Danfoss VLT 4000 User manual

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
mm
2000 mm 176F1826 176F1825 176F1850
2200 mm NA NA 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.