Danfoss VLT® FC-Serie Output Filter Guide

MAKING MODERN LIVING POSSIBLE
Output Filters Design Guide
VLT® AutomationDrive FC 300
VLT® AQUA Drive FC 200
VLT® HVAC Drive FC 100
Contents
Output Filters Design Guide
Contents
1 How to Read this Design Guide
1.1.2 Abbreviations
2 Safety and Conformity
3
3
4
2.1 Safety Precautions
4
2.1.1 CE Conformity and Labelling
4
3 Introduction to Output Filters
5
3.1 Why use Output Filters
5
3.2 Protection of Motor Insulation
5
3.2.1 The Output Voltage
5
3.3 Reduction of Motor Acoustic Noise
7
3.4 Reduction of High Frequency Electromagnetic Noise in the Motor Cable
7
3.5 What are Bearing Currents and Shaft Voltages?
8
3.5.1 Mitigation of Premature Bearing Wear-Out
8
3.5.2 Measuring Electric Discharges in the Motor Bearings
9
3.6 Which Filter for which Purpose
10
3.6.1 du/dt Filters
10
3.6.2 Sine-wave Filters
12
3.6.3 High-Frequency Common-Mode Core Kits
14
4 Selection of Output Filters
15
4.1 How to Select the Correct Output Filter
15
4.1.1 Product Overview
15
4.1.2 HF-CM Selection
17
4.2 Electrical Data - du/dt Filters
18
4.3 Electrical Data - Sine-wave Filters
20
4.4 Sine-Wave Filters
25
4.4.1 du/dt Filters
26
4.4.2 Sine-Wave Foot Print Filter
27
5 How to Install
28
5.1 Mechanical Mounting
28
5.1.1 Safety Requirements for Mechanical Installation
28
5.1.2 Mounting
28
5.1.3 Earthing
29
5.1.4 Screening
29
5.2 Mechanical Dimensions
30
5.2.1 Sketches
30
6 How to Programme the Frequency Converter
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38
1
Contents
Output Filters Design Guide
6.1.1 Parameter Settings for Operation with Sine-wave Filter
Index
2
38
39
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How to Read this Design Gui...
Output Filters Design Guide
1 1
1 How to Read this Design Guide
This Design Guide will introduce all aspects of output filters
for your VLT® FC Series Drive; From choosing the right
output filter for the application to instructions about how to
install it and how to program the Frequency Converter.
Danfoss technical literature is also available online at
www.danfoss.com/BusinessAreas/DrivesSolutions/
Documentations/Technical+Documentation.
1.1.1 Symbols
Symbols used in this manual:
NOTE
Indicates something to be noted by the reader.
CAUTION
Indicates a general warning.
WARNING
Indicates a high-voltage warning.
✮
Indicates default setting
1.1.2 Abbreviations
Alternating current
AC
American wire gauge
AWG
Ampere/AMP
A
Automatic Motor Adaptation
AMA
Current limit
ILIM
Degrees Celsius
°C
Direct current
DC
Drive Dependent
D-TYPE
Electro Magnetic Compatibility
EMC
Electronic Thermal Relay
ETR
Drive
FC
Gram
g
Hertz
Hz
Kilohertz
kHz
Local Control Panel
LCP
Meter
m
Millihenry Inductance
mH
Milliampere
mA
Millisecond
ms
Minute
min
Motion Control Tool
MCT
Nanofarad
nF
Newton Meters
Nm
Nominal motor current
IM,N
Nominal motor frequency
fM,N
Nominal motor power
PM,N
Nominal motor voltage
UM,N
Parameter
par.
Protective Extra Low Voltage
PELV
Rated Inverter Output Current
IINV
Revolutions Per Minute
RPM
Second
s
Synchronous Motor Speed
ns
Torque limit
TLIM
Volts
V
IVLT,MAX
The maximum output current.
IVLT,N
The rated output current
supplied by the frequency
converter.
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3
Safety and Conformity
Output Filters Design Guide
2 Safety and Conformity
2 2
NOTE
Never attempt to repair a defect filter.
2.1 Safety Precautions
Equipment containing electrical components
may not be disposed of together with domestic
waste.
It must be separately collected with electrical
and electronic waste according to local and
currently valid legislation.
NOTE
The filters presented in this design guide are specially
designed and tested for Danfoss Drives frequency converters
(FC 102/202/301 and 302). Danfoss takes no resposibility for
the use of third party output filters.
NOTE
The phased out LC-filters that were developed for the
VLT5000 series and are not compatible with the VLT FCseries frequency converters.
However, the new filters are compatible with both FC-series
and VLT 5000-series
MCC 101/102
Design Guide
NOTE
2.1.1 CE Conformity and Labelling
What is CE Conformity and Labelling?
The purpose of CE labelling is to avoid technical trade
obstacles within EFTA and the EU. The EU has introduced the
CE label as a simple way of showing whether a product
complies with the relevant EU directives. The CE label says
nothing about the specifications or quality of the product.
The low-voltage directive (73/23/EEC)
Frequency converters must be CE labelled in accordance
with the low-voltage directive of January 1, 1997. The
directive applies to all electrical equipment and appliances
used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage
ranges. Danfoss CE-labels in accordance with the directive
and issues a declaration of conformity upon request.
690V applications:
For motors not specially designed for frequency converter
operation or without double insulation, Danfoss highly
recommend the use of either du/dt or Sine-Wave filters.
NOTE
Sine-wave filters can be used at switching frequencies higher
than the nominal switching frequency, but should never be
used at switching frequencies with less than 20% lower than
the nominal switching frequency.
NOTE
du/dt filters, unlike Sine-wave filters, can be used at lower
switching frequency than the nominal switching frequency,
but higher switching frequency will cause the overheating of
the filter and should be avoided.
Warnings
CAUTION
When in use the filter surface temperature rises. DO NOT
touch the filter during operation.
WARNING
Never work on a filter in operation. Touching the electrical
parts may be fatal - even after the equipment has been
disconnected from the drive or motor.
CAUTION
Before servicing the filter, wait at least the voltage discharge
time stated in the Design Guide for the corresponding VLT®
to avoid electrical shock hazard.
4
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Introduction to Output Filt...
Output Filters Design Guide
3 Introduction to Output Filters
3.1 Why use Output Filters
This chapter describes why and when to use Output Filters
with Danfoss Drives frequency converters. It is divided into
three sections:
•
•
•
Protection of Motor Insulation
Reduction of Motor Acoustic Noise
Reduction of High Frequency Electromagnetic
Noise in Motor Cable
3.2 Protection of Motor Insulation
3.2.1 The Output Voltage
The output voltage of the frequency converter is a series of
trapezoidal pulses with a variable width (pulse width
modulation) characterized by a pulse rise-time tr.
3 3
•
the motor cable (type, cross-section, length,
screened or unscreened, inductance and
capacitance)
•
the high frequency surge impendance of the motor
Because of the impedance mismatch between the cable
characteristic impedance and the motor surge impedance a
wave reflection occurs, causing a ringing voltage overshoot
at the motor terminals - see following illustration. The motor
surge impedance decreases with the increase of motor size
resulting in reduced mismatch with the cable impedance.
The lower reflection coefficient (Γ) reduces the wave
reflection and thereby the voltage overshoot.
In the case of parallel cables the cable characteristic
impedance is reduced, resulting in a higher reflection
coefficient higher overshoot. For more information please
see IEC61800-8.
When a transistor in the inverter switches, the voltage across
the motor terminal increases by a du/dt ratio that depends
on:
Illustration 3.1 Example of converter output voltage (dotted line) and motor terminal voltage after 200 meters of cable (solid line).
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Introduction to Output Filt...
Output Filters Design Guide
Typical values for the rise time and peak voltage UPEAK are
measured on the motor terminals between two phases.
Two different definitions for the risetime tr are used in
practice. The international IEC standards define the rise-time
as the time between 10 % to 90 % of the peak voltage Upeak.
The US National Electrical Manufacturers Association (NEMA)
defines the rise-time as the time between 10 % and 90 % of
the final, settled voltage, that is equal to the DC link voltage
UDC. See following illustrations.
The IEC and NEMA definitions of risetime tr
Illustration 3.2 IEC
To obtain approximate values for cable lengths and voltages
not mentioned below, use the following rules of thumb:
1.
Rise time increases with cable length.
2.
UPEAK = DC link voltage x (1+Γ); Γ represents the
reflection coefficient and typical values can be
found in table below
(DC link voltage = Mains voltage x 1.35).
