Danfoss VLT 4000 Bedienungsanleitung

This instruction sheet is for the installation of back-channel cooling kits available for the VLT®

series drives. These kits are designed and tested to be used with Rittal TS8 enclosures

1800, 2000 and 2200 mm in height. Other enclosure heights are not supported. In addition to

the enclosure a 200 mm vented base/plinth is required.

The minimum enclosure depth is 500 mm (600mm for E2 frame) and the minimum enclosure

width is 600 mm (800mm for E2 frame). The maximum depth and width are as required by

the installation. When using multiple drives in one enclosure mount each drive on its own

back panel and support along the mid-section of the panel. The ductwork kits are very similar

in construction for all frames. The D3 and D4 kits do not support “in frame” mounting of the

drives. The E2 kit is mounted “in frame” for additional support of the drive. These kits can be

used with IP00/ Chassis drives as listed in Table 1 and are suitable for use only with Rittal

TS8 IP20 and UL & NEMA 1 and IP54 and UL & NEMA 12 enclosures.

Using these kits as described removes 85% of the losses via the back channel using the

drive’s main heat sink fan. The remaining 15% must be removed via the door of the Rittal

enclosure. (Refer to Note 2 on Page 2 for air flow requirements.)

INSTRUCTIONS

INSTALLATION OF BACK-CHANNEL COOLING KIT FOR FRAMES D3, D4 & E2

Instruction No: 175R5640 V3 Aug 13, 2008 Page 1 VLT®is a registered trademark of Danfoss A/S

Rittal TS8

Enclosure Frame D3

Kit Part No. Frame D4

Kit Part No. Frame E2

Kit Part No.

1800 mm

176F1824

176F1823 Does not

fit in 1800

2000 mm

176F1826

176F1825

176F1850

2200 mm

176F0299

Table 2. Kit Part NumbersTable 1. Applicable Frames

and Drives

All D3, D4 and E2 Frames

*** IP00 ONLY ***

VLT4000

(North America)

VLT5000

VLT5000FLUX

VLT6000

VLT8000

VLT HVAC

VLT Aqua

VLT Automation

Kit Contents

• Ductwork components

• Mounting hardware

• Gasket material

• 175R5631 View of Ductwork components, D3 and D4 frames

• 175R1037 View of Ductwork components, E2 frame

• 175R5639 Template for drive location in “D” frames

Required Tools

• Metric Socket Set, 7-19mm

• Socket Extensions

• Torx Driver Set T10-T40

• Torque Wrench 6-50 in-lbs (.7-6 N-M)

Torque Requirements

1. 10 mm, M5 Nuts torque to 20 in-lbs (2.3 N-M)

2. T25 Torx screws torque to 20 in-lbs (2.3 N-M)

Instruction No: 175R5640 V3 Aug 13, 2008 Page 2

Notes:

1. The photos in this instruction are based on a D4 Frame installation. D3 and E2 frame

drives use parts similar to those in the photos however they are sized appropriately for

those drives.

2. A doorfan(s) is required on the enclosure to remove the heat losses not contained in the

backchannel of the drive and any additional losses generated from other components in-

stalled inside the enclosure. The total required air flow must be calculated so that the ap-

propriate fans can be selected. Some enclosure manufacturers offer software for perform-

ing the calculations (i.e. Rittal Therm software).

If the VLT is the only heat generating component in the enclosure, the minimum airflow re-

quired at an ambient temperature of 45°C for the D3 and D4 frame drives is 391 m3/h (230

cfm). The minimum airflow required at an ambient temperature of 45°C for the E2 frame

drive is 782 m3/h (460 cfm).

3. If external duct work is added to the exhaust path of the drive, additional back pressure will

be created that will reduce the cooling of the drive. The drive must be derated to accom-

modate the reduced cooling. First, the pressure drop must be calculated, then refer to the

derating tables located in the VLT High Power Operating Instructions.

Photo 3. Bottom duct adapter

Install gasket material on the back openings of

the drive (Photo 2) prior to installation on the en-

closure back panel.

D3 and D4 frames: Use the template provided

with the kit (175R5639) to determine the drive

location on the back panel of the enclosure. The

template is referenced to the top-left corner of the

back panel. Therefore the template may be used

with any size back panel and both the 1800 mm

and 2000 mm high enclosures.

E2 frame: Use the measurements on Drawing

175F1037, Sheet 2 to determine the drive loca-

tion.

Photo 4. Bottom duct adapter w/

Photo 2. Drive open-

ings on rear are not

used in this applica-

tion.

Instruction No: 175R5640 V3 Aug 13, 2008 Page 3

Prior to installing the back panel in the enclosure,

apply the gasket on both sides of the bottom duct

adapter as shown in Photos 3 and 4.

Install the two mounting brackets on the drive

chassis and then install the bottom duct adapter

on the bottom of the drive as shown in Photo 5.

The installation of the bottom plate is easier while

the back panel is outside the enclosure. The

curved leading edge of the bottom duct adapter is

to the front of the drive and down. IMPORTANT:

Install the bottom plate after the drive has been

installed on the back panel to assure proper gas-

ket coverage. Photo 5. Bottom duct adapter in-

stalled

Attached to chassis brackets

Photo 7. Drive installed

in cabinet—D4 Frame

Before installing the back panel with the drive in

the enclosure, remove and discard the rear-most

screws (Photo 6) that are located on the top cover

of the drive. The holes will be used to fasten the

top ductwork with longer screws provided with the

kit.

