Aer3500l 4601 D Rev - 03

AER3500L-4601-D
Liquid Cooled Rectifier Module - Data Sheet
REV: 03
DATE: October 20, 2021
Avid Controls Inc.
41261 Park 290 Drive, Waller, TX 77484, USA
[email protected]
(+1) (281) 640-8600
AVID Controls Inc. pursues a policy of continuous product improvement and innovation. This may not be
the latest revision of this publication and may not reflect all current product changes. Contact AVID Controls
Inc. for the latest revision of this Data Sheet and information on other product enhancements.
Page 1 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

AER3500L-4601-D
INTENTIONALLY BLANK

AER3500L-4601-D
Contents
1. Introduction ............................................................................................................................................ 4
1.1 Overview.......................................................................................................................................... 4
1.2 Power Device Details ...................................................................................................................... 6
1.3 Typical Applications ........................................................................................................................ 6
1.4 Related Documents .......................................................................................................................... 6
2. WARNINGS .......................................................................................................................................... 7
3. External Requirements ........................................................................................................................... 8
3.1 DC Link Pre-Charge ........................................................................................................................ 8
3.2 Over-Current Protection .................................................................................................................. 8
3.3 Over-Temperature Protection .......................................................................................................... 8
3.4 Input Inductance .............................................................................................................................. 9
3.5 Fuses ................................................................................................................................................ 9
3.6 12-Pulse Systems ............................................................................................................................. 9
3.7 Coolant Flow ................................................................................................................................... 9
4. Specification ......................................................................................................................................... 10
4.1 Electrical – Power Section ............................................................................................................. 10
4.2 Power Connections ........................................................................................................................ 11
4.3 Electrical – Control Connections ................................................................................................... 12
4.4 Cooling .......................................................................................................................................... 14
4.5 Environmental................................................................................................................................ 15
4.5.1 Operating ................................................................................................................................ 15
4.5.2 Storage & Transport ............................................................................................................... 16
4.6 Mechanical ..................................................................................................................................... 17
5. Contact Details for Sales, Service and Support .................................................................................... 18
6. Document Revision History ................................................................................................................. 18
AVID CONTROLS and the logo are registered trademarks of Avid Controls Inc.

AER3500L-4601-D
1. Introduction
1.1 Overview
• The AER3500L-4601-D is a liquid cooled module containing two identical standard 3-phase DIODE
rectifier modules, along with MOV and SNUBBER protection for the DIODES.
• The combined current rating of the two rectifier bridges is 3500A DC (average).
• The following schematic shows the power circuits of the AER3500L-4601-D:

AER3500L-4601-D
• The following illustration shows the mechanical arrangement of the module:
Air-bleed valve for coolant Lifting point 20 mm (0.75”)

diameter
TB1 – Control connections
R1 – AC phase connection
S1 – AC phase connection
T1 – AC phase connection
R2 – AC phase connection
S2 – AC phase connection
RECT 1/2– DC negative
connection point
T2 – AC phase connection
Ground (Earth) terminal

RECT 2+ DC positive
connection
Cooling system connections
RECT 1+ DC positive Stop screw (behind DC

connection terminal insulator)
• The module fits into the standard cabinet mounting frames used for liquid cooled DELTA modules, Avid
Extreme Inverter modules and MVRL2100 liquid cooled inverter modules.
• To help with system design, a 3D model of the AER3500L-4601-D may be downloaded from
https://avidcontrolsinc.com/step-files/.

AER3500L-4601-D
1.2 Power Device Details
• The following table details the main attributes of the power devices used in the unit. See the previous
schematic for context:
Device Main Parameters Notes
RECTIFIER Reverse Voltage = 2.2kV

Type is Infineon DZ1070N22K
DIODES Nominal Current = 1100A
For MOVs to operate correctly, the unit must be
Nominal Voltage = 750Vac
operated with input reactors on all AC
MOVs Peak Current = 40kA
connections.
Energy Rating = 1200J
Type is TDK/EPCOS B72240B0751K001
Capacitance = 0.3 µF +/- 10% For SNUBBERS to operate correctly, the unit
DEVICE
Resistance = 14.7 Ω +/- 5% must be operated with input reactors on all AC
SNUBBERS
150W max. connections.
1.3 Typical Applications
• The AER3500L-4601-D is typically used in MV3000 or AE3000 AC drive systems to provide a high-
power DC link for multiple inverter modules.
• In these applications, the temperature of the AER3500L-4601-D is monitored by an MV3000 Common

