Bitzer VARIPACK FDU+6 User manual

CB-100-2
VARIPACK - external BITZER Frequency Inverters (FI)
Translation of the original Operating Instructions
English....................................................................................................................................................... 2
VARIPACK − externe BITZER Frequenzumrichter (FU)
Originalbetriebsanleitung
Deutsch ..................................................................................................................................................... 43
VARIPACK − convertisseurs de fréquences (CF) BITZER externes
Traduction des instructions de service d’origine
Français..................................................................................................................................................... 84
FDU+6, FDU+12
FEU+16, FEU+24
FGU+32, FGU+38
FHU+45, FHU+60, FHU+73
FJU+87, FJU+105, FJU+145
FKU+180, FKU+205, FKU+260
Document for electrically skilled installers
Dokument für elektrisch unterwiesene Monteure
Document pour des monteurs instrués électriquement

CB-100-22
Table of contents
1 Introduction............................................................................................................................................................3
2 Safety ....................................................................................................................................................................3
2.1 Authorized staff..............................................................................................................................................3
2.2 Residual risks ................................................................................................................................................3
2.3 Safety references...........................................................................................................................................3
2.3.1 General safety references.................................................................................................................. 3
3 Technical data .......................................................................................................................................................4
3.1 Modular design of the VARIPACK frequency inverter ...................................................................................6
4 Mounting................................................................................................................................................................7
4.1 Transport and storage ...................................................................................................................................7
4.2 Ventilation......................................................................................................................................................7
4.3 Switch cabinet mounting................................................................................................................................8
4.4 Through-switch cabinet mounting (option).....................................................................................................9
4.4.1 Mounting work for through-switch cabinet mounting........................................................................ 11
4.5 Mounting in machinery room (option) ..........................................................................................................13
4.5.1 Mounting instructions for the IP21 kit............................................................................................... 14
4.6 Mounting the fixtures for power cables and control cables..........................................................................15
5 Electrical connection............................................................................................................................................16
5.1 Earth connection..........................................................................................................................................17
5.2 Power connections (voltage supply cable and motor cable)........................................................................17
5.3 Control connections (inputs and outputs) ....................................................................................................18
5.4 Operating modes .........................................................................................................................................20
5.4.1 Capacity control of the compressor depending on an external setpoint signal................................ 20
5.4.2 Capacity control of the compressor as a function of the evaporation pressure ............................... 21
5.5 Electromagnetic compatibility (EMC)...........................................................................................................22
5.5.1 Analysis of the harmonics FDU+6 .. FKU+260 ................................................................................ 23
5.6 Safe Torque Off (STO) ................................................................................................................................24
5.7 Schematic wiring diagrams..........................................................................................................................26
5.7.1 Schematic wiring diagrams semi-hermetic reciprocating compressors ........................................... 26
5.7.2 Schematic wiring diagrams semi-hermetic screw compressors ...................................................... 29
6 Control functions..................................................................................................................................................33
6.1 Extension module for pressure control ........................................................................................................35
7 Data communication with the VARIPACK frequency inverter .............................................................................37
7.1 Communication via the BEST SOFTWARE ................................................................................................37
7.2 Removable control panel (with display and keypad) ...................................................................................38
7.2.1 Kit for external mounting of the control panel .................................................................................. 38
7.2.2 Control panel setup and operation................................................................................................... 39
7.3 Interfaces for communication via ModbusRTU and ModbusTCP/IP .........................................................39
8 Commissioning of the VARIPACK frequency inverter.........................................................................................39
9 Fault messages and monitoring functions...........................................................................................................40
10 Maintenance........................................................................................................................................................41

