Danfoss iC7 Series Installation Manual

Liquid-cooled dc filter

Hide thumbs Also See for iC7 Series:

Application manual (382 pages)

Design manual (224 pages)

Operating manual (82 pages)

page of 22

/ 22
Bookmarks

Quick Links

Download this manual

Installation Guide

iC7 Series Liquid-cooled DC Filter OF7D1

1 Overview

DC Filter

1.1

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).

DC10L

Figure 1: Liquid-cooled DC Filters

AuxBus temperature measurement board

Capacitor terminals

Contents of the Delivery

1.2

Figure 2: Items Included in the Delivery

DC Filter, DC10L or DC12L

AuxBus terminals, 2 pcs

Available options:

+ANN1 = Push-in cooling connectors

+AO20 = 2.0 m (6.6 ft) cooling hose

DC12L

Inductor terminals

Cooling connectors

AuxBus cable, 3 m (9.8 ft)

AuxBus isolation board installation kit

AN440742702344en-000301 / 172K0616C |

Need help?

Do you have a question about the iC7 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Danfoss iC7 Series

Page 1 Installation Guide iC7 Series Liquid-cooled DC Filter OF7D1 1 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.
Page 2 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 iC7 Series Air-cooled and Liquid-cooled System Modules Installation Safety Guide. Installation Requirements The products described in this guide have the protection rating IP00/UL Open Type.
Page 3 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Mechanical Installation Figure 3: Example of Mounting the DC Filter in the Cabinet Vertically Mounting brackets Mounting holes in aluminum parts Mounting holes in sheet metal parts Figure 4: Example of Mounting the DC Filter Horizontally Danfoss Drives Oy ©...
Page 4 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Mechanical Installation Dimensions of the DC Filter 2x40=80 (2x1.58=3.15) 3xØ4.5 Ø18 (3xØ0.18) (0.51) (0.59) (1.65) (Ø0.71) (5.91) 323.5 6xM8 (12.74) (0.39) 64.5 (0.39) (2.54) (0.59) 3xM6 14 (0.55) (25.83) (0.39) (0.79) (1.14)
Page 5 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Cooling Requirements 5x40=200 (5x1.58=7.87) 6xØ4.5 (6xØ0.18) Ø18 (0.83) (1.61) (0.51) (Ø0.71) (5.91) (0.63) 3xØ12.5 (3xØ0.49) 323.5 (12.74) 5xM6 (1.58) 14 (0.55) (0.59) (4.53) (25.83) 49.5 49.5 (0.87) (0.79) (4.53) (1.95) (2.36) (2.36)
Page 6 General Information on Cooling NOTICE For more detailed information about the requirements for liquid-cooling, see the iC7 Series Liquid-cooled System Modules Design 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.
Page 7 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Cooling Requirements DC12L: 1.25 l (0.330 gal) l/min Figure 7: Pressure Drop with Water, DC10L l/min Figure 8: Pressure Drop with Water, DC12L 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).
Page 8 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Table 1: Recommended Connectors Connector Tightening torque Pipe Pipe ferrule Parker 69111621 MALE STUD 20–30 Nm PA 16/13 pipe Parker 1827-16-13 1/2"BSPP SS STEEL 31 6L D16 (177–265 in-lb) EPDM SEAL...
Page 9 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation 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.
Page 10 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation 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 mm (AWG 6) DC12L: 35 mm...
Page 11 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Use M8 screws and tightening torque 17–20 Nm (150–177 in-lb). Terminals DC10L DC12L U/T1’ U/T1 U/T1’ U/T1 V/T2 V/T2’ V/T2’ V/T2 W/T3 W/T3’ W/T3’ W/T3 – – Figure 10: Terminals of the DC Filter...
Page 12 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Figure 11: Removing the Cover of the AuxBus Isolation Board Install the PCB insulator. Mount the spacer screw on the front of the module. Use an 8 mm hex bit and tighten the screw to torque 0.4 Nm.
Page 13 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Figure 13: Mounting the AuxBus Isolation Board Connect the AuxBus wire harness to terminal X78 on the AuxBus isolation board and to terminal X77 on the system module. Figure 14: AuxBus Wire Harness Connection Mount the relief plate with a M4x8 screw.
Page 14 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Figure 15: Mounting the Relief Plate Reinstall the cover of the AuxBus isolation board. Use the old M4x8 combi screw or the spare one provided in the delivery. Use a TX20 bit and tighten the screw to torque 2.2 Nm.
Page 15 NOTICE For the drive to be able to protect the filters, AuxBus must be connected. For more information about AuxBus, see the iC7 Series Liquid-cooled System Modules Design Guide. Procedure To access the AuxBus temperature measurement board, remove the cover.
Page 16 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Control unit Star coupler board Control unit Integration unit Integration unit Power unit 1 Power unit 1 Power unit 2 DC Filter DC Filter Figure 19: AuxBus Topology Route the cable so that there is no risk of getting in touch with bare busbars or terminals.
Page 17 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Electrical Installation Wiring Diagrams 4.10 – Figure 21: Wiring Diagram, DC10L DC-bus fuses, option Source DC- fuses, option DC/DC converter module DM10L DC Filter DC10L DC-filter inductor Source fuses, option Discharging resistor...
Page 18 These conditions can include, for example, extreme temperature, dust, high humidity, hours of use, corrosive environment, and loading. For operation in stressful conditions, Danfoss offers the DrivePro® Preventive Maintenance service. DrivePro® services extend the lifetime and increase the performance of the product with scheduled maintenance including customized part replacements. DrivePro® services are tailored to your application and operating conditions.
Page 19 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Maintenance Table 7: Maintenance Schedule for Liquid-cooled Filters (continued) Component Inspection Preventive maintenance actions Service schedule interval Grounding 1 year – The drive system requires a dedicated ground wire connecting the drive, the output filter, and the motor to the building ground.
Page 20 Contact your local Danfoss office for further information on environmental aspects and recycling instructions for professional recyclers. End-of-life treatment must follow international and local regulations. All products are designed and manufactured in accordance with Danfoss company guidelines on prohibited and restricted substances. A list of these substances is available at www.danfoss.com.
Page 21 Installation Guide | iC7 Series Liquid-cooled DC Filter OF7D1 Maintenance This symbol on the product indicates that it must not be disposed of as household waste. Do not dispose of equipment containing electrical components together with domestic waste. It must be handed over to the applicable take-back scheme for the recycling of electrical and electronic equipment.
Page 22 Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to form, fit or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies.

This manual is also suitable for:

Ic7-hybrid Of7d1