Danfoss iC7 Series Installation Manual
Liquid-cooled system modules, active front-end, grid converter, inverter, and dc/dc converter modules
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Also See for iC7 Series:
- Application manual (382 pages) ,
- Design manual (224 pages) ,
- Operating manual (82 pages)
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Summary of Contents for Danfoss iC7 Series
- Page 1 Installation Guide iC7 Series Liquid-cooled System Modules Active Front-End, Grid Converter, Inverter, and DC/DC Converter Modules drives.danfoss.com |...
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Page 3: Table Of Contents
Installation Guide | iC7 Series Liquid-cooled System Modules Contents Overview Safety and Installation Awareness Checking the Delivery and the Contents Unpacking the Product Lifting the System Modules Lifting the System Modules with Integration Unit Lifting the Filters Mechanical Installation Installation Requirements... - Page 4 Installation Guide | iC7 Series Liquid-cooled System Modules Electrical Installation Control System of the System Modules Grounding Principles Prerequisites for Cable Installation Recommended Installation of Motor Cables Installing the Cables 4.5.1 Field Cabling Installation 4.5.2 Installing the Cables, AFE and GC (AR10L, AR12L) 4.5.3...
- Page 5 Installation Guide | iC7 Series Liquid-cooled System Modules Commissioning Commissioning the System Modules Measuring the Insulation Resistance of the Motor Cable Measuring the Insulation Resistance of the Mains Cable Measuring the Insulation Resistance of the Motor Preparing for a PC Connection...
- Page 6 Installation Guide | iC7 Series Liquid-cooled System Modules | Danfoss Drives Oy © 2024.03 AN389643231588en-000101 / 172F6360A...
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Page 7: Safety And Installation Awareness
MADE IN Nordborgvej 81, 6340 Nordborg FINLAND Denmark SCCR 100 kA UL volt. 525-600V Figure 1: Product Label for iC7 Series Liquid-cooled System Modules Model code of the product Product number Serial number Power, input, and output ratings for high overload... -
Page 8: Lifting The System Modules
Installation Guide | iC7 Series Liquid-cooled System Modules Lifting the System Modules Attach the lifting device in the hole on the top of the system module. If necessary, lift the system module into a vertical position. Figure 2: Lifting the System Module Lift the system module to the required location. -
Page 9: Lifting The Filters
Installation Guide | iC7 Series Liquid-cooled System Modules Lift the system module to the required location. Lifting the Filters Use these instructions to lift the L Filter, the LC Filter, the dU/dt Filter, the dU/dt and Common-mode Filter, and the DC/DC Filter. -
Page 10: Mechanical Installation
Installation Guide | iC7 Series Liquid-cooled System Modules Mechanical Installation Installation Requirements The system modules that are described in this guide have the protection rating IP00/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. -
Page 11: Installing System Modules Into A Cabinet Horizontally
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 6: The Mounting Brackets and the Installation of System Modules into the Cabinet Mounting brackets Support bars Installing System Modules into a Cabinet Horizontally 2.3.2 Install the system module into the cabinet in a horizontal position on its left side. -
Page 12: Installing System Modules Into A Cabinet On Their Backsides
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 7: Mounting Holes of the System Module in Horizontal Position Mounting holes View from the front View from the bottom Attach the system module to the mounting brackets of the cabinet. -
Page 13: Installing System Modules With Integration Units
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 8: Mounting Holes of the System Module on its Backside Mounting holes View from the side View from the bottom Attach the system module to the mounting brackets of the cabinet. - Page 14 Installation Guide | iC7 Series Liquid-cooled System Modules Figure 9: Mounting Holes of the System Module, AFE with the Integration Unit Mounting holes in aluminum parts Mounting holes in sheet metal parts Attach the system module to the mounting brackets of the cabinet.
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Page 15: Installing System Modules With Integration Units Into A Cabinet Horizontally
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 10: The Mounting Brackets and the Installation of System Modules with the Integration Unit into the Cabinet Mounting brackets Installing System Modules with Integration Units into a Cabinet Horizontally 2.4.2 Install the system module into the cabinet in a horizontal position on its left side. -
Page 16: Installing System Modules With Integration Units Into A Cabinet On Their Backsides
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 11: Mounting Holes of the System Module with the Integration Unit in Horizontal Position Mounting holes View from the front View from the bottom Attach the system module to the mounting brackets of the cabinet. -
Page 17: Installing Filters
Installation Guide | iC7 Series Liquid-cooled System Modules Mounting holes View from the bottom Attach the system module to the mounting brackets of the cabinet. The mounting brackets are not included in the delivery. Installing Filters Installing L Filter into a Cabinet, 400 A, 1000 A 2.5.1... - Page 18 Installation Guide | iC7 Series Liquid-cooled System Modules Figure 14: Installing the L Filter into a Cabinet (1640 A) The mounting holes at the top The bracket The mounting holes at the bottom Use the bracket to attach the filter from below.
