SELECTION
The kit includes 2 power terminal mounting plates, select
the correct plate for the enclosure. Illustration 1.4 shows the
plate for IP20/Chassis enclosures. Illustration 1.5 shows the
plate for IP21/Type 1 and IP54/Type 12 enclosures.
1. Position 3 current sensors on top of the power
terminal mounting plate so that the cable connectors
face the back of the drive. Ensure that the airow
arrows on the sensors point toward the front of the
drive.
2. Secure 6 M4x10 thread-forming screws (T20), 2 in the
base of each current sensor. Torque to 2.0 Nm
(17.7 in-lb).
3. Connect the wire harness to the current sensors, 1
cable to each current sensor.
4. Route the cables through the cable guides.
1 M4x10 thread-forming screw
2Current sensor
3 Current sensor cable connector
4Mounting hole
5 Power terminal mounting plate
6Mounting hole
7Wire guide
8Cable clip
Illustration 1.5 Back View of Power Terminal Mounting Plate and
Current Sensors
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.
7
1.4.2 Installing Power Terminal Mounting
Plate
To install the new power terminal mounting plate in the drive,
use the following steps. Refer to Illustration 1.4 and
Illustration 1.5.
1. Position the power terminal mounting plate in the
drive.
2. Fasten the plate with 7 M5x11 thread-cutting screws
(T25).
3. Connect the wire harness to the MK100 connector on
the power card.
4. Connect the fan cable to the mixing fan cable
connector.
5. Insert the mixing fan into the fan housing, with the
label facing the open side of the housing.
6. With the fan label facing up, insert the mixing fan
assembly into the slot in the plate and press. The fan
assembly is level with the plate when properly
seated.
7. For the IP21/Type 1 and IP54/Type 12 enclosures
only, fasten 4 ground nuts with captive washer
(10 mm) in the power terminal mounting plate.
8. For IP20/Chassis enclosures only, fasten 3 nuts
(8 mm) at the bottom of the plate.
1.4.3 Installing Motor Terminal Block
To install the motor terminal block, use the following steps.
Refer to Illustration 1.4.
1. Position the output terminal block by sliding it
upward under the 2 metal retaining clips on the
power terminal mounting plate.
2. Fasten 2 M5x12 machine screws (T25) at the bottom
of the terminal block.
3. Position the 3 Nomex tubes, 1 in the middle of each
current sensor.
4. Insert 3 cylinder busbars, 1 inside each Nomex tube.
5. Replace the U motor busbar:
5a Slide the insulator sleeve over the U busbar.
5b Fasten 1 screw (T30) in the current sensor
end of the busbar.
5c Fasten 1 thread-forming screw (T25) in the
middle of the busbar.
6. Replace the V motor busbar:
6a Fasten 1 screw (T30) in the current sensor
end of the busbar.
6b Fasten 1 thread-forming screw (T25) in the
middle of the busbar.
7. Replace the W motor busbar:
7a Fasten 1 screw (T30) in the current sensor
end of the busbar.
7b Fasten 1 thread-forming screw (T25) in the
middle of the busbar.
8. Position the EMC shield between the mains input
terminal block and motor terminal block and secure
with 1 screw (T25).
9. Reconnect wiring to the motor terminals, and replace
the U/V/W terminal label.
1.4.4 Installing Brake Terminals (Optional)
To replace the optional brake terminals, if any, use the
following steps.
1. Install the brake terminal block by fastening 2 nuts
(13 mm) in the block.
2. Install the R (-) terminal:
2a Fasten 1 thread-forming screw (T25) at the
terminal block.
2b Fasten 1 additional nut (13 mm).
3. Install the R (+) terminal:
3a Fasten 1 thread-forming screw (T25) at the
terminal block.
3b Fasten 1 additional screw (T40).
1.4.5 Installing Mains Input Terminal Block
1. Position the mains input terminal block on the power
terminal mounting plate and slide it upward under 2
metal retaining clips.
2. Fasten 2 screws (T25) at the bottom of the mains
input terminal block.
3. Route the current sensor wiring through the cable
retaining clips.
4. Place the R/S/T terminal label above the terminal
connections.
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
8
Danfoss A/S © 07/2018 All rights reser ved. MI70V202
1.4.6 Installing AC Input Busbars
To install the AC input busbars, use the following steps. The
AC input busbars can look
dierent
when the drive includes
extra input options, such as an RFI lter or mains fuses.
Illustration 1.2 shows the AC input busbars congured to
include mains fuses.
1. The next step diers 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
No options
1. Position the 3 AC input busbars in the drive.
2. Secure 3 nuts (13 mm), 1 in the top of each AC input
busbar.
3. Fasten 3 nuts (13 mm), 1 in the bottom of each AC
input busbar.
4. Connect the customer mains input power wiring.
5. Replace the air bae and secure with 4 screws (T25)
and 2 nuts (13 mm).
Mains fuses only
1. Position the 3 AC input busbars in the drive.
2. Secure 3 nuts (13 mm), 1 in the top of each AC input
busbar.
3. Install the 3 mains fuses by securing 6 nuts (13 mm),
1 at each end of the fuses.
4. Connect the customer mains input power wiring.
5. Replace the air
bae
and secure with 4 screws (T25)
and 2 nuts (13 mm).
RFI lter only
1. Connect the RFI cable to MK100 on the RFI printed
circuit card.
2. Fasten the RFI
lter
to the side channels of the drive
with 4 thread-cutting screws (T20).
3. Secure the top of the RFI lter using 3 nuts (13 mm),
1 per phase.
4. Secure the bottom of the RFI lter using 6 nuts
(13 mm), 2 per phase.
5. Connect the customer mains input power wiring.
6. Replace the air bae and secure with 4 screws (T25)
and 2 nuts (13 mm).
Mains fuses and RFI lter
1. Connect the RFI cable to MK100 on the RFI printed
circuit card.
2. Fasten the RFI lter to the side channels of the drive
with 4 thread-cutting screws (T20).
3. Secure the top of the RFI lter using 3 nuts (13 mm),
1 per phase.
4. Install 3 mains fuses using 6 nuts (13 mm), 1 at each
end of the fuses.
5. Connect the customer mains input power wiring.
6. Replace the air bae and secure with 4 screws (T25)
and 2 nuts (13 mm).
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.
9
Danfoss can accept no responsibility for possible errors in catalogues, 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 materi al are property of the respective companies. Danfoss
and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
Danfoss A/S
Ulsnaes 1
DK-6300 Graasten
vlt-drives.danfoss.com
*MI70V202*
MI70V202130R0678 07/2018
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