CB-100-2 3
1 Introduction
The VARIPACK frequency inverters (FI) have been de-
veloped for use in refrigeration, especially for capacity
control of BITZER compressors. In addition to speed
control, the VARIPACK frequency inverters can also
take over control functions of the refrigeration system.
These Operating Instructions describe the
BITZER VARIPACK frequency inverters for refrigera-
tion compressors. For any further information regarding
the programming of the Modbus RTU and Modbus
TCP/IP interface, see BEST SOFTWARE 2.9 or newer.
The VARIPACK frequency inverters have been built in
accordance with state-of-the-art methods and current
regulations. Particular importance has been placed on
user safety. These Operating Instructions must be kept
available in the vicinity of the VARIPACK frequency in-
verter!
2 Safety
2.1 Authorized staff
All work done on frequency inverters may only be per-
formed by qualified and authorized staff who have been
trained and instructed accordingly. Local regulations
and guidelines apply with respect to the staff's qualifica-
tion and expertise.
2.2 Residual risks
Frequency inverters may present unavoidable residual
risks. That is why any person working on this device
must carefully read these Operating Instructions!
The following rules and regulations are mandatory:
• relevant safety regulations and standards (e.g.
EN378-2 and EN60204-1),
• generally accepted safety rules,
• EU directives,
• national regulations.
2.3 Safety references
are instructions intended to prevent hazards. Safety ref-
erences must be stringently observed!
!
!
NOTICE
Safety reference to avoid situations which may
result in damage to a device or its equipment.
CAUTION
Safety reference to avoid a potentially hazard-
ous situation which may result in minor or mod-
erate injury.
WARNING
Safety reference to avoid a potentially hazard-
ous situation which could result in death or seri-
ous injury.
DANGER
Safety reference to avoid an imminently hazard-
ous situation which may result in death or seri-
ous injury.
2.3.1 General safety references
DANGER
Life-threatening voltages inside the frequency
inverter housing!
Contact can lead to serious injuries or death.
Never open the FI housing in operation! Switch
off the main switch and secure it against being
switched on again.
Wait for at least 5 minutes until all capacitors
have been discharged!
Before switching on again, close the FI housing.
DANGER
Wrong or insufficient earthing may result in life-
threatening electric shocks upon contact with
the VARIPACK frequency inverter!
Earth the complete VARIPACK frequency in-
verter permanently and check the earth contacts
at regular intervals!
Prior to any intervention in the device, check all
voltage connections for proper insulation.
!
!
NOTICE
Risk of frequency inverter failure caused by
over-voltage!
Never carry out high-voltage tests or an insula-
tion test on lines in operation, without having
disconnected the frequency inverter beforehand
from the circuit to be tested!

CB-100-24
CAUTION
In operation, the heat sink of the VARIPACK fre-
quency inverter will get hot.
Risk of burns upon contact!
Prior to performing work on the VARIPACK fre-
quency inverter, disconnect the power supply
and wait for at least 15 minutes until the heat
sink has cooled down.
3 Technical data
VARIPACK frequency inverter
Operating voltage 380 .. 480V/3/50 Hz ±10%. , 380 .. 480V/3/60 Hz ±10%.
Operation on IT networks on request. To obtain compatibility with this network con-
figuration and the network monitoring installed there, the integrated EMC filters
must be deactivated and special external filters must be used.
Operation on generators, emergency power unit and networks equipped with power
factor correction units only after consultation with BITZER.
Earth fault current >10mA
Enclosure class Enclosure class − IP20 or OpenTypeUL and cUL
Overvoltage categoryIII
Storage -25°C .. +55°C
Transport -25°C .. +70°C
Place of installation • Permitted ambient temperature 0°C .. +50°C. From an ambient temperature of
40°C, a decrease in capacity by 2% per degree Celsius (Derating). The selection
in the BITZER SOFTWARE can take this directly into account.
• Permitted relative humidity: max. 85%, non-condensing (EN60721-3-3 classes
3K3 and 3C3).
• Maximum allowable altitude above sea level: 2000m. From 1000 m above sea
level, a decrease in capacity by 1% per 100 m (Derating). The selection in the
BITZER SOFTWARE can take this directly into account.
• Environment according to EN60664-4: Pollution degree 1, non-flammable, non-
corrosive.
Vibrations Test according to EN 60068-2-6 (Fc), 10 cycles per axis on each of three mutually
perpendicular axes
• 10 Hz<f< 57 Hz sinusoidal 0.075 mm amplitude.
• 57 Hz<f<150 Hz sinusoidal 1 g.
Safe Torque Off (STO) Safe Torque Off is a safety function for the electrical power drive, see chapter Safe
Torque Off (STO), page 24.
EMC The compressor with frequency inverter (FI) meets the EU EMC directive 2014/30/
EU see chapter Electromagnetic compatibility (EMC), page 22.