3.
du/dt =
du/dt =
0.8 × U PEAK
tr
0.8 × U DC
tr ( NEMA )
(IEC)
Illustration 3.3 NEMA
(NEMA)
(For du/dt, rise time, Upeak values at different cable lengths
please consult the drive Design Guide)
Motor power [kW]
Zm [Ω]
Γ
<3.7
2000 - 5000
0.95
90
800
0.82
355
400
0.6
Table 3.1 Typical values for reflection coefficients (IEC61800-8).
Various standards and technical specifications present limits
of the admissible Upeak and tr for different motor types. Some
of the most used limit lines are shown in the figure below:
•
IEC60034-17 – limit line for general purpose motors
when fed by frequency converters, 500V motors.
•
IEC60034-25 – limit for converter rated motors:
curve A is for 500V motors and curve B is for 690V
motors.
•
NEMA MG1 – Definite purpose Inverter Fed Motors.
If, in your application, the resulting Upeak and tr exceed the
limits that apply for the motor used, an output filter should
be used for protecting the motor insulation.
Illustration 3.4 Limit lines for Upeak and risetime tr.
6
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Introduction to Output Filt...
Output Filters Design Guide
3.3 Reduction of Motor Acoustic Noise
The acoustic noise generated by motors has three main
sources:
1.
The magnetic noise produced by the motor core,
through magnetostriction
2.
The noise produced by the motor bearings
3.
The noise produced by the motor ventilation
When a motor is fed by a frequency converter, the
pulsewidth modulated (PWM) voltage applied to the motor
causes additional magnetic noise at the switching frequency
and harmonics of the switching frequency (mainly the
double of the switching frequency). In some applications this
is not acceptable. In order to eliminate this additional
switching noise, a sine-wave filter should be used. This will
filter the pulse shaped voltage from the frequency converter
and provide a sinusoidal phase-to-phase voltage at the
motor terminals.
3.4 Reduction of High Frequency
Electromagnetic Noise in the Motor
Cable
When no filters are used, the ringing voltage overshoot that
occurs at the motor terminals is the main high-frequency
noise source. This can be seen in the figure below that shows
the correlation between the frequency of the voltage ringing
at the motor terminals and the spectrum of the highfrequency conducted interference in the motor cable.
Besides this noise component, there are also other noise
components such as:
•
The common-mode voltage between phases and
ground (at the switching frequency and its
harmonics) - high amplitude but low frequency.
•
High-frequency noise (above 10MHz) caused by
the switching of semiconductors - high frequency
but low amplitude.
Illustration 3.5 Correlation between the frequency of the ringing voltage overshoot and the spectrum of noise emissions.
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Introduction to Output Filt...
Output Filters Design Guide
When an output filter is installed following effect is achieved:
3 3
•
In the case of du/dt filters the frequency of the
ringing oscillation is reduced below 150kHz.
•
In the case of sine-wave filters the ringing
oscillation is completely eliminated and the motor
is fed by a sinusoidal phase-to-phase voltage.
Remember, that the other two noise components are still
present. The use of unshielded motor cables is possible, but
the layout of the installation should prevent noise coupling
between the unshielded motor cable and the mains line or
other sensitive cables (sensors, communication, etc.). This
can be achieved by cable segregation and placement of the
motor cable in a separate, continuous and grounded cable
tray.
3.5 What are Bearing Currents and Shaft
Voltages?
Fast switching transistors in the frequency converter
combined with an inherent common-mode voltage (voltage
between phases and ground) generate high-frequency
bearing currents and shaft voltages. While bearing currents
and shaft voltages can also occur in direct-on-line motors,
these phenomena are accentuated when the motor is fed
from a frequency converter. The majority of bearing
damages in motors fed by frequency converters are because
of vibrations, misalignment, excessive axial or radial loading,
improper lubrication, impurities in the grease. In some cases,
bearing damages are caused by bearing currents and shaft
voltages. The mechanism that causes bearing currents and
shaft voltages is quite intricate and beyond the scope of this
Design Guide. Basically, two main mechanisms can be
identified:
•
Capacitive coupling: the voltage across the bearing
is generated by parasitic capacitances in the motor.
•
Inductive coupling: caused by circulating currents
in the motor.
The grease film of a running bearing behaves like isolation.
The voltage across the bearing can cause a breakdown of the
grease film and produce a small electric discharge (a spark)
between the bearing balls and the running track. This
discharge produces a microscopic melting of the bearing ball
and running track metal and in time it causes the premature
wear-out of the bearing. This mechanism is called Electrical
Discharge Machining or EDM.
8
3.5.1 Mitigation of Premature Bearing WearOut
There are a number of measures that can be taken for
preventing premature wearing and damage of the bearings
(not all of them are applicable in all cases – combinations
can be used). These measures aim either to provide a lowimpedance return path to the high-frequency currents or to
electrically isolate the motor shaft for preventing currents
through the bearings. Besides, there are also mechanical
related measures.
Measures to provide a low-impedance return path
•
Follow EMC installation rules strictly. A good highfrequency return path should be provided between
motor and frequency converter, for example by
using shielded cables.
•
Make sure that the motor is properly grounded and
the grounding has a low-impedance for highfrequency currents.
•
Provide a good high-frequency ground connection
between motor chassis and load.
•
Use shaft grounding brushes.
Measures that isolated the motor shaft from the load
•
Use isolated bearings (or at least one isolated
bearing at the non-driving end NDE).
•
Prevent shaft ground current by using isolated
couplings.
Mechanical measures
•
Make sure that the motor and load are properly
aligned.
•
Make sure the loading of the bearing (axial and
radial) is within the specifications.
•
•
Check the vibration level in the bearing.
Check the grease in the bearing and make sure the
bearing is correctly lubricated for the given
operating conditions.
One of the mitigation measures is to use filters. This can be
used in combination with other measures, such as those
presented above. High-frequency common-mode (HF-CM)
filters (core kits) are specially designed for reducing bearing
stress. Sine-wave filters also have a good effect. dU/dt filters
have less effect and it is recommended to use them in
combination with HF-CM cores.
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Output Filters Design Guide
3.5.2 Measuring Electric Discharges in the
Motor Bearings
9
12
50 - 200
MHz
Level in dBµV
130BT119.10
The occurrence of electric discharges in the motor bearings
can be measured using an oscilloscope and a brush to pick
up the shaft voltage. This method is difficult and the
interpretation of the measured waveforms requires a deep
understanding of the bearing current phenomena. An easy
alternative is to use an electrical discharge detector
(130B8000). Such a device consists of a loop antenna that
receives signals in the frequency range of 50MHz – 200MHz
and a counter. Each electric discharge produces an electromagnetic wave that is detected by the instrument and the
counter is incremented. If the counter displays a high
number of discharges it means that there are many
discharges occurring in the bearing and mitigation measures
have to be taken to prevent the early wear out of the
bearing. This instrument can be used for experimentally
determining the exact number of cores needed to reduce
bearing currents. Start with a set of 2 cores. If the discharges
are not eliminated, or drastically reduced, add more cores.
The number of cores presented in the table above is a
guiding value that should cover most applications with a
generous safety margin. If the cores are installed on the drive
terminals and you experiment core saturation because of
long motor cables (the cores have no effect on bearing
currents), check the correctness of the installation. If cores
keep saturating after the installation is made according to
EMC best practice, consider moving the cores to the motor
terminals.
130BB729.10
Introduction to Output Filt...
Frequency in Hz
Illustration 3.6 Mains line conducted noise, no filter.
Illustration 3.7 Mains line conducted noise, sine-wave filter.
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3 3
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Introduction to Output Filt...
Output Filters Design Guide
3.6 Which Filter for which Purpose
The table below shows a comparison of du/dt and Sine-wave filter performance. It can be used to determine which filter to use
with your application.
Performance criteria
du/dt filters
Sine-wave filters
High-frequency common-mode filters
Motor insulation
stress
Up to 150 m cable (screened/
unscreened) complies with the
requirements of IEC60034-17
(general purpose motors). Above
this cable length the risk of “double
pulsing” (two time mains network
voltage) increases.
Provides a sinusoidal phase-to-phase
Does not reduce motor insulation stress
motor terminal voltage. Complies with
IEC-60034-17* and NEMA-MG1
requirements for general purpose
motors with cables up to 500m (1km for
VLT frame size D and above).
Motor bearing stress Slightly reduced, only in highpower motors.
Reduces bearing currents caused by
circulating currents. Does not reduce
common-mode currents (shaft
currents).
