Danfoss iC7 Series Liquid Cooled DC Filter Installation Guide

Danfoss iC7 Series Liquid Cooled DC Filter

Specifications
The iC7 Series Liquid-cooled DC Filter OF7D1 is designed to provide current control and voltage-boosting capabilities for DC/DC converters. It smoothens current and voltage waveforms, making them suitable for various DC sources or loads. Electrical sizes available: DC10L (570 A) and DC12L (1200 A).

Product Usage Instructions

Mechanical Installation:

• Safety Information
  • WARNING: SHOCK HAZARD FROM THE COMPONENTS – The components are live when connected to mains. Do not make changes when connected.
  • CAUTION: BURN HAZARD – The filter gets hot during operation. Do not install on a combustible surface or touch when hot. Only qualified personnel should perform the installation.

Installation Requirements
Follow the instructions in this guide and relevant local regulations. Refer to the operating guide for the iC7 Series System Modules.

Installing the Filter into a Cabinet

1. Install the filter vertically or horizontally in the cabinet.
2. Attach the filter from the mounting holes to the cabinet.

Dimensions of the DC Filter
Refer to the dimensions provided for proper installation of the DC10L or DC12L filter.

Overview

DC Filter
A DC/DC converter requires a DC filter between the DC source and the converter for current control and the ability to boost voltage. The filter also smoothens the current and voltage waveform, making them suitable for most DC sources or loads.

There are 2 electrical sizes of the filter: DC10L (570 A) and DC12L (1200 A).

1. AuxBus temperature measurement board
2. Inductor terminals
3. Capacitor terminals
4. Cooling connectors

Contents of the Delivery

1. DC Filter, DC10L or DC12L
2. AuxBus cable, 3 m (9.8 ft)
3. AuxBus terminals, 2 pcs

Available options:

• +ANN1 = Push-in cooling connectors
• +AO20 = 2.0 m (6.6 ft) cooling hose

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 the Filter into a Cabinet

Procedure

1. Install the filter into the cabinet in a vertical or horizontal position.
2. See 2.4 Dimensions of the DC Filter.

• Attach the filter from the mounting holes on the frame to the cabinet.
• For aluminum parts, use M6 grade 8.8 screws with a thread depth of 6–14 mm (0.24–0.55 in), and a tightening torque of 6–8 Nm (53–71 in-lb).
• For sheet metal parts, use M5 (DIN 7500) screws with a maximum thread depth of 20 mm (0.79 in), and a tightening torque of 3–4 Nm (27–35 in-lb).

1. Mounting brackets
2. Mounting holes in aluminum parts
3. Mounting holes in sheet metal parts

Dimensions of the DC Filter

1. Center of gravity

2. View from the bottom

3. View from the top

4. Center of gravity

5. View from the bottom

6. View from the top

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

  • 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:

• 6.7 l/min (1.77 gal/min) with water
• 8.7 l/min (2.30 gal/min) with 30% glycol
• 10.1 l/min (2.67 gal/min) with 50% glycol

The liquid volume per element:

• DC10L : 0.70 l (0.185 gal)
• DC12L : 1.25 l (0.330 gal)

Cooling Circuit Connectors
The DC filter has cooling circuit connectors in the manifold plate. 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. The inlet and outlet connectors are at the bottom of the filter. An alternative outlet connector is available at the top of the filter. If the optional outlet connector at the top is used, the outlet connector at the bottom must be closed with a plug. 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

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 DC Filter
Install the DC filter between the DC/DC converter and the DC source. See 4.9 Wiring Diagrams.

Cable Requirements

• It is recommended to use symmetrical cables with an even number of conductors for DC+ and DC-.
  • 3-core cable: Use 2 conductors for DC+ and DC-, and the 3rd conductor for PE.
  • 4-core cable : Use 2 conductors for DC+ and 2 conductors for DC-.
• It is recommended to use cables with common shielding. Connect the cable shield to ground at both ends.
• If single-core shielded cables are used, ground the cable shield only from 1 end.
• Use single-core unshielded cables only if EMI protection is not necessary, or it is ensured by other means.
• Cable insulation must be rated for minimum 90 °C (194 °F).
• Use symmetrical cabling with modules connected in parallel. Each module must have the same number of cables with equal cross-section.

Cable Sizes for the Connections to DC Source
Table 2: Cable Sizes for the Connections from the DC-filter Inductors to the DC Source

Filter size| Current (I L) [A]| 1-core cable Cu [mm 2]| 3-core cable Cu mm 2| 4-core cable Cu mm 2
---|---|---|---|---
DC10L| 300| 3x(1×95)| 2x(3×70)| 1x(4×70)
360| 3x(1×95)| 2x(3×70)| 1x(4×70)
420| 4x(1×95)| 2x(3×95)| 1x(4×95)
480| 4x(1×95)| 2x(3×95)| 1x(4×95)
570| 4x(1×120)| 2x(3×120)| 1x(4×120)
DC12L| 720| 5x(1×95)| 3x(3×95)| 2x(4×70)
840| 6x(1×95)| 3x(3×95)| 2x(4×70)
960| 7x(1×95)| 3x(3×120)| 2x(4×95)
1080| 7x(1×95)| 3x(3×120)| 2x(4×95)
1200| 8x(1×95)| 4x(3×120)| 2x(4×120)

1. 3-core cables: Use 2 conductors for ‘plus’ and ‘minus’, and 3rd conductor for PE.
2. 4-core cables: Use 2 conductors for ‘plus’ and 2 conductors for ‘minus’.

