Danfoss iC7 Series Air Cooled LCL Filter Installation Guide

: July 25, 2024
: Danfoss

Table of Contents

iC7 Series Air Cooled LCL Filter
Specifications
Product Usage Instructions
1. Safety Information
2. Installation Requirements
3. Installing the LCL Filter into the Cabinet
Q: What are the electrical sizes available for the LCL
Q: What are the protection ratings offered for the LCL
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)

iC7 Series Air Cooled LCL Filter

“`html

Specifications

Product Name: iC7 Series Air-cooled LCL Filter OF7Z3
Filter Sizes: LCL10 (514 A) and LCL11 (816 A)
Protection Ratings: IP00 and IP54
Delivery Contents: LC Filter, L Filter, AuxBus cable (3 m)

Product Usage Instructions

1. Safety Information

WARNING: SHOCK HAZARD FROM THE COMPONENTS – The
components of the drive are live when connected to mains. Only
qualified personnel should perform the installation.

CAUTION: BURN HAZARD – The filter gets hot
during operation. Do not install it on a combustible surface.

2. Installation Requirements

Follow the installation instructions provided in this guide and
adhere to relevant local regulations. Make sure to read the
operating guide for the iC7 Series System Modules for additional
safety information.

3. Installing the LCL Filter into the Cabinet

This section provides the recommended steps for installing the
iC7 Series Air-cooled LCL Filter and AFE modules with an
integration unit.

3.1 Mounting Brackets Installation

Procedure:

Install mounting brackets to the cabinet (not included in the
delivery).
Mount the L Filter to the back wall of the cabinet.
Mount the front of the L Filter to a mounting bracket.

3.2 Integration Unit Installation

Procedure:

Install the integration unit of the AFE module into the
cabinet.
Push and slide the LC Filter into the cabinet, on top of the L
Filter.
Push and slide the AFE module into the cabinet.

FAQ

Q: What are the electrical sizes available for the LCL

Filter?

A: The LCL Filter is available in two electrical sizes: LCL10
(514 A) and LCL11 (816 A).

Q: What are the protection ratings offered for the LCL

Filter?

A: The LCL Filter comes with protection ratings of IP00 and
IP54.

“`

Installation Guide
iC7 Series Air-cooled LCL Filter OF7Z3
1 Overview
1.1 LCL Filter
The LCL Filter is used as an input filter with AFE or grid converter modules in applications where regenerative or low-harmonic functionality is required. The LCL Filter reduces switching noise, and ensures correct power quality and minimal interruption to the grid. There are 2 electrical sizes of the filter: LCL10 (514 A) and LCL11 (816 A). Both filter sizes are available with protection ratings IP00 and IP54.
1.2 Contents of the Delivery
The LCL Filter consists of 2 parts. The LC Filter and L Filter are delivered on separate wooden pallets.

e30bk945.10

1

2

3

Illustration 1: Items Included in the Delivery

1

LC Filter

2

L Filter

3

AuxBus cable, 3 m (9.8 ft)

AN447722806364en-000101 / 172K1109 | 1

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Mechanical Installation

2 Mechanical Installation
2.1 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.
2.2 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.
2.3 Installing the LCL Filter into the Cabinet
This is the recommended installation procedure for iC7 Series Air-cooled LCL Filters and AFE modules with an integration unit. See the installation dimension in 2.5 Dimensions of the LCL Filter.
Procedure 1. Install mounting brackets to the cabinet.
Mounting brackets are not included in the delivery. 2. Install the L Filter into the cabinet.
– a. Mount the L Filter to the back wall of the cabinet. –

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

b. Mount the front of the L Filter to a mounting bracket.

1

22222

e30bj968.11

Mechanical Installation 11

Illustration 2: Installing the L Filter

1

The mounting holes at the back

2

The mounting holes in the front

3. Install the integration unit of the AFE module into the cabinet.

1

2222 2

11

e30bj970.11

Illustration 3: Installing the Integration Unit of the AFE Module

1

The mounting holes at the back

2

The mounting holes in the front

AN447722806364en-000101 / 172K1109 | 3

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide
4. Push and slide the LC Filter into the cabinet, on top of the L Filter. 111 1