Reduces bearing stress by limiting
common-mode high-frequency
currents
EMC performance
Eliminates motor cable ringing.
Does not change the emission class.
Does not allow longer motor cables
as specified for the frequency
converter’s built-in RFI filter.
Eliminates motor cable ringing. Does
not change the emission class. Does not
allow longer motor cables as specified
for the frequency converter’s built-in
RFI filter.
Reduces high-frequency emissions
(above 1 MHz). Does not change the
emission class of the RFI filter. Does not
allow longer motor cables as specified
for the frequency converter.
Max. motor cable
length
100m ... 150 m
With guaranteed EMC performance:
150m screened.
Without guaranteed EMC
performance: 150m unscreened.
With guaranteed EMC performance:
150 m screened (frame size A, B, C), 300
150m screened and 300m unscreened. m screened (frame size D, E, F), 300 m
Without guaranteed EMC performance: unscreened
up to 500m (1km for VLT frame size D
and above)
Acoustic motor
switching noise
Does not eliminate acoustic
switching noise.
Eliminates acoustic switching noise
from the motor caused by magnetostriction.
Relative size
15-50% (depending on power size). 100%
5 - 15%
Voltage drop**
0.5%
none
4-10%
Does not eliminate acoustic switching
noise.
Table 3.2 Comparison of du/dt and sine-wave filters.
*) Not 690V.
**) See general specification for formula.
Advantages:
3.6.1 du/dt Filters
The du/dt filters consist of inductors and capacitors in a low
pass filter arrangement and their cut off frequency is above
the nominal switching frequency of the drive. The
inductance (L) and capacitance (C) values are shown in the
tables in the section Electrical Data - du/dt Filters in the
chapter Selection of Output Filters. Compared to Sine-wave
filters they have lower L and C values, thus they are cheaper
and smaller. With a du/dt filter the voltage wave form is still
pulse shaped but the current is sinusoidal - see following
illustrations.
•
Protects the motor against high du/dt values and
voltage peaks, hence prolongs the lifetime of the
motor
•
Allows the use of motors which are not specifically
designed for converter operation, for example in
retrofit applications
Features and benefits
du/dt filters reduce the voltage peaks and du/dt of the
pulses at the motor terminals. The du/dt filters reduce du/dt
to approx. 500V/μs.
10
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Introduction to Output Filt...
Output Filters Design Guide
Application areas:
Danfoss recommends the use of du/dt filters in the following
applications:
•
•
Applications with frequent regenerative braking
•
Motors placed in aggressive environments or
running at high temperatures
•
•
Applications with risk of flash over
•
Applications with short motor cables (less than 15
meters)
•
690 V applications
Motors that are not rated for frequency converter
operation and not complying with IEC600034-25
3 3
Installations using old motors (retrofit) or general
purpose motors not complying with IEC 600034-25
Illustration 3.9 With du/dt filter
Upeak [kV]
130BB113.11
Voltage and current with and without du/dt filter:
50m dv/dt filter
150m dv/dt filter
15m dv/dt filter
rise time [µs]
Illustration 3.8 Without filter
Illustration 3.10 Measured du/dt values (rise time and peak
voltages) with and without du/dt filter using 15m, 50m and 150m
cable lengths on a 400V, 37kW induction motor.
The du/dt value decreases with the motor cable length
whereas the peak voltage increases (see illustration above).
The Upeak value depends on the Udc from the drive and as
Udc increases during motor braking (generative) Upeak can
increase to values above the limits of IEC60034-17 and
thereby stress the motor insulation. Danfoss therefore
recommends du/dt filters in applications with frequent
braking. Furthermore the illustration above shows how the
Upeak increases with the cable length. As the cable length
increases, the cable capacitance rises and the cable behaves
like a low-pass filter. That means longer rise-time tr for longer
cables. Therefore it is recommended to use du/dt filters only
in applications with cable lengths up to 150 meters. Above
150m du/dt filters have no effect. If further reduction is
needed, use a sine-wave filter.
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Introduction to Output Filt...
Output Filters Design Guide
Filter features:
3 3
•
•
•
IP00 and IP20 enclosure in the entire power range
•
Possibility of connecting screened cables with
included decoupling plate
•
Compatible with all control principles including
flux and VVC+
•
Filters wall mounted up to 177A and floor mounted
above that size
Side by side mounting with the drive
Reduced size, weight and price compared to the
sine-wave filters
Illustration 3.11 525V - with and without du/dt filter
insulation and flash-over. Danfoss therefore recommends
du/dt filters in applications with motor cable lengths shorter
than 15m.
3.6.2 Sine-wave Filters
Sine-wave filters (are designed to) let only low frequencies
pass. High frequencies are consequently shunted away
which results in a sinusoidal phase to phase voltage
waveform and sinusoidal current waveforms. With the
sinusoidal waveforms the use of special frequency converter
motors with reinforced insulation is no longer needed. The
acoustic noise from the motor is also damped as a
consequence of the sinusoidal wave condition. The sinewave filter also reduces insulation stress and bearing
currents in the motor, thus leading to prolonged motor
lifetime and longer periods between services. Sine-wave
filters enable use of longer motor cables in applications
where the motor is installed far from the drive. As the filter
does not act between motor phases and ground, it does not
reduce leakage currents in the cables. Therefore the motor
cable length is limited - see table Comparison of du/dt and
sine-wave filters in section Which Filters for which Purpose
The Danfoss Drives Sine-wave filters are designed to operate
with the VLT® FC Series Drives. They replace the LC-filter
product range and are backwards compatible with the VLT
5000-8000 Series Drives. They consist of inductors and
capacitors in a low-pass filter arrangement. The inductance
(L) and capacitance (C) values are shown in tables in the
section Electrical Data - Sine -wave Filters in the chapter
Selection of Output Filters.
Features and benefits
As described above, Sine-wave filters reduce motor
insulation stress and eliminate switching acoustic noise from
the motor. The motor losses are reduced because the motor
is fed with a sinusoidal voltage, as shown in illustration 525V
- with du/dt filter. Moreover, the filter eliminates the pulse
reflections in the motor cable thus reducing the losses in the
frequency converter.
Advantages:
Illustration 3.12 690V - with and du/dt filter
Source: Test of 690V 30kW VLT FC 302 with MCC 102 du/dt
filter
The illustrations above show how Upeak and rise time
behaves as a function of the motor cable length. In installations with short motor cables (below 5-10m) the rise time is
short which causes high du/dt values. The high du/dt can
cause a damaging high potential difference between the
windings in the motor which can lead to breakdown of the
12
•
Protects the motor against voltage peaks hence
prolongs the lifetime
•
•
•
Reduces the losses in the motor
•
Decreases electromagnetic emissions from motor
cables by eliminating high frequency ringing in the
cable
Eliminates acoustic switching noise from the motor
Reduces semiconductor losses in the drive with
long motor cables
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Introduction to Output Filt...
Output Filters Design Guide
•
Reduces electromagnetic interference from
unscreened motor cables
•
Reduces the bearing current thus prolonging the
lifetime of the motor
Voltage and current with and without Sine-wave filter:
Illustration 3.13 Without filter
Application areas:
Danfoss recommends the use of Sine-wave filters in the
following applications:
•
Applications where the acoustic switching noise
from the motor has to be eliminated
•
Retrofit installations with old motors with poor
insulation
•
Applications with frequent regenerative braking
and motors that do not comply with IEC60034-17
•
Applications where the motor is placed in
aggressive environments or running at high
temperatures
•
Applications with motor cables above 150m up to
300m (with both screened and unscreened cable).
The use of motor cables longer than 300m
depends on the specific application
•
Applications where the service interval on the
motor has to be increased
•
•
690V applications with general purpose motors
3 3
Step up applications or other applications where
the frequency converter feeds a transformer
Example of relative motor sound pressure level
measurements with and without Sine-wave filter
Illustration 3.14 With sine-wave filter
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Introduction to Output Filt...
Output Filters Design Guide
3 3
Features:
•
IP00 and IP20 enclosure in the entire power range
(IP23 for floor standing filters)
•
Compatible with all control principle including flux
and WC+
•
•
•
Side by side mount with drive up to 75A
•
Filters wall mounted up to 75A and floor mount
above
•
Parallel filter installation is possible with
applications in the high power range
Filter enclosure matching the drive enclosure
Possibility of connection unscreened and screened
cables with included decoupling plate
3.6.3 High-Frequency Common-Mode Core
Kits
High-frequency common-mode (HF-CM) core kits are one of
the mitigation measures to reduce bearing wear. However,
they should not be used as the sole mitigation measure.