Cable Sizes for the Connections to DC/DC Converter
The cables must be as short as possible and the length for each phase as equal as possible.

Table 3: Cable Sizes for the Connections from the DC-filter Inductors to the DC/DC Converter

Cable Sizes for the DC-filter Capacitor Connections
For connecting the minus terminal of the DC-filter capacitor to the DC bus, use copper cable or single wire with at least 1100 V DC voltage, and 90 °C (194 °F) temperature rating. To optimize the performance of the DC-filter capacitor, make sure that the wire between the capacitor and the DC bus is as short as possible.

Minimum cable sizes

• DC10L: 16 mm2 (AWG 6)
• DC12L: 35 mm2 (AWG 2)

Grounding
Ground the DC 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.

Source DC+ Fuses
To protect the equipment, install fuses between the DC Filter and the source DC+.

Table 4: Recommended Source DC+ Fuses

Filter size| Rated current (I L) [A] (1)| Number of fuses| Fuse size| Part number (Mersen)| Fuse U n [V]| Fuse I n [A]| I cp, mr [A] (2)
---|---|---|---|---|---|---|---
DC10L| 300| 3| 72| D72SG120V250QF| 1200| 250| 1600
360| 3
420| 3
480| 3| 72| D72SG120V315QF| 1200| 315| 2200
570| 3
DC12L| 720| 3| 272| D272SG120V500QF| 1200| 500| 3100
Filter size| Rated current (I L) [A] (1)| Number of fuses| Fuse size| Part number (Mersen)| Fuse U n [V]| Fuse I n [A]| I cp, mr [A] (2)
---|---|---|---|---|---|---|---
| 840| 3| | | | |
960| 3
1080| 3| 272| D272SG120V630QF| 1200| 630| 4400
1200| 3

1. Nominal current of the DC/DC converter with low overload (110%). Allows a +10% load variation for 1 minute every 5 minutes.
2. Minimum required prospective short-circuit current at 5 ms pre-arcing time. If there is a short-circuit fault in the common DC bus, a multiplied Icp, mr value is required.

Installing the Cables
Procedure

• Connect the DC cables to the inductor terminals U, V, W, and U’, V’, W’.
• DC10L: Use M8 screws and tightening torque 17–20 Nm (150–177 in-lb).
• DC12L: Use M10 screws and tightening torque 35–40 Nm (310–354 in-lb) or M12 screws and tightening torque 65–70 Nm(575–620 in-lb).
• Connect the DC cables to the capacitor terminals + and -.
• Use M6 screws and tightening torque 6–9 Nm (53–80 in-lb).
• Connect the grounding cable to the PE terminal.
• Use M8 screws and tightening torque 17–20 Nm (150–177 in-lb).

Terminals

Table 5: DC Filter Terminal Descriptions

V/T2′

W/T3′

|
+| DC+ connection point for DC source to filter capacitor
–| DC- connection point for DC source to filter capacitor
PE| Grounding terminal for filter frame

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 6: 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. To access the AuxBus temperature measurement board, remove the cover.
2. AuxBus temperature measurement board
3. Cover
4. Connect the AuxBus cable between the filter and the power unit. If there are several power units and filters, connect each filter to the power units individually.
5. Connect the end of the AuxBus cable where the insulation was removed to terminal X79 on the power unit.
6. Connect the other end of the AuxBus cable to terminal X86 on the AuxBus temperature measurement board.

  *  **X206** Temperature measurement input
  *  **X85** AuxBus in
  *  **X86** AuxBus out

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

4. Ground each AuxBus cable at 1 end at the X79 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.

5. Stripping length, 15 mm (0.59 in)

6. Strain relief

7. Grounding

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

Wiring Diagrams

1. DC-bus fuses, option

2. Source DC- fuses, option

3. DC/DC converter module DM10L

4. DC Filter DC10L

5. DC-filter inductor

6. Source fuses, option

7. Discharging resistor

8. Capacitors

9. DC source/load

10. DC-bus fuses, option

11. Source DC- fuses, option

12. DC/DC converter module DM12L

13. DC Filter DC12L

14. DC-filter inductor

15. Source fuses, option

16. Discharging resistor

17. Capacitors

18. DC source/load

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 property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

FAQ

Q: What are the available electrical sizes of the DC filter?
A: The available electrical sizes are DC10L (570 A) and DC12L (1200 A).

Q: Can anyone perform the installation of the DC filter?
A: Only qualified personnel should perform the installation described in the guide to ensure safety and proper setup.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>