CB-100-2 5
The selection and assignment of the VARIPACK fre-
quency inverters to the BITZER reciprocating com-
pressors is done by means of the BITZER SOFTWARE
under the ACCESSORIES button.
Type Enclos-
ure
Weigh
t
Rated
output
cur-
rent
Power (at
400V)
Special fea-
tures
CE compliances / certific-
ates
Fan rating(s)
kg A kW C2 EMC
filter
STO CE UL① cUL
①
cTick m3/h cfm
FDU+6 D 4.5 5.5 2.2 Integ-
rated
✔ ✔ ✔ ✔ ✔ --- ---
FDU+12 D 4.5 12 5.5 Integ-
rated
✔ ✔ ✔ ✔ ✔ 45 27
FEU+16 E 6.8 16 7.5 Integ-
rated
✔ ✔ ✔ ✔ ✔ 56 33
FEU+24 E 6.8 23 11 Integ-
rated
✔ ✔ ✔ ✔ ✔ 56 33
FGU+32 G 10.0 32 15 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x45 2x27
FGU+38 G 10.0 38 18 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x45 2x27
FHU+45 H 22.3 45 22 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x89 2x53
FHU+60 H 22.3 60 30 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x89 2x53
FHU+73 H 22.3 73 37 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x89 2x53
FJU+87 J 42.8 87 45 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x45 2x27
FJU+105 J 42.8 105 55 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x89 2x53
FJU+145 J 42.8 145 75 Integ-
rated
✔ ✔ ✔ ✔ ✔ 2x89 2x53
FKU+180 K 89.0 180 90 Ex-
ternal*
✔ ✔ --- --- ✔ 3x133 3x80
FKU+205 K 89.0 205 110 Ex-
ternal*
✔ ✔ --- --- ✔ 3x133 3x80
FKU+260 K 89.0 260 132 Ex-
ternal*
✔ ✔ --- --- ✔ 3x133 3x80
①: Only for switch cabinet mounting.
* External EMC filter for C2 EMC limit: Part number: 347 955 02, Designation: 3359-250-28
Tab.1: Technical data, compliances and fan ratings

CB-100-26
3.1 Modular design of the VARIPACK frequency
inverter
2
1
3
4
5
6
7
8
9
5a
10
11
5b
Fig.1: Modular design of the VARIPACK frequency inverter
1 Power stack 2 Heat sink
3 Upper housing cover 4 Lower housing cover
5 Control module with
5a: Terminal strip
5b: SD card slot
6 Extension kit for pressure control (option)
7 Interface extension with real-time clock 8 Control module cover
9 Removable control panel (with display and
keypad) (option)
10+11 Fixing plates

CB-100-2 7
4 Mounting
Information
Mount the VARIPACK frequency inverter always
vertically.
The fixtures for the power cables and control cables are
delivered as standard in the accessories kit and must
be mounted together with the ferrite core or the ferrite
cores (see figure 11, page 18) up to VARIPACK hous-
ing size FJU+145, in order to achieve the EMC
classC2 according to EN61800-3.
4.1 Transport and storage
!
!
NOTICE
Risk of damage to the VARIPACK frequency in-
verter!
Do not lift or set down the VARIPACK fre-
quency inverter at the connections.
Place it on clean, flat and dry surfaces only.
Storage in well-ventilated places and protected
from high temperatures, moisture, dust and
metal particles only!
Storage temperature: -25°C..+55°C.
Transport temperature: -25°C..+70°C.
4.2 Ventilation
!
!
NOTICE
The VARIPACK frequency inverters give off
heat in operation.
Insufficient or blocked air circulation and air sup-
ply at the ventilation slots and at the heat sink of
the VARIPACK frequency inverter can lead to
failure due to overheating!
Observe the minimum clearances for ventilation
(see figure 2, page 7)!
When two or more VARIPACK frequency invert-
ers are mounted side by side, add up the clear-
ances!
When using filter fans, the required air volume flow
(m3/h) must be carefully determined to ensure sufficient
cooling of all electrical devices in the switch cabinet.
For protection from temperatures below 0°C and for
avoiding condensation, a switch cabinet heater may be
required, depending on the installation site and the cli-
matic conditions.
Rated values of the VARIPACK fans, see table 1, page
5.
B
A
C
Fig.2: Minimum ventilation clearances at switch cabinet mounting
and through-switch cabinet mounting
Types Minimum ventilation clear-
ances
A
mm
B
mm
C ①
mm
FDU+6 .. FHU+73 10 75 75
FJU+87 .. FKU+260 10 100 100
Tab.2: Minimum ventilation clearances at switch cabinet mounting
and through-switch cabinet mounting
①: Minimum ventilation clearance without taking into
account free space for cables.