Even when HF-CM cores are used, the EMC-correct installation rules must be followed. The HF-CM cores work by
reducing the high-frequency common-mode currents that
are associated with the electric discharges in the bearing.
They also reduce the high-frequency emissions from the
motor cable which can be used, for example, in applications
with unshielded motor cables.
14
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Selection of Output Filters
Output Filters Design Guide
4 Selection of Output Filters
4.1 How to Select the Correct Output Filter
An output filter is selected based on the nominal motor current. All filters are rated for 160% overload for 1 minute, every 10
minutes.
4.1.1 Product Overview
To simplify the Filter Selection Table below shows which Sine-wave filter to use with a specific drive. This is based on the 160%
overload for 1 minute every 10 minutes and is to be considered guideline.
Mains supply 3 x 240 to 500V
Rated filter
current at 50 Hz
Minimum
switching
frequency [kHz]
Maximum output
frequency [Hz] With
derating
Code number
IP20
Code number
IP00
Frequency converter size
2.5
5
120
130B2439
130B2404
4.5
5
120
130B2441
130B2406
8
5
120
130B2443
130B2408
10
5
120
130B2444
130B2409
P4K0
17
5
120
130B2446
130B2411
P2K2 - P4K0 P5K5 - P7K5 P5K5 - P7K5
24
4
100
130B2447
130B2412
P5K5
38
4
100
130B2448
130B2413
P7K5
48
4
100
130B2307
130B2281
P11K
P22K
P22K
62
3
100
130B2308
130B2282
P15K
P30K
P30K
P18K
P37K
P37K
200-240 V
380-440 V
441-500 V
PK25 - PK37 PK37 - PK75 PK37 - PK75
PK55
P1K1 - P1K5 P1K1 - P1K5
PK75 - P1K5 P2K2 - P3K0 P2K2 - P3K0
P11K
P4K0
P11K
P15K - P18K P15K - P18K
75
3
100
130B2309
130B2283
115
3
100
130B2310
130B2284
P22K - P30K P45K - P55K P55K - P75K
180
3
100
130B2311
130B2285
P37K - P45K P75K - P90K P90K - P110
260
3
100
130B2312
130B2286
P110 - P132
P132
410
3
100
130B2313
130B2287
P160 - P200
P160 - P200
480
3
100
130B2314
130B2288
P250
P250
660
2
70
130B2315
130B2289
P315 - P355
P315 - P355
750
2
70
130B2316
130B2290
P400
P400 - P450
880
2
70
130B2317
130B2291
P450 - P500
P500 - P560
1200
2
70
130B2318
130B2292
P560 - P630
P630 - P710
1500
2
70
2X 130B2317
2X 130B2291
P710 - P800
P800
Table 4.1 Filter Selection
MG.90.N4.02 - VLT® is a registered Danfoss trademark
15
4 4
Selection of Output Filters
Output Filters Design Guide
Mains supply 3 x 525 to 600/ 690V
Rated filter
current at 50 Hz
Minimum
switching
frequency [kHz]
13
28
4 4
Maximum output
frequency [Hz] With
derating
Code number
IP20
Code number
IP00
2
70
130B2341
130B2321
PK75 - P7K5
2
100
130B2342
130B2322
P11K - P18K
45
2
100
130B2343
130B2323
P22K - P30K
P37K
76
2
100
130B2344
130B2324
P37K - P45K
P45K - P55K
115
2
100
130B2345
130B2325
P55K - P75K
P75K - P90K
165
2
70
130B2346
130B2326
P110 - P132
260
2
100
130B2347
130B2327
P160 - P200
303
2
70
130B2348
130B2329
P250
430
1.5
60
130B2370
130B2341
P315 - P400
530
1.5
100
130B2371
130B2342
P500
660
1.5
100
130B2381
130B2337
P560 - P630
765
1.5
60
130B2382
130B2338
P710
940
1.5
100
130B2383
130B2339
P800 - P900
1320
1.5
60
130B2384
130B2340
P1M0
Table 4.2 Filter Selection
Generally the output filters are designed for the nominal
switching frequency of the VLT FC-Series drives.
NOTE
Sine-wave filters can be used at switching frequencies higher
than the nominal switching frequency, but should never be
used at switching frequencies with less than 20% lower than
the nominal switching frequency.
NOTE
du/dt filters, unlike Sine-wave filters, can be used at lower
switching frequency than the nominal switching frequency,
but higher switching frequency will cause the overheating of
the filter and should be avoided.
16
MG.90.N4.02 - VLT® is a registered Danfoss trademark
Frequency converter size
525-600 V
525-690 V
Selection of Output Filters
Output Filters Design Guide
CAUTION
4.1.2 HF-CM Selection
The cores can be installed at the frequency converter’s
output terminals (U, V, W) or in the motor terminal box.
When installed at the frequency converter’s terminals the
HF-CM kit reduces both bearing stress and high-frequency
electromagnetic interference from the motor cable. The
number of cores depends on the motor cable length and
frequency converter voltage and a selection table is shown
below:
Cable A- and Blength frame
[m]
T5
T7
C-frame
D-frame
E-frame + F
T5
T7
T5
T7
T5
T7
50
2
4
2
2
2
4
2
2
100
4
4
2
4
4
4
2
4
150
4
6
4
4
4
4
4
4
300
4
6
4
4
4
6
4
4
Check the core temperature during commissioning. A
temperature above 70°C indicates saturation of the cores. If
this happens add more cores. If the cores still saturate it
means that the cable capacitance is too large because of: too
long cable, too many parallel cables, cable type with high
capacitance.
Applications with parallel cables
When parallel cables are used the total cable length has to
be considered. For example 2 x 100m cables are equivalent
with one 200 m cable. If many paralleled motors are used a
separate core kit should be installed for each individual
motor.
The ordering numbers for the core kits (2 cores/package) are
given in the following table.
Core dimension [mm]
Weight Packaging
dimension
W
w
H
h
[kg]
When installed in the motor terminal box the HF-CM kit
reduces only bearing stress and has no effect on the electromagnetic interference from the motor cable. Two cores is
sufficient in most cases, independent of the motor cable
length.
A and B 130B3257 60
43
40
25 22 0.25
130x100x
70
C
130B3258 102 69
61
28 37 1.6
190x100x
70
D
130B3259 189 143 126 80 37 2.45
235x190x
140
Danfoss provides the HF-CM cores in kits of two pieces/kit.
The cores are oval shaped for the ease of installation and are
available in four sizes: for A and B frames, for C frames, for D
frames, for E and F-frames. For F-frame drives one core kit
shall be installed at each inverter module terminals.
Mechanical mounting can be made with cable ties. There are
no special requirements regarding mechanical mounting.
E and F 130B3260 305 249 147 95 37 4.55
290x260x
110
w
Danfoss
part no.
d
[mm]
130BB728.10
W
VLT
frame
size
d
H
h
In normal operation the temperature is below 70°C.
However, if the cores are saturated they can get hot, with
temperatures above 70°C. Therefore it is important to use
the correct number of cores to avoid saturation. Saturation
can occur if the motor cable is too long, motor cables are
paralleled or high capacitance motor cables, not suitable for
frequency converter operation, are used. Always avoid motor
cables with sector-shaped cores. Use only cables with roundshaped cores.
