Danfoss Vacon NXP Guide

Design Guide
DC Filters
VACON® NXP DC/DC Converter
drives.danfoss.com

1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
5
5.1
5.2
5.3
6
6.1
6.2
7
7.1
7.2
7.3
7.4
7.5
7.6
Contents
Introduction 4
Purpose of this Design Guide 4
Additional Resources 4
Version History 4
Safety 5
Safety Notice 5
Safety Symbols 5
Warnings 5
Product Overview 7
DC Filter for DC/DC Converter 7
Voltage and Current Range 7
Cooling 7
DC Filter Types 7
Selection 9
Selecting the DC Filter 9
DC Filter Selection, Air-cooling 9
DC Filter Selection, Liquid-cooling 11
Installation Guidelines 13
Cabling 13
Thermal Protection 13
Mounting 14
Maintenance 16
Preventive Maintenance Recommendations 16
Recommended Disposal 16
Specifications 17
General Specifications 17
Environmental Data 17
Cooling System Requirements 18
Technical Data 18
Dimensions 20
Terminal and Torque Specifications 23
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Contents
DC Filters
Design Guide

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1 Introduction
1.1 Purpose of this Design Guide
This design guide is intended for qualified personnel, such as:
Project and systems engineers.
Design consultants.
Application and product specialists.
The design guide provides technical information for the DC filters used in VACON® NXP DC/DC Converter applications. Its purpose
is to provide design considerations and planning data for integration of the device into a system. It caters for the selection of the
filters for the application in a diversity of installations. Reviewing the detailed product information in the design stage enables de-
veloping a well-conceived system with optimal functionality and efficiency.
The filter range is designed for typical Energy Storage systems which is the main application area for DC/DC converters.
1.2 Additional Resources
Other resources are available to understand installation, programming, operation, and options.
The VACON® NXP DC/DC Converter operating guide provides information about the installation and operation of the VACON®
NXP DC/DC Converter application.
The VACON® NXP DC/DC Converter application guide provides greater detail on how to work with the application software and
how to set the parameters of the AC drive modules.
VACON® NXP Common DC Bus and VACON® NXP Liquid-cooled Common DC Bus user manuals provide detailed information for
the installation, commissioning, and operation of the AC drive modules.
The operating and installation guides for VACON®options give detailed information about specific drive options.
Supplementary publications and manuals are available from Danfoss. See www.danfoss.com for listings.
1.3 Version History
This design guide is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this design guide is English.
Table 1: VACON® NXP DC/DC Converter DC Filters Design Guide Version History
Version
Remarks
A
First release
AJ377845348678en-000101 / 172F47854 | Danfoss A/S © 2023.01
Introduction
DC Filters
Design Guide

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2 Safety
2.1 Safety Notice
These instructions are intended for the use of personnel who are experienced in the installation, operation, and maintenance of
power quality filters. Because of the high voltages required by the application, the personnel involved in the installation, operation,
and maintenance of these filters must be aware of the necessary safety precautions for this type of equipment. Carefully read the
instructions in this manual before installing the DC filter.
The Danfoss DC filter has been run through several demanding factory tests before the delivery. Carefully inspect the package for
any damage that may have occurred during the transportation. Follow the instructions for unpacking the DC filter and carefully
inspect it for any signs of possible damage. If the installation of this equipment is going to be in the future, cover and store the filter
in a clean and dry location.
When the DC Filter has been in storage, before applying power to the filter, make sure that there is no condensation on the internal
components of the filter.
2.2 Safety Symbols
The following symbols are used in this guide:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.3 Warnings
DANGER
SHOCK HAZARD FROM TERMINALS
The terminals and components of the filter can be live 5 minutes after the filter is disconnected from the mains. Touching any of
the exposed power connectors during operation or while voltage is present can cause death or serious injury.
Do not touch the terminals when the filter is connected to mains. Before working on the DC filter, wait at least the voltage
discharge time stated in the manual for the corresponding DC/DC converter. Use a measuring device to make sure that there
is no voltage.
CAUTION
DAMAGE FROM INSUFFICIENT GROUNDING
Insufficient grounding can damage the DC filter.
The DC filter must be grounded before switching on the power. To ground the filter, use the terminal marked with the PE
symbol. Make sure that the ground connection is clean and all varnish is removed.
AJ377845348678en-000101 / 172F4785 | 5Danfoss A/S © 2023.01
Safety
DC Filters
Design Guide

