Danfoss iC7-Hybrid PowerHouse: Efficient Outdoor Power Conversion for H₂ Electrolyzers
The iC7-Hybrid PowerHouse is a fully enclosed outdoor power conversion solution, optimized for all electrolyzer applications. It features unrivaled power density and new filter technology, making it ideal for demanding outdoor environments in any climate condition.
This system comprises liquid-cooled modules with Grid Converter application software, integrated into an outdoor enclosure. It includes low-voltage switchgear, control equipment, and a high-current electrolyzer start-up and polarization unit.
The iC7-Hybrid PowerHouse is depicted as a robust, grey and red outdoor enclosure, designed for demanding environments. It is a compact, modular unit housing advanced power conversion technology.
Highlights
- Superior power density & efficiency
- Reliable liquid cooling system
- Service corridor enables service in any weather
- Modular design allows for customer-specific requirements
- Grid code compliance
- Simulation models reduce time to market
Competitive clean energy enabler
Features and Benefits
| Feature | Benefit |
|---|---|
| Purpose-built product dedicated to electrolyzer applications | Fit-for-purpose in your industry increases competitiveness and reduces engineering effort |
| Superior power density | Smaller footprint on site reduces levelized cost of hydrogen |
| Quality in focus – world's most reliable power converter | High uptime and low operating expenses |
| Supported by DrivePro Lifecycle services for global service capability | High uptime and long term planning capability |
| Engineering support from expert staff and a range of engineering tools | Go to market faster |
Learn more about iC7-Hybrid at iC7.danfoss.com
Reduces Levelized Cost of Hydrogen
The iC7-Hybrid PowerHouse optimizes the total cost of hydrogen production by contributing to OPEX, CAPEX, and efficiency. A traditional SCR rectifier feeds the electrolyzer with DC having a high ripple factor, which reduces electrolyzer efficiency. In comparison, the iC7-Hybrid PowerHouse produces nearly perfect DC with a low ripple factor, allowing the electrolyzer to operate at much higher efficiency.
- Harmonic distortion towards the AC grid is typically < 3% with a unity power factor, eliminating the need for STATCOM or other compensation devices.
- Supplies clean DC current within the required DC voltage window, accommodating electrolyzer cell voltage increases from beginning-of-life (BoL) to end-of-life (EoL).
- Utilizes the latest technology for excellent power conversion efficiency.
The iC7-Hybrid PowerHouse is suitable for alkaline, AEM, PEM, and SOEC electrolyzers.
MyDrive® Virtual Simulation Models Reduce Time to Market
Remove constraints of the physical environment with MyDrive® Virtual simulation models. FMU models of Grid Converter are available for system simulation, and models for tools like PSCAD and PowerFactory are also provided for grid simulation.
Internal Layout and Connections
The internal layout of the iC7-Hybrid PowerHouse is illustrated, showing distinct sections for power conversion and control. Key components include the MIS section (2x4000 A), the LC+GC section (8xAR12L), and the DC section. The system features coolant distribution, dual AC inputs (2 x 4000 A), and integrated DC fuses, DC distribution, and DC output terminals.
Grid Converter Application Software Key Features
Control references
- DC voltage control (AFE)
- DC power and DC current
- Active and reactive AC power limit controllers
Fit for purpose application features
- Online transition between control modes during run state
- Independent converter paralleling in same common AC and DC bus
- Fall back to open loop in case feedback is lost
- Filter & transformer pre-magnetization
- Main circuit breaker and pre-charge control
- I/O, fieldbus, PC and control panel control place changeover during run state
- Dedicated fieldbus control and status words & fieldbus customizer
Fieldbus protocols
- Modbus TCP
- PROFINET RT
Key Specifications
| Characteristic | Specification |
|---|---|
| Converter principle | Modular AC to DC Grid Converter, SiC MOSFET-based up to 1500 V DC, IGBT based up to 830 V DC |
| DC power rating | Up to 2 x 4.5 MW or 1x 9 MW at 690 V AC input voltage |
| DC operating voltage range | 640-1500 V DC |
| DC output current | Up to 8500 A or 2 x 4250 A |
| Nominal AC input voltage | 525-690 V 50/60 Hz, 380-500 V 50/60 Hz |
| Nominal input AC current | 2 x 3850 A or 1 x 7600 A |
| Power conversion | AC-to-DC configuration. 1 or 2 individual converters enable 1 or 2 electrolyzer stacks per iC7-Hybrid PowerHouse |
| Scalability | Modular design which can be extended for customer-specific sections |
| Protection rating | IP54 outdoor rated enclosure for coastal areas. Power electronics (PCBA, IGBT) installed in IP67 converter enclosures. |
| Corrosion class | C5 |
| Cooling system | Integrated HVAC system for sensitive electronics and losses to air: Liquid-cooled: Built-in liquid-to-liquid heat exchanger. |
| CEC and Euro efficiency at 1250 V DC | > 99% |
| Harmonic grid distortion | < 3% THDi |
| Power factor | Adjustable |
| Additional features | Built-in high-current electrolyzer start-up and polarization unit up to 500 A DC |
| Protective devices | Low-voltage air circuit breakers, AC and DC fuses on every converter module |
| Environment | Ambient temperature -30 to +40 °C, Sound pressure <80 dB(A) (standard) |
| Compliance | CE, SIL2 compliant converter. Planned: UL1741, CSA C22.2 No 107.1 |
| Dimensions of power converter | Length: 3300 mm (depending on output options), Width: 2360 mm, Height: 2740 mm |
| Weight [kg] | < 8000 |
| Transport and service access | Fits inside open type 20 ft shipping platform, Forklift/moving platform pockets, Padlock-lockable entrance doors, Two entrances to avoid confined space, Integrated lifting aid for heavy converter part maintenance/repair, Middle maintenance area under roof is large enough to fit in an EU pallet (800 mm+) |
| Mains and DC connections | AC connection: Busbar trunking system at the end of the converter, DC connection: Busbar or cable connection at the side of the converter |
| Heat management | Integrated HVAC unit for handling heat losses to air, Customer coolant inlet temperature up to +35 °C, Customer coolant liquid outlet temperature up to +40 °C, Customer coolant flow rate 370 l/min, Heat losses to liquid up to 105 kW |
iC7 Series | Danfoss
iC7 Series | Danfoss
iC7-Hybrid | Danfoss