Drive Controller and if limits are exceeded, a TRIP signal is generated.
• The AER3500L-4601-D may be used as a DIODE rectifier in any application that provides the
EXTERNAL REQUIREMENTS detailed below.
1.4 Related Documents
• Since the AER3500L-4601-D is primarily intended for use alongside Avid MVDL & AEI-L liquid
cooled inverter modules, the following documents provide much necessary information:
o T1693EN, MV DELTA Liquid Cooled Drive System
o T1679EN, MV3000 Drive Range Software Technical Manual

AER3500L-4601-D
2. WARNINGS
• This equipment may be connected to more than one live circuit.
• AER3500L-4601-D is a DIODE ONLY rectifier. Over-current and over-temperature protection must be
implemented within the external application. Isolation to protect equipment and personnel must be
implemented in the external application.
• Wait at least eight minutes after isolating all supplies and check all voltages have reduced to a safe level
before working on the equipment.
• Surfaces on the coolant pipes can reach high temperatures and remain hot for some time after power is
removed. Ensure that all coolant has cooled to a safe temperature and the equipment is suitably drained
and isolated before the external pipework is disconnected from the equipment.
• AC & DC busbars can reach high temperatures and remain hot for some time after power is removed.
Ensure they have cooled to a safe temperature before working on the unit.
• Unit is heavy: 125 kg ( 275 lb. ).
• The unit has an open-chassis (IP00) design. It must be enclosed in a suitable cabinet for use.
• The unit contains several clear polycarbonate shrouds to reduce the risk of accidental contact. After
installation, these shrouds MUST be re-attached to the unit:

AER3500L-4601-D
3. External Requirements
• The AER3500L-4601-D is a DIODE ONLY rectifier – therefore it is unable to interrupt or limit current
levels in the connected AC or DC circuits.
3.1 DC Link Pre-Charge
• When inverter units containing large DC link capacitor banks are connected to the RECT output
terminals of the AER3500L-4601-D, those inverter units must be pre-charged to approximately 1.41 x
the RMS value of the input mains supply.
• An external circuit must provide this pre-charge before the AEI3500L-4601-D is connected.
• Note that the AER3500L-4601-D can be disconnected during pre-charge on either the AC side (all
phases must be disconnected) or the RECT side (in which case either positive or negative must be
completely disconnected from the inverter modules until pre-charge is complete).
• It is the responsibility of the user to ensure that pre-charge design, rating and protection meet the
application requirements.
3.2 Over-Current Protection
• The AER3500L-4601-D cannot limit or interrupt current.
• To protect the AER3500L-4601-D and all external components, suitably designed and rated current
interruption devices (usually AC side fuses and breakers) must be included in the application.
• The use of correctly rated high-speed semiconductor fuses at all AC connections is recommended. This
can provide protection from over-current damage for the AER3500L-4601-D in the event of a load-side
short circuit. See section 3.5 for further details.
3.3 Over-Temperature Protection
• The AER3500L-4601-D monitors the internal heatsink temperature using both an NTC thermistor for
analog temperature indication and open-on-overtemp thermostats for simple over-temperature
indication.
• Again, the AER3500L-4601-D cannot disable current flow in the case of an over-temperature condition
– an external function MUST disable current when an over- temperature condition is signaled.
• See the Specification section for details of the over-temperature signals.

AER3500L-4601-D
3.4 Input Inductance

• For parallel operation of the two rectifier bridges, input reactors of at least 15µH per-phase are required
to balance currents.
• In all applications, a minimum effective input inductance of 15µH is required between the AER3500L-
4601-D and the source of any high voltage transients. This is required for the MOVS and PHASE
SNUBBERS to effectively protect the RECTIFIER DIODES. This can be provided by discrete inductors
or by the leakage inductance of transformers that are “downstream” of the transient voltage sources.
• This inductance is also required to provide for fuse-protection of the AER3500L-4601-D.
3.5 Fuses
• To protect the AER3500L-4601-D module from damage due to output short-circuits, it is necessary to
use high-speed semiconductor-type fuses for all AC inputs.
• Due to the very high rating of the unit, it is expected that parallel fuses will be required – this should be
implemented in accordance with the fuse manufacturer’s guidelines for parallel operation.
• The total I2T during the fuse clearing event must be less than 6x106 A2s. Note that for two fuses in
parallel the total I2T is 4X the value for each fuse.
• To maintain this I2T, the 690V network transformer (or generator line-up) must have a sub-transient
impedance of at least 22µH – this is equivalent to a per-unit value of 5% based upon the expected full
load current of the rectifier at rated DC load.
• The following fuses are recommended by Avid for use with the AER3500L-4601-D at full rated current:
Manufacturer Family Rating Number Paralleled Total I2T