Install the backpanel in the enclosure (Photo 7).

Use Rittal PS4593.000 brackets (minimum one

per side at the middle of the drive) with

appropriate support strip for additional support

of the backpanel. For the D4 frame use two

supports per side. Consult the Rittal manual for

additional support requirements if additional

components are mounted on the same back

panel.

Photo 6. Top of IP00/Chassis drive

Instruction No: 175R5640 V3 Aug 13, 2008 Page 4

Photo 9. The top duct work partially assem-

bled with bottom flange

Temporarily install the top duct section as

shown in Photo 10. Use the top duct cover

piece to mark the enclosure top for the open-

ing. Alternately, Drawing 175R5639 can be

used to mark the enclosure for cut-out loca-

tion.

Photo 10. Top duct work and enclosure

top installed

Photo 8. Top duct assembly

The top duct work cover is composed of the

following pieces as shown in Photo 8. From

left to right:

• top duct closing plate

• drive bracket

• duct

• vented top cover

Photo 11. Enclosure top with cutout

Cut the enclosure top. Do not apply gas-

ket to enclosure top (the gasket is part of

the duct work).

Instruction No: 175R5640 V3 Aug 13, 2008 Page 5

Photo 12. Top duct assembled with gas-

ket

Photo 13. Gasket applied to both sides

drive bracket and grated cover

Photo 14. Top duct ready to be installed

on drive

For the final installation of the duct work, as-

semble the top duct as shown in Photos 12, 13

and 14. Gasket is applied to several surfaces

as shown (refer to drawing 175R5631 Sheet 2,

exploded view of components). The top duct

closing plate is left off for the installation of the

duct work on the drive. The top duct work is

attached to the drive using existing holes on

the top cover of the drive. Use the 5 longer

screws (supplied with kit) to install the top duct

work. The duct work will fit over the drive

mounting bolts.

Once the duct work is attached to the drive, the

duct closing plate can be attached. The top

duct work assembly is complete.

Photo 16. Top duct installed

Photo 15. Gasket folds over the edge to

form seal between the duct and top vented

cover

Closing plate

Instruction No: 175R5640 V3 Aug 13, 2008 Page 6

Photo 20. Enclosure top installed

Install top duct cover assembly using

the longer T25 screws provided with

the kit in the existing drive top cover

holes. Reference Photos 17, 18 and

19.

Apply the gasket to the top duct

closing plate and install. Install the

enclosure top. Reference Photos 20

and 21.

Photo 21. Top view of Rittal enclosure

Photo 18. Top duct closing plate with gasket

Photo 17. Top duct installed

Photo 19. Top duct closing plate in-

Instruction No: 175R5640 V3 Aug 13, 2008 Page 7

Remove the front two enclosure gland

plates. The duct assembly is used to

mark the bottom of the enclosure for the

bottom cutout.

Temporarily install the bottom ductwork

as shown in Photo 25. Use the inside of

the ductwork to mark the bottom of the

enclosure for the opening. Alternately,

drawing 175R5639 can be used.

The bottom duct assembly pieces are

shown in Photo 22. Refer to drawing

175R5631, Sheet 3. Install the gasket as

shown. Assemble the bottom duct less

the cover. Assembly includes the mount-

ing of 3 angle brackets on the front and

sides of the partially assembled bottom

duct. The bottom duct collar is bolted to

the duct using 3 -T25 screws in the outer-

most holes of the brackets. Tighten

screws to compress the gasket. Refer-

ence Photo 23. Photo 22. Bottom duct pieces

Photo 23. Bottom duct partially assembled

Photo 24. Completely assembled bottom

duct work

Photo 25. Duct work temporarily in-

stalled to mark cut-out on the gland

plate

Instruction No: 175R5640 V3 Aug 13, 2008 Page 8

The cutout is made on the inner most gland plate

Remove the remaining two gland plates for the

installation of the bottom duct assembly.

Photo 26. Enclosure bottom cutout

The bottom duct work is rotated into place as

shown in Sketch. 1. The bottom duct work is de-

signed to fit tightly. The upper part of the duct

fits under the bottom duct adapter and requires a

tight seal, permitting the enclosure to maintain its

IP54 and UL & NEMA 12 ratings.

Photo 27. Bottom duct work installed

Sketch 1. Installation of bottom duct

Instruction No: 175R5640 V3 Aug 13, 2008 Page 9

After the bottom duct work is positioned in place,

remove the three T25 screws from the outer holes in

the mounting brackets on the sides and front of the

duct work and move them to the inner holes of the

same brackets. Tighten the three screws to the

specified torque.

The bottom duct work is not fastened to the enclo-

sure.

Photo 28. Move mounting screws

from the outer hole to the inner hole

Outer hole Inner hole

Install the front cover of the duct and the cable

clamp bracket if used. Install the two remaining

gland plates.

Instruction No: 175R5640 V3 Aug 13, 2008 Page 10

Photo 29. Installed ductwork

Note: The cable clamp bracket is grounded

through the screws that secure the bracket to

the duct. If additional grounding is desired the

grounding strap that is supplied with the kit may

be installed.

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