Installation Guide for Danfoss models including: OF7Z5, e30bl022.10, e30bl024.10, iC7 Series Liquid Cooled L Filter, iC7 Series, Liquid Cooled L Filter, Cooled L Filter, Filter
iC7-Hybrid | Danfoss
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DocumentDocumentInstallation Guide iC7 Series Liquid-cooled L Filter OF7Z5 1 Overview 1.1 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. e30bl022.10 e30bl024.10 400 A 1000 A Illustration 1: Liquid-cooled L Filters 1.2 Contents of the Delivery 3 1 1640 A 3 4 2 Illustration 2: Items Included in the Delivery 1 L Filter, 400 A, 1000 A, or 1640 A 3 2 AuxBus temperature measurement board (installed) 4 Push-in cooling connectors, 2 pcs (available as option +ANN1) AuxBus cable, 3 m (9.8 ft) Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 1 iC7 Series Liquid-cooled L Filter OF7Z5 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 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Mechanical Installation 2.3 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. e30bi308.11 1 Illustration 3: Square Holes for Installing the L Filter into a Cabinet (400 A, 1000 A) 1 Mounting holes 3. Use the mounting holes to attach the filter. Attach the filter from all the corners: top front, top back, bottom front, and bottom back. Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 3 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide 1 Mechanical Installation e30bi307.11 2 Illustration 4: Installing the L Filter into a Cabinet (400 A, 1000 A) 1 The mounting holes at the top 2 The mounting holes at the bottom 2.4 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. 4 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide 1 1 2 2 Illustration 5: Installing the L Filter into a Cabinet (1640 A) 1 The mounting holes at the top 2 The mounting holes at the bottom 3. Use the bracket to attach the filter from below. e30bi309.11 Mechanical Installation e30bi310.11 1 Illustration 6: Bracket for Installing the L Filter into a Cabinet (1640 A) 1 The bracket Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 5 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide 2.5 Dimensions of the L Filter Ø9.5 x 14 (0.37) 105 (4.13) 129.5 (5.10) 119 (4.69) 5 (0.20) 356 (14.02) 307 (12.09) 10 (0.39) 190 (7.48) 300 (11.81) 264 (10.39) Ø9.5 x 14.5 (0.37) Ø13 x 18 (0.51) Ø13 (0.51) 119 (4.69) 105 (4.13) 105 (4.13) 292 (11.50) 190 (7.48) 10 (0.39) 41 (1.61) 184 (7.24) 5 (0.20) 70 (2.76) Illustration 7: Dimensions of the L Filter, 400 A 381 (15) 368 (14.49) 297 (11.69) 4 (0.16) 4 (0.16) Mechanical Installation e30bi311.10 356 (14.02) 359 (14.13) 176 (6.93) 125 (4.92) Ø10 (0.39) 165 (6.50) 189 (7.44) 6 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 100 (3.94) 429.5 16.91) 189.5 (7.46) 179 (7.05) 5 (0.20) e30bi312.10 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Ø11 x 14 (0.43) 105 (4.13) 10 (0.39) 190 (7.48) 300 (11.81) 264 (10.39) Ø9.5 x 14.5 (0.37) Ø13 x 18 (0.51) Ø13 (0.51) 105 (4.13) 105 (4.13) 292 (11.50) 190 (7.48) 10 (0.39) 404 (15.91) 356 (14.02) 119.5 (4.70) 5 (0.20) 245 (9.65) Illustration 8: Dimensions of the L Filter, 1000 A Danfoss A/S © 2023.08 416 (16.38) 345 (13.58) 4 (0.16) 4 (0.16) Mechanical Installation 404 (15.91) 406.3 (16) 236 (9.29) 185 (7.28) Ø10 (0.39) 225 (8.86) 249.9 (9.84) AN447722950367en-000101 / 172K1111 | 7 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide 242.5 (9.55) 228.5 (9) 35 (1.38) 14 (0.55) 247 (9.72) 195 (7.68) Ø4.5 (0.18) Ø18 (0.71) 14 (0.55) 9 (0.35) 13 (0.51) A 50 (1.97) 13 (0.51) 39 (1.54) 24 (0.94) 308.5 (12.15) 18 (0.71) 18 (0.71) 8.5 (0.33) Ø4.5 (0.18) 23.5 (0.93) 65 (2.56) 233.5 (9.19) 100 (3.94) Ø11.5 x 16.5 (0.45) 309 (12.17) 275 (10.83) 294 (115.7) 607 (23.90) 523 (20.60) 466 (18.35) 32.5 (1.27) 24.5 (0.96) 65 (2.56) 100(3.94) 100 (3.94) A B 13 (0.51) 112 (4.41) 298.5 (11.75) 245 (9.65) 49.5 (1.95) 10 (0.39) Ø18 (0.71) 10 (0.39) 25 (0.98) 74 (2.91) 75 (2.95) 171 (6.70) 170 (6.70) 13 (0.51) 96 (3.78) 10 (0.39) 10 (0.39) 25 (0.98) Ø4.5 (0.18) Ø18 (0.71) 30 (1.18) 50 (1.97) Ø4.5 (0.18) 240 (9.45) 17.5 25 (0.69) (0.98) 520 (20.47 160 (6.30) Illustration 9: Dimensions of the L Filter, 1640 A A The terminal on top of the filter B The terminal on top of the filter 468.5 (25.53) 535 (21.06) 544 (21.42) 18 (0.71) 39 (1.54) Mechanical Installation e30bi313.10 13 (0.51) B 50 (1.97) 13 (0.51) 9 (0.35) 18 (0.71) 13 (0.51) 13 (0.51) 8 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Cooling Requirements 3 Cooling Requirements 3.1 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. HOT COOLANT Hot coolant can cause burns. - Avoid contact with the hot coolant. CAUTION CAUTION 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. NOTICE 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. 