CB-100-28
4.3 Switch cabinet mounting
The VARIPACK frequency inverter is mounted in the
switch cabinet using the fixing plates.
FDU+6 .. FHU+73
The alternative bores, arranged at a spacing of 15mm,
can be used to move the fixing plates upwards or
downwards.
BB1
H
H2
F
LB2
H1
B1
F
H3
X
B1
B3
FKU+180 .. FKU+260
Fig.3: Dimensional drawing FDU+6 .. FKU+260 for switch cabinet mounting (drawing shows FDU with optional control panel)
B
mm
B1
mm
B2
mm
B3
mm
F H
mm
H1
mm
H2
mm
H3
mm
L
mm
X
mm
FDU+6, FDU+12 100 80 10 --- M4 286 270 7 332 255 46
FEU+16, FEU+24 125 100 13 --- M4 333 320 7 398 255 62
FGU+32, FGU+38 150 125 13 --- M4 383 370 7 455 255 72
FHU+45..FHU+73 220 190 13 --- M5 480 465 7 588 287 108
FJU+87..FJU+145 260 220 20 --- M6 670 650 10 870 316 200
FKU+180..FKU+260 330 285 23 143 M8 800 780 10 1055 374 255

CB-100-2 9
4.4 Through-switch cabinet mounting (option)
When mounted by through-switch cabinet mounting,
the heat sink (of enclosure class IP54) of the
VARIPACK frequency inverter is outside the switch
cabinet.
Thus,
• a smaller switch cabinet can be used since a large
portion of the heat generated by the VARIPACK fre-
quency inverter is dissipated outside the switch cab-
inet.
• the ventilation of the switch cabinet can be reduced
to a minimum.
• the VARIPACK frequency inverter can be kept clean
and dry more easily.
102
79
286
6
74
M4
253
2
262
83
M4
250
46
332
Fig.4: Dimensional drawing FDU+6, FDU+12 for through-switch cabinet mounting (with optional control panel)
B
B1
B2
L
H
H1
H2
ØF
ØF
L2
B3
H3
X
L1
H4
Fig.5: Dimensional drawing FEU+16 .. FHU+73 for through-switch cabinet mounting (with optional control panel)

CB-100-210
B6
B5
B
H
D1
H2
D2
H3
H1
L1 L2
X
H4
ØF
B2
B1
B3
B4
ØF
L
Fig.6: Dimensional drawing FJU+87 .. FKU+260 for through-switch cabinet mounting (with optional control panel)
B
mm
B1
mm
B2
mm
B3
mm
B4
mm
B5
mm
B6
mm
D1
mm
D2
mm
F
FEU+16, FEU+24 125 104 1 102 --- --- --- --- --- M4
FGU+32, FGU+38 150 129 1 127 --- --- --- --- --- M4
FHU+45..FHU+73 220 196 1 195 --- --- --- --- --- M5
FJU+87..FJU+145 260 218 5 227 292 312 26 208 220 M6
FKU+180..FKU+260 330 275 13 300 360 380 26 219 320 M8
H
mm
H1
mm
H2
mm
H3
mm
H4
mm
L
mm
L1
mm
L2
mm
X
mm
FEU+16, FEU+24 336 309 6 297 398 253 72 181 62
FGU+32, FGU+38 383 359 6 347 455 253 72 181 72
FHU+45. FHU+73 480 456 12 440 588 287 95 192 108
FJU+87..FJU+145 670 641 15 617 870 310 99 211 200
FKU+180..FKU+260 800 765 10 745 1055 374 128 246 255