MG.90.N4.02 - VLT® is a registered Danfoss trademark
17
4 4
18
MG.90.N4.02 - VLT® is a registered Danfoss trademark
745
800
880
450
500
560
355
400
90
110
132
160
200
250
315
11
15
18.5
22
30
37
55
75
525V operation requires a T7 drive
400
450
500
600
658
147
177
212
260
315
395
480
24
32
37.5
44
61
73
90
106
For derating with motor frequency consider 60 Hz rating=0.94 x 50Hz rating and 100Hz rating= 0.75 x 50Hz rating
630
315
355
75
90
110
132
160
200
250
11
15
18.5
22
30
37
45
55
3)
630
450
290
192
108
86
54
27
The filter enclosure is IP20 for wall-mounted filters and IP23 for floor-mounted filters
780
880
500
344
242
131
94
58
32
2)
590
658
303
315
443
160
177
480
105
80
106
90
40
678
730
780
540
590
130
160
190
240
303
361
443
21
27
34
40
52
65
80
105
250
300
315
400
450
500
160
200
75
90
110
132
7.5
11
15
18.5
30
37
45
55
360
395
429
523
596
659
253
303
113
137
162
201
14
19
23
28
43
54
65
87
441 - 500V 525 - 550V
kW A
kW
A
1)
130B2853
130B2854
130B2851
1302852
1302849
130B3850
130B2847
130B2848
130B2841
130B2842
130B2844
130B2845
130B2838
130B2839
44
380 - 440V
kW A
VLT power and current rating
315
355
400
500
560
630
110
132
160
200
250
11
15
18.5
22
30
37
45
55
75
90
344
380
410
500
570
630
131
155
192
242
290
13
18
22
27
34
41
52
62
83
108
551 - 690V
kW
A
850
550
398
315
205
145
130
37
W
Maximum
filter losses
4 4
130B2835
130B2836
Code number
Filter current rating at given voltage and motor frequency [A]2)
IP00/IP20(IP23)1)
380V @ 60Hz
460/480V @ 575/600V
690V
and 400/440V 60Hz and
@ 60Hz
@ 50Hz
@ 50Hz
500/525V @
50Hz3)
15
13
17
30
50
99
66
43
20
111 15
95
110 13.6
150 10
L
C
uH nF
Filter data
Selection of Output Filters
Output Filters Design Guide
4.2 Electrical Data - du/dt Filters
du/dt Filter 3x380-500V IP00
1160 750
For derating with motor frequency consider 60Hz rating=0.94 x 50Hz rating and 100Hz rating= 0.75 x 50Hz rating
525V operation requires a T7 drive
3)
560
780
1000 1380 850
1100 1530 1000
500 730 500
800
2)
880
1460
1700
800
1260
The filter enclosure is IP20 for wall-mounted filters and IP23 for floor-mounted filters
500
800
1000
450
For F-frame drives, parallel filters shall be used, one filter for each inverter 710
module.
1108
1317
659
988
441 - 500V 525 - 550V
kW A
kW
A
380 - 440V
kW A
690V
@ 50Hz
380V @ 60Hz 460/480V @
and 400/440V 60Hz and
@ 50Hz
500/525V @
50Hz3
575/600V
@ 60Hz
VLT power and current size
Filter current rating at given voltage and motor frequency [A]2
1)
2 x 130B2849
2 x 130B2852
2 x 130B2851
2 x 1302852
or
3 x 130B2849
3 x 130B3850
2 x 130B2853
2 x 130B2854
or
3 x 130B2851
3 x 130B2852
3 x 130B2853
3 x 130B2854
Code number
IP00/IP20(IP23)1
1000
1200
900
1060
1260
945
551 - 690V
kW
A
W
Maximum
filter losses
L
uH
C
nF
Filter data
Selection of Output Filters
Output Filters Design Guide
4 4
MG.90.N4.02 - VLT® is a registered Danfoss trademark
19
20
MG.90.N4.02 - VLT® is a registered Danfoss trademark
1Equivalent
130B2282
130B2308
130B2283
130B2309
130B2284
130B2310
130B2285
130B2311
130B2286
130B2312
*) 120Hz
71
109
171
247
75
115
180
260
18
13
7.5*
5*
3.5*
2*
195
135
86
56
46.5
36
28.5
STAR-connection value
59
62
45.5
48
156
36
17
130B2411
130B2446
9.5
38
10
130B2409
130B2444
7.5
23
8
130B2408
130B2443
4
2.5
24
4.5
130B2406
130B2441
130B2412
130B2447
130B2413
130B2448
130B2281
130B2307
2.5
Filter Current Rating
@ 50Hz @ 60Hz @ 100Hz
A
A
A
3
3
3
3
3
4
4
4
5
5
5
5
5
Switching
Frequency
kHz
74.8
88
115
143
170
22
30
37
45
59.4
46.2
30.8
24.2
10.6
12.5
16.7
18.5
15
11
7.5
5.5
2.2
3
3.7
45
55
75
90
110
132
37
30
90
106
147
177
212
260
73
61
44
32
37.5
15
18.5
22
24
13
16
10
11
5.5
7.5
4
55
75
90
110
132
160
37
30
22
15
18.5
11
5.5
7.5
4
80
105
130
160
190
240
65
52
40
27
34
21
11
14.5
8.2
VLT Power and Current Ratings
@ 200-240V
@ 380-440V
@ 441-500V
kW
A
kW
A
kW
A
0.37
1.3
0.37
1.1
0.25
1.8
0.55
1.8
0.55
1.6
0.37
2.4
0.75
2.4
0.75
2.1
1.1
3
1.1
3
0.55
3.5
1.5
4.1
1.5
3.4
0.75
4.6
1.1
6.6
2.2
5.6
2.2
4.8
1.5
7.5
3
7.2
3
6.3
450
500
650
680
350
300
270
160
150
90
100
125
65
65
75
80
50
60
@ 200-240V
W
460
500
600
700
820
900
350
310
270
170
180
150
110
125
95
70
80
Filter Losses
@ 380-440V
W
45
50
60
60
70
430
500
600
680
800
880
330
280
260
160
170
150
100
115
90
70
80
@ 441-500V
W
45
50
60
60
65
0.2
0.3
0.5
0.75
0.85
1.1
1.6
2.4
3.1
5.2
6.9
13
141
99
60
30
30
14.7
10
10
10
6.8
4.7
2.2
1
uF
mH
29
Cy-Value1
L-value
4 4
130B2404
130B2439
Code
Number
IP00/IP20
Selection of Output Filters
Output Filters Design Guide
4.3 Electrical Data - Sine-wave Filters
Sine-wave Filter 3x380-500 V IP00/IP20
1Equivalent
STAR-connection value
Code
Filter Current Rating
Number
@ 50Hz @ 60Hz @ 100Hz
IP00/IP20
A
A
A
130B2287
410
390
308
130B2313
130B2288
480
456
360
130B2314
130B2289
660
627
495
130B2315
130B2290
750
712
562
130B2316
130B2291
880
836
660
130B2317
130B2292
1200
1140
900
130B2317
2x130B2291
1500
2X130B2317
2x130B2292
1700
2X130B2318
*) 120Hz
800
880
990
1120
1260
1460
450
500
560
630
710
800
2
2
2
1700
745
400
2
1000
600
658
315
355
3
2
480
250
1100
500
560
630
710
800
1000
450
355
400
315
1530
730
780
890
1050
1160
1380
678
540
590
443
VLT Power and Current Ratings
@ 200-240V
@ 380-440V
@ 441-500V
kW
A
kW
A
kW
A
160
315
200
303
200
395
250
361
3
3
Switching
Frequency
kHz
@ 200-240V
W
3400
3600
3600
3800
2900
2000
2100
1400
Filter Losses
@ 380-440V
W
1050
1200
3300
3400
3600
3800
2800
1900
2000
1350
@ 441-500V
W
1050
1100
Cy-Value1
uF
198
282
423
495
564
846
L-value
mH
0.13
0.11
0.14
0..2
0.11
0.075
Selection of Output Filters
Output Filters Design Guide
Sine-wave Filter 3x380-500V IP00/IP20
4 4
MG.90.N4.02 - VLT® is a registered Danfoss trademark
21
22
MG.90.N4.02 - VLT® is a registered Danfoss trademark
1Equivalent
130B2326
130B2346
130B2327
130B2347
130B2329
130B2348
130B2323
130B2343
130B2324
130B2344
130B2325
130B2345
130B2322
130B2342
287
303
STAR-connection value
247
260
109
115
157
72
76
165
42.5
26.5
12.35
45
28
13
227
195
123
86
57
33.5
21
9.75
2
2
2
2
2
2
2
2
Filter Current Rating
Switching
@
@ 50Hz @ 60Hz
Frequency
100Hz
A
A
A
kHz
220
90
110
150
180
11
15
18.5
22
30
37
45
55
75
kW
0.75
1.1
1.5
2.2
3
4
5.5
7.5
290
131
155
192
242
18
22
27
34
41
52
62
83
100
A
1.7
2.4
2.7
4.1
5.2
6.4
9.5
11.5
@ 525-550V
200
90
110
132
160
30
37
45
55
75
kW
303
137
162
201
253
46
56
76
90
113
A
@ 525-600V
250
110
132
160
200
A
290
131
155
192
242
13
18
22
27
34
46
54
73
86
108
@ 690V
11
15
18.5
22
30
37
45
55
75
90
kW
VLT Power and Current Ratings
1600
1050
1150
1100
1250
360
450
500
800
850
W
@ 525-550V
1600
1000
1100
1050
1200
230
250
280
300
330
420
450
750
800
W
120
125
125
130
130
140
160
170
@ 525-600V
Filter losses
1600
1000
1100
1050
1200
180
230
250
280
300
360
450
500
750
850
W
@ 690V
4 4
130B2321
130B2341
Code
Number
IP00/IP20
0.5
0.6
0.9
1.3
2
3.4
5.5
11.7
mH
L-value