3.2 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 Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 9 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Cooling Requirements 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 2555% 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) e30bi115.10 bar 1.6 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 2 4 6 8 10 12 14 16 l/min Illustration 10: Pressure Drop, L Filter OF7Z5, 690 V/400 A e30bi117.10 bar 1.6 1.5 1.4 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 2 4 6 8 10 12 14 16 l/min Illustration 11: Pressure Drop, L Filter OF7Z5, 690 V/1000 A 10 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Cooling Requirements bar e30bi118.10 1.6 1.5 1.4 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 2 4 6 8 10 12 14 16 l/min Illustration 12: Pressure Drop, L Filter OF7Z5, 690 V/1640 A 3.3 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 Connector Tightening torque Pipe Pipe ferrule Parker 69111621 MALE STUD 1/2"BSPP SS STEEL 31 6L D16 EPDM SEAL 2030 Nm (177265 in-lb) PA 16/13 pipe Parker 1827-16-13 2 1 e30bj144.10 Illustration 13: Inlet and Outlet Connectors of the L Filter 1 Inlet/outlet connector 2 Inlet/outlet connector Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 11 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Electrical Installation 4 Electrical Installation 4.1 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. 4.2 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. 4.3 Cable Requirements For information about recommended cable types and required cable sizes, see the iC7 Series Liquid-cooled System Modules Operating Guide. 4.4 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. 4.5 Installing the Cables Procedure 1. Connect the mains AC cables to terminals L1, L2, and L3. Use M10 screws and tightening torque 3540 Nm (310354 in-lb). 2. Connect the AC cables from the AFE to terminals L1', L2', and L3'. Use M10 screws and tightening torque 3540 Nm (310354 in-lb). 3. Connect the grounding cable to the PE terminal. Use M8 screws and tightening torque 1720 Nm (150177 in-lb). 12 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Electrical Installation e30bl023.10 4.6 Terminals 400/1000 A L1 1640 A L2 L3 L1' L2' L3' L1 L2 L3 L1' L2' L3' PE PE Illustration 14: Terminals of the L Filter Table 2: L Filter Terminal Descriptions Terminal Description L1, L2, L3 AC connection point for mains input L1', L2', L3' AC connection point for output to AFE PE Grounding terminal for filter frame 4.7 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 0.220.25 Nm (1.92.2 in-lb). Table 3: Wiring of the AuxBus Terminals Pin Wire color Signal 1 White +24 V 2 Brown GND 3 Green CAN_H 4 Yellow CAN_L 5 Grey +24 V Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 13 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Electrical Installation e30bk577.10 21 12 3 Illustration 15: The Ready AuxBus Cable 1 Terminals 2 Wires 3 Shield removed 4.8 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. - a. Connect the end of the AuxBus cable where the insulation was removed to terminal X85 on the LC Filter. - b. Connect the other end of the AuxBus cable to terminal X86 on the AuxBus temperature measurement board. e30bk560.10 X201 X202 X86 X203 X204 X205 X85 X206 Illustration 16: Terminals on the AuxBus Temperature Measurement Board X206 X85 Temperature measurement input AuxBus in X86 AuxBus out 14 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide Electrical Installation e30bi251.11 Control unit Integration unit Power unit 1 X79 Control unit Star coupler board Integration unit Power unit 1 X79 Power unit 2 X85 X86 LC Filter X85 X86 LC Filter X86 L Filter X86 L Filter Illustration 17: AuxBus Topology for AFE and Grid Converter Modules AR10L and AR12L 2. Route the cable so that there is no risk of getting in touch with bare busbars or terminals. 3. 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. 1 e30bj147.10 2 3 Illustration 18: Using the Cable Clamps 1 Stripping length, 15 mm (0.59 in) 2 Strain relief 3 Grounding 4. At the terminal X86 end of the cable, place the cable in a cable clamp for strain relief. Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 | 15 iC7 Series Liquid-cooled L Filter OF7Z5 Installation Guide 4.9 Wiring Diagrams 1 2 L1 L1' L1 L2 L2' L1 L2 L3 L3' L2 L3 L3 Electrical Installation 3 4 L1 L1' L2 L2' L1 L3 L3' L2 L3 1 L1 DC+ 2 L2 DC- 3 L3 5 DC+ DC- e30bk925.10 PE PE Illustration 19: Wiring Diagram, L Filter and Single Power Unit 1 L Filter 2 AC fuses, loose option 3 LC Filter, loose option 1 2 3 4 AFE module AM10L 5 DC fuses, loose option 4 L1 L1' L1 L2 L2' L1 L2 L3 L3' L2 L3 L3 L1 L1' L2 L2' L1 L1 L3 L3' L2 L2 L3 L3 1 DC+ 2 DC- 3 1 DC+ 2 DC- 3 5 DC+ DC- DC+ DC- e30bk926.10 PE PE Illustration 20: Wiring Diagram, L Filter and Parallel Power Units 1 L Filter, loose option 2 AC fuses, loose option 3 LC Filter, loose option 4 AFE module AM10L 5 DC fuses, loose option 16 | Danfoss A/S © 2023.08 AN447722950367en-000101 / 172K1111 iC7 Series Liquid-cooled L Filter OF7Z5 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. Danfoss A/S © 2023.08 *172K1111A* AN447722950367en-000101 / 172K1111 | 17