CB-100-2 11
4.4.1 Mounting work for through-switch cabinet
mounting
Graphical explanations, see figure 7, page 12 and see
figure 8, page 13.
• Unscrew the fixing plates.
• Dismount the upper (A) and lower (B) housing cov-
ers.
Dismounting the upper housing cover:
FDU+6 and FDU+12:
To allow the upper housing cover to be slid forward and
dismounted, with these types the control module must
be dismounted (see figure 7, page 12).
Dismounting the control module (see figure 7, page
12):
1. First pull the control panel forward and take it off.
2. Unscrew the screw in the centre of the control mod-
ule, slide the control module cover slightly down-
ward and take it off.
3. Unscrew the captive screw and slightly lift the con-
trol module at the lower edge.
4. Slide the control module upward as far as it will go
and then take it off the frequency inverter.
• Now compress the plastic clip under the upper hous-
ing cover (A). This will open the lock.
• Slide the cover forward and take it off.
FEU+16 .. FKU+260:
With these types, the control module does not need to
be dismounted, in order to take off the housing cover
(see figure 8, page 13).
• Introduce a screwdriver far into the slot of the upper
housing cover (A) and press the clip towards the
right. This will open the lock.
• Next, slide the housing cover downward.
Dismounting the lower housing cover:
To allow the lower housing cover to be slid forward and
dismounted, with some types the control module must
be dismounted first.
Dismounting the control module (see figure 7, page
12):
1. First pull the control panel forward and take it off.
2. Unscrew the screw in the centre of the control mod-
ule, slide the control module cover slightly down-
ward and take it off.
3. Unscrew the captive screw and slightly lift the con-
trol module at the lower edge.
4. Slide the control module upward as far as it will go
and then take it off the frequency inverter.
• Introduce the screwdriver into the slot of the lower
housing cover (B) and press it slightly towards the
left. This will open the lock.
• Next, slide the lower housing cover downward.
• In the accessories kit: Place the delivered gasket (D)
around the frequency inverter in such a way that the
free space between the switch cabinet wall (C) and
the FI is sealed airtight.
• Mount the VARIPACK frequency inverter to the
switch cabinet wall using 4 fixing screws (E) (see fig-
ure 8, page 13).
FGU+32 .. FKU+260:
• With these types, the additional lateral fastening
clips must be fixed with screws. They are included in
the through-switch cabinet mounting kit.
Then replace upper and lower housing covers or slide
them on until the plastic clips lock.
Information
If mounting is continued directly with the elec-
trical connection, the lower housing cover can
remain unmounted.
FDU+6 and FDU+12 and all other types in which the
control module was dismounted:
• Replace control module and slide it upwards until the
clip locks.
• Screw in captive screw.
• Place the control module cover until the clip locks
and tighten it.

CB-100-212
1) 2)
3) 4)
Fig.7: Dismounting the control module

CB-100-2 13
A
E (4x)
B
D
C
Fig.8: Detailed view of the through-switch cabinet mounting (ex-
ample FDU)
A Upper housing cover
B Lower housing cover
C Switch cabinet wall
D Gasket (in the accessories kit)
E Fixing screws
4.5 Mounting in machinery room (option)
For free mounting in machinery room, the IP21 kit must
be mounted, see chapter Mounting instructions for the
IP21 kit, page 14. The exterior dimensions of the
VARIPACK frequency inverter will increase accord-
ingly, see figure 9, page 13.
L2
B4
H4
Fig.9: Dimensional drawings FDU+6 .. FKU+260 with free mounting with IP21 kit (drawing shows FDU with optional control panel)
B4
mm
H4
mm
L2
mm
FDU+6, FDU+12 135 391 285
FEU+16, FEU+24 160 445 300
FGU+32, FGU+38 215 505 300
FHU+45..FHU+73 300 660 355
FJU+87..FJU+145 360 940 480
FKU+180..FKU+260 450 1160 520

CB-100-214
4.5.1 Mounting instructions for the IP21 kit
For the FI types: FDU, FEU, FGU, FHU.
Unscrewing upper plate. To do so, unscrew the 4
marked screws.
Screw down IP21 cover in place of the upper fixing
plate.
• To allow the upper housing cover to be slid for-
ward and dismounted, with frequency inverters
FDU the control module must be dismounted
(see figure 7, page 12 and see page 11).
• Introduce a screwdriver far into the slot of the up-
per housing cover and press the clip towards the
right. This will open the lock.
• Next, slide the housing cover off.
Secure IP21 cover additionally using the screws in-
cluded in the kit.
Finally replace upper housing cover or slide it on
until the plastic clips lock.
For frequency inverters FDU, mount the control
module again (see page 11).