136
94
66
47
33
20
10
47
uF
Cy-Value1
Selection of Output Filters
Output Filters Design Guide
Sine-wave Filter 3x525-690V IP00/IP20
1Equivalent
130B2241
130B2270
130B2242
130B2271
130B2337
130B2381
130B2338
130B2382
130B2339
130B2383
130B2340
130B2384
Code
Number
IP00/IP20
STAR-connection value
1250
726
765
1320
627
660
893
503
530
940
408
430
990
705
573
495
397
322
Filter Current Rating
@
@ 50Hz @ 60Hz
100Hz
A
A
A
1.5
1.5
1.5
1.5
1.5
1.5
Switching
Frequenc
y
kHz
898
1060
1260
670
820
970
730
596
630
450
480
560
523
A
344
429
375
kW
260
300
@ 525-550V
670
750
850
1000
560
450
500
400
kW
250
315
939
1108
1317
763
596
659
523
A
360
429
@ 525-600V
986
898
1060
1317
730
570
630
500
A
344
410
@ 690V
800
900
1000
1200
710
560
630
500
kW
315
400
VLT Power and Current Ratings
3350
3400
4500
4700
3850
2800
2900
2500
W
1850
2100
@ 525-550V
4300
4600
3300
3800
2800
2850
2500
W
1800
2050
@ 525-600V
Filter losses
3350
3350
4300
4700
3800
2700
2850
2400
W
1800
2000
@ 690V
Cy-Value1
uF
272
340
408
476
612
816
L-value
mH
0.35
0.28
0.23
0.2
0.16
0.12
Selection of Output Filters
Output Filters Design Guide
Sine-wave Filter 3x525-690V IP00/IP20
4 4
MG.90.N4.02 - VLT® is a registered Danfoss trademark
23
24
130B2543
17
17
13.6
5
Switching
Frequenc
@ 50Hz @ 60Hz @ 100Hz
y
A
A
A
kHz
10
10
8
5
Filter Current Rating
2.2
3
3.7
10.6
12.5
16.7
5.5
7.5
13
16
A
10
kW
4
kW
A
@ 380-440V
@ 200-240V
5.5
7.5
kW
4
11
14.5
A
8.2
@ 441-500V
VLT Power and Current Rating
100
100
W
@ 200-240V
100
100
W
60
@ 380-440V
Filter losses
100
100
W
60
@ 441-500V
4 4
130B2542
Code
Number
3.1
3.1
mH
5.3
L-value
2.04
2.04
uF
1.36
Cy-Value1
Selection of Output Filters
Output Filters Design Guide
Sine-wave Foot Print Filter 3x200-500V IP20
MG.90.N4.02 - VLT® is a registered Danfoss trademark
Selection of Output Filters
Output Filters Design Guide
4.4 Sine-Wave Filters
Surroundings:
Isolation class:
EIS 155
EIS 180
Max. allowed ambient temperature
2.5A up to 75A
115A up to 2300A
45°C
Electrical data:
2.5kV / 1min.
AC and DC
1.6x rated current for 1 minute, every 10 minutes
Over voltage test [voltage/time]
Overload capacity
Voltage drop (phase to phase):
Sine- wave filter 500V:
2.5A
4.5A - 480A
660A- 1200A
Sine-wave filter 690V:
4.5A - 480A
40V
30V
50V
83V
Voltage rating
3 x 200-500V AC and 3 x 525-690V AC
Nominal current I¬N @ 50Hz
2,5 – 1200A for higher power, modules can be paralleled
Motor frequency
0-60Hz without derating. 100/120Hz with derating (only 500V up to 10A)
Ambient temperature
-25° to 45°C side by side mount, without derating
Min. switching frequency
fmin 1,5kHz – 5kHz, depending on filter type
Max. switching frequency
no limit
Overload capacity
160% for 60 sec. every 10 min.
Enclosure degree
IP00 and IP20 (IP23 all floor standing filters)
Approval
CE, UL and cUL(up to and including 115A), RoHS
The voltage drop can be calculated using this formula:
lout[%]
110%
ud = 2 × π × f m × L × I
fm = output frequency
L = filter inductions
I = current
Temperature derating curve
current derating
100%
130BB068.11
Technical Specifications
90%
80%
70%
60%
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Ambient temperature [ºC]
Illustration 4.1 Filter Diagram
MG.90.N4.02 - VLT® is a registered Danfoss trademark
25
4 4
4 4
Selection of Output Filters
Output Filters Design Guide
4.4.1 du/dt Filters
Technical Specifications
Voltage rating
3 x 200-690V
Nominal current @ 50Hz
up to 880A. F-frame current ratings are achieved by filter paralleling, one filter per inverter module.
Motor frequency derating
50Hz
Inominal
60Hz
0.94 x Inominal
100Hz
0.75 x Inominal
Minimum switching frequency
no limit
Maximum switching frequency
nominal switching frequency of the respective FC 102, 202 or 302
Overload capacity
160% for 60 seconds, every 10 min.
Enclosure degree
IP00, IP 20 for wall-mounted, IP23 for floor mounted. IP21/NEMA 1 available for wall-mounted using
separate kits.
Ambient temperature
-10° to +45°C
Storage temperature
-25° to +60°C
Transport temperature
-25° to +70°C
Maximum ambient temperature (with
derating) Maximum altitude without
derating
55°C
Maximum altitude without derating
1000m
Maximum altitude with derating
4000m
Derating with altitude
5%/1000m
MTBF
1481842 h
FIT
1,5 106 / h
Tolerance of the inductance
± 10%
Degree of pollution EN61800-5-1
II
Overvoltage category EN61800-5-1
III
Environmental Conditions Load
3K3
Environmental Conditions Storage
1K3
Environmental Conditions Transport
2K3
Noise level
< frequency converter
Approvals
CE (EN61558, VDE 0570), RoHS, cULus file E219022 (pending)
26
MG.90.N4.02 - VLT® is a registered Danfoss trademark
Selection of Output Filters
Output Filters Design Guide
4.4.2 Sine-Wave Foot Print Filter
Technical Specification
Voltage rating
3 x 200-500V AC
Nominal current I¬N @ 50Hz
10 – 17A
Motor frequency
0-60Hz without derating. 100/120Hz with derating (see derating curves below)
Ambient temperature
-25° to 45°C side by side mount, without derating (see derating curves below)
Min. switching frequency
fmin 5kHz
Max. switching frequency
fmax 16kHz
Overload capacity
160% for 60 sec. every 10 min.
Enclosure degree
IP20
Approval
CE, RoHS
Illustration 4.2 Temperature derating
4 4
Illustration 4.3 Output frequency derating
MG.90.N4.02 - VLT® is a registered Danfoss trademark
27
Output Filters Design Guide
130BB726.10
5 How to Install
5.1 Mechanical Mounting
5.1.1 Safety Requirements for Mechanical
Installation
WARNING
Pay attention to the requirements that apply to integration
and field mounting kit. Observe the information in the list to
avoid serious damage or injury, especially when installing
large units.
The filter is cooled by natural convection.
To protect the unit from overheating it must be ensured that
the ambient temperature does not exceed the maximum
temperature stated for the filter. Locate the maximum
temperature in the paragraph Derating for Ambient
Temperature.
If the ambient temperature is in the range of 45°C - 55°C,
derating of the filter will become relevant.
U
PE
V
W
Illustration 5.1 Correct installation
130BB727.10
5 5
How to Install
5.1.2 Mounting
•
All wall mounted filters must be mounted vertically
with the terminals at the bottom.
•
Do not mount the filter close to other heating
elements or heat sensitive material (such as wood)
•
The filter can be side-mounted with the frequency
converter. There is no requirement for spacing
between the filter and frequency converter.
•
Top and bottom clearance is minimum 100mm
(200mm for foot print filters).
•
The surface temperature of IP20/23 units does not
exceed 70°C.
•
The surface temperature of IP00 filters can exceed
70°C and a hot surface warning label is placed on
the filter.
Illustration 5.2 Wrong installation. The PE should not go through
the core.