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CAUTION
LIFTING HEAVY LOADS
The center of gravity of the unit can be in an unexpected location. Unbalanced loads can fall over or tilt unexpectedly during
lifting and transport. Falling loads can cause death, serious injury, or damage to the equipment.
Take proper lifting precautions:
Never walk under suspended loads.
Wear personal protective equipment.
Observe the weight of the unit and make sure that proper lifting equipment is used.
Before lifting the load, check the center of gravity.
Use the lifting holes to lift the filter. Never use the electrical connectors or terminals of the filter for lifting purposes.
CAUTION
BURN HAZARD FROM HOT SURFACES
The filter surface turns hot during operation.
Wait for the filter to cool down before touching it.
NOTICE
DAMAGE FROM LOOSE CONNECTIONS
Loose or improperly secured connections can damage the filter or lead to decreased performance.
Only a qualified electrician is allowed to perform the electrical installation of the DC filter.
NOTICE
ELECTROMAGNETIC INTERFERENCE
Noise and EMI from the cables can cause malfunctions in the installation.
To reduce noise and EMI, and to prevent malfunctions in the installation, use shielded cables:
Between the DC/DC converter output and DC filter input
Between DC-filter output and Energy storage input
AJ377845348678en-000101 / 172F47856 | Danfoss A/S © 2023.01
Safety
DC Filters
Design Guide

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3 Product Overview
3.1 DC Filter for DC/DC Converter
The DC filter is used as an energy storage and damping element between the DC source and the DC/DC converter.
The filter inductor stores energy and reduces the di/dt slope of the load current. The stored energy is released back to the system
with decreasing current.
The DC filter reduces the harmonic content of the load current and keeps it at an acceptable level. The amount of ripple current
allowed in the system depends on the type of energy storage.
Sometimes the DC filter consists only of an inductor. In some applications, capacitors are needed, and an LC filter is used.
e30bj349.10
DC+
DC-
Battery
DC Filter
DC/DC Converter
+
-
L
1
C
DC
Illustration 1: Example DC/DC Converter Application with a DC Filter
3.2 Voltage and Current Range
The DC filter is designed for 380–690 V AC voltage systems. The voltage span across the DC filter is typically high. The difference
between input and output voltage can be as high as 1100 V, that is 1150 V D input and 50 V DC output. Due to the high voltage
difference, a high inductance value is required to guarantee proper functionality in all operation points. The DC filters are designed
according to a 5 kHz switching frequency.
The current range of the DC filters is 10–1150 A.
3.3 Cooling
The cooling methods used for DC filters:
Natural convection (AN)
Forced air cooling (AF)
Liquid cooling
For the cooling method used for each filter type, see 7.4 Technical Data.
3.4 DC Filter Types
An L-type inductor is used as default and the same inductor can be used as the inductor part for an LC filter. A typical filter solution
consists of three 1-phase inductors which are installed at the outputs of the individual phases of the DC/DC converter.
Note: The type codes are for filter assemblies, which include three 1-phase inductors. For example, LDC-0092-5-0-APt consist of 3 x
92 A, 750 V DC inductors.
Example
The type code can have this format, for example:
LDC-0092-5-0-APtX
Table 2: Type Code Description
Code
Description
LDC
Filter type
AJ377845348678en-000101 / 172F4785 | 7Danfoss A/S © 2023.01
Product Overview
DC Filters
Design Guide

Code
Description
LDC = DC inductor
0092
Maximum current [A]
5
Nominal voltage
2 = 200 V
5 = 500 V
6 = 690 V
0
Protection rating
0 = IP00
2 = IP21
5 = IP54
A
Cooling method
A = Natural convection
B = Forced air cooling
C = Liquid cooling
Pt
Temperature measurement type
Pt = Pt100 temperature sensor
Tr = Thermal relay
X
Reserved for variants
AJ377845348678en-000101 / 172F47858 | Danfoss A/S © 2023.01
Product Overview
DC Filters
Design Guide