CB-100-2 15
For the VARIPACK frequency inverters FJU and FKU.
For these types, the upper fixing plate need not be
unscrewed!
Screw the IP21 cover directly to the upper fixing
plate. Then proceed in the same manner as for
types FDU .. FHU.
4.6 Mounting the fixtures for power cables and control
cables
The fixtures for the power cables and control cables are
delivered as standard in the accessories kit and must
be mounted together with the ferrite core or the ferrite
cores (see figure 11, page 18) up to VARIPACK hous-
ing size FJU+145, in order to achieve the EMC
classC2 according to EN61800-3.
Graphical explanations, see figure 10, page 15.
Mounting the rear fixture for the power cables:
• Remove the lower housing cover (see chapter
Through-switch cabinet mounting (option), page 9). If
necessary, first the control module must be dismoun-
ted (see page 11)
• Place the fixture from behind at the bottom on the
two fixing holes and insert the delivered screws from
the front and tighten them.
• Replace lower housing cover and, if necessary,
mount control module again (see page 11).
Mounting the front fixture for the control cable:
• Remove the control module cover (see chapter
Through-switch cabinet mounting (option), page 9).
• Unscrew the interface extension containing the real-
time clock. To do so, loosen the captive screw of the
interface extension and press the right and left
plastic clips towards the inside. This will open the
lock.
• Pull out the interface extension towards the front.
• Screw the fixture for the control cable into the now
visible right and left fixing holes from the front using
the enclosed screws.
• Replace the interface extension until the plastic clips
lock and tighten the captive screw.
• Screw down the control module cover again.
M4
A
B
Fig.10: Mounting the fixtures for power connection cables and control cables using the example of FEU+16 for switch cabinet mounting
A Front fixture for control cables B Rear fixture for power cables

CB-100-216
5 Electrical connection
Before performing any work on the electrical system:
DANGER
Life-threatening voltages inside the frequency
inverter housing!
Contact can lead to serious injuries or death.
Never open the FI housing in operation! Switch
off the main switch and secure it against being
switched on again.
Wait for at least 5 minutes until all capacitors
have been discharged!
Before switching on again, close the FI housing.
DANGER
As soon as the VARIPACK frequency inverter is
energized, the capacitors in the FI DC link are
charged.
From this moment on, all electrical components
in the VARIPACK frequency inverter present
risks!
The operation of the VARIPACK frequency inverter re-
quires the following electrical connections:
• VARIPACK earth connection.
• VARIPACK power connections (power cable and
motor cable).
• VARIPACK control connections.
For the selection of the cable diameters, fuses and
tightening torques of the earth and power connections,
see table 3, page 16. Use fuses of type gL/gG or
mount thermal overload switch of the appropriate char-
acteristic.
Type Rated in-
put current
Minimum .. Maximum cable diameters and tightening
torques (in Nm)
Fuses
Power connections Earth connections Max. rated fuse current (A)
A Nm Nm Stand-
ard
UL, cUL (type)
FDU+6 7.6 0.05..6mm20.56..
0.8
M4
Ring cable lug
1.8 10 10 (Class J)
FDU+12 10.6 16 20 (Class J)
FEU+16 14.5 20 25 (Class J)
FEU+24 20.4 25 30 (Class J)
FGU+32 28.5 1..10mm2
(16mm2 with cable
connector)
1.35 M4
Ring cable lug
1.8 32 40 (Class J)
FGU+38 33.5 40 50 (Class J)
FHU+45 40 1.3..25mm22.0 M5
Ring cable lug
3.6 63 60 (Class J)
FHU+60 54.7 80 80 (Class J)
FHU+73 66.2 100 100 (Class J)
FJU+87 78.8 Pin M8 for cable lugs
or wire end sleeves
up to a length of
26.5mm
(min. 25mm2)
20 M8
Ring cable lug
20 125 125 (A50QS-125-4)
FJU+105 95.8 160 150 (A50QS-150-4)
FJU+145 130 200 200 (A50QS-200-4)
FKU+180 160 Pin M8 for cable lugs
or wire end sleeves
up to a length of
32mm
(min. 25mm2)
20 M8
Ring cable lug
20 250 250 (A50QS-250-4)
FKU+205 198 315 300 (A50QS-300-4)
FKU+260 236 400 350 (A50QS-350-4)
Tab.3: Cable diameters, tightening torques and fuses