Mechanical installation of HF-CM
The HF-CM cores have an oval shape to allow easier installation. They should be placed around the three motor phases
(U, V and W). It is important to put all three motor phases
through the core, else the core will saturate. It is also
important not to put the PE or any grounding wires through
the core, else the core will loose its effect. In most
applications several cores have to be stacked.
The cores can vibrate due to the alternating magnetic field.
When close to the cable’s isolation or other parts, it is
possible that the vibration causes the wearing of the core or
cable isolation material. Use cable ties to secure the cores
and cable.
28
PE
U
V
W
MG.90.N4.02 - VLT® is a registered Danfoss trademark
How to Install
Output Filters Design Guide
5.1.3 Earthing
The filter must be earthed before switching the power on
(high leakage currents).
Common mode interferences are kept small by ensuring that
the current return path to the VLT has the lowest possible
impedance.
•
Choose the best earthing possibility (e.g. cabinet
mounting panel)
•
Use the enclosed (in accessory bag) protective
earth terminal to ensure the best possible earthing
•
Remove any paint present to ensure good electrical
contact
•
Ensure that the filter and frequency converter make
solid electrical contact (high frequency earthing)
•
The filter must be earthed before switching the
power on (high leakage currents)
unscreened cables are employed it should be
ensured that the installation minimizes the
possibility of cross-couplings with other cables
carrying sensitive signals. This can be achieved by
measures such as cable segregation and mounting
in earthed cable trays.
•
The cable screen must be solidly connected at both
ends to the chassis (e.g. housing of filter and
motor).
•
When IP00 filters are installed in cabinets and
screened cables are used, the screen of the motor
cable should be terminated at the cabinet cable
entry point.
•
All screen connections must exhibit the smallest
possible impedance, i.e. solid, large area
connections, both ends of screened cable.
•
For maximum cable length between VLT and
output filter:
Below 7.5kW: 2m
Between 7,5 - 90kW: 5-10m
Above 90kW: 10-15m
5.1.4 Screening
It is recommended to use screened cables to reduce the
radiation of electromagnetic noise into the environment and
prevent malfunctions in the installation.
•
Cable between the frequency converter output (U,
V, W) and filter input (U1, V1, W1) to be screened or
twisted.
•
Use preferably screened cables between the filter
output (U2, V2, W2) and the motor. When
NOTE
The cable between frequency converter and filter should be
kept as short as possible
NOTE
More than 10m is possible but Danfoss strongly discourge
such installations, due to the risk of increased EMI and
voltage spikes on the filter terminals.
Illustration 5.3 Wiring diagram
For F-frame drives parallel filters shall be used, one filter for
each inverter module.
The cables or bus bars between inverter and filter should
have the same length for each module.
The paralleling connection should be after the du/dt filter,
either at the filters' terminals or at the motor terminals.
MG.90.N4.02 - VLT® is a registered Danfoss trademark
29
5 5
How to Install
Output Filters Design Guide
5.2 Mechanical Dimensions
5.2.1 Sketches
Wall Mounted Sine-wave filters
Floor Mounted Sine-wave filters
5 5
Illustration 5.4 IP00 Wall mounted
Illustration 5.6 IP00 Floor mounted
Illustration 5.5 IP20 Wall mounted
Illustration 5.7 IP23 Floor mounted
30
MG.90.N4.02 - VLT® is a registered Danfoss trademark
Output Filters Design Guide
130BB524.10
How to Install
A
b
c
f
e
A
C
a
d
A
5 5
Illustration 5.8 IP20 Wall mounted foot print filters
B
B
b
Illustration 5.10 IP20 wall mounted
A
A
c
f
e
130BB523.10
Wall mounted du/du filters
A
a
d
C
Illustration 5.9 IP00 wall mounted
MG.90.N4.02 - VLT® is a registered Danfoss trademark
31
Output Filters Design Guide
C
130BB525.10
Floor mounted du/du filters
A
A
b
a
B
f
e
A
C
130BB526.10
Illustration 5.11 IP00 floor mounted
Illustration 5.14 L-shaped terminal kit 130B3138
(Only for du/dt filters)
f
e
B
b
a
24
130BB529.10
23
18
A
34
88
Illustration 5.12 IP23 floor mounted
ø13
16
130BB527.10
15
8
80
10
88
35
.5
62.5
25
5
12.5
23
34
Illustration 5.15 L-shaped terminal kit 130B3139
(Only for du/dt filters)
15
5 5
How to Install
30
Illustration 5.13 L-shaped terminal kit 130B3137
(Only for du/dt filters)
32
MG.90.N4.02 - VLT® is a registered Danfoss trademark
MG.90.N4.02 - VLT® is a registered Danfoss trademark
IP23
IP00
IP23
IP00
IP23
IP00
IP23
130B2848
130B2849
130B3850
130B2851
130B2852
1302853
130B2854
792
400
425
350
425
300
425
295
370
395
475
395
475
445
525
300
660.5
375
325
325
325
275
325
279
279
379
379
379
379
429
429
275
a
940
290
700
250
700
250
700
115
118
155
157
155
158
185
188
190
B
779
159
660
123
660
125
660
85
85
125
125
125
125
155
155
100
b
918
283
620
270
620
235
620
170
242
220
248
220
248
235
335
235
C
11.5
11.5
11.5
11.5
11.5
11.5
11.5
11.5
c
13
13
13
13
13
13
13
13
d
11
11
13
11
13
11
13
6.2
6.2
6.2
6.2
6.2
6.2
6.2
6.2
11
e
22
22
17
22
17
22
17
6
6
6
6
6
6
6
6
22
f
182
72
78.5
47
67.5
36
64.5
4.6
6.3
12.7
16.2
22
25.5
27
30
33
kg
Weight
floor
floor
floor
floor
floor
floor
floor
wall
wall
wall
wall
wall
wall
wall
wall
floor
Mounting
4 x M10
4 x M10
2 x M10
2 x M10
2 x M10
2 x M10
M10
16
16
50
50
50
50
95
95
M10
mm2
6
6
1
1
1
1
3/0
3/0
AWG
Wire cross section
For floor mounted filters, an optional terminal connection kit is available for the case of installation. Please see the L-shaped terminal kit sketches.
The kit is not included in the filter delivery and should be ordered separately.
