Danfoss iC7 Series Liquid Cooled L Filter Installation Guide

Danfoss iC7 Series Liquid Cooled L Filter

Specifications

• Product Name: iC7 Series Liquid-cooled L Filter OF7Z5
• Electrical Sizes: 400 A, 1000 A, 1640 A
• Contents of Delivery: L Filter, AuxBus temperature measurement board, Push-in cooling connectors (optional), AuxBus cable

Product Usage Instructions

Mechanical Installation

• Safety Information
  • WARNING: SHOCK HAZARD FROM THE COMPONENTS The components of the drive are live when the drive is connected to mains. – Do not make changes in the AC drive when it is connected to mains.
  • CAUTION: BURN HAZARD The filter is hot during operation. – Do not install the filter on a combustible surface. – Do not touch the filter when hot.

Only qualified personnel are allowed to perform the installation described in this guide. Follow the instructions in this guide and relevant local regulations. Also, read the instructions and safety information in the operating guide for the iC7 Series System Modules.

Installation Requirements
Ensure that you follow all safety precautions and guidelines provided before proceeding with the installation.

Installing L Filter into a Cabinet, 400 A, 1000 A

1. Install the filter into the cabinet in a vertical position.
2. Align the filter so that the pins fit into the square holes at the back wall of the cabinet.
3. Use the mounting holes to attach the filter securely from all corners: top front, top back, bottom front, and bottom back.

Installing L Filter into a Cabinet, 1640 A

1. Install the filter into the cabinet in a vertical position.
2. Use the mounting holes to attach the filter securely from all corners: top front, top back, bottom front, and bottom back.
3. Use the provided bracket to attach the filter securely from below.

Overview

L Filter
The L Filter is used together with an LC Filter to create an LCL input filter for AFE or grid converter modules in applications where regenerative or low- harmonic functionality is required.

There are 3 electrical sizes of the filter: 400 A, 1000 A, and 1640 A.

Contents of the Delivery

1. L Filter, 400 A, 1000 A, or 1640 A
2. AuxBus temperature measurement board (installed)
3. Push-in cooling connectors, 2 pcs (available as option +ANN1)
4. AuxBus cable, 3 m (9.8 ft)

Mechanical Installation

Safety Information

WARNING
SHOCK HAZARD FROM THE COMPONENTS

• The components of the drive are live when the drive is connected to mains.
• Do not make changes in the AC drive when it is connected to mains.

CAUTION
BURN HAZARD

• The filter is hot during operation.
• Do not install the filter on a combustible surface.
• Do not touch the filter when hot.
• Only qualified personnel are allowed to perform the installation described in this guide.

Follow the instructions in this guide and relevant local regulations. Also read the instructions and safety information in the operating guide for the iC7 Series System Modules.

Installation Requirements

• The products that are described in this guide have the protection rating IP00/UL Open Type. Install them in a cabinet or other enclosure 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 cabinet must also be sufficiently strong for the weight of the system modules 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 L Filter into a Cabinet, 400 A, 1000 A

Procedure

1. Install the filter into the cabinet in a vertical position.
2. Align the filter so that the pins of the filter fit into the square holes at the back wall of the cabinet.
3. Mounting holes
4. Use the mounting holes to attach the filter.

Attach the filter from all the corners: top front, top back, bottom front, and bottom back.

1. The mounting holes at the top
2. The mounting holes at the bottom

Installing L Filter into a Cabinet, 1640 A

Procedure

1. Install the filter into the cabinet in a vertical position.

2. Use the mounting holes to attach the filter.
   Attach the filter from all the corners: top front, top back, bottom front, and bottom back.

3. The mounting holes at the top

4. The mounting holes at the bottom

5. Use the bracket to attach the filter from below.

6. The bracket

Dimensions of the L Filter

1. The terminal on top of the filter
2. The terminal on top of the filter

Cooling Requirements

Safety in Liquid-cooling
WARNING

• POISONOUS COOLANTS
  • Glycols and inhibitors can be poisonous. If touched or consumed, they can cause injury.
  • Prevent the coolant from getting into the eyes.
  • Do not drink the coolant.

CAUTION

• HOT COOLANT
  • Hot coolant can cause burns.
  • Avoid contact with the hot coolant.

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

Be careful when operating the cooling system.

NOTICE

• INSUFFICIENT COOLING CAPACITY
  • Insufficient cooling can cause the product to become too hot and thus become damaged.
  • To make sure that the cooling capacity of the cooling system stays sufficient, make sure that the cooling system is vented, and that the coolant circulates properly.
• DAMAGE TO COOLING SYSTEM
  • If the coolant circulation is stopped too soon, high-temperature components can cause rapid local increase in the coolant temperature, which can damage the cooling system.
  • Do not stop the cooling system when stopping the drive. Keep the coolant circulation flowing for 2 minutes after the drive has been stopped.

General Information on Cooling
NOTICE
For more detailed information about the requirements for liquid-cooling, see the iC7 Series Liquid-cooled System Modules Operating Guide.

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

The allowed antifreeze coolants are the following ethylene glycols and propylene glycols.

• Ethylene glycols: DOWCAL 100 or Clariant Antifrogen N
• Propylene glycols: DOWCAL 200 or Clariant Antifrogen L

These glycols already include corrosion inhibitors. Do not add any other inhibitor. Do not mix different glycol qualities because there can be harmful chemical interactions. The glycol concentration of the coolant must be 25–55% by volume, according to the specified ambient temperature. Higher concentration reduces cooling capacity. Lower concentration results in biological growth and inadequate amount of corrosion inhibitors. Antifreeze must be mixed with purified water. To gain full performance of the product, the temperature of the coolant entering the system module must be a maximum of 45 °C (113 °F). Typically, 95% of the power losses are dissipated in the coolant. It is recommended to equip the cooling circulation with temperature supervision.