Mersen Protistor® size 33 aR 690V 900A 2 3.1x106 A2s
Cooper Square body DIN 43 653
900A 2 3.7x106 A2s
Bussmann 690V/700V (IEC/UL). Size 2
3.6 12-Pulse Systems
• For 12-pulse operation, two balanced three-phase input supplies, 30° phase shifted from each other are
required. An inter-bridge transformer is also required on the RECT side.
3.7 Coolant Flow
• A suitable cooling system must be provided that always maintains adequate flow of suitable coolant –
see the Specification section of this Data Sheet for more details.

AER3500L-4601-D
4. Specification
4.1 Electrical – Power Section
Value
Specification AER3500L- Notes & Applicable Conditions
4601-D
60s Overload = 110% once per 10 minutes, Average <= Continuous
3500A AC Voltage = Any within specification
Continuous DC Coolant Temp. = 60°C
Current, total for
60s Overload = 150% once per 10 minutes, Average <= Continuous
both bridges
2567A AC Voltage = Any within specification
Coolant Temp. = 60°C
Total DC current (above) must also be respected
Continuous current
in any individual
1565A RMS The system designer must ensure that AC phase voltage imbalance, or
AC phase
Star/Wye-Delta imbalance in a 12-pulse system, does not cause any
connection
phase to exceed this current
AC Supply Voltage 690 V ac rms (nominal), +/- 10% long term, +/- 15% for 0.5 to 30 cycles
690Vac RMS 43 to 63 Hz
& Frequency
Maximum DC
1250 Vdc Typically during regeneration of inverter units
Operating Voltage
TN or TT (earthed/grounded neutral).
AC Network Type Can also be connected to IT network (delta/isolated neutral); if IT network separated from
public mains supply by an isolating transformer.
Insulation BS EN 61800- Also conforms to UL 840, CSA C22-2 No. 0.2, EN 50178 and UL508C
Standards 5-1: 2007 (when used with external transient suppressors compliant to UL 1449)

AER3500L-4601-D
4.2 Power Connections
Specification Value, Notes & Applicable Conditions
External power cables must be mechanically supported – the AER3500L-4601-D

General Requirements terminals are NOT SUITABLE for support.
Care must be taken to limit bend radii of cables as specified by the manufacturer.
M10 studs with provided non-marring nut/washer assemblies for Power.
Terminal Fastenings
M10 threaded insert for ground/earth.
Max: 40 Nm / 360 in-lb. / 30 ft-lb.
M10 Fastener Torques
Min: 27 Nm / 240 in-lb. / 20 ft-lb.
AC Terminals : R1, S1, T1, R2, S2, T2: Three M10 studs per connection.
RECT1+ & RECT2+: Three M10 studs per connection.
Fastener Count
RECT1/2-: Six M10 studs per connection.
GROUND: One M10 threaded insert.
Maximum Cable/Crimp This size, using high temperature cables, is recommended for 100%
185 mm2
Cross Section utilization of the AER3500L-4601-D current rating.
Due to high currents per cable, high temperature cables of sufficient size must be
used to achieve the full rating of the AER3500L-4601-D.
Cable Type If more cables are needed than studs provided, then small adapter busbars should be
used. The AER3500L-4601-D online 3D model may be used to help design these or
contact Avid Controls for assistance.
3 X M10 stud for

AC Connection
(six places)
These studs are

3 X M10 stud for not for cable 6 X M10 stud M10 Bolt+Insert for
RECT+ Connections terminals – do for RECT- GROUND connection
(2 Places) not remove or Connections
loosen these
nuts

AER3500L-4601-D
4.3 Electrical – Control Connections
• The AER3500L-4601-D provides only NTC thermistor and thermostat signals to the control system.
• These are connected to a pluggable terminal block, TB1 on the front of the module.
• TB1 is compatible with the older MV3000 rectifier modules, and its pinout is shown below:
• The thermistor and thermostats are mounted on the liquid-cooled heatsinks, directly adjacent to the
hottest DIODE.
• The thermostats open at 90°C.
• IT IS IMPERATIVE THAT IF THE THERMOSTATS OPEN, THE APPLICATION DISABLES

CURRENT THROUGH THE AER3500L-4601-D. FAILURE TO DO SO CAN RESULT IN
DESTRUCTION OF THE AER3500L-4601-D.