22

e30bj969.11

Mechanical Installation

Illustration 4: Installing the LC Filter

1

The upper mounting holes in the front

2

The lower mounting holes in the front

5. Push and slide the AFE module into the cabinet.

11

1

22

2

e30bj971.11

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Mechanical Installation

1

The upper mounting holes in the front

2

The lower mounting holes in the front

6. Mount the top front bracket. 7. Attach the LC Filter and AFE module to the front brackets at the top and bottom.

2.4 Cooling Requirements
The maximum ambient operating temperature of the LCL Filter is 40 °C (104 °F), with derating up to 55 °C (131 °F).
The product requires forced air cooling. Make sure that the cooling airflow through the filter is sufficient. The minimum airflow is 3 m/s (10 ft/s).

e30bk889.10

Illustration 6: Airflow Through the LCL Filter

AN447722806364en-000101 / 172K1109 | 5

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

2.5 Dimensions of the LCL Filter

2 x Ø9 (0.35)

5 x Ø5.5 (0.22)

72 R10 (2.84)

Ø25 (0.98)

3 x M8

300 (11.81) 259 (10.20)

Mechanical Installation

e30bi172.11

Ø13 (0.51)

M12
99 (3.90) 189 (7.44) 279 (10.98)

M12 78
(3.07)
39 (1.54) 23 (0.91)

921 (36.26)
1576 (62.05)

584 (22.99)

2 x Ø9 (0.35)

R7.5 3 x M8

280 300 (11.02) (11.81)

7 x Ø6 (0.24) 90° x Ø9 (0.35) Illustration 7: Dimensions of the LCL Filter in mm (in)

505 (19.88)
555 (21.85)

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

3 Electrical Installation
3.1 Power Cabling
Install the LCL Filter at the input of the active front-end. If the AFE has parallel power units, install a separate LCL Filter at the input of each power unit. See 3.10 Wiring Diagrams.
3.2 Cable Requirements
For information about recommended cable types and required cable sizes, see the iC7 Series Air-cooled System Modules Operating Guide.
3.3 Grounding
Ground the LCL 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 according to IEC 60364-5-54; 543.1. The connection must be fixed.
3.4 AC Fuses
The front-end modules in the drive system must be equipped with fast-acting AC fuses to limit the damage of the drive system. Install AC fuses at the input terminals of the LCL Filter. The AC fuses are not included in the LCL Filter delivery. For the recommended fuse types and required fuse sizes, see the iC7 Series Air-cooled System Modules Operating Guide.
3.5 Installing the Cables
1. Connect the input cables of the LC Filter to the output terminals of the L Filter.
Use M12 bolts and tightening torque 70 Nm (620 in-lb).
2. Connect the mains cables to the mains terminals of the L Filter with internal cables or busbars.
Use M12 bolts and tightening torque 70 Nm (620 in-lb).
3. Connect the output terminals of the LC Filter to the input terminals of the power unit.
Use M12 bolts and tightening torque 70 Nm (620 in-lb).
4. Connect the grounding cable to the PE terminal.
Use M8 screws and tightening torque 20 Nm (177 in-lb).

AN447722806364en-000101 / 172K1109 | 7

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide
3.6 Terminals

Electrical Installation

e30bk891.10

1
L1 2 L2
L3

Illustration 8: Terminals of the LCL Filter

1

Terminals between L Filter and LC Filter

2

L Filter input terminals L1, L2, L3

L3 L2 3 L1

3

LC Filter output terminals L1, L2, L3

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

3.7 Connecting the LCL Filter Fan Supply
To enable the functioning of the LCL Filter fan, do these steps. Table 1: DC- link Voltage Supply
Item Maximum load current Maximum voltage

Value 2 A 800 V DC

Table 2: Connector X121 Item Connector Maximum wire insulation diameter Wire stripping length Conductor size Fine-stranded conductor

Value Wago, 831-3103/037-000 7 mm (0.3 in) 14 mm (0.6 in) maximum 10 mm2/AWG8 ferrule maximum 6 mm2

Table 3: Cable Requirements Area Requirements
IEC Minimum 800 V DC voltage Minimum 2 A current
UL Minimum 600 V Minimum size AWG14 Minimum rated for 80 °C (176 °F)

Example wire Leoni BETAtrans® 4 GKW-ENX R 1800 V M, 1×2.5 mm2, order number 312474
UL AWM style 10269, AWG14

NOTICE
The LCL Filter fan supply is protected with internal fuses. Use external fuses if the local safety regulations or installation conditions require fuse protection.
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.
Procedure (LCL Filter and AFE in an enclosure) 1. Consider ambient temperature and other installation conditions. 2. Refer to the local safety regulations. 3. Protect the installation against mechanical and environmental damage and use strain relief when necessary. 4. Connect the DC-link voltage supply from the DC link to the LCL Filter connector X121.
Pay attention to the correct polarity. Do not connect the supply between the AFE module and the DC fuses. The supply connection point is after the AFE module fuses.