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Page 19: Cooling
Installation Guide | iC7 Series Liquid-cooled System Modules Cooling Insertion of Pipes into Cooling Circuit Connectors The insertion length of a Ø16 mm (0.63 in) pipe is 29 mm (1.14 in). Make a mark on the pipe where it can be checked that the pipe is correctly inserted into the cooling circuit connector. -
Page 20: Inlet And Outlet Connectors Of System Modules With Integration Units
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 16: Inlet Connectors of IM10L (left) and IM12L (right) Inlet connectors Figure 17: Outlet Connectors of IM10L (left) and IM12L (right) Outlet connectors Inlet and Outlet Connectors of System Modules with Integration Units 3.2.2... -
Page 21: Inlet And Outlet Connectors Of The L Filter
Installation Guide | iC7 Series Liquid-cooled System Modules Inlet connector Outlet connector Figure 19: Optional Outlet Connectors of IR10L (left) and IR12L (right) Optional outlet connector Inlet and Outlet Connectors of the L Filter 3.2.3 Figure 20: Inlet and Outlet Connectors of the L Filter... -
Page 22: Bending The Pipes
Installation Guide | iC7 Series Liquid-cooled System Modules There are 2 ways to make permanent bends to the pipes. The quickest and easiest way is to make the bend in the air by bending it by hand. Do this if only 1 bend is needed and the ... -
Page 23: Bending Pipes With A Bending Jig
Installation Guide | iC7 Series Liquid-cooled System Modules Make sure that the heat gun does not fall down. Slowly move the pipe back and forth while rotating it over the heat gun. The aim is to heat the pipe evenly over the entire bending area to around 150–170 °C (302–338 °F). Examples of heating times: When making a simple L-bend, a suitable heating time is approximately 2 minutes for a distance of 5–10 cm (2–4 in). - Page 24 Installation Guide | iC7 Series Liquid-cooled System Modules Figure 21: Pipe Bending Jig Example Pipe Silicon cord Pipe holders Bending wheel Set the heat gun temperature to 200 °C (392 °F). Slowly move the heat gun back and forth over the entire bending area.
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Page 25: Electrical Installation
Installation Guide | iC7 Series Liquid-cooled System Modules Electrical Installation Control System of the System Modules Modular control unit Fiber cable mounting plate Customer PLC Fieldbus cable Max. 8 AuxBus AuxBus LC Filter LC Filter AuxBus AuxBus L Filter L Filter... - Page 26 Installation Guide | iC7 Series Liquid-cooled System Modules Table 1: Minimum Distances from Motor Cables to Other Cables Distance to other cables Length of the shielded motor cable [m (ft)] [m (ft)] 0.3 (1.0) ≤ 50 (164) 1.0 (3.3) ≤ 150 (492) Before starting, make sure that none of the components of the AC drive is live.