• The minimum nominal flow rate of the coolant:
  • 7.5 l/min (1.98 gal/min) with water
  • 9.8 l/min (2.59 gal/min) with 30% glycol
  • 11.3 l/min (2.99 gal/min) with 50% glycol
• The liquid volume per element:
  • 400/1000 A : 0.20 l (0.053 gal)
  • 1640 A: 0.60 l (0.159 gal)

Cooling Circuit Connectors
The L Filter has cooling circuit connectors at the top of the filter. The internal thread size is G1/2. The depth of the threads is 13 mm (0.51 in). The maximum tightening torque is 30 Nm (265 in-lb). Push-in connectors are available as option +ANN1. Each connector can be used for coolant input or output. Do not connect filters in series. Connecting in series requires high flow rates and high pressure because of the temperature rise of the coolant in the filters.

Table 1: Recommended Connectors

(177–265 in-lb)

| PA 16/13 pipe| Parker 1827-16-13

1. Inlet/outlet connector
2. Inlet/outlet connector

Electrical Installation

Electrical Installation Safety

WARNING
OVERHEATED CABLES

• Overheated cables are a fire hazard.
• Because of several possible cable installations and environmental conditions, it is important to consider local regulations and IEC/EN standards.

Route the wires away from sharp edges, screw threads, burrs, fins, moving parts, drawers, and similar parts, which can abrade the wire insulation. For the main circuit, use double insulated wires or protect the wires with, for example, a protective sleeve or wrap to minimize the risk of short circuit. Maintain separation between the main and control circuit wires.

Installing the L Filter
Install the L Filter between the LC Filter and the AC grid. If the AFE has parallel power units, install a separate L Filter for each of them. See 4.9 Wiring Diagrams.

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

Grounding
Ground the L Filter in accordance with applicable standards and directives. Unless local wiring regulations state otherwise, the cross-sectional area of the protective grounding conductor must be at least ½ times of the phase conductor and made of the same material when the phase conductor cross-section is above 35 mm2 (AWG 2) according to IEC 60364-5-54; 543.1. The connection must be fixed.

Installing the Cables

Procedure

1. Connect the mains AC cables to terminals L1, L2, and L3.
   Use M10 screws and tightening torque 35–40 Nm (310–354 in-lb).

2. Connect the AC cables from the AFE to terminals L1′, L2′, and L3′.
   Use M10 screws and tightening torque 35–40 Nm (310–354 in-lb).

3. Connect the grounding cable to the PE terminal.
   Use M8 screws and tightening torque 17–20 Nm (150–177 in-lb).

Terminals

Table 2: L Filter Terminal Descriptions

Preparing the AuxBus Cable

1. Cut the cable to the required length.
2. To reveal the wires, strip the cable at both ends.
3. At 1 end of the cable, remove approximately 15 mm (0.59 in) of the insulation of the cable.
4. Strip the wires 7 mm (0.28 in).
5. Connect the wires to the terminals included in the delivery. Use the tightening torque 0.22–0.25 Nm (1.9–2.2 in-lb).

Table 3: Wiring of the AuxBus Terminals

1. Terminals
2. Wires
3. Shield removed

AuxBus Connections

• NOTICE
  • For the drive to be able to protect the filters, AuxBus must be connected.
  • For more information about AuxBus, see the iC7 Series System Module operating guides.

Procedure

1. Connect the AuxBus cable between the L Filter and the LC Filter. If there are several parallel filters, connect each L Filter to the LC Filters individually.

2. Connect the end of the AuxBus cable where the insulation was removed to terminal X85 on the LC Filter.

3. Connect the other end of the AuxBus cable to terminal X86 on the AuxBus temperature measurement board.

4. X206 Temperature measurement input

5. X85 AuxBus in

6. X86 AuxBus out

7. Route the cable so that there is no risk of getting in touch with bare busbars or terminals.

8. Ground each AuxBus cable at 1 end at the X85 terminal. To make the grounding connection, attach the shield of the cable to the frame with a cable clamp.
   The lower part of the cable clamp fixes the cable to the plate and provides strain relief. The upper part provides ~360° grounding for the cable shield.

9. Stripping length, 15 mm (0.59 in)

10. Strain relief

11. Grounding

12. At the terminal X86 end of the cable, place the cable in a cable clamp for strain relief.

Wiring Diagrams

1. L Filter

2. AC fuses, loose option

3. LC Filter, loose option

4. AFE module AM10L

5. DC fuses, loose option

6. L Filter, loose option

7. AC fuses, loose option

8. LC Filter, loose option

9. AFE module AM10L

10. DC fuses, loose option

Vacon Ltd, a Member of the

• Danfoss Group Runsorintie 7
• FIN-65380 Vaasa
• www.danfoss.com

Danfoss can accept no responsibility for possible errors in catalogs, 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 material are the property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

FAQ

Q: Can I install the L Filter horizontally?
A: No, it is recommended to install the L Filter vertically as per the installation instructions to ensure proper functionality and safety.

Q: What should I do if the filter gets too hot during operation?
A: If the filter gets too hot during operation, ensure you do not touch it and allow it to cool down before attempting any maintenance or adjustments.

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