AN447722806364en-000101 / 172K1109 | 9

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide
23 4 1

Electrical Installation

e30bj310.10

e30bj306.11

Illustration 9: Fan Supply Connector of the LCL Filter

1

Fan supply (X121)

2

465800 V DC (+)

1

2

3

Empty

4

0 V DC (-)

X121 +-

3

4

L1

DC+

L2

DC-

L3

PE

Illustration 10: Diagram of the LCL Filter Fan Supply

1

AC fuses

2

LCL Filter

3

AFE module

4

DC fuses

3.8 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).

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

5. Connect the wires to the terminals included in the delivery. Use the tightening torque 0.220.25 Nm (1.92.2 in-lb).

Table 4: Wiring of the AuxBus Terminals

Wire color

Signal

1

White

+24 V

2

Brown

GND

3

Green

CAN_H

4

Yellow

CAN_L

5

Grey

+24 V

e30bk577.10

21

12

3

Illustration 11: The Ready AuxBus Cable

1

Terminals

2

Wires

3

Shield removed

3.9 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. 1. Connect the thermocouple wire from the L Filter to terminal X205 on the AuxBus temperature measurement board of the LC Filter. The thermocouple wire of the LC Filter is connected to terminal X206.

AN447722806364en-000101 / 172K1109 | 11

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

e30bl036.10

e30bk890.10

X205 X206
Illustration 12: Thermocouple Wiring in the LCL Filter 2. 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. – a. Connect the end of the AuxBus cable where the insulation was removed to terminal X25 on the power unit. – b. Connect the other end of the AuxBus cable to terminal X86 on the LCL.
X86
Illustration 13: Location of the X86 Terminal on the LCL Filter

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

e30bj298.11

Control unit Optical fiber cable

Control unit

Optical fiber cable

Star coupler board Optical fiber cable

Optical fiber cable Optical fiber cable

Power unit 1
X25 AuxBus cable
X86 Upper part of LCL Filter 1
X205 Sensor cable

Power unit 2
X25 AuxBus cable
X86 Upper part of LCL Filter 2
X205 Sensor cable

Power unit 3
X25 AuxBus cable
X86 Upper part of LCL Filter 3
X205 Sensor cable

Lower part of LCL Filter 1

Lower part of LCL Filter 2

Lower part of LCL Filter 3

Illustration 14: AuxBus Topology
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 X25 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.
1

e30bj147.10

2

3

Illustration 15: Using the Cable Clamps

1

Stripping length, 15 mm (0.59 in)

2

Strain relief

3

Grounding

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

AN447722806364en-000101 / 172K1109 | 13

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

3.10 Wiring Diagrams

1

2

L1 L2 L3

Electrical Installation

e30bh862.11

3

4

L1

DC+

L2

DC-

L3

PE

Illustration 16: Wiring Diagram, AFE Module and LCL Filter

1

AC fuses (option)

2

LCL Filter

3

AFE module

4

DC fuses (option)

AN447722806364en-000101 / 172K1109

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

1

2

L1 L2 L3

3 2

3 2
L1 L2 L3
3
PE

4
L1 DC+
L2 DC-
L3

Electrical Installation

5

6

DC+ DC-

e30bh863.11

4

5

L1 DC+
L2 DC-
L3

4
L1 DC+
L2 DC-
L3

5
DC+ DC-

Illustration 17: Wiring Diagram, AFE Modules with Parallel Power Units and LCL Filters

1

Common AC bus

2

AC fuses (option)

3

LCL Filters

4

AFE modules

5

DC fuses (option)

6

Common DC bus

AN447722806364en-000101 / 172K1109 | 15

iC7 Series Air-cooled LCL Filter OF7Z3 Installation Guide

Electrical Installation

Vacon Ltd, 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.

172K1109A

AN447722806364en-000101 / 172K1109