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Page 27: Recommended Installation Of Motor Cables
Installation Guide | iC7 Series Liquid-cooled System Modules (DC-DC) (BCU) Figure 23: Cabling Principle Grounding bar of the control cable Control cable Grounding conductor Mains cables Motor cables Strain relief The grounding clamp, 360° grounding Recommended Installation of Motor Cables If the power units are connected in parallel without output filters or only with a common-mode filter, the recommended common coupling point of motor cables is at the motor terminals. -
Page 28: Installing The Cables
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 24: Recommended Installation Inverter module Common coupling point at the motor terminals Figure 25: Alternative Installation Method Inverter module Installing the Cables Field Cabling Installation 4.5.1 The field cabling terminals are not included in the delivery of the system module. Install field cabling to the appropriate terminals. -
Page 29: Installing The Cables, Inu (Ir10L, Ir12L)
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 26: The Mains Terminals and Grounding Terminal of AFE and GC, AR10L (left) and AR12L (right) Mains terminal L1 Mains terminal L2 Mains terminal L3 Grounding terminal Connect the mains cables to the corresponding mains terminals. -
Page 30: Installing The Cables, Dc/Dc Converter (Dr10L, Dr12L)
Installation Guide | iC7 Series Liquid-cooled System Modules Motor terminal U Motor terminal V Motor terminal W Grounding terminal Connect the motor cables to the corresponding motor terminals. See the bolt sizes in 7.2.1 List of Cable Size Information. See the correct tightening torques in 7.1 Tightening... -
Page 31: Installing The Cables, Inu (Im10L, Im12L), Afe And Cg (Am10L, Am12L), And Dc/Dc Converter (Dm10L, Dm12L)
Installation Guide | iC7 Series Liquid-cooled System Modules Installing the Cables, INU (IM10L, IM12L), AFE and CG (AM10L, AM12L), and DC/DC Converter 4.5.5 (DM10L, DM12L) Find the power terminals below the system module. Notice the location of the different terminals. -
Page 32: Installing The Cables With The Power Terminal Adapter, Inu Im10L, Im12L
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 30: Installing Power Terminal Adapters to the Terminals, and Cables to the Power Terminal Adapter, Example of IR10L Power terminal adapter Motor cables Use M10 pressure balancing washers SFS 3738, M10 conical spring washers DIN 6796, and M10 grade 8 hex nuts DIN 934. -
Page 33: Installing The Dc Fuses To The Dc Terminals
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 31: Installing Power Terminal Adapters to the Terminals, and Cables to the Power Terminal Adapter, Example of IM10L Power terminal adapter Motor cables Use M10 pressure balancing washers SFS 3738, M10 conical spring washers DIN 6796, and M10 grade 8 hex nuts DIN 934. - Page 34 Installation Guide | iC7 Series Liquid-cooled System Modules Figure 32: Installing Busbars to the DC Fuses M12 nut M12 spring washer M12 washer Busbar Stud Fuse Visual indicator Attach DC-terminal busbars to the DC terminals of the system modules. Use Combi M8 screws.
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Page 35: Changing The Emc Protection Level
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 34: Installing DC Fuse Assemblies Changing the EMC Protection Level Changing the EMC Protection Level, AR10L 4.7.1 In an IT system, to change the EMC protection level of the AC drive from C3 to C4, disconnect the LC Filter ground capacitor. -
Page 36: Changing The Emc Protection Level, Ar12L
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 36: Level C4 After the change, write "The EMC level was changed from C3 to C4", and the date on the "product modified" label. If the label is not yet attached, attach it on the drive near the product label. -
Page 37: Changing The Emc Protection Level, Lc Filter, Of7Z1, 380 A
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 38: Level C4 After the change, write "The EMC level was changed from C3 to C4", and the date on the "product modified" label. If the label is not yet attached, attach it on the drive near the product label. -
Page 38: Changing The Emc Protection Level, Lc Filter, Of7Z1, 760 A
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 40: Level C4 After the change, write "The EMC level was changed from C3 to C4", and the date on the "product modified" label. If the label is not yet attached, attach it on the drive near the product label. -
Page 39: Auxbus Communication
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 42: Level C4 After the change, write "The EMC level was changed from C3 to C4", and the date on the "product modified" label. If the label is not yet attached, attach it on the drive near the product label. -
Page 40: Auxbus Cabling