1)
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
A
Enclosure Dimensions [mm]
IP00/
IP20(IP23)
130B2835
130B2836
130B2838
130B2839
130B2841
130B2842
130B2844
130B2845
130B2847
Code
number
30/22.1
30/22.1
30/22.1
130B313
8
130B313
9
130B313
9
Terminal L-shaped
screw
terminal
torque
kit1)
Nm/ft-Ib Partnum
ber
4/3
N/A
4/3
N/A
6/4.5
N/A
6/4.5
N/A
6/4.5
N/A
6/4.5
N/A
12/9
N/A
12/9
N/A
18/13.3 130B313
7
18/13.3 130B313
7
30/22.1 130B313
8
30/22.1 130B313
8
30/22.1 130B313
8
How to Install
Output Filters Design Guide
5.2.2 Physical Dimensions
5 5
33
34
MG.90.N4.02 - VLT® is a registered Danfoss trademark
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP20
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
130B2404
130B2439
130B2406
130B2441
130B2408
130B2443
130B2409
130B2444
130B2411
130B2446
130B2412
130B2447
130B2413
130B2448
130B2281
130B2307
130B2282
130B2308
130B2283
130B2309
130B2284
130B2310
130B2285
130B2311
130B2286
130B2312
130B2287
130B2313
130B2288
130B2314
130B2289
130B2315
500
580
530
610
330
670
450
940
450
940
480
940
600
1050
620
1290
570
430
430
400
400
290
580
412
430
610
312
257
268
330
257
268
257
190
200
268
190
a
200
A
430
500
524
650
536
650
560
650
630
760
683
800
170
170
170
150
150
130
90
90
75
75
B
b
380
460
235
610
445
610
330
610
310
720
435
760
135
125
125
120
120
90
70
70
60
60
Table 5.1 500V Sine-wave Filter - Physical dimensions
Enslosure
450
522
402
782
506
782
675
782
650
742
764
1152
260
260
260
259
258
260
260
205
12
12
12
12
12
8
8
8
205
206
205
7
7
c
205
205
C
19
19
19
19
19
11
11
11
8
8
d
13
11
13
11
13
11
13
11
13
11
13
11
9
9
9
9
9
6.5
6.5
6.5
4.5
4.5
e
26
15
26
15
26
15
25
15
26
15
26
15
20
20
20
9
9
6.5
6.5
6.5
5
5
f
kg
50
54
68
87
87
113
125
190
190
245
235
310
310
445
2.5
3.3
3.3
4.2
4.6
5.8
6.1
7.1
7.8
9.1
14.4
16.9
17.7
19.9
34
39
36
41
floor
floor
floor
floor
floor
floor
wall
wall
wall
wall
wall
wall
wall
wall
wall
wall
Wall/Floor
2xM12
2xM12
M12
M8
M10
M12
M10
M8
50
50
50
16
16
4
4
4
4
4
mm2
5/0
4/0
3/0
3/0
1 - 2/0
1 - 2/0
6 - 1/0
6 - 1/0
6 - 1/0
20 - 4
20 - 4
24 - 10
24 - 10
24 - 10
24 - 10
24 - 10
AWG
Max. wire cross section
5 5
Code number
500V Sine-wave Filter - Physical dimensions
Mounting
Measurements / Dimensions
Weight
direction
30/22.1
30/22.1
30/22.1
30/22.1
15/11.1
18/13.3
15/11.1
15/11.1
8/5.9
8/5.9
2/1.5
2/1.5
0.6/0.44
0.6/0.44
0.6/0.44
0.6/0.44
0.6/0.44
Nm/ft-lb
Terminal screw
torque
How to Install
Output Filters Design Guide
IP00
IP23
IP00
IP23
IP00
IP23
A
660
1290
760
1290
740
1290
690
690
610
610
a
680
800
682
800
682
800
B
370
760
380
760
360
760
b
684
1152
893
1152
936
1152
C
c
Measurements / Dimensions
Table 5.2 500V Sine-wave Filter - Physical dimensions
130B2290
130B2316
130B2291
130B2317
130B2292
130B2318
Code number Enclosure
d
e
13
11
13
11
13
11
f
26
15
26
15
25
15
470
605
640
810
680
815
kg
Weight
floor
floor
floor
Wall/Floor
Mounting direction
500V Sine-wave Filter - Physical dimensions
2xM12
2xM12
2xM12
mm2
Nm/ft-lb
30/22.1
30/22.1
30/22.1
6/0
6/0
For field wiring use cooper
bus bars only
Terminal screw
torque
AWG
Max. wire cross section
How to Install
Output Filters Design Guide
5 5
MG.90.N4.02 - VLT® is a registered Danfoss trademark
35
36
MG.90.N4.02 - VLT® is a registered Danfoss trademark
IP00
IP20
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
IP00
IP23
130B2321
130B2341
130B2322
130B2342
130B2323
130B2343
130B2324
130B2344
130B2325
130B2345
130B2326
130B2346
130B2327
130B2347
130B2329
130B2348
130B2241
130B2270
130B2242
130B2271
130B2337
130B2381
130B2338
130B2382
130B2339
130B2383
130B2340
130B2384
680
1260
790
1290
900
1290
1140
1260
880
1304
270
670
310
670
360
670
430
670
480
910
550
910
540
1290
590
1290
430
A
800
800
660
640
638
640
418
630
540
490
500
430
380
310
260
220
412
a
650
800
677
790
684
800
584
800
740
860
410
500
410
500
410
500
400
500
490
650
540
650
660
800
680
800
150
B
620
350
760
365
764
430
760
453
760
760
505
760
610
295
610
240
460
320
460
320
460
280
460
120
b
794
1152
794
1152
884
1152
928
1152
1054
1302
368
522
378
522
440
522
478
522
542
782
493
782
641
1152
643
1152
260
C
12
c
Measurements / Dimensions
Table 5.3 690V Sine-wave filter - Physical Dimensions
Enclosure
19
d
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
13
11
9
e
26
15
26
15
26
15
26
15
26
15
26
15
26
15
26
15
25
15
26
15
26
15
26
15
26
15
9
f
430
610
540
675
540
670
700
775
1020
1020
14.5
16.7
30
55
45
70
75
105
120
150
165
220
220
285
228
370
330
550
kg
floor
2xM12
2xM12
2xM12
floor
floor
2xM12
2xM12
M12
M10
M10
M8
M8
M8
M8
M8
16
mm2
6/0
6/0
5/0 - 6/0
5/0
4/0 - 5/0
4/0 - 5/0
2/0 - 4/0
2/0 - 4/0
2 - 1/0
4-2
6-4
8-6
20 - 8
20 - 8
AWG
Max. wire cross section
floor
floor
floor
floor
floor
floor
floor
floor
floor
floor
wall
wall/floor
Weight Mounting direction
690V Sine-wave filter - Physical Dimensions
5 5
Code
number
30/22.1
30/22.1
30/22.1
30/22.1
30/22.1
18/13.3
18/13.3
18/13.3
15/11.1
15/11.1
15/11.1
15/11.1
15/11.1
2/1.5
Nm/ft-lb
Terminal screw
torque
How to Install
Output Filters Design Guide
A2
A3
130B2542
130B2543
A
282
282
a
257
257
Table 5.4 Foot Print Sine-Wave Filter - Technical Data
Foot Print
Code Number
B
90
130
70
110
b
202
212
C
10
10
c
11
11
d
Foot Print Sine-Wave Filter - Technical Data
Dimensions
e
6
6
f
15
15
8
11.5
[kg]
Weight
Max. Wire Cross
Section
mm2
4
4
Mounting
Direction
wall
wall
How to Install
Output Filters Design Guide
5 5
MG.90.N4.02 - VLT® is a registered Danfoss trademark
37
6 6
How to Programme the Freque...
Output Filters Design Guide
6 How to Programme the Frequency Converter
•
The VLT® switching frequency must be set to the
value specified for the individual filter. Please
consult the VLT® Programming Guide for the
corresponding parameter values.
•
With an output filter installed only a reduced
Automatic Motor Adaption (AMA) can be used.
NOTE
du/dt filters, unlike Sine-wave filters, can be used at lower
switching frequency than the nominal switching frequency,
but higher switching frequency will cause the overheating of
the filter and should be avoided.
NOTE
Sine-wave filters can be used at switching frequencies higher
than the nominal switching frequency, but should never be
used at switching frequencies with less than 20% lower than
the nominal switching frequency.
6.1.1 Parameter Settings for Operation with Sine-wave Filter
Parameter no.
Name
Suggested setting
14-00
Switching Pattern
For Sine-wave filters choose SFAVM
14-01
Switching Frequency
Sine-wave: Choose value
du/dt: Choose max. value
14-55
Output Filter
Choose Sine-wave filter fixed
14-56
Capacitance Output Filter
Set the capacitance*
14-57
Inductance Output Filter
Set the inductance*
*) For FLUX control principle only. Values can be found in the chapter Selection of output filter section Electrical Data - du/dt Filters and section
Electrical Data - Sine-wave Filters
38
MG.90.N4.02 - VLT® is a registered Danfoss trademark
Index
Output Filters Design Guide
Index
Mounting
28
N
A
Abbreviations
3
Accessory Bag
29
Acoustic Noise
12
Aggressive Environments
11
C
Cable Length
10
Capacitance
10
Capacitors
10
NEMA
NEMA-MG1
6
10
P
Phase-to-phase
7
Pulse Reflections
12
Pulsewidth Modulated
7
R
CE Conformity and Labelling
4
Reflection Coefficient
5, 6
Common-mode Voltage
7
Regenerative Braking
11
Conducted Noise
9
Retrofit
11
Cut Off Frequency
10
RFI filter
10
Ringing Oscillation
D
Du/dt Ratio
5
S
Safety Requirements For Mechanical Installation
E
Earthing
Electromagnetic
Screened Cables
29
5, 7
8
Sinusoidal
Step Up Applications
28
29
7, 8
13
Electromagnetic Emissions
12
EMC
10
T
EMC performance
10
The Low-voltage Directive (73/23/eec)
4
Tr
6
F
Flash Over
11
U
Upeak
G
General Purpose Motors
General Warning
11
3
H
6
V
Voltage Drop
10
Voltage Peaks
10
Harmonics
7
W
High Frequency
7
Wave Reflection
High-frequency Noise
7
High-voltage Warning
3
5
I
IEC
6
IEC 600034-25
11
IEC60034-17
10
IEC-60034-17*
10
Impedance
5
Inductance
10
Inductors
10
Insulation
Insulation Stress
5
10
L
LC-filter
12
M
Magnetostriction
7
Maximum Cable Length
29
Motor Bearing Stress
10
Motor Cable
5
MG.90.N4.02 - VLT® is a registered Danfoss trademark
39
www.danfoss.com/drives
130R0457
MG90N402
*MG90N402*
Rev. 2010-05-03