CB-100-2 17
5.1 Earth connection
EN61800-5-1 (product standard for adjustable speed
electrical power drive systems) and
DINEN50178DINVDE0160 (Electronic equipment
for use in power installations) have special earth re-
quirements as soon as an earth leakage current of
3.5mA is exceeded.
• The protective earth conductor cross-section for the
line conductors (L1, L2, L3) <16mm² must, in single
wire, be 10mm2 or must have two wires with the re-
spective phase cross-section each.
• For line conductors (L1, L2, L3) ≥16 mm² and ≤35
mm², the protective earth conductor must have a
cross section of 16mm².
• For line conductors (L1, L2, L3) >35 mm², the pro-
tective earth conductor cross-section must be at
least 50% of that of the phases used (L1, L2, L3).
All exposed metal parts in the VARIPACK frequency in-
verter are protected with a basic insulation and connec-
ted to the protective earth conductor.
WARNING
The VARIPACK frequency inverters can gener-
ate a direct current in the protective earth con-
ductor.
Risk of electric shock upon contact!
Wherever a residual current device (RCD) or a
residual current monitoring device (RCM) is
used for protection against direct or indirect con-
tact, only a RCD or RCM of type B (according to
IEC/EN60755) is permitted on the power supply
side!
Residual current circuit breakers (RCD or FI switch)
• Use only FI circuit breakers (RCD) sensitive to all
types of currents of type B that are capable of also
detecting residual direct currents.
• Select the RCD with respect to the system configura-
tion and environmental conditions.
5.2 Power connections (voltage supply cable and
motor cable)
DANGER
Wrong or insufficient earthing may result in life-
threatening electric shocks upon contact with
the VARIPACK frequency inverter!
Earth the complete VARIPACK frequency in-
verter permanently and check the earth contacts
at regular intervals!
Prior to any intervention in the device, check all
voltage connections for proper insulation.
Graphical explanations, see figure 11, page 18.
• Guide voltage supply cable and motor cable through
the intended cable entries under the cable clips into
the VARIPACK frequency inverter (see figure 11,
page 18) and connect to the power terminals. Ob-
serve the tightening torques of the terminals (see
table 3, page 16).
– Connect the voltage supply cable to the terminals
L1, L2, L3 and the protective earth conductor.
– Connect the motor cable to the terminals U(M1),
V(M2), W(M3) and the protective earth conductor.
– Observe the information regarding electromag-
netic compatibility (EMC) (see chapter Electro-
magnetic compatibility (EMC), page 22)!
• As standard, the VARIPACK frequency inverters are
equipped with a shut-off function, the Safe Torque
Off (STO). Due to the STO function, the main con-
tactor before or after the VARIPACK frequency in-
verter may be omitted (see chapter Schematic wiring
diagrams semi-hermetic reciprocating compressors,
page 26). For further information on the STO func-
tion, see chapter Safe Torque Off (STO), page 24.

CB-100-218
A
B C
D
E
Fig.11: Power connections (voltage supply cable and motor cable)
with fixture
A Earth connection B voltage supply
cable / terminals for
nominal supply
voltage
C Motor cable / motor
terminals
D Cable clips
E Ferrite core
5.3 Control connections (inputs and outputs)
Information
To meet the EMC and safety requirements, the
control module must be connected to the pro-
tective earth conductor outside the device!
Information
The entire external wiring must be approved for
maximum system voltage!
All control and signal terminals guarantee safety
extra low voltages (SELV), i.e., they are protec-
ted by double insulation.
Specification of the control connections:
• Cables completely without or with non-insulated wire
end sleeves: 0.25..1.5 mm².
• Cables with insulated wire end sleeves: 0.25..0.75
mm².
Digital inputs
• Function
– X13:2:DI1 (Start)
Compressor start command.
– X13:3:DI2 (Force)
Operation of the compressor at a minimum fre-
quency of 50Hz.
– X13:4:DI3 (p01 ￫ 2)
External control: without function.
With extension module: Switch over from evapor-
ation temperature setpoint 1 to 2.
– X12:1:DI4 (pc1 ￫ 2)
External control: without function.
With extension module: Switch over from con-
densing temperature setpoint 1 to 2.
– X12:2:DI5 (Reset)
Reset of faults.
– X12:3:DI6 (Detection)
Automatic detection of the extension module.
• Technical data
– Status:
Off: 0..5V DC
Undefined: 5..15 V DC
On: 15..24V DC
– Max. input voltage: ±30V DC
– Input impedance: 3,3kΩ.
– Input current: 7.3mA ±10% at 24VDC
– Common on X10:4
Analogue inputs
• Function
– X11:1:AI1 (mA/p0)
External control: Setpoint as 4..20mA signal.
X10: 2: Common
With extension module: Input for low pressure
coming from the extension module (￫X11:1)
– X11:2:AI2 (V/pc)
External control: Setpoint as 0..10 V signal
X10: 2: Common
With extension module: Input for high pressure
coming from the extension module (￫X11:2)
• Technical data
– Input signal: 0..10V or 4..20 mA