Installation Guide | iC7 Series Liquid-cooled System Modules Terminals Wires Shield removed AuxBus Cabling 4.8.2 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. -
Page 41: Control Installation
Installation Guide | iC7 Series Liquid-cooled System Modules Control Installation Assembling the Control Unit Mounting Plates Use these instructions to assemble the mounting plate of the modular control unit. All the parts can be found in the accessories bag. Assemble the mounting plate as shown in the illustration. -
Page 42: Installing The Control Unit
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 46: Attaching Mounting Plates to Each Other Attach the mounting plates onto the cabinet with screws by the 4 mounting holes in the corners of the mounting plates. The screws are not included in the delivery. Use an M4/M5 screw. -
Page 43: Installing The Control Cables Into The Control Terminals
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 47: Connecting the Fieldbus Cable and the Fiber Cables PLC (not included in the delivery) Fieldbus cable Control board Star coupler board Fiber cables Power units Installing the Control Cables into the Control Terminals Install the control cables into the control terminals. -
Page 44: Control Board Connections
Installation Guide | iC7 Series Liquid-cooled System Modules Control cable Cable clamp Grounding plates Strip the control cables. Attach the control cables to the cable clamps on the suitable grounding plate. The lower part of the cable clamp fixes the cable to the plate and provides strain relief. The upper part provides ~360°... - Page 45 Installation Guide | iC7 Series Liquid-cooled System Modules Figure 50: Control Board Terminal Block and Terminal Numbering Status indicators (FAULT, WARN, READY) Fieldbus indicators (ST, X1, X2) and Ethernet port indicators (X0) Control panel connector (X9) Fiber optic link to power unit (X80)
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Page 46: Star Coupler Board
Installation Guide | iC7 Series Liquid-cooled System Modules Table 3: STO Terminal Signals (X33) for the Inverter Module (continued) Terminal Function Description S.INB- - Safe Input Channel B S.FB- - STO Feedback 1) Terminals 41A, 41B, 45A, and 45B have double pins to make connections easier. -
Page 47: Star Coupler Board Connections
Installation Guide | iC7 Series Liquid-cooled System Modules Figure 51: The Star Coupler Board with 16 Ports Board configuration status indicator +24 V power status indicator Power unit connection status indicators Fiber connection to the power unit (X301–X316) +24 V power supply (X65) -
Page 48: I/O And Relay Option Connections
Installation Guide | iC7 Series Liquid-cooled System Modules I/O and Relay Option Connections X101 X102 X103 Figure 52: I/O and Relay Option Terminal Block and Terminal Numbering Table 7: I/O and Relay Option Signals Terminal Function Connector type I/O terminal 2 x 11 spring force connector 0.2–1.5 mm... - Page 49 Installation Guide | iC7 Series Liquid-cooled System Modules Table 8: I/O Terminal Signals (X13) (continued) Terminal Function DGND DGND DO 1 DO 2 AO 1 +10 V ref. AI 1 AI 2 Table 9: Thermistor Input Signals (X51) Terminal Function Description Thermistor input, galvanically isolated.
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Page 50: Connecting The Control Panel
Installation Guide | iC7 Series Liquid-cooled System Modules Table 11: Relay 2 Signals (X102) Terminal Function Description Configurable relay output. Switching capacity: • 24 V DC/8 A • 250 V AC/8 A • 125 V DC/0.4 A Minimum switching load: 5 V/10 mA... - Page 51 Installation Guide | iC7 Series Liquid-cooled System Modules The microSD card Push the new microSD card into the hole. The contact area must face the text μSD on the right. To remove the microSD card, push it. The microSD card pops out.
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Page 52: Commissioning
Installation Guide | iC7 Series Liquid-cooled System Modules Commissioning Commissioning the System Modules Follow these instructions to commission the drive. Read the safety instructions in the Safety Guide and obey them. Make sure that the device connected to the drive output is installed correctly. -
Page 53: Measuring The Insulation Resistance Of The Motor Cable
Before connecting the DC source to the DC/DC converter, power on the DC/DC converter and pre-charge the DC filter capacitors to the same voltage as the DC source. See the iC7 Series DC/DC Converter Application Guide for details. Measuring the Insulation Resistance of the Motor Cable Use these instructions to check the insulation of the motor cable. -
Page 54: Preparing For A Pc Connection
Installation Guide | iC7 Series Liquid-cooled System Modules Preparing for a PC Connection Use these instructions to connect the drive or several drives to a PC with an RJ45 cable. Connect an RJ45 cable to the PC. To connect several drives at the same time, use an Ethernet switch between the PC and the control unit. -
