Danfoss iC7 Series Pre Charging Unit Installation Guide
- June 1, 2024
- Danfoss
Table of Contents
Danfoss iC7 Series Pre-Charging Unit
Specifications
- Product: iC7 Series Pre-charging Unit
- Compatibility: AFE and GC Modules
- Dimensions (IEC): 292mm x 240mm x 239mm
- Dimensions (UL): 292mm x 240mm x 239mm
Product Usage Instructions
Mechanical Installation
Safety Information
DANGER:
Always wait for the capacitors to fully discharge before performing any
service or repair work. The discharge time is 5 minutes.
WARNING:
Components are live when connected to mains, avoid making changes in this
state.
Installation Requirements
Install the pre-charging unit horizontally in the cabinet using M5 screws.
Cooling Requirements
CAUTION:
Avoid touching the pre-charging resistor when hot, and do not install it on a
combustible surface.
Electrical Installation
Electrical Installation Safety
Ensure proper grounding and follow electrical safety procedures when
connecting the unit to power sources.
FAQ
-
Q: What should I do if the warning indicator lights are off but high voltage may still be present?
A: Always wait for the capacitors to discharge fully before performing any service or repair work. Use a measuring device to ensure no voltage is present. -
Q: How many mounting screws should be used for industrial installations?
A: In industrial installations, use a minimum of 4 M5 screws to secure the pre-charging unit to the cabinet.
Overview
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.
Illustration 1: The Pre-charging Unit
- Charging resistors
- Fuse switch
- Contactor
- Terminal blocks
- Rectifier and snubber capacitor
Mechanical Installation
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 the 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 cables.
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 the mains.
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 enclo-sure 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.
Installing the Pre-charging Unit into the Cabinet
Install the pre-charging unit into the cabinet in a horizontal position.
Procedure
- 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.
Illustration 2: Mounting Holes of the Pre-charging Unit
- Preferred mounting holes
- Alternative mounting holes
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 the top and bottom is necessary for sufficient cooling airflow.
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.
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.
Illustration 3: Keep-out-area Around the Pre-charge Unit 10–30 UL Types, UL 98
Dimensions of the Pre-charging Unit, IEC
Illustration 4: Dimensions of the Pre-charging Unit in mm (in), IEC
Dimensions of the Pre-charging Unit, UL
Illustration 5: Dimensions of the Pre-charging Unit in mm (in), UL
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 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 circuits. Maintain separation between the main and control circuit wires.
Cable Requirements
Table 1: Mains Terminals Line 1, Line 3, Line 5
| Item | Value |
|---|---|
| Terminal type | Screw terminal |
| Tool | Flathead |
| Wire size (Cu) | 4–10 mm2 (10–8 AWG), solid or stranded, with a minimum |
insulation temperature rating of 75 °C.
Strip length| 12 mm (0.47 in)
Torque per wire size| 4–6 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 | Spring terminal |
| Wire size (Cu) | 4–10 mm2 (10–8 AWG), solid or stranded, with a minimum |
insulation temperature rating of 75 °C.
Strip length| 15 mm (0.59 in)
Table 3: Control Terminals A1, A2
| Item | Value |
|---|---|
| Terminal type | Screw terminal |
| Tool | Pozidriv 2 or flat head 5.5 mm (0.22 in) |
| Wire size | 1–2.5 mm2 (18–14 AWG) |
| Strip length | 10 mm (0.39 in) |
| Torque | 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.
Table 4: Grounding Terminal PE
| Item | Value |
|---|---|
| Terminal type | Ring or fork terminal, size M8 Reference terminal type (UL): |
• P8-38R-Q (AWG 8, Panduit)
• P10-38R-L (AWG 10, Panduit)
Wire size (Cu)| 4–10 mm2 (10–8 AWG)
Fuses
Use only these fuse types in the fuse switch of the pre-charge unit.
Table 5:
Standard| Fuse I n [A]| Fuse U n [V AC]| Fuse type|
Part number, Mersen| Part number, Eaton
---|---|---|---|---|---
IEC| 40| 690| NH gG size 000| H000GG69V40| 40NHG000B-690
UL| 40| 600| Class J, Time-delay, 2–3/8 x 1–1/16 in (60×27 mm)| AJT40| LPJ-
40SP
Terminals
Illustration 6: Terminals of the Pre-charging Unit
- Left Pre-charging unit 10/20
- Right 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
DC-|
---|---
A1 A2| Pre-charging circuit, contactor coil terminal. Coil voltage range
100–250 V AC, 50/60 Hz.
PE| Grounding terminal for the pre-charging circuit
See the wiring diagrams in the Pre-charging Unit Wiring Diagram and the Control Wiring Diagram.
Installing the Power Cables
Procedure
- Attach the mains cable to the mains terminals Line 1, Line 3, and Line 5 of the pre-charging unit.
- Attach the grounding conductor of the mains cable to the PE terminal of the pre-charging unit.
- See the cable requirements in Cable Requirements.
- See the location of the main terminals in Terminals.
- Attach the DC cable to the DC terminals DC+ and DC- of the pre-charging unit.
- See the cable requirements in Cable Requirements.
- See the location of the DC terminals in Terminals.
Pre-charging Unit Wiring Diagram
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
Control Wiring Diagram
Illustration 8: Pre-charging Control Wiring Diagram
- Short-circuit protected
- Pre-charging contactor control
- Main input device control
- 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.
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