AER3500L-4601-D
• The thermistor has the following characteristic
Temp. Resistance Temp. Resistance Temp. Resistance Temp. Resistance

°C kΩ °C kΩ °C kΩ °C kΩ
0.0 13.168 30.0 4.159 60.0 1.647 90.0 0.626
5.0 10.850 35.0 3.487 65.0 1.434 95.0 0.531
10.0 8.925 40.0 2.951 70.0 1.242 100.0 0.482
15.0 7.340 45.0 2.523 75.0 1.065 105.0 0.497
20.0 6.047 50.0 2.176 80.0 0.901 110.0 0.598
25.0 5.000 55.0 1.890 85.0 0.752
• The following polynomials allow Resistance (in kΩ) and Temperature (in °C) to be estimated from each
other (with about 2°C maximum error):
𝑛=6
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = ∑ 𝐾𝑡𝑛 ∙ 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑛

𝑛=0
𝑛=4
𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = ∑ 𝐾𝑟𝑛 ∙ 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑛

𝑛=0
Coefficients:
n=0 n=1 n=2 n=3 n=4 n=5 n=6

Ktn 1.343212E+02 -8.276622E+01 3.075495E+01 -6.380161E+00 7.125432E-01 -4.011640E-02 8.919915E-04
Krn 1.316766E+01 -5.064362E-01 8.972572E-03 -7.785761E-05 2.608998E-07
• It is strongly recommended that the application reduces the current if the thermistor temperature exceeds
85°C (Resistance < 750 Ω), and it must disable current for temperatures above 90°C (Resistance <
530Ω), or when the thermostats open.

AER3500L-4601-D
4.4 Cooling
Specification Value, Notes & Applicable Conditions

Water / Ethylene Glycol
Maximum 50% Ethylene Glycol
Coolant Type
With suitable corrosion inhibitors for aluminum cooling
elements of the AER3500L-4601-D
Minimum Coolant Flow 25 liters/min (6.6 US-GPM)
Maximum Coolant Inlet Pressure 300kPa (45psi)
Maximum Coolant Inlet Temperature 60°C
Minimum Coolant Inlet Temperature 0°C
Coolant must be strained to remove particles
Coolant Strainer Maximum recommended strainer mesh is 0.7mm (0.028”)
Inspect and clean strainer every six months
Check coolant constituent concentration every six months
Coolant Lifetime Remove coolant, flush system with de-ionized water and refill
with new coolant every 24 months.
Coolant Connection 2x Quick-Disconnect at bottom of unit
Valve on unit. Coolant must be bled of all air during
Coolant Air-Bleed
commissioning.
At 3500A DC Continuous: 7kW
At 2600A DC Continuous: 5kW
Typical Heat Load to Coolant
It is recommended to design the cooling system based upon
20% more than these values
Drip pipe for

bleed valve

AER3500L-4601-D
4.5 Environmental
4.5.1 Operating
Specification Value
Ambient Temperature
(Internal cabinet 0 to 50°C
temperature)
5% to 95% RH
Humidity
Unit must not be operated in the presence of condensation.
Pollution Degree 2 as per IEC60664-1, UL 840 & CSA C22.2 No. 0.2-93
Pollution i.e. clean, free from dust, condensation and conductive or corrosive gases.
Maximum chemicals 15ppm H2S, 25ppm NO2, 25ppm SO2
Normal operating altitude up to 1000 m (3280 ft) above sea level.
Altitude From 1000 m (3280 ft) to a maximum of 2000 m (6551 ft) derate by 7.3%
per 1000 m (3280 ft).
To IEC 61800-2 which specifies ‘Class 3M1’ of IEC 60721-3-3 and to the
vibration requirements of EN50178.
The product complies with the more severe requirements from both
standards - this is given as the data represented in the following table:
Vibration
Frequency Limit Frequency Limit
2 to 9 Hz 0.3mm amplitude 57 to 150 Hz 9.81 m/s2 accel.
9 to 18.4 Hz 1 m/s2 accel. 150 to 200 Hz 1 m/s2 accel.
18.4 to 57 Hz 0.075mm amplitude