Page 55: Specifications
Installation Guide | iC7 Series Liquid-cooled System Modules Specifications Tightening Torques Table 13: Tightening Torques and Bolt Lengths of the Terminals Bolt Tightening torque Maximum length of Tightening torque [in- Maximum length of [Nm] bolt under the busbar bolt under the busbar... - Page 56 Installation Guide | iC7 Series Liquid-cooled System Modules Table 15: Field Cable Sizes for AFE and GC Modules, 525–690 V AC Model code Frame Cu [mm Al [mm iC7-60SLxx07-236AE00Fx Ax10L 3x150+70 3x240+72 iC7-60SLxx07-300AE00Fx 3x240+120 2x(3x120+41) iC7-60SLxx07-334AE00Fx 2x(3x95+50) 2x(3x150+41) iC7-60SLxx07-380AE00Fx 2x(3x120+70)
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Page 57: Internal Cable Sizes For Afe And Gc Modules, 525-690 V Ac
Installation Guide | iC7 Series Liquid-cooled System Modules Internal Cable Sizes for AFE and GC Modules, 525–690 V AC 7.2.3 Table 16: Bolt Sizes for the AFE and GC Modules Bolt size for internal cable or busbar Number of grounding terminals/bolt size... -
Page 58: Alternative Cable Sizes For Marine Installations, Afe Or Gc Modules 525-690 V Ac
Installation Guide | iC7 Series Liquid-cooled System Modules Table 17: Field Cable Sizes for INU Module, 525–690 V AC (continued) Model code Frame Motor cable Cu [mm Motor cable Al [mm iC7-60SLIN07-1795E00Fx 3 x Ix12L 9x(3x120+70) 9x(3x185+57) iC7-60SLIN07-2080E00Fx 9x(3x150+70) 12x(3x150+41) -
Page 59: Alternative Cable Sizes For Marine Installations, Inu Modules 525-690 V Ac
Installation Guide | iC7 Series Liquid-cooled System Modules Table 18: Cable Sizes for AFE or GC Modules 525–690 V AC for Marine Applications (Marine cables according to IEC 60092-352) (continued) Model code Frame Mains cable Cu [mm iC7-60SLxx07-850AE00Fx 2 x Ax12L... - Page 60 Installation Guide | iC7 Series Liquid-cooled System Modules Table 19: Cable Sizes for INU Modules 525–690 V AC for Marine Applications (Marine cables according to IEC 60092-352) (continued) Model code Frame Motor cable Cu [mm iC7-60SLIN07-465E00Fx Ix12L 3x(3x95) iC7-60SLIN07-525E00Fx 4x(3x95)
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Page 61: Source Cable Sizes For Dc/Dc Converter Modules, 640-1100 V Dc And 640-1200 V Dc
Installation Guide | iC7 Series Liquid-cooled System Modules Source Cable Sizes for DC/DC Converter Modules, 640–1100 V DC and 640–1200 V DC 7.2.7 Table 20: DC/DC Converter Module 640–1100 V DC and 640–1200 V DC Source Cable Sizes, IP00/Open Type. Model code Frame 1-core cable Cu... -
Page 62: Fuses
Installation Guide | iC7 Series Liquid-cooled System Modules Fuses List of Fuse Size Information 7.3.1 This topic lists the links to find the fuse size tables for the system modules. 7.3.2 AC Fuses for AFE or GC 525–690 V AC, IP00/Open Type ... - Page 63 Installation Guide | iC7 Series Liquid-cooled System Modules Table 22: AC Fuses for AFE or GC 525–690 V AC, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses size...
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Page 64: Dc Fuses For Afe Or Gc 640-1200 V Dc, Ip00/Open Type
Installation Guide | iC7 Series Liquid-cooled System Modules DC Fuses for AFE or GC 640–1200 V DC, IP00/Open Type 7.3.3 Table 23: DC Fuses for AFE or GC 640–1200 V DC, IP00/Open Type Frame Rated Number Fuse Part number Fuse U... -
Page 65: Dc Fuses For Inu 640-1200 V Dc, Ip00/Open Type
Installation Guide | iC7 Series Liquid-cooled System Modules Table 23: DC Fuses for AFE or GC 640–1200 V DC, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses size... -
Page 66: Dc-Bus Fuses For Dc/Dc Converter, Ip00/Open Type
Installation Guide | iC7 Series Liquid-cooled System Modules Table 24: DC Fuses for INU 640–1200 V DC, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses size iC7-60SLIN0x-1795E00Fx 3 x Ix12L... -
Page 67: Source Dc+ Fuses For Dc/Dc Converter, Ip00/Open Type
Installation Guide | iC7 Series Liquid-cooled System Modules Table 25: DC-bus Fuses for DC/DC Converter, Voltage Classes B5 and 07, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses... -
Page 68: Source Dc- Fuses For Dc/Dc Converter, Ip00/Open Type
Installation Guide | iC7 Series Liquid-cooled System Modules Table 26: Source DC+ Fuses for DC/DC Converter, Voltage Classes B5 and 07, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses... - Page 69 Installation Guide | iC7 Series Liquid-cooled System Modules Table 27: Source DC- Fuses for DC/DC Converter, Voltage Classes B5 and 07, IP00/Open Type (continued) Frame Rated Number Fuse Part number Fuse U Fuse I Model code cp, mr current of fuses...
- Page 70 Installation Guide | iC7 Series Liquid-cooled System Modules | Danfoss Drives Oy © 2024.03 AN389643231588en-000101 / 172F6360A...
- Page 71 ...
- Page 72 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.
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