CB-100-2 19
– Max. input current: <25mA (current signal)
– Max. input voltage: ±24VDC (voltage signal)
– Input impedance:
Voltage range: 22kΩ
Current range: 120Ω
Digital outputs
• Function
– X12:4:DO3(Comp. 2)
External control: without function.
With extension module: Start of the 2nd com-
pressor.
• Technical data
– Output signal: 24VDC (minimum 21VDC)
– Max. output current: 140mA.
(The maximum available total current is 140mA,
either individually or as the sum of digital outputs
and the +24VDC power supply on the user
side).
Analogue outputs
• Function
– X11:3:AO1 (Fan)
External control: without function.
With extension module: control signal for con-
denser fan 0..10V.
– X11:4:AO2
Reserve.
• Technical data
– Output signal: 0..10V.
– Max. output current: 10mA, with short-circuit pro-
tection.
– Output impedance: Voltage range ≥1kΩ.
Relays
• Function
– X14:1:Relay 1A ￫ X14:2:Relay 1B
Compressor is ready to operate.
– X14:3:Relay 2A ￫ X14:4:Relay 2B
Compressor is running (factory setting) or no error
can be configured via the parameter logic of out-
put DO1.
• Technical data
– Potential-free relay.
– Switching current range: 1mA to max. 3A of res-
istive load
– Switching voltage range: 5VAC to max.
250VAC or 30VDC
– Protection against inductive or capacitive loads
must be provided by external measures.
Information
The STO inputs must be activated to allow the
compressor to start!
STO (input circuit)
• Function (see chapter Safe Torque Off (STO), page
24)
– X10:1:Input A and X10:3:Input B.
STO inputs (Safe Off Torque).
Inputs must be switched simultaneously.
– X10:2:Common and X10:4:Common.
Terminals are connected internally. Thus, only
one cable core is required.
• Technical data
Typical input current at 24 V: 9 mA
– Status:
Off (recommended): 0..5VDC
Undefined: 5..21,6VDC
On (recommended): 21.6.. 26.4VDC
– Max. input voltage:±30V DC
STO status
• Function (see chapter Safe Torque Off (STO), page
24)
– X10:5status A ￫ X10: 6:StatusB
This output is active (closed), if the STO circuit is
in the safe state, i.e., if the FI does not allow the
motor to produce a torque.
• Technical data
– Potential-free semiconductor relay.
– Max. voltage: ±30V.
– Max. output current: 150mA.
– Thermal overload protection integrated.
– Resistance between the output terminals:<6Ω.

CB-100-220
5.4 Operating modes
The VARIPACK frequency inverter can be operated in
two different operating modes:
• Capacity control of the compressor depending on an
external setpoint signal (see chapter Capacity con-
trol of the compressor depending on an external set-
point signal, page 20).
• Capacity control of the compressor depending on the
evaporation pressure, which will require the optional
extension module for pressure control (see chapter
Capacity control of the compressor as a function of
the evaporation pressure, page 21).
In addition to direct evaporation pressure control, the
condenser fan can also be controlled via a 0..10V
output signal and a second compressor can be connec-
ted.
5.4.1 Capacity control of the compressor depending
on an external setpoint signal
"Min..Max" control characteristic
The VARIPACK frequency inverters can be activated
without change in parameters by a0..10V or
4..20mA signal according to the "Min..Max" control
characteristic.
• In the "Min..Max" control characteristic, the com-
pressor will start as soon as the DI1 (X13: 2) start
command is given. The setpoint signal will control
the frequency linearly between the minimum and
maximum frequencies of the compressor.
– If a 0..10V signal is used, it must be connected
to the input AI2 (X11:2).
– If a 4..20mA signal is used, it must be connec-
ted to the input AI1 (X11:1).
Graphical explanation of the "Min..Max" control char-
acteristic, see figure 12, page 20.
0
f [Hz]
I [mA]
4 8 12 16 20
4 .. 20 mA
f [Hz]
02 4 6 8 10 12
0U [V]
0 .. 10 V
fmax
fmin
fmax
fmin
Fig.12: "Min..Max" control characteristic