AER3500L-4601-D
4.5.2 Storage & Transport
Specification Value
-25 to +55°C Storage

Temperature -25 to +70°C Transport
Storage and Transport without coolant
Relative Humidity < 95% (non-condensing)
Altitude Will withstand air transport

To IEC 61800-2 which specifies Class 2M1 of IEC 60721-3-2 when
equipment is packed for transport:
Frequency Limit
Vibration
2 to 9 Hz 3.5 mm amplitude
9 to 200 Hz 10 m/s2 accel.
200 to 500 Hz 15 m/s2 accel.
To IEC 61800-2 which specifies Class 2M1 of IEC 60721-3-2 when

Drop - Transport
equipment is packed for transport: 0.1m (mass >100 kg)

AER3500L-4601-D
4.6 Mechanical
Specification Value
1263mm (Height) x 535mm (Depth) x 334mm (Width)
Dimensions
[ 49.7-in (Height) x 21.1-in (Depth) x 13.1-in (Width) ]
125 kg
Weight
[ 275 lb. ]
IP00 (to IEC 60529: 1989; BS EN 60529:1992), (NEMA 1)
Enclosure –
These modules must always be installed in an appropriate enclosure with
Ingress Protection
restricted access.
3D model(s) of the AER3500L-4601-D may be downloaded from https://avidcontrolsinc.com/step-files/

AER3500L-4601-D
5. Contact Details for Sales, Service and Support
• Address: Avid Controls Inc.

41261 Park 290 Drive
Waller, TX 77484, USA
• Email: [email protected]
• Telephone: (+1) (281) 640-8600
6. Document Revision History
Rev. Date Author Changes

00 12th July 2019 Mark Woods Original Issue
01 24th April 2020 Mark Woods Improved shroud diagrams and crimp size information
Heat load figures changed
02 January 11th 2021 Gary Pace Additional information for external protection included
Some format changes
Fusing and external inductor information added
03 October 20th, 2021 Gary Pace
Maximum AC current specified

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AER3500L-4601-D

Liquid Cooled Rectifier Module - Data Sheet

Page 1 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Page 2 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Page 3 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

• The following schematic shows the power circuits of the AER3500L-4601-D:

Page 4 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

• The following illustration shows the mechanical arrangement of the module:

Air-bleed valve for coolant Lifting point 20 mm (0.75”)

TB1 – Control connections

Ground (Earth) terminal

Cooling system connections

RECT 1+ DC positive Stop screw (behind DC

Page 5 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

1.2 Power Device Details

Device Main Parameters Notes

RECTIFIER Reverse Voltage = 2.2kV

1.3 Typical Applications

• In these applications, the temperature of the AER3500L-4601-D is monitored by an MV3000 Common

1.4 Related Documents

o T1693EN, MV DELTA Liquid Cooled Drive System

o T1679EN, MV3000 Drive Range Software Technical Manual

Page 6 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Page 7 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

3.1 DC Link Pre-Charge

3.2 Over-Current Protection

• The AER3500L-4601-D cannot limit or interrupt current.

3.3 Over-Temperature Protection

• See the Specification section for details of the over-temperature signals.

Page 8 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

3.4 Input Inductance

Manufacturer Family Rating Number Paralleled Total I2T

3.6 12-Pulse Systems

3.7 Coolant Flow

Page 9 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Page 10 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

4.2 Power Connections

Specification Value, Notes & Applicable Conditions

External power cables must be mechanically supported – the AER3500L-4601-D

3 X M10 stud for

These studs are

Page 11 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

4.3 Electrical – Control Connections

• The thermostats open at 90°C.

• IT IS IMPERATIVE THAT IF THE THERMOSTATS OPEN, THE APPLICATION DISABLES

Page 12 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

• The thermistor has the following characteristic

Temp. Resistance Temp. Resistance Temp. Resistance Temp. Resistance

𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = ∑ 𝐾𝑡𝑛 ∙ 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑛

𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = ∑ 𝐾𝑟𝑛 ∙ 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑛

n=0 n=1 n=2 n=3 n=4 n=5 n=6

Page 13 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Specification Value, Notes & Applicable Conditions

Drip pipe for

Page 14 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

Page 15 of 18 Copyright © 2019-2021 Avid Controls Inc. DTS-01551-ASY-A-REV_03

4.5.2 Storage & Transport

-25 to +55°C Storage

Relative Humidity < 95% (non-condensing)