4 Selection
4.1 Selecting the DC Filter
Two operating conditions are given for filter selection in the tables, one at high voltage and another at low voltage. The high volt-
age refers to the maximum storage voltage in the application. The low voltage is the voltage level at 50% duty cycle of the drive,
which is thermally the worst case condition for the DC filter.
The filter selection can differ depending on the energy storage requirements. The selections in the tables are recommendations.
The selection is typically made according to the maximum output current at low voltage.
4.2 DC Filter Selection, Air-cooling
Table 3: DC Filter Selection for Air-cooled 500 V Drives According to Energy Storage Requirements
Drive enclo-
sure size
Drive type
High Voltage @ 750 V DC, fs= 5 kHz
Low Voltage @ max current, fs= 5 kHz
Iout nominal [A]
Filter selection
Iout max [A]
Filter selection
FR4
NXI_0004 5
< 4.8
LDC-0010-6-0-Axx
8
LDC-0010-6-0-Axx
NXI_0009 5
< 10
18
NXI_0012 5
< 13.4
24
FR6
NXI_0016
< 18
LDC-0010-6-0-Axx
32
LDC-0020-5-0-Axx
NXI_0022 5
< 26
44
NXI_0031 5
< 35
LDC-0020-5-0-Axx
62
NXI_0038 5
< 43
76
LDC-0030-6-0-Axx
NXI_0045 5
< 51
90
FR7
NXI_0061 5
< 69
LDC-0030-6-0-Axx
122
LDC-0050-6-0-Axx
NXI_0072 5
< 82
144
NXI_0087 5
< 100
LDC-0050-6-0-Axx
174
LDC-0092-5-0-Axx
NXI_0105 5
< 121
210
FR8
NXI_0140 5
< 161
LDC-0092-5-0-Axx
280
FI9
NXI_0168 5
< 196
336
LDC-0170-6-0-Axx
NXI_0205 5
< 239
410
NXI_0261 5
< 304
LDC-0170-6-0-Axx
500
NXI_0300 5
< 350
500
FI10
NXI_0385 5
< 454
770
LDC-0270-5-0-Axx
NXI_0460 5
< 542
LDC-0270-5-0-Axx
920
LDC-0420-5-0-Axx or LDC-0400-6-0-Bxx
NXI_0520 5
< 613
930
FI12
NXI_0590 5
< 695
2 x LDC-0170-6-0-Axx
1180
2 x LDC-0270-5-0-Axx
NXI_0650 5
< 766
1300
NXI_0730 5
< 870
1460
NXI_0820 5
< 977
1640
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Selection
DC Filters
Design Guide

Drive enclo-
sure size
Drive type
High Voltage @ 750 V DC, fs= 5 kHz
Low Voltage @ max current, fs= 5 kHz
Iout nominal [A]
Filter selection
Iout max [A]
Filter selection
NXI_0920 5
< 1096
2 x LDC-0270-5-0-Axx
1750
2 x LDC-0400-6-0-Bxx
NXI_1030 5
< 1227
1750
FI13
NXI_1150 5
< 1370
LDC-0540-6-0-Bxx
2300
LDC-0900-5-0-Bxx
NXI_1300 5
< 1549
2550
NXI_1450 5
< 1727
LDC-0900-5-0-Bxx
2550
FI14
NXI_1770 5
< 2109
2 x LDC-0400-6-0-Bxx
3540
2 x LDC-0900-5-0-Bxx
NXI_2150 5
< 2561
2 x LDC-0540-6-0-Bxx
4300
NXI_2700 5
< 3217
5000
Table 4: DC Filter Selection for Air-cooled 690 V Drives According to Energy Storage Requirements
Drive enclosure size
Drive type
High Voltage @ 1025 V DC, fs= 5 kHz
Low Voltage @ max current, fs= 5 kHz
Iout nominal [A]
Filter selection
Iout max [A]
Filter selection
FR6
NXI_0010 6
< 11.1
LDC-0010-6-0-Axx
14.6
LDC-0010-6-0-Axx
NXI_0013 6
< 14.6
19
NXI_0018 6
< 20.3
26.3
NXI_0022 6
< 25
32
NXI_0027 6
< 31
39
LDC-0020-5-0-Axx
NXI_0034 6
< 39
LDC-0020-5-0-Axx
49
FR7
NXI_0041 6
< 47
60
NXI_0052 6
< 60
62
FR8
NXI_0062 6
< 71
LDC-0030-6-0-Axx
90
LDC-0030-6-0-Axx
NXI_0080 6
< 92
117
LDC-0050-6-0-Axx
NXI_0100 6
< 117
LDC-0050-6-0-Axx
135
FI9
NXI_0125 6
< 146
183
LDC-0092-6-0-Axx
NXI_0144 6
< 168
LDC-0092-6-0-Axx
210
NXI_0170 6
< 198
248
NXI_0208 6
< 245
250
FI10
NXI_0261 6
< 308
LDC-0170-6-0-Axx
382
LDC-0170-6-0-Axx
NXI_0325 6
< 383
475
NXI_0385 6
< 454
490
NXI_0416 6
< 490
490
FI12
NXI_0460 6
< 548
2 x LDC-0092-6-0-Axx
673
2 x LDC-0170-6-0-Axx
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Selection
